HFPL, EMERGENCY PREPAREDNES DOC NO.: EMS/EPRP/001/8.

2/TM
MADDUR AND RESPONSE PLAN REV NO./DATE:02/11.10.2018
Page 1 of 8
TITLE: EMERGENCY PREPAREDNES AND RESPONSE PLAN

01. PURPOSE: To mitigate the Emergency situation.

02. SCOPE: This instruction covers steps to be taken by all employees during emergency situation
across the Organisation.

03. RESPONSIBILITY:

Performer : All employees working in organisation.

Verifier : Department Head(s)/Section In-charges.
Manager : Plant Head.

SN ACTIVITY/ ASPECTS IMPACTS POTENTIAL

PRODUCT/ EMERGENCY
SERVICE SITUATION
1 Gas Cutting Potential risk of Air pollution Fire and air pollution
operation explosion during gas cutting
operation
2 Handling & Potential risk of Air pollution Fire and Air pollution
storage of gas explosion during handling of gas
cylinders cylinders
(Oxygen, DA,
LPG)
3 Storage of oil Potential spillage Land Fire or land
of oil contamination contamination due to
spillage of oil
4 Operation of Potential spillage Land Fire due to leakage or
diesel generator of fuel oil due to contamination rupture of fuel oil tank
tank rupture

5 Storage of oil- Potential falling of Land Fire or land

soaked cotton oil-soaked cotton contamination contamination due to fall
waste waste of oil-soaked cotton
waste
6 Operation of DG Potential Risk of Air pollution Air pollution due to
/ HDG gaseous leakage leakage of gas or
damage of chimney

Prepared & Issued By: Reviewed & Approved By:

Associate Management Representative Management Representative
HFPL, EMERGENCY PREPAREDNES DOC NO.: EMS/EPRP/001/8.2/TM
MADDUR AND RESPONSE PLAN REV NO./DATE:02/11.10.2018
Page 2 of 8
TITLE: EMERGENCY PREPAREDNES AND RESPONSE PLAN

04. OPERATIONAL CRITERIA & RESPONSE TO EMERGENCY SITUATIONS:

4.1 Activity: Gas Cutting operation

Aspect: Potential risk of explosion
Impact: Air pollution
Potential Emergency Situation: Fire and air pollution during gas cutting operation
4.1.1 During the operation, ensure that there is no gas leakage.
4.1.2 In case of gas leakages stop the operation and Switch “off” the regulator of the gas
cylinder.
4.1.3 Disconnect the gas pipe and close the lid of the cylinder and handover to the store
department for replacing or correct the leakage point from the external provider.
4.1.4 If any electrical installations / cables are near the operation, ensure power supply to
such installations is switched “off” by informing the concerned electrical personnel.
4.1.5 In case of any emergency, Emergency declarer of the respective department shall
declare whether it is emergency situation or not. If yes, then following points are
applicable
4.1.6 Blow the emergency siren (continuously for 1min) to alert the person working in and
around the area.
4.1.7 After hearing the emergency siren sound, inform to all the personnel’s / employees
working in the plant to assemble in the nearest safe assembly area.
4.1.8 Till the emergency situation is mitigated all the personnel’s / employees shall wait in the
safe assembly area.
4.1.9 Use sand or fire extinguishers for the mitigation
4.1.10 Inform concerned persons immediately. (Plant Head & Administration Head).
4.1.11 In case of fire in non-electrical installation zone, ensure availability of water in the tank.
4.1.12 Use Water from the Pipeline to mitigate the fire.
4.1.13 After mitigating the emergency situation, clean the complete area and remove all
unwanted materials and store at the waste storage area.
4.1.14 After the emergency situation declarer declares that emergency situation is mitigated,
explain about the emergency incident / about the mock drill to people assembled in the
safe assembly area. Then the assembled personnel’s / employees can leave to their
respective working area.

Prepared & Issued By: Reviewed & Approved By:

Associate Management Representative Management Representative
HFPL, EMERGENCY PREPAREDNES DOC NO.: EMS/EPRP/001/8.2/TM
MADDUR AND RESPONSE PLAN REV NO./DATE:02/11.10.2018
Page 3 of 8
TITLE: EMERGENCY PREPAREDNES AND RESPONSE PLAN

4.2 Activity: Handling and storage of gas cylinders (oxygen, DA, LPG).
Aspect: Potential risk of explosion.
Impact: Air Pollution.
Potential Emergency Situation: Fire and Air pollution during handling of gas
cylinders.

4.2.1 To check the valve/seal to ensure that there is no leakage.

4.2.2 Put the cylinder cap before loading/unloading, so that it prevents the breakage of
valve/seal.
4.2.3 Take care while loading/unloading and storing at the storage area, if not possible to
handle by two persons take the help of third person.
4.2.4 Store the cylinders in vertical position, close with cap and lock with chain.
4.2.5 In case of any emergency, Emergency situation declarer of the respective department
shall declare whether it is emergency situation or not. If yes, then following points are
applicable
4.2.6 Blow the emergency siren (continuously for 1min) to alert the person working in and
around the area.
4.2.7 After hearing the emergency siren sound, inform to all the personnel’s / employees
working in the plant to assemble in the nearest safe assembly area.
4.2.8 Till the emergency situation mitigated all the personnel’s / employees shall wait in the
safe assembly area.
4.2.9 Use sand or fire extinguishers for the mitigation
4.2.10 Inform concerned persons immediately. (Plant Head & Administration Head).
4.2.11 In case of fire in non-electrical installation zone, ensure availability of water in the tank.
4.2.12 Use Water from the Pipeline to mitigate the fire.
4.2.13 After mitigating the emergency situation, clean the complete area and remove all
unwanted materials and store at the waste storage area.
4.2.14 After the emergency situation declarer declares that emergency situation is mitigated,
explain about the emergency incident / about the mock drill to people assembled in the
safe assembly area. Then the assembled personnel’s / employees can leave to their
respective working area.

Prepared & Issued By: Reviewed & Approved By:

Associate Management Representative Management Representative
HFPL, EMERGENCY PREPAREDNES DOC NO.: EMS/EPRP/001/8.2/TM
MADDUR AND RESPONSE PLAN REV NO./DATE:02/11.10.2018
Page 4 of 8
TITLE: EMERGENCY PREPAREDNES AND RESPONSE PLAN

4.3 Activity: Storage of oil (Fresh & used)

Aspect: Potential spillage of oil
Impact: Land contamination
Potential Emergency Situation: Fire or land contamination due to spillage of oil
4.3.1 Use good condition pumps while pumping of oils.
4.3.2 Use a secondary container while transferring oil from barrel to container.
4.3.3 While transferring oil from barrel to the container use cotton waste / cotton cloth to
avoid the slippage of handle while pumping the oil and to avoid the spillage of oil.
4.3.4 Use sponge or wood powder to absorb the spilled Oil.
4.3.5 In case of any emergency, Emergency situation declarer of the respective department
shall declare whether it is emergency situation or not. If yes, then following points are
applicable
4.3.6 Blow the emergency siren (continuously for 1min) to alert the person working in and
around the area.
4.3.7 After hearing the emergency siren sound, inform to all the personnel’s / employees
working in the plant to assemble in the nearest safe assembly area.
4.3.8 Till the emergency situation mitigated all the personnel’s / employees shall wait in the
safe assembly area.
4.3.9 Dilute the Oil with large amount of wood powder/mud/sand.
4.3.10 Inform concerned persons immediately. (Plant Head & Administration Head).
4.3.11 In case of fire in electrical installation zone use sand or fire extinguishers.
4.3.12 In case of fire in non-electrical installation zone, ensure availability of water in the tank.
4.3.13 Use Water from the Pipeline to mitigate the fire.
4.3.14 Collect the Oil-soaked Wood powder/Mud/Sand and dispose it in the designated area
or in dustbin.
4.3.15 After mitigating the emergency situation, clean the complete area and remove all
unwanted materials and store at the waste storage area.
4.3.16 After the emergency situation declarer declares that emergency situation is mitigated,
explain about the emergency incident / about the mock drill to people assembled in the
safe assembly area. Then the assembled personnel’s / employees can leave to their
respective working area.

Prepared & Issued By: Reviewed & Approved By:

Associate Management Representative Management Representative
HFPL, EMERGENCY PREPAREDNES DOC NO.: EMS/EPRP/001/8.2/TM
MADDUR AND RESPONSE PLAN REV NO./DATE:02/11.10.2018
Page 5 of 8
TITLE: EMERGENCY PREPAREDNES AND RESPONSE PLAN

4.4 Activity: Operation of Diesel generator

Aspect: Potential spillage of fuel oil due to tank rupture
Impact: Fire Hazard & Land Contamination
Potential Emergency Situation: Fire due to leakage or rupture of fuel oil tank
4.4.1 Identify the type of leakage (drop / heavy).
4.4.2 Place appropriate tray/tin/barrel to collect the drop leakage and arrest the leakage.
4.4.3 In case of leakage, Switch off the Diesel generator & all its Accessories.
4.4.4 Inform Maintenance head about the leakage.
4.4.5 Maintenance personnel shall isolate the DG electrical mains.
4.4.6 Close the inlet valve and place an appropriate tray to collect the leaking oil.
4.4.7 Use tray to collect the leaking fuel oil
4.4.8 To avoid land contamination use sponge or wood powder to absorb the spilled Oil.
4.4.9 Repair the tank by appropriate means.
4.4.10 Ensure proper arresting of fuel oil tank leakage due to rupture by testing before
operating.
4.4.11 Dispose the oil-soaked sponge and wood powder to designated area
4.4.12 In case of any emergency, Emergency situation declarer of the respective department
shall declare whether it is emergency situation or not. If yes, then following points are
applicable
4.4.13 Blow the emergency siren (continuously for 1min) to alert the person working in and
around the area.
4.4.14 After hearing the emergency siren sound, inform to all the personnel’s / employees
working in the plant to assemble in the nearest safe assembly area.
4.4.15 Till the emergency situation mitigated all the personnel’s / employees shall wait in the
safe assembly area.
4.4.16 Inform concerned persons immediately. (Plant Head & Administration Head).
4.4.17 In case of fire switch “off” the DG & its accessories.
4.4.18 In case of fire ensure availability of water in the tank.
4.4.19 Use Water from the Pipeline / water tank to mitigate the fire.
4.4.20 Use sand or fire extinguishers for mitigation.
4.4.21 In case of heavy fire contact nearest fire station.
4.4.22 After mitigating the emergency situation, clean the complete area and remove all
unwanted materials and store at the waste storage area.
4.4.23 After the emergency situation declarer declares that emergency situation is mitigated,
explain about the emergency incident / about the mock drill to people assembled in the
safe assembly area. Then the assembled personnel’s / employees can leave to their
respective working area.

Prepared & Issued By: Reviewed & Approved By:

Associate Management Representative Management Representative
HFPL, EMERGENCY PREPAREDNES DOC NO.: EMS/EPRP/001/8.2/TM
MADDUR AND RESPONSE PLAN REV NO./DATE:02/11.10.2018
Page 6 of 8
TITLE: EMERGENCY PREPAREDNES AND RESPONSE PLAN

4.5 Activity: Storage of oil-soaked cotton waste

Aspect: Potential falling of oil-soaked cotton waste
Impact: Fire Hazard & Land Contamination
Potential Emergency Situation: Fire or land contamination due to fall of oil-soaked
cotton waste
4.5.1 Store that oil-soaked cotton waste at the designated area
4.5.2 Do not carry out any activity that catches fire near oil-soaked cotton waste stored area.
4.5.3 In case of any emergency, Emergency situation declarer of the respective department
shall declare whether it is emergency situation or not. If yes, then following points are
applicable
4.5.4 Blow the emergency siren (continuously for 1min) to alert the person working in and
around the area.
4.5.5 After hearing the emergency siren sound, inform to all the personnel’s / employees
working in the plant to assemble in the nearest safe assembly area.
4.5.6 Till the emergency situation mitigated all the personnel’s / employees shall wait in the
safe assembly area.
4.5.7 If any electrical installations / cables are near the fire, ensure power supply to such
installations is switched “off” by informing the concerned electrical personnel.
4.5.8 Use sand or fire extinguishers.
4.5.9 Inform concerned persons immediately. (Plant Head & Administration Head).
4.5.10 In case of fire in non-electrical installation zone, ensure availability of water in the tank.
4.5.11 Use Water from the Pipeline to mitigate the fire.
4.5.12 In case of heavy fire contact nearest fire station.
4.5.13 To avoid land contamination, use a container/bag for storage.
4.5.14 To avoid land contamination, use sponge or wood powder to absorb the spilled Oil from
oil-soaked cotton waste.
4.5.15 Collect the Oil-soaked cotton waste, wood powder and dispose it in the designated area
or in dustbin.
4.5.16 After mitigating the emergency situation, clean the complete area and remove all
unwanted materials and store at the waste storage area.
4.5.17 After the emergency situation declarer declares that emergency situation is mitigated,
explain about the emergency incident / about the mock drill to people assembled in the
safe assembly area. Then the assembled personnel’s / employees can leave to their
respective working area.

Prepared & Issued By: Reviewed & Approved By:

Associate Management Representative Management Representative
HFPL, EMERGENCY PREPAREDNES DOC NO.: EMS/EPRP/001/8.2/TM
MADDUR AND RESPONSE PLAN REV NO./DATE:02/11.10.2018
Page 7 of 8
TITLE: EMERGENCY PREPAREDNES AND RESPONSE PLAN

4.6 Activity: Operation of DG / HDG

Aspect: Potential risk of gas leakage
Impact: Air Pollution
Potential Emergency Situation: Air pollution due to leakage of gas or damage of
chimney

4.6.1 Identify the leakages if any and seal the leakages before the starting the operation.
4.6.2 In case of any emergency, Emergency situation declarer of the respective department
shall declare whether it is emergency situation or not. If yes, then following points are
applicable
4.6.3 Blow the emergency siren (continuously for 1min) to alert the person working in and
around the area.
4.6.4 After hearing the emergency siren sound, inform to all the personnel’s / employees
working in the plant to assemble in the nearest safe assembly area.
4.6.5 Till the emergency situation mitigated all the personnel’s / employees shall wait in the
safe assembly area.
4.6.6 Stop the respective process.
4.6.7 Inform concerned persons immediately. (Plant Head & Administration Head).
4.6.8 Switch on the exhaust fans or open the windows/doors to send out the gas fumes
generated.
4.6.9 Repair or replace the chimney.
4.6.10 After mitigating the emergency situation, clean the complete area and remove all
unwanted materials and store at the waste storage area.
4.6.11 After the emergency situation declarer declares that emergency situation is mitigated,
explain about the emergency incident / about the mock drill to people assembled in the
safe assembly area. Then the assembled personnel’s / employees can leave to their
respective working area.

Prepared & Issued By: Reviewed & Approved By:

Associate Management Representative Management Representative
HFPL, EMERGENCY PREPAREDNES DOC NO.: EMS/EPRP/001/8.2/TM
MADDUR AND RESPONSE PLAN REV NO./DATE:02/11.10.2018
Page 8 of 8
TITLE: EMERGENCY PREPAREDNES AND RESPONSE PLAN

Contact
SN Person to be contacted Purpose
Number
1 Plant Head 9945536101 For guidance in mitigating
damages
2 Security 8147236719 For information & necessary
action

05. REFERENCES

Operational control procedure to avoid Air Pollution

EMS/OCP/001/8.1/AP

Operational control procedure to avoid land contamination due to spillage of used oil/grease
EMS/OCP/010/8.1/LC

Operational control procedure of to avoid land contamination due to spillage of cotton waste
EMS/OCP/008/8.1/LC

06. List of Emergency Situation Declarer

Emergency
SN Department Situation Contact Number
Declarer
01 Heat Treatment Mr.Ramakrishna 9036037822
02 Maintenance Mr.Ravikumar 9164226615
03 Toolroom Mr.Niranjan 9945536125
04 Manufacturing Mr.Ashwath 9945536119
05 Quality Mr.Shashi.C.M. 9945536101
06 Administration Mr.Sandeep 9945536124

07. KEY PERSONS TO BE CONTACTED DURING EMERGENCY

SN Person to be contacted Contact No Purpose
1 Top Management 9880697758 For Information.
2 Head of the Plant For Mitigating the emergency
Mr.Shashi.C.M. 9945536101 situation.
Mr.Ashwath 9945536119
3 Mr. Sandeep Kumar 9945536124 For information and for
(Head of the Admin) communicating with external
agencies like Fire Station &
Medical Unit.
4 Nearest fire station 08232236699 For Mitigating Fire.
5 Near Medical unit 08232232030 For Ambulance and Medical
assistance.

Prepared & Issued By: Reviewed & Approved By:

Associate Management Representative Management Representative