Onsite Emergency Plan o K

XYZ/EHS/OEP/01
Address Of Your Company
ON SITE EMERGENCY PLAN

Month & Year
REVISION -I
Prepared By
Safety Officer
[Names & Signature]
Page 1 of 49
Checked By
Safety Manager
Approved By
Unit Head
XYZ/EHS/OEP/01
INDEX
CHAPTER
NO.
PAGE NO.
TOPIC
PREFACE
PREAMBLE
5 -9
1
Emergency
2
Nature of Emergency
3
Process Description
4
Identification of Hazardous Area
5
Objectives of the Plan
6
Emergency Control Center
7
Assembly Points
8
Codification of Sirens
9
Training
& Education
Training
& Education
10 Mock drill
11 Updating the Plan
EMERGENCY ORGANISATION
KEY PERSONNEL AND THEIR

RESPONSIBILITIES
1
2
3
4
5
6
7
Site Controller
Incident Controller
Personnel / Administrative Manger
Security Officer
Departmental Heads
First Aid team
Factory Fire Squad Personnel
5
5
6
6
7
7
8
8
9
9
9
10
10
11 - 15
11
12
13
13
14
14
15
EMERGENCY ACTION PLAN
16-22
6.
LIST OF ANNEXURES
23-49
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LIST OF ANNEXURES
A.
Brief description of the manufacturing process
B.
Telephone numbers of Police, Fire Brigade, Hospitals & other outside

Emergency Services
C.
Telephone numbers & addresses of Key Personnel
D.
Telephone numbers of MARG members.
E.
List of Fire and Rescue Squad Members
F.
Information on Fire hydrant System
G.
List of fire Extinguisher.
H.
List of Personnel Protective Equipment.
First aid medical facilities.
List of Some hazardous Chemical and action.
Scenario Based Emergency action.
Emergency organization Chart
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CHAPTER 1
PREFACE
1.1 The enclosed On-site Emergency Plan is made for the Bulk drug manufacturing
plant of M/s XYZ Ltd. Plot No: XYZ, MIDC, ___________
1.2
The plant has a manufacturing facility to produce Bulk Drug viz..
1.3
The plant is designed and equipped to handle hazardous chemical and to carry
out various processes and operations on these chemicals. The plant is provided
with Fire Hydrant system, Fire extinguishers and Scrubber system. In addition to
this adequate types and number of Personal Protective Equipement, First Aid
Boxes, Eye washers, Ventilation system has been provided.
1.4
Considering the types of operations carried out in the plant and the nature, extent
of hazards existing, the management of M/s XYZ LTD thought it necessary to
have some system of tackling an emergency.
1.5
The formulation of this document is an outcome of the above thought process.
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CHAPTER 2
PREAMBLE
In spite of various preventive and precautionary measures taken in the plant, the
possibility of a mishap cannot be totally ruled out. Hence, the need to prepare a
Contingency Plan for dealing with incidences which may still occur and are likely to
affect LIFE and / or PROPERTY, both within the plant and in the immediate
neighborhood.
Such an emergency could be the result of malfunction of the Plant & Equipment or nonobservance of operating instructions. It could, at times, be the consequence of acts
outside the control of plant management like severe storm, earthquake, flooding, or
deliberate acts of arson or sabotage.
A Major Emergency in the plant is one that may cause serious injury or loss of life and
damage to the property.
This On Site Emergency Plan (OEP) explains the code of conduct of all personnel in the
plant along with the actions to be carried out in case of an Emergency. This plan gives
the guidelines for employees, contractors, transporters, etc. It not only defines
responsibilities but also informs about prompt rescue operations, evacuations,
rehabilitation, co-ordination and communication.
1.
EMERGENCY:
An Emergency is a situation, which may lead to or cause large-scale damage or
destruction of life, property or environment within or out side the Factory. Such
an unexpected situation may be too difficult to handle
for the normal work force
within the plant.

2.
NATURE OF EMERGENCY:
The emergency specified in the OEP refers to occurrence of one or more of the
following events: -
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a.
Fire/Explosion.
b.
Major accident such as structural or building collapse, overturning of road

tanker containing flammable substances.
3.
c.
Natural calamities like storm, flood, earthquake, etc.,
d.
Sabotage act of terrorism, civil commotion, air raid etc.
PROCESS DESCRIPTION:
A brief description of the Manufacturing Process is given in Annexure A.
4.
IDENTIFICATION OF HAZARDOUS AREAS:
HAZARD
Explosion
AREA
Boilers / Transformers Malfunctioning of the

/ Receivers for the Air Safety Valve
compressors.
Flammable Petroleum
Product Storage Tank
/ Drum Storage
area
Fire
PROBABLE CAUSE OF THE

ACCIDENT
External fire causing

pressure built up in the
tanks / barrels
H.S.D. / FO Storage Flammable vapor / air

Area
mixture and source of
ignition.
Flammable Petroleum Formation on pool in the
Product
Storage dyke wall and source of
Tank / Drum Storage ignition.
Shed /Production Area
External fire Built up of
internal pressure Failure
of the top cover Tank on
Fire
Spillage
.
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Acid / Alkali Storage Spillage of Acid / Alkali due

Area
to rupture of the pipe line,
collapse of the storage tank
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5.
OBJECTIVES OF THE PLAN:

a)
To control the emergency, localise it and if possible eliminate it.
b)
To avoid confusion, panic and to handle the emergency with clear cut
actions.
c)
To minimize loss of life and property to the plant as well as to the

neighbourhood.
d)
To make head count and carry out rescue operations.
e)
To treat the injured persons.
f)
To preserve records and to take steps to prevent

recurrence.
g)
6.
To restore normalcy.
EMERGENCY CONTROL CENTRE:

For the purpose of handling emergency, the following Emergency Control
Centres has been identified.
During normal working hours - The Administrative Office
During other times - The Security Office.
All communications to and from will originate at this CONTROL CENTRE. The
Emergency Control Center will have the following: a)
A copy of ON-SITE EMERGENCY PLAN.
b)
List of important telephone numbers such as Police, Fire

Brigade, Hospitals, and other outside Emergency Services, etc.
(Refer Annexure B).
c)
List of key Personnel with addresses and telephone numbers.

(Refer Annexure C).
7.
d)
List of Fire and Rescue Squad Members (Refer Annexure E).
e)
Plant layout indicating storage of hazardous materials
f)
List Fire Extinguisher. (Refer Annexure G).
g)
Fire Fighting System (layout of Fire Hydrants)
h)
List of Personal Protective Equipment (Refer Annexure H)
i)
First Aid box.
ASSEMBLY POINTS
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In case of an EMERGENCY the employees should assemble near the defined

Assembly Points, as indicated below:
Fire Fighters - Area near Security Gate.
First Aiders - Area near Security Gate.
Others - Area near Security Gate.
Wind direction to be determined by the WIND SOCKS installed on top of the

Engineering Building. THE EMPLOYEES SHOULD RUN PERPENDICULAR TO
THE WIND DIRECTION AND NOT AGAINST / ALONG THE WIND DIRECTION.
8.
CODIFICATION OF SIRENS
Sr.
1.
SIRENS
30 SECOND
INDICATES
ON SITE
AUTHORITY
INCIDENT
2.
CONTINUOUS
1 MINUTE
EMERGENCY (ALERT)
EMERGENCY
CONTROLLER
SITE CONTROLLER
CONTINOUS
CONTROLLED
(ALL CLEAR)
NOTE: 1)
EMERGENCY SIREN TO BE SOUNDED ONLY IF REQUIRED
2)
ALL EMPLOYEES IN AREAS OTHER THAN AFFECTED TO CONTINUE

WORK UNLESS DISASTER SIREN IS BLOWN.
3)
NO EMERGENCY ORGANIZATION MEMBER WILL LEAVE THE

EMERGENCY SPOT UNLESS `ALL CLEAR SIREN BLOWN.
------------------------------
9.
TRAINING AND EDUCATION:
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Experience with on site emergency planning has proved the need of training and
rehearsal. Major emergency procedure should be laid down clearly and convincingly to
everyone on site particularly Key Personnel and Essential workers.
It is obvious that in house or outdoor training is essential. The duties and responsibilities
of each person and the emergency procedure to be followed by him should be very
clear.
a. Seminar/refresher guidance On Site Emergency Plan.
b. Emergency instruction Booklet.
Seminar: Seminar is conducted in house/. Site controller will explain the plan to all
associated concerned employees.
Expert from outside explain the plan to all associated concerned employees. Expert
from also may be invited to impart training.
Emergency instruction Booklet:
Emergency instruction Booklet contains all detailed emergency duties. The booklet
contains
Emergency duties,
Reporting relationship.
Thus everyone is conspicuous about his role in the Emergency Plan.
10.
MOCK REHEARSAL:
Inform all the employees about mock drill.
Fix the date for mock drill.
Observers will not be involved in the exercise. They will monitor the Mock drill.
Emergency Siren / alarm will be raised.
After hearing the Siren / alarm, Emergency procedure will be followed as
mentioned in the OEP.
Observer will note down the activities with respect to the time.
11.
UPDATING THE PLAN:
As and when required the On Site Emergency Management plan will be updated. After
each drill the plan will be thoroughly received to take account of shortcoming and
accordingly plan will be updated.
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CHAPTER - 3
EMERGENCY ORGANISATION
Responsibility will be automatically delegated in absence of concern person/s in
following manner.
SITE CONTROLLER:
xyz
INCIDENT CONTROLLER:
DUTY OFFICER ON SUNDAYS/HOLIDAYS
ADVISORY COMMITTEE:
ALL HODs, Sachin K. Thorat
COMMUNICATION COMMITTEE:
P&A DEPARTMENTS
------------------------------
CHAPTER - 4
KEY PERSONNEL & THEIR RESPONSIBILITIES
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Key Personnels Responsibility during normal working hours :1.
Site Controller:
He will retain overall responsibility for the factory and its personnel. As soon as
he is informed of the emergency he shall proceed to the control room and meet
the P&A. Manager. His duties shall be:
i)
Assess the magnitude of the situation and decide if staff needs to be

evacuated from their assembly points.
ii)
Exercise direct operational control over areas other than those affected.
iii)
Maintain a continuous review of possible development and assess in

consultation with Incident Controller and other Key personnel as to whether
shutting down of the plant or any section of the plant and evacuation of
persons is required.
iv)
Liaison with Senior Officials of Police, Fire Brigade, Directorate of Industrial

Safety, provide advice on possible effects on areas outside the factory
premises.
v)
Control rehabilitation of affected areas on discontinuation of emergency.
vi)
Issue authorised statements to news media, and ensure that evidence is

preserved for inquiries to be conducted by statutory authorities.
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2.
Incident Controller:
On hearing of an emergency siren he will rush to the scene of the occurrence
and take overall charge and report to Site Controller. On arrival he will assess
the scale of emergency and decide if major emergency exists or is likely and
inform the Communication Officer accordingly.
(1)
Direct all operations within the affected areas with the priorities for safety of
personnel minimise damage to the plant, property and minimise loss of
materials.
(2)
Pending arrival of Site Controller, assume the duties of his post and, in
particular.
(3)
(a) Direct the shutting down and evacuation of plant and areas likely to be
adversely affected by the emergency.
(b)
(4)
Ensure that all Key personnel and outside help are called in.
Provide advice and information to the Fire squad & Security Officer and the
local fire service as and when they arrive.
(5)
Ensure that all non-essential workers/staff of the areas affected are

evacuated to the appropriate assembly points, and the areas are searched
for casualties.
(6)
In the event of failure of electric supply and internal telephones, set up

communication point and establish contact with Emergency Control Centre.
(7)
Report on all significant developments to the P. & A manager.
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(8)
Have regard to the need for preservation of evidence so as to facilitate any

inquiry into the causes and circumstances, which caused or escalated the
emergency.
3.
Human Resources Manager:

He will also work as liaison Officer and will be stationed at the Main Entrance
(Security Office near Main Gate) during the emergency.
He will under the
direction of the site Controller handle police, press and other inquiries, receive
reports from roll-call leaders from assembly points and pass on the absentee
information to the Incident Controller. His responsibilities shall include (1)
To ensure that casualties receive adequate attention, to arrange additional

help if required and information relatives.
(2)
To control traffic movements into the factory and ensuring that alternative
transport is available when need arises.
(3)
When emergency is prolonged, arrange for the relief of personnel and

organise refreshments / catering facility.
(4)
From information received, advise the Site Controller of the situation,

recommending (if necessary) evacuation of staff from assembly points.
(5)
Recruit suitable staff to act as runners between the Incident Controller and
himself if the telephone and other system of communication fails due to
whatsoever reasons.
(6)
Maintain prior agreed inventory in the control centre.
(7)
In case of prolonged emergency involving risk to outside areas by windblown materials, contact local Meteorological Office to receive early
notification of changes in weather conditions.
4.
Security Officer:
On hearing alarm advise fire squad and security staff in the factory of the incident
zone and cancel the alarm. He will also announce through telephone or
messengers to the HR Manager, Incident Controller and Site Controller that
incident has occurred in such and such zone. He will open the gates nearest to
the incident and stand by to direct the emergency service.
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If told of a large escape of gas he shall inform the Incident Controller by

telephone and stand-by the telephone to receive further messages.
On hearing the emergency alarm, he will immediately contact Site Controller and
on his advice call the local fire brigade. In case fire is discovered but no alarm is
sounding he shall receive information about location from the person discovering
the fire and thereafter immediately consult the Site Incident Controller and make
announcement on telephone telling the staff location of the incident and to
evacuate to their assembly points. He will continue to operate the switchboard
advising the calls connected with the incident to the Communications Officer.
5.
Departmental Heads:
The Departmental head wherein the incident has taken place will report to
Incident Controller and provide assistance as required. They will decide which
members of their staff they require at the scene.
6.
First-aid Teams:
The Personnel Manager shall keep in security the roll call lists for the fire
and first-aid teams on duty. Each Departmental Head for his shift-team
appoints roll call leaders and first aiders. Roll call leaders shall check their
rolls as members of the services report for emergency duty. Names of any
unaccounted for absentees will be informed to the Security Officer.
Members of first-aid Teams will report to the Incident Controller on hearing
of the alarm in day time. The Emergency vehicle driver, if safe to do so,
shall collect the emergency vehicle and park nearest to the scene of the
incident. First aider shall inform the incident controller that the Emergency
Vehicle is leaving the site, giving the name of the patient and destination i.e.
hospital or doctors room and request the Incident Controller to inform the
destination (hospital, etc.) advising them about the casualties reaching
there.
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7. Factory Fire Squad Personnel:

The duty Fire fighting Squad under the command of the Security Officer
shall be responsible for fire fighting and rescue. On hearing the alarm, they
shall proceed to the place of incident. The men at security gate shall find
out the location of the emergency and proceed to the site of the occurrence.
At the incident scene, a team members detailed for this purpose will check
squad members against roll-call sheet. At the site, all the squad members
will respond to the advice and information given by the Incident Controller
On arrival of the local fire brigade, they will also assist in fire-fighting work
with the advice of the Incident Controller.
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CHAPTER - 5
EMERGENCY ACTION PLAN
ANY ONE NOTICING EMERGENCY SITUATION LIKE FIRE, EXPLOSION, TOXIC
GAS LEAKAGE ETC. MUST
DOs
Attract the nearby person/employee by shouting FIRE FIRE FIRE.
Seek help from the persons working nearby.
Try to control the incident at its initial stage with available means/sources quickly.
Inform Shift In-charge / Duty Officer (In Night Shift ) about the Incident.
DONTs
Do not be panicky.
Do not run Walk fast.
INCIDENT CONTROLLER MUST

DOs
A. IF FIRE / OTHER INCIDENTS ARE CONTROLLABLE
Approach the emergency site immediately taking note of wind direction.
Assess the situation.
Inform Security Officer, Tell NAME, TYPE OF INCIDENT, ACTION TAKEN, HELP
NEEDED and Order Security Officer/Guard to inform all KEY persons.
Take lead in controlling emergency until such time concerned Section Manager takes
over the charge.
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DONTS
Do not be panicky.
Do not lose temperament.
B. IF FIRE/OTHR INCIDENTS ARE NOT CONTROLLABLE

In Addition to Above (A)
Order to blow emergency `ALERT Siren (30 second continuous).
Organize Fire fighting / rescue team members to control the Incident.
Take stock of situation if required shut down the plant / process in affected area.
Call Fire Brigade if situation demands.
Evacuate affected area.
Organize head count of the plant.
Act as INCIDENT CONTROLLER till such time senior person takes charges as
indicated in Emergency organisation
NOTE: 1) Messenger will wait until such time Security Officer arrives.
2) Also inform Telephone Operator.
SECURITY OFFICER / GUARD
DOs
Do not allow any vehicle to come inside the factory.
Do not entertain any outside call except for emergency purpose.
Do not allow visitors to move around.
Inform all key persons about location and type of emergency.
Follow this sequence Inform concerned HOD/Section Head, Main Site Controller,
Main Incident Controller & Safety Officer and other KEY persons.
Inform Main Site Controller about Government visitors, if any.
DONTs
Do not entertain any outside call except for emergency purpose.
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Do not allow visitor to move around, from reception.
SECURITY GUARD
DOs
Immediately report at Security Gate in shortest possible time.
Follow instructions of Officer In-charge.
Assist in controlling emergency.
Assist in controlling contractors, vehicle movement and mob.
Assist in cordoning off the area.
Take note of wind direction while approaching emergency site.
Render all possible help for controlling overall situation.
DONTs
Do not leave the site unless asked to do so.
EMERGENCY VEHICLE DRIVER

DOs
Immediately start vehicle and reach rescue squad assembly point (near security
gate).
Rescue squad members to emergency site.
Take vehicle near to emergency site as directed.
Take note of wind direction.
Reverse the emergency vehicle for quick transports of injured, if any.
Keep vehicle engine running.
Always be on Drivers seat of the vehicle.
Take the injured to the hospital as directed.
DONTs
Do not leave the vehicle.
Do not take the vehicle very near to the site.
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INCIDENT CONTROLLER
DOs
Approach emergency site as early as possible taking note of wind direction.
Take stock of situation.
Interact with all concerned departments as the situation demands.
Keep Main Site Controller informed about the latest emergency situation on
continuous basis.
SITE CONTROLLER
DOs
Will approach emergency site immediately / Assess the situation.
Consult Incident Controller.
Consult advising Committee Members.
Instruct Main Incident Controller.
Communicate to higher ups and Govt. authorities, if required.
Decide upon need for evacuation and blow `Disaster Siren.
After getting satisfied with the situation, give instruction to blow ALL CLEAR Siren.
DONTs
Do not instruct to blow ALL CLEAR siren unless the situation is fully under control.
Dont evacuate the entire plant unless the situation demands.
FIRE FIGHTING SQUAD ON HEARING SIREN

DOs
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Inform fellow employees/Officers.
Report to Fire Squad Assembly point.
Find out emergency location.
Approach emergency site immediately.
Take quick action as per the instructions from Incident controller.
Bring emergency under control as early as possible.
DONTs
Do not leave process/equipment in UNSAFE CONDITION.
Do not leave emergency site unless ALL CLEAR siren blown.
Do not use improper fire extinguisher.
Do not be panicky.
RESCUE SQUAD
DOs
Report to assembly point near Gate.
Get in touch with security about location and type of emergency.
Approach emergency site quickly with Breathing Apparatus set and First Aid box.
Get in touch with incident controller.
Follow instructions of Incident controller.
Render first aid to the injured, hospitalize, if required.
Accompany him to hospital and assist Doctor / Nurse.
Search for missing person in that area, if required.
Help in head count.
ALL GENERAL EMPLOYEES EXCEPT THOSE WHO ARE IN EMERGENCY
ORGANIZATION ON HEARING SIREN
DOs
Be alert and be available if required.
Wait for further instructions.
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Bring down the process/plant/equipment in SAFE CONDITION in case of DISASTER

siren as per instructions from Incident Controller.
Approach respective safe assembling points route as taking note of wind direction.
Help in taking roll call.
After hearing ALL CLEAR, go back to the departments.
Start the work again after setting instruction from Incident controller.
DONTs
Do not be panicky. Do not run.
Do not approach emergency site unless asked for.
Do not engage telephone except for emergency purpose. Keep lines free.
TECHNICAL TEAM: ENGINEERING DEPARTMENT / ENVIRONMNET, SAFETY AND
HEALTH DEPARTMENT ON HEARING SIREN
DOs
Be available in Engineering Department at respective location for any help.
Approach emergency site with required with tools and equipments and should work
on instructions of Incident controlle.
Help Incident Controller to provide technical assistance.
Isolate lines, process equipments, if required by Incident Controller.
Provide emergency equipments like Fire Extinguisher, Hoses, etc., if asked by
Incident Controller.
Provide stop gap arrangements as per the requirement of Incident Controller.
Carry out electrical isolation of area as per instructions from Incident Controller.
ADVISORY COMMITTEE (ALL DEPARTMENT HEADS)
DOs
Approach emergency site as early as possible.
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Render advise to Main Incident Controller and Main Site Controller to control
emergency.
COMMUNICATION COMMITTEE (P&A)
DOs
Consult Main Site Controller
Give necessary instructions to security / Telephone Operator.
Give instruction to Security to control traffic / crowd.
Look after injured, communicate with the family members, if situation demands.
Arrange transportation, if required.
DONTs
Do not communicate to any one or brief press without permission of Main Site
Controller.
GENERAL INTRUCTIONS
DOS
Stop work at height. / Stop all hot works.
Stop all vessel entry.
Take note of wind direction.
On hearing Disaster Siren evacuates as per evacuation route without running and
panicky and assembles at respective safe Assembly Points.
DONTs
Do not use telephone except for emergency purpose.
Do not start work at height, vessel entry, hot work unless permit conditions are
verified.
Do not allow unauthorized person to approach emergency site.
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-------------------ANNEXURE A
BRIEF DESCRIPTION OF THE MANUFACTURING PROCESS
BRIEF MANUFACTURING PROCESS OF ---------------------Stage I:
Stage II:
Stage III:
Stage IV:
BRIEF MANUFACTURING PROCESS OF --------------------Stage I:
Stege II:
Stage III:
BRIEF MANUFACTURING PROCESS OF --------Stage I:
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Stage II:
BRIEF MANUFACTURING PROCESS OF -----------------
----------------------------
ANNEXURE B
TELEPHONE NUMBERS OF POLICE, FIRE BRIGADE, HOSPITALS, AND
OTHER OUTSIDE EMERGENCY SERVICES
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POLICE DEPT-
FIRE BRIGADE
M.S.E.B. OFFICE: -
GRAMPANCHAYAT OFFICE :-
HOSPITALS :-
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ANNEXURE C
TELEPHONE NUMBERS AND ADDRESSESOFKEY PERSONNEL
LIST OF KEY PERSONS
NAME
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RESIDENCE TEL. NO.
XYZ/EHS/OEP/01
------------------------------
ANNEXURE D
MUTUAL AID SCHEME MEMBERS
MUTUAL AID RESPONSE GROUP
NAME
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COMPANY
OFFICE PHONE
XYZ/EHS/OEP/01
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ANNEXURE E
LIST OF FIRE AND RESCUE SQUAD MEMBERS
FIRE FIGHTING SQUAD
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FIRST AIDER(RESCUE SQUAD)
XYZ/EHS/OEP/01
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ANNEXURE F
EMERGENCY CONTROL SYSTEM FIRE HYDRANT SYSTEM
An underground Fire Hydrant System has been installed in the plant with rings around all
blocks to achieve maximum coverage. Water reservoir of 135m3 (Hydrant tank) + 20 m3
(MIDC Storage tank with feed from the MIDC water supply has been provided at highest
point in the plant. Following are the details of the system.
a. Water Reservoir- 135+20 m3.
b. Type of Hazard- Pharamaceutical, Ordinary Hazard.
c. Design Code-TACs Fire Protection Manual.
d. Total no. of Fire Hydrant including landing Values, Watermonitor-19 Nos.
e. Automatic Operation-Jockey pump of 10.8 m3/hrs@70Mhead capacity
with pressure switches.
f.
Stand by arrangement-Diesel Generator with AMF control panel.
g. Nos of Hose Boxes-External-18 nos

h. Nos of Hoses-36
i.
Nos of Nozzles-15 mm bore-17 nos.
j.
Hydrant flexible rill-6 nos.
k. Electric Driven main pump

-No 1
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- 70 M head 38 M3/hour flow at 7 kg./cm2
XYZ/EHS/OEP/01
l.
One Jockey pump provided of capacity 23 m3 /hr 91 M Head.
m. Auto changeover switch operated DG set System ensures that the

hydrant pump is kept working.
--------------------------------------------
ANNEXURE G
FIRE EXTINGUSHER
List of Fire Extinguishers
The company has trained personnel for fire fighting and its intends to improve the fire
fighting skills of their employee by conducting training on Fire fighting. There are 44
portable fire extinguishers, the break-up of which is as under: -
Sr.No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
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Area
Location
Type
DCP
DCP
DCP
FOAM
DCP
DCP
DCP
DCP
DCP
DCP
FOAM
DCP
DCP
FOAM
DCP
CO2
DCP
Capacity
5 KG
5 KG
5 KG
50 Lit
5 KG
5 KG
5 KG
5 KG
5 KG
5 KG
50 Lit
5 KG
5 KG
50 Lit
5 KG
3.0 KG
5 KG
XYZ/EHS/OEP/01
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
Sr.No.
Location
36
37
38
39
40
41
42
43
44
CO2
DCP
CO2
CO2
DCP
DCP
FOAM
DCP
CO2
DCP
DCP
CO2
DCP
DCP
DCP
CO2
CO2
DCP
6.5 KG
10 KG
3.0KG
3.0 KG
5 KG
10 KG
50 Lit
5 KG
6.5 KG
5 KG
5 KG
3.0 KG
5 KG
5 KG
5 KG
3.0 KG
3.0 KG
5 KG
Type
CO2
DCP
DCP
DCP
DCP
CO2
FOAM
DCP
DCP
Capacity
3.0 KG
5 KG
5 KG
5 KG
5 KG
3.0 KG
9 KG
5 KG
5 KG
Total Fire Extinguisher:

Sr. No
1
Types of Extinguisher
DCP
CO2
Foam
Sand Buckets: 05 Nos
Page 31 of 49
Total Nos.
29
06
09
XYZ/EHS/OEP/01
------------------------------
ANNEXURE H
LIST OF PERSONAL PROTECTION EQUIPMENT
LIST OF PERSONEL PROTECTIVE EQUIPMENTS
ITEM
Safety Helmet
Safety Goggles
Safety Shoes
PVC Apron
Asbestos Gloves
Rubber Gloves
Eye Wash Fountain
Gum Boots
Cloth Mask
Safety Belt
Organic Vapor Mask
Self Contained Breathing Apparatus
Page 32 of 49
NOS.
100
20
52
05
05
50
05
02
10
04
10
01
XYZ/EHS/OEP/01
ANNEXURE I
FIRST AID MEDICAL FACILITIES.
The company has provided First AID boxes at security office. Following are the
contents of First aid.
1.
Tincture iodine.
2.
Eye wash solution.
3.
Burnol
4.
Soframycin (ointment)
5.
Sterilized cotton wool.
6.
Band-aid.
7.
Antiseptic Solution (Dettol)
8.
Bandage.
9.
Paracetamol tablets.
10.
Iodex.
11.
Pair of scissor.
The company has got its own transport facilities to take the injured to the hospital.
The nearest hospitals are _________________________________
Page 33 of 49
XYZ/EHS/OEP/01
------------------------------
Sr.
Name
Boiling points
No
Flash
points
Methanol
64
11
Explosive limits
TLV
Action to be taken
in
Lower %
Upper
VOL
6
% VOL
36
200
PPM
Use AFFF For
extinguishing fire.
Use SCBA and Othe

2
Toluene
110
1.3
6.8
100
PPE.
Use AFFF For
extinguishing fire.
Use SCBA and Othe

3
MDC
39.8
12
23
50
PPE
Use SCBA and Othe
Ethyl
77
-4
11.5
400
PPE
Use AFFF For
Acetate
extinguishing fire.
Use SCBA and Othe

5
IPA
82
12
12
400
PPE
Use AFFF For
extinguishing fire.
Use SCBA and Othe

6
Ethanol
Page 34 of 49
77
13
3.3
19
PPE
1000 Use AFFF For
XYZ/EHS/OEP/01
extinguishing fire.
Use SCBA and Othe

7
n-Hexane
68
-21
1.1
7.5
50
PPE
Use AFFF For
extinguishing fire.
Use SCBA and Othe

PPE
ANNEXURE J
List of some Hazardous Chemicals and Action
List of some Hazardous Chemicals and Action

Sr
Name
No
DMF
Boiling
Flash
Explosive
TLV
points
points
limits
Lower
in
Upper
VOL
2.2
VOL
15.2
153
58
Action to be taken
PPM
10
Use AFFF For

extinguishing fire.
Use SCBA and
Acetone
56.5
-20
2.5
12.8
500
Other PPE
Use AFFF For
extinguishing fire.
Use SCBA and
10
THF
66
-14
11.8
200
Other PPE
Use AFFF For
extinguishing fire.
Use SCBA and
11
Di-ethyl ether
35
-45
1.9
36
400
Other PPE
Use AFFF For
extinguishing fire.
Use SCBA and
Other PPE
Page 35 of 49
XYZ/EHS/OEP/01
12.
TriethylAmine
90
-9
1.2
10
Use AFFF For

extinguishing fire.
Use SCBA and
13
Dimethylamine 7.4
-6
2.8
14.4
10
Other PPE
Use AFFF For
extinguishing fire.
Use SCBA and
Other PPE
ANNEXURE K
SCENARIO BASED EMERGENCY ACTION
Based on the reactions involved during the production process and the raw
material involved the possible hazards are indentified. The action for the
emergency situation is given.
Product Name
Sr.
Type of Reaction
Critical raw material
Possible Hazards
Action
no
1
Oximination
Methylene chloride
Irritating to eyes, skin
Immediately flush
with burning pain
with large amount of
etching and redness.
water; if inhaled
Gastrointestinal
remove to fresh air.
irritation with nausea,

vomiting and diarrhea,
may cause kidney
damage. CNS
depression, followed
by headache, dizziness,
drowsiness.
Liq. Ammonia
Page 36 of 49
Ammonia vapors are
Immediately flush
highly irritant and
corrosive.
water. Use respiratory
XYZ/EHS/OEP/01
protection.
Hydroxylamine
Harmful if swallowed,
Immediately flush
hydrochloride
inhaled or absorbed
through skin, causes
water to any area of
burn to any area of
contact.
contact.
Triethylamine
Methanol
Corrosive and
Immediately flush
irritating to the eyes,
skin, all living tissues
and respiratory tract.
contact.
Flammable liquid,
Follow fire action in
causes severe eye
case of fire.
irritation, may cause
Immediately flush
blindness if
swallowed; may cause
skin irritation, CNS
contact.
depression, and liver,

kidney damage.
2
Silylation
2-Methoxy propane
Flammable liquid and
Follow Fire action in
vapor may cause flash
case of Fire.
fire, harmful if
Immediately flush
swallowed, inhaled or
absorbed through skin,
causes burn to any area body contact.

of contact.
Hexamethyldisilazane Highly flammable,
corrosive and harmful
case of Fire.
to any area of contact.
Immediately flush
water.
Page 37 of 49
Pyridine
Irritant to eyes and
Immediately flush
hydrobromide
skin.
XYZ/EHS/OEP/01
water.
Toluene
Keep away from heat
and ignition source;
case of Fire.
harmful if swallowed,
Immediately flush
inhaled or absorbed
through skin; causes
water.
burns to any area of

contact.
Sodium carbonate
May cause eye burn;
Immediately flush
irritation to skin and
respiratory tract;
water.
harmful if swallowed
3
Methylation
Methyl iodide
or inhaled.
Potentially fatal if
If breathing is difficult
inhaled; harmful if
oxygen should be
swallowed, respiratory
administered by
tract irritation, skin
qualified personal and
irritation, eyes
wash with water if
irritation and CNS
contact with skin and
depression.
eyes.
Immediately flush
Dimethylsulfoxide
Corrosive and
irritating to the eyes
water.
and skin, all living

tissues and respiratory
tract.
Dimethylamine
Extremely flammable
case of Fire.
(40%)
liquid and vapor may
Immediately flush
cause flash fire,
water.
inhaled or absorbed
through skin, causes
burn to any area of
contact.
Page 38 of 49
Immediately flush
XYZ/EHS/OEP/01
Potassium hydroxide
May causes burn to the
eyes, skin, respiratory
water.
and gastrointestinal
4
Deprotection
Sodium bisulfite
tract.
Harmful if swallowed,
If swallowed, induce
may cause irritation.
vomiting immediately
after giving two glass
of water.
Immediately flush
water.
Formic acid
Corrosive and
Immediately flush
irritating to the eyes,
skin, all living tissues
water.

Ethanol
Flammable liquid

case of fire.
Sodium Hydroxide
May causes burn to the
Immediately flush
eyes, skin, respiratory
and gastrointestinal
water.
tract.
2. Product Name
Sr.
Type of
Critical raw
no
1
Reaction
material
Cycloalkylation 1,3dibromopropane
Possible Hazards
Action
Follow Fire action in case
vapor; harmful if
of Fire. Remove to fresh
swallowed or inhaled;
air; If not breathing give
affects CNS; causes
artificial respiration; if it
irritation to skin, eyes
is difficult give oxygen.
Give large amount of

water to drink.
DMSO
Page 39 of 49
Corrosive and irritating
Immediately flush with
to the eyes and skin, all
water.
living tissues and
XYZ/EHS/OEP/01
respiratory tract.
large amount of water to

any area of contact.
Toluene
Keep away from heat
of Fire. Immediately flush
inhaled or absorbed
water.

contact.
Methylene
Irritating to eyes, skin
chloride
with burning pain
large amount of water; if
etching and redness.
inhaled remove to fresh
Gastrointestinal
air.
irritation with nausea,

vomiting and diarrhea,
may cause kidney
damage. CNS
depression, followed by
headache, dizziness,
drowsiness.
4-Chloro
Hazardous in case of
phenylacetonitrile
skin contact, eye contact
plenty of water. If inhaled
or inhalation, severe
remove to fresh air. If not
exposure can result in
breathing give artificial
death.
respiration.
Tandem
Bromomethyl
Grignard
propane
vapor; harmful if
swallowed or inhaled;
affects CNS; causes
reduction
water to drink.
Magnesium metal
Page 40 of 49
Highly inflammable,
Follow fire action in case
XYZ/EHS/OEP/01
and harmful if
of fire. Immediately flush
swallowed or inhaled.
Irritating to eyes, nose,
water.
throat, skin and CNS;

over exposure to the
vapor may cause
headache, drowsiness.
Isopropyl alcohol
Flammable liquid;
harmful if swallowed or
inhaled. Irritating to
eyes, nose, throat, skin
water.
and CNS; over exposure

to the vapor may cause
Tetrahydrofuran
Keep away from heat
of Fire. Immediately flush
inhaled or absorbed
water.

contact.
Ethyl acetate
vapor. Harmful if
swallowed or inhaled.
Affects CNS; causes

water to drink.
water.
Page 41 of 49
Sodium
Highly flammable,
In case of skin, eyes
borohydride
toxic, contact with water
contact flush with copious
liberate flammable
amount of water. Follow
gases. Toxic in contact
fire action in case of fire.
XYZ/EHS/OEP/01
with skin and if

swallowed, very toxic
by inhalation; causes
burns and react violently
with water.
Hexane
Flammable liquid;
water.

3
Methylation
Formic acid
Corrosive and irritating
to the eyes, skin, all
large amount of water.
living tissue and

respiratory tract.
Formaldehyde
Poison, danger; suspect
cancer hazard; may
cause cancer; vapor
harmful if inhaled or
absorbed through skin.
Causes irritation to skin,
eyes, and respiratory
water to drink.
tract; Strong sensitizer,
causes blindness if
water.
swallowed; flammable
liquid and vapor.
IPA. HCl
Flammable liquid;
water.

Page 42 of 49
XYZ/EHS/OEP/01
3. Product Name
Sr.
Type of Reaction
Critical raw
Possible Hazards
Action
no
1
Cyanation
material
2,3-Dichloro
Corrosive
In case of contact wash
benzoyl
off immediately with
chloride
water.
Cuprous
Poison; Danger; may be
A cyanide antidot kit
cyanide
fatal if swallowed,
should be available in
inhaled or absorbed
any cyanide work area.
through skin. Contact
In case of cyanide
with acid liberates
poisoning start first air
poisonous gas; causes
treatment and flush
severe eye irritation and
skin with plenty of
possible burn. Affect
water.
blood, cardiovascular
system, CNS and thyroid.
Acetonitrile
Keep away from heat and
ignition source; harmful if case of Fire.

absorbed through skin;
causes burns to any area

of contact.
Toluene
ignition source; harmful if case of Fire.

absorbed through skin;
causes burns to any area

of contact.
Hexane
Page 43 of 49
Flammable liquid;
case of fire.
inhaled. Irritating to eyes,
XYZ/EHS/OEP/01
nose, throat, skin and
CNS; over exposure to

the vapor may cause
2
Condensation and
Sulfuric acid
cyclisation
Vapor may cause pulm
Remove to fresh air,
irritation and eye
Resuscitate if not
irritation; severe chem.
breathing; flush with
burn to eyes and skin
plenty of water.
4. Product Name
Sr.
no
1
Type of Reaction
Critical raw
Possible Hazards
Action
Dehydroiodination
material
Iodine
Vapor severely irritate and
can burn mucous membrane
case of Fire. Remove
and respiratory tract; excess
to fresh air; If not
tears, tightness in chest,
breathing give artificial
headache; inflammation of
respiration; if it is
the nasal mucous, bronchitis,
difficult give oxygen.
rapid heart beat, diarrhea and
wt. loss.
water to drink.
water. Iodine stains can
be removed by
immediate washing
skin by 5% sodium
thiosulphate solution.
Pyridine
Irritation of eyes, skin,
Inhalation remove to
respiratory tract, chest pain,
fresh air, Resuscitate if
difficulty in breathing, CNS
not breathing; flush
effects like headache,
with plenty of water.
dizziness, nausea and

vomiting, redness or burns of
eyes/skin lever or kidney
damage.
Methanol
Page 44 of 49
Flammable liquid, causes
XYZ/EHS/OEP/01
severe eye irritation, may
case of fire.
cause blindness if swallowed;
may cause skin irritation,
large amount of water
CNS depression, and liver,
kidney damage.
HCl
Poison; danger; corrosive
Remove to fresh air. If
liquid and mist cause severe
not breathing give
burns to all body tissue; may
artificial respiration; if
be fatal if swallowed or
it is difficult give
inhaled. Inhalation may cause
oxygen. Do not induce
lung damage. Extreme heat of vomiting. Give large

contact with metal can
amount of water to
release flammable hydrogen
drink. In case of
gas.
contact, immediately
flush with plenty of
water. Follow fire
action in case of fire.
Sulfuric
Vapor may cause pulm
Remove to fresh air,
acid
irritation and eye irritation;
Resuscitate if not
severe chem. burn to eyes
breathing; flush with
and skin.
plenty of water.
Sodium
Inhalation, irritation to
Flush with plenty of
thiosulphate
mucous membrane, mild
water.
irritation of eyes and skin.

Sodium
May causes burn to the eyes,
hydroxide
skin, respiratory and
gastrointestinal tract.
Hesperidin
May cause skin and eye
irritation; may cause
respiratory and digestive tract

irritation.
5. Product Name
Sr. Type of
Critical raw
no
material
Reaction
Page 45 of 49
Possible Hazards
Action
XYZ/EHS/OEP/01
Condensation
Methanol
Flammable liquid, causes severe
eye irritation, may cause
case of fire.
blindness if swallowed; may
cause skin irritation, CNS
depression, and liver, kidney
damage.
Dimethyl
Formamide
Poison; danger, combustible;
Inhalation remove to
may be fatal if swallowed;
fresh air, Resuscitate if
inhaled or absorbed through skin.
not breathing; flush
Keep away from heat, sparks and
with plenty of water.
flame. Irritation of breathing

vapors.
Acetic acid
Strongly corrosive and causes
serious burns. Lachrymator; may
plenty of water.
cause irritation to eyes, skin and
Remove from exposure
respiratory tract.
and move to fresh air.

If breathing is difficult,
give oxygen.
Hydrochloric
acid
Poison; danger; corrosive liquid
Remove to fresh air. If
and mist cause severe burns to all
not breathing give
body tissue; may be fatal if
artificial respiration; if
swallowed or inhaled. Inhalation
it is difficult give
may cause lung damage. Extreme oxygen. Do not induce

heat of contact with metal can
vomiting. Give large
release flammable hydrogen gas.
amount of water to
drink. In case of
contact, immediately
flush with plenty of
water. Follow fire
action in case of fire.
Toluene
Page 46 of 49
ignition source; harmful if
case of Fire.
swallowed, inhaled or absorbed
XYZ/EHS/OEP/01
through skin; causes burns to any
area of contact.
May cause eye, skin, digestive
Chloromethyl
tract irritation, liver and kidney
plenty of water.
aniline
damage
Remove from exposure

and move to fresh air.
If breathing is difficult,
give oxygen.
ANNEXURE L
EMERGENCY ORGANIZATION CHART
Page 47 of 49
XYZ/EHS/OEP/01
Site controller
Incident Controller
Fire
fighting
Squad
Page 48 of 49
First aid
P & .A.
Squad
Dept
Engineering Security
Dept.
EHS Manager
Shift In
charge

Onsite Emergency Plan o K

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Address Of Your Company

ON SITE EMERGENCY PLAN

KEY PERSONNEL AND THEIR

EMERGENCY ACTION PLAN

Brief description of the manufacturing process

Telephone numbers of Police, Fire Brigade, Hospitals & other outside

Telephone numbers & addresses of Key Personnel

Telephone numbers of MARG members.

List of Fire and Rescue Squad Members

Information on Fire hydrant System

List of fire Extinguisher.

List of Personnel Protective Equipment.

First aid medical facilities.

List of Some hazardous Chemical and action.

Scenario Based Emergency action.

Emergency organization Chart

The plant has a manufacturing facility to produce Bulk Drug viz..

The formulation of this document is an outcome of the above thought process.

for the normal work force

within the plant.

Major accident such as structural or building collapse, overturning of road

Natural calamities like storm, flood, earthquake, etc.,

Sabotage act of terrorism, civil commotion, air raid etc.

IDENTIFICATION OF HAZARDOUS AREAS:

Boilers / Transformers Malfunctioning of the

PROBABLE CAUSE OF THE

External fire causing

H.S.D. / FO Storage Flammable vapor / air

Acid / Alkali Storage Spillage of Acid / Alkali due

OBJECTIVES OF THE PLAN:

To control the emergency, localise it and if possible eliminate it.

To minimize loss of life and property to the plant as well as to the

To make head count and carry out rescue operations.

To treat the injured persons.

To preserve records and to take steps to prevent

EMERGENCY CONTROL CENTRE:

During normal working hours - The Administrative Office

During other times - The Security Office.

A copy of ON-SITE EMERGENCY PLAN.

List of important telephone numbers such as Police, Fire

List of key Personnel with addresses and telephone numbers.

List of Fire and Rescue Squad Members (Refer Annexure E).

Plant layout indicating storage of hazardous materials

List Fire Extinguisher. (Refer Annexure G).

Fire Fighting System (layout of Fire Hydrants)

List of Personal Protective Equipment (Refer Annexure H)

First Aid box.

In case of an EMERGENCY the employees should assemble near the defined

Fire Fighters - Area near Security Gate.

First Aiders - Area near Security Gate.

Others - Area near Security Gate.

Wind direction to be determined by the WIND SOCKS installed on top of the

EMERGENCY SIREN TO BE SOUNDED ONLY IF REQUIRED

ALL EMPLOYEES IN AREAS OTHER THAN AFFECTED TO CONTINUE

NO EMERGENCY ORGANIZATION MEMBER WILL LEAVE THE

TRAINING AND EDUCATION:

UPDATING THE PLAN:

Key Personnels Responsibility during normal working hours :1.

Assess the magnitude of the situation and decide if staff needs to be

Maintain a continuous review of possible development and assess in

Liaison with Senior Officials of Police, Fire Brigade, Directorate of Industrial

Control rehabilitation of affected areas on discontinuation of emergency.