ON SITE

EMERGENCY PLAN OF HM PROTEINS LIMITED REGISTERED OFFICE

H-31, NISHAT COLONY, 74 BUNGALOWS BHOPAL-462003, Ph. 0755-2570699

Works Village Sukhi Sewania Bhopal - Vidisha road, Bhopal-462010 0755-2885205, 2802053

INDEX
S.No. 1 2 3 4 5 6 Verification Silent features of the plan On site emergency Plan - An introduction Information about Plant, Process and storage Material process flow chart annex-11 PARTICULARS PAGE NO. 1 2 3 4-8 9

Material to be stored and possible hazard, list of plant and 10 machinery

7 8 9 10 11

Safety data sheet of hazardous chemicals In house facilities and safety measures provided in plant List of fire extinguishers\fire bucket provided General guide line FDR emergency first AID Management flow chart A. Commercial Section B. Technical Section List of important telephone numbers (To be utilised in emergency)

11-26 27-29 30-31 32-45

46 47 48

12

HM PROTEINS LTD.
H-31, Nishant Colony, 74 Bunglows Bhopal-462003 Phone - 0755-2570699 Ref.No. Date: 16.04.2010

VERTIFICATION
The information furnished in the on SITE EMERGENCY PLAN has been verified by me and is submitted seeking Modification/Suggestions from your office to make the document viable. I also assure, that I will immediately review/ament the documents and seek your comments before any change in the plant, Machinery, Building structure, Substance, Storage and manufacture process is intended or otherwise after atleast Twenty Four Months from this date 16/04/2010 until the Factory (for any reason) is not closed for even in later case it will be our's liability to inform closure of the Factory to your office and dispose off all the hazardous substance / material of the factory in such manner rendering those safe for life and environment.

S.S. SISODIA (Factory Manager)

Place : Bhopal (M.P.) Date : 16/14/2010

SILENT FEATURES OF THE PLANT

1 2 Name of the factory Address : : HM Proteins Limited Works: Village Sukhisewana Bhopal-Vidisha Road, Bhopal (M.P.) Phone 0755-2885205, 2885209 3 4 5 6 7 Nature of Industry Product Capacity No of Employees Power : : : : : Agro - Chemical Doc (De-oilcake) and Vegetable oil 500 TPD 210 750 KVA DG Sets 2 Nos - each of 500KVA Name of Address of : the Directors 2. 3. 8 Key persons of the : emergency plans 1. 2. 3. 4. 5. 6. 7. 1. Harshad Pranial Mehta, MD Nishat Colony, 74 Bungalow, Bhopal R.K. Patel, Director Ashish Jodh, Director General Manager Production Manager Plant Foreman Time office in charge Electrical Engineer Commercial in charge Security officer / Supervisors

ON SITE EMERGENCY PLAN AN INTRODUCTION

Since, the creation of life on earth overall disasters have occurred, natural as well as man made and man has learnt to survive from these by building around him protective barriers such as against Fury of Floods, Earthquakes and other various calamities. Today, Industrial Employees has to face several hazards consequent to advancement in science and Technology. Which has lead to massive, rapid and complicated process. The employees of today may not be quite familiar with such modern systems. Much of the harm can minimized by a careful evalution of the possibilities for disasters and evolving a proper plan to meet such emergencies. Thus, the Modern Industries carry inherent potential as for as hazard are concerned both to the Industrial employees and to the public, living around the Industries. It is essential to take these emergencies and thik and plan for emergencies in advance.

OBJECTIVE OF EMERGENCY PLANNING

1. 2. 3. 4. 5. 6. 7. 8. 9. To provide resource and methods for effective control of emergencies arising out of leakage, explosion and fire due to hazardous chemicals. To prevent the emergency turning into a disaster. Synchronized action from all the coordinating agencies with least possible delay. To minimize damages to the property, people and environment. Effective rescue operation and treatment of the causalities. To train the people to act efficiently and with confidence in an emergency. To bring back normal situation in the least possible time. To provide authorities information to the news media and Govt. Agencies. To minimize its occurrence.

(i)

INFORMATION ABOUT PLANT, PROCESS & STORAGE:

The Solvent extraction Industry is an important agriculture based industry this industry has evolved from batch type solvent extraction system to sophisticated continuous solvent extraction plant and is MOST important, because solvent (Hexane) which is highly inflammable and is used as on extraction of Oil/DOC from Soyabeen seed. Careless handling of the plant can cause disaster. It is a 500 TPD Capacity Plant located at Village Sukhisewania, Vidisha Road, Bhopal (M.P.) (Location Plant is enclosed) (ii) DESCRIPTION OF PROCESS The plant comprising of following units :(i) Solvent Extraction Plant 500 Ton/Day Capacity.

(iii) DIFFERENT STAGES IN THE PROCESS: The entire extraction process is divided into the following stages :(a) (b) (c) (d) (e) (iv) Preparation of raw material suitable for extraction. Extraction Desolventisation of extracted material Distillation of miscella Meal finish and begging

PREPARATION OF RAW MATERIALS

This is very important operation as there is necessary of bringing each and every oil-bearing cell of the oil seed in contact with the Solvent. This is done in the preparatory section by cleaning the material after dehusking and breaking in into piaces of 3mm size and then by injecting steam into the material to make it soft and converting the entire materials into flakes. Flakes are then cooled and crisped while being passed through the conveyor of the extraction plant. (v) EXTRACTION The extractor consists chiefly of a very slow moving conveyor in a closed chamber. Material from the preparatory section while moving slowly on the

conveyor forms a bed and is continuously washed with miscella and finally with fresh Solvent. The miscella passes through the meal bed and collects in various hoppers kept below the bed. (vi) DESOLVETISATION OF EXTRACTED MATERIALS:

The extracted material from the extractory contains, certain quantity of solvent in it. It is therefore treated in the disolventilisation section by discharging the extracted material into an aritight chain conveyor, which takes the material to a series of desolventisers. (vi) DISTILLATION OF MISCELLA The extracted solution of oil in Hexane-called miscella received from the extractor i.e. first received in tank and then pumped to the distillation chamber, which operates under vaccum. The miscella is heated by steam in the distillation chamber and Hexane in miscella torn into vapour, which is led to the condenser through an entrainment separator. The oil, thereafter, goes to the final product tank. (viii) SOLVENT RECOVERY Condensers, which are of floating head type, condense the vapour received from the distillation chamber. The condensed liquid, which is a mixture of hexane and water is fed to a Solvent water-separator where the pure solvent (Hexane) is separated from water. The uncondensed gases from the condenser are led to contact cooler where they are washed with cold water spray from contact cooler, they are led to observers where residual Solvent vapour is absorbed in an absorbing oil and no condensable gases are released into the atmosphere. (ix) MEAL FINISH AND BAGGING The de-oiled meal from the extraction plant is led in a current of air to the bagging room. The meal is not only conveyed but also cooled to about 450C to 500C due to contact with the conveying air. The meal is mixed with enough

moisture by the humidifier to bring up the moisture content. The humidified meal is then bagged. (x) FLOW DIAGRAM The flow diagram is enclosed-See Annexure II. OIL REFINING PROCESS : (PROPOSED) The process of refining oil consists of three operations explained below: i) ii) iii) i) Neutralization. Bleaching and Deodorization. NEUTRALISATION: The process is carried out in a cylindrical tank with conical bottom and starrier. The Crude Oil is first pumped into this tank (called and trailer) and heated to about 50 to 650 C and washed with a weak solution of phosphoric acid. The gums mucilage and portentous matter flocculates and separates from the oil and settles to the bottom as "Gums". The gums are drained from bottom. The oil with calculated amount of caustic soda solution, when it is reacts with free fatty acids forming soap. This soap settles to the bottom of the Neutralizer and is called soap stock. The Caustic Soda also re-acts with pigments, protentous and colouring matter in oil and these are eliminated to a large extent in Neutralizing process and go with soap. The soap settled at the bottom also contains small quantities of Neutral entrapped in it and is lost with soap stock. The efficiency of Neutralizing operation is determined by the least possible loss of Neutral Oil in soap stock. As such in this operation the quantity of original oil is reduced by its free fatty acid content plus quantity of neutral oil in soap stock plus impurities.

After draining of the soap the oil that is now free from fatty ACIDS and impurities is washed repeatedly with hot water to get it free from any caustic soda and soap. These dissolve in the bottom after settling. Neutralizing also removes bulk of the colour of the Crude Oil and makes it lighter. B. CONTINUOS PROCESS The continuous process for the refining of Crude Oil is carried out through centrifugal separator. Crude Oil after treatment with phosphoric acid passed through centrifugal to remove Phosphatides and pigments. Then after treatment with Caustic soda. Oil and Soap stock are separated in centrifugal separator and the neutralised oil is washed with water for the removal of soap. The wasning water is also separated from the oil by centrifugal separation. (ii) BLEACHING The neutral oil is then in a cylindrical vessel, called Bleacher for bleaching . Bleacher provided with an agitator and kept in vaccum. The neutral oil heated under vaccum upto 1100 and kept in vaccum. The neutral oil heated under vaccum upto 100-1100 C. After drying the oil, Activated Bleaching Earth and Carbon is taken into Bleacher Activated Bleaching earth and carbon is taken into Bleacher Activated Bleaching Earth and Carbon work an adsorption theory. Colouring matter such as Chlorophyll and Carotene as well as the impurities such as trace amounts of phospholipid, soap and peroxide absorbed by the activated bleaching earth and carbon. Bleaching process carried out for 30 minutes and then oil cooled into Bleaching under vaccum up to 70-800 C. After cooling the oil, bleached oil is filtered through the filter process into bleached oil tank. (iii) DEODORISATION

Crude flavour and taste producing compounds in oil are all volatile substance. Odourants are also produced by thermal decomposition during deodorisation, at high temperatures. The common odoriferous compounds are (i) High molecular weight ketones and aldehydes, (ii) Cyclic Hydrocarbons (iii) Free fatly acids (iv) Essential oils and, (v) Peroxides. The concentrations of these are generally less than 0.1% and the volatility of some these substances are very low. The effective process for removal of odoriferous our oils adopted in industry is known as deodourisation by at high temperature and under high vaccum. Bleached oil received from Bleacher is taken into the vassel called deodouriser under high vaccum and heated upto 180-1900 C and all odouriferaus matter are removed by steam distillation process. Thereafter, the oil is coolled and filtered through the filter press. The filtered deodourised oil is taken into tank and packed subsequently.

MATERIALS TO BE STORED & POSSIBLE HAZARD

S.No. 1. 2. 3. 4. 5. 6. 7. Material Seed Coal Package Material Qty. to be Stored 30000 M.T. 1200 M.T. Possible Hazard Fire Hazard Fire Hazard Fire Hazard Fire Hazard Safety Measure Taken Fire Hydrant System provided Fire Hydrant System provided Fire extinguisher & Sand buckets provided -do-

(Jute 1 lacs Bags. PP Bags 1 lacs) Oil (Solvent 2200 M.T. Extracted Oil) Approx D.O.C. 24000 M.T. Hexane 90 KL 30 KL Diesel *H2SO4 Acid 20 M.T. under planning

Fire Hazard -doFir Explosion -doHazard Toxic & Gas Mask, Gumboot, Burning Apron, Hand Gloves are provided to the workman

LIST OF PLANTS & MACHINERIES Seed cleaner, Belt Conveyor, Bucket Elevator Preparatory - Cleaner, Cracker, Cooker, Flacker. S.E.P. - Extractor, Desolventiser & Toaster, Pneumatic Conveying system. Refinery - Separator, Mixer, Bleacher, Air Compressor, Filters, Deodouriser. Steam Boiler. Electric Sub-station.

Note : Continues process refinery is proposed

SAFETY DATA SHEET OF HAZARDOUS CHEMICALS n-Hexane H2SO4 Acid NaoH n Hexane

SECTION - I Material identification and use-n-Hexane, used as solvent for all seed extraction. Chemical Name SECTION - II Physical Data Physical State Colour Liquid Clear Colourless Odour Specific Gravity Boiling Point Solubility Mild, Gasoline like Fain Odour 066 at (Water-1) 690C Insoluble in water, solsuble in alcenol, acetone & other 100mm Hg at 15.80C Pressure 200C C6H14 (Hezyl Hydride) Ch3 (Ch2)4 Ch3

Molecular Weight 86.18 Vapour Density 2.97

M.P.

93.80C

Vapour

Coefficient of 0.00243 0 expansion per C SECTION - III

Vapour Weigh per 3.48 liter, gms at 15.50C

FIRE & EXPLOSION HAZARD OF MATERIAL Flammability Lower Explosion Upper Explosion Volatile and Flash point highly flammable 1.2% 7.5% Auto ignition Temperature 230C 2600C -

Sensitivity develop discharge

to Low conductivity static

Spontaneous Heating

No

(Can easily generate electrostatic charges) Fire & Explosion when exposed to heat or flame hazard. Heat of combustion 11,651 Kcal/kg (gross) SECTION IV REACTIVITY DATA Chemical reactivity - reacts vigorously with oxidizing materials. SECTION V TOXICOLOGICAL PROPERTIES OF MATERIAL Thresahold limit value (TLV) ACGIH- ppm (180mg/m3)

Immediate danger to lite & health (IDLH) 5000 pm Ihnalation 5000 ppm for 1/2 hr 2500-1000 ppm for 12hrs/day 2500-500 ppm Markeo Vertigo Drowsiness, Fatigue, Loss of Appetite Parenthesis in distal extremities. Muscle weakness, cold pulsation in extremities, blurred vision, headacne, anoirexia of appetite distal

2000 pm for 1/6 hrs No symptoms 1000- Ratique, loss 500 mp for 3-6 months parenthesis Entry route Contact with skin & mucous membrane Group effect of vapour

Inhalation & Skin absorption Give sensation of burning With general anesthetics in the class of central nervous system depressant. Midly irritating to mucous membrane

SECTION VI PREVENTIVE MEASURES 1. Protective Equipment Personal Protective equipment Rubber gloves & boots Google : : : : Type of work involved Continuous Contact of head or feet Eye contact confined space

Gas mask with organic vapour : conister/self contained breathing Apparatus with full face mask 2. 3. 4. Engineering Control Leaks & spills procedures Storage Requirement : : :

Good low level ventilation (minimum air changes six times/hr.) Small spills can be absorbed with non-combustible absorbtants. Underground Storage tanks as per petroleum Act 1934 and the Petroleum Rules, 1976. * Tanks pipelines & accessories bonded earthed.

5. 6.

Electrical Requirements Fire Hazards

: :

Flame proof No naked flames, hot elements, no smoking use of non-sparking tools, no hot surfaces. Foam, Dry powder, carbon dioxide or halogented hydrocarbon type, heated container may be cooled by spraying with water from safe distance. Provision of automatic sprinkler system. Follow work permit system & adopt preventive maintenance system, examined by competent person. All the vessels and tanks bearing potential vapours in flammable range should be provided with explosion vents of adequate size.

7.

Fire

8.

Maintenance

9.

Explosion Vents

SECTION VII 1. 2. 3. Hexane comes in contact with eye, wash large quantities of water. On skin contact. Flush the contaminated portion with soap or mild detergent and water, if irrigation persists get medical attention. If the chemical is swallowed, give large quantities of water and induce vomiting. FIRE SAFETY DATA SHEET : HEXANE (C6 H14) USES AND APPLICATIONS Hexane (also known as Hexyl Hydride or n-Hexane) is a saturated aliphatic hydrocarbon obtainable from petroleum oil by distillation straight run gasoline that have been stripped of natural gas. It is sold commercially as a mixture of isomers with six carbon atoms, boiling at 60-700C. It is used as solvent for oil seed extraction, in glues and adhesives, used for the production footwear, as reaction medium for various polymerization reactions, in pharmaceuticals, lacquers and printing ink industries. IMPORTANT PROPERTIES : Physical State Colour Odour Boiling Point Flash Point Auto Ignition Temperature Flammability Limits Molecular weight Specific Gravity Vapour Density Vapour Pressure Threshold Limit Value (TLV) Liquid Clear Colourless Mild, Gasoline like odour 680C -22.00C 2530C 1.2 to 6.5% by volume in air 86.18 0.7 at 200C (Water=1) 3.0 (Air=1) 100 mm Hg 15.80C ACGIH-50 ppm (180 mg/m3) (1983)

Immediate Danger to life and Health 5000 ppm (1975) (DLH) Chemical Reactivity Reacts strongly with oxidizing agents RECOMMENDED STORAGE AND HANDLING PRACTICES Large quantities of hexane should be stored preferably in underground storage tanks away from plant building, according to appropriate standards and statutory regulations. Small quantities can be stored in sealed drums of not more than 200 liters capacity and kept in a cool place with good low level ventilation. Tanks, Pipelines and accessories should be bonded together and earthed. The vents should be protected by flame arrester. Hexane handling equipment can be designed and maintained to eliminate leakage of liquid and vapour. Operation under slight pressure is preferable to vaccum operation to prevent air from entering the system. Compressed air should not be used for filling, discharging or handling due to its susceptibility to generate static electrical charge. HEALTH HAZARDS : Hexane can be grouped with general anesthetics in the class of central nervous anesthetics in the class of central nervous depressant. Vapours are mildly imitating to mucous membrance. If may enter system by inhalation or through skin absorption. Direct contact with lungs tissues can result in chemical pneumonitis, pulmonary oedema and hemorrhage. Absorption through skin is extremely low. Contact with skin and mucous membrane gives sensation of burning. The substance irritates eyes. PERSONAL PROTECTION : Rubber gloves and boots are to be worn if work requires continuous contct with hands or feet. Goggles are to be used for avoiding probable contact with eyes. While entering confined spaces containing hexane, personnel should be equipped with gas mask with organic vapour canister or self contained breathing apparatus with full face piece:

FIRST AID : If hexane comes in contact with eyes, wash with large quantities of water. In case of contact with skin, flush the contaminated portion with soap or wild detergent and water. If irritation persists get medical attention. If the chemical is swallowed, give large qualities of water and induce vomiting. FIRE AND EXPLOSION HAZARDS : Hexane is a volatile and highly inflammable liquid and its mixtures with air in the flammability range are explosive. Being heavier than air it may travel along the ground and provoke distance ignition and flashback. Due to its low conductivity, it can easily generate electrostatic charges. PREVENTION OF FIRE AND EXPLOSION : Smoking or other open flames should not be permitted in presence of hexane whether in process or in storage. Electrical equipment and used in atmosphere should be of flameproof type. All equipment and pipelines must be properly bonded and grounded. Vapour detection equipment can be used for routing checking and monitoring. No Cammra, No Battery used no trecot cloths. FIRE FIGHTING : Small fires involving hexane can be put off with the aid of CO2. Halon or dry chemical power type extinguishers. Large splits of tanks fires are best extinguished by foam. Deluge water spray systems are suitable for controlling fires involving storage tanks. SULPHURIC ACID SUBATANCE IDENTIFICATION : Formula Synonyms Appearance and odour H2SO4 Oil of vitriol colorless to dark brown, oily, odourless liquid.

PREMISSIBLE EXPOSURE LIMIT (PEL) : The current OSHA standard for sulfuric acid is I milligram of sulfuric acid per cubic meter of air (mg/m3) averaged over and eight hour work shift. HIOSH has recommended a permissible exposure limit of 1 mg/m3 averaged over a work shift of up to 10 hours per day, 40 hours per week. The NIOSH criteria document for sulfuric acid should be consulted for more detailed information. HEALTH HAZARD : Routes of exposure Sulfuric acid can affect the body if it is inhaled or if it comes in contact with the eyes or skin. It can also affect the body if it is swallowed. Effect of overexposure 1. Short term exposure : Sulfuric acid may cause irritation of the eyes, nose and throat. Breathing in the mist of vapor may cause teeth erosion or the mouth to become sore and also difficulty in breathing. Splashes in the eyes or on the skin will cause severe skin burns. 2. Long term exposure: Repeated or prolonged to dilute solutions of sulfuric acid may cause irritation of the skin. Repeated or prolonged exposure to mists or vapour of sulfuric acid may cause erosion of the teeth, chronic irritation of the eyes or chronic inflammation of the nose, throat and bronchial tubes. Recommended medical surveillance The following medical procedures should be made available to each employee who is exposed to sulfuric acid at potentially hazardous levels. 1. Initial Medical Examination : The purpose is to detect pre-existing conditions that might place the exposed employee at increased risk and to establish a baseline for future heath monitoring. Examination of the

respiratory system, eyes and teeth should be stressed. The skin should be examined for evidence of chronic disorders. -14" X 14" chest roentgenogram: Sulfuric acid may cause acute lung damage. Surveillance of the lung is indicated. - FVC and FEV (1 sec) : Sulfuric acid is reported to cause pulmonary function impairment. Periodic surveillance is indicated. 2. Periodic Medical Examination : The aforementioned medical examinations should be repeated on an annual basis, except that an x-ray is considered necessary only when indicated by the results of pulmonary function testing. Summary of toxicology Sulfuric acid mist severely irritates the eyes, respiratory tracts and skin. Concentrated sulfuric acid destroys tissue due to its severe dehydrating action, whereas the dilute from acts as a milder irritant due to acid properties. The L C 50 of mist of 1-micron particle size for an 8 hours exposure was 50 mg/m3 for adult guinea pits to 2 mg/m3 for 5 days caused pulmonary edema and thickening of the alveolar walls: exposure of guinea pig to 2 mg/m2 for 2 hour caused and increase in pulmonary edema from inhalation. Sequelae were pulmonary fibrosis, residual bronchitis and pulmonary emphysema; in addition, necrosis of the skin resulted in marked scarring. In human subjects, concentrations of about 5 mg/m3 were objectionable, usually causing cough, an increase in respiratory rate and impairment of ventilatory capacity. Workers exposed to concentration of 12.6 to 35 mg/m3 had a markedly higher incidence of erosion and discoloration of teeth than was noted in unexposed individuals, Splashed in the eye, the concentrated acid causes extremely severe damage, often leading to blindness, whereas dilute acid produces more transient effects from which recovery may be completed. Repeated exposure of workers to the mist causes chronic conjunctivitis,

tracheobronchitis, stomatitis and dermatitis, as well as dental erosion. While ingestion of the liquid is unlikely in ordinary industrial use, the highly corrosive nature of the substance May be expected to produce serious mucous membrane bums of the mouth and esophagus. CHEMICLA AND PHYSICAL PROPERTIES : Physical Data 1. 2. 3. 4. 5. 6. 7. 8. 1. Molecular weight: 98 Boiling point (760 mm Hg): 270C (518F) Specific gravity (water=1): 1.84 Vapour density (air=1 at boiling point of sulfuric acid): 3.4 Melting point: 3 C (37 F) Vapour pressure 20C(68F) : less than 0.001 mm Hg Solubility in water, g/100 g water at 20C (68F): Miscrible in all proportions. Evaporation rule. Reactivity Hazardous decomposition products: Toxic gases and vapors (such as sulfuric acid fume, sulfur dioxide and carbon monoxide may be released when sulfuric acid decomposes. 2. Special Precautions: Liquid sulfuric acid will attack some forms of plastics, rubber and coatings. Flammability 1. Sulfuric acids not combustion itself, but is highly reactive and capable of igniting finely divided combustible materials on contact. Fires involving small amounts of combustibles may be smothered with dry chemical. Water applied directly to sulfuric acid causes evolution of heat and splattering. Sanitation Skin that becomes contaminated with sulfuric acid should be immediately

washed or showered to remove any sulfuric. EMERGENCY FIRST AID PROCEDURES : In the event of an emergency, institute first aid procedures and send for first aid or medical assistance. Eye ExposureIf liquid sulfuric acid or solutions containing sulfuric acid get info the eyes, wash eyes immediately with large amounts of water, lifting the lower and upper occasionally. Get medical attention immediately. Contact lenses should not be worn when working with this chemical. Skin ExposureIf liquid sulfuric acid or solutions containing sulfuric acid get on the skin, immediately flush the contaminated skin with water. If liquid sulfuric acid or solution containing sulfuric acid penetrate through the clothing, remove the clothing immediately and flush the skin with water. Get medical attention immediately. BreathingIf a person breathes in large amount of sulfuric acid, move the exposed person to fresh air at once. If breathing has stopped, perform artificial respiration. Keep the effected person warm and at rest. Get medical attention as soon as possible. Swallowing If liquid sulfuric acid or solution containing sulfuric acid have been swallowed and the person is conscious, give him large quantities of water immediately to dilute the sulfuric acid. Do not attempt to make the exposed person vomit. Get medical attention immediately.

 RescueMove the effected person from the hazardous exposures. If the exposed person has been overcome, notify someone else and put info effect the establishment emergency rescue procedures. Do not become a casualty. Understand the facility's emergency rescue procedures and know the locations of rescue equipment before the need arises. Spills, Leaks and Disposal Procedures Persons not wearing protective equipment and clothing should be restricted from areas of spills or leaks until cleanup has been completed. If sulfuric acid is applied or leaked the following stops should be taken1. 2. Ventilate area of spill or leak. Collect spilled or leaked material in the most convenient and safe manner for reclamation or for disposal in a secured sanitary landfill. Sulfuric acid should be absorbed in vermiculite, dry sand, earth or a similar material . It may be also be diluted and neutralized. Waste Disposal Method: Sulfuric acid may be placed in sealed containers or absorbed in vermiculite, dry sand, earth or a similar material and disposed of in a secured sanitary landfill. It may be diluted and neutralized.

SODIUM HYDROXIDE
Substance Identification : Formula : NaOH Synonyms: Caustic soda, lye Appearance and odour: White, odourless solid liequid Permissible Exposure Limit f (PEL) The current OSHA standard for sodium hydroxide is 2 milligrams of sodium hydroxide per cubic meter of air (mg/m) averaged over an weight hour work shift. NIOSH has recommended that the permissible exposure limit be changed to a ceiling of 2 mg/m over a 15-mifnute period. The NIOSH criteria document for sodium hydroxide should be consulted for more detailed information. Health Hazard Information Routes to Exposure Sodium hydroxide can affect the body if it is inhaled or if it comes in contact with the eyes or skin. It can also affect the body if it is swallowed. Effects of Overexposure Sodium hydroxide is a strong alkali and is corrosive to any tissue with it comes in contact. Effect from inhalation of the dusts and mists will very from mild irritation to destructive burns depending on the severity of exposure. Severe pneumonitis may occur. Sodium Hydroxide as a solid or in dusts, mists or solutions may cause irritation of the eyes and with grater exposure, severe burns with possible blindness. Contact of the skin with sodium hydroxide as a solid or dusts, mists or solution may cause skin irritation and with greater exposure, severe burns with scarring. Swallowing solid sodium hydroxide or solutions of sodium hydroxide may cause severe burns of the mouth, throat and stomach. Death may result, severe scarring of the throat may occur on recovery after swallowing sodium hydroxide. An increased number of esophagus cancer have been reported to occur in individuals who have scarring of the esophagus from swallowing sodium hydroxide. Reporting signs and symptoms A physician should be contacted if anyone develops any signs or symptoms and suspects that are caused by exposure to sodium hydroxide.

 Recommended Medical Surveillance The following medical procedures should be made available to each employee who is exposed to sodium hydroxide at potentially hazardous levels. 1. Initial Medical Examination -A complete history and physically examination: The purpose is to detect pre-existing conditions that might place the exposed employee at increased risk and to establish a baseline for future health monitoring. Examination of the eyes and respiratory tract should be stressed. The skin should be examined for evidence of chronic disorders. 14" X 17X chest roentgenogream: Sodium hydroxide causes human lung damage. Surveillance of the lung is indicated. FVC and FEB (1 sec) : Sodium hydroxide is a respiratory irritant, Persons with impaired pulmonary functions may be at increased risk from exposure. Periodic surveillance is indicated. 3. Periodic Medical Examination: The aforementioned medical examinations should be repeated on an annual basis, except that an x-ray is considered necessary only when indicated by the pulmonary function testing or by signs and symptoms of respiratory disease. Summary of Toxicology Sodium hydroxide is a strong alkali; dust and solutions cause injury to the eyes, mucous membranes and skin. Although inhalation is usually of secondary importance in industrial exposures, the effects from the dust of mist will vary from mild irritation of the moose at 2 mg\m to severe pneumontis, depending on the severity of exposures. The greatest industrial hazard is rapid tissue destruction of eyes or skin upon contact with the eyes causes disintegration and sloughing of conjunctival and corneal epithelium, corneal pacification, marked edema and ulceration; after 7 to 13 days either gradual recovery begins or there is progression ulceration and permanent corneal pacification. On the skin, solution 25 to 50% cause the sensation of irritation within about 3 minutes; with solutions of 4% this does not occur until after several hours. If not removed from the skin, severe burns with deep ulceration will occur; exposure to the dust or mist causes multiple small buns with temporary loss of hair. Ingestion produces severe pain in the esophagus and stomach, corrosion of the lips, mouth, tongue and pharynx and the vomiting of large of mucous; cases of sqamous cell carcinoma of the

esophagus have occurred with latent periods of 12 to 42 years after ingestion; these cancers may have been sequelea of tissue destruction and possibly scar formation rather than from a direct carcinogenic action of sodium hydroxide itself. Chemical and Physical Properties Physical Data 1. 2. 3. 4. 5. 6. 7. 8. Molecular weight: 40 Boiling point (760 mm Hg): 1390 C (2534 F) Specific gravity (water=1): 2.13 Vapour density (air=1 at boiling point of sodium hydroxide): not applicable Melting point: 310 C (590 F) Vapour pressure at 20 C (68F) : Essentially zero Solubility in water, g/100 g water at 20C (68F): 50 Evaporation rate (but y 1 acetate =1) : Not applicable.

Personal Protective Equipment: Employees should be provided with and required to use impervious clothing, gloves, face shields (eight-inch minimum) and other appropriate protective clothing necessary to prevent any possibility of skin contact with sodium hydroxide or solutions of sodium hydroxide. Employees clothing may have become contaminated with solid sodium hydroxide, employees should change into uncontaminated clothing before leaving the work premises. Where there is any possibility of exposure of an employee's body to sodium hydroxide or solutions of sodium hydroxide, facilities for quick drenching of the body should be provided within the immediate work area for emergency use. Non-impervious clothing which becomes contaminated with sodium hydroxide should be removed immediately and not reworn until the sodium hydroxide should be removed immediately and not reworn until the sodium hydroxide is removed from the clothing. Clothing contaminated with sodium hydroxide should be placed in closed containers for storage until it can be discarded or until provision is made for the removal of sodium hydroxide from the clothing. If the clothing is to be laundered or otherwise cleaned to remove the sodium hydroxide, the

person performing the operation should be informed of sodium hydroxide hazardous properties. Employees should be provided with a required to use dust and splash proof safety goggles there is any possibility of sodium hydroxide or solutions of sodium hydroxide contacting the eyes. Where there is any possibility that employee's eyes may be exposed to sodium hydroxide or solutions of sodium hydroxide and eye wash fountain should be provided within the immediate work area for emergency use. Sanitation Skin that becomes contaminated with sodium hydroxide should be immediately washed or showered to remove any sodium hydroxide. Eating and smoking should not be permitted in areas where sodium hydroxide or solutions containing sodium hydroxide are stored. Emergency First Aid Procedures : In the event of an emergency, institute first aid procedures and send for first aid procedures and send for first aid or medical assistance. Eve Exposure If sodium hydroxide, as a solid or in dusts, mists or solutions, get into the eyes, wash eyes immediately with large amounts f water, lifting the lower and upper lids occasionally. Get medical attention immediately. Contact lenses should not be worn then working this chemical. Skin Exposure If sodium hydroxide, as a solid or in dusts; mists or solutions, gets on the skin, immediately flush the contaminated skin with water. If sodium hydroxide, as a solid or in dusts, mists or solutions, penetrates through the clothing, remove the clothing immediately and flush the skin with water. Get medical attention immediately. Breathing If a person breathes in large amounts of sodium hydroxide, move the exposed person to fresh air at once. If breathing has stopped, perform artificial respiration. Keep the effected person warm and at rest. Get medical attention as a soon as possible.

Swallowing If solutions of sodium hydroxide have been swallowed and the persons is conscious, give him large quantities of water immediately to dilute the sodium hydroxide. Do not attempt to make the exposed person vomit. Get medical attention immediately. Rescue Move the effected person from the hazardous exposure. If the exposed person has been overcome, notify someone else and put into effect the establishment emergency rescue procedures. Do not become a casualty. Understand the facility emergency rescue procedures and know the locations of rescue equipment before the need arises. Spill and Disposal Procedure Persons not wearing protective equipment and clothing should be restricted from areas of spills until cleanup has been completed. If sodium hydroxide is spilled, the following steps should be taken 1. 2. ventilate area of spill. Dilute with water and neutralize with 6 molar hydrochloric acid.

Waste disposal method Sodium hydroxide may be disposed of in sealed containers in a secured sanitary landfill.

IN HOUSE FACILITIES & SAFETY MEASURE PROVIDED IN THE PLATN

1.

Fire Extinguishers -

67 Nos. (DCP, foam type Soda Acid Type including Trolley mounted 45 Kgs-2 Nos.)

2. 3.

Fire Sand Buckets -

18 Nos.

Auto Water Sprinkler system in Solvent Plant connected with Over Head Tank of 30KL Capacity and a pump immediately run when Emergency occurs.

4. 5.

Overhead Storage Tanks of 30 KL. Capacity. Water Pond Storage Capacity 350 KL. With pump house in Solvent Plant.

6. 7. 8.

Auto Steam cutoff valve in case of power failure. Gas Detector. All Godowns. Stores covered by Water pipe line Hydraunt system & Hoses connected.

9.

There are 2 Nos. Hexane tanks, Capacity 30 KL. Each underground buried in sand provided with 6 M. high vent pipe & Tyres Valve as per norms of Explosive Department.

10.

Personal protective Equipments provided: Helmet Mask Ear Plug Hand Gloves Gum Boot Rubber Apron Safety Goggles 10 Nos. 20 Nos. 25 Nos. 15 Pairs. 10 Pairs. 4+Nos. 10 Nos.

11. 12. -

Alarm Point Time Office S.E.P. First Aid Boxes at Electric Sub-station Time Office Refinery.

At-Admn. Officer-Emergency Control Room-1 (ECR-1) Alternate ECR (ECR-II) All Floors. SEP Section.

SAFETY MEASURES ALLOTED i) PRECAUTION AGAINST FRICTION: Non-Sparking type tools are being used in Solvent Extraction Plant made by Brass e.g. Tamni, Hammer, Chisel, etc. ii) a) PRECAUTION AGAINST POWER FAILURE : Over head water storage tank is provided for feeding of water by gravity to condensers automatically in case of power failure. b) Magnetic value is provided in the plant to cut off steam automatically in the case of power Failure. c) Flame proof toarch in SEP

MAGNETIC SEPERATOR: Raw material, which is feed in the Extractor, is always passed through electric magnetic drum and permanent magnet provided in different chutes so as to remove iron pieces during its transfer. iv) VENTING: Thyros valve is provided in Solvent storage tank at 6 meters above the ground level, so as to avoid Internal and External pressure and reentering vapours in the building in which Solvent Plant is located.

v)

WASTE WATER: Wastewater is passed through the Desolventiser and also through Solvent Trap size 12Ft x 7.8" x 9" so as to ensure removal of Solvent before water is discharged from premises.

vi)

VAPOUR DETECTION: Suitable type flame proof and portable vapour detector is provided so as/check leakages of solvent vapours at various locations of Solvent Extraction Plant.

vi)

LOG BOOK: A logbook of Plant Operations is also maintained in tire Plant and all details are furnished therein.

vii) a) b)

LOCATION AND LAYOUT: Solvent Extraction Plant is constructed at a distance beyond 30 meters from the nearest residential locality. 1.5 meter high continuous fencing well has already been provided around the Solvent Extraction Plant upto a minimum distance of 15 meters from the Plant.

c)

Boiler House and other buildings where open flame processes are carried out, are located beyond 30 meters distance from the Plant.

viii) ELECTRICAL INSTALLATION: a) b) c) d) All electrical motors and other electrical equipment installed in Solvent Extraction Plant are of flameproof construction. All Electrical cables have been fixed underground wherever necessary. Shock Charts and Danger Boards have been fixed at various places. Electrical shunt is provided in all the lines of Solvent Extraction Plant and Solvent Storage tank is connected to earth so as to avoid any accident arises in the electrical potential of such part, above the earth potential.

LIST OF FIRE EXTINGUISHERS & FIRE BUCKETS PROVIDED LOCATION SHED NO. TYPE OF EXTINGUISHERS PROVIDED IN DRG 1. DOC Godown 2. PREP 3. Seed Godown 4. S.E.P. 4 Nos. Water Presser Type 1 No. DCP Type (Panel Room) 2 Sand Bucket Stand 2 Nos. DCP Type (One Panel) 2 Nos. Soda Acid Types 1 No. Sand Bucket Stand 2 Nos. Soda Acid Type 1 No. Sand Bucket Stand 5 Nos. DCP Type 4 Nos. Foam Type 1 No. (Trolley mounted foam Type) (In Hexane Tank Area) 1 No. Foam type-Hexane

Unloading station. 5. Sub station D.G. Room (L.T. Panel Room) 6. Laboratory 2 Nos. Sand Bucket Stand 5 No. D.C.P. Type 1 No. CO2 1 No. Sand Bucket Stand 1 No. Soda Acid Type

7. 8.

Boiler Room Office

1 No. D.C.P. Type (Near Panel) 1 No. Soda Acid Type 1 No. D.C.P. Type 1 No. Soda Acid Type 1 No. D.C.P. Type 2 No. Soda Acid Type (Trolley Mounted) 1 No. Foam Type 1 No. Foam Type 1 No. D.C.P. 1 No. Foam Type

9.

Stores

10. Oil Storage Tanks

11. Diesel Tank (Underground) 12. Workshop 13. Hexane Tank (Underground) 14. Refinery

1 No. D.C.P. 1 No. CO2 2 Nos. Foam 2 Nos. D.C.P. 2 Nos. D.C.P. 2Nos. CO2 2 Nos. Soda Acid Fire Bucket Stand

Note : Should be in stores for emergency use

GENERAL GUIDE LINE FOR EMERGENCY FIRST AID (A) ELECTRICAL HARADS 8, PRECAUTIONARY MEASURES: The electric injuries may occur anywhere. It may be caused by direct current, alternative current or from lightening. The severity of the injuries by electric shock depends upon: 01 02 The amount of current flowing through the body. The path of current is taken through body to the earth a weaker current passing through the chest is more dangerous than a relatively stronger current passing through the lower limbs. 03 04 05 01 02 03 04 05 06 07 08 Length of time, victim is in contact. Type of electric energy AC or DC. Physical condition of the victim.

FOLLOWING SIGNS AND SYMPTOMS ARE FOUND IN ELECTRIC: Sudden spasm (Jurk of the muscles) May be unable to release hands, which holds the points. Burn. Severe Pain. Cries aloud and falls on the ground. Unconsciousness. Breathing impaired or stopped. Burns leading to revere surgical shocks.

EXPLOSION Explosion is mainly of following natures : Explosion of the equipments generally occur in oil filter transformer or oil circuit breaker. Explosion of oil filter equipments or cable is usually due to overheating is responsible - defective oil or damaged equipment is the main cause of the explosion. Periodically testing of oil and cables will be done to avoid explosion.

POWER CABLES : The are secured properly, and are protected from physical hazards. All junction boxes are protected and supported. Checking of earthling is necessary. To avoid accidents by electricity following safety measures are adopted: 01 02 03 04 05 06 07 08 09 10 11 12 13 Dum aged plugs, wires and switches etc. are not to use. The electrical equipment with screwdriver etc. are not touched unless and until the supply is cut off. The equipment is not touched with wet hands when supply is there. Many machine is single point are not connected other wise risk of fire will be obvious. Loose and hanging wires are not kept out fittings are kept proper and safe. broken plugs are not used. Plug top of 03 pins only for small machines are used, because one of the pin is preserved for earthling. Connect the equipment with supply through plug. Match stick for holding the terminals, are not attached. Water is not poured to extinguish fire caused by electricity cut off supply by main switch immediately, and proper fire extinguisher used. Before carrying out repairing of equipment; the main switch is put off and fuses are taken out. Fuse wire of proper size are to be used. Many equipments in one socket are not connected avoid extra load on it. Proper care should be taken to save electrocuted.

14

Affected person is touched after switching off or separating wire with the help of dry rope or bamboo wooden sticks etc. Provide first aid applying artificial breathing system to the affected person.

15

Rubber insulated tools and rubber hand cloves for working during supply or in MT Line, are used.

16

Where there is danger caution board is fixed to keep yourself away from the site.

17

Always equipment of ISI market preferred.

The above precautions and practice certainly saves from the accidents in factory as well as at home. FIRST AID IN ELECTRICAL SHOCK: Any delay in First Aid in Electric shocks is a delay for ever, hence the first abider must not get excited and must not endanger his life. 01 02 03 The current must be cutoff or the plug should be pulled out. The first abider must not touch the victim or the live conductor. If it is difficult to cut off the current, the victim has to be separated by using a dry coat rope, stick etc. 04 If there is a dry wooden chair or rubber sheet, the first order must stand on it and then separate the victim. 05 06 If the cloths are smoldering, the spark should be extinguished. Artificial respiration is to be started immediately. This may be done whenever the victim is in unconscious while and pulse less. The artificial respration should be continued till the doctor has arrived. (one may like to

continue for at least 08 hours before abandoning the care as dead. When the patient start swallowing, one may understand that spontaneous breathing is being revived. Artificial respiration should be continued till normal movement of breathing is fully established, as the respiration may fail again if left earlier. 07 A blanket should be out around the patient. The patient must be kept warm to treat the shock. He may be given warm, sweet drinking if he is conscious otherwise not, as it may harm him. 08 Superficial burns of lightening strange may be covered with a septic dressing. The deeper burns caused from contact with live conductors maybe covered with clean sheet and the patient evacuated to a hospital without any further delay. 09 External cardiac message may be given if the pulse is not felt or even artificial respiration. (B) 01 02 03 04 05 FIRST AID IN CASE OF BURNS: Act Quickly Put the Affected part in clod water. If immersion in cold water is not possible then pour cold water. Put sterilized dressings on effected part. Send for medical care immediately.

(C) FIRE PREVENTATION For prevention of fire following practice is adopted 01 02 Whenever highly inflammable goods are stored like gas cylinders, electrical appliances are used, cautiously. Waste papers, waste wooden pieces along with inflammable goods at a place are not kept.

03 04 05 06 07 08

Inflammable materials, lubricants in proper containers are stored in to tins with tight lid and also label on it is placed. Knowledge of fire extinguisher is provided to the employees where the equipment is placed and how to use it. Open fire is kept away. All of use are educated about the consequences of storing petrol. kerosene near store. Storing area is checked periodically and inflammable items, cloths etc., are put away from stores. Alertness proves fruitful in fighting fire hazards and saving society from huge loss of person and property.

09 10 11

Fire fighting equipments are kept in good working condition. Security personnel's and workers are trained in fire fighting to face situation in mishap. Type of Fire a) Solid Fire b) Solvent Fire c) Electric Fire d) Gaseous Fire Type of Suitable Extinguisher Water Spray/D.C.P. Form Type Cot/D.C.P. Cot

(D)

Safe Practice For Working: While working in The factory, people do not bother for safety rules, but no sooner accident occurs, they admit and understand that safety has got the first and foremost place. The workers are trained for following safe practice.

01

Always use tools, which are in proper good working condition.

02

Keep your work place clean and arrange things in their proper place & order.

03

Know the know-how of the machines and before operating the machines, get yourself acquainted.

04 05 06 07

Kept the safety guards in proper position. Follow permit to work system while carrying out maintenance work. Observe safety rules/precautions strictly. Keeping in view the requirement - use safety boots without nails, helmets, safety belts, goggles, nose mask, hand gloves etc., as and when required.

08

Keep your officer concerned informed of the situation in case you feel any danger without any delay.

09

Caution your fellow worker about the dangerous situation whenever you observe him working negligently and ignoring the safety rules.

10 11 12 13

Adopt proper process and avoid short cut. This is dangerous. Do not pour oil, grease and cotton waste or floor. Keep passage clear, see that rope, tools waste are not there. If you are not aware of any dangerous consequences of a particular job, consult & seek advise from your superior that only undertake it.

14 15

Do not consume intoxicants while you are in duty. Put on tight cotton uniform while on duty.

16

Put safety belt and inspect the work place properly whenever your required to undertake job at a height. Safe working is best working.

Precautions Observed While Performing Jobs At Height: 01 02 03 04 05 06 07 08 09 10 Proper and strong ladder is used Ladder in a proper place is put. Oil and grease is cleaned from the place. Hook at the top of top of ladder is attached. Putting tools on ladder is avoided. A slight mistake may cause fatal accident, hence proper care is taken. If required men engaged to hold the ladder in the ground. The site is checked before work. The tools in used are tied upto avoid falling. The safety belt is a life saving device for those working at high leve, hence the belts are provided. 11 The safety belts whenever required are made available to make one selfsafe. (F) 01 02 First Aid For Cuts, Wounds & Burns : Cover wound with clean cloth/sterile gauze and supply pressure. Apply bandage. Elevate wound above heart, if there is not fracture of bone, apply hand pressure over wound.

03

Use a toumiquet only if there is serve bleeding. Note time when it is applied because a tourniquet should not regain tight for along period. (You must have expert training in applying tourniquet.)

04

If a body part is sieved, send it along with the victim to the Hospital surgeon may be able to suture it back.

For Burns And Scale Never use iodine, cotton oil or greasy ointment. 01 For surface burns or minor nature, submerge, the part in cold water. Cover lightly with sterile dry clothing. 02 For 2nd degree burns showing blisters and severe pain cut away clothing. Immersed effected part of the body in cold water for 1 to 2 hours. Apply clean wet dressing. Cover with sterile cloth. 03 For 3rd degree bums where skin is charred or destroyed (Showing white of the skin) leave clothing in place. Cover with thick moist, sterile cloth; elevate burnt part of the body, if possible. Transfer victim to a Hospital. 04 If medical help is delayed, wash your hands remove victim's clothing very gently - Do Not Pull - leave the cloth sticking to the flesh, cut around it, cover the burnt with layers of dry clean dressing. Do Not Apply Ointments., Oils & Antiseptics. 05 Take steps to prevent the victim going into a state of shock, if patient is unconscious not vomiting, give plain glass of water or a solution of 1 teaspoon salt and half a tea spoon baking soda in 250 MI., water give in small sips. Major Emergencies

I)

Earthquake, flood, storm / cyclone structural collapses, landslides not/arson/sabotage, pressure vessel - boiler etc. System failure, toxic\corrosive chemicals and fire and or dust explosion are considered major hazards. The last two of these are common in solvent industries.

ii)

Synopsis Of the Plan : Minor emergencies will be handled by trained plant personnel. The aim of their action will be minimize\control the situation by implementing the actions laid down for each type of emergency.

iii)

Method of Declaring Emergency And Activating Emergency Plan: Since emergencies may be of minor nature or a major one, it is necessary to rapidly determine the potential severity of each emergency situation and take appropriate action. Major emergency will be notified by two Km. range alarms located at gate after one minute interval. Minor emergency will be notified by the local alarm located at gate.

iv)

Making The Emergency Known: In side the factory : For emergency, all personnel will be ready to carry out the appropriate emergency actions as stipulated in the plan.

v)

Call in Of Key Personnel : During non business hours or on holidays. Key personal will be called in during major emergency. This is the responsibility of Factory Manager.

vi)

Evacuation : As a precautionary measure, it is necessary to evacuate personnel from effected areas particularly those of non-essential categories. They will be directed to assemble at open near main office.

Type of Emergency and Action Taken :

a) Leakage from pipelines, value, flanges etc. i) Minor Hazards e.g. with solvent Procedures: - Stop the pump. - Carton of the area around the leak. - Station one operator near the leak and send information to supervisor. - The plant in charge will organize to drain out the solvent, purge the line equipment with nitrogen etc, and arrange to attend the leak. ii) Major Hazards - The following procedures will be undertake :a) Press the emergency alarm will shout. b) Inform production manager/plant in charge. c) Production manager will direct to stop all the operations of the plant. d) Shall call essential workers with personal protective equipments to control the situation at the effected area.

On Site Emergency Planning and Duties Of Personnel: The emergency planning of the factory has been formulated on the consideration that in spite of taking all the precautionary measures as recommended. If any disaster, hazard takes place because of slight negligence, oversight or error, plant personnel shall be in a position to handle the situation in effective manner and the required help as assistance can be obtained to minimize loses. Following three consideration have been taken, on which the emergency planning is based: (A) (B) (C) Types of emergencies, which can take place in the factory. Key personnel (who shall be available in the factory) Sequence of operations required in case of emergency or system of site alert and response. (A) Types of Emergencies : The emergencies that can occur in the factory is fire hazard and explosion harzard. (B) Key Personnel: Emergency can take place in any hour of the day. As such during the time of emergency all key personnel and safety committee shall be responsible to control the incident. Safety committee consists of following persons and the fire fighting personnel's. 1. Name of the Persons General Manager (i) (ii) Responsibility To declare state of Emergency. Overall Controller of situation delegation of orders & evaluation of severe consequences.

2.

Production Manager

3.

Plant In-charge

4. 5. 6.

Security Supervisor Time Office l/c. Stores l/c

(iii) To be in contact with local govt. Admn. & Authorities for additional help (if required) (i) To assist person no (i) and in case person no (i) is absent due to leave, he will takeover all the responsibilities of person no (i) (ii) Act as a In-charge of emergency control room. (iii) To direct & guide subordinate, officers for effective control of emergency. (i) To lead the team and emergency control at site. (ii) To help & guide the workers for plant operation/stoppage of machineries, power shut off and other major operation to prevent spread of hazard. (iii) Auto water system may be put in operation sprinkler system provided in the sep should be checked and see that the water of the sep overhead tank of 50KL gives water properly in the function of the sprinkler. (iv) To asses the situation & type of emergency and to inform person no (i) & (2) about the situation. To lead the fire fighting team at site under guidance of plant in-charge / production manager. To assist person No. (1), (2) & (3) and act as per their guidance. To give first Aid to affected persons & will also be responsible for rescue operation.

Other persons i.e. Accounts In-charge & Sales In-charge will rush to ECR & will act. under the guidance of person No. (1), (2) & (3), In case of shift duty shift Engineer/Plant Supervisor will be the incharge of Emergency control room & will make adequate arrangements to make the emergency and also to intimate immediately to Sr. No. (1), (2) & (3) about the situation. (d) Different Place From Where Emergency Alarm Can be Raised :

(e) (i)

ECR-Main & Second (Admn. Office & Time Office) Solvent Extraction Platn. Refinery.

Sequence of Operation In Case of Emergency Any person who notices fire, will shout - fire - fire (Aag-Aag-Aag) and will raise emergency alarm from the nearest point.

(ii)

Solvent Plant operator will his assistance will do the following jobs (a) (b) (c) Start water sprinkle system. Close volve of mother tank of n-hexane. will inform sub-station from where switch off power supply.

(iii) (iv)

Preparatory Operator: Will switch off the machineries. Boiler Attendant: On hearing siren, will close steam supply volve to the plant.

(v)

Pump Operator : Will start hydrauant pump which is on direct line from sub-station.

On hearing siren (i) (ii) Production Manager will immediately rush to the ECR Plant incharge will rush to the site and after assenssing the situation they will inform position to factory manager & ECR incharge. First they will assist in evacuation of plant & help to effected person. (iv) All Staff members & workers should stop their work/ machineries and should reach to ECR to help.

(v)

Fire fighting team under supervision of security officer will start their operation,

(vi)

Accident victim will be sent to hospital after giving First Aid as Site.

(vii) It should be ensured that the Massage has been communicated to lacal Admn. Authorities in case of Major Hazard and they are kept informed about latest position. (viii) Unwanted persons should not be collected near incident spot. (ix) As soon as emergency is over - "All Clear" will be declared by the factory manager & plant will be re-started. (x) The report of accident will be made to the Dy. Director, I.H.S. Bhopal within 24 hours of accident for information & investigation. Schedule Rehearsal of The Plan : As it is advised in the plan it will be periodically rehearsal led once in six months. Any change is there in plant & machineries, facilities available; this plan will be updated and shall be intimated to the officers concerned. Assessment Of Physical Range Of Effect The effect of Fire / Explosion will be limited to the factory premises only. No effect will be spreaded outside because the factory is situated in 3.054 hectares are and no residing population is there is 2 Km. area. Only agriculture land is there.

PROCESS ETP
TREATMENT PROCESS Effluents from the waste heat boiler are taken to a SS stripping vessel where large volume of air is injected to carry out the following functions. Assist in cooling the wastewater Remove traces of Hexane

The waste water is further taken to a reaction vessel where calculated amount of Alum solution + bleaching powder solution is dosed for protein coagulation. The coagulated mass is made to settle down by gravity in the settling Zone provided. The supernatant liquor is then passed on to a battery of fitters, comprising of Duat Media filter to be followed by a polishing bag filter. The output is taken to the cooling pond for reuse in the operations of condenser cooling. The backwash water and hopper drain is are taken to the sludge drying beds. ANALYTICAL DATA Due to unforeseen predicament, we have to close the PLANT form the year 1999 to Aug. 2007 and hence question of flow monitoring of these yeas does not ariese. Flow estimates monitoring per day will be as under AVERAGE FLOW TOTAL FLOW 1140.60 LPH 27374.40 LPO

LIST OF IMPROTANT TELEPHONE NUMBERS

(TO BE UTILIZED IN EMERGENCY)

S.no. 1 2 3 4 5 6

Name Collector Suppt police (Rural) CMO Civil Hospital Fire Brigade (Nagar Nigam) Police Station HM Proteins Ltd.

Place Bhopal Bhopal Bhopal Bhopal Sukhi Sewania Bhopal

Offi/Resi Office Office Office Office Office Head Office Factory Resi Mobile Office Resi. Mobile Mobile

Tel. Number 0755-2540494 0755-2443223 0755-2557134 0755-101 0755-2885223 0755-4256561-3 0755-288205, 2885209 0755-2051596 Mob. No. 9993091031 0755-251996 9993091031 0755-2885205-2802053 0755-4290190 09754813721 9993091031

7 8 9

Shri H.P. Mehta HM Proteins Ltd. 1. General Manager 2. Production MR. Harshad Mehta Director

Bhopal Sukhi Sewania Bhopal

Note : All telephones are available on the notice board kept in the security office of the factory.