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Annexure – 8 - On-site Emergency Plan

ON-SITE EMERGENCY PLAN

OF
M/s Malbros International Pvt. Ltd.,
Village-Mansoorwal, Tehsil-Zira, Faridkot Road, District-
Ferozepur, Punjab, India. Pin-142047

2016
-------Prepared By------

M/s Excellent Professional Solution,


Second Floor, Nankana Complex,
Opposite Bus Stand, Ludhiana
Contact-7355887070 & excellent.eps@gmail.com

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TABLE OF CONTENTS

Sr. No.
Desciption Page No.
1. Introduction 05
2. Profile of The Company 07
3. General Information of Plant 10
4. Technical Features of Plant 13
5. Effluent Handling Section 17
6. Terminologies Related to Hazards 20
7. Different Phases of Disaster 23
8. Scope , Intent And Objective of Plan 24
9. Classification & Description of Emergencies 26
10. Emergency Mitigation & Preparedness 35
11. Emergency Response Procedures And Measures 37
12. Roles And Responsibilities 40
13. Fire Protection System & Sops 47
14 Communications Services & Infrastructure 54
i. Communication Flow Chart 54
ii. Flow of Information 55
iii. Siren Codes 56
iv. Details of the Emergency Control Centre (ECC) 56
v. Assembly Point and Their Area Coordinator 57
vi. Declaration of on-site and off–site emergencies 58
vii. Medical Facilities 58
viii. Evacuation 60
ix. Information to Public 60
x. Reporting of the Incident 60

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xi. Action after reporting of incident by the entity 61


xii. Termination of emergency 61
xiii. Emergency Recovery Procedures 62
xiv. Integration of the Onsite Emergency Plan (OEP) With
62
The National Disaster Management Plan (NDMP)
xv. Security Threat Plan 64
xvi. Off-Site Emergency Plan 64
xvii. Plan Updation 66
xviii. Glossary 66
15 Hazard Identification, Hazard Analysis And Risk Assessment 67
16 Incident Prevention Measures 69
17 Post Emergency - Recovery Measures 70
18 Important Telephone Numbers 72
19 Fire Fighting Equipment & Personal Protective Equipment 73
20 Product Storage Capacity And Chemical Data 74
19 Fire Fighting Equipment & Personal Protective Equipment 73
20 Product Storage Capacity And Chemical Data 74
Annexxure-A : Material Safety Data Sheets of Hydrochloric Acid 75
Annexxure-B : Material Safety Data Sheets of Ammonium
76
Hyrdoxide
Annexxure-C : Material Safety Data Sheets of Sulphuric Acid 77
Annexxure-D : Material Safety Data Sheets of Ethanol 78
Annexxure-E : Material Safety Data Sheets of Diesel 83
Annexxure-F : Incident Reporting Format –For Compilation 85
Annexxure-G : Resource Mobilization (Men and Equipment) to be Kept
88
Ready in Due Course of Time
Annexxure-H: List of Relevant Statutes on Management of Hazardous
90
Substances
Annexxure-I: The Important Roles And Responsibilities Of Various
Stakeholders 91

Annexxure-J: Plant Layout with marking of Assembly Points


92

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LIST OF ANNEXXURES
Annexxure-A : Material Safety Data Sheets of Hydrochloric Acid

Annexxure-B : Material Safety Data Sheets of Ammonium Hyrdoxide

Annexxure-C : Material Safety Data Sheets of Sulphuric Acid

Annexxure-D : Material Safety Data Sheets of Ethanol

Annexxure-E : Material Safety Data Sheets of Diesel

Annexxure-F : Incident Reporting Format –For Compilation

Annexxure-G : Resource Mobilization (Men and Equipment) to be Kept Ready


in Due Course of Time

Annexxure-H: List of Relevant Statutes on Management of Hazardous


Substances

Annexxure-I: The Important Roles And Responsibilities Of Various


Stakeholders

Annexxure-J: Plant Layout with marking of Assembly Points

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1. INTRODUCTION

The adoption of new technologies has worked marvels for industry, while consumer
has been benefited from this commercial boom; the nation has also been able to set
a brisk pace of industrial growth. This augurs well for everyone. However, there is a
need to be cautious in dealing with these technological changes. If not handled
properly, they can create several environmental problems: contamination of water
resources, coal and ash dust, mist, particulate etc. Atmospheric changes as well as
loss of precious plant and animal life. These hazards also endanger human life.

Chemicals which are hazardous like Acids, Liquid Ammonia, HCL, H2SO4& Alum
materials which are inflammable like Lubricating and Servo Oil, Rice Husk, Light
Diesel Oil are being more widely used in distillery plants. Improper handling of
these materials, may lead to uncontrollable hazards, costly accidents and in rare
cases may lead to disasters.

In the wake of such disasters, legislation has been enacted to tighten safety norms.
But there is still scope for system failures. In order to generate emergency plan,
each part / section of the plant of the complete plant as a whole need to be studied
and analyzed critically from safety point of view. To control effectively the rise of
such situations, it is imperative to plan “ON –SITE EMERGENCY PLAN”.

Awareness of total plant operations and strict adherence to environmental safety


standards is an integral part of our operations. An environmental protection
department has been established and working efficiently to monitor all
environmental related activities.

In managing an emergency (fire, explosion and hazardous release) one has to


consider whether the life and health of the employees, contract staff & workers
working in the plant are endangered as also is there any damage to property.This
manual will generate awareness among all the employees, contract staff & workers,
working in plant premises, to adhere to environmental safety standards and also
provide information for managing any emergency effectively.

After the incident of Bhopal gas disaster and supreme court directions in case
of M/S. Sriram Foods and Fertilizers, the Govt. of India has made some important
amendments to the Factories Act 1948 in the year 1987 with incorporation of
special provisions relating to hazardous process and a new chapter i.e. Chapter IVA
under which the provisions like sections 41A, 41B, 41C, 41D, 41E, 41G & 41H

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covering all hazardous process industries are added. Under the provision of Section
41-B (4) every occupier shall with the approval of the Chief Inspector of Factories
draw up an On-site Emergency Plan and detailed disaster control measures for his
factory and make known to the workers employed therein and to the general public
living in the vicinity of the factory the safety measures required to be taken in the
event of an accident taking place. This is the statutory provision laid down in the act
for preparation of On-site Emergency Plan to control disaster in the factories. Any
accidents may cause emergency and it may lead to disaster, which may cause heavy
damage to plant, property, harm to person and create adverse affects on production.

The manufacturing process carried out in M/s Malbros International Pvt. Ltd.,
Village-Mansoorwal, Tehsil-Zira, Faridkot Road, District-Ferozepur, Punjab,
India comes under the category of Hazardous Process at Item Number 12 as
“Fermentation Industries (Distilleries and Breweries)” in The First Schedule made
under the Section 2 (cb) of the Factories Act, 1948. The need of the onsite
emergency plan was felt due to the statutory requirement as applicable to the
hazardous process under different legislations by State as well Central
Governments. This Onsite Emergency plan is made to comply with the Section 41-
B(4) of the Factories Act, 1948 as applicable to this plant.

Although the similar provisions regarding onsite emergency plan also exists under
Rule 13 of the Punjab Control of industrial Major Accident Hazards Rules, 1993
and Rule 13 of Manufacture, Storage and Import of Hazardous Chemicals Rules,
1989 but these rules are only applicable to MAH units which derive this designation
if they store or process some threshold quantities of different chemicals as specified
in schedules annexed to PCIMAH Rules-1993 & MSIHC Rules-1989.

Also it is recommended to participate actively and become a active member of


different meetings or mock drills conducted by district and local crisis groups
constituted under Emergency Planning, Preparedness & Response for Chemical
Accidents Rules-1996. Along with this regular interaction with other group
members, departments, governmental agencies and in particular office of
Directorate of Factories which will give exemplary exposure in handling different
types of emergencies.

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2. PROFILE OF THE COMPANY

Company introduction and its work profile


The Oasis Group of Companies‟ is a fast growing conglomerate having diversified
business operations in the field of Distilleries, Breweries, Hospitality, Diamonds,
Exports and Government Contracts. Oasis Group in the year 1987. Since, then the
Oasis Group has a remarkable growth and within a span of almost 30 years has
emerged to be one of the fastest growing liquor group.

Pride of Indian liquors, „The Oasis Group of Companies‟ was incepted in the year
1987. Since then the Oasis Group is growing by leaps and bounds operating in the
field of Distilleries and Breweries. The Oasis Group has a turnover of Rs. 1500
crores in 2014-15 and targets to achieve Rs. 2000 crores by the next financial year.
The Oasis Group presently operates 5 distilleries across the country with a
collective production of approximately 20 crores litres of Grain Based Extra Neutral
Alcohol, making it one of the largest Grain Spirit producers in the Country.

The Group enjoys a very important position amongst the liquor companies in
Punjab by virtue of owning two „State-of-the-Art‟ Grain Distilleries at Ferozepur
and Bhatinda and a bottling unit at Sandhe Hasham-Ferozepur, further
complemented with substantial wholesale and retail outlets which has helped the
Group cover the complete channel of liquor distribution thereby making it a major
player in Punjab.

Oasis Group is a significant player amongst the emerging Indian spirits market with
their International Quality Grain based spirits, Indian Made Foreign Liquor with
consistency of quality, delivery, superior consumer experience, thereby creating
maximum value amongst its connoisseurs.

With the introduction of its Premium Whisky-Blue Patrol, an Imported Vatted Malt
Scotch blend this year, the Oasis Group stands firm with yet another launch of
Super Premium Whisky with dynamic Packaging and blend by next year. The Oasis
Group now plans to broaden its brand base by entering into Semi premium &
Premium Segments in Whisky, Brandy and White Spirits.

Presently the Oasis Group operates in approximately 18 states in India, besides


Union Territories and is also exporting to a number of countries. The Oasis Group
operates in most of the prominent civil Indian Made Foreign Liquor markets. Since
the Oasis Group is a preferred supplier to the Canteen Stores Department (CSD)
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which caters to the Esteemed Indian Armed Forces, the Oasis Group enjoys an
absolute PAN India presence for its IMFL brands.

The Oasis Group provides different varieties of whiskey, vodka, rums scotch etc.
The Oasis Group supports old age homes, hospitals etc.

The Oasis Group has already launched a Pure Herbal Diet Whisky which is blended
out of Aloe Vera, Ginseng & Garcinia. The Oasis Group hopes to project this blend
as a health conscious Whisky.

The group is in the process of launching a tripled distilled Green Apple and Orange
flavored Vodka in the Premium Segment shortly, besides a Premium Grapes Spirit
Brandy for the South Indian market.

Oasis Group is the leading group having five state of the art distilleries in India that
produces Extra Neutral Alcohol (ENA) from grain. The Oasis Group presently
operates 5 distilleries across the country with a collective production of
approximately 18 crores litres of Grain Based Extra Neutral Alcohol, making it one
of the largest Grain Spirit producers in the Country.

Oasis Group boasts of providing the finest quality of ENA that is formulated as per
industrial norms and standards. The Oasis Group also exports Extra Neutral
Alcohol in different parts of the world.

Oasis Group is one of the largest IMFL (Indian Made Foreign Liquor) producers in
the country. It is a significant player amongst the emerging Indian spirits market
with its International Quality Grain based spirits, Indian Made Foreign Liquor with
consistency of quality, delivery, superior consumer experience, thereby creating
maximum value amongst its connoisseurs. Oasis Group is first of its kind in the
country which has sophisticated in-house facilities to produce molasses and non-
molasses based neutral spirits from completely automated Distillation Plants.

Oasis group is the top manufacturer of producing Country Liquor in India with a
sizeable market share. It aims to provide premium quality Country liquor to an
ordinary man, who savors its taste, at the most reasonable rate, Oasis Group aims to
create a stronghold in the country liquor market and intends to extend the depth of
supply coverage for reaching untapped markets and pursue growth by increasing
their penetration in more states and setting up more production units in other
locations. Oasis Group has almost track record of manufacturing quality ethanol,

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extra neutral alcohol and producing quality ethanol, rectified spirits, extra neutral
alcohol and potable country liquor.

Oasis Group specializes in making Distillers Dried Grain Soluble (DDGS), which is
a cereal by product of the ENA production process. The Oasis Group is one of the
largest producers of high nutrient DDGS in India with protein content of minimum
45%. DDGS is an excellent feed ingredient for livestock and poultry diets.

Oasis DDGS are highly digestible, increases efficiency, enhances palatability and
lowers toxicity. Our state-of-the-art distilleries are completely compliant with top-
notch quality norms. Moreover, great care is taken to maintain international
standards of hygiene and handling.

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3. GENERAL INFORMATION OF PLANT

The Malbros International Pvt. Ltd.layout is shown in the figure below.

Incorporated in 2007, Malbros International Pvt. Ltd. is a leading alcoholic


beverage company, which accounts for the manufacture of a special range of
branded Whiskey, Country Liquor, Rum, Vodka and Gin. MIL Distillery is one of
the most efficiently-run distilleries in India manufacturing high grade Extra Neutral
Spirit (ENA) from Grain with a production capacity of 1.2 Million Litres per annum
of Grain Neutral Spirit. It is a state-of-the-art grain based distillery at „Zira‟ district
Ferozepur, Punjab. It is an integrated plant having facilities for producing Rectified
Spirit ENA 90000 and Bottled Liquor.

The Unit is self-sufficient in meeting the fuel and power requirement by way of
backward integration of utilizing its effluent for generating the bio-gas which, in
turn, is utilized for generating the steam and power for its captive requirement.MIL
Distillery also manufactures various brands of IMFL and Country Liquor.
In dry milling, the entire starchy grain is first ground into flour, referred to in the
industry as “meal,” and processed without separating out the various component
parts of the grain. The meal is slurried with water to form a “mash.” Enzymes are

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added to the mash to convert the starch to dextrose, a simple sugar. Ammonia is
added for pH control and as a nutrient to the yeast.

The mash is processed in a high-temperature cooker to reduce bacteria levels ahead


of fermentation. The mash is cooled and transferred to fermenters where yeast is
added and the conversion of sugar to ethanol and carbon dioxide (CO2) begins.

The fermentation process generally takes about 40–50 hours. During this part of the
process, the mash is agitated and kept cool to facilitate the activity of the yeast.
After fermentation, the resulting “beer” is transferred to distillation columns where
the ethanol is separated from the remaining “stillage.” The ethanol is concentrated
to 190 proof using conventional distillation and then is dehydrated to approximately
200 proof in a molecular sieve system.

The stillage is sent through a centrifuge that separates the coarse grain from the
solubles. The solubles are then concentrated to about 30 percent solids by
evaporation, resulting in Condensed Distillers Solubles (CDS) or “syrup.” The
coarse grain and the syrup are then dried together to produce Dried Distillers Grains
with Solubles (DDGS), a high quality, nutritious livestock feed. The CO2 released
during fermentation is captured and sold for use in carbonating soft drinks and
beverages and manufacturing dry ice.

POSTAL ADDRESS OF FACTORY:


Malbros International Pvt. Ltd.
Village Mansoorwal, Tehsil Zira
District Ferozepur
Punjab, India. 142047
Phone: 01682- 262107, Fax: 01682-262007
Cell: 099148-00006, 098140-94394
E-mail: malbros@ymail.com

REGISTRED OFFICE:
Oasis group of companies
HD-8, Pitampura, Near Madhuban Chowk,
New Delhi - 110026, India
Phone:+91 - 011-27312685, 011-25229720,
011-25229721Fax: 011-27317765
Cell:+91 - 9899450255, 9873900090
Email: info@oasisgrp.in

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Demographic Information of Plant


The site for the Distillery and Bottling Project is located on Zira-Faridkot road
(N.H. 54) about 8.5 km from Zira town towards Faridkot, Ferozepur District. It is
situated near about 2.4 km to Sugar Mill Zira. The site falls under seismic zone IV.
The average mean daily maximum ambient temperature is about 350C and the
relative humidity ranges between 25%-75%.
The different demographic establishments that fall under 5km from plant are: -

S.No Name of Villages


1 Ratol Rohi
2 Mansoorwal Kalan
3 Mansoorwal
4 Sunehar
5 Bhandala purana
6 Mahian Wala Kalan
7 Wakilan Wala

Working Hours:

Shifts Hours Employees strength in


each shift
1St Shift 6:00am to 2:00pm 40
2nd Shift 2:00pm to 10:00pm 40
3rd shift 10:00pm to 6:00am 40
General 9:00am to 6:00pm 100

(General Shift With lunch break from 1.00PM to 2.00PM and 30 Minutes by
rotation in other regular shifts)

Weekly Holiday for General Shift: Sunday

Weekly Holiday for Shift: Any one of the week day during the Week

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4. TECHNICAL FEATURES OF PLANT

1. Grain Storage:
Grains are procured from various sources, such as FCI Storage godowns through
agencies and are unloaded into large Storage Silos after Pre-Cleaning. Storage Silos
are specially designed to keep the Grains in good condition for longer durations and
also avoid its deterioration and theft, etc. It is being proposed to have 30 – 45 days
of Grain Storage facility in the Distillery.

2. Grain Cleaning, Milling and Flour Handling:


The grain is lifted in bucket elevators, screened followed by removal of stones and
iron matter. Cleaned Grains are then milled using dry milling process in Hammer
Mills. The flour is fed through the bucket elevator and conveyed to the Batch
Tipping Machine through a Screw Conveyor. The flour addition is metered through
the Batch Tipping Machine with load cell arrangement, before transferring the flour
to the Slurry Tank through another Screw Conveyor (pre-masher) for slurry
preparation process. It is being proposed to have 4 x 16 TPH as milling
paraphernalia for this Distillery.

3. Slurry Preparation & Liquefaction:


Grain flour and process water is fed at controlled rate to Initial Liquefaction tank.
Mixed slurry is taken to the Initial Liquefaction Tank where additional quantity of
water is added as per requirement. Viscosity reduction Enzyme and stabilizing
chemicals and a portion of liquefying enzyme are also added at this stage. This
slurry is then “cooked” in the jet cooker.

The slurry is continuously pumped to a steam jet cooker where high-pressure steam
rapidly raises the slurry temperature. The mixture of slurry and steam is then passed
through the Retention Vessel. The retention vessel has sufficient capacity to provide
the desired retention time at a given flow rate. The cooked mash is discharged to a
Flash Tank. The cooking process, accomplished in the above manner, converts the
slurry into a hydrated, sterilized suspension and is therefore susceptible to enzyme
attack for liquefaction. The gelatinized mash from the Flash Tank is liquefied in the
Final Liquefaction Tank where liquefying enzyme (alpha-amylase) is added. The
liquefied mash is cooled in Mash Cooler and transferred to Saccharification cum
fermentation section. This process initiates the formation of sugar. The gelatinized
mash from the Flash Tank is liquefied in the Final Liquefaction Tank where
liquefying enzyme (alpha-amylase) is added. The liquefied mash is cooled in Mash
Cooler and transferred to Saccharification cum Fermentation section.

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4. Hi-ferm-Nm Saccharification and Instantaneous Fermentation:


Yeast Activation:
Yeast seed material is prepared in water-cooled Yeast Activation Vessel
by inoculating sterilized mash with Active Dry Yeast. Optimum temperature is
maintained by cooling water. The contents of the Yeast Activation Vessel are then
transferred to Fermenter.

5. Saccharification & Instantaneous Fermentation:


The Liquefied starch slurry comprising Dextrins is partly taken for Yeast
development in Yeast Activation vessel and majorly transferred into the Fermenter.
Amyloglucozydase and other nutrient Enzymes are first added to Saccharify
the Starch Slurry causing formation of Sugars. Immediately, the Active Yeast is
introduced in the system for simultaneous Fermentation. The process of
fermentation is to convert the fermentable substrate into alcohol. To prepare the
mash for fermentation, it may have to be diluted with water. The pH of the mash is
adjusted by the addition of acid. Yeast is available in sufficient quantity to initiate
fermentation rapidly and complete it within the cycle time. At the start of the cycle,
the fermenter is charged with mash and contents of the Yeast Activation Vessel.
Significant heat release takes place during fermentation. This is removed by
passing cooling water through the Fermenter PHE‟s to maintain an optimum
temperature. The recirculating pumps also serve to empty the fermenters into Beer
Well. After the fermenters are emptied, they are cleaned with water and
caustic solutions and sterilized for the next batch. The carbon dioxide evolved
during the process is vented to atmosphere after recovery of alcohol in a scrubber.

6. Ethanol Distillation:
Fermented wash from wash holding tank T-01 is pumped by wash feed pump P-01
to the top of degassing column (C-2) after preheating the same in beer heater E-02
and spent wash heat exchanger E-01. The vapors along with non-condensable gases
from the top of degassing column (C-02) are rectified in Heads column (C-03), to
expel the high volatiles, technically known as heads. Bottom liquid from the
degasser flows into analyzer column (C-01) where alcohol is stripped from the
liquid. The liquid from bottom of analyzer column (C-01) is completely stripped of
alcohol and is pumped out by thick slop discharge pump P-02 through heat
exchanger E-01 where it preheats the fermented wash before it enters degassing
column. The slop from the analyser column will be feed in to decanter. The dilute
alcohol vapors from near the top of analyzer column (C-01) are condensed first in

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beer heater (E-02) while exchanging heat with wash feed and then in analyzer
condenser (E-03). Degasser and analyzer operate under vacuum. The condensate
from E-02 and E-03 is collected in Rectifier Feed Tank V-02. The vapors for
stripping alcohol are generated from analyzer column bottom liquid in the analyzer
column re-boiler (E-04) by using the rectified column top vapors, as discussed
subsequently. Vapors from the top of heads column (C-03) are condensed in heads
column condenser (E-06) and then in head column vent condenser (E-07). Part of
the condensate is returned to column C-03 as reflux while a small portion is taken
out as an impure spirit cut. Liquid from bottom of C-03 is also taken into Rectified
feed tank V-02.Dilute alcohol water mixture from rectifier feed tank (V-02) are
pumped by rectifier feed pump (P-04) through rectifier feed pre-heater E-11 in
to rectifying column (C-04). Rectifier and its associated equipment work under
pressure so that these vapors can supply the necessary heat for generating the
vapors.

The condensate from E-04 is then pumped as Reflux to rectifying column C-04.
Rich alcohol vapors at a concentration of 95.5% v/v from top of rectifying column
(C-04) are condensed first in Analyzer (E-04) and then in Reflux Vent Condenser
(E-05). The liquid from E04 and E-05 are collected in Rectifier Reflux Tank (V-
01). Part of the liquid from E-05 may be drawn off as impure spirit. The impure
spirit cut will be maintained as little as possible to maintain aldehyde levels to meet
the required limits in Absolute Alcohol. Liquid from the reflux tank (V-01) is
pumped by Product Pump (P-03) partly as product and partly as reflux to the top of
the Rectifying Column (C-04). The necessary rectifying vapors to C-04 are
generated by boiling the C-04 bottom liquid in Rectifier Column Re- boiler E-08
using medium pressure steam. Some side streams are drawn from rectifier column
as light and heavy fractions of higher alcohols called fusel oils and cooled in fusel
oil coolers E-09 and E-10 and are mixed with water and allowed to separate out in
fuel oil separator F-01. All vents from E-03, E-07, V-02 and E-05 are connected to
Vent Gas Absorber (C-05) where the vent gases are scrubbed with water to recover
entrained alcohol. The scrubber water is used for washing the fuel oils in fuel oil
separator to recover alcohol from the fuel oil fractions. The absorber vent is
connected to vacuum pump (G-01) which is used to create vacuum in the analyzer
and degasser. Absolute alcohol is manufactured by dehydration of Rectified
Spirit. The process adopted here is based on Pressure Swing Adsorption (PSA)
system using Molecular Sieves (3-A). The flow scheme is shown in above referred
flow diagram. Rectified spirit, after preheating by waste hot streams, is vaporized
and superheated in E-03 and E-04 by using medium pressure steam at 6 Kg/cm2g
pressure. Hot vapors at kg/cm² g pressure and 130° C temperature pass through
PSA column S-01A/S-01B where the water vapors are retained while water free

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alcohol is released as vapors. The vapors are condensed in E-07 and E-08 and
collected as Absolute Alcohol. When the molecular sieve bed is saturated with
water the alcohol vapors are shifted to the other tower and the first tower is taken
for regeneration. Regeneration is done first by pressure releasing and creating
vacuum and then by elutriating with dehydrated alcohol vapors from the tower in
dehydration operation. The vapors are condensed in E-06 and E-05 and the vent
vapors are recovered through scrubber C-02. Vacuum can be created vacuum by P-
04. (Eductor may also be considered for this duty). Product is cooled in E-09 and
transferred to Absolute Alcohol receiving tank and then on to storage tank. This
process utilizes the following columns namely Analyser, Degassifier, Aldehyde,
Pre-Rectifier Column, P/R Stripper Column, Rectifier-cum Exhaust, Extractive
Distillation (ED) Column, Fusel Oil Concentration Column and Simmering
Columns. The Analyser, Degassifier, Aldehyde, Pre-Rectifier Columns are
operated under Vacuum whereas Simmering, Extractive Distillation, FOC Columns
are operated under Atmospheric condition. The Rectifier-cum-Exhaust Columns are
operated under Pressure.The energy requirement for Analyser Column & Pre-
rectifier is met by Rectifier Column top vapours. The Rectifier Column top vapours
are condensed in a thermo-siphon reboilers connected to a flash tank and then flash
vapours out of soft water feed are injected into Analyser Column.

The energy requirement of the Simmering Column is met by the top vapours of
Extractive Distillation Column while that of the FOC Column is through direct
steam. In the distillation scheme offered, all Columns are designed for all the
products.

7. Alcohol Daily Receivers & Bulk Storage:


Alcohol is first taken to Daily receiver storage tanks, which is based on the State
Excise laws, storage for three days considering the weekly holidays of two days.
Thereafter, the alcohol is transferred to Bulk Storage Tanks after taking the daily
receiver Dip. This is transferred using flameproof pumps. Final dispatch of alcohol
is metered and again is carried out using special flameproof pumps. The Bulk Spirit
Storage is proposed to be set up for 30 days.

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5. EFFLUENT HANDLING SECTION


1. Decantation Section:
Decantation section comprises of Centrifuge Decanters, operating at high rpm
which are used for separation of suspended solids from Spent Slops coming out of
Distillation section. The Wet cake thus separated has 30-35% w/w solids, as
removed from bottom of Decanters. This is directly loaded on the trolleys parked
below. Thin slops coming out of Decanter are collected in a tank and are transferred
for part recycle & further for Evaporation into thick syrup.

2. Integrated Evaporation Section:


The suggested treatment scheme is a 5 FF and 2 Forced circulation Evaporation
Plant forThin Slops Evaporation. The following points will elucidate the basic
working principle:
 Shell & Tube type Evaporators with highly efficient liquid distributor
working on the principle of Falling Film Evaporation have been used,
with Plate type Pre-heaters for preheating of FEED stream which serves the
purpose of energy conservation.
 Simmering and ED column vapour is fed to the fifth and sixth effect
evaporator shell side at the given pressure and temperature as the heating
medium.
 The Feed from the Feed balance tank is taken to the PHCOND to make the
best heat recovery.
 The Feed after getting heated to the predetermined temperature in preheater
is fed from the first effect evaporator which is Falling Film Evaporator -1
 The flow path isgiven below.

INLET FEED – E5 – E6-E3-E4- E7-E2 – E1 – OUTLET PRODUCT

 Vapour generated in1st effectVLS (VapourLiquidSeparator) are used as heat


source in the 2nd effect.
 A Shell & tube type Multi-pass Surface condenser is employed for
condensing the shell side vapours.
 The Pure and the process condensate are collected in receiving vessels.
 Highly efficient operating pumps will be provided for pumping the required
fluid.The operation of the plant will be under vacuum. Vacuum is created
with the help of a waterring vacuum pump.
 The plant will have high level of automation to get consistent output at
required concentration.

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 The system operates under vacuum. Water-ring vacuum pumps are used
to maintain a desired vacuum.
 Cooling water from cooling tower is used in the surface condensers for
condensing the vapours.

CONCLUSION
The thick syrup thus obtained is mixed with the Wet Cake obtained from Decanter
Centrifuges using specially designed Ribbon type mixer and this enriches the
protein content in the fibrous suspended solids separated earlier in Decanter. This
Protein & Fiber rich DWGS is directly sellable as Cattle/ Poultry Feed. However,
in order to increase the shelf life of such by-product, it is necessary to dry the
product,with minimum possible moisture content.

System Description For DWGS Dryer


Wet distiller‟s grains shall be fed into the dryer housing at controlled rate through a
suitable feeding system. The Rotary Tube Bundle is enclosed in an insulated
dryer housing and on its outer flights are fixed. Dry saturated steam is to be
supplied to the tube bundle through rotary joint at one end & the condensate is
discharged through rotary joint mounted at other end.

During the course of rotation, these flights pick up the material and shower them on
to the tube bundles. The heat transfer is primarily by conduction. The water
vapours are exhausted through an Exhaust Blower & passed through a cyclone
separator for separating fines.Dry product partially recycled back to Feed
conditioner for feed conditioning through Product Screw & Recycle Conveyor.
Entire operation of the Dryer is controlled through Control panel.

System description for cooling & conveying


 DWGS below product screw is discharged into charging hopper of pneumatic
conveying system.
 Rotary feeder feeds it into the conveying line.
 Ambient air is used for conveying.
 The material gets conveyed to product collector &discharged from rotary
discharge valve.
 Exhaust air is vented to atmosphere.
 The conveying system is lean phase suction type, using centrifugal blower as
prime mover. The conveying air quantity is designed considering cooling
requirement & to cool the product before discharge.

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6. TERMINOLOGIES RELATED TO HAZARDS

Following are the list of definitions used in this document, unless the context
otherwise requires: -

a) “boiling liquid expanding vapour explosion (BLEVE)” means the violent


rupture of a pressure vessel containing saturated liquid or vapour at a temperature
well above its atmospheric boiling point and the resulting flash evaporation of a
large fraction of the superheated liquid which produces a large vapour cloud which
burns in the form of a large rising fireball due to ignition;

b) “chief incident controller” means the person who assumes absolute control of
the unit and determines action necessary to control the emergency;

c) “disaster” means an occurrence of such magnitude as to create a situation in


which the normal patterns of life within an industrial complex are suddenly
disrupted and in certain cases affecting the neighborhood seriously with the result
that the people are plunged into helplessness and suffering and may need food,
shelter, clothing, medical attention protection and other life sustaining
requirements;

d) “disaster management plan “mean a well-coordinated, comprehensive response


plan to contain loss of life, property, environment and provide speedy and
effective recovery by making the most effective use of available resources in case
of a disaster;

e) “emergency” means a situation or scenario which has the potential to cause


serious danger to persons, environment or damage to property and which tends to
cause disruption inside or outside the premises and may require the help of outside
resources;

f) “hazard” means an event related to the property of substance or chemicals with


a potential for human injury, damage to property, damage to the environment, or
some combination thereof;

g) “incident” means an unplanned or unintended or intended event having potential


to cause damage to life, property and environment;

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h) “incident record register” means a register containing complete information


pertaining to all incidents covering near miss, and all other incidents leading to
Level-I, Level-II and Level-III emergencies;

i) “leak” means release or discharge of a dangerous chemicals or substances or


material into the environment;

j) “Level-I emergency” means an emergency as defined under below;

k) “Level-II emergency” means an emergency as defined under below;

l) “Level-III emergency” means an emergency as defined under below;

m) "occupier” of an installation means the person who has ultimate control over
the affairs of the installation;

n) “off-site emergency” means an emergency that takes place in an installation and


the effects of emergency extends beyond the premises or the emergency created
due to an incident, catastrophic incidents, natural calamities, etc. It no longer
remains the concern of the installation management alone but also becomes a
concern for the general public living outside and to deal with such eventualities
shall be the responsibilities of district administration;

o) “off-site emergency plan” means a response plan to control and mitigate the
effects of catastrophic incidents in above ground installation (AGI) or
underground installations (UGI) or road transportation. This plan shall be prepared
by the district administration based on the data provided by the installation(s), to
make the most effective use of combined resources, i.e. internal as well as external
to minimize loss of life, property, environment and to restore facilities at the
earliest;

p) “on-site emergency” means an emergency that takes place in an installation and


the effects are confined to the Installation premise‟s involving only the people
working inside the plant and to deal with such eventualities is the responsibility of
the occupier and is mandatory. It may also require help of outside resources;

q) “on-site emergency plan” means a response plan to contain and minimize the
effects due to emergencies within the installations which have a potential to cause
damage to people and facilities within the installation premises;

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r) “risk” means the chance of a specific undesired event occurring within a


specified period or in specified circumstances and it may be either a frequency or a
probability of a specific undesired event taking place;

s) “risk analysis” means the identification of undesired events that lead to the
materialization of a hazard, the analysis of the mechanisms by which these
undesired events could occur and, usually, the estimation of the extent, magnitude,
and likelihood of any harmful effects;

t) “risk assessment” means the quantitative evaluation of the likelihood of


undesired events and the likelihood of harm or damage being caused by them,
together with the value judgments made concerning the significance of the results;

u) “risk management” means the programme that embraces all administrative and
operational programs that are designed to reduce the risk of emergencies involving
acutely hazardous materials. Such programs include, but are not limited to,
ensuring the design safety of new and existing equipment, standard operating
procedures, preventive maintenance, operator training, incident investigation
procedures, risk assessment for unit operations, emergency planning, and internal
and external procedures to ensure that these programs are being executed as
planned;

v) “site incident controller” means the person who goes to the scene of the
emergency and supervises the actions necessary to overcome the emergency at the
site of the incident;

w) “spill” means an unintended release or discharge of hydrocarbon or any other


dangerous liquid into the environment;

x) “transport emergency (TREM) card” means a card containing details about the
nature of hazards, protective devices, telephone numbers and actions related to
spillage, fire, first aid and other details of national and international (UN) numbers
or signage which is common in India and abroad;

y) “unconfined vapour cloud explosion (UVCE)” means the formation of vapour


cloud due to release of significant quantity of liquefied hydrocarbons into the
atmosphere and its explosion due to ignition which may cause high over pressure
and low pressure that cause very heavy damage.

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7. DIFFERENT PHASES OF DISASTER

In view of the hazards associated with Fermentation Industries (Distilleries and


Breweries) it is required to develop on-site emergency plan. Such plan will ensure
establishment of a system, which would make optimum use of available resources
for speedy containment of the disaster, protecting the health and safety of people,
nearby residences and workers as well as minimizing damage to property and
environment. There are other external agencies involved in the activities associated
with disaster situation e.g. Civil Administration, Fire services, Medical, Police,
Army, Voluntary organizations etc., which calls for an organized multi-disciplinary
approach to disaster management.

 Warning Phase
Many disasters are preceded by warning signals like liquid hydrocarbons leaks
developing into vapor cloud, weather forecast giving advance warning of
meteorological disasters, uncontrolled chemical reactions ending up in explosion
etc. Warning phase provides a cushion to put into action the remedial measures to
counter the disaster.

 Period of Impact
This is the period when the disaster strikes and very little can be done to minimize
its impact. This period can last for a few seconds (as in case of explosions) to many
days (as in case of tank fire, natural calamities etc.)

 Rescue Phase
The rescue phase starts immediately after the impact and continues until necessary
measures are taken to rush help to combat the situation and to evacuate people to
safer places.

 Relief Phase
During this phase relief measures are organized internally. External help can also be
summoned to augment the internal resources.

 Rehabilitation Phase
This is the final phase in disaster management, during this period, estimating the
damages, payments of compensation, rebuilding the damaged property etc. are
done. Inter disciplinary effort, total co-ordination within the organization is required
to be implemented and aid from statutory bodies, experts can be availed.

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8. SCOPE , INTENT AND OBJECTIVE OF PLAN

SCOPE

The scope shall cover:

(i) the identification of emergencies;


(ii) the mitigation measures that attempt to reduce and eliminate the risk or
disaster;
(iii) the preparedness that to develop plans for actions when disaster or
emergencies occur;
(iv) the responses that mobilize the necessary emergency services including
responders (primary, secondary and tertiary) like fire service, police service,
medical service including ambulance, government as well as non-
governmental agencies;
(v) the post disaster recovery with aim to restore the affected area to its original
conditions;

INTENT

It is intended to apply this document –

(a) to develop an ONSITE EMERGENCY PLAN (OEP)that should be concise


and informative so that members of the emergency control organization should
be able to quickly refer to the action plan to determine important functions that
are being carried out;
(b) to manage an emergency and not to use OEP just as reference material for
training and shall be made applicable -
(i) to prevent casualties - both on-site and off-site;
(ii) to reduce damage to property, machinery, public and environment;
(iii)to develop a state of readiness for a prompt and orderly response to an
emergency and to establish a high order of preparedness (equipment,
personnel) commensurate with the risk;
(iv) to provide an incident management organogram with clear missions and lines
of authority (incident command system, field supervision, unified command);
(v) to ensure an orderly and timely decision-making and response process
(notification, standard operating procedures);
(vi) to maintain good public relations;

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Note: No two locations shall be identical in respect of layout, surroundings,


products, storage quantities, meteorological data etc. Therefore, ONSITE
EMERGENCY PLAN (OEP) will be location specific as per the available
resources.

OBJECTIVE

Objective of the plan are to provided a system, capable of taking fast and effective
action in a emergency situation in order to :-
i. Safe guard the factory personnel inside & public outside the factory.
ii. Effect the rescue & treatment of causalities.
iii. Safe guard the property and environment.
iv. Bring the incident under control.
v. Treatment of casualties, Head count, and information and assisting relatives.
vi. Provide authorities information to the news media.
vii. Ensure rapid return to normal operation after emergency.
viii. Preserve relevant records and equipment‟s the subsequent inquiry.
ix. Developing factory personal to ensure its at no panic on such occasion of
safe, skilled, action will minimize the casualities, injuries and damages of
other nature.
x. To maintain & culminate good image in public & National interst.

Elimination will require prompt action by operations and works emergency


staff using, for example, fire–fighting equipment, water sprays etc.
Minimizing the effects may include rescue, first aid, evacuation, rehabilitation
and giving information promptly to people living nearby.

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9. CLASSIFICATION & DESCRIPTION OF EMERGENCIES

The views of the possible hazards that can arise out of the daily operations in the
distillery plant, various measures are adopted to prevent the occurrence of a major
accident. This comprises of:
 Built in safety measures, alarms, trips and interlocks etc.
 Standard safe operating and maintenance procedures permit system etc.
 Training of all the involved staff in normal and emergency operating
procedures.
 Training of all employees in safety, fire fighting and first aid.
However, in spite of these precautions, it is required to foresee situation of major
accident and plan for taking timely action to minimize the effects of such incident
on the safety and health of persons working in the plant as well as those living
around the premises. Generally, Emergencies can be categorized into three broad
levels on the basis of seriousness and response requirements, namely: –

Level 1: This is an emergency or an incident which


a) can be effectively and safely managed, and contained within the site, location
or installation by the available resources;
b) Has no impact outside the site, location or installation.

Level 2: This is an emergency or an incident which –


a) cannot be effectively and safely managed or contained at the location or
installation by available resource and additional support is alerted or
required;
b) is having or has the potential to have an effect beyond the site, location or
installation and where external support of mutual aid partner may be
involved;
c) is likely to be danger to life, the environment or to industrialassets or
reputation.

Level 3: This is an emergency or an incident with off-site impact which could be


catastrophic and is likely to affect the population, property and environment inside
and outside the installation, and management and control is done by district

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administration. Although the Level-III emergency falls under the purview of


District Authority but till they step in, it should be responsibility of the unit to
manage the emergency.

Level-I and Level-II shall normally be grouped as onsite emergency and Level-III
as off-site emergency according to the hazards/risks associated as follow:

Sr No Type of Applicable Causes of Emergency


Emergency Plan

Small Fire due to:

 Spilling from the flanges/Pipeline/


Hammer Blinds/Gate Valves
 Pinhole leakage from Pipelines
 Failure of gasket resulting in leakage

 Fire in Electric Panels, Oil Room and


alcohol storage
Onsite  Hazards in Waste treatment processes
1 Level – I Emergency
Plan  Minor Injuries & other risks in Cleaning
of barrels, which have held chemical
substances
 Exposure to fugitive dust, noise, and
other emissions
 Housekeeping practices requiring
contact with solid and liquid wastes
 Emission/spillage etc. from storage &
handling – without any fire

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Major Fire due to:


 Spillages from tank truck due to over
flow while loading
 Spillages from storage tank during
receipt.
 Floating roof getting struck in the
tank. Tank containment failure.
 Leakage from pipeline due to damage
by external sources, sabotage,
Onsite pilferage
2 Level – II Emergency  Failures caused by corrosion defects,
Plan
 Failures caused by miscellaneous
factors such as pipe material defects,
natural hazards
 Failure of mechanical structure
 Failure of civil structure
 Deposition of toxic pollutants in
vegetation / other sinks and possible
sudden releases due to accidental
occurrences
3 Level – III Offsite  Burst of product Pipelines inside
(Disaster) Emergency
& outside premises.
Plan
 Failure of storage tanks.
 Pool Fires
 Vapour cloud explosion.
 Agitation / forced entry by external

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group of people.
 Natural Perils – Earthquake, Flood,
Tsunami Sabotage, Bomb Explosion /
Threat.
 Exposure to pollutants released from
offsite/ storage/related activities
 Contamination due to accidental
releases or normal release in
combination with natural hazard

Further, Hazard analysis involves the identification and quantification of the


various hazards (unsafe condition) that exist in the plant. On the other hand, risk
analysis deals with the identification and quantification of the risk, the plant
equipment and Personnel are exposed to, due to accidents resulting from the
hazards present in the plant. Risk analysis involves the identification and
assessment of risks to the population exposed to hazards present. This requires an
assessment of failure probability, credible accident scenario, vulnerability of
population etc. Much of this information is difficult to get or generate
consequently, the risk analysis in present case is confined to maximum credible
accident studies and safety and risk aspect related to proposed Grain based
Distillery and power plant. Activities requiring assessment of risk due to
occurrence of most probable instances of hazard and accident are both onsite and
off-site.

Consequences of default or non-compliance


There shall be a system for ensuring compliance to the provision of these
regulations through developing a well-defined ONSITE EMERGENCY PLAN
(OEP) and conduction of mock drill and safety audits during the construction,
commissioning and operation phase, as well as on an on-going basis. There shall
also be a system of do‟s and don‟ts regarding safety, mock drills or real
emergencies for the visitors before entering an establishment. This should be
supported by written instruction sheet for the visitor and ensured that visitor is
accompanied by plant representative on forward visit and return gate.
1) The Board shall monitor the compliance of ONSITE EMERGENCY PLAN
(OEP), Technical Standards and Specifications including Safety Standards either

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directly or indirectly by accredited third party through separate regulations on


third party conformity assessment.
2) In case of any deviation or shortfall, in achieving the recommended standards
the entities are liable to penal provisions under the provisions of the technical
standards, specifications including safety standards.

DIFFERENT EMERGENCY SCENARIOS- Onsite / Offsite Emergency

Emergency Scenarios Threats


Serious injuries / Fatality or illness
Medical Heart Attack/ Health related Issues
Fire & Explosion
Structural failure
Pipeline leak or rupture
Operational Sabotage
Flood
Cyclone
Natural Disasters Earthquake
Chemical /Lube Oil/ Hydrocarbon Product
spill
Environmental Volatile Vapour cloud release
Bomb threat
Sabotage
Security Kidnap and Ransom

 Natural Peril – Earthquake & Flooding


A flood possibility cannot be ruled out. Though floods are not likely to cause any
direct damage to distillery facilities or associated equipment, it may however cause
power/cable failures. Emergency shutdown system should be in place to tackle such
situations. Plant lies in Zone -3 of Earthquake zone.

 Sabotage / Bomb Threat


In case of any sabotage, the worst expected consequence would be a large release of
flammable hydrocarbons and/or fire involving property damage or harm to human.
Bomb threats could be real as well as hoax. However, all bomb threats should be
taken seriously. Details of the conversation should be immediately furnished to the
incident controller, who should in turn contact the local police as well as the district
collector. The employees and contractors shall be given training to prevent entry of

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unauthorized persons / material and sharing information on actual incidents of


sabotage/ terrorist activity.

PROBABLE CAUSES OF EMERGENCIES

The common causes for the above events are tabulated below for reference and the
ONSITE EMERGENCY PLAN (OEP) should be prepared by the installation to
deal with the following emergencies.

Man made Natural Calamities Extraneous

 Heavy Leakage  Flood  Riots/Civil


 Fire  Earth Quake Disorder/ Mob
 Explosion  Cyclone Attack
 Failure of Critical  Outbreak of Disease  Terrorism
Control system  Excessive Rains  Sabotage
 Design deficiency  Tsunami  Bomb Threat
 Unsafe acts  War / Hit by missiles
 In-adequate  Abduction
maintenance  Food Poisoning/
Water Poisoning

HAZARDS AND SAFETY MEASURES FOR STORAGE & HANDLING OF


ALCOHOL :

Physical Properties:
Chemical Formula : C2H5OH Molecular Weight : 456.

Sp. Gravity : 0.7147

Highly volatile, colourless, bitter in taste, surest smell, and highly inflammable
liquid. It is mixable in all proportions with water, eathers and other alcohol. Its flash
point is as low as 400 C and can catch fire at elevated temperature. It forms
explosive mixture with air, if mixed to the extent of 2.6% by weight. It has no
severe effect on skin or tissues if inhaled. It has fire hazard. Possible measures have
to be taken for arresting the same in time. Step has been taken to install sprinkler
system on and around the storage tanks.

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The alcohol will be directly fed to the bottling unit mechanically and no manual
handling will be involved which will reduce the risk of spillage in the storage area.
Following precautionary measures would be taken for safety:

Handling And Storage:


 Keeping away from heat, sparks and open flame, care will be taken for
avoidance of spillage, skin and eye contact, well ventilation, Use of approved
respirator if air contamination is above acceptable level will be promoted.
 Keeping away from oxidizers, heat and flames.
 Avoidance of plastics, rubber and coatings in the storage area.
 Cool, dry, & ventilated storage and closed containers.
 Grounding of the container and transferring of equipment to eliminate static
electric sparks.

In case of any emergency following measures would be taken:


• FIRST AID MEASURES: For Skin contact, Eye contact, & Inhalation.
• FIRE FIGHTING MEASURES:
Use of extinguishing media surrounding the fire as water, dry chemicals (BC or
ABC powder), CO, Sand, dolomite, etc

Foam System for firefighting will be provided to control fire from the alcohol
storage tank. The foam thus produced will suppress fire by separating the fuel from
the air (oxygen), and hence avoiding the fire & explosion to occur in the tank. Foam
would blanket the fuel surface smothering the fire. The fuel will also be cooled by
the water content of the foam. The foam blanket suppresses the release of
flammable vapors that can mix with the air.

Special Fire Fighting Procedures; Keeping the fire upwind. Shutting down of all
possible sources of ignition, keeping of run-off water out of sewers and water
sources. Avoidance of water in straight hose stream which will scatter and spread
fire. Use of spray or fog nozzles will be promoted, cool containers will be exposed
to flames with water from the side until well after the fire is out.
Hazardous Decomposition Products: gases of Carbon Monoxide (CO) & Carbon
Dioxide (CO2).

•ACCIDENTAL RELEASE MEASURES: For Spill Cleanup well Ventilation,


Shutting off or removal of all possible sources of ignition, absorbance of small
quantities with paper towels and evaporate in safe place like fume hood and burning
of these towels in a safe manner), Use of respiratory and/or liquid-contact
protection by the Clean-up personnel will be promoted.

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ELECTRICAL HAZARDS:

Though, flame, proof fittings are provided Electrical injuries may occur any where.
It may be caused by direct current, alternative current or from lightening. The
security of the injuries by electric shock depends upon :
1. The amount of current flowing through the body.
2. The path of current has 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 limits.
3. Length of the victim is in contact.
4. Type of electric energy AC or DC.
5. Physical condition of victim.

Following signs and symptoms are found in electric shocks:


1. Sudden spasm
2. May be unable to release hands which holds the live point.
3. Burns
4. Cries aloud and falls on the grounds.
5. Several pain.
6. Unconsciousness.
7. Breathing impaired or stopped.
8. Burns leading to severe surgical shocks.

FIRST AID / COUTNER MEASURING

Any delay in first aid in electric shock is a delay for ever, hence the person Giving
the first aid must not get excited and must not endanger his life.

1. The current must be cut off or the plug should be pulled out.
2. He must not touch the victim or the live conductor.
3. If it is difficult to cut the current, the victim has to be separated by using a
dry coat rope, stick etc.
4. If there is the dry wooden chair or rubber sheet, he must stand on it and then
separate the victim.
5. If the cloths are smoldering, the spark should be extinguished.
6. Artificial respiration is to be started immediately. This may be done
whenever the victim is in unconsciousness while the pulses. The artificial
respiration should be continued till the doctor has arrived one may like to continue
for atleast 8 hours before obarconing the case as dead.

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When the patient start swallowing, one may understand that spontaneous breathing
is being received. Artificial respiration should be continued till normal movement
of breathing is fully established as the respiration may falls again if left earlier.
7. A blanket should be out around the patient. The patient has be kept warm to
treat the shock. He may be given warm, sourest drink if he is conscious otherwise
not, as it may harm him.
8. Superficial bones of lightening strange may be covered with a septic
dressing. The deeper bums caused from contact with live conductors may be
covered with clean sheet and the patient taken to a hospital without any further
delay.
9. External cardiac massage may be given if the pulse is not felt or even
artificial respiration.

Power Cables
It is to be secured properly. It is to be protected from physical hazards. All junction
boxes should be protected and supported. Checking of ear things is necessary. All
junction box should be filled with compound.

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10. EMERGENCY MITIGATION & PREPAREDNESS


After determining the risk level, the following actions shall be required for
mitigation of emergency: -
a. Basic requirement of ONSITE EMERGENCY PLAN (OEP)
Basic requirement needs to be assessed prior to development of OEP as per the
requirements to handle Level-I and Level-II emergency.
b. Resource mobilization
Resource mobilization shall include manpower requirement, firefighting materials,
appliances or equipment, safety equipment, communication facilities, transport, list
of emergency drugs and appliances, etc. as given in Annexures.
c. Incident preventing measures and procedures.
The incident prevention measures and procedures at installation or other locations
shall include the following:-
a) health safety and environment (HSE) policy;
b) proper layout and inter facility distances (the layout should not have any
crisscross movement of men and materials);
c) safety committees with fair participation of Union leaders and workers;
d) safety audits and inspections shall be carried out with the help of prescribed
checklists.
e) work permit system (including confined space and entry permit);
f) early warning alarm system in the installation (gas monitoring system, heat
detection, high level alarms, low pressure/high pressure alarms etc.)
especially in the vicinity of storage tanks, filling station, delivery points and
along with periphery with the indication in the central control room;
g) in-built safety interlocks system in design such as safety relief valves (SRVs),
thermal safety valves (TSVs), non-returning valves (NRVs), remote operated
valves (ROVs) and other various emergency trip systems in Installations;
h) fire protection (preferably automatic) and HSE Management system;
i) drill for visitors including assembly procedure and escape route, do‟s and
don‟ts written instructions before entry, etc.;
j) setting up of safety MIS system and sending Exception reports to the head of
organizations or CEO;
k) all standby equipment‟s should be tried and operated periodically and
recorded. Similarly back up power for safety equipment and instrument
should be checked periodically and observations be recorded;
l) check points for incident prevention measures are also given in Chapter on
Incident Prevention Measures.

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d. Emergency Drills and Mock Exercises


(a) To evaluate the thoroughness and effectiveness of an OEP, it is necessary to
conduct periodic table top exercises full-scale or announced, and unannounced
drills. Each site should hold drills on the night shifts, change shifts as well as during
the day.
(b) Drills should present a variety of Emergency scenarios and designed to challenge
each segment of the organization. Limited scale drills are useful and should be used
by Chief of each Support Service to train his own team. Plans should be made to
have periodic mass casualty exercises. These exercises should attempt to simulate
as closely as possible a fire, explosion, or toxic agent release and comparison of the
prescribed time lines and the actual received.
(c) The warning system, first aid, evacuation procedures and the definitive treatment
procedures should all be tested periodically.
(d) Some of the drills should also include the participation of outside groups and
agencies such as police, fire companies, ambulance service, civil defence
organizations and mutual aid groups.
(e) Testing and mock drills for onsite emergency plan shall be carried once in three
months and for offsite emergency plan twelve months.
(f) For other installations, the mock drill shall be carried out once a year. However, for
locations having more than one industry member, the annual mock drill can be
carried out by one industry member in turn, thus ensuring one mock drill in every
year at the location.
(g) These mock drills will enable the unit/location to assess the capability of the
individual and performance as a group. The frequent discussions and drills will
help in eliminating the confusion and shortcomings, if any.
(h) Each Mock Drill should be recorded with observations and deficiencies to be
rectified within 24 hours.
e. Training
An OEP shall be easier to use if training material and general philosophy on
emergency prevention and control are kept separate from the working plan.
(a) Training shall be imparted to all the personnel likely to be involved directly or
indirectly to the emergencies including employees, contract workers, transport
crew and security personnel.
(b) Contract personnel and contract laborer shall be allowed to start work only after
clearance of attending and passing safety training.
(c) Refresher training shall be conducted at regular intervals.
(d) The basic requirements of Central Motor Vehicles Rules, 1989 pertaining to
dangerous or hazardous goods transport must be complied by the transporters
and for this the loading section must conduct training of tank truck crew.

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11. EMERGENCY RESPONSE PROCEDURES AND MEASURES


Containing the consequences of an emergency requires well planned and
documented procedures to ensure prompt response and coordination among various
task groups. The following response procedures as prevalent in the location shall be
carried out:
a. Zoning and Maps.
This document can be referred to identify different Risk zones on the layout based
on the Risk level experienced from all hazards in the facility
a) The zones and maps shall be prepared highlighting the Incident prone areas of
the unit so that in case of an emergency it serves as a basis for taking the action.
This indicates the size of the area within which human life is seriously
endangered by the consequences of incident. This should also indicate the
location of assembly points and emergency control rooms. The map should also
have marked 24 wind directions to facilitate easy access in case of emergencies.
b) The entities shall help District Disaster Management Authority (DDMA) in
finalizing the full drawn map of installations and nearby areas under their
operations having presence of habitats which are vulnerable and sensitive like
old age homes, schools, prison, etc.
c) Wind speed and direction should be recorded with the help of anemometer and
declaration of off-site emergencies should be immediately communicated to
DDMA.
b. Layout/flow diagram -
Detailed layout and flow diagram for different activities such as Product Lines,
filling system, emergency shutdown system isolation valves etc. should be detailed.
The important control valves should be highlighted.

c. Manpower data
All the staff at the installation is trained in firefighting and all new staff is given
charge after undergoing extensive firefighting training. In addition, trained staffs
are given refresher training courses periodically.

The details (designation) and duties of the staff are given below in the “Fire
Organization Chart”.

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Name of the Personnel Designation Role assigned in FOC


Sh. Dalbir Singh AGM Chief Incident Controller/Site
Incident Controller
Capt. Lakhwinder Singh Head-Combat Leader of Emergency Combat
Team Team:-To terminate the TLF
Operations, reach the place of incident
with nearest available firefighting
equipment, start firefighting with
water & foam mixture.
Mr. Satinder Singh Asst. Leader of Rescue Team:-To call
Manager- various important outside agencies, to
HR communicate important information to
control room and to be in touch with
Chief Incident Controller/Site Incident
Controller.
Mr. S K Srivastava Manager Leader of Auxillary Team:-To reach
Utility the place of fire/incident and to
provide all possible help to
Emergency Combat Team according
to situation.
Mr. Vikram Singh Bedi Manager Member of Auxillary Team:-To
Mechanical reach the place of fire/incident and to
provide all possible help to
Emergency Combat Team according
to situation.
Mr. Sanjiv HR Executive Member of Rescue Team:-To call
various important outside agencies, to
communicate important information to
control room and to be in touch with
Chief Incident Controller/Site Incident
Controller.

d. Emergency Control Organization and Responsibilities


Overall objectives of an emergency control organization shall be:
a. to promptly control problems as they develop at the scene.
b. to prevent or limit the impact on other areas and off-site.
c. to provide emergency personnel, selecting them for duties compatible with
their normal work functions wherever feasible. The duties and functions
assigned to various people shall include making full use of existing

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organizations and service groups such as fire, safety, occupational health,


medical, transportation, personnel, maintenance, and security.
d. Employees must assume additional responsibilities as per laid down
procedure of ONSITE EMERGENCY PLAN (OEP) whenever an emergency
alarm sounds.
e. In setting up the organization, the need for round-the-clock coverage shall be
essential. Shift personnel must be prepared to take charge of the emergency
control functions or emergency shutdown of system, if need be, until
responsible personnel arrive at the site of emergency. The organization
should have an alternate arrangement for each function.

e. Organization chart.

Affected Stake
Holders and Off-Site Incident
Government Commander
Authorities (District Medical Services
Magistrate) and Ambulance

Municipal transport
rescue and
rehabilitation team
Fire Brigade
Services

Police
Services

CHIEF INCIDENT
CONTROLLER

Mutual Aid

SITE INCIDENT
CONTROLLER
Level – I
Level II
Level III ---------

Support Administration and Fire Safety and Operation Team,


Communication Fire Team /HSE technical team,
Services * Coordinator Coordinator etc.

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Note:*
(1) Above is a typical and basic organogram for control of emergency. Entity can
merge the functions as per their other statutory requirements and based on
level of risk and range of operations. The organization shall have to address
all services and support system required and available to it.

(2) Support Services Include Communication Services,


Engineering/Maintenance Services, Medical and Occupational Health,
Human Resource and Welfare Service, Security, Media/Public Relations,
Transport and Logistics, Finance, Contract and Procurement and
Environmental Services.

(3) Role of both CIC and SIC can be merged depending upon the requirement.

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12. ROLES AND RESPONSIBILITIES


Chief Incident Controller.
The Chief Incident Controller (CIC) is the facility manager in facilities. He shall
have overall responsibility to protect personnel, site facilities, and the public before,
during, and after an emergency or disaster. The CIC shall be present at the main
emergency control center for counsel and overall guidance. Responsibilities of the
Chief Incident Controller shall include the following: -

a) preparation, review and updation of the ONSITE EMERGENCY PLAN (OEP)


as per Check List-5;
b) assessment of situation and declaration of emergency;
c) mobilization of main coordinators and key personnel;
d) activation Emergency Control Centre;
e) taking decision on seeking assistance from mutual aid members and external
agencies like Police, Fire Brigade, Hospitals etc.;
f) continuous review of situation and decide on appropriate response strategy;
g) taking stock of casualties and ensure timely medical attention;
h) ensuring correct accounting and position of personnel after the emergency;
i) ordering evacuation of personnel as and when necessary;
j) taking decision in consultation with District Authorities when an Off-site
emergency to be declared.
Fire Chief
a) To reach the site and take charge
b) Access the gravity of the situation and activate emergency response plan
c) Co-ordinate with Team in-charge of the fire fighting
d) Ensure visitors, contractors and labors safely assemble at designated place
e) Ensure safe evacuation of people /TTs/ properties
f) Seek help of local administration, members of mutual aid and reporting office
g) Reassess the emergency and if the situation goes out of control, activate off site
emergency plan in coordination with district authorities

Site Incident Controller (SIC)


The Site Incident Controller shall be identified by the Chief Incident Controller and
will report directly to him. SIC should be nominated by the entity in each shift 24
hrs. Responsibilities of the Chief Incident Controller shall include the following: -

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a) The SIC shall maintain a workable emergency control plan, establish


emergency control centers, organize and equip the organization with ONSITE
EMERGENCY PLAN (OEP) and train the personnel;
b) The SIC shall be capable of making quick decisions and taking full charge;
c) The SIC shall communicate to the Emergency Control Centre where it can
coordinate activities among groups;
d) The SIC shall be responsible for ensuring that appropriate local and national
government authorities are notified, preparation of media statements, obtaining
approval from the CIC and releasing such statements once approval received;
e) The SIC shall also ensure the response to the incidents or the emergencies, as
the case may be, is in line with entity procedures, coordinating business
continuity or recovery plan from the incident. He must ensure next of kin are
notified in a timely manner;
f) The SIC shall also co-ordinate if any specialist support is required for the above
purpose; and
g) The SIC shall decide on seeking assistance of mutual aid members and external
agencies like police, fire brigade, hospital etc.

Administration and Communication Coordinator


Responsibilities of the administration and communication controller shall include
the following: -

a) to coordinate with mutual aid members and other external agencies;


b) to direct them on arrival of external agencies to respective coordinators at
desired locations.
c) to activate the medical center and render first aid to the injured. arrange
ambulance and coordination with hospitals for prompt medical attention to
casualties;
d) to ensure head counts at assembly points;
e) to arrange procurement of spares for firefighting and additional medicines and
drugs;
f) to mobilize transport to various teams for facilitating the response measures;
g) to monitor entry and exit of personnel into and out of premises;
h) to ensure only authorized personnel enter into the premises;
i) To regulate the flow of traffic into and out of premises and control the mob
outside, if any, with the assistance of the police.
j) to provide administrative and logistics assistance to various teams; and

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k) to arrange evacuation as directed by the chief incident controller, and in


coordination with the civil authorities like police, panchayat/municipal
authorities etc.

Fire Safety Coordinator and Fire Team.


Responsibilities of the Fire and Safety Coordinator shall include the following: -
a) to activate emergency sirens as per the practiced codes;
b) to take charge of all firefighting and rescue operations and safety matters;
c) to ensure that key personnel are called in and to release crew of firefighting
operations as per emergency procedure;
d) assess functioning of his team and communicate with the CIC and or
administrative controller for any replenishment or, replacement of manpower or
firefighting equipment;
e) direct the fire brigade personnel and mutual aid members to their desired roles
as also proper positioning of the manpower and equipment;
f) to decide the requirement of mutual aid and instruct fire station, who, in turn
will contact mutual aid members;
g) to coordinate with outside fire brigades for properly coordinated firefighting
operation;
h) to ensure that casualties are promptly sent to first aid center / hospital;
i) to arrange requirement of additional firefighting resources including help from
mutual aid partners;
j) ensure empty and loaded trucks are removed to safer area to the extent possible
so as not to affect emergency handling operations;
k) continually liaise with the SIC and or CIC and implement the emergency
combat strategies as communicated by him; and
l) ensure adequate hydrant pressure in the mains and monitor water level in the
reservoir.
Note: Fire chief shall wear identification jackets at the site of disaster so that he is
clearly distinguished among firefighting personnel and is visible from a distance.

Additional Teams

1. Fire/Emergency Combat Team


 On hearing the sound and seeing the indicator available near the gate barrier, rush
to the spot of fire/ emergency or follow red flag carried by security guard.
 Rush to the site & start extinguishing fire with fire extinguishers at the initial
stage when fire is small.

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 Start using water from nearby hydrant/ monitor/ foam as the case may be till fire
is extinguished as per wind direction.
 Receive instructions from fire chief & coordinate for operation of firefighting
equipment‟s.
 In case of other emergency like leakage of product, arrest the source while it is
being diluted with fine water spray.
 Keep on updating information to fire chief & suggest for necessary assistance if
required.
 After getting clearance from fire chief & hearing clear siren, assemble at
assembly point.

2. Auxiliary team
 Rush to the site & report to fire chief.
 Coordinate with fire combat & rescue team in charges for replenishment.
 Collect fire extinguishers, nozzles, foam nozzles, foam cans & make them ready
to supply all these to fire combat team members at the spot of fire.
 Keep on updating information to fire chief.

3. Rescue team
 Reach at the site & report to fire chief.
 To coordinate for PPES/ evacuation/ first aid/stretcher/ rescue operations.
 To identify casualty & give first aid.
 Keep on updating information to fire chief.
 Give head count to fire chief.
 To safe guard documents, records & other important files.
 To communicate with mutual aid members, district administration, police, fire
brigade & other external agencies & controlling office.
 Arrange drinking water & food.
 Communicate with public arriving at gate.

Security Coordinator
The Security Coordinator reports to the Chief / Site Incident Controller and is
responsible for security of the installation during any incident or emergency
situation and for implementing the actions below:

a) Obtaining an approved visitor list from the security department or reception for
ensuring that personnel on the list are escorted to reception by security staff;

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b) Maintaining security of the office in the event of an office evacuation;


c) Providing office security and assisting authorities in the event of civil unrest or
when required organizing additional security at the emergency scene;
d) Obtaining initial briefing from Chief / Site Incident Controller and providing
security information and or status reports to Site Incident Controller during the
emergency;
e) Assuming responsibility for any task delegated by Chief Incident Controller;
and
f) Assessing the emergency, identify security specific problems and recommend
solutions to Chief Incident Controller.

Head of HSE or any other designated personnel


Maintenance of ONSITE EMERGENCY PLAN (OEP) Records
There shall be maintenance of ONSITE EMERGENCY PLAN (OEP) records for
all kind of emergencies covering near Miss, Level-I, Level-II and Level-III.
Organization shall maintain an Incident Record Register for the above purpose and
post–disaster documentation like resources deployed, relief, rehabilitation measures
and lesson learned to avoid re-occurrence of any such emergency. Head of HSE or
any other designated personnel by the CIC/SIC shall be responsible for maintenance
of such records.

1) A good public relations program is extremely important in an emergency


situation. Inquiries will normally be received from the media, government
agencies, local organizations and the general public.
2) This section of the Response Plan shall include a public relations or media
plan. It should identify an Information Officer that is well-equipped and
trained in media relations.
3) Initial releases shall be restricted to statements of facts such as the name of
the installation involved, type and quantity of spill, time of spill, and
countermeasure actions being taken. All facts must be stated clearly and
consistently to everyone.

Note- Plans shall also be developed to utilize local media and television stations for
periodic announcements during an emergency. This shall also assist in reducing
rumors and speculation.

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Recorder
The Recorder responsibility is to maintain an accurate time record of key
information received from the incident or emergency location and to record the
actions initiated by the site incident controller and for implementing the emergency
response actions below:

a) to record key incident events/actions on incident status board/display


manually or electronically;
b) to maintain essential equipment checklist status;
c) to ensure all status and information is up to date and correctly displayed;
d) to take all necessary recorded material to the alternate ECC room in the event
of emergency in main ECC room; and
e) to maintain a log book.

Roles and responsibilities of stakeholders including external agencies


Role and responsibilities of stakeholders including external agencies such as
District Authority, police, fire service, revenue department, health department,
pollution control board, National Disaster Response Force (NDRF) and State
Disaster Response Force (SDRF).

For roles and responsibilities of above stakeholders and responders, primarily


district collector as Head of emergency operation and other authorities under his
charge including external agencies, has been defined in Schedule–V. These roles
and responsibilities are generally in line with National Disaster Management
Guidelines on Chemical Disasters, April, 2007, brought out by National Disaster
Management Authority.

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13. FIRE PROTECTION SYSTEM & SOPs

i. Classification of Fire
A small spark of fire may result into loss of machines and the damage by fire may
high economic losses. This type of losses can be avoided by preventing and
controlling the fire instantly for which fire–fighting group will be established.
Different classes of fire are explained as follow:
Class (A)-Fire involving combustible materials like wood, paper, cloth etc.
Class (B) -Fire due to liquid materials like oil, diesel, petroleum products and all
inflammables.
Class (C) -Fires involving domestic and industrial gases like butane and propane
etc.
Class (D) -Metal fires etc.
Class (E) -Electrical fires due to short circuiting etc.

ii. Recommendations to be followed to avoid fire:

 Any other flammable materials in the installation shall be stored in a non-


flammable chamber with a minimum safety distance of 15 M from compressor
station/ electrical installation.
 All approaches to machines, compressors, storage facilities and work places
shall be free from obstacles, so that they are readily accessible in an emergency.
 The electrical installations shall be inspected by a competent Electrical Inspector
as per IE Rules and compliance shall be made as pointed out in the inspection.
Records shall be maintained for all periodic inspections.
 The flameproof characteristics of electrical equipment shall be checked through
visual checks, condition of gasket, completeness and tightness of bolts, glands and
as recommended by manufacturer's product catalogues /test certificates.
 No unauthorized additions or modifications, whether temporary or permanent,
shall be taken up.
 Proper illumination to be ensured for all operating and non-operating areas.
 All electrical maintenance at the Automotive Station shall be undertaken by
licensed electrical technician under supervision of authorized person.
 Each installation shall have minimum two numbers hand held explosive meter in
working conditions and two self-contained breathing apparatus(SCBA) at all times.

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 Establish which would house and keep in readiness, the following types of
equipment and arrangements. CO2 extinguishers, Dry powder chemical
extinguisher, Foam extinguishers ,80 mm. spray hoses ,Fire brigade,Fire hydrant,
Protocol (chemical to combat oil fires). In order to avoid fire in cable galleries, all
the power and control cables of FRLS type (Fire Resistant Low Smoke) will be
used.

Firefighting facilities need to be carefully planned after considering the availability


of municipal fire tenders etc. Survey shall be conducted at set frequency to establish
the requirements related to fire suppression system and equipment‟s, with reference
to mandatory regulations and organization‟s requirements; objectives shall be set to
comply to the requirements/guidelines

iii. SOP for Fire Water Tanks

a) In case of any shortage of water in tanks arrange for replenishment of water


b) All hydrant valves must be fully closed. The bypass valve from hydrant to
storage tanks must be in closed condition
c) Ensure fire water is not used for any other purpose. No tap off to be taken
from hydrant for this purpose to feed other system
d) Location may find the possibility of water harvesting where there is acute
shortage of water
e) Ensure double earthing of fire water storage tanks
iv. SOP for Hydrant System
a) Ensure isolation valves near loop junction
b) Ensure isolation valve, kept closed due to repair, is tagged conspicuously and
reopened immediately after repair without fail
c) Ensure installation of strainers before the butter fly/ other valves to prevent
chocking of valves seat for internally coated pipeline
d) Ensure that hydrants and monitors are not installed inside the dyke areas or at
any inaccessible area
e) Ensure no valve is closed on the hydrant line for sprinkler of the tanks, pump
house and gantry
v. SOP for Dry Chemical Powder fire extinguishing system
a) Ensure safety clip of all extinguishers
b) Ensure safety pin on the CO2 cartridge of trolley mounted extinguishers
c) Ensure that extinguishers are placed on hanger at easily accessible position

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d) Ensure stand, painted fire red with rain protection cover for extinguishers
placed in open
e) Ensure that no extinguisher is placed on the ground
f) Ensure max. running distance to locate extinguisher does not exceed 15m
g) Ensure that top surface of installed extinguisher is not more than 15 m above
the floor/ground level
h) Ensure minimum 10% of the total refills in the extinguisher is maintained at
the location
i) Ensure that extinguishers are painted whatever required and bottom of the
extinguisher are always in good condition
j) Ensure that any extinguisher failing in hydro test is condemned
k) Ensure that hydro testing of fire extinguisher is carried out once in five year
vi. SOP for Fire Detection & communication System
In case of emergency, nearest MPC to be operated, this will indicate an alarm in the
fire alarm panel present in the control room and repeat panel in the security cabin

Ensure that:
a) Security has access to direct telephone after office hours
b) Availability of emergency telephone numbers list in security cabin and other
important places
c) That the handle of hand operated sirens are attached to the sirens.

vii. Safety Instructions to be followed at the time of fire


a. Do’s
 Attend to the casualty as quick as possible.
 Get through history of the accident.
 Make the casualty self-comfortable while giving first aid.
 Uncover the casualty as little as possible.
 For fracture: Whenever possible use splint to restrict movement. The fracture
can be recognized by - excruciating pain, swelling, and loss of muscle power,
deformity and unnatural movements.
 Transport a lower jaw fracture casualty with the face downward position or
sitting position.
 In case of fracture of collarbone, upper limb – use triangular bandage to
support as slings, triangular slings to prevent pull by upper limbs to injuries
to chest, shoulder and neck.

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 In case of fracture of hand, the forearm is bandaged by use of the simple


spiral in the lower half and reverse spiral for the upper half.
 A casualty with the fracture of the spine, pelvis, kneecap, leg must be lifted
with a blanket list or the emergency method.
 In case of external wounds stop bleeding initially by pressing gently the
wound site & elevating arm or leg if there is no fracture, rest and continue to
keep still until clot forms. Clean the wound with antiseptic. Put a sterile
dressing, fix with bandage or clean cloth and take the casualty to a doctor.
 In case of internal wounds like lings, stomach, kidney – rest the casualty and
ask him to keep still and take them to a hospital as quickly as possible.
 Treat for shock if casualty feels faint or giddy, vomits. Put the casualty
comfortably on his back, loose tight clothing, but do not remove clothing and
admit to a hospital on top priority.If there is no chest or abdominal injury and
the patient is conscious, give sips of water, hot tea or coffee or tender coconut
water and admit to a hospital on top priority.
 In case of Asphyxia (suffocation), make air passages clear and give artificial
respiration for want of oxygen in the circulating blood.The artificial
respiration is given after placing the casualty face upwards on hard surface
and mouth to mouth method, external heart compression – with arms straight,
rock forwards pressing down on the lower half of breast bone at a pressure of
60 to 80 times per minute.
 In case of snakebite, apply a constructive bandage on the heart side tight
enough to obstruct and stop flow of venom to all parts of the body.
 Constructive bandage should be released once in 20 minutes for at least 2 to 3
minutes.
 Wash the wound with soap and water. Flush with lot of water and cover the
wound with sterile dressing. Get medical aid or send person on stretcher to
the hospital as quickly as possible.
 In case of dog bite, wipe the saliva away from the wound. Wash the wound
thoroughly with plenty of soap and water, cover the wound with a dry, sterile
dressing and send the patient to the hospital for treatment of wound and also
to protect from rabies and other infections.
 In case of burns, do not remove the clothing unnecessarily. Immerse the
burnt part in the cold water for 10 minutes. Do not use any ointment. Dress
the wound with clean materials. Do not open the blisters. Sips of water or
tender coconut can be frequently given. Transport to hospital.
 In case of epilepsy, the casualty may lose consciousness for few seconds. Do
not stop convulsions; remove objects that may cause injuries. Wipe froth

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from the mouth. After regaining consciousness, accompany casualty to a


doctor.
 In case of foreign body in the eye, avoid rubbing the eyes. Instruct to blink
the eyelids in a cup full of water. If not successful, make a pointer with the
corner of a clean handkerchief moisten it and try to remove the foreign body
with it. If acids, quick lime gets into the eye, flush the eye with plenty of
water, dress the eye, and send him to a doctor.
b. Don’ts
 Do not try to set right a dislocated joint.
 Avoid movement of part if fracture occurs as far as possible.
 Do not use spirit near the eye or an open wound.
 Do not apply bandages too tight so as to impede circulation.
 Do not neglect a dog or monkey bite.
 Do not induce vomiting where a casualty is unconscious.
 Do not give a key bunch or an iron article in the hands of a casualty.
 Do not administer oil to casualty of Rat poisoning.
 Do not administer salt solution for vomiting to a casualty in case of
poisoning.
 Do not attempt to do too much and take the responsibilities of qualified
doctor.
 Do not feed a casualty when you suspect an internal injury or when he is
unconscious having fits.
 Do not waste much time in a condition of internal bleeding or head injury but
transport the casualty as quickly as possible to a hospital.
 Do not apply oil or ink on burns and scalds.
 With a snake bite casualty is reported do not waste time in using, “Mantras,
Tantras and Pooja” but transport him to a hospital immediately as possible.

viii. Resources for controlling Emergency


To meet all possible emergencies, installation has to provide a number of systems
and resources based on the risk level as identified above in addition to requirements
under the Factories Act, 1948 and other statutory regulations applicable to the
installation.

The available emergency control systems and facilities within the installation shall
be as under: -
a) fire and gas detection system

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b) fire protection system (Active and Passive)


c) firefighting systems
d) ambulance facility in house, if not available then should be available on
urgent call basis.
e) rescue facilities and personal protective equipment (PPEs)
f) first aid and medical facilities round the clock with availability of minimum
one nurse (24X7) and doctor in the first aid room.
g) communication facilities
h) escape route and evacuation zones
i) emergency shutdown system
Required resources shall be suitably incorporated into the plan. Number and type
shall be as per the relevant code, standards and best practices in the industry. This
section shall also identify sources of local assistance including telephone numbers
and names of contacts for:
a) fire departments
b) police
c) municipal and provincial agencies
d) hospitals
e) doctors
f) other relevant company facilities
g) mutual aid organizations
h) co-operatives
i) surface transport services
j) safety and monitoring equipment suppliers
k) spill response and/or cleanup services

Installations shall also determine type of resources such as equipment, personnel,


technology, expertise, etc. provided by the respective governments under different
conditions.

ix. Record Regarding Mock Drills

Sr.
No. Check-point
1 Whether mock fire / emergency response drills are held
2 If yes, periodicity of emergency response drills
3 Mock drills cover all types of probable emergencies
4 If yes, the details of other members including names and contact nos. of

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concerned officials
5 List of fire fighting equipments available
6 Compatibility of safety equipment including District Fire Services with
said location has been tested and documented in the DMP
7 Details of water storage available including District Fire Service and
mechanism to utilize the same in the said location well documented in the
DMP
8 Details of firefighting foams concentrate/chemicals available including
nearest Fire Service has been incorporated
9 Details of lead time for response of District Fire Service has been
documented in the DMP
10 Periodicity of safety training for officers, staff, contractor workers, TT
crew and security personnel mentioned in the ONSITE EMERGENCY
PLAN (OEP).

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14. COMMUNICATIONS SERVICES & INFRASTRUCTURE


The Communications Coordinator shall ensure the following actions below:
a) Ensuring the ECC equipment and systems are maintained to a high standard and
remain functional throughout the emergency.
b) Ensuring a back-up communication system is available in the event of the ECC
Room is not available.
c) Providing quality and diverse communication systems for use in routine and
emergency situations.
d) CONTROL ROOM - Communication Facilities in M/s Malbros are Intercom
Telephone, P&T Telecom, Wireless (Mobile) Communication System.

i. Communication Flow Chart

Employee/
Police Security
Public
Fire and gas
detection
system/ SCADA
EMERGENCY
System
CONTROL
CENTRE
(ECC)
First MANAGEMENT
Responder TEAM
(Head Operations, Head CRISIS
Maintenance, Head MGMT
Technical, Head HSE, GROUP
SITE INCIDENT
Fire safety/HSE Head Security, Head
Coordinator and CONTROLLER
(HR)
fire team
District
CHIEF INCIDENT Administration
and Central
CONTROLLER
Govt. agencies
Info. to Fire Mutual Aid
Brigade, Police, Members
Medical and
Government Others (required Note: Level I
Authorities coordinators of the
installation) Level II

Level III

Note:
1. above is a typical communication flow chart for notification of emergency.
2. Wherever communication exists for any level of emergency, it automatically
implies that the communication exists for all higher levels of emergencies.

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ii. Flow of Information


a) Control Centre shall receive the information form field either in person or from the
various systems available in the installation.
b) on receipt of information, the control room shift In-charge will actuate the
ONSITE EMERGENCY PLAN (OEP) and notify the emergency to site incident
controller.
c) Control room shift in-charge will act as site incident controller till arrival of
designated person.
d) SIC or CIC depending upon the level of emergency will actuate the ONSITE
EMERGENCY PLAN (OEP) and inform the concerned authorities as depicted
above in the chart.
Note: Apart from the above main function, the role and responsibility of other
support services such as finance, material etc. should also be detailed.
iii. Siren Codes
1) The Emergency siren/s should be located suitably to cover the whole area with the
operational control within the installation. These should be tested at least once in a
week to keep them in working condition.
2) Emergency siren code should be as follows, namely: -
a. Emergency Level-I: A wailing siren for two minutes.
b. Emergency Level-II and III: Same type of siren as in case of Level – I and II but
the same will be sounded for three times at the interval of one minutes i.e.(wailing
siren 2min + gap 1 min + wailing siren 2min + gap 1min + wailing siren 2min)
total duration of Disaster siren to be eight minutes.
c. ALL CLEAR: Straight run siren for two minutes.
d. TEST: Straight run siren for two minutes at frequency at least once a week
e. Public address system should be provided with message.
3) Codification of Sirens in M/s Malbros is as follow:

Sr. SIRENS INDICATES AUTHORITY


1. 30 SECOND ON SITE INCIDENT
CONTINUOUS EMERGENCY (ALERT) CONTROLLER
2. 1 MINUTE EMERGENCY SITE CONTROLLER
CONTINOUS CONTROLLED
(ALL CLEAR)
An alarm does more than just emergency warning. It also instructs people to carry
out specific assignments, such as reach to assembly point for further instructions

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and actions, or carry out protective measures; this can be achieved only if the
people are familiar with the alarm systems and are trained to respond to it.

iv. Details of the Emergency Control Centre (ECC)


Each installation shall have the provision of ECC preferably with a back- up
arrangement.
a) The ECC shall be away from potential hazards and provide maximum safety to
personnel and equipment.
b) Preference should be given to a non-combustible building of either steel frame or
reinforced concrete construction.
c) The ECC should have at least two exits and adequate ventilation .

To direct and coordinate the operations, the administrative/office building has been
nominated and developed as the Emergency Control Center. In an emergency it is
almost essential to evacuate affected person from inside the factory to a safer place. It
is also essential to evacuate non-essential workers to streamline Emergency Action
Plan activities and ensuring safety of those people. The evacuation will be effected
after getting information from the Works Incident Controller soon after emergency
arises. On evacuation all contract laborers, visitors etc. other than those notified as
team member shall assemble at the assembly point for receiving further instructions.

At the time of the emergency On-site Chief Controller assisted by other designated
coordinators shall take position here to perform their duties. Its location is outside the
area of potential hazards and is easily approachable.

Both the Emergency Control Center have the following resources available at all
times:
 4 Copies of the On-site Emergency Plan.
 Layout Plan of the complex.
 Plans of work illustrating the following:
 Plan of chemical storage tanks with pipeline details
 Sources of safety equipment
 Fire Hydrant System Layout
 Stock of firefighting equipment
 Location of assembly points
 Location of works in relation to surrounding community
 A list of telephones of key and essential staff of the company along with their
addresses and residential numbers.

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 Copies of the local Telephone Directories.


 A list of important telephones like neighboring industries, local Fire Brigade,
Hospitals, Chief Inspector of Factories.
 Personal Protective Equipment.
 First – Aid Kit.
 Communication equipment –
 Telephone
 Public Address System
 Requisite stationary items: notepads, pens and pencils. Facilities for recording the
sequence of events should be provided to assist in investigating causes, evaluating
performance, and preparing reports. This can range from a pan board, logbook to a
tape recorder with a person assigned to record pertinent information.
 Personnel to act as messengers.
 Binoculars, Torches and explosive meters.
 ECC should also have dedicated computer with LAN/ internet facility to access the
installation data and also it should have the latest and updated soft copies of all
standard operating practices (SOP) etc.

The communication equipment is checked periodically to ensure that they are


functional. The Emergency Management Control Center is capable of being activated
within a few minutes upon declaration of an emergency.

v. Assembly Point and Their Area Coordinator

Assembly Point -In an emergency, it will almost certainly be necessary to evacuate


personnel from affected areas and, as a precautionary measure, to further evacuate
nonessential personnel from areas likely to be affected should the emergency
escalate. The evacuation will be effected on getting necessary message from Site
Controller. On evacuation, employees should be directed to pre-determined safe
place called Assembly Point.

Escape Routes -The roads leading to the Assembly Points are the designated
escape routes. The escape routes will be clearly marked with arrow marks for easy
escape.

 The Assembly point of the location is Near Entry Gate.


 As soon as the non-essential contract laborers come to know of the emergency they
shall reach the assembly point without delaying further to ensure their safety and
security.

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 The assembly point should be clearly marked with directional display board along
the route. Route should be well lighted with florescent marking.
 During an emergency, pre-designated persons would take charge of this point and
take the roll call of the people reporting. Provisions should be made for assembly
points, communication and headcount facilities at assembly points, and personnel to
control the movement of assembled employees.

S.No. Name of Location of AssemblyPoint Area


Plant/Unit/Area/Building Coordinator

1 Site office Near Entry Gate Security


2 Training Center In front of training center Security

vi. Declaration of on-site and off–site emergencies


1) An emergency starts as a small incident which may become a major incident with
passage of time. At the initial stages, the emergency organization chart shall be
put into action. If the incident goes beyond control the on-site emergency plan will
be actuated by the chief incident controller at the appropriate stage as considered
necessary.
2) During idle shift or holidays, the security personnel will combat the incident as per
the ONSITE EMERGENCY PLAN (OEP) organization chart and at the same time
inform various emergency controllers for guidance and control the situation.
3) When emergency becomes catastrophic and evacuation beyond the plant premises
is considered necessary by the chief incident controller, the situation will be
handed over to district authority for implementing the off-site emergency plan.
4) The management of emergency henceforth has to be controlled by the district crisis
management group under the supervision of the District Collector/DDMA.

In addition to preparation of on-site emergency plan, furnishing relevant information


to the district authorities for the preparation of off-site emergency plan is a statutory
responsibility of the occupier of every industry handling hazardous substance.
vii. Medical Facilities
a. Details of Medical Facilities Inside the Plant
Ziraand Talwandi Bhai is a major location, which has Hospitals. The range of
medical facilities available in the city is very wide and all major hospitals have
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specialized treatment units for a wide variety of ailments and medical conditions. It
has therefore not been required by any organization to build up its strong in-house
facilities.

b. First Aid Boxes


A first aid centre with adequate facilities shall be provided. It shall be maintained
round the clock. Four first aid boxes have been provided at various work stations to
take care of first aid in case of any injury.

c. Medical Facilities Available Outside the Plant


List of the Medical Facilities Available outside the plant is:

Sr No Name of The Hospitals Location Distance Telephone


From Site Numbers
1 Osahan Hospital Ferozepur Road 8 KM 9815160152
Zira
2 Civil Hospital Zira 8 KM
3 Dr. V P Chawala Hospital Talwandi Bhai 8 KM 94171-22186
4 Civil Hospital Talwandi Bhai 8 KM 9780096696

d. Emergency Transport Facility

Sr No Name of agency Location Number & Type Contact no. Service


Type
1 Osahan Hospital Zira 02 Ambulances 9815160152 Paid
2 Own Factory 03 Passanger Emergency
Premises Cars Control
Centre

e. Lists of Antidotes and Emergency Medicines


The following medicines are available in the First Aid Boxes:
 Burnol
 Dispirin
 Sterile Gauze
 Surgical Dressing
 Gauze Dressing
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 Potassium Permanganate
 Iodine Tincture
 Cotton
 Scissors
 Savlon

In addition, Snake antivenom is also available in the plant.

viii. Evacuation
1) Planning and training on evacuation techniques are important in preventing
injuries. Evacuation of local communities or people near the site may be prudent
depending on the situation and down-wind dispersion information etc. Although
this action will normally be initiated and handled by district authorities, the
affected installation shall help to implement such evacuation.

2) This evacuation plan shall also consider:


a. basis for recommending on-site or off-site actions
b. authorize person for area or site evacuation
c. mode of communication
d. training in locating exits from buildings, areas and the site
e. location of escape equipment
f. provisions for flashlights or other supplemental lighting
g. which areas can function as safe area
h. moving crosswind from gas or fume releases, etc.
i. provision of food and drinking water at assembly point and transfer point.

3) If evacuation takes place after initial head counts are reported, means for
recounting may be necessary. Where it is safe to do so, areas being evacuated
should be thoroughly searched to ensure everyone has departed safely. Portable
mobile vehicle for announcement should be available in the emergency.

ix. Information to Public


The safety measures to be taken in the event of an emergency shall be made known to
the general public who are likely to be affected.

For the purpose, use of Dos' and Don‟ts' shall be prepared and furnished to the Crisis
Management Group. Display boards carrying do‟s and don‟ts should be located

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outside the gate as well as in the neighboring colonies and other habitat areas in the
immediate vicinity.

x. Reporting of the Incident


All incidents covered under Level-I should be maintained by the entity for inspection
whenever called for inspection and Level-II and Level-III shall be reported to the
Board in the format specified and placed in Annexures including near miss incident.
The above report should be submitted within 48 hours after occurrence of the
incidents or any other reason triggering major incident.

Investigation report of all major incidents shall be submitted to the Board. An


incident shall be treated as Major if any of the following occurs;

a) fire for more than 15 minutes


b) explosion / blowout
c) fatal incident.
d) loss above Rs. 10.0 Lac
e) cumulative man hours lost more than 500 hrs.
f) plant shutdown / outage due to the incident
g) Level-III incident

xi. Action after reporting of incident by the entity


After reporting of the incidents to Board, Nodal officer of the Board (head of
Technical Standards the specifications and safety group) shall have responsibility of
informing all the Members of the Board and shall coordinate with appropriate level in
National Disaster Management Authority (NDMA) till normalization of the situation.

xii. Termination of emergency


Termination activities should concentrate on giving accurate information to people
who need it most especially employees, neighborhood, District Authorities engaged
in offsite emergencies, and should begin as soon as the emergency phase of the
operation is completed.

The termination of emergency shall be declared through siren as per the Siren Code
defined by industry in case of Level- I and II. For Level-III termination of emergency
shall be declared by District Authority through appropriate mode of information
transfer so as to reach each and every one.

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xiii. Emergency Recovery Procedures


After the emergency, the following activities need to be carried out in detail.

a) information to statutory authorities.


b) incident investigation.
c) damage assessment.
d) salvage of products, de-contamination, clean-up and restoration.
e) a detailed report shall be prepared based on the entire experience of the incident,
including restorations, limitations and lessons learnt.
f) ambient air monitoring at the site as well as 5 km radius of the installation by State
Pollution Control Board to determine the contamination level affecting health.

xiv. Integration of the ONSITE EMERGENCY PLAN (OEP) with the


NATIONAL DISASTER MANAGEMENT PLAN (NDMP)
a. NATIONAL DISASTER MANAGEMENT PLAN (NDMP)
On 23 December 2005, the Government of India took a definite step towards NDMP
by enacting the NDMP ACT, 2005. The NDMP Act, 2005 is a Paradigm Shift from a
response and relief-centric approach to a proactive and comprehensive mindset
towards NDMP covering all aspects from prevention, mitigation, preparedness to
rehabilitation, reconstruction and recovery.

Similar to National Authority at the Centre, the State Government is to establish a


State Disaster Management Authority for the State. The State Authority is to be
headed by the Chief Minister of the State as the Chairperson. Every State
Government, in turn, is to establish a District Disaster Management Authority for
every district in the State with the District Collector as the Chairperson.

The Central Government is empowered to take further measures as it deems fit for
the purpose of disaster management like deployment of naval, military and air forces,
other armed forces of the Union or any other civilian personnel as may be required
for the purposes of this NDMPAct. Government of India is empowered to establish
institutions for research, training, and developmental programs in the field of disaster
management as per this Act.

The national vision is to build a safer and disaster resilient India by developing a
holistic, proactive, multi-disaster and technology driven strategy for NDMP. This
will be achieved through a culture of prevention, mitigation and preparedness to
reduce the impact of disasters on people. The entire process will centre stage the

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community and will be provided momentum and sustenance through the collective
efforts of all government agencies supported by Non-Governmental Organizations
(NGOs).

National Disaster Management Structure showing the interactive linkage among


various agencies for synergized management of disaster is given below;

Note: Since PNGRB has been constituted by PNGRB Act, 2006, it should be
identified under Ministries / Departments of Govt. of India.

Abbreviations for NDMA:

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NDMA : National Disaster Management Authority


NEC : National Executive Committee
DM : Disaster Management
NCC : National Cadet Corps
NCDM : National Committee on Disaster Management
NDMRCs : National Disaster Mitigation Resource Centres
NDRF : National Disaster Response Force
NSS :National Service Scheme
NYK :Nehru Yuva Kendra
NGOs : Non-Governmental Organizations
SDMA :State Disaster Management Authority
SEC :State Executive Committee
DDMA :District Disaster Management Authority

b. Integration of ONSITE EMERGENCY PLAN (OEP) with NDMP


This ONSITE EMERGENCY PLAN (OEP) document has been developed taking
into account all possible inputs on the subjects from various stake holders. Efforts
have also been made to synergize this with the document on National Disaster
Management Guide (Chemical Disasters) Industrial brought out by National
Disaster Management Authority.

xv. Security Threat Plan


1) With increase in terrorist activities towards the end of 20 th century and installations
having, significant role in national economy, sabotage and bomb threats to such
installation should also be considered in the disaster management plan. Such as
high level of alertness measures, strengthening security measures by security
gadgets mechanical and electronic security gadgets. In any of such situation, city
police/ administration should be informed immediately and their help should be
sought.

xvi. Off-Site Emergency Plan


The Off-site Emergency Plan, which is the responsibility of the District Emergency
authority, deals with measures to prevent and control emergencies affecting the
public and the environment. This plan considers the possible effects of incidents
from any industry on the neighboring population and the remedial measures. In this
context, Malbros will furnish to the District Emergency Authority the following
technical inputs to enable it to prepare the contingency plan accordingly:

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 Inventory of hazardous chemicals


 MSDS of such chemicals
 Types of emergencies
 Nature, extent and likely effects of such incidents
 Risk and Environmental Impact Assessment
 The District Emergency Authority, based on severity of any emergency in product
distribution network will declare off-site emergency
a. Educational Programs
The plant management shall periodically undertake a comprehensive awareness
program for dealers, tank truck crew and contractors. The educational material
shall be prepared in local, Hindi and English language. Local audio visual media
available should be used for such educational programs. Need based participation
of the local district authority, regional transport office, local fire service
department and local police shall be considered.
b. Investigation of Asset/Equipment Failure
Besides reporting and recording of all instances of asset related failures, damage to
the environment and third party property shall also be recorded. Failure
investigating team shall comprise of personnel trained in failure investigations. The
data from all failure occurrences should be analyzed for trends so that proper
initiatives including training could be taken to minimize failures.
c. Prevention of Accidental Ignition
Site Specific Risk Assessment should be carried out before commencing any repair
activities. The outcome of such risk assessment should be documented and
considered while preparing safety plan for the repair work. No hot work should be
undertaken without proper work permit issued by authorized personnel. Specific
consideration shall be given during simultaneous operations by different
contractors with likely overlap of their operations.
d. Responsibilities of Malbros in Off-Site Emergency Plan
 Malbros shall identify and evaluate incident scenarios that would create hazardous
conditions in the area adjacent to the product distribution network and routes of
tank trucks and dealers location for public distribution .The extension of critical
on-site major incidents like major fire or explosion to an off-site location crossing
the perimeter of Malbros should be informed immediately to the local
governmental agencies to take charge of the situation

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 Malbros shall extend a specialist advice and other emergency equipment‟s/


facilities to assist local authorities in mitigating major incidents like fire, explosion,
spill, major road accidents, natural calamities etc.
 Malbros shall establish a channel of communication with the local authorities for
emergency communication
 Thus, all the possible external coordination / liaison with a view to mitigate and
minimize the incident impact / consequence outside plant boundary shall be done
within the shortest possible time.

xvii. Plan Updation


It is necessary that the Emergency Plan is reviewed and updated upon the following
situations:
 Lapses / problems identified during emergency exercises and real incidents.
 During any major changes/modifications in operating facilities or emergency
equipment‟s
 Accident/incident investigation process(reported internally as well as from
external occurrence) and the recommendations therefrom
 Changes in the organization structure / communication facilities, rescue and
support means and their identities
 Health /safety audits reports
 At least once in two years at the minimum

xviii. Glossary
DMP Disaster Management Plan NH No hazard from the event
Impact criteria level Not
OEP Onsite Emergency Plan NR
Reached
HAZCHEM Hazardous Chemical IRPA Individual Risk per Annum
Unconfined Vapour Cloud
CFO Chief Fire Officer UVCE
Explosion
HSE Health Safety Environment MSDS Material Safety Data Sheet
TT Tank Truck QRA Quantitative Risk Assessment

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15. HAZARD IDENTIFICATION, HAZARD ANALYSIS AND


RISK ASSESSMENT

Sr.
No. Check-point
1 Which of the following procedures or techniques for hazard identification has
been used in the IRD/ installation :
1) HAZOP/HAZAN
2) Incident Consequences and Analysis
3) Event Tree Analysis
4) Fault Tree Analysis
5) Failure Modes, Effects and Criticality Analysis
6) Risk Assessment
7) What if, analysis
8) Other accredited practice
Hazard Identification :
2 Is the installation covered under the definition of “Major Incident Hazard
Installation” as per the Manufacture Storage and Import of Hazardous
Chemicals Rules 1989 (Amended 1994 and 2004. If yes, please specify the
site notification and safety reports
3 If yes, whether major Incident hazards identified and steps taken for their
prevention
4 Whether design deficiencies, failures or errors which can contribute to hazards
and cause abnormalities leading to an Incident are identified
5 What are the measures undertaken to counter above deficiencies or, errors
6 Consequences of a major Incident on the workers, people in the
neighborhood and the environment are considered
7 Steps envisaged for mitigation of the consequences of such incident
8 Does the installation produce / handle / use / import / store any hazardous
chemicals as defined under MSIHC Rules 1989 (Amended 1994 and 2004)
9 If yes, whether a list of these chemicals, preferably in alphabetical order with
their maximum licensed storage quantities is displayed
10 Are material safety data sheets (MSDS) of these chemicals are prepared /
obtained in the prescribed format as per MSIHC Rules and State Factory
Rules
11 Whether a system for disseminating information about these MSDS to
concerned workers are existing
12 Are there a system of labeling of containers / storage tanks for the chemicals /
hazardous substances

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13 Whether estimation of maximum possible quantity of each hazardous


substance are considered including any vehicle (TT/TW) on site or within 500
mtrs of the site.
14 Whether location, configuration and condition under which the hazardous
substances are stored and handled are clearly declared
Vulnerability Analysis :
15 Whether zones of influence or vulnerable zones are estimated by considering
the maximum single storage of hazardous substance and maximum loss
scenario
16 Whether effects of influence on the vulnerable zones are made after
considering the population, facilities and environment encompassed inside
that zone
Risk Analysis :
17 Whether a relative measure of the probability and consequences of various
possible hazardous events including worst case scenario are taken into account
18 Whether risks are calculated by multiplying the probability of occurrence of
each event by the consequences of that event and then summing up the results.
19 Whether all types of events possible in petroleum installations are considered
including i) storage tanks on fire, ii) pool fire [burning pool of liquid fuel], iii)
Flange joint leakage in pipelines, iv) Fire in TT or TW gantry, and v) rupture
of hoses.
Risk Reduction Measures :
20 Whether measures for reduction of identified high risks are included by
reducing the consequences through hazard mitigation measures
21 Whether steps have been considered to reduce risks to the exposed population
by increasing safe distances by acquiring property around the facility, if
possible
HAZOP Study
22 Whether the above method is applied if the location handles more than
specified storage and / or critical operations
23 Whether the study systematically identifies all possible deviations from
normal operations
24 Whether risk levels are established for each deviation after considering the
probability and consequences of each such events
25 Whether potential means for detection of such events and preventive measures
are recommended by the study

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16. INCIDENT PREVENTION MEASURES

Sr.
No. Check-point
1 Whether Safety, Health and Environment Policy of the location is displayed
2 Whether the Safety Policy is documented and duly approved by the top management
3 Whether the Safety Policy is well structured to cover all elements of Safety, Health and
Environment protection
4 Whether the layout is convenient from operation and safety aspects and meets
minimum distance norms
5 Whether a duly constituted Safety Committee is functioning in the location with
representation from workmen/staff
8 Whether all unsafe developments and likely risks are deliberated in the meetings and
appropriate steps are recommended for eliminating such risks
9 Whether compliance status of recommendations of earlier Safety Committee meetings
are discussed before taking up new issues.
10 Whether performance and shortcomings observed during recent mock disaster drills
form part of the discussions in safety committee meetings
11 Is the safety committee minutes are recorded and signed by all the attending members
13 Whether periodical safety audits and inspections by internal and external audit teams
are conducted in defined intervals
14 Whether a system of regular monitoring of such audit compliances by controlling
offices / HO are in place
15 What is the composition of external audit teams to ensure impartiality of audit findings
16 Whether Work Permit System have been implemented

17 Whether work permits are issued for hot work, cold work, electrical work and vessel
entry jobs
18 Whether the location-in-charge or his authorized nominee remain the issuer for all hot
work and vessel entry permits for enhanced safety and control.
19 Whether work permits are duly closed at completion of the stipulated jobs, duly
certified by the supervising officer
20 Whether heat detectors in tank sprinkler systems, high level alarms of tank farm
management system are provided and checked for regular functioning
21 Whether in-built safety interlocks provided in the design are adequately specified and
checked for regular functioning

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17. POST EMERGENCY - RECOVERY MEASURES


Sr.No. Check-point
Salvage of product
1 Check that spilled / accumulated product contents are transferred to the OWS or
collected in drums.
2 Check whether the quality and quantity estimation of the product extracted from
OWS has been done for further disposal in line with standing QC guidelines by either
transferring to service tanks or to nearest refinery for blending / reprocessing or not.
3 Check that correct stock accounting of spilled product as loss has been completed in
accounting system.
4 Check that affected area has been completely cleaned and dried after evacuation of
spilled product.
5 Declare that affected area after salvage operations is fully clean and safe for
movement of the working personnel.
6 Check that all drains are not having any residual oil/product and are thoroughly
cleaned and dried.
7 Check that all control valves on product lines and OWS lines outside dyke area and
drains are completely closed after removal of the spilled product.
8 Check that interlocking system of tanks / gantry has been re-activated for normal
operations.
9 Check whether the soil testing of the affected area, if required, has been done to
assess the soil contamination level to meet the Environmental – SPCB norms /
requirements.
Taking care of affected manpower
10 Whether physical accounting of all personnel on duty during and after the incident are
ascertained by the Site Incident Controller and reconciled immediately
11 Whether the first-aid treatment and post-incident health check of the affected
personnel has been undertaken in time
12 Whether these personnel are declared fully physically fit before allowing them to
resume their normal duties
13 Whether the records for such first aid and treatment of the affected personnel are
maintained in a well-defined format
Addressing media and outside bodies
17 Whether the incident was appropriately informed to the local media in line with the
respective company‟s Press and Media Policy
18 Whether the role of neighboring population during the drill / disaster is suitably
informed to the population during subsequent meetings with local administration /
panchayat etc. for necessary improvements
19 Whether the awareness and preparedness on disaster is regularly assimilated / shared
with nearby public / societies and stake holders.
Reporting

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20 Check whether that disaster incident report was communicated to respective


controlling office / HQ promptly in a standard format.
21 Whether the incident reports are also sent to concerned State Level Industry
Coordinator on time.
22 Check that detailed report on disaster in proper format was communicated to Factory
inspector / Labour inspector / SPCB / District Magistrate.
Investigation
23 Whether investigation teams are constituted as per respective company policies
24 Whether RCA (Root Cause Analysis) of the disaster is conducted by the investigating
team
25 Whether detailed investigation into effective functioning of interlocks, detection
devices, automation controls and applicable norms are carried out to find out possible
improvements in design / construction / operations / maintenance and training aspects
etc.
26 Whether a system of initiating appropriate corrective measures including suitable
revisions to the Disaster Management Plan are adopted based on findings of the
investigation
Damage Assessment – Monetary and Physical
27 Check the valuation / cost of product loss / down gradation on account of
contamination, if any / Property / Structures / damaged assets – equipments.
28 Whether repairs and maintenance cost of property, assets and equipment are assessed.
29 Whether any penalty by statutory authorities like SPCB / Factory Inspector and
Labour Commissioner are assessed.
30 Whether possible impact on environment are also assessed and appropriate measures
are taken
31 Whether damage assessment also include potential erosion of reputation – from
company, industry and national perspectives
Clean up and Restoration
32 Whether the affected area has been fully cleaned and cleared after due clearance from
investigation team
33 Check whether heat detectors, high level alarms, in built safety systems (NRV, TSV
etc.) are fully functional after the disaster incident.
34 Check whether all firefighting equipment like – hoses / nozzles / Fire Extinguishers
etc. have been put back at designated places and are fully ready for reuse
35 Whether clear procedures are in place to allow resumption of normal operations

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18. IMPORTANT TELEPHONE NUMBERS


LOCAL ADMINISTRATION
Fire Brigade Contact No.
Control Room 101
Central fire station Zira 01682-2749619
Fire Station Ferozepur 01632-101,9463109501
Fire Station Moga 01636-220123,101
Ambulance Osahan Hospital Zira (02 Nos.) 9815160152
District Authorities Contact No.
Deputy Commissioner, Ferozpur 01632-244006,008
Sr. Superintendent of Police, Ferozpur 01632-246697,244049
SDM Zira 01682-250117
DSP Zira 01682-250150,9646292176
Police Station Zira 01682-250185,183
SHO Zira 01682-250185,183
CMO/ SMO 01632-245173,242964
Sarpanch Mansoorwal
Sarpanch Ratoul 9814135579
Sarpanch Sanehar 9814555622
Deputy Directors of Factories 9463871982
Assistant labor Commissioner 01632-245317
Punjab Pollution Control Board ASR 9878950554
KEY PERSONAL OF M/s MALBROS INTERNATIONAL PVT. LTD.
Name Designation Contact No.
Mr. Pawan Bansal CAO 9914800006
Mr. Munish Tyagi AVP(Tech) 9781219007
Mr. Brijesh Srivastava Head -Operations, 9914919007
Mr. Y.S. Parihar Head Bottling Operation 9914932653
Mr. Rajinder Singh Head Purchase 9914932868
Mr. Dalbir Singh Head – Maintenance, 9914932277
Mr. S.K. Srivastava Head -Electricals, 9914932867
Mr. Vikram Singh Bedi Head –Mechanical 9914932866
Mr. Vinod Kumar Head – Civil, 9914948822
Mr. Satinder Singh In charge - Fire & Safety 9914932837
Mr. Lakhwinder Singh Head - Security 9914932839
Dr. Jaswant Singh Medical Officer 9815160152

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19. FIRE FIGHTING EQUIPMENT & PERSONAL PROTECTIVE


EQUIPMENT
Sr. No. Type of Equipment Capacity UOM Quantity
1 Fire Water Tank 200 KL 1
2 Fire Water Tank 200 KL 1
3 Bore Well 50 KL/Hr. 2
Fire Water Pump(Diesel Engine
4 171 KL/Hr. 2
Driven)
Jockey Pump(Electric Motor
5 10.8 KL/Hr. 2
Driven)
6 Mobile Foam Trolley 50 Ltr. 9
7 Mobile Foam (A+B) 9 Ltr. 14
8 Dcp Fire Extinguisher 10 Kg 3
9 Dcp Fire Extinguisher 5 Kg 4
10 Dcp Fire Extinguisher 6 Kg 10
11 Co2 Fire Extinguisher 4.5 Kg 15
One per
12 Safety Helmet -- 25
person
13 Safety Shoes -- Pair 10
14 First Aid Box -- Kit 5
15 Rubber Hand Gloves (Nitrile) -- Pair 2
16 Electrical Hand Gloves 33 KV 2
17 Safety Goggle -- -- 24
18 Ear Muff -- -- 4
19 Ear Plug -- -- 12
20 Nose Mask -- -- 10
21 Electrical Siren 3 Km 0
22 Hand Operated Siren 1 Km 0
23 Red & Green Flag For Fire Drill -- -- 01 in each col
24 Hose Box -- -- 10
25 Fire Hose -- -- 20
26 Sand Drum With Scoop -- -- 1
27 Sand Buckets -- -- 12
28 Jet Nozzle -- -- 12
29 Universal Nozzle -- -- 4
30 Water curtain nozzle -- -- 2
31 Non-sparking Tools -- Kit 2
32 Oil Absorbent Kit -- Kit 1

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20. PRODUCT STORAGE CAPACITY AND CHEMICAL DATA

EXTRA NEUTRAL ALCOHOL / RECTIFIED SPIRIT/ IMPURE


SPIRIT RECEIVER SAND STORAGES
Sr.No. Tank Name Unit Capacity
1 Receiver No-1 KL 60
2 Receiver No-2 KL 60
3 Receiver No-3 KL 60
4 Receiver No-4 KL 15
5 Receiver No-5 KL 45
6 Receiver No-6 KL 100
7 Spirit Storage No-1 KL 750
8 Spirit Storage No-2 KL 750
9 Spirit Storage No-3 KL 105
10 Spirit Storage No-4 KL 200
11 Spirit Storage No-5 KL 165
12 Spirit Storage No-6 KL 165

CHEMICAL DATA
SL NAME OF THE COMMERCIAL STORAGE METHOD BELOW/ ABOVE
NO CHEMICAL TECHANICAL QUANTITY OF THE GROUND
NAME STORAGE

Above the ground


1 Ethanol (96% Extra Neutral 2500 KL Tanks & Separate Room
conc.) Alcohol
Above the ground
2 Liquor ammonia Liquor ammonia 1000 Liters Liters & Separate Room

3 Lubricant Oil Lubricant Oil 10 Barrels Barrels Above the ground


Hydrochloric
4 Hydrochloric acid 10 Cans Cans Above the ground
acid

5 Sulphuric acid Sulphuric acid 01 Cans Cans Above the ground

Servo Lubricant Above the ground


6 Servo Lubricant Oil 02 Barrels Barrels & Separate Room
Oil

Alum Alum 20 Solid Lump


7 Above the ground

74 | P a g e M/s Malbros International Pvt. Ltd., Village-Mansoorwal, Tehsil-Zira, Faridkot Road,


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