model _onsite emergency mgt. plan

8/7/2019 Model _Onsite Emergency Mgt. Plan

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ON-SITE

EMERGENCY MANAGEMENT PLAN

Issued By

HEALTH SAFETY ENVIRONMENT DEPARTMENT

M/S. SUPREME PETROCHEM LTD

Village Amdoshi/Wangani, Wakan-Roha RoadTal. Roha, Dist. Raigad 402106.

ISSUE NO. 02 REVISION NO. 03


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6th April 20071. This plan is prepared as per the requirements stipulated under Manufacture, Storage and Import of Hazardous ChemicalsRules 1989 as amended and the Factories Act and the Rules made thereunder.

2. It covers the potential emergency scenarios at Line 10, Line 11, Line 12, Tank Farm, Unloading area, SPS, Warehouse I / II,Engineering Stores, Initiator storage, Water Block, Utility I / II, Main Sub Station etc.

3. The Emergency scenarios are taken from the revised Risk Analysis carried out for existing as well as for the expansionactivities. In addition, emergency scenarios are also taken from the Register of Environmental Aspects during emergencyconditions.

4. The observations and recommendations from various mock drills and table- top exercises are taken into consideration whilereleasing this Revision.

5. The plan will only undergo revisions in case of change in mitigation plans, addition / alteration / expansion of existing facilities

which has a potential to result an on-site emergency situation, addition or deletion of Risks, Change in Statutory requirements etc.Separate revisions will not be issued under circumstances such as changes in designation, phone numbers, manpower reshuffleetc.

6. This plan shall be mailed to all users at SPL Works and all HODs/HOSs shall keep the plan as electronic version on theircomputer workstation. However hard copy shall be maintained at Security, Control Room, Fire Station, Occupational HealthCentre, Site Controller and Incident Controller.

7. All HODs and HOSs are requested to go through the plan and communicate role of Incident Informer and responsibilitiesduring the emergency to SPL and contract employees working with respective departments.

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ON SITE EMERGENCY PLAN

REVISION SHEET

Sr.No.

Location ofAccident/Incident

Date ofAccident/Incident

Source ofInformation

Review ofApplicabilit

y

Nature ofRevision

Remarks Sign

1

2

3

4

5

6

7

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TABLE OF CONTENTS

SR.NO. CONTENTS PAGE NUMBERS

1 Important Telephone Numbers 6 10

2 Name and address of person furnishing information. 11

3 Key personnel and their responsibilities 12 26

4 Guidelines for gathering at Assembly Points. 27 28

5 Details of Outside organization. 29

6 Details of liaison arrangement between the organizations. 29

7 Information about Preliminary Hazard Analysis. 29 31

8 Details about the Site. 32

9 Description of hazardous chemicals. 33 34

10 Likely dangers to the plant. 35

11 Effects of fire and explosion. 35

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SR.NO.

CONTENTS PAGE NUMBERS

12 Risk Summary 36 37

13 Details on

13.1 Safety and Security System. 38 40

13.2 Hazard control plans. 40 60

13.3 Instrumentation system. 60

13.4 Design features of the buildings. 60

13.5 Operational Surveillance. 61

13.6 Maintenance system. 61

14 Communication facilities. 62

15 Fire fighting facilities and installations. 62 66

16 First Aid facilities / Medical services 67

17 SPL Site Plan Available in hard copy

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1. Important Telephone Numbers SPL Key Personnel.

Sr.No.

Name Designation Intercom No. Mobile Number Office Resi

Central Control Room-ECC 1 Shift in-Charge / Panel Engineers. 111 -- --

Security ECC 2. Security Officer On duty. 444 -- --Occupational Health Center Male Nurse On duty 509 -- --

Fire Station Fire Operator On duty 555 -- --1 Mr. K. V. Mujumdar Chief Executive Operations 550 650 9820120870

2 Mr. A. K. Majahan Asst. General Manager-Production_PS 516 665 9822618849

3 Mr. U. D. Vaishampayan Asst. General Manager HSE 533 664 98223074014 Mr. R. B. Thorat Asst. General Manager Engg. 565 662 9822618850

6 Mr. R. P. Shinde Asst. General Manager MHD 532 618 98226143547 Mr. J. L. Joshi Asst. General Manager PR&A 585 242634 9422689990

8 Dr. (Ms.) S. G. Rathod Advisor Medical. 544 706 9869669203

9 Mr. P. Pallaniappan Manager Civil. 541 637 942116842611 Mr. A. M. Kalikar Manager Inst. Engg. 557 672 9850358063

12 Mr. V. P. Mhatre Manager Mech. Engg. 562 661 942249595813 Mr. G. Raghava Rao Manager Production_SPS 414 666 --

14 Mr. A. P. Thulaseedas Sr. Manager Production_SPS 416 636 9822602257

15 Mr. S. K. Salunke Jt. Manager HR&A 584 263432 942209606116 Mr. S. G. Sawant Asst. Manager - Security 590 658 9960333802

17 Mr. V. A. Mulay Asst. General Manager QCA 523 648 9869228827

18 Mr. M. G. Kulkarni Dy. Manager HSE 533 277443 9423253932

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Important Telephone Numbers Outside SPL.

Sr.No. Details Of Contact Telephone No.Government Officials:

1 Grampanchayat, Amdoshi-Wangani 02194-222480

2 Sarpanch 02194-223631,3 Police Station, Nagothane 02194-263520/242233

4 Sub-Divisional Magistrate, Mangaon 02140 - 2631415 Tahsildar, Roha 02194-222226

6 Chief Executive Officer, Roha 02194-242220

7 District Collector, Alibag 02141-222001/2223228 Directorate of Industrial Safety and Health, Raigad. 022 27578587

9 Directorate of Industrial Safety and Health, Maharashtra State. 022 23522230/31/3210 Maharashtra Pollution Control Board, Raigad. 022 27576034 / 27562132

11 Maharashtra Pollution Control Board, Mumbai. 022 24010437/24020781/24037124

12 Petroleum and Explosive Safety Organization (Formerly CCE) 022 2757594613 District Health Officer, Raigad 02141 222077 / 78.

14 Certifying Surgeon, Maharashtra State. 022 2352223515 Office of Electrical Inspector Div. II, Thane. 022 253544201.

16 Boiler Inspectorate 022 23521388.

Emergency Response Centers:1 Emergency Response Center, HOCL, Rasayani 02192 250041 to 45.

2 Emergency Response Center, MIDC, Mahad. 02145 232738.

Crisis Groups:1 Local Crisis Group, Mangaon 02140 263141 / 242202 / 2422072 District Crisis Group, Raigad. 02141 222118 / 222001

3 State Crisis Group, control room, Mantralaya. 022 2027990 / 2854168.

Mutual Aid Response Groups (MARG):1 Coordinator, Mahad. 02145 232309 / 02145 232053.

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Sr.No. Details Of Contact Telephone No.2 Coordinator, Roha 02194 263531 / 263701

3 Coordinator, Central Raigad. 02141 2381314 Coordinator, Patalganga 02192 250041

5 Coordinator, Taloja 022 27412778

Fire Stations:1 Roha MIDC Fire Station 02194 263600.

2 IPCL, Fire Station, Nagothane 02194 222280.3 RCF, Fire Brigade, Thal, Alibag. 02141 265413 /238131

4 GAIL Fire Station, Usar, Alibag. 02141 2654135 HPCL Fire Station, Usar, Alibag 02141 265376

6 Vikram Ispat Fire Station, Salav, Alibag. 02144 260110-15.

7 MIDC Fire Station, Mahad 02145 2324058 MIDC Fire Station, Khopoli 02192 262401.

Doctors and Hospitals:

1 Primary Health Centre, Nagothane 02194 2220352 Dr. Kokane Hospital, Nagothane 02194 222202 / 224323

3 Dr. Gupta Nursing Home, Nagothane 02194 222152 / 2222204 Dr. Sachin Vairagi (Orthopedic Surgeon), Pen 02143 257292 / 9850822331.

5 Dr. Purohit Hospital (Orthopedic Surgeon), Panvel 022 224529226 Gandhi Hospital (Burn unit/with various specialists), Panvel 022 27465023

7 Lifeline Hospital, (With various specialists) Panvel 022 27458171 / 27461260

8 Dr. Devendra Jadhav (Ophthalmologist), Roha 02194 243435 / 243661\ 094224942639 Dr. Haldipurkar (Ophthalmologist), Panvel 022-274522228 /2745314 (R)

10 Dr. Ashok Jadhav (Physician), Roha 02194 244646 / 24355311 Dr. Dhruv Hospital, Roha (General Surgeon) 02194 263218.

12 Dr. Ashok Lavate (Dental Surgeon), Pen 02143 256610 / 252120.

13 Dr. Bhat, Roha (Gynecologist) 02194 242672.14 Dr. Wagale (Pediatrician) hospital, Roha 02194 242609 / 242809

15 Wockhardt Hospital ( Dr. Suresh G. Vijan ) 022 55994444, 09820064998.16 Sion Hospital 022 24076385/ 86.

17 Civil Surgeon, Alibag, Raigad 02141 222157 / 222017.

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Sr.No. Details Of Contact Telephone No.18 Leelavati Hospital, Bandra, Mumbai. 022 26438281/82.

Blood Banks:1 Janakalyan Blood Bank, Mahad. 02145 222604

2 Blood Bank Panvel. 022 27450890

3 Blood Bank Alibag. 02141 - 222204.4 Red cross Society, Mumbai 022 22663195.

5 Sion Hospital, Mumbai 022 24076388.Ambulance Services:

1 R. C. F. Hospital, Alibag 02141 2223942 Medical College Hospital, Alibag 02141 227928

3 Star Helpline, Alibag 02141 223409

4 Dhanvantari Arogya Seva, Alibag 02141 2215565 Vadkhal Grampanchayat, Pen 02141 253444/252415.

6 IPCL Hospital, Nagothane 02194 222280-85

7 Nagothane Grampanchayat 02194 2222018 MIDC, Dhatav 02194 263600

9 Public Health Centre, Pali 942337654010 Panvel 27452332/27453522/27453701/27452337

11 Taloja 27412960/2741081012 JNPT, Uran 27242326

13 Uran Corporation 27222320

14 Indira Gandhi Gramin Rugnalaya 2722272215 Bhushan Steel, Khopoli 02192 274295

16 Upjilla Rugnalaya, Karjat 02148 22206917 Kokan Bank, Mahad 02145 223086

18 Mahad Nagar Parishad Karyalaya 02145 222116

19 Gramin Rugnalaya, Mahad 02145 222127Shelters:

1 Agarwal High School, Nagothane 02194 2220582 Primary School, Amdoshi --

3 Petrochemicals Vidyalaya, Nagothane 02194 222280.

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Sr.No. Details Of Contact Telephone No.Bakeries:

1 Nagothane Bakery 02194- 2222412 Dhavir Bakery 02194 242116

3 Kohinoor Bakery 02194 - 244110

Heavy Equipment:1 Mr. Janardan Shedge, Roha 02194 242300

2 Mr. Vishnu Lokhande, Dhatav 02194 2639393 M/s. Ballaleshwar Crane Services, Wakan 02194 242049.

Maharashtra State Transport: (ST Depot)1 Nagothane 02194 222023.

2 Roha 02194 242217.

3 Alibag 02141 222006.4 Pen 02143 274044.

Maharashtra State Electricity Board (MSEB):

1 Roha 02194 2422062 Dhatav 02194 263618

3 Nagothane 02194 2221474 Kansai 02194 238653.

Telephone Exchange:1 Dhatav 02194 263500.

2 Roha 02194 242650 / 242640.

3 Nagothane 02194 222003 /198Railway Stations:

1 Station Master, Nagothane 02194 222028.2 Station Master, Roha. 02194 232348.

3 Station Master, Pen. 02194 252529.

Press Authorities:1 Roha Taluka Patrakar Sangh 02194 244177.

2 Nagothane Press Club 02194 222108.3 Raigad Press Club 02194 222290.

2. Name of Person furnishing information:

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MR. K. V. MUJUMDARCHIEF EXECUTIVE - OPERATIONSM/S. SUPREME PETROCHEM LIMITED,Village Amdoshi - Wangani, Wakan-Roha Road,Tal Roha, District. Raigad 402 106.Phone : 02194 - 222540 to 48.

Fax : 02194 - 222537.

3. Key Personnel and their responsibilities:

By considering the various scenarios it is seen that the emergency need to be contained in stages. Following phasesare considered based on the emergency response time ;

Phase I : Upto first 20 minutes after the occurrence.

Phase II : From 20 minutes to 45 minutes after the occurrence.

Phase III : From 45 minutes onwards.

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Phase wise responsibility matrix is as under

Key Personnel Designation RoleSpecific responsibility / duties during

Phase 1upto 20 mins.

Phase IIfrom 20 to 45 mins.

Phase IIIfrom 45 mins

onwards.

Incident Informer Any personnoticing the

Incident

IncidentInformer

Incidents occurring in any part of Complex shall be communicated toCCR/SIC by pulling MCP followed by PA system, Telephone or inperson.

If without risk, try to contain / extinguish / rescue / isolate, or wait forinstructions till arrival of SIC / HOD / HOS.

Be available at the spot and wait for instructions.

Panel Engineers /Panel officer

Officer /Engineer

Production-PS

Plantcoordinator

Communicate message received from incident informer to shift In-charge. In case SIC is not communicated within two minutes (afterthe message received from Incident Informer), then perform theduties of SIC till his arrival.

Communicate exact location of emergency to Fire Dept and Securitydept,

Operate siren to declare emergency as per instructions of SIC Informthe name of SIC to Security to enable him to instruct the guardsaccordingly.

Communicate about emergency also to HOD Prd_PS or HSE or E&Ior DCE - Operations.

Announce on PA system about i) Location of emergency, ii)cancellation of work permits, iii) assembling of AFS members at CCRand iv) instruct employees who are not connected with incident toassemble at nearest assembly point.

Repeat the announcement in English, Marathi and Hindi.

Maintain co-ordination between plant and CCR.

Raise all clear siren followed by Announcement on PA system about" ALL CLEAR " of emergency in English, Marathi and Hindi onreceiving instructions in person from Incident Controller.

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onwards.

Shift In-charge

(Designated officer in-charge of the shift)

Shift In-charge Plant / Incident

coordinator

After receiving information from Incident informer or from Panel

Officer, rush to the spot. Assess the magnitude of situation and instruct Panel Officer to

declare emergency.

Supervise casualty search/rescue operation, instruct TM (Fire/HSE) /AFS Members accordingly.

Instruct TM (Fire/HSE) / AFS Members about the manner and type offire fighting equipment / Special PPE to be used.

In presence of Asst. General Mgr Prd.-PS, work as per hisinstructions.

In absence of DCE-O and Asst. General Mgr Prd.-PS perform their

duties as described thereunder. Arrange for Assembly Point No. 2 (near utility), No. 3, (near pump

house) and No. 4 (near ETP) co-ordination during silent hours.Arrangement for Assembly Point co-ordinators to be done by usingavailable employees during silent hours. In this case SIC should usehis own decision.

Work as per the directives of Incident Controller.

Monitor work environment in the area before giving "All Clear" siren.

Shall arrange to give "All Clear" on receipt of instruction in personfrom Incident controller.

Mr. U. D.Vaishampayan

Asst. GeneralMgr (HSE)

HSE/IncidentCoordinator

After hearing the siren, rush to the incidentspot and work as per the instructions fromIncident controller.

Take charge of all safety and firerequirement.

Co-ordinate with Site and Incident Controllersand work as per their instructions.

Liaise withStatutory bodies /other externalagencies, underinstructions fromSite or IncidentController.

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onwards.

Mr. M. G. Kulkarni Dy. Manager.

(HSE )

Fire / HSE

Coordinator

Mobilize fire tender

and fire fightingequipment.

Co-ordinate all firefighting and rescueoperations

Act as per thedirectives of Incidentcontroller.

Supervise firefighting / rescue

operation.

Assist in searching

for casualties andrescue.

Diagnose casualtiesgive first-aid andmobilize causalitiesto the medicalcenter under theinstruction ofIncident controller.

Organize outside

assistance in firefighting and rescueoperations ifrequired under theinstruction of Sitecontroller.

Team Member(Fire/HSE)

Team Member(Fire/HSE)

Fire/RescueCoordinator

Rush to theincident spot with firetender followed byambulance aftergiving intimation toCCR. Consider winddirection & roadstatus while turningout the vehicles.

Turnout fire

tender, ambulanceand fire fightingappliances near theincident spot andinform SIC about itsreadiness.

Assist in searchingfor casualties andtheir removal to themedical centerunder theinstruction ofSIC/Incidentcontroller.

Assist in searchingfor casualties andtheir removal to themedical centerunder theinstruction ofIncident controller

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onwards.

Search for

casualties andarrange for rescue /first aid / shifting atOHC, as perinstructions ofSIC/incidentcontroller.

Start fire-fightingoperation under theinstructions fromSIC/Incidentcontroller.

Liaise withincident controller foreffective control

Utilize auxiliaryfire squad for firefighting and rescue.

Male NurseOn duty

Team Member(HSE/OHC)

MedicalCoordinator

Organize first aid totreat the affected.

Call trained first-

Aiders to OHC ifrequired.

Give feedback aboutthe first aid given toMedical officer andwork as per the

Assists the Medicalofficer in providingmedical aid to the

injured personnel.

Work as per theinstructions fromMedical Officer /

Incidentcoordinators.

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onwards.

instructions of

medical officer. Assist medical officer

in treatment andcasualty shifting tohospital.

In absence ofmedical officerperform his duties.

Dr. Ms. S. G. Rathod Advisor -Medical

Medicalco-ordinator

Take charge ofentire medialtreatment operation.

Ensure casualtymobilization toneighboringhospitals as requiredin consultation withincident controller /site controller andgive constantfeedback to themabout the status of

casualties.

Liaise with localhospitals foradditional help ifrequired.

Co-ordinate fortransport with Sec /PR department forcasualtiesmobilization.

Contact designatedhospital/ nursinghomes informingthem about the

emergency.

Work as per theinstructions fromIncident or SiteController.

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onwards.

Mr. S. G. Sawant/

Security Officer (s)on Duty

Asst. Manager

Security/SecurityOfficer

Communication /

gate control /head count /

fire and rescueassistance

After hearing the siren and after receiving communication from

Central control room ensure control of men and vehicles at maingate. All other gates will be closed unless and otherwise instructed bySite Controller.

Communicate to key personnel in seriatim as per list given below - During working hours (1000 hrs. to 1800 hrs.) the emergency

need to be communicated to CE (O) (either directly or through theirPA.) and to QCA - Mec - Ins - PR&A / HRD Deptt .

During silent hours (1800 hrs. to 1000 hrs.) the emergencycommunication should be done by Officer in-charge - Security inseriatim to

Employees staying at SPL Township (HODs of Prd - PS, Mec, Ins,Ele, Civil, HSE, Medical officer, Fire Engr, MHD, SPS, QCA).

CE (O) at township residence or at Mumbai Residence.

Employees staying at Roha - HOS -PR&A / HOS-HR&A.

Send vehicles as per the need to Key personnel.

Communicate the name of Incident Controller to Security Office,Depute 2 security guards to report to CCR.

During silent hours arrange for Assembly Point 1 (Admn. Bldg. porch)co-ordination.

Give head count of SPL employees, contract employees, visitors,drivers and cleaners of vehicle to CCR within 1.5 Hrs of occurrence

of incident. Allow only personnel as listed above to enter the operational area.

Other employees or contractors (if any) to be permitted to enter theoperational area only on specific instructions from Site Controller.

Ensure no vehicle movement on road to plant.

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onwards.

Mr. A. K. Mahajan Asst. General

ManagerProd-PS

Incident

controller

After hearing the

siren rush to thecentral control room(ECC-1) and takecharge as IncidentController as well asSite Controller tillarrival of SiteController.

Ensure that theemergency plan hasbeen activated bycommunication tofire and securitydept.

Give directions tooperating personnelfor fighting theemergency based onthe informationavailable in RiskSummary of On -

site emergencymanagement Plan.

On arrival of SiteController, handoverthe charge of SiteControl to him and

Provide advice and

information to thefire and securitypersonnel and localfire service as andwhen they arecalled.

Ensure that all non-essential personnelof the affected areaare evacuated tothe appropriateassembly points.

Maintaincommunication withthe CCR to keepSite Controllerinformed about thestatus.

Instruct employees(including visitors

and contractors)working atAdministrationbuilding, SPS Dept.,MHD (WH I / II,Bagging, stores),

Establish contact

and maintaincommunicationwith theEmergency controlcenters andAssembly pointsand continuouslyreview the situationwith the sitecontroller.

Depending uponthe situation shallinstruct personsgathered atassembly point togo back to normalworking spot andinstruct accordinglyto ECC 1 and 2.

Shall instruct inperson to SIC to

'call off'emergency.

During evacuation,Instructions are tobe given to vehicledrivers on route to

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onwards.

rush to incident spot.

Take charge ofemergencyoperations at theincident spot.

Assess themagnitude of theincident and decidefurther course ofaction.

QCA, Technical

Center should go tonearest assemblypoint if required.Instructions shall begiven to oneHOD/HOS availablein each of theabove areas.

be followed and

safe place wherethe personnel areto be taken.

Mr. K. V. Mujumdar Chief Executive

- Operations

Site Controller After hearing thesiren, rush to thecentral control room.(ECC-1)

Take charge of SiteController from theIncident Controller.

Review the situationin the affected areawith the IncidentController. Assessthe magnitude ofthe emergency anddecide thenecessity to call forany outsideassistance.

Instruct employees(including visitors

and contractors)working atAdministrationbuilding, SPS Dept.,MHD (WH I / II,Bagging, stores),

Ensure thatmedical aid ispromptly providedto the casualtiesand their relativesare informed.

Organizeevacuation andtransportation ofpersonnel from theassembly points toa safe location in or

outside the plant. Keep corporate

office andconcernedGovernmentAgencies press

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onwards.

QCA, Technical

Center should go tonearest assemblypoint if required.Instructions shall begiven to oneHOD/HOS availablein each of theabove areas.

etc. informed of the

emergency and ifnecessary arrangeinformation to theoutside habitantsthrough police.

Take head-countreport from officerin charge securityand from HOS (HR& A) and decidefurther course of

action. After giving all

clear shall arrangefor head count bycommunicatingwith HOD/HOS foridentifying missingpersons, if any.

Mr. J. L. Joshi Asst. GeneralManager

( PR & A )

Liaison co-ordinator

After hearing thesiren, be available

on the seat and waitfor the instructionsfrom site controller.

Assist SiteController in the

areas ofcommunications,public relations,Transportation, foodsupply, Mobilizationof casualties to the

Liaise with Externalagencies under

instructions includingfamilies of thecasualties under theinstructions from SiteController.

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onwards.

hospitals as per the

directives of HSEDeptt.

Provide informationand assistance tothe nearbycommunityrepresentatives /Press Authorities /Police Authoritiesas per thedirections from Site

Controller.Mr. V. P. Mhatre Manager

(Mech)Engineering/

Assembly pointco-ordinator

Arrange for sending representative to Assembly Point No. 3 (near Pumphouse) for co-ordination.

After hearing the siren, rush to the incident spot and work as theinstructions from Site/Incident controller.

Mr. R. B. Thorat Asst. GeneralManager

(Engg. Div)

Engineering /Assembly point

co-ordinator

Arrange for sending representative to Assembly Point No. 2 (near utility) forco-ordination.

After hearing the siren, rush to the incident spot and work as theinstructions from Site/Incident controller.

Mr. G. RaghavaRao/Mr. A. P. Thulseedas

Manager /Sr.Manager

(Prd - SPS)

SPS co-ordinator

After hearing the siren, be available on seat and wait from the instructionsfrom Site/incident controller.

Perform normal operations if SPS area is not incident spot or instructed bySite controller.

Mr. S. K. Salunke Jt. Manager( HR & A )

Communicationco-ordinator

After hearing thesiren, be availableon seat and waitfrom the instructions

Co-ordinatetransportation /communicationactivities as per the

Act as per thedirectives from Site/ IncidentController.

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onwards.

from incident

controller. Arrange for sending

representative toAssembly Point No.1(Admin Bldg. porch)for co-ordination.

directives from

Incident Controller.

Give Head Count

of SPL employeesto CCR within 1.5hours of theincident.

Mr. V. A. Mulay Asst. GeneralManager(QCA)

QCA co-ordinator

Day time :

After hearing the siren, be available on seat and wait for theinstructions from incident controller.

The departmental AFS members should report OHC after hearingsiren and assist OHC staff

Depute representative at Assembly Point No.4 (at ETP) for AssemblyPoint co-ordination.

Silent Hours:

Departmental AFS members should report to OHC.

Other persons should available in QCA department or work as perthe instructions from Incident Controller.

Team member(Production -PS / SPS)- Other than

AFSMembers.

PlantCoordinator

Do not leave the place unless your workplace is an incident spot.

In case the job need to suspended for whatsoever reason and time, itshould be suspended in safe condition, with prior permission fromSIC or Panel Engineers.

Shall assist Incident controller in handling the emergency includingfire fighting and rescue operations.

Communicate plant conditions to CCR and act per the directives ofSIC / Panel officers for safe shutdown/ isolation.

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onwards.

Team member

(Mechanical)- Other thanAFS Members

Mechanical

Coordinator

Mechanical Technician if available, shall reach CCR with emergency

toolbox and report Incident / site controller. If you are doing some job and it need to be suspended for

whatsoever reason and time, it should be suspended in safecondition.

Work as per the instructions of Incident controller.Team memberInstrumentation

- Other thanAFS Members

Inst.Coordinator

Instrument Technician shall reach CCR with emergency toolbox andreport to site / incident controller.

If you are doing some job and it need to be suspended forwhatsoever reason and time, it should be suspended in safecondition.

Work as per the instructions of Incident controller.Team member( Electrical )- Other thanAFS Members

Ele.Coordinator

Electrical technician shall rush to substation and man it and followinstructions from Site / incident controller.

If you are doing some job and it need to be suspended forwhatsoever reason and time, it should be suspended in safecondition.

Work as per the instructions of Incident controller.Assemblypoint co-ordinator

Assembly pointco-ordination

After hearing the siren, shall arrange to rush to the designatedassembly point after informing to HOD/HOS.

If the assembly point is rendered unsafe due to effect of the incidentshall divert/guide the persons assembled to another assembly pointand keep CCR informed about it.

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onwards.

Contractors (Mechanical,

electrical, Civil, Occasionalservices), Visitors andTruck/tanker drivers andcleaners.Canteen employees.

After hearing the siren should go to the nearest assembly point.

Before leaving the workplace, should ensure that the job in hand (ifany) is suspended in safe condition.

Canteen employees shall remain inside the cafeteria bldg. If it is notincident spot.

Driver of emergency van ofCCR

*After hearing the siren should report to CCR from the nearesttelephone, be available near CCR and act as per the instructionsreceived from CCR.

IMPORTANT INSTRUCTIONS DURING THE EMERGENCY:

1. The HOD / HOS as listed under Key personnel and designation column, should perform the duties as described thereunder. Inabsence of HOD / HOS, the Officer-in-charge of concerned departments shall follow the above instructions.

2. After hearing the siren or after the communication about emergency, employees (including visitors and contractors) working atAdministration building, SPS Dept., MHD (WHI/II, Bagging, engg. stores, scrap yards, steel yards, EB Storage, projectstores/office, etc), QCA, Technical Center, contractor sheds and Switch Yard should not leave their place unless they areinstructed by their HOD or their workplace is an incident spot. All the normal operations and activities in the above mentionedareas should be continued unless and otherwise instructed by incident controller. The incident controller shall arrange to informany one available HOD/HOS each of the above areas about evacuation or stopping of the operations if necessary, however it isthe responsibility of the concerned HOD/HOS to inform all other personnel in their respective areas about the instructioncommunicated by the incident controller.3 If your workplace is an Incident Spot ( e. g. SPS, MHD (WHI/II, Bagging, engg. stores, scrap yards, steel yards, EB Storage,project stores/office, etc),/ Security - Admn block / Workshop / QCA / Switch yard, sub station etc.) Work as co-incident controller

and perform / co-ordinate the duties of incident controller in consultation with Incident controller / Site Controller.4. Don't engage telephone lines of your department, CCR, Fire Station and Security. Don't enquire about status of emergency.5. Avoid panic behaviour and over enthusiasm.

6. Keep communication clear, concise and complete.7. Consider wind direction while fire fighting, rescue, choosing assembly point and evacuation.

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onwards.

8. Within one hour of giving all clear siren, all HODs/HOSs shall inform Site Controller or incident controller at CCR about the

head count for missing persons if any (SPL employees, visitors and contract employees) associated with their department.9. Work permits are suspended after declaration of emergency. Re-start of work after All Clear shall only be done after freshrenewal of the Work Permit from SIC.

10. Employees handling emergency must wear all personal protective equipment like safety helmet, safety goggles/face shield,full face/half face respirator, Apron, hand gloves, safety shoes/gum boots. Special Protective equipment such as airline respirator,BA Set, fire suit, PVC suit etc. shall be used as per the instructions from SIC/Incident controller.

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4. GUIDELINES FOR GATHERING AT ASSEMBLY POINT AND EVACUATION PROCEDURE

Assembly

point no.Location Assembly point user departments in case of emergency at Evacuation

route.Tank Farm GPPS/HIPS/RD/Pelletizer/

boiler-htrblock

( Plant area )

ChlorineLeak at

CoolingTower

ChlorineLeak at

waterblock

InitiatorStorage

EthylBenzene

storage/switchyard

Engg.Stores /

Warehousearea

Main sub-stn area

QCA /Work-

Shop area

1 Admin.bldg. porch

- Truck / car drivers / visitors at front area / Front area employees.- MHD employees should use Assembly point 1 in case of emergency at Plant Area and Chlorine leak emergency at

Cooling tower / water block area and at main sub-station area.

From MainGate.

2 Near UtilityBlock

Engg. Strs /Warehouse

-- -- -- MHD/Workshop

QCA /Cafeteria /

Tech.center

MHD/ Mec- Inst /Elec.

Workshopfirst flr

-- -- Engg. Strs /MHD

From Gate No.2

3 Near Firepump hose

Engg. Strs /MHD ( in

suspicion ofsecondaryfire ) / Mec-

Inst /Workshopfirst floor

Mec - Inst /Workshop first

floor

-- -- -- -- Engg.Strs /

MHD/Mec - Inst /

Elec.Workshop first flr

-- Mec - Inst /Elec.

Workshopfirst flr.QCA /

Employeesat Cafeteria /Tech. Center

From GateNo. 2 / 3

4 Near ETP QCA /Employeesat Cafeteria

/ Tech.center

QCA /Employees at

Cafeteria /Tech. center

Mec/ Inst /Elec.

Workshop firstflr. QCA /

Employees at

Cafeteria /Tech. center

-- QCA /Employees

atCafeteria /

Tech.

center

QCA /Employe

es atCafeteria/ Tech.

center

Workshop,QCA / at

Cafeteria /Tech.center

-- From Gate No.2 / 3

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5. Outside organization if involved in assisting during the on-site emergency:

a ) Type of Accidents.b ) Responsibility assigned.

No. There is no outside organization is envisaged to be involved during the on-site emergency. The Company is a member ofMutual Aid Response Group, Local and District Crisis Groups constituted by Directorate of Industrial Safety and Health andDistrict Collectorate Hence additional resources in terms of Trained manpower, fire fighting equipment, personal protectiveequipment, medical facilities, rescue equipment, special gadgets etc can be augmented as per the directives from these groups.

6. Details of liaison arrangement between the organizations:

Liaison arrangements between the organizations are governed under the directives from Mutual Aid Response Group, Local andDistrict Crisis Groups. The members of these groups meet periodically to review on-site and off-site emergency preparedness,training requirements to employees, villagers, police, revenue and other interested parties.

7. Information on Preliminary Hazard Analysis:

a) Type of Accidents.b) System elements or events can lead to major accident.c) Hazards.d) Safety relevant components.

Detailed Preliminary Hazard Analysis is conducted by considering various scenarios. In addition, activity wise risk assessments

are conducted and documented under Register of Hazard Identification and Risk Assessment of respective department.

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PRELIMINARY HAZARD ANALYSIS

INCIDENT/ACCIDENT

SYSTEM HAZARDOUS ELEMENT SAFETY - RELEVANT COMPONENTS.

AREA: STYRENE STORAGE / TANKFARM.

1. Spillage ofstyrene.

Storage tank 02FB 502 A/B02FB 805

Overflow of styrene due to- Faulty LG.- Malfunctioning of controlvalves.- Accidental spillage.

- Level gauges/ continuous monitoring on DCS.- Continuous monitoring of all controls and redundant controlsprovision.- Provision of dike with spill collection arrangement.- S.S. studs are used with steel braided hose.

2. Spillage ofstyrene.

Styrene tanker (unloadinghose )

Spillage of styrene duringunloading due to - Flange /bolts failure.- Incorrect fittings.- Hose rupture / burst.

- Fittings are done by trained operators.- Master valve for closing the drain valve provided.- Periodic safety inspections of all tankers being done.- Periodic safety inspections of hose being done.

3. Spillage of

Furnace oil.

- Furnace oil Tanker.

(unloading).- From F.O. collection pot(while transferring fromCO2 / pot simultaneously.)

- Maloperation.

- Incorrect fittings.- Hose rupture / burst.- NRV at suction fails.- Maloperation (Filter valvekept open.)

- SOP for loading /unloading tanker is prepared.

- F.O. Spill containment tank s provided.- Periodic safety inspections of hose being done.- SOP for transfer is available.

4. Pool Fire Major hydrocarbon spillagein area.

- Accidental spillage .

- External fire / ignitionsource.

- Emergency plan prepared and operational.- Sprinkler / foam pourer system provided.- Deluge valve (manual and remotely ) operated provided.- No smoking / no hot job regulations strictly being observed.- No combustible storage near the vicinity.- Periodic grass cutting being carried out regularly.- Storage is under inert atmosphere.

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INCIDENT/ACCIDENT

SYSTEM HAZARDOUS ELEMENT SAFETY - RELEVANT COMPONENTS.

AREA : PEROXIDE HANDLING1. Fire /Explosion.

1. Cold storage shed.

2. Reaction Vessel.

- Compressor failure.- Thermal decomposition due to

delayed use.

- Runaway reaction due tochange in proportion of feed

- Two independent compressors with redundant power supplyprovided.

- Stored at or below +7 C i.e much below the SADT valve(42C )- Used as first in first out principle. (Well documented systemavailable)- Quality / labeling being checked and inspected duringreceipt.- The storage temperature is constantly monitored on DCS aswell as on locally.- The storage room is made up of fragile construction to allowsafe dispersion of the contents.- Inventory of storage is very less.- Emergency plan is available and operational.

- Peroxide processed in dilute condition. i.e. mixed with whiteoil / mineral oil.

2. Spillage ofinitiator / contact orexposure to theoperatingpersonnel.

- Solution preparationvessel.

During handling of peroxidecarboys (accidental spillage )

- Personal protective equipment ( helmet, face-shield, hand gloves )are provided and being used .- SOP for solution preparation available.

AREA : GPPS / HIPS PLANT - REACTION SECTIONOvertemperature/Over pressure.

- Polymerization reactor.(Prepoly reactor)

- Runway reaction due to1. Maloperation.2. Malfunctioning of interlocks, tripsetc.3. External fire.4. Power failure / DG failure.

- Sop for start-up , operations, a safe shutdown prepared arefollowed.- The reaction is carried out at vacuum and at near the boilingpoint of styrene.- The reaction is monitored constantly on DCS and on field.- Runway reaction killer (diluents) is provided.- Redundant control instrumentation is available.- Critical equipment are provided with power from DieselGenerator.- Trained operators are employed for mounting the plant / DCSround the clock.- Emergency plan is made and is operational.

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8. Details about the Site :

a) Location of dangerous substances.b) Seat of Key personnel.c) Emergency Control Room.

The location of dangerous substances is indicated on Site plan wherein location of emergency control room, key personnel,escape routes, vehicular routes etc. are shown.

There are two emergency control centers;

- Emergency Control Centre 1 : Central Control Room.- Emergency Control Centre 2 : Main Gate ( Security )

List of equipment / essentials at Emergency Control Centers:

1. On Site Emergency Management Plan.2. Site Layout.3. Important telephone numbers.4. Personal Protective Equipment Kit.5. Blood Group register.6. Trem-cards.7. Material Safety Data Sheet (MSDS) only at CCR ECC1.

8. List of Qualified First- Aiders

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9. Description of Hazardous Chemicals at plant Site:

a) Chemicals (Quantities and toxicological data)b) Transformation if any, which could occur.c) Purity of hazardous chemicals.

a) With reference to the list of hazardous chemicals stipulated under the MSIHC Rule, the Company handles 29 chemicals,however all are being handled in very small quantities in quality control lab for testing and analysis purpose except StyreneMonomer which is a principle raw material for manufacture of Polystyrene. Toxicological data for all the chemicals handledat SPL is available under MSDS and the hard copies of MSDS are available with QCA/HSE/OHC/ECC1.

List of Chemicals covered under

The Manufacture Storage and import of Hazardous Chemicals Rules,

The Maharashtra Factories (Control of Industrial Major Hazard) Rules and

The Maharashtra Factories Rules as amended.

SR. NO. NAME OF THE CHEMICAL QUANTITYSTORED / HANDLED

1 Acetone 80 lit.

2 Ammonia 25 lit. in Lab and max. filled 4 to 5 cylinders in utilities.

3 Bromine 1 lit.

4 2- Butanone 100 lit.

5 Benzene 25 lit.

6 Cyclohexanone 1 lit.

7 Carbon disulphide 10 lit.

8 Carbon tetrachloride 10 lit.

9 Cumene 1 lit.

10 Copper sulphate 2 kg.11 Chloroform 25 lit.

12 Copper chloride 2 kg.

13 Chlorine Max. 3 cylinders of 80 Kg, each

14 Ethylene dichloride 1 lit.

15 Formaldehyde (37 % solution) 1 lit.

16 Hexane 25 lit.

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SR. NO. NAME OF THE CHEMICAL QUANTITYSTORED / HANDLED

17 Hydrochloric Acid 15 lit.

18 Iodine 1000 gms.

19 Manganese and compound (Manganese oxide) 1 kg.

20 Ethylene chloride 10 lit

21 Methyl Alcohol 1 lit.

22 Phenol 1 lit.23 Phosphoric acid 1 lit.

24 Sodium azide 5 kg.

25 Sulphuric acid 30 kg.

26 Styrene Monomer 8412 KL (Maximum storage Capacity)

27 Toluene 25 lit.

28 Xylene 2 lit.

29 Zinc sulphate 1000 gms.

b) Transportation: There is no any cross-country pipeline transport however styrene monomer is being transported from Mumbaito SPL Site by road tankers. A separate transport emergency management plan has been prepared and is available at HSEDeptt..

c) Purity of Hazardous Substances: It is indicated on container (in case of lab chemicals) and for styrene monomer the purity isnormally more than 99 %.

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10. Likely dangers to the plant

The likely dangers to the plant include Pool fires from spillage of styrene monomer and/or other hydrocarbons, runaway reactionin process sections, spillage of hydrocarbon due to the vehicular accidents, release of chlorine/ammonia from cylinders, thermaldecomposition of organic peroxides.

11. Enumerate effects of

i) Stress and Strain caused during normal operation

ii) Fire and explosion inside the plant and effect if any of fire explosion outside.

Fire and Explosion possibilities inside the plant are studied by using various hazard identification techniques namely Hazop,Risk Assessment study considering maximum credible loss scenarios, Quantitative Risk Assessment Study etc.

Effects of fire and explosion inside the plant are enumerated under the section - risk summary. Possibility of fire and explosionoutside the complex is practically negligible since there is no working industrial unit within 3 km area of SPL. Distance fromWakan-Roha road to PS manufacturing plant is more than 1 kilometer and from highway is around 2.5 Kilometers.

However, risks arising out of war and nuclear outfalls have not been considered for preparation of On- Site EmergencyManagement Plan.

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12. Risk Summary

Sr.No.

Scenario Weather Condition

ReleaseRate

ReleaseDuration

PoolDia

IDLHDistance

Pool Fire ImpactDistance (m)

FlashFire

ImpactDistance

Massin

vapourCloud

Lateignitiondistance

Explosionimpact

Distance (m)

Kg/s Sec. M M 4Kw/M2

12.5Kw/M2

37.5Kw/M2

M Kg M 0.03Bar

0.1Bar

0.3Bar

1 SM storagetank outlet

nozzlefailure

F 1 167 3600 59 -- 68 40 NR 30 -- -- -- -- --

D 3 167 3600 59 -- 81 41 NR 31 -- -- -- -- --

D3

2 SM storageTank pumpdischarge

nozzle

Failure

F 1 12.6 300 23 -- 31 15 NR 15 -- -- -- -- --

D 3 12.6 300 22 -- 45 18 NR 15 -- -- -- -- --

3 StyreneTanker(20 MT)

unloadinghose failure

F 1 13 1453 52 -- 55 30 NR 29 8.02 20 67 40 30

D 3 13 1453 51 -- 68 30 NR 29 0.18 10 23 16 13

4 FO Tanker unloading

hose failure

F 1 10.7 905 -- -- 43 24 NR 2 -- -- -- -- --

D 3 10.7 905 -- -- 60 25 NR 2 -- -- -- -- --

5 HSD tankoverflow

F1 0.723 180 -- -- 17 10 5 1 -- -- -- -- --

D3 0.723 180 -- -- 18 14 5 1 -- -- -- -- --

6 Line 11Reactor line

rupture

F 1 1.31 300 -- -- 21 10 5 6 -- -- -- -- --D 3 1.31 300 -- -- 27 17 5 8 -- -- -- -- --

7 F 1 1.16 300 -- -- 20 9 4 11 0.2 10 24 16 13

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Sr.No.

Scenario Weather Condition

ReleaseRate

ReleaseDuration

PoolDia

IDLHDistance

Pool Fire ImpactDistance (m)

FlashFire

ImpactDistance

Massin

vapourCloud

Lateignitiondistance

Explosionimpact

Distance (m)

Kg/s Sec. M M 4Kw/M2

12.5Kw/M2

37.5Kw/M2

M Kg M 0.03Bar

0.1Bar

0.3Bar

Line 12 Inletreactor linerupture

D 3 1.16 300 -- -- 25 16 5 15 0.13 10 22 15 13

8 Line 10,/11 / 12 REBtank outlet

nozzlefailure

F 1 104 764 14 -- 32 18 14 19 0.13 10 22 15 13

D 3 104 764 14 43 25 14 16 0.04 10 19 14 12

9 Line 10 / 11/12 REB tank

to pumpdischarge

nozzlefailure

F1 12.6 300 22 -- 45 18 NR 15 -- -- -- -- --

D3 7.58 300 18 -- 28 13 6 14 -- -- -- -- --

10 TBC bedinlet linerupture

F1 4 300 -- -- 27 14 9 3 -- -- -- -- --

D3 4 300 -- -- 38 21 9 2 -- -- -- -- --

11 Hot oil pumpdisch nozzle

failure

F1 29.9 180 -- -- 34 17 NR 1 -- -- -- -- --

D3 29.9 180 -- -- 50 21 NR 1 -- -- -- -- --

12 Ammoniacompressoroutlet linerupture

F1 0.753 1063 -- -- 19 16 NR 3 -- -- -- -- --

D3 0.753 1063 -- -- 16 14 NR 3 -- -- -- -- --

13 Chlorinecylinder

outlet tubingrupture

F1 0.536 149 -- 2598(7542)

-- -- -- -- -- -- -- -- --

D3 0.536 149 -- 448(1600)

-- -- -- -- -- -- -- -- --

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Radiation Intensity Thermal Damage Overpressure (bar) Damage to Equipment/ people37.5 KW/m2 100% Fatality 0.3 > 50% eardrum damage

12.5 KW/m2 30% Fatality in 30 Sec.. 0.1 1% death, > 1% eardrum damage4 KW/ m2 0% Fatality 0.03 Slight injury from flying objects

D - Neutral weather,F - Stable weather Gas dispersion simulations are performed for two sets of weather conditions namely, atmospheric stability Class F

with wind speed of 1 m/s and Class D with wind speed of 3 m/s.NR - NOT REACHED-- Indicates NO HAZARD

Distances under IDLH column in bracket are for 1/10th of IDLH value. (IDLH for Chlorine is 25 ppm, for Ammonia is 500 ppm and forStyrene is 5000 ppm. IDLH Immediately dangerous to life and health represents the maximum concentration of a chemical from which,in the event of respirator failure, one could escape within 30 minutes without a respirator and without experiencing any escape-impairing(severe eye irritation) or irreversible health effects. (NIOSH 1978)

Only other probable hazard identified is the run away reaction condition in the polymerization reactors. The possibility ofrun away polymerization reaction was studied and found to be very low in view of various measures incorporated in thereactors such as automatic temperature control, automatic feed and initiator cut -off, injection of ethyl benzene as adiluents, relief against overpressure etc.

On-site Emergency plan takes into account the above accident scenarios based on which procedures have beendeveloped for safe handling of emergency including evacuation of personnel.

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13. Details regarding;

13.1) Warning Alarm safety and Security Systems:

Warning alarm systems

- Manual Call Point (MCP) 93 nos. are installed at peripheral areas of plant, buildings and roads.- Zone monitoring units (ZMU) 17 nos. are installed inside PS plants.- Smoke detectors (ionization type) 26 nos. are installed at CCR, Pelletizers, Sub-Station, SPS CCR and SPS Lab.- Smoke detectors (optical type) 27 nos. installed at above locations.- Fixed Type LEL detectors 10 nos. installed at Plant and Tank Farm.- Portable LEL / O2 detectors available in HSE Dept.- Emergency Sirens.- Public Address System.

Safety Systems:

- The Company has a full-fledged Health Safety Environment department with qualified staff reporting directly to the UnitHead.

- The Company is having a well established Quality Management System conforming to ISO 9002 Standard,Environmental Management System conforming to ISO 14001 Standard and Health and Safety Management System

conforming to Occupational Health and safety Assessment Series Specifications ( OHSAS 18001 Specification).- Declared Health and Safety Policy with full fledged HSE Department as a part of line function reporting to Chief

Executive ( Operations ).- Spacious Site layout having adequate safety distances more than statutory norms.- Provision of wide roads with road barrier and laid down internal transportation system for various vehicles and

pedestrians.

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- Strict compliance of No Smoking regulation in entire complex.- Entry of vehicles in operating areas permitted only with spark arrester fitted at the exhaust of the vehicle.- Administration block, kitchen is isolated from main plant area. The factory front area has been provided with a paved

parking facility for around 50 tankers / trucks.- Separate storm water drain network with provision of fire/ hydrocarbon traps and flow diversion gates at different

locations.- Provision of two lagoons of 3500 m3 capacity each for emergency containment..- Dedicated water supply from Jack well constructed on Amba River.- Dedicated electricity supply from 220 KVA Switch Yard constructed by SPL. The Company is having 2 DG sets of 2.3

MW and one DG set of 1 MW respectively.- Availability of fire protection system with provision of 7654-m3 water storage. This surpasses the requirement for 4 hrs.

Water storage.- In-house HSE Library having publications / books and periodicals obtained from various voluntary organizations in the

field (From National / International sources)- Separate guidelines published on " Off the Job Safety " and circulated amongst employees.- Meticulous works permit system with periodic permit audit system.

- Well-established HSE training activity including detailed training need assessment and training modules for variousgroups.

- The Company is an approved drivers training institute by Government of Maharashtra, Home Department for impartingtraining on Safe Transportation of Dangerous Goods by Road.

- Dedicated team of employees and contractors committed towards health safety and environmental issues.- The Company has reserved more than 33 % of the acquired land for the purpose of green belt around the Complex and

separate forest development programme for afforestation purpose for promotion of greening activities in and around theComplex.

- Adherence to international engineering standards in design, construction and testing of the equipment and hardware.

Security Systems:

- Systems developed in line with the checklists from Shell / GE.- Dedicated entry and exit for personnel and materials.- Safety instructions for visitors, employees and contractors.- Personnel and vehicle inspection system.

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- Biometric access control system by using finger print.- On-line head-count system- Vigilance over no smoking / no tobacco / no alcohol policy.- Restriction on use of mobiles and pagers.- Internal Transportation System.

Security department is responsible to manage Emergency Control Centre II, which is well equipped with adequatefacilities.

13.2) Hazard control plans - technical and organizational precautions.

Detailed procedures for the Pool fire scenarios as discussed earlier have been prepared and being rehearsed six monthly.The specific preventive and mitigate plan for the above scenarios is as under;

SCENARIO 1: Chlorine cylinder outlet tubing rupture leading to dispersion of chlorine gas.

1.1 Prevention:

1.1.1 Inspection of cylinder at the time of receipt for any defects in valve / corrosion and periodic area inspection etc.1.1.2 Proper storage and handling (i.e. protection of cyl inder from sunlight / direct exposure to water, maintenance of regulators).1.1.3 Ensure that cylinder spanner (key) is always kept on the running cylinder valve.1.1.4 Training to employees handling chlorine about chlorine kits / emergency management.

1.2. Mitigation :

1.2.1 In case of liquid chlorine leak use the BA set and rotate the cylinder so that the leaking portion will come at the top leadingto gas leaks only. Don't use water directly on leaking chlorine cylinder portion.

1.2.2 Normally cylinder leaks from it's valve due to spindle damage or thread damage, observe the source of leak and bringchlorine emergency kit to the location.

1.2.3 By using the BA set / gas masks fit the chlorine kit to the cylinder.

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1.2.4 Meantime arrange for caustic flakes and prepare a solution in water in chlorine absorption bath.

1.2.5 Absorb chlorine in bath, monitor the temperature periodically.

1.2.6 If the leak stil l continued or further aggravated, take decision of evacuation as per the evacuation procedure.

SCENARIO 2: Ammonia compressor outlet line rupture leading to dispersion of ammonia gas.

2.1 Prevention:

2.1.1 Regular inspection of the lines, valves, etc. for any sign of leakage and taking immediate corrective action.

2.1.2 strict adherence of NO smoking regulation.

2.1.3 Strict adherence of permit to work system.

2.1.4 Training to employees about handling of ammonia / emergency management.

2.2. Mitigation :

2.2.1 By using the BA set / gas masks isolate the inlet / outlet valves. Don't use directly on leaking ammonia portion.

2.2.2 Use water spray to suppress the vapours.

2.2.3 Divert storm water / fire water to west lagoon by closing the diversion gate (No.2 &3)

2.2.4 Wear gas masks when operating in the affected areas to protect themselves from the irritating ammonia vapours. In

absence of gas mask, cover your nose / mouth with wet cloth.

2.2.5 All incoming / outgoing traffic to/from the factory should be stopped. Essential traffic may be allow through main / flyoverSide Gate.

2.2.6 If the leak stil l continued or further aggravated, take decision of evacuation as per evacuation procedure.

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SCENARIO 3: Styrene tank pump discharge nozzle failure leading to pool fire in styrene storage area.

3.1 Prevention:

3.1.1 Regular inspection of the lines, valves, dike, drains etc. for any sign of leakage and taking immediate corrective action.

3.1.2 Strict adherence of NO smoking regulation.


3.1.4 Regular preventive maintenance of electrical appliances to avoid any loose contacts or other causes of sparks / flash over.

3.1.5 Training to employees about handling of styrene / emergency management.

3.1.6 Periodic work environment monitoring in % LEL and in PPM.

3.2. Mitigation :

3.2.1 Isolate the main tanks 502 A, 502 B if possible by closing the main valves.

3.2.2 Use Dry chemical powder or foam to extinguish fire.

3.2.3 Activate sprinkler or water spray and keep fire water monitor on stand by.

3.2.4 Stop tanker unloading / loading operations. Do not start the engine of the vehicle and stop the engine if engine is in runningcondition and ask tanker drivers to vacate the place.

3.2.5 Trip styrene transfer pumps from storage tank and from day tank to process plant.

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3.2.6 Proceed for an orderly shutdown of GPPS, HIPS and Third Line units, if required.

3.2.7 Monitor overflow of OWS pit in Tank farm and divert storm water / fire water to west lagoon by closing the diversion gate(No.2 &3)3.2.8 Wear gas masks when operating in the affected areas to protect themselves from the irritating styrene odour. In absenceof gas mask, cover your nose / mouth with wet cloth.

3.2.9 All incoming / outgoing traffic to / from the factory should be stopped. Essential traffic may be allow through main / flyoverSide Gate.

3.2.10 If situation aggravated further, take decision of evacuation.

SCENARIO 4: Styrene storage tank outlet nozzle failure leading to pool fire in styrene storage area.

4.1 Prevention:






4.2. Mitigation :

4.2.1 Isolate the main tanks 502 A, 502 B if possible by closing the main valves.


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4.2.4 Stop tanker unloading / loading operations. Donot start the engine of the vehicle and stop the engine if engine is in runningcondition and ask tanker drivers to vacate the place.

4.2.5 Trip styrene transfer pumps from storage tank and from day tank to process plant.

4.2.6 Proceed for an orderly shutdown of GPPS, HIPS and Third Line units, if required.

4.2.7 Monitor overflow of OWS pit in Tankfarm and divert storm water / fire water to west lagoon by closing the diversion gate(No.2 &3)

4.2.8 Wear gas masks when operating in the affected areas to protect themselves from the irritating styrene odour. In absenceof gas mask, cover your nose / mouth with wet cloth.

4.2.9 All incoming / outgoing traffic to/ from the factory should be stopped. Essential traffic may be allow through main / flyover

Side Gate.


SCENARIO 5 :Adsorption bed inlet line rupture leading to pool fire in TBC bed area.

5.1 Prevention:

5.1.1 Regular inspection of the lines, valves, flanges etc. for any sign of leakage and taking immediate corrective action.




5.2. Mitigation :

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5.2.2 Keep fire water monitor on stand by.

5.2.3 Stop styrene tanker unloading / loading operations and ask tanker drivers to vacate the place.

5.2.4 Trip styrene transfer pumps from storage tank and from day tank to TBC bed.

5.2.5 Proceed for an orderly shutdown of GPPS and Third line units, if required.

5.2.6 Monitor overflow of OWS pit in Tankfarm and divert storm water / fire water to west lagoon by closing the diversion gate(No.2 &3)


5.2.8 All incoming / outgoing traffic to/ from the factory should be stopped. Essential traffic may be allow through main / flyoverSide Gate.


SCENARIO 6: Spillage of SM from transfer line on pipe rack at battery limit leading to pool fire.

6.1 Prevention:

6.1.1 Regular inspection of the lines, valves, flanges etc. for any sign of leakage and taking immediate corrective action.



6.1.4 Regular preventive maintenance of electrical appliances to avoid any loose contacts or other causes of sparks / flashovers.

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6.2. Mitigation :

6.2.1 Trip styrene transfer pumps from storage tanks and try to contain the spilled material by spreading sand.

6.2.2 Proceed for an orderly shutdown of GPPS and Third line units, if required.


6.2.4 Keep mobile foam tender and trolley as a stand by and use if required.

6.2.5 In case of fire start the sprinklers system at intermediate storage tank.

6.2.6 Start water curtain located between Intermediate storage tank and Heater block.

6.2.7 Monitor overflow of OWS pit in Tank farm and divert storm water / fire water to west lagoon by closing the diversion gate(No.2 &3)




SCENARIO 7: Styrene tanker (10/20MT) hose failure leading to pool fire in styrene unloading area.

7.1 Prevention.

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7.1.1 Ensure strict adherence of loading / unloading procedure.

7.1.2 Ensure No Smoking.

7.1.3 Ensure no hot work in the vicinity.

7.1.4 Periodic checks for studs, SS hose and tanker valves, earthing connections and lugs.



7.2 Mitigation:

7.2.1 Try to close the tanker drain valve / master valve without risk.

7.2.2 Spilled styrene should be contained by spreading sand.

7.2.3 Activate sprinklers in loading bay of tank farm.

7.2.4 Stop tanker unloading / loading operations. Donot start the engine of the vehicle and stop the engine if engine is in runningcondition and ask tanker drivers to vacate the place.

7.2.5 Get mobile foam monitor trolley and foam tender as standby.

7.2.6 Monitor overflow of OWS pit in Tankfarm and divert storm water / fire water to west lagoon by closing the diversion gate

(No.2 &3)


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SCENARIO 8: FO outlet nozzle failure leading to pool fire in FO storage area.

8.1 Prevention:


8.1.2 strict adherence of NO smoking regulation.


8.1.5 Training to employees about handling of FO / emergency management.

8.2. Mitigation :

8.2.1 Isolate the main tank 602, if possible by closing the main valve.



8.2.4 Stop tanker unloading / loading operations. Do not start the engine of the vehicle and stop the engine if engine is in running

condition and ask tanker drivers to vacate the place.

8.2.5 Trip FO transfer pumps from storage tank to Heater block.

8.2.6 Proceed for an orderly shutdown of GPPS, HIPS and Third Line Heaters, if required.

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SCENARIO 9: FO pump discharge nozzle failure leading to pool fire in FO storage area.

9.1 Prevention:






9.2. Mitigation :

9.2.1 Isolate the main tanks 602 if possible by closing the main valves.



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9.2.4 Stop tanker unloading / loading operations. Do not start the engine of the vehicle and stop the engine if engine is in runningcondition and ask tanker drivers to vacate the place.

9.2.5 Trip FO transfer pumps from storage tank to Heater block.

9.2.6 Proceed for an orderly shutdown of GPPS, HIPS and Third Line Heaters, if required.





SCENARIO 10: HSD tank overflow leading to pool fire in HSD storage area.

10.1 Prevention:

10.1.1 Regular inspection of the level gauge, dike, drains etc. for any sign of leakage and taking immediate corrective action.




10.2. Mitigation :


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10.2.3 Stop tanker unloading / loading operations. Do not start the engine of the vehicle and stop the engine if engine is inrunning condition and ask tanker drivers to vacate the place.





SCENARIO 11: Thermia pump discharge nozzle failure leading to pool fire in Hot oil storage area.

11.1 Prevention:






11.2. Mitigation :

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11.2.1 Isolate the main tanks 506 if possible by closing the main valve.




11.2.5 Trip Hot oil transfer pumps from storage tank to Process area (expansion tank).





SCENARIO 12: FO tanker hose failure during unloading of FO tanker.

12.1 Prevention :

12.1.1 Ensure strict adherence of unloading procedure.

12.1.2 Ensure No Smoking.

12.1.3 Ensure no hot work in the vicinity.

12.1.4 Periodic checks for studs, SS hose and tanker valves, earthing connections and lugs.

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12.2 Mitigation:

12.2.1 Try to close the tanker drain valve / master valve without risk.

12.2.2 Spilled FO should be contained by spreading sand.



12.2.5 Get mobile foam monitor trolley and foam tender as standby.





SCENARIO 13: GPPS / HIPS / Third line reactor inlet line rupture leading to pool fire.

13.1. Prevention:

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13.1.1 Ensure no smoking rules are followed.

13.1.2 Ensure strict adherence of permit to work system.

13.1.3 Periodic inspection checks for any small leaks of Hydrocarbon and Polymer.

13.1.4Training to employees about handling of styrene / emergency management.


13.2 Mitigation:

13.2.1 Trip styrene transfer pumps from storage tank to day tank and from day tank to process plant.

13.2.2 Initiate emergency shutdown of GPPS/HIPS/ Third line units.



13.2.5 Activate sprinklers or water spray and foam injection system and keep fire water monitors on stand by.





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SCENARIO 14 :Prepoly / Third line REB tank outlet nozzle failure leading to pool fire in Intermediate storage area.

14.1 Prevention:

14.1.1 Ensure strict adherence of NO smoking regulations.

14.1.2 Ensure strict adherence of permit to work system.

14.1.3 Periodic inspection checks of dike and pumps for any leaks.

14.1.4 Operators vigilance.



14.2 Mitigation:

14.2.1 Stop styrene tanker unloading operation and ask tanker drivers to vacate the area.


14.2.3 Proceed for an orderly shutdown of GPPS, HIPS and Third Line units.

14.2.4 Start sprinklers provided on intermediate storage tanks and water curtain provided near Boiler and Heater Block.


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SCENARIO 15 : HIPS / Third line recycle styrene pump discharge nozzle failure leading to pool fire in Intermediatestorage area.

15.1 Prevention:

15.1.1 Regular inspection of the lines, valves, flanges, dike, drains etc. for any sign of leakage and taking immediate corrective

action.




15.1.5 Operators vigilance.



15.2 Mitigation:

15.2.1 Isolate the main tanks 804, 804A if possible by closing the main valves.

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15.2.3 Stop styrene tanker unloading operation and ask tanker drivers to vacate the area.


15.2.5 Proceed for an orderly shutdown of GPPS, HIPS and Third Line units.

15.2.6 Start sprinklers provided on intermediate storage tanks and water curtain provided near Boiler and Heater Block.





SCENARIO 16 :Spillage / fire to peroxide storage due to thermal decomposition.

16.1 Prevention:

16.1.1 Keep storage temperature always below 10oc, ensure working of both compressors.

16.1.2 Weekly checking and carboys (inside room) for any leaks.

16.1.3 Use the material on first in first out principle.

16.1.4 Periodic inspection of light - fittings.

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16.2 Mitigation:

16.2.1. An emergency with respect to the initiator storage may be considered when:-

i) Bulging is observed ( i .e. carboys) due to thermal decomposition.

ii) Large quantity of spillage of initiators.

iii) Failure to start the compressors leading to non-availability of refrigeration to cold room for quite a long duration.

The recommended emergency procedure is as follows;

16.2.2 Inform the control room and fire station about the incident.

16.2.3 The concerned Shift - in- charge / shift superintendent should take a stock of the situation and activate the on - siteemergency plan accordingly, if found necessary.

16.2.4 With the help of available resources and fire squad, the containment and absorption of spilled material should be startedimmediately.

16.2.5 Avoid contamination of spilled material with domestic sewer / storm water drain.

16.2.6 Segregate the other combustibles from the spilled area / cover the spilled material with large amount of sand and keepunder observation of competent person.

16.2.7 In case of bulging of carboys or total refrigeration system failure contact immediately to the supplier and ask for arefrigerated vehicle from them.

16.2.8 Till arrival of the refrigerated vehicle from supplier the depressurization operation should be kept continued with properprecautions.

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16.2.9 On arrival of the refrigerated vehicle, transfer all the carboys into the vehicle container and store it below 10Ctemperature. Observe periodically for any pressure rise.16.2.10 If the pressure rising is observed then take the decision to incinerate the initiator ( in consultation with site / incidentcontroller ).Scenario 17 : Two emergencies occurring simultaneously.

- Incident informer shall communicate about incident to CCR / Fire Station by MCP or telephone.- On receipt of message, senior engineer / officer available in CCR, shall rush to the spot and assess the situation.- The senior engineer / officer along with the incident informer shall arrange to isolate / control / contain / extinguish /rescue (as the case may be), if without risk by using available resources.- In the meantime, shall inform CCR (Site controller) and the main incident controller about the incident and action taken.- Site Controller in consultation with main incident controller shall arrange for mobilization / augmentation of followingadditional resources - The list is exhaustive but not limited to :

- Additional manpower from SPL Township / Dawawalla Complex.

- Deputing full time standby operators at Jack well, Fire pump house, DG Room, tank farm, ETP etc. for ensuringuninterrupted supply of important utilities.- Notification of accident / incident to DISH, Police, SDO, SDM, other concerned Govt. Authorities, family

members of affected persons, Grampanchayat authorities and press authorities.- Arrangement of additional fire tenders / ambulances / Fire and safety equipment, trained manpower, rescue

equipment, etc. from member industries of LCG, DCG and MARG / fire stations in consultation with DISH,MPCB, Police, local and district authorities,.

- Giving directions to Security Dept or designated officer to appraise Grampanchayat members about theincident. Standby vehicles / spark arrestors shall be kept at Security to escort statutory authorities / pressauthorities / police etc. to the incident spot. Or nearest assembly point as per the instructions from IncidentController.

- Site Controller / Incident controller shall appraise the Local, District, DISH and press authorities about theinformation.

- Control over accident / emergency by using additional resources under the instructions from Main IncidentController. Take actions considering effects of both the incidents to each other or combined effects on theplant. These actions may include crash shutdown of plant, isolation, cooling, evacuation, and fire fighting, spill/ leak control etc, so as to minimize impact on all personnel, environment and property.

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- Give all clear after ensuring head count, safe evacuation, environment monitoring, absence of any residualrisks etc.

- All key personnel / other designated employees shall work as per the instructions from incident controller only.

13.3) Instrument Systems: Measuring instruments - reliability, servicing and maintenance :

- All measuring instruments have been listed those critical for safety of plant and otherwise with a detailed maintenanceprogramme.

- A full-fledged Instrumentation department headed by qualified, experienced engineers having dedicated staff isavailable round the clock.

- Adequate redundancy has been provided to all critical instruments with back-up by an un-interrupted power supply.- Yearly maintenance of all instruments along with testing of operability of all safety interlocks is carried out and records

are maintained.- All leak detection instruments ( LEL detector - portable and fixed / oxygen detector / Fire alarm system etc ) are tested

at periodic intervals.

13.4) Precautions in designing of the foundation and load bearing parts of the building :

- Protection of structural steel against fire by encasing with concrete.- In addition to the above, the stability of the building have been inspected by competent person every five years and

stability certificates are available for all buildings.- The load bearing capacity is 25 MT / M2.

13.5) Continuous surveillance of operations:

- A Distributed Control Circuits System ( DCS ) has been provided to facilitate continuous surveillance of all the plantoperations.

- A blast proof central control room for process control, The process controls are through DCS with built-in redundancyand fail safe design.

- The Central Control Room is manned round the clock with qualified trained engineers.

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- The field operators / technicians are also qualified / trained and are available in field round the clock.

13.6) Maintenance and repair work according to the generally recognized rules of Good engineeringpractices :

- The full-fledged Engineering Department having four sections namely, Electrical Engg. Department / Mechanical Engg.Department / Instrumentation Engg and Civil Engg. Department headed by qualified, experienced Graduate Engineersreporting to the Unit Head is available and is manned round the clock by qualified, trained staff / technicians havingDiploma Engineering in re

model _onsite emergency mgt. plan

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