Document No.

COR/HRM/EPP/02
On –Site Emergency Preparedness Rev. No. & Date 03; 23/01/2011
Plan-Saswad Factory
Page 1 of 48

ON-SITE EMERGENCY PREPAREDNESS

PLAN

FOR

KIRLOSKAR PNEUMATIC CO. LTD,

PLANTSASWAD PUNE-412301

Prepared by – Safety Officer Approved by – HOD HRM

EHS/MR/F/37
 Document No. COR/HRM/EPP/02
On –Site Emergency Preparedness Rev. No. & Date 03; 23/01/2011
Plan-Saswad Factory
Page 2 of 48

Contents
1. INTRODUCTION
2. DISTRIBUTION LIST
3. REVISION STATUS AND APPROVAL STATUS OF THE PLAN
4. COMPANY PROFILE
5. OBJECTIVES OF THE PLAN
6. REQUIREMENTS OF EMERGENCY PLAN
7. DETAILS FURNISHED IN THE ON-SITE EMERGENCY PLAN BY:-
8. KEY PERSONNEL OF THE ORGANIZATION AND RESPONSIBILITIES
ASSIGNED TO THEM IN CASE OF AN EMERGENCY.
9. EXTERNAL AGENCIES CONTACT DETAILS INVOVED DURING
EMERGENCY
10. INFORMATION ON THE PRELIMINARY HAZARD ANALYSIS
11. DETAILS ABOUT SITE
12. EMERGENCY CONTROL ROOM (ECC). –
13. DESCRIPTION OF HAZARDOUS CHEMICALS AT THE PLANT SITE.
14. LIKELY DANGERS TO THE PLANT
15. POTENTIAL HAZARD CASES CONSIDERED
16. GENERAL GUIDELINES FOR EMPLOYEES
17. MEASURES TO BE EMPLOYED FOR MEETING THE OBJECTIVES
18. HAZARD CONTROL MEASURES IN CASE OF EMERGENCIES
19. EMERGENCY ACTION PLAN
20. IDENTIFIED EMERGENCY & ACTION PLAN
21. EMERGENCY PERSONNEL'S RESPONSIBILITY DURING DAY SHIFT
22. EMERGENCY PERSONNEL'S RESPONSIBILITIES DURING NIGHT SHIFTS
AND HOLIDAYS.
23. COMMUNICATION FACILITIES
24. DETAILS OF OTHER SERVICES AVAILABLE ONSITE
25. METHOD OF REPORTING EMERGENCY
26. EMERGENCY ASSEMBLY POINTS:
Prepared by – Safety Officer Approved by – HOD HRM
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On –Site Emergency Preparedness Rev. No. & Date 03; 23/01/2011
Plan-Saswad Factory
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27. EMERGENCY ACTIONS

28. SHUT DOWN PROCEDURE
29. POST EMERGENCY
30. CORRECTIVE ACTIONS
31. REHEARSAL / SIMULATION /MOCK DRILL

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 Document No. COR/HRM/EPP/02
On –Site Emergency Preparedness Rev. No. & Date 03; 23/01/2011
Plan-Saswad Factory
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KIRLOSKAR PNEUMATIC CO. LTD

Saswad Plant PUNE 412301.
ON SITE EMERGENCY PLAN

1. INTRODUCTION

The ultimate aim was to use the hazardous processes, materials under
control in safe way and try to minimize the health, environment damage in
case of an accident/ dangerous occurrence.

A major emergency in a factory is one, which has the potential to cause a

serious injury, or loss of life. It may cause extensive damage to property
and serious disruption both inside and outside the factory. It would
normally require the assistance of outside emergency services to handle
it effectively and timely. Although the emergency may be caused by
number of different factors like plant failure, human error, earthquake,
vehicle crash, fire, explosion or toxic release.

Prevention of accident through superior design, operation, maintenance

and inspection, achieving all these will reduce the risk of an accident, but
it will not eliminate all together, complete safety is hard to achieve and an
essential part of major hazard control is concerned with mitigating the
effects of a major accident.
An important element of mitigation is emergency planning. Emergency
planning means recognizing that accidents are possible, assessing the
consequences of such accidents and deciding an emergency procedure,
both on-site & out-site, that would need to be implemented in the event of
an emergency. It is an aspect of safety management.

On site emergency management planning is the responsibility of site

management.

On these requirements of Emergency Preparedness, at KPCL we have

carried out this exercise by adhering the guidelines framed under The
Maharashtra Factories (Control of Industrial Major Accidents Hazards)
Rules, 2003

2. DISTRIBUTION LIST

¾ The protected copy (read only) of Onsite plan is available to all

employees on intranet (Shashwat)

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On –Site Emergency Preparedness Rev. No. & Date 03; 23/01/2011
Plan-Saswad Factory
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3. REVISION STATUS AND APPROVAL STATUS OF THE PLAN

Effective
No. Document No. Brief description of revision Revised to
date

1  Plant wise not identified EHS/MR/F/37/REV.00 1-Nov-08

2  EHS/MR/F/37/REV.00 Site plans are added to the document EHS/MR/F/37/REV.01 1-Jun-10

Emergency Action Plan

3  EHS/MR/F/37/REV.01
Identified Emergency & action plan
Method Of reporting Emergency
Emergency assembly Points:
Emergency Actions
Shutdown Procedure COR/HRM/EPP/02 15-Oct-10
Post Emergency actions
Corrective Actions
Simulation Mock drill procedure

4 EPR-Emergency Specific procedures

COR/HRM/EPP/02 for Heat Treatment furnace at Saswad COR/HRM/EPP/02, rev. 03 23-Jan-11
included

  

  

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On –Site Emergency Preparedness Rev. No. & Date 03; 23/01/2011
Plan-Saswad Factory
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4. COMPANY PROFILE

(a) About the Company -.

The company is located at Kirloskar Pneumatic Co. Ltd Near Waghire
College Pune-Saswad road Saswad, Tal-Purandhar. Dist-Pune 412301Total strength
of the company is around 150 including managerial staff.
Main activity of the company is manufacturing of Air Conditioning compressors and
various types of PGS projects.
Operations are carried out in following major sections-
1. Fabrication Shop
2. Machine Shop
3. Assembly Shop & Testing
4. Painting & Dispatch
5. Project Assembly & testing
Manpower:
Shift- Contractors Total
Employees
wise
Shift I 100 25 125
Shift II 34 07 41
Shift III NA NA NA

FACTORY SURROUNDINGS:
North Side: Electronica Machine tools
South Side: Open area, Kirloskar Chillers & Saswad Town
East Side: Open area, Highway Pune – Saswad.
West Side: Open Land.
5. OBJECTIVES OF THE PLAN
On-Site emergency preparedness plan has the following objectives:
¾ Safeguard lives and property at site and in its vicinity area.
¾ Contain the incident and bring it under control;
¾ Minimize damage to lives, property and environment;
¾ Rescue and treat casualties;
¾ Evacuate people to safe areas;
6. REQUIREMENTS OF EMERGENCY PLAN
¾ Pre-Emergency

Pre – Emergency means the preparatory stage of the plan. If the planning period
and it should come out to ensure that the prepared plan contains all required

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Plan-Saswad Factory
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provisions and details of facility to handle and to contain the emergency situation
successfully. The unit has to consider maximum and possible worst scenario for
emergency purpose while planning. The unit has to develop and maintain the
essential facilities, so that the emergency can be controlled and the damages are
minimized in the shortest period with proper use of all available resources.
The unit should be duly prepared and ready all the time to encounter any
possible emergency, while it may strike or not. Being a Heavy Engineering unit
and knowing the hazards of the chemical, stored, handled or processed in the
factory, the quick response action must be created within unit.
The structure of the plan may vary depending on the number of employees,
materials, process, availability of recourses, location of site, size and complexity
of the unit. It should ensure to work out a plan with possibilities of various
emergencies with likely to arise within unit. Further the periodical rehearsal is
also to be carried out to check and examine the effectiveness, awareness and
preparedness of the plan as well as services. The emergency planning is not a
substitute for good design, plant operating and maintenance practices.
Therefore, the Onsite Emergency Action Plan must be followed to avoid
emergency

¾ CHECK SCHEDULE

Check all the fire – fighting equipment’s, installations and machineries for their
conditions, physical availability, work ability and take necessary actions for
replacement and maintenance, if required. Check resources of water. Keep all
emergency and essential Telephone Nos. with contact persons, suppliers for the
same handy. Contact details may be displayed on the boards installed at
prominent locations in the plant and offices. Maintain the co- ordination with other
fire – services.

¾ Personnel Protective Equipment

Check all the personnel protective equipment’s provided at different places for
their condition sound working, maintenance’s and replacement, whenever
required. Also keep the note of sufficient stock of required personnel protective
equipments.

¾ Safety System

Check the working of all safety devices, interlock systems and ensure that safety-
guards, railings, fencing, etc. are in position. The safety equipment should always
be kept available in working condition. The safety motivation and safety training
is the continuous process and it is necessary to arrange such type of training

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Plan-Saswad Factory
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periodically. Check the monitoring instruments, wherever provided, whether they

are indicating correct parameters or not.

¾ Preventive Maintenance

A scheduled periodical preventative maintenance and inspection of the plants,

Pressure vessels, centrifuges, equipment’s, storage tanks, air compressors, D.G.
Sets etc. are as per laid down procedures and check that records are maintained
properly. Check the test, examination and certification have been carried out
within reasonable period.

¾ Training

By imparting an effective training to the plant supervisors, inspectors, and

education and training of the workers from time to time, the awareness is to be
kept alive all the time to ensure safety awareness, preparedness for emergency
situations, good housekeeping, discipline, etc. Display of safety slogans,
operative instructions and motivation for safety should be made part of the
company’s normal activities. All the persons earmarked for the emergency
services are to be trained to respond to the emergency.

¾ Monitoring The Environment

Constant and rigorous monitoring of environment is required for detection of a

possible damage or a risky situation arises.

¾ Potentiality on Liaison

Keep the constant liaison with nearby industries, fire services, police department,
medical services, statutory authorities, district administration, for pre emergency
situation. Liaison with local Crisis Group and District Crisis Group should also be
maintained.

¾ Exercise / Mock Drill / Rehearsal

Organize the periodical mock drill / rehearsal as per suggested format by
creating an emergency situation so as to verify preparedness and awareness as
well as shortcomings on the part of the person to overcome the same. Provide
sufficient time prior to mock drill to the emergency services and public for proper
response to exercise and provide training also. Record the deficiencies of the
system during the trial and take appropriate actions to improve the efficiency of
the plan in terms of preparedness and response.

¾ Maintenance of Records

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Keep the records of the monitoring conditions, safety systems, storage levels,
process condition, etc. and maintain the log- books, registers etc. Keep the
M.S.D.S. and onsite emergency plan with required details.

¾ Emergency Control Room

The equipped Emergency Control Room should be in working order. The plant
layout maps, drawing, storage details, Material safety Data Sheets (MSDS),
emergency operations, manuals etc. should be kept and should be updated
continuously. List of essential telephone Nos. is also maintained up to date. The
senior and expert person should be posted as in charge of the control room.

¾ Command & Control

The organization chart, for the emergency plan has been given which explains
the chart of command, channel of information flow, and actions as required
during the emergency. The single organizational structure has been created on
striking emergency and the same shall be continued till the emergency over. The
Shift Supervisor shall take the initial charge as incident controller; he will be
coordinating with various agencies effectively to combat the situation. The
security office room will be used as emergency control Room. The security gate
will be used as Assembly point. The Factory Manager will act as site main
controller for the unit. On arrival, he will supervise all activities with the help of
asst. Plant in- charge. The duties & responsibilities have been defined as per
below.

¾ WARNING ALARM AND SAFETY AND SECURITY SYSTEMS.

The Emergency Siren system is installed at Terrace of Canteen Building
(covering the entire site), the actuating control panel is at ECC (Time Office),
personnel at Time office are trained to actuate the Emergency Siren.

Incase of electric failure manual Emergency Siren is provided at Security

Maingate.

¾ CODIFICATION OF SIRENS
Sr. SIRENS INDICATES AUTHORITY
1. 30 SECONDS ON SITE SITE CONTROLLER
Continuous Whelming EMERGENCY (ALERT)
Sound
2. 30 SECONDS EMERGENCY SITE CONTROLLER
Continuous sound CONTROLLED

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(ALL CLEAR)

¾ NOTE:
¾ EMERGENCY SIREN TO BE SOUNDED ONLY IF REQUIRED
¾ ALL EMPLOYEES IN AREAS OTHER THAN AFFECTED TO CONTINUE

WORK UNLESS DISASTER SIREN IS BLOWN.

¾ NO EMERGENCY ORGANIZATION MEMBER WILL LEAVE THE EMERGENCY

SPOT UNLESS `ALL CLEAR’ SIREN BLOWN.

7. DETAILS FURNISHED IN THE ON-SITE EMERGENCY PLAN BY:-

NAME & ADDRESS OF THE PERSON FURNISHING THE INFORMATION.

Name: Mr. Sandeep R Kulkarni (Factory Manager-Overall site Incharge)

Works: Plot No-1, Hadapsar Industrial estate pune-13.

Residence: Flat No- A –1/601 Prasad Nagar Wadgaon Sheri Pune-411014

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Plan-Saswad Factory
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8. KEY PERSONNEL OF THE ORGANIZATION AND RESPONSIBILITIES ASSIGNED

TO THEM IN CASE OF AN EMERGENCY.

NAME DESIGNATION/DEP RESPONSIBILITY INTER. RESID.. TEL.

T ASSIGNED TEL. No. No.
D R SHINDE DGM-MFG SITE CONTROLLER 9881460092

A K PATIL HOD ADMIN SITE CONTROLLER 2001 9822978091

INCIDENT
N M BAPAT SAFETY OFFICER 2907 9822978093
CONTROLLER
INCIDENT
S S KADBANE PLANT ENGG 2203 9689943969
CONTROLLER
AS INCIDENT
ACR- MFG 2101 9850969431
CHHAPKHANE CONTROLLER
SAGAR INCIDENT
ACR-MFG 2101 9823969345
KHALADKAR CONTROLLER
INCIDENT
M MSHINDE DISPATCH 2201 9922970216
CONTROLLER
S M JOSHI INCIDENT
STORES 2403 9922970217
CONTROLLER
INCIDENT
Y R PATIL SPARES 9881343527
CONTROLLER
INCIDENT
G P NIRFARAKE PROJECTS 2110/14 9881379299
CONTROLLER
INCIDENT
A S PATIL PROJECTS 9850816651
CONTROLLER
FIRST AID TEAM
R B JAGTAP ASSEMBLY 9011567432
LEADER
FIRST AID TEAM
S G KHARADE PLANT ENGG
LEADER
FIRE FIGHTING
G P VARPE QA 2801 9822022580
TEAM LEADER
EVACUATION
P D MOKASHI QA 2801 9922424126
TEAM LEADER

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9. EXTERNAL AGENCIES CONTACT DETAILS INVOVED DURING EMERGENCY

NAME OF THE RESPONSIBILITY CONTACT NUMBER
ORGANISATION ASSIGNED
Statutory Authorities: Help during On site & 26361353
Div. Commissioner Pune. Off site Emergency.
Collectorate Office compound

Police commissioner, Pune 26122202

Police Control room
Addl. Director, Industrial Safety 24266918
& Health Pune
Dy.Director, Industrial Safety & 24268898
Health Pune.

Police: Saswad Police station 02115-222333

HOSPITALS: Medical attention

/ DOCTORS: Surgical, burns cases
Chintamani Hospital Orthopedics, trauma 02115-222037
case, 9822327986
Khade Hospital Eye injuries
Medical emergencies 02115-222561

MUNCIPAL CORPORATION Local infrastructure 02115-222349

Ambulance Services
Water Works Supply of industrial 02115-222349
water
M S E B:
Jr. Engg Saswad Pune 02115-223196
Electrical supply
Phursungi Power House 020-26980270

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Fire Brigades
Hadapsar Ind. Estate Fire fighting 02115-222349
Pune Cantonment
PMC-
PCMC-

MPCB, SRO- Pune-I Environmental troubles 020-25811029

10. INFORMATION ON THE PRELIMINARY HAZARD ANALYSIS

¾ TYPE OF ACCIDENTS
a. Fire
b. Explosion
c. Burn
d. Significant aspect, hazard

¾ SYSTEM ELEMENTS OR EVENTS THAT CAN LEAD TO A MAJOR

ACCIDENT

¾ Storage & use of HSD, LDO

¾ Paint & Thinner storage & use
¾ Various types oil storage and handling
¾ Electrical transformer and distribution systems
¾ Storage & usage of gas cylinders

¾ HAZARDS.

Sr. Areas Hazard / Risk

1. Paint and Thinner Storage Fire

3. HSD, LDO Storage Fire

4. Spray Paint Booths Fire

5. Compressor Testing Fire

6. Oil storage and handlings Fire

7 Electrical distribution systems Fire and burn injuries

8 Pneumatic testing of component Bursting of vessels

Followed
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By explosion

This shows the major risk involved the fire hazards and subsequently losses to
property damages and burn injuries to manpower, which resulted to major
accidents and Emergency situation in factory premises.

¾ SAFETY RELEVANT COMPONENTS.

SYSTEM ELEMENT SAFETY RELEVENT COMPONENTS

a) Paint booth: -
Flame proof electrical fitting.
Effective ear things are provided to electrical distribution
Paint booths,
and equipments as well as paint booth.
b) Down draft solvent vapor collection with water curtain
absorption system is provided.
c) Traces of solvent vapors along with water mist,
generated during the tank water circulation of paint
booth are blown above the work shed to disperse the
vapors at elevated atmosphere.
d) Situated at isolated location- by heat
producing/creating activities.
e) Maintaining inventory of flammable material at
nearby area on day-to-day basis.
f) Fire extinguishers are posted at strategic location.

Located at segregated places

Transformer oil is checked annually for stipulated
Electrical transformer and norms.
distribution areas Effective earthling grid is provided to distribution system
and stimulated annually.

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On –Site Emergency Preparedness Rev. No. & Date 03; 23/01/2011
Plan-Saswad Factory
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Relevant component of compressor are tested at

stipulated pressure testing norms before assembling
Compressor testing areas the compressor and followed during test performance.
Isolated compressor test beds are provided.

Smoke and heat detection system is installed for early

ISD detection and followed by the warning actuating device.

Heat Treatment Furnace Due to Solvent leakage, fire Hazard may occur in the
Shed

11. DETAILS ABOUT SITE

¾ LOCATION OF DANGEROUS SUBSTANCES.

1. Paint and thinner storage area near main gate

2. Electrical transformers,. Dept. and ACR test bed area
3. Paint shops

Location is shown in the attached Site master plan

¾ SEAT OF KEY PERSONNEL

NAME LOCATION
Mr. D R Shinde ACR-MFG Machine Shop
Mr. A K Patil HRM Office
Mr. N M Bapat Safety Officer-M/C Shop
Mr. A S Chhapkhane Mfg-Office M/C Shop

12.EMERGENCY CONTROL ROOM (ECC). –

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¾ During normal working hours – The (HRM) Office

¾ During other times - The Security Office

¾ Internal telephone no: 2001

External telephone no.: 02115-222409/403
For the purpose of handling emergency, the following Emergency Control
Centre has been identified.
All communications to and from will originate at this CONTROL CENTRE.
The Emergency Control Center will have the following: -
¾ Fire extinguishers layout and control points.
¾ Layout duly marked with areas where large inventories of flammable
materials are stored.
¾ General water supply layout.
¾ Location of water storage for fire fighting purpose.
¾ Sufficient stock of safety equipments and protective devices for use in
emergency.
¾ Road map of entire plant.
¾ Map indicating assembly points where people can be directed to gather
in case of emergencies.
¾ Additional copies of general factory plans in which necessary areas can
be marked and given to the persons dealing with the disaster so that
they are clear about the location where they have to go.
¾ List of persons who have done training courses in Safety Fire Fighting,
First Aid who could be called to the main control room in case of
emergency.
¾ List of doctors, hospitals along with their phone nos.
¾ Telephone nos. of fire brigades, blood bank, police control room, local
police stations and such other relevant information.

13. DESCRIPTION OF HAZARDOUS CHEMICALS AT THE PLANT SITE:

DETAIL LIST IS ATTACHED AT THE END OF THE PLAN.

CHEMICALS (quantities & toxicological data)

Chemical Name Average storage quantity

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Paint &Thinners 2 KL
Various types of oils 3 KL

For toxicological data MSDS sheets are enclosed.

14. LIKELY DANGERS TO THE PLANT: -

Disaster / Emergency may occur due to -

(a) Company activities such as improper usage and storage of flammable

materials, lack of preventive maintenance, leakage from storage
carriers, Fire in the vicinity, Mob Violence Riots, Food Poisoning, Plane
Crash, Animal bites, Insect bites, Bombing etc. and

(b) Natural calamities as thunder, storm, earthquake, Flood, Lightening

etc. The action plan worked out for the disaster control is based on the
above-mentioned causes.

In case of KPCL, due to factory activity, there is no probable risk to

surrounding area of the factory as the manufacturing process is of General
Engineering type and adequate provisions have been made for disaster
control.
Emergencies occur in any unit handling hazardous/flammable
chemicals due to the LOSS OF CONTROL. Hence loss prevention is
the only basic technique of avoiding such emergencies. These
emergencies are classified as
a. Fire
b. Explosion
c. Toxic release

The consequences are providing in the form of fatality of human being

at different distances in case of various fires or explosions or toxic
vapor release. The vapor cloud releases are hazardous to structures,
glasses, and partial damages to human body & indicated in the form of
eardrum rupture.

15. POTENTIAL HAZARD CASES CONSIDERED

a) Fire Hazards
b) Bursting of vessels/receivers while testing of high-pressure
compressors followed by explosions.
c) Electrical fires.
d) Food Poisoning.
16. GENERAL GUIDELINES FOR EMPLOYEES

• Do not panic.

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• Do not approach the incident site as a spectator. Instead, stay at your

place unless otherwise instructed in this manual for certain group of
employees. Otherwise leave the place by bringing the operation at
zero energy level and assemble at predetermined emergency
assembly location.
• Do not engage communication channels / telephones except for
handling the emergency.
• Do not move unnecessarily.
• Pay proper attention to instructions received from the Task Force.

17.MEASURES TO BE EMPLOYED FOR MEETING THE OBJECTIVES:

• Define and assess the hazardous incidents.

• Provide the information to all concerned.

• Warning and advising affected people.

• Call-up for assistance from outside.

• Inform the employees, authorities and general public about the

assessed risks, safeguards provided, residual risk and the role to

be played by one and all in the incident.

• Collecting data on latest developments, other information and

requirements and disseminating the same.

• Coordinating action taken by various agencies.

18. HAZARD CONTROL MEASURES IN CASE OF EMERGENCIES

MANAGEMENT PLAN FOR HANDLING EMERGENCY

To deal with any emergency, the arrangement for immediate deployment

or appointment of key personnel and their specific responsibilities must be
well laid out. It may be noted that in an organization of KPCL, one or
more tasks, referred to hereunder, may have to be performed by one
person for effective and prompt action in case of an emergency.

KEY PERSONNEL

• It must be understood that the first few minutes after the start of an
incident are most vital in prevention of escalation. Therefore, the

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personnel available at the complex on round the clock duty basis play the
most important role. Some of them are the KEY PERSONS.

• The chart is illustrative and should be kept updated. It should be found at

all times in the Emergency Control Center (ECC).

• It is to be appreciated that Key Persons remain the first line fighters. The
role of various coordinators is to assess the situation from time to time,
take appropriate decision in consultation with the Chief Coordinator (Site
Controller) and to provide timely resources.

• In case of an emergency, the two most important people are the SITE
CONTROLLER and the INCIDENT CONTROLLER. The Site Controller
takes overall command and coordinates all activity within and outside
while the Incident Controller takes charge of the incident site to tackle the
emergency.

ORGANIZATION CHART FOR ON-SITE EMERGENCY MANAGEMENT.

SITE CONTROLLERS

INCIDENT CONTROLLER

COMMUNICATION COORDINATOR

TASK FORCE

NOTES:
• In case of the Incident, Controller being present on site, the standby
personnel will report to him for directions.
• All the other employees will assemble at the emergency assembly points.

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19.EMERGENCY ACTION PLAN

ANY ONE NOTICING EMERGENCY SITUATION LIKE FIRE, EXPLOSION, TOXIC

GAS LEAKAGE ETC. MUST
DO’s

• Attract the nearby person/employee by shouting “FIRE – FIRE – FIRE. “

• Seek help from the persons working nearby.
• Try to control the incident at its initial stage with available means/sources quickly.
• Inform Shift In-charge / Duty Officer (In Night Shift ) about the Incident.

DON’Ts

• Do not be panicky.
• Do not run – Walk fast.
INCIDENT CONTROLLER MUST
DO’s

IF FIRE / OTHER INCIDENTS ARE CONTROLLABLE

• Approach the emergency site immediately taking note of wind direction.
• Assess the situation.
• Inform Security Officer, Tell – NAME, TYPE OF INCIDENT, ACTION TAKEN, HELP
NEEDED and Order Security Officer/Guard to inform all KEY persons.
• Take lead in controlling emergency until such time concerned Section Manager takes
over the charge.

DON’TS
• Do not be panicky.
• Do not lose temperament.
B. IF FIRE/OTHR INCIDENTS ARE NOT CONTROLLABLE
In Addition to Above (A)
• Order to blow emergency `ALERT’ Siren (30 second continuous).
• Organize Fire fighting / rescue team members to control the Incident.
• Take stock of situation if required shut down the plant / process in affected area.
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• Call Fire Brigade if situation demands.

• Evacuate affected area.
• Organize head count of the plant.
• Act as INCIDENT CONTROLLER till such time senior person takes charges as
indicated in Emergency organization

NOTE: 1) Messenger will wait until such time Security Officer arrives.
2) Also inform Telephone Operator.

SECURITY OFFICER / GUARD

DO’s
• Do not allow any vehicle to come inside the factory.
• Do not entertain any outside call except for emergency purpose.
• Do not allow visitors to move around.
• Inform all key persons about location and type of emergency.
• Follow this sequence – Inform concerned HOD/Section Head, Main Site Controller,
Main Incident Controller & Safety Officer and other KEY persons.
• Inform Main Site Controller about Government visitors, if any.
DON’Ts
• Do not entertain any outside call except for emergency purpose.
• Do not allow visitor to move around, from reception.

SECURITY GUARD
DO’s

• Immediately report at Security Gate in shortest possible time.

• Follow instructions of Officer In-charge.
• Assist in controlling emergency.
• Assist in controlling contractors, vehicle movement and mob.
• Assist in cordoning off the area.
• Take note of wind direction while approaching emergency site.

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• Render all possible help for controlling overall situation.

DON’Ts
• Do not leave the site unless asked to do so.

EMERGENCY VEHICLE DRIVER

DO’s
• Immediately start vehicle and reach rescue squad assembly point (near security
gate).
• Rescue squad members to emergency site.
• Take vehicle near to emergency site as directed.
• Take note of wind direction.
• Reverse the emergency vehicle for quick transports of injured, if any.
• Keep vehicle engine running.
• Always be on Driver’s seat of the vehicle.
• Take the injured to the hospital as directed.

DON’Ts
• Do not leave the vehicle.
• Do not take the vehicle very near to the site.

INCIDENT CONTROLLER
DO’s

• Approach emergency site as early as possible taking note of wind direction.

• Take stock of situation.
• Interact with all concerned departments as the situation demands.
• Keep Main Site Controller informed about the latest emergency situation on
continuous basis.

SITE CONTROLLER
DO’s
• Will approach emergency site immediately / Assess the situation.
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• Consult Incident Controller.

• Consult advising Committee Members.
• Instruct Main Incident Controller.
• Communicate to higher ups and Govt. authorities, if required.
• Decide upon need for evacuation and blow `Disaster Siren’.
• After getting satisfied with the situation, give instruction to blow ALL CLEAR Siren.
DON’Ts
• Do not instruct to blow ALL CLEAR siren unless the situation is fully under control.
• Don’t evacuate the entire plant unless the situation demands.
FIRE FIGHTING SQUAD ON HEARING SIREN
DO’s
• Inform fellow employees/Officers.
• Report to Fire Squad Assembly point.
• Find out emergency location.
• Approach emergency site immediately.
• Take quick action as per the instructions from Incident controller.
• Bring emergency under control as early as possible.
DON’Ts
• Do not leave process/equipment in UNSAFE CONDITION.
• Do not leave emergency site unless ALL CLEAR siren blown.
• Do not use improper fire extinguisher.
• Do not be panicky.
RESCUE SQUAD
DO’s
• Report to assembly point near Gate.
• Get in touch with security about location and type of emergency.
• Approach emergency site quickly with Breathing Apparatus set and First Aid box.
• Get in touch with incident controller.
• Follow instructions of Incident controller.
• Render first aid to the injured, hospitalize, if required.
• Accompany him to hospital and assist Doctor / Nurse.

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• Search for missing person in that area, if required.

• Help in head count.
ALL GENERAL EMPLOYEES EXCEPT THOSE WHO ARE IN EMERGENCY
ORGANIZATION ON HEARING SIREN
DO’s

• Be alert and be available if required.

• Wait for further instructions.
• Bring down the process/plant/equipment in SAFE CONDITION in case of DISASTER
siren as per instructions from Incident Controller.
• Approach respective safe assembling points route as taking note of wind direction.
• Help in taking roll call.
• After hearing ALL CLEAR, go back to the departments.
• Start the work again after setting instruction from Incident controller.

DON’Ts

• Do not be panicky. Do not run.

• Do not approach emergency site unless asked for.
• Do not engage telephone except for emergency purpose. Keep lines free.

TECHNICAL TEAM: ENGINEERING DEPARTMENT / ENVIRONMNET, SAFETY AND

HEALTH DEPARTMENT ON HEARING SIREN
DO’s
• Be available in Engineering Department at respective location for any help.
• Approach emergency site with required tools and equipments and should work on
instructions of Incident controller.
• Help Incident Controller to provide technical assistance.
• Isolate lines, process equipments, if required by Incident Controller.
• Provide emergency equipments like Fire Extinguisher, Hoses, etc., if asked by
Incident Controller.
• Provide stopgap arrangements as per the requirement of Incident Controller.
• Carry out electrical isolation of area as per instructions from Incident Controller.
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ADVISORY COMMITTEE (ALL DEPARTMENT HEADS)

DO’s
• Approach emergency site as early as possible.
• Render advise to Main Incident Controller and Main Site Controller to control
emergency.
COMMUNICATION COMMITTEE – (P&A)
DO’s

• Consult Main Site Controller

• Give necessary instructions to security / Telephone Operator.
• Give instruction to Security to control traffic / crowd.
• Look after injured, communicate with the family members, if situation demands.
• Arrange transportation, if required.

DON’Ts

• Do not communicate to any one or brief press without permission of Main Site
Controller.

GENERAL INTRUCTIONS
DO’S

• Stop work at height. / Stop all hot works.

• Stop all vessel entry.
• Take note of wind direction.
• On hearing Disaster Siren evacuates as per evacuation route without running and
panicky and assembles at respective safe Assembly Points.

DON’Ts

• Do not use telephone except for emergency purpose.

• Do not start work at height, vessel entry, hot work unless permit conditions are
verified.
• Do not allow unauthorized person to approach emergency site

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20.IDENTIFIED EMERGENCY & ACTION PLAN

Some time due to individuals’ carelessness, accidents take place. These types of
accidents may lead to a major incident. Some of the Potential Accidents & The actions
taken during this period are given below: -

In case of Electrical Short circuit due to unauthorized Operation: -

INDIVIDUAL WORKER ON THE SPOT:

¾ Remove injured persons from the spot to First Aid Centre. First Aid is an
immediate and temporary care, given to the victim of an accident or sudden
illness.
¾ First aid is to preserve life, assist recovery, prevent aggravation and minimize
complication at later date and minimize pain / agony
¾ Ask near by co-worker to inform the matter to SUPERVISOR.
¾ Inform the maintenance department to take further necessary action.
Remove the patients from the source of danger. Make the air passage clear and clean.
Restore natural breathing by artificial respiration. Send the patient to the hospital.
In case of Snakebite due to unauthorized movement at boundary: -
Act quickly. Do not allow the person to run. Apply a ligature above to the wound (In
between the heart and wound) if the bite is in the leg or hand. Wash the wound with
Potassium permanganate solution or with soap or water.. Reassure the patient and
immediately hospitalize.
In case of Burns and Injury: -
* Place the part under running cold water.
* Cover the wound with several layers of sterilized cloth
* Artificial respiration if needed
* Prevent or treat shock
* Immediate medical attention
Inhaling of fumes / Chemical burns on the eyes: -
Immediate washing of the Eyes at least for fifteen minutes. Apply sterile bandage and
send the patient to the hospital.
Suffocation: -
Remove the patient from the source. Restore respiration by artificial respiration. Send
the patient to the hospital if necessary.
Unconsciousness: -

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Make the patient lie down in prone position. Check breathing, pulse & heartbeat. Loosen
tight clothing. Clean the airway. Give artificial respiration. Give external cardiac
massage. Transport the patient to the hospital.
SHIFT INCHARGE /SUPERVISIOR

¾ Rush to the spot

¾ See the injured person are moved to first aid centre and if required moved to
hospital.
¾ Organize ambulance/ Transport available and additional work force to move the
individual to hospital.
¾ See there is no unwanted worker near the accident site/move all to a safe
assembly area.
¾ Inform the matter to HR/P&A and Plant Head
¾ Inform the security guards who are the coordinators.
¾ Study the root cause of the accident.
¾ Carryout detailed root cause analysis.
¾ Submit the report to Plant Head.
CO-ORDINATOR:
Security guards / Rescue team of the Factory will be performing the duties of
coordinator on hearing the accident and will ensure the following: -
¾ Rush to the accident site.
¾ Evacuate the injured persons to first aid centre and further to hospital.
¾ See no unwanted persons are around that area.
¾ Prepare the detailed report on damage, salvage, injuries, hospitalized and cause
of incident/ initiate root cause analysis.
¾ See necessary corrective actions are taken and implemented.
EMERGENCY IN HEAT TREATMENT PLANT
Due to Solvent leakage, fire Hazard may occur in the Shed,
Precautionary Measures installed:
¾ Solvent vapor detection system installed at four station
¾ Incase of any leakage

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THE WORKER ON THE SPOT:

¾ If there is any type of Leakage of Gas, it will be immediately detected by the
system, in that case the Siren will get activated and on the display screen
will show the location of the leakage, the operator should immediately stop
the valve and or collect the solvent in safe container.
¾ If the leakage is beyond manual control, in such case to avoid further
danger, the present operator must close the valve of concern Gas
carburizing service tank, and also necessary precaution to avoid scattering
of chemical spillage.
¾ Whenever such incidence occurs, immediately the gas cutting and welding
operation should be stop, as well as electrical equipment should not be
turned on or off which may result in spark or vapor can catch fire.
¾ Whenever such occurrence happens all chemicals in stored in service
tanks should be collected through safe method and must be stored in
another safe place and fire extinguisher should be brought near Gas
carburizing process unit, which will be used only incase of fire hazard.
¾ Jet water should be sprayed on the affected area, which will dissolve the
chemical in the water and danger of fire will be eliminated.
¾ It should be ensured that dust should not be accumulated in the service
tank cabinet it should be kept dust free.
¾ And ensure while cleaning the cabinet water on floor or any other object
should come into the contact of the Gas detection unit for which provided
cap should be used.

SECURITY GUARDS:

¾ See the plant is put off.

¾ See required additional labors are mustered and provided to the contractor.
¾ Provide necessary materials like sand bag, fire extinguishers and sands.
¾ See no worker is near by the plant and all persons not required are removed
from that area.
¾ Inform the matter to coordinator SHIFT INCHARGE /SUPERVISOR, HR, Site
Controller.
¾ Over see the removal of all the waste properly as there are hazardous materials.
¾ Study the root cause for the failure of the plant.
¾ Recommend the course of action to be taken so that such incident does not take
place in future.

COORDINATOR/TEAM LEADER:
The Site Controller will be the coordinator for these type of incident:-
¾ On hearing rush to the spot.
¾ See the plant is put off.

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¾ See necessary safety equipments are provided to the labors (Like face mask,
hand gloves, gum boot etc)
¾ See no unwanted persons entered that area.
¾ See required fire extinguisher/ sand available to pour over the fire.
¾ Make sure these items are removed and disposed off as per laid down
procedure.
¾ Study the root cause for the failure of plant with premises engineer.
¾ Prepare a detailed report on the failure salvage disposal and root cause analysis.
¾ Recommend a proper remedial action for this and see that the recommended
action is implemented.
¾ Inform the Site Controller the action taken and disposal of the hazardous
materials.

SUDDEN SPURT OF LEAKAGE HAZARDOUS MATERIAL/ OIL

Due to failure of old pipes line oil/steam may suddenly spurt off from the line or machine.
The actions taken during these emergencies are:

WORKER ON THE SPOT: On seeing the oil leakage the worker should do the
following:
¾ Immediately shut off the machine.
¾ Stop the flow of oil to the machine/pipe line by closing it at the main.
¾ Shut off the power supply to the area.
¾ Inform the matter to Supervisor.
¾ Try to put sand /saw dust over the oil spilled over.
¾ Remove other materials from that area.
¾ Remove other workers from that area.

SUPERVISOR /INCHARGE

¾ On seeing / hearing rush to the spot.

¾ See all machine are put off.
¾ See the oil line is shut off.
¾ Power supply to the area is put off.
¾ Inform the incident to HR/P&A.
¾ Ask Security guards to provide additional labour to remove the spilled oil from the
area.
¾ See other unwanted materials are removed from that place.
¾ See no other unwanted persons are there.
¾ Study the root cause for this incident.
¾ Carryout the detailed analysis of the problem.

The Rescue team

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¾ Rush to the spot

¾ See the oil supply is cut off.
¾ See the power supply is put off.
¾ See no UN -wanted materials are there, if so remove them from that area.
¾ See the workers are provided with proper safety kits like gloves, mask etc.
¾ Muster additional work force to remove the spilled oil.
¾ See the salvaged items are disposed off as per mitigate procedures.
¾ Investigate the root cause of the incident in detail.
¾ Submit a detailed report to the Plant Head
¾ Recommend corrective actions.
¾ Ensure remedial actions are taken and implemented accordingly.
¾ All hazardous materials are disposed off as per mitigate procedure.

IDENTIFICATION OF THE INCIDENCE: - MASS FOOD POISONING

¾ Persons approaching with symptoms of Vomiting, Nausea, Fainting, and

Stomach ache, Loose Motion etc. after consumption of Food prepared in the
Company canteen.

¾ Arrange for immediate Medical assistance to the persons approaching the OHC.
The company Doctor will assess the situation and accordingly take the required
action. Whether to provide internal Medical relief or arrange for external medical
assistance.

IDENTIFICATION OF AFFECTED AREA: -

¾ To find out in which lunch break the affected persons consumed food.

¾ Immediately stop canteen serving.

¾ Try to Investigate with the affected persons, which they consumed Items
in the canteen.

¾ Identify the common food consumed by the affected persons.

¾ Seal the Food prepared.

¾ Location wise Identify through the rescue team the whereabouts of the
Persons who were scheduled in the same shift and consumed food
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prepared in the canteen. Assemble them at the Ganesh Hall and examine
for Food Poisoning symptoms and its severity.

¾ Immediately liaison with nearby hospital and arrange for accommodation

of affected persons for facilitating Medical relief.

¾ Monitor the health symptoms of the affected persons.

¾ The rescue team will be assisting OHC in the relief activity.

21. EMERGENCY PERSONNEL'S RESPONSIBILITY DURING DAY SHIFT

1. Site Controller:
.
Responsibilities:

The Site Controller will assume the overall responsibility for the factory site
and its personnel. His duties are to:

¾ Assess the magnitude of the situation and decide if staff needs to be

evacuated from their assembly points to identified safer place,
¾ Exercise direct operational control over areas other than those
affected,
¾ Undertake a continuous review of possible developments and assess
in consultation with Key Personnel as to whether shutting down of the
plant operations or evacuation of personnel if required,
¾ Liaise with senior Police, Fire brigade, Medical officers and Factory
Inspectorate and provide advice on possible effects on areas outside
the factory premises,
¾ Look after the rehabilitation of affected persons after discontinuation of
emergency,
¾ Issue authorised statements to news media and ensure the evidence is
preserved for inquiries to be conducted by statutory authorities.
¾ Permit resumption of normal operations only after post emergency
clean up.
2 Incident Controllers:
Responsibilities:

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Immediately, on knowing about the emergency, he will rush to the incident

site and take overall charge and report to the Site Controller. On arrival,
he will assess the extent of emergency and decide if major emergency
exists and inform the Communication Officer accordingly. His duties will
be to:
¾ Direct all operations to stop within the affected area taking into
consideration priorities for safety of personnel, minimise damage to the
plant, property, environment and minimise loss of materials,
¾ Provide advice and information to the Fire fighting team and Security
staff and to the local Fire Service,
¾ Ensure that all non-essential workers / staff of the areas affected are
evacuated to the appropriate assembly points (gate) and the areas are
searched for casualties,
¾ Set up communication point and establish contact with Emergency
Control Center (ECC),
¾ Report on all significant development to the communication officer.
¾ Have regard to the need to preserve the evidence so as to facilitate
any enquiry into the causes and circumstances of the incident.
¾ Assess damage and plan for post emergency clean up before advising
Site Controller to resume normal operations.

3. External Coordinator: Human Resource Manager

Designated Person: Mr. A K Patil
Responsibilities:
The External Coordinator will also work as a liaison man and will be
stationed at the main gate. He will, under the directions of the Site
Controller, handle Police, Press and other enquiries.
His responsibilities shall be:
Liaison with external agencies and call fire brigade aqua
¾ To ensure that casualties receive adequate attention / to arrange
additional help if required and inform relatives.

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¾ To control traffic movements into the factory and ensure alternative

transport is available when required.
¾ When emergency is prolonged, arrange for relief of personnel and
organize refreshments / catering facilities.
4 Communication Coordinator:
Designated Person: 1. Mr. G P Nirfarake
(In order of availability) 2. Mr. Yoovraj Patil
Responsibilities:
On hearing the alarm, he will proceed to the Control Room and maintain
communication with the Incident Controller. He will:
¾ Advise the Site Controller of the situation, recommend evacuation of
staff from assembly point,
¾ Recruit suitable staff as runners between the Incident Controller and
himself,
¾ Maintain prior agreed inventory in the control room,
¾ Any other work as per directions of Site Controller or Incident
Controller.
5 Sr. Security Officer:
Designated Person: 1. Mr. P R Kadam
(In order of availability) 2. Mr. K A Mhaske
The main in-charge of this function will be responsible for fire fighting. On
hearing the alarm , he shall reach the site and get directed by the Incident
Controller to fight the fire.
He shall be responsible for organizing the fire fighting team; ensuring that
the personnel are using correct personal protective equipment and he
shall direct the resources so as to put them to optimum utility.
¾ Fire fighters: The list is attached at the end
¾ First Aiders: The list of trained first Aiders is attached at the end
¾ Evacuation/Rescuer: Security Personnel present at the site.
6 Other Personnel:
Telephone Operator on duty:

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After receiving the information/emergency given, he will immediately contact

the Site Controller and work as per Site Controller’s advice and call the local
fire brigade or mutual aid scheme members, if require.
He will ensure that all internal communication lines are available for dealing
with the disaster. He will give direct communication to telephone lines in
control room. He will keep the list of important telephone numbers such as
fire brigades, ambulance services, hospitals etc.
7 Operation Manager (Utility & Services) :
After getting the information or knowing about the emergency situation, he
will report to Incident Controller and provide assistance as required. He will
decide which member of their staff / workers require at the Site. He will
ensure that adequate water supply is made available at the Site He will
arrange for electrical shut down from main receiving station. These people
should report to Incident Controller for directions.
8. Other department heads:
The Departmental head wherein the incident has taken place will report to
Incident Controller and provide assistance as required. They will decide which
members of their staff they require at the scene.
The Various department head on hearing the Emergency should take charge
and facilitate evacuation of his respective department towards the nearest
Assembly point and should he rush to the assembly point.
9.First-aid Team Members:
The Personnel Manager shall keep in security the roll call lists for the fire and first-
aid teams on duty. Each Departmental Head for his shift-team appoints roll call
leaders and first Aiders. Roll call leaders shall check their rolls as members of the
services report for emergency duty. Names of any unaccounted for absentees will
be informed to the Security Officer.
Members of first-aid Teams will report to the Incident Controller on hearing of the
alarm in daytime. The Emergency vehicle driver, if safe to do so, shall collect the
emergency vehicle and park nearest to the scene of the incident. First aider shall
inform the incident controller that the Emergency Vehicle is leaving the site, giving
the name of the patient and destination i.e. hospital or doctor’s room and request the

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Incident Controller to inform the destination (hospital, etc.) advising them about the
casualties reaching there.
10. Factory Fire Squad Personnel:
The duty Fire fighting Squad under the command of the Security Officer shall be
responsible for fire fighting and rescue. On hearing the alarm, they shall proceed
to the place of incident. The men at security gate shall find out the location of the
emergency and proceed to the site of the occurrence. At the incident scene, a
team members detailed for this purpose will check squad members against roll-
call sheet. At the site, all the squad members will respond to the advice and
information given by the Incident Controller On arrival of the local fire brigade,
they will also assist in fire-fighting work with the advice of the Incident Controller.

22.EMERGENCY PERSONNEL'S RESPONSIBILITIES DURING NIGHT

SHIFTS AND HOLIDAYS.
Security Officer / Supervisor:
¾ As soon as he becomes aware of the emergency and its location, he will
proceed to the scene. On arrival, he shall assess the scale of the incident and
direct the operations for containment or extinguishment with the following
priorities:
¾ Secure the safety of persons. This may require evacuation to the assembly
points (gate). In the event of escape of material if the wind direction is
adverse, choose appropriate assembly point,
¾ Try to minimize damage to plant, property and the environment,
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¾ Have regard to the need for preserving evidence that may facilitate enquiry
later on.
¾ Arrange to inform Site Controller, Incident Controller. Also call for other
personnel till Site Controller / Incident Controller arrives.
¾ Act as Incident Controller till his arrival.
¾ Advise local Police/Fire stations/Mutual aid members as deemed necessary.

23. COMMUNICATION FACILITIES

The success of any emergency management preparedness/plan will depend
entirely on how well and how timely was the communication. More effective the
communication system better will be the outcome and more effective
implementation of the emergency management plan. It is vital for gathering
information, for overall coordination and for passing timely information. Company
is having all communication facilities so that messages can be sent immediately
such as internal telephones, external telephones, E-mails, Mobile phones to
Key persons, walkie-talkie set etc.

24. DETAILS OF OTHER SERVICES AVAILABLE ONSITE

OCCUPATIONAL HEALTH CENTER

KPCL-Saswad has Occupational health center (OHC) necessary material and

equipment to handle emergencies. It has following features.
• Well-equipped department with qualified and experienced staff.
• First aid services are available on all working days.
• There is well-equipped ambulance with the driver available round the clock
for shifting any emergency case.

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• It has full range of routine as well as emergency medicines available for the
treatment of injuries. The doctor issues a pack of medicines for continued
treatment proportional to the nature of injury/accident.
• Emergency first-aid box duly equipped are available to deal with on-site
cases in case emergency arises. All the shops are equipped with first aid
boxes with necessary first aid material. The material is replenished as and
when required through OHC.
• The OHC is equipped with necessary resuscitation equipment like -- There
are two observation beds available for short-term follow-up of the patients.
• The Management has recognized few hospitals near / around area for further
treatment of surgical, medical, orthopedic, hand surgery emergencies.
• The doctor and social welfare counselors maintain a liaison and follow up
with these hospitals telephonically and by hospital visits.

EMERGENCY POWER
DG set is installed available to ensure emergency power supply to critical areas,
if normal electricity fails.

WATER SOURCE
There is abandoned water storage capacity in the available tanks.
THE EMERGENCY TELEPHONE NUMBERS
The emergency telephone nos. are provided to all departments and displayed in
key locations.

25. METHOD OF REPORTING EMERGENCY

SEQUENTIAL ACTIONS DURING EMERGENCY

Incident
There are possibilities of occurrences of various types of the accidents or mishaps in the
factory premises or around the factory. Most of the occurrences will be of minor nature.
While few occurrences may be of major type. If the factory is fortunate enough, there
may not be a single incident or mishap during its lifespan. However, when any incident
occurs, it cannot be distinguished immediately whether it is minor or major, the
subsequent development, or gravity of situation or seriousness of such occurrence is
required safe handling irrespective of its nature, if it cannot be controlled.
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It should be general practice that whenever any person notices the accident/ fire/
explosion/ mishap at the site, he should immediately shout “FIRE”, “FIRE” or “HELP” ,
“HELP” and such message should reach to the Supervisor/ Shift Officer/ Senior Person
of the unit.

Responding Actions
It is needless to mention that the root cause of occurrence should be removed
immediately. Similarly, if any incident takes place in the premises, using available
resources, within the factory as well as nearby, to their optimum, it should be so
responded that the incident is contained immediately before spreading. If the incident
looks severe and could not be controlled by simple efforts, the Shift Officer or Senior
Personnel should rush to the place and make every effort to control the incident using
various resources at the site.

Further, if the incident is uncontrollable even using own resources, he should

immediately call for additional helps form outside resources such as Mutual Aiders, Fire
Brigade, etc. He should act the incident Controller and immediately start the following
actions.

¾ Sound the siren or ring the emergency bell.

¾ Take continuous responding actions with the use of other helps.

¾ Call the higher authorities and Site Main Controller.

While conveying the messages regarding the incident, the following details
should be incorporated.

• Brief description of incident

• Type of help required & direction

• Chemical involved & Quantity

• Action immediately taken

• Development of the incident

The person who first detects any type of hazard or emergency will report to
emergency control centre (Time Office) through available communication channel.

Personnel at ECC will receive the first hand information and he should immediately
pass on the same to the Incident controller. Depending upon the gravity the ECC
will actuate the Emergency Siren

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 Document No. COR/HRM/EPP/02
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(a) Incident Controller will give the information about the Incident in brief to Site
Controller.
(b) Try to control the emergency, leakages by available means.
On receiving the information of the Incident controller Rescue crew (Task Force)
should rush to the Incident Site with fire extinguishers / mobile water tanker and
assess the magnitude of situation and try control the situation. Time office is the
main emergency control center for disaster control and has been marked on the
plan. The control room acts as focal point in case of an emergency from where the
operations to handle the emergency are directed and co-coordinated. It is equipped
with Site plan; external and internal telephone numbers and connections, hospital
telephone numbers etc. The public address system such as loudspeaker, list of
essential telephone numbers, list of key persons and their addresses, a list of
chemical and hazardous substances and their safety data sheets.
¾ TASK FORCE:
The trained fire squad members are available for handling the emergency situation in
the factory shift-wise. The task force will consist of the following:

(a) Trained fire squad members.

(b) Elect. and Maintenance. Staff Workers on duty.
(c) Security guards.

¾ Duties of Task Force:

a) Fire Fighting
b) Emergency engineering work i.e. isolating equipment and process materials.
c) Movement of equipments to or from the scene of the Incident.
d) Provision of first aid.
e) Acting as runners, manning assembly points and communication centers
26.EMERGENCY ASSEMBLY POINTS:
In case of emergency, upon hearing the warning alarm employees of the
company, contractors, and visitors will assemble at the nearest Assembly point.
The designated assembly point observer will take the roll call and communicate it
with Site controller.

Prepared by – Safety Officer Approved by – HOD HRM

EHS/MR/F/37
 Document No. COR/HRM/EPP/02
On –Site Emergency Preparedness Rev. No. & Date 03; 23/01/2011
Plan-Saswad Factory
Page 40 of 48

A list updated for employees department-wise shift-wise is made available so

that roll call could be taken.
LOCATION OF EMERGENCY ASSEMBLY POINTS: -
1. Near Ganapati Mandir
2. Near HRM & Admin office
ALL ASSEMBLY POINTS ARE MARKED WITH YELLOW COLOR
IDENTIFICATION BOARD. (The site Map attached shows the location)

27. EMERGENCY ACTIONS

¾ On receiving information, the Emergency Control Centre will activate and

urgently establish the contact with the required persons, agencies and
authorities.

¾ The essential workers, responsible to carry out certain specific functions, will
have to start work immediately. Plant engineering, civil dept, Security.

¾ The non-essential workers should go to the assembly center. The Roll Call
should be started.

¾ The cordoning the incident area will be ensured. (By Task Force)
¾ The water should be sprayed on the flammable storage tank, even if not caught
under fire. (By Task force)

¾ The experts for the responding to emergency situation will be consulted, if

required.

¾ The authorized officer will provide authentic information for incident to Press/
Public only.(External Co-Coordinator)

¾ Removal of the flammable, dangerous materials, cylinders, etc. will be arranged

along with isolation from fire.

¾ The trapped personnel, if any, in incident will be rescued (By Task Force)

¾ All assistant will be provided to the Fire Brigade to control spreading of fire.

¾ Any remotest possibility of re-ignition or explosion will be looked into and

controlled.
28. SHUT DOWN PROCEDURE:

¾ The Plant Engg department personnel present on the site, on hearing the
Emergency siren will instantly establish contact with the Site controller:-

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¾ They will gather the information on where the Mishap or emergency has
occurred, the nature and extent of damage accordingly:
¾ The Main electrical supply will be cut-off/ switch-off. Similarly, the pipelines
supplying flammable gas, liquid or chemicals will be immediately shut –off by
valves and will be isolated from the process line.
¾ The rescue team members shall assist the Plant Engg personnel.
¾ After mitigation they will analyze the situation and as per instructions of Site
controller will arrange for re-start of the plant or the section.

This process shall be known and communicated to Maintenance and plant Engg
Head.

29. POST EMERGENCY

The internal committee will be formed to investigate into the causes of the accident/
incident comprising Key persons listed above they will ensure the all below points: -

Once the emergency situation will be bought under control, following post emergency
actions will have to be taken.

¾ The affected area will be declared safe from any toxic and other after effects by
Maharashtra Pollution Control Board authority after through checking and
confirmation.

¾ Then the Government authority will declare the emergency as over and
rehabilitation work will be started in the area.

¾ Then emergency clear siren will be blown.

¾ The rehabilitation work will be started in the affected area. It will be ensured that
all fires are extinguished and there is no risk of re-ignition prior to
commencement of rehabilitation.

¾ It will be ensured that there is no chance of secondary explosion.

¾ The wreckage and debris at incident site will not be disturbed, expect for
rescuing the injured personnel or for recovering the dead bodies, until permitted
to do so by the statutory Authority.

¾ All victims, dead or alive, will be systematically identified and the records will be
kept accordingly. If asked for, necessary information may be provided to the
victim’s relatives.

¾ All relevant information will be recorded.

¾ Photographs/video of incident site will be taken or suitable sketches of the

incidence will be prepared.
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Plan-Saswad Factory
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¾ The incident will be reported to the statutory Authorities with complete details of
occurrence/ accident, if not informed.

¾ Necessary permission for restarting the plant will be obtained from the statutory
Authorities.

¾ The registers for recording the incident, relevant entries, details, inventory, list of
persons, etc. will be maintained and all the relevant documents, log books, maps,
registers and all records taken from the site will be preserved.

¾ The record of help, Co-operation etc. from Mutual Aiders and sought from others
will be maintained and letters of gratitude will be initiated to all of them.

¾ Details of expenses incurred during the emergency will be worked out and
allocated to different heads and the records will be maintained. Statement for
total expenditures will be prepared.

¾ All necessary cooperation will be extended and help will be provided to the
Agencies, Authorities, who will be enquiring into the incident.

¾ The internal committee will be formed to investigate into the causes of the
accident/ incident, if necessary.

30. CORRECTIVE ACTIONS

¾ The accident is always eye- opener toward the irregularities. Similarly, the
occurrence of major emergency directly indicates the shortcomings or weakness
of the plant, handling method, transportation, working procedure, storage
procedure, unsafe condition or unsafe actions, etc. It may reveal from the
investigation or recommendations of the committee.

¾ Necessary corrective steps/ actions in light of the investigation report or findings

are required to be taken to ensure that such emergency accidents do not repeat.
Therefore, modification, alterations, changes in operation, instruction, process,
handling, etc. as suggested by investigating Authority and internal committee
should be implemented accordingly to make the plant working

31. REHEARSAL / SIMULATION /MOCK DRILL

Exercise / Rehearsal / Simulation for working of ON- SITE- EMERGENCY PLAN are
known as MOCK DRILL. As a normal practice, it is recommended to conduct the
Mock Drill at an interval of around 6 months, or after modification of hazardous
process, storage, plant operation, and extension.

OBJECTIVE 
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 Document No. COR/HRM/EPP/02
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Plan-Saswad Factory
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It is necessary that all aspect of emergency plan are tested sufficiently often to
ensure that the personnel and equipment involved in emergency plan carry out their
responsibility and function as specified and particular to:

¾ Test the response from workers, emergency services, and other responsible
persons.
¾ Test and evaluate the interaction of various agencies / authorities involved and
ensure that all components are properly coordinated.

¾ Evaluate the available resources, equipment, their effectiveness, accuracy

¾ Gain more and more experience.

AUTHORITY OF EXERCISE / REHEARSAL

The site controller of the Company is required to assume the responsibilities to make
decision be seen as legitimate.

Table Discussion
The first part of experience is ‘Table Top’ exercise to test emergency plan may not in
any way interrupt the day-to-day running of their respective concerns. This exercise
will recognize the difficulties involved and practical approaches to encounter the
same. The scenarios will be decided and consideration will be given to live practices
involving all concerned at suitable intervals, in addition to those of a theoretical
nature.

NATURE
Origin, date and time, location and duration of Mock Drill exercise etc. will be pre-
decided in particular manner.

AFFECTED AREA
It is the indication of the spread of disaster. This will be reflected in Blue print, given
detailed of original place, units, surrounding identities etc.

PREPARATION STAGE
The responsibilities & duties will be allotted to each group, services, etc. involving all
personnel. Educative meeting will be arranged and the role of each participant group
will be explained in detail.

SEQUENTIAL ACTIONS
The whole exercise / rehearsal will be arranged in the form of sequential actions, to
be taken one by one, as per Onsite Emergency Action Plan. Thus, actual exercise
will be conducted, as rehearsal.

OBSERVATIONS

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Plan-Saswad Factory
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The outside / third party will perform the role of observers and they will submit their
reports on various site- observations with shortcomings and good features.

DE- BRIEF MEETING

On completion of exercise, a de-briefing meeting will be convened to discuss the
features of conducted exercise; to give views on performance of each area; explain
difficulties; resources; limitation; planning; etc. All these observations along with
corrective steps will be noted and the reports will be prepared circulated to
concerned and maintained.

List of Fire Fighting team (Rescue Team) for Saswad plant

MEMBER OF TASK FORCE
1 ACR Administration S.B.Nair
2
Saswad ACR Projects shed Ganesh Nirfarake
3 Jagdish Zha
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4 P T Kurhade
5 V B Dusang
6 S A Mahajan
7 Swapnil Gawad
8 P C Bodke
9 Machine shop S S Khaladkar
10 G M Lawande
11 N N Raut
12 Fabrication Shop I K Sayyad
13 Assembly shop S V Vaidya
14 Dispatch / Paint shop A S Mane
15 N D Rithe
17 N S Wangikar
18 Plant Engg S S Kadbane
19 S G Kharade
20 Spares / Stores Maruti Amane
21 Materials Dept. V S Raut
22 Security P R Kadam
23 K A Mhaske
24 S T Memane
25 V M Chandgude
26 R N Pawar
27 Casuals S B Mhetre
28 Canteen V K Gupta

First aid Trained Employees & Contractors for Hadapsar & Saswad plant
MEMBERS OF TASK FORCE
Contractor
First aid s Name (If
Sr.No. Div Department Nomination T.No. appli)
1 ACD ACD Machine shop P B Pathare 10181
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2 Plant Engg. ACD V V Kikle 8355

3 ACD BOP Assembly P R Khamkar 10440
4 ACD EH/RBC Assembly G S Dixit 4622
5 Dispatch T S Kawade 7060
6 GSU+ Centrifugal Assly T B Kamble 9032
Shot blasting / Pattern
7 shop N K Gaikwad
Hardseles
8 Foundry S R Memane Engg
9 TRM New TRM Shed S Perodiya 10404
10 Heat treatment V P Jagtap 10135
11 P G Sawant 10397
12 TRM CNC/ Machine shop A A Salunkhe 10052
13 S S Chougule 10458
14 Plant Engg. TRM A.R.Thosar 10181

Eagle
15 CORPORATE Administration Building S P Bhalke Services
16 COMMAN R & D Building R V Nigade 10299
17 Materials Bldg D S Sonar 10114
18 ACR / IT Building L T Pande 8163
20 Canteen R R Hirve 10544
Security
22 Security Hadapsar R M Ghodake Officer
Eagle
23 B A Kale Securities
Shamrao &
24 OHC S S Kapare Sons
25 ACR (SASWAD) Machine shop Santosh Patil 10569
26 Assembly shop L D Kirdat 7017
27 ACR Projects Jagdish Zha 10593
28 Stores / IT / Materials S S Jagtap 8759
29 Security Saswad P R Kadam 10623

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 Document No. COR/HRM/EPP/02
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LIST OF AMBULANCE DRIVERS HADAPSAR &

SASWAD

Sn First
o Name Of security Personnel Cell Number Aid Fire fighting
1 JSO R M Ghodake 9922959694 Yes YES
2 Dighe R B 9767413724 Yes YES
3 Jadhav N D 9604602214 Yes YES
4 Pisal D S 9822964889 Yes YES
5 Sanjay P Bhosale (Saswad) 9881469413 YES
6 Sharad P Bhosale (Saswad) 9766874542 YES
HADAPSAR EMPLOYEES TRAINED ON FIRE FIGHTING IN AUGUST
2010
Sno Name Dept
1 S D PATIL HEAT TREATMENT
2 R J RANAWARE ACD ASSEMBLY
3 M S GAWALI ACD ASSEMBLY
4 N V TIKHE PLANT ENGG
5 D B TAMBE ACD ASSEMBLY
6 B P DIXIT ACD ASSEMBLY
7 V W KANASE HEAT TREATMENT
8 D D MANE ACD ASSEMBLY
9 K R MHETRE PLANT ENGG
10 A K SHINDE CORP-QA
11 M E GAIKWAD IT
12 D R JAGDALE ACD-MACHINE SHOP
13 VINOD BANSODE HRD
14 D S RATHOD SECURITY GUARD
15 S P SURYAWANSHI SECURITY GUARD
16 A S KALE HRM
17 S T JADHAV TRM M/C SHOP
18 K R JAGTAP TRM M/C SHOP
19 JADHAV S R TRM M/C SHOP
20 S V KUMBHAR TRM M/C SHOP
21 B S LIKHANDE PAINT SHOP
22 T S KAVADE DESPATCH
23 M Y KULKARNI CIVIL
24 R S MEMANE FOUNDRY
25 S M AGARKAR STORES
26 YOGESH SARAF IT

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SASWAD EMPLOYEES TRAINED ON FIRE FIGHTING IN AUGUST

2010
1 ANAND KULKARNI PROCUREMENT
2 A S MANE MFG ENGG
3 D G GUMASTE ACR-ASSEMBLY
4 PRADEEP DEV ACR-PROJECTS
5 JAGDEESH HARLAPUR ACR-PROJECTS
6 M D KAMBLE ACR-PROJECTS
7 S A MAHAJAN ACR-PROJECTS
8 S G PHATANGARE ACR-PROJECTS
9 GANESH NIRFARAKE ACR-PROJECTS
10 P B PATIL ACR-ASSEMBLY
11 G M LAWANDE ACR-M/C SHOP
12 N N RAUT ACR-M/C SHOP
13 B V MANE ACR-M/C SHOP
14 V G KENGAR FABRICATION
15 P W THAKARE QA
16 UMESH JADHAV YASH ENGG
17 S A KALASKAR
18 V B DUSANG QA
19 B V KUMBHARKAR SECURITY GUARD
20 PRAKASH KADAM SECURITY OFFICER
21 M R GUPTA
22 N G BADHE
23 I K SAYYED FABRICATION

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On –Site Emergency Preparedness Rev. No. & Date 03; 23/01/2011
Plan-Saswad Factory
Page 49 of 48

EMERGENCY ORGANIZATION CHART

Site controller

Incident Controller

Fire First HRM Utility Produc Security Safety Off Shift In

fightin Dept. charge
aid Dept Manager tion
g
Squad Squad Heads

Prepared by – Safety Officer Approved by – HOD HRM

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