ISCL Kutchh DREIA Emergency Prepardnes Plan

INDIAN STEEL CORPORATION LTD.
EMERGENCY MANAGEMENT PLAN
Disaster preparedness
Where observation is concerned, Chance favors the prepared mind

---Louis Pasteur
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SALIENT FEATURES OF THE PLANT

Indian Steel Corporation Limited has set up a 2, 00,000 TPA Cold rolled Coils/sheets and Galvanized coils/ sheets which is locatedin Survey No.370, Near Bhimasar Railway crossing, village Bhimasar Ta. Anjar, Kutch - 370240. The plant is spread over approx. 75 Acres of land. The site is at a distance of 21 Kilometers by road from Gandhidham Railway Station. 1. 2. Name of the Factory Address of the Factory : : M/s Indian Steel Corporation Limited. Survey no 370,Near Bhimasar, Railway Crossing, Ta.Anjar, Kutch-370240 Phone. 02836-285371 / 2 / 3 Fax No.: 2836285375 Mr. S.N.Sadawarti , Director. Mr.R.K.Gupta .G.M.( E ) COLD ROLLING AND GALVANIZING C.R. Coils / Sheet &.Galvanized coils/sheets
3. 4. 5. 6.
Occupier Factory Manager Nature of Industry Product
: : : :
7.
Capacity
2, 00,000 MT/Year
8. 9. 10.
No. Of Employees Power Connection Source
: : :
450 Max. 6500 KVA GEB SR. VP VP (OPS) GM ( OPS ) G.M. (Proj) G.M. (Elec ) AGM AGM (CGL) Sr. Manager SR Manager MM SR Manager Manager Admin
11.
Key Persons of the Emergency Plan
Mr. Dinesh Sethi : Mr.D.K.Bhalerao Mr. Ajay Mishra : Mr.V.Badjatya : Mr.R.K.Gupta : Mr.B.K.Singh : Mr.Osatwal : Mr. P. Yelsetwar : Mr. Dhanuka : Mr. Girish Mathur : Mr.Karwasara
MATERIAL TO BE STORED & POSSIBLE HAZARD

S.No.Material 1. * HCL in Storage Tank HCL Acid 30% Conc. Quantity 120 MT Possible Hazard Toxic & Burning Safety Measures Taken Gas Mask, Gum-Boot, Apron, Hand Gloves are provided. 02 No. Shower near storage
2.
HCL Acid in Pickling Plant 15 to 18% Conc.
20-25 MT
Toxic & Burning
Safety Shower 2 Nos.in pickling Plant.
3.
Ammonia
21MT
Toxic
Safety Shower 1 Helmets, Hand gloves

O2 Type breathing apparatus etc.
Gas Masks 4. Propane 146MT 2 Tanks Fire & Explosion Fire Fighting Equipment & Fire Hydrant Line.
Storage tanks are kept on the platform duly lined with acid proof bricks. Also the platforms are made at a safe place surrounded by RCC walls duly lined with acid proof bricks. Hence the chances of any seepage is NIL in case of any leakages. Propane tanks are installed on Rcc structure and complied with the statutory Norms.
MANUFACTURING PROCESS WITH ITS FLOW DIAGRAM:

It is Cold Rolling Plant. HR Strips in coil form is the raw material of cold rolling. First this HR Coil is slitted or trimmed in required width and them passed through acid bath for pickling the surface. This coil is afterwards sent on Cold Rolling Mill (CR Mill) and it is rolled to the requirement of final product. After rolling this material can directly sent to market as full hard grade or it is sent to annealing furnaces for relieving the stresses which are developed during rolling. The annealed material is then skin passed to remove the sharp yield points & to improve the metallurgical properties. Finally after skin passing the CR strips is slitted or trimmed width wise & cut in length wise as per the final requirement of customers.
FLOW DIAGRAM
H.R.RECEIPT
H.R.SLITTER
PICKLING 04 Hi ROLLING MILL
C.R.REWINDING
(TRIMMING & PARTING)
CGL ZINC COATING
CUT TO LENGTH
PACKING OF SHEET
Corrugation machine & packing
EMERGENCY PREPAREDNESS PLAN
SCOPE OF THE PLAN:

The Emergency preparedness Plan of the Company is divided in two Parts: (i) On-site emergency plan : In this plan, the Company officers are given predesignated responsibilities for dealing with the emergency. (ii) Off-site emergency plan : In this, different Government Agencies will be informed about the emergency for necessary help from them. 1. TYPE OF EMERGENCIES :
PURPOSE:
An emergency can not be always prevented but it can be controlled within limits and its effects can be minimized by using the best resources available at that time. Emergency planning is a management function and it should be penetrated up to the every person available, workforce. Managements have evaluated the activities, operation, and processes carried out within the works before starting to plant.
SAFETY PARAMETER:
The Company established all safety parameters required by the statutory and Mandatory and also considering its social responsibility. Storage Bullets are well protected with fire hydrant system / Monitors and with bund/dyke walls around the tanks. Storage Bullets are also protected with sprinkler system. In addition to this we also provide additional sprinkler for unloading tanker. For both the gases we are in the process to install early gas leakage detection system for timely alert & action.
Objectives of the emergency plan.

1. To provide resources and methods for effective control of emergencies arising out of leakage, explosion and fire due to hazardous chemicals. 2. To prevent the emergency turning into disaster. 3. Synchronized action from all the coordination agencies with least possible delay. 4. To minimize damage to property, people and environment. 5. 6. 7. 8. Effective rescue operation and treatment of the casualties if any. Train the people to act efficiently and with confidence in an emergency. To bring back the normal situation in the least possible time. To provide authoritative information to the news media and government agencies. 5
2.
9. No panic among general public in vicinity & nearby area. SCOPE OF THE PLAN : The Disaster Management Plan of the Company is divided in two Parts: (iii) On-site emergency plan : In this plan, the Company officers are given predesignated responsibilities for dealing with the emergency. (ii) Off-site emergency plan: In this, different Government Agencies will be informed about the emergency for necessary help from them.
3.
TYPE OF EMERGENCIES : i) ii) iii) Fire Explosion Natural Calamities
4.
OVER ALL OBJECTIVES : The overall objectives of the emergency plan will be i) To localize the emergencies and to eliminate them.
Elimination will be done by emergency shut-off procedures, operating safety inter-locks and safety valves, using fire fighting installations and equipments, etc. ii) To minimize the effect of the accidents on the employees and property.
Minimizing the effect will be done by rescue operations, first aid, evacuation of the plant personnel, rehabilitation and giving promptly information to the nearby residents. 5. IDENTIFICATION OF HAZARDS : Following hazards are identified in the plant: 1) Storage of LPG - propane leakage emergency Propane leakage and fire emergency 2) Storage of Ammonia: Ammonia leakage emergency
Storage Bullets is well protected with fire hydrant system / Monitors and with bund/dyke wall around the tanks. Storage Bullets are also protected with sprinkler system. In addition to this we also provide additional sprinklers for protection to the tankers during unloading.
5.
propane, and AMMONIA
HAZARD FROM PROCESS
The plant process is itself fire hazardous in nature as there will be handling of HCL,
& ZINC in liquid bath.
Hazard identification
Gas leakage Fire Explosion Natural Disaster
Mitigation Measures
(1) On-site emergency plan (2) Off site emergency plan For On site emergency plan we evaluate the basics and distinctive requirements of each site for handling the foreseen emergencies of hazards.
Parameters
1. Size and nature of the work within the factory premises. 2. The location of the plant and site. 3. The nature of the input used. 4. The nature of the process. 5. The available resource for handling the situation. 6. The number of the people present in the shift.
Training and rehearsal
We ensure that the proper training of all staff and workers for handling the emergency and they must be able to carry out their specified tasks efficiently at the time of the emergency. Number of time during emergency it was experienced that work force behaves in a manner in which way they have trained. If trained properly they are helpful to control the situation. If not, they will worsen the situation.
Role of key personal

Action necessary for one emergency may differ from the other, for handling any emergency different skill required because of different causes. Actions should commence and guided by the fixed people and the responsibility and the duties in the emergency must be given to the nominated key personnel for making the use of the resources available and to avoid any confusion at the time of emergency.
Other key personal

It includes the senior managers in production, safety, security and personal dept.
Essential workers (Plant supervisor, chemist, operators, etc.)

Duty and responsibility are as under. 1. They must be ready to shut down the adjoining plants which are nearer to the incident. 2. They should provide the personal protection equipment and the fire fighting equipment. 3. Act as messenger in case of failure of the communication. 4. They should record the evacuated person and casualties.
Non essential person.

Advise them to leave the affected area and report at the safe assembly point. Generally daily contract labor, visitors and truck staff are non aware of the emergency hence it is a moral responsibility of the individual to take them out when any emergency arise.
Establishment of the control room

Direction and co-ordination of operations to handle the emergency are relayed from the emergency control centre.
The emergency control room must be equipped with the following equipment and information for better control of the situation
1. There must be sufficient number of telephone. 2. There must be at least two copies of the list of key person with address and telephone number and there role. 3. I) II) III) IV) V) There must be layout plan to show Area which may be subjected to high risk. Storage area of compressed gas cylinders. Location of assembly point and medical centre. Location of the hydrant system. Centre must be equipped with emergency lighting.
Raising Alarm: raising alarm of the emergency is very simple but it is very clearly understood by the individual and make them aware of the different type of siren signals. To consider the all fact to avoid panic and work hamper during different level of emergency we bifurcate the siren system with one another and training for the same is confirm by conducting the mock drill. Assembly point: Evacuated person must be assembling at the assembly point. Great care must be taken so that people dont come in contact with affected area while reaching the assembly point. The assembly point will be safest location and in two different locations so in case of wind direction it can be change.
Head count:
It is a duty and responsibility of the personal manager to keep up to date daily report of employees within the works and who have been sent out side for outside duty. Arrival and departure of the contractor, visitors and drivers records to be kept ready for the day and night. 8
ON SITE EMERGENCY PLAN ISCL

Main elements of on-site emergency plan are as follows:
Emergency Control Room
Emergency Control Room will be in the TIME OFFICE which is located near the Cold Rolling Mill Entrance. It is provided with a) b) c) d) e) f) An adequate number of telephones with all facilities to contact anyone inside the plant as well as outside agencies. Plan for fire hydrant system. Location for assembly point and first-aid centre. Plan for surrounding habitation within one Km. Range. Nominal roll of employees. List of key persons and their addresses with telephone numbers.
ASSEMBLY POINT Assembly point is set up for pickling employees near main pump house area and for Galvanizing & CRM employees near Time office area. At these assemblies point, in case of emergency, all the people working in the plant would assemble. Manager (P&A) and their staff will take charge of this point and take the roll call as the people gathered. This point is having up to date list of company employees and contractor employees. Senior officials of the plant areas will also help / guide and coordinate the activities. COMMUNICATION SYSTEM The factory has got intercom telephone and outside lines, fax and telex. The building for communication is far away from the plant activity and will be work efficiently. The security dept also having the walky talky and can be utilized in emergency to coordinate the job. EMERGENCY SERVICES a) Plant fire brigade: The factories have got its own well Trained Fire personnel and impart training to the staff for handling any type of the emergency. The duty security and trained staff under the command of Sr. Manager (Fire & Safety) shall be responsible for fire fighting and rescue operation. On hearing the fire alarm, they shall proceed to the place of incident. At the site, all the members of plant fire brigade will respond to the advice and information given by the incident controller. On arrival of Municipal Fire Brigade, if called they will also assist in fire fighting work. b) Fire fighting facilities: Fire hydrant system has been installed in the plant. The hydrant system has got a fire water tank with capacity of 1030M3 which is connected with a raw water reservoir with of 2108M3 capacity. An electric pump (capacity of 27.3 M3/hr and 70 M head) is installed to feed the system with water. The system remains under pressure with a jockey pump of capacity 11 M3/Ltr and 70 M head. If any one of the fire hydrant valve is opened electric pump will get operated because of pressure drop in the system. In case of emergency a utility operator will ensure continuous supply of water to the system. This system will be monitored on daily basis. Suitable types of fire extinguishers have been installed in the plant at their respective places. Extinguishers are tested periodically.
MEDICAL FACILITIES A well-equipped first aid centre with trained staff is located at the main entrance of the mill. This medical centre has got a vehicle which can be used for shifting casualties at the time of emergency. If required, the casualties will be sent to Govt. hospital and Ram bag medical centre. First-Aid Boxes at various places are provided in the plant. We have appointed Dr. Amar Rathi as Medical Officer of the plant .
RESCUE FACILITIES The fire /security and some of the company employees are trained in rescue operations. Rescue ladders, stretchers, rope and other rescue equipments are available in the plant. PLANT SAFETY ARRANGEMENT Safety equipments like Safety Helmet, Safety shoes and Hand Gloves, Asbestos Apron, Safety Shower and other safety equipment supplied to the concerned employees by the Safety Officer. Safety work permit for carrying out the dangerous jobs like working in height, working in vessels in the plant is implemented. Safety committees under the Chairmanship of Sr. vice president are working for general plant safety arrangement. 1. KEY PERSONNEL AND THEIR RESPONSIBILITIES : i) SITE CONTROLLER : In case of emergency, Sr. vice president will be the site controller. After receiving information about the emergency, he will proceed to the emergency control room (Time office) and shoulder overall responsibility for the factory and the employees. His duties shall be: a) Assess in consultation with incident controller and other key personnel as to whether shut down the plant or affected section of the plant and evacuation of persons if required. b) Assess the magnitude of the situation and decide if employees need to be evacuated from their assembly points. c) Liaison with Senior Officials of Police, Fire Brigade, Civil Hospital, Gdham and Factory Inspectorate and other Government Officers, etc. d) Issue authorized statements to news media, and ensures the evidence is preserved for enquiries to be conducted by statutory authorities. e) To ensure that casualties are receiving adequate attention. ii) INCIDENT CONTROLLER:
Head of mill / galvanizing / pickling will act as the incident controller in there respective dept. On hearing of an emergency siren he will rush to the scene of the occurrence take overall charge and then report to the site controller. His duty will be: a) b) c) Direct all operations within the affected areas with the priorities for safety of personnel minimize damage to the plant, property and environment and minimize the losses. Order for the shut down & direct the evacuation of plant and areas likely to be adversely affected by the emergency; after consulting the site controller. Ensure that all-key personnel and outside help are called in.
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d) e)
Provide advice & pass on information to the Sr.Mgr (Fire & Safety) and the local fire service as and when they arrive. Ensure that all non-essential workers / staff of the areas affected are evacuated to the appropriate assembly points, and the affected areas are searched for casualties. Report all significant developments to the communication officer. Have regard to the need for preservation of evidence so as to facilitate any enquiry into the causes & circumstances which may have caused or escalated the emergency.
f) g)
i)
PERSONNEL / ADMINISTRATION COORDINATOR :
Manager (Admin) will be responsible for Personnel & Administration coordination during emergency. He will report to the site controller and remain stationed at the emergency control room. He will, under the direction of the Site Controller, handle Police, Press and other enquiries, receive reports from roll-call leaders of assembly points and pass on the absentee information to the site controller. His responsibilities shall include. a) b) To ensure that casualties are getting adequate attention, to arrange additional help if required and inform relatives of injured persons. When emergency is prolonged, arrange for the relief of personnel and organize refreshments/ catering facilities.
ii)
COMMUNICATION OFFICER :
OFFICER (P&A.) will be the Communication Officer during emergency. He will, on hearing the alarm, proceed to control center and maintain communication with the incident controller. His responsibilities will be: a) b) c) iii) Arrange for evacuation of staff/ workmen from the assembly points. Appoint suitable staff to act as runners between the incident controller and himself if the telephone & other system of communication fail due to whatsoever reasons. After getting advice from the Site Controller, he will call local fire brigade, police and mutual aid scheme members.
SECURITY ARRANGEMENTS COORDINATOR :
Manager (Security ) will be the security arrangement coordinator during the emergency. His duties will be: a) b) c) To control traffic movements into the factory and to ensure that alternate transport is made available when need arises. To provide additional security staff for rescue and fire fighting operations. Restrict the entry of unauthorized persons in the factory or in the affected areas.
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d) iv)
Direct the outside emergency services towards the affected areas.
MEDICAL SERVICES CO-ORDINATOR :
Personal Officer will be the medical service coordinator during emergency. His responsibilities shall include: a) b) v) Attending the casualties / injured persons for first aid, and if required, arranging for their shifting at Civil Hospital, Gandhidham. Arrange for suitable anti-dotes for affected persons.
FIRE FIGHTING & SAFETY CO-ORDINATOR:
Sr,Manager (Fire & Safety) will be the fire fighting coordinator during emergency. On hearing the fire alarm he shall proceed to the place of accident. His duties will be: a) b) c) d) e) f) g) h) To study the nature of fire and arrange required suitable fire fighting appliances and material. To extinguish the fire with the help of fireman, security staff, and trained company employees. To cancel the raised fire alarm. To do all necessary arrangements salvaging unaffected company property. To take necessary advice for fire fighting from the incident controller. To direct the fire- tender personnel for fire fighting. To assist the local fire brigade personnel. To arrange for refilling of used fire extinguishers and cleaning and maintenance of used fire appliances after the emergency.
vi)
SERVICES COORDINATORS : A. General Manager (ELE) & shift in charge will be the coordinator for electrical jobs. He will report at the incident site immediately and his duties will be : a) b) c) To isolate necessary equipments by disconnecting its power supply as directed by the incident controller. To provide electrical supply during emergency for safety equipments. To direct an electrician at the Pump House for ensuring continuous electrical power supply to the electrically operated fire pump.
B. Manager (Utility) will be coordinating the utility services during emergency. He will send hydrant system. C. Departmental Heads:
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At the time of emergency, all the departmental heads will report to the incident controller and provide assistance as required. They will decide which members of their staff they require at the scene. D. ON DUTY SECURITY OFFICER/SUPERVISOR : On duty Security Officer/Supervisor remains round the clock in the factory. After hearing the fire alarm, he will immediately contact the site controller. He will also inform all the key persons. About any failure of telephone systems during emergency, he will immediately inform the communication officer through a messenger. 2. EMERGENCY PERSONNELS RESPONSIBILITIES OUTSIDE NORMAL WORKING HOURS OF THE FACTORY: Shift Managers of respective areas will be responsible to attend the emergency during outside normal working hours for factory. On hearing the continuous siren or if informed he will immediately proceed to the site of the incident. On arrival, he shall assess the scale of the incident and direct and prepare within the affected areas, the following priority-wise: a) b) c) d) e) f) Secure the safety of persons, which may require evacuation to the assembly point. Minimize damage to plant, property and the environment. Minimize loss of materials. Have regard to the need for preserving evidences that would facilitate subsequent enquiry. Inform shift engineer in-charge as to what services are/ are not required. He should immediately inform the incident and site controller and hand over the charge of operation to the Incident Controller when he arrives at the site.
3. EMERGENCY ACTIONS WITHIN 15 MINUTES OF OCCURRENCE The continuous siren, internal and external telephone systems are the best communication media for taking emergency action by the key persons within 15 minutes of occurrence. A response time for the factory fire personal is less than one minute. Fire hydrant system will also be operated instantaneously as it remains in auto position. The plant has got sufficient number of emergency exits, which could be used for evacuation of the people. 4. FACILITIES AVAILABLE WITH THE FACTORY : a) FIRE FIGHTING FACILITY :
The factory has got fire hydrant system, which works, in auto position. Extinguishers are installed in the plant at the respective places. b) MEDICAL FACILITY :
A well-equipped first-aid Medical Centre with trained personnel is located in the factory. c) MATERIAL HANDLING :
Heavy-duty cranes including mobile cranes, forklifts, trucks, trolleys are being used in the plant. The same could be used at time of emergency for handling the materials. d) PERSONAL PROTECTIVE EQUIPMENT : 13
Safety helmets, Safety goggles, leather hand gloves, Ear plugs, Asbestos Apron, Leg guards, Eyes and Body wash fountain etc. are available in the plant. 5. OFF SITE EMERGENCY PLAN : Type of emergency facilities / actions required from outside bodies: a) b) c) Fire-fighting facilities required: - factory has got its own fire fighting facilities but during emergency, local fire brigade may be called .LOCAL fire brigade and will take approximately 30 minute to reach at the ISCL site. Police help required: During emergency, for evacuation of the people, traffic control, security arrangement, etc. police help may be required Anjar police station about 17 KM from the site and will take about 30 minute to reach at the site. Medical help required: Seriously injured personnel may be referred / sent to the Civil Hospital, Ghandidham or Anjar depending upon the gravity / type of injuries.
(Details of the ambulance services and their phone numbers are given in the annexure.)
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MATERIAL SAFETY DATA SHEET

HYDROCHLORIC ACID
A) PHYSICAL PROPERTIES
Chemical Formula Molecular weight Flash point Specific Gravity Vapor pressure Density Gas Liquid
: HCL : 36.5 : None : 1.19 (commercial concentrated or fuming acid with 20 % at30 oC. : 4.0 atm at 17.8 oC : 1.638 g/lit at 0 o C : 1.194 gm/cc at -36 oC
Important Characteristics of Hazardous Chemicals
: Soluble in water in all proportions. : Colorless to slightly yellow fuming, Pungent liquid. TLV : 5 ppm (7 mg/m3) part per million. Flammability / explosion : Non-flammable, non-explosive Fatal dose
Reaction with water
Solubility in water Color and Odor
It reacts with water or stream to produce toxic & corrosive fumes.

Reaction with metals & other elements
Anhydrous hydrogen Chloride is not corrosive but aqueous solution is corrosive to nearly all metals like copper, zinc, lead, aluminum liberating hydrogen gas in air. Zn + 2HCL ZnCL2+ H2 Cu+ 2HCL CuCL2+ H2 Hydrogen so generated forms an explosive mixture with air.
Reaction with inorganic & organic compounds
Hydrochloric acid reacts with sulphide to form chlorides and hydrogen sulphide. ZnS+2HCL ZnCL2+H2S It reacts with caustic soda to form salt and water. NaOH+ HCL NaCL +H2O
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REMEMBER
EFFECT of Hydrochloric Acid in various Concentrations Hydroulicloric acid concentration in Effects Air,(ppm) 35 Cause irritation of throat after short exposure.
50-100 1000-2000
Tolerable for one hour. Dangerous even on short exposure.
FIRE/EXPLOSION/CORROSION HAZARDS
HAZARDS FIRE EXPLOSION CORROSION Highly corrosive to most of the Metals With evolution of hydrogen gas, which Is highly explosive when mixed with air Corrosion action on metals increases With increase in temperature, Concentration And other factors. PRECAUTION/EXTINGUSHING AGENT NIL NIL Keep away from naked flame and heat. Do not Carry out any welding/cutting job until the Tank is completely emptied and washed Thoroughly with water.
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First-Aid and Medical management symptoms. Skin contact

1. 2. 3. 4. 5. Burning sensation Inflammation and painful blisters. Burns that may be very painful and become white Profound damage to tissues. State of shock i) Cold sweat-pale complexion. ii) Rapid and weak pulse. iii) Cold hands and feet. iv) Tendency of faint.
Eye contact
1) 2) 3) 4) 5) Watering from eyes Burning sensation in eyes & eyelids, with ulceration of the tissues Inflammation of eyes {conjunctivitis} Opaqueness of the cornea Loss of sight
Inhalation
1) Irritation of mucous membranes {nose, eyes, throat, mouth} 2) Watering of eyes, coughing. 3) Rapid breathing, difficulty in breathing 4) Head ache 5) Fits of coughing 6) Face & lips become blue 7) Salivation & giddiness 8) Muscular weakness 9) Nausea 10) Ulceration of mucous membrane {nose}
Ingestion
1) Irritation & burning sensation of lips, mouth & throat 2) Abundant salivation 3) Pain in swallowing 4) Intense thirst 5) Ulceration of the mucous membrane 6) Color of the tongue will become GRAY 7) Burning sensation at the back of throat & stomach 8) Edema of the glottis 9) Nausea & vomiting, even of blood 10) Difficulty in breathing 11) Perforation of the stomach may occur 12) State of shock: Cold sweat - pale complexion 17
Rapid & weak pulse Cold hand & feet Tendency to faint 13) convulsions & coma 14) death
FIRST AID
Skin contact.
1. 2. 3. 4. Immediately remove the victim from the affected area. Immediately remove the clothing from the affected area. Wash the affected area with the large amount of water. Dust the affected area with powdered sodium bicarbonate, then again wash affected area with mild soap. 5. Rinse the affected area with tepid water. 6. Dry the skin carefully using a clean and soft towel. In case of burn and blister. 7. Dress the victim in clean cloths or keep him warm using a blanket. 8. If the victim in the state of shock: 9. Keep him covered by the blanket. 10. Lay him on his back and carry him on a stretcher.
Eye contact
1 2 3 4 Remove the victim from the affected area.. Quickly wipe away any excess of the chemical. Wipe affected eyes with large amount of the chemical. If pain still remains, put one or two drops anaesthetizing eye salve or one drop of BENOXANATE at 0.4% into the eye. 5 If the pain remains, wash the eye again for at least 15 minutes. 6 Do not use any oil or oily ointment without medical advice.
B) CHEMICAL PROPERTIES
Hydrochloric acid: 1. 2. 3. 4. 5. 6. It is a fuming liquid. It is completely soluble in water. The vaporous are heavier than air and settles on ground level. It is hygroscopes liquid and absorbs moisture moderately. Do not put water directly on the large leakage. It reacts with metals to liberate hydrogen gas, which is explosive. It reacts with strong alkalize to liberate large quantity of heat.
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FIRE EXTINGUISHMENT Fires involving small amounts of combustible ignited by contact with Hydrochloric acid, may be smothered with dry chemical. HEALTH HAZARDS - 30 % Concentrated HCL as a sharp corrosive and destructive action on all living mater, including human tissues, not by virtue of its acidity but because of its affinity for water. it effectively removes the element of water from any organic materials with which it comes in contact, thus it can burn and char the skin. It is even more rapidly injurious to the mucous membrane and exceedingly dangerous to the eyes. Dilute hydrochloric acid does not possess the property of charring. It irritates the skin and mucous membrane by virtue of its acidity. Repeated contact with dilute solution may cause dermatitis. Splash injuries to the eyes are the most serious adverse health effect of HCL in industry, because contact with concentrated acid of any magnitude is capable of causing irreparable corneal damage resulting in blindness. At the same time, acid burns of the eyelids and surrounding parts of the face will produce permanent scar with disfigurement. Exposure of teeth to Hydrochloric acid at the mist concentration causes first, etching of the dental enamel and then erosion of enamel and dentine with loss of tooth substance. The damage is limited to the parts of the teeth which are exposed to direct impingement of acid mist droplets upon the surface. Inhalation of Hydrochloric acid is high enough concentration causes an irritation or tickling of the nose and throat, sneezing and coughing which is somewhat likened to the effects of breathing dusty air. At levels below these detectable by the foregoing subjective effects, HCL causes a reflex increase in the rate, and domination of the depth of respiration, with reflex bone- choconstriction resulting in increased pulmonary air flow resistance. Exposure to higher concentrations or for longer periods may result in bronchitis symptoms, discharge of mucus, bleeding from the nose and watering of the eyes. Exposure to HCL has also been reported to result inconjuctivities, frequent respiratory in factions, and digestive disturbances. A single over exposure to HCL may lead acutely to laryngeal, tracheobronchial, and even pulmonary edema, and chronically to pulmonary fibrosis, residual bronchiectasis, and pulmonary emphysema. Chronic exposure causes acid necrosis of teeth. Ingestion of even dilute solutions of the acid causes severe burns of the cucous membrane of the mouth, throat and stomach. FIRST-AID: It is essential to wash and remove any HCL that comes in contact with the body immediately as any delay may result in serious injury.
Skin Contact Get under emergency shower immediately. Remove all contaminated clothing as rapidly as possible while under the shower. If no safety shower is available flush the affected area with large amounts of running water for at least 15 minutes.
Caution Do not attempt to neutralize the acid with Alkali, since the heat of neutralization accentuates the burn. No Ointment should be applied unless prescribed by the physician. 19
Eye Contact:
Using eye fountains, irrigate the eyes immediately with copious quantities of clean water. Hold the eye lids part to ensure contact of water with all tissues of the eyes and eye lids. If the fountains are not available, pour water over the eyes by holding eyelids open for at least 15 minutes.
Caution No oil or ointment should be used unless prescribed by an eye specialist.
Inhalation:
Remove the victim to an uncontaminated area. If the victims is unconscious, check for breathing and for pulse If breathing has ceased start artificial respiration immediately If breathing and pulse are normal, place the victim in the recovery position. If the victim is conscious, make him lie or sit down quietly. If the breathing becomes rapid and bubbly, place him in the sitting up position and give Oxygen. (Oxygen should be administered by the authorized person only). Oxygen resuscitation apparatus should be available in the aid-room. Transfer to hospital, in either case, as soon as possible.
Ingestion If liquid HCL has been swallowed and the person is conscious, give him large quantities of water immediately to dilute the acid. Give him milk to drink if available. Keep patient warm. Do not attempt to induce vomiting. Do not give anything by mouth to an unconscious victim. Get the medical attention immediately.
STORAGE AND HANDLING:-
Storage . Lead lined tanks are recommended for HCL. Smaller quantities of HCL stored in FRP tank or glass carboys or bottles. The building in which the acid containers are stored should be constructed of fire resistant material, having acid resistant floor fitted with retaining sills and adequate drainage. It should be kept in cool, well ventilated area away from other chemicals, especially organic materials, nitrates, chlorates, carbides, metal powers, peraoxides and explosives. Electrical installations should be of acid resistant type. Acid fumes from leaking containers can cause corrosion to steel and metal structure in the vicinity. Therefore, these should be well-protected by plaint of the appropriate type. Smoking should be strictly prohibited in the area. All containers should be clearly labeled. Glass or plastic containers should be adequately protected against impact. They should be on racks above the floor level to facilitate flushing of the floors in event of leakage. 20
Glass carboys containing acid should not be stored one on the top of another. Drums should be with the plugs up and should be vented once a week and more often in hot weather, to release Hydrogen build up. Storage period of acid in drums should be kept to a minimum. Bulk storage tanks of acids must be mounted on foundations lined with acid proof material. It is necessary to provide acid-proof basin to the storage tanks with proper drainage to prevent seepage of acid into the ground, thus endangering the foundations. Tanks should be fitted with over flow pipes leading to an adjacent container and located within bunds that will retain the total contents of the tank in the event of leakage or spillage. The bund should be have acid proof lining and should drain into an acid resistant concrete sump. Tanks should be equipped with vents of such sizes so as to maintain the tanks at atmospheric pressure during filling and emptying. Vents should be connected to a caustic pot. The top of the tank should be accessible by an independent, metallic ladder for inspection. The use of the top of the tank for standing during inspection should not be allowed as it may be corroded due to action of acid mist. Tanks should be protected from external corrosion by coating them with a suitable material such as bitumen, epoxy paint, etc.
Handling Using only minimum concentration necessary for the process. Never pour water into acid. When diluting, always pour acid into water, stirring constantly. Whenever possible acid should be pumped through sealed systems to prevent all dangers of contact. Whenever individual containers are to be transported or decanted, only experienced person should be allowed to undertake the work and the appropriate equipment should be employed as follows: Large containers should be transported on hand trucks or power trucks. Small containers such as bottles should be carried in safety bottle carriers, which provides protection against impact and retain acid in of damage. Decantation should be done by means of special siphons, transfer pump, drum or carboy tilting cradles etc. Where acid is mixed with other chemicals, workers must be made fully aware of any violent or dangerous reaction. Where the process produces acid mist or vapors, such as in electroplating, exhaust ventilation should be installed.
Carboys _
The carboys should not be carried on shoulders. Never handle carboys by the cap or neck of the bottle. Be sure caps are securely fastened before moving either filled or empty carboys. Never use air pressure to empty carboys. Use tippler Siphon pump etc. for removing contents. The carboys should never be walked on bottom edges. Use hand trucks. Wear face shields, rubber gloves, apron, boots and acid proof suit when opening carboys. Keep face and hands to be side of the carboy, while opening. Naked glass carboys or bottles should never be moved or transported, except when packed in suitable boxes or crates. Do not use HCL containers for any other liquid.
21
Empty carboys should be thoroughly washed with water before being sent out.
Drums Avoid rough handling of drums. Drums should be emptied by gravity only, using faucet or safety siphon fabricated material resistant to HCL. Use of air pressure for emptying drums is extremely dangerous and should never be attempted. Since drums may contain Hydrogen gas they should never be struck with a spark producing tool.
Handling through pipelines All valves on acid lines must be provided with a hood made out of lead sheet to prevent of acid from leaky valve glands. Flange joints on acid lines are to be covered with a loose cover of lead sheet which will prevent acid from spraying around in case of a leak at joint.
Tank and equipment cleaning & repairs Maintenance operation should be subjected to a permit to work system; each permit should be accompanied with detailed instructions on safe working procedure. Storage tank must be thoroughly cleaned before undertaking any repair/ maintenance work. Repair should be carried out under the supervision of a responsible person. For cleaning the tank, first shut off, put a blind flange or disconnect pipelines in or out of the tank and drain the tank as completely as possible. Wash thoroughly with large quantities of water, sludge out any residues that can not be drained. Then add soda ash or lime in sufficient quantity to neutralize any residual acid. Ensure neutralization, fill the tank completely with water and drain out. Introduce a source of fresh air to ensure complete purging. Before entering the tank, ensure that no harmful gas or vapor is present. Test for present of hydrogen. Person entering the tank should wear full protective equipment and safety belt and life line. One person should always stationed outside the tank for rescue purpose, to hold the life line. Note: - On all closed systems which are opened for hot work, section involved must be isolated as far as possible both directions.
Loading and unloading of tankers Whenever practicable, unloading should be accompanied by pumping. Compressed air should not be used for unloading. Tankers should be fitted with pressure gauge, safety valve and release valve. If a spill or over flow should occur during transferring operation, the pump should be stopped, valves shut off and spill cleaned up before other actions are taken. Water in ample quantity should be available at the unloading station for immediate use. No naked flame of any kind should ever be permitted near any to the openings of the tanker for any purpose. Under no circumstances should be discharge pipe be opened until all pressure in the tank has been released.
22
Transportation by Road Tankers A label identifying the corrosive hazard of HL (class 8 under the United Nations Committee of Experts on the Transportation of Dangerous Goods classification) should be prominently affixed on tankers carrying Hydrochloric Acid. An Emergency Information Panel containing the correct technical name, United Nations number, the Hazchem code, the name and telephone number of the emergency services, the consigner or other agency from whom expert information and advice may be obtained should be conspicuously marked on the tanker carrying hydraulic Acid at three places, e.g. on each side of the vehicle and also its rear. The Panel should be of the standard size prescribed. The drivers of the tankers carrying HCL must carry with them instructions in writing in the form of Transport Emergency Cards (TREM CARDS) regarding nature of hazard, personal protective equipment to be used, first-aid treatment and advice for dealing with fire, accident spillage or leakage. These instructions should be in English, Hindi and the languages of the states of dispatch, transit and destination. The drivers of the vehicles carrying Hydrochloric Acid should be fully trained in actions to be taken in case of transit emergencies. The manufacturers should establish a special cell for giving advice over telephone and specialist assistance at the incident site.
PERSONAL PROTECTIVE EQUIPMENT :Workers employed in the manufacture, handling or use of Hydrochloric Acid should wear suitable personal protective equipment, including chemical goggles, face screens, gloves, neoprene or PVC boots and acid resistant trousers, the legs of which should fall over the boots and not be tucked into them. To enter a tank or closed vessel in an emergency airline respirator should be worn. For normal maintenance and repair work, employees should wear gas tight clear vision rubber goggles, rubber apron, rubber gloves and gum boots. SPILLAGE TREATMENT : Instruct others to keep at a safe distance, well away from the spillage area. Wear protective acid-proof overall, gloves, suitable footwear, e.g. PVC safety boots. Spills of concentrated acid evolve irritating toxic fumes of HCL . Therefore it is recommended that an approved respirator or self-contained breathing apparatus be worn when tackling the spill. Ensure adequate ventilation. Cover the spillage with sand, solid sodium bicarbonate or a Soda ash-calcium hydroxide mixture (50-50). Work slowly and carefully, mixing the chemicals to slurry. Carefully scoops up the slurry and wash the neutralized mixture down the drain diluting with plenty of running water. Neutralization of concentrated acids produces heat. Therefore, allow approximately 2-3 minutes between all the treatment steps above. Do not clean the acid spillage with rags or saw dust fire may result. In any case do not discharge acid directly to any waterway as it could cause killing of fish and be harmful to down-stream users.
EMPLOYEE TRAINING:-
23
Training of employees in safe handling of HYDROCHLORIC Acid of great importance. All the persons engaged in handling, transporting and using Hydrochloric Acid are made aware of the potential hazards and the actions to be taken in the event of any emergency. All employees are made familiar with the use of personal protective equipment. Some of the process operators are given instruction and training in first aid and in the use of Oxygen resuscitation apparatus. Workers are encouraged to practice scrupulous hygiene; daily baths is supplemented by daily mouthwash, using a solution of 2% sodium bicarbonate. At the end of a shift a super fatted cream is also worked into the hands to prevent the skin from becoming dry and losing its elasticity. MEDICAL EXAMINATION: Workers have been received pre-employment examination are particularly directed at the detection of chronic respiratory, gastro-intestinal or nervous diseases. A periodical thorough medical examination takes place once in two year.
DO AND DONT FOR Hydrochloric Acid.

DO 1. 2. : Store HCL in acid proof tanks. Store in a shed/ building constructed of fire/resistant material..
3. Store in cool and well-ventilated area away from organic materials, like nitrates, chlorates, metal powder. 4. 5. 6. 7. 8. Use acid resistance type electrical installation in storage area. Use only minimum concentration required for the process. Pump the material through sealed system to prevent all dangers of contact. Wear face shields, rubber gloves, apron, boots and acid proof suit while working. Use approved Respirator or self- contained breathing Apparatus while tackling spread.
Donts:
1. 2. 3. 4. 5. 6. 7. Do not smoke in the area of storage & process. Do not pour water into HCL Do not use air pressure to empty containers. Do not allow naked flame in the storage/process area. Do not clean the spillage with rags or sawdust. Do not discharge HCL directly to any waterway. Do not allow untrained/inexperienced persons to handle.
24
Trade name Chemical Name
LIQUEFIED PETROLEUM GAS : propane Formula Permissible Exposure Limit (1000 mg/m3) : : C3H6, 1000 ppm.
Physical Description
Colorless, Odorless Gas (for smelling Odorant added)
Chemical and Physical Property :
MW: 42 to 99 BP : -41C to -0.6C MP : Sol : Insoluble Fl.P. -60C UEL : 9.5% LEL : 1.9%
Incompatibilities Health Hazards Route of Entry Symptoms First Aid Eye:
Strong oxidizer
: :
Inhalation, Skin and/or eye contact. Lightheadedness, drowsiness. If this chemical gets into the eyes, immediately wash the eyes with large amounts of water, occasionally lifting the lower and upper limbs. Get medical attention immediately Contact lenses should not be worn when working with this chemical.
Skin
If this chemical gets on the skin, immediately flush the contaminated skin with water. If this chemical penetrates through the clothing, immediately remove the clothing and flush the skin with water Get medical attention promptly.
25
Breath
If a person breathes in large amounts of this chemical, move the exposed person to fresh air at once. If breathing has stopped, reform artificial respiration. Keep the affected person warm and at rest. Get medical attention as soon as possible. Very danger when exposed to heat, flame or oxidizer, to fight fire water spray, CO2 or Dry chemical powder extinguishers to be Used. Stop flow of gas. To be packed in bottled gas. To be stored in Cool area. Non-combustible construction. Dilute with lot of air. If leaked stop flow of gas. Disposed of by burning at a safe location. 150MT
Fire Hazards
Packing and storage Disposal
: :
Quantity Stored
26

AMMONIA (ANHYDROUS)
Material Safety Data Sheet SECTION-I : MATERIAL IDENTIFICATION & USE
Material Name/Identifier Manufacturers Name Street Address AMMONIA(ANHYDROUS) GSFC Suppliers Name GSFC P.O. FERTILIZERNAGAR Street Address P.O.FERTILIZERNAGAR City VADODARA DT. State GUJARAT City VADODARA DT. State GUJARAT Postal Code 391750 Emergency Tel.No.372451 Postal Code 391750 Emergency Tel.No.372451 Chemical Name AMMONIA Chemical Identity PUNGENT GAS OR LIQUID Trade Name & Synonyms Product Use 1) AMMONIA ANHYDROUS AMMONIA GAS SPIRIT OF HART SHORN
MANUFACTURING OF FERTILIZERS
(INTERNAL CONSUMPTION) 2) MANUFACTURING OF INDUSTRIAL CHEMICALS SECTION-II HAZARDOUS INGREDIENTS OF MATERIAL

Hazardous Ingredients RESPIRATORY TANT Approx. concentration % 99.5% C A S No. UN Number CAS NO 7664-41-7 UN NO 1005 LD-50 (Specify species and route 350 mg/kg ORAL-RAT LC-50 (Specify species and tests 200 PPM/4HRS LCLD ihl-rat Specific Gravity 0.771 Freezing Point (C)
SECTION-III PHYSICAL DATA FOR MATERIAL

Physical State GAS Vapour Pressure (mm) 10 ATM AT 25.7 C Vapour Density (Air=1) 0.597 Odour & appearance EXTREMELY PUNGENT Evaporation Rate 40C RATE 25% of POOL N-13 0C 11%: 33 C ALMOST- 0 pH ALKALINE Odour Threshold (ppm) 46.8 PPM Boiling Point (C) -33.4 -77.7 Coefficient Water/oil distribution NA YES WHEN EXPOSED TO HEAT OR FLAME MODERATE EXPLOSION EXPOSED TO FLAME OR FIRE: AMMONIA + AIR IN FIRE CAN DETONATE
Solubility in Water (20C) VERY SOLUBLE IN WATER
Density (g/ml) 0.771
SECTION-IV FIRE & EXPLOSION HAZARD OF MATERIAL

Flammability : Yes/No If YES under what conditions:
Means of Extinction Special Procedures Flash Point (C) and method
WATER,FOAM,DCP,CO2 SHUT OFF SUPPLY Lower Explosive Limit Upper Explosive Limit (% by volume) (% by volume) 16% 25% Auto Ignition Temp (C) TDG Flammability Classification Hazardous Products of 651 2 DOT Combustion TOXIC AMMONIA AND NOx Explosion data sensitivity to chemical Impact NA Sensitivity to Static discharge YES
SECTION-V : REACTIVITY DATA

Chemical Stability : Yes/No. If no under what condition YES STABLE UNDER NORMAL CONDITIONS
27
Incompatibility to other substances: Yes/No If Yes, which ones
YES MERCURY,CHLORINE,IODINE,BROMINE,CALCIUM SILVER OXIDE OR HYDROCHLORIDE CAN FORM EXPLOSIVE MXTURES NA TOXIC NOx FUMES AMMONIA COLORLESS,PUNGENT ODOUR GAS
Reactivity under what conditions Hazardous products of decomposition Material Name & Identities
SECTION-VI Toxicological Properties of material

Route of entry: Skin contact Inhalation: acute Skin absorption Inhalation: Chronic Eye Contact Ingestion: SKIN CONTACT, EYE-CONTACT, INHALATION ACUTE
Effects of Chronic Exposure to material Effects of Acute exposure to material:
IRRITANT TO EYES, NOSE & THROAT ACUTE 2500 PPM EXPOSURE FOR 30 MTS. DURATION CAN BE FATAL Intencity of material NA NA
Exposure Limits 11V 25 PPM Sensitisation of material NA Synergistic Material (Materials which would worsen the adverse effects)
SECTION-VII : Preventive Measures

Personal Protective Equipments Gloves (Specify) Respiratory (Specify) RUBBER/PVC Footware Clothing (Specify) (Specify) RUBBER/PVC Engineering Controls (eg. ventilation enclosed process) etc. specify also ) Leak & spill containment & decontamination procedures recommended Waste Disposal procedures recommended Handing procedure & equipments Storage requirement Special shipping information
SELF CONTAINED BREATHING APPARATUS
Eyes (Specify)
GAS TIGHT GOGGLES
AMMONIA CANISTER AND GAS MASK
PVC APRON AND SUIT
Others (specify)
NA ENCLOSED PROCESS: WATER CURTAIN,FIXED AIRLINE RESPIRATOR AT HANDLING PLACE SHUT OFF LEAK IF SAFE TO DO SO WEAR RESPIRATORY AND FULL PROTECTIVE CLOTHING IN THE SPILLED AREA STAY UPWIND, KEEP PEOPLE AWAY. DILUTE WITH WATER PUMPING THROUGH PIPELINES STORE IN A COOLWELL VENTILATED AN ISOLATED AREA
VENTING SAFETY RELIEF 250 PSI FOR AMMONIA UNDER PRESSURE VACUUM FOR AMMONIA AT ATMOSPHERE PRESSURE
SECTION-VIII : First-Aid Measure

First-Aid Measures INHALATION : REMOVE VICTIM TO FRESH AIR, INHALE WARM VAPOUR AND GIVE ARTIFICIAL RESPIRATION, IF NOT BREATHING EYE-CONTACT : WASH WITH PLENTY OF WATER OR ASOLUTION OF 0.5 TO 1% ALUM. SKINS CONTACT : WASH WITH CLEAN WATER AND APPLY A LOTION CONSISTING OF 5% SOLUTION OF ACETIC,CITRIC,TARTARIC,OR SALICYLIC ACID DIAGNOSTIC TEST : ECG.SPUTUM GRAM STAIN AND CULTURE DLC. ARTERAL BLOOD GAS ANALYSIS. TREATMENT : OXYGEN THERAPY-SKIN TREATMENT SAME AS THERMAL BURNS.COLD BROIC ACID COMPRESSES FOR EYES. GIVE LARGE QUANTITIES OF 0.5% CITRIC ACID SOLUTION TO SWALLOW SPECIAL HIGH RISK GROUPS: PERSONS WITH HISTROY OF EYE AND PULMONARY DISEASES. Sources used ENCYCLOPAEDIA OF safety & Health
28
Additional Information:
DISASTER MANAGEMENT EVACUATE DANGER AREA USE WATER CURTAIN TO PREVENT TO PREVENT SPREADING OF GAS CUT OFF SUPLY
SECTION-IX : Prepared by (Group Department etc.)

SAFETY UNIT
Phone No 2888/2777(INT) 372451 EXT.3088
Date 25/7/88 UP DATED ON 5/8/94
Earthquake Companys structure is very safe and consider all parameter / aspect to zone v earthquake Do & dont during earthquake: For Crain operator: Apply the brake of CT & LT Load down safely without risk to machine and man Dont leave the crane without manning. Dont panic it may cause danger to individual /staff / machinery. Utility After earthquake check for all joints /connections and fittings, it may displace/dislocate and may cause leakage and create other emergencies. CYCLONE RELATED INFORMATION following are the website codes, through which the required information regarding the position of Cyclone can be ascertained; 1.www.imd.ernet.in 2.www.supertyphoon.com/indian.html 3.www.npmoc.navy.mil/products 4.www.solar.ifa.hawaii.edu/tropical/tropical.htm 5.www.wunderground.com/tropical
Signalling system at Kandla Port or any other port Signal no Type of warning I Cautionary II Warning III Cautionary IV Warning V Danger moderate intensity. VI Danger VII Danger and near the port. VIII Great Danger Description Storm may be formed A storm has formed Port is threaten by squally weather Great justifying extreme measure of precaution port will experience severe weather from a storm & Expected to cross the coast . port will experience severe weather,may cross over Great intensity, severe weather 29
IX Great danger port will experience severe weather from a storm and cross the coast X Great danger Severe weather,great intensity,cross over and near the port. XI failure of communication Communication with metrological head qtr.has broken down Precaution during the possibility of cyclone. 1.Stop the hazardious process and chemical plant . 2.Overhead cranes must park and apply all break and possible hold with the help of wire rope. 3.Come and stay at inside the RCC structure. 4. Dont create panic and rumors. 5. contract labor of the company who are residing nearby in temporary shed must be called and give them the protection. AFTER CYCLONE OVER. 1. Inspect the all structure, machine, equipment for its correctness. 2. Check all connection of the utility services including electric. 3. Check and ensure the stability of the storage chemical if any and its joints etc. 4. Inspect the any unsafe condition and restore the normal operation of the plant.
GENERAL GUIDE LINE FOR EMERGENCY FIRST AID

[A] ELECTRICAL HAZARDOUS & PRECAUTIONARY MEASURES : The electric injuries may occur by direct current, alternative current of from lightening. The severity of the injuries by electric shocks depends upon : 1. 2. The amount of current flowing through the body. The path of current is taken through body to the earth weaker current passing through the chest is more dangerous than a relatively stronger current passing through the lower limbs. Length of time, victim is in contact. 30
3.
4. 5.
Type of electric energy, AC or DC. Physical condition of the victim.
FOLLOWING SINGS & SYMPTOMS ARE FOUND IN ELECTRIC SHOCKS 1. 2. 3. 4. 5. 6. 7. 8. Sudden Spasm. May be unable to release hands which hold the live points. Burn. Severe Pain. Cries aloud and falls on the ground. Unconsciousness. Breathing impaired or stopped. Burns leading to severe surgical shock.
EXPLOSION : Explosion is mainly of following natures. Explosion of the equipments generally occur in power transformer or oil circuit breaker. Explosion in transformer or cable is usually due to overheating. The main cause of explosion in transformer is due to poor quality of oil. Periodically testing of oil to done to avoid explosion. POWER CABLES : They are secured properly, and are protected from physical hazardous. All junction boxes are protected and supported. Checking of earthlings is necessary. To avoid accidents by electricity following safety measures are adopted : 1. Damaged plug, wires and switches etc., are not used. 2. The electrical equipment with screw driver etc., are not touched unless and until the supply is cut-off. 3. The equipment is not touched with wet hands, when supply is there. 4. Many machine at single point sources should not be connected other wise risk of fire will be obvious. 5. Loose and hanging wires are not kept but fittings are kept proper and safe. 6. Broken plug are not used. 7. Plug top of 03 pins only for small machines are to be used, because one of the pin is preserved for earthing. 8. Connect the lighting appliances equipment with supply through plug. Match stick for holding the terminals, are not attached. 9. Water is not poured to extinguish fire caused by electricity, cut-off supply main switch immediately, proper fire extinguisher used. 31
10. 11. 12. 13. 14.
15. 16. 17.
Before carrying out repairing of equipment, the main switch is put off or cut-off and fuses are taken out. Fuse wire of proper size are be sued. Many equipments in one socket are not connected avoid extra loan unit. Proper care should be taken to save electrocuted. Affeted person is touched after switching off or separating wire with the help of dry rope or bamboo wooden sticks etc., provide first aid applying artificial breathing system to the affected person. Rubber insulated tools and rubber, had-gloves for working during supply or in MT line, are used. Where there is danger, caution board is fixed to keep yourself away from the site. Always equipment of ISI marked preferred. The above precautions and practice certainly saves from the accident in factory as well as at home
FIRST AID IN ELECTRICAL SHOCK :

ANY DELAY IN FIRST AID IN ELECTRIC SHOCK IS A DELAY FOR EVER, HENCE THE FIRST AIDER MUST NOT GET EXCITED AND MUST NOT ENDANGER HIS LIFE. 1. 2. 3. 4. 5. 6. The current must be cut-off or the plug should be pulled-out. The First Aider must not touch the victim or the live conductor. If it is difficult to cut off the current, the victim has to be separated by using a dry coat rope, stick etc. If there is a dry wooden chair or rubber sheet, the first aider must stand on it and then separator the victim. If the cloths smouldering, the spark should be extinghished. Artificial respiration is to bee started immediately. This may be done whenever the victim is unconscious and pulseless. The artificial respiration should be continued till the doctor has arrived. One may like to continue for at-least 8 hours before abandoing the care as dead. When the patient start swallowing, one may understand that the spontaneous breathing is being revived. Artificial respiration should be continued till normal movement or breathing is fully established, as the respiration may fail again if left earlier. A blanket should be put around the patient. The patient must be kept warm to treat the shock. He may be given warm, sweet drinks if he is conscious otherwise not, as it may harm him. Superficial burns of lightening strange may be covered with a septic dressing. The deeper burns caused from contact with live conductors may be covered with clean sheet and the patient evacuated to a hospital without any further delay. External cardiac message may be given if the pulse is not felt or even artificial respiration.
7.
8.
9.
[B]
FIRST AID IN CASE OF BURNS : 1. 2. 3. 4. 5. Act quickly. Put the affected part in cold water. If immersion in cold water is not possible then pour coldwater. Put sterlised dressings on effected part. Send for medical care immediately.
32
LIST OF EMERGENCY CONTACT NUMBER

1. COMMUNITY SERVICE
Name of Authority SP Bhuj An jar Police Station Gdham Police Station Bhimasar Police Station District disaster Management committee. Collector control room Bhuj. Factory Inspector Fire Chief KANDLA PORT JMD KARGIL RAMA CYLINDER Sr .MANAGER Fire & Safety, ISCL Civil Surgeon GDHAM Telephone Office Residence Mobile 02832-250444 / 250250/253593 02836-242517/242813 028360283602832 -252347 / 231733 02836-260020 02836-270176 / 270178 /09825227041 02836-285543--285547 02836-285337 02836-285403 09328150230 02836 - 250554
Air Force Duty Officer, Bhuj 02832-252501 / 252502 Air Force, Bhuj 02832- 223450 Civil Defense GDham 02836 - 220221 Dist. Collector, Kutch 02832-250020/250194 Depot Manager, GSRTC GDHAM Station Superintendent, GDHAM Railway 02836-220011 Dist Commandant Home-Guard HP-Gas Dealer 02836-221716 SURPANCH BHIMASAR 09825195935 WATER SUPPLIER (Mira Enterprises) 09824206373/9879556373/9879586373 2. VOLUNTEER GROUPS GDHAM Red Cross Society 234854,232736
General Hospital, Bhuj

Civil Surgen , Bhuj Referral Hospital, Anjar Ram bag Hospital Divine Life, Adipur Railway Hospital, Gandhidham
222850
250554 242455 220263 261802 231874
fff
33
RESPONSIBILITY WITH NAME AND CONTACT DETAILS
VP (OPR) GM(PRO) GM TEC GM GAL GM ELE
AGM MILL
AGM GAL
AGM ELE
MGR SHIFT I/C
MGR
MGR
SHIFT I/C
SHIFT I/C
ASSENBLY POINT
UTILITY COMMUNTION TRANSPORT/ P&A/ SAFETY / SECURITY.
ASSEMBLY POINT
EVACUATION
34
Mobile Nos.
Mr.D.K.Bhalerao Mr. Vijay Badjatya Mr. J.P.Gupta Mr. R.K.Gupta Mr.Ajay Misra Mr.P.K.Sharma Mr.P. Mahato Mr.B.K.Singh Mr.Prabhakar yelsetwar Mr.K.K.Vishwakarma Mr.Osatwal Mr.D.R.Karwasara Mr.N.D.Gupta Mr.Girish Mathur Mr.N.K.Vyas Mr.Dhanuka Mr.Saxena Manish Mr.Gulabchand Mr.Ajit shukla 09925048750 09825323391 09879550664 09825157364 09898466703 09898811754 09879222054 09879951291 09879819841 09328150230 09427234448 09426944467 09427441545 09879520034 09879564881 09427443188 09925094388 09879215451 09427234927
ISCL
Gujarat Adani Port ltd. Mundra
02838-288201 to08
LIST OF THE Hospital General Hospital, Bhuj Civil Surgeon, Bhuj Referral Hospital, Anjar Ram bag Hospital Divine Life, Adipur Railway Hospital, Gandhidham 02832-222850 02832 250554 02836- 242455 02836- 220263 02836-261802 02836-231874
35
HYDRANT VALVE LIST

Point No. 01 02 03 04 05 06 07 08 09 10 11 12 13
14 &15
Location 4 Hi Mill/Column No - C 1 4 Hi-Mill / Column No C 5 Pickling Area / Column No- D4 Pickling Area / Column NO D 8 Pickling /Column No D 11 Pickling / Column No D 15 Pickling /Column No D 18 Pickling / Column No - D -21 Ammonia Yard --- 2 Monitor Ammonia Yard - inside Ammonia Yard - inside Propane Yard 2 Monitor Propane Yard - inside Propane Yard inside
36
LIST OF FIRE EXTINGUSHER

Sr.No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 Section Elc. SubStation Elc. SubStation Elc. SubStation Elc. SubStation Elc. SubStation ADM Block ADM Block 4Hi-Mill 4 Hi-Mill 4 Hi -Mill 4 Hi-Mill 4 Hi-Mill 4 Hi-Mill 4 Hi-Mill 4 Hi- Mill 4 Hi -Mill 4 Hi -Mill 4 Hi -Mill 4 Hi -Mill 4 HI -Mill 4 Hi -Mill 4 Hi -Mill 4 Hi -Mill Oil Cellar Oil cellar Oil cellar Oil cellar Oil Cellar Oil Cellar Pickling Pickling Pickling Pickling Location Electric Sub Station Electric Sub-Station Electric Sub-Station Electric Sub -Station Electric Sub-Station Entry ADM Building ADM conference Hall H.T Room/4Hi-Mill ECR 4 Hi-Mill ECR) 4 Hi-Mill ECR In front of 4 Hi-Mill ECR Near 4 Hi mill/column no-B 7 Near DCC Panel/Mill Back Side Entry Blower Room Entry Blower Room H.P Power Pack Room/Mill West Side 4 Hi Mill column no-C 5/ C6 4 Hi-Mill Column no- C8/C9 Nr. Grinding Machine/Colu. NoA 13 Entry ADM to 4 Hi-Mill Area 4 Hi-Mill Pulpit 4 Hi-Mill Crane No - 1 4 Hi-Mill Crane No - 2 Coolant tank/Oil tank Coolant tank/Oil tank Staircase/In front of L. P Valve Stand Near L. P Valve Stand Near L. P Valve Stand ECR Cable Room Pickling Exit/Column no-E1/E2 Hot Dryer Entry Pickling Pickling ECR Make In-Time Fire In-Time Fire In-Time Fire Kamal Industries Marine Hardware Supremax Equipment Supremax Equipment Supremax Equipment Supremax Equipment Kamal Industries In-Time Fire Kamal Industries Supremax Industries In-Time Fire In-Time Fire In-Time Fire Peter Auto kits Mahavir Industries Supremax Industries In-Time Fire Supremax Industries Mahavir Industries Mahavir Industries Supremax Industries Supermax Industries Mahavir Industries Supremax Equipment Supermax Equipment Peter Auto kits Mahavir Industries Mahavir Industries Mahavir Industries Supremax Industries Type DCP- 5 Kg DCP- 5 Kg DCP- 5 Kg. CO2- 4.5 Kg DCP- 50Kg CO2- 4.5Kg Co2- 4.5 Kg DCP 4.5 Kg CO2- 4.5 Kg DCP- 22.5 Kg DCP- 5 Kg CO2 22.5 Kg CO2 4.5 Kg DCP- 5 Kg. DCP- 5 Kg. DCP- 5 Kg. DCP- 10 Kg. DCP- 5 Kg. DCP- 10 Kg. DCP 5 Kg. CO2 4.5 Kg DCP- 5 Kg. DCP- 5 Kg. C02- 4.5 Kg. CO2- 4.5 Kg. DCP- 5 Kg. CO2 4.5 Kg CO2- 4.5 Kg DCP- 10 Kg CO2- 4.5 Kg. DCP - 5 Kg DCP- 5 Kg. CO2- 4.5 Kg. 37
34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 58 (A) 59 60 61 62 63 64 65 66 67 68 69 70 71 72
Pickling Pickling Boiler House Boiler House Weigh Bridge Nil Ammonia Yard Ammonia Yard Ammonia Yard Propane Yard Propane Yard Propane Yard Propane Yard Propane Yard Propane Yard Propane Yard Propane Yard Pump House Nil CGL CGL CGL CGL CGL CGL CGL CGL CGL CGL CGL CGL CGL CGL CGL CGL CGL CGL Central Store Central Store Central Store
Pickling ECR Pickling Crane Boiler ECR Boiler ECR Weigh Bridge Office Nil Ammonia Yard Ammonia Yard Ammonia Yard Propane Yard Propane Yard Propane Yard Propane Yard Propane Yard Propane Yard Propane Yard Propane Yard Pump House Nil Entry CGL/Column NoFurnace Platform/Briddle-2 Furnace Platform East Side Zinc Pot /Column NoEast Side Zinc Pot/Column NoZinc Pot Cellar Zink Pot Cellar CGL Pull PIT CTL /Corrugation CTL ECR CGL Exit ECR CGL Exit ECR Furnace Platform Furnace Platform Briddle-2 CGL Entry ECR CGL Entry ECR CGL Entry ECR Chemical Treatment Plant Central Store Central Store Central Store
Kamal Industries Mahavir Industries Supremex Eqp. Kamal Industries Mahavir Industries Nil Peter Auto kits Pvt Ltd Peter Auto kits Pvt Ltd Marine Hardware Syndic Synthoex Synthoex Synthoex Synthoex Synthoex Synthoex Synthoex Synthoex Kamal Industries Nil Supremex Eqp. In-Time Fire Supremex Eqp. Supremex Eqp. Supremex Eqp. Supremax Eqp. Monark Monark Supremex Eqp. Monark Marine Monark Supremax Eqp. In-Time Fire Monark Monark Supremex Eqp. Supremex Eqp. Supremex Eqp. Mahavir Industries Mahavir Industries
CO2- 4.5 Kg. DCP- 5 Kg Co2 - 4.5 Kg. CO2- 4.5 Kg DCP - 5 Kg Nil DCP 10 Kg. DCP- 10 Kg. DCP- 50 Kg. DCP - 10 Kg. DCP - 10 Kg. DCP - 10 Kg. DCP - 10 Kg. DCP- 10 Kg. DCP - 10 Kg. DCP - 10 Kg. DCP-10 Kg. CO2- 4.5 Kg. Nil. DCP- 10 Kg. DCP- 5 Kg. DCP- 10 Kg. DCP- 10 Kg. DCP- 10 Kg. CO2 4.5 Kg. CO2 4.5 Kg. CO2- 4.5 Kg. DCP- 10 Kg CO2- 4.5 Kg CO2- 4.5 Kg CO2- 4.5 Kg DCP- 10 Kg DCP- 5 Kg CO2- 4.5 Kg CO2- 4.5 Kg CO2 - 4.5 Kg DCP 10 Kg CO2- 4.5 Kg DCP - 5 Kg DCP 5 Kg 38
73 74 75 76 77 78 79 80 81 82
Central Store Central Store CGL Q/C CGL CGL CRCA CRCA Spare Spare
Central Store Room Central Store Room Near Grinding Machine In front of Q/C Crane Crane DG DG Stock Stock
Supremex Eqp . Supremex Eqp.
Mahavir Industries Mahavir Industries Mahavir Industries Supremex Eqp. Mahavir Indu. Supremex Eqp.
CO2 4.5 Kg CO2 4.5 Kg DCP 10 Kg CO2 4.5 Kg DCP 5 Kg DCP 5 Kg DCP 5 KG CO2 4.5 Kg DCP 5 /10 Kg CO2 4.5 Kg
We Installed Extinguishers as per TAC Norms. All Extinguishers are ISI Mark
39
VERIFICATION The information furnished in the documents on the subject has been verified by me and is submitted seeking modification/suggestions from your office to make the document viable. I also assure that I will immediately review and amend the documents and seek your consent before any change in the plant, Machinery, Building, Structure, substances storage manufacturing process is intended or otherwise after at least every period of twenty four months from this date 01/10/06 until the factory, (for any reason is not closed for ever, in later case it will be our liability to inform closure of the factory to your office and dispose off all of the factory in such a manner hazardous substance/material
rendering those safe for the life and environment.
Signature Factory Manager Indian Steel corp. Bhimasar , kutch.
Date.
40

ISCL Kutchh DREIA Emergency Prepardnes Plan

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ISCL Kutchh DREIA Emergency Prepardnes Plan

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INDIAN STEEL CORPORATION LTD.

EMERGENCY MANAGEMENT PLAN

Where observation is concerned, Chance favors the prepared mind

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SALIENT FEATURES OF THE PLANT

Occupier Factory Manager Nature of Industry Product

No. Of Employees Power Connection Source

Key Persons of the Emergency Plan

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MATERIAL TO BE STORED & POSSIBLE HAZARD

HCL Acid in Pickling Plant 15 to 18% Conc.

Toxic & Burning

Safety Shower 2 Nos.in pickling Plant.

Safety Shower 1 Helmets, Hand gloves

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MANUFACTURING PROCESS WITH ITS FLOW DIAGRAM:

PICKLING 04 Hi ROLLING MILL

CGL ZINC COATING

Corrugation machine & packing

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EMERGENCY PREPAREDNESS PLAN

SCOPE OF THE PLAN:

Objectives of the emergency plan.

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TYPE OF EMERGENCIES : i) ii) iii) Fire Explosion Natural Calamities

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HAZARD FROM PROCESS

Role of key personal

Other key personal

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Essential workers (Plant supervisor, chemist, operators, etc.)

Non essential person.

Establishment of the control room

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ON SITE EMERGENCY PLAN ISCL

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PERSONNEL / ADMINISTRATION COORDINATOR :

SECURITY ARRANGEMENTS COORDINATOR :

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Direct the outside emergency services towards the affected areas.

MEDICAL SERVICES CO-ORDINATOR :

FIRE FIGHTING & SAFETY CO-ORDINATOR:

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MATERIAL SAFETY DATA SHEET

Important Characteristics of Hazardous Chemicals

Solubility in water Color and Odor

It reacts with water or stream to produce toxic & corrosive fumes.

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Tolerable for one hour. Dangerous even on short exposure.

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First-Aid and Medical management symptoms. Skin contact

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Caution No oil or ointment should be used unless prescribed by an eye specialist.

STORAGE AND HANDLING:-

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