On-Site Emergency Plan

ICE MAKE REFRIGERATION PVT. LTD SURVEY # 226 / 227, DANTALI INDUSTRIAL ESTATE, GOTA VADSAR ROAD, VIA AHMEDABAD, AT.: DANTALI, TA. KALOL, DIST.: GANDHINAGAR 382721 PH. NO. : 098791 07881 / 784 Website: www.icemakeindia.com Email: hr@icemakeindia.com On-Site Emergency Plan (December - 2015) Prepared By Shriji EHS Management Services Ahmedabad 1

Preface The management of ICE Make Refrigerations Pvt. Ltd. Survey no. 226,227, Dantali Industrial Estate, Gota-vadsar Road, At.: Dantali, Ta,:Kalol, Dist.: Gandhinagar has entrusted us for the task of preparing on-site emergency plan for their expansion work. Accordingly, We have prepared on-site emergency plan for any emerging out of storage, use, handling and transport of hazardous chemicals to be used in the plant area. The factory is proposed to store hazardous chemicals and hence it falls under category Hazardous Process i-e section (2cb) of factories Act. Hence management has decided to prepare On Site emergency Plan. And once plan is prepared, it is decided to conduct mock drill. This is the management s pursuance regarding hazards and measures to be taken in case of any emergency while operating the plant. We have tried fully to prepare the plan as per the data provided by the management. Mr.Rajendrabhai Patel - Director and Mr. Hirenbhai Limbachia HR & Safety Dept., have extensively participated in preparing the plan. The plan will be useful to the management in combating emergency. Place : Ahmedabad Date : 28/12/2015 Shriji EHS Management Services 2

INDEX Sr.NO. Content Page Part I (Guidelines) 1 Preface 2 2. Chapter-I Preliminary 5 3. Chapter-II Risk and Environmental Impact Assessment 12 4. Chapter-III Emergency Organization 22 5. Chapter-I V Communication System 29 6. Chapter-V Action on site 33 7. Chapter-VI Off-site Emergency Plan 40 8. Chapter-VII Training, Rehearsal and Records 43 9 Chapter-VIII First Aid 45 Annex No. Part II (Annexure Section) 1. Identification of the factory 48 2. Map of the Area 49 3. Factory Layout 50 4. Storage Hazards and Controls 51 5. Material Safety Data sheets 52 6. Process and Vessel Hazardous and Controls 64 7. Other Hazards and Controls 65 8. Trade Waste Disposal 66 9. Records of Past Incidents 67 10. Gas Dispersion Concentrations 68 11. Evacuation Table 69 12. Environmental Impact Assessment 70 13. Weather Conditions 71 14. Incident Controllers 72 15. Deputy Incident Controllers 73 16. Site Main Controller 74 17. Key Personnel 75 18. Essential Workers 77 19. Assembly Points 78 20. Emergency Control Center 79 21. Fire & Toxicity Control Arrangements 80 3

22. Medical Arrangements 83 23. Transport and Evacuation Arrangements 84 24. Pollution Control Arrangements 87 25. Other Arrangements 88 26. Alarms and Sirens 89 27. Internal Phones 90 28. External Phones 91 29. Nominated Persons to declare Major Emergency 92 30. Form to record Emergency Telephone Calls 93 31. Statutory Communication 94 32. Separation Distances 95 33. Emergency Instruction Booklet 96 A List of Fire Extinguishers 100 B List of First-Aid Boxes 101 C List of Personal Protective Equipments (PPES) 102 D Health Check up Records 103 E List of Sand Buckets 105 F List of Safety Guards 106 Emergency procedure local language 107 4

PART I CHAPTER 1 PRELIMINARY 1.0 INTRODUCTION OF EMERGENCY PLAN Today s world produces many kind of chemicals in enormous quantities, probably beyond safe manageable levels, and that too in many cases with record speed. People working in chemical factories, transporting the chemicals and using chemicals are constantly exposed to chemical hazards like explosion, fire, gas leakage, spillage of chemicals etc. Disaster means accident causing catastrophic situation in which the day to day patterns of life are in many instances, suddenly disrupted and people are plunged in to helpless ness and suffering and as a result need protection, clothing, shelter, medical and social care and other necessities of life. Disaster may occur by natural phenomenon or by men or by men s impact upon the environment. This plan has been prepared in view of the potential hazards prevailing in our factory and in the surrounding area. A sincere effort is made to give action plan for all other not only ourselves but for concerned agencies such as workers, office staff, general public, surrounding people, fire brigade, transporters, Government Authorities etc. This plan is in two parts. The first part explains basic requirements, definitions, objectives, hazard identification, risk analysis and environmental impact assessment, organizational set up, communication system, actions on site, link with off-site emergency plan and the aspect of training, rehearsal and records The second part is given as Annexure Section containing 33 useful annexure. The information in annexure will also be useful to our unit as well as to the surrounding units as a mutual aid and to the Government in preparing Off-site Emergency Plan under Chemical Accidents (Emergency Planning, Preparedness and Response) Rules 1996. It reveals strengths and weaknesses in the plan and suggests residual preparedness if any. 5

1.1 ABOUT ORGANISATION M/s. ICE MAKE Refrigerations Pvt. Ltd. proposes for the expansion of the existing manufacturing capacity of refrigeration units, with manufacturing of PUF at site. The existing unit is located at Survey no. 226,227, Dantali Industrial Estate, Gota-vadsar Road, At.: Dantali, Ta:, Kalol, Dist.: Gandhinagar, company is proposing the expansion of existing unit within this premises. There will be no requirement of new construction, as having existing setup for infrastructure as well as of existing manufacturing set up. The unit will employ @ 180 no. of direct labours, staff and contractor s labours and indirect employment after the expansion. The Product name and capacities are shown here in table 1. Table -1 - LIST OF PRODUCTS AND RAW MATERIALS WITH THEIR QUANTITIES A. The Product details with capacities (existing and proposed) Product name Existing capacity, Unit/month Proposed expansion in Unit/month All type of Commercial & Industrial Refrigeration Equipment using PUF Total capacity in Unit/month 200 nos. 1000 nos. 1200 nos. B. The Raw Materials Consumption details (existing and proposed) Existing Expansion Total Raw material (kg/month) (kg/month) (kg/month) Polyol (1,1-dichloro-1- fluoroethane (HCFC 141b) Tris (2-chloro-1- methylethyl) phosphate) - 26,400 26,400 Diphenyl Methane Di-isocyanate (MDI) - 34,200 34,200 6

C. Fuel Consumption Fuel name Consumption Existing Expansion Total HSD 10 lph - 10 lph (Reusing) Wood Frames (waste materials) received in Packing materials of Raw Materials - 20 kg/day 20 kg/day D. The Raw Materials Fitting Assembly details (existing and proposed) No. Existing Expansion Total Raw material (Unit/Month) (Unit/Month) (Unit/Month) 1 Compressor 192 nos 950 nos 1,142 nos 2 Condenser 190 nos 950 nos 1,140 nos 3 Aluminum checker 360 nos 1,800 nos 2,160 nos plates 4 Condenser unit 10 nos 50 nos 60 nos 5 Copper tubes 3,000 kgs 15,000 kgs 18,000 kgs 6 Door closer 180 nos 900 nos 1,080 nos 7 Fan motors 380 nos 1,900 nos 2,280 nos 8 Refrigerant A 404 CFC free 135 kgs 675 kgs 810 kgs B R 22-150 kgs 150 kgs C R - 134-300 kgs 300 kgs 9 Gasket (door) 850 MTR 4,250 MTR 5,100 MTR 10 G. P. Sheet 23,500 kgs 1,17,500 kgs 1,41,000 kgs 11 Handel 170 nos 850 nos 1,020 kgs 12 Heater 22 nos 110 nos 132 nos 13 Hingis 320 nos 1,600 nos 1,920 nos 14 M. S. Angel 3700 kg 18,500 kgs 22,200 kgs 15 PVC Door Profile 490 MTR 2,450 MTR 2,940 MTR 16 S. S. Angel & Sheet 5,000 kg 25,000 kgs 30,000 kgs 17 Heat Exchanger - 11 nos 11 nos 18 Evaporator - 60 nos 60 nos 1.2 IDENTIFICATION OF THE FACTORY : Annexure-1 gives basic information about the factory. 1.3 FACTORY LAYOUT PLAN Factory layout plan showing the various details required for emergency preparedness such as entry and exit gates, plant, storage area, emergency control center, assembly 7

point, location of process and non chemical vessels, etc. shown in the enclosed Annexure 3. Area of the factory is sufficient for safe working and factory compound and building are well maintained. Ways and passages are free from obstruction. 1.4 VARIOUS USEFUL DEFINITIONS Some definitions relevant to emergency planning are given below 1.4.1 ACCIDENT An accident is an unplanned event, which has a probability of causing personal injury or property damage or both. It may result in physical harm in the shape of injury or decease to people, damage to property, loss to the company, a near miss or any combination of these effects. 1.4.2 MAJOR ACCIDENT A major accident is a sudden, unexpected, unplanned event, resulting from uncontrolled developments during an industrial activity, which causes, or has the potential to cause (a) (b) (c) (d) (e) Serious adverse effects immediate or delayed resulting to death, injuries, poisoning or hospitalization to a number of people inside the installation and / or to persons outside the establishment. Significant damage to crops, plants or animals, significant contamination of land, water or air. An emergency intervention outside the establishment e.g. evacuation of local population, stopping or local traffic. Significant changes in the process operating conditions such as stoppage or suspension of normal work in the concerned plant for a significant period of time. Any combination of above effects. 1.4.3 EMERGENCY An emergency could be defined as any situation, which presents a threat to safety of person and/or property. It may require out side help also. 1.4.4. MAJOR EMERGENCY A major emergency occurring at a work is one that may affect several departments within it or may cause serious injuries, loss of life, extensive damage to property or serious 8

disruption outside the works. It will require the use of outside resources to handle it effectively. Usually the result of a malfunction of normal operating procedures, it may also be precipitated by the intervention of an outside agency, such as a sever electrical storm, flooding, crashed aircraft or deliberate acts or arson or sabotage Emergency due to operating conditions such as uncontrolled reactions, small fire, small gas leak, spill, failure or power, water, air, steam, cooling media, scrubbing media etc. and which can be locally handled by plant personnel without outside help is not considered as major emergency. Operating instructions in the safety manual shall cover this area, though the on-site emergency plan will also be useful. 1.4.5 DISASTER Disaster is a catastrophic situation in which the day to day patterns of life are in many instances, suddenly disrupted and people are plunged in to helplessness and suffering, and as a result need protection, clothing, shelter medical and social care other necessities of life, such as: a) Disasters resulting from natural phenomena like earthquakes, volcanic eruptions, storm, surges, cyclones, tropical storms, flood, land slides, fierce fires and massive insect infestation. Also in this group, violent draught which will cause a creeping disaster leading to famine, disease and death must be included. b) Second group includes disastrous events occasioned by man, or man s impact up on the environment, such as armed conflict, industrial accidents, factory fires, explosions and escape of toxic gases or chemical substances, river pollution, mining or other structural collapses, air, sea, rail and road transport accidents, aircraft crashes, collisions of vehicles carrying inflammable liquids, oil spills at sea and dam failures. 1.4.6 HAZARDS Hazard is a physical situation, which may cause human injury, damage to property or the environment or some combination of these criteria. 1.4.7 RISK Risk is the likely hood of an undesired event (i.e. accident, injury or death) occurring with a specified period or under specified circumstances. It may be either a frequency or a probability depending on the circumstances. 9

1.4.8 THE ON-SITE EMERGENCY PLAN The on-site emergency plan deals with measures to prevent and control emergencies within the factory and not affecting outside public or environment. 1.4.9 THE OFF-SITE EMERGENCY PLAN The off-site emergency plan deals with measures to prevent and control emergencies affecting public and the environment outside the premises. The manufacturer should provide the necessary information on the nature, extent and likely effects of such incidents. 1.5 OBJECTIVES OF THE EMERGENCY PLAN 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 the time. Emergency planning is a management s function and it should not be considered in isolated. Management should evaluate the activities, operations and processes carried out within the works before starting to plan an emergency operation. A check must be made to ensure that all required steps have already been taken which are included in emergency planning. Considering our number of employees, materials and processes, availability of resources, location of site, size and complexity of the works, we have prepared this emergency plan. In our plan, we have shown the clear instructions without overlap or confusion for all concerned staff members. The same details are prepared as per Annexure No. 33 1.5.1 THE OBJECTIVE OF THE EMERGENCY PLANNING ARE AS UNDER (a) (b) (c) (d) To define and to assess emergencies, including risk and environmental impact assessment. To prevent the emergency turning into a disaster. To safeguard employees and people in vicinity. To minimize damage to property or / and the environment (e) To inform employees, the general public and the authority about the hazards / risks assessed, safeguards provided, residual risk if any and the role to be played by them in the event of emergency. 10

(f) (g) (h) (i) (j) (k) (l) (m) (n) (o) To be ready for Mutual Aid if need is raised to help neighboring unit. Normal jurisdiction of an OEP is the own premises only, but looking to the time factor in arriving the external help or off-site plan agency; the jurisdiction must be extended outside to the extent possible in case of emergency occurring outside. To inform authorities and mutual-aid centers to come for help. To effect rescue and treatment of casualties. To identify and list any dead. To inform and help relatives. To secure the safe rehabilitation of affected areas and to restore normalcy. To provide authoritative information to the new media. To preserve records, equipments etc. and to organize investigation into the cause of the emergency and preventive measures to stop its reoccurrence. To ensure safely of the works before personnel re-enter and resume work. To work out a plan with all provisions to handle emergencies and to provide for emergency preparedness and periodical rehearsal of the plan. 11

CHAPTER 2 RISK AND ENVIRONMENTAL IMPACT ASSESSMENT 2.0 INTRODUCTION Identification, analysis and assessment of hazards and risk provide vital information to Risk Management. Due to non-availability of failure rate data, reliability rate, gas dispersion rate, suitability of Industry for Indian environment, acceptable criteria for risk to public and environment etc. the complete Risk Assessment is not possible. Based on available data, we have made the hazard identification for our factory. While doing so, best available technology is used in design, installation, operation and maintenance of different processes, plants, equipments and machineries. There are mainly three hazards in our factory: (a) Fire hazards (b) Spillage of chemicals. (c) Toxic release 2.1 AVAILABLE FACILITIES SHOWN ON FACTORY To control and to minimize the various hazards, various facilities are available in the factory and the same is shown on the factory layout plan. The same is given in the Annexure 2. Some of the facilities are listed below: (a) (b) (c) (d) (e) (f) (g) (h) (i) (j) Entry and exit gates. Boundary wall. Situation of various departments. Emergency control center. Situation of fire extinguishers, storage of fire extinguishers. First Aid centers. Process area Storage area for raw material and bonded storage area for hazardous chemicals Storage of finished products. Drinking water centers. 12

(k) (l) (m) Situation of Siren. Administrative block. Assembly point. The factory lay out plan is kept in Security office/emergency CONTROL CENTRE so that the concerned authority can take proper and immediate action. 2.2 OTHER FACILITIES SHOWN IN THE KEY PLAN The Annexure 2 gives the idea of surrounding vicinity and emergency time facilities such as: (1) Surrounding area, population, and residential premises. (2) Factory location. (3) Approaches to the factory. (4) Hospital, nursing home (5) Fire station (6) Police station (7) Railway/bus stand (8) Mutual aid center. (9) North direction, wind direction, wind velocity, etc. This key plan is also kept in the Emergency Control Center so that proper and immediate action can be taken by the concerned authority. 2.3 STORAGE HAZARDS AND CONTROLS In Factory lay out plan, we have shown the place where the raw materials including hazardous substances are stored. The complete details regarding hazardous raw material, are given in the enclosed Annexure No. 4. Where as the complete details regarding material identification, their use, hazardous ingredients of material, physical data for material, fire and explosion hazard of material, reactivity data, toxicological properties of material, personal protective method and first aid measures is given in the enclosed Annexure 5 (MSDS). Release of explosive and flammable chemicals and may create emergency if proper precautionary measures are not taken. 13

2.4 ABOUT VARIOUS CATEGORIES OF HAZARDS The storage hazards can be divided in following three different categories: (a) Fire hazards (b) Spillage of chemicals. (c) Toxic release Above hazards should be taken into consideration because some of the chemicals used, stored are having flammable, and toxic & corrosive properties. Now we will describe about each hazards in details. 2.4.1 FIRE HAZARDS In our factory the most common hazard is of fire. In our factory EDC and Pyridine are stored/ used which is flammable, and can cause dangerous Fire hazards and in spite of all precautionary measures, risk cannot be avoided. Hence, substance that is susceptible to fire and explosion is stored separately at the distance to stop the fire developing with other area methanol is stored separately and storage is approved by controller of explosives. The fire may take place because of any one or more of the following reasons; (a) Naked flame (b) Hot surfaces (c) Leakage, spillage (d) Electric spark (e) Static electricity (f) Rise in temperature & pressure beyond permissible limit. TO CONTROL THE FIRE HAZARDS, FOLLOWING ACTIONS ARE TAKEN It is very important for the factory to take all possible steps to pre-empt a fire whenever it can occur and thus avert the possible disaster. In our factory several precautionary measures has been taken to prevent a fire and to fight it promptly and extinguish it even if a fire does occur in any part of the factory. The important measures are out lined below (a) Naked flames, hot surfaces and other ignition sources should be eliminated from the area, where flammable materials are stored and handled. 14

(b) (c) (d) (e) (f) (g) (h) (i) (j) Flammable chemicals stored with all recommended storage and handling practices. Storage and process areas are posted with No Smoking signs. Smoking is prohibited throughout the factory. All management staff, Executives on their rounds to factory ensures the compliance. Protective equipments are for use during transferring operations. Flameproof and short circuit proof electrical fittings will be provided in EDC and Pyridine Storage and Process area. While unloading Flammable chemicals electrostatic spark is avoided. Earthing of all storage tanks and all electrical installation have been carried out All required personal protective equipments are kept in every plant and provided to workers working in hazardous area. Sufficient amount of water and bore wells available in the factory to put out the fire of other origin. Two under ground water tank of capacity 10,000 liters capacity each are kept. EDC and Pyridine Methanol is pumped in closed pipeline. On site emergency plan is prepared. 2.4.2 LEAKAGE & SPILLAGE HAZARD OF CHEMICAL The second major hazard is leakage or spillage of toxic chemical. These chemicals cause chemical burns. As storage and transport of liquid chemicals are carried out in closed system there is ordinarily no chance of any splashing of chemical. TO CONTROL THE SPILLAGE HAZARD, FOLLOWING ACTIONS ARE TAKEN (a) (b) (c) (d) (e) (f) (g) All Storage tanks are under ground provided with dike wall & sand filling All liquid chemicals are stored in tank or drum. Pegs and clamps are provided to empty out any tank having uncontrollable leakage. Spare tanks & barrels of sufficient quantity kept ready.liquid chemicals are transferred by closed pipeline. The pipe lines are painted with different colors to distinguish it.. Leak pans will be provided for collecting leakage, if any. 15

(h) Out going effluent will have to be blocked and taken to effluent treatment plant. It will be discharged after treatment only. Continuous neutralization will also be arranged. 2.4.3 TOXIC RELEASE HAZARD Ice Make Refrigeration Pvt.Ltd. is a middle scale factory where another hazard is of toxic release MDI, Polyol is used which is Toxic and can cause Toxic hazards. In spite of all precautionary measures, risk can not be avoided. The toxic release may take place because of any one or more of the following reasons; (a) Gas leakage from pipe joint (b) Gas release from safety valve (c) Gas leakage from vent (d) Rise in temp. & pressure beyond permissible limit (e) Liquid spillage TO CONTROL THE TOXIC HAZARDS, FOLLOWING ACTIONS ARE TAKEN It is very important for the factory to take all possible steps to pre-empt a toxic release whenever it can occur and thus avert the possible disaster. In our factory several precautionary measures has been taken to prevent a toxic release and to fight it promptly and control it even if a toxic release does occur in any part of the factory. The important measures are out lined below. (a) All pipe joints are provided with heavy duty champion gaskets to prevent any leakage (b) MDI, Polyol and approachable place. (c) Protective equipments are for use during transferring operations. (d) All required personal protective equipments are kept in every plant and provided to workers working in hazardous area. (e) Self breathing apparatus will be provided and workers will be trained about their use. (f) Workers are trained to control any kind of leakage. (g) On site emergency plan is prepared. 16

2.4 PROCESS HAZARDS (Annexure-6) (1) Toxic Release (2) Fire 2.5 CONTROL MEASURES PROVIDED Looking to the nature of materials processed normal temperature and pressure involved, wide range of characteristics of processes and nature of operations, following process controls and interlocks have been employed. (a) (b) (c) (d) (e) (f) (g) (h) (j) (l) Procedures and actions have been well defined and know to all operating personnel for safe start up and shut down of plant. Fire extinguisher and sand buckets are also installed in the plant area. All the motors and other machines are provided with safety guards. All exposed parts of moving machineries are provided with suitable guards for personnel safety. All elevated structures are protected with lightening arrestors. Insulation of piping as per requirement is provided. Regarding all components of the plant proper certificates are taken. Also testing and inspection shall not be compromised before deliveries. All procedures are well defined and standardized with safety angle. Temp.controlled by thermostat. Emergency power supply from D.G. set. 2.5.1 OPERATIONAL SAFETY : (1) Hand gloves, safety goggles, dust mask, helmets, self-breathing apparatus, safety shoes etc. safety appliances are provided to workers. (2) First Aid kit is kept available in Emergency control center. (3) Non destructive thickness measurements are carried out to prevent sudden bursting by thinning out of metal by erosion or corrosion. (4) Preventive maintenance to avoid failure is carried out. External inspection of piping and testing of lifting tackles cranes etc. is bearing done at regular interval. 17

2.6 LEAKAGES: CONTROLS Depending on the leaking rate / source etc., the Following actions will be taken: (a) Isolation / Cutting of supply of the leaking point transfer to some other vessels / equipments using protective appliances like hand gloves, gum boots, gas mask, PVC suits, etc. (b) Dilution / Flushing with large quantities of water, fumes / vapors will be knocked down with large quantities of water. (c) If leakage is from tank / road tanker, attempts will be made to transfer the content of the tank road tanker to some other suitable spare tank as in case of toxic chemicals. (d) Out going effluent will have to be blocked and taken to effluent treatment plant. It will be discharged after treatment only. Continuous neutralization will also be arranged. 2.7 OTHER HAZARDS AND CONTROLS (Annexure-7) In our factory, in addition to the storage hazards, process hazards and vessel hazards there are few more hazards which are possible: (a) (b) (c) (d) (e) Hazards due to electric short circuit. Fall Accident Natural calamity Bad housekeeping Structural collapse. 2.7.1: HAZARDS DUE TO ELECTRIC SHORT CIRCUIT Electric short circuit is possible because of any one or more of the following reasons : (a) (b) (c) Loose wiring. Faulty equipment. Lack of earthing 18

(d) (e) Choking Overheating. Proper earthing, periodical checking of contacts, proper insulation of equipment, flame proof fitting in solvent area, electrician to be provided 2.7.1 Fall Accident Falling from height is possible any where in the plant when workman is working at height without safety belt. Safety belt, helmet, safety platform will be provided at the time of work supervised. 2.7.2 Natural Disaster Earth quake, lightening, structure collapse, accidental gas release from neighboring unit is possible natural disaster Lightening arrester, fire fighting equipment and PPEs make ready, mutual aid, on site / off-site emergency plan to be activated 2.7.3 Bad house keeping Minor or major injury is possible due to bad house keeping. Proper handling, regular cleaning, proper placement of material will be observed in plant. 2.7.4 HAZARDS DUE TO STRUCTURAL COLLAPSE: Structural collapse is possible because of any one or more of the following reasons: (a) (b) (c) (d) (e) Corrosion. Old structure. Heavy load. Extensive vibration. Heavy stress on structure. To avoid the above, regular checking will be done by a competent authority in above case, if major emergency may arise suddenly, the outside emergency services can be utilized. 2.8 RECORDS OF PAST INCIDENTS (NO PAST MAJOR INCIDENT) 19

2.8.1 ABOUT RISK ASSESSMENT PLAN The risk assessment can be broadly divided in the following heads: (a) Identification of hazards. (b) Causes of hazards. (c) The measures for reducing the hazards. (d) Hazard operability study. Considering the above, now we will study about the details regarding various hazards available in our factory. 2.8.2 IDENTIFICATION OF HAZARDS OF FACTORY The following three are the main hazards in our factory. (a) Fire hazards (b) Spillage of chemicals. (c) Toxic release More details about above all hazards are given in previous points of this report. Probability or frequency of above hazards will give details regarding risks involved and analysis of the same will give details regarding how they could occur. The estimation of the extend, magnitude and likelihood of any harmful effects or consequences will give details regarding risk analysis. 2.9 LIMITATIONS OF RISK ASSESSMENT PLAN The risk assessment study has following limitations.- (a) (b) (c) (d) (e) (f) (g) (h) Non-availability of norms for our Country. Non-availability of correct analysis data. High cost for getting expertise from foreign developed Countries. Lack of expertise in our Country. Difficulty of checking the final results with experiments. Non-availability of past accident data about damages. Complexity and laboriousness of the techniques. Non-availability of acceptable criteria. 20

2.10 VARIOUS METHODS AVAILABLE FOR RISK ASSESSMENT Various methods are available for the risk assessment. We are giving hereunder a method to identify the potential hazards and operability problems that foreseen by studying the logic of operation. (a) To define a process sequence. (b) To apply a guide word. (c) To generate a deviation. (d) To found out probable causes. (e) To derive possible consequences. (f) To evaluate need for action. 21

CHAPTER-3 EMERGENCY ORGANIZATION 3.0 No plan will succeed without effective organization. Emergency Organization is the heart of On-site and Off-site Emergency plan. Due weightage has been given to select and assign suitable responsibilities to the most appropriate person from the respective departments in our factory. Due care has been exercised to earmark the emergency duties from day to day responsibilities. The emergency organization shall prove effective, if activities are carried out in a defined way. To get the maximum advantage of the emergency organization, we have defined the activities of various officers / workers in the following manner. 3.1 INCIDENT CONTROLLER (IC) Primary duty of incident controller is to take charge at the scene of the incident. In the initial stages he may be required to take decisions involving the operation of the other plants or to stop or continue any process and to take technical decisions to control the incident. Therefore he should have full knowledge for these purposes. For our purpose, General Manager - Operations is appointed as Incident Controller. In the absence of Incident Controller the next person either production in charge or shift chemist whoever present, will be Incident Controller. 3.1.1 THE RESPONSIBILITIES OF INCIDENT CONTROLLER DURING ON SITE EMERGENCY Being received the primary information from runner about the occurrence, Incident Controller will access the situation and he will try to control the emergency by internal resources. If the situation seen is uncontrollable, he will consult S.M.C. to declare emergency and will sound the siren to announce emergency in the factory as well as ask for mutual aid from surroundings. Further declaring off-site emergency, He will also inform the fire brigade, police, Dist. Disaster Controller and Factory Inspector. He will arrange for safety equipments and tools for the member of rescue teams. He will evacuate non essential workers near Assembly point. He will search for causalities. He will call all key personnel, essential workers and allot them duties. 22

3.2 DEPUTY INCIDENT CONTROLLER One officer in each shift has been identified as Dy. IC, he will assist Incident Controller and will help in mobilizing the required gadgets. Dy.-Incident Controller will carry out internal communication and will confirm with other service department about their actions and he will co-ordinate between Incident Controller and Site Main Controller (S.M.C.). Their functions are mentioned in Annexure 33. Their name, designation, place of availability, etc. are given in Annexure 16. In case of non-availability of both Incident Controller and Deputy Incident Controller We have appointed other substitute persons to take the charge of I.C. and Dy. I.C. their details are given in Annexure 15. 3.2.1 RESPONSIBILITIES OF DY. INCIDENT CONTROLLER DURING ON SITE AND OFF SITE EMERGENCY In absence of Incident Controller, Dy. Incident Controller will take charge of I.C. and will work in the same line as that I.C. the duties and responsibilities of Dy. I.C. during onsite and off-site will remain the same as given in Point No. 3.4.4 and 3.5 of this plan. 3.3 SITE MAIN CONTROLLER (S.M.C.) He has overall responsibility for directing operations and calling outside help from Emergency Control Center. As he is required to take decision by collaboration between the senior managers at the site (works) and the senior officers of the outside services, the top executive (C.E.O.) is appointed as site main controller The moment, the message is received site main controller. are supposed to reach the plant site either with their vehicle or with alternate transport arrangement without wasting a single minute. Their duties / functions in emergency are mentioned in details in Annexure 33, name, designation, place of availability, etc. is given in Annexure 16. 3.3.1 RESPONSIBILITIES OF SITE MAIN CONTROLLER. DURING ON-SITE AND OFF- SITE EMERGENCY (a) (b) (c) Declare emergency. Get it touch with the District Authority or its nominees to take over the control of the emergency. Inform mutual aid facilities and seek their help if they have the required facilities. 23

(d) (e) (f) (g) (h) (i) (j) (k) (l) (m) (n) (o) (p) (q) (r) (s) (t) (u) (v) (w) Call Incident Controller and ask him to proceed with the work of controlling the incident. Inform fire brigade if help is required. Inform factory medical officer and hospital authority. Ask the security to account for personnel. Arrange to get ambulances to send injured workers to hospitals, in case of causality. Nominate a person to give information to the media public, and members of families of the affected area. Arrange for admission of the injured workers and affected public to the hospitals. Find out how many members of the public are likely to be affected. Arrange through police to warn the public and advise the public regarding the precautions to be taken. Advise the police to evacuate people from the localities likely to the affected. Arrange alternate shelter and food for the evacuated public and workers. Inform police and advise them to control traffic law and order. Also ask them to help in taking injured to hospitals. Take the help of outside experts, if necessary. Inform the factory inspector and G.P.C.B. Remain in touch with the Incident Controller and keep the public informed about the status of emergency. Assemble the pre-decided team of workers to assist to perform the above functions. Advise the services like water, electricity, etc. if these have to be cut of resumed for safety of the public. Give all clear signal after the emergency has come under complete control. Arrange to send the evacuated workers and public back to their homes and assist them to resettle. If services have been cut off, inform the concerned services to restart after the emergency is controlled 24

3.4 RUNNER S AND THEIR RESPONSIBILITIES DURING ON-SITE AND OFF-SITE EMERGENCY. The entire runner s of Site Main Controller, Incident controller and Dy. Incident Controller are to remain alert all the time on receiving the message about any emergency. After receiving the massage, it will be the duty of runner to rush to security office or to incident controller. 3.5 KEY PERSONNEL In the light of information received on the developing situation at the emergency, key personnel will take directive from Site Main Controllers to control emergency in the respective fields. We will nominate, Key Persons to handle the situation of emergency person wise. Annexure 17 gives complete detail of persons and their duties in normal and abnormal situation. In case of unavailability of these persons next person will also be nominated. In the emergency instruction booklet, we have added their duties person wise. 3.5.1 RESPONSIBILITIES OF KEY PERSONNEL DURING ON-SITE & OFF-SITE EMERGENCY (a) (b) (c) (d) (e) (f) The communication will be established by telephone or by sending person with special message by available vehicle When grave emergency is declared, all the workers will have to leave their work and to reach at safe place knowing the wind direction indicated by the flag hosted at the highest place and as per announcement the plant will be shut down, workers will gather near the assembly point. We will select a team of workers in each shift and they will take roll call of workers and remove the affected workers to safe place and will provide the medical help which will be kept ready by Incident Controller by summoning the doctor as soon as the emergency is declared. Counting of workers take place immediately at gate and compared with those present. Injured workers to be shifted to hospital, if required with the help of police. Lists of hospital, ambulances are kept in the office, as well as with security office near the gate. Arrangement will be made by the Incident Controller / Site Main controller to inform the relatives of injured workers and Liaison will be maintained with fire brigade and police about the extent of likely spread of gas / fire. 25

3.6 ESSENTIAL WORKERS Workers those are trained for fire fighting and first aid are selected as essential workers. Essential workers are identified and listed in emergency plan. Many more employees will be trained for the fire fighting and first aid in each group. So their services can be utilized, if required. Their list will be available in Emergency Control Center (E.C.C.). Identified essential workers are supposed to report at EMERGENCY SIGHT to take instruction from Incident Controller. Details of their functions are mentioned in Annexure 33. 3.7 RESPONSIBILITIES OF FACTORY MEDICAL OFFICER (a) (b) (c) (d) (e) (f) Send assistant to the place where evacuated workers are reporting. Ensure that those requiring medical assistance are separated. Treat all those who can be treated within the factory. Get in touch with Doctors of different hospitals and inform them the nature of injuries etc. Inform out side hospitals about antidotes and their availability / supplier etc. Supply antidotes to out side hospitals, if not available and are required by them. 3.8 ASSEMBLY POINTS Open space near security gate is decided as Assembly Point because, 1. It is away from the process plant. 2. It has separate approaches. 3. Open space is adequate enough to assemble even at one point. Looking to the wind direction and emergency site, the assembly point is selected at security gate, as there are separate approaches available in case of evacuation; vehicle entry is available on the very spot. Details of assembly point are given in Annexure 19. 3.9 EMERGENCY CONTROL CENTRE Administrative office/security office will be declared as Emergency Control Center, Location of E.C.C. is away from the place hence it is considered as an ideal one. Telephone and other facilities required with required documents are well displayed near the emergency control center for ready reference, Site Main Controller will operate from 26

Emergency Control Center, and details regarding Emergency Control Center are given in Annexure 20. 3.10 FIRE AND TOXICITY ARRANGEMENTS Adequate fire fighting equipments and personal protective equipments will be available in factory premises. Portable fire extinguishers will be installed at various locations in plant and will be easily accessible too. They will be regularly inspected for their working conditions. In the same fashion, all personal protective appliances will be maintained in good working condition so the same can be utilized in emergency. Essential workers and other personnel will be regularly trained to use both fire fighting and personal protective equipments. Details of such information are given in Annexure 21 (A, B, C). 3.11 MEDICAL ARRANGEMENTS First Aid boxes will be provided in every department. These boxes equipped with all required first aid facilities like bandages, antidotes, antiseptics to deal with minor injuries and to help in major exposure, until the victim is transferred to the hospital or until the doctor arrives. First Aid box will be in charge of trained person. A stand by emergency vehicle is always kept if victims are required to be transferred to outside hospitals. Telephone numbers of nearby factories are also available, if ambulances are required at a short notice. FMO is also available on call. Moreover, efforts will be put to train essential workers and other employees to give first aid. Details of such information are given in Annexure 22 (A, B). 3.12 TRANSPORT / EVACUATION ARRANGEMENT After declaring the emergency depending on the situation (1) Non-essential persons like casual contract labourers, other non required company workers, will be evacuated to pre-determined safe assembly points or outside the factory depending on the severity. There are no. of safe assembly points which may be utilized depending on the wind direction, distance from the incident. (2) People residing outside the Company and at close distances, will be requested to evacuate. They will be evacuated and transported to safe places / shelters. 27

(3) Help of Police, Civil Authorities etc. will be taken for evacuating outside people. (4) Personnel required to be transported to medical care, will be transported to hospital by ambulance or vehicle available. (5) SMC along with respective key personnel will arrange for such activities including rescue and transportation of injured persons, casualties etc. (6) Transportation arrangements will have to be made for people / essential workers / experts / key personnel to be brought from their houses 3.13 USE OF EXTERNAL AUTHORITIES (1) Experts on safety, health, pollution control special technologist will be contacted and their skills will be utilized. A list of such experts should be kept ready with phone numbers, mobile numbers, etc. so that at the time of emergency they can be available easily. (2) Police, District Collector, Factory Inspector, Controller of Explosive, Pollution Control Board Experts, Health and Medical Officer etc. will be contacted and called in for help. (3) R&B Civil Engineers also can be contacted for specialized activities like temporary shelter requirements, digging work, provision of facilities in Public Building etc. (4) Help of Institution, Social Organizations, Corporation, and Voluntary Bodies etc. will be taken as per need. A list of such organization will be kept ready with telephones. Communication in normal times will help speedy response. 28

CHAPTER-4 COMMUNICATION SYSTEM 4.0 we have gone through the details regarding the assessment of risks and their possible environmental impact till now. To deal with the any hazardous situation, we have to make communication system up-to-date and ready in all respect. The efficient communication is a very crucial factor in handling an emergency. The emergency organization will prove worth only if the communication system operates effectively and in time / everything will be paralyzed, The communication system beginning with raising the alarm (siren) declaring the major emergency and procedure to make it known to others is given hereunder. 4.1 RAISING THE ALARM Any employees of our company noticing an emergency will raise the alarm (siren). Essential workers will act as messengers for spreading the emergency position. 4.2 EXTERNAL TELEPHONE(Annexure 28) (a) All-important EXTERNAL TELEPHONE NUMBERS are listed in Annexure 28. (b) It is very essential to have a complete list of external telephone to communicate with the following in case of any emergency. 1. Key personnel residing outside the township. 2. Mutual Aid facilities, hospitals, ambulances, fire brigades, transports etc. 3. Authorities like Dist. Collector, DSP, SRP, Home guards etc. 4. Inspector of Factories / Dept. of Explosives, Electrical inspector, Boiler inspector etc. 4.3 DECLARING THE MAJOR EMERGENCY (Annexure 29) Once the incident has been noticed by somebody in the plant shift in charge / operator will be informed immediately. He will act as incident controller (IC) to control the emergency simultaneously. Other plant control rooms will be informed immediately as per priority and requirements. 29

(a) (b) (c) (d) Occupier and other staff etc. will be informed immediately. Fire and safety key personnel, maintenance key personnel and other key personnel will also be informed at the earliest possible. Now to decide whether the emergency is a major or not, is very important. We have to declare it at the earliest, making the necessary judgment of the incident for any major emergency or potential for the same. Care will have to be taken so that immature judgment does not occur and inadequate thought is not given as declaration of major emergency puts many agencies into action. We have nominated persons to declare the major emergency at the earliest with adequate judgment. There may be joint decision also but it must be without wasting the time 4.4 TELEPHONE MESSAGES After knowing the emergency and emergency declaration or on receiving the emergency message on telephone, They should be precise, sharp, attentive and quick in receiving and noting the message and then for immediate subsequent action of further communication. The complete details of the instruction in the event of declaration of emergency are given in Annexure No. 33. 4.5 COMMUNICATION OF EMERGENCY The state of emergency has to be communicated to the following group of people. (a) Inside the factory to the workers including key personnel and essential workers, who are on duty and or inside the factory premises during normal working hours. (b) To the key personnel and essential workers who are not on duty and are outside the factory premises besides the normal working hours. (c) To the outside emergency services including Government Authorities, (d) To the neighboring firms and the general public in the vicinity. Now we are giving details regarding the system which we have planned the effective implementation for the above. 30

4.5.1 INSIDE THE FACTORY TO THE WORKERS To handle the emergency safely and timely, all following information are made known to the workers in the shade of booklet so that they prepare themselves to prevent or to control the emergency. (a) Safety manual and booklets. (b) Hazards involved in the process. (c) MSDS of all the hazardous chemicals used by us. (d) Various physical and health hazard. (e) Various measure to ensure safety and control of physical and health hazard. (f) Various measure to be taken by the workers to ensure the safe handling, storage and transportation of hazardous chemicals. (g) Various personal protective equipments available for handling hazardous chemicals. (h) Messaging of various label and marking on containers of hazardous chemical. (i) Measures to be taken by the workers in case of spillage or leakage of hazardous chemicals. (j) Worker s role in emergency. 4.5.2 KEY PERSONNEL AND ESSENTIAL WORKERS Key personnel and essential workers are available in all shifts or can be made available with short notice. But due to some reasons, if they are outside or not on duty and if their help is required, their where about is available in the Annexure 14 to 18 which are kept in the emergency control center. List of the name in order of priority is kept near telephone junction. 4.5.3 OUTSIDE EMERGENCY SERVICES & AUTHORITY Once the declaration of emergency is made, we have planned to inform the following services immediately. (a) (b) (c) (d) Fire Brigade Police station ESI hospital Ambulance 31

(e) (f) (g) (h) (i) (j) (k) (l) Civil defense Hospital / Private Nursing home Key personal of mutual aid scheme Pollution control board Factory Inspector, Regional Collector, District Collector. Municipality Press, Radio and TV The phone numbers with concerned person for the above agencies are available near telephone 32

CHAPTER-5 ACTION ON-SITE 5.0 The purpose of preparing on-site emergency plan is readiness of the unit for any kind of emergency and also to plan the co related activities. We have planned the following three stage activities as they are co-related for emergency preparedness and emergency actions with subsequent follow ups. (a) Pre-emergency activity. (b) Emergency time activity and (c) Post emergency activity 5.1 PRE-EMERGENCY ACTIVITY To take care for pre-emergency activity, the care should be taken for the following important aspects. (a) Internal safety survey. (b) Third party survey. (c) Non-destructive testing. (d) Safety valves testing. (e) Fire system testing. (f) Mutual aid scheme. (g) Mock drill and training. (h) Protective equipments. (i) Communication. (j) Emergency light. (k) Emergency control light (l) Plant assemblies and assembly points. (m) Liaison with State authorities. (n) Hospital facilities. (o) Outside shelters (p) Statutory information. 33

5.1.1 INTERNAL SAFETY SURVEY We have made an attempt to combat any emergency that may arise and have prepared a short procedure or action to be taken by every one to fight against such events. In our factory at any time minimum one Supervisor / Chemist always remain present and at any time incident controller can be contacted to take the emergency charge. Some of the important points are as under : (a) We have already identified various hazards in plant area and are keeping a sharp and alert watch on various likely emergency spots. (b) Protective equipments are regularly checked and kept easily accessible and easily workable during emergency. (c) Other personal protective equipments are also kept ready duly tested at a regular interval. (d) Other safety installation like available quantity of running water is regularly watched twice a day. (e) Other facilities like vehicles are also kept ready in working condition to combat any emergency. (f) To combat leakage of liquid materials sufficient stock of Sand is kept available nearby the storage area. (g) Fire water pumps, system and hose pipes are regularly watches to see the flow of water and working condition. (h) Suggestions from worker s and other staff always welcomed for any requirement / modification to make the system more reliable and effective 5.1.2 THIRD PARTY SAFETY AUDIT The third party safety audit as per IS 14489 will be planned. 5.1.3 PRESSURE VESSEL TESTING:- Pressure vessels are fitted with safety valves. List of Pressure vessels along with testing procedure is made. All vessels are tested as per statutory requirement and record is kept in form no.11. 34

5.1.4 NON DESTRUCTIVE TESTING The thickness of pressure vessels and also storage tanks are measured by N.D.T. methods and up to date records are maintained. 5.1.5 FIRE SYSTEM TESTING Fire extinguishers are installed in plant area and other places of factory, wherever required, and periodically checked tested, and refilled 5.1.6 MUTUAL AID SCHEME We have an agreement of mutual aid scheme with our neighboring unit. It will help us at the time of emergency. 5.1.7 MOCK DRILLS AND TRAINING We have included following things in our future action plan for training of the employees on handling safety equipments in emergency. (a) (b) (c) (d) (e) (f) (g) (h) (i) Procedure of safe shut down and isolation. Action to be taken if emergency arises from any fire, explosion, collapsing of structure or equipments etc. Time to time, knowledge of safety measures and controls. List of emergency tools, fire fighting procedure. Operation of artificial respiratory equipments such as S.B.A, organic vapor gas mask etc. Workers are given practical training for the fire fighting regularly by an expert. Use of P.P.E. such as hand gloves, helmet, shoes, apron etc. to deal with the emergency, we have planned to go through a practical rehearsal so that on-site personnel can be fully trained for emergency situation All list of Do s and Don ts is prepared. Mock drill conducted at every six months. 5.1.8 COMMUNICATIONS Details about above pre-emergency activities are already given in Chapter-4 35

5.1.9 EMERGENCY LIGHTS / EMERGENCY CONTROL LIGHTS We will procure number of torches / batteries required in our emergency control center, so that they can be used in case of emergency 5.1.10 ABOUT EMERGENCY CONTROL ROOM One emergency control room is identified near the emergency control center and it is equipped with all the required safety items in sufficient number. 5.1.11 PLANT - ASSEMBLIES & ASSEMBLY- POINTS Above pre-emergency facilities is introduced earlier with details in the Chapter No. 3 Emergency Organization Point Nos. 3 & 5 5.1.12 LIAISON WITH STATE AUTHORITY Site man controller is assigned the liaison work with state authorities listed in Annexure No 28. 5.1.13 HOSPITAL FACILITIES Emergency is a situation, that may arise in any chemical plant, consequences of such emergency, may lead towards the hospitalization of workers and others. For medical facilities in case of emergency all the victims will be sent to Civil Hospitl, Sola. The hospital is equipped with all the facilities including good doctors. 5.1.14 SHELTER Near by School and Industry Association Hall will be used for temporary shelter to the affected persons 5.1.15 STATUTORY INFORMATION Statutory information to workers, public, state govt. authority is supplied. 5.2 EMERGENCY TIME ACTIVITY During emergency time, the staff in the plant at various levels with pre-assigned duties is expected to work in a co-ordinated manner to meet the emergency situation, to combat the emergency condition and to bring the plant to normal with the help of the resources available within and outside the plant 36

5.3 POST EMERGENCY ACTIVITY Post emergency activities comprise of steps taken after the emergency is over so as to establish the reasons of the emergency and preventive measures. The following steps are suggested for our factory: (a) Collection of records. (b) Conducting inquiries and conducting preventive measures. (c) Making insurance claims. (d) Preparation of inquiry reports & suggestion schemes. (e) Implementation of inquiry reports recommendation. (f) Rehabilitation of the affected persons within the plant and outside the plant. (g) The restart of the plant. 5.4 SAFE CLOSE DOWN If necessary, full or partial close down of the plant should be followed under the judgment and guidance of the Incident Controller or Site Main Controller and trained essential worker will help in controlling the situation. Our factory is a middle scale unit and hence safe close down procedure will not be complicated. 5.5 MEDICAL TREATMENT Urgent search of injured workers is most important. All such persons must be given prompt first aid and medical treatment at the earliest. 5.6 ACCOUNTING FOR PERSONNEL Total strength of workers will be @ 170 in our plant.. So it will not be a difficult task for accounting. The following procedure will be adopted: (1) A list of the names & addresses of all employees, home addresses, their dept. of work will be maintained by personnel dept (2) Records of the employees [attendance register/ muster roll] present on a particular day or shift can be known from main office. Also leave records will be known from main office. Officer s presence can be known only in department. Shift schedules will also be maintained in the dept. and in main office. 37

(3) Shift change time may create confusion. In such cases, records will help depending on outgoing or incoming record (4) Knowledge of Supervisors, Colleagues of the employees etc will help to take account of presence. (5) Accounting will be done by the respective shift in-charge or designated persons and overall accounting will be done by the Personnel dept. (6) Record of arrival and departure of all visitors will be maintained by the security dept. together with the names of personal / officers of the company to whom they have met. (7) In immediately affected area, the IC / SMC etc. will arrange for a search to locate any injured persons or casualties. Other workers / colleagues also will give information regarding the same. Further search may be made by Police / Local Authority / Local Fire Brigade Officer and will also arrange for such Trained Personnel who will do such activities. (8) Personnel dept. (Nominated person from personnel dept.) will record the names, where known of casualties taken to the respective reception areas and the location e.g. hospital to which they are subsequently sent. The police will have to inform names of the fatal casualties to arrange for formal identification. (9) In-charge of the Safe Assembly points will record the names and depts. of people reporting at assembly points. (10) A responsible person will collect the lists, to compare them against the nominal roll or list of those believe to be on site inform the police of any believed to be missing. IC will be informed and arrangement will be made for further search 5.7 ACCESS TO RECORDS The relatives of casualties will need to be informed. We have kept this information handy so that the proper action can be taken by emergency control center. 5.8 PUBLIC RELATIONS Inevitably, a major incident will attract the attention of the press, television and radio services. We will make an arrangement for authoritative releases of information to them in the event of emergency. 38

5.9 ABOUT REHABILITATION The senior fire brigade officer will not signal the end of the emergency until he is satisfied that all fires are extinguished and there is no scope for re-ignition. The statutory powers of factory inspector will be considered before disturbing the evidence. 39

CHAPTER-6 OFF SITE EMERGENCY PLAN 6.0 The Off site emergency plan is made based on events, which could affect people and Environment out side the premises. The off site plan is largely a matter of ensuring the co-ordination of existing services and their readiness as far as possible, for the specific hazards and problems, which may arise in as incident. Briefly we can give two main purposes of the plan as under: (a) (b) As per details given in earlier chapter No. 2 to provide the local district authorities, police, fire brigade, doctors etc. the basic information of risk and environmental impact assessment and to appraise them of the consequences and the protection / prevention measures and control plans and to seek their help to communicate with the public in case of major emergency. To assist the district authorities for preparing the off site emergency plan for the district or particular area. We have made our key personnel and other fully aware about this aspect. The function of the off site plans are as under : 6.1 THE STRUCTURE OF THE OFF SITE EMERGENCY PLAN It includes the following:- (1) Organizational set up:-incident controller Site main controller, Key personnel, etc (2) Communication facilities-list of important telephones (3) Specialized emergency equipment- Fire fighting equipment (4) Specialized Knowledge-Trained people (5) Voluntary Organization Details of organization (6) Chemical information - M.S.D.S. of hazardous substances (7) Meteorological information-weather condition, Wind velocity etc (8) Humanitarian arrangement-transport, First aid, Ambulance (9) Public information-press, Media (10) Assessment-Collecting information on the causes of the emergency, reviewing the efficiency and effectiveness of plan 40

6.2 ROLE OF THE FACTORY MANAGEMENT The on site and off site plans are dovetail so that the emergency services are summoned at the appropriate time and are provided with accurate information and a correct assessment of situation. 6.3 ROLE OF THE EMERGENCY CO-ORDINATION OFFICER (ECO) The various emergency services will be co-ordinate by an ECO. The emergency control center of our factory and other control centers may be utilized by ECO to keep the liaison with the S.M.C. 6.4 ROLE OF LOCAL AUTHORITY Generally the duty to prepare the off-site plan lies with the local authority. They may have appointed an emergency planning officer (EPO) to prepare whole range of different emergency within the local authority area. 6.5 ROLE OF FIRE AUTHORITY The control of a fire is normally the responsibility of the senior fire brigade officer who would take over the handling of the fire from the Incident Controller on arrival at the site. 6.6 ROLE OF POLICE The overall control of an emergency is normally assumed by the police with a senior officer designated as emergency coordinating officer. Formal duties of the police during emergency include protection of life and property and controlling traffic movements. 6.7 ROLE OF HEALTH AUTHORITIES Health authorities, including doctors, surgeons, hospitals, ambulances etc. have a vital role to play following a major accident and they should form an integral part of the emergency plan. Major off site incidents are likely to require medical equipments and facilities in addition to those available locally. 41

6.8 ROLE OF THE MUTUAL AID AGENCIES Some type of mutual aids are available from the surrounding factories and other agencies listed in chapter No. 3 should also be utilized, as per need, as a part of the on site and off site emergency plan. 6.9 THE ROLE OF THE FACTORY INSPECTORATE In the event of an accident, the factory inspector will assist the Dist. Emergency Authority for information and help in getting mutual aid from surrounding factories 42

CHAPTER-7 TRAINING, REHEARSAL AND RECORDS 7.0 TRAINING, REHEARSAL AND RECORDS Extensive experience in the chemicals industry with on-site emergency planning has proved the need and value of rehearsal of emergency procedures. This exercise will help to refine the procedure by identifying deficiencies and difficulties. It is recommended that a major emergency exercise should be conducted at a regular interval by arrangements with the outside services. Emergency plans need to be tested when first devised and thereafter to be rehearsed at suitable interval. Their normal training and experience will generally qualify individual personnel with duties under the plans in day to day operations. Rehearsal or exercises are important for all personnel likely to be involved in an incident on or off the site. After each rehearsal or practice the plan should be reviewed to take account of any shortcomings highlighted by the exercise. 7.1 ABOUT SOME CHECK POINTS For assessing the adequacy of the emergency plan, followings are the most helpful checkpoints. (a) (b) (c) (d) (e) (f) Does the plan cover the range of incidents that can realistically be anticipated? The incidents considered should range from small events that can be dealt with by works personnel without outside help to major accidents. Have the consequences of the various incidents considered been adequately assessed? Are there sufficient resources in terms of personnel and equipment on the site to carry out emergency plan for the various incidents in conjunction with the public emergency services? Have the time scales been assessed correctly? Is there a logical sequences of action for each person given a role in the plan? Were key personnel, especially the nominated I.C. consulted in the preparation of the plan. 43

(g) (h) (i) Is there 24 hours cover to take account of absences due to sickness or and holidays? Is there satisfactory co-operation with the local emergency services and or district or regional emergency planning offices? At sites where an off site plan to protect people and the environment outside the site in the event of an incident is appropriate? What is the procedure for initiating the off site plan and is this satisfactory? 7.2 RECORDS AND UPDATING THE PLAN All records of various on site and off site emergency plans of the factories in the jurisdiction, the dist., emergency control plan and modification by experience and suggestion, rehearsals and conclusion of such plans and the inquiries shall be well maintained and preserved by the dist. Emergency authority or the emergency planning officer and the factory inspectorate for the purpose of review and further guidance. 7.3 EMERGENCY INSTRCUTION BOOKLET At many places of this plan, we have mentioned that the duties / functions of particular role is mentioned in the Annexure. The summary details are given in Annexure No. 33. For workers, the instructions are given in Gujarati Language. 44

CHAPTER - 8 FIRST AID We have added this chapter in this plan because it is the most essential thing for any person to possess this knowledge for the benefit of himself and others. To rule out any minor injury, mild exposure with the dangerous substance or to fight the acute exposure at once and with available mean. The following rules are intended only for the initial treatment of minor injuries with the help of a trained First aider. Every injury must receive immediate medical attention. It is important that you know: Who is the FIRST AIDER in your department / section. The location of the First Aid Box and its key. The location of the nearest telephone and hospital telephone number. 8.1 CHEMICAL BURNS 1 All corrosive chemicals should be washed off the skin immediately with plenty of water. Use the nearest safety shower. 2 If drops of corrosive liquid splash on the face, the eyes must be kept closed until the drops are washed away with copious amounts of water. 3 Chemical splashes in the eye must be immediately washed out with plenty of water. The eyelids should be forcibly held apart so that the entire surface of the eye is thoroughly irrigated and the contaminates flushed out. Send the injured person immediately to the Medical Center. 4 The flushing should be carried out for atleast 15 minutes and if required, continue flushing until a transport arrives and on the way to the Medical Center. 8.2 EYE INJURIES 1 With splashed of irritant chemicals in the eyes, first-aid should be immediate, as detailed above 45

2 Loss unattached foreign bodies under or on the eyelid should be removed with a wet piece of clean cotton or an applicator, if the particle is on the corner or attached to the surface of the eye, refer immediately to the Medical Center. ELECTRIC SHOCK 1 Turn off the current at the main switch before attempting to rescue a person in contact with a live circuit. If this is not possible, stand on a dry mat or wood and use rubber gloves, a coat or dry wooden material to protect the hands. 2 Render artificial respiration, if necessary. 8.3 POISONING Whenever you handle poisonous substances, ensure that Suitable instructions and protective equipments are provided. Handling and operational methods are as safe as possible. Antidotes are available at hand Poisoning by swallowing is a rare occurrence. More important are the hazards through inhalation and skin absorption. Call or send for the medical officer, ambulance or first aider, whichever is quickest. Do this at once and when the doctor arrives, give precise details of the poison is known, the specific antidote will be known and available. Keep any vomited material for examination. Remember that swift action on may help in saving a life. INHALATION Where poisonous, vapor fumes or dusts have been inhaled, remove the patient from exposure as quickly as possible using suitable protective equipment and breathing apparatus. Keep the patient warm and lying down till medical aid is available. If breathing has stopped, start artificial respiration immediately. SKIN CONTACT When poisoning results from contact with or absorption through the skin, remove all contaminated clothing at one, preferably under a safety shower and flush the affected areas with plenty of water. 46

After thorough removal of the chemical, keep the patient warm, preferably lying down and send for medical treatment. SWALLOW When poisoning is caused due to swallowing, swift action is necessary. If the patient is vomiting give him warm water to drink freely, to aid in vomiting when the poison is suspected to be corrosive: dilute the poison by giving large amounts of water. (Note: Corrosives cause yellow or gray burns on the lips and the skin). After the stomach has been evacuated by free vomiting, keep the patient warm, preferably lying down and watch for symptoms of shock. In cases of severe poisoning, if breathing has stopped, start artificial respiration and continue till the doctor takes charge. UNCONSCIOUS PATIENT The following medical aid is even more urgent for this type of emergency, while help is being sought: Lay the patient on his stomach, head to one side, mouth open, with head unsupported. This allows any vomit to escape through the mouth and prevents it from falling down the wind pipe into the lungs. To leave an unconscious patient on his back may cause his death. If breathing fails or becomes slow or irregular, start artificial respiration at once and continue until medical aid arrives. Never give anything by mouth to an unconscious patient. Always remember that a case of poisoning is a REAL MEDICAL EMERGENCY and that while you are giving the above treatment, someone else must simultaneously take steps to obtain prompt medical aid or transport to the Medical Center 47

No. 1. Full Name & address of the Factory 2. Full Name & address of the Occupier Part II (Annexure Section) Annexure l IDENTIFICATION OF THE FACTORY Particulars ICE MAKE REFRIGERATION PVT. LTD Survey # 226 / 227, dantali industrial estate, gota vadsar road, via Ahmedabad, at.: dantali, ta.: kalol, dist.: Gandhinagar 382721 Website:www.icemakeindia.com E Mail: info@icemakeindia.com Mr. Chandrakant Patel - Managing Director 23,apurva Bungalows, Nr.utsav party plot, B/h tejendra prashad Bungalows, Sola road Memnagar,Ahmedabad- 380052 Phone Ph. NO. : 098791 07881 / 784 3. Full Name & address of the Manager Mr. Rajendra Patel Director ( operations) 22/A,sarvoday society Vibhagh-1,Opp.Agrawal Tower,bhuyangdev cross road Sola road Ahmedabad- Phone Ph. NO. : 098791 07881 / 784 4. Manufacturing process (Products) 5. Manpower Shift wise. All type of Commercial & Industrial Refrigeration Equipment using PUF General (G) 27 27 First (A) 67 --- 67 Second (B) 66 --- 66 Third (C) 27 --- 27 Total Workers 187 --- 187 48

Annexure 2 : Map of the Area 49

Annexure 3 : Factory Layout 50

Annexure 4 : Storage Hazards & Controls Sr. No. Name of the Hazardous substance mention Concentration (if any) Maximum Storage Quantity Actually Stored Place of its storage 1 Polyol 16 Tons. -- 0.2KL carboys, max. 80 nos. State and Operating procedure & Temp NTP Type of hazard possible and control measures provided Toxic & corrosive liquid Control Measures Provided: Spare tank provided to transfer the material in case of leak. Stock of dry sand is kept near the storage area, provision of Respiratory protective equipments & personal protective equipments, Safety shower & eye wash unit installed. Strict supervision while unloading, regular testing & inspection of tanks In charge person Name & Phone No. Designation Dharmendra Patel - Sr.Supervisor Ajay Patel Supervisor (O) 405 M- 9924090372 (O) 408 (M)- 9824166709 2 MDI 18 MT --- 0.2KL carboys, max. 90 nos. Liquid stored at ambient temperature & atmn. Pressure Toxic & corrosive liquid Control Measures Provided: Spare tank provided to transfer the material in case of leak. Stock of dry sand is kept near the storage area, provision of Respiratory protective equipments & personal protective equipments, Safety shower & eye wash unit installed. Strict supervision while unloading, regular testing & inspection of tanks Do Do 51

CHAPTER - 5 The list of M.S.D.S. of Hazardous Chemicals are as follows:-- Sr. No. 1 MDI 2 Polyol Name of Raw Materials 52

Material Safety Data Sheet Polyol 1. PRODUCT AND COMPANY IDENTIFICATION Manufacturers Name: Development Associates, Inc. Product Name: Z7500 Part A Chemical Family/Name: Polyesterglycol,Polypropyleneglycol, and additive mixture. 2. COMPOSITION / INGREDIENT INFORMATION Component CAS # % Exposure limits(source) Polyester polyol trade secret 40-60 none(5) Polyether polyol trade secret 40-60 none(5) Additive Mixture trade secret 0-5 none(5) Source of Exposure Limit Data: 1 ACGIH Threshold Limit Values 2. Federal OSHA Permissible exposure limit 3. DA Exposure Guidelines 4. Chemical Manufacturer Recommended Guidelines 5. None Established 3. HAZARDS IDENTIFICATION HMIS HEALTH 1, FIRE 1, REACTIVITY 0 Threshold Limit Value: Not established by ACGIH or OSHA Routes of Entry: At room temperature by skin absorption or ingestion. If heated or atomized by inhalation. Signs and Symptoms of Exposure: Eyes: Redness and irritation. Skin: Rash, redness Ingestion: Nausea, irritation of digestive track. Inhalation: Irritation of respiratory system. Acute Effects of Overexposure: Eye Contact: May cause severe eye irritation. Ingestion: May cause irritation of gastrointestinal track and nausea. Skin Contact: May cause severe skin irritation. May cause allergic skin reactions in some individuals. Skin Absorption: Slightly toxic by skin absorption. Inhalation: Airborne aerosols or vapors from heated material may cause severe respiratory system irritation. Chronic Effects of Exposure: Constant exposure to skin may cause chronic dermatitis. Other chronic effects are unknown. Conditions Aggravated by Exposure: Respiratory ailments, dermatitis, other conditions unknown. Carcinogenicity: This product and its constituents are not listed as carcinogens by IARC, NTP or regulated as carcinogens by OSHA at this time. Routes of Entry: At room temperature primary routes are ingestion or skin absorption. If the material is heated or atomized the vapors or aerosol may cause exposure via inhalation. 53

4. FIRST AID MEASURES Emergency and First Aid Procedures: Eyes: Irrigate w/flowing water immediately and continuously for 15 minutes. Obtain medical attention. Swallowing: Give water or milk. Do not induce vomiting. Call a physician. DO NOT GIVE ANYTHING BY MOUTH TO AN UNCONSCIOUS PERSON. Skin Contact: Remove contaminated clothing wash before reusing. Wash affected area well with soap and water. Consult physician. Inhalation: Remove to fresh air. Obtain medical attention. 5. FIRE AND EXPLOSION DATA Flash Point 350oF (175oC)TCC. Flammable Limits in Air % Volume Upper: n/d Lower: n/d Extinguishing Media: Foam, CO2, or Dry Chemical Unusual Fire and Explosion Hazards: Do not breathe smoke when burning. Irritating and or toxic vapors and gasses when burned. Special Fire Fighting Procedures: Fire fighters should wear full emergency equipment including self contained breathing apparatus. Do not direct solid stream of water or foam into hot, burning pools, this may cause frothing and increase fire intensity. 6. ACCIDENTAL RELEASE MEASURES Steps to be Taken in Case Material is Released or Spilled: Contain spills with dams of absorbent material such as Zip Zorb. Absorb material and shovel into drums. Use appropriate safety equipment. Do Not flush to sewers. 7. HANDLING AND STORAGE Precautions to be Taken in Storage and Handling: Avoid skin and eye contact. Avoid breathing vapors if generated. Exercise reasonable care and cleanliness. Storage Temperatures 25-500C (77-1220F). Condition material to 30-600C (86-1400F) before using. Mix well under dry atmosphere before using. 8. EXPOSURE CONTROLS/PERSONAL PROTECTION Eye Protection: Adequate eye protection as required to prevent contact during handling. i.e. Safety glasses, splash goggles, face shield. Skin Protection: Rubber Gloves, aprons and other protective clothing as required to prevent contact. Remove any contaminated clothing and wash before use. Routinely wash hands, arms and face with soap and water after handling. Do not smoke or eat until hands and face have been washed. Ventilation and Respiratory Protection: Good room ventilation is required. General mechanical ventilation is normally satisfactory. Use organic vapor respirator or supplied air respirator where supplemental protection is needed. Follow OSHA regulations when using personal protective equipment. Other: Eye wash, safety shower. 54

9. PHYSICAL AND CHEMICAL PROPERTIES Appearance clear liquid Color slight yellow tint Odor mild Boiling Range decomposes over 150oC. Melting Point super cools, sets to glass <10oC. Evaporation Rate(BuAcet=1) not volatile Vapor Density (air=1) n/a Weight per Gallon 8.9 Specific Gravity 1.07 Solubility in Water(%) very slight Percent Volatile negligible 10. STABILITY AND REACTIVITY Stability Stable Conditions to Avoid High heat (over 225oF) Incompatibility (materials to avoid) Oxidizing materials. Hazardous Polymerization Will not occur. Hazardous Decomposition Products By fire: CO2, CO, partially decomposed hydrocarbons, other undetermined irritating and or toxic fumes or vapors. 11. TOXICOLOGICAL INFORMATION Polyether polyol: Skin rabbit LD50: >2000 mg/kg; dermal rat LD50: >2000 mg/kg; ingestion oral rat LD50: >2000 mg/kg. 12. ECOLOGICAL INFORMATION Data unavailable 13. DISPOSAL CONSIDERATIONS Waste Disposal Method: If discarded in its purchased form, this product is not hazardous waste either by listing or by characteristic. However, processing, use or contamination of this product may change its hazardous waste status. Under RCRA, it is the responsibility of the product user to determine, at the time of disposal, whether a material is a hazardous waste. State and local disposal regulations may differ from federal disposal regulations. Dispose in accordance with all federal, state, and local waste disposal laws and regulations. Incineration is the preferred method. 14. TRANSPORT D.O.T. Shipping Name none Technical Shipping Name Z7500 Part A Polyol, Plastic Related Material D.O.T. Hazard Class not regulated UN/NA Number none NMFC Item Plastic material liquid, NMFC-156240 Class 60 55

15. REGULATORY All components of this mixture are listed in the TSCA inventory. For details on regulatory requirements you should contact the appropriate agency in your state. 16. OTHER This data is offered in good faith as typical values and not as a product specification. The information in this data sheet was compiled from information supplied by the vendors of the components of this compound. No warranty, either expressed or implied is hereby made. The recommended industrial hygiene and safe handling procedures are believed to be generally applicable. However, each user should review these recommendations in the specific context of the intended use and determine whether they are appropriate. The information on this data sheet is only to assist in the safe handling of this material, and may contain trade secrets which may not be divulged to anyone except the users of this material and health care and hygiene professionals as required for its safe use. No license or permission to infringe any patent or breach any trade secret is given. 56

Safety data sheet MDI Product: ISOCYANATE B1001 1. Substance/preparation and company identification ISOCYANATE B1001 Use: Chemical Manufacturer/supplier:BASF India Ltd, 1st Floor, VIBGYOR Towers, Plot No. C 62, G Block, Bandra Kurla Complex, Mumbai 400051, INDIA Telephone: +91 22 6661-8000 Telefax number: +91 22 6758-2753 Emergency information: International emergency number: Telephone: +49 180 2273-112 2. Composition/information on ingredients Chemical nature P-MDI (Content (W/W): 100 %) CAS Number: 9016-87-9 3. Hazard identification Harmful by inhalation. Irritating to eyes, respiratory system and skin. Limited evidence of a carcinogenic effect. May cause sensitization by inhalation and skin contact. Harmful: Danger of serious damage to health by prolonged exposure through inhalation. 4. First-Aid Measures General advice: Immediately remove contaminated clothing. If inhaled: Keep patient calm, remove to fresh air, seek medical attention. On skin contact: After contact with skin, wash immediately with plenty of water. Consult a doctor if skin irritation persists. On contact with eyes: Immediately wash affected eyes for at least 15 minutes under running water with eyelids held open, consult an eye specialist. On ingestion: Immediately rinse mouth and then drink plenty of water, do not induce vomiting, seek medical attention. Note to physician: Symptoms: tightness in the chest, coughing, difficulty breathing Hazards: Symptoms can appear later. Information on: Diphenylmethane-4,4'-diisocyanate (MDI) Hazards: Respiratory sensitization may result in allergic (asthma-like) signs in the lower respiratory tract including wheezing, shortness of breath and difficulty breathing, the onset of which may be delayed. Repeated inhalation of high concentrations may cause lung damage, including reduced lung function, which may be permanent. Substances eliciting lower respiratory tract irritation may worsen the asthma-like reactions that may be produced by product exposures. 57

Treatment: Treat according to symptoms (decontamination, vital functions), no known specific antidote, administer corticosteroid dose aerosol to prevent pulmonary odema. 5. Fire-Fighting Measures Suitable extinguishing media: dry powder, carbon dioxide, alcohol-resistant foam, water spray Specific hazards: carbon dioxide, carbon monoxide, hydrogen cyanide, nitrogen oxides, isocyanate The substances/groups of substances mentioned can be released in case of fire. Special protective equipment: Wear self-contained breathing apparatus and chemical-protective clothing. Further information: Keep containers cool by spraying with water if exposed to fire. Dispose of fire debris and contaminated extinguishing water in accordance with official regulations. 6. Accidental Release Measures Personal precautions: Use personal protective clothing. Ensure adequate ventilation. Use breathing apparatus if exposed to vapours/dust/aerosol. Environmental precautions: Do not empty into drains. Do not discharge into the subsoil/soil. Methods for cleaning up or taking up: For large amounts: Pump off product. For residues: Pick up with absorbent material (e.g. sand, sawdust, general-purpose binder). Dispose of absorbed material in accordance with regulations. Neutralize with a solution of 5-10 % Sodium carbonate, 0,2-2 % detergents and 90-95 % water. 7. Handling and Storage Handling Provide suitable exhaust ventilation at the processing machines. Ensure thorough ventilation of stores and work areas. Avoid aerosol formation. When handling heated product, vapours of the product should be ventilated, and respiratory protection used. Wear respiratory protection when spraying. Danger of bursting when sealed gastight. Protect against moisture. Products freshly manufactured from isocyanates can contain incompletely reacted isocyanates and other dangerous substances. Clean up contamination as soon as they occur. Provide basic employee training to prevent/minimize exposures. Storage Keep away from water. Segregate from foods and animal feeds. Segregate from acids and bases. Suitable materials for containers: carbon steel (iron), High density polyethylene (HDPE), Low density polyethylene (LDPE), tin (tinplate), Stainless steel 58

Further information on storage conditions: Keep container tightly closed in a cool, well-ventilated place. Protect against moisture. Formation of CO2 and build up of pressure possible. Danger of bursting when sealed gastight. 8. Exposure controls and personal protection Components with occupational exposure limits Diphenylmethane-4,4'-diisocyanate (MDI), 101-68-8; Personal protective equipment Respiratory protection: Respiratory protection in case of vapour/aerosol release. Combination filter for gases/vapours of organic compounds and solid and liquid particles. Hand protection: Chemical resistant protective gloves (EN 374) Suitable materials also with prolonged, direct contact (Recommended: Protective index 6, corresponding > 480 minutes of permeation time according to EN 374): butyl rubber (butyl) - 0.7 mm coating thickness nitrile rubber (NBR) - 0.4 mm coating thickness chloroprene rubber (CR) - 0.5 mm coating thickness Unsuitable materials polyvinylchloride (PVC) - 0.7 mm coating thickness Polyethylene-Laminate (PE laminate) - ca. 0.1 mm coating thickness Eye protection: Safety glasses with side-shields (frame goggles) (e.g. EN 166) Body protection: safety shoes (e.g. according to EN 20346) General safety and hygiene measures: Do not breathe vapour/spray. With products freshly manufactured from isocyanates body protection and chemical resistant protective gloves is recommended. Wearing of closed work clothing is required additionally to the stated personal protection equipment. No eating, drinking, smoking or tobacco use at the place of work. Take off immediately all contaminated clothing. Hands and/or face should be washed before breaks and at the end of the shift. At the end of the shift the skin should be cleaned and skin-care agents applied. 9. Physical and Chemical Properties Form: liquid Colour: brown Odour: earthy, musty ph value: not applicable Melting point: < 0 C Boiling point: 200 C (1,013 mbar) Flash point: > 204 C Flammability: not flammable Lower explosion limit: For liquids not relevant for classification and labelling., The lower explosion point may be 5 15 C below the flash point. Upper explosion limit: For liquids not relevant for classification and labelling. 59

Ignition temperature: > 600 C Explosion hazard: not explosive Vapour pressure: < 0.01 Pa (25 C) Density: 1.22 g/cm3 (25 C) Relative density: approx. 1.22 (20 C) Relative vapour density (air): 8.5 (20 C) Solubility in water: Reacts with water., hydrolyzes Miscibility with water: Reacts with water. Partitioning coefficient n-octanol/water (log Pow): not applicable Viscosity, dynamic: 100-250 mpa.s (25 C) Other Information: If necessary, information on other physical and chemical parameters is indicated in this section. 10. Stability and Reactivity Conditions to avoid: Temperature: < 15 C Avoid moisture. Thermal decomposition: > 230 C Substances to avoid: acids, alcohols, amines, water, Alkalines Corrosion to metals: No corrosive effect on metal. Hazardous reactions: Reacts with water, with formation of carbon dioxide. Risk of bursting. Reacts with substances which contain active hydrogen. No hazardous decomposition products if stored and handled as prescribed/indicated. 11. Toxicological Information Acute toxicity Assessment of acute toxicity: Virtually nontoxic after a single ingestion. Virtually nontoxic after a single skin contact. Of moderate toxicity after short-term inhalation. LD50 rat (oral): > 10,000 mg/kg LC50 rat (by inhalation): approx. 0.493 mg/l 4 h LD50 rabbit (dermal): > 10,000 mg/kg Irritation Assessment of irritating effects: Eye contact causes irritation. Skin contact causes irritation. Primary skin irritation: Irritant. Primary irritations of the mucous membrane: Irritant. Assessment other acute effects Assessment other acute effects: Causes temporary irritation of the respiratory tract. Sensitization Assessment of sensitization: The substance may cause sensitization of the respiratory tract. Sensitization after skin contact possible. 60

Repeated dose toxicity Assessment of repeated dose toxicity: The substance may cause damage to the lung even after repeated inhalation of low doses, as shown in animal studies. Genetic toxicity Assessment of mutagenicity: The substance was mutagenic in various test systems with microorganisms and cell cultures; however, these results could not be confirmed in tests with mammals. Carcinogenicity Assessment of carcinogenicity: Indication of possible carcinogenic effect in animal tests. However, the relevance of this result for humans is unclear. The substance was tested in form of respirable aerosols. Reproductive toxicity Assessment of reproduction toxicity: Repeated inhalative uptake of the substance did not cause damage to the reproductive organs. Developmental toxicity Assessment of teratogenicity: Animal studies gave no indication of a developmental toxic effect at doses that were not toxic to the parental animals. Experiences in humans coughing, dyspnea, tightness in the chest, temporary influenzal symptoms: Can severely irritate the eyes and respiratory tract depending upon the concentration. 12. Ecological Information Ecotoxicity Assessment of aquatic toxicity: There is a high probability that the product is not acutely harmful to aquatic organisms. No toxic effects occur within the range of solubility. Toxicity to fish: LC0 (96 h) > 1,000 mg/l, Fish (other) Aquatic invertebrates: EC0 (24 h) > 500 mg/l, daphnia (other) Aquatic plants: EC0 (72 h) 1,640 mg/l, Scenedesmus subspicatus (OECD Guideline 201) Mobility Assessment transport between environmental compartments: Adsorption to solid soil phase is not expected. Persistence and degradability Assessment biodegradation and elimination (H2O): Poorly biodegradable. Elimination information: < 10 % BOD of the ThOD (28 d) (OECD Guideline 302 C) (aerobic, activated sludge) Under test conditions no biodegradation observed. Bioaccumulation potential Assessment bioaccumulation potential: Does not significantly accumulate in organisms. 61

Bioaccumulation potential: Accumulation in organisms is not to be expected. Other adverse effects Adsorbable organically-bound halogen (AOX): This product contains no organically-bound halogen. Additional information Other ecotoxicological advice: Do not release untreated into natural waters. Do not allow to enter soil, waterways or waste water channels. 13. Disposal Considerations Incinerate in suitable incineration plant, observing local authority regulations. Dispose of isocyanate waste in dry containers and never mix together with other wastes (reaction, dangerous pressure build up). Contaminated packaging: Contaminated packaging should be emptied as far as possible; then it can be passed on for recycling after being thoroughly cleaned. 14. Transport Information Domestic transport: Not classified as a dangerous good under transport regulations Sea transport IMDG Not classified as a dangerous good under transport regulations Air transport IATA/ICAO Not classified as a dangerous good under transport regulations 15. Regulatory Information Regulations of the European union (Labelling) Regulation 1272/2008/EC on classification, labelling and packaging of substances and mixtures, amending and repealing Directives 67/548/EEC and 1999/45/EC, and amending Regulation 1907/2006/EC: Hazard symbol(s) Xn Harmful. R-phrase(s) R20 Harmful by inhalation. R36/37/38 Irritating to eyes, respiratory system and skin. R40 Limited evidence of a carcinogenic effect. R42/43 May cause sensitization by inhalation and skin contact. R48/20 Harmful: Danger of serious damage to health by prolonged exposure through inhalation. S-phrase(s) S23.3 Do not breathe vapour/spray. S36/37 Wear suitable protective clothing and gloves. S45 In case of accident or if you feel unwell, seek medical advice immediately (show the label where possible). Hazard determining component(s) for labelling: P-MDI 62

Other regulations If other regulatory information applies that is not already provided elsewhere in this safety data sheet, then it is described in this subsection. 16. Other Information Recommended use: polyurethane component, industrial chemicals Vertical lines in the left hand margin indicate an amendment from the previous version. The data contained in this safety data sheet are based on our current knowledge and experience and describe the product only with regard to safety requirements. The data do not describe the product's properties (product specification). Neither should any agreed property nor the suitability of the product for any specific purpose be deduced from the data contained in the safety data sheet. It is the responsibility of the recipient of the product to ensure any proprietary rights and existing laws and legislation are observed. 63

Annexure 6: process and vessel hazards and controls Sr. No. Name of the plant, Department or place 1 Production Plant Name of the hazardous process and operation Mixing of chemicals + Injecting + Assly + Pressing + Materials in the process operation with their quantity ( proposed) MDI + Polyol Name of the vessel and its location Closed vessel with isolated room Operating parameters (pressure, temperature etc.) NTP Types of hazards possible (exothermic. Run away pressure release, toxic release, fire, explosion etc. Toxic, if leakage Ver less possibility of fire Control measures provided No manual handling, enclosed reaction, no gas fume generation, Name & Designation Mr. Anil Barot Production- RFM In charge person Telephone Number (O) 904 (M) - 9727762213 Cutting 64

No. Name of the possible hazard or emergency Its source & reason Annexure 7: Other Hazards & Controls Its effects on persons, property & environment Place of effect Control measures provided In charge Person Name & Phone No. Designation 1 2 3 4 5 6 7 8 1 Electric Short Circuit fire in electric motor, transformer,panel board Burn, electric shock, injury/death, property loss Plant premises, area pertaining to particular equipment Mr. Nikhil Patel Maintenance Electrical & Mechanical Loose wiring, faulty equipments, lack of earthing, chocking, over heating 2 Fall accident Working at height 3 Natural Disaster, Earth quake, lightening, structure collapse, accidental gas release from neighboring unit Natural 4 Housekeeping Bad housekeeping Injury death, property damage Production hindrance, chemical leak, toxic release Injury (minor / major) Anywhere in the plant Plant premises and near by population Plant premises Proper earthing, periodical checking of contacts, proper insulation of equipment, flame proof fitting in solvent area, electrician to be provided Safety Belt, Helmet PPE s Work Permit Form Lightening arrester, fire fighting equipment and PPEs make ready, mutual aid, offsite emergency plan to be activated Proper handling, regular cleaning, proper placement of material Mr. Anil Barot Production- RFM Mr. Hiren Limbachiya HR Head Mr. Hiren Limbachiya HR Head (O) 412 (M) - 9574624503 (O) 904 (M) - 9727762213 (O) 114 (M) - 9879016955 (O) 114 (M) - 9879016955 65

No. Type and Name of Trade Waste Its generation per day Place of its generation Annexure 8: Trade Waste Disposal Place of safe disposal Treatment method of safe disposal (Ref. 1) Alarm indicating accidental release or release in excessive proportion Monitoring and control measures provided. In charge person Name & Designation 1 2 3 4 5 6 7 8 9 10 1 Discarded 150 Plant No provided Production Drums/Containers Nos./month manager Decontaminate & reuse or sold to registered recyclers 2 Used/Spent Oil 100 Lit/year Plant Send to actual recyclers Will be sold to registered recyclers Send to actual recyclers Production manager Phone No. 66

No. Type of incident (major accident, emergency or disaster) Date & time of occurrence Its place Duration Annexure 9 : Records of Past Incidents Time required in controlling it No. of workers working at that time Person affected Person died Effects on the survivors Inside Outside Inside Outside Immediate Delayed the the the the factory factory factory factory Subseque nt safety measures provided 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Oth er det ails NO PAST INCIDENT 67

Annexure 10 : Gas Dispersion Concentrations Assuring leak rate (Q) = 3 Kg/sec. i.e. 3 10 6 mg/sec and velocity (u) = 2 and 5 M/sec, downwind concentrations of some gases at various distances are calculated and tabulated as follows: Product: Maximum concentration (PPM) in downwind direction at distance X, wind velocity = 2 M/sec. for most unstable after noon weather condition. Gas 100M 200M 300M 400M 500M 70M 1 KM 2 KM 3 KM 4 KM 5 KM Chemicals used in the factory have no characteristics to disperse in the atmosphere during leakage/spillage, however separate Risk Assessment is carried out, and storage of chemical will be decided accordingly. Note: For other weather condition respective curve should be chosen. Product: Maximum concentration (PPM) in downwind direction X, Wind velocity = 5 M/sec. for most unstable weather condition (A). If spillage, sand bags will kept ready, and chemical dispersion will not go beyond company premises. Note: For other weather condition respective curve should be chosen.. 68

Annexure 11: Evacuation Table Material Evacuation Table based on prevailing wind speed Radius of immediate Dimension of Evacuation Area danger area (KM) Downwind (KM) Crosswind (KM) NIL 69

ANNEXTURE-12 Environmental Impact Assessment Sr. No Dist. in meter Environment (neighbor ing factory, residential colony, village etc) Population with composition Possible consequence & Assessment Types of control Day time Night time Risk assessment measures Healthy Vuln erab le Total Health y Vuln erab le Total Type of risk & effect possible Dura tion of risk No.of people, property may be affected Frequ ency of the hazard Accept able criteria Available in the factory Required from outside 1 50 Own premises 10 0 10 5 0 5 Small 2 100 Own premises 50 5 55 30 2 32 leak of MDI, 3 500 estate/public 300 40 340 150 20 170 Polyol road 4 1 k.m. estate/ 1000 400 1400 1000 200 1200 dantali village 5 2 k.m. Dantali/gota /vadsar part 7000 800 7800 3000 200 3200 Fire due to MDI, Polyol 10 Mts 20 Mts 05 person may be affected, Property not affect 05 person may be affected, Property not affect Not recorde d so far Not recorde d so far NIL but care is required. NIL but care is required Fire extinguish er Sand Bags Fire brigade Mansa 70

Annexure 13: Weather Conditions Sr. No. Period of the year MONTH Wind Velocity (Km/h) Wind direction towards Weather conditions dry, moist, rainy, cold, hot, stable, unstable, stormy. 1 2 3 4 5 1 Jan 10 to 15 km/h North -West Cold and stable D Pasquill Classification A To F 2 Feb North -West Dry and stable D 3 Mar South -west Dry and stable D 4 April 10 to12km/hr South -west Dry and stable D 5 May 4.0 to 20 South -west HOT D km/hr 6 June 6.0to12.0 South -west Moist and Hot D km/hr 7 July South -west Hot and Rainy D-F 8 Aug South -west Hot and Rainy D-F 9 Sept. South -west Hot and Rainy D-F 10 Oct 10.0to12.0 South -west RH -50 %@ D km/hr 11 Nov North- West Dry D 12 Dec North- West Cold and stable D 71

Annexure 14: Incident Controllers Shifts Incident Controller Runner General & First Name & Designation Qualific ation Place of availability In the factor y Residence address In the factory Phone No. Residence Name & Designatio n Place of availabilit y Phone No. 1 3 4 5 6 7 8 9 10 11 Mr.Dharmendra H.S.C Plant 184-.Sector -6 405 992409037 Mr. Jignesh Plant 99248461 patel,chankyapuri, 2 Barot (QC 23 ghatlodiya,ah Head) Sr.Supervisor medabad General & First Mr. Ajay patel H.S.C Plant Village - ognaj,opp.priv ate school.tadascroi dist- Ahmedabad 408 982416670 9 Vasudev harjibhai patel Supervisor Plant 99785285 01 72

Annexure 15: Deputy Incident Controllers Site Main Controller s Next Person Name in Place of availability Phone No. No. Name & Place of priority Designation Qualification In the Residence In the Phone No. Residence Designation availability order factory Address factory 1 2 3 4 5 6 7 8 9 10 11 1 Mr. Anil Engineer ITRSM Plant Gota housing 903 9727762213 Mr. Amrish Operation 9879107881 Barot colony, Patel Ahmedabad 2 Mr. Ketan Patel Superviser RFM Cold Room Refrigeration DME Mechanical Plant Vadsar road, vadsar, 410 9879107784 Mr. Harshad Chauhan Operation 9724472601 73

Annexure 16: Site Main Controller Site Main Controller s Next Person Name in Place of availability Phone No. No. Name & Place of priority Designation Qualification In the Residence In the Phone No. Residence Designation availability order factory Address factory 1 2 3 4 5 6 7 8 9 10 11 1 Mr. Director DIP Plant 22/A,sarvoday 904 9879111985 Mr. Ajay Operation 9824166709 Rajendra society Vibhagh- Patel Patel 1,Opp.Agrawal Tower,bhuyangdev cross road Sola road Ahmedabad- 2 Mr. Hiren Limbachia HR&Admin. -- Plant Block no-34/2 chh type, sector no-16 gandhinagar 114 98791016955 Mr.Pintu Patel Plant 9978528501 74

No. Departme nt Name (he may be called at any time for this plan) Designati on Qualifi cation Annexure 17: Key Personnel In the fact ory Place of availability Residence address In the facto ry Phone No. Residenc e Name & Designa tion In the Fac tor y Next Person s Place of availability Residenc e Address Phone No. In the Factor y 1 2 3 4 5 6 7 8 9 10 11 12 13 14 1 Spillage/Le Mr. Atit 110 75670969 987911 akage Patel 79 1985 2 Fire & Safety Mr. Hiren Limbachiya 3 Security Mr. Abransingh Rathod 4 Pollution Mr. Hiren Control MR-EHS M Com Plan t & Offi ce HR & Sefty Officer Security In charge HR & Safety MBA- HR Under Graduat e Graduat e Plan t / Offic e Main Gate Plan t / Offic e 1/B, Akshar Baug Soc. Maninagar Block no- 34/2 chh type, sector no-16 gandhinagar Company Quarter Block no- 34/2 chh type, sector no-16 gandhinagar 114 98790169 55 400 99241380 20 114 98790169 55 Mr. R.P. Patel Director Mr. Hiren Op erat ion 22/A, Sarvoday Soc, Agraval Tower, Sola, A Bad Do Reside nce 079-274393 36 HR 114 397901 6955 Do 75

5 Production Mr. Ajay Bhai Production PUF Panel 6 Personnel & Transport Gautambha i Production Graduat e Logistics Graduat e Plan t Offic e Village - ognaj, opp.private school. ta-dascroi dist-ahd. 25, Radhey Soc, Krushninaga r, Ahmedabad 408 98241667 09 103 98250410 54 Mr. R.P. Patel Director Op era tio n Mr. R.P. Patel 22/A, Sarvoday Soc, Agraval Tower, Sola, A Bad 987911 1985 079-274393 36 7 Maintenan ce Mr. Nikhil Maintenan ce Dept. BE Plan t n/1 dhwarkesh society Ta: kalol Dist Gandhinaga r 412 95746245 03 Mr. R.P. Patel Director Op era tio n 22/A, Sarvoday Soc, Agraval Tower, Sola, A Bad 987911 1985 079-274393 36 76

Annexure 18: Essential Workers Shifts Group No. (Any in group shall be available in each shift & on holiday on call) Name and Designation Trained for work of Place of availability In the Factory Residence address Phone Number In the Factory Residence Personal Protective Equipment required 1 2 4 5 6 7 8 9 10 Day Time 1 Mr. Dhanji Parmar Mr. Baldev Desai Mr.Chirag Parekh Leakage/Spillage Fire Fighting Emergency Engg. Work Runner Plant --- 9879107881 Hand gloves, Gum boots safety goggles Face Mask. Night Time 1 Mr.Anil Patel Mr.Kalpesh Patel Evacuation Leakage/Spillage Fire Fighting Emergency Engg. Work Leakage/Spillage Fire Fighting Emergency Engg. Work Plant ---- 9879107784 B.A. Set Helmets Safety belts Fire suit 77

Identification No. Annexure 19: Safe Assembly Points Location Accommodation At time of emergency capacity Person In charge Nearest Name & Place of availability Phone Number phone Designation In the Residence In the Residence number Factory Address Factory 1 2 3 4 5 6 7 8 9 10 1 Main Gate 50 Security security ---- --- Near Supervisor cabin security 9879107881 cabin 9879107784 Shift Chemist PPE that will be provided Hand gloves, Gum boots safety goggles Face Mask. B.A. Set Helmets Safety belts Fire suit 78

Annexure 20: Emergency Control Center Location of the Center: Adm. Office Phone Nos. of the center: (1) External No. Items kept in the center Numbers of Quantity Person who will handle / operate this item Last Its period of operation Present 1 2 3 4 5 6 7 1 Helmet 20 Essential Workers Key Personnel Checked Periodically Checked Periodically 2 Self Breathing 0 apparatus 3 Stretcher 0 0 4 First aid box 0 7 5 P.P.E. List 6 Torch 0 1 7 First aider 0 2 8 Site plan layout 1 set 9 On Site plan 1 set 10 Rain coat, Umbrella 10 11 Fire suit 0 1 12 Stationary Adequate 13 D C P fire List extinguisher 14 CO2 tyre fire extinguisher List Notes 79

Annexure 21(A): Fire & Toxicity Control Arrangements Other source and capacity No. of hydrant point No. of fire pumps, type & capacity No. of hose reels & total length No. of fire tenders and capacity Lifting height FIXED No. of Sprinklers/ Monitors Pressure PORTABLE Lifting height Pressure Alternate power arrangement 1 2 3 4 5 6 7 8 9 10 11 No. of Co2 Extinguish ers Separate List 80

Annexure-21(B) Type of powder & total quantity Dry Powder Type Foam Type Water Jel products Other Extinguishers No. of portable Extingu isher Tonner Type of foam & total quantit y No. of portable extingui sher Tonne r No. & size of blanket Other Jel product quantity Type No or quantit y Personal Protective Equipments Respiratory Non-respiratory Type No Type No 12 13 14 15 16 17 18 19 20 21 22 23 24 25 As per List -- -- -- -- -- NIL NIL None -- Canister 3 Hand gloves Helmets Safety belts Safety goggles Fire suit Gum Boots Air line Gas Mask Canister type Gas Mask As Per require ment 81

Annexure 21 (C) MUTUAL AID ARRANGEMENTS Mutual Aid Arrangements Name & Address of the factories & Fire Stations Approx dist. Contact FFE available PPE available Person phone Type Qty Type Quantit y No. of experts & trained person available Decontamination substance available Gas detectors available Other equipment available 26 27 28 29 30 31 32 33 34 35 36 37 Deep kiran Food Pvt. Ltd. Near by Mr. Ashok Patel 02764-286821 286822 Adequate -- 2 Water None NIL Dipak Polyplast Pvt.Ltd. Nearby Mr. Mukund Patel 02764-286844 286855 Sufficient 3 82

Annexure 22: Medical Arrangements Sr.n o Name & location For key personal & essential workers see Annexure 17 & 18 First aid Cetres / Ambulance Room / OHC / Hospital phone No Name & Desi. In charge person Residence Facilit ies & Equip ment Antidote avail ble First aide availa ble Acco mmod ation Place of availa bility Ambulance van or alternate arrangement Capac ity Facility in the van Driver name & address Phone Addre ss 1 2 3 4 5 6 7 8 9 10 11 12 13 14 1. First aid box With security watchman 6542639 5 First aider. -------- Plant/ office All Yes Suffici ent. Teleph one No Facility Sufficient 108. 2 Civil Hospital Sola 079-2664359 C.M.O 9875969 605 Facility Sufficient 3 Dr.N.J.Joshi 9426035 908 General Practitionor Dispe nsary 83

Annexure 23 : Transport & Evacuation Arrangement For Key personnel and essential workers see Annexure 17 & 18 and for Assembly points See Annexure 19. Type of siren, if any, for evacuation Name & location Own Transport Center Phone No. In charge Person Sr. Name & Residence No design.. Phon Address e Type & No. Own Vehicles Capacity No. & type of public warning instruments (refer Page 40) Driver s Name & address 1 2 3 4 5 6 7 8 9 10 Office 9043 Haresh Desai Plant 9042 Baldev Desai 97277 02327 97277 62243 12/279,Go kul aawas,jod hpur char rasta,satali te, 1 GJ-1-CV- 2376 2 GJ-18- AV-6595 4 Person Horn Pls. Refer legal motor vehicle act 4 Person 84

Sr. No Name, address & distance Phone No Name & designation Annexure 23 (Contd.) Outside shelters for evacuated persons In charge Person Phone Residence Address Accommodati on capacity Facilities available 11 12 13 14 15 16 17 18 1 Community Hall. Secretary 100 People Drinking water, Kitchen, Toilet, Urinal, Bathroom, Fan, sitting facility etc. 85

Annexure 23 (Contd.) Mutual Aid Arrangements Sr. No. Name & address of the factory & outside transport centers including Bus & Railway Stn. Dist. Phone No. In charge Person Vehicles available Name & designation Phone Residence Address Sr. No. Type & No. Capacity No. & type of public warning instruments Driver s Name & address 19 20 21 22 23 24 25 26 27 28 29 30 1 Ambulance 1.55K m. 101,108 Fire Officer -------- 1 Van Adequate Horn. Employee 2 Bus station 1 Lapkaman vilage 1 Bus Adequate Horn. Employee 86

Annexure 24 : Pollution Control Arrangement For key personal & essential workers see Annexure 17 & 18 for trade waste disposal. See Annexure. 8 Water pollution Control Type and Capacity of effluent treatment plant No of Sample monitoring centers & its frequency Other control Measu res Logbook & records In charge person s name, addres s & phone s Air monitoring No. and place of sample monitori ng centers Type, parameters & frequency of tests Wind directio n indicato r velocity meter Instrume nt available Logbook & records In charge person s address & phones Consent taken from G.P.C.B. for zero discharge 87

For Key personnel and essential workers see Annexure 17 & 18 Annexure 25 : Other Arrangements Sr.No Type and name of Qty Plac Phone In charge person s Mutual Aid Arrangements arrangements e of No. Name & Residence Place Qty. In charge person s available avail Desig. Phone Addres where available Name Phone Address abili s availabl designa Off Res. ty e tion 1 2 3 4 5 6 7 8 9 10 11 12 13 14 1. Heavy Vehicles nil -- -- -- -- -- -- -- -- 2. Lifts, Cranes etc. nil -- -- -- -- -- -- -- -- 3. Transporters for -- -- -- -- -- -- -- -- -- materials 4. Power alternative one No. D.G. set -- -- -- -- -- -- -- -- 5. Utilities alternatives 6. Special equipments/ instruments Cani ster Gas Mas k -- -- -- -- -- -- -- -- -- 7. Special Materials -- -- -- -- -- -- -- -- -- -- -- 8. Test facilities 1 Office -- -- -- -- -- -- -- -- -- 9. Special information -- -- -- -- -- -- -- -- -- -- 10. Others -- -- -- -- -- -- -- -- -- -- -- 88

Sr no Plant wise alarm points Plant / dept. / location Name & No. of location floor Area of each floor Sr. no. of the alarm point Annexure 26 : Alarms & sirens Its place of locatio n Type of the alarm of siren Its period of checkin g The alarm (signal heard seen) at Sound difference if any Type of emergency Type of alarm or siren Duration of sound ing 1 2 3 4 5 6 7 8 9 10 11 12 13 1 Plant Area G.F. F.F. As per map Electric Weekly 1 K.M. Fire, and explosion Conti nious 1 Product ion PUF Panel Gas leak All clear Pause repeat Pause repeat 30sec. Once Pause repeat Continuous for 2 min. Type of sound of alarm /siren Typical type 89

Annexure 27 : Internal Phones Sr. No. Name and location of plant Phone number Name and Design. Person available on this phone Design. or duty under on-site plan if any Mobile number 1. Office Mr.Rajendra Patel S.M.C. 9879111985 2 Office Mr. Vipul Patel S.M.C 9879095193 3 Plant Mr.Dharmendra Patel I.C. 9924090372 4 Plant 65426395, Mr Ajay Patel I.C. 9824166709 5 Plant 9879107881 Mr. Jignesh Barot I.C./Key personnel 9924846123 6 Plant 9879107784 Mr.Vasudev Patel I.C./essential worker 9978528501 7 Plant Mr. Anil Barot Dy.I.C. 9727762213 8 Plant Mr. Ketan Patel Dy.I.C. 9727762214 9 Plant Mr Hiren Limbachia Dy.I.C./Key Personnel 9879016955 10 Plant Mr.Dhanji Parmar Essential worker 9727701496 11 Plant Mr.Anil Patel Essential worker 9879107784 12 Plant Mr.Baldev Desai Essential worker 9727762243 13 Plant Mr.Chndrakant Patel Key Personnel 9825051052 90

Annexure 28 External Phones Sr. no. Name and Design. Place Phone no. Code Office Resi. 1 Dist. emergency control center Gandhinagar 079 23259220 2 Police control room Gandhinagar 079 23222337, 100 3 Collector Gandhinagar 079 23259030 4 D. D. O. Gandhinagar 079 23223266 5 Police Commissioner Ahmedabad 079 25630700, 25630600 6 Police Station Kalol 02764 221394, 09824863399 7 Deput. Director, Ind safety & Health Gandhinagar 079 23233231 8 Fire brigade - Gandhinagar Gandhinagar 079 23222742 9 Blood Bank Shradhha Deep Gandhinagar 09328237138 10 Ashirvad Blood bank Gandhinagar 079 23221584 91

Annexure 29: Nominated persons to declare major emergency Sr. no. Name of the plant department or location Name & designation of the nominated person to declare major emergency Duty or designation given, under the on-site/ off-site emergency plan. Phone no. Phone No. Residence 1 2 3 4 5 6 7 1 Adm. Office Mr. Hiren Limbachia Address S.M.C. 114 9879016955 Block no-34/2 chh type, sector no-16 gandhinagar 2 Plant Mr. R.P. Patel S.M.C. 101 9879111985 22/A, Sarvoday Soc, Agraval Tower, Sola, A Bad 92

Annexure 30 : A form to record emergency telephone call Part A : Essential Information Details of call as reported Caller s Name & designation Date Time Phone no. Purpose of call. Is any particular advice required immediately? Name of chemicals. To be spelt our clearly Brief description of incident. Fire/ Explosion/ Liquid Spill/ Gas release. Quantity involved. Packaging/ storing/ handling/ using details. Location of incident. Cause, if known, in brief. Part B : Information to be obtained if readily available. Has anyone been injured? Affected by chemicals? What first-aid has been given? Has any one been taken to hospital? If Yes, address of the hospital. Is the road blocked? Who owns the chemicals? Has the owner been informed? Yes/ No Yes/No Yes/ No Yes/No If yes, how many? Closed to traffic? Yes/ No If caused by vehicle, Vehicle Number and Name & Address of the Owner _---- Has the owner been informed? Yes/ No To whom was the load consigned? 93

ANNEXURE - 31 : STATUTORY COMMUNICATION Statutory information to be given to : Periodicity of such information to be given The workers Safety literature, training programme The general public and neighboring firms District Emergency Authority Factory Inspectorate Yes, to be implemented. As and when co-ordination meeting called by the authority At every revision of the plan or as and when asked by them Date of last information given To how many persons Suggestions, received, if any. Year 2008 All Oral suggestions during discussion. Information booklet under preparation. To the neighbouring firms & public. ----- do ---- Copy of emergency plan to be given. ----- do ---- Copy of emergency plan to be given. Committee meeting None Yes (As per the remark in Visit book) Last date of implementation of Useful suggestions. Implimented when received. It is an ongoing process. None. None It is an ongoing process. 94

Annexure 32 - Separation Distances Sr. No Substance Separation distance (M) Distance at present Capacity Nos. 1 2 3 4 5 6 1 MDI 200L, drum 80 nos. Nil Separately stored 2 Polyol 200 l, drum 90 nos. Nil Separately stored 95

Annexure 33: Emergency Instruction Booklet Sr. No. Role to be played as [Name, emergency designation viz. Incident controller, particular key person or essential worker doing the job of ] 1 Site Main Controller (SMC) His emergency duties/ functions (Narrate in short and clear sentences and in 1,2, 3) Immediately after being aware of the emergency, he will go to the ECC. On arrival, he will 1. Relieve the I.C. off responsibility for overall main control. 2. On consultation with the IC, decide whether major emergency exist and on declaration of major emergency, ensure that the outside emergency services and mutual aid are called. The off site plan activated and if necessary, nearby factories and population are informed. 3. Ensure that the key persons are called in 4. Exercise direct operational control of those parts of the work outside the affected area. 5. Continuously review and assess possible development to determine the most probable course of event. 6. Direct the safe close down and evacuation of workers from plants in consultation with the IC and key personnel. If necessary arrange for evacuation of neighbouring population. 7. Ensure that casualties are reveiving adequate attention, arrange for hospitalization of victims and additional help if required. Ensure that the relatives are advised. 8. Inform and liase with the CF office of the fire & police services. District emergency authority and with the Director Industrial Safety & Health, provide advise on possible effects on areas outside the unit. 9. Ensure the accounting of personnel, rescue of missing persons. 10. Control traffic movement within the factory premises 11. Issue authorized statement to the news media. Also refer (Other relevant document of the factory viz. Safety Manual etc.) Booklet prepared as per Rule 68-K/P/L He should report at (the incident place or control room etc.) Emergency control centre 96

2 Incident Controller (IC) 12. Ensure that proper consideration is given to the preservation of evidence arrange for photograph / video 13. Control rehabilitation of affected areas and victims of cessation of the emergency. Do not re-start unless it is ensured safe to start and cleared by the authorities. Immediately after being aware of the emergency, he will proceed to the scene. On arrival, he will. 1. Access scale of emergency and decide if a major emergency or likely. On his decision, he will activate the On site emergency plan, and if necessary, the off site emergency plan. 2. Inform site main controller and perform as site main controller till his arrival and he will depute his deputy incident controller on the scene and he will go to the ECC. Particularly he will. (a) Direct the shutting down of plant and evacuation of workers from the plant and areas likely to be affected by the emergency. (b) Ensure that the outside emergency services including mutual aid services have been called in. (c) Ensure that key personnel have been called in. 3. Direct the operations within the affected area with following priorities. (a) Secure safety of persons. (b) Minimize damage to plant, property & environment. (c) Minimize loss of material. 4. Direct rescue & fire fighting operation until arrival of fire brigade. 5. Search for casualties. 6. Evacuate non essential workers to the assembly point. 7. Set up a communication point & establish telephone / messenger contact as appropriate with the ECC. 8. Give advice & information as requested to the head of fire brigade and other emergency services. 9. Brief the SMC and keep informed of developments. 10. Preserve evidence that will be necessary for subsequent into the cause of the emergency and concluding preventive measures. Booklet prepared as per Rule 68-K/P/L The accident site 97

3 Deputy Incident Controller (Dy. I.C.) 4 Key Personnel (As per Annexure-17) 5 Essential Workers (As per Annexure-18) 6 First Aid / Medical Team (As per Annexure-18) 7 Public Relation team / Manager 1. Immediately reach at the scene of incident & help I.C. 2. Will act as IC in his absence 3. Will ensure about the emergency by communication to utilities effluent plant and other departments. 4. Will appraise Government & other authorities. 1. Will take other directives from IC & SMS 2. Individual key person will act in his respective duties 1. Hearing the siren, will rush to the scene of incident to take directives from IC. 2. Help in fire fighting. First aid & other services. 1. On hearing the bell, send vehicle near the plant for removal of the affected. 2. Help in fire fighting. First aid & other services. 3. Inform doctor about the emergency & probable casualties. 1. team is headed by manager 2. Appraise SMC about activity to be done for emergency control 3. Take instructions from IC. For the plant activities. 4. Make all possible arrangements for victims. 5. Arrange for transport & evacuation arrangement MSDS of all hazardous chemicals used in the unit Accident sites Emergency control centre First aid site Office 98

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Annexure-A LLIST OF FIRE EXTINGUISHER Sr.No. IDNo. Type Dept./Area Capacity DUE DATE Location 1 2 3 4 5 6 7 1 FE-01 ABC TYPE DF FABRICATION 5 KG 2 FE-02 ABC TYPE DF FABRICATION 5 KG 3 FE-03 ABC TYPE DF FITTING 5 KG 4 FE-04 ABC TYPE STORE WINDOW 5 KG 5 FE-05 ABC TYPE CR SHEETMETAL/CR PANEL 5 KG 6 FE-06 ABC TYPE CR PANEL 5 KG 7 FE-07 ABC TYPE CR SHEETMETA/CR PANELL 5 KG 8 FE-08 ABC TYPE CR RFM 5 KG 9 FE-09 ABC TYPE CR PACKING 5 KG 10 FE-10 ABC TYPE MANITENANEC 5 KG 11 FE-11 ABC TYPE STORE 5 KG 12 FE-12 ABC TYPE CANTEEN 5 KG 13 FE-13 ABC TYPE PENTARY 2.5 KG 14 FE-14 CO2 DF RFM 7 KG 15 FE-15 CO2 CR RFM 7 KG 16 FE-16 ABC TYPE GATE -2 5 KG 17 FE-17 ABC TYPE DF FITTING/DF RFM 5 KG 18 FE-18 CO2 DF ASSEMBLEY 7 KG 22-01- 2017 22-01- 2017 22-01- 2017 22-01- 2017 22-01- 2017 27-01- 2017 22-01- 2017 23-09- 2018 22-01- 2017 23-07- 2018 22-01- 2017 18-08- 2018 04-04- 2018 01-01- 2019 01-01- 2019 22-01- 2017 22-01- 2017 01-01- 2019 HALL NO 01 HALL NO 01 HALL NO 02 HALL NO 03 HALL NO 03-04 HALL NO 03 HALL NO 03-04 HALL NO 05 HALL NO 08 MAINTENANCE STORE CANTEEN PENTRY HALL NO 02 HALL NO 05 HALL NO 16 HALL NO 02 HALL NO 02 100

Annexure-B List of First Aid Box SR NO ID No. LOCATION Contact Person 1 FA 01 CR PACKING Amrish Patel 2 FA 02 DF FABRICATION Kanubhai Thakor 3 FA 03 DF RFM/FITTING Anil Barot 4 FA 04 CR PANEL /CR SHEETMETAL Ajay Patel 5 FA 05 CR DOOR Sanjay Prajapati 6 FA 06 CR RFM Ketan Patel 7 FA 07 STORE Dharmendra Bhai LIST OF CONTENT IN FIRSTAID BOX SR.NO ITEM REMARKS 1 CIPLADINE ONTIMENT 2 BURNOL BURN CREAM 3 HYDROGEN PEROXIDE SOLUTION 4 IODINE TINCTURE U.S.P 5 GAUZE ROLLER BANDAGE 6 COTTON ANTISEPTIC DISINFECTANT USE TO QUIKLY CLEAN AND SANITIZE SMALL SUPERFICIAL WOUNDS IN INJURIES THAT NEED FOR PROTECTION AND STABILIZATION BETTER TREATMENTS FOR WOUNDS 101

Annexure-C Personal Protective Equipments List Sr No. Description of PPE s Location & Stock Availability 1 Helmet Stores 5 Nos. 2 Safety Shoes HR Min. 50 Nos. 3 Mask Stores Min. 10 Nos. 4 Ear Plug Stores Min. 10 Nos. 5 Safety belt Maintenance Min. 1 Nos. 6 Goggles Stores Min. 10 Nos. Qty Issued Responsibility Usage 2 Nos. Maintenance Height work 165 Nos. HR Plant Operations 18 Nos. Plant Grinding, Supervisor PUF process 9 Nos. Plant Grinding, Operation welding 1 Nos. Maintenance Height 12 Nos. Plant Supervisors work Process 102

Annexure-D Health check up 103

104

Annexure-E List of Sand Buckets Sr No. Location 1 Out side plant 2 Hall 1 3 Hall 2 4 DF Fabrication 5 Dispatch 6 Maintenance 7 Out side stores 105

MC ID No. Annexure-F List of Safety Guards Machine name Location SM-01 Shearing Machine DF-Fabrication WM-01 Welding machine Welding kit WM-02 Welding machine Welding kit WM-03 Welding machine Welding kit AWM-01 Argon Welidig machine Welding kit AWM-02 Argon Welidig machine Welding kit AC-01 Air Compressure Wheel Guard HP-01 Hydraulic Press Press wheel guard HP-02 Hydraulic Press Press wheel guard HP-03 Power press Press wheel guard PUF-01 Puf panel machine Surrounding Safety guard 106