NAVIN FLUORINE INTERNATIONAL LIMITED,DEWAS ON SITE EMERGENCY PLAN Document No. : NF/OEP/01/04 Supersedes : NF/OEP/01/03 Effective Date : 1 | P a g e NAVIN FLUORINE INTERNATIONAL LIMITED,DEWAS ON SITE EMERGENCY PLAN Document No. : NF/OEP/01/04 Supersedes : NF/OEP/01/03 Effective Date : INDEX Sr. No. Content Page No. 1.0 Introduction 1 2.0 Objectives of Emergency Management Plan 1 3.0 Elements of Emergency Plan 1 2 4.0 Types of Emergencies 2 2 5.0 Emergency Action 2 5.0 6.0 Emergency Organogram 7 7.0 Emergency Communication System 10 8.0 Duties of Plant Personnel 11 9.0 Map of Dewas city showing NFIL location 17 Appendix Appendix 1 NFIL Block Plan / Site plan, Emergency Control Centre, As- 18 sembly Points, Fire hydrant line, Fire hydrant pump room, Water storage, Fire bucket stand, Fire extinguisher. as an annexures. Appendix 2 Fire fighting facility and plant location, List of fire extin- 19 guisher and Fire Alarm System. Appendix 3 Safety Personal Protective Equipment’s at NFIL 22 Appendix 4 Location of the manual call points in the respective areas. 23 Appendix 5 Emergency Control Centre 25 Appendix 6 NFIL Products and Packaging Description 27 Appendix 7 Manufacturing process in brief and process flow chart 28 as an annexures. Appendix 8 list of key chemicals / gases with storage 30 capacity & mode of storage in bulk quantity Appendix 9 List of Licences as an annexures 31 Appendix Fire Hazard Properties and EAC of Chemicals at NFIL. 32 10 Appendix Medical Assistance 35 11 Appendix Following is the list of hospitals in Dewas, their contact 36 12 numbers. Appendix Guidelines For Safe Handling Of AHF Cylinder / Tonner 37 2 | P a g e NAVIN FLUORINE INTERNATIONAL LIMITED,DEWAS ON SITE EMERGENCY PLAN Document No. : NF/OEP/01/04 Supersedes : NF/OEP/01/03 Effective Date : 13 Appendix List Of Trained First Aider 44 14 Appendix Telephone Numbers of Important Outside Agencies 45 15 Appendix Telephone Numbers of Key People in organisation 46 16 Appendix Department wise Manpower in NFIL 47 17 Appendix Mock Trial Review 48 18 Appendix Risk and consequence analysis report with preventive 50 19 measures of toxic & critical raw material Appendix Emergency Preparedness for Uncontrolled Situation 53 20 Appendix Emergency procedure for natural disaster 55 21 Appendix Food poisoning Emergency 57 22 Appendix Transport Emergency due to Accident of vehicle carrying 60 23 hazardous cargo, Leakage of cylinder / container Appendix Utilities failure emergency management 62 24 Appendix Proposal to liquidate residue 66 25 Appendix Last Mock drill observation and action plan 69 26 Appendix Integrated Management System Policy As an annexure 69 27 Appendix List of Antidote 70 28 Distribution list 74 3 | P a g e NAVIN FLUORINE INTERNATIONAL LIMITED,DEWAS ON SITE EMERGENCY PLAN Document No. : NF/OEP/01/04 Supersedes : NF/OEP/01/03 Effective Date : APPROVAL: Signing of this approval page indicates agreement with approach de- scribed in this document. Prepared By: Functional Name Designation Signature & Area Date Environment, Health and Pravin Thakor Asst. Manager Safety Reviewed By: Functional Name Designation Signature & Area Date Environment, Shashikant Pawar Sr. Manager Health and Safety Production Shailendra Chaudhari Sr. Manager Maintenance Shashikant Prajapati Manager Administra- tion& Secu- Saket Sharma Sr. Manager rity Manufactur- Subba Reddy GM Technical ing Approved By: Functional Name Designation Signature & Area Date Site Head Anil Birari Site Head 4 | P a g e NAVIN FLUORINE INTERNATIONAL LIMITED,DEWAS ON SITE EMERGENCY PLAN Document No. : NF/OEP/01/04 Supersedes : NF/OEP/01/03 Effective Date : 1. INTRODUCTION A major emergency in industry is the one which has a potential to cause serious in- juries to people, extensive damage to property and serious disruption to normal ac- tivity both inside and outside the factory area. It can also lead to major environ- mental pollution. It is likely that in the event of an emergency, there may be a panic and the response action could be chaotic and ineffective causing confusion. To avoid such a situation, it is desirable to plan in advance and design an emergency response action that is well co-ordinated between the plant personnel as well as outside agencies. This emergency management plan specifically deals with "On-site Emergency" i.e. with respect to accidents which take place in the industry and their effects are con- fined to the factory premises involving only the people working in the factory. 2. OBJECTIVES This emergency management plan aims at the following objectives. 1. Careful evaluation of all possibilities that can lead to an emergency 2. Preparing an action plan and making plant personnel aware about method of com- munication, their duties and how to co-ordinate with outside agencies 3. Controlling the incident, and localising the emergency 4. Minimising the damage to property, health and environment 5. Giving speedy treatment to the injured 3. ELEMENTS OF EMERGENCY PLAN This emergency management plan has been prepared with the involvement of the ex- perienced operating staff, members of the safety committee, line managers as well as other management staff who will play a key role in the emergency management. 1. Since most of the emergencies in a chemical plant arise out of handling of hazardous chemicals, the plan has dealt in details with hazardous properties of the chemicals and their inventory levels. 2. It has contemplated the probable emergency scenarios and immediate containment action with respect to each one of them. 3. The use of fire-fighting as well as safety equipments is essential during containment. This plan gives the details of fire fighting facilities, safety equipments and its loca- tion. 4. The plan has elaborated the system of communicating the emergency situation to various people working within the plant as well as to the external authorities. It has a list of the key people and external agencies who may be contacted in case of emer- gency. 5. It has laid down the duties of the individuals involved in emergency action. 5 | P a g e NAVIN FLUORINE INTERNATIONAL LIMITED,DEWAS ON SITE EMERGENCY PLAN Document No. : NF/OEP/01/04 Supersedes : NF/OEP/01/03 Effective Date : 6. It includes information on the first-aid treatment for chemical injuries. It also con- tains the information on hospitals and Doctors who may be called for help for the treatment of injured persons. 7. The emergency plan also contains the location map of NFIL, Dewas. This will be help- ful in judging which areas are threatened depending on weather conditions and by the spread of the emergency, so that off-site emergency action can be initiated. Dy. Directorate of Industrial Health & Safety Dewas. Directorate of Industrial Health & Safety, Indore. Police Commissioner Dewas. Chief Fire Officer, Dewas Corporation. The plan document has been loaded on the main network server in NFIL and can be accessed by all the network users. This facility also lends easy and rapid updating of the document, as soon as the content changes. 4. TYPES OF EMERGENCIES At NFIL, Dewas; following types of emergencies can occur:- 4.1. Release of toxic gases (AHF / Sulfur Tetrafluoride / Chlorine / Ammonia etc.) due to: The corrosion of pipelines, equipment’s, nozzles of reactor/vessels. Failure of gaskets of the flange joints, during loading/unloading of chemicals, Failure of stuffing boxes or mechanical seals in pumps, Failure of scrubber, Leakage of AHF/SF4 from cylinder valve or body, Leakage of toxic gases from neighbouring in- dustry, Power failure, which result to release of toxic gases from different process stages. 4.2 Fire emergency involving:- LDO/Furnace oil / Diesel oil, Fluoro benzene, Hydrogen gas, Organic chemicals & solvents, Other combustibles like dry grass, Electric short circuits etc. 4.3 Structural Failures due to Corrosion/ Ageing. 4.4 Transport Emergency due to Accident of vehicle carrying hazardous cargo, Leakage of cylinder / container etc. 4.5 Emergency Procedure for Diversion of Storm Water Drain to ETP. 4.6 Emergency procedure for natural disaster. 4.7 Emergency procedure for natural disaster and food poisoning. 4.8 Emergency procedure for utilities failure. 4.9 Liquid nitrogen (Cryogenic Liquids) leakage 4.10 Process Scrubber failure. 5.0 EMERGENCY ACTION The Emergency Action in case of toxic gas leakage or fire is listed below. 5.1 Toxic gas leaking from process equipment’s/ Pipelines: − Determine the point of leakage. − Identify the leaking gas (AHF / Chlorine/ SF4/ Ammonia etc.) and estimate the quantity of toxic fluid hold-up in the leaking equipment. In case of major leakages, stop the production plant immediately. 6 | P a g e NAVIN FLUORINE INTERNATIONAL LIMITED,DEWAS ON SITE EMERGENCY PLAN Document No. : NF/OEP/01/04 Supersedes : NF/OEP/01/03 Effective Date : − Isolate the equipment by shutting off the valves of supply lines. This should be done after the person has adequately protected himself with proper Personal Protective Equipment’s. − Stop supply of steam to the leaking equipment’s (like reboilers) immediately to re- duce its Temperature. − Depressurise (vent) the contents of leaking equipment in to the scrubber, if possible. − Transfer the contents of the equipment to other process vessel, if possible. − In case of leakage of acids, neutralise the leaking liquid by hydrated lime or soda ash. − Activate the fire squad and call fire tender. If required. - Check wind direction. - Neutralised material packed into proper container and send to TSDF Site, and fire / cooling Water flow divert to ETP drainage. 5.2 Emergency Actions to be taken in case of fire: − Identify source/ type of fire. − Assess the severity of fire. − Isolate the equipment by shutting off the valves of supply line (carrying flammable material). This should be done after the person has adequately protected himself with proper PPEs or by auto control system.