Disaster Management

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KHAPERKHEDA THERMAL POWER STATION Rev No. : 01

MSPGCL Rev.date : 20.06.2015
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DISASTER MANAGEMENT PLAN Doc No. : KHG/STN/DMP
KHAPERKHEDA THERMAL POWER STATION
MAHARASHTRA STATE POWER GENERATION COMPANY LIMITED
DISASTER MANAGEMENT PLAN

(ON SITE EMERGENCY PLAN)
Revised on 20 Jun 2015
Sign of issuing authority

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Contents
1. BACKGROUND INFORMATION ......................................................................................... 7
(1. A) BASIS OF THE PLAN...................................................................................................................... 7
(1. B) METHODOLOGY TO PREPARE DMP ............................................................................................. 7
(1. C)OBJECTIVE OF THE PLAN .............................................................................................................. 7
(1. D) DISASTER MANAGEMENT IN INDUSTRY...................................................................................... 7
1. D.1 DISASTER MANAGEMENT ACTIVITY ......................................................................... 8
1. D.2 TYPES OF DISASTER .......................................................................................... 8
1.D.3 DEGREES OF DISASTER ....................................................................................... 8
1. D.4 MODE OF ACTION ............................................................................................. 8
1. D.5 STAGES OF DISASTER ....................................................................................... 9
2. ABOUT KHAPERKHEDA THERMAL POWER PLANT ................................................................. 10
(2. A) CLIMATIC DETAILS: ......................................................................................................................... 10
(2. B) KHAPERKHEDA TPS AT GLANCE ................................................................................................................ 10
3. DISASTER SCENARIOS IN TPS/ DISASTER PRONE AREAS ...................................................... 11
(3. A) AREAS PRONE TO DISASTER IN POWER SECTOR: ...................................................................... 11
(3.B) EVENTS CAUSES PLANT ORIENTED DISASTER .................................................................................... 11
4. DISASTER MANAGEMENT COMMITTEE ...................................................................... 13
(4.A) THE DISASTER MANAGEMENT COMMITTEE ................................................................................................ 13
(4.B) THE DISASTER MANAGEMENT TEAMS ....................................................................................................... 13
B.1 FIRE FIGHTING & RESCUE TEAM.............................................................................. 13
B.2 MEDICAL HELP TEAM........................................................................................... 14
B.3 COORDINATION TEAM ......................................................................................... 15
B.4 SECURITY & TRAFFIC CONTROL TEAM ...................................................................... 16
B.5 COMMUNICATION & LIAISON TEAM ......................................................................... 17
B.6 VEHICLE CONTROL TEAM ..................................................................................... 18
B.7 MAINTENANCE TEAM........................................................................................... 19
B.8 WELFARE TEAM ................................................................................................. 20
B.9 LOGISTIC TEAM ................................................................................................ 21
(4.C ) OTHER FUNCTIONS AND PERSONNEL ............................................................................................... 22
C.1 PLANT CONTROL AND SHUT DOWN....................................................................... 22
C.2 CHEMICAL LEAK STOPPAGE .................................................................................. 23
C.3 CRISIS CONTROL TEAM ........................................................................................ 23
5. OTHER REQUIREMENTS OF DISASTER MANAGEMENT ........................................................... 24
5.1 KEY PERSONNEL, DUTIES & RESPONSIBILITIES ................................................................................................ 24
5.1.1 SITE MAIN CONTROLLER (SMC) ........................................................................ 24
5.1.2 SITE INCIDENT CONTROLLER (SIC) .................................................................. 26
5.2 EMERGENCY CONTROL CENTRE (ECC) .................................................................................................. 27
5.3 ALARM SYSTEM .................................................................................................................................... 28
5.4 ASSEMBLY POINT.................................................................................................................................. 30
5.5 COMMUNICATION ............................................................................................................................... 31
5.5.1 COMMUNICATION TO PERSONNEL WITHIN THE PLANT ...................................................... 31

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5.5.2 EXTERNAL COMMUNICATION ................................................................................... 32

5.6 AWARENESS ............................................................................................................................................ 32
5.6.1 TRAINING ...................................................................................................... 32
5.6.2 MOCK-DRILLS ................................................................................................ 33
5.7 HAZARDOUS MATERIAL STORAGE................................................................................................................ 34
5.8 RISK ASSESSMENT ..................................................................................................................................... 40
5.9 FACILITIES AVAILABLE FOR HAZARD CONTROL & RISK MINIMISATION ................................................................. 41
5.9 A. LIST OF FIRE EXTINGUISHERS ................................................................................ 41
5.9 B SECURITY ......................................................................................................... 45
6. PROCEDURES ....................................................................................................... 47
6.1 PROCEDURES TO TESTS OF DMP.......................................................................................................... 47
6.2 PROCEDURE TO DECLARE EMERGENCY .......................................................................................................... 47
6.3 PROCEDURE TO MITIGATION / EMERGENCY RESPONSE ................................................................................... 48
6.4. PROCEDURE TO CALL OFF EMERGENCY & RETURNING TO NORMALCY ................................................................ 51
6.5 . PROCEDURE TO CONDUCT MOCK DRILL ....................................................................................................... 52
6.6 PROCEDURE TO UPDATE PLAN (DMP) ......................................................................................................... 54
6.7 PROCEDURE TO UPDATE ECC ...................................................................................................................... 55
6.8 NOTIFICATION PROCEDURE & COMMUNICATION SYSTEM ................................................................................ 55
7. LISTS................................................................................................................ 56
7.1 LIST OF KEY PERSONNEL ............................................................................................................................. 56
7.2 IDENTIFIED PERSONS.................................................................................................................................. 57
7.3 LIST OF FIRE FIGHTERS ( LIST TO BE UPDATED BY FIRE OFFICER) ......................................................................... 59
7.4 LIST OF FIRST AIDERS ( LIST TO BE UPDATED BY MEDICAL OFFICER)..................................................................... 60
7.5 LIST OF MEDICAL HELP TEAM ( LIST TO BE UPDATED BY MEDICAL OFFICER).......................................................... 60
7.6 LIST OF BLOOD DONORS ( LIST TO BE UPDATED BY MEDICAL OFFICER) ................................................................ 60
7.7 TRAINED FIRST AIDERS ( LIST TO BE UPDATED BY MEDICAL OFFICER) .................................................................. 60
7.8 TRAINED FIRE FIGHTING PERSONS ( LIST TO BE UPDATED BY FIRE OFFICER).......................................................... 61
7.9TRAINED SECURITY HELP PERSONS(LIST TO BE UPDATED BY SECURITY OFFICER) ..................................................... 61
7.10 SAFETY COMMITTEE MEMBERS ( LIST TO BE UPDATED BY SAFETY OFFICER) ........................................................ 61
7.11 VOLUNTEERS ( LIST TO BE UPDATED BY CONCERN SECTION HEAD) ................................................................... 64
7.12 LIST OF GOVT AUTHORITIES (MARG)(LIST TO BE UPDATED BY MEDICAL OFFICER).............................................. 64
7.13 LIST OF MEDICAL FACILITY NEAR BY ( LIST TO BE UPDATED BY MEDICAL OFFICER) ................................................ 64
8. PLANT INFORMATION ............................................................................................. 66
8.1 PLANT PROCESS ........................................................................................................................................ 66
8.2 INFORMATION ABOUT PLANT .................................................................................................................... 67
8.3 ORGANOGRAM ...................................................................................................... 68
8.4 LIST OF DMP TEAM LEADERS ( LIST TO BE UPDATED BY SAFETY OFFICER) ........................................................... 69
8.5 TELEPHONE LIST OF SITE/SECTIONS ( LIST TO BE UPDATED BY TELEPHONE OPERATOR) ......................................... 69
8.6 LIST OF HAZARDOUS MATERIAL STORAGE...................................................................................................... 71
8.7 LIST OF FACILITIES AVAILABLE FOR HAZARD CONTROL & RISK MINIMISATION ....................................................... 74
8.9 LIST OF ELECTRIC CONNECTION ISOLATORS FOR MAJOR AUXILIARIES .................................................................. 74
9. MATERIAL SAFETY DATA SHEET (MSDS) ........................................................... 75

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9.1 MATERIAL SAFETY DATA SHEET (MSDS) FOR CHLORINE (CL2) ............................................................ 75
9.2 MATERIAL SAFETY DATA SHEET (MSDS) OF AMMONIA ...................................................................... 77
9.3 MATERIAL SAFETY DATA SHEET (MSDS) FOR AMMONIA SOLUTION (NH4OH) :- ................................. 79
9.4 MATERIAL SAFETY DATA SHEET (MSDS) FOR OZONE (O3) ................................................................... 80
9.5 MATERIAL SAFETY DATA SHEET (MSDS) FOR HYDROGEN (H2)............................................................. 82
9.6 MATERIAL SAFETY DATA SHEET (MSDS) FOR HYDROCHLORIC ACID (HCL) ........................................... 83
9.7 MATERIAL SAFETY DATA SHEET (MSDS) FOR CAUSTIC SODA (NAOH) :- ................... 86
9.9 MATERIAL SAFETY DATA SHEET (MSDS) FOR LPG IN CYLINDERS .......................................................... 88
9.11 MATERIAL SAFETY DATA SHEET (MSDS) FOR ACETYLENE (C2H2) IN CYLINDERS ................................ 93
9.12 MATERIAL SAFETY DATA SHEET (MSDS) FOR CARBON MONOXIDE (CO) .......................................... 96
9.13 MATERIAL SAFETY DATA SHEET (MSDS) FOR FREON 22 ..................................................................... 99
9.14 MATERIAL SAFETY DATA SHEET (MSDS) FOR -R 32 ........................................................................... 101
10 .OTHER INFORMATION ...................................................................................105
1. LIST OF LOCAL AUTHORITIES(GRAMPANCHAYAT, NAGAR PALIKA, SARPANCH, POLICE STATION, .............................. 105
2. LIST OF SCHOOLS, DHARMASHALA, MANGALKARYALAYA, NEARBY ..................................................................... 106
3. LIST OF UNION(PRESIDENT & SECRETARY) ..................................................................................................... 107
4. LIST OF NGOS.......................................................................................................................................... 108
5. LIST OF RESCUE MATERIAL .........................................................................................108
6. EQUIPMENTS REQUIRED FOR DMP .............................................................................................................. 108
7. PLANT MAP MOVEMENT ROADS ................................................................................................................. 109
8. PLANT MAP (HAZARDOUS MATERIAL STORAGE & ASSEMBLY POINTS) ............................................................... 109
9. PLANT PROCESS AREA MAP & FACILITIES LOCATION MAP ................................................................................. 109
10. VULNERABILITY MAP ............................................................................................................................... 109
11. METEOROLOGICAL DATA ................................................................................................................. 112
12. ANNEXTURES ................................................................................................ 115
ANNEXTURE- 1 : PLANT CONTROL AND SHUT DOWN TEAM ..................................................115
ANNEXTURE -2 : PROCEDURE FOR STOPPING A CHLORINE LEAK ........................................................................ 115
ANNEXTURE -3: CHEMICAL LEAK STOPPAGE TEAM......................................................................................... 116
ANNEXTURE- 4 :MOCK DRILL RECORD .......................................................................................................... 117
ANNEXTURE -5: CRISIS CONTROL TEAM ........................................................................................................ 118
ANNEXTURE -6 : DOCUMENTS IN ECC ......................................................................................................... 119
ANNEXTURE -7 : FORMAT "RECORD OF TELEPHONE MESSAGES” ...................................................................... 119
ANNEXTURE -8: TELEPHONE DIRECTORY INTERNAL & EXTERNAL ........................................................... 119
ANNEXTURE – 09: HYDROGEN EMERGENCY PROCEDURE ....................................................................... 119
ANNEXTURE – 10: FUEL OIL, LUB OIL, TRANSFORMER OIL SPILLS AND GAS LEAKS EMERGENCY PROCEDURE ............. 120
ANNEXTURE – 11: EMERGENCY PROCEDURES FOR CHEMICAL SPILLAGE ................................................ 120
ANNEXTURE – 12: FIRE EMERGENCY PROCEDURE........................................................................................... 123
ANNEXTURE – 13:EXPLOSION EMERGENCY PROCEDURE .................................................................................. 123
ANNEXTURE –14: CYCLONE EMERGENCY PROCEDURES .......................................................................... 124
ANNEXTURE – 15:FLOOD EMERGENCY RESPONSE PROCEDURE .............................................................. 125
ANNEXTURE – 16: EARTHQUAKE EMERGENCY PROCEDURE .............................................................................. 126
ANNEXTURE – 17: TERRORIST THREATS/TERRORISM EMERGENCY PROCEDURE ................................................... 127

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ANNEXTURE – 18: BOMB THREATS EMERGENCY PROCEDURE .......................................................................... 128

ANNEXTURE – 19: NOTIFICATION PROCEDURE & COMMUNICATION SYSTEM ....................................................... 130
ANNEXTURE – 20.1: PLANT MAP 4 SETS X210 MW ...................................................................................... 132
ANNEXTURE – 20.2: PLANT MAP 1 SET X 500 MW ....................................................................................... 133

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Revision / Amendments of Record
Issue/Revision Number
Pag
Amen Sectio Old Reason for Reviewe Approv
e Date New Date
d No n No No Change d by ed by
No No
01.05 31.05. Safety

01 All All 02/00 03/00 Ref DCN No CE
.09 2012 Officer
50, 31.05 05.09. Safety

02 7 03/00 03/01 Quarterly review CE
51 .2012 2012 Officer
50,
27.06. Safety
03 7, 8 51, Quarterly review
52,55 2014 Officer
61
20.06. Addition of Safety
04 All 03/00 04/01
2015 500MW activities Officer

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1. BACKGROUND INFORMATION
(1. A) BASIS OF THE PLAN

For developing this Disaster management Plan (On Site Emergency Plan) following statute
and documents are taken into considerations.
i) The Factories Act 1948 Chapter IV Sect 41 B(4), The MFR1963 Rule 73O,73Q
ii) The Maharashtra Factories( Control of Major Industrial Hazards) Rules 2003Rule 12
Schedule XI under Rule 13(1) of the MSIHC Rules, 1989.
iii) The document titled “Crisis & Disaster Management Plan for Power Sector” of Ministry of
Power, Govt. of India.
iv) The CEA guidelines.
v) Elements of the On-site Emergency Plan under the APELL (Awareness and Preparedness
for Emergencies at Local Level) Handbook developed by the United Nations
Environment Programme.
vi) The Disaster Management Act 2005.
vii) The Chemical Accidents (Emergency Planning, Preparedness and Response) Rules,
1996
(1. B) METHODOLOGY TO PREPARE DMP

DMP is usually prepared in two parts; On-Site DMP and Off-Site DMP.
The On-Site DMP is administrated by the owner or occupier of the installation, guidelines
provided as per above A
The Off-Site DMP is administrated by the District Magistrate with the assistance of other
relevant authorities.
Aim of DMP is to identify, contain and ultimately bring the incident under control and
minimize the losses especially human loss.
(1. C)OBJECTIVE OF THE PLAN

1) To identify the type of consequences and related major accidents.
2) To control the incident and take actions as quickly as possible.
3) To ensure rescue operations and treatment of casualties.
4) To safeguard the employees and evacuate those belonging to non-essential services.
5) To minimize damages to the property and environment
6) To minimize lead time for normalization of production activities and civil life in around
the factory
7) To prevent nearby employees, plant, property, from getting affected.
8) To provide essential information and enquiry.
(1. D) DISASTER MANAGEMENT IN INDUSTRY

A Disaster is an event of nature or manmade that leads to sudden disruption of normal
life of society, causes damage to life and property to such an extent that normal social and
economic mechanism available are inadequate to restore normalcy.
To overcome or to control natural or industrial disaster a documented plan required. This

plan is called as DISASTER MANAGEMENT PLAN.
"Disaster management" according to Disaster Management Act 2005 means a continuous

and integrated process of planning, organising, coordinating and implementing measures
which are necessary or expedient for-

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(i) Prevention of danger or threat of any disaster;

(ii) Mitigation or reduction of risk of any disaster or its severity or consequences;
(iii) capacity-building;
(iv) Preparedness to deal with any disaster;
(v) Prompt response to any threatening disaster situation or disaster;
(vi) Assessing the severity or magnitude of effects of any disaster;
(vii) Evacuation, rescue and relief;
(viii) Rehabilitation and reconstruction;
1. D.1 DISASTER M ANAGEMENT ACTIVITY

basically comprises of three stages, i.e.
· Pre- Disaster Stage - this includes preventive checks and measures and mock drills.
· Emergency Stage - each person has an action card to define the individual
responsibilities and action expected from him on getting the
first information.
· Post-Disaster Stage - this includes action for safe termination of emergency,
resumption of normalcy and rehabilitation, essential information
and enquiry.
1. D.2 TYPES OF DISASTER

Disaster is an event which causes severe disruption to life of number of people or to the
project activities resulting in suffering and loss of life and property.
Disasters can be
I) Natural- earthquakes, , flood, cyclone, major fire, biological disaster, etc.
II) Manmade- war, riot, sabotage, terrorist activities, strike, etc.
III) Plant oriented- Due to design errors, operational defects, chemical changes,
failure of equipments, human errors etc. (in the plant area).
1.D.3 DEGREES OF DISASTER

Disaster can be classified in 3 types depending on its effects.
1. LO - Can cause injury, illness and equipments damage but not very serious and
quickly manageable.
2. MID - Critical situation, can cause serious injuries to personnel, serious illness
property and equipment damage.
3. HIGH - Catastrophic situation, major danger, can cause deaths, major widespread
illness, injuries, loss of major property and equipments. Immediately
uncontrollable.
The above contingencies will be declared by the Site Main Controller.

The following will be the mode of action during different degrees of disaster.
1. D.4 MODE OF ACTION

HIGH DISASTER- Catastrophic condition.
All employees to be evacuated. Local administration to be properly
informed and interacted.
MID DISASTER- All project activities to be stopped.
All employees to be in safe place. To be ready for High disaster
situation. Inform local administration.
LOW DISASTER- Activities in the affected area stopped.
To be ready for MID disaster condition.

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1. D.5 STAGES OF DISASTER

The duration of disaster's effect can be divided into following stages:
Warning:
The natural calamities which may lead to disasters e.g. flood, cyclone can often be
predicted. There are possibilities of disasters during local trouble, riot and war etc. also.
All facilities to encounter the disaster should be kept ready and employees in full alert.
Impact:
This is the time when the disaster actually strikes and very little can be done to counter
the situation. The impact period may be of few seconds (like explosion or earthquake) or
for days (like flood, fire etc.).
Rescue:
This is the most important stage which starts before the predicted disaster of just after
the impact. All available resources need to be immediately engaged in operation.
Relief:
This is a longer stage of work depending on the degree of disaster. Work during this
stage will need external help for medical, food, clothing and shelter.
Rehabilitation:
This is an important stage in terms of future planning. It includes rebuilding of damaged
properties, restart of project work, compensation etc.

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2. ABOUT KHAPERKHEDA THERMAL POWER PLANT
Khaperkheda Thermal Power Station is situated at 21 KM north of Nagpur. It is a power

generating station under Maharashtra State Power Generation Company Ltd.
Nagpur is situated on North Latitude – 210.09; East Longitude – 790.09 at 247 - 305
metres above sea level.
(2. A) CLIMATIC DETAILS:
Nagpur generally has a dry tropical weather. The climate of Nagpur follows a typical
seasonal monsoon weather pattern. The peak temperatures are usually reached in May/June
and can be as high as 48oC. The onset of monsoon is usually from July and the season
extends up to September, with monsoon peaking during July and August. After monsoons,
the average temperature varies between 27oC and approx 6 to 7oC right through December
and January
Humidity 70% to 20%
Wind blows with maximum ( 22 Km / Hrs or higher) in the month of February and on set
of monsoon season i.e. in end of May and first week of June. This is due to generating low
pressure area in this region. Rest of time wind speed is below 5 to 7 Km./Hrs.
A maximum wind speed of 114 km/hr was recorded on 22nd May, 1970.
Forest Cover is 28% i.e. 2818 sq. kmrs (for Nagpur District)
(2. B) KHAPERKHEDA TPS AT GLANCE
1) Installed capacity 210 MW x 4 sets + 500 MW x 1 set. Total 1340 MW

2) Land acquired 485 hectors (210 MW)
60 hectors (500 MW)
3) Location 21 Kms. From Nagpur city. Off Chhindwada Road
on Dahegaon – Kamptee Road MSL 291.8 Meters.
4) Approach to P.S. a) State High way Nagpur – Chhindwada via Dahegaon.

b) National High way Nagpur – Jabalpur Via kamptee.
c) S.E. Railways –Narrow gauge–Nagpur–Saoner route.
5) Date of commissioning Unit No. I 26/03/1989 210MW

Unit No. II 08/01/1990 210MW
Unit No. III 31/05/2000 210MW
Unit No. IV 07/01/2001 210MW
Unit No. V 16/04/2013 500MW
6) Water Source From Pench reservoir through Pond No. 3 of Koradi TPS gravity pipe
line.(1600 mm dia & 22 Km. long)
7) Water requirement 210 MW X 4 Sets :- 65,000 to 70,000 M³ per day.

500 MW X 1 Sets :- 35,000 to 40,000 M³ per day.
8) Cooling System Cooling towers.
Natural Draft Cooling Tower for 500 MW

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9) Coal source Rail fed power station

WCL - Saoner, Dumri khurd.
MCL - BOCM, LOCM, Mahanadi.
SECL - Old / New Kusmunda, Junnardeo.
10) Coal requirement 210 MW X 4 Sets :- 12,000 – 14,000 T per day.

500 MW X 1 Sets :- 93,000 – 96,000 T per day.
11) Ash disposal -- Lean phase system at Waregaon - 7 Km. away from Power Station.
-- Ash bund area under submergence -282 Hectors.
-- Total ash holding capacity - 6.1 MM³
-- 210 MW X 4 Sets :- Daily ash deposit - @ 4500T
500 MW X 1 Sets :- Daily ash deposit - @ 3500T
-- Water through waste weir is recycled & used.
12) Power Evacuation. -- Connected to Maharashtra State Grid

210 MW X 4 Sets : through double circuit 220 KV lines.
500 MW X 1 Sets : through double circuit 400 KV lines.
Feeders (10 Nos.) – Kanhan, Kalameshwar, Bhandara, Ambazari – I & II,

Bhugaon I & II, Koradi, Kaulewada I & II.
3. DISASTER SCENARIOS IN TPS/ DISASTER PRONE AREAS

DISASTERS RESULTS IN DISRUPTION IN POWER GENERATION DUE TO:
I) Natural- earthquakes, flood, cyclone, major fire, biological disaster, etc.
II) Manmade- war, riot, sabotage, terrorist activities, strike, etc.
III) Plant oriented- Due to design errors, operational defects, chemical changes,
failure of equipments, human errors etc. (in the plant area).
(3. A) AREAS PRONE TO DISASTER IN POWER SECTOR:

Large power station using large quantities of steam at very high temperatures and
pressure produced due to combustion of several hundred tones of fuel per hour. Mal-
operation of any single system can lead to possible loss of life and property.
(3.B) EVENTS CAUSES PLANT ORIENTED DISASTER

I)EXPLOSION/IMPLOSION IN
1) Furnace
2) Mill fire/explosion
3) Coal bunkers
4) Electrostatic precipitators
5) Duct works
6) Turbine
7) Hydrogen Generation Plant
8) Hydrogen in Generator
9) Hydrogen cylinders at Manifold
ii) Fire in thermal power station:

1) Cable gallery
2) Switch gear rooms
3) Air pre-heaters

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4) Transformers
5) Fuel oil storage tanks
6) Fuel oil rakes
7) Coal conveyers
8) Coal storage
9) Coal rakes
iii)Release of Gases / Chemicals:

a) Chlorine ( Water Treatment Plant I / II)
b) Ammonia (Ammonia dozing manifold At unit1, Unit 2, Unit 3, Unit 4)
c) Ozone ( Ozone plant at Unit 4 side, 500 MW near CW pump House )
d) Acid & Alkali storage tanks in WTP I / II
iv)Sources of Chemical Disasters

Chemical accidents may originate in:
I) Manufacture and formulation installations including process operations; maintenance

and disposal.
II) Handling and storage
III) Transportation (road, rail, air, water, and pipelines).
v)Structural failures
1. Due to explosion
2. After effects of major fire
3. Due to weakening, corrosion
4. Due to earthquake
vi)Radio Active Materials

Radiation due to radio-active materials, used in instruments, during store
handling & pre-disposal stage

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4. DISASTER MANAGEMENT COMMITTEE
Disaster Management Committee will work under the Chairmanship of the Dy. Chief
Engineer(Admin) for exercising and implementing the On Site Emergency Plan (DMP).
Member Secretary of this committee would be the Safety Officer. Other committee members
will be the team leaders of various activities identified under this plan.
(4.A) THE DISASTER MANAGEMENT COMMITTEE

The Disaster Management Committee will
1. Provide required infrastructure,
2. provide training,
3. Maintain & monitor decided activities under DMP,
4. maintain all required documentation,
5. Conduct Mock Drills,
6. Carryout testing & updating the plan.
(4.B) THE DISASTER MANAGEMENT TEAMS

1. Fire Fighting & rescue team
2. Medical help team
3. Coordination team St I, St II
4. Security & Traffic control team
5. Communication & Liaison team
6. Vehicle control team
7. Maintenance team St I, St II
8. Welfare team
9. Logistic team
The Disaster Management Teams, team Leader, responsibilities & duties
The nature of responsibilities are based on their day to day activity, and duties are
based on Pre-During-Post emergency activities.
B.1 FIRE FIGHTING & RESCUE TEAM
Team Leader
Fire Officer
Safety Officer
Team Members
Jr Fire Officer
Driver Cum Fire Engine Operator
Fire Fighters
Trained Workers for Fire fighting
Trained rescue team
B.1.1 Responsibilities & duties
Pre Disaster Stage

1. Ensure availability of required equipment, vehicles, PPEs.
2. Prepare specialized groups for Fire fighting, chemical release, rescue, etc.

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3. Keep data of contact numbers of team members & display at easy accessible location.
4. Keep data of contact numbers of key persons, fire tender services, & display at easy
accessible location
5. Keep ready all reporting forms & proforms.
6. Keep ready list of equipment, life saving equipment, suppliers, & service providers,
etc.
7. Keep ready information regarding storage, handling of hazardous materials.
8. Display plant map, especially for hydrant lines, deluge valves, roads, etc.
9. Provide training to the staff.
10. Maintain & Monitoring of Fire extinguisher, deluge valves, emulsifier system, fire
tenders, sprinkler system, detection system, etc.
11. Record keeping of all activities.
12. Conduct fire mock drills, active participation in DMP mock drill.
13. Fire fighting team shall be all the time ready for attending any type of fire-call.
Emergency Stage
14. The Team/ Crew shall reach the incident spot immediately ensuring the tender is fully
equipped , after receiving fire call from shift in-charge
15. As soon the team reaches the spot, the leader shall assess the nature of fire, if the
fire is due to electricity ensure closure of electrical supply or ask to shut off the
electrical supply to the local operator.
16. Use necessary fire extinguishing media & control/extinguish the fire.
17. Rescue the persons engulfed under fire
18. Ask for help from nearby fire stations.
19. Inform to the site incident controller, shift in-charge, safety officer that the fire is
under control.
20. Ensure that fire is fully & completely extinguished
21. Report to the site incident controller, shift in-charge, safety officer after completely
fire extinguished.
Post Disaster Stage

23. Prepare detailed report.
24. Prepare List of Consumed fire extinguishers, water & other extinguishing media.
25. Activities of staff.
26. Possible root cause
27. Observations, hurdles, problems during activity.
28. Corrective & preventive measures to be suggested for improvement.
29. Future planning.
30. Submit the report to Disaster management committee.
B.2 MEDICAL H ELP TEAM

Team Leader
Medical Supdt
Team Members
Asstt. Medical Officer
Dispensary Staff
Trained First aiders

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Pre Disaster Stage
1. Ensure that all necessary first aid boxes, medicines, life saving equipments, antitodes,
are adequately available.
2. Ensure Readiness of ambulance, first aiders, medical team, first aid equipments,
medicines required for mitigation at site & at hospital.
4. Keep data of contact numbers of key persons, medical help centers, & display at easy
accessible location
5. Keep data of blood donors & blood banks, NGOs, nearby Volunteer medical
practitioners, to provide facilities in emergency.
6. Keep ready all reporting forms & proformas.
7. Keep ready information regarding storage, handling of hazardous materials.
8. Display plant map, especially for roads, assembly point, hazard free zones etc.
10. Maintain & Monitoring ambulance, first aiders, medical team, first aid equipments,
medicines required for mitigation at site & at hospital
12. Conduct mock drills/ active participation in mock drills & DMP mock drills.
13. Medical help team shall be all the time ready for attending any type of injury calls.
Emergency Stage
14. Assess injuries & Provide first aid to the casualties
15. Send the casualties to the nearby Govt hospitals, private & nominated hospitals, &
ensure that medical help is provided to them.
16. Make available blood from blood banks.
17. Report the SIC & SMC regarding flow and nature of casualties.
18. Maintaining records of affected persons, treatment given to them etc.
Post Disaster Stage

19. Follow up the treatment, improvement, fitness & joining,
22. Prepare List of Consumed fire extinguishers, water & other extinguishing media.
B.3 COORDINATION TEAM

Team Leader (St I)
Dy Chief Engineer I
Team Members
Dy Chief Engineer II
Safety Officer
Operation services I
Purchase Dept
Finance & accounts

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Team Leader (St II)

Dy Chief Engineer II
Team Members
Dy Chief Engineer I
Safety Officer
Operation services II
Purchase Dept
Finance & accounts
B.3.1Responsibilities & duties

Pre Disaster Stage
1. Keep in touch with the Disaster management committee
2. Participate in mock drills
3. Conduct meeting for verification of activities of other teams, in coordination with DM
committee chairman.
4. Keep ready all required data for coordination.
Emergency Stage
5. Assist the Site Main Controller, act as site main control if SMC is not at station, not in
ECC
6. Coordinate with emergency control centre, & provide all necessary information.
7. Guide Site Incident Controller, Operation Incharge regarding closure of production.
8. Keep Contact with the team leaders & coordinate them to work properly.
9. Coordinate & cooperate the teams for mitigation in pre-decided & scheduled task.
10. Guide for safety of workforce during activities.
11. If required arrange for extra manpower, material, finance, to keep the mitigation
work smoothly.
12. Liaison with the external agencies called to assist in mitigation.
13. Immediate Record keeping of all activities.
Post Disaster Stage

15. Verify the activities carried out during emergency are as predefined.
B.4 SECURITY & T RAFFIC CONTROL TEAM

Team Leader
Sr Manager Security
Team Members
Dy Manager Security
Watchmen

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Private security incharge

Volunteers
Pre Disaster Stage

1. Ensure availability of required equipments, vehicles, PPEs.
2. Prepare specialized groups for security, traffic control, barricading the area, rescue,
assembly point discipline, head counting etc.
3. Define Monitoring of Gates, entry & exit of vehicles,
4. Prepare required forms & proformas for activities
6. Conduct security mock drills, active participation in DMP mock drill.
7. Display plant map, especially for hazardous location, roads, assembly point, hazard free
zones etc.
accessible location
Emergency Stage
10. Security personals & nominated volunteers shall barricade the site with human chain or
the suitable & available equipments.
11. All gates shall be closed for no entry except those are permitted and authorized. Entry
of each person & vehicle shall be noted without any time delay
12. Plan & guide the vehicle movement to avoid rush/traffic jam. Maintain different traffic
ways for up & down. Follow merry- go round system. Provide priority to the emergency
vehicles eq: fire tender, ambulance etc.
13. Ensure no theft during emergencies.
14. Maintain discipline & peace at assembly point
15. Assist time keeper for head count.
Post Disaster Stage
17. Verify the activities carried out during emergency are as predecided
B.5 COMMUNICATION & LIAISON TEAM

Team Leader
Dy Chief Engineer (Administration)
Team Members
Executive Engineer Purchase
Workers representatives
Time Office messenger

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Pre Disaster Stage

1. Keep in touch with the Disaster management committee
2. Participate in mock drills
3. Conduct meeting for verification of activities of other teams, in coordination with DM
committee chairman.
4. Keep ready all required data for coordination.
5. Keep ready list of media persons, unions, NGOs, Gos, as required.
Emergency Stage
6. Keep in contact with SMC
7. Provide information to media, political leaders.
8. Provide information to the mob outside, relatives, & general people.
9. Ask help/assistance from unions, NGOs, Gos, as required.
10. In case of failure of electronic network communication, send messengers to inform
concerned authorities.
11. Inform to the relatives of injured & dead persons.
Post Emergency stage

B.6 VEHICLE CONTROL TEAM

Team Leader
Executive Engineer CHP
Team Members
Assitt Engineer Vehicle Maint.
Vehicle Mint Staff
4.6.1 Responsibilities & duties

Pre Emergency stage
1. Keep ready all departmental vehicles and list of vehicle providing agencies.
2. Keep ready list of vehicle provider, nearest to power station.
3. Keep list of skilled & cool temperament drivers.
4. Display plant map, especially for hazardous location, roads, assembly point, hazard free
zones etc.
accessible location
7. Train the ream members for disaster management plan.

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Emergency Stage
8. Depute skilled & cool temperament drivers as required
9. Guide & deploy well maintained vehicles on emergency
10. Keep record of the provided & deputed vehicles. Provide identification to vehicles used
for mitigation.
11. Keep contact with emergency Control Centre & provide information of vehicles deployed
12. Control the timings of drivers, so that not to get over exertion.
13. Record all the activities and vehicle deployed, in & out time, location, duty hours of
drivers.
Post Emergency stage

14. Payments to all service providers.
B.7 MAINTENANCE TEAM

Team Leader (St I)
Supdt Engineer Maint I
Team Members
Executive Engineer Elect Maint (EM)
Executive Engineer Boiler Maint (BM)
Executive Engineer Turbine Maint (TM)
Executive Engineer Testing Instrumentation & Control (TIC)
Executive Engineer CHP
Respective Team of Trained & skilled engineers& workers
Team Leader (St II)

Supdt Engineer Maint II
Team Members
Executive Engineer Elect Maint (EM II )
Executive Engineer Boiler Maint (BM II)
Executive Engineer Turbine Maint (TM II)
Executive Engineer Testing Instrumentation & Control (TIC II)
Executive Engineer CHP II
Respective Team of Trained & skilled engineers& workers
Mutual aid may be called to mitigation and early restart the plant.

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Pre disaster stage

1. Keep ready list of Team members
accessible location
4. Active participation in DMP mock drill.
5. Prepare specialized groups electrical, mechanical teams, etc.
6. Ensure availability of required equipments, PPEs.
7. Keep ready Temporary Lighting system eq: flood lamps, extension boards, fans,
exhaust fans, Torches, High beam Torches, Generators etc
8. Keep skilled & trained team ready to assist maintenance of equipments& machinery
damaged due to disaster.
9. Keep ready gas cutting sets, welding machines & cables, hack saw blades, scaffolds,
rope, ladders, crane & lifting equipments ready and in healthy condition.
10. Keep ready all required equipments & machinery & skilled workforce to resume
normalcy of the plant Ensure readiness of diesel generating sets under daily checking,
keep ready list of generator providing agencies.
12. Conduct mock drills, active participation in DMP mock drill.
Emergency stage
13. Report to the site.
14. Work in coordination with SIC,
15. Ensure Electric supply of all required areas is cut off.
16. Provide Temporary Lighting on top priority at required areas
17. Concentrate on the affected equipments, plant & machinery and immediate action to
reinstate the system.
Post disaster stage

24. Update the activities
B.8 WELFARE TEAM

Team Leader
Dy CE Administration
Team Members
Welfare officer
Asstt welfare officer
Volunteers

Pre Disaster Stage

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1. Keep ready list of volunteers & NGOs

2. Keep ready list Readymade food providers, rest rooms (schools, mangal karyalays,
club, guest houses, etc)
accessible location
5. Active participation in DMP mock drill.
Emergency stage
6. Inform the facilities to be ready.
7. Provide all required facilities at assembly point & rest rooms.
8. Provide tea, snacks, food & drinking water to the work force, volunteers engaged in
normalcy activity.
9. Provide clothings to the affected persons.
10. Provide facility of vehicle to shift/ transport casualties & affected persons to the rest
rooms
11. Maintaining records of persons shifted for shelter, persons provided with clothing &
blankets, etc.
Post disaster stage

12. Follow up the treatment, improvement, fitness & joining in consultation with medical
team,
19. Update the activities
B.9 LOGISTIC TEAM

Team Leader
Dy Exe. Engineer Civil
Team Members
Asstt Engineer Civil
Civil Maint Staff

Pre Disaster Stage
1. List out required equipments & ensure availability, eq; breathing apparatus, statures,
kudali, phawdas, sabbals, ghamelas & vehicles, PPEs.
2. Prepare specialized groups for Fire fighting, chemical release, rescue, etc.
accessible location
6. Conduct rescue mock drills, active participation in DMP mock drill.

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Emergency stage
7. Report to the site.
8. Work in coordination with SIC, fire fighters & medical team
9. Search the persons those who are trapped under debris, fire, and rescue them safely
from disaster site,
10. Shift casualties to safe zone & hand over to medical help team
11. Record the casualty & location
12. Mark searched & rescued area
Post Disaster Stage

14. Activities of staff.
(4. C ) OTHER FUNCTIONS AND PERSONNEL
Following functions are required to be carried out in order to effectively tackle

the emergency.
C.1 Plant control/shut down

C.2 Chemical leak stoppage (Chlorine/Ammonia/ozone)
C.3 Crisis Control team
C.4 Other requirements of Disaster Management
C.1 PLANT CONTROL AND SHUT DOWN
Team: Each unit ( each unit, WTP, CHP) has a team to control the operations in the area
or shut it down as per the advice of the SMC. The shift In-Charge of the unit available at the
time of emergency would head the team. Typical composition of the team is given in unit-
wise is given in ANNEXURE 1.
C.1.1Functions
[ A] Team Leader
(1) Know and understand Safe Operating Procedures (SOPs) for controlling or shutting
down various operations.
(2) Ensure that the team members also know and understand the SOPs.
(3) Guide the team in efficiently controlling/shutting down the operations in consultation
with the SMC.
(4) Keep the contact details of all the team members handy especially for any specific
operation vis-à-vis person so that they can be contacted when not on duty.
(5) Ensure that sufficient number of different categories of skilled personnel is available
and used for the purpose.
(6) Ensure own safety and the safety of team members.

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B] Team Members
(1) Know, understand and follow SOPs in doing the work under the direction of the leader.
(2) Ensure that each team member can be contacted in case of emergency.
C.2 CHEMICAL LEAK STOPPAGE

(Chlorine/Ammonia/ozone)
The possible scenario, which may lead to an emergency.
a) Leakage of Chlorine, either from a tonner or a manifold,

b) Leakage of Ammonia, either from a cylinder or a manifold,
c) Leakage of Ozone, either from a Generating unit or a manifold,
As soon as it becomes evident that there is a leakage of such gases (either in a

tonner, cylinder, manifold or generating unit), the leak stoppage team, as recognized in the
plant, would swing into action on the instructions from Site Incident Controller and try to
stop the leak using the Gas Leak Stoppage Kit. The procedure for stopping the Chlorine leak
is given in ANNEXURE 2.
C.2.1Functions
[A] Team Leader

The shift In-Charge of WTP is the team leader. The details of team are given in ANNEXURE
3. This function is considered very crucial and therefore frequency of the Chemical release
stoppage Mock-drill would be carried out once a month in each plant area by this team and
the records to be maintained in the pro-forma given in ANNEXURE 4.
(1) Prepare team for different types of Chemical leakage/release

(2) Provide required equipments & PPEs
(3) Provide Training the team members.
(4) Conduct mock trials
(5) Contact SIC on site, identify the source and cause and assess extent of leakage.
(6) Put the SOP in action.
(7) Plan Stoppage.
(8) Guide the team members in stopping the leak.
(9) If leak cannot be stopped, arrange to neutralize the leaking Chlorine as mentioned in
the SOP.
(10) Ensure that the team members are proficient in the SOP.
(11) Ensure safety of team members and own safety.
(12) Ensure that the team members can be contacted if not on duty.
(13) Ensure that the appropriate personal protective equipment (PPE) and the Chlorine leak
stoppage kit are well maintained and are easily accessible.
[B]Team Members
(1) Know, understand, practice and be proficient in SOP for stopping Chlorine leakage
(including the use of Chlorine Leak Repair Kit).
(2) Stop Chlorine Leak as per the SOP and under the guidance of the Team Leader.
(3) Ensure that each member can be contacted easily during emergency.
(4) Participate in drills of Chlorine leak stoppages as and when required.
C.3 CRISIS CONTROL TEAM

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KhTPS plant installation is categorized under seismic zone and while installing all
considerations has been taken in seismic point of view. Natural calamities are like
Earthquake, Floods, Storms and Cyclone.
The chances of Earthquake, Storms, Cyclone and Flood are rare but after heavy rain
fall the water may enter into the minus level plant such as Reject belts, Hoppers of wagon
tippler, BOBR, TT2 etc.
The mainly crisis are Strike, Bomb Threat and Terrorist attack and the chances are
rare. The disaster management plan should be able to respond quickly and effectively to
such unexpected events and situation by the Disaster Management Team.
C.3.1Functions
[A] Team Leader
The Dy Chief Engineer(Admin) is the team leader. Under his guidance team is formed i.e.
given in Annexure 5.
i) Train the team members to handle the crisis in natural calamities.

ii) Allocate the team members to different locations and brief them about the procedure.
[B]Team Members
i) Know, understand and follow the operation process to evacuate the peoples from the
place.
ii) Always consult and take guidance from Leader.
iii) Brought out the injured peoples to the nearest Assembly Point.
5. OTHER REQUIREMENTS OF DISASTER MANAGEMENT
5.1 KEY PERSONNEL, DUTIES & RESPONSIBILITIES
The effective emergency plan requires that, in the event of an accident nominated
individuals are given specific responsibilities, often separate from their day-to-day activities.
The two principle people are
(I) Site Main Controller (SMC)

(II) Site Incident Controller (SIC).
5.1.1 SITE MAIN CONTROLLER (SMC)

i) Identified Persons
The Chief Engineer is the SMC.
Normally, the CE is available in the general shift. On the receipt of Emergency call
from SIC, the CE assume the position of SMC and take the charge of ECC.

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The alternate SMC would be as under: -
Alternate SMC I. Dy Chief Engineer . I ( for 210 MW)
I. Dy Chief Engineer . II ( for 500 MW)
The contact details of the above key persons are given in 7.1 KEY PERSONS
ii)Responsibilities/Duties of the Site Main Controller (SMC)
a) The SMC has an overall responsibility for directing operations and calling outside help.
Depending on the location of the emergency and the prevailing wind direction, the SMC
(or his Alternate) will decide and use one of the Emergency Control Center for handling
and controlling the emergency. He will then proceed to that ECC and take overall
control of the emergency. He has the authority to take any decision for the whole
Plants. Specific responsibilities/duties of the SMC are as under:
b) After assuming the position as SMC, he would get the information from the SIC and
take overall control of the emergency.
c) On consultation with the SIC and his assessment, decide whether major emergency
exists or likely to take place, necessity to alert the public emergency services, inform
authorities and nearby population, etc.
d) After communication with SIC, SMC finds it is beyond the control, then he declares an
Emergency by actuating a siren.
e) Ensure that the key personnel are called in.
f) Exercise direct operational control of those parts of the plants outside the affected area.
g) Continually review and assess existing and possible developments to determine most
probable course of events and effective methods to deal with them.
h) Direct safe shut down and evacuation of plants in consultation with the Site Incident
Controller and other key personnel.
i) Ensure that casualties are receiving adequate attention. Arrange for hospitalization of
victims and additional help if required. Ensure that their relatives are advised.
j) If necessary inform and liaise with Chiefs of Fire and Police Services, District Emergency
Authority and with the Office of Addl. Director Industrial Safety and Health.
k) In the event of prolonged emergencies involving risk to outside areas due to wind
blown gas (such as Chlorine)
l) Ensure accounting of personnel and rescue of missing ones.
m) Arrange control of traffic movement within the Plants.

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n) Arrange maintenance of chronological record of the emergency.
o) Issue authorised statements to the press or the media. Also inform senior officers.
p) Control rehabilitation of affected area after the emergency.
q) Ensure everything is under control and declare normalcy through blowing siren.
5.1.2 SITE INCIDENT CONTROLLER (SIC)
i) Identified Persons
Superintending Engineers (For OPR),
Superintending Engineer (For CHP)
Executive Chemists (For WTP)
Normally, are available at general shift.
Assistant Site incident controller
The Executive Engineers (PCR), Asstt/Junior Engineers (CHP) and Sr. Chemists (WTP )
are Shift In-charge of their respective units. In principle, the Executive Engineers,
Asstt/Junior Engineers (CHP) and Sr. Chemists (WTP ) of the affected respected unit/area, is
the SIC round the clock for any emergency. As soon as the concern/respective
Superintending Engineers (OPR), Superintending Engineer (CHP) and Executive Chemists
(WTP ) reaches to the incident, they will assumes the positions of SIC. Their contact details
are given in 7.2 IDENTIFIED PERSONS
ii) Duties and Responsibilities of the Site Incident Controller
a) Primary duty of the Site Incident Controller (SIC) is to take charge of the scene of
emergency. In the initial stages, he may be required to take decisions regarding
operation of the plant as to whether they should continue their operations or shut down
the plant and to take decisions to control the incident. The main responsibilities of the
Site Incident Controller are as under:
b) As soon as he assumes the position as SIC, after noticing an emergency situation or
after receiving such information, he should assess the scale of emergency and
immediately activate the on-site emergency plan and inform to SMC and ECC.
c) His main function is to direct all operations at the scene of emergency, i.e.
d) Search for trapped persons or casualties, if any. Prepare for rescue promptly.
e) Initiate rescue operations till the rescue team arrive and take over the rescue work.
f) Evacuation of non-essential persons to the allocated Assembly Point.
g) Try to avoid secondary damages.
h) Set up communication network with the Emergency Control Centre. [Using Intercom or
walkie-talkie].

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i) Direct all operations within the affected area with following priorities –
j) Secure safety of personnel. Give priority to saving life and preventing further injury.
k) Minimise damage to plant, property and the environment.
l) Minimise loss of material.
m) Give advice and information as required by the emergency responders or emergency
services.
n) Keep the SMC informed of the developments.
o) Preserve evidences, which would be necessary for subsequent investigation to find out
the immediate and underlying causes of the emergency and for concluding preventive
measures.
p) Possible risk scenario is the release of chlorine gas (refer 5.8). When there is such a
leakage, he would direct the technical team for stopping the leakage and guide them.
He would also ensure that he himself and the technical team use necessary personal
protective equipment prior to entering the danger zone.
q) He will direct the rescue team.
r) He will assess whether the leakage / explosion can be stopped or controlled and consult
the Site Main Controller.
5.2 EMERGENCY CONTROL CENTRE (ECC)

ECC is a place from where SMC would provide direction/guidance and co-ordinate various
activities to effectively handle the emergency situation. The SMC would take charge of the
ECC during emergency. All the key personnel (except SIC and the persons he would need)
would assemble in ECC after knowing that the on-site emergency has been notified /
declared. While selecting the location of ECC, due care has been taken that it should not fall
under any risk.
a) LOCATIONS
The ECC is located at Security office at Administrative bldg (SAUDAMINI) marked as "[E]" on
the Plants layout. This is shown in the layout given in Plant Map.
ECC has been equipped with same equipment/facilities given in below –
b) EQUIPMENT/FACILITIES IN ECC
1. Two big tables, chairs & storing cabinets
2. Copies of documents will present as per ANNEXURE 6.
3. Two direct P&T/external telephone lines with one line dedicated to only outgoing calls
and the other for incoming calls. The telephone number for receiving only incoming
calls is 6666 & outgoing calls 5555.
4. Wireless communication equipment connecting to all the other plants of Kpkd TPS.

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5. List of Important telephone numbers (Police, District Collector, Addl Director, Industrial
Safety & Health, Hospitals, etc.) painted on a board and displayed conspicuously in the
ECC.
6. A set of latest Nagpur Telephone Directory.
7. List of key personnel, giving contact details such as their residential addresses,
telephone numbers, etc.
8. Two intercom lines along with internal telephone directory.
9. Nominal roll of employees.
10. Note pads, pencils, erasers and other stationery for sending or recording messages
giving format (refer ANNEXURE 7) for recording telephone messages.
11. Copies of On-Site and Off-Site Emergency Plans.
12. Map of plant layout, showing hazardous material storage location, vehicle movement ,
13. Torches, umbrellas, raincoats, PPE etc.
14. Tape recorder/ latest facility to record the voice
c) PERSONNEL REQUIRED IN ECC
Site Main Controller (SMC) or his Alternate
Assistant to SMC/ Coordination Team
Telephone Attendant
Three Messengers( time office attendant)
All required documents & equipments will be controlled, maintained & monitored by Safety
Officer.
5.3 ALARM SYSTEM

a) Locations for Activating
Raising the alarm is the first step in the implementation of On-Site Emergency Plan (DMP).
Any employee noticing an unusual event can raise or at least alert someone who can then
raise the alarm. This procedure has the advantage of permitting the earliest possible warning
of any potential abnormal situation. In the presence of good accident preparedness, any
employee of the facility or operator should know what initial step to take (e.g., by activating
the break glass type manual fire alarm). For raising an alarm, any person noticing will
contact SIC/ Fire station by;
b) Public Address System

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Horns, Sirens
Telephone message/ fax messenger/ hotlines
Sending message through a messenger, or fax machine or contacting over cellular phone/
pager
While giving the message, the person should:
Identify oneself
State briefly the type of emergency i.e. whether fire, explosion or a toxic release.
Give the location of the incident
Estimate the severity of the incident and return to the area of incident and await instructions
from Shift In-Charge.
Check wind direction and move crosswind of the incident site.
Conduct a preliminary check and try to identify the cause, type and location of the accident.
Standby to render all possible assistance.
c) Locations of Sirens and their Operations
They would be audible at every location of the Plants including inside the buildings.
These sirens are also connected to a battery set so that whenever there is a power failure
linkage it can work on battery. The switching to battery in case of power failure is
automatic.
d) Type of the Siren
The following alarm system may be considered which will easily identified the chlorine
leakage/ fire at plant.
1. Chemical (Chlorine/ammonia/Ozone) Leakage Alert: -
The siren to indicate that the on-site emergency has been declared would be that of wailing
sound (high pitch followed by low pitch frequently for 1 minute.
2. Fire/ Explosion Alert: -
The siren blow would be a wailing sound, short and intermittent siren (25 second on, 5
second off, 3 times).
3. All Clear Siren: -

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When the emergency situation has been brought under control and the area is safe an "ALL-
CLEAR” siren would be activated by the SMC from the ECC in consultation with the SIC. It
would be a continuous sound of the same pitch for 1 minute.
e) Actuation of Emergency Siren
After hearing an alarm or information from any employee about an incident in the unit/
plant, SIC would rush to incident immediately. SIC, if found it is beyond his control, informs
the SMC. In-betweens, SMC would make contact with the attendant of ECC. In turn
attendant in the ECC would inform to the identified members of ECC. After that SMC would
rush to ECC. After assuming the position of SMC in ECC, directs to make contact with other
senior members in the plant. SMC will make communication set up with SIC about the
situation. After communication with SIC, SMC founds it is beyond the control then he
declares an Emergency by actuating a siren.
f) Sequence of Actions after Declaration of Emergency
After declaration of an emergency, SMC instructs to inform the outside Fire Brigade, Hospital
and Police Stations and also for help from other GO and NGO‟s.
The SMC contacts SIC on intercom to know about the incident.
The maintenance team approaches the incident site to attend emergency.
The other plant In-charges occupy their office to receive instructions from SMC.
The other teams carry out their respective functions.
SMC is in continuous interaction with the SIC and other senior persons in each site.
SIC in consultation with the other team leaders informs the situation to SMC.
SMC in consultation with the SIC and their juniors decides whether to stop process or not.
5.4 ASSEMBLY POINT
All non-essential persons within the plant area (who are not assigned any duty during
emergency) would evacuate their work area and report to one specific Assembly Point. The
Assembly Point will be selected by the SMC. The decision to evacuate the work area by the
non-essential persons will be taken by the SMC after getting feedback from the Site Incident
Controller.
a) Location
There are 6 assembly points AP-1, AP-2, AP-3 and AP-4 (for 210 MW x 4sets) A5,A6 (for 500
MW x 1set in the plant. These points are indicated in the Plant Map.
Assembly Point No. 1 = AP1 = Near the Time office 210 sets.
Assembly Point No. 2 = AP2 = Near SE CHP Office (Open Ground)

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Assembly Point No. 3 = AP3 = Near ESP Unit 4 open end

Assembly Point No. 4 = AP4 =For WTP near Salt Lagoon
Assembly Point No. 5 = AP5 =For O&M staff for 500MW near Canteen
Assembly Point No. 6 = AP6 = Near SE CHP Office 500MW (Open Ground towards WTP)
While selecting the Assembly Point ensure that all persons within the units do not have to
approach the affected area to reach the point or any assembly point do not lies in the path of
wind blowing leaked Chlorine. Only one Assembly Point should be used for easy head-count
and quick accounting for missing persons, if any.
5.5 COMMUNICATION
a)Persons
The ECC Operator is to be identified by SMC.
b) Responsibilities
1. To receive all incoming calls, note them down in the format "Record of Telephone
Messages” as given in Annexure 7.
2. To telephonically contact SMC and other persons as required by the Plants Incident
Controller or SMC.
3. To ensure that communication system is always kept in good working condition.
4. To keep records of all incoming and outgoing calls.
COMMUNICATION OF EMERGENCY
Communication is considered to be very crucial to effectively handle the emergency.
5.5.1 COMMUNICATION TO PERSONNEL WITHIN THE PLANT

As the emergency develops, it become necessary to communicate with personnel dispersed
over the Plants such as personnel on the affected area, personnel in other threatened area,
personnel in other areas throughout the Plants and most important the key personnel.
One-way to communicate is by i) sounding the siren ii) declaration of emergency and iii)
implementation of emergency procedures. Siren should be backed with DC power.
Another means to give specific instructions using intercoms. However, direct communication
is better effected through a walkie-talkie system especially between the Site Incident
Controller and Site Main Controller.
The SIC briefs the SMC about status of the incident, its likelihood to affect other plants and
also area beyond the fence. He also discusses with the SMC the approach he would follow in
controlling the incident. The SMC, through the intercom system, remain in contact with
other personnel briefs them on the strategy he would like to follow and get their views and

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instructs them to be in preparedness. If the situation demands help of any of them he seeks
the same.
5.5.2 EXTERNAL COMMUNICATION

Key Personnel not immediately available at the Site
The SMC gets in touch with the key personnel through external telephones and gives them
instructions.
a) Communication to nearby residents
Telephonic contact with pre-determined persons in the nearby areas. Public address system
in Autorickshaw will be used for announcing to the nearby areas.
b) Communication with Local Authorities & Response Agencies
The SMC and Welfare officer would, if they thinks fit, informs the local authorities such as
District Collector; Office of the Addl. Director, Industrial Safety & Health; Police, Fire Brigade
etc.
c) Names & Telephone Numbers
The telephone directory has been prepared and kept at strategic places such as; ECC,
entrance gate, plant offices. The Telephone Directory is in 2 sections - First for Internal
personals and second for external. This is enclosed at ANNEXURE 8.
d) Designated Persons for Media Contacts
The person designated is Dy Chief Engineer Admin/ Welfare Officer. In the absence of Dy
Chief Engineer Admin/ Welfare Officer, alternately he can delegate this function to one of the
senior persons available on site who would carry it out under guidance from the SMC.
e) Procedure for notifying families of injured
The persons who would be authorises, as mentioned in 7.1 & 7.2, and SMC or one of the
senior person from Plants who was appointed by SMC for arrange to notify families of injured
persons. The messages would not make the family panic but give information as to where
be them receiving treatment. In case of any fatality only SMC would make proper
arrangement to inform the families.
f) Central Reporting Office
ECC would be the Central Reporting Office.
5.6 AWARENESS
5.6.1 TRAINING
Training would be undertaken as follows:

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a) Training of Group Leaders: All the group leaders would undergo training in following
areas
b) Role of team leader in emergency,
c) Knowledge of Hazards: Location of inflammable material store, Chemicals stored,

transported handled and used; their physical & chemical properties, what to do during
emergency etc.
d) Procedure for reporting emergency
e) Siren Systems
f) Location-wise types & the numbers of fire extinguishers, and their structures, how to
use them, etc.
g) Types, numbers and locations of different types of required PPEs, situations where
they should be used, method of using etc.
h) Different types of PPEs to be used by responders and others, their particular use in
situations, method of using them.
i) Evacuation Procedure - i.e. assembling at Assembling Points, Head Counts, their

records, followed by method of evacuation and release.
j) Frequency of update and documentation of emergencies.
Training of Responders
Different responder teams would be given in depth training on the respective aspects of
responses such as Fire Fighting, Rescue Operations, Medical Responses, Traffic Control, Head
Count at Assembly Points, etc.
Training of Group Leaders, Incident Controller & Site Main Controller.
A training workshop would be conducted to understand not only role of individual group
leader but also issue of co-ordination, chain of command etc. through simulation and Table-
Top Exercises.
Training Programme on how to conduct Drills as mentioned under point No. 5.6.2 below.
The above training would be periodical. The Safety Officer in consultation with SMC would
decide the periodicity.
5.6.2 MOCK-DRILLS
a) The emergency plans and emergency preparedness level would be tested

through the following drills: -
1. Table-Top Exercise (TTE)

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Page : 34
2. Functional Exercise (FE)
3. Full-Scale Exercise (FSE)
b) Guidelines for conducting mock drills.
1. The above mockdrills will be carried out under the directives of Disaster Management
Committees.
2. All elements/procedures of the On-Site Emergency Plan would be first tested through
TTE and perfected as much as possible.
3. The plan then would be modified/updated Functional Exercises basically to ensure

proper functioning of various equipments such as fire fighting equipment, fire hydrant
system.
4. The Full Scale Drill would be conducted to know understanding, preparedness level of
all groups.
5. Initially TTE & FE would be conducted at least once a month.
6. The FSE would be conducted once in 3 months initially tapering down to once in 6
months within a period of 2 years hence.
5.7 HAZARDOUS MATERIAL STORAGE

5.7.1 At 210 MW
A. WATER TREATMENT PLANT 210 MW

YEARLY AVERAGE CHEMICAL HANDLED
SN CHEMICALS UNIT Location QUANTITY
As per available
information
1 Hydrochloric Acid MT Acid tank area 107.435
2 Caustic Soda Lye ( 100 % Basis) MT Acid tank area 32.115
3 Alum MT Godown PTP 129.16
4 Hydrated Lime MT Godown PTP 12.94
5 Liquid Ammonia LTR 1146
6 Hydrazine Hydrate KG 2028
7 Tri. Sod O‟ Phosphate KG 1000
8 Potassium Hydroxide KG 55
9 Common Salt MT Godown 3022
10 Resins
(a) Cation LTR 5220
(b) Strong Base Anion LTR 4380
(c) Weak Base Anion LTR 3320
11 PAC ( Poly Aluminium Chlorides) MT -
12 Bleaching powder MT 6.90

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Page : 35
13 Sod. Hexa M Phosphate KG 1600

14 Chlorine Chlorination
(a) Tonners 950 kg Cylind plant 07
ers
(b) 100 Kg Cylind 02
ers
16 Ammonia Cylinders Chlorination
(a) 50 Kg Cylinders Cylind plant & 73
ers Ammonia
Dozing
U1, U2&u3
17 Hydrogen H2 generating 580
(a) Cylinders of M 3
Cylind station
ers H2 manifold at
Unit 1,2,3&4
(b) Cylinders of M3 Cylind
ers
18 Ozone Self As per
(6 kg per hr Generation) gener requirement
ated basis
B. OPERATION / OPERATION SERVICES

Sr No Material Quantity Location
1 Fuel oil ----- Oil storage Tank back side of OHP
LDO, ( Low Diesel Oil) 1500KL
FO (Fuel Oil) 2000 KL X 3 Nos
2 Hydrogen Gas cylinder 25 cylinders each U# 1to4 Turbine basement out side
Average stock per unit unit
C. TESTING INSTRUMENTATION & CONTROL

1 Radio- active material 5 3 on slurry mixer tank (AHP2) for density
measurement
2 at TIC store in sealed room (spare )
2 Add that is hazardous/
inflammable
D. TURBINE MAINT
1 Turbine Lub Oil 800 Ltr BFP Floor
1 No. Barrel Ner COP
5 No. Section Oil godown Ner CW pump (U#1)
stock
2 Gear box oil 1 No. Section Oil godown Ner CW pump (U#1)
stock
3 Hydraulic pump/coupling 1 No. Barrel Near COP

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Page : 36
oil 2 No. Section Oil godown Ner CW pump (U#1)

stock
4 MOT (Main Oil Tank) 35 KL 4.2 Mtr level of Unit 1, 2, 3, 4
Capacity
5 Grease 1 No. Section Oil godown Ner CW pump (U#1)
Add diff grease list stock
6 DG fuel oil capacity 1000 Ltr Comp
stock
7 Air condition Gas U#1&2 600 Kg A/C plant
U# 3&4 1080 Kg A/C plant
2 Nos. Section Store
E.BOILER MAINT
1 Lub Oil 15 Brls. Oil Godown (Near ID fan U#1 )
2 Gear box oil 15 Brls. Oil Godown (Near ID fan U#1 )
3 Grease Add diff grease 02 Brls. Oil Godown (Near ID fan U#1 )
list
4 Acetylene Gas cylinder 04 Nos. Cylinder Room godown before B/M
(DF) Store
5 O2 gas cylinders 20 Nos. Cylinder Room godown before B/M
Store
F.ELECTRICAL MAINT
1 Lub Oil Nil
2 Gear box oil Hp 90 300 Ltr Work Shop (E/M)
3 GreaseAdd diff grease list Nil
4 Transformer Oil
Generating xmer,
Station xmer, 5.237 KL Ozone plant near (E/M Store )
UAT, (25 Barrels
ESP Xmer, 0f 209 ltrs)
other aux xmer oil at CHP,
AHP, WTP
5 Silicon oil 410 Ltr Work Shop (E/M)
6 Vaccum VM 40 oil 460 Ltr Work Shop (E/M)
G.MAJOR STORES
1 Lub Oil 28.5 Oil Shed
2 Gear box oil ------ -------
3 Hydraulic coupling oil ------- -------
4 Grease Add diff grease 0.182 Oil Shed
list
5 Transformer Oil
Generating xmer, Station
xmer, 2.926 Oil Shed
UAT,

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Page : 37
ESP Xmer,
other aux xmer oil at
CHP, AHP, WTP
H.ASH HANDLING PLANT

1 Lub Oil 0
Sp 46 420Ltr.
SS 68 87 Ltr.
2 Gear box oil Spc -100 210 Ltr.
Sp -460 420 Ltr. Oil Room adjacent to New Godown
3 Grease Ep2, 182 Kg No 2
Ep3 0
Add diff grease list
I. COAL HANDLING PLANT

Sr Material Quantity Location
No
1 Lub Oil Nil
2 Gear box oil (SS-320 ) 40 Ltr In metallic portable shed near
CHP office building.
( SS-320 ) 400 Ltr
In closed oil storage shed near
3 Hydraulic coupling oil(SS-68 & 900 Ltr. coal sampling room
46)
4 Grease Add diff grease list 200 Kg
5 LPG Gas cylinder 1 No. Near Locomotive maintenance

6 O2 gas cylinders 3 No. room
7 Max Coal storage at Stacking 2.5 Lacs MT Coal stock pile A,B,&C
Reclamation
8 Max Bunker coal capacity 3000 MT
(in all bunkers of each unit )
9 Length of conveyor belt Sr No
wise
10 High Speed Diesel 20KL Diesel pump
5.7. 2 At 500 MW
A. WATER TREATMENT PLANT 500 MW

As per available
information
1 Hydrochloric Acid MT Acid tank area 90 MT
2 Caustic Soda Lye ( 100 % Basis) MT Acid tank area 48 MT
3 Alum MT PTP Godown 30 MT
4 Hydrated Lime MT Godown PTP

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Page : 38
5 Liquid Ammonia LTR SWAS/Gen Lab 2500 Lits

6 Hydrazine Hydrate KG SWAS/DM pl. 5000
7 Tri. Sod O‟ Phosphate KG SWAS 1000
8 Potassium Hydroxide KG
10 Resins DM /Soft pl. 25000 ltrs.
(d)
(e)
(f)
11 PAC ( Poly Aluminium Chlorides) MT PTP Godown 30 MT
12 Bleaching powder MT PTP Godown 5 MT
(c) Tonners 950 kg Cylind plant 01
ers
(d) 100 Kg Cylind 0
ers
(b) 50 Kg Cylinders Cylind plant & 0
ers Ammonia
Dozing
U1, U2&u3
(c) Cylinders of M 3
Cylind station
ers H2 manifold at
Unit 1,2,3&4
(d) Cylinders of M3 Cylind
ers
18 Ozone Self As per Commensing from
(6 kg per hr Generation) gener requirement SEPT 15
ated basis
B. OPERATION / OPERATION SERVICES

LDO, ( Low Diesel Oil) 2000 KL
FO (Furnace Oil) 2000 KL X 2
2 Hydrogen Gas cylinder 25 cylinders U# 5 Turbine basement out side
Average stock per unit
C. TESTING INSTRUMENTATION & CONTROL

1 Radio- active material 3 3 on slurry mixer tank (AHP2 HCSD

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Page : 39
mixing tank 1, 2, 3) for density

measurement
inflammable
D. TURBINE MAINT
stock
stock
stock
4 MOT (Main Oil Tank) KL Turbine basement U5
Capacity
stock
E.BOILER MAINT
list
(DF) Store
Store
F.ELECTRICAL MAINT
1 Lub Oil Nil
4 Transformer Oil
Generating xmer,
UAT, (25 Barrels
AHP, WTP

ISSUE : 04
Page : 40

G.ASH HANDLING PLANT

1 Lub Oil 0
Sp 46 20Ltr.
SS 68 295 Ltr.
Sp -460 AHP Store @, back side of Service
3 Grease Ep2, 190 Kg Bldg.II
Ep3 0
H. COAL HANDLING PLANT

Sr Material Quantity Location
No
1 Lub Oil Nil
2 Gear box oil (SS-320 ) 40 Ltr In metallic portable shed near
CHP office building.
( SS-320 ) 400 Ltr
46)

Reclamation
wise
10 High Speed Diesel 20KL Diesel pump
5.8 RISK ASSESSMENT

Sr Hazardous Material Risk Remarks
No
1 Hydrogen generating station is present under water Explosion
treatment plant. The hydrogen is generated from
own generating station and used for generator
cooling purposes. MSDS of Hydrogen is given in 9.3
2 Chlorine is used as algaecide & disinfectant in water Toxic release
& is supplied in Tonner (900 Kg Gas) & cylinders of
100Kg at Water Treatment Plant. MSDS of Chlorine
is given in 9.1
3 Ozone generating station are present under water Toxic release
treatment plant. The Ozone is generated from own

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Page : 41
generating station and used for algaecide &

disinfectant in water . MSDS of Ozone is given in
Annexure-5.
4 Ammonia is used to control flue gas SPM, and is Toxic release
provided by agency in 100 Kg cylinder under water
treatment plant. MSDS of Ammonia is given in
Annexure-5.
5 Hydrochloric acid is used for water treatment MSDS Corrosive
of HCl is given in Annexure-5 release
6 Caustic Soda, Acid, Poly Aluminum Chloride and Corrosive
other large number of chemicals of small quality are
used in the water treatment plant.
7 The mineral oil is used for lubricating of machines Fire
8 The mineral oil is used for cooling transformers. Fire
9 The FO & LDO are used as fuel. MSDS of FO & LDO Fire
is given in Annexure-5.
10 The Diesel used as vehicle fuel. MSDS of Diesel is Fire
given in Annexure-5.
11 LPG is used for metal cutting/fabrication in 19.4 Kg Fire
cylinders. MSDS of LPG is given in Annexure-5. Explosion
12 Acetylene is used for metal cutting/fabrication in Fire
19.4 Kg cylinders. MSDS of Acetylene is given in
Annexure-5.
13 Oxygen is used for metal cutting/fabrication in 19.4 Fire
Kg cylinders. MSDS of Oxygen is given in Annexure- Explosion
5.
5.9 FACILITIES AVAILABLE FOR HAZARD CONTROL & RISK MINIMISATION
5.9 A. LIST OF FIRE EXTINGUISHERS

5.9.A1 FIRE FIGHTING
Sr.
TYPE OF EQUIPMENT NUMBER LOCATION
No.
1 Fire Extinguishers
a. DCP 75 kg. Fire Ext. 016 Nos
b. DCP 70 kg. Fire Ext. 005 Nos
c. DCP 22.5 kg. Fire Ext. 005 Nos
d. DCP 10 kg. Fire Ext. 316 Nos
List attached
e. DCP 5 kg. Fire Ext. 042 Nos
f. CO2 22.5 kg. Ext. 039 Nos
g. CO2 6.7 kg. Ext. 303 Nos
h. CO2 4.5 kg. Ext. 023 Nos
i. AFF Foam 9 ltr. Fire Ext 010 Nos
j. Water CO2 9 ltr. Fire Ext. 011 Nos
2 Mobile Unit
a. Multipurpose Tender 03 No. In fire section having 1000 kgs Dry
chemical powder vessel & 500 ltr. AFFF

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Page : 42
tank with 2 Nos CO2 Fire Extinguishers.

b. Water Tender 01 No. In 500MW fire section having 2800 Ltr
water tank & 250 Ltr foam only water
3 Fixed System
a. Hydrant system 368 Nos Internal & External in power station.
b. Foam system 04 Nos OHP in all 4 Nos Furnace oil tanks
c. Water spray system 04 Nos OHP in all 4 Nos Furnace oil tanks
d. Water monitor 04 Nos OHP in all 4 Nos corners
e. High velocity water spray 04 Nos To all 4 Nos GT, UAT, ST transformers.
f. Water spray system To all cable gallery LT / Ht s wel as LT
-- transformer & all coveyor CHP belt,
boiler houses, Seal oil pump, lub oil
tank.
g Smoke detection system -- To all HT/LT cable gallery & pannel
board.
5.9.A 2 METHOD OF HANDLING VARIOUS TYPE OF FIRE
Sr. TYPE OF FIRE TYPE OF FIRE EXT. TO Remark

No. BE USED
a. Carbonus fire Water CO2 type fire Ext.
b. Oil fire AFFF, DCP, CO2 fire Ext. Do not use Water CO2 type fire Ext.
c. Gases fire CO2, DCP fire Ext.
d. Metal fire DCP fire Ext.
5.9.A 3 FIXED FIRE DETECTION AND PROTECTION SYSTEM
MONTHLY WORK SCHEDULE OF FIRE FIGHTING SECTION
SR. Nomenclature of Fire Protection / Fire Detection Data on Premises installed

NO. System items protected
1 (a) Water Sprinkler system and Emulsifier On all LT,HT Transformers.
(b) Water Spray System On all conveyor system Boiler
Burner Front.
2 Foam On all Fuel Oil Tanks
3 Medium Velocity Water Spray System On all Fuel Oil Tanks & cable
vaults of main plant & LT
Transformer
4 Smoke Detectors At all Control Rooms, Switch
Gear Rooms, Cable Galleries.
5 Linear heat Sensing Cable (LHSC) Detector system. All Conveyor Belts
5.9.A 4 DETAILS OF FIRE FIGHTING EQUIPMENTS AVAILABLE IN THE FACTORY.

5.9.A.1 AT 210 MW
a) No. of Fire equipments Capacity Qty.
i) Water CO2 9 Ltr 12 Nos.
ii) Dry Chemical Powder (DCP) 75 Kg 16Nos.
70Kg 04 Nos

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Page : 43
22.5 Kg 05 Nos
10Kg 316 Nos
5 Kg 42 Nos.
iii) Aqueous film forming foam 9 Ltr 160 Nos
iv) CO2 Type 22.5 Kg 39 Nos.
6.7 kg 383 Nos.
5 Kg. 25 Nos.
b) Fire Tender / Trailer pump 4 nos fire tender
2 nos diesel driven 60 gpm
1nos petrol drven 1600 gpm
c) Max. Quantity of Foam available 1400 Ltrs
d) Water jet monitors Nos. 6Nos.
e) Water storage tank & its capacity. Water storage tank having
capacity 1,00,000 m2
f) No. of hydrant points 368 Nos.
g) No. of hose reels & total length. 4 Nos. (app. 35 30Mtr.
Mtr. / Each)
h) Aqua Mist gun 1Nos.
i) Water Gun 1Nos .

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Page : 44
5.9.A.2 AT 5000 MW
Available Fire Extinguishers 500MW
Sr. Location AFFF AFFF DCP DCP C02 C02 C02 Total
No 9 Itr 50 Itr 5 kg 25 kg 4.5 kg 6.7 kg 22.5 kg kg
1 Security office 1 1 2
2 canteen 2 1 3
3 CW Pump house 3 2 5
4 Ozone Plant 1 1 2
5 Service Building ground floor boiler 2 1 3
mainantance
6 Service Building ground 1 1 2
7 Service Building first floor 2 2 4
8 Service Building second floor 2 2 4
9 Service Building third floor 2 2 4
10 Service Building fourth floor 2 2 4
11 Turbine basement Zero Mtr Left side 2 1 2 2 7
12 Turbine basement Zero Mtr Right side 2 1 5 2 10
13 6.6 kv Panal room 2 2 1 2 7
14 240 V Panel Room 12.5 mtr 2 2 1 5
15 Battery room 4 2 6
16 turbine 8.5 mtr service building side 2 2 1 2 7
17 turbine 8.5 mtr right side 3 2 2 7
18 PCR Room 3 3 2 1 9
19 Turbine floor PCR side 3 3 1 1 3 11
20 Turbine floor 17th mtr service 3 3 1 1 3 11
building side
21 turbine 24 mtr right side 2 2 4
22 turbine 24 mtr left side 2 2 4
23 Boiler MCC room 3 2 5
24 Boiler firing floor near cabin 2 3 1 6
25 firing floor compressor side 3 3 1 7
26 Bunker level right side 1 1
27 Bunker level left side 1 1
28 AC Room 2 2 4
29 Boiler basement cabin side 2 1 3
30 Compressor room 4 4 8
31 VFD feeder control room 3 6 9
32 ESP and VFD Control room 3 4 7
33 AHP Control room 4 6 10
34 AHP Slurry pump house 2 2 4
35 OHP Control room 2 3 2 1 8
36 CHP Loco shade 2 3 5
37 CHP Control room 2 2 4
38 WT Plant 3 2 5
39 DM Plant 5 4 9
ISSUE : 04
Page : 45
40 Wagon tippler 5 3 8
41 TP 102 1 1
42 ETP Plant 2 2 4
43 Filter pump house 1 1 2
44 Chemical dosing plant 2 1 3
45 RWP fire pump house 5 4 9
46 Crusher house 2 2
47 TP 105 Bunker cabin 1 1
48 TP 106 1 1
49 TP 107 1 1
50 TP 108 1 1
51 TP 107 2 1 3
52 TP 106 2 1 3
53 TP 103 2 1 3
54 ID Fan 2 2 4
55 FD Fan 2 2 4
56 LUB Oil Near Chimney 4 2 6
57 ESP Top RH 4 4 2 10
58 ESP Top LH 4 4 2 10
59 Panel room Near foam tank 2 1 3
60 Electrical panel at service building 2 2 4
ground floor
61 CHP Panel room 4 4 8
62 AHP Control room 3 4 7
63 Generator room 2 2 2 6
64 Panel room near TP 102 2 2 4
65 STP (Near WTP) 2 3
Total 32 2 157 2 32 102 3 325
5.9 B SECURITY
S Particulars
No
1 Map showing gates
2 List of Camera 05 cameras are there at Main monitoring screen for all
Provided on gate (1):-Gat no.1 Bridge camera install at various
( 2):-Gat no 2 Mutton gate location with at auto
(3):- Service building patrolling & zooming facility.
(4):-BHEL gate (AHP area )
(5):- CHP tower
3 Watch tower facility 1) There are 4 watch Tower at various
location as
1) Near Railway Track of Saoner Railway
called as Sillewara gate tower.
2) Near D.point Area.
3) Bhanegaon Railway Gate.

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Page : 46
4) Hydrogen plant Tower.

4 Entry /exit Control 1) Through Bridge Gate 24 Hours. Both having hand metal
system for 2) Through Gate No 2 on the particular detector mirror detector
employees schedule time. &manual cheeking with the
help of male & female guard.
Identity card checking.
5 Entry /exit Control 1) Form Bridge Gate. Same as above with
system for contract 2) Form Gate No.2 Verification of identify card
workers checking
6 Entry /exit Control Only Bridge gates security officer Verification of person with
system for Visitors sophisticated photo identify card issuing detail bio data feed in system
centre installed than bricking & issuing visitor
pass with all detail of person
concern person section and
time protocol.
7 Entry /exit Control Visitors pass at bridge gate security office Same as above.
system for VIPs centre.
8 Information available Notice Board of prohibited area displayed Notice board about current
at gate at both G.No.1&2 happening & board
department Natures for
security section employees.
9 Patrolling facilities Patrolling track available round the plant Patrolling track with light
and colony Area. facility available.
10 Designation wise
man power at
security section
11 Control system for
BOMB
BOMB THRETNING

TERRIRIST ATTACK

CROUD/ MOB

ISSUE : 04
Page : 47
6. PROCEDURES
6.1 PROCEDURES TO TESTS OF DMP
As mentioned against para 5.6.2 Drills, regular tests of Emergency Organisation as

well as procedures would be carried out through exercises based on simulated
emergencies. Besides these exercises the tests would include -
i. Siren System - The Siren System would be tested at 10.00 a.m. on every Monday,
observations noted and corrective actions would be taken. The testing would include -
activation system, intensity of the siren at different places so that all in the Plants, etc
distinctly hears it.
ii. Use of the Chemical Leak Stoppage Kit - Testing of this kit to its ability to stop the
leakage would be done once in six months with compressed air cylinder at the
pressure of the gas used in the tonner/cylinder/manifold.
iii. Breathing Apparatus Set - Breathing Apparatus Sets would be tested for their leak
proofness and supply of oxygen for the rated time. This would also be done once in
the six months.
iv. Portable Fire Extinguishers - Testing of operation of different types of fire

extinguishers and their periodical inspection, repair / replacement of parts etc. Check
lists would be developed and enclosed as an Annexure to this Plan - All the fire
extinguishers would then subjected to this inspection periodically i.e. every month and
record such inspection would be maintained. This also includes testing of operation of
the portable fire extinguishers that can be done through conducting drills. It would
serve dual benefits one of testing the operation at the same provides the personal in
testing their skill in handling these equipments. Record of such drill as also
observations would be kept. The prime responsibility to organise the testing,
inspection and examination would be with Safety Department.
v. Evacuation Practice - How to assemble at Assembly Points, take head count and
transporting them to a safe place. This practice would be done on a sample basis
once in six months initially and then once a year
6.2 Procedure to declare emergency
a)Actuation of Emergency Siren
After hearing an alarm or information from any employee about an incident in the unit/
plant, SIC would rush to incident immediately. SIC, if found it is beyond his control,
informs the SMC. In-betweens, SMC would make contact with the attendant of ECC. In
turn attendant in the ECC would inform to the identified members of ECC. After that SMC
would rush to ECC. After assuming the position of SMC in ECC, directs to make contact
with other senior members in the plant. SMC will make communication set up with SIC

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about the situation. After communication with SIC, SMC founds it is beyond the control
then he declares an Emergency by actuating a siren.
b) Sequence of Actions after Declaration of Emergency
1. After declaration of an emergency, SMC instructs to inform the outside Fire Brigade,
Hospital and Police Stations and also for help from other GO and NGO‟s.
2. The SMC contacts SIC on intercom to know about the incident.
3. The maintenance team approaches the incident site to attend emergency.
4. The other plant In-charges occupy their office to receive instructions from SMC.
5. The other teams carry out their respective functions.
6. SMC is in continuous interaction with the SIC and other senior persons in each site.
7. SIC in consultation with the other team leaders informs the situation to SMC.
8. SMC in consultation with the SIC and their juniors decides whether to stop process or
not.
6.3 PROCEDURE TO MITIGATION / EMERGENCY RESPONSE
a) COMMUNICATIONS
i) Communication for Notifying On-Site Emergency -
ii) Channel of Communications
b) EVACUATION PROCEDURE
The Evacuation Procedure is in two parts viz. assembling at Assembly Points and
transporting to safer place.
1) All the non-essential persons are advised by the respective in-charge to assemble
at Pre-identified Assembly Points.
2) The designated persons would take head count.
3) As per instructions to the staff taking the head counts the assembled persons are
allowed to leave after noting down their names and plant.
c) MEDICAL
The rescue persons bring the injured persons after giving them first aid to the Medical
Center on stretchers located within the Plant. The medical staff treats them. However, if
he finds that the injured requires treatment, which cannot be provided locally he sends
the injured person through an ambulance to the pre-identified, pre-informed nearby
hospital. He keeps on informing about the conditions of injured to the SMC from time to
time. He also is a person who organises training for first-aider, medical and para-medical
staff.
d) UTILITY FAILURE PROCEDURE
Utilities such as water supply, power are considered very important and hence
continuous supply is required to be ensured during emergency. Power supply is required
basically to equipment with which emergency is handled. Therefore, power supply to
such equipment is ensured through use of batteries or separate power supply using DG
sets. A person is deputed at each of the utilities for this purpose.
e) INDIVIDUAL UNIT EMERGENCY PROCEDURE
Each of the Units is required to develop a procedure as to what is to be done in case of
emergency occurring in the unit or if it occurs in some other units. This should form a

ISSUE : 04
Page : 49
part of this On-site Emergency Plan. The workers of this unit is required to be made
aware of the procedure by circulating the same and also displaying at conspicuous place
in the Plant
f) CHEMICAL LEAK STOPPING PROCEDURE
Written procedure for stopping the leak for different gases /oils are given.
f.1 CHLORINE
In case of leakage of Chlorine the identifying team with emergency leak stoppage kit
and PPE should approach to be site and work under the guidance of SIC. The leak
stoppage procedure and non-leak emergency procedure is given in Annexure2.
f.2 HYDROGEN
In case of leakage of Hydrogen the identifying team with emergency leak stoppage
kit and PPE should approach to be site and work under the guidance of SIC. The leak
stoppage procedure is given in Annexure 9.
f.3 OIL/PETROLEUM PRODUCT
The procedure of leakage of Petroleum products/ Oil is given in Annexure 10.
f.4 CHEMICAL PRODUCTS
The procedure of spillage pf Chemical products is given in Annexure 11.
f.5 AMMONIA
The procedure of leakage of Ammonia from Gas cylinder is given in Annexure 11.
f.6 OZONE
The procedure of spillage of Chemical products is given in Annexure 11.
g) FIRE RESPONSE PROCEDURE
In case of fire on any unit, the fire team with their PPE should approach the site and
work under/follow the guidance of that SIC. The procedure to fight the fire is given in
Annexure 12.
h) EXPLOSION RESPONSE PROCEDURE
In case of explosion on inside a unit, the fire team with their PPE should approach
the site and work under/ follow the guidance of that SIC. The process to fight/mitigate
the explosion is given in Annexure 13.
i) NATURAL DISASTER RESPONSE PROCEDURE
i.a Cyclone

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Page : 50
As per the venerability map of india, published y National Disaster Management

Institute, this area is affected very rarely due to cyclone. If pre-information is
available of Cyclone, then procedure is given in Annexure 14.
i.2 Flood
As per the venerability map of india, published by National Disaster Management

Institute, this area is affected very rarely due to flood. If there is any emergency then
follow the response procedure given in Annexure 15.
i.3Land Slide in the reservoir

Institute, this area is affected very rarely due to landslide. There is no reservoir near
plant to have effects of land slide.
i.4 Earthquake

Institute, this area is affected very rarely due to earthquake. If there is any
emergency then follow the response procedure given in Annexure 16.
j) MAN MADE CRISIS DISASTER MANAGEMENT PROCEDURE
j.1Terrorist Attacks
The procedure is given in Annexure 17.
The necessary steps to be taken against Terrorist attack:
1) Strong security arrangements to be provided at all entry points to the plants.

2) Information furnished to the District Administration to take appropriate security
action.
3) Only the authorized persons may be allowed to gain entry into the plant.
4) Continuous internal security must be in force at all times.
5) Close watch must be kept on the suspicious persons, unattended vehicles around the
plant.
6) Modern communication & information system shall be provided with suitable back ups.
SECURITY SYSTEM:
There should be 100% foolproof security mechanism for the following services:
1) Automated access control system

2) Alarm points
3) Identification of employees, contractors, visitors
4) CCTV
5) Crisis Management policies and procedures

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Page : 51
j.2 Bomb Threat
1) A thorough search should be carried out by the security and police agencies who are
well versed in dealing with such situations.
2) In case a bomb being found or a suspected, sand bags be placed around the object to
reduce the impact of damage in the event of an explosion.
3) The nearest police or army unit who invariably have trained personnel for this purpose
should be called for disposal.
If there is any emergency, then follow the procedure given in Annexure 18.
6.4. PROCEDURE TO CALL OFF EMERGENCY & RETURNING TO NORMALCY

a Authorisation:
Only SMC is authorised to take the decision to "Call Off" the emergency after ensuring
with Site Incident Controller and other key personnel that the situation is safe to
return to normal operations.
b Calling Off the Emergency: Emergency would be called off by the SMC by actuating
"ALL CLEAR" siren by SIC after authorized by SMC.
c Communication to convey calling off of Emergency
c.1 All persons within the Plants are informed through "ALL CLEAR SIREN".
c.2 The SMC also contacts senior person in each plant conveying that the emergency has
been called off. He further instructs them what do next.
c.3 External persons such as District Collector, Office of Jt. Director, industrial Safety &
Health, Police, and Civil Defense etc. are again contacted by the SMC or his designate.
Communication of “calling” off emergency is as important as conveying proclamation
of emergency.
d Returning to Normalcy
When the "ALL CLEAR" siren is blown, it indicates end of emergency. However each
plant to resume to normal operation has laid out procedure.
e Sequence of Actions after the "ALL CLEAR" given is blow.
i) SMC contacts all plants to communicate them the emergency has been called
off and instructs for actions required to be taken by the person inside.
ii) The senior person in each plant takes a small meeting of all his workers and
briefs them and instructs them to go back.
iii) The SIC in consultation with the senior-most official of the Plants and takes
necessary steps to resume supply of electrical power.
iv) Plants start operation as laid down procedure.

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6.5 . PROCEDURE TO CONDUCT MOCK DRILL
a. MOCK REHEARSAL:
 Inform all the employees about mock drill.

 Fix the date for mock drill.
 Observers will not be involved in the exercise. They will monitor the Mock drill.
 Emergency Siren / alarm will be raised.
 After hearing the Siren / alarm, Emergency procedure will be followed as mentioned in
the OEP.
 Observer will note down the activities with respect to the time.
b. Mock drills OBJECTIVES
1. Educating and training employees, contract workers to react for any emergency /
disaster
2. To develop ability to take correct action at the time of emergencies.
3. To evaluate the Emergency Response Plan and Standard Operating Procedures of the
Industry.
4. To highlight the Roles and Responsibilities of various key persons.
5. To enhance Coordination among DMP Teams.
6. To generate Public Awareness by their involvement
7. To identify the gaps/deficiencies in Resources, Manpower, Communication, exercising
and in any other field.
8. To review Disaster Management Plan.
c. Defining Emergency Preparedness

 Emergency Preparedness – against natural & manmade hazards
 Building up Infrastructure, Knowledge and Capabilities
 Personnel augmentation and their training plans.
 Community preparedness
 Communication plan
 Funding Policies
 Integrated DM Plan
 Covering complete DM Cycle
d. Testing of Emergency Preparedness Plans
 Training and Re-training of all stakeholders/service providers
 Awareness among Community
 Specialized response at industry/district/state/ national level
 Coordination between various Emergency Support Functionaries
 Testing the organized response through conduct of Mock Exercise
e. Improvements in Exercising
 Practiced Regularly.
 Standard Format.
 To prepare for Chemical Mock Exercise.
 To test and evaluate the outcome.
f. STEPS
Step 1

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Page : 53
Coordinating Conference
(a) Delineating objectives of Mock Exercise.
(b) Scope of Exercise.
(c) Selection of the area/scenario for Mock Exercise.
(d) Date, time and Venue for Table Top and Mock Exercise.
(e) Participants
Step 2
Table Top Exercise.
• Precursor to Mock Exercise.
• Scenarios are initially painted. Subsequent situations are painted as realistically as
possible.
• Details of Coordination and Safety are discussed.
• The Gaps are identified and Remedial Measures taken.
Step 3
Mock Exercise.
There may be two types of drills

(i)Pre-announced Drills: When the workforce are expecting a mock drill, it is called as Pre-
announced Drills. The objectives of Pre-announced Drills are:
I. To ensure everyone has read and understand procedures.
II. To Test how everyone reacts to a more specific hazard / emergency.
III. To determine ability of workforce to locate and operate fire extinguishers & other
containing equipments.
(ii) Unannounced Drills: Unannounced drills are a good way to test people‟s ability to react
to a hazardous situation they weren‟t expecting.
The objectives of Unannounced Drills are:
i) To ensure everyone in the premises can clearly hear the alarms and immediate
actions to be taken by key persons.
ii) To discover if the workforce know the exit routes and take correct action.
iii) To determine whether workforce with special roles (in the case of an emergency)
know what steps are to be taken,
iv) To find out how long it takes to get “all clear” of the emergency.
PROCEDURE
For Pre announced : all concerned to be aware regarding date & time.
For Un announced : Only Chief Engineer, DyCE, Concerned Supdt Engineer, to be
aware regarding date & time, to avoid panic.
• Observers are detailed, briefed and format for assessment issued.
• Self Assessment Formats are given to all key persons.
• Scenarios are formulated after due deliberations and the Mock Exercise is conducted
by painting of scenarios in a sequential manner.
• Sequence of events and Administrative Arrangements are finalized after discussion
with Disaster management committee.
• Actions are taken on ground by concerned key persons on orders of their own
departments.
• ECC operation.
• Action by DMP teams.
Step 4
Submission of Final Report.

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Page : 54
• Reports are prepared & submitted to all.

• Lessons Learnt are discussed in meetings & circulated to all concerned.
6.6 PROCEDURE TO UPDATE PLAN (DMP)
It is necessary that the on-site emergency plan be tested periodically. As mentioned under
6.5 above, the testing of the plan would be through Table-Top Exercise, Functional Exercise
and Full-Scale Drill.
1 REVIEW OF THE PLAN
This plan is a dynamic document and would be reviewed / updated in following

situations: -
i) The plan would be tested from time to time. Short comings/ lacunas that would
be surfaced during testing of the plan, would be recorded/ documented,
discussed during debriefing session following the test, decisions are taken to
include them in the plan.
ii) If there were a change in process (s), which may add scenario(s) of possible
emergencies, the plan would be modified taking into account these additional
scenario(s).
iii) Change in contact details such as addresses, telephone.
iv) At least once in six months
2 RESPONSIBILITY
Updating the Plans would be the responsibility of the Safety Officer. This would also
include updating of contact information such as address, telephone numbers etc.
3 PROCEDURE
The Plan would be updated after authorized by the SMC in writing. The Safety Officer
would submit the proposal as mentioned in 6.5.f step4 above, duly supported by
justifications to the SMC. After its approval the Safety Officer would accordingly
update the plan and circulate it to the concerned persons. For minor change i.e.
Telephone Nos. not required authorization.
4 CONTROL OF THE EMERGENCY PLAN DOCUMENT
The On-Site Emergency Plan when finalized and approved by the management of the KTPS,
sufficient number of copies would be printed, each copy would be identified by a certain
number and issued to different persons who have roles to play during the emergency. A
register would be maintained indicating which identified copy is issued to a specific person.
Complete responsibility of getting the management's approval, printing a number of copies,
giving them identification numbers, issuing them, registering the issue, would be the
responsibility of the Safety Officer. It will also be his responsibility to replace the copies after

ISSUE : 04
Page : 55
each modification by giving them identification numbers and re-registering them. This is
required to ensure that only up-dated copies are with
6.7 PROCEDURE TO UPDATE ECC

The following documents & equipments shall be monitored & maintained regularly at each
quarter
a) Documents to be kept in ECC
i) Details of inventories of hazardous material e.g. location, maximum

quantity, type of storages, etc.
ii) Works Layout indicating therein location of ECC, Location wise/ Type wise/ Capacity
wise portable fire extinguishers, Assembly Points, Lunch Room, Canteen, Casualty Treatment
Centre, First-Aid Centre, Siren Activating Points, Pantry Area, Railway siding etc.
b) PPEs - Location wise, Type wise numbers
c) Roads prominently marked on the layout indicating exists
d) Area Map showing surrounding areas especially sensitive population such as schools,
public places, hospitals etc.
e) Plans to be kept in ECCs that can be used as the emergency and corresponding emergency
actions develop.
i. Affected Area
ii. Area Evacuated
iii. Emergency Vehicles & Equipment
iv. Safe Escape Routes towards assembly points
v. Other relevant information.
f) Important phone Nos.
i. Contact No. of SMC (Intercom & P&T)

ii. Contact No. of SIC (Intercom & P&T)
iii. List of contact No. of Government officials
iv. List of contact No. of Mutual Aid Persons
v. Internal Intercom directory
g) All equipments and facilities mentioned in ECC shall be monitored
6.8 NOTIFICATION PROCEDURE & COMMUNICATION SYSTEM
Please refer annexure 19

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Page : 56
7. LISTS
7.1 LIST OF KEY PERSONNEL

SR. NAME DESIGN. & Responsibility SEAT Contact No.
NO. S/Shri SECTION LOCATION OFFICE RESI.
EXT. NOS.
1 S S Jadhao Chief Occupier Saudamini 09822115290
Engineer /Service Bldg I
210 MW
2 B O Bagde Dy. Chief
Responsible for Saudamini 08888865263
Engineer I
O&M 210 MW sets /Service Bldg I
4 H H Rangari SE(O)-I
Incharge of plant Service Bldg I 09850389177
operation Activities
5 B S Wankhede SE (M) -I Incharge of Service Bldg I 09850389179
plant Maint
Activities
6 H K Awchar S.E CHP Incharge of CHP CHP Service 09850991170
Activities Building
7 Deshpande Dy EE (Civil) Incharge of plant & Saudamini 08408889300
colony civil maint
8 R G Borikar EE (CHP) Incharge of CHP CHP office 09850389173
Activities
9 Y N Geranj Ex.Chem-I Incharge of Water WTP I 08888865263
treatment plant
COMMON
10 C K Sawaitul Dy.Chief Manager & Saudamini 09850331342
Engineer General
Admn administration
11 C D Sortey Safety Accident prevention Service Bldg I 08888838941
Officer related activity
12 D V Urkude Sr Manager Incharge of Saudamini 09011407332
Security Security Activities
13 A K Santra Fire Officer Incharge of Fire Fire Station 08408889307
Fighting Activities
14 Dr. M B Medical Medical related Dispensary 08805000903
Bhagat Supdt. activity Vidhuit Vihar
15 P S Nikam Welfare Welfare related Saudamini 09850909987
Officer activity
500 MW
16 GS Dy. Chief Responsible for Saudamini 08888865263
Kumarwar Engineer II O&M 500 MW sets /Service Bldg II
17 S D Paunikar SE(O)-II Incharge of plant Service Bldg II 09850389177
operation Activities

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Page : 57
18 S S Titare SE (M) -II Incharge of Service Bldg II 09850389179

plant Maint
Activities
19 B N Ingle EE (CHPII) Incharge of CHP CHP office II 09850389173
Activities
20 V R Ramteke Ex.Chem-II Incharge of Water WTP II 08888865263
treatment plant
7.2 IDENTIFIED PERSONS
SITE MAIN CONTROLLER (SMC)

Telephone Nos.
Sl. Name (starting Designation Reside- Admn Bldg Plant Res.
No. with surname) ntial
Address
1. 2. 3. 4. 6. 5.7.
Chief Engineer I Type 07113-
1. Shri. Kpkd
07113-268563 268168 to 268561
Jadhao S. S Colony
237091 268172
6501
M : 09822115290
ALTERNATE SITE MAIN CONTROLLER (ASMC)
1. 07113-268168 07113- 07113-
Shri Dy Chief to 268172 268168 to 268668
Bagde B O EngineerI 6002 268172
6502
M : 8888865263
2 07113-268168
Shri Dy Chief to 268172
Kumarwar G S Engineer II 6804
M : 8888838932
3 Dy Chief 07113-268168
Shri Engineer to 268172
Sawaitul C K Admin 6002
M : 9850331342
SITE INCIDENT CONTROLLER (SIC)

Name (starting Designation Reside- Telephone Nos. Mobile
with surname) ntial Address
1. 2. 3. 4. 5. 6.
1. Shri Supdt 6006 09850389177
A H H Rangari Engineer 6806
(210 MW Sets) Op IA

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Page : 58
Shift Incharge All time Shift I/C : 6101 88888 38934

available at PCR I/C : 6102 88888 38935
ASSTT Unit I Unit Plant I/C : 4103
SITE INCIDENT
CONTROLLER Shri M M Patil 07350008627
FOR UNIT 1&2 Shift Incharge All time Shift I/C : 6201 88888 38933
Unit II Unit Plant I/C : 6203
Shift Incharge All time Shift I/C : 6301 88888 38937

ASSTT Unit III Unit Plant I/C : 6303
SITE INCIDENT
CONTROLLER Shri A H Warudkar 07350008628
FOR UNIT 3&4 Shift Incharge All time Shift I/C : 6401 88888 38938
Unit IV Unit Plant I/C : 6403
1. Shri Supdt 5003 09850389177

B S D Paunikar Engineer 5266
(500 MW set) Op IA
ASSTT Shift Incharge All time Shift I/C : 5101 88888 38934
SITE INCIDENT available at PCR I/C : 5102 88888 38935
CONTROLLER Unit V Unit Astt.Plant I/C :
FOR UNIT 5 5104
3 Shri Supdt 6675 09423603118

H K Awchar Engineer 6975
CHP CHP
ASSTT Shift Incharge All time 237026 08888867756
SITE INCIDENT available at 6657
CONTROLLER for CHP Control Unit 6658
CHP 210 MW Room
sets
ASSTT Shift Incharge All time 237026 08888867756
CHP Control Unit 6658
CONTROLLER for
Room 500 MW
CHP 500 MW set sets
4 Shri Y N Geranj Executive 6681 08888865263
WTP 210 MW Chemist 6981
Sets
ASSTT Shift Incharge All time
CONTROLLER for Unit

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Page : 59
WTP I
WTP
4 Shri V R Executive 5485 7350008626

Ramteke WTP Chemist 4981
500 MW set
Shift Incharge All time
ASSTT
available at 5287
SITE INCIDENT
Unit 5282
CONTROLLER for
WTP II WTP 500 MW
7.3 LIST OF FIRE FIGHTERS ( LIST TO BE UPDATED BY FIRE OFFICER)

Sr No Name designation Contact No
1 Shri A.K. SANTRA Fire.Officer 08408889307
2 Shri S.N.KOLAMKAR Jr.FO
3 Shri D.M.MAKHE Jr.FO
4 Shri A.A.KHAN Jr.F.O
5 Shri L.N.ZOPE D/Optr
6 Shri S.Y.KHEWALE D/Optr
7 Shri S.R.RAUT D/Optr
8 Shri D.J,MAIND D/Optr
9 Shri D.S.POHARE D/Optr
10 Shri V.M.BHOYAR Fireman
11 Shri N.D.WANDARE Fireman
12 Shri N. S .NARAD Fireman
13 Shri P.R.PARATE Fireman
14 Shri L.T.JADHAV Fireman
15 Shri S.S. BORADE Fireman
16 Shri. K.U. THAKARE Fireman
17 Shri. S.Y. GAONKAR Fireman
18 Shri. P.P. PATIL Fireman
19 Shri. N.B.LUTE Fireman
20 Shri. N.T. BARDE Fireman
21 Shri P. K. BANSODE Fireman
22 Shri B.S.CHEWARE Fireman
23

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7.4 LIST OF FIRST AIDERS ( LIST TO BE UPDATED BY MEDICAL OFFICER)

Sr No Name designation Contact No
7.5 LIST OF MEDICAL HELP TEAM ( LIST TO BE UPDATED BY MEDICAL OFFICER)

SR NAME DESIGNATION CONTACT NO
NO
7.6 LIST OF BLOOD DONORS ( LIST TO BE UPDATED BY MEDICAL OFFICER)

SR NAME DESIGNATION CONTACT NO
NO
7.7 TRAINED FIRST AIDERS ( LIST TO BE UPDATED BY MEDICAL OFFICER)

SR NAME S/SHRI SECT DESIGNATION CONTACT NO
NO
1 M.B. Rahangdale, Electrical S.S.A.
Maintenance
2 S.Y. Khewale, Fire Fighting Fireman Fireman
3 M.P. Chandragire,
4 S.R. Gite, W.T.P. Jr. Lab Asstt.
5 R.K. Talekar, C.H.P. Art. B
6 A.R. Kirnapure, Art. B
7 D.B. Tinkhede, TIC Art. A
8 J.D. Laudkar, Art. B
9 L.S. Nikose, Boiler CH-I
10 D.S. Dhore, Maintenance S.S.A.
11 S.M. Patil, Turbine S.S.A.
Maintenance
12 L.G. Nimje, Civil Maintenance Art – C
13 Z.S. Bembare, S.S.A.
14 S.N. Sheikh, Security Jr. S.O.
15 D.R. Hate, Watchman
16 N.A. Iwnathe, Major Store S.H.

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17 M.M. Chaudhari, Safety J.E.

18 R.M. Chaudhari, Hospital First Aid Asstt.
7.8 TRAINED FIRE FIGHTING PERSONS ( LIST TO BE UPDATED BY FIRE OFFICER)

SR NAME SECT DESIGNATION CONTACT NO
NO
7.9TRAINED SECURITY HELP PERSONS(LIST TO BE UPDATED BY SECURITY OFFICER)

NO
7.10 SAFETY COMMITTEE MEMBERS ( LIST TO BE UPDATED BY SAFETY OFFICER)

7.10.A SAFETY COMMITTEE 210 MW
Sr.
SECTION Members
No.
1 Dy. Chief Engineer President
2 Safety officer Secretary
3 Dy. Chief Engineer ADMin Mgmt Repre.
4 Supdt Engineer Op I A Mgmt Repre.
5 Supdt Engineer MPD Mgmt Repre.
6 Supdt Engineer Mint 1 Mgmt Repre.
7 Supdt Engineer Civil Mgmt Repre.
8 Supdt Engineer CHP Mgmt Repre.
9 Medical Supdt Mgmt Repre. 8805000903
10 Ex. Chmemist Mgmt Repre. 8408889328
11 Welfare Officer Mgmt Repre.
12 Security officer Mgmt Repre. 9403111859
13 TURBINE MAINT. A.N. Pundge JE 9403604260
14 BOILER MAIN. Sh N.A.Thaware Jr Engr 9423604132
15 ELECTRICAL MAIN. Sh S .N.Ghorse Tech II 9423602435
16 TIC Mr.V.R.Subramanya AE 8975767894

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Page : 62
17 WATER TREATMENT PLANT Mr R.K.Singh Chemist 9372974755

18 ASH HANDLING PLANT Mr P.P. Chavan Jr Engr 9960413130
19 OPERATION SERVICES Sh Sapkal Jr Engr 9226436757
Sh S B Khade Jr Engr (MM) 9860833503
20- Sh P.B Tekale Jr Engr (EM) 9423324657
COAL HANDLING PLANT
23 Sh V.D.Borse Jr Engr (Op) 9766857388
Sh D.R.Savasakade tech III (VM) 8888758877
Sh R.N.Bhonde Sub Engr U-1 9890233123
Unit - I
Sh Syed Abid Ali Tech III 7620467814
Sh R B Juware Sub Engr U-2 9423629094
Unit -II
24- Sh D M Jagnade Tech I U-2 9423605386
OPERATION
32
Sh.S.S.Patil JE 9764001293
Unit -III
Sh.P.R. Akhare Tech.III
Unit - Sh.N.G. Ahirrao JE
IV Sh.V.V. Kshirsagar Tech III
33 CIVIL MAINT. sh V.F. Kadhao AE.(C)
34 SECURITY Sh B K Kulkarine Dy mang
35 Major Store Sh P Wankhede Stores Helper
36 Fire Fighting Sh D.N. Pande Fire man 9860760901
Annual Contract Section
1 M/s ABU Constructions AHP Sh Chandrakant Ghodmare 9373123479
2 M/s Adhau Contractor AHP Sh Keshao Gajbhiye 8484033099
3 M/s Adore Contractor AHP Sh Nandkishor Girhe 9657770662
4 M/s Ahfaz Ahmed Contractor AHP sh purushottam Bagde 8180804552
M/s Dewaji N.Kubde
5 AHP sh Ganesh N.Shende 9970221478
Contractor
6 M/s Balki Associates WTP Sh Nilesh Satpute 9371997309
7 M/s Ashok Goods Cle. Serv. op 1 Sh Balaji Marotrao Hande 9970461907
8 M.F Jain Civil Sh Govind Shahane 8605050449
9 S.R. Gawande Civil Sh Dipak Bhoyar 9021375898
10 S.R. Gawande Civil Sh Ayub khan 9850217889
11 Manorama cont Civil Sh Ashok Wasnik 9822522375
12 M.F Jain Civil Sh Suresh David 9604599492
13 M/s D.N.kubdeContractor EM Sh B.G.Kale 9561370886
14 M/s Kunal Constructions BM Sh Ravi Shende 9960988040
15 M/s Adore Contractor BM Sh Dinesh Kakade 9922940336
16 M/s Rajesh Ent. BM Sh Dipak Barde 9960350068
17 M/s Devajin .Kubde TIC Sh A.S.Bariskar 9765977136
18 D.R Contractor FM Sh D.R.Borkar 9765860072
19 M/s LBC CHP Sh M.M.Bhasme 9922083904
20 M/s M.F.Jain Contractor CHP Sh Ajay Vyavhare 9850467927
21 M/sP.B.Kundu CHP Sh Santosh Pote 9975056084
7.10.B SAFETY COMMITTEE 500 MW

ISSUE : 04
Page : 63
Phone / Mobile
SECTION 500mw MEMBER
No.
1 Dy. Chief Engineer-II President 8888838932
2 Dy. Chief Engineer ADMin MgmtRepre.
3 Supdt Engineer OP-II MgmtRepre.
4 Supdt Engineer CHP-II MgmtRepre. 9850389172
5 Supdt Engineer Maint-II MgmtRepre. 8888838931
6 Supdt Engineer Cvil MgmtRepre.
7 Medical Supdt MgmtRepre. 8805000903
8 Ex. Chemist MgmtRepre. 7350008626
9 Ex. Engineer (Cvil) MgmtRepre.
10 Welfare Officer MgmtRepre.
11 Security Officer MgmtRepre. 9403111859
12 Ex. Engineer (Safety) Secretary
1) S.B. Thengne (JE) 9665850687
1 Operation Services -II
2) Chetan Bhakare (Tech-III) 9552560905
1) D.G.Agrawal (Dy.EE) 9226118443
2 Operation
2) A.R.Nachane (Tech-II) 9730753977
1) C.N.Wanjari
3 Turbine Maint.-II
2) S.A.Bangle
1) C.D. Lakhe (AE) 9823331064
4 C & I-II
2) D.B. Kudawale (Tech-III) 9822291233
Test- II 1) R.W.Kopulwar (Tech-I) 8975769645
1) G.N Motpuse (JE) 8806702121
6 Electrical Maintance-II
2) P.S.Kukde (Tech-III) 9420303041
1) K.B.Mahajan (AE)
7 Boiler Maintacne -II
2) K.A. Choudhari (Tech-III) 7038866852
1) M.P.Sawant ( JE ) 8975756908
8 Ash Handling Plant-II
2) P.S Wankhade(Tech-I) 9604950166
1) N.J.Jambhulkar (AE)
9 Coal Handling Plant-II
2) S.B.Neulkar (Tech-III) 9420187574
1) L Y Bunnawar (Chemist) 7774933569
10 Water Treatment Plant-II 2) R.S.Rajput (Tech-III) 9922979491
3) M.S Nile (Tech-III) 8446442718
11 CIVIL MAINT.II S.A.Badwaike Je 8087284878
12 Fire Fighting V.B.Pawar 9923779489
Contractors
Sr Annual Contract Section
Representatives
1 M/s Deepak Construction Praful Dhoke 8975492125
2 M/s Deepak Construction OS II Ashok Bhimgade 9637662512
3 M/s Deepak Construction Dilip Yeole 9890561241
4 M/s M.F Jain RaJan Dhoke 8007849713
WTP II
5 M/s M.F Jain Sidharth Jamgade 9421406959
6 D.N Kubde R.G. Deshbratar 9028889454
7 D.N Kubde EM II A.N. Borkhede 8275396697
8 D.R. Construction B.R.Chaturvedi 8857058937
9 M/s ABU Construction Rakesh Kaithwas
BM II
10 M/s Ahafaz Ahmad Raju Bhurke 7744932453

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Page : 64
11 M/s MRP Nair Sunil Shahan 9545513581

12 M/s Kunal cont Vivek Bhad 8793667699
AHP II
13 M/S G.Y Lonare 9890239408
14 M/s D.R. Costruction Test II D.B.Manapure 8975660420
15 M/s D.R. Costruction Nandakishor.Wankhede 8390607287
C&I
16 M/s D.R. Costruction Lilish Chandankar 9011192537
7.11 VOLUNTEERS ( LIST TO BE UPDATED BY CONCERN SECTION HEAD)

NO
7.12 LIST OF GOVT AUTHORITIES (MARG)(LIST TO BE UPDATED BY MEDICAL OFFICER)

GOVT. OFFICERS
1. COMMISSIONER OF POLICE, NAGPUR 2560601, 9819890000

2565002
2. CONTROL ROOM 2564333,
2564334
3. Divisional Director, Nagpur 2532123
4. District Head Home guard, Nagpur 2705828/ 0712-3465334.
2461986
5. District Collector, Nagpur 2564973 2561755
6. Nagpur Doordarshon 2510506 2510136
7. Deputy Collector, Saoner 232275 232210
8. Tahasildar, Saoner 232212 232268
9. Deputy Director, Industrial Safety & Health 2530745 2267810
7.13 LIST OF MEDICAL FACILITY NEAR BY ( LIST TO BE UPDATED BY MEDICAL

OFFICER)
BLOOD BANK
1. Govt. Medical College, Nagpur 2744671 (Ex- 229)
2. Mayo General Hospital, Nagpur 2728622 (Ex- 134)
2726126
3. E.S.I. Hospital, Nagpur 2744765 / 2744337
4. Daga Memorial Hospital, Nagpur 2729202 / 2770666
5. Jivan Jyoti Blood Bank & Components 2231660/ 2230876 /
2436167
6. Mure Memorial Hospital, Nagpur 2522370
7. Hedgewar Blood Bank,Gokulpeth, Ngp. 2528292
8. City Blood Bank, Infront of Daga Hospital, 2769251

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Nagpur
9. Matru Seva Sangha, Nagpur 2522393 (Ext. 3)
2522287
10. Life Line Blood Bank 6618222
11. Rainbow Blood Bank 2460101, 6636666
HOSPITAL
1. Ayourvedik Hospital, Nagpur 2742592
2. C.G.H.S, Nagpur 2510620, 2565169
3. Central India Inst. of Medical Science 2233381 / 2236441/ 2237662
4. Daga Memorial Hospital, Nagpur 2729202

5. Dental College, Nagpur 2744496
6. Dr. Dalvi Memorial Hospital, Nagpur 2766414
7. Indira Gandhi Medical College, Nagpur 2725274, 2726126
8. Matru Seva Sangha, Nagpur 2522393, 2522287
9. Mayo Hospital, Nagpur 2726126 / 2728622
10. Medical College, Nagpur 2744671
11. Mental Hospital, Nagpur 2583044
12. Mure Memorial Hospital, Nagpur 2522370
13.
14. Homeopathic College & Hospital, Nagpur 2746502
FIRE FIGHTING SERVICES ( LIST TO BE UPDATED BY FIRE OFFICER)
1. Thermal Power Station Koradi 07109 - 262141 to 262146
2. Nagpur Mahanagar Palica, Fire Fighting Services 2567777 (Ext. 101)
2557861
3. Director, National Fire Fighting Services, Nagpur 2565074/ 2562611/ 2565614
4. Western Coal Field Ltd. Sillewara 268320/ 268115/ 268124

ISSUE : 04
Page : 66
8. PLANT INFORMATION
8.1 PLANT PROCESS
Switch Yard
Generating
Transformer
Oil Generator Hydrogen

FO/ LDO Generating Plant
Turbine
Condenser Cooling Tower
Oil Handling Condensate

Plant Ozone
Boiler
Water Treatment
Plant Water
Milling plant Ammonia

Drinking Water Chlorine
Electro Static
Precipitator
Coal handling plant
Ash Handling FOR

Plant Plant &
Colony
Coal
Railways
Ropeways
Ash bund

ISSUE : 04
Page : 67
8.2 INFORMATION ABOUT PLANT
Full name & address of the factory: Khaperkheda Thermal Power Station, Koradi
District Nagpur – 441 102, Maharashtra
Registration No 20/NAG/2M(I) :: License Renewal No.:094037
Phones: Phone: (07113) 268168 to 172, 268236, 268131
Fax No.: 07113 – 268239(Off) / 268123(Site) Email – cegenkpkd@mahagenco.in
Full name & address of the Occupier: Contact Nos
Shri S.S. Jadhao Office Residence

Chief Engineer 07113-268563 (P) 07113-268561
Khaperkheda Thermal Power Station, 07113- 268168-70 ( R)
I Type Prakashnagar, (O)
Nagpur.441102. Extn:
4001,4501,4801(R)
M : 9822115290
Full name & address of the Manager (Deputy Chief Contact Nos
Engineer)
Office Residence
Shri C K Sawaitul Office
Dy. Chief Engineer Admn 07113- 268168-70
Khaperkheda Thermal Power Station, (O)
II/3/2 Type Prakashnagar, Extn: 4003,4503,
Nagpur.441111.
M: 9850331342
Full name & address of the Deputy Chief Engineer Phones
Shri BO Bagade 07109 –268668, Residence

Dy. Chief Engineer - I 07113- 268168-70 07109 –
Khaperkheda Thermal Power Station, (O) 262166,
II/2/2 Type KTPS Colony, Extn:
Nagpur.441111. 4002,4502,4802(R)
M: 8888865263
Full name & address of the Deputy Chief Engineer Phones
Shri G. S. Kumarwar 07109 –268668, Residence

Dy. Chief Engineer - II 07113- 268168-70 07109 –
Khaperkheda Thermal Power Station, (O) 262166,
II/2/2 Type KTPS Colony, Extn:
Nagpur.441111. 4002,4502,4802(R)
M: 8888865263
S HIFT D ETAILS :
S HIFT C OMMENCEMENT C LOSURE L UNCH T IME
G ENERAL 07.30 17.00 12.00 to13.30
B 07.00 15.00 No Lunch break
C 15.00 23.00 No Lunch break
A 23.00 07.00 No Lunch break

ISSUE : 04
Page : 68
8.3 ORGANOGRAM EE – OP U1,2,3,4
EC – WTP I
SE
Op I EE– TSC/IMS
EE – OS I
EE - FQAD
EE - TIC
Dy. C E-I EE – BM I
SE EE – TM I
M-I
EE – AHP I
EE – EM I
SE EE – CHP I
CHP
EE – CHP II
EE – OP U5
EC – WTP II
SE
Dy. C E-II Op II EE – OS II
Chief
EE – TIC II
Engineer
EE – BM II
SE EE – TM II
M - II
EE – AHP II
EE – EM II
Welfare Section
Security Section
Sr Mgr HR
Gen Mgr F&A
EE – Maj Stores
Dy EE – Civil Maint
Dy CE EE - Purchase
Admin
SE Safety Section
MPD
Fire Fighting
EE - MPD
Medical
Dispensary
Supdt

ISSUE : 04
Page : 69
8.4 LIST OF DMP TEAM LEADERS ( LIST TO BE UPDATED BY SAFETY OFFICER)

DMP TEAMS TEAM LEADER CONTACT NO
Fire Fighting & Rescue team Fire Officer 08408889307
Medical help team Medical Supdt 08805000903
Coordination team Dy CE I 08888865263
Dy CE II
Security & Traffic control team Sr Mgr Security 09011407332
Communication & Liaison team Dy CE Admn 09850331342
Vehicle control team Asstt Engr VM 09423063606
Maintenance team Supdt Maint I 09850383179
Supdt Maint II
Welfare team Welfare Officer 08408889325
Logistic team Dy EE Civil Maint 08408889300
8.5 TELEPHONE LIST OF SITE/SECTIONS ( LIST TO BE UPDATED BY TELEPHONE

OPERATOR)
Sr. NAME OF THE POST Contact numbers
No.
1 Chief Engineer
2 Dy. Chief Engineer I (210)
Dy. Chief Engineer II (500)
3 Dy. Chief Engineer (Admin)
4 S.E. (OP I)
5 S.E. (M)
6 Dy.E.E. (Civil)
7 S.E. (CHP)
8 Medical Supdt.
9 Ex. Engineer (B/M) I
10 Ex. Engineer (AHP) I
11 Ex. Engineer (T/M) I
12 Ex. Engineer (E/M) I
13 Ex. Engineer (TIC) I
14 Ex. Engineer (OS) I
15 Ex. Chemist (W.T. Plant) I
16 Ex. Engineer (Major Store)
17 Ex. Engineer (CHP) I
18 Ex. Engineer (CPS)
19 Ex. Engineer (Trg S C)
20 EE MIS
21 Ex. Engineer Gen (U – 1 & 2)
22 Ex. Engineer Gen (U – 3 & 4)
23 Shift Incharge Unit I
24 Shift Incharge Unit II
25 Shift Incharge Unit III
26 Shift Incharge Unit IV
27 Dy E E Engineer (Civil)

ISSUE : 04
Page : 70
28 Fire Officer
29 Sr Manager HR (EO)
30 Chief Manager(F&A) (Dy. C.A.O.)
31 Welfare Officer
32 Sr Manager (Security)
33 Head Time Keeper (Time Office)
34 Safety Officer
Sr. Location
No.
1 Plant Incharge U1, S/I ,PCR I/C, Plant
I/c
2 Plant Incharge U2 S/I ,PCR I/C, Plant I/c

5 Boiler Basement U1&U2/
6 Boiler Basement U3&U 4
7 Firing floor U1
8 Firing floor U2
9 Firing floor U3
10 Firing floor U4
11 6.6 KV room U1,
12 6.6 KV room U 2,
13 6.6 KV room, U3,
14 6.6 KV room U4
15 Comp room U1,
16 Comp room U2,
17 Comp room U3,
18 Comp room U4
19 AHP Pump house
20 AHP control room
21 Ammonia dozing
22 Ozone plant
23 CW pump U1&U2
24 CW pump U3&U4
25 Civil maint colony
26 Workshop
27 DM plant control room
28 Hydrogen gen plant
29 RWP/FF pump house
30 CHP Maint
31 CHP Control room
32 Elect maint colony

ISSUE : 04
Page : 71
8.6 LIST OF HAZARDOUS MATERIAL STORAGE
W.T. PLANT

1 Hydrochloric Acid MT Acid tank area 107.435
2 Caustic Soda Lye ( 100 % Basis) MT Acid tank area 32.115
3 Alum MT Godown PTP 129.16
4 Hydrated Lime MT Godown PTP 12.94
5 Liquid Ammonia LTR 1146
6 Hydrazine Hydrate KG 2028
7 Tri. Sod O‟ Phosphate KG 1000
8 Potassium Hydroxide KG 55
10 Resins
(g) Cation LTR 5220
(h) Strong Base Anion LTR 4380
(i) Weak Base Anion LTR 3320
11 PAC MT -
12 Bleaching powder MT 6.90
(e) Tonners 950 kg Cylinders plant 07
(f) 100 Kg Cylinders 02
(c) 50 Kg Cylinders Cylinders plant & 73
Ammonia
Dozing
U1, U2&u3
3
(e) Cylinders of M Cylinders station
(f) Cylinders of M3 Cylinders H2 manifold at
Unit 1,2,3&4
18 Ozone Self As per
(6 kg per hr Generation) generate requirement
d basis
OPERATION / OPERATION SERVICES

LDO, 1500KL
FO 6000 KL
2 Hydrogen Gas cylinder 25 cylinders U# 1to4 Turbine basement out side
Average stock per unit each unit

ISSUE : 04
Page : 72
TESTING INSTRUMENTATION & CONTROL

1 Radio- active material 5 3 on slurry mixer tank (AHP2) for
density measurement
2 on tic store (no 3) in sealed room
(spare )
inflammable
TURBINE MAINT

stock
stock
stock
4 MOT Capacity
stock
BOILER MAINT

list
(DF) Store
Store
ELECTRICAL MAINT

1 Lub Oil Nil
4 Transformer Oil

ISSUE : 04
Page : 73
Generating xmer,
UAT, (25 Barrels
AHP, WTP
MAJOR STORES

1 Lub Oil 28.5 Oil Shed
2 Gear box oil ------ -------
3 Hydraulic coupling oil ------- -------
4 Grease Add diff grease 0.182 Oil Shed
list
5 Transformer Oil
Generating xmer, Station
xmer, 2.926 Oil Shed
UAT,
ESP Xmer,
other aux xmer oil at
CHP, AHP, WTP
ASH HANDLING PLANT

1 Lub Oil 0
Sp 46 420Ltr.
SS 68 87 Ltr.
Sp -460 420 Ltr. Oil Room adjacent to New Godown
3 Grease Ep2, 182 Kg No 2
Ep3 0
COAL HANDLING PLANT

1 Lub Oil Nil
2 Gear box oil (SS-320 ) 40 Ltr In metallic portable shed near CHP
office building.
( SS-320 )
400 Ltr
46)

ISSUE : 04
Page : 74

Reclamation
wise
8.7 LIST OF FACILITIES AVAILABLE FOR HAZARD CONTROL & RISK

MINIMISATION
8.9 LIST OF ELECTRIC CONNECTION ISOLATORS FOR MAJOR AUXILIARIES

ISSUE : 04
Page : 75
9. MATERIAL SAFETY DATA SHEET (MSDS)
i. Chlorine √
ii. Ammonia√ NH3 & (NH4OH)
iii. Ozone√
iv. Hydrogen√
v. Hydrochloric acid√
vi. Caustic soda lye√
vii. Hydrazine Hydrate√
viii. LPG√
ix. Oxygen√
x. Acetylene√
xi. Air conditioning Gas ( freon 22 & RA 32
xii. Carbon di oxide√
xiii. Radio Active material
9.1 MATERIAL SAFETY DATA SHEET (MSDS) FOR CHLORINE (CL2)

USES & APPLICATIONS :- Chlorine gas is used in thermal plant for chlorination of water &
to restrict the Algae in C.T. Pond.
IMPORTANT
PROPERTIES
Physical Stage : Gas or liquid under pressure
Colour : Greenish Yellow (Gas) or Amber (liquid)
Odour : Acutely irritating
Specific gravity : 1.4 at 20°C (Water = 1.0)
Vapour Density : 2.5 (Air = 1.0) at 20°C.
Vapour Pressure : 6.8 bars at 20°C.
: 3 ppm (9mg / m³) (STEL Value)
IDLH Level : 25 ppm
Solubility : Slightly soluble in water and alkalis
Chemical Reactivity : Reacts slightly with water forming weak solution of
Hydrochloric and hypoclorous acids.
: It is corrosive to common metals at ordinary temperatures
dry chlorine reacts with aluminium, arsenic, gold, mercury etc.
: On heating above 120°C it reacts with steel, iron, copper,
lead etc. at certain temp.
: Chlorine reacts spontaneously with hydrogen to form
hydrogen chloride.
HEALTH HAZARDS :-
1. Respiratory Irritant
2. In extreme cases, breathing difficulty may cause death due to suffocation.
3. React with body moisture to form acid at high concentration.
4. Act as an asphyxiate.
5. Liquid chlorine causes skin burns.
6. Burning of eyes and nose.
PERSONAL PROTECTION :-

ISSUE : 04
Page : 76
1. Prevent skin contact appropriate clothing.

2. Goggles for eye protection.
3. Respiratory protective equipment i.e. breathing apparatus, gas mask.
FIRST AID :-
1. Secure medical attention quickly.
2. In case of inhalation if the victim is conscious lay him down with the upper part of
the body elevated loosen his clothing, belt and covering with blanket.
3. If victim is unconscious but breathing, let him inhale pure air till doctor arrives.
4. If liquid chlorine enters the eye, immediately flood the eyes gently with clean fresh
water.
FIRE & EXPLOSION HAZARDS :-

1. Welding, cutting or other hot work on the equipment of chlorine should not be
started until the system has been purged with steam and dried with hot air.
2. Prevent contact of chlorine with hydrogen, acetylene and ammonia as they form
explosive mixtures.
FIRE FIGHTING :-
1. If fire threatens cylinder of chlorine should be moved in the open safe place.
2. Heated Cylinders should be kept cool by spraying with water from safe position
provided no chlorine leakage.
3. Fire fighting personal must wear a breathing apparatus.
STORAGE & HANDLING :-

1. Storage area must be properly ventilated.
2. Ventilation must be sufficient to prevent accumulation of vapour pockets.
3. The fan intake should be located near the floor.
4. Do not store full & empty cylinders together.
5. Store chlorine in areas where there will be no contact with any materials that react
with it.
HANDLING OF SPILLS & LEAKS :-

1. In case of spillage all unprotected personal must leave the area.
2. If possible the spillage should be contained.
3. Any leaks in line, equipments or container must be given prompt attention. As it will
grow worse due to corrosion at the point of leakage.
CHECK FOR LEAKS :-

A rage dipped in ammonia water & tied to a stick will help to locate a leak because white
fumes of ammonia chloride form at the point of leakage.
MEDICAL SURVEILLANCE :-
Replacement and periodical medical examination with emphasis on eyes, respiratory
tract, teeth, skin, & pulmonary functions at least once in a year.

ISSUE : 04
Page : 77
9.2 MATERIAL SAFETY DATA SHEET (MSDS) OF AMMONIA

USES & APPLICATIONS :- Ammonia Anhydrous Ammonia is an irritating, flammable, and
colorless liquefied compressed gas packaged in
cylinders under its own vapor pressure of 114 psig at 70 F
IMPORTANT
PROPERTIES :-
Physical Stage Gas
Colour : Clear and colourless gas
Odour : sharp, strong odour similar to “smelling salts”
which is readily detectable at 20 ppm
Specific gravity : (air=1): 0.5
:
SKIN CORROSIVITY: : Ammonia is corrosive to the skin.
Threshold Limit Value LC50 (Inhalation): 7338 - 11590 ppm (rat, 1 hour); 2000
ppm (rat, 4 hours)
LD50 (Oral): Not applicable
LD50 (Dermal): Not applicable
:
HEALTH HAZARDS :-
EYE CONTACT: Exposure to Ammonia can cause moderate to severe eye irritation.
INGESTION: Ingestion is not a likely route of exposure for Ammonia.
INHALATION: Ammonia is severely irritating to nose, throat, and lungs. Symptoms
may include burning sensations, coughing, wheezing, shortness of breath, headache
and nausea. Overexposure may also cause central nervous system effects including
unconsciousness and convulsions. Upper airway damage is more likely and can result in
bronchospasm (closing of the airway). Vocal chords are particularly vulnerable to
corrosive effects of high concentrations. Lower airway damage may result in fluid build
up and hemorrhage.
Death has occurred following a 5 minute exposure to 5000 ppm.
SKIN CONTACT: Vapor contact may cause irritation and burns. Contact with liquid may
cause freezing of the tissue accompanied by corrosive caustic action and dehydration
ENGINEERING CONTROLS:
VENTILATION: Provide adequate natural or mechanical ventilation to maintain
Ammonia concentrations below exposure limits.
RESPIRATORY PROTECTION:
Emergency Use: Self-contained breathing apparatus (SCBA) or positive pressure airline
with full face mask with escape pack should be worn in areas of a large release or
unknown concentration.
EYE PROTECTION: Safety glasses for handling cylinders. Chemical goggles with full
faceshield for connecting, disconnecting or opening cylinders.
SKIN PROTECTION: Leather gloves for handling cylinders. Rubber or Neoprene gloves,
and chemical resistant outergarment should be worn when connecting or disconnecting
cylinders. Total encapsulating chemical suit may be necessary in large release area.
Fire resistant suit and gloves in emergency situations.
OTHER PROTECTIVE EQUIPMENT: Safety shoes are recommended when handling

ISSUE : 04
Page : 78
cylinders. Safety
FIRST AID :-
EYE CONTACT: Flush eyes with large quantities of water. Seek medical attention
immediately.
INGESTION: Ingestion is not a likely route of exposure for Ammonia.
INHALATION: Remove person to fresh air. If not breathing, administer artificial
respiration. If breathing is difficult, administer oxygen. Obtain prompt medical
attention.
SKIN CONTACT: Flush affected area with large quantities of water. Remove
contaminated clothing immediately. If liquid comes in contact with skin, remove
contaminated clothing and flush with plenty of
lukewarm water for several minutes. Seek medical attention immediately.
NOTE TO PHYSICIAN: Bronchospasm may be treated with the use of a
bronchodialator such as albuterol and an anticholinergic inhalant such as Atrovent.

It poses an immediate fire and explosion hazard when concentrations exceed
15%; therefore, area must be ventilated before entering. Wear self-contained
breathing apparatus (SCBA) when entering release area if concentrations exceed
allowable exposure limits. Fully protective suits are required in large releases.
Always be aware of fire and explosion potential in the case of large releases.
FIRE FIGHTING :-
EXTINGUISHING MEDIA: Dry chemical, carbon dioxide or water.
SPECIAL FIRE FIGHTING INSTRUCTIONS: Evacuate all personnel from area. If possible
without risk, stop the flow of Ammonia, then fight fire according to types of materials
that are burning. Extinguish fire only if gas flow can be stopped. This will avoid
possible accumulation and re-ignition of a flammable gas mixture. If possible, move
adjacent cylinders away from fire area. Keep adjacent cylinders cool by spraying with
large amounts of water until the fire burns itself out. Self-contained breathing
apparatus (SCBA) may be required.
UNUSUAL FIRE AND EXPLOSION HAZARDS: Most cylinders are designed to vent
contents when exposed to elevated temperatures. Pressure in a cylinder can build up
due to heat and it may rupture if pressure relief devices should fail to function. Runoff
from firefighting may be contaminated; check pH.
Ammonia can form explosive compounds when combined with mercury.
HAZARDOUS COMBUSTION PRODUCTS: Oxides of nitrogen
Some of these materials may react violently with water. Small fires can be fought
DCP,CO2, water-spray or regular foam. Larger fires have to be extinguished with
water-spray, fog or regular foam. Remove the container from the fire area.

STORAGE: Store cylinders in a well-ventilated, secure area, protected from the
weather. Cylinders should be stored upright with valve outlet seals and valve protection
caps in place. There should be no sources of ignition. All electrical equipment should be
explosion-proof in the storage areas. Storage areas must meet National Electrical
Codes for class 1 hazardous areas. Flammable storage areas should

ISSUE : 04
Page : 79
be separated from oxygen and other oxidizers by a minimum distance of 20 ft. or by a

barrier of noncombustible material at least 5 ft. high having a fire resistance rating of at
least ½ hour. Ammonia cylinders should not be stored near acids or acid-forming
gases. Post “No Smoking or Open Flames” signs in the storage or use areas. Do not
allow storage temperature to exceed 125 F (52 C). Storage should be away from
heavily traveled areas and emergency exits. Full and empty cylinders should be
segregated. Use a first-in first-out inventory system to prevent full containers from
being stored for long periods of time.
Caution: Ammonia cylinders are subject to theft and misuse. Cylinders should be
stored and used in controlled areas.
HANDLING: Do not drag, roll, slide or drop cylinder. Use a suitable hand truck
designed for cylinder movement. Never attempt to lift a cylinder by its cap. Secure
cylinders at all times while in use. Use a pressure reducing regulator or separate control
valve to safely discharge gas from cylinder. Use a check valve to prevent reverse flow
into cylinder. Never apply flame or localized heat directly to any part of the cylinder.
Do not allow any part of the cylinder to exceed 125 F (52 C). Once cylinder has
been connected to properly purged and inerted process, open cylinder valve slowly and
carefully. If user experiences any difficulty operating cylinder valve, discontinue use
and contact supplier. Never insert an object (e.g., wrench, screwdriver, etc.) into valve
cap openings. Doing so may damage valve causing a leak to occur. Use an adjustable
strap-wrench to remove over-tight or rusted caps. All piped systems and associated
equipment must be grounded. Electrical equipment should be non-sparking or
explosion-proof.
Only a recommended CGA connection should be used. Adapters should not be used.
Use piping and equipment adequately designed to withstand pressures to be
encountered. If liquid product is being used, ensure steps have been taken to prevent
entrapment of liquid in closed systems. The use of pressure relief devices may be
necessary. Dedicated inert gas cylinders with in line back-flow protection should be
used for purging.
SPECIAL REQUIREMENTS: Always store and handle compressed gases in accordance
with Compressed Gas rules
9.3 MATERIAL SAFETY DATA SHEET (MSDS) FOR AMMONIA SOLUTION (NH4OH) :-
USES & APPLICATIONS :-
IMPORTANT
PROPERTIES :-
Physical Stage : liquid
Colour : Clear and colourless liquid.
Odour : Extremely pungent and of characteristic odour
Specific gravity : 0.9229 at 25°C
Ammonia content : 20 % NH3 (min.)
Vapour Pressure :
Threshold Limit Value : 25 PPM (TWA Value)
: 35 PPM (STEL Value)

ISSUE : 04
Page : 80
HEALTH HAZARDS :-
It is very caustic and is capable of causing severe damage to eyes and skin. The gas
irritates the mucous membranes and lungs if inhaled. Fire may produce irritating or
poisonous gases. Run off from fire control or dilution water may cause pollution.
It is very caustic and can affect eyes and skin, hence it is essential to use PPE while
handling this chemical. Eyes should be protected with goggles. It is essential to use
breathing mask to avoid inhaling the fumes.
FIRST AID :-
In the event of any person getting affected. Move the victim to fresh air and call
emergency medical care. In case of contact with material, immediately flush skin or
eyes with running water for at least 15 minutes. Remove and isolate contaminated
clothings and shoes at the site. Keep victim quit and maintain normal body
temperature.

Some of these materials may burn, but non of them ignites readily. Flammable /
poisonous gases may accumulate in tanks and hopper cars. Some of these materials
may ignite combustibles such as wood, paper, oil etc.
FIRE FIGHTING :-
Easily combustible materials such as wood, paper, oil etc. should not be stored along
with the containers having ammonia solution.
Some of these materials may react violently with water. Small fires can be fought
DCP,CO2, water-spray or regular foam. Larger fires have to be extinguished with
water-spray, fog or regular foam. Remove the container from the fire area.

Do not touch or walked through spilled materials. Stop leak if possible without
risk. Small spills may be taken care of by throwing sand or other non-combustible
absorbent materials & place it into containers for later disposal. For larger spills contain
by making dikes far ahead of liquid spills for later disposal.
9.4 MATERIAL SAFETY DATA SHEET (MSDS) FOR OZONE (O3)

USES & APPLICATIONS :- Ozone gas is used in thermal plant to restrict the Algae in C.T.
Pond.
IMPORTANT
PROPERTIES
Physical Stage : Gas
Colour : Colorless to bluish
Odour : Pungent odor similar to the smell after strong lightning storms.
Specific gravity : 2.144 g/L
Vapour Density : 1.7 (Air = 1.0) at 20°C.
Vapour Pressure : NA

ISSUE : 04
Page : 81
IDLH Level : NA
Solubility : Solubility in H2O % by Weight: 0.49
Chemical Reactivity : Ozone is a powerful oxidizing agent and reacts with all oxidizable
materials , both organic and inorganic. Some reactions are highly
explosive. Alkenes, benzene and other aromatic compounds, rubber,
dicyanogen, bromine diethyl ether, dinitrogen tetroxide, nitrogent
trichloride, hydrogen bromide, and tetrafluorohydrazine.
: Highly reactive, ozone concentrations above 15% can explode on
contact with organic substances, especially strong reducing agents.
HEALTH HAZARDS :-
7. Inhalation: Causes dryness of the mouth, coughing, and irritates the nose, throat, and chest.
May cause difficulty in breathing, headache, and fatigue. The characteristic sharp, irritating odor
is readily detectable at low concentrations (0.01 to 0.05 ppm).
8. Skin: Absorption through intact skin is not expected
9. Eye Contact: Ozone is an irritant to the eyes causing pain, lacrimation, and general inflammation
10. Ingestion: Not a route of exposure.
4. Positive pressure air line with mask or self-contained breathing apparatus should be available for
emergency use
5. Goggles for eye protection.
FIRST AID :-
5. Inhalation: Remove to fresh air; if breathing is difficult a trained person should administer
oxygen. If respiration stops, give mouth-to-mouth resuscitation. Get medical attention.
6. Ingestion: Not an expected route of exposure.
7. Skin Contact: Wash skin thoroughly with soap and water.
8. Eye Contact: Immediately flush eyes with large amounts of water for at least 15 minutes, while
forcibly holding eyelids apart to ensure flushing of the entire eye surface. If irritation, pain, or
other symptoms persist seek medical attention.
9. Acute: May cause irritation of skin, eyes, and mucous membranes of the respiratory tract.
Drowsiness, dizziness, headache, and fatigue have been associated with exposure
10. Chronic: Long term health effects are not expected from exposures to ozone. A partial
tolerance appears to develop with repeated exposures.

3. . Ozone is an unstable gas which, at normal temperatures, decomposes to diatomic oxygen. At
elevated temperatures and in the presence of certain catalysts such as hydrogen, iron, copper
and chromium, this decomposition may be explosive.
FIRE FIGHTING :-
4. Use extinguishing media suitable for surrounding fires..

6. Storage area must be properly ventilated.
7. Ventilation must be sufficient to prevent accumulation of vapour pockets.
8. Keep away from heat, sparks and flame. Avoid contact with eyes, skin and clothing.
Avoid breathing. Use with adequate ventilation.

ISSUE : 04
Page : 82

4. If inhaled, remove to fresh air. Get medical attention for any breathing difficulty.
CHECK FOR LEAKS :-

Persons not wearing protective equipment and clothing should be restricted from areas of leaks until
cleanup has been completed. If ozone is leaked, the following steps should be taken:
1. Ventilate area of leak to disperse gas.
2. Stop flow of gas.
9.5 MATERIAL SAFETY DATA SHEET (MSDS) FOR HYDROGEN (H2)

USES & APPLICATIONS :- Hydrogen is used in the production of hydrogenates oils.
In Power Plant it is used as coolant in generator casing to cool
the generator winding.
IMPORTANT
PROPERTIES :-
Colour : Colourless
Odour : Odourless
Flammability Limits : 4 % - 76 % (by volume in air)
Vapour Density :0.07 (Air = 1)
Vapour Pressure : Gas at 20°C
Solubility : Insoluble in water and common solvents
Chemical Reactivity : Reacts violently with oxidizing agent, specially halogens
causing fire and explosion hazards.
HEALTH HAZARDS :-
1. It is non – toxic but in large amount / concentration can causes asphyxiation.
2. Liquid hydrogen or its vapours when in contact with skin causes cold contact burn.
This will vary in severity with temperature and the time of exposure
3. Inhalation of vapour or cold gas produces respiratory discomfort in the case of short
exposure
Not applicable
FIRST AID :-
The affected person should be removed immediately to fresh air and pulse and
respiration should be observed. If necessary artificial respiration should be administrated
and the person should be transferred to hospital. Oxygen may be given if necessary

The potential hazard of liquid hydrogen is severe, mainly for the following reasons :-
a) Extremely low temperature in liquid state.
b) Very large liquid to gas expansion ratio (1:850 at room temperature)
c) Wide range of flammability limits after it has vaporized to gas.

ISSUE : 04
Page : 83
d) Poor visibility of its flame that can injure instantly anyone coming into contact
with it.
FIRE FIGHTING :-
1. In the event of leakage of gas from a cylinder or process facility getting ignited it
should be extinguished only by closing the valve or isolating hydrogen feed to fire by
other suitable controls.

1. The greatest danger involved in the production, use and storage of hydrogen gas with
which it ignites and explodes. It to come into contact with liquid hydrogen.
2. On ignition, the mixture release large amount of energy in the form of heat or
explosive force, its violence depending on combustion conditions.
3. Outdoor storage should be in a securely fenced compound. Cylinders should
preferentially be stored under cover for protection fro direct rays of the sun.
4. When possible, the store should be a detached, non – combustible building. If the
store has to be a part of a building used for other purpose it should be -
a) Entirely of non – combustible construction.
b) Separated from other parts of the building by fire resisting walls and floors and
c) On the ground floor (never in basement) in a room against outside wall, with door
(s) leading direct to the open.

The gas should be vented slowly along with adequate inert purging or flared.
PREVENTION OF FIRE AND EXPLOSION :-

1) Naked lights, cigars, cigarette ends, sparks from static or live, discharges metal
impacts, heat from molten metal, welding or cutting from friction in moving parts,
sparks or heat from electrical faults and hot surfaces are some of the sources that
may lead to fire.
2) Vessels containing liquid hydrogen should be kept away from heat.
3) Maintenance / repair work, filling or emptying on any of the hydrogen storage /
transfer equipment should be done under work permit.
9.6 MATERIAL SAFETY DATA SHEET (MSDS) FOR HYDROCHLORIC ACID (HCL)
USES & APPLICATIONS :- Hydrochloric acid is available & used in aqueous as welding a
anhydrous form. Aqueous hydrochloric acid is also known as
muriatic acid anhydrous form is known as hydrogen chloride.
It is used for the manufacture of ammonium chloride,

chlorinated organic chemicals, dyes, dye, intermediates, acetic
acid, acetic anhydride, synthetic flavours etc.
IMPORTANT
PROPERTIES

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Physical Stage : Liquid

Commercial grade : 28% - 30%
Colour : Colourless to slightly yellow
Odour : Sharo, pungent
Specific gravity : 1.14 - 1.19
Boiling point : 110ºC
Flammability : Non-flammability
Threshold Limit Value : 5 ppm ( 7 kg/m³)

IDLH Level : 100 ppm.
HEALTH HAZARDS :-
1) Hydrochloride acid is toxic of inhaled or ingested.
2) Skin causes severe burns.
3) Inhalation of excessive concentrations of hydrogen chloride vapours cause severe
irritation of upper respiratory tract.
4) Ingestion of hydrochloric acid causes severe burns of the mucous membranes of
mouth, esophagus, & stomach pain, difficulty in swallowing, intense thirst, nausea &
vomiting, followed by diarrhoea & in severe cases by collapse & death.
5) Hydrochloride acid is toxic of inhaled or ingested.
6) Skin causes severe burns.
1) Chemical safety goggles with approved impact -resistant glass.
2) Rubber hand gloves, protective clothing made of rubber or acid resistant fabric,
rubber shoes having built in steel toe caps.
3) Plastic face shields with forehead protection & safety helmets are recommended for
use by workman.
4) Approved industrial canister type gas masks fitted with proper canister for absorbing
hydrogen chloride vapours can be used in work place. Where concentration is less
than 2%
5) Chemical safety goggles with approved impact -resistant glass.
FIRST AID :-
Hydrochloric acid is splashed into the eyes, spilled or sprayed on the body, the affected
part should be flushed with large quantities of water.
Remove the contaminated clothing to prevent the victim from further acid burns. In case
vapours are inhaled remove the victim immediately from contaminated area to fresh air.
If the employees is overcome by sudden leak of hydrogen chloride, he should be quickly

remove to fresh air & given artificial resuscitation in case breathing has stopped.
To prevent the development of pulmonary oedema, pure oxygen should be administered.
Persons who have ingested hydrochloric acid should make to drink lime water or milk of
magnesia. Seek immediate medical help.

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Hydrochloric acid both aqueous & anhydrous are not fire hazards. However hydrogen
chloride readily devolves in water to from hydrochloric acid which attacks most of the
metals with the evolution of explosive hydrogen.

Hydrochloric acid should be stored in rubber lined or FRP coated steel tanks & HDPE
carboys, storage tank should be in the open, above ground, surrounded by bund walls
carboys, & cylinder of hydrogen chloride should be stored in detached, non combustible.
Cool, well-ventilated storage area separated from oxidizing substances.
Acid proof bricks or steel & concrete protected suitable with an acid resistant surface
coating is the preferable material of construction for areas where hydrochloric acid is
stored or handled.
High silicon cast iron, few copper & nickel alloys, karabate & HDPE can be used as
materials of construction for pumps, valves, fittings & pipelines where hydrochloric acid
handed.
Electrical fixtures should be of vapour-proof type & wiring should be tight rigid metal
conduits protected with an acid resistant coating.
Storage tank & process equipment should be provided with vents & arrangement should
be made either to absorb the escaping vapours by water spray & dilute them or to
naturalize them by scrubbing through an alkaline solution.
Workman should be given training in proper handling of hydrochloric acid.

Spilled hydrochloric acid should never be left unattended.
To stop the leakage & shut off all sources of ignition.
Wear protective clothing & gloves.
Persons exposed to operations involving the handling of hydrochloric acid or hydrogen
chloride should undergo replacements & periodic medical examination with special
emphasis on skin disorders chronic diseases of the upper respiratory tract & vision
impairment.
Persons regularly exposed to processes involving hydrogen chloride or hydrochloric acid

& slowing the above symptoms should be removed permanently from the process.
WASTE DISPOSAL :-
For waste disposal of hydrochloric acid, state & local regulations regarding health
pollution should be followed when waste acid is to be discharged into a city system,
neutralization to prevent corrosion of the sewerage system.

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9.7 MATERIAL SAFETY DATA SHEET (MSDS) FOR CAUSTIC SODA (NAOH) :-
USES AND Caustic Soda is used in the manufacturer of rayon, cellophane,
APPLICATIONS mercerized cotton, detergent soap, bulb and paper, explosives
and dyestuff.
It is also used in chemical industry.
IMPORTANT
PROPERTIES :-
Physical Stage : Solid deliquescent.
Colour : White or light grey
Specific gravity : 2.12
Threshold Limit Value : 2 mg/m³
Boiling point : 139°C
Melting Point : 310 to 329°C
Solubility : Soluble in water, alcohol, glycerol.
Chemical Reactivity : A strong base can react violently with acids and many
organic chemicals. Caustic Soda corrodes metals such as
aluminum, tin, lead, zinc and alloys containing these metals,
slowly corrodes iron, copper and morel metal.
HEALTH HAZARDS :-
1) Caustic Soda is solid and in solution, has a markedly corrosive action upon all
body tissues.
2) Its corrosive action on tissues causes burns and deep ulceration.
3) Inhalation causes damage to the upper respiratory tract and to lung tissue.
1) Cup type rubber framed goggles with impact resistance lenses
2) Wearing of full face shield, mechanical filter respirator, rubber gloves, aprons &
boots.

Caustic soda & its solutions will not burn or support combustion. However, solid
when contact with moisture may generate sufficient heat to ignite combustible materials.
FIRE FIGHTING :-
Easily ignitable, combustible materials and metals should not be stored along with the
containers having solid Caustic Soda.
While fighting fires, self – contained breathing apparatus operated in pressure
deemed or other sensitive pressure mode should be used.

Drums or containers stored indoors should be kept in separate area with floor drains
that direct liquids to a safe location.

A small spills and leaks can be washed away with large quantity of water. Drainage
should be directed away from work areas. Adequate ventilation should be provided in
areas where mist or dust is present. In case of spillage all unprotected personal must
leave the area.

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Person require to work should undergo pre employment examination. Periodical
examination of such persons should be done by physician at least once in a year.
WASTE DISPOSAL :-
Waste Caustic Soda solution should not be discharged directly into sewers and streams.
It should be converted to mental neutral stage (Ph + 7) and then diluted with water in a
well designed effluent treatment system.
9.8 MATERIAL SAFETY DATA SHEET (MSDS) FOR HYDRAZINE HYDRATE (N 2H4H2O)
IMPORTANT
PROPERTIES
Physical Stage : Liquid. Available concentration : 80 % and 100 %
Colour : Colourless
Odour : Pungent (Ammonia like)
Specific gravity : 1.027 – 1.032 gm / cc at 25°C
pH value : 9.5 to 20°C for 1 % solution
Chemical Reactivity It is a powerful reducing agent.
HEALTH HAZARDS :-
It is corrosive to skin and eyes and therefore rubber garments and goggles should be
used.
Some persons may be very sensitive to the fumes. It is toxic if ingested through skin
absorption.
Avoid breathing vapours and keep upwind.
Wear positive pressure self contained breathing apparatus.
Wear appropriate chemical protective gloves, shoes and goggles.
FIRST AID :-
Move victim to fresh air and call emergency medical care.
If not breathing, provide artificial respiration.
If breathing is difficult, give oxygen.
In case of skin getting affected with material, immediately flush the affected part and
eyes with running water for at least 15 minutes.
Remove the contaminated clothings and shoes at the site.

The material itself does not burn or burns with difficulty.

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FIRE FIGHTING :-
Extinguish fire using agent suitable for type of surrounding fire.
Cool all affected containers with flooding quantity of water.
Apply water from a safe distance.

Hydrazine hydrate attacks rubber, glass and cork and therefore it should be stored in
high density polythene container.

Keep the material out of water sources and sewers.
WASTE DISPOSAL
Keep the material out of water sources and sewers.
9.9 MATERIAL SAFETY DATA SHEET (MSDS) FOR LPG IN CYLINDERS

USE AND APPLICATIONS :-
LPG is the abbreviation of 'Liquefied Petroleum Gas'. The term is used to describe a
verity of hydrocarbons which exist is vapours under ambient conditions temperature &
pressure. Saturated hydrocarbon in the form of propane (C3 H8) & butane (C4 H10) constitute
of commercially available LPG. The sources of LPG can be either natural gas, liquids of the
crude petroleum oils.
LPG is used as a fuel for heating, cooling, industrial process, heating, cutting & welding,
internal combustion engines, Blowlamps & also as feedstock for petroleum chemical
manufacture. They are also used to produce special atmosphere in heat treatment furnaces in
cigarette lighters & aerosols they are used as propellant.
IMPORTANT PROPERTIES :-
Typical properties of commercial Commercial Commercial
LPG grades Butane propane
Physical Stage Gas Gas
Colour Colourless Colourless
Odour All LP gases should be obqurised by the addition of
10 to 20 ppm. Concentration of warning agent
ethyl mercaptan or other organosulphur
compounds such as trtrehydrothiophen (THP).
Relative density at 15.6°C. (water 0.57-0.58 0.50-0.51
= 1)
Relative density of gas (air = 1) at 1.90-2.10 1.40-1.55
15.6°C & 1 atm
Ratio of gas volume to liquid 233 274
volume at 15.6°C & 1 atm.
Boiling point (°C) at atmosphere -2 - 45
Auto ignition temperature in air 287 432
(°C)

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Flammable limits (% volume in air) 1.8 - 9.0 2.2 – 10

Maximum flame temperature in air 1990.6 1978.3
(°C)
Vapour pressure at specified maximum

pressure (bars)
Temperature (°C)
- 40.00 - 1.30
-17.88 - 3.11
0 1.93 5.52
37.80 5.86 15.50
45.00 6.89 18.60
65.00 9.70 25.34
HEALTH HAZARDS :-
Under atmospheric pressure & at low concentrations, Hydrocarbon gases are not
toxic for humans. The presence of hydrocarbons (at a total concentration exceeding 3mg
/ m³) has no long term harmful effects on man. However, high concentrations
hydrocarbon gases displace oxygen thus causing asphyxia. Liquefied hydrogen gases are
much more dangerous & toxic if they contain sulphur compounds, particularly hydrogen
sulphides.

The degree of fire & explosion hazards of LPG is high, mainly for the following reasons.
a) Extremely low boiling point.

b) Large liquid to gas expansion ratio (245 to 270) at room temperature & subsequently
the air / LPG flammable mixture is 40 to 100 times gaseous volume of LPG.
c) Poor visibility of the ignitable & high burning velocity (0.38 meters ./ sec.) that can
injure instantly anyone coming into contact with it, on amount of high calorific value
of LPG (22000 M Cal / kg. Approximately)
d) Ability to ignite & burn as a deflagration, giving rise to a fire ball with intensive
radiation flame may result in explosion.
FIRE FIGHTING :-
In the event of leakage of gas from a cylinder getting ignited, it should be
extinguished only by closing the valve or isolating LPG feed to fire by other suitable
controls.
When the fire brigade arrives, they should be informed of the position of all
cylinders & equipment processing & storing LPG.
The following steps may be taken before arrival of the fire brigade, if no undue risk is
involved.
 Cylinders which have not become heated should be moved to safe place as quick as
possible, after ensuring that valves are shut.

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 Cylinders & equipment, which have become heated, should be cooled by spraying
water from a safe position. The person directing the spray should be taking up a
position where he would be protected from possible explosion.
Cylinders involved should be reused only after subjecting them hydraulic &
hydrostatic stretch test as per IS:5844 . In the even of fire, explosion, accident, notifies
the department of explosives in the areas.

Marking, repairing, filling, testing / retesting, handling storage & transportation of the
cylinders should be done in accordance with gas cylinder rules. Outdoor storage should
be in a security fenced compound. Cylinder should preferably be store under cover for
protection from direct rays of the sun. Where possible, the store should be a detached,
non-combustible building. If the store has to be a part of a building used for other
purpose it should be: -
a) Entirely of non-combustible construction.

b) Separated from other parts of the building by fire resisting wall & floors and
c) On the ground floor (never in basement) in a room against outside wall, with doors
leading direct to then open.
Means of venting an explosion should be provided e.g. lightly constructed root for a
single-storey building & light panels as external walls, arranged to blow out into a safe
area. Where there are stores above. Stores should have cool atmosphere with good low-
level ventilation. The store should not be used for other good or for any purpose other
than cylinder storage. Oxygen & chlorine cylinders should not be in the same store of
LPG cylinders. The location of the doors & the layout of the store should be such that
there is access to all parts of the store room. Ekits should be kept free from obstruction.
Cylinders should be stored & used in upright position. Fenced area, housing LPG storage
& processing facilities, should have conspicuous warning notices all around indicating the
presence of PLG & prohibiting smoking & use naked flames.
Empty cylinders should be marked & stored separately & handled as carefully as full
one because empty cylinders normally contain LPG vapour & also some traces of liquid. A
regulator should always be used to maintain the out let pressure at a proper & uniform
valve. Before the regulator is removed from a cylinder, the cylinder valve should be
closed & all gas released from the regulator. Cylinders should not be allowed to come
into violent contact with one another or with any hard object. Cylinders with damaged
valves or threads should immediately be labelled appropriately & returned to the
supplier. Cylinders should always be kept away from acids, corrosive substances &
flammable liquids. Cylinder valves & fitting should be kept clean. Valves should be
opened slowly. Tests or leakage should be done by brushing with soapy water & never
with a naked flame. Electrical equipment in storage / filling / handling area should
conform to statutory requirements. Operators should wear leather gloves while handling
cylinders at filling station, loading / unloading them at the transport vehicle, or stocking
them for storage.

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a) Naked lights, cigarette ends, sparks from static on live discharges, metal impacts,
heat for molten metal, sparks from welding or cuttings, friction in moving parts & hot
surface are some of the sources that may lead to fire.
b) Cylinders containing LPG should be kept away from heats, since the low boiling point
requires little heat input to evolve a large volume of gas.
c) Maintenance / repair work & filling / empty on any of the LPG storage / transfer /
bottling equipment should be done under work permit.
d) Identify leaks in cylinders. Rectify by lightening glands, nuts, etc. if leakage dose not
stop, remove them to open area, notify the supplier. Keep valve closed even for
empty cylinders.
e) To ensure fire safety, the composition, filling pressure quantity of LPG should be
conform to IS : 1448 (P:70) - 1968, ( Reaffirmed 1980) pressure regulator & other
devices to IS : 4784-1968 & 4786-1968, filling ratios to IS : 3710 - 1970, rubber
hose to IS : 9573 -1980
9.10 MATERIAL SAFETY DATA SHEET (MSDS) FOR OXYGEN (O2)
USES AND
Oxygen is used to intensify combustion for flame cutting and
APPLICATIONS welding along with acetylene, propane and other fuel gases. It
is used for hardening, scarping and cleaning metals, steel
manufacture, production of synthesis gas and other chemicals.
The medical uses of oxygen are as a resuscitation agent and
heart stimulant. Oxygen is also used as an inhalant in such
activities as high altitude flying deep sea diving and as a rocket
propellant.
Physical Stage : Gas or liquid under pressure
Colour : Colourless
Odour : Odourless
Specific gravity : 1.14 (of liquefied gas)
Vapour Density : 1.11
Threshold Limit Value : 1 ppm (3mg / m³) (TWA Value)
: 3 ppm (9mg / m³) (STEL Value)
IDLH Level : 25 ppm
Solubility :: Moderately soluble in water
Chemical Reactivity : Reacts slightly with water forming weak solution of
Hydrochloric and hypoclorous acids. It is corrosive to common
metals at ordinary temperatures dry chlorine reacts with
aluminium, arsenic, gold, mercury etc. On heating above 120°C
it reacts with steel, iron, copper, lead etc. at certain temp.
Chlorine reacts spontaneously with hydrogen to form hydrogen
chloride.
HEALTH HAZARDS :-
Inhalation of 100% Oxygen under pressure can cause nausea, dizziness, irritation of
lungs, pulmonary inflammation, hemorrhage, pulmonary edema, pneumonia, and

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collapse. Liquid Oxygen may cause frost bite or severe cold burns of skin and eyes.
Safety goggles or face shields, insulated gloves, long sleeves, trousers worn
outside boots of over high- top shoes offer protection while handling liquid Oxygen. Wear
special personal protective clothing that will not ignite on contact with liquid Oxygen, this
is designed to prevent liquid Oxygen from coming in contact with the skin the, causing
severe cold burns.
FIRST AID :-
In case of inhalation, in all but the most severe cases (Pneumonia), recovery is
rapid after reduction of Oxygen pressure, supportive treatment should include immediate
sedation, anticonvulsive therapy of needed, and rest.
In case of frost bite of the skin, do not remove clothes, first rinse only, then
remove clothes. Rinse skin with plenty of water or shower and then transport to hospital.
In case of frost bite burns affecting the eyes, first rinse with plenty of water, then
transport to a hospital.

Oxygen is not combustible in itself but enhances combustion of other substances.
Heat impact necessary to ignite many materials reduces with increasing oxygen
concentration. Oil oases may ignite spontaneously in the presence of compressed
oxygen.
Liquid oxygen can explode on contact with organic substances and readily ox
disable materials. Oxygen gas cylinders may explode if they are involved in a fire and
become heated.
FIRE FIGHTING :-
In the event of a leakage from a pipeline or cylinder, the supply should be cut off
as soon as possible.
If a fire threatens cylinders, those which have not become heated should be
moved to a safe place in the open as quickly as possible making sure that valves are
turned off first.
Cylinders which have become heated or which cannot be easily moved should be
kept cool by spraying water from a safe position.
The fire brigade should be called immediately and when they arrive at the
premises they should be informed of the position of all cylinders even if they are not
directly threatened by the fire.
PREVNTION OF FIRE AND EXPLOSION :-

To prevent occurrence of fires open flames sparks, smoking and contact with
combustible and reducing substances should be prevented. Ventilation should be
provided and clothing should not be brought into contact with oxygen.
The recommended storage and handling practices when followed will help prevent fire
and explosion of oxygen gas cylinders.
Oxygen storage should be separated from combustible substances and reducing
agents and should be in a cool. Well ven5ilq53e location. Cylinders should preferably be
stored under cover where they can be protected against the direct rays of the sun. The
store should preferably be a detached on combustible any purpose other than cylinder
storage. Oxygen cylinders should not be stored along with cylinders containing ammonia,

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acetylene, LPG or any other flammable gases.

Empty cylinders should be kept separate from full ones although they may be
kept in the same store, distinctive notices or markings should be displayed to prevent
confusion. A common practice is to chalk „MT‟ on empty cylinders.
The store should be indicated by suitable notices. The location of the doors and
the layout of the stores should be such that cylinders may be removed easily in the
event of a fire. Exits should be kept free from obstruction. Cylinders should be stared so
that there is easy access to all garts of the storage. Cylinders are to be stored of bright
in suitable stands. When cylinders are not being used, protective cans should be screwed
down over the valves. Cylinders should not be dropped or allowed to come into violent
contact with one another or with any other hard object.
If cylinders are stored in the open, the area should be properly fenced to prevent
unauthorized access and no cylinder should be within 2 m of the fence.
Liquid oxygen is usually stored in an insulated tank from which after evaporation,
the gas is supplied through pipes to the working areas. Such tanks are to be provided
with adequately designed pressure relief‟s and vents to atmosphere.
Care is necessary while re-charging the tank to prevent any liquid oxygen
spillage, and no source of ignition should be present.
Please used for conveying liquid oxygen should be clean, substantial gauge, free from
leaks and not unduly exposed to vibration. Equipment used for transferring liquid oxygen
should not be made of combustible or readily ox disable materials.

Prohibit smoking in the area where spillage has occurred keep organist materials
and sources of ignition away. Attempt to identify the source of leakage and take steps to
isolate the leakage at the source.
WASTE DISPOSAL :-
Disposal of gases is a complex problem and should be under an only by personnel
who are familiar with the gas involved and one disposal procedure. If proper disposal
procedure is not known then isolate the leaking cylinder in invented as open area and
contact the supplier for disposal procedures.
Since oxygen is a supporter of combustion, it should be ensured that the disposal
does not take place in a place where other flammable substances, gases and sportiest
ignition are present since the flame could be enhanced in an oxygen enriched
atmosphere.
9.11 MATERIAL SAFETY DATA SHEET (MSDS) FOR ACETYLENE (C2H2) IN

CYLINDERS
USES AND Acetylene is used along with oxygen for welding, cutting,
APPLICATIONS:- metallising, building up worn surfaces, surface hardening, flame
chloride, synthetic rubber, vinyl acetate. It finds its use in
chemical industry and to some extent in glass industry also.

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Colour : Colourless
Odour : Odourless when pure. Commercial grades have garlic like
odour
Boiling point : - 84°C.
Auto Ignition : Varies depending on factors like gas – air mixture
Composition, pressure, water vapour content and initial
temperature. Mixtures containing 30 % or more acetylene with
air at atmospheric pressure can ignite around 305°C
Explosive Limits : LEL 2.5 % HEL 82 % (By volume in air)
Toxicity : Non – toxic when pure. Mildly anaesthetic in mixture with
Oxygen.
Vapour Density : 0.91 (air = 1)
Solubility : Moderately soluble in water and many organic liquids.
Highly soluble in acetone.
Chemical Reactivity Forms explosive compounds with copper, silver and Mercury,
may explode violently when mixed with chlorine or fluorine in
the presence of sunlight.
HEALTH HAZARDS :-
Inhalation may cause dizziness, drowsiness and possibly suffocation.
When entering confined spaces suspected to have acetylene gas, persons should use
suitable breathing equipment. For very high concentrations, every effort should be made
to provide sufficient ventilation to dilute the gas before entering the space.
Persons entering such spaces should not use shoes with exposed iron nails or
similar items which may cause sparking.
FIRST AID :-
The affected persons should be removed immediately to fresh air and pulse and
respiration should be observed. If necessary, artificial respiration should be
administered and the person should be removed to hospital. Oxygen may be given if
needed.

HOW AN ACETYLENE CYLINDERS BURNS :-
1) Depends upon the location

2) Size of the leak
3) Cylinder pressure.
Small leaks of gas escaping through packing glands on valve or around fused plug will
burn if ignited but may not grow in size.
Larger leaks from cylinder valve or regulator connection may become ignited & create
sufficient heat to cause melting of the fusible metal in fused plug.

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With fusion of metal from the relief device a loud sound may be heard when the gas
is released. When fused plug releases a large value of acetylene will rush out and may
get ignited by source of ignition.
Because of its wide explosive range, even a small leakage of acetylene, on contact
with a spark, can lead to an explosion. Explosion of acetylene develops pressure higher
than explosion of most other gases and air, therefore, more violent and damaging.
Acetylene can also decompose violently (especially when under pressure) when
subjected to heat or shock, even in mercury, it react spontaneously to form explosive
acetylates. Its mixture with chlorine and fluorine can explode violently in the presence of
sunlight.
FIRE FIGHTING :-
When the fire brigade arrives, they should be informed of the position of all cylinders.
The following action may be taken before the arrival of the brigade, if no undue risk is
involved:
1) Cylinders which have not become heated, should be moved to a safe place as
quickly as possible, making sure that valves are shut.
2) Cylinders which have become heated should be cooled by spraying water from a
safe position (A solid jet should not be applied). The area should be evacuated if
cylinders can not be cooled).
3) Burning gas from a leak should be extinguished only by shutting off the leak.
4) A cylinder involved in a fire should not be used without consulting the suppliers.

Cylinders should be stored and handled in upright position. Only cylinders meant
for acetylene should be used to fill acetylene. Cylinders should be stored under cover to
protect them against direct rays of the sun. The cylinder stores should be of suitable
construction, preferably with explosion venting facility. Cylinders of chlorine and oxygen
should not be stored with acetylene cylinders.
Empty cylinders should be marked and stored separately. Before the regulator is
removed from a cylinder, the cylinder valve should be closed and all gas released from
the regulator. Exits from stores should be easily accessible and free from any
obstruction.
Cylinders should not be allowed to come into violent contact with one another or
with any hard subject.
If cylinders are lifted by cranes, rope slings should be used to lift a platform, cage
or cradle with the cylinders housed and secured in vertical position. Cylinders with
damage valves or thread should immediately be labelled appropriately and return to the
supplier.
For movement in hand trolleys, secure the cylinder in a relatively upright position.

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Identify leaks in cylinders and fittings by application of soap solution. Try to rectify leaks
by tightening gland nuts. If leak persist remove cylinder to an isolated place.

Cylinder, filler material and solvent (acetone) should conform to standard requirements.
Never attempt to transfer acetylene from one cylinder to another or mix acetylene with
other gases in a cylinder, or fill any other gas in a acetylene cylinder. When acetylene is
used through torches or other devices equipped with shut off valves on acetylene supply
connections, the pressure of acetylene should be reduced through a suitable pressure
regulator attached to he cylinder valve.
Identify leaks in cylinders, rectify them by tightening glands, nuts etc., if possible
remove them to a place well away from any possible ignition and allow the gas to
escape. Place warning with a naked flame. Notify the supplier. Never point a burning
acetylene torch towards an acetylene cylinder. Cylinders should be removed from the
working areas and put in a store at the end of working period. Valve protection caps
should always remain in place before and after the use of cylinders. Keep valves closed
even for cylinders supposed to be empty.
Persons require to work in areas where exposure is encountered should received pre
employment and periodical medical examination which should include medical and
exposure history, physical examination, cardiac and respiratory tests and haematology
test.
9.12 MATERIAL SAFETY DATA SHEET (MSDS) FOR CARBON MONOXIDE (CO)
USE AND APPLICATIONS Carbon monoxide is also known as carbonic oxide. Sometime it
is called flue gas in view of its presence usually high percentage
in exhaust & flue gases. Carbon monoxide is used in the
manufacture of ethylene, methanol, phosgene, metal carbonyls,
acids & esters. It is widely used as reducing agent for
recovering high purity Nickel from crude one. Large amounts of
carbon monoxide are used in fuel gas mixtures with hydrogen &
other gases for industrial heating.
IMPORTANT
PROPERTIES
Colour : Colourless Gas
Odour : Ouderless

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Auto ignition temp. : 610ºC.

Threshold Limit Value : 35 ppm. (NIOSH)
: 50 ppm. (ACGIH)
Flammability limits : 12.5 - 74.2% (by volume in air)
IDLH Level : : 1500 ppm.
Solubility : slightly soluble in water, soluble in alcohol & benzene, readily
soluble in hydrochloric acid & ammoniacal solution of cuprous
chloride.
HEALTH HAZARDS :-
Carbon monoxide is highly toxic. When inhaled, its acts by combining with haemoglobin
of red cells in blood to form carboxyl haemoglobin. Haemoglobin, supplies oxygen to all
part of the body from lungs, has about 300 times more affinity for 60 than for oxygen. It
therefore readily combines with CO instead of absorbing Oxygen even when the
atmosphere contains oxygen. This results an interference of oxy-haemoglobin
dissociation & oxygen transport in blood.
At high concentrations (0.4% i.e. 4000 ppm) carbon monoxide can prove fatal less than
an hour. At concentrations 500 - 1000 ppm. ( 0.05 - 0.1% ) it causes headache,
nausea, discomfort & mental disorientation exposure to less than 400 ppm. (0/04%)
causes initially similar symptoms but these effects disappear within 8 - 10 hours after
exposure ends. It is important to note that being Colourless & odourless, carbon
monoxide gives no warnings of its presence, & inhalation of excessive concentrations
can result in serious ill- effects leading to death.
All workers, employed in area where there is hazard of high concentration of CO in the
air should be adequately instructed about its hazardous properties, symptoms of
poisoning & emergency producer. CO can be present in exhaust emissions of petrol &
diesel driven vehicles & other equipment or process area where incomplete combustion
may take place. Fires in AC rooms & ill-ventilated building may produce substantial
quantities of CO. respiratory protective equipment should be used in emergencies for
evacuation purposes and during clean on of the area. For concentrations up to 2%
(20,000 ppm. ) air purifying gas mask (canister type) may used for a period not
exceeding 30 minutes if oxygen deficiency is not encountered. Self-contained breathing
apparatus or air supplied positive pressure respiratory protection equipment is preferred
for atmosphere containing CO. body should be allowed to work alone in areas where
exposure to concentrations of carbon monoxide is anticipated. Exhaust ventilation as the
best means or controlling carbon monoxide concentrations. Systems using CO should be
designed for locating & operating in the open.
FIRST AID :-
If carbon monoxide vapours are inhale, remove the person immediately from the
contaminated area to fresh air location & keep him conformably warm. If respiration is
weak, artificial resuscitation should be administered until normal breathing has resumed.
It is important to hasten the elimination of CO from blood stream, should poisoning
occur. Pure oxygen is preferred for Co elimination, but a mixture of oxygen & 7.10%

ISSUE : 04
Page : 98
carbon dioxide can be more effective in eliminating carbon monoxide as such a mixture
acts as a powerful respiratory & cardiac stimulant including deep breathing & rapid
ventilation of the lungs. Use of drugs should be avoided. The patient should be treated as
a convalescent & given at least 48 hours bed rest. Immediately medical attention for
casualties exposed to carbon monoxide is recommended.
Carbon monoxide is a highly flammable gas. A mixture of carbon monoxide & air within
the flammability limits presents a serious & explosion hazard.
PREVENTION OF FIRE & EXPLOSION HAZARDS :-

1. Open flame, hot elements & other ignition sources should be eliminated from the
area where carbon monoxide is stored or used.
2. The air in the storage & working areas should be regularly checked for leaks using a
gas detector. Totally enclosed system should be used for process involving carbon
monoxide.
3. Adequate exhaust ventilation should be provided in process areas so that air borne
concentration is below the threshold limit value.
4. All valves, pipelines, vents & safety devices should be located so that can be easily
inspected & maintained.
5. All electrical equipments which are exposed to flammable concentrations of carbon
monoxide should be of flame proof-type.
FIRE FIGHTING :-
Small fires involving leaked carbon monoxide should be extinguished by closing the valve
or plugging the leak. Dry chemical powder & carbon dioxide extinguisher are suitable for
small fires involving carbon monoxide. Cylinders which are not involved in the fire should
be moved safe place or keep cool using water spray. Large fires should be tackled by the
fire brigade. Fire fighting personal should be made aware of the hazards of carbon
monoxide & should be provided with self-contained breathing apparatus.

Carbon monoxide cylinders should be stored in an enclosure of non-combustible
construction from other parts of the building by fire resisting walls of at least one hour
resistance. The storage area should have good ventilation & explosion venting systems.
It should be protected against prolonged exposure to heat. When stored in buildings with
other occupancies, the CO cylinders should be kept at least 20 (0.1m) away from oxygen
cylinders, chlorine & other highly oxidizing substances, corrosive materials flammable
liquid & highly combustible materials. It is recommended that carbon monoxide cylinders
in use be grounded & protected by check valves or suitable traps to prevent suck back of
process material into the cylinders. Recommended practices for handling these cylinders.
Air in the storage & working areas should be regularly sampled with a gas detector check
for leaks.

ISSUE : 04
Page : 99
Carbon monoxide leaks should never be left unattended. All sources of ignition should be
kept away, the area ventilated & check for the concentration of carbon monoxide. Self-
contained breathing apparatus should be used while sampling & attending leaks.
Person exposed to carbon monoxide atmosphere should undergo pre employment
medical examination with special emphasis on cardiovascular disorders, anaemia &
special respiratory insufficiency by a physician who is acquainted with the occupational
hazards involved. Pregnant woman should not be employed in areas where there is a risk
of high concentrations of CO in the air.
9.13 MATERIAL SAFETY DATA SHEET (MSDS) FOR FREON 22

USES & APPLICATIONS :- Used in the Air conditioning Plant
General or Generic ID: HALOGENATED HYDROCARBON
Boiling Point (for product) -41.4 F (-40.7 C) @ 760.00 mmHg
Vapor Pressure (for product) 7805.000 mmHg @ 77.00 F
Specific Vapor Density 7.000 @ AIR=1
Specific Gravity 1.194 @ 77.00 F
Liquid Density 9.950 lbs/gal @ 77.00 F
1.194 kg/l @ 25.00 C
Percent Volatiles 100.0 %
(Including Water)
Evaporation Rate FASTER THAN ETHYL ETHER
Appearance No data
State LIQUID
Physical Form HOMOGENEOUS SOLUTION
Color CLEAR & COLORLESS
HEALTH HAZARDS :-
May form: carbon dioxide and carbon monoxide, hydrogen chloride, hydrogen fluoride,
phosgene, various hydrocarbons.
Eye Can cause eye irritation. Symptoms include stinging,
tearing, redness, and swelling of eyes.
Skin May cause mild skin irritation. Prolonged or repeated
contact may dry the skin. Symptoms may include redness,
buring, drying and cracking of skin, and skin burns.
Swallowing Swallowing small amounts of this material during
normal handling is not likely to cause harmful effects.
Swallowing large amounts may be harmful.
Inhalation Breathing of vapor or mist is possible. Breathing small
amounts of this material during normal handling is not
likely to cause harmful effects. Breathing large amounts
may be harmful.
Symptoms of Exposure stomach or intestinal upset (nausea, vomiting,
diarrhea), irritation (nose, throat, airways), central

ISSUE : 04
Page : 100
nervous system depression (dizziness, drowsiness,

weakness, fatigue, nausea, headache,
unconsciousness), and death.
Target Organ Effects No data
Developmental No data
Information
Cancer Information No data
Other Health Effects No data
Primary Route(s) of Inhalation, Skin contact
Entry
Hazardous Polymerization Product will not undergo hazardous polymerization.
Hazardous May form: carbon dioxide and carbon monoxide, hydrogen
Decomposition chloride, hydrogen fluoride, phosgene, various
hydrocarbons.
Chemical Stability Stable.
Incompatibility Avoid contact with: strong oxidizing agents.
Chemical splash goggles in compliance with OSHA regulations are advised;
however, OSHA regulations also permit other type safety glasses. Consult your safety
representative
Wear resistant gloves such as: nitrile rubber, Wear normal work clothing covering
arms and legs..
If workplace exposure limit(s) of product or any component is exceeded (See
Exposure Guidelines), a NIOSH/MSHA approved air supplied respirator is advised in
absence of proper environmental control. OSHA regulations also permit other
NIOSH/MSHA respirators (negative pressure type) under specified conditions (consult
your industrial hygienist). Engineering or administrative controls should be
implemented to reduce exposure.
Provide sufficient mechanical (general and/or local exhaust) ventilation to maintain
exposure below TLV(s).
FIRST AID :-
Eyes If symptoms develop, immediately move individual away
from exposure and into fresh air. Flush eyes gently with water
for at least 15 minutes while holding eyelids apart; seek
immediate medical attention.
Skin Remove contaminated clothing. Wash exposed area with soap
. and water. If symptoms persist, seek medical attention.
Launder clothing before reuse
Swallowing Do not induce vomiting. This material is an aspiration
hazard. If individual is drowsy or unconscious, place on left side
with the head down. Seek medical attention. If possible, do
not leave individual unattended.
Inhalation If symptoms develop, immediately move individual away
from exposure and into fresh air. Seek immediate medical
attention; keep person warm and quiet. If person is not
breathing, begin artificial respiration. If breathing is
difficult, administer oxygen.
Note to Physicians Inhalation of high concentrations of this material, as could

ISSUE : 04
Page : 101
occur in enclosed spaces or during deliberate abuse, may be

associated with cardiac arrhythmias. Sympathomimetic drugs
may initiate cardiac arrhythmias in persons exposed to this
material.

Never use welding or cutting torch on or near drum (even empty) because product
(even just residue) can ignite explosively
FIRE FIGHTING :-
Wear a self-contained breathing apparatus with a full facepiece operated in the
positive pressure demand mode with appropriate turn-out gear and chemical
resistant personal protective equipment. Refer to the personal protective
equipment section of this MSDS
Extinguishing Media :: water fog.

Containers of this material may be hazardous when emptied. Since emptied
containers retain product residues (vapor, liquid, and/or solid), all hazard precautions
given in the data sheet must be
observed

Small Spill Absorb liquid on vermiculite, floor absorbent or other absorbent
material.
Large Spill Prevent run-off to sewers, streams or other bodies of water. If
run-off occurs, notify proper authorities as required, that a spill has
occured. Persons not wearing protective equipment should be
excluded from area of spill until clean-up has been completed. Stop
spill at source, dike area of spill to prevent spreading, pump liquid
to salvage tank. Remaining liquid may be taken up on sand,
clay, earth, floor absorbent, or other absorbent material and
shoveled into containers.
DISPOSAL Waste Management Information
CONSIDERATION Dispose of in accordance with all applicable local, state and
federal regulations. Ventilate area of spill. Allow material to
evaporate.
9.14 MATERIAL SAFETY DATA SHEET (MSDS) FOR -R 32

USES & APPLICATIONS Used in the Air conditioning Plant
General or Generic ID: HALOGENATED HYDROCARBON
IMPORTANT PROPERTIES
APPEARANCE :Colorless liquefied gas
ODOR Faint ethereal odor
SPECIFIC GRAVITY 0.98 at 20 deg. C(water = 1.0):
SOLUBILITY IN WATER (weight %): Insoluble

ISSUE : 04
Page : 102
BOILING POINT 51.7°C (-61.1°F)

pH: Not applicable
VAPOR DENSITY 1.86 at normal boiling point (air = 1.0):
VAPOR PRESSURE 10,319(mmHg at 20 deg. C):
% VOLATILES: 100
CHEMICAL STABILITY Stable under normal conditions.
INCOMPATIBILITIES Reacts with finely divided metals such as aluminum, zinc,
magnesium, and alloys containing more then 2%
magnesium. Can react violently if in contact with alkali
metals and alkaline earth metals such as sodium,
potassium, or barium.
HAZARDOUS Hydrogen fluoride by thermal decomposition and hydrolysis.
DECOMPOSITION
PRODUCTS:
CONDITIONS TO AVOID Keep away from heat, sparks, and flame. Avoid high
temperatures.
HAZARDOUS Will not occur.
POLYMERIZATION:
CHEMICAL STABILITY: Stable under normal conditions.
INCOMPATIBILITIES: Reacts with finely divided metals such as aluminum, zinc,
magnesium, and alloys containing more then 2%
magnesium. Can react violently if in contact with alkali
metals and alkaline earth metals such as sodium,
potassium, or barium.
EMERGENCY OVERVIEW: This product is a flammable, liquefied gas. Contents under pressure.
Cylinders may rupture and rocket under fire conditions. Thermal decomposition can produce
toxic and corrosive gases. Vapors are heavier than air. May cause asphyxia. Liquid splashes
or spray may cause freeze burns (frostbite). High vapor concentrations may cause dizziness
or more severe anesthetic effects. Very high exposures can cause potentially fatal abnormal
heart rhythm. Read the entire MSDS for a more thorough evaluation of the hazards.
HEALTH HAZARDS :-
May form: carbon dioxide and carbon monoxide, hydrogen chloride, hydrogen fluoride,
phosgene, various hydrocarbons.
SKIN: Liquid splashes or spray may cause freeze burns.
EYES: Liquid splashes or spray may cause freeze burns.
INGESTION: Extremely unlikely to occur in use.
SKIN ABSORPTION: This product will probably not be absorbed through human
skin.
INHALATION: Exposure to high vapor concentrations can induce
anesthetic effects progressing from dizziness, weakness,
nausea, to unconsciousness. Very high exposures can cause
abnormal heart rhythm, which is potentially fatal. It can act
as an asphyxiant by limiting available oxygen.
OTHER EFFECTS OF None Expected.
OVEREXPOSURE:
Hazardous Polymerization Product will not undergo hazardous polymerization.
Hazardous May form: carbon dioxide and carbon monoxide, hydrogen

ISSUE : 04
Page : 103
Decomposition chloride, hydrogen fluoride, phosgene, various

hydrocarbons.
Chemical Stability Stable.
Incompatibility Avoid contact with: strong oxidizing agents.
SKIN PROTECTION: Take all precautions to prevent skin contact. Use gloves and
protective clothing made of material that has been found by user
to be impervious under conditions of use to prevent the skin
from becoming frozen for contact with liquid. User should verify
impermeability under normal conditions of use prior to general
use. Additional protection such as an apron, arm covers, or full
body suit may be need depending on conditions of use.
EYE PROTECTION: Use chemical safety goggles or safety glasses and a face shield
when there is potential for eye contact.
RESPIRATORY Not normally needed if controls are adequate. If needed, use
PROTECTION: NIOSH/MSHA approved respirator for organic vapors. For high
concentrations and oxygen-deficient atmospheres, use positive
pressure air-supplied respirator.
FIRST AID :-
SKIN: Immediately wash with plenty of warm water (do not rub). Thaw
affected area with water. Remove contaminated clothing. Caution:
clothing may adhere to the skin in case of freeze burns. If symptoms
(irritation or blistering) develop, get medical attention.
EYES: Immediately flush with plenty of water. After initial flushing, remove
any contact lenses and continue flushing for at least 15 minutes. Hold
eyelids open during flushing. Have eyes examined and treated by
medical personnel.
INHALATION: Move victim to fresh air. Keep warm and at rest. If breathing is
labored, give oxygen. If only breathing has stopped, give artificial
respiration with a pocket mask equipped with a on-way valve to
prevent exposure to product or body fluids. If breathing has stopped
and there is no pulse, give cardiopulmonary resuscitation (CPR). Get
immediate medical attention.
INGESTION: Highly unlikely, but should this occur, freeze burns will result. Do not
induce vomiting unless instructed to do so by a physician.
ADVICE TO Symptomatic and supportive therapy, as indicated. Administration of
PHYSICIAN: epinephrine or similar sympathomimetic drugs should be with special
caution and only in situations of emergency life support as cardiac
arrhythmias may result.

Reacts with finely divided metals such as aluminum, zinc, magnesium, and alloys
containing more the 2% magnesium. Can react violently if in contact with alkali metals
and alkaline earth metals such as sodium, potassium, or barium.
During a fire the product can form toxic and corrosive gases such as hydrogen fluoride.
Flammable liquefied gas. Container may burst under intense heat. Ruptured cylinders

ISSUE : 04
Page : 104
may rocket or fragment. Heavy vapor may suffocate.

Certain mixtures of HFC-32 and chlorine may be flammable under some conditions.
FIRE FIGHTING :-
Suitable extinguishing medium is dry powder. Allow escaping gas to urn under
controlled conditions. Extinguish only if escape of gas can be rapidly stopped as it may
form a flammable vapor cloud.
.DISPOSAL CONSIDERATIONS
DISPOSAL METHOD:
Discarded product is not a hazardous waste under RCRA, 40 CFR 261. However, HFC-32
should be recycled, reclaimed, or destroyed whenever possible.
CONTAINER DISPOSAL:
May contain explosive vapors. Do not distribute, make available, furnish, or reuse
container when emptied of the original product. Do not weld or use cutting torch on or
near container. Empty container retains product residue. Return containers to supplier.
REFRIGERATION APPLICATION:
Subject to “no venting” regulations of Section 608 of the Clean Air Act during the
service or disposal of equipment.

Wear appropriate personal protective equipment. A safety shower and eyewash station
should be nearby and ready for use.
This product is a flammable, liquefied gas, which exits the container at temperatures
capable of causing freeze burns (frostbite). Ensure personnel are trained in handling and
storing cylinders. Secure containers at all times. Keep containers closed when not in
use.
Ensure there is adequate ventilation or use proper respiratory protection in poorly
ventilated or confined areas. Avoid causing and inhaling high concentration or vapor.
Atmospheric levels should be controlled to below the occupational exposure limit and
kept as low as practicable.
Prevent liquid or vapor from entering sumps or sewers since vapor is heavier than air
and may form suffocating atmospheres.
Do not put mixtures of HFC-32 with air or oxygen under pressure; do not use such
mixtures for leak or pressure testing.
Do not heat containers.
Liquid transfers between containers may generate static electricity. Ensure adequate
grounding.
Avoid trapping liquid between closed valves or overfilling containers as high pressures
can develop with an increase in temperature.
Avoid HFC-32 contact with flames or very hot surfaces.
STORAGE RECOMMENDATIONS:
Keep containers tightly closed, in a cool, well-ventilated place. Keep containers dry.
Keep from incompatibles, open flames, hot surfaces, welding operations, and other heat
sources.
STORAGE TEMPERATURE:
Store at temperature not exceeding 125 deg. F. (52deg. C).
ACCIDENTAL This product is a flammable, liquefied gas, which exits the container
RELEASE at temperatures capable of causing freeze burns (frostbite).
MEASURES Contents under pressure. Ruptured cylinder may rocket or
fragment.

ISSUE : 04
Page : 105
Precautions should take into account the severity of the leak or

spill.
Move unprotected personnel upwind of leaking container. Remove
ignition sources and ventilate the spill area. Use recommended
personal protection and shut off the leak, if without risk. If possible,
elevate leak position to highest point of container (should leak gas,
not liquid). Water should never be put on leak nor should cylinder
be immersed. If possible, dike and contain spillage. Prevent liquid
from entering sewers sumps, or pit areas since vapor is heavier
than air and can create a suffocation atmosphere. Capture material
for recycle or destruction if suitable equipment is available.
Notify applicable government authority if release is reportable or
could adversely affect the environment.

1) Naked lights, cigars, cigarette ends, sparks from static or live, discharges metal
impacts, heat from molten metal, welding or cutting from friction in moving
parts, sparks or heat from electrical faults and hot surfaces are some of the
sources that may lead to fire.
2) Vessels containing liquid hydrogen should be kept away from heat.
3) Maintenance / repair work, filling or emptying on any of the hydrogen storage /
transfer equipment should be done under work permit.
10. OTHER INFORMATION

Lists to be updated by Welfare Officer
1. LIST OF LOCAL AUTHORITIES (GRAMPANCHAYAT , NAGAR PALI KA, SARPANCH , POLICE STATION ,
CORPORATORS )
AaO.iva.koMd`¸ KaprKoDa¸ 5 ik.maI. pirsaratIla gaàmapMcaayatI
AnauM gaavaaMcaI naavao gaavaaMcaI laaoksaM#yaa sarpMca dUrQvanaI ËM.
ËM.
1 2 3 4 5
01 icacaaolaI À KaprKoDa 11478 EaI homaraja saI. Pairhar 9822931087

ISSUE : 04
Page : 106
02 BaanaogaaMva 6003 saaO. sauima~ata[- icaKlao 9822470014
03 paoTa 2215 EaI A$Na Bagavaana zakro 9011986350
04 canakapur 9845 EaI A$Na Bagavaana zakro 9011986350
05 isallaovaaDa 8503 saaO. Cayaa ramarava Zaolao 9922336149
06 dhogaaMva 3754 EaI jaI.ela. ramaokr
07 baInaa 3279 EaI e.jaI. inaKaDo 9850756966
08 vaarogaaMva 1662 EaI dovaravajaI jaI. paMDo 9325594602
09 DaorlaI 1158 saaO esa. Ema. AaMjanakr
10 isaMgaaorI 504 EaI e.baI. icaKlao
11 [TgaaMva 1163 saaO.ela e. jaunaGaro
Paoilasa sToSana
KaprKoDa 4059¸ 4859 07113 268126
2. LIST OF SCHOOLS , DHARMASHALA , MANGALKARYALAYA , NEARBY

AaO.iva.koMd`¸ KaprKoDa 5 ik.maI. pirsaratIla SaaLa
Anau SaaLaMcao naava ivaVaqaI- saM#yaa mau#yaaQyaapk durQvanaI ËM Ba`maNaQvanaI
ËM mau#yaaQyaaipka ËM
icacaaolaI KaprKoDa
01 SaMkrrava cavhana ivaValaya va kinaYz mahaivaValaya¸ p`kaSanagar vasaaht¸ 2442 saaO.saaLuMko 07113-268443
KaprKoDa. 9922924283
02 maharaYT/ ivaValaya va kinaYz mahaivaValaya¸ p`kaSanagar vasaaht¸ 2673 EaI razaoD 07113-268134
KaprKoDa. 9325483090
03 ijalha pirYad pàqaimak SaaLa¸ p`kaSanagar vasaaht¸ KaprKoDa. 150 EaI iSaMdo
04 iD.e.vhI. pàqaimak SaaLa¸ p`kaSanagar vasaaht¸ KaprKoDa. 550 saaO. sauima~a ipllao
05 rNaJaaoDdasa pàqaimak ijalha pirYad SaaLa¸ vaa^D- naM.4¸ KaprKoDa. 150 saaO. isaMQaU paTIla 9371040154
06 ijalha pirYad pàqaimak SaaLa¸ vaa^D- naM.1¸ icacaaolaI KaprKoDa. 102 saaO. sauinata ra}t 9370073935
Baanaogaava
07 ba^. SaoYarava vaanaKoDo¸ klaa va vaaiNajya mahivaValaya¸ Baanaogaava. 450 EaI ramakRYNa TaLo 9423408169
08 ]cca pàqaimak SaaLa¸ vaa^D- naM.5 Baanaogaava. 150 saaO. naagarkr
09 ]cca pàqaimak SaaLa¸ vaa^D- naM.4 naivana Baanaogaava. 125 EaI Aahuto
vaarogaaMva
10 ijalha pirYad pàqaimak SaaLa¸ vaarogaaMva. 175 saaO. pMKraja
paoTa
11 ijalha pirYad pàqaimak SaaLa¸ paoTa. 60 saaO. rava
canakapur

ISSUE : 04
Page : 107
12 ijalha pirYad pàqaimak SaaLa¸ canakapur. 250 saaO. daDo

13 maha%maa fulao hayaskula¸ canakapur. 325 EaI AMjanakr
isallaovaaDa
14 ]cca pàqaimak SaaLa marazI¸ isallaovaaDa. 311 EaI jaaogaI
15 ]cca pàqaimak SaaLa ihMdI¸ -1 isallaovaaDa. 400 EaI pzaNa
16 ]cca pàqaimak SaaLa ihMdI¸ -2 isallaovaaDa. 300 saaO. ]ko
17 maharaYT/ ivaValaya¸ isallaovaaDa. 625 EaI ][-ko
18 [MiglaSa pàyamarI skula¸ isallaovaaDa. 605 saaO. ilalaI
ibanaa
19 ]cca pàqaimak SaaLa¸ ibanaa 210 EaI Aamaaonao
20 AiSvanaI maaQyaimak ivaValaya¸ ibanaa 225 saaO. ramaToko
3. LIST OF UNION (PRESIDENT & SECRETARY)

AiQakarI kma-caarI saMGaTnaa¸ va pdaiQaka-yaaMcaI maaihtI
Anau saMGaTnaocao naava pdaiQaka-yaacao naava pdnaama Ba`maNa QvanaI ËM.
ËM.
01 kayaa-layaIna kma-caarI saMGaTnaa 1´ EaI saitSa eca barbaTo AQyaxa 9850247071
2´ EaI DI.ena. ballaaro saicava 9850332804
02 ga`^jyaueT [MijainaAsa- AsaaoiSaeSana 1´ EaI QaIrja doSamauK ]paQyaxa 9158881404
2´ EaI Amaaola yaadgaIro saicava 9422913624
03 sabaa^DI-naoT [Mijainayasa- AsaaoiSaeSana 1´ EaI ko.Dblyau baolasaro AQyaxa 9689900372
2´ EaI DI.baI. kLMbao saicava 9423600972
04 maharaYT/ rajya maagaasavagaI-ya ivaVut kma-caarI 1´ EaI Aar.jaI maoEaama AQyaxa 9970304157
saMGaTnaa 2´ EaI iBamarava caËo saicava 9561605488
05 ivaVut xao~ taMi~k kamagaar yauinayana 1´ EaI ko.jaI. SaoMDo AQyaxa 7387865431
2´ EaI esa,.esa. Aija-tvaar saicava 9850893755
06 maharaYT/ sToT [lao@T/IisaTI baaoD- vak-sa- foDroSana 1´ EaI Aar.pI. laaDkr AQyaxa 9270087318
2´ EaI p`maaod KaorgaDo saicava 9822197307
07 ivadBa- raYT/Iya [laoi@T/klsa vak-sa- yauinayana 1´ EaI esa.vaaya. Kovalao AQyaxa 9881011228
2´ EaI Aar.ena. ixarsaagar saicava 9881202541
08 BaartIya kamagaar saonaa 1´ EaI naroMd` Basmao AQyaxa
2´ EaI SaMkr Gaaorsao saicava 9423602435
09 maharaYT/ rajya ivaVut Eaimak saovaa saMGaTnaa 1´ EaI AaoMkar Gaulao AQyaxa 9823709467
2´ EaI caMd`kaMt ragaITo saicava
10 maharaYT/ rajya ivaja inaima-tI kamagaar saMGaTnaa 1´ EaI esa.baI. pvaar AQyaxa
2´ EaI eca.ko. doSamauK saricaTNaIsa
11 bahujana ivaVut AiBayaMta¸ AiQakarI va 1´ EaI rajana BaanauSaalaI AQyaxa
kma-caarI faorma 2´ EaI sauroSa igarDkr rajya saicava
12 raYT/Iya ivaja D/ayavhr va i@lanar AsaaoiSaeSana 1´ EaI Qanaraja laaoMKDo ]paQyaxa 9923203525
2´ EaI esa.Aar. marGaDo sahsaicava

ISSUE : 04
Page : 108
4. LIST OF NGOS
5. LIST OF RESCUE MATERIAL

Sr No Description Location Quantity
1 Gas cutting Set
2 Kudali
3 Pawadha
4 Sabbals
5 Torches
6 Ropes
7 Stretcher
8 Head torch
9 Fire rescue mask
10
6. EQUIPMENTS REQUIRED FOR DMP
Equipments required for DMP Locations Quantity
1 Wind socks : Salt godown 210 MW sets

Environment Square 210 MW sets
Canteen 500 MW
2 Siren with DC back up Time Office

3 Gas detection meters Chlorine Dosing Plant
Ammonia Store
Ammonia Dosing
H2 generating Plant
H2 Filling Manifold Each unit
Ozone Plant
4 Generators: Locations
5 Temporary lighting arrangement EM Colony
6 Temporary Drinking Water supply Colony Drinking Water plant
7 Fluorescent Jackets for all key Time Office
persons
8 Tents with sitting arrangements Civil Maint Colony
9 Public addressing system Time Office
(Megaphone) Fire fighting
Security
10 Walkie talkie sets: Locations
11 First aid kits All Maint & operation Sections
Time Office
Fire fighting
Security

ISSUE : 04
Page : 109
12 Danger boards/direction Chlorine Dosing Plant

boards/Identification boards Ammonia Store
Ammonia Dosing
H2 generating Plant
H2 Filling Manifold Each unit
Ozone Plant
13 Barricading tapes Time Office
Fire fighting
Security
14 SCBA Location Fire fighting
15 PPEs List & Locations ECC
16 Chemical Stoppage kit: List & Chlorine Dosing Plant
Locations Ammonia Store
Ammonia Dosing
Ozone Plant
7. PLANT MAP MOVEMENT ROADS

Please refer ANEXTURE 20
8. PLANT MAP (HAZARDOUS MATERIAL STORAGE & ASSEMBLY POINTS)

9. PLANT PROCESS AREA MAP & FACILITIES LOCATION MAP

10. VULNERABILITY MAP
Vulnerability Zones in India : Seismic Zones

ISSUE : 04
Page : 110
Source of information : www.imd.ernet.in
There are five seismic zones named as I to V as details given below:-

Zone V: Covers the areas liable to seismic intensity IX and above on Modified Mercalli
Intensity Scale. This is the most severe seismic zone and is referred here as Very High
Damage Risk Zone.
Zone IV: Gives the area liable to MM VIII. This, zone is second in severity to zone V.
This is referred here as High Damage Risk Zone.
Zone III: The associated intensity is MM VII. This is termed here as Moderate
Damage Risk Zone.
Zone II: The probable intensity is MM VI. This zone is referred to as Low Damage
Risk Zone.
Zone I: Here the maximum intensity is estimated as MM V or less. This zone is
termed here as Very Low Damage Risk Zone.

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11. METEOROLOGICAL DATA
METEOROLOGICAL DATA
Meteorological facts pertaining to the atmosphere, such as wind, temperature, air
density, Rain, etc.
Wind Speed Air density /
Wind direction Temperature Rain
Month m/s Hum.
Min Max Min Max Min Max Min Max Min Max
Jan-07 0.10 2.50 W NE 130c 300c 32% 50%
0 0
Feb-07 0.10 2.50 W NE 16 c 33 c 23% 43%
0 0
Mar-07 0.10 2.10 SW NE 16 c 38 c 20% 80%
0 0
Apr-07 0.10 2.10 NW NE 25 c 41 c 17% 58%
May-07 0.10 2.90 NW SE 280c 440c 19% 58%
0 0
Jun-07 0.10 2.90 SW NE 26 c 37 c 16% 83%
Jul-07 0.10 3.10 SW NE 240c 340c 62% 96%
0 0
Aug-07 0.10 1.80 SW NE 23 c 33 c 50% 77%
Sep-07 0.10 2.20 SW NE 240c 330c 47% 77%
0 0
Oct-07 0.10 1.20 SW NE 18 c 33 c 32% 92%
Nov-07 0.10 1.20 SW NE 210c 310c 28% 70%
0 0
Dec-07 0.10 1.80 E W 17 c 34 c 28% 51%
Jan-08 0.10 1.40 SW NE 120c 300c 20% 90%

Feb-08 0.10 2.20 SW NE 100c 330c 15% 87%
0 0
Mar-08 0.10 2.60 NW SE 18 c 36 c 29% 83%
0 0
Apr-08 0.10 2.50 NW SE 22 c 40 c 13% 93%
May-08 0.10 4.30 NW SE 280c 400c 23% 54%
Jun-08 0.10 3.40 SW NE 270c 330c 56% 78%
Jul-08 0.10 2.30 SW NE 250c 320c 67% 90%
Aug-08 0.10 3.50 SW NE 250c 310c 66% 89%
Sep-08 0.10 0.90 N S 240c 320c 61% 90%
Oct-08 0.10 0.90 E NE 200c 320c 42% 84%
Nov-08 0.10 0.90 NW SE 140c 320c 29% 91%
Dec-08 0.10 1.10 SW W 130c 260c 29% 90%
Jan-09 0.10 2.10 NW SE 120c 300c 26% 90%
Feb-09 0.10 4.70 NW SE 180c 350c 17% 90%

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Mar-09 0.10 2.40 N S 190c 380c 15% 60%
Apr-09 0.10 3.40 NW SE 220c 440c 12% 54%
May-09 0.00 2.40 W SE 260c 420c 13% 69%
Jun-09 0.30 2.50 W NE 260c 420c 23% 100%
Jul-09 0.10 3.20 SW NE 240c 340c 62% 100%
Aug-09 0.10 2.00 NW NE 220c 340c 78% 100%
Sep-09 0.00 2.60 SW-NE S 250c 360c 56% 85%
Oct-09 0.00 0.90 SW NE 260c 330c 59% 85%
Nov-09 0.00 1.30 SE-NW NW-SE 120c 300c 36% 100%
Dec-09 0.60 0.8 NE NW 150c 300c 44% 98%
Jan-10 0.6 0.9 SE NE 100c 310c 18% 87%
Feb-10 0.9 1.2 N NW 130c 380c 15% 88%
Mar-10 0.9 1.0 NE NW 130c 380c 15% 88%
Apr-10 1.9 2.2 SW W 240c 460c 10% 41%
May-10 1.2 1.8 SE SW 270c 460c 10% 41%
Jun-10 2.5 ¹ SW ¹ 240c 440c 10% 99%
Jul-10 1.8 ¹ SW ¹ 230c 370c 44% 99%
Aug-10 1.5 ¹ SW ¹ 220c 370c 46% 99%
Sep-10 1.5 ¹ SW ¹ 220c 360c 52% 99%
Oct-10 1.1 ¹ NW ¹ 170c 390c 29% 99%
Nov-10 1.3 ¹ SE ¹ 200c 350c 42% 92%
Dec-10 1.0 ¹ NE ¹ 200c 310c 11% 95%
Jan-11 1.0 ¹ N ¹ 130c 310c 22% 59%
Feb-11 1.0 ¹ N ¹ 130c 310c 22% 59%
Mar-11 1.0 ¹ SE ¹ 240c 450c 10% 72%

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Apr-11 1.0 ¹ SE ¹ 240c 450c 10% 72%
May-11 1.0
Jun-11 2.4 ¹ NW ¹ 230c 440c 17% 95%
Jul-11 2.0 ¹ WE ¹ 210c 380c 20% 89%
Aug-11 1.6 ¹ SW ¹ 230c 370c 36% 99%
Sep-11 1.2 ¹ SW ¹ 210c 390c 18% 99%
Oct-11 1.1 ¹ SW ¹ 210c 370c 20% 81%
Nov-11 1.2 ¹ NW ¹ 140c 380c 10% 92%
Dec-11

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12. ANNEXTURES
ANNEXTURE- 1 : PLANT CONTROL AND SHUT DOWN TEAM

LOCATION Team Leader Team Members
Generating Units Shift Incharge Plant Incharge
Unit I, II, III, IV, V (Executive Engineer) PCR Incharge
Asst Plant Incharge
Boiler Desk Incharge
Turbine Desk Incharge
All Local Incharge/s
Water Treatment Plant Shift Incharge All Local Incharge/s
I, II (Sr Chemist) Chlorine Dosing Plant
Ammonia Dosing Plant
Ozone Dosing Plant
Hydrogen Generating & filling Plant
Coal Handling Plant Shift Incharge All Local Incharge/s
I, II (Asstt Engineer) Wagon Tippler
Crusher House
Stacker reclamation
Bunker House
ANNEXTURE -2 : PROCEDURE FOR STOPPING A CHLORINE LEAK
The worst-case scenario is the leak of a full 900-kg chlorine tonner, causing a leak of
upto 900 kg of gaseous chlorine into atmosphere.
With a good on-site Emergency Plan (EMP), coupled with the correct and timely action by
staff so that the incident is controlled well and the on-site emergency would not turn into an
off-site emergency.
Ascertain the wind direction.

An operator from the plant having emergency would wear the self-contained breathing
apparatus (SCBA) and go near the leaky tonner from the upwind side to find out the place
from where chlorine is leaking.
After assessing the leak, the operator will return quickly and inform his Foreman about
the nature and extent of leak.
If it is possible to stop the leakage just by isolating the chlorine tonner(s), by isolation, he
will do it immediately. For example, any leak from connecting tubing or piping system can
be stopped in this manner.
If isolation is not going to be helpful and emergency management plan needs to be
initiated, the Foreman of the plant having emergency will initiate the emergency siren.
The neighboring plants, on hearing the siren, will send one operator each along with an
SCBA to the plant having emergency for assisting the staff of there.

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If there is a chlorine leak from a tonner or cylinder itself (e.g., from tonner or cylinder
valve or body), the operator wearing SCBA will pick up the required items from the
chlorine kit box and proceed to the leaky tonner/cylinder from upwind direction.
The operator will stop the leak by sealing the source of leak by using the gadgets from
the chlorine kit. Usually, this task should not take more than 10 minutes.
The Foreman of the plant having emergency will send either the operator from his plant
wearing SCBA or another operator wearing SCBA to check the surrounding atmosphere
for presence of chlorine by using a swab soaked in ammonia solution. Thick white fumes
of ammonium chloride will indicate presence of chlorine.
It is recommended to confirm the extent of chlorine in atmosphere, using a Dragger
apparatus. If chlorine is found to be less than the TLV of chlorine, that is 0.5 ppm (1.5
mg/mg) in air, normalcy can be restored.
T HE LEAKY TONNER OR CYLINDER SHOULD BE DISPOSED OF SAFELY BY NEUTRALISING THE ITS

CONTENTS SAFELY OR IN CONSULTATION WITH THE MANUFACTURER OF CHLORINE .
NON LEAK EMERGENCY Procedure
a) In case of FIRE.
i) Close the cylinder valve. Stop dosing.
ii) Avoid heating of cylinder by spraying water continuously.
iii) Avoid direct heating.
iv) Remove cylinder from site to a safe & cool area.
b) In case of FLOOD.
i) Close the cylinder valve. Stop dosing.
ii) Ensure no entering water into cylinder.
iii) Remove cylinder from site to a safe & cool area.
c) In case of LANDSLIDE.
i) Ensure no leakage from cylinder.
ii) Remove cylinder from site to a safe & cool area.
ANNEXTURE -3: CHEMICAL LEAK STOPPAGE TEAM

Chlorine Dosing Plant Sr Chemist Trained persons
Ammonia Dosing Plant Fire Fighting & Rescue Staff

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Ozone Dosing Plant Medical Help Team
Hydrogen Generating&
filling Plant
ANNEXTURE- 4 :MOCK DRILL RECORD
ASSESSMENT OF THE ON-SITE EMERGENCY R ESPONSE PLAN

to Fire incident / Chemical leak at Khaperkheda TPS.
Date :-
Location:-
Scenario:-
Sr. SEQUENCE OF EVENTS Time (Hours) Total Time

No. Required
1. Gas leak / fire noticed by the incident informer.
2. Gas leak / fire informed by the Incident Informer (

Local Incharge)
1. Fire Fighting/ Gas leak stoppage Team
2. Medical Help (Ambulance)
3. Shift Incharge ( Asstt SIC)
3. Shift Incharge ( Asstt SIC) informed to –

S.E. (Op) / E.C. (WTP) / S.E. (CHP) -------------- ---------------
(a)
the Site Incident Controller -------------- --------------
4 Site Incident Controller informed to-

Security Officer
Safety Officer
Welfare Officer
Medical Officer
Chief Engineer/ Dy Chief Engineer
The Site Main Controller
5 SMC declared EMERGENCY through coded siren

operated by Time keeper

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6 Reporting time to site
1. Fire Fighting/ Gas leak stoppage Team -------------- ---------------

2. Medical Help (Ambulance)
-------------- --------------
3. Shift Incharge ( Asstt SIC)
-------------- --------------
4. S.E. (Op) / E.C. (WTP) / S.E. (CHP)
5. Security & Traffic control team -------------- --------------
6. Safety Officer
-------------- --------------
7. Medical Officer
Concerned Authorities reached Emergency Control
7.
Room
-------------- ---------------
1. Chief Engineer SMC
-------------- --------------
2. Coordination team
-------------- --------------
3. Communication & Liaison team
-------------- --------------
4. Vehicle control team
5. Welfare team -------------- --------------
6. Logistic team -------------- --------------
8. Vehicles reached Emergency Control Room –
Fire Water Tender -------------- --------------

Ambulance (1 No.) -------------- --------------
9. CONTROL OPERATIONS -
Incident controlling team started action.
Control of event.
Rescue operation of casuality started.
Operation over.
Siren for “ALL CLEAR”
10. OBSERVATIONS–
ANNEXTURE -5: CRISIS CONTROL TEAM

Dy Chief Trained persons
Engineer(Admin) Fire Fighting

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Medical Help
ANNEXTURE -6 : DOCUMENTS IN ECC

Sr Document title Location
No
1 Details of inventories of hazardous material e.g. location,
maximum quantity,
type of storages, etc.
2 Works Layout indicating therein location of ECC, Location
wise/ Type wise/ Capacity wise portable fire
extinguishers, Assembly Points, Lunch Room, Canteen,
Casualty Treatment Centre, First-Aid Centre, Siren
Activating Points, Pantry Area, Railway siding etc.
3 PPEs - Location wise, Type wise numbers
Roads prominently marked on the layout indicating
exists
Area Map showing surrounding areas especially
sensitive population such as schools, public places,
hospitals etc.
Plans to be kept in ECCs that can be used as the
emergency and corresponding emergency actions
develop.
i. Affected Area
ii. Area Evacuated
iii. Emergency Vehicles & Equipment
iv. Safe Escape Routes towards assembly points
v. Other relevant information.
Important phone Nos.

i. Contact No. of SMC (Intercom & P&T)
ii. Contact No. of SIC (Intercom & P&T)
iii. List of contact No. of Government officials
iv. List of contact No. of Mutual Aid Persons
v. Internal Intercom directory
ANNEXTURE -7 : FORMAT "RECORD OF TELEPHONE MESSAGES”
ANNEXTURE -8: TELEPHONE DIRECTORY INTERNAL & EXTERNAL
ANNEXTURE – 09: HYDROGEN EMERGENCY PROCEDURE
To detect a small, local hydrogen leakage/ fire (the flame is nearly invisible), use a H2
detector. If leakage/ fire is present, perform the following:

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Shut off the hydrogen source.
Let the fire burn itself out (If the flame is snuffed out, it may re-ignite and cause greater
damage.)
If you have received hands-on training in the proper operation of a fire extinguisher then you
may use the same.
Use water spray to protect people and equipment from the thermal stress in case of small
fire.
ANNEXTURE – 10: FUEL OIL, LUB OIL, TRANSFORMER OIL SPILLS AND GAS
LEAKS EMERGENCY PROCEDURE
All known or suspected petroleum products spill and gas leaks (to include LPG, chlorine, etc.)
are to be reported to the fire department. When calling, be specific as to the building and
location of the spill or leak.
ANNEXTURE – 11: EMERGENCY PROCEDURES FOR CHEMICAL SPILLAGE
1. Organic acids (limited to C, H and O composition). The procedure is as

follows:-
- Eliminate all sources of ignition and instruct others to keep at a safe distance,
well away from the spillage area.
- Open windows if possible, and close laboratory doors on the way out. Aim to
ventilate the area but isolate the material.
- Decide whether to control the spillage on site, or to evacuate the building by

sounding the fire alarm and calling the local fire brigade.
- Wear a laboratory coat or protective acid-proof overall, nitride rubber gloves or

gauntlets, eye and/or face protection, self-contained breathing apparatus,
suitable footwear, e.g. PVC safety boots.
- Carefully mix the acidic compound with dry soda ash, sodium bicarbonate or
sodium carbonate. Mix well and add water if necessary. Scoop up the slurry
into plastic buckets and wash until neutral, neutralising with 6M ammonium
hydroxide or 6M hydrochloric acid until the pH paper indicates a neutral
solution. Once neutralised, wash to drain with an excess of water (x1000
volume of slurry) if consent permits.
2. Inorganic acids. The procedure is as follows:-

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sounding the fire alarm and calling in the local fire brigade.
- Wear a laboratory coat or protective acid-proof overall, nitrile rubber gloves or

gauntlets, eye and/or face protection, self-contained breathing apparatus and
suitable footwear (e.g. PVC safety boots).
- Neutralisation of concentrated acids produces heat. Allow approximately two or

three minutes between treatment steps.
- The following steps can clear up spills:
(a) cover the spillage with solid sodium bicarbonate or a soda ash-calcium
hydroxide mixture (50-50); work slowly and carefully, mixing the chemicals
into slurry
(b) carefully scoop up the slurry and wash the neutralised mixture slowly down
the drain, diluting with plenty of cold running water all the time; this should be
done only if the consent permits.
3. Alkalis - Note that these compounds may react violently with water.

sounding the fire alarm and calling in the local fire brigade.
- Wear a laboratory coat, protective gloves or gauntlets, eye and/or face

protection, and protective footwear
- For small spills:
(a) cover the spillage with an excess of dry soda ash or sodium bicarbonate,
and mix well
(b) Slowly and carefully add the resulting mixture to butyl alcohol in a large
container, such as a five-liter beaker or bucket
(c) allow the contents to stand in a fume cupboard for 24 hours before washing
to drain with a large excess of water, if consent permits.

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ANNEXTURE – 12: FIRE EMERGENCY PROCEDURE
1. If you discover a fire or fire-related Emergency such as smoke, the odor of burning or
abnormal heating of material:
 Verbally warn others in the area;

 Pull the fire alarm station;
 When the emergency personnel arrive, identify yourself as the caller and give
them information about the fire plus any other information regarding possible
hazards in the area. This should include stored chemicals, flammable materials or
other relevant information. Emergency personnel may not be familiar with recent
renovations or other changes so your familiarity with the building can be valuable.
 Extinguish the fire if you have the equipment, training and a safe escape route.
 If possible, shut off equipment or experiments before leaving.
 vacate the building using your primary exit route. If that is blocked, use the
secondary exit route. Have these routes planned well in advance of an emergency.
 Close the door tightly behind you when leaving.
 Use the stairs only, avoid the elevators. (Elevators have a tendency to become
chimneys for smoke and fire.)
 If smoke is a problem, crawl on the floor to escape, or seal your door and room
ventilation and call for help via the phone or by signaling out the window.
 Do not re-enter the building until it is declared safe by the authorities.
ANNEXTURE – 13:EXPLOSION EMERGENCY PROCEDURE
1. If an explosion occurs in your building, Evacuate Immediately. Inform the fire siren
station on the way out of the building.
2. Render assistance to others, only if you can do so safely. (See guidelines for basic first
aid. Note that moving a victim can compound many times injuries).
3. If possible, and only if you can do so safely and quickly, shut off equipment or
experiments before leaving. Be aware an electrical spark could set off another
explosion.
4. Evacuate the building using your primary exit route. If that is blocked, use the
secondary exit route. Have these routes planned well in advance of an emergency.
5. Close the door tightly behind you.
6. Use the stairs only; avoid the elevator as it could set off another explosion.
7. If smoke is a problem, crawl on the floor to escape, or seal your door and room
ventilation and call for help via the phone or by signaling out the window.
8. When the emergency personnel arrive:
 Identify yourself;
 Give them any information you have about the explosion;
 Provide information about hazards in the area;
 Provide information about any personnel remaining in the building.
9. Do not re-enter the building until it is declared safe by the authorities.

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ANNEXTURE –14: CYCLONE EMERGENCY PROCEDURES
1. Pre-cyclone season checks - these checks shall be carried out at the beginning of the
cyclone season.
1.1 Electricity Supply
Check that all trees adjacent and under the overhead power lines are trimmed and will
not foul the lines. If necessary arrange with Mackay Electricity Board to have the trees
lopped.
1.2 Storm Water Drains
Ensure that all storm water drains and guttering is free of obstruction
2. Procedure as Cyclone Approaches
These procedures are divided into two sections:
Green Alert
When the Weather Bureau advises that a cyclone or potential cyclone is located within
600 kilometres, but where there is NO strong indication of gales affecting within 24
hours is called as Green Alert.
Red Alert
When the Weather Bureau advises that a cyclone is within 600 kilometres and gales
are expected within 24 hours, then it is „Red Alert‟.
2.1 Clearances
2.1.1 Control Centre
A Cyclone Control team will function under the ECC.
2.2 Green Alert Procedures
2.2.1 check that the electric pumps are in working order.
2.2.2 check that all rubbish bins and other items of plant which could become flying debris
are placed in secure locations, preferably indoors.
2.2.3 check that all building materials are properly secured.

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2.2.5 Departmental projects, experiments etc., which could be affected by failure of

electricity, gas or water should be safeguarded. It is the responsibility of the Heads of
Departments to establish their own procedures to cater for this type of emergency.
2.3 Red Alert Procedures
2.3.1 Departmental projects, experiments etc. shall be safeguarded as per departmental

requirements.
2.3.3 All doors and windows to be secured. If the building is occupied during the cyclone,
windows shall be operated in accordance with standard cyclone procedure, i.e. those
on one side away from wind should be opened.
2.3.4 all heavy sliding and roller doors shall be shut and locked in the shut position.
2.3.5 Electric driven stand-by pump shall be checked.
2.3.7 A final check shall be made of storm water drains to ensure inlets are not blocked.
2.3.8 A final check shall be made around buildings to ensure that all loose items have been
secured.
2.3.9 All plantings etc. shall be moved from display benches in the bush house and stored
beneath the benches.
2.3.10 Keys to all pool vehicles except those used by watchmen shall be available at the Main
Building.
3. After Cyclone has passed
3.1 Immediately after the cyclone has passed all buildings shall be checked or damage
and details should be forwarded to the Control team.
3.3 Security arrangements shall be provided for any damaged or open buildings.
3.4 Cleaning and mopping up of damaged buildings should be carried out as soon as
possible.
3.5 Loose equipment secured during Green and Red Alert shall be returned to normal
locations.
ANNEXTURE – 15:FLOOD EMERGENCY RESPONSE PROCEDURE
CLEAN-UP AFTER FLOOD EMERGENCY
1. As soon as it is safe to enter the flooded area, use mops, wet vacuums and paper
towels to remove water and clean affected area.

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2. In order to retard the growth of mold, temperature and humidity must be low. Turn
off heat or use air conditioning. Use fans and open doors and windows to circulate air.
Remove wet debris and carpeting form the area. Leave lights on if possible.
3. Carefully move damaged materials to a work area that has low temperature, low
humidity and good air circulation.
4. Thoroughly soaked books and books with coated paper should be frozen as soon as
possible after evaluation.
- Wrap books loosely in freezer paper
- Pack books flat in boxes, preferably plastic milk crates of a uniform size for
transportation to freezer facility. Label all boxes.
- Keep an inventory of books packed and removed to freezer facility.
*If books cannot be frozen before drying, interleave the pages with unprinted newsprint or
paper towels.
5. Wet books with covers intact can be air-dried.
- Cover worktable with unprinted newsprint or paper towels.
- Stand books on head end (i.e. upside down). Do not fan pages; open the covers
slightly and let stand while draining. If time allows, place a toothpick under
each cover midway from front to back to keep the boards tilted back slightly.
- Place paper towels between the front and back covers and the adjacent
Flyleaves. Change these towels and the towels or paper under the book
frequently.
- As the books dry, slowly and carefully begin interleaving with newsprint or paper
towels at intervals of 50 pages starting from the back of the book. Keep book
upright during the interleaving/drying stage.
2. Books, which are only wet around the edges can be interleaved with newsprint or
paper towels working from the back of the book.
6. Arrangements should be made to monitor the flood area for potential after- effects of
water damage.
ANNEXTURE – 16: EARTHQUAKE EMERGENCY PROCEDURE

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During a major earthquake you will experience shaking of the earth or building. This shaking
may start out as a gentle rocking motion that grows violent, or it may begin as a violent jolt.
You will find it difficult to walk during the shaking.
During the quake
1. Stay where you are, get under a desk or table or stand in a doorway or the corner of
the room or near the support column. Do not seek cover under tables or benches in
laboratories. Chemicals could spill and harm you. If possible, extinguish fires, flames
or other sources of ignition.
2. If you are outside get into an open area away from buildings, power lines and trees.
3. Do not use elevators.
4. If you are driving, pull over to the side of the road and stop immediately. Avoid
overpasses and power lines. Stay inside the vehicle until the shaking has stopped.
After the quake
1. Gather your valuables and leave the building quickly. If necessary, provide assistance
to those who have been trapped in the building, including those with mobility
impairments or those who are trapped by debris. Gather at the designated meeting
location.
2. If persons are injured or cannot be accounted for, or if you know someone is still
trapped in the building. If there is no answer or the line is busy.
3. To expedite rescue and emergency services, a sign should be posted on the front of
the building denoting that all of the occupants got out or that people may be trapped
in the building. If you know someone is trapped, note the time, date, number of
victims and their last known locations on the sign.
4. Check for injuries, but do not move seriously injured people unless the danger in the
area is greater than their injuries.
5. Remember, a significant earthquake will affect the entire city and county. You may
have to fend for yourself and your fellow workers for quite a long time. Render
whatever aid you can provide, but remember that you are responsible for your
personal safety.
6. Use telephones only to report emergencies (i.e., gas leaks, fire, injuries).
7. Physical Plant or other trained individuals should turn off utilities.
8. Never touch downed utility poles or lines. Avoid damaged building equipment.
9. Do not use your vehicle unless there is an emergency. Keep the streets clear for
emergency vehicles.
Be prepared for aftershocks. Aftershocks are usually smaller than the main quake, but they
may be strong enough to topple already damaged buildings.
ANNEXTURE – 17: TERRORIST THREATS/TERRORISM EMERGENCY PROCEDURE
Toxic/Irritant Gas
1. Immediately evacuate the building, using your preplanned evacuation route.

2. Call the local police. Inform them of the situation with as much information as is available.

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Infectious Agents
1. Leave the material in the same location where it was found or opened. Immediately
vacate and isolate the area.
2. Call the local police at 9-911. Inform them of the situation with as much information as is
available.
ANNEXTURE – 18: BOMB THREATS EMERGENCY PROCEDURE
1. Bomb threats may be received by telephone, e-mail or letter. If you receive a bomb
threat, remain calm and obtain as much information as possible:
 Exact location of the bomb

 When is it going to explode
 What kind of bomb is it
 Why was it placed here
 Who the caller is
2. All efforts in case of bomb threat or bomb explosion are to be coordinated by Disaster
Management Team
3. Call local police and Explosive Detective (Bomb) Squad. Provide them any information
that you have received, specifically the location and the time the bomb is supposed to
explode.
4. Record the threat calls for facilitating investigation.
5. If the threat was made in writing, do not handle the letter or note any more than
necessary.
6. Do not touch or move any unfamiliar objects, and wait for police to arrive on the
scene.
7. The Safety Officer on site will determine if an evacuation is warranted. If the building
is evacuated, account for all building occupants at the designated meeting area.
Steps to be taken in dealing with parcel bomb or suspected parcel I letter bomb
1) Do not open letters/parcels of the following nature:
i. Senders name not written

ii. Name is miss-spelt
iii. There are holes ill the envelopes for safety wires
iv. There are protruding wire(s) or tin foils
2) Parcels/letters with smell of oil/perfumes, shall be dealt as under:
i. Do not cut or open suspected letter or parcel.

ii. Separate the suspected letter or parcel and keep it in a safe place

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separately
iii. Ask for help from Bomb Disposal Squad. A bomb threat drill should be
periodically be carried out for being prepared to deal with such threats as
and when they occur.
DANGERS AND THREATS DURING STRIKE
1) Workers may try to stop the entry of officers and loyal workers by picketing in front of gates
and threatening on the way and residence of such loyal workers.
2) Stoppage of work and obstructing loyal workers
3) Use of indecent language against officers & loyal workers
4) Malafide distortion of incidents including blowing up of small incidents by

fermenting colour to create disturbance.
5) Sabotage and damage to installations and equipments
6) Staging demonstration in front of gates and shouting of slogans.
7) Creating disturbances wherever possible.
8) Setting on fire of vehicles and other equipments.
9) Violation of Section-144 and offering arrests in large numbers.
10) Dharnas, hunger strike in front of main gate or at Station Incharge's residence or other
officers of the plant.
11) Disruption of essential services such as water supply, fuel , canteen, etc.
12) Serious mischief by undesirable elements.
13) Concealing Arms/Ammunitions under garments and its misuse in a crowd.
The workers during such situation gather in large numbers and being instigated by their leaders can
go to create serious disturbances and law and order problems.

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ANNEXTURE – 19: NOTIFICATION PROCEDURE & COMMUNICATION SYSTEM
DMP
ACTION PLAN
INCIDENT INFORMER
FIRE FIGHTING
SITE SUPERVISOR / 2: 
OPERATER SHIFT IN CHARGE
AMBULANCE PCR U1&2
PCR U3&4
WTP I
3:  CHEMICAL LEAK CHP C/R I
STOPPAGE TEAM PCR 5
WTP 500

CHP C/R II
1: 
SHIFT INCHARGE
1: 
2:  INCIDENT
SECURITY
SITE
SAFETY
OFFICER
SITE INCIDENT CONTROLLER

1:  1: 
S.E. OP I –
Dy CE. I
S.E. OP II –
3:  Dy CE. II
S.E. CHP –
Dy CE. Admin
3: 
2: 
2: 
EMERGENCY CONTROL
SITE MAIN CONTROLLER CENTRE
Chief Engineer. REACHES TO ACTION THROUGH
1: 
ECC after site Dy CE. I / II /
verification Dy CE. Admin. /

ISSUE : 04
Page : 131
After verification of site conditions

Emergency will be declared by SMC through Coded Siren
code of siren – FIRE : Wailing sound (25 sec. ON, 5 sec OFF) 3 times
Chemical Leakage : Wailing sound (high & low pitch) for one min
DMP
DISASTER MANAGEMENT TEAM
ACTION PLAN
(Should take immediate predefined action on hearing Emergency Siren)
Team & Team Leaders
Fire Fighting & Rescue team Fire Officer 08408889307
Action Plan From Emergency
Medical help team Medical Supdt 08805000903
Control Room Coordination team Dy CE I 08888865263
Dy CE II
Security & Traffic control team Sr Mgr Security 09011407332
Communication & Liaison team Dy CE Admn 09850331342
Vehicle control team Asstt Engr VM 09423063606
Maintenance team Supdt Maint I 09850383179
Supdt Maint II
Welfare team Welfare Officer 08408889325
Logistic team Dy EE Civil Maint 08408889300
1.
DECLARE EMERGENCY Time Office I :- 6611,6666
Time Office II :- 6611,6666
BLOW SIREN THROUGH TIME OFFICE –
SHUT DOWN OF PLANT
IF FOUND NECESSARY THROUGH G.M.-I / II Koradi TPS. F/F

07109- 263811, 12, 13
INFORM DISTRICT FIRE FIGHTING SERVICES

INFORM POLICE SERVICES
101 / 0712-2567777, 2562395, 2562374, 2567029,
KORADI =0712-2566800 / NAGPUR =0712-2561222 Sarpanch Shri
CALL BOMB SQUAD Tahsildar Saoner
Other Corporator
0712-2561222 / 2564333
INFORM PUBLIC IN THE VICINITY
INFORM UNIONS SEA – Shri

GEA – Shri
Tantrik - Shri
CALL VARIOUS MEDICAL ORGANISATIONS Magasvargiya – Shri
Govt Med.Hosp. -0712-2744671 Federation - Shri
IGMC- 0712-2728621 to 2728627 Kamgar Sena Shri
INFORM DISTRICT EMERGENCY AUTHORITIES Addl Dir. IS&H 0712-2564545 office

(Mutual Aid Response Group - MARG ) Dy Dir IS&H 9850603641 Shri Kamble
Electrical Inspector 9423051214
STATEMENT TO MEDIA
Dy Collector (Coord) 0712-2531976
Dist Collector 0712-2531972
DIRECT TIME OFFICE
TO HEAD COUNT PERSONS

INFORMATION TO
RELATIVES OF INJURED
IN CASE OF DEATH
SEEK HELP FORM GOS & POLICE

CALL
VARIOUS SOCIAL ORGANISATIONS
GIVE ALL CLEAR
THROUGH CODED SIREN

ISSUE : 04
Page : 132
ANNEXTURE – 20.1: PLANT MAP 4 SETS X210 MW

ISSUE : 04
Page : 133
ANNEXTURE – 20.2: PLANT MAP 1 SET X 500 MW
WAY TO 210 MW CHP

CHIMNEY
COAL STORAGE
OIL STORAGE
OZONE PLANT
ESP
CHLORINE DOZING
STORAGE
BOILER
TURBINE
NDCT Xrmer Yard

CANTEEN
SWITCH YARD
Not Under MAHAGENCO
CHP CONTROL ROOM
CHEMICAL STORAGE
At WTP
ECC
At
Security
office
Emergency Control Room

Assembly Point
Hazardous Material Storage

ISSUE : 04
Page : 134
MEANING OF THE TERMS USED IN THIS DOCUMENT
Accident: An unintended, unexpected event occurring suddenly, causing or having potential to

cause death, injury and/or illness to persons, damage to property and/or the environment or
any combination of these.
Crisis: It is defined as an event of acute danger, which can cause sudden disruption of basic
requirement supplies such as water, food, power supply, raw material etc. The event is caused
either due to human error / equipment failure or sabotage by antisocial elements.
Dangerous Occurrence: An incident having potential to cause serious injury and/ or material
damage.
Disaster: It is a catastrophic situation in which the day-to-day patterns of life are, in many
instances, suddenly disrupted and people are plunged into helplessness and suffering and, as a
result, need protection, clothing, shelter, medical and social care and other necessities of life
from government and other governmental and non-governmental agencies.
Emergency: It has the potential to cause serious injury or loss of life and/or property or
degradation of environment and which tends to cause disruption inside and/or outside the
Plants and may require the use of external resources for mitigation.
Hazard: It is a physical or chemical condition, having potential to cause bodily harm to any
person, property or environment (alternatively, a risk source).
Hazardous Process: It means any process or activity in an industry, where, unless special
care is taken, the materials handled therein would cause material impairment to the health of
the persons engaged in or connected therewith or results in the pollution of the general
environment. Refer the definition in the Factories Act, 1948.
Incident Command System (ICS): A management tool used by responders to facilitate an

incident. The system includes such features as common terminology, standardised
communication and modular structure. It is flexible and can be utilised on incidents of any
size.
IDLH (Immediately Dangerous to Life & Health): The term is expressed in parts per
million (ppm) and reflects the atmospheric level of any toxic material, corrosive or asphyxiant
that poses a danger to life or would cause irreversible or delayed adverse health effects or
would impair the ability of an individual to escape the area.
Major Accident: An incident involving loss of a life inside or outside the installation, or ten or
more injuries or release of harmful or toxic chemicals or explosion or fire or spillage of
hazardous chemicals resulting in an on-site or off-site emergency or adverse effect on
environment. (Refer definition in the Manufacture, Storage and Import of Hazardous Chemicals
Rules, 1989).

ISSUE : 04
Page : 135
Manufacturing Process: It means any process for making, altering, repairing, finishing,
packing, oiling, washing, cleaning, demolishing or otherwise treating or adapting any article or
substance with a view to its use, sale, transport, delivery or disposal, and includes pumping of
water. Refer the definition in the Factories Act, 1948.
Off-Site Emergency: An emergency, the potential effects of which are anticipated to cross the
boundary outside the Plants.
On-Site Emergency: An emergency, the potential effects of which are anticipated to be within
the boundary of the Plants, affecting persons, property or environment within the Works.
Risk: It is a measure of the chance that damage to life, health, property and/or the
environment will occur as a result of a hazard. Thus, risk is the product of probability of
occurrence of an incident and consequences (i.e., damage or loss). (Probability of occurrence
of an accident and severity of consequences for people, production and the environment are
required to be taken into account while evaluating „Risk‟).
Threshold Limit Value (TLV): A set of standards established under various statutes for
concentrations of airborne substances in workroom air. They are time-weighted averages
based on conditions that it is believed persons may be repeatedly exposed to day after day
without adverse effects.

ISSUE : 04
Page : 136
Abbreviations Used
Sr
No Abbreviation Details
AP Assembly points
BM Boiler Maint
TM Turbine Maint
EM Electrical Maint
TIC Testing instrumentation & control
AHP Ash handling Plant
CHP Coal Handling Plant
WTP Water treatment Plant
OHP Oil Handling Palnt
CE Chief Engineer
DMP Disaster Management Plan
Dy CE Dy. Chief Engineer
ECC Emergency control centre
EE Executive Engineer
GOs Government Organisations
LPG Liquefied Petroleum Gas
MSDS Material Safety Data Sheet
MoE Ministry of Environment
NGOs Non Government Organisations
PPEs Personal Protective Equipments
SCBA Self Containing Breathing Apparatus
SE Supdt Engineer
SH Section Head
SIC Site incident Controller
SMC Site Main Controller
SOP Safe Operating Procedure
Xmers Transformers

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ISSUE : 04

KHAPERKHEDA THERMAL POWER STATION Rev No. : 01

KHAPERKHEDA THERMAL POWER STATION

MAHARASHTRA STATE POWER GENERATION COMPANY LIMITED

DISASTER MANAGEMENT PLAN

Revised on 20 Jun 2015

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5.5.2 EXTERNAL COMMUNICATION ................................................................................... 32

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ANNEXTURE – 18: BOMB THREATS EMERGENCY PROCEDURE .......................................................................... 128

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Revision / Amendments of Record

01.05 31.05. Safety

50, 31.05 05.09. Safety

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(1. A) BASIS OF THE PLAN

(1. B) METHODOLOGY TO PREPARE DMP

(1. C)OBJECTIVE OF THE PLAN

(1. D) DISASTER MANAGEMENT IN INDUSTRY

To overcome or to control natural or industrial disaster a documented plan required. This

"Disaster management" according to Disaster Management Act 2005 means a continuous

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(i) Prevention of danger or threat of any disaster;

1. D.1 DISASTER M ANAGEMENT ACTIVITY

1. D.2 TYPES OF DISASTER

1.D.3 DEGREES OF DISASTER

The above contingencies will be declared by the Site Main Controller.

1. D.4 MODE OF ACTION

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1. D.5 STAGES OF DISASTER

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2. ABOUT KHAPERKHEDA THERMAL POWER PLANT

Khaperkheda Thermal Power Station is situated at 21 KM north of Nagpur. It is a power

(2. A) CLIMATIC DETAILS:

Humidity 70% to 20%

(2. B) KHAPERKHEDA TPS AT GLANCE

1) Installed capacity 210 MW x 4 sets + 500 MW x 1 set. Total 1340 MW

4) Approach to P.S. a) State High way Nagpur – Chhindwada via Dahegaon.

5) Date of commissioning Unit No. I 26/03/1989 210MW

7) Water requirement 210 MW X 4 Sets :- 65,000 to 70,000 M³ per day.

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9) Coal source Rail fed power station

10) Coal requirement 210 MW X 4 Sets :- 12,000 – 14,000 T per day.

12) Power Evacuation. -- Connected to Maharashtra State Grid

Feeders (10 Nos.) – Kanhan, Kalameshwar, Bhandara, Ambazari – I & II,

3. DISASTER SCENARIOS IN TPS/ DISASTER PRONE AREAS

(3. A) AREAS PRONE TO DISASTER IN POWER SECTOR:

(3.B) EVENTS CAUSES PLANT ORIENTED DISASTER

ii) Fire in thermal power station:

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iii)Release of Gases / Chemicals:

iv)Sources of Chemical Disasters

I) Manufacture and formulation installations including process operations; maintenance

vi)Radio Active Materials

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4. DISASTER MANAGEMENT COMMITTEE

(4.A) THE DISASTER MANAGEMENT COMMITTEE

(4.B) THE DISASTER MANAGEMENT TEAMS

The Disaster Management Teams, team Leader, responsibilities & duties

B.1 FIRE FIGHTING & RESCUE TEAM

Pre Disaster Stage

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