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INTRODUCTION :
UNDERSTANDING OF MATERIAL SAFETY PARTICULARLY IN CHEMICAL
INDUSTRIES IS IMPORTANCE TO ENSURE SAFETY DURING THE HANDLING
& STORAGE AND TRANSPORTATION
ONE OF THE BEST METHODS OF ELIMINATING ACCIDENT IS TO
UNDERSTANDING THE PROPERTIES.
MATERIAL SAFETY DETA SHEET
MATERIAL : RAW, F.P. IN PROCESS MATERIAL
SAFETY
: IDENTIFIES & SUMMARIZES SAFETY, ENVIRONMENTAL
ASPECTS ALONG WITH ASSOCIATED HEALTH HAZARDS
POSED WHILE STORING , HANDLING, TRANSPORTATION
OF SAID MATERIAL
DATA:
:IMPORTANCE PHYSICAL & CHEMICAL PROPERTIES OF
CHEMICALS IS LISTED WHICH WILL HELP IN DETERMINING
THE NATURE OF MATERIAL BEING HANDLED.
SHEET
: SUMMERY SHEET – IDENTIFYING HAZARDS & NECESSARY
PRECAUTIONS/ PREVENTIVE MEASURES.
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1.)
PRODUCT IDENTIFICATION :
CAS NO : CHEMICAL ABSTRACT SERVICE REGISTRY NUMBER IS A
NUMERIC DESIGNATION OF A CHEMICAL ASSIGNED BY THE AMERICAN
CHEMICALS SOCIETY ‘S CHEMICAL ABSTRACT SERVICE AND UNIQUELY
IDENTIFIES A SPECIFIC CHEMICAL COMPOUND.
SYNONMY NAME : COLLOIDAL SULFUR, FLOWERS OF SULFUR
CHEMICAL FORMULA : S8
CAS NAME : PHOSPHOROUS ACID, TRYMETHLY ESTER.( TMP )
2.)
COMPOSITION/INFORMATION ON INGREDIENTS :
SULFUR “: PERCENT 100 % .
SEPARATE MSDS SHEET FOR SEPARATE COMPOSITION
FOR E. G. ACIDS
3.)
HAZARDS IDENTIFICATION :
NFPA SIGNALS :
HEALTH
: 0,1,2,3
1
FIRE
: 0.1,2,3
3
REACTIVITY
: 0.1,2,3
0
CONTACT RATING : 0.1.2.3
1
LAB PROTECTIVE EQUIPMENTS :
NFPA SIGNALS :
0
= INDICATES ALMOST NO HAZARDS
1,2,3,
= AS NUMBER INCREASES THE DEGREE OF THE HAZARDS
INCREASES
4
= HIGHEST HAZARDS
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4. )
FIRST AID MEASURES :
INHALATION,
SKIN CONTACT
INGESTION
- VAPOR, DUSTS, FUMES ETC
- SPLASH., SAME CLOTH FOR 2-3 DAYS.
- EATING TOBACOO, PADIKI, EATING IN
WORKPLASH AREA
CHRONIC EFFECT : IT IS THE EFFECTS ON PROLONGED EXPOSURE OF
CHEMICALS , IT MAY AFTER 5 YERS, 10 YEARS, 15 YERS. EXAM OF
ASBESTOSIS.
ACUTE EFFECT : IMMEDIATE EFFECT
5.)
FIRE FIGHTING MEASURES :
AUTO IGNITION TEMPERATURE : IT IS ALSO KNOWN AS IGNITION
TEMPERATURE. - LOWEST TEMPERATURE AT WHICH SELF SUSTAINED
COMBUSTION OF THE OF A SOLID, LIQUID OR GAS IS INITIATED OR
CAUSED IN THE ABSENCE OF SPARK OR FLAME.
FLASH POINT : THE FLASH POINT OF THE FLAMMABLE LIQUID IS THE
LOWEST TEMPERATURE AT WHICH IT GIVES OFFS ENOUGH VAPOR TO
FORM A FLAMMABLE MIXTURE WITH AIR NEAR THE SURFACE OF THE
SOLID OR WITHIN THE CONTAINER.
EXPLOSIVE LIMITS OR FLAMMABLE LIMITS, EXPLOSIVE RANGE
LOWER EXPLOSIVE LIMITS :
IN CASE OF MOST FLAMMABLE LIQUIDS, GASE, & DUSTS : --THERE IS A MINIMUM CONCENTRATION OF VAPORS , GAS OR DUST IN AIR
BELOW WHICH THE PROPAGATION OF FLAME DOES NOT OCCUR ON
CONTACT WITH THE SOURCE OF IGNITION .
UPPER EXPLOSIVE LIMITS : THERE IS A MAXIMUM CONCENTRATION
OF VAPORS , GAS OR DUST IN AIR ABOVE WHICH THE PROPAGATION OF
FLAME DOES NOT OCCUR ON CONTACT WITH THE SOURCE OF IGNITION .
FIRE LOAD : IT IS THE HEAT GENERATED PER UNIT AREA IN CASE OF FIRE.
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6.)
ACCIDENTAL RELEASE MEASURES :
THIS SECTION INFORMS ABOUT THE PROCEDURE TO BE FOLLOWED IN
CASE OF RELEASES OF CHEMICALS ( THIS IS SEPARATE FOR ALL
CHEMICALS LEAVING FEW COMMON THINGS.)
USE OF PPE : SUITS,
NON SPARKING TOOLS ESPECIALLY IN SOLVENT
VENTILATION, REMOVAL OF IGNITION SOURCES
WATER SHOWERING.
7. )
HANDLING & STORAGE :
STORAGE : VENTILATED, COOL, AWAY FROM SOURCES OF
IGNITION, EARTHING
EXPLOSION RELIEF PROVISIONS. ( S.V./RD/FLAME ARRESTER )
HANDLING : USE OF PPE, SCBA, HAND SAMPLER, PROPER TOOLS,
DIFFERENT FOR ALL CHEMICALS.
8. ) EXPOSURE CONTROLS /PERSONAL PROTECTION
SKIN PROTECTION
EYE PROTECTION
PERSONAL RESPIRATORS : HALF FACE PIECE MASK.SCBA
9.)
PHYSICAL & CHEMICAL PROPERTIES
APPEARANCE
:
ODOR
:
SOLUBILITY
: WITH WATER – HELPS FOR NEU’N, DILUTION
SPGR
: LEAK/SPILL VAPOUR
PH
: HELP TO DETERMINE THE NEUTRALIZATION MEDIA.
( ACIDIC / BASIC )
: IT IS THE TEMPERATURE AT WHICH LIQUID
SUBSTANCES GET CONVERTED INTO VAPOR FORMS.
BOILING POINT
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MELTING POINT : IT IS THE TEMPERATURE AT WHICH FLAMMBLE SOLID
CONVERTED INTO LIQUID STATE.
VAPOR DENSITY : IT IS THE RATIO OF A WEIGHT OF VOLUME OF PURE
VAPOUR OR GAS TO AN EQUAL VOLUME OF DRY AIR AT THE SAME
TEMPRATURE & PRESSURE.
VD LOWER THAN 1 INDICATES – TEND TO RISE IN A RELATIVELY CALM
ATMOSPHERE.
VD HIGHR THAN 1 INDICATES – SETTLES DOWN ON THE GROUND LEVEL ,
TRAVEL FOR A LONG DISTANCE – SPARK, FLASH BACK.
V.P : IT IS MEASURE OF THE TENDENCY OF A MATERIAL TO FORM
VAPOURS. HIGHER THE V.P, MORE LIKELY ARE THE CHANCES OF VAPOUR
TO BE RELAESED INCREASING FIRE HAZARDS IN CASE OF FLAMMABLE
LIQUIDS.
10. )
STABILITY & REACTIVITY
STABILITY :
HAZARDOUS DECOMPOSITION PRODUCT :OR BYPRODUCT OF
FIRE
HAZARDOUS POLYMERISATION :
INCOMPATIBLE :
CONDITIONS TO AVOID : H2S, HEAT,SPARKS
11. )
TOXICOLOGICAL INFORMATION
THRESHOLD LIMIT VALUE : TLV REFERS TO AIR BORNE CONCENTRATION
OF SUBTANCE & REPRESENTS THE CONDITION UNDER WHICH IT IS
BELIEVED THAT NEARLY ALL WORKESES MAY BE REPEATEDLY EXPOSED
DAY AFTER DAY WITHOUT ANY ADVERSE EFFECTS.
TLV- TWA : IT IS THE TIME WEIGHTED AVERAGE CONCENTRATION FOR
NORMAL 8 HOUR WORK DAY AND 40 HR WORK WEEK TO WHICH NEARLY
ALL WORKESE MAY BE REPEATEDLY EXPOSED DAY AFTER DAY WITHOUT
ANY ADVERS EFFECT
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TLV ; STEL : IT IS A 15 MINUTE TIME WEIGHTED AVERAGE EXPOSURE
WHICH SHOULD NOT BE EXCEEDED AT ANY TIME DURING THE WORK DAY
.EXPOSURE AT THE SEL SHOULD NOT BE MORE THAN FOUR TIME AND
THERE MUST BE ATLEST 60 MINUTES INTERVAL BETWEEN TWO
SUCCESSIVE EXPOSURE AT STEL.
TLV – CELING : IT IS THE CONCENTRATION WHICH SHOULD NOT BE
EXCEEDED DURING ANY PART OF THE WORKING HOURS.
LD 50 : IT IS A PRECISE DOSE OF SUBSTANCE VIA ANY ROUTE WHICH IS
EXPECTED TO CAUSE THE DEATH OF 50% OF AN ENTIRE DEFINED
EXPERIMENTAL ANIMAL POPULATION. THE UNIT IS MG/KG OF BODY
WEIGHT
IDLH : IMMIDIATE DANGER TO LIFE & HEALTH IT IS THAT
CONCENTRATION WHICH PERSON CAN HAVE FEW BREATH AND HE MAY
DIE.
12. )
ECOLOGICAL INFORMATION :
EFFECTS ON ENVIRONMENT ( TRESS, PLANTATION , )
EFFECTS ON WATER OF SEA, PONDS, RIVERS & AQUATIC FILE
13. )
DISPOSAL CONSIDERATION :
AT DESIGNATED FACILITY : LIKE BEIL, GIDC PUMPING STATION.,
DUMPING, INCINERATION, LAND FILLING, TO SEA, INCINERATION.
14. ) TRANSPORT INFORMATION
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ANSWER NO :
UNSAFE CONDITIONS ARE THOSE CONDITIONS WHICH ARE IF NOT
CORECTED MAY LEAD ANY ACCIDENT/INCIDENTS.
FOLLOWING ARE TEN MOST UNSAFE CONDITIONS :-
1. OPEN MANHOLE ON WORKING PLATFORM, FLOORS, ROAD.
2. LOOSE EARTHING/WIRING OF ELECTRICALS CONNECTION
3. WORKING PLATFORM/STAIRCASE WITHOUT THE RAILING
4. LEAKAGE OF CHEMICALS FROM FLANGE, VALVES, JOINTS
5. MOVING MACHINERY WITHOUT GUARDS
6. GAS ALARMS NOT WORKING
7. POOR LIGHTING & VENTILATION
8. SLIPPERY FLOORS, WATER LOGGING INSIDE THE PLANT
9. POOR HOUSEKEEPING.
10. INSTRUMENT ESPECIALLY PRESSURE GUAGE/TEMPERATURE GUAGE
NOT WORKING/MALFUNCTIONING ON CRITICAL EQUIPMENT.
WHENEVER YOU FIND SUCH CONDITIONS IN THE PLANT YOU MUST
REPORT TO YOUR IMMEDIATE SUPERVISOR/OFFICER. OR ALSO TO THE
SAFETY OFFICER.
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TRAINING REFRESHER MODULE FOR TANK FARM OPERATOR
FOLLOWING TRAININGS SHALL BE GIVEN TO TANK FARM OPERATOR ,












SOP FOR UNLOADING OPERATION
SOP OF WORK PERMIT SYSTEM
DETAILS OF WORK PERMIT FOR UNLOADING OPERATION
PROPERTIES OF CHEMICALS IN TANK FARM
MSDS OF CHEMICALS IN TANK FARM
PUMP OPERATION
SAFETY MEASURES REQUIRED DURING THE UNLOADING &
LOADING OPERATION
POLLUTION CONTROL MEASURES DURING UNLOADING &
LOADING OF CHEMCALS IN TANK FARM
RESPONSIBILITIES OF TANK FARM OPERATOR
SAMPLING PROCEDURES
DECONTAMINATION PROCEDURES OF CHEMICALS IN TANK
FARM
PERSONAL PROTECTIVE EQUIPMENT GUIDELINES
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BASIC PROPERTIES OF HAZARDOUS CHEMICALS USEFUL DURING THE
EMREGENCY
NAME OF THE
CHEMICALS
CHLORINE
B.P
F.P
-34
N.A.
AUTO
IGINI
TEMP
SP.
GR
V.D.
FLAMM
ABLE
EXTINGUISHIG
METHOD
SOLUBL IN
WATER
NEUTRALISING MEDIA
/ SPILL CONTROL
2.47
2.98
NO
WATER, DCP,
CO2, FOAM
<1%
N.A
1.83
4.42
Highly
None
WET SAND / EARTH
1.57
4.75
Non
flamma
.
WATER SPRAY ,
WET SAND
DCP,
CO2, FOAM
Decompos
e
exothermic
ally in
water
Reacts
with water
VACCUM OR SWEEP
OFF
PHOSPHOROUS
280
PCL3
75
P2S5
N.av
N.av
Non
com.
N. Av
N.av.
Yes
ANHYDROU
S AMMONIA
-33. 3
651
n.ap
0.6
Not
flamm.
Under
conditi
ons.
METHANOL
64.7
Not
flam
m.
Under
condit
ions.
12.0
464
0.79
1.11
Highly
TMP
109.0
N.
Ap.
1.05
4.28
Yes
AMMONIA
AQUEOUS
N.
Av.
N.
Ap.
651
0.9
0.59
SULFUR
445
207
232
2.07
8.9
Slightly
P2S5
513
---
---
2.03
---
Highly
DETA
77
90
N. Av
1.17
NaSH
120
N. Av
N. Av
1.31
N.
Av.
N. Av
30
CO2, DCP,
DO NOT USE
WATER
DIRECTLY ON
FIRE
WATER FOG IS
BEST
5%
NO CLEAN UP AS IT
WILL NOT LEAVE
RESIDUE WHEN
SPILLED.
complete
DRY SAND, EARTH
In soluble
DRY SAND, EARTH
WATER SPRAY,
DCP, C02
Complete
WATER SPRAY
ONLY, NO
SOLID
STREAMS OF
WATER
CO2, DCP, SAND
Insoluble
NEUTRALISE WITH
WITH DILUTE HCL OR
DRY SAND, EARTH.
-------
WATER SPRAY,
DCP, C02
FOAM, DCP,
CO2,
N.
Flamm.
ALL THE TEMPERATURES ARE IN DEGREE CENTRIGRADE.
N. AV. : NOT AVAILABLE
SOURCE : M. S. D. S.
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N. AP. : NOT APPLICABLE
Reacts
With water
Slightly
Soluble
Complete
-----SAWDUST.
TRAINING LEVEL
SR. TRAINING
NO. LEVEL
TARGET GROUPE MINIMUM HRS INTHE
YEAR
01
LEVEL 0
CASUAL LABOLUR &
FITTER, TECHNICIAN
TWENTY FOUR
02
LEVEL 1
OPERATORS,
ADMINISTRATIVE STAFF
TWENTY HRS
03
LEVEL 2
PRODUCTIN OFFICERS,
ENGINNERS
SIXTEEN HRS
04
LEVEL 3
MANAGER & ABOVE
EIGHT HRS.
TOPICS TO BE COVERED
GENERAL SAFTY IN CHEMICAL INDUSTRY
FIRE PREVENTION , PROTECTION 7 FIGHTING
ON SITE EMMERGENCY PLAN
FIRST AID
SAFE MAINTENANCE PRACTISE I THE PLANT
ELECTRICAL SAFETY
ROLE OF INSTRUMENTATION I N SAFET
COST OF ACCIDENT
SUPERVISOR ROLEIN SAFETY MANAGEMENT
RESPONSIBLE CARE
GOOD INFRASTUCTURE – A KEY TO PREVENT THE ACCIDNET
ACCIDNENT INVESTIGATION – A MANAGEMENT PROGRAMME
WAREHOUSE SAFETY
HAZOP/HAZAN
DETAIL ACTIONPLAN
IMPORTANCE OF WORK PERMIT SYSTEM
LEARNIG FROM THE PAST ACCIDNET OFD OUR OWN INDUSTRY
VIDIO FILM
VIDI FILM
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WHY NEED OF TRAINING
TO MAKE AWARE ABOUT THE HAZARD.
‘’OUR MIND KNOWS WHAT OUR EYES SEE’ …………… EXAMPLE
HOW TRAINING IS HELPFUL
EXAMPLE OF V.M. SATHE
PRACTISING SAFETY IS JUST LIKE MEDICAL PRACTIONER
DOCTOR SAVES LIFE FROM DISEASE
SAFETY SAVES LIFE FROM HAZARD
TYPES OF HAZARD IN CHEMICALS
1. TOXICITY HAZARD
2. FLAMMABILITY HAZARD
3. REACTIVITY HAZARD
TOXICITY HAZARD



DEFINATION
ROUTE OF ENTRY OF CHEMICAL IN HUMAN BODY
METHODS OF PROTECTION OF BODY PARTS
FLAMMABILITY HAZARD


REASON OF FIRE
HOW IT CAN BE AVOIDED
REACTIVE HAZARD

REACTIVITY OF CHEMICALS
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PLANT PERSON SHALL KNOW BEFORE HANDLING CHEMICALS FOR
SAFE HANDLING




HAZARDOUS PROPERTIES OF THE CHEMICALS
DECONTAMINATION PROCEDURES IN CASE OF SPILLAGE
FIRST AID IN CASE OF EXPOSURE ( TO EXPLAIN ‘FIRST AID’ IN
BRIEF )
SPECIAL PRECAUTIONS IF REQUIRED
GENERAL PRECAUTIONS


WASH THE HANDS BEFORE TAKING FOOD
FOLLOW THE INSTRUCTIONS GIVEN TO YOU
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ON SITE EMERGENCY PLAN
PAST INDUSTRIAL ACCIDENTS SUCH AS

BHOPAL GAS TRAGEDY

FIRE IN LPG BOTTLING PLANT OF MEXICO CITY

FIRE IN THE STORE OF GLAXO AT BASEL, SWITZERLAND
It is well proved that when on site safety precaution fails effective Emergency Plan for
site working persons, and people living in the vicinity of installation becomes particularly
important.
On site plan for handling emergency can be matter of life & death
NOW A DAY IT IS STATUTORY RQUIREMENT TO PREPARE ON SITE
PLAN UNDES SECION 41B, 2CB, 87 & MISCH RULES 1989.
PVP
WHAT IS AN EMERGENCY ?
AN EMERGENCY IS ANY UNPLANNED EVENT THAT CAN CAUSE DEATH OR
SIGNIFICANT INJURY TO EMPLOYEES OR TO THE PUBLIC.
EMERGENCY MEANS SUDDEN LEAKAGE, SPILLAGE OF CHEMICVALS, GAS
OR FAUILER OF MACHINERY , EQUIPMENT, BRUSTING /EXPLOSION OF
VESEELS/PLANTS, FIRE IN THE VESSELS,TANKFARM.
hs/tread/5101msdstrg prg/05
PVP
WHY DOES THE EMERGENCY ARISE ?
95 % HUMAN ELEMENT
( EQUIPMENT FAILURE, OPERATIONAL MISTAKE, POOR
MAINTENACE, SABOTAGE, INSTRUMENTATION FAILURE,
05 % NATUARAL CALAMITIES
( FLOOD, EARTHQUKE, CYCLONE, LIGHTENING. )
WHAT AN EMERGENCY CAN DO ?
AN EMERGENCY CAN SHUT DOWN YOUR BUSINESS OR ORGANIZATION,
DISRUPT OPERATIONS, CAUSE PHYSICALS OR ENVIRONMENTAL DAMAGE
AND / OR THREATEN THE FINANCIAL STANDING OR PUBLIC IMAGE OF THE
ORGANIZATION.
THERE ARE TWO TYPES OF EMERGENCY

ON SITE EMRGENCY

OFF SITE EMERGENCY
PVP
OBJECTIVE OF EMERGENCY PLANNING.

LOCALIZE THE EMERGENCY & IF POSSIBLE ELLIMIMNATE IT.

MINMIZE THE EFFECT ON PEOPLE , PROPERTY & SURROUNDINGS.
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WHAT IS EMERGENCY PLAN ?
EMERGENCY PLAN IS A COMPREHENSIVE SYSTEM SET UP TO ADDRESS
AND HANDLE NATURAL & MAN MADE HAZARDS,. IT SHALL INCLUDE
PREVENTION, PREPAREDNESS, RESPONSE AND RECOVERY.
PLANNING IS A CRUCIAL COMPONENT IN ANY SAFETY & HEALTH
PROGRAMME INCLUDING EMERGENCY ACTION
PLANNING IS PREVENTION & PREPAREDNESS
PVP
EMERGENCY PLAN IS A TEAM WORK. IT IS LIKE A MARRIGE.
JUST IMAGINE THE SCENE OF EMERGENCY
FIRE HAS OCCURRED IN THE STOARGE VESSEL WHICH IS FULL OF
MATERIAL LIVING THE TOXIC GAS AROUND IT AND IT HAS CAUSED THE
INJURY TWO THREE FOUR PEOPLE.
UNDER ABOVE CONDITION IF NO EMERGENCY PLAN EXITS, IMAGINE
WHAT WILL HAPPEN.
FIRST STEP IN PREPARING ON SITE PLAN IS
1. )
IDENTIFICATION OF HAZARDS
2.)
CAPABILITY ASSESMENT INCLUDE




Employee Skill ( special skill possessed by employee )
Equipment(fire protection, rescue equipment, ppe, communication facilities , clean
up procedure, medical facilities)
Local Response Capability ( DPMC, Police department )
Facilities include ECC , AP
3. ) Appointement of Person
hs/tread/5101msdstrg prg/05
SMC
IC
Formation of different Team
Defining the role of each individual
Defining the duties of SMC.IC.DY.IC, Observer.
hs/tread/5101msdstrg prg/05
ON SITE EMERGENCY PLAN
PAST INDUSTRIAL ACCIDENTS SUCH AS

BHOPAL GAS TRAGEDY

FIRE IN LPG BOTTLING PLANT OF MEXICO CITY

FIRE IN THE STORE OF GLAXO AT BASEL, SWITZERLAND
It is well proved that when on site safety precaution fails effective Emergency Plan for
site working persons, and people living in the vicinity of installation becomes particularly
important.
On site plan for handling emergency can be matter of life & death
NOW A DAY IT IS STATUTORY RQUIREMENT TO PREPARE ON SITE
PLAN UNDES SECION 41B, 2CB, 87 & MISCH RULES 1989.
WHAT IS AN EMERGENCY ?
AN EMERGENCY IS ANY UNPLANNED EVENT THAT CAN CAUSE DEATH OR
SIGNIFICANT INJURY TO EMPLOYEES OR TO THE PUBLIC.
EMERGENCY MEANS SUDDEN LEAKAGE, SPILLAGE OF CHEMICVALS, GAS
OR FAUILER OF MACHINERY , EQUIPMENT, BRUSTING /EXPLOSION OF
VESEELS/PLANTS, FIRE IN THE VESSELS,TANKFARM.
WHY DOES THE EMERGENCY ARISE ?
95 % HUMAN ELEMENT
( EQUIPMENT FAILURE, OPERATIONAL MISTAKE, POOR
MAINTENACE, SABOTAGE, INSTRUMENTATION FAILURE,
05 % NATUARAL CALAMITIES
( FLOOD, EARTHQUKE, CYCLONE, LIGHTENING. )
WHAT AN EMERGENCY CAN DO ?
AN EMERGENCY CAN SHUT DOWN YOUR BUSINESS OR ORGANIZATION,
DISRUPT OPERATIONS, CAUSE PHYSICALS OR ENVIRONMENTAL DAMAGE
hs/tread/5101msdstrg prg/05
AND / OR THREATEN THE FINANCIAL STANDING OR PUBLIC IMAGE OF THE
ORGANIZATION.
THERE ARE TWO TYPES OF EMERGENCY

ON SITE EMRGENCY

OFF SITE EMERGENCY
OBJECTIVE OF EMERGENCY PLANNING.

LOCALIZE THE EMERGENCY & IF POSSIBLE ELLIMIMNATE IT.

MINMIZE THE EFFECT ON PEOPLE , PROPERTY & SURROUNDINGS.
WHAT IS EMERGENCY PLAN ?
EMERGENCY PLAN IS A COMPREHENSIVE SYSTEM SET UP TO ADDRESS
AND HANDLE NATURAL & MAN MADE HAZARDS,. IT SHALL INCLUDE
PREVENTION, PREPAREDNESS, RESPONSE AND RECOVERY.
PLANNING IS A CRUCIAL COMPONENT IN ANY SAFETY & HEALTH
PROGRAMME INCLUDING EMERGENCY ACTION
PLANNING IS PREVENTION & PREPAREDNESS
EMERGENCY PLAN IS A TEAM WORK. IT IS LIKE A MARRIGE.
JUST IMAGINE THE SCENE OF EMERGENCY
FIRE HAS OCCURRED IN THE STOARGE VESSEL WHICH IS FULL OF
MATERIAL LIVING THE TOXIC GAS AROUND IT AND IT HAS CAUSED THE
INJURY TWO THREE FOUR PEOPLE.
UNDER ABOVE CONDITION IF NO EMERGENCY PLAN EXITS, IMAGINE
WHAT WILL HAPPEN.
FIRST STEP IN PREPARING ON SITE PLAN IS
1. )
IDENTIFICATION OF HAZARDS
2.)
CAPABILITY ASSESMENT INCLUDE



Employee Skill ( special skill possessed by employee )
Equipment(fire protection, rescue equipment, ppe, communication facilities , clean
up procedure, medical facilities)
Local Response Capability ( DPMC, Police department )
hs/tread/5101msdstrg prg/05

Facilities include ECC , AP
3. ) Appointement of Person





Site Main Controller
Incident Controller
Formation of different Team
Defining the role of each individual
Defining the duties of SMC.IC.DY.IC, Observer.
We need to collect the information needed to complete the plan through the following
four steps.





Conducting hazard or risk analysis
Location ; where from hazard is likely to initiate
Quantity : maximum quantity likely to be released during the emergency
Potential risks.
Likelihood of release of substances and its consequence.
Other hazards to be considered are










Whether the material is flammable
Whether water can be used or not
Reactivity with other materials, whether forms hazardous substances or release
heat or gas
Likelihood of damage to property
Likelihood of damage to environment
Size of the vulnerable zone in case of release of gas
Number of people likely to be present within the vulnerable area.
Sensitive populations within the vulnerable zone
Essential services facilities within the vulnerable zones
Types of emergency procedures to be followed.
Following Resources are required for the tackling the emergency







Equipment
Fire protection system & equipment
Rescue equipment
Alarm system
Public address system
Radio communications
Flash lights
hs/tread/5101msdstrg prg/05





Spare batteries
Medical facilities
Protective gears needed during the emergency. Whether they are available to tat
facilities and to the emergency responders
Sampling and monitoring devices to determine concentrations levels and their
availability at the site
Containment and clean up procedures
ONE SHOULD PLAN OR EMERGENCIES BY FIRST DOING EVERYTHING
REASONABLE TO PREVENT THEM. ONCE YOU HAVE ACCOMPLISHED THIS ,
PREPARE FOR THE EMERGENCIES BY DEVELOPING AN EMERGENCY
ACTION PLAN.
PVP

RESPONSE PROGRAMME ARE DESIGNED TO COMBAT EMERGENCY
WHEN THEY HAVE OCCURRED AND INCLUDE MEASURES SUCH AS

IMPLEMENTATION OF EMERGENCY PLANS.

ACTIVATION OF EMERGENCY OPERATIONS CENTERS

MOBILIZATION OF RESOURCES

ISSUANCE OF WARNINGS & DIRECTIONS

PROVISION OF MEDICAL & SOCIAL SERVICES AND DECLARATION OF
EMERGENCIES.
OBJECTIVES OF EMERGENCY PLANNING
TIME AND AGAIN HISTORY HAS SHOWN THAT A WELL THOUGHT ,
PLANNED AND CO-ORDINATED RESPONSE HELPS IN PREVENTING
PERSONAL INJURY, PROPERTY DAMAGE AND LESSEN THE RESULTING
CONFUSION.
THE MAIN OBJECTIVES OF EMERGENCY PLANNING ARE :
LOCALIZE THE EMERGENCY AND IF POSSIBLE ELIMINATE IT
hs/tread/5101msdstrg prg/05

MINIMIZE
THE
SURROUNDINGS.
EFFECTS
ON
PEOPLE,
PROPERTY
AND
ON SITE PRECAUTIONS ARE DESIGNED TO PREVENT MAJOR INDUSTRIAL
ACCIDENTS FROM OCCURRING OR IF THEY DO OCCUR, TO LIMIT THEIR
EFFECTS.
WHILE PREPARING THE ACTION PLANS
FOR HANDLING THE
EMERGENCIES FOLLOWING STEPS ARE OF GREAT IMPORTANCE FO
MAKING AN EFFECTIVE EMERGENCY PLANNING
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REPORTING OF AN EMERGENCY
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OPERATION & SHUT DOWN OF CRITICAL EQUIPMENT
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EMERGENCY EVACUATION & EXIT ROUTE
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NAMES & REGULAR JOB TITLES OF PERSONS OR DEPARTMENTS
WHO CAN BE CONTACTED FOR FURTHER INFORMATION & HELP

RESCUE & MEDICAL AIDS AND HEAD COUNT FOR EMPLOYEES.
On site emergency plan describes in detail an organizations policy and procedures for
coping with an emergency situation at site.
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appointment of key personnel to implement the emergency plan.
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appoint a person from each work unit to carry out protective actions & other
related emergency procedures.
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establish a central location for coordination of and decision making .
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appoint a single person to validate and co ordinate the dissemination of
emergency information.
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establish adequate communication and warning capabilities.
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establish damage assessment capabilities.
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protect vital records.
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WHILE PREPARING THE ACTION PLANS
FOR HANDLING THE
EMERGENCIES FOLLOWING STEPS ARE OF GREAT IMPORTANCE FO
MAKING AN EFFECTIVE EMERGENCY PLANNING

REPORTING OF AN EMERGENCY

OPERATION & SHUT DOWN OF CRITICAL EQUIPMENT

EMERGENCY EVACUATION & EXIT ROUTE

NAMES & REGULAR JOB TITLES OF PERSONS OR DEPARTMENTS
WHO CAN BE CONTACTED FOR FURTHER INFORMATION & HELP

RESCUE & MEDICAL AIDS AND HEAD COUNT FOR EMPLOYEES.

through identification of hazards.

information on availability of external services such as fire , ambulances , hospital
etc.
We need to collect the information needed to complete the plan through the following
four steps.
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Conducting hazard or risk analysis
Location ; where from hazard is likely to initiate
Quantity : maximum quantity likely to be released during the emergency
Potential : risks.
Likelihood of release of substances and its consequence.
Other hazards to be considered are
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Whether the material is flammable
Whether water can be used or not
Reactivity with other materials, whether forms hazardous substances or release
heat or gas
Likelihood of damage to property
Likelihood of damage to environment
Size of the vulnerable zone in case of release of gas
Number of people likely to be present within the vulnerable area.
Sensitive populations within the vulnerable zone
Essential services facilities within the vulnerable zones
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Types of emergency procedures to be followed.
Resources :
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Employee skills
Equipment
Fire protection system & equipment
Rescue equipment
Alarm system
Public address system
Radio communications
Flash lights
Spare batteries
Medical facilities
Protective gears needed during the emergency. Whether they are available to tat
facilities and to the emergency responders
Sampling and monitoring devices to determine concentrations levels and their
availability at the site
Containment and clean up procedures
type of materials required for the containment , neutralization and clean up are they
available.
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SOMETHING MORE ABOUT THE FIRE

FIRE
IS
A
CHEMICAL
REACTION
BETWEEN
FLAMMABLE/COMBUSTIBLE SUBSTANCE & OXYGE.

MINIMUM OXYGEN REQUIREMENT FOR THE FIRE TO OCCUR IS 16%.

IN PURE ATMOSPHERE OF OXYGEN ( I.E. 100% O2 ) EVEN MATERIAL
BELIVED TO BE NON COMBUSTIBLE WILL ALSO IGNITE RAPIDLY.
THE
THERE ARE FOUR STAGES OF THE FIRE
A.
INCIPIENT STAGE : NO VISIBLE FLAME, NO SMOKE, VERY LITTLE
HEAT,
COMBUSTION BEGIN TO TAKE PLACE
B.
SMOULDERING STAGE : SMOKE BECOME VISIBLE, BUT NO FLAME,
COMBUSTION INCREASES
C.
FLAME STAGE : POINT OF IGNITION OCCURS, FALME BECOME VISIBLE
D.
HEAT STAGE : LARGE AMOUNT OF HEAT, FLAME, SMOKE GASES
PRODUCED.
DURING FIRE FOLLOWING GASES ARE PRODUCED.
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CARBON DIOXIDE
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CARBON MONOXIDE
PHOSGENE
HYDROGEN CYNIDE
AMMONIA
HYDROGEN SULFIED
PERSONS TRAPPED IN THE FIRE ARE MOSTLY DIE DUE TO
SUFFOCATION OR INHALATION OF THESE GASES RATHER THAN BURN
INJURY.
FUNDAMENTAL OF FIRE PREVENTION, PROTECTION & FIGHTING
PREVENT THE OUTBREAK OF FIRE
PROVIDE FOR EARLY DETECTION OF THE FIRE
PREVENT THE SPREAD OF IRE
PROVIDE FOR EXTINGUISHEMENT OF FIRE
PROVIDE FOR IMMEDIATE EVACUATION OF THE PERSONNEL.
( SAFETY DEPARTMENT )
INTRODIUCTION;
BREAK DOWN IS DUE TO IMPROPER MAINTENANCE IN A PLANT & ANY
ERROR OR NEGLIGENCE IN ATTENDING THIS BREAKDOWN CAN LEAD
WOULD BE DISASTROUS FOR BOTH THE PLANT AND SURROUNDING.
TRACK RECORD ALWAYS SAY THAT THE MAINTENANCE IS ALWAYS
TAKEN IN A VERY LIGHTLY AND MANY ACCIDENTS ARE HAVE BEEN DUE
TO THIS.
ANY BREAKDOWN IN PLANT CALLS FOR RECTIFICATION. MOST
CHEMICALS 7 RELATED OPERATIONS ARE HAZARDOUS IN NATURE AND
ANY BREAKDOWN IN THE SYSTEM INCREASES THE CHANCES OF HAZARD
OCCURRENCE. AND A MAINTENANCE OPERATION WHICH IS NOT
PROPERLY ORGANIZED AND UP TO THE MARK ADDS TO THE HAZARD.
Accidents at piper alpha, Flixborough and at the Mendsun are the few example of the
such types of accidents.
The main causes of the disaster are
1. Improper maintenance facilities.
2. Improper design
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3. No up to maintenance procedure
4. ( ambiguity in the terms of maintenance operation ns and sharing of the
responsibilities. 0
5. Hazards associated within the existing facility
6. Negligence during the maintenance operation
7. Untrained professional
In India there had been 87 major accidents due to the above reason
Hazards associated with a maintenance :
Case studies
Isolation : Any equipment or unit on which work is to be done must be isolated
from the other unit containing hazardous materials it is a major sources of accidents.
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Failure to isolate : -- pump repair
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Inadequate isolation :--- on line reactor – grinding leak of vapour from
explosion
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Early removal of isolation : ethylene compressor - leakage & explosion.
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Isolation not removed. : Storage tank under maintenance .
Component identification :
Many accidents have occurred because of opening of the wrong equipment or the
wrong equipment itself.
Experience shows that the identifying the equipment by describing it or indicating its
location or showing it to the workers is not enough as by the time maintenance team
gets ready , they may forget and open up some other equipment.
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Line to be opened marked with chalk and opened the line having also chalk
mark
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Row of seven pump marked haphazardy and asked to open 7th nos. of pump.
Trapped material
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Naphtha tank to be repaired not properly cleaned.
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Acid tank to be repaired & work started after 4o day forming of the hydrogen.
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Trapped pressure.
In spite of proper isolation there may be chances of trapped pressure inside the
equipment.
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Raghuvir sing.
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Slide
Delayed maintenance
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Acid tank repaired after forty day
Reactor checked in the morning and work started in second shift of other day
flammable vapoure goes inside the tank.
Wrong way of maintenance
There are some maintenance activities which needs extra care however this as a
common maintenance practice personal neglect the these sensitivities and adopt easy
way procedure.
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Breaking of eight inch pipe of hot solvent all bolts were opened one by one &
when last bolt opened the trapped material under high pressure came out.
Tank repair or demolition
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A tank contain flammable material no proper cleaning men went inside stated
welding and completely burned inside.
Hot working : The tank was cleaned, purged, washed, and fire permit was issued
after gas test, on starting welding tank wall got fire from inside. – thin wall of
hydrocarbon it should be tested.
CONTROL OF MAINTENACE HAZARDS.
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PREPERATION FOR MAINTENANCE.
BEFORE STARTING THE ACTUAL MAINTENANACE OPERATION A SERIES
OF ACTIVITES HAVE TO BE COMPLETED.A LARGE NUMEBERS OF
ACCIDENT HAVE BEEN OCURRED DURING THE THIS STAGE OF
MAINTENANCE.
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Prpoer identifiacrtion – Plant often seem a confusing maze of vessel & pipework.
Permenant identification for equipment
Identification of tag where much breaking of pipe & joints occurs.
De pressurizations
Cooling
Isolation
Four types of isolation
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a closed & locked valve or valve
a double bock and bleed valve system
a slip plate
physical disconnection.
In case of pressurized hydrocarbon physical disconnection is better.
Emptying of container
Once the plant has been isolated then the next step is to remove the content of the
vessel.
Liquid – easily pump able
Gas – vapour - different method gas freeing which may be used to replace them with
air.
Removal of material by 
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Forced ventilation
Flushing with water & forced ventilation
Purging
Steaming.
In case of steaming ( for cleaning ) gas freeing occurs at the same time.
Solid material are flammable, toxic, Pyrophoric, inflammable dust may give rise to
dust explosion. ( e. g. Sulfur storage. )
CLEANING
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Before the equipment is opened up for repaired it must be free from all hazardous
materials. The method of removal of hazardous material depend upon its nature &
degree of hazards.
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Water washing water & air used for cleaning oil - accidents
Chemical cleaning
Steaming – no excessive pressure- proper drain up condensate ( S. P two bar
for thirty minutes )cleaning
progress can be monitored buy oil contents in moisture
 Water jetting – H.P water jetting can cut most metal,
polymer
 Shot blasting – used for cleaning the surface of particularly for painting.
 Manual cleaning – residues which are difficult to remove by above –
laborious, full precaution requires.
TESTING
Checking of flammable vapours Inflammable residues remained in the tank evaporates
 Solid residues, evaporated when they get heat from welding
 Due to isolation which are not leak tight.
 Chemical reactions ( water + steel = h2)
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