Emergency Preparedness Plan


An emergency is a situation, which may lead to or cause large-scale damage or destruction to life or property or environment within or outside the factory. Sometimes the Emergency results into uncontrollable situations and leads towards disaster. Such an unexpected severe situation may be too great for the normal workforce in the area within the plant. In any industry, an emergency can arise at any moment and this depends on the type of

  • Structure
  • Raw Materials
  • Machines / Plant
  • Nearby Industries etc.


The emergency has been identified and can be specified in one or more of the followings with source and effect:

Sr. No. Emergency Source Effect
1 Fire / Explosion Electrical Panels, Flammable oil storage tanks, Compressors, coolants,  paints, etc. Small fires, complete equipment loss, complete Area burn out.
Air pollution
Soil pollution.
Dangers to Human beings
2 Spillage of flammable / Hazardous Oils & coolants etc  Hydraulic oil, Furnace Oil, Coolant etc. Fire
Soil pollution.
Injury by slippage
3 Electric Shock Electrical panels, Power Distribution Board, DG Set, Overhead Crane, Voltage stabilizer, Electric Transformer & Machine Operated by electricity, etc. Burns, suffocation, Death. Toxic chemical ingestion into the bloodstream
4 Accidents – Factory (Major) Fall from height & Falling of Heavy Materials, Dies, Bins or other Heavy objects. Fracture
5 Accidents-Transport Accident due to the transportation of man & material Death or Injury to Body
6 Personal confinement Toilets, offices, Basement Suffocation
7 Natural calamities such as storm,  earthquakes, etc. Nature Structural collapse, Death
8 Structure collapse Office building, & Any Wall or a part Of Factory building. Serious injury, Major Fracture, Death
9 Riots, Arson, Sabotation Anti-Social elements. Serious injury, major Fracture, Death.
10 LPG leakage Fire Hazard Serious injury, Death
11 TANK DYKE Fire Fire Hazard Serious injury, Death
12 Electric fire Fire Hazard Serious injury, Death
13 Office fire Fire Hazard Serious injury, Death
14 Person on flames Fire Hazard Serious injury, Death
15 Food/Water Poisoning Health Hazard Poisoning, Death
16 Bomb hoax Bomb Threat Explosion, Death, fear
17 Burn-Minor Health Hazard Burn injury
18 Electric shock casualties Health Hazard Injury, Death
19 Non Functioning of STP and ETP Spillage of untreated water on the ground Land Contamination


The objective of the major emergency procedure should be to make maximum use of the combined resources of the works and the outside services to

  • Effect the rescue and treatment of casualties;
  • Safeguard other people;
  • Minimize damage to property and the environment;
  • Initially, contain and ultimately bring the incident under control;
  • Identify any deed and provide for the needs of relatives;
  • Provide authoritative information to news media;
  • Secure the safe rehabilitation of affected areas;
  • Preserve relevant records of equipment by the subsequent inquiry into the cause and circumstances of emergency;

4.0  EMERGENCY MANAGEMENT & KEY PERSONS                                        

During the emergency situation, it is generally seen that chaos and confusion rules leading to more damage. In Emergency Management, just like in normal operations where there are managers, engineers, supervisors, operators, etc., who are assigned specific tasks to run the business, similarly during an emergency also there are persons with specific duties. These persons are known as ‘Key Personnel’.

Following are the persons who are responsible to face the emergencies.


If required external help in case of an Emergency will be sought from appropriate sources. The required assistance from the probable sources has already been informed and consent obtained for the same.


5.1 Name & Address of the persons furnishing the information:



5.2 Any Individuals  

When an emergency occurs, the person who observes it must evaluate the gravity of the emergency and he should alert all the factory personnel by activating the Emergency Siren.  The emergency siren is activated just by pressing the Emergency Siren push button located at the main gate & other different locations. Then he immediately reports to the Emergency Control Centre (Main Security gate) and informs about the Emergency location.

5.3 Site Controller:

The Site Controller will assume overall responsibility for the factory/storage site and its personnel. His duties are to:

i) Assess the magnitude of the situation and decide if staff needs to be evacuated from their assembly points to identified safer areas

ii) Exercise direct operational control over areas other than those affected.

iii) Undertake a continuous review of possible developments and areas in consultation with key personnel as to whether shutting down of the plant or any section of the plant and evacuation of personnel are required.

iv) Liaise with senior officials of Police, Fire Brigade, Medical, and Factories Inspectorate and provide advice on possible effects on areas outside the factory premises.

v) Look after rehabilitation of affected persons on discontinuation of emergency.

vi) Issue authorized statements to news media and ensures that evidence is preserved for inquiries to be conducted by the statutory authorities.

5.4 Incident Controller:

The Head of the unit will act as an incident controller for that unit. Immediately on knowing about an emergency, he will rush to the incident site and take overall charge and report to the Site Controller. On arrival, he will assess the extent of emergency exists and inform the Communication Officer accordingly. His duties will be to:

i) Direct all operations to stop within the affected area taking into consideration priorities for the safety of personnel, minimize damage to the plant, property and environment and minimize loss of materials

ii) Provide advice and information to the Fire/Security Officers and local fire service;

iii) Ensure that non-essential workers/staff of the areas affected are evacuated to the appropriate assembly point and the areas are searched for causalities

iv) Set up communication points and establish contact with the Emergency Control Centre in the event of failure of electric supply and internal telephones

v) Report on all significant developments to the communication officer and

vi) Have regard to the need to preserve the evidence so as to facilitate an enquiry into the cause and circumstances which caused or escalated the emergency.

5.5 Communication Officer:

He will also work as Liaison Officer and will be stationed at the main entrance (Gate House) during the emergency. He will handle police, Press and other enquiries, receive reports from roll-call leaders from assembly points and pass on the absentee information to the Incident Controller. He shall maintain regular communication with the Incident Controller. He will:

  1. Ensure that casualties receive adequate attention/ to arrange additional help if required and inform relatives;
  2. Control traffic movements into the factory and ensure that alternative transport is available when the need arises; and
  3. When an emergency is prolonged, arrange for the relief of personnel and organize refreshments/food.
  4. Advise the Site controller of the situation, recommending evacuation of staff from assembly points if necessary.
  5. Maintain proper agreed inventory in the control room.
  6. Maintain a log of the incident on tape
  7. In case of a prolonged emergency involving risk to outside areas by wind-blown materials, he shall contact the local meteorological office to receive early notification of changes in weather conditions.

5.6 Security Officer-

Security Officer will be responsible for fire fighting. On hearing the fire alarm, he shall reach the fire station immediately and advise fire and security staff in the factory of the incident zone. He will convey the message to the communication officer, Incident Controller and Site Controller about the incident zone. He will direct emergency services. He shall

1) Announce over the PAS in which zone the incident has occurred and on the advice of the Shift Executive In-charge inform the staff to evacuate the assembly service.

2) Inform the Shift Executive In-charge

3) Call Incident Controller, Engineering/ Production Manager, Personnel and Administrative Manager, Departmental Head in whose plant the incident occurred.

4) Security Supervisor for each unit will act as the Security officer for that unit.

5.7 Receptionist:

On hearing the emergency alarm, the receptionist shall immediately contact Site Controller and on his advice will call the local Fire-brigade and or Police station and safety committee members. In case the PAS and telephone system becomes inoperative, she shall inform the communication officer through the messenger. In case the fire is detected and the alarm is not in operation, she shall receive information about the location from the person who detected the fire and immediately consults the Incident Controller. On his advice, she shall contact the Security Guard and advised him to make an announcement on PAS about the incident and the location of the incident and to evacuate to their assembly point. She will continue to operate the switchboard advising the callers and pass all calls connected with the incident to the Communication Officer.

5,8 Departmental Heads:

The HODs will report to the Incident Controller and provide assistance as required. They will decide the staff they require at the incident site.

5.9 Maintenance In-Charge and Electricians: 

They will report the scene of the incident and close down the services as directed by the Incident Controller

  5.10 Shift Executive In-charge:

As soon as he becomes aware of the emergency and its location, he will proceed to the scene. He shall assess the scale of the incident and direct operations within the affected areas with the following priorities:

  1. Secure the safety of persons, which may require evacuation to the assembly points in the event of an escape of materials if the wind is from an adverse direction.
  2. Minimize damage to plant, property and the environment.
  3. Prevent spreading and damage to outside the premises.
  4. Minimize loss of materials;
  5. Have regard to the need for preserving evidence that may facilitate subsequent enquiry.
  6. Inform shift engineer-in-charge as to what services are needed or not needed.
  7. Hand over the charge of the operation to the Incident Controller when he arrives at the site.
  8. Advice the Security Officer at Gate whether to make an announcement on PAS or not to call the Senior Staff to the factory, if necessary.

5.11 First-Aid Teams:

The Personnel Manager shall keep the roll call lists for the fire and First Aid team on duty. The First Aid team is appointed by each Departmental Head for his shift team. Roll call leaders shall check their roles as a member of the services and report for emergency duty. Name of unaccounted persons or absentees will be informed to the Security Officer. Members of First Aid teams will report to the shift Executive In-Charge or Incident Controller on hearing the alarm and follow his directions.

3.12 Factory Fire Fighting Personnel:

The duty of the Fire Fighting personnel under the command of the Security Officer shall be responsible for fire fighting and rescue. On hearing the alarm they shall proceed to the place of the incident if know, or otherwise, they shall report to the Security Gate. The men at security Gate shall find the location of the emergency, the equipment and proceed to the site or occurrence. At the site, the team will respond to the directions given by the Incident Controller


6.0  Roles  & Responsibilities for Safety Teams:                                                                         

After confirmation of the emergency location from the Emergency Control Centre, concerned teams will start functioning. The team leaders will coordinate and communicate with the management. The team member fights the emergency under instructions of the leader. The team will ensure that:

  • The emergency does not spread.
  • The head count is taken in consultation with Liaison Manager and if necessary search operation for missing person/s. is undertaken.
  • Every member of the team uses the required Personal Protective Equipment while the operation is going on.
  • First aid is arranged.
  • Additional fire fighting equipment for the fire fighting team is arranged.
  • The smooth rescue operation is facilitated.
  • The emergency will be informed to fire brigade, neighbouring industries.
  • Medicines are provided.
  • Send injured to the hospital if necessary.
  • Records of first aid and hospitalization are maintained.
  • The help of other people is taken to control the emergency.
  • Remaining part of the plant is safe.
  • The area is cordoned off.
  • Necessary tools, equipment to handle any repair work are mobilized.
  • The main power supply line is cut – off if necessary.
  • Maintenance and repair are undertaken.
  • Conduct safety committee meetings every 3 months or in case of an emergency.

Team members of the safety committee:


7.0 EMERGENCY CONTROL CENTRE                                         

For the purpose of handling the emergency, Emergency Control Centre is very much essential. In the factory, Security Office at the Main Entrance is declared as Emergency Control Centre. All activities pertaining to the emergency will be carried out from this centre. The emergency Control Centre will be equipped with

  • Plant Layout indicating storages of hazardous material and fire fighting equipment and first aid box locations.
  • Material Safety Data Sheet of all chemicals handled in the premises.
  • List of all employees with addresses, tel. No., contact person and if possible blood group.
  • List of important telephone numbers such as police, fire brigade, hospitals, Directorate of Industrial Safety and Health, Pollution Control Board, etc.
  • A separate list of team members with their addresses and telephone numbers.
  • The facility of Direct Telephone Line.
  • Equipment such as Torch, Rope, and necessary Personal Protective Equipment, whistle, etc.
  • Note pads and pen/pencils to record the messages and record of activities pertaining to emergency
  • First aid box with proper medicines.


Assembly point is displayed in front of the main gate and known to everyone which is ensured at the time of safety audit. The area of assembly point has been set at farther from the location of likely hazardous events, where employees, contractors and visitors must assemble in case of emergency. Up- to date list pre-designated employees must be available with the Site in charge at the assembly point in case of assembly of the employees.  The site in charge shall then do the roll call of the people present so that their presence can be marked.


The factory Main “Emergency Siren” is located at the main gate. This will be used for raising the alarm and also for “All Clear” signals in case of emergency.


In case of Fire / Explosion / natural calamity etc. any person noticing it must evaluate the severity of the emergency and he should alert all the factory personnel by activating the Emergency Siren.  The emergency siren is activated just by pressing the Emergency Siren push button located at the main gate. Then he immediately reports to the Emergency Control Centre and informs about the Emergency location. As soon as the alarm is heard, the safety team members will contact the Security office at the Main Entrance and the safety team will rush to the Emergency location. The safety Team & other team members will assemble at the assembly point.

11.0 Communication System:

Alarms should be followed by an announcement over the Public Address System or verbally by shouting. In case of failure of alarm system communication should be by the security guard who will make an announcement through the Public Address system. Mobile Phones, landlines etc could be used as a mode of communication for an emergency. If everything fails a messenger could be used for sending the information.

12.0 Action Plan For Various Emergencies.



Emergency Actions to mitigate the emergency
1 Fire / Explosion Raising emergency alarm
Shut down machines and Main power supply
Evacuation, Assembly at Assembly Point.
Fire fighting
Rescue Operation
First aid or Hospitalization
Final Declaration of  “All Clear” Situation
2 Major Spillage of flammable/ hazardous oils


Raising emergency alarm
Switch Off Power Supply of the equipment
Evacuation, Assembly at Assembly Point.
Isolate & Barricade the area of spill
Control the spillage to avoid the spread
Stop all the work of welding, electrical etc
Fire fighting
Final Declaration of  “All Clear” Situation
3 Electric Shock Switch Off Power Supply of the equipment
Rescue the person.
Call the ambulance, provide first aid
4 Accidents – Factory (Major) Contact company doctor/hospital
Rescue Operation
5 Accidents-Transport Contact Ambulance/ Hospital, provide first aid

Inform HR Dept

Inform Police

6 Personal confinement Call fire brigade
Raising emergency alarm
7 Natural calamities

Such as storm,

earthquakes, etc.

Evacuation, Assembly at Assembly Point.
Raising emergency alarm
Isolate & Barricade if necessary
Fire fighting
Rescue Operation
Evacuation, Assembly at Assembly Point.
Final Declaration of  “All Clear” Situation
8 Structure collapse


Raising emergency alarm
Evacuation, Assembly at Assembly Point.
Isolate & Barricade if necessary,
Rescue Operation,
Final Declaration of  “All Clear” Situation
9.a Riots, Arson, Sabotaging (Inside the premises of the organization) Inform HR Head, Plant Head, MD, Security, Immediately.

Inform the Police immediately.

The Security shall isolate the area of Rioting with its total force.

All work should stop immediately. The employees from the rest of the premises shall be evacuated immediately.

The ambulance should be kept in Stand by to meet any eventually.

Inform Hospital immediately to prepare for any emergencies.

As soon as the police arrive the area of rioting should be handed over to police.


9.b Riots, Arson, Sabotaging(Outside the premise) Inform HR Head, Plant Head, MD, Security, Immediately.

Inform the Police immediately.

The ambulance should be kept in Stand by to meet any eventually.

Inform Hospital immediately to prepare for any emergencies.

The gates should be closed and no person and vehicle should be allowed to leave the company premises.

Security should man the gates with full force and should prevent the entry of any unauthorized person inside the company premises.

In the case of more than 8 hours of riot situation, the Admin should ensure adequate food and water is available for the employees.

Once all clear signal is received from the police, the normal operation shall resume in the organization


  1. LPG leakage

(Common for Both with fire as well as without fire)

1.      Take immediate steps to stop LPG leakage

2.      Stop all operations

3.      All out effort should be made to contain the spread of leakage/fire

4.      Saving the human shall get priority in comparison to stock/assets.

5.      Plant personnel without specific duties should assemble at the nominated place

6.      All vehicles except those required for emergency use should be moved away from the operating area, in an orderly manner at pressure –nominated route

7.      Depending upon the severity, electrical system except for control supplies, utilities, lighting and fire fighting system, should be isolated

8.      If the feed to the fire cannot be cut off, the fire must be controlled and not extinguished.

9.      Start water at areas involved in or exposed to fire risks.

10.  In case of leakage of LPG without fire and inability to stop the flow, take all precautions to avoid the source of ignition.

11.  Block all roads in the adjacent area and render internal/external support for the purpose if warranted.

b. LPG leakage without fire. 1.      Follow the general instructions given above if escaping LPG is not on fire, close any valve which will stop the flow.

2. In some cases like leakage from the cylinder without a fire, it may be desirable to move the cylinder to some remote area such as a block of the isolated roadway or open field where it can be allowed to leak safely without a source of ignition nearby. However, if this is to be done, the vessel must be moved in an upright position. Never drag the vessel in a manner which might damage the valve or pipeline. Any attempt to turn a cylinder back upright to move it to some remote location should be done carefully to avoid damage to valve and pipelines.

c. LPG leakage with fire 1. Take basic action as detailed in as above

2. Extinguish fires – A small fire at the point of leakage should be extinguished by enveloping with a water spray or a suitable smothering agent such as carbon dioxide or a dry chemical powder. However, it is against, stressed that LPG fire should not except in special circumstances explained earlier, be extinguished until the escape of product has been stopped.

3. Fire Fighting Procedure: Fire fighting procedures would be vary depending upon various factors such as nature, sources sizes, location, etc. of fire. Basic fire fighting techniques have been explained earlier section. However, for the purpose of guidelines, fire fighting techniques for a few common are as follows:

4.Fire on the cylinder: If a cylinder is exposed to radiant heat from external fire, it should be kept cool by water sprays to prevent excessive pressure rise in the vessel. Water must be applied without delay in the heat affected area. Cooling the cylinder with the water reduces the heat input to the vessel and thereby reduces the pressure, thus reducing the rate of discharge.

5.Fire on vapour escaping from the pipeline /fittings (Flame not playing on the vessel)

6. Try to shut off the LPG supply by closing the valve.

7. Try to extinguish the fire. If not possible.

8. Allow the fire to continue till exhaustion

9. Spray vessel with water to cool it if the vessel is being heated by radiation from the flame or if the flame is endangering other plant equipment. Cool adjacent cylinder and structures.


Tank Dyke Fire

1. In case a fire occurs in the dyke area due to flange leak in the manifold area, the fire is to be extinguished with the help of foam.

2. Use of DCP if the fire is small, otherwise use water spray or foam.

3. Cooling of lines /flanges is to continue until the incident/site controller gives the instructions to stop.

4.If tank collapses and the product is spread in the dyke area with fire.

5. Withdraw manpower in and around the tank dyke area.

6. Use foam monitors of vehicles to spray and spread foam in the affected dyke area

If tank dyke area is on fire and full product is in the dyke then water to be used judiciously otherwise flooding of dyke area may cause the overflow of oil from the dyke area to open drains.

12 Electrical Fire 1.Disconnection of the electric supply of the affected area.

2.Attempt to extinguish the fire with the help of DCP/CO2 fire extinguishers

3. If the fire still persists, ensure complete isolation of electric supply of that area and use of water.

13 Office fire 1.Disconnection the electric supply of the affected area.

2.Attempt to extinguish the fire with the help of DCP/CO2 fire extinguishers

3. Save all records from the fire.

14 Person on Flames 1. Bring the water gel blanket

2. Open the bag inside the container to remove the blanket. If the bag is already open such blanket should not be used for burn victims

3. The blanket can be held as a screen between the victim and the fire

4. If possible lay down the victim and wrap the blanket around the victim. Leave the victim wrapped in a blanket and seek medical help

15 Food/Water Poisoning 1. Persons observing the symptom should inform the location in charge of assessing the situation

2. The shift in charge should call the doctor and ambulances and also alert all hospitals to meet any exigencies

3. To render first aid and induce vomiting to the affected persons

4. The ambulances and vehicles available should be mobilized to be in readiness to transport a large number of people if required

Assistant Manager-SHE to report to the location in charge of required sanitation and medical assistance.

16 Bomb Hoax 1. Person noticing on an object like a bomb, should bring it to the notice of the nearest available officer.

2. The officer should carefully observe the same from a distance and raise the alarm

3. The area should cordon off.

4. Police control and fire control to be informed for their arrival and inspection of the area.

After the bomb is diffused, all clear siren should be sounded by the watchmen.

17 Burn –Minor 1. Pour cool water on the burn area till the burning sensation is reduced.

2. Cover it lightly with a clean cotton cloth.

3. Do not apply butter, oil, ointments or any home remedies

4. Get Medical help

18 For Electric shock casualties 1. Electric shock results in irreversible damage to brain cells followed by deterioration of the other organs

2. Rescue and first aid

3. Do first thing first, quickly and without fuss or panic. Switch off the supply if this can be done at once. If not possible, use a dry stick, dry cloth or other non-conductors to separate the victim of electrical contact. The rescuer must avoid receiving shock himself be wearing gloves or using a jacket to pull the victim.

19 Non Functioning of STP and ETP In case STP or ETP is not working properly, the abnormality of so should be informed to the maintenance department.

In case the maintenance department closes the ETP or STP plant, the untreated water should be stored in Sock pit in case of STP and Septic tank in case of ETP.  After the STP and ETP start functioning normally the water from the sock pit and septic tank should be treated before discharge.


12.1 All Company Employees


  •  Do not panic & cause a stampede.
  • Do not run and prevent others from doing so.
  • Do not go anywhere else.
  • Do not wait to collect personal belongings.


  •  Stop work on getting information or hearing the alarm.
  • Switch off the machines and the main power supply.
  • Gather at the assembly point.
  • Contact Management
  • Take visitors to a safer place.


After hearing the alarm they will follow the following steps:

  1. Give attention to all instructions.
  2. Stop work. Do not panic.
  3. Do not wait for personal belongings.
  4. Assemble at the assembly point.
  5. Do not go to the emergency site.
  6. Do not spread rumours.
  7. Do not engage in communication systems.


The employees will be informed about ‘On–Site Emergency Plan’ in details, with the help of training programmes. For the success of this plan not only training will be organized but mock drills also will be organized minimum once a Year. Mock drills will help to understand the role to be played by everyone during the emergency. The Core members of the Disaster / Emergency control will be given the refresher training at the interval of every One Year.


The success of the “On-site emergency plan” is very much dependent on planned and unplanned mock drills. Mock drills help employees to be familiar with their roles and ensure accuracy of the onsite Emergency Plan. Following is the procedure for conducting a Mock drill.

  • Inform all the employees about mock drill procedures.
  • Fix the date and time for mock drill.
  • The mock drill will be monitored by the observer/s not involved in the exercise.
  • The emergency alarm will be raised.
  • After hearing the alarm, the Emergency Procedure will be followed. All clear signals will be given after the emergency is over.
  • Observer/s will note down the activities with respect to the time.
  • Lacunae observed in the system will be studied carefully.
  • Records of drills will be maintained.

After each drill, the plan will be thoroughly reviewed to take into account of the omissions or shortcomings for improvement.

15.0 Details of liaison arrangement between the Organization:

All the organization involved in assisting during the emergency were contacted and apprised of the details of the plant, like process; hazardous material handled; likely emergency incidents; steps taken to avoid/reduce risk mitigation methods, resource availability etc. The details are as follows:

 15.1 POLICE

Sr.No Name of Police Station Tel.No


SR. no Fire Station Tel no


Sr.No Name of Hospital Tel No


As and when required, this ‘On – Site Emergency Plan’ will be updated and informed to all. If necessary, after each drill the plan will be thoroughly reviewed to take account of shortcomings.


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