It was a record year of all sorts - Many old records archived

1
(ISO 90012008, ISO 140012004 BS OHSAS
180012007 CERTIFIED PLANT)
E R D M P WADILUBE INST.
2
(ISO 90012008, ISO 140012004 BS OHSAS
180012007 CERTIFIED PLANT)
By Mr. H. C. Murmu
Dated 28.09.2012
3
(ISO 90012008, ISO 140012004 BS OHSAS
180012007 CERTIFIED PLANT)

• Plant Commissioned in 1956 at Wadibunder, Malet
  Road,
• Mumbai 400 009.
• It is situated between Muzawar Pakhadi Road
  P. D Mello Road,
• Yellow Gate of Princesses Dock (MbPT) at
  South Side
• Total Area of the Installation is 57766 Sq.
  Mtr.
• Plant produces 200 various grades of Lubricant
  Oils.
• Total capacity of the Plant is 110 TMT.
• Total Manpower 204 Workmen 29 Management
  Staff.

4
(ISO 90012008, ISO 140012004 BS OHSAS
180012007 CERTIFIED PLANT)
5
(ISO 90012008, ISO 140012004 BS OHSAS
180012007 CERTIFIED PLANT)

• Receipt Storing of Base Oil, Additives,
  Packaging Materials
• Manufacturing of MAK Lubricants
• Filling of MAK Lubricants in various packs
• Storing Dispatch of finished products

6
(ISO 90012008, ISO 140012004 BS OHSAS
180012007 CERTIFIED PLANT)

• Base Oil Storage Tanks (25 nos.), Additive
  Storage Tanks (7 nos.),
• Blending Tanks (33 nos.)
• Tank Lorry Filling Gantry (2 nos.), Truck
  Loading Platform (1 no.)
• High Speed Filling Machines (OCME 2 nos.
  Orbit 1 no.)
• Mather Platt Filling Machines (2 nos.)
• Barrel Filling Machines ( 9 nos.)
• 20 Ltr. Filling Machines (4 nos.)
• 50 Ltr. Filling Machine ( 1 no.)
• Transformer Oil Manufacturing Unit (1 no.)
• Filling Shed Warehouse

7
(ISO 90012008, ISO 140012004 BS OHSAS
180012007 CERTIFIED PLANT)

• Boilers (2 nos.) - 6 Ton / Hour Capacity
• Compressors (6 nos.) - 600 CFM, 325 CFM,
  300 CFM
• Fork Lift Trucks (16 nos.) - 2 Ton Capacity
• LP Steam Heating Line
• Raw Water, Soft Water, DM Water,
• Cooling Water Drinking Water
• Fire Water System
• D G Set

8
(ISO 90012008, ISO 140012004 BS OHSAS
180012007 CERTIFIED PLANT)
An Emergency is a situation which may lead to or
cause large scale damage or destruction of life,
property or environment within or out side the
Factory. Such an unexpected situation may be
too difficult to handle for the normal work-force
within the plant.
The emergency specified in the OEP refers to
occurrence of one or more of the following events
-
MAN MADE NATURALS
Fire/Explosion. Natural calamities like storm, flood, earth quake, tsunami etc.,
Major accident such as structural or building collapse, overturning of road tanker containing flammable substances. Natural calamities like storm, flood, earth quake, tsunami etc.,
Sabotage act of terrorism, civil commotion, air raid etc. Natural calamities like storm, flood, earth quake, tsunami etc.,
9
(ISO 90012008, ISO 140012004 BS OHSAS
180012007 CERTIFIED PLANT)
Based on the inspection of the operations carried
out in the factory, the following Hazardous Areas
have been identified
HAZARD AREA PROBABLE CAUSE OF ACCIDENT
Explosion L.P.G. Cylinder in management tea room / canteen (outside the manufacturing area) External fire causing pressure built up in the cylinder
Explosion Boiler House Malfunctioning of the safety valve
Fire L.P.G. Cylinder in management tea room / canteen (outside the manufacturing area) Flammable Vapour / air mixture and source of ignition
Fire Tank Farm / Tanker Unloading Gantry Leakage of Flammable Petroleum Product (HSD) from valves / pipelines, some source of ignition such as electric spark
Fire Additive Storage Area Leakage of Flammable additives, from drums / toto bins and some source of ignition such as electric spark
Fire Empty Cartoon Store Source of ignition such as electric spark
Fire Scrap Yard Source of ignition such as electric spark
10
(ISO 90012008, ISO 140012004 BS OHSAS
180012007 CERTIFIED PLANT)
In the present plan no calculations have been
made to ascertain the extent of damage that may
be caused due to various scenarios envisaged in
Chapter No. 3.   From the tank farms existing in
the installation, it is seen that the main fire
hazard posed is due to storage of High Speed
Diesel Oil in three above ground storage tanks,
each with a capacity of 150 kl.
11
(ISO 90012008, ISO 140012004 BS OHSAS
180012007 CERTIFIED PLANT)

• Following are the objectives of this Onsite
  Emergency Plan.
• To control the emergency, localize it and
  if possible to
• eliminate it.
• To avoid confusion, panic and to handle the
  emergency with
• clear-cut actions.
• To minimize loss of life and property to the
  plant as well as
• to the neighborhood.
• d) To make head count and carry out rescue
  operations.
• e) To treat the injured persons.
• f) To preserve records and to take steps to
  prevent recurrence.
• g) To restore normalcy.

12
(ISO 90012008, ISO 140012004 BS OHSAS
180012007 CERTIFIED PLANT)

• For the purpose of handling emergency, an
  Emergency Control Centres has been identified and
  shown in the Site Plan given at Annexure 1.
  (Cabin of the Installation Manager). All
  communications will originate at this Emergency
  Control Centre, which will have the following-
• A copy of ON-SITE EMERGENCY PLAN.
• Organogram Chart showing the responsibilities
  of different personnel (Refer Annexure 2)
• Local Plan (Refer Annexure 3)
• d) List of Important Telephone Nos. such as
  Police, Fire Brigade, Hospitals and other
  outside
• Emergency Services etc. (Refer Annexure 4)
• e) Details of Fire Fighting Equipments. (Refer
  Annexure 5 6).

13
(ISO 90012008, ISO 140012004 BS OHSAS
180012007 CERTIFIED PLANT)
PROCEDURE FOR MOCK DRILLS   a) Inform all the
employees about MOCK DRILLS and the signal to be
given. Fix the date and LOCATION OF THE EMERGENCY
for MOCK-DRILLS. MOCK DRILLS will be monitored
by observers (who will be one of the Senior
Officers) not involved in the exercise. b) Raise
the Siren for Emergency. After hearing the siren
LIAISON OFFICER, CO-RDINATOR, should move to
the EMERGENCY SITE. SITE CONTROLER should alert
FIRE/SECURITY TEAM ask them to run towards the
emergency location along with appropriate fire
fighting equipment. The fire attendants will run
to carry out their duties. c) He should depute
persons for calling the fire Brigade. d) RESCUE /
EVACUATION TEAM should work in co-ordination with
FIRE / ENGINEERING TEAM. i) CHIEF CONTROLLER
should communicate with the public Address system
about MOCK DRILLS. This is to check the working
of PA system. j) All clear signal should be
raised after half an hour.  
14
(ISO 90012008, ISO 140012004 BS OHSAS
180012007 CERTIFIED PLANT)

• Chief Controller (Plant Manager)
• On getting information about emergency, he
  proceed to the Emergency Site and takes over all
  charges of all activities for dealing with
  emergency.
• He remains in the Emergency site till the
  Emergency is called off so that all on crew are
  aware of the location of his availability.
• He communicates and co-ordinates amongst various
  team leaders.
• He is the final authority on all matters related
  with Management of emergency such as fire
  fighting emergency control, rescue operation,
  calling outside agencies for assistance, welfare
  evacuation, transportation, rehabilitation,
  Liaoning, Public relations etc.
• Chief Co-ordinator (Manager Ops.)
• On getting information he goes to the Control
  Room and takes all the information.
• Co-ordinates the activities of all the teams.
• Takes responsibilities of Law and Order and keeps
  liaisons with Police and Fire brigade.
• Site Controller (Engineering Maint. Incharge)
• On getting information rushes to the site. He
  takes the following actions if emergency is not
  controlled.
• Reports to chief Controller and Chief
  Co-ordinator.
• Regulates entry and exit of personal required for
  controlling Fire / Emergency
• Directs fire fighting team.
• Arrange PPEs if required.
• Reports to Chief Controller

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(ISO 90012008, ISO 140012004 BS OHSAS
180012007 CERTIFIED PLANT)

• Liason Officer (Dy. Manager Admin.)
• Maintain Liaison with Press / Government
  agencies, Neighborhood regarding the emergency
  and instruction from Chief Controller.
• Disclose all the necessary information in the
  Plant so as to avoid rumors and confusion

• Evacuation Team Leader (QA-Lab. Manager)
• He is responsible for providing transport
  facilities for removal of casualty to Medical
  Center / Hospital.
• Arrange for evacuation of Employees, Contractors,
  Workers, Visitors, Vehicles.
• Team of four persons will be dedicated for safe
  evacuation of physically disable employees.

• Fire Security Team
• This team will take care of fire fighting
  operations under the supervision of Site
  Controller.He is responsible for providing
  transport facilities for removal of casualty to
  Medical Center / Hospital.
• Arrange for evacuation of Employees, Contractors,
  Workers, Visitors, Vehicles.
• Team of four persons will be dedicated for safe
  evacuation of physically disable employees.

16
(ISO 90012008, ISO 140012004 BS OHSAS
180012007 CERTIFIED PLANT)
Wadilube Installation Fire Order
Chief Fire Officer
Overall
Incharge Mr. V. R.
Kharche, Plant Incharge / Alt.
Manager (Ops.) Mr. S.S.Sharmarthi
Dy. Chief Fire Officer Dy. Chief
Fire Officer Dy. Chief Fire
Officer (Fire Fighting)
(Co-Ordination At Plant)
(Outside Asstt.)
Dy.Mgr.(HSSE)
Dy. Mgr.(Ops.)
Dy. Mgr.
(LOGISTICS) Mr..H. C. Murmu
Mr. P. V. Patel
S.B.Balasubramanian Alt. Mgr. Lab QC Mr. Ravi
Bhatia Alt. Officer (Plg.)
Mr.Lalit Sherkar Alt. Dy.Mgr.(Admn)
Mr.V.S.Degwekar
Group I Group II Group III
Group IV Group V Group VI
Officer Engg. Officer SPF
Officer P/H 2 Officer Logistics
QC Officer. LAB) Planning With ENGG.
Officer B/Filling Officer Blend/Floor
Officer (Del.Sec.) with Staff
Officer Staff with
Staff with Staff
with Staff At Lab Gate
Mr. Lalit Sherkar



LVD

• Delivery
• Stop Loading
• Remove the Truck to
• Safe Area
• Planning
• A/C for Trucks
• Move to Safe Area
• Cashier
• Keep cash valuable
• Documents in Safe

• Fitter
• Start Fire Water Pump
• Electrician
• Switch Off Elect. MAINS
• G O
• Supply Fire Fighting Equipt.
• Boiler Attd.
• Switch Off Boiler Report to
• FIRE SITE

Stop All Operation Respond Immediately
For FIRE FIGHTING
Stop Pumps Close Tank Valves Report to Fire
Site As Stand By
Close LAB Work Control Over Gate For IN /
OUT Direct Fire Tenders To Fire Site

• Liaise with Police
• Liaise with Hospital
• Liaise with External
• Assistant
• Assist in Rescue First
• Aid
• LVD Remain In Readiness
• In Car

17
(ISO 90012008, ISO 140012004 BS OHSAS
180012007 CERTIFIED PLANT)
LIST OF IMPORTANT TELEPHONE NUMBERS
EXTERNAL AGENCY TELEPHONE NO.
MUMBAI FIRE BRIGADE 101 / 23086181
AMBULANCE 102
POLICE 100
DONGRI POLICE STN 23753676
SEWREE POLICE STN 66567261 / 2
WADALA POLICE STN 24185250
J.J. HOSPITAL 23735555
G. T. HOSPITAL 22621644
BOMBAY HOSPITAL 22067676
BEST 23474242 / 22066661
DIRECTOR CIVIL DEFENCE 22843600 / 67
FACTORY INSPECTOR 23522232
BPCL SEWREE 24183644
PRINCE ALLY KHAN HOSPITAL 23777911
18
(ISO 90012008, ISO 140012004 BS OHSAS
180012007 CERTIFIED PLANT)
DETAILS OF FIRE FIGHTING EQUIPMENTS

• i) Fire Extinguishers
• 75 Kg DCP Trolley --- 2 Nos.
• 10 Kg DCP type extinguisher --- 125 Nos.
• 5 Kg DCP type extinguisher --- 14 Nos.
• 22.2 Kg CO2 extinguisher --- 1 No.
• 9 Kg CO2 extinguisher --- 7 Nos.
• 6.8 Kg CO2 extinguisher --- 32 Nos.
• 4.5 Kg CO2 extinguisher --- 28 Nos.
• 2.0 Kg CO2 extinguisher --- 18 Nos.
• Fire Buckets --- 68 Nos.
• ii) Details of Hydrant System
• Hydrant Monitors --- 8 Nos.
• Single Hydrant Valve --- 16 Nos.
• Double Hydrant Valve --- 12 Nos.
• Sprinklers --- 125 Nos.
• iii) Fire Water Storage Capacity
• Two tanks of 3900 540 KL each aggregating to
  total storage of

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(ISO 90012008, ISO 140012004 BS OHSAS
180012007 CERTIFIED PLANT)
NAMES OF THE EMPLOYEES TRAINED IN FIRST AID /
FIRE FIGHTING
(LIST OF FIRST AID COURSE ATTENDED)
Mr. S.S. Shrivardhankar Mr.
P. D. Jadhav Mr. P. J. Katu
Mr. S. J. Patil Mr. R. V. Pednekar
Mr. S. D. Yadav Mr. D. H. Gohil
Mr. V. S. Lad Mr. V. S.
Palkar Mr. P. T.
Dhavle Mr. M. D. Mane
Mr. M. V. Lad Mr. M. V. Govandi
Mr. L. R. Dhuri Mr. T. D. Sawant
Mr. V. S. Jadhav Mr. Y. S. Keni
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(ISO 90012008, ISO 140012004 BS OHSAS
180012007 CERTIFIED PLANT)
LIST OF PERSONNEL TELEPHONE NUMBERS

• Sr.No. Name Residence No. Office No.
• 1) Mr. V.R. Kharche 25540382/
  23751270
• 
  25996219
• Mr. Sandeep S. 28797166
  23727104
• Mr. G. Srinivasulu 65201977 23702047
• Mr. H.C.Murmu 9820953328 23702047
• 5) Mr. V. S. Degwekar 9762215688 23751320

21
(ISO 90012008, ISO 140012004 BS OHSAS
180012007 CERTIFIED PLANT)
LIST OF P P Es

• Safety shoes
• Safety goggles
• Safety helmet
• Safety harness
• Hearing protection
• Hand gloves
• Protective clothing
• Respirator
• Aprons

22
(ISO 90012008, ISO 140012004 BS OHSAS
180012007 CERTIFIED PLANT)

• IN CASE OF TOXIC SPILLS
• Any Person noticing the spill will inform
  immediately to Supervisor / Dept. Head
• Immediately stop source of leak if possible.
• Inform Engineering Dept. and take necessary
  action.
• Instruct people / workmen to evacuate the area.
• Ascertain the nature of material.
• Check the area clear of people / workmen and
  organize emergency shutdown.
• Organize clean-up.
• In case of exposure / splash to any workmen, give
  immediately water shower, sent them to medical
  attention.
• Inform Security Officer on duty and obtain
  necessary help.
• Inform Production Manager, Safety Manager through
  emergency control centre.

• 2. IN CASE OF FIRE
• After receiving the information from the Plant
  Security Officer reach to the site for fire
  immediately.
• He will find exact location of the fire and start
  combating the fire with the first aid fire
  fighting equipments.
• Inform Fire Emergency Co-ordinator of the Plant
  and his team will reach the site.
• Security Guard at the Main gate shall control
  traffic movement and also guide other emergency
  team members.
• Fire pumps will start automatically when pressure
  drops down.
• Department head Plant Manager will also rush to
  the site.
• Site main controller and incident controller will
  perform their duties.

23
(ISO 90012008, ISO 140012004 BS OHSAS
180012007 CERTIFIED PLANT)

• 3. IN CASE OF INJURY
• Any workmen at site will help to take away
  injured person / workmen from the area.
• First aider available will render necessary First
  Aid and take him to Hospital.
• Workmen must inform at the Main Gate about the
  incident and to the Supervisor / Officer of the
  Department.
• The concerned Operator takes care of the
  operations in the affected area.
• Supervisor concerned will inform Department Head,
  Production Manager and Safety Manager.

24
(ISO 90012008, ISO 140012004 BS OHSAS
180012007 CERTIFIED PLANT)

• ACTION PLAN FOR ELECTRICAL FIRE
• Disconnection of the electric supply of the
  affected area.
• Attempt to extinguish the fire with the help of
  DCP/CO2 fire extinguishers.
• If the fire still persists, ensure complete
  isolation of electric supply of that area
• and use water.
• ACTION PLAN FOR OFFICE FIRE
• Disconnection the electric supply of the
  affected area.
• Attempt to extinguish the fire with the help of
  DCP/CO2 fire extinguishers.
• Save all records from fire.
• ACTION PLAN FOR PERSON AFLAME
• Bring the water gel blanket.
• Open the bag inside the container to remove
  blanket. If the bag is already open, such
• blanket should not be used for burn victims.
• The blanket can be held as a screen between the
  victim and the fire.

25
(ISO 90012008, ISO 140012004 BS OHSAS
180012007 CERTIFIED PLANT)

• ACTION PLAN FOR OIL FIRE
• Attempt to extinguish the fire with the help of
  DCP fire extinguishers.
• If the fire is not controlled, use water spray.
• ACTION PLAN FOR FOOD / WATER POISONING
• Persons observing the symptom should inform the
  location in change for assessing the
• situation.
• Safety Officer should announce instructions of
  the location in charge to all employees.
• Shift in charge should call the doctor and
  ambulances and also alert all hospitals to
• meet any exigencies.
• To render first aid and induce vomiting to the
  affected persons.
• The ambulances and vehicles available should be
  mobilized to be in readiness to
• transport large number of people if required.
• Safety Officer to report to location in charge
  for required sanitation and medical
• assistance.

26
(ISO 90012008, ISO 140012004 BS OHSAS
180012007 CERTIFIED PLANT)

• Command Center
• Plant managers cabin
• Bomb Threat Evacuation
• Bomb threat assessment committee is formed
• Committee includes
• Coordinator -
  Plant Manager
• Alternate Coordinator - Ops.
  Manager
• Safety Committee member - Safety Officer
• Plant security Incharge - Dy. Mgr.
  Admin
• Local Police Representative - Police S.I.
• Incharge fire brigade - Mumbai
  fire Brigade Officer

27
(ISO 90012008, ISO 140012004 BS OHSAS
180012007 CERTIFIED PLANT)

• Responsibiliteies of Member
• Coordinator
• Inform all members Supervisor of area
• Start maintaining logbook of all members of BTAC
• Collect information from receiver of bomb threat
• Inform Police, Medical aid, Fire station bomb
  squad
• Arrange sufficient sand bags
• Alternate Coordinator
• To act in absence of co-ordinator

28
(ISO 90012008, ISO 140012004 BS OHSAS
180012007 CERTIFIED PLANT)

• Evacuation Plan
• Incharge - Filling
• Assisit coordinator to evacuate area
• Close down the facility to avoid damage
• Help Search Team
• Restrict unnecessary movement
• Cordoned Area
• Assist local police
• Incharge - Security
• Cordoned affected area
• Restrict private personal vehicles
• Consult with coordinator
• Assist search Team
• Inform Police control room and fire brigade

29
(ISO 90012008, ISO 140012004 BS OHSAS
180012007 CERTIFIED PLANT)

• Search Team
• Comprise of
• Safety officer
• Departmental Incharge
• Employees working in that department
• Not to be more than six members
• Should have following equipments
• Bomb Detectors
• Metal Detectors
• Search Mirrors
• Emergency Lights
• Flash Lights
• Stethoscopes
• Metallic and non-mettallic probe
• Screw drover set
• Chalks or line power for marking the search area
• Search Team should locate the object and contact
  the concerned experts

30
(ISO 90012008, ISO 140012004 BS OHSAS
180012007 CERTIFIED PLANT)

• Evacuation Plan
• Co-ordinator should signal the concerned
  departments for evacuating premises one by one
• Minimum safe distance should be 300 mts
• Necessary help of civic authorities should be
  taken

31
(ISO 90012008, ISO 140012004 BS OHSAS
180012007 CERTIFIED PLANT)

• Evaluation of Bomb Threat
• Genuine Threat
• Hoax Threat

32
(ISO 90012008, ISO 140012004 BS OHSAS
180012007 CERTIFIED PLANT)