Health & Safety Instructions and Procedures:

HS-IP / E 9.1 – On-site Emergency Preparedness Plan

Issue: 5 Copy No:

Issue Date: 18.10.2006

Approvals

Author: A R Rex Approval: Sekhar P.

Amendment History

Issue Total No Description Change Date

Number Of Pages Raised By Effective

Issue 3 23 Amended with the suggestions for Ananth L 24.12.2004

improvements from the Mock drill
Issue 4 23 Amended with the suggestions for Gokul Suresh 15.08.2006
improvements from the Mock drill
Issue 5 23 Amended with additional First Gokul Suresh 18.10.2006
aider name and modification of
layout

Cooper Bussmann India Pvt Ltd Health & Safety Procedures & Instructions HS-IP / E 9.1 Issue 5 1
 Cooper Bussmann India Pvt. Ltd.

On Site Emergency Preparedness Plan

Cooper Bussmann India Pvt Ltd Health & Safety Procedures & Instructions HS-IP / E 9.1 Issue 5 2
 Contents
1.0 Application
2.0 Purpose
3.0 Roles & responsibilities
4.0 Summary
5.0 Description of the Facility
6.0 Definitions
7.0 On Site Emergency Preparedness Plan

Annexure
I List of Site Co ordinators
II List of Trained Emergency response team
III Emergency Response Team members details.
IV List of fire fighting equipments & its location in the site layout.
V Site evacuation Plan
VI List of chemicals, its hazardous nature & first aid measures
VII List of emergency control equipments
VIII Inspection format for emergency control equipments inspection
IX Plant lay out with emergency exits

1.0 Application:
This procedure applies to all manufacturing location of Cooper Bussmann - India.

Cooper Bussmann India Pvt Ltd Health & Safety Procedures & Instructions HS-IP / E 9.1 Issue 5 3
2.0 Purpose:
Emergency planning is required to ensure a structured response to any emergency on the premises. The response of each
& every employee in an emergency should be planned, such that there is / are minimum injuries to the employees and
material damage.

3.0 Roles & Responsibilities

It is the responsibility of the Incident co ordinator to administer the Emergency response plan. He
 Shall ensure evaluation of the procedure is being conducted by qualified personnel (Internal or External).
 Shall ensure necessary training has been provided to all Emergency co-ordinators and team members at required
intervals. Refresher training shall be given once in a year.
 Shall ensure the effectiveness of the training and identify wherever retraining is required.
 Communication of this emergency response plan to all the employees
 Shall ensure periodic review of this procedure will be made in order to assure completeness and determine if
revisions /additions are necessary. Any revisions or additions necessary will be published and distributed to all
responsible personnel to be included in this procedure.
 Shall ensure that half yearly mock drills are conducted and minuted. The minutes shall be documented.

The Power and utility in charge shall be responsible for rendering engineering support to the Emergency response team.
 Shall ensure that all emergency response equipments shall be maintained in good working condition.
 Shall ensure that all the evacuation plans are maintained with version control, all the emergency exits, emergency
lighting in good operating condition.

Copies of this procedure will be maintained by the emergency control center, emergency co ordinators and with other
responsible personnel as identified in this plan.
During certain hours when no emergency co ordinator is available in the site, the Shift In charge will take up various
responsibilities as mentioned in the roles and responsibilities during other shifts. He also serves as the central point of
communication between Cooper Bussmann personnel and outside emergency personnel until the Emergency response
team arrives at the facility.

The following are the various personnel in the Emergency Response Team:

Emergency Response Team

Cooper Bussmann India Pvt Ltd Health & Safety Procedures & Instructions HS-IP / E 9.1 Issue 5 4
 S
Responsibility General Shift Other Shifts
No

Mr S Varadharajan /
1 Site Main Co ordinator Shift In charge
Mr S Senguttuvan

Mr. Antony Rocky Rex /

2 Incident Co-ordinator Shift In charge
Mr. [Link] Suresh
Mr [Link] /
Medical & Administration In Shift Emergency Response team
3 Mr Namasivayam R
charge member

Mr Rubesh /
4 Power & Utility In charge Mr. Balakumar / Mr [Link]
Mr [Link]

Communication & Telephone

5 [Link] / Mr V Raja Security Guard
In charge

Emergency Control Center In Mr Sandeep /

6 Security Guard
charge Mr Raghunath

7 Site Co ordinators Identified charge hands as per the annexure

First aid & fire fighting

8 Identified Emergency response team
activities

4.0 Summary:
This section describes about preparation and implementation of on-site emergency plan for ensuring total safe shutdown
and total evacuation in case of an emergency. The program has a detailed On Site Emergency Program (OSEP) with roles
and responsibilities of the various co ordinators.

5.0 Description of the facility

The Cooper Bussmann India Pvt. Ltd facility located in Sedarapet, Pondicherry manufactures electrical circuit protection
devices for electrical and electronic applications

See Appendix A for Plant evacuation plan.

Cooper Bussmann India Pvt Ltd Health & Safety Procedures & Instructions HS-IP / E 9.1 Issue 5 5
The facility encompasses 32700 Sq ft with 22000 Sq ft of building area with approximately 175 personnel inside the plant in
a shift. Total number of employees in the facility is 350.

The operation within the facility include product assembly, product testing, Research and Development, distribution and
general office activities

6.0 Definitions:

Employee: Employee means any person including the operator, staff, trainee, temporary and contract casuals.

Emergency Response Team (ERT). An organized group of employees within a facility who are knowledgeable, trained,
and skilled when there is an emergency.

Drill: An exercise involving a credible emergency that requires an ERT to perform an emergency operation.

Training: The process of achieving proficiency through instruction and hands-on practice, in the operation of equipment and
systems expected to be used in performance of assigned duties.

Fire Emergency: Situations when any minor / major fire / explosions in the shop floor shall be considered as fire
emergencies.

Medical Emergency: Situations when any major accident / natural calamity causes a severe damage to the employee or
any health disorders which is severe that has to be attended immediately shall be considered as emergency.

Gas Emergency: Any leakage of gases inside the plant premises that creates a flammable air mixture shall be considered
as emergency.

Snake threat: Situation of a snake entering the shop floor & employees are not able to locate it shall be considered as
emergency.

Chemical spillage: Situation when any quantity of hazardous chemical spills on the shop floor shall be considered as
emergency.

Electric shock: Situations where any employee gets electric shock shall be considered as emergency.

7.0 On-Site Emergency Plan

1. The on-site emergency plan shall be prepared and must be available with all the Managers and identified emergency
co ordinators.

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2. Plant shall prepare emergency shutdown procedures for all the zones in the plant. This procedure shall be checked for
effectiveness through periodic mock-drills.
3. It shall address among other emergencies the following:
 Fire
 Medical Emergency
 Chemical Spillage or / releases
 Snake threat
 Structure Collapse
 Floods
 Gas Leakage
 Terrorist and Bomb threat
 Electric shock
4. Among other things, it shall contain:
 Activities after declaration of emergency
 Role of the person first noticing the incident
 Role of supervisors and officers at the site
 Role of security staff
 Role of various designated emergency co ordinators
 Operating instructions for total safe shut-down for every zones
 List of trained Emergency response team
 Important telephone numbers
 Addresses and telephone numbers of doctors
 Emergency communication flow chart
5. All concerned people shall be trained in implementation of the emergency plan. The effectiveness of the training shall
be assessed in the mock drills conducted.
6. All emergency co ordinators shall identify person(s), who will perform their duties in case of their non-availability from
the plant. Display boards to show key-responsible person (emergency co ordinators) for all shifts shall be put.
7. An Emergency Control Centre shall be made available in the plant where first hand information about the emergency
site can be provided.

7.1 General Evacuation Procedure:

After safe shut downing the section the Site Co ordinators shall segregate and remove all the flammable materials from the
location to a safe location. Then he / she shall initiate the evacuation of all employees.
Site Co ordinators (incase of siren activation) has to ensure
1. Total evacuation from their respective zones
2. Assembling at the designated assembly areas.
3. A total head count by “taking roll” at the designated meeting points.

He / She should have the list of personnel present in his zone, taken on daily basis, at the start of shift and updated after tea
breaks, in the prescribed format as per Annexure and kept in their pockets. For example if the employee prime zone is
Accounts office i.e Zone E and he was in zone B, then he shall assemble only in the zone E assembly area.

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After every one has assembled at the assembly area, the list of assembled persons shall be cross verified with the list of
personnel present in the respective zones.

The security guard shall be responsible for the visitors and contractors. He shall take a roll call of the persons at their
designated assembly point and cross verify with the list available at the security office.

Once the Head count is done and if any person is found missing the Site co ordinators shall be responsible to trace and
rescue the missing person. The information to be communicated to the Incident co ordinator.

During night shift, the shift in charge shall be responsible to co ordinate all the activities of site co ordinator.

If the Site co ordinators find any injured person he shall refer the person to the medical In charge for treatment.

After receiving the “all clear’” signals from the Site main co ordinator, the respective co ordinators instruct their people to
renter the factory premises

7.2 General Reporting Procedure

The first person who sees the emergency should sound the emergency alarm and inform his supervisor / officer / manager.
He should communicate to the Communication officer also. The employee on his way to communication officer, if he sees
any emergency co ordinator, he shall inform him also. The supervisor of the section takes up the safe shutting down and
evacuation activity. The communication officer informs the Incident co ordinator, Site main co ordinator and other
emergency co ordinators.
During shifts other than general, the first person shall inform his supervisor & Shift in charge. He also informs the security
guard. In turn the security guard informs all the emergency co ordinators.
The first person shall declare emergency by pressing the siren for Fire, Structure collapse, Earthquake and gas leakage
emergencies.
Site Main co ordinator (GM - Operations) shall declare emergency for Floods & terrorist & bomb threat.
Emergency shall not be declared for Medical & electrical emergency.
Only the sectional people shall evacuate for any chemical spillage or snake threat emergency.

7.3 Roles and Responsibilities of Various Personnel in Case of an Emergency (General Shift)

FIRST PERSON WHO SEES THE EMERGENCY SITUATION

1. Shouts - “Emergency .. Emergency…" and puts on the emergency siren.

2. Informs Shift Supervisor about the emergency - who informs Shift Engineer / electrician
3. Switch off the power to his equipment.
4. Informs the telephone co ordinator
5. He shall move to the assembly area and inform the security.

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SITE CO ORDINATOR

1. Safe shutdown of effected area / section.

2. Segregation & removal of flammable material from effected site
3. Provide necessary guidance & help to Fire fighting squads & Security Staff
4. Evacuate other employees to assembly area
5. Take head count at assembly area.

SITE MAIN CO ORDINATOR (SMC)

1. Exercise direct control over areas other than those affected.
2. Maintains a continuous review of situation with Site Co ordinator & Incident Co ordinator
3. Liaise with Senior company officials, police, fire brigade, Medical & Factory Inspectorate
4. Ensure evidence is preserved for enquiries to be conducted by statutory authorities.
5. He shall declare the All clear signal only after receiving the clearance certificate from the Utility & Power In charge.
6. Give ALL CLEAR signal after ensuring the safe re-entry.

INCIDENT CO ORDINATOR (IC)

1. Rushes to the site & takes over all charge & reports to SMC
2. Assess the scale of emergency & advises SMC to declare Major Emergency, if required.
3. Directs all operations including shutting down & evacuation
4. Reports all significant developments to Communication Officer
5. On failure of Power supply set up communication point & establishes contact with ECC.
6. He shall ensure cleaning the affected area.
7. He shall remove the scattered, unwanted material from the site and transfer them to a safe location.

COMMUNICATION OFFICER

1. Handles all communications.

2. Recruit suitable staff to act as runners between IC & himself in case telephone & other communication fail.
3. He shall keep a record of all incoming & outgoing messages pertaining to emergency and maintain Log of Incident.
4. Inform Local authorities, police, hospital for aid and assistance.
5. Report to Government & Regulatory agencies as per local law & Head Office in case of Major Accident.
6. On hearing emergency siren informs Incident co ordinators, site main co ordinator, & other designated co
ordinators proceeds to ECC & maintains communication with IC.
7. He shall not disclose any information without prior permission of Site Main Co ordinator.

POWER & UTILITY IN CHARGE

1. On hearing emergency rush to utility control room & close down services as requested by IC.

Cooper Bussmann India Pvt Ltd Health & Safety Procedures & Instructions HS-IP / E 9.1 Issue 5 9
 2. Provide necessary back up services for controlling emergency.
3. Ensure water for hydrant system are supplied
4. Ensure pump starts automatically in sequence with the pressure switches.
5. He will maintain a standby to start pumps manually, if need be.
6. Switches off Electricity to affected area / whole plant as the case maybe
7. After normalcy is restored in the site, he shall inspect the site for any hazards & certify the site for ALL CLEAR
signal. He shall check for all the energy sources.

EMERGENCY CONTROL CENTER IN CHARGE

1. The Emergency Control Centre In-charge shall co-ordinate all activities relating to provision of additional fire
fighting / rescue / first aid to the endangered site, traffic control inside the plant, and evacuation of the casualty to
the hospital.
2. He shall maintain all the emergency control equipments in good working condition. He shall inspect the
equipments once in 3 months and maintain record of the same.
3. He shall be in charge for the employees assembled in the assembly area.
MEDICAL & ADMINISTRATION INCHARGE

1. On hearing emergency he shall keep necessary equipment, medicines, etc in ready condition for treatment
2. Provide primary first aid to the affected employee.
3. Ensure ambulance is sent to the effected area on advice of IC
4. He will contact local hospitals regarding the emergency & alert them to receive the effected persons
5. He will call for additional ambulances from local hospitals, if need be.
6. He is responsible to maintain sufficient medicine in the first aid boxes at all times.
7. He shall check the expiry dates of the medicines once in three months and ensure that all the medicines are within
the prescribed expiry date.
As an administration In charge
1. Works as Liaison officer under direction from SMC.
2. Receive reports from roll call leaders from assembly areas & pass on information to SMC
3. Ensures casualties receive adequate medical attention & arrange additional help if required.
4. Controls Traffic movement into factory & ensure alternate transport is arranged when need arises.
5. When emergency is prolonged arranges for additional relief personnel.
6. Liaise with the Utility In charge for water.
7. Keep track of all chemicals handled in the plant and disseminate information when required.

SHIFT SUPERVISOR (AFFECTED AREA)

1. Brings immediately all operations to Safe Shut Down

2. Ensures fire does not spread into other areas by arranging to remove all flammable material from the affected site
3. Instructs Engineer / Electrician to isolate power supply
4. Shift supervisor shall assist the Incident Co ordinator for any assistance.

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SHIFT SUPERVISOR (OTHER AREAS)

In case of an emergency
1. Carry out Safe Shut down of operations
2. Take head count at central assembly area
3. Wait for in the assembly area for any help required by the emergency control center co ordinator. They shall not
move from the assembly area without the permission of the Emergency control center co ordinator.

FIRE FIGHTERS / FIRST AIDERS / OTHER OPERATORS

1. Remove all the flammable substances from the area affected.

2. Fight the emergency along with Security to extinguish fire
3. Provide First aid to affected people
4. Once the emergency is under control, the fire fighters / first aiders will coordinate with the house keeping team to
remove the debris.

SECURITY GUARDS
1. Transfer the emergency control equipments to the site
2. Immediately close the gates and ensure that no persons / vehicle transaction happens at the gate
3. Fight the emergency along with the section personnel.
4. One security guard should always guard the gate.

7.4 Following are the responsibilities of various personnel during emergencies in the plant other than General
Shifts

SECURITY GUARD:
He performs the role of Communication officer & ECC In charge

1. Handles all communications. On hearing siren he proceeds to ECC & maintains communication with IC
2. Inform Local authorities, police, hospital for aid and assistance.
3. On hearing emergency siren informs Incident co ordinators, site main co ordinator,
Communication officer & other designated co ordinators
4. He keeps the board free for essential calls.
5. He shall keep a record of all incoming & outgoing messages pertaining to emergency
6. He shall not disclose any information without prior permission of Site Main co ordinator.
7. The Emergency Control Centre In-charge shall co-ordinate all activities relating to provision of additional fire
fighting / rescue / first aid equipment to the endangered site, traffic control inside the plant, and evacuation of the
casualty to the hospital.
8. He shall maintain all the emergency control equipments in good working condition.
9. Works as Liaison officer under direction from SMC.
10. Receive reports from roll call leaders from assembly areas & pass on information to SMC

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 11. Ensures casualties receive adequate medical attention & arrange additional help if required.
12. Controls Traffic movement into factory & ensure alternate transport is arranged when need arises.
13. When emergency is prolonged arranges for additional relief personnel.
14. Liaise with the Utility In charge for water.

SHIFT IN CHARGE
Maintain Log of Incident. He carries out the functions of Site Main Co ordinator, Incident Co ordinator & Medical In charge..
He directs all the plant personnel in order to fight the emergency.
1. Exercise direct control over areas other than those affected.
2. Maintains a continuous review of situation with Site Co ordinator & Incident Co ordinator
3. Recruit suitable staff to act as runners between IC & himself in case telephone & other communication fail.
4. Liaise with Senior company officials, police, fire brigade, Medical & Factory Inspectorate
5. Ensure evidence is preserved for enquiries to be conducted by statutory authorities.
8. Rushes to the site & takes over all charge & reports to SMC
9. Assess the scale of emergency & advises SMC to declare Major Emergency, if required.
10. Directs all operations including shutting down & evacuation
11. Reports all significant developments to Communication Officer
12. On failure of Power supply set up communication point & establishes contact with ECC.
13. Give ALL CLEAR signal after ensuring the safe reentry.
14. Report to Government & Regulatory agencies as per local law & Head Office in case of Major Accident.

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7.5 Emergency preparedness plan for various emergencies:

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Cooper Bussmann India Pvt Ltd Health & Safety Procedures & Instructions HS-IP / E 9.1 Issue 5 15
Cooper Bussmann India Pvt Ltd Health & Safety Procedures & Instructions HS-IP / E 9.1 Issue 5 16
Cooper Bussmann India Pvt Ltd Health & Safety Procedures & Instructions HS-IP / E 9.1 Issue 5 17
Annexure I
Site Co ordinator listing:
Cooper Bussmann India Pvt Ltd Health & Safety Procedures & Instructions HS-IP / E 9.1 Issue 5 18
AREA ZONELEADER ASSEMBLY AREA

A 1
DTA – GROUND FLOOR B 1
C 2

DTA – FIRST FLOOR D 3

E 3

EOU GROUND FLOOR F 4

G 4
H 5
I 5

Visitors and Contractors J 5

Annexure II

TRAINED FIRST AIDERS

SL EMPLOYEE NAME Emp Shift
No
1 Nazar A 24 G
2 Kavitha K 37 R
3 Saritha D 51 R
4 Sivagami A 79 R
5 Kuttalingam S 18 R
6 Jayasundari A 80 R
Cooper Bussmann India Pvt Ltd Health & Safety Procedures & Instructions HS-IP / E 9.1 Issue 5 19
7 Josphinemary A 35 R
8 Ramachandiran S 85 R
9 Raja S 49 R
10 Gopalakrishnan S 84 R
11 Anoop K C 2405 G
12 Raja S 2409 R
13 Kalyanasundaram E 1769 G
14 Punitha K 46 R
15 Natarajan R 144 R
16 Ramesh A 30 R
17 Siva R 176 R
18 Marian Victor T 2498 G
19 Senthil Kumar T 128 R
20 Kumar R 152 R
21 Durgadevi P J 23 R
22 Kalpana K 150 R
23 Rubbesh kumar G A 2464 G
24 Pasupathirajan T 2446 G
25 Shahul hameed M 2506 G
26 Jayakumar P 2489 G
27 Muthulakshmi L 101 R

G – General shift
R – Rotating shift

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 ANNEXURE III

FIRE EXTINGUISHER – AUTHORISED USERS

Sno Employee Name Emp No Shift

1 Kalyanasundaram E 1769 G
3 Narayanan S 25 R
4 Kumaravel E 75 R
5 Nazar A 24 G
6 Ramachandiran S 2522 G
7 Josphinemary A 0035 R
8 Murugaperumal J 2474 G
9 Jayasundari A 0080 G
10 Anoop K C G
11 Durgadevi P J 023 R
12 Ramesh A 30 R
13 Bhaskar G 137 R
14 Saritha D 51 G
15 Murugan M 120 G
16 Vijaya Kumar S 130 R
17 Seetha R 40 R
18 Senthil Kumar T 128 R
19 Senthil Nathan P 6318 R
20 Soosai M 11778 R
21 DOSS K C 5136 R
22 Thiyadar T J 11778 R

G - General Shift
R - Rotating Shift

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Annexure IV

EMERGENCY TELEPHONE NUMBERS

LOCATION PHONE

FIRE STATION General 101

Dhanvandhiri Ngr 2372913
Main 2336238

POLICE STATION General 100

Saderapet outpost 2677404

AMBULANCE JIPMER 2272380-89

GH 2336050

HOSPITAL JIPMER 2272380-89

GH 2336050
E S I-Gorimedu 2272123

Annexure V
Emergency response plan overview.

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 GENERAL SHI FT
STRUCTURE

FI RST PERSON TO NOTI CE THE EMERGENCY TELEPHONE OPERATOR

COMMUNI CATES TO ALL

EMERGENCY CO ORDI NATORS
GENERAL MANAGER
SITE MAIN CO ORDINATOR
ALTERNATE : PRODUCTION MANAGER

SAFETY CO ORDI NATOR PURCHASE MANAGER PERSONNEL OFFI CER MANUFACTURI NG ENGG MANAGER
I NCI DENT CO ORDI NATOR ADMI NI STRATI ON I NCHARGE COMMUNI CATI ON OFFI CER POWER & UTI LI TY I NCHARGE
ALTERNATE : SAFETY OFFI CER ALTERNATE:PURCHASE OFFI CER ALTERNATE:FI NANCE OFFI CER ALTERNATE: SR ENGI NEER (ME)

ZONE LEADER
FI RE FI GHTERS FI RST AI DERS ENGI NEER / ELECTRI CI AN
SI TE CO ORDI NATOR

OTHER OPERATORS SECURI TY GUARDS

OTHER SHI FT
STRUCTURE

FI RST PERSON TO NOTI CE THE EMERGENCY

SHIFT ROASTER
(SITE MAIN CO ORDINATOR / INCIDENT CO ORDINATOR)

SECURI TY GUARDS SHI FT I N CHARGE SHI FT ENGI NEER

FI RE FI GHTERS FI RST AI DERS ELECTRI CI AN

The Shift Roaster (SMC) shall immediately communicate to the ERT personnel for help.
The SMC shall direct various staff members on the activities of emergency.

EMERGENCY SITUATIONS
Emergency Situation / Location Safe Assembly Point

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 Fire of Cartons –DTA & EOU Main Gate

Fire/LoC of Thinner and Resin – Both DTA & Main Gate

EOU
Fire/LoC of Diesel Oil – Generator room Main Gate
Fire/ Explosion of hydrogen and LPG storage Main Gate
yard inbetween DTA and EOU
Fire of waste paper near Transformer yard Main Gate

Fire/LoC of Diesel – Behind Laboratory (H6) Main Gate

Fire – Office Room – Both DTA and EOU Main Gate

DETAILS OF STORAGE OF SUBSTANCES PRESENTING MAJOR ACCIDENTS HAZARDS.

Sl. Hazardous Type of Storage Capacity of Number of Maximum

No. Substances Storage Storages Inventory
1 LPG Cylinder 17 Kg each - 5 1 6 Nos
Nos of cylinder
2 Hydrogen Cylinder 3 cylinder – 40 1 3 Nos
KG
3 Oxygen Cylinder 3 Cylinder 1 3 Nos
4 Diesel Drums –Diesel 3 Drums
Generator shed

Storage Conditions: Ambient temperature & pressure.

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