Verfication: An ISO 9001:2008 Registered Company

FORWARD ENGINEERING
ENGINEERING INDUSTRIES (BHOPAL)

An ISO 9001:2008 Registered Company
For Permanent High Power Flow
44, B.H.E.L. Ancillary Estate,

Habibganj, Bhopal 462024 (M.P) INDIA
Tel.No. : +91-755-2588676, 2588543, 4076803
Fax
: +91-755-2588543
Web
: www.forwardengg.com
Email : feibpl@sify.com , feibpl@sancharnet.in
VERFICATION
This is to verified that the details provided in the On Site Emergency Plan submitted herewith are true as per
best of my knowledge
for Forward Engineering Industries.
SALIENT FEATURE OF FACTORY
Unit M/s Forward Engineering Industries is a Small Scale Unit and registered ancillary to M/s B.H.E.L. Bhopal
since 1963. We are engaged in manufacturing of Electrical and Mechanical components required in Jointing
Assemblies, Switchgears, Transformers, Traction Motors, Rectifiers and other product required by BHEL or
other customers as per their specifications.
Main Machine shop is equipped with various machines. We have our Plating Shop where we carry out
Plating when ever required as per customers order occasionally.
Fire Fighting Equipment :- Fire extinguishers available.
Personal Protective Equipment/Appliances :- Gumboots, Acid Alkali Proof Hand Gloves, Apron available in
the factory.
Emergency Control Room & Facilities available :- Our units main work is manufacturing by machining
Electroplating is secondary work. Basically electroplating is batch type job work and manual involvement is
more. The emergency does not occurs due to any Mechanical or continuous process plant. As such
automatic or emergency alarming facilities not provided by us.
Page 1 of 12
2010-11/FORMAT/ONSITE EMERGENCY PLAN
FORWARD ENGINEERING

Tel.No. : +91-755-2588676, 2588543, 4076803
Fax
: +91-755-2588543
Web
ONSITE EMERGENCY PLAN & DETAILED DISASTER

CONTROL MEASURE IN ELECTRO PLATING SHOP
INDEX
OJECTIVES
DEFINITION
LOCATION
MANUFACTURING PROCESS
SIGNIFICANCE OF ACIDS ETC.
LIKELY MAJOR EMERGENCIES
HANDLING, STORAGE ETC.
TYPE OF EMERGENCY AND ACTION TAKEN
IN HOUSE FACILITIES AVAILABLE
SAFETY MEASURES
RESPONSIBILITIES SHARED AMONG EMPLOYEES
OUT SIDE EMERGENCY SERVICES.
NEAREST-FIRE STATION, HOSPITAL, POLICE STATION.
ELECTRIC SUB STATION
LAY OUT PLAN
PROCESS FLOW DIAGRAM
Page 2 of 12
FORWARD ENGINEERING

Tel.No. : +91-755-2588676, 2588543, 4076803
Fax
: +91-755-2588543
Web
OBJECTIVE OF EMERGENCY PLAN

PLAN
Objectives of Onsite Emergency Plan are to provide for System Capable of taking fast and effective action in
an emergency situation in order to :(a) Safe guard the factory personnel inside and the public outside.
(b) Effect the rescue and treatment of casualties.
(c) Safe guard the property and environment.
(d) Bring incident under control.
(e) Provide authoritative information.
(f)
Ensure rapid return to normal operation after emergency.
(g) Preserve relevant records and equipments.
DEFINITION
The principle of Electroplating in defined as If a Direct Current is passed through an Electrolyte. Metal will
be deposited on the cathode and corresponding amount of metal will be eaten away from the anode the
composition of the electrolyte remains unchanged. Science of electroplating has been developed from this
principle.
In the Electroplating process, the object is to be plated is made the cathode and a solution containing a salt
of the Metal to be deposited is used as the electrolyte, the anode may be made of the metal to be deposited
or other conductor, when the low voltage direct current is passed through the solution, electrolysis takes
place as a result of which the metal is deposited on the articles which forms the cathode.
Page 3 of 12
FORWARD ENGINEERING

Tel.No. : +91-755-2588676, 2588543, 4076803
Fax
: +91-755-2588543
Web
INFORMATION
Our Unit M/s FORWARD ENGINEERING INDUSTRIES, situated in an industrial Area established by M/s B.H.E.L.
Bhopal at Habibganj, on Plot No. 44, BHEL Ancillary Estate, Habibganj, Bhopal. We are a small scale Unit
having Reg.No. J/SSI/DI/MP/61-BPL/(47)/ECW/64/96 Dated 04-04-1964
Name of Partners:Our Unit is a Partnership Firm and following listed person are partners:I. Shri M.J. Sampat
II. Smt. U.M. Sampat
A-38, A-Sector, BDA Colony,
III. Shri H.M. Sampat
Shahpura,
Bhopal 16
IV. Shri C.M. Sampat

V. Smt. R.H. Sampat
We are engaged in manufacturing of Non-Ferrous Electrical & Mechanical Components for M/s B.H.E.L.
Bhopal. Being an approved Ancillary to them. These non ferrous components of Copper, Brass etc. some
times as per their orders. We processed the finished components for Electroplating like Silver, Tin etc. on
rare occasion.
Page 4 of 12
FORWARD ENGINEERING

Tel.No. : +91-755-2588676, 2588543, 4076803
Fax
: +91-755-2588543
Web
MANUFACTURING PROCESS
There are many kind of Electroplating such as Zinc Plating, Nickel Plating, Copper Plating, Tin Plating &
precious Metal Plating, Process description of various plating are as follow:1. Preliminary Treatment:
Since the surface of materials of Ferrous/Non-Ferrous as received is oily, greasy or rusty. It must be
degreased as the first step. Impurity or grease greatly effects efficiency in Mechanical or Chemical Polishing.
Degreasing and Acid pickling are generally used in the preliminary treatment.
2.
Polishing :
Polishing improves the adhesion and finish of the plating. Belt Polishing, Buffing or Barrel Finish are
commonly used.
(a) Belt polishing is especially useful as rough polishing of material because of its powerful polishing
ability.
(b) Buffing is used in the three process cutting down, intermediate and finish buffing.
(c) Barrel grinding is a process by which many small pieces are polished at the same time.
3.
Prior Treatment :
The surface of the Raw material is usually contaminated with impurities which soul should be completely
removed by proper means to provide a smooth and clear plating surface. Acid Treatment and degreasing
are carried out in the prior treatment. Acid treatment is done by acid pickling, acid dipping or etching then it
is neutralized and washed with water. A degreasing agent of the solvent type is mainly used to remove
buffing waste grease, machine oil and rust proof oil. Alkali degreasing is a common degreasing
Page 5 of 12
FORWARD ENGINEERING

Tel.No. : +91-755-2588676, 2588543, 4076803
Fax
: +91-755-2588543
Web
method and has been widely used for a long period of time. Electrolytic degreasing which used direct
current has been widely used now a days.
4.
Plating :
The buffed and degreased material is next placed with the plating bath to be electroplated. The metal is
finally placed in the plating barrel or hung on racks in the plating bath to be plated. The metallic ions
provided in the plating bath are precipitated on the cathode which is a metal to be plated.
All anodes are double plated except those in chromium plating. Different brighteners are used to provide
smoothness and brightness to the surface of the metal plating.
5.
Finish Treatment :
The plated metal pieces are rinsed with hot water and then dried finally.
SIGNIFICANCE OF PLATING CHEMICALS LIKE ACIDS
Chemical for Pickling

Pickling is a practice termed as a pretreatment for subsequent finishing operation such as electroplating,
polishing, painting etc. following chemicals in dilute form are used for pickling because the primary
requirement of a good pickling solutions is that it should remove all contaminations rapidly but attack the
base metal as little as possible :
1.
Sulphuric Acid : Sulphuric Acid is the acid which is used in the largest quantities in pickling of
metals. It is used in Dilute form for pickling steel and copper, Sulphuric Acid is normally used in
Page 6 of 12
FORWARD ENGINEERING

Tel.No. : +91-755-2588676, 2588543, 4076803
Fax
: +91-755-2588543
Web
concentrations of 10-12% for pickling. The solutions must be prepared by adding the acid very
slowly to the bulk of cold water.
2.
Hydrochloric Acid : Hydrochloric Acid is used for pickling Iron 10-12% Hydrochloric Acid is
generally used for pickling. Hydrochloric Acid dissolves most metals, particularly in the presence
of air, the advantages of Hydrochloric Acid as against Sulphuric Acid for pickling of iron are faster
speed at room temperature, better solubility for some types of rust and scale. Superior surface
condition of the pickled parts and finally the fact that acid which remains on the surface is both
less in volume more easily rinsed off.
3.
Nitric Acid : Main use for Nitric Acid in the pickling are for dipping of Copper & Copper Alloys,
Nitric Acid is used for Ferrous Metals only for the final dipping, particularly when a light gray
clean surface is required.
4.
Alkalis & Salts : Caustic Soda solutions are used for pickling aluminium & in special case. Sodium
Carbonate is used for neutralizing and passivating spickled iron. The most important alkaline
salts are used in pickling solutions are tertiary Sodium Dichromate Solution of about 1% are used
for passivating i.e. in order to prevent rusting of pickled parts.
5.
Tin Plating Bath : The soda stannate bath used for Tin Plating is made up as follows in one gallon
of Water we put Soda Stannate 350 Grams, Caustic Soda 65 Grams, Soda Accetate 65 Grams,
Oxidising Salt 15 Grams. This solution works at room temperature and owing to its high
conductivity the pressure required is just under 1 Volts.
6.
Nickel Plating : Following are constituted in a Nickel Plating Bath - Sulphate Solution: Nickel is
mainly electro electro deposited from Nickel Sulphate solution which contains a certain amount
of chlorides. A typical basic composition is as follows:- Nickel Sulphate 310 grams, Nickel
Chloride 50 grams, Boric Acid 40 grams. This formulation is of the high efficiency type and when
the bath is maintained at a pH value of e.g. 3 to 4 and a temperature of 40 to 40 it is possible to
Page 7 of 12
FORWARD ENGINEERING

Tel.No. : +91-755-2588676, 2588543, 4076803
Fax
: +91-755-2588543
Web
use current density between 30 D 100A/Sq.ft depending on the type of work being processed
and on the degree of solution agitation or work movement.
The Properties of the nickel coating deposited from this type of solution can be profoundly
affected by the addition of either inorganic or organic compounds.
LIKELY MAJOR EMERGENCIES HANDLING, STORAGE ETC.

The usual plating process involves so many chemicals, acids etc. In a plating plant there may be accidents,
emergencies occurs:1.
In Preparation of Solution :- During the preparation of chemical solution there may be chance of
causalities due to manual involvement.
2.
Storage of Chemicals ;- In storage of chemicals, Acids etc. in case of not proper there may be
even of spillage.
3.
Handling :- Emergencies may occur mainly during handling of plating chemicals.
4.
Mechanical Equipment :- In the absence of proper guards/screens fitted with mechanical

equipments may cause damage.
5.
Electrical Equipments :- In case of irregularities of Electrical Installation separate insulated

earthing systems.
6.
Accidents may happen due to ignorance of safety equipments like hand gloves, Boots, Masks
during plating works.
Page 8 of 12
FORWARD ENGINEERING

Tel.No. : +91-755-2588676, 2588543, 4076803
Fax
: +91-755-2588543
Web
TYPE OF EMERGENCY AND ACTION TAKE
1.With the provision of proper facilities and the exercise of reasonable care by the operatives.
Electroplating should not be considered as being in any way a hazardous operation. The processing
equipments supplied in corporate appropriate safety provisions and the growing use of automation is
lessening the need for operators to come into close contact with the processing solutions.
The Electroplating plant will incorporate the appropriate safety features as follows :
(01)
In all network areas the floor should be non-slip smooth washable and resistant to chemicals.
(02)
Ventilation : In shop where electroplating and other chemicals treatments are under taken
ventilation for which exhaust fans are provided.
(03)
Provision of services e.g. water etc. the drainage is in accordance with the appropriate
regulations, water connection, connection provided at proper position for swilling of floors and
for dilutions in case of any accidents.
(04)
Drains are constructed that there is no danger of injury arising from vapors, fumes etc.
(05)
Plant Maintenance: We are regularly maintained the plant equipments to avoid any accidents.
(06)
All electrical equipment installed are comply with the appropriate regulations in damp corrosive
conditions.
(07)
Preparations of Solutions: All chemical solutions are to be prepared in accordance with the
appropriate instruction sheets and the safety precautions given in these instruction sheets
carefully followed.
(08)
Storage of Chemicals : A separate storage is allocated for plating chemicals. The storage is
adjacent to the point of usage to avoid the necessity for transporting small quantities of
chemicals through other departments. Sacks and Drums of chemicals are stored on a dry floor.
Page 9 of 12
FORWARD ENGINEERING

Tel.No. : +91-755-2588676, 2588543, 4076803
Fax
: +91-755-2588543
Web
Washing facilities are provided in plating shop in case of spillage, chemicals can be rapidly
washed from the skin.
(09)
Protective Clothing : During solution preparation and chemical additions made and in all cases
where manual processing is being undertaken the appropriate clothing like Rubber Hand Gloves,
Gum Boots, Apron is provided.
RESPONSIBILITIES SHARED AMONG EMPLOYEES

1.
Mr. M.J. Sampat
Partner
2.
Mr. H.M. Sampat
Partner
3.
Ms. Rameeza
Electroplating In Charge
Control of Emergencies
Control of Workers
4.
Mr. Vivek Sharma
Looking / Keep informed to outside authorities like police

Station, Fire Station.
OUT SIDE EMERGENCY SERVICES

1. Nearest Fire Fighting Station
Pul Bogda Fire Sub Station

Near Muncipal Corporation Office,
2. Nearest Hospital
Jay Prakash Hospital, 1250 Quarters.

Tulsi Nagar, Bhopal.
3. Nearest Police Station
Govindpura (Bhopal) Police Station.

Near Natraj Community Hall.
4. Nearest Electric Sub Station
Page 10 of 12
Kasturba Nagar, Sub Station.
FORWARD ENGINEERING
Sr.No.
List of Hazardous Raw Materials

Tel.No. : +91-755-2588676, 2588543, 4076803
Fax
: +91-755-2588543
Web
Maximum Qty. of Stored at any one time
1.
Trichloroethylene
35 Ltr
2.
Steelex K-20
10 Kg
3.
Gin Bond 814
10 Kg
4.
Hydrochloric Acid Commercial Grade
120 Ltr
5.
Sulphuric Acid Commercial Grade
180 Ltr
6.
Nitric Acid Commercial Grade
90 Ltr
7.
Chromic Acid Commercial Grade
5 Kgs
8.
Zinthox 982 L Commercial Grade
4 Kg
9.
Tin Maintenance Brightener Commercial Grade
5 Kg
10.
Caustic Soda Commercial Grade
100 Kgs
11
Copper Salt
5 Kg
12
Nickel Salt
10 Kg
13
Zinc Salt
25 Kgs
14
Tin Salt
5 Kgs
15
Silver Salt
2 Kgs
RISK ASSESMENT
Basically Electroplating shop is not a continuous process plant. In our workshop we performed 2-3 types of
Electroplating in bath type of production. As and when required we processed the components called for
electroplating.
It is difficult to asses the risks clearly, any how we hereby giving some details of
circumstances where we found risks during operation.

1) During the manual handling of jobs to be electroplate in various operation like cleaning, washing
before hanging in plating baths and after plating, washing rinsing.
2) Acid Pickling When acid pickling process taken place the acid fumes comes out. These fumes
may cause the damage due to negligence of operator if not weared proper masks etc.
Page 11 of 12
FORWARD ENGINEERING
Tel.No. : +91-755-2588676, 2588543, 4076803
Fax
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3) Mechanical Equipments are not involved with importance in an electroplating work but
whatever equipment like cathode rod movement, Jigs etc. must be properly handle.
4) Electrical Equipments like Rectifier, Temp. Controller, Ampere hours meter are constantly
involved with electroplating solutions and risk of current leakage may be there.
Therefore we consider that the risk in electroplating shop occur due to improper house keeping, mishandling
of jobs, faulty storage of chemicals etc. but definitely not so dangerous to human being.
PREVENTIVE ARRANGEMENT
ARRANGEMENT MADE IN FACTORY
1.
In our Unit electroplating work shop is totally located in a separately constructed work shed.
2.
Since the work is of manual type and risks factors related to man power basically. We have
provided safety masks, rubber hand gloves and long gum boots to the workers doing plating
work.
3.
Bath room having flowing clean water is nearby the electroplating shop in case of any chemical
contacts to the workers.
4.
Chemicals like Acids, Plating solutions stored in a separately constructed store to avoid damages.
Proper drainage systems with drains attached with three big collection tanks to collect the
effluent water produced after plating work contain rinsing water acid alkali etc. This is to
provide proper neutralization of waste water in required manner.
5.
To avoid congestion of Acid fumes ventilation and exhaust fans installed in plating shop.
6.
We have made arrangements as per the required safety measures and implementation.
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Page 12 of 12
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FORWARD ENGINEERING

ENGINEERING INDUSTRIES (BHOPAL)

44, B.H.E.L. Ancillary Estate,

for Forward Engineering Industries.

SALIENT FEATURE OF FACTORY

2010-11/FORMAT/ONSITE EMERGENCY PLAN

44, B.H.E.L. Ancillary Estate,

ONSITE EMERGENCY PLAN & DETAILED DISASTER

2010-11/FORMAT/ONSITE EMERGENCY PLAN

44, B.H.E.L. Ancillary Estate,

OBJECTIVE OF EMERGENCY PLAN

Ensure rapid return to normal operation after emergency.

(g) Preserve relevant records and equipments.

2010-11/FORMAT/ONSITE EMERGENCY PLAN

44, B.H.E.L. Ancillary Estate,

A-38, A-Sector, BDA Colony,

III. Shri H.M. Sampat

IV. Shri C.M. Sampat

2010-11/FORMAT/ONSITE EMERGENCY PLAN

44, B.H.E.L. Ancillary Estate,

2010-11/FORMAT/ONSITE EMERGENCY PLAN

44, B.H.E.L. Ancillary Estate,

SIGNIFICANCE OF PLATING CHEMICALS LIKE ACIDS

Chemical for Pickling

2010-11/FORMAT/ONSITE EMERGENCY PLAN

44, B.H.E.L. Ancillary Estate,

2010-11/FORMAT/ONSITE EMERGENCY PLAN

44, B.H.E.L. Ancillary Estate,

LIKELY MAJOR EMERGENCIES HANDLING, STORAGE ETC.

Handling :- Emergencies may occur mainly during handling of plating chemicals.

Mechanical Equipment :- In the absence of proper guards/screens fitted with mechanical

Electrical Equipments :- In case of irregularities of Electrical Installation separate insulated

2010-11/FORMAT/ONSITE EMERGENCY PLAN

44, B.H.E.L. Ancillary Estate,

TYPE OF EMERGENCY AND ACTION TAKE

2010-11/FORMAT/ONSITE EMERGENCY PLAN

44, B.H.E.L. Ancillary Estate,

RESPONSIBILITIES SHARED AMONG EMPLOYEES

Mr. M.J. Sampat

Mr. H.M. Sampat

Mr. Vivek Sharma

Looking / Keep informed to outside authorities like police

OUT SIDE EMERGENCY SERVICES

Pul Bogda Fire Sub Station

Jay Prakash Hospital, 1250 Quarters.

3. Nearest Police Station

Govindpura (Bhopal) Police Station.

4. Nearest Electric Sub Station

2010-11/FORMAT/ONSITE EMERGENCY PLAN

Kasturba Nagar, Sub Station.

List of Hazardous Raw Materials

44, B.H.E.L. Ancillary Estate,

Maximum Qty. of Stored at any one time

Gin Bond 814

Hydrochloric Acid Commercial Grade

Sulphuric Acid Commercial Grade

Nitric Acid Commercial Grade

Chromic Acid Commercial Grade

Zinthox 982 L Commercial Grade

Tin Maintenance Brightener Commercial Grade

Caustic Soda Commercial Grade

circumstances where we found risks during operation.