The Director of Factories, Telangana has issued Circular FACT-MAH/OHS/5/2026 under the OSH Code 2020 — requiring all High Risk Factories handling combustible dusts and hazardous processes to complete mandatory safety studies. Non-compliance risks plant shutdown, prosecution and personal liability.
📄 View Official Government Circular →
All High Risk Factories handling combustible dusts, hazardous processes and dangerous operations in Telangana must comply immediately. Issued by: Mohan Babu Yaralagadda, Director of Factories, Telangana.
Applies to all factories classified as High Risk under the OSH Code 2020 handling any of the following:
MCC, cellulose, starch, sugar, aluminium powder and similar materials that can form explosive dust clouds
Any process involving flammable, reactive or toxic materials that can cause fire, explosion or chemical release
Operations classified as dangerous under Schedule II of the Factories Act including drying, pulverising, blending of combustible materials
Pharmaceutical, Chemical processing, Food & Starch, Agrochemical, FMCG and allied manufacturing industries in Telangana
Get a free 30-minute expert review — we confirm applicability, identify mandatory studies, and outline your compliance path.
All requirements are mandatory under Section 6 of the OSH Code 2020. Sigma-HSE delivers every one of these end-to-end.
From DHA and HAC to HAZOP, QRA, Fire Adequacy Study, Safety Audits and Training — one partner for full compliance.
Mapped to the 9 mandatory sections of Circular FACT-MAH/OHS/5/2026
| Service / Study Required | Pharma | Chemical | Allied |
|---|---|---|---|
| ▪ Section 1 & 2 — Hazard Studies & Dust Testing | |||
| A. Dust Hazard Analysis (DHA)Mandatory — updated every 3 years per the circular | ✓ Mandatory | ✓ Mandatory | ⚠ Review |
| B. Hazardous Area Classification (HAC)All electrical equipment in dust atmospheres must be flameproof | ✓ Mandatory | ✓ Mandatory | ⚠ Review |
| C. Dust Testing — MIE, MIT, LOC, MECCircular explicitly requires MIE, MITL, MITC, LOC, MEC for all materials | ✓ Mandatory | ✓ Mandatory | ⚠ Review |
| D. QRA — Quantitative Risk AssessmentOn-Site Emergency Plan must be based on QRA (Section 8a) | ✓ Mandatory | ✓ Mandatory | ⚠ Review |
| ATEX & Explosion Risk AssessmentFlameproof/explosion-proof equipment in dust atmospheres (Section 2a) | ✓ Mandatory | ✓ Mandatory | — N/A |
| EERA — Escape, Evacuation & Rescue AnalysisEscape routes at strategic locations (Section 8f) | ✓ Mandatory | ✓ Mandatory | ⚠ Review |
| Risk AssessmentReviewed annually per Section 7c | ✓ Mandatory | ✓ Mandatory | ✓ Mandatory |
| Fire Adequacy StudyFire detection, alarm, sprinklers and firefighting equipment (Section 8c, 8e) | ✓ Mandatory | ✓ Mandatory | ⚠ Review |
| ▪ Section 7 — Audits, Documentation & Reviews | |||
| HAZOP / HAZID StudyMandatory for all critical operations (Section 7b) and Management of Change (Section 9f) | ✓ Mandatory | ✓ Mandatory | ⚠ Review |
| Annual Process Safety AuditThird-party safety audit per MSIHC Rules (Section 7a) | ✓ Mandatory | ✓ Mandatory | ✓ Mandatory |
| SOP PreparationStandard Safe Operating Procedures for all operations (Section 7e) | ✓ Mandatory | ✓ Mandatory | ✓ Mandatory |
| Job Safety Analysis (JSA)Required to identify hazards and risks (Section 7f) | ✓ Mandatory | ✓ Mandatory | ✓ Mandatory |
| On-Site Emergency Plan (OSEP)Based on QRA, with mock drills every 6 months (Section 8a, 8b) | ✓ Mandatory | ✓ Mandatory | ✓ Mandatory |
| PSSR — Pre-Startup Safety ReviewStartup/shutdown operations per standard safety protocols (Section 9g) | ✓ Mandatory | ✓ Mandatory | ⚠ Review |
| Incident InvestigationNear miss and incident analysis mandatory (Section 9a) | ✓ Mandatory | ✓ Mandatory | ✓ Mandatory |
| ▪ Section 6 — Training & Competency | |||
| Safety Induction TrainingMandatory before deployment for all workers (Section 6b) | ✓ Mandatory | ✓ Mandatory | ✓ Mandatory |
| Fire Safety TrainingInternal fire & rescue team trained shift-wise (Section 8d) | ✓ Mandatory | ✓ Mandatory | ✓ Mandatory |
Sigma-HSE has delivered process safety services across 300+ companies in India — including major Telangana Pharma and Chemical plants.
Over 200 completed studies covering Hazardous Area Classification, Dust Hazard Analysis, ATEX Assessment and Electrostatic Hazard Analysis across Pharma, Chemical, Food and allied sectors.
Full combustibility profiling for 300+ companies including MIE, MIT, LIT, Kst & Pmax, MEC, LOC — exactly the parameters named in the Telangana circular. The only parameters that can reliably size explosion protection.
100+ HAZOP and full PHA suite studies completed for Indian process industry clients — including QRA, SIL, LOPA and emergency relief sizing for chemical and pharma plants.
Get a detailed, facility-specific compliance plan — free of charge. Includes timeline, study sequence and cost estimate.
We cover every section of the circular — from the first site assessment to regulator-ready report submission.
We run the exact tests named in the circular — MIE, MIT (MITL & MITC), LOC, MEC, Kst & Pmax — in our ISO-accredited laboratory. Our test data is accepted by regulators and forms the foundation of all explosion protection design.
View Testing Services →Our specialists conduct full Dust Hazard Analysis and HAC zone studies aligned with the circular's requirements. Reports include material classification, area drawings, equipment recommendations, and explosion protection strategies.
View DHA Service →Our PHA team runs HAZOP, HAZID, QRA and EERA studies for all critical operations as required by Section 7b and 8a of the circular. Full documentation formatted for MSIHC Rule compliance and Factories Dept. submission.
View HAZOP Service →Third-party safety audits per MSIHC Rules, SOP preparation, JSA, PSSR and incident investigation — all delivered in regulator-ready format. Section 7 of the circular is fully covered by our audit team.
View Audit Service →We develop QRA-based On-Site Emergency Plans, fire adequacy studies covering detection, alarm, suppression systems, and conduct mock drill facilitation — directly meeting Section 8 of the circular.
View Fire Safety →Safety induction programmes, hazardous process worker training, annual refresher courses, fire warden certification and mock drills — delivered on-site at your Telangana facility as required by Sections 6 and 8d.
View Training →All sectors that handle combustible dusts or hazardous processes in Telangana
Sigma-HSE's DHA and HAZOP team identified critical gaps we had completely overlooked internally. Their structured approach — from dust testing through to hazardous area classification and emergency planning — got us fully compliant well ahead of the regulatory deadline, with zero disruption to our production schedule. Their reports were accepted by the Factories Department without a single revision request.
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Talk to Our Experts TodayBook a free 30-minute expert call. We review your facility, map every mandatory requirement, and give you a clear timeline and cost estimate — no obligation.
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