On-site Emergency Preparedness National Workshop on Disaster Management 24-26 Sept 08 at...

On-site Emergency Preparedness

National Workshop on Disaster Management

24-26 Sept 08 at Secunderabad, A.P.

A.Y. Sundkar

NATIONAL SAFETY COUNCIL

Sl.No

Name of Chemical Involved

Death Injury Place & Year

1 Methane 136 77 Cleveland, Ohio, USA 1944

2 LPG (BLEVE) 18 90 Feyzin, France, 1966

3 LNG 40 - Staten Island, New York, 1973

4 Methane 52 - Mexico, 1985

FEW MAJOR DISASTERS IN WORLD

EXPLOSION

Sl.No


Death

Injury Place & Year

1 Dimethylether 245 3800 Germany, 1948

2 Kerosene 32 16 Germany, 1954

3 Cyclohaxane 28 89 Flixborough, UK, 1974

4 Propylene 14 107 Beek, Netherlands, 1975

4

TOXIC RELEASE

Slno


Death

Injury Place & Year

1 Phosgene 10 - Poza Rica, Mexico, 1950

2 Chlorine 7 - Germany, 1952

3 Ammonia 30 25 Colombia, 1977

4 Methyl Isocyanite

2500 250000

Bhopal, India, 1984

Off-site Emergency Plan

On-site Emergency Plan

Physical Protection (Dikes)

Physical Protection (Relief Devices)Automatic Action (Sprinkler, etc.)Critical Alarms, Operator Supervision, Manual Intervention

Basic Controls, Process Alarms, Operator Supervision

Typical Layers of ProtectionMitigation system responses

Chemical Accidents in India (2002-06)

26Fire in LPG fired oven

28.10.04Anil Enterprises, Zakhira, Rohtak

8.

58Explosion 25.11.03IDL Gulf Oil,

Kukkatpally, Hyderabad

7.

192Toluene 11.6.03Ranbaxy Lab Ltd., Mohali, Punjab

4.

--LPG leak - Tank lorry

5.10.03BPCL Bottling Plant, Dhar

5.

88-Liquid Chlorine

13.10.03Orient Paper Mills, Amla, Shahdol, MP

6.

--Toluene fire 6.7.04HIL Udyogmandal, Kerala

9.

--Fire in Motor spirit Tank

7.3.03IOC Refineries, Digboi3.

18 W

(300 vill)

-Chlorine Release

20.12.02IPCL, Gandhar 2.

204Chlorine Gas 5.9 02 GACL, Vadodara 1.

InjuryDeath

ImpactSourceDateIndustrySl.No.

Product loss of Rs.11.5 crore


--Fire 15.6.05Gujrat Refinery 17.

20-Chlorine release

1.12.04PWD premises 16.

132Explosion in slurry settler

29.10.04Gujrat Refinery, Vadodara

13.

21Fire in Dryer room

30.10.04Ranbaxy Laboratories Ltd., Mohali, Punjab

14.

-1Explosion 23.11.04Kekule Pharma Ltd. 15.

5-Ammonia 22.7.05Coromondal Fertiliser, Ltd., Ennore

18.

81Hexane release & fire

31.5.04Chemical Factory, Dombivilli, Maharashtra

12.

27-Chlorine leak 18.7.04Chemplast, Metture, TN 11.

--Benzene fire 12.04.04Shyamlal Industries, Vatva, Ahmedabad

10.

InjuryDeath



2Fire 25.10.06RIL, Jamnagar25

236Cl release 29.3.06Kanoria Chemicals & Industries Ltd , UP

22

-5Spillage of haz chemical

18.07.06Anjana Explosives Ltd, AP

23

-1Gas Release19.9.06Ravi Organics Ltd , UP. 24

-1Fire 29.12.05IOCL, Mathura21

41Explosion 3.11.05Orchid Chemicals & pharmaceuticals Ltd, TN20.

22Explosion/ Fire

4.10.05 Gulf Oil Corporation Ltd., Hyderabad

19.

InjuryDeath


-

EMERGENCY …

“A situation created by an accidental release or spill of hazardous chemicals which poses a threat to the safety of workers, residents, the environment or property”

MSIHC Guidelines by MoEF, 1996

EMERGENCY PLAN …

“A formal written plan which, on the basis of

identified potential accidents together with

their consequences, describes how such

accidents and their consequences should be

handled, either on-site or off-site”

Guiding Principles: Chemical Accident Prevention Manual, OECD, 2003

Disaster Management …

means a continuous and integrated process of planning, organising, coordinating and implementing measures which are necessary or expedient for:

i) Prevention of danger or threat of any disaster;

ii) Mitigation or reduction of risk of any disaster or its severity or

consequences;

iii) Capacity building;

iv) Preparedness to deal with any disaster;

v) Prompt response to any threatening disaster situation or

disaster;

vi) Assessing the severity or magnitude of effects of any disaster;

vii) Evacuation, rescue and relief;

viii) Rehabilitation and reconstruction

The DM Act, 2005

EMERGENCY may caused by

1. Process and Safety System failure

- Technical Errors (Design defects, fatigue, metal failure, corrosion, etc.)

- Human Errors (neglecting safety instructions, deviating from specified procedure, etc.)

2. Natural Calamity

3. Sabotage/Terrorist Attack

Emergency normally manifest in three basic forms

• Fire

• Explosion or

• Toxic

Emergencies with chemical industry concern are :

1. Plant Emergency (On-site) Off-site Emergency

2. Transport Emergency

• To mitigate effects of Emergency requires –

- Thoughtful Planning

- Better Preparedness

- Quicker Response

• Emergency Planning not substitute for maintenance of good safety systems, procedures

and practices

• Accident Prevention through good design, operation, maintenance and inspection

EMERGENCY PLANS

• Emergency Planning is an important element of mitigation

• On-site & Off-site emergencies are separate but are to be consistent

• Transport Emergency requires different treatment

EMERGENCY PLANS

The Plan should be kept simple and flexible, but capable of being scaled up or down as circumstances demand

EMERGENCY PLANNING

STATUTORY FRAME-WORK

FACTORIES ACT, 1948 Section 41 A to H – Hazardous Processes

Section - 41 B (4)

• Occupier to draw up an On-Site Emergency Plan & Disaster Control Measures for his factory

• Make safety measures to be taken in the event of an accident known to-

- Workers

- Public in the Vicinity

• MAH Installations – Threshold Quantity

• Industrial Activity at a Site Handling Hazardous Chemicals and Isolated Storage Equal to or in Excess of Threshold Quantities.-Schedules-2&3 column 3

Unit Isolated Storage AMMONIA : 50 T 60 T LPG : 15 T 50 T CHLORINE : 10 T 10 T

MSIHC Rules, 1989

MANUFACTURE, STORAGE AND IMPORT OF HAZARDOUSCHEMICALS,

RULES,1989 (MSIHC RULES) 13. PREPARATION OF ON-SITE EMERGENCY

PLAN BY THE OCCUPIER (1) Occupier to prepare and keep up-to- date an On-Site Emergency Plan with specified details (Schedule11) detailing– - dealing with major accidents on site

- name of the Person responsible for Safety on site - names of authorised persons to take actions as per the Plan in case of an

Emergency.

MANUFACTURE, STORAGE AND IMPORT OF HAZARDOUSCHEMICALS,

RULES,1989 (MSIHC RULES)

(2) The Occupier to ensure that the On-Site Plan includes modifications and all persons on site affected by the Plan are informed accordingly.

(4) The Occupier to ensure to conduct a mock drill of the On-Site Emergency Plan every 6

months.

(5) Detailed report of mock drill to be made immediately available to the authority.

APELL – A Process for responding to Technological Accidents

- Developed by UNEP in 1986

- Implemented in India in 1992 in six-high risk Industrial Areas

1. Introduction

• Legal Requirement

• Basis of the Plan

• Purpose and objective

• About Factory – location; name & address of the person furnishing the information, no. of people and brief process description

2. Plant Emergency Organization

• Designated person in-charge/alternates

- SC, IC, Leader of communication, Fire & Rescue, Medical, Security, Logistics

• Functions of each key individual and group

• Telephone numbers (office and home) for key people/alternates

• Emergency Control Centre /alternate (ERC)

• Assembly Points

3. Plant Risk Evaluation • Quantity of hazardous materials • Location of hazardous materials (on Factory Layout)

• Properties of each (MSDS sheets)

• Likely Dangers to the Plant – Emergency Scenario (s) summary location-wise

• Location of isolation valves • Special fire fighting procedures (if any)

• Special handling requirements

4. Area Risk Evaluation

• Properties of hazardous materials at nearby plants

• Nearby residence and population centre

• Contacts (names, telephone numbers) at other sites.

• Established procedures for notification of chemical releases at other sites in area

• Natural Calamities which can lead to emergency – Flood, Cyclone, Earthquake

5. Notification Procedures & Communications Systems

● Declaration of Emergency

● Communication System • Alarm Systems

• Communication equipment (radios, hot lines, etc.)• Designated person for media contacts• Procedure for notifying families of injured

employees• Central reporting Office (ERC)

6. Emergency Equipment and Facilities

• Fire fighting equipment • Emergency medical supplies• Toxic gas detectors (where needed)• Wind direction/speed indicators• Self-contained breathing apparatus• Protective clothing• Other on-site equipment to be specified

according to local conditions• Containment capabilities

7. Procedure for Returning to Normal Operations

● Authorisation

● Declaration of the end of emergency

● Communication of the Declaration of end of emergency

8. Training and Drills

• Training of Team Leadres• Training of Emergency Responders• Emergency Drill

- Frequency and Responsibility (MSIHC – 6 months)

9. Regular Tests of Emergency Organization/Procedures

• Simulated emergencies

• Documented, frequent alarm system

• Frequent tests of fire fighting equipment

• Evacuation practice

• On-going emergency preparedness

committee

10. Plan Updates

• Annual or more frequent if needed

• Reflect results of drills and tests

• Review of the Plan

• Responsibility for updating the Plan

11. Emergency Response Procedures

• Communications• Evacuation or safe haven• Medical (include handling of multiple injuries)• Special procedures for toxic gas releases

(chlorine, etc.)• Hurricane procedures (coastal areas only)• Utility failure procedures• Individual unit emergency procedures• Bomb threat procedures

12. Detailed Operating Manuals(for each process unit and utility system)

• Start-up / Shut-down emergency procedures

• Analysis of potential incidents

• Emergency response and action to be taken

for each incident

On-Site Emergency Plan – Separate Section

“Information for use in the Off-Site Emergency Plan” which may include :

• Summary of Risk Analysis, vulnerability zone for those scenarios which can escalate into off-site emergencies.

• List of resources required to handle the off-site emergencies foreseen in the On-site Plan, their assessment of the adequacy.

• If own resources (such as equipment, trained man-power, medical help, etc.) are not adequate to meet such off-site emergencies, what is the arrangement (formal or informal) made to get the additional resources (e.g. Mutual Aid or arrangement with the Public Response Agencies) mentioning the salient terms of such arrangements.

Contents of the separate section contd…

• What resources can be spared by the industrial unit for use in the Off-site Emergency arising out of on-site emergencies of other units and what is the arrangement for releasing such resources.

• How Community awareness programme has been planned? How the community has been identified (from which zone-part or full vulnerability zone)? Have the key opinion makers who can play active role have been identified? (Give list alongwith their contact details). Has the selection of the community or that of key persons in the community been done in consultation with the District Authority? etc.

Contents of the separate section contd…

• Has Insurance under the Public Liability Insurance Act been

obtained? Give summary.

• Designate a Contact person who would be authorised to co-

ordinate for Off-site Plan and his contact details

• Technical Team (chemical-wise) in case of an Off-site

Emergency taken place due to escalation of an On-site

incident, contact details of its members.

THANK YOUTHANK YOU

Works Main Controller (WMC)

Security Gate No.2 orSecurity Gate No.4

Support Team to WMC

Logistics TeamLeader -

Traffic Control Team

Leader -

Incident Controller

Communication TeamLeader (Head – ER&D)

Area In-charges of the Affected Areas

Medical TeamLeader -

Plant Control and Shut Down Team Fire & Rescue Team

Leader -

Corporate Office at”

ORGANISATION CHART

Facility where Accident Take Place

Hospital

Cinema Hall

School

OISD Standard – 117 Fire Protection Facilities for Petroleum Depots,

Terminals and Pipeline Installations

• Alarm/communication SystemElectrical/hand operated Fire Siren with code

1. Small Fire - No Siren

2. Major Fire - A wailing siren for 2 min. ( 3 times for 30 sec with an interval of 15 sec in

between

3. Disaster - Same as above but interval of 2 min

4. All Clear - Straight run for 2 min.

5. Test - Straight run for 2 min.

Ref :

1. Factories Act, 1948

2. MSIHC Rule, 1986

3. CA(EPPR) Rules, 1996

4. PLI Act

5. Major Hazard Control – A Practical Manual by ILO

6. Hazardous Material Emergency Planning Guide by National Response Team, USA

GAPS OBSERVED IN THE

ON-SITE EMERGENCY PLANS

Introduction

• Developed Off-site Emergency Plans

- Tuticorin- Haldia

• On-site emergency if uncontrolled become off-site emergency

• Better on-site preparedness and therefore planning can avert off-site emergency.

• For preparation of Off-site Emergency Plan, On-site Emergency Plans (OEP) is the basis as there is close relation between them.

• Decided to scrutinise on-site plans

Introduction Contd.

• Scrutinised on-site Emergency plans of MAH Units by a team of NSC Officers and experts

Tuticorin - 13 PlansHaldia - 16 Plans

• For scrutinising the OEPs checklist developed

• Gaps observed in OEPs

• In Plant Emergency Organization following were missing

- Alternative member to Designated persons

- Functions of key individuals/groups

- 24 hrs. telephone numbers for key persons and their

alternates

- Emergency Control Room facility


• Plant Risk Evaluation• Absence of information on:

– quantity, type of storages and locations of hazardous

materials

– characteristics, dangers, toxicological data and emergency

response of Hazardous Chemicals.

– Location of isolation valves

– Special fire fighting procedures (if any)

– Identification/ description of representative scenarios

– Development of the scenarios on real time basis

– Marking of Vulnerability Zone on layout plan including those

which may escalate into Off-site emergences

Gaps observed in OEPs contd….

Area Risk Evaluation

Emergency Scenario

- Consequences of accidents in neighbouring plants creating on-site/off-site emergency as a part of Area Risk Evaluation

- Consideration of Natural calamites triggering on-site emergencies

- Security arrangements to combat threats (sabotage, terrorist attack, etc.)


• Notification Procedures and Communication System

Absence of information on:

- Communication equipment (hot lines, Walky-Talky, etc.)

- Neighbouring industry

- Nearby residents

- Designated person for media contacts

- Procedure for notifying families of injured


• Assessment of the resources by the Plant Management

i) Absence of information about Trained Manpower (Technical, Medical & Fire fighters)

ii) Emergency Equipment and Facilities:• Fire fighting equipment • Emergency medical supplies• Toxic gas detectors (where needed)• Wind direction/ indicators• Self-contained breathing apparatus• Protective clothing

iii) Arrangement with organizations (formal or informal) for additional resources required to handle the emergencies

• Gaps observed in OEPs contd….

• Training

– Types vis-à-vis level of participation, frequency of training


• Regular tests of emergency organization/ procedures – Information not available

– Types vis-à-vis target groups, frequency, documentation, methodology of Drills

– Simulated emergencies

– Testing and Documentation of alarm system

– Frequent tests of fire fighting equipment

– Evacuation practice


• Plan Updates

In general there is no coverage of plan updates. In specific :

– Frequency

– Reflect results of drills and tests

– History Sheets giving details of updates/revisions including date of Preparation of the Plan

– Responsibility on a person to update the Plan


• Emergency Response Procedures• • Not mention about

– Medical response procedure for handling multiple injuries

– Procedure for arrangement in case of utility failure

– Bomb threat procedures

– Location of Assembly Points and marking on the Layout Plan

– Escape routes


General• Pages not numbered

• Absence of contents page

• Some cases the content does not match with the matter in the plan

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