EMERGENCY RESPONSE & DISASTER CONTROL

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EMERGENCY RESPONSE DISASTER CONTROL
By Asghar Naveed Safety Unit Manager. Haider I
Chaudhry Safety Engineer.
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Engro Fertilizers Limited

• Vision Statement
• To be the premier Pakistani enterprise with a
  global reach, passionately pursuing value
  creation for all stake holders.

Company Profile Engro Fertilizer Ltd. urea
manufacturing site is located at Daharki, 600 km
north of Karachi-Pakistan. The site produces
about 2850 MeT/day urea. Consumption of
fertilizers increased in Pakistan, paving the way
for the company called Engro, an acronym for
energy for growth.
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Background

• Engro Fertilizers Limited gives the highest
  importance to safe operations, safe work
  practices, and protection of the environment and
  the health of its employees in the conduct of its
  business.
• In an endeavor to keep it abreast with the World
  Class Safety Standards, Engro Fertilizers Limited
  has aligned safety management systems with Dupont

No Major Emergency Since 1968
Emergency Response Disaster Control
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What is Emergency Response ER
INPUTS
Design Consideration
Information Package
Consolidated ER Plan Manual
Emergency Handling
Activate ER Plan
Training Stewardship
Mutual Assistance
Community Awareness for Emergency Response
OUTCOME
Emergency Response Disaster Control
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Design Considerations
Inherently Safe Process Design
Layers ofProtection
PHA
CA
Management of Change Approval
PSSR

• Layers of Protection
• The current site has the gadgets and documented
  procedures which entails and governs all the
  existing reviews and new facilities.

Emergency Response Disaster Control
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Information Package

• Process Design Basis
• PIDs, PFDs, IE Diagrams
• Process description
• Standard operating guidelines conditions
• Maximum intended Inventories
• Data history references
• Revisions new process technologies

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• PSI (Process Safety Information) package for
  each operating unit

PSI Package
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• Equipment Design Basis
• Safety critical components
• Control of vendor manual

Hazards of Materials
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Consolidated ER Plan Manual
ER Structure

• Core Contents (ER Manual)
• Role statements.
• Assembly locations.
• Emergency Shutdown Procedures.
• Fire fighting Toxic Release handling
  techniques.
• Emergency Handling Techniques
• Rescue Plans (Medical Assistance, etc.)
• Layout of Emergency Safety Equipment
• Misc information (Population around, typical Wind
  reference diagram, etc.)
• Critical Equipments and latest communication
  devices

• Two-fold action plan.
• Written comprehensive emergency preparedness
  plan.
• Separate emergency plan for each hazard/threat,
  including plans for flood, sabotage war
  emergency etc.

Part I
Emergency Response Disaster Control
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EmergencyHandling
Community Emergency Response
Mutual Assistance
Communication Channel Detection, Declaration and
Communication
Surrounding Community
Government Public Authorities NDMA Media
CMT formed
Guides the Squad for rescue and containment
Communicates with the authorities and Gov agencies
Relevant Management
Area Unit Manager Safety Advisor Chief Medical
Advisor Security Incharge
PA Services Incharge
Security Guard (Colony)
Security Guard (Plant)

• Squad consists of 14 members
• Control and Containment of Leakage
• Fire Fighting
• Conduct Rescue Operation

Responds to Emergency
Disaster Occurs
Squad
Alerts
SS or SIC Sounds Alarm
Part II
Emergency Response Disaster Control
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Training Stewardship

• Training
• Training of employees for all possible
  emergencies
• Skill certification system
• Weekly Quarterly simulated exercises
• Involvement of ES, employees contract employees
  and community
• Skill certification of ES
• Emergency Shutdown procedure.

Emergency Response Disaster Control
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Mutual Assistance

• Survival Chances improve
• Pool knowledge, equipment personnel with
  neighbors.
• Procedures developed.

Emergency Response Disaster Control
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CAER

• CAER program has been prepared in conjunction
  with local community.
• Training/ coordination with community
• Involvement of local government functionaries
• Program structure compliments DuPont
• Benchmarked with TATA GNFC

Bridging Gaps
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Legend
Ariel View
Population
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• Developed by International Council of Chemical
  Association
• The goal is to assure emergency preparedness and
  to foster community right-to-know.
• It demands a commitment to openness and community
  dialogue. The code has two major components
• To initiate and maintain a community outreach
  program
• Assuring that each facility has an emergency
  response program
• A socio economic survey was done in 2007 to
  ascertain social economic needs of locals. 11
  villages (in 2 km radius) covered.

Villages
Emergency Response Disaster Control
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Community Engagement Model
Phase I
Phase III
Community Awareness Emergency Response 2010
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Current Population ready to be engaged in the
Quarterly Drills.
CAER Timeline
Kalo Burero
Kalo Burero
Community needs Hospital, Water supply, Gas,
Drainage, Vocational Institute.

• Nov, 2009
• Thursday Drill Exercise observed by Social
  Workers of Kalo Burero.
• First Aid CPR Training was conducted for Kalo
  Burero social workers at EFert.
• Gadgets for emergency communication in villages
  approved order placed at Kalo Burero

Feb, 2009 Infrastructure Development (drains,
bricks soling) adoption of boys school.

• Aug, 2009
• Emergency Organization Table developed.
  Assignments given Leader, Deputy Leader Street
  Social Workers assigned at Kalo Burero.
• First Aid Fire Fighting Trainings for
  volunteering Social Workers of Kalo Burero.

May, 2008 Engro Visit Boys and Girls from Kalo
Burero Schools .
Oct, 2008 Quiz Competition Kalo Burero Boys
School.
Nov, 2008 Quiz Competition Kalo Burero Girls
School.
TA 09 (Apr) People trained appointed as Safety
Facilitator and Scaffolding Inspector
Nov, 2007 Lunch for Kalo Burero at Manufacturing
Division Canteen.
Community Awareness Emergency Response 2010
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1st National Mock DrillConducted by EFERT NDMA

• Working and coaching the nearby populations for
  more than two years has led us to a position
  where we involved the local and nation-wide
  authorities and Engro along with NDMA (National
  disaster management authority) conducted the
  first ever Mock Emergency Drill earlier this
  year.
• Preparedness level of nearby village in a large
  scale Mock Exercise in which ammonia leakage and
  fire at the manufacturing facility was simulated.
  
• Participation by DDMA, DESTO and Urban Search
  Rescue Team.
• Outcomes of the drill Consolidation of ER Plans
  of nearby Industries located at the Fertilizer
  Belt in Sindh.

Emergency Response Disaster Control
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VIDEO ndma.video

• Duration 05 min