On-site Emergency Preparedness

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On-site Emergency Preparedness National Workshop
on Disaster Management 24-26 Sept 08 at
Secunderabad, A.P. A.Y. Sundkar NATIONAL SAFETY
COUNCIL
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FEW MAJOR DISASTERS IN WORLD
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EXPLOSION
 
 
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TOXIC RELEASE
 
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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 Protection
Mitigation system responses
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Chemical Accidents in India (2002-06)
Product loss of Rs.11.5 crore
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Chemical Accidents in India (2002-06)
Impact
Source
Date
Industry
Sl.No.
Injury
Death
-
-
Benzene fire
12.04.04
Shyamlal Industries, Vatva, Ahmedabad
10.
27
-
Chlorine leak
18.7.04
Chemplast, Metture, TN
11.
8
1
Hexane release fire
31.5.04
Chemical Factory, Dombivilli, Maharashtra
12.
13
2
Explosion in slurry settler
29.10.04
Gujrat Refinery, Vadodara
13.
2
1
Fire in Dryer room
30.10.04
Ranbaxy Laboratories Ltd., Mohali, Punjab
14.
-
1
Explosion
23.11.04
Kekule Pharma Ltd.
15.
20
-
Chlorine release
1.12.04
PWD premises
16.
-
-
Fire
15.6.05
Gujrat Refinery
17.
5
-
Ammonia
22.7.05
Coromondal Fertiliser, Ltd., Ennore
18.
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Chemical Accidents in India (2002-06)
Impact
Source
Date
Industry
Sl.No.
Injury
Death
2
2
Explosion/ Fire
Gulf Oil Corporation Ltd., Hyderabad
19.
4.10.05
Orchid Chemicals pharmaceuticals Ltd, TN
4
1
Explosion
3.11.05
20.
-
1
Fire
29.12.05
IOCL, Mathura
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23
6
Cl release
29.3.06
Kanoria Chemicals Industries Ltd , UP
22
-
5
Spillage of haz chemical
18.07.06
Anjana Explosives Ltd, AP
23
-
1
Gas Release
19.9.06
Ravi Organics Ltd , UP.
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2
Fire
25.10.06
RIL, Jamnagar
25
-
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• 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
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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
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• Disaster Management means a continuous and
  integrated process of planning, organising,
  coordinating and implementing measures which are
  necessary or expedient for
• Prevention of danger or threat of any disaster
• Mitigation or reduction of risk of any disaster
  or its severity or consequences
• Capacity building
• Preparedness to deal with any disaster
• Prompt response to any threatening disaster
  situation or disaster
• Assessing the severity or magnitude of effects
  of any disaster
• Evacuation, rescue and relief
• Rehabilitation and reconstruction

The DM Act, 2005
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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
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• 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
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EMERGENCY PLANS

• 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

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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

The Plan should be kept simple and flexible,
but capable of being scaled up or down as
circumstances demand
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EMERGENCY PLANNING STATUTORY FRAME-WORK
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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

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MSIHC Rules, 1989

• MAH Installations Threshold Quantity
• Industrial Activity at a Site Handling Hazardous
  Chemicals and Isolated Storage Equal to or in
  Excess of Threshold Quantities.-Schedules-23
  column 3
• Unit Isolated Storage
• AMMONIA 50 T 60 T
• LPG 15 T 50 T
• CHLORINE 10 T 10 T

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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.

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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.

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ELEMENTS OF ON-SITE EMERGENCY PLAN (Based on
APELL Model)
APELL A Process for responding to
Technological Accidents - Developed by
UNEP in 1986 - Implemented in India in 1992 in
six-high risk Industrial Areas
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• 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

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• 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

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• 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

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• 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

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• 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)

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• 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

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7. Procedure for Returning to Normal
Operations ? Authorisation ? Declaration
of the end of emergency ? Communication of
the Declaration of end of
emergency
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• 8. Training and Drills
• Training of Team Leadres
• Training of Emergency Responders
• Emergency Drill
• - Frequency and Responsibility
• (MSIHC 6 months)

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• 9. Regular Tests of Emergency Organization/Proce
  dures
• Simulated emergencies
• Documented, frequent alarm system
• Frequent tests of fire fighting equipment
• Evacuation practice
• On-going emergency preparedness committee

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• 10. Plan Updates
• Annual or more frequent if needed
• Reflect results of drills and tests
• Review of the Plan
• Responsibility for updating the Plan

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• 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

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• 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

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• 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.

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• 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.

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• 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.

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THANK YOU
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ORGANISATION CHART
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Cinema Hall
Hospital
Facility where Accident Take Place
School
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OISD Standard 117 Fire Protection Facilities
for Petroleum Depots, Terminals and Pipeline
Installations

• Alarm/communication System
• Electrical/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.

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• Ref
• Factories Act, 1948
• MSIHC Rule, 1986
• CA(EPPR) Rules, 1996
• PLI Act
• Major Hazard Control A Practical Manual by ILO
• Hazardous Material Emergency Planning Guide by
  National Response Team, USA

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GAPS OBSERVED IN THE ON-SITE EMERGENCY PLANS
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• 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

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• Introduction Contd.
• Scrutinised on-site Emergency plans of MAH Units
  by a team of NSC Officers and experts
• Tuticorin - 13 Plans
• Haldia - 16 Plans
• For scrutinising the OEPs checklist developed

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• 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

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• Gaps observed in OEPs
• 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

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• 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.)

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• Gaps observed in OEPs contd.
• 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

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• Gaps observed in OEPs contd.
• Assessment of the resources by the Plant
  Management
• 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

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• Gaps observed in OEPs contd.
• Training
• Types vis-à-vis level of participation, frequency
  of training

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• Gaps observed in OEPs
• 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

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• Gaps observed in OEPs
• 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

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• Gaps observed in OEPs
• 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

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• Gaps observed in OEPs contd.
• General
• Pages not numbered
• Absence of contents page
• Some cases the content does not match with the
  matter in the plan