EMERGENCY RESPONSE & DISASTER CONTROL

ByAsghar Naveed;

Safety Unit Manager.

Haider I Chaudhry;Safety Engineer.

Engro Fertilizers LimitedVision 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”.

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

Emergency Response & Disaster Control

No Major Emergency

Since 1968

What is Emergency Response [ER]

Design Consideration

Information Package

Mutual Assistance

Community Awareness for Emergency Response

Consolidated ER Plan &

Manual Activate ER Plan

INPUTS

OUTCOME

Emergency Response & Disaster Control

EmergencyHandling

Training & Stewardship

Design Considerations

Emergency Response & Disaster Control

Layers ofProtection

Layers of ProtectionThe current site has the gadgets

and documented procedures which entails and governs all the existing reviews and new

facilities.

Inherently Safe

Process Design

PHA

CA

Management of Change

Approval

PSSR

Process Design Basis:

• P&IDs, PFDs, I&E Diagrams;• Process description;• Standard operating guidelines &

conditions;• Maximum intended Inventories;• Data history & references;• Revisions & new process

technologies

Information Package

PSI (Process Safety Information) package for each operating unit

Equipment Design Basis:

• Safety critical components• Control of vendor manual

PSI Package

Hazards of Materials:

1

2

3

• Two-fold action plan.• Written comprehensive

emergency preparedness plan.• Separate emergency plan for

each hazard/threat, including plans for flood, sabotage & war emergency etc.

ER Structure

Emergency Response & Disaster Control

Consolidated ER Plan & Manual

Core Contents (ER Manual)

Role statements.Assembly locations.Emergency Shutdown Procedures.Fire fighting & Toxic Release handling techniques.Emergency Handling TechniquesRescue Plans (Medical Assistance, etc.)Layout of Emergency & Safety EquipmentMisc information (Population around, typical Wind reference diagram, etc.)Critical Equipments and latest communication devices;

Part I

EmergencyHandling

Disaster Occurs

SS or SIC & Sounds

Alarm

Squad

Security Guard (Plant)

Area Unit ManagerSafety Advisor

Chief Medical AdvisorSecurity Incharge

Security Guard (Colony)

Responds to Emergency

General Manager

U Senior VP & CEOU

Production Manager

Alerts

Relevant Management

PA & Services Incharge

Surrounding Community

Government & Public Authorities

NDMAMedia

Community Emergency Response

Mutual Assistance

CMT formed

Guides the Squad for rescue and containment & Communicates with the

authorities and Gov agencies

Squad consists of 14 members• Control and Containment of Leakage

• Fire Fighting• Conduct Rescue Operation

Communication Channel Detection, Declaration and Communication

Part II

Emergency Response & Disaster Control

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.

Training & Stewardship

Emergency Response & Disaster Control

Mutual Assistance

• Survival Chances improve

• Pool knowledge, equipment & personnel with neighbors.

• Procedures developed.

Emergency Response & Disaster Control

• 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

Emergency Response & Disaster Control

Bridging Gaps

CAER

Kalo Burero

Bago Bhutto

Kotla Mirza

Ariel View

Population

Area (Covered by this Program)

HighwayMetalled Road

Jeepable Track/ TrailRailway Line

Taluka BoundaryCanals

SettlementGraveyard

Settlement Within 2 km of Facility

Settlement Outside 2 km of Facility

Legend

Emergency Response & Disaster Control

Emergency Response & Disaster Control

Bago BhuttoKotla MirzaJhando BughioJan Mohammad BughioKalo BureroJhungSajan MalikShahnawaz BureroNathu BhuttoNur Hassan ShahVi

llage

s

• 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.

• Visit Village community• Identify notables• Invite notable to dinner at

Plant Canteen• Identify & shortlist social

projects for village• Plant visit by boy school

students & teachers• Plant visit by girls school

students & teachers• Quiz competitions of boys/girls

school on Fire, Traffic (Engro will develop/ provide the quiz

• Identify social workers (volunteers) for Civil Defense.

• Conduct training on (First Aid, Fire fighting, Home safety, electrical safety) of social workers with help of Civil Defense & Engro.

• Initiate infrastructure improvement/ social projects, schools up lifts (through school adoption program), mosques, drinking water, sewage system.

• Career Counseling Workshops• Develop organization of social workers.• Quiz competitions in boys/girls school

First Aid, Fire, Traffic.• Involve Agri business to help the

agricultures.

• Conduct Fire drills.• Lectures in schools on First Aid

training/ environmental awareness.

• Complementation of social projects

• Grant scholarships to students• Invite notable to dinner at Plant

Canteen.• Community Engagement thru

Volunteers with quarterly drill.

Phas

e II

Community Engagement ModelPh

ase

I

Phas

e III

Community Awareness & Emergency Response 2010

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.

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

CurrentPopulation ready to be engaged in the Quarterly Drills.

2008

2010

2009

Nov, 2007Lunch for Kalo Burero at Manufacturing Division Canteen.

May, 2008Engro Visit Boys and Girls from Kalo Burero Schools .

Oct, 2008Quiz Competition Kalo Burero Boys School.

Nov, 2008Quiz Competition Kalo Burero Girls School.

TA ’09(Apr)People trained & appointed as Safety Facilitator and Scaffolding Inspector

Kalo Burero Population 1500

Source of Income•Agriculture

•Services•Others

% age

Literacy Rate•Male

•Female

% age

Access to Media (TV) 60%

Schools Boys & Girls Primary School

100%

100%

Community needs: Hospital, Water supply, Gas, Drainage, Vocational Institute.

Kalo Burero

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

Community Awareness & Emergency Response 2010

CAER Timeline

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

VIDEO: ndma.videoDuration: 05 min