emergency response preparedness program
TRANSCRIPT
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EMERGENCY RESPONSE AND PREPAREDNESSPROGRAM
Document Title
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Rev No. Start Date Doc No. Page
REVISION HISTORY
Ref. No.Doc.
Rev. No.Page No.Affected
Originator Date Details of Changes
N/A 00 N/A NB Sadongdong 12/02/2010 originate
IMPORTANT:THIS COVER SHEET FORM IS PART OF THE FOLLOWING DOC SHEETS AND IS NOTTO BE DISCARDED UNLESS SUPERCEDED BY A REVISED ISSUE. UNAUTHORIZEDREPRODUCTION IS STRICTLY PROHIBITED.
Name Department Date
Originator :
NB Sadongdong Safety / TDEM
Checked by :ES Deonaldo Safety / TDEM
Approved by :
Koji Sakamoto Plant Manager NOTE : USE BLACKPEN FOR SIGNING
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TABLE OF CONTENTS
1 INTRODUCTION............................................................................................7
1.1 GENERAL INTRODUCTION..........................................................................71.2 SCOPEOFTHE PLAN.................................................................................71.3 AUTHORITY STATEMENT............................................................................81.4 PLAN DISTRIBUTION..................................................................................9
1.4.1 LOCATION AND PLAN IDENTIFICATION NUMBERS..............................91.4.2 PLAN INFORMATION AND CONTACT PERSON...................................10
1.5 PLAN UPDATING PROCEDURES................................................................101.6 PLAN TRAINING.......................................................................................11
1.6.1 BASIC TRAINING PROGRAMS...............................................................111.6.2 OTHER TRAINING...................................................................................121.6.3 EMERGENCY RESPONSE TEAM MEMBERS........................................121.6.4 TRAINING FREQUENCY.........................................................................12
1.7 PLAN DRILLSAND EXERCISES.................................................................121.7.1 EXERCISE DOCUMENTATION...............................................................13
2 GENERAL INFORMATION..........................................................................13
2.1 ORGANIZATIONAND PERSONNEL RESPONSIBILITIES.................................132.1.1 EMERGENCY RESPONSE TEAM...........................................................14
2.1.2 KEY PROJECT PERSONNEL AND OUTSIDE GROUPS........................142.1.3 MEDIA RELATION POLICY......................................................................16
2.2 EMERGENCY ALERTING PROCEDURES.....................................................162.3 EVACUATIONAND PERSONNEL ACCOUNTABILITY......................................17
2.3.1 EMERGENCY RESPONSE TEAM HEAD (PLANT MANAGER)..............172.3.2 OPERATION TEAM..................................................................................182.3.3 FIRE FIGHTING AND FIRST AID TEAM..................................................182.3.4 UTILITIES TEAM......................................................................................182.3.5 GUIDANCE AND PUBLIC RELATIONS TEAM........................................182.3.6 MONITORING TEAM................................................................................19
3 EMERGENCY PROCEDURES....................................................................20
3.1 H2S GAS LEAK.......................................................................................203.1.1 EMERGENCY EQUIPMENT.....................................................................213.1.2 ALARM SYSTEM......................................................................................213.1.3 H2S GAS LEAK AT THE H2S HOLDER...................................................213.1.4 H2S GAS LEAK AT THE AREA OTHER THAN THE H2S HOLDER.......273.1.5 CLEARANCE/ LIFTING OF THE EMERGENCY......................................273.1.6 H2S EMERGENCY PROCEDURES - NIGHT SHIFTAND HOLIDAYS....28
3.2 ACID LEAK..............................................................................................293.2.1 ACID LEAK FROM THE PIPELINE (PLANT SITE)..................................293.2.2 ACID LEAK FROM THE PIPELINE (PIER SITE)......................................313.2.3 ACID LEAK FROM THE LORRY (PLANT SITE)......................................32
3.2.4 ACID LEAK FROM THE LORRY (PIER SITE).........................................34
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3.2.5 ACID LEAK FROM THE LORRY (MACADAM ROAD).............................35
3.3 POWER FAILURE.....................................................................................37
3.4 AIR FAILURE...........................................................................................403.5 FIRE.......................................................................................................433.5.1 COAL FIRE (AT PIER COAL STOCKYARD)............................................433.5.2 METHANOL FIRE (PIER SITE)................................................................443.5.3 METHANOL FIRE (PLANT SITE).............................................................463.5.4 SULFUR FIRE (PIER SITE)......................................................................473.5.5 SULFUR FIRE (PLANT SITE)...................................................................49
3.6 TRAFFIC ACCIDENTS...............................................................................503.6.1 SULFURIC ACID LORRY.........................................................................51ESTIMATEOFQUANTITYSPILLEDANDRATEOFRELEASEIFCONTINUING;...............52CAUSEOFTHEACIDSPILL;..................................................................................52SOURCEOFTHEACIDSPILL;AND.........................................................................52
LOCATIONOFSPILLANDDIRECTIONOFSPREADIFMOVING...................................52IFTHEREISDANGEROFSPILLSPREAD, COORDINATEWITHCONCERNEDEMPLOYEESON:..........53LAY-OUTOFADDITIONALSPILLBOOMS;AND.........................................................53BLOCKINGOFFOFCHEMICALSPREAD..................................................................53AFTERLEAKHASBEENSTOPPEDANDSLICKCONTAINED, EFFECTAPPROPRIATECHEMICAL
RECOVERYPROCEDURES......................................................................................533.6.2 METHANOL TRUCK.................................................................................533.6.3 CHEMICAL/MS PRODUCT TRUCK.........................................................561. ESTIMATEOFQUANTITYSPILLEDANDRATEOFRELEASEIFCONTINUING;............572. SOURCEANDCAUSEOFTHECHEMICALTRUCK SPILL;AND................................573. LOCATIONOFSPILLANDDIRECTIONOFSPREADIFMOVING................................574. IFTHEREISDANGEROFSPILLSPREAD, COORDINATEWITHCONCERNEDEMPLOYEESON:.......575. LAY-OUTOFADDITIONALSPILLBOOMS;AND......................................................576. BLOCKINGOUTOFCHEMICALSPREAD...............................................................57SPILLSRECOVERYPROCEDURE:..........................................................................571. FORSOLIDSPILLAGES (SULFUR, SLAKEDLIME, CAUSTICSODA,ANDFLOCCULANT)572. CLEANSPILLSINAMANNERTHATFINEPARTICLESWILLNOTDISPERSEINAIR.....573. CONTAINSPILLAGESANDTRANSFERTOACONTAINERFORRECOVERY...............574. WASHTHEAREA, WHERECHEMICALSPILLSHAPPENED, WITHWATERANDCOLLECTTHEWASHINGSUSINGPUMP, VACUUMTRUCK, ORANYOTHERMEANS...........................577. COORDINATEWITHEMO FORPROPERDISPOSAL..............................................57IFLARGEQUANTITYOFSPILL, CLEANUPPROMPTLYBYPUMP, VACUUMPUMPORANYOTHER
MEANS. 58
KEEPTHERECOVEREDSPILLSINACLOSEDCONTAINER........................................58COORDINATEEMO FORPROPERDISPOSAL..........................................................58A. RESPONDSTOTHEREPORTED CHEMICALSPILLANDDIRECTSTHEACTIONSOFTHEOTHERMEMBERSOFTHEEMERGENCYRESPONSETEAM..................................................58B. GETSUPDATEFROMTHECHEMICAL SPILL TEAMLEADER(PRODUCTIONMANAGER) OFTHEPRESENTCONDITIONOFTHECHEMICALSPILL........................................................58C. ENSURESCHEMICALSPILLHASCOMPLETELYBEENCONTROLLED.......................58
3.7 TYPHOON, FLOOD, HEAVY RAINAND LANDSLIDES....................................583.7.1 PLANT SITE OPERATION.......................................................................583.7.2 LANDSLIDES AND FLOODING...............................................................61EXACTLOCATIONOFTHELANDSLIDE....................................................................61ESTIMATEDVOLUMEOFSOILERODED..................................................................62
ESTIMATEDAREAAFFECTED................................................................................62
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STATUSOFMOVEMENTS (ACTIVEORINACTIVE)....................................................623.7.3 QUARTERS, HOUSING AND SCHOOL...................................................62GENERALCLEAN-UPHOUSEKEEPING. THISMUSTBEDONEWHILEONEISINCOMPLETECONTROL
OFCONDITIONI.E., BEFORETHETYPHOONARRIVALS.............................................62BREAKABLEOBJECTSSHOULDBEPLACEDINSIDECUPBOARDS..............................62HOUSES/QUARTERSSHOULDBEVENTILATEDBYOPENINGWINDOWS. THEWINDOWSATTHESIDE
AWAYFROMTHEWINDSHOULDBEOPENEDTOEQUALIZEAIRPRESSURE. WHENWINDCHANGESDIRECTIONASTYPHOONMOVESALONGITSPATH, THEWINDOWSTHATAREOPENEDONTHELEEWARDSIDEWILLENDURETHEMOSTOFTHEWINDCHANGE. THESEWINDOWSMUSTTHENBECLOSEDANDTHESEONTHEOPPOSITESIDESHALLBECRANKEDOPEN...................62ALLLOOSEOBJECTSOUTSIDEHOUSES/QUARTERSSHOULDBEPICKEDUP, EITHERSTORED
UNDERCOVERORSECURED.................................................................................63REMEMBERTHATANYOBJECTLIFTEDANDHAULEDBYTREMENDOUSWINDCANBEDEADLY
INSTRUMENTTOINJUREORKILL............................................................................63
WITHOUTTHESLIGHTESTDOUBTELECTRICALPOWERWILLBELOSTVERYSOONAFTERTHETYPHOONBEGINS. THISWILLTHENREQUIREPLANNINGFORLIGHTANDALTERNATEMETHODOFCOOKINGANDHEATINGFOOD...............................................................................63LANTERNSSUCHAS PETROMAXWITHSUFFICIENTFUELANDAFEWEXTRAMANTLESMUSTBE
ATHAND. BATTERYPOWEREDLANTERNSSHOULDBECONSIDEREDASTHEYPREVENTLOSSOFAFIREHAZARD. ALSOEXTRABATTERIESANDABULBORTWOFORPOSSIBLEREPLACEMENT........63FLASHLIGHTWITHADEQUATEBATTERIESANDEXTRABULB....................................63CANDLESSHOULDONLYBEUSEDASALASTRESORT...........................................63OPENEDFLAMESNOMATTERHOWSMALLPOSEHAZARDS.....................................63BESURETOHAVEANADEQUATESUPPLYOFFOOD...............................................63WATER 63HAVECONTAINERSFILLEDWITHWATERAGAINSTTHEPOSSIBILITYTHATTHESUPPLYMAYFAIL.
63BUCKETSORPAILSMUSTBEAVAILABLEINTHEEVENTOFFIRE.............................63MAINTAINADEQUATESUPPLYOFCANNEDFOODSTHATMAYBESERVEDCOLD.......64EMERGENCY.......................................................................................................64KNOWLOCATIONOFMAINCIRCUITBREAKERFORALLELECTRICALPOWERENTERING
HOUSE/QUARTERFORSWITCHINGOFFWHEREANDWHENNECESSARY...................64
3.8 ACCIDENTSAT CBNC COMPLEX.............................................................643.8.1 MEDICAL EMERGENCY RESPONSE.....................................................643.8.2 RESPONSES ON OCCUPATIONAL FATALITIES ..................................653.8.3 WHEN A FATALITY HAPPENS................................................................66
3.9 TAILINGS DAM EMERGENCY.....................................................................673.9.1 SAFE ACCESS ROUTES TO THE TAILINGS DAM................................673.9.2 AREAS THAT MAY BE IMPACTED.........................................................673.9.3 CONDITIONS THAT WILL CALL FOR A DAM EMERGENCY.................683.9.4 LEVEL 1 (IMPENDING DAM FAILURE)...................................................693.9.5 LEVEL 2 (DAM FAILURE; NEARBY FACILITIES IMPACTED)................713.9.6 LEVEL 3 (DAM FAILURE; IMPACTING THE COMMUNITY)...................723.9.7 SPECIAL EQUIPMENT AND RESOURCES REQUIRED........................733.9.8 TESTING AND REVISION OF THE PLAN...............................................73
LIST OF TABLES_______________________________________________________________________________________
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TABLE 1 ERPP DISTRIBUTION.....................................................................9
TABLE 2 COMPOSITION OF THE EMERGENCY RESPONSE TEAM (ERT)14
TABLE 3 KEY PROJECT PERSONNEL TO BE CONTACTED DURINGEMERGENCIES..............................................................................................15
TABLE 4 LOCAL AND NATIONAL ORGANIZATIONS AND SERVICE PROVIDER....15
TABLE 5 EMERGENCY EQUIPMENT...........................................................21
TABLE 6 PHASES/STAGES DURING LEAK AT THE H2S HOLDER.........21
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1 INTRODUCTION1.1 General Introduction
The Coral Bay Nickel Corporation - Emergency Response and Preparedness
Program (ERPP) is intended to handle emergencies of a particularly serious nature,
which are likely to involve hazards to personnel, damage to equipment and cause
serious inconvenience to the general public. This plan also aims to prevent injury
and the loss of lives and property during emergencies. This is attained by
instructing employees and management what to do for every conceivable
emergency.
1.2 Scope of the Plan
An advance emergency planning, therefore, should be intensified to be able to
handle emergencies effectively such as:
I. H2S Gas Leak
II. Acid Leak
a. Acid Leak from the Pipeline (Plant site)
b. Acid Leak from the Pipeline (Pier site)
c. Acid Leak from the Lorry (Plant site)
d. Acid Leak from the Lorry (Pier site)
e. Acid Leak from the Lorry (Macadam Road)
III. Chemical Spills
a. Chemical Spills (Laboratory)
b. Oil Spills (Plantsite)
IV. Power Failure
V. Air Failure
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VI. Fire
a. Coal Fire (Pier Coal Stockyard)
b. Methanol Fire
i. Pier site
ii. Plant site
c. Sulfur Fire
i. Pier site
ii. Plant site
VII. Traffic Accident
a. Sulfuric Acid Lorry
b. Methanol Truck
c. Chemical Truck
VIII. Typhoon/Flood/Heavy Rain/Landslides
IX. Accidents at the CBNC Complex
X. Tailings Dam Emergency
XI. Emergency on Nuclear Equipments and Devices
XII. Earthquake
XIII. Medical Emergencies/Outbreaks
The Emergency Response and Preparedness Program is designed to handle such
emergencies on a planned and orderly manner. It is intended that everyone who
has a part to play in disaster control should know his/her responsibilities.
1.3 Authority Statement
The Emergency Response and Preparedness Program, upon approval by the
CBNC Plant Management, grants the authority to company officials to implement
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the plan in order to terminate any emergency. The Emergency Coordinator is
authorized to perform the coordination and overall implementation of the said plan.
The emergency coordinator will be designated depending on which area the
emergency or incident occurred. All other employees and persons concerned are
enjoined to cooperate fully with the designated personnel in carrying out the
appropriate response called for by an emergency.
1.4 Plan Distribution
An electronic copy of the Emergency Response and Preparedness Program shallbe made available for easy access by CBNC employees at the File Server in PDF
format. The master copy shall be maintained by the Document Control Custodian.
This plan shall be made available for review by all employees. Likewise, a copy
shall be submitted to Mines and Geosciences Bureau (Central Office) and
Department of Labor and Employment (Bureau of Working Conditions).
1.4.1 LOCATION AND PLAN IDENTIFICATION NUMBERS
Since CBNC electronic file will be made readily available through the
Common File Server, printed hard copies shall be made available for the
following personnel who do not have a direct access to the file server. The
plan shall be identified with a number on the binder spine to control its
dissemination. Table below indicates the distribution and location of the said plan.
Table 1 ERPP Distribution
PlanNumber
Department Location
ERPP-1 Office of the Plant
Manager
Office of the Plant Manager , CBNC
ERPP-2 RTNMC Management Office of the Res. Mine Manager,
RTNMC
ERPP-3 RTNMC Safety Office Safety Engineers Office, RTNMC
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ERPP-4 JGC/JMAINT JGC/ JMAINT Office
ERPP-5 SMCC Management Office of the Project Manager, SMCC
ERPP-6 MANNJ Trading MANNJ Manager s Office
ERPP-7 DCR MPS DCR MPSs Managers Office
ERPP-8 PCBSI Office of the Branch Manager
ERPP-9 Barangay Rio Tuba Office of the Barangay Chairman
ERPP-10 RTNFI Hospital Office of the Medical Director
ERPP-11 CBNC SAFETY Safety Office
ERPP-12 Office of the President CBNC Makati Office
These plans shall be kept in their designated locations at all times so that they
can easily be obtained when needed. The Emergency Response and
Preparedness Program shall always be updated.
1.4.2 PLAN INFORMATION AND CONTACT PERSON
The plan may be obtained from the Department Managers and Safety Section
upon the approval of the Plant Manager.
1.5 Plan Updating Procedures
The Safety and Health Committee will review the ERPP once a year, every time an
emergency occurs, or when new and revised legislation affecting it as promulgated.
The addition, revisions and modifications formulated by this committee shall be
incorporated in the plan. The Plant Manager, in collaboration with the Central
Safety and Health Committee, shall be responsible for the dissemination of these
changes.
In case of revision, the history revision page shall be indicated with the revision
number,date revised, and the revised items. The revised section will be printed in
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its entirety. All pages of the revised section will bear the revision date and
designated reference numbers, that is, mm/dd/yy. This procedure ensures that
there will be no confusion between current and obsolete portions of the manual.
1.6 Plan Training
The Plant Manager is responsible for the design and conduct of training programs
for employees. The training needs of employees shall depend on their functions
and vulnerability to accidents and emergencies. Current skills of employees in
relation to emergency situations shall likewise be considered. Based on thesefactors, the employees will be classified into groups. The training program shall
focus on the following:
Roles and Responsibilities of the employees
Emergency Plan Procedures
Evacuation Procedures
1.6.1 BASIC TRAINING PROGRAMS
Regardless of designation, each employee shall be provided with training on the
following:
A. Emergency Plan Procedures
B. Emergency Evacuation Procedures
C. Basic Fire Fighting Procedures (Fire Extinguishers)
D. Basic First Aid, and
E. Basic Cardio Pulmonary Resuscitation (CPR) Procedures
The training program will enable all employees to identify conditions, which might
lead to an emergency situation. Immediate identification of a potentially
dangerous situation will be most helpful in damage control.
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Response Time of the Emergency Response Team members
and plant personnel
Adherence to Plan Procedures.
1.7.1 EXERCISE DOCUMENTATION
The exercises shall be documented using the Emergency Response Exercise
Evaluation Form (Please see Appendix 3) which shall be completed by the
Safety Section afterthe evaluation meeting which shall be conducted immediately
after the exercise to be attended by Department Managers and Department
Supervisors who are present. The report shall discuss the results of the exercise,
problems encountered during the execution of the plan and any recommendations
for improvement and modifications of the existing plan which shall be applied in
the next exercises. The report shall be signed by the attendees to signify their
approval.
2 GENERAL INFORMATION
2.1 Organization and Personnel Responsibilities
In an emergency, the Emergency Response Team Head (Plant Manager) is
responsible for implementing appropriate action to ensure the safety of the
employees and visitors in the operating premises. Management authorizes him to
carry out the tasks and functions laid down in the plan.
If he is not present in the event of an emergency, the assigned Sub Head/s will
assume his responsibilities. The contact numbers of the Emergency Response
Team Head (Plant Manager), his Sub Heads and all members of the Emergency
Response Team shall always be available and shall be prominently displayed in
strategic areas within the operating premises.
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2.1.1 EMERGENCY RESPONSE TEAM
Table below is the composition of the Emergency Response Team. The team will
be directly under the direction of the Plant Manager.
Table 2 Composition of the Emergency Response Team (ERT)
Name Position Team DesignationContact
Numbers
Mr. Koji Sakamoto Plant Manager Head, ERT 09175404666
Mr. Arturo T.Manto
Vice President forEnvironment and
External Affairs
Sub Head, ERT 09178219754
Mr. Isao NishikawaManager, ProductionDept.
Head, Operation Team at Plantsite (Production)Sub Head, ERT
09175810551
Mr. DiosdadoParaiso
Asst Manager,Production Dept.
Sub Head, Operation Team atPlantsite (Production)
09178064635
Mr. HidehikoHarada
Manager, General AffairsDept.
Head, Guidance and PublicRelations TeamSub Head, ERT
09155384172
Mr. Warlito B.Tabanag
Manager, PersonnelSect
Sub Head, Guidance and PublicRelations Team
09178551271
Mr. Ernesto A.
Llacuna
Manager, Comrel SectSub Head, Guidance and Public
Relations Team
09165718013
Mr. ShigeruOnozaki
Manager, MaintenanceDept.
Head, Maintenance TeamSub Head, ERT
09178036079
Mr. Takao NiiyamaManager, Purchasingand Logistics Dept.
Head, Operation Team atPlantsite and Pier site (PLD)Sub Head, ERT
09178540446
Mr. Yuji Tange Manager, Utilities Dept.Head, Operation Team atPlantsite (Utilities)Sub Head, ERT
09178544843
Mr. Erwin S.Deonaldo
Head, Safety SectionHead, Firefighting and First AidTeamsSub Head, ERT
09178551271
Mr. Briccio Abela Head, EMQC UnitHead, Monitoring TeamSub Head, Guidance and PublicRelations Team
09178506099
Mr. Reginaldo Z.Mia
Medical Director, RTNFIHospital
Head, Medical Team 09273195984
Ms. RaquelTantoco
Safety Coordinator,Safety Section
Log Recorder / Documentation
2.1.2 KEY PROJECT PERSONNEL AND OUTSIDE GROUPS
Key Project Officers shall be informed during major emergencies. Their names,
designations and contact numbers are indicated below:
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Table 3 Key Project Personnel to be contacted during Emergencies
Name PositionContact
Numbers
Mr. Takanori Fujimura President, CBNC 09175384488
Mr. Koji Sakamoto Plant Manager, CBNC 09175404666
Mr. Arturo T. MantoVice President for Environment andExternal Affairs
09178219754
Mr. Isao Nishikawa Manager, Production Dept. 09175810551
Mr. Hidehiko Harada Manager, Gen. Affairs Dept. 09155384172
Mr. Shigeru Onozaki Manager, Maintenance Dept. 09178036079
Mr. Takao Niiyama Manager, PLD 0917540446Mr. Yuji Tange Manager, Utilities Dept. 09178544843
Mr. Erwin S. Deonaldo Head, Safety Section 09178551271
Mr. Briccio Abela Head, EMQC Section 09178506099
Mr. Bernardo M. Dacyon,Jr.
Resident Mine Manager, RTNMC 09178937267
Hon. Bgy. Capt. GomerMiano
Bgy. Capt. , Rio Tuba 09214028419
Other individuals and groups not connected with the company may be calledduring an emergency. The contact numbers of these entities shall likewise beprominently displayed in strategic areas within the operating premises.
Table 4 Local and National Organizations and Service Provider
Organization Contact Person Contact Numbers
RTNFI Hospital Dr. Reginaldo Z. MiaHospital Director
09273195984
Rio Tuba Barangay Disaster CoordinatingCouncil
Gomer MianoBarangay Captain
09214028419
Municipal Disaster Coordinating Council
Bureau of Fire Protection Bataraza
Philippine Air ForceRio Tuba Detachment
1Lt. Romar CatotalComm. Officer2Lt. Elias Garry
GregorioAsst. Comm. Officer
Philippine National Red Cross (PNRC)Puerto Princesa City, Palawan Chapter
Miss Arsenia TadiqueAdministrator
(048) 4336362
Philippine National Red Cross (PNRC)-ManilaNational Headquarters, Bonifacio Drive, PortArea, Manila
Mrs. Lourdes GenatoManager, SafetyServices
(02) 5279979
Mines and Geosciences Bureau (MGB-Central)
Horacio C. RamosDirector
(02) 9288642
Mines and Geosciences BureauRegion IVB MIMAROPA
Mario A. CatarrojaOIC, Office of theRegional Director
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Organization Contact Person Contact Numbers
Bureau of Working Conditions (BWC)-Occupational Health and Safety Division,OSHC Complex, North Avenue, Cor. Scienceroad, Diliman, Quezon City
Dir. Ma. Brenda L.VillafuerteDirector
(02)920-2585(02)920-2381
Bureau of Working ConditionBWC-DOLE, Region IVB
Josefino I. TorresRegional Director
PNP Western CommandPuerto Princesa, Palawan
Tirso R. DangaVice Admiral
2.1.3 MEDIA RELATION POLICY
In the event of an emergency, only the President or his designated spokesperson
is authorize to give information to the public in behalf of the company. No other
person is allowed to disseminate information regarding the incident.
2.2 Emergency Alerting Procedures
The Coral Bay Nickel Corporation High Pressure Acid Leach Project maintains a
state-of-the-art system to alert the employees and other people concerned in an
emergency.
In case of Fire, the fire alarm system will be automatically activated. The sound willimmediately warn people of the fire and signal the start of evacuation procedures.
Fire fighting team will be activated.
Notification procedures vary depending on the magnitude of the situation. Bigger
events will call for more people involvement. In case of a serious or facility-wide
emergency, the appropriate means of notification is through the paging system and
the activation of the siren.
In case of gas leakage, detectors located at strategic locations activates the gas
alarms to warn all personnel of the emergency. Corresponding announcements
through paging system follows.
Reporting of any other type of emergency shall be done using telephones or mobile
phones and handheld radios. , Telephone directories shall likewise be placed in
strategic areas accessible to all employees.
For handheld radios, channel 9 is designated as emergency channel._______________________________________________________________________________________
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2.3 Evacuation and Personnel Accountability
Certain emergencies may require the evacuation of all or part of the facility. An
early warning system will effect a safe and timely evacuation and will communicate
the perilous situation to all personnel concerned.
The following procedures apply to all evacuations.
The Hydrometallurgical Processing Plant site complex area has designated three
(ABC) Safety Zone Headquarters depending on the wind direction. One is located
at the northwest portion of the plant site (A), another is at the Southwest portion (B)
and at the Northeast portion (C). Announcement thru the paging system will be
done three times to inform everybody of the designated safety zone headquarters.
In case of evacuation, employees are to leave the area by the designated route to
the designated evacuation point.
Upon arrival at the designated evacuation point, the employee reports directly to his
supervisor. The supervisor does a head count of all employees under his
supervision and reports missing personnel and location last seen to the Department
Managers who will then report to the Plant Manager.
2.3.1 EMERGENCY RESPONSE TEAM HEAD (PLANT MANAGER)
a. Immediately after confirming any emergency call from the Department
Manager concerned or from the Safety Section Head, ERT Head shall
immediately order the various team leaders to gather pertinent data and other
information necessary for an investigation. The team shall lay out plans to
control the situation.
b. The team shall inspect and report on hazards to personnel, particularly the
possibility of explosion, fire, leakage, presence of harmful gases or liquids and
collapsing structures.
c. All employees shall be informed of hazardous situations immediately on orders
of the ERT head.
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d. Assist in the evacuation of personnel from hazardous situations.
2.3.2 OPERATION TEAM
a. Coordinates with the ERT Head, pertaining to the emergency.
b. Takes full responsibility on operational emergency procedures
c. Provide heavy equipment such as wheel loaders, bulldozers, and
backhoes for clearing and emergency rescue work
2.3.3 FIRE FIGHTING AND FIRST AID TEAM
a. Immediately proceeds to the assembly area upon the first call for instructions.
b. Stays at assembly area and wait for further instruction depending on the
situation.
c. Fire fighting team to be activated only should there be fire.
d. First aid team to be readied all the time in any type of emergency.
2.3.4 UTILITIES TEAM
a. Provide temporary electrical lighting and power as required.
b. To maintain electrical power supply necessary at the disaster areas.
c. Clear or barricade weakened structures, which pose danger.
d. Coordinate with Emergency Response Team.
e. Supply engineering information such as plant layout, piping and wiring
drawings as required.
f. Conduct thorough investigation of disaster and record all pertinent
information.
2.3.5 GUIDANCE AND PUBLIC RELATIONS TEAM
a. Provide transportation as required.
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b. Should transport injured persons, without any delay, to a designated first aid
station for treatment.
c. Maintain enough number of service vehicles available for use anytime.
d. Coordinates with the nearby communities and persons affected for proper
evacuation
e. Determine the status of all personnel affected by the disaster. Gather
information on injured personnel or any fatalities.
f. Notify promptly the next of kin of all affected employees.
g. Under supervision from the Plant Manager, maintain exclusive channel of
communication with public news media. Deal with all inquiries from the general
public.
h. Accommodate evacuees at Evacuation Center and provide food services as
may be required.
i. Coordinates with the Medical Team in case victims are to be brought to thehospital.
2.3.6 MONITORING TEAM
a. Makes communication with ERT Head with regards to the affected areas in
the vicinity of the plant and the other impact areas.
b. Assists the Public Relations Team in the efficient evacuation of nearby
residents
c. Reports from time to time the situation at different monitoring areas until it
is proclaimed safe.
2.3.6 MEDICAL TEAM
a. Provides medical treatment to the injured.
b. Arranges hospitalization of seriously injured persons.
c. Coordinates in the operation of Rescue Team on First Aid procedures
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2.3.7 LOG RECORDER
a. Records the sequence of events of the occurrence of an emergency.
b. Keep records of the account of the emergency for future references.
c. Documents emergency drills and exercises.
3 EMERGENCY PROCEDURES
3.1 H2S Gas Leak
Hydrogen sulfide gas (H2S) handling is one of the most deadly occupational
hazards. When H2S gas is inhaled, it is rapidly absorbed by the lungs into the
blood, which initially induces rapid breathing. This is followed by respiratory
inactivity. At higher concentration, H2S exerts an immediate paralyzing effect on the
respiratory centers. Death due to asphyxia is a certain outcome, unless artificial
respiration is promptly provided. This sequence of events represents the most
important toxic effect of H2S.
Hydrogen sulfide in low concentrations is easily recognized by its characteristic foul
odor similar to rotten eggs. However, continued exposure will temporarily deaden
ones ability to smell the gas. This leads to the person believing that the gas is
gone when probably it is still there. Therefore, a person should always check with
the gas detectors for actual gas concentration in the atmosphere.
To determine the presence of H2S within the plant site complex area, thirty
four (34) H2S Gas detectors were strategically installed and linked to the DCS
at the Central Building.
PPEs must be maintained in good working condition and made available at all
times. These include self-contained air breathing apparatus (SCABA), half mask
respirators, safety glasses, safety gloves, safety boots, safety shoes, and water
washing equipment. The mask must have good fit with all face types.
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3.1.1 EMERGENCY EQUIPMENT
Table 5 Emergency Equipment
EquipmentGOB
No. of Units
PSO
No. of Units
Bullhorn or Megaphone 2 3
H2S Portable Meter 1
Badge Type H2S Meter 2 8
First Aid Kit 2 5
Radio Transceivers 12 1
Self-Contained Air Breathing Apparatus
(SCABA) with Cylinders12
Air Line Mask 2
First Aid Kit 3 3
White Board 3 9
3.1.2 ALARM SYSTEM
If there is H2S Gas leakage detected by the H2S Gas detectors, the alarm
in the DCS room and the siren are automatically activated. A continuous loud
siren sound will be heard all over the plant site area (see Appendix 9 for the
location of the paging speakers)
3.1.3 H2S GAS LEAK AT THE H2S HOLDER
Table 6 Phases/Stages during Leak at the H2S Holder
H2S Gas Concentration Description/ Activities
Process Area: 5 ppmOutside Proc. Area: 1ppm
DCS Alarms.The Production Manager per DCS operators information informsthe Plant manager.
Plant site1st Stage:Process Area: 5- 29 ppm
1st Stage : Emergency Procedure activated. Each EmergencyResponse Team on standby.
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H2S Gas Concentration Description/ Activities
Outside Proc. Area:1- 9 ppm2nd Stage:Process Area:>30ppmOutside Proc. Area >10ppm(Local Dectector Alarm)
2nd Stage: All personnel evacuate from the buildings to the SafetyZone
RTNMC WS/Upper Kinurong> 1 ppm
1. The local community residents (Kinurong) are evacuated toRTNMC Town site
2. RTNMC employees,Radar Personnel and BCI / PSSIcompound personnel are evacuated to Town site
1. For DCS Operator
a. Informs MS Supervisor of the detected gas concentration inside the
H2S Holder through the DCS monitors.
b. The DCS operator announces through the paging system that H2S gas
leaked at the H2S gas holder and instructs all employees at the MS and
H2S plant areas to evacuate their respective areas immediately upon
instruction from the Production Supervisor. This announcement is
repeated 3 times (English and Filipino).
c. The DCS operator reports the situation to the Production Supervisor.
He feeds back actual gas concentration per DCS Monitor regularly
d. At a concentration of 10ppm, the DCS operator, upon receiving order
from the Production Supervisor who went to the H2S Gas holder to get
actual reading, will then push water spray switch to on position.
e. The DCS Operator (Production) initiates the operation of the following
upon order from Production Supervisor
1. Decrease or put flow at necessary rate to empty H2S gas
holder the soonest time possible.
2. H2S plant emergency shutdown bypassing emergency
switch for H2S compressors
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f. The DCS Operator (Utilities) upon receiving order from the Utilities
Superviso, puts operation to hot standby status.
g. DCS Operator announces through the paging system the plant
situation upon order form the Production Supervisor. This
announcement is repeated three times.
h. Upon order from Fire Fighting and First Aid Team Head, DCS operator
calls attention of the members of firefighting and first aid teams to
assemble at designated area.
i. At a concentration of 30ppm, the DCS operator upon receiving the
instruction of the Production Supervisor, announces to all employees
and contractors through the paging system to evacuate to safety zone,
which is to be determined depending on the wind direction. Emergency
response teams are then advised to switch to channel 9, designated as
emergency channel. This announcement shall be repeated three times
in English and Tagalog.
j. The DCS Operator wears his SCABA and proceeds to the Safety
Zone for the Roll Call after emptying H2S Holder and putting operation
to shutdown mode.
2. For MS Shift Foreman and H2S Operator
a. Upon getting information from the DCS Operator that H2S leak occurred
at the H2S gas holder, the H2S operator immediately evacuates to the
H2S Utility DCS Room. The MS Shift Foreman brings a radio
transceiver, together with the H2S Operator, immediately wears their
SCABA, proceeds to the H2S gas holder, and checks the H2S gas
holder concentration.
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b. At a concentration of 10ppm, the MS Shift Foreman confirms it to the
DCS Operator and informs Production Manager
c. At a concentration of 30ppm, the Production Supervisor confirms to the
DCS operator and informs Production Manager.
d. The Production Supervisor, upon instruction of the Production Manager,
activates the NaOH spray and evacuates to Central Building with H2S
Operator.
e. Upon hearing the announcement to evacuate to safety zone, ProductionSupervisor and H2S Operator proceed to safety zone and reports for
the roll call.
3. For Production Manager
a. Upon getting information from Production Supervisor, Production
Manager immediately proceeds to the Central Building DCS Room or
advises Production Supervisor of necessary actions to be done.
b. At a concentration of 10ppm, Production Manager informs the Plant
Manager.
c. Production Manager instructs the DCS Operator to announce first
step emergency procedures.
d. At a concentration of 30ppm, the Production Manager instructs
Production Supervisor to activate the NaOH spray and evacuate to
safety. He then reports the situation to Plant Manager. After this, he
instructs the DCS Operator to announce Emergency Evacuation.
e. Upon establishing the Safety Zone Headquarters, the Production
Manager instructs the MS Shift Foreman and DCS Operator to monitor
gas concentration at the Utility building.
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f. Upon the report of the Guidance and Monitoring Team Head that the
Upper Kinurong gas concentration is greater than 1ppm, the Production
Manager immediately reports information to the Plant Manager.
4. For General Affairs Manager and Guidance Team Members
a. At a gas concentration of 10ppm, the General Affairs Manager
proceeds to the Central Building DCS Room.
b. Upon the announcement by the DCS Operator, that the first stage
emergency procedure effects, the guidance and monitoring teamassembles at the General Office Building.
c. At a gas concentration of 30ppm, the Plant Manager instructs the
monitoring team to proceed to assigned monitoring stations. Monitoring
team head dispatches members to assigned monitoring stations
d. Each member of the Guidance and Public Relations Team and
Monitoring Team proceed to their respective stations and reports to
respective team heads upon reaching their posts.
e. The Monitoring Team Head instructs the personnel assigned at the
RTNMC WS to get reading of H2S gas concentration.
f. Upon receiving the information that the gas concentration at RTNMC
Warehouse is over 1ppm, the Monitoring Head Team reports the
information to the Plant Manager who also instructs the Guidance and
Public Relations Team Head to instruct RTNMC management and the
Radar Station to evacuate their personnel immediately to the RTNMC
Town site.
g. Upon receiving the information that the gas concentration at the Upper
Kinurong is over 1ppm, the General Affairs Manager instructs the
Guidance and Public Relations Team to evacuate residents of BCI and
PSSI compounds to RTNMC Town site.
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h. Using CBNC Service Bus, the assigned Guidance and Public Relations
team member supervises the transport of residents to RTNMC Town
site and upon arrival, reports to the Guidance and Public Relations
Team Head that all residents have already been evacuated.
5. For Plant Manager
a. Upon hearing the siren and the announcement of the Production
Manager, the Plant Manager immediately proceeds to the General
Office Building.
b. At a gas concentration of 10ppm, the Plant Manager instructs all
managers to initiate emergency procedures.
c. At a gas concentration of 30ppm, the Plant Manager instructs all
managers to evacuate all personnel.
d. Upon establishing the Safety Zone Headquarters, the Plant Manager
observes proper monitoring of personnel at the evacuation site.
e. Upon knowing that the gas concentration at RTNMC WS is over 1ppm,
the Plant Manager instructs the General Affairs Manager to instruct
RTNMC management and the Radar Station to evacuate their
personnel immediately to the Town site.
f. Upon knowing that the gas concentration at the Upper Kinurong is over
1ppm, the Plant Manager instructs the General Affairs Manager to
evacuate residents to RTNMC Town site.
6. For Members of the Fire Fighting and First Aid Team
a. Upon the declaration of the Emergency Procedures, the fire fighting and
first aid team proceeds to the designated assembly area.
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b. Stay at the site and wait for further instruction, or depends on actual
situation. Fire fighting team is to be activated if fire occurs and first aid
team is to be activated if injured person/s is/are noticed.
7. Maintenance Team Head
a. Coordinates with maintenance contractors in case of evacuation.
8. For All Other Employees
a. At a gas concentration of 30ppm and upon the announcement to
evacuate to safety zone, all employees evacuate to the evacuation
area.
b. Stay at the headquarters and to be counted during the employee roll
call.
3.1.4 H2S GAS LEAK AT THE AREA OTHER THAN THE H2S HOLDER
(Similar procedure for H2S Gas Leak at H2S Gas Holder)
3.1.5 CLEARANCE/ LIFTING OF THE EMERGENCY
If H2S gas in Upper Kinurong Area is no longer detected
a. If H2S gas concentration at the Upper Kinurong, RTN Assay Lab area can
no longer be detected, the Monitoring Team assigned to get the reading
reports the information to the Monitoring Team Head, who also reports the
information to the Plant Manager.
b. The Plant Manager, upon getting the information tells the Guidance and Public
Relations Team to inform evacuated residents that the emergency is cleared.
c. The Guidance and Public Relations Team upon getting this instruction informs
the residents to go home, in coordination with the Barangay officials. CBNC
service bus available transports back the residents.
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a. If H2S gas concentration at the RTNMC Workshop area can no longer be
detected, the Monitoring Team member assigned to get the reading reports
the information to the Plant Manager.
b. The Plant Manager, upon getting the information declares that the emergency
is over and orders the emergency headquarters to be disbanded.
c. Guidance and Public Relations Team informs RTN Management of the
situation.
d. The fire fighting team returns the fire truck to the firefighting equipment-parkingarea.
e. Other employees who evacuated to the Safety Zone Headquarters return to
their respective work areas.
3.1.6 H2S EMERGENCY PROCEDURES - NIGHT SHIFT and HOLIDAYS
DCS operator, upon the alarm of the DCS Monitor, shall follow the following
procedures:
a. With the corresponding stages of the gas concentration, follow the established
procedures as if it happens during the day shift.
b. Using the radio, the DCS Operator shall call the concerned Shift Supervisor for
immediate information and for immediate information to the Production
Manager.
c. Production Manager informs Plant Manager who will then inform also other
department managers.
d. If the gas concentration persists to rise reaching 10ppm, members of the
Emergency Organization are immediately notified through their cellular phones
and proceeds to the plant site for the next step following the established
procedures.
1. Plant Manager (Station at JTA), town site.
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a. Upon receipt of the report, gives instruction and dispatches emergency
response team
b. Maintains communication links
c. Proceeds to Plant site/General Office Building for the next procedure to
follow
2. Guidance and Public Relations Team
a. Upon receiving the information from DCS Operator, proceed to JTA
to secure vehicle
b. Receive instruction from the Plant Manager
c. Proceed to Plant site for the next step following the established
procedure
3.2 Acid Leak
Sulfuric Acid (H2SO4) is the main acid utilized in the HPAL operations of CBNC.
Hazardous materials like this acid can cause unreasonable risks to health, safety or
property when it leaks.
3.2.1 ACID LEAK FROM THE PIPELINE (PLANT SITE)
1. DCS Operator
a. Obtain from the caller the exact location and nature of the problem.
b. Inform shift supervisor for possible stoppage of acid pumps
c. Inform the Operation Team Head (Production Manager) as reported by
the caller.
2. Operation Team Head (Production Manager)
a. Upon receiving the information from the DCS operator, he informs the
HPAL Foreman to proceed to the location where the leak was reported.
b. He directs actions of the Acid Leak Response Team members.
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c. Provide for the proper clean-up and removal of spilled chemicals.
d. He informs the ERT Head (Plant Manager) of the present condition of
the leak.
3. Acid Leak Response Team members
a. Proceeds immediately to the location where the leak was reported with
complete personal protective equipment and necessary equipment
needed including but not limited to pH paper, vacuum trucks, sand
bags, shovels, etc.
b. Upon arrival, report by radio and give an initial assessment of the
situation such as:
o Estimate of quantity spilled and rate of release if continuing
o Source and cause of the acid leak
o Location of leak and direction of spread if moving
o Securing the area by installing barricade and/or sandbags if canals
are affected.
c. For small spills, cover with lime or limestone to neutralize the acid and
prevent corrosion of metals and formation of hydrogen gas while for
large spills, dikes or ditches must be closed before the spills reach to
the dikes or ditches.
d. Wash the spills with water to a proper drain.
e. After leak has been stopped and spill contained, effect appropriate acid
recovery procedures.
4. ERT Head (Plant Manager)
a. Responds to the reported acid leak and direct the actions of the other
members of the Emergency Response Team.
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b. Ensure that the necessary actions such as leak stoppage, containment
and recovery are initiated.
c. Gets update from the Operation Team Head (Production Manager) of
the present condition of the leak.
d. Ensures proper clean-up and removal of acid spill.
3.2.2 ACID LEAK FROM THE PIPELINE (PIER SITE)
1. The Person who discovers the Acid Leak
a. Informs unloading leader to stop the acid pump.
b. Informs Pier Site Logistics Section Head (Acid Leak Team Sub-leader)
the exact location and nature of the problem.
2. The Acid Leak Team Sub-Leader
a. Assesses the extent of the leak and inform the Acid Leak Pier Site
Team Head (Purchasing and Logistics Manager).
3. Acid Leak Response Team members
a. Upon receiving the information from the Acid Leak Team Sub-Leader,
proceeds immediately to the location where the leak was reported.
b. Upon arrival, report by radio and give an initial assessment of the
situation such as:
a. Estimate of quantity spilled and rate of release if continuing
b. Source and cause of the acid leak
c. Location of leak and direction of spread if moving
c. For small spills, cover with lime or limestone to neutralize the acid and
prevent corrosion of metals and formation of hydrogen gas while for
large spills, dikes or ditches must be closed before the spills reach to
the dikes or ditches.
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a. Upon receiving the information from the DCS operator, he informs the
HPAL Foreman to proceed to the location where the leak was reported.
b. He directs actions of the Acid Leak Response Team members.
c. Provide for the proper clean-up and removal of spilled chemicals.
d. He informs the ERT Head (Plant Manager) of the present condition of
the leak.
3. Acid Leak Response Team members
a. Proceeds immediately to the location where the leak was reported.
b. Upon arrival, report by radio and give an initial assessment of the
situation.
c. Prepare containers beside the Acid Lorry and contain the acid leaking
towards the containers.
d. If there is danger of the spill spread, coordinate with other members of
the Acid Leak Team to layout additional spill booms and blocking of
acid spread.
e. After leak had stopped and contained, effect appropriate acid recovery
procedure.
f. For small spills, cover with lime or limestone to neutralize the acid and
prevent corrosion of metals and formation of hydrogen gas while for
large spills, dikes or ditches must be closed before the spills reach to
the dikes or ditches.
g. Wash the spills with water to a proper drain.
In case leak at the acid lorry is noted at Plantsite, it will then not be allowed
to travel back to piersite. Instead, it will be referred to Maintenance
Department for repair. Basically, a round check after unloading is conducted
before giving go signal to travel back to Piersite.
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4. ERT Head (Plant Manager)
a. Responds to the reported acid leak and direct the actions of the other
members of the Emergency Response Team.
b. Ensure that the necessary actions such as leak stoppage, containment
and recovery are initiated.
c. Gets update from the Operation Team Head (Production Manager) of
the present condition of the leak.
d. Ensures proper clean-up and removal of spilled acid.
3.2.4 ACID LEAK FROM THE LORRY (PIER SITE)
1. The Person who discovers the Acid Leak
a. Informs the Pier Site Logistics Section Head (Acid Leak Team Sub-
leader) the exact location and nature of the problem.
b. Requests to stop loading activity as needed.
2. The Acid Leak Team Sub-Leader
a. Assesses the extent of the leak and inform the Operation Team Head
(Procurement and Logistic Manager). In addition, the latter will inform
Plant Manager.
b. Directs action of acid leak response team member
3. Acid Leak Response Team membersa. Proceeds immediately to the location where the leak was reported.
b. Upon arrival, report by radio and give an initial assessment of the
situation.
c. Prepare containers beside the Acid Lorry and contain the acid leaking
towards the containers. Acid can also be transferred to empty lorry.
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d. If there is danger of the spill spread, coordinate with other members of
the Acid Leak Team to layout additional spill booms and blocking of
acid spread.
e. After leak had stopped and contained, conduct appropriate acid
recovery.
f. Cover small spills with lime or limestone to neutralize the acid and
prevent corrosion of metals and formation of hydrogen gas.
g. Wash the spills with water to a proper drain.
4. ERT Head (Plant Manager)
a. Responds to the reported acid leak and direct the actions of the other
members of the Emergency Response Team.
b. Ensure that the necessary actions such as leak stoppage, containment
and recovery are initiated.
c. Gets update from the Operation Team Head (Production Manager) of
the present condition of the leak.
d. Ensures proper clean-up and removal of spilled acid.
3.2.5 ACID LEAK FROM THE LORRY (MACADAM ROAD)
1. The person who discovers the leak shall:
a. As much as possible call the attention of the acid lorry driver or thedriver of the escort truck.
b. Immediately informs guards at the nearest location of thesituation.
2. The escort truck driver
a. Informs RTN Supervisor of the situation
b. Calls the attention of the acid lorry driver.
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c. Dumps limestone to affected area.
3. Acid lorry driver
a. Parks the lorry at the side of the road where there are less pedestrians.
b. Informs RTN MH Supervisor
c. Makes initial barricading of the area.
d. Assists in the traffic situation.
4. RTN MH Supervisor
a. Immediately informs PLD Supervisor of the situation
b. Proceeds to the area to assist.
5. PLD Supervisor / Manager
a. Immediately informs PLD Manager, who immediately informs the Plant
Manager and other department managers.
b. Proceeds to the area to assess the situation
c. Calls Safety Office to assist in barricading the area.
6. The Acid Leak Team Sub-Leader
a. Assesses the extent of the leak and inform the Operation Team Head
(Procurement and Logistic Manager). In addition, the latter will inform
Plant Manager.
b. Directs action of acid leak response team member
7. Acid Leak Response Team members
a. Proceeds immediately to the location where the leak was reported.
b. Upon arrival, report by radio and give an initial assessment of the
situation.
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c. Prepare containers beside the Acid Lorry and contain the acid
leaking towards the containers. Acid can also be transferred to empty
lorry.
d. If there is danger of the spill spread, coordinate with other
members of the Acid Leak Team to layout additional spill booms and
blocking of acid spread.
e. After leak had stopped and contained, conduct appropriate
acid recovery.
f. Cover small spills with lime or limestone to neutralize the
acid and prevent corrosion of metals and formation of hydrogen gas.
g. Wash the spills with water to a proper drain.
8. ERT Head (Plant Manager)
a. Responds to the reported acid leak and direct the actions of the other
members of the Emergency Response Team.
b. Ensure that the necessary actions such as leak stoppage, containment
and recovery are initiated.
c. Gets update from the Operation Team Head (PLD Manager) of the
present condition of the leak.
d. Ensures proper clean-up and removal of spilled acid.
3.3 Power Failure
The Coral Bay Nickel Corporation Hydrometallurgical Processing Plant in any
eventuality may experience power failure due to tripping of the Steam Turbine
Generator (STG) or any other possible causes.
To be able to address this kind of an emergency situation, there is a need to
establish emergency procedures to continue the operation of important plant
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facilities while some other lesser important facilities are sequentially shut
down.
As soon as the electric power is cut off, emergency generators automatically start.
After 40 seconds from power cut-off, the first emergency generator supplies power
and then the second generator synchronizes to the first generator.
During power failure, the following procedures shall be adopted:
1. Utility DCS Room Operator shall:
a. Immediately informs the Production Department through the Production
DCS Operator that power failure has occurred. He then informs the Utility
Superintendent about the situation.
b. Check the starting condition of the emergency Generating Sets by
confirming that the air compressors, raw water pump, cooling tower
pump, cooling tower fan are in normal operating condition.
c. Check the instrument air pressure, plant air pressure and raw water
through the DCS. He coordinates with Production.
d. Instructs key personnel to proceed to RTNMC Power Plant and start the
emergency generating sets to restore electric power supply to RTNMC
Town site.
e. Opens the hand blow valve (HV-132) manually through the DCS and
adjusts the pressure of the steam drum to 5 MPA or less. The High
Pressure Steam of the boiler is likewise reduced.
f. Instructs the Utility Operator to proceed to the local panel. Utility Operator
will do the manual tripping of the turbine by pushing the Remote Trip
button on the TCP.
g. Instructs the Utility Operator to check the DC Oil Pump of the Steam
Turbine Generator. Also to be checked are the following:
1. Turbine Rotation (or RPM) has decreased._______________________________________________________________________________________
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2. Auxiliary Lube oil pump and the control oil pump have started
automatically.
3. The DC oil pump has already started at the Turbine Building.
4. Lube oil pressure and control oil pressure are in normal operating
condition.
h. Instructs the operator to turn the Steam Turbine Generator. The Utility
operator checks that the turning motor operates immediately after the
turbine rotation has decreased. The turbine shaft shall also rotate slowly.He further checks on the lube oil pump pressure and control oil pressure
are operating normally. The Utility Operator then closes the entrance
valve of the Steam Turbine Generator and opens the drain valve.
2. Production DCS Room Operator
a. The DCS operator informs the Production Manager that Power failure
occurred.
3. Production Foremen and Shift Leaders
a. The Foreman and Shift Leader see to it that water flushing of the
pipeline from Ore Thickener Underflow pump to 02TK01 / 202TK01 is
done. (Ore Preparation Area)
b. The autoclave is boxed. (HPAL Area)
c. Water flushing of suction and discharge line of each thickener underflow
pump by using self-circulation line is done. (CCD/NTRL Area)
d. Confirms scrubber operation (De-Zn / MS Areas)
e. Confirms discharge valve of the Geho Pump (to tailings dam) is closed.
(FNTRL)
f. Inspects leakages that can cause environmental hazards. (Chemical)
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g. Confirms H2S gas supply valve to the H2S Reactor is closed. (H2S
Plant)
4. Field Operators
a. Inspect each equipment and/ or facilities. Inspect for spillages/ leakages
(General)
b. Conducts water flushing of the slurry feed pump. (HPAL)
c. Confirms the valve for each reactor on the H2S Gas injection line is
closed. (De-Zn/MS)
5. Production Manager/ Utility Manager
a. Informs the Plant Manager that the necessary measures to be taken
during power failure are properly carried-out.
3.4 Air Failure
The CBNC Hydrometallurgical Processing Plant may experience air failure thereby
affecting valve operations in the MS plant.
To be able to address this kind of an emergency, there is a need to establish
emergency procedures.
When the air pressure goes down immediately reaching to 560KPaG of L alarm
level, the following procedures shall be adopted:
1. Utility DCS Room Operator
a. Immediately informs the Production Department through the Production
DCS Operator that plant air pressure is going down to 560KPaG of Low
Alarm Level and requires production to reduce consumption. He then
informs the Utility Superintendent about the situation.
b. The supply of the Neutralization (NTRL) basin bubbling air shall be
stopped when during the time of air pressure reduction, it is being used.
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c. If air pressure reaches to 500KPaG, the Utility DCS operator shall
advise Production to stop their operation. However, in this shutdown
operation, Production shall still proceed following standard operating
procedures.
d. If air pressure reaches to 400KPaG, the operator shall inform
Production Dept. that Utility Section will stop Boiler and Turbine
Operation. Operator stops the turbine manually. Production will proceed
with the SOPs being followed properly. After such instructions,
Production shall inform Utility that the shutdown operations were
completed.
2. Production DCS Room Operator
a. The DCS operator informs Foreman or Shift Leader, and Production
Manager that Air Failure occurred.
3. Production Foremen and Shift Leaders
a. The Foreman and Shift Leader see to it that valves on the Low
Pressure and High Pressure water line closes. Stop ore feed to prevent
ore clogging. To prevent clogging of ore thickener drain line, water flush
the pump and stop. Confirm that there are no air leaks (Ore Prep
Area).
b. The autoclave is boxed. All feed types shall be stopped. Since some
acid in the lance and feed slurry in the pipes can remain, once air
pressure recovers, Nitrogen (N2) purging or raw ore water flushing as
well as autoclave cooling shall be implemented. Since
02HV130/202HV130 is closed, the vent line shall be opened and
autoclave temperature is decreased to discharge pressure. While
adjusting the manual valve for plant air to scrubber, decrease air
volume. Pressure is set at 180 to 90KPaG to minimize effect on other
areas (HPAL Area).
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c. When instrument air pressure decreases, there will be no problem
indicated in the Pre-Neutralization Area. If limestone is needed, the by-
pass line can be used. If flash tank overflow decreases and
03TK13/203TK13 level drops, stop operation of 03PU08/203PU08.
Check if air leaks occur. (Pre-NTRL Area)
d. Control Valves must be closed and since there is a possibility of
overflow from 03TK08/203TK03, the following measures are taken:
Secure 03TK08/ 26TK01/ 26 PD01 lines; Close CCD overflow line
valves starting from CCD 7. CCD 7 drain is the same as previously
indicated but discharging operations to F- NTRL is stopped. When Pre-
Neutralization slurry is stopped, CCD Underflow (U/F) pumps are
stopped in order. Check for air leaks. (CCD Area)
e. Discharge from the CCD and Chemical addition line is stopped, thus,
NTRL needs to be stopped with the following measures: Flocculant
supply is stopped. Coagulant supply is also stopped. Seed from CCD is
also stopped. NTRL slurry discharge is adjusted to the barest minimum.
Check for air leaks. (NTRL Area)
f. H2S supply line valve is closed and the following measures are taken:
Stop the flow from 04PU01/204PU01. Check for air leaks (De-Zn Area).
g. The feed line to the reactor (including seed), H2S supply line, NaOH
addition line to scrubber, gas and effluent discharge line and barren
liquor discharge line will be closed. On the other hand, 06TH01 /206TH01discharge line valve holds for the previous condition and MS
Slurry can be discharged to 06TK04/206TK04. Raw water line for
condenser and MS seed cyclone recirculation line valve is opened.
Following measures are to be followed: Stop flocculant supply. Stop
pumps for each feed. Confirm whether 06CP01/206CP01 valve
(06PV301/206VP301) is FC (Fail Closed) or not. Check for air leaks.
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h. Chemical line will be stopped and F-NTRL Slurry discharge to Tailings
Dam will stop with the following measures in place: CCD underflow
slurry pump is stopped. Barren liquor pump is stopped. The
neutralization water pump is stopped. All sump pumps are stopped.
De-Zn slurry pump also stopped. CCD Mixing Tank pump also stopped.
Check for air leaks. (F-NTRL)
4. Production Manager/ Utility Manager
a. Informs Plant Manager the necessary measures to be taken during air
failure are properly carried-out.
3.5 Fire
An early response and correct action in the event of fire does not only limit the
losses in terms of property, but in most cases, minimize the dangers to human lives
as well.
Prompt action of CBNC employees and adequate preparation in the event of fire,
can only be attained thru anticipation of its effect and careful planning. However,
the best situation is where everyone in the company is fire safety conscious and
prevents the occurrence of fire.
3.5.1 COAL FIRE (AT PIER COAL STOCKYARD)
1. The Person who discovers the Coal Fire
a. Informs the Pier site Fire Fighting Team Leader the exact location of the coal
fire.
2. The Pier Site Fire Fighting Team Leader
a. Assesses the extent of the coal fire and informs the Purchasing and
Logistics Manager, who shall then inform the ERT Head (Plant Manager)
b. Coordinate with Plant site Fire Fighting Team Leader for possible additional
fire fighters.
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3. Pier Site Fire Fighting Team members
a. Upon receipt of the call that fire has occurred, fire fighting team members
proceed immediately to the location.
b. The first arriving member will report by radio that they are on-scene and their
initial assessment of the situation.
c. If fire has just started, attempt to extinguish it. Be aware of related dangers
such as explosion. Protect other installations from fire or explosion.
d. In case of explosion, escape promptly because of the danger of recurrence.
4. ERT Head (Plant Manager)
a. Responds to the reported coal fire and direct the actions of the other
members of the Emergency Response Team.
b. Gets update from the Pier site Fire Fighting Team Leader of the present
condition of the coal fire at pier.
c. Ensures coal fire has completely been extinguished.
3.5.2 METHANOL FIRE (PIER SITE)
1. The Person who discovers the Methanol Fire
a. Informs the Pier site Fire Fighting Team Leader the exact location of the
Methanol fire at Pier.
b. Assesses the extent of fire and informs Purchasing and Logistics
Manager and the later will decide for mass evacuation of neighboring
residents
2. The Pier Site Fire Fighting Team Leader
a. Verifies the extent of the Methanol fire and informs the Purchasing and
Logistics Manager, who shall then inform the ERT Head (Plant
Manager)
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b. Coordinates with Plant site Fire Fighting Team Leader for possible
additional fire fighters
3. Pier Site Fire Fighting Team members
a. Upon receipt of the call that fire has occurred, fire fighting team
members proceed immediately to the location.
b. The first arriving member will report by radio that they are on-scene and
their initial assessment of the situation.
c. If fire has just started, attempt to extinguish it. Be aware of related
dangers. Protect other installations from fire or explosion. Vapor may
travel to the source of ignition and flash back to methanol container;
explosion in this case is possible.
d. In case of explosion, escape promptly because of the danger of
recurrence.
e. Keep away unnecessary personnel and isolate the hazard area.
f. Stay upwind and keep out of low areas.
g. Leave the area immediately when rising sound from venting safety
device or any discoloration of tank due to fire is observed.
4. ERT Head (Plant Manager)
a. Responds to the reported Methanol Fire and direct the actions of the
other members of the Emergency Response Team.
b. Decides the evacuation of the neighboring community.
c. Gets update from the Pier site Fire Fighting Team Leader of the present
condition of the Methanol Fire at pier.
d. Ensures Methanol fire has completely been extinguished.
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3.5.3 METHANOL FIRE (PLANT SITE)
1. The Person who discovers the Methanol Fire
a. Informs H2S DCS Operator (CB) the exact location of the Methanol Fire at
the Plant Site.