on-site em preparadness

8/11/2019 On-site Em Preparadness

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National Safety Council

9/22/2014 1

Onsite EmergencyPreparedness

M M Kulkarni

DirectorNational Safety Council


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Sl.No.

Accident Date &Time

ChemicalInvolved

Event Death ,(Injury)

1. FlixboroughNypro Factory, UK

1.6.744.53 pm (Sat)

Cyclohexane VCE 28(104)

2. Saveso, Italy 10/7/7612.37 pm(Sat)

TCDD Toxic release Evacuation

3. Mexico, USA 19/11/845.40 am(Mon)

LPG BLEVE 500

4. Bhopal 2.12.840015 (Mon)

MIC Toxic release 3000(> 2 lacs)

5. Sandoz Warehouse FireSwitzerland

1.11.86(Sat)

AgroChemicals

Fire waterentered inriver

RhineRiverpolluted

7. PHILLIPSPasadena,Texas, USA

23.10.891 pm

polyethylene VCE 23(300)

8. IPCL, Nagothane 5.11.907.10 pm

Propane VCE 32(22)

9. HPCL Refinery VIZAG

7.9.976.30 am (Sun)

LPG VCE 58

Chemical Accidents - A Fact of life


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Learning from Accidents

If we closely analyse these Chemical Accidents, fewobvious things come out :

Most of these Accidents happened in either

Night Hours or early morning Hours

WeekendsWhat we learn from above is that our DM Preparedness should

be based on Round the clock preparation rather than merelyrestricting preparation during general shift.

More focus is required for 2 nd and 3 rd shifts whenemployee population remains thin & much less

physical presence of management staff.


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Chemical Accidents in India (2002-06)

26Fire in LPGfired oven

28.10.04 Anil Enterprises, Zakhira,Rohtak

8.

58Explosion25.11.03IDL Gulf Oil,Kukkatpally, Hyderabad

7.

192Toluene11.6.03Ranbaxy Lab Ltd.,Mohali, Punjab

4.

--LPG leak -Tank lorry

5.10.03BPCL Bottling Plant, Dhar

5.

88-Liquid

Chlorine

13.10.03Orient Paper Mills, Amla,

Shahdol, MP

6.

--Toluene fire6.7.04HIL Udyogmandal,Kerala

9.

--Fire in Motor

spirit Tank

7.3.03IOC Refineries, Digboi3.

18 W(300 vill)

-ChlorineRelease

20.12.02IPCL, Gandhar2.204Chlorine Gas5.9 02GACL, Vadodara1.

InjuryDeath

ImpactSourceDateIndustrySl.No.

Pro

duct loss ofRs.11.5 crore


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--Fire15.6.05Gujrat Refinery17.

20-Chlorinerelease

1.12.04PWD premises16.

132Explosion inslurry settler

29.10.04Gujrat Refinery, Vadodara

13.

21Fire in Dryerroom

30.10.04Ranbaxy LaboratoriesLtd., Mohali, Punjab

14.

-1Explosion23.11.04Kekule Pharma Ltd.15.

5- Ammonia22.7.05Coromondal Fertiliser,Ltd., Ennore

18.

81Hexanerelease & fire

31.5.04Chemical Factory,Dombivilli, Maharashtra

12.

27-Chlorine leak18.7.04Chemplast, Metture, TN11.

--Benzene fire12.04.04Shyamlal Industries, Vatva, Ahmedabad

10.

InjuryDeath

ImpactSourceDateIndustrySl.No.


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2Fire 25.10.06RIL, Jamnagar25

236Cl release 29.3.06Kanoria Chemicals &Industries Ltd , UP22

-5Spillage ofhaz chemical

18.07.06 Anjana Explosives Ltd, AP

23

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

-1Fire29.12.05IOCL, Mathura21

41Explosion3.11.05Orchid Chemicals &pharmaceuticals Ltd, TN

20.

22Explosion/Fire

4.10.05Gulf Oil Corporation Ltd.,Hyderabad

19.

InjuryDeath

ImpactSourceDateIndustry

Sl.No.

-


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Emergency Preparedness : Need of Hour

These Accidents embarked theneed of a robust Emergency

Preparedness System.

Equal focus on Macro & Micro

level Planning.

Involvement of All levels


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EMERGENCY

A situation created by an accidentalre lease or s p i l l o f hazardou s c hem icals

w hich po ses a threat to the safety ofw ork ers , res idents , the env i ron m ent or

property

MSIHC Guidelines by MoEF, 1996


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EMERGENCY PLAN

A formal written plan which, on the basis of

ident i f ied po tent ia l acc idents to gether wi ththei r cons equ ences , desc r ibes h ow suc h

acc iden t s and the ir co nsequences sh ou ld b e

hand led, ei ther on -s i te or o ff- site

Guiding Principles: Chemical Accident Prevention Manual, OECD,2003


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EMERGENCY may caused by

1. Process and Safety System failure

- Technical Errors (Design defects, fatigue, metalfailure, 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 basicforms

Fire

Explosion or Toxic

Emergencies with chemical industry concern are :

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

2. Transport Emergency


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To mitigate effects of Emergency requires - Thoug ht fu l Plann ing- B etter Preparednes s

- Quic ker Resp on se

Emergency Planning not substitute formaintenance of good safety systems, proceduresand practices

Accident Prevention through good design,operation, maintenance and inspection

EMERGENCY PLANS


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Emergency Planning is an important element ofmitigation

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 ascircumstances demand


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EMERGENCY PLANNING

STATUTORY FRAME-WORK


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FACTORIES ACT 1948 Section 41 A to H HazardousProcesses Section - 41 B (4)

Occupier to draw up an On-Site EmergencyPlan & Disaster Control Measures for hisfactory

Make safety measures to be taken in theevent of an accident known to- - Workers - Public in the Vicinity


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MAH Installations Threshold Quantity

Industrial Activity at a Site Handling Hazardous

Chemicals and Isolated Storage Equal to or inExcess of Threshold Quantities.-Schedules-2&3column 3

Unit Isolated Storage

AMMONIA : 50 T 60 T LPG : 15 T 50 T CHLORINE : 10 T 10 T

MSIHC Rules, 1989


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13. PREPARATION OF ON-SITE EMERGENCYPLAN BY THE OCCUPIER(1) Occupier to prepare and keep up-to-

date an On-Site Emergency Plan withspecified details (Schedule11) detailing - dealing with major accidents on site- name of the Person responsible for

Safety on site

- names of authorised persons to takeactions as per the Plan in case ofan

Emergency.


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(2) The Occupier to ensure that the On-SitePlan includes modifications and allpersons on site affected by the Plan areinformed accordingly.

(4) The Occupier to ensure to conduct a mockdrill of the On-Site Emergency Plan every 6months.

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


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APELL A Process for responding to TechnologicalAccidents

- Developed by UNEP in 1986

- Implemented in India in 1992 in six-high riskIndustrial Areas

- Recommended in NDMA Guidelines


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1. Introduction

Legal Requ irem ent

Bas is of the Plan Purpo se and ob jec t ive

Ab out Fac to ry l oca tion ; n am e & address o f

the person furn ish in g the info rm at ion , no . ofpeop le and b r ief p rocess desc r ip t ion


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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 nearbyplants

Nearby residence and population centre

Contacts (names, telephone numbers) at othersites.

Established procedures for notification ofchemical releases at other sites in area

Natural Calamities which can lead toemergency Flood, Cyclone, Earthquake


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5. Notification Procedures & CommunicationsSystems

Declarat ion 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 NormalOperations

Authorization

Declaration of the end of emergency

Communication of the Declaration of endof 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/Procedures

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

Resp on s ib i l i ty for up dat ing 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

Separate section on Off site Emergency Plan


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Information for use in the Off-Site Emergency Plan :

Summary of Risk Analysis, vulnerability zone forthose scenarios which can escalate into off-siteemergencies.

List of resources required to handle the off-site

emergencies foreseen in the On-site Plan, theirassessment 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 theadditional resources (e.g. Mutual Aid orarrangement with the Public Response Agencies)mentioning the salient terms of such arrangements.

Separate section on Off-site Emergency Plan


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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 thearrangement for releasing such resources.

How Community awareness programme has beenplanned? How the community has been identified(from which zone-part or full vulnerability zone)?Have the key opinion makers who can play activerole have been identified? (Give list alongwith their

contact details). Has the selection of the communityor that of key persons in the community been donein consultation with the District Authority? etc.


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Has Insurance under the Public Liability Insurance Act been obtained? Give summary.

Designate a Contact person who would beauthorised to co-ordinate for Off-site Plan and hiscontact details

Technical Team (chemical-wise) in case of an Off-site Emergency taken place due to escalation of anOn-site incident, contact details of its members.


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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, OperatorSupervision, ManualIntervention

Basic Controls, Process Alarms,Operator Supervision

Typical Layers of ProtectionMitigation system responses


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THANK YOU


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THANK YOU


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means a continuous and integrated process of

planning, organising, coordinating and implementingmeasures which are necessary or expedient for:

i) Prevention of danger or threat of any disaster;i i ) Mit igat ion or reduct io n of r isk of any disas ter or i t s sever i ty or

consequences ;

i i i ) Capaci ty bu i ld ing;

iv) Preparedness to deal w i th any disas ter ;

v) Prom pt respon se to any threatening disas ter s i tuat ion or

disas ter ;v i ) As sess in g the sever i ty or magni tu de of effects of any disas ter ;

vi i) Evacu ation, resc ue and rel ief;

v i i i ) Rehabi l i tat ion and recons t ruc t ion

The DM Act, 2005

Disaster Management

ORGANISATION CHART


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Works Main Controller(WMC)

Security Gate No.2 orSecurity Gate No.4

Support Team to WMC

Logistics TeamLeader -

Traffic ControlTeam

Leader -

Incident Controller

Communication TeamLeader (Head ER&D)

Area In-charges of theAffected Areas

Medical TeamLeader -

Plant Control and ShutDown Team Fire & Rescue Team

Leader -

Corporate Office at

ORGANISATION CHART


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Facility where Accident Take Place

Hospital

Cinema Hall

School

OISD Standard 117


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Fire Protection Facilities for Petroleum Depots,Terminals and Pipeline Installations

Alarm/communication SystemElectrical/hand operated Fire Siren with code1. Small Fire - No Siren

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

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 :

1.Factories Act, 1948

2.MSIHC Rule, 1986

3.CA(EPPR) Rules, 19964.PLI Act

5.Major Hazard Control A Practical Manual by ILO

6.Hazardous Material Emergency Planning Guide byNational Response Team, USA

on-site em preparadness

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