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On-site Emergency Preparedness National Workshop on Disaster Management

On-site Emergency Preparedness National Workshop on Disaster Management 24-26 Sept 08 at Secunderabad, A.P. A.Y. Sundkar NATIONAL SAFETY COUNCIL. FEW MAJOR DISASTERS IN WORLD. Sl. No. Name of Chemical Involved. Death. Injury. Place & Year. 1. Methane. 136. 77.

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On-site Emergency Preparedness National Workshop on Disaster Management

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  1. On-site Emergency Preparedness National Workshop on Disaster Management 24-26 Sept 08 at Secunderabad, A.P. A.Y. Sundkar NATIONAL SAFETY COUNCIL

  2. FEW MAJOR DISASTERS IN WORLD Sl. No Name of Chemical Involved Death Injury Place & Year 1 Methane 136 77 Cleveland, Ohio, USA 1944 2 LPG (BLEVE) 18 90 Feyzin, France, 1966 3 LNG 40 - Staten Island, New York, 1973 4 Methane 52 - Mexico, 1985

  3. EXPLOSION Sl. No Name of Chemical Involved Death Injury Place & Year 1 Dimethylether 245 3800 Germany, 1948 2 Kerosene 32 16 Germany, 1954 3 Cyclohaxane 28 89 Flixborough, UK, 1974 4 Propylene 14 107 Beek, Netherlands, 1975

  4. TOXIC RELEASE Sl no Name of Chemical Involved Death Injury Place & Year 1 Phosgene 10 - Poza Rica, Mexico, 1950 2 Chlorine 7 - Germany, 1952 3 Ammonia 30 25 Colombia, 1977 4 Methyl Isocyanite 2500 250000 Bhopal, India, 1984 4

  5. 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

  6. Chemical Accidents in India (2002-06) Sl.No. Industry Date Source Impact Death Injury 1. GACL, Vadodara 5.9 02 Chlorine Gas 4 20 2. IPCL, Gandhar 20.12.02 ChlorineRelease - 18 W (300 vill) 3. IOC Refineries, Digboi 7.3.03 Fire in Motor spirit Tank - - 4. Ranbaxy Lab Ltd., Mohali, Punjab 11.6.03 Toluene 2 19 5. BPCL Bottling Plant, Dhar 5.10.03 LPG leak - Tank lorry - - 6. Orient Paper Mills, Amla, Shahdol, MP 13.10.03 Liquid Chlorine - 88 7. IDL Gulf Oil, Kukkatpally, Hyderabad 25.11.03 Explosion 8 5 8. Anil Enterprises, Zakhira, Rohtak 28.10.04 Fire in LPG fired oven 6 2 9. HIL Udyogmandal, Kerala 6.7.04 Toluene fire - - Product loss of Rs.11.5 crore

  7. Chemical Accidents in India (2002-06) Sl.No. Industry Date Source Impact Death Injury 10. Shyamlal Industries, Vatva, Ahmedabad 12.04.04 Benzene fire - - 11. Chemplast, Metture, TN 18.7.04 Chlorine leak - 27 12. Chemical Factory, Dombivilli, Maharashtra 31.5.04 Hexane release & fire 1 8 13. Gujrat Refinery, Vadodara 29.10.04 Explosion in slurry settler 2 13 14. Ranbaxy Laboratories Ltd., Mohali, Punjab 30.10.04 Fire in Dryer room 1 2 15. Kekule Pharma Ltd. 23.11.04 Explosion 1 - 16. PWD premises 1.12.04 Chlorine release - 20 17. Gujrat Refinery 15.6.05 Fire - - 18. Coromondal Fertiliser, Ltd., Ennore 22.7.05 Ammonia - 5

  8. Chemical Accidents in India (2002-06) Sl.No. Industry Date Source Impact Death Injury 19. Gulf Oil Corporation Ltd., Hyderabad Explosion/ Fire 2 2 4.10.05 Orchid Chemicals & pharmaceuticals Ltd, TN 20. 3.11.05 Explosion 1 4 21 IOCL, Mathura 29.12.05 Fire 1 - 22 Kanoria Chemicals & Industries Ltd , UP 29.3.06 Cl release 6 23 23 Anjana Explosives Ltd, AP 18.07.06 Spillage of haz chemical 5 - 24 Ravi Organics Ltd , UP. 19.9.06 Gas Release 1 - 25 RIL, Jamnagar 25.10.06 Fire 2 -

  9. 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

  10. 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

  11. 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

  12. 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

  13. 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

  14. 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

  15. 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

  16. EMERGENCY PLANNING STATUTORY FRAME-WORK

  17. 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

  18. 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-2&3 column 3 • Unit Isolated Storage • AMMONIA : 50 T 60 T • LPG : 15 T 50 T • CHLORINE : 10 T 10 T

  19. 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.

  20. 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.

  21. 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

  22. 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

  23. 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

  24. 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

  25. 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

  26. 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)

  27. 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

  28. 7. Procedure for Returning to Normal Operations • ●Authorisation • ● Declaration of the end of emergency • ● Communication of the Declaration of end of emergency

  29. 8. Training and Drills • Training of Team Leadres • Training of Emergency Responders • Emergency Drill • - Frequency and Responsibility • (MSIHC – 6 months)

  30. 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

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

  32. 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

  33. 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

  34. 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.

  35. 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.

  36. 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.

  37. THANK YOU

  38. ORGANISATION CHART Corporate Office at” Works Main Controller (WMC) Security Gate No.2 orSecurity Gate No.4 Support Team to WMC Communication Team Leader (Head – ER&D) Traffic Control Team Leader - Logistics Team Leader - Incident Controller Medical TeamLeader - Area In-charges of the Affected Areas Plant Control and Shut Down Team Fire & Rescue Team Leader -

  39. Cinema Hall Hospital Facility where Accident Take Place School

  40. 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.

  41. 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

  42. GAPS OBSERVED IN THE ON-SITE EMERGENCY PLANS

  43. 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

  44. 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

  45. 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

  46. 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

  47. 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.)

  48. 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

  49. 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

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

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