National Safety Council

9/22/2014 1
Onsite Emergency
Preparedness


M M Kulkarni
Director
National Safety Council
National Safety Council
9/22/2014 2
Sl.
No.
Accident Date &
Time
Chemical
Involved
Event Death ,
(Injury)
1. Flixborough
Nypro Factory, UK
1.6.74
4.53 pm (Sat)
Cyclohexane VCE 28
(104)
2. Saveso, Italy 10/7/76
12.37 pm
(Sat)
TCDD Toxic release Evacuation
3. Mexico, USA 19/11/84
5.40 am
(Mon)
LPG BLEVE 500
4. Bhopal 2.12.84
0015 (Mon)
MIC Toxic release 3000
(> 2 lacs)
5. Sandoz Warehouse Fire
Switzerland
1.11.86
(Sat)
Agro
Chemicals
Fire water
entered in
river
Rhine
River
polluted
7. PHILLIPS
Pasadena,Texas, USA
23.10.89
1 pm
polyethylene VCE 23
(300)
8. IPCL, Nagothane 5.11.90
7.10 pm
Propane VCE 32
(22)
9. HPCL Refinery
VIZAG
7.9.97
6.30 am (Sun)
LPG VCE 58
Chemical Accidents - A Fact of life
National Safety Council
9/22/2014 3
Learning from Accidents

If we closely analyse these Chemical Accidents, few
obvious things come out :
Most of these Accidents happened in either
Night Hours or early morning Hours
Weekends
What we learn from above is that our DM Preparedness should
be based on Round the clock preparation rather than merely
restricting preparation during general shift.
More focus is required for 2
nd
and 3
rd
shifts when
employee population remains thin & much less
physical presence of management staff.
National Safety Council
9/22/2014 4
Chemical Accidents in India (2002-06)
2 6 Fire in LPG
fired oven
28.10.04 Anil Enterprises, Zakhira,
Rohtak
8.
5 8 Explosion 25.11.03 IDL Gulf Oil,
Kukkatpally, Hyderabad
7.
19 2 Toluene 11.6.03 Ranbaxy Lab Ltd.,
Mohali, Punjab
4.
- - LPG leak -
Tank lorry
5.10.03 BPCL Bottling Plant, Dhar 5.
88 - Liquid
Chlorine
13.10.03 Orient Paper Mills, Amla,
Shahdol, MP
6.
- - Toluene fire 6.7.04 HIL Udyogmandal,
Kerala
9.
- - Fire in Motor
spirit Tank
7.3.03 IOC Refineries, Digboi 3.
18 W
(300 vill)
- Chlorine
Release
20.12.02 IPCL, Gandhar 2.
20 4 Chlorine Gas 5.9 02 GACL, Vadodara 1.
Injury Death
Impact Source Date Industry Sl.
No.
Product loss of
Rs.11.5 crore
National Safety Council
9/22/2014 5
- - Fire 15.6.05 Gujrat Refinery 17.
20 - Chlorine
release
1.12.04 PWD premises 16.
13 2 Explosion in
slurry settler
29.10.04 Gujrat Refinery,
Vadodara
13.
2 1 Fire in Dryer
room
30.10.04 Ranbaxy Laboratories
Ltd., Mohali, Punjab
14.
- 1 Explosion 23.11.04 Kekule Pharma Ltd. 15.
5 - Ammonia 22.7.05 Coromondal Fertiliser,
Ltd., Ennore
18.
8 1 Hexane
release & fire
31.5.04 Chemical Factory,
Dombivilli, Maharashtra
12.
27 - Chlorine leak 18.7.04 Chemplast, Metture, TN 11.
- - Benzene fire 12.04.04 Shyamlal Industries,
Vatva, Ahmedabad
10.
Injury Death
Impact Source Date Industry Sl.
No.
National Safety Council
9/22/2014 6
2
Fire
25.10.06 RIL, Jamnagar 25
23 6
Cl release
29.3.06 Kanoria Chemicals &
Industries Ltd , UP
22
- 5 Spillage of
haz chemical
18.07.06 Anjana Explosives Ltd,
AP
23
- 1 Gas Release 19.9.06 Ravi Organics Ltd , UP. 24
- 1 Fire 29.12.05 IOCL, Mathura 21
4 1 Explosion 3.11.05
Orchid Chemicals &
pharmaceuticals Ltd, TN
20.
2 2 Explosion/
Fire
4.10.05
Gulf Oil Corporation Ltd.,
Hyderabad
19.
Injury Death
Impact Source Date Industry Sl.
No.
-
National Safety Council
9/22/2014 7
Emergency Preparedness : Need of Hour
These Accidents embarked the
need of a robust Emergency
Preparedness System.
Equal focus on Macro & Micro
level Planning.
Involvement of All levels
National Safety Council
9/22/2014 8
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
National Safety Council
9/22/2014 9
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
National Safety Council
9/22/2014 10
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
National Safety Council
9/22/2014 11
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
National Safety Council
9/22/2014 12
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

EMERGENCY PLANS
National Safety Council
9/22/2014 13

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
National Safety Council
9/22/2014 14
EMERGENCY PLANNING

STATUTORY FRAME-WORK
National Safety Council
9/22/2014 15
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
National Safety Council
9/22/2014 16

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

MSIHC Rules, 1989
National Safety Council
9/22/2014 17
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.
National Safety Council
9/22/2014 18
(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.
National Safety Council
9/22/2014 19
APELL A Process for responding to Technological
Accidents
- Developed by UNEP in 1986
- Implemented in India in 1992 in six-high risk
Industrial Areas
- Recommended in NDMA Guidelines
National Safety Council
9/22/2014 20
1. 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
National Safety Council
9/22/2014 21
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
National Safety Council
9/22/2014 22

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

National Safety Council
9/22/2014 23

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
National Safety Council
9/22/2014 24

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)
National Safety Council
9/22/2014 25
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
National Safety Council
9/22/2014 26

7. Procedure for Returning to Normal
Operations

Authorization

Declaration of the end of emergency

Communication of the Declaration of end
of emergency
National Safety Council
9/22/2014 27
8. Training and Drills

Training of Team Leadres
Training of Emergency Responders
Emergency Drill
- Frequency and Responsibility
(MSIHC 6 months)



National Safety Council
9/22/2014 28

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
National Safety Council
9/22/2014 29
10. Plan Updates


Annual or more frequent if needed

Reflect results of drills and tests

Review of the Plan

Responsibility for updating the Plan
National Safety Council
9/22/2014 30
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
National Safety Council
9/22/2014 31
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
National Safety Council
9/22/2014 32
Information for use in the Off-Site Emergency Plan:
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.
Separate section on Off-site Emergency Plan
National Safety Council
9/22/2014 33
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.
National Safety Council
9/22/2014 34
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.
National Safety Council
9/22/2014 35
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
National Safety Council
9/22/2014 36
National Safety Council
9/22/2014 37
National Safety Council
9/22/2014 38
means a continuous and integrated process of
planning, organising, coordinating and implementing
measures which are necessary or expedient for:

i) Prevention of danger or threat of any disaster;
ii) Mitigation or reduction of risk of any disaster or its severity or
consequences;
iii) Capacity building;
iv) Preparedness to deal with any disaster;
v) Prompt response to any threatening disaster situation or
disaster;
vi) Assessing the severity or magnitude of effects of any disaster;
vii) Evacuation, rescue and relief;
viii) Rehabilitation and reconstruction
The DM Act, 2005
Disaster Management
National Safety Council
9/22/2014 39
Works Main Controller
(WMC)
Security Gate No.2 or
Security Gate No.4
Support Team to WMC
Logistics Team
Leader -
Traffic Control
Team
Leader -

Incident Controller

Communication Team
Leader (Head ER&D)

Area In-charges of the
Affected Areas

Medical Team
Leader -
Plant Control and Shut
Down Team

Fire & Rescue Team
Leader -
Corporate Office at
ORGANISATION CHART
National Safety Council
9/22/2014 40

Facility where Accident Take Place
Hospital
Cinema Hall
School
National Safety Council
9/22/2014 41
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.
National Safety Council
9/22/2014 42
Ref :
1. Factories Act, 1948
2. MSIHC Rule, 1986
3. CA(EPPR) Rules, 1996
4. PLI Act
5. Major Hazard Control A Practical Manual by ILO
6. Hazardous Material Emergency Planning Guide by
National Response Team, USA