Disaster Management Plan for Thermal Power Plants

Safety Module: Disaster Management Plan, Rev 0.0, Mar 2007

 Natural disasters (earth quake, flood etc.,) Technical disasters sabotage, collapse of buildings, release of gases, major fires, explosions.
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Disaster (Major Emergency)

A disaster occurring in the plant may affect/cause several sections within it serious injuries / loss of lives, Extensive damage to property Serious disruption out side the works area It will require the best use of internal resources as well as outside resources to handle it effectively.

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 ON-SITE EMERGENCY : An accident which takes place in an industry handling hazardous materials and its effects are confined to the factory premises involving only the people working in the factory. OFF-SITE EMERGENCY: If an accident takes place in an industry handling hazardous materials and its effects are felt outside the factory premises, the situation thus generated is called an Off-Site Emergency
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Is Power Industry A Hazardous Industry?

Yes, In accordance with the provision of Schedule 2 (C), (b) read with The Factories Act 1948, power generating industry is classified as hazardous process under item 5 thereof. According to Section 41-b, para 4, of Factories Act 1948, all factory engaged in hazardous processes must have disaster plan.

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Section 41-b, Para -4 of Factories Act 1948

Provisions of

Every occupier shall, with the approval of chief inspector, draw up on site emergency plan and detailed disaster control measures for his factory and make known to the workers employed there in and to the general public living in the vicinity of factory the safety measure required to be taken in the event of an accident taking place.

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Section 41-b, Para -5 of Factories Act 1948

Every occupier of a factory shall,(A) If factory engaged in a hazardous process on the commencement of the Factories (amendment) Act, 1987 (20 of 1987), within a period of thirty days of such commencement; and (B) If such factory proposes to engage in a hazardous process at any time after such commencement, within a period of thirty days before the commencement of such process,

Provisions of

Inform the chief inspector of the nature & details of the process in such form and in such manner as may be prescribed.

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Laws relevant to disaster management, emergency planning, preparedness & response

Factories Act, 1948 (major amendment in 1987) Environment (Protection) Act, 1986 Manufacture, Storage, Use & Import of hazardous chemicals Act, 1989 Chemical Accidents (Emergency Planning, Preparedness & Response) Rules, 1996

Hazardous wastes (Management & Handling) Rules, 1989

Public Liability Insurance Act, 1991 Water (Prevention & Control of Pollution) Act, 1974 Air (Prevention & Control of Pollution) Act, 1981 Public Nuisance Act Explosives Act, 1884/Rules, 1983 (includes Gas Cylinders Rules, 2004) Petroleum Act, 1934/Rules, 2002 etc.
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Aim of the Disaster Plan

The emergency planning is aimed to ensure safety of life, protection of environment,

installations and restoration of production

(generation of electricity).

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Objective of the Plan

The plan is developed to make best possible use of resources at its command and / or out side agencies for the following purposes. 1. Safe guard others by evacuating them to safer places; 2. Rescue of victims and treating them suitably to effect speedy recovery at hospital; 3. Identify the personnel affected / dead; 4. Inform relative of those deceased / effected; 5. Providing relevant record / data needed as evidence for subsequent enquiry; 6. Rehabilitation of the affected;

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Cause of Major Disasters in Power Plants

Fast spreading fires Explosions Bursting of pipe lines / vessels Uncontrolled release of toxic / corrosive / flammable liquids Slow isolated fires Uncontrolled release of toxic / flammable gases / dusts Breach of dams, / ash dykes Floods

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Fire Hazards In Power Plants

Coal handling plant: Coal dust accumulation on
conveyor decks, cable trays, head & tail pulleys, Crusher house and vibrating screen floors, Bunker house ,

Belt sway, belt tension, Failure of belt joints, Snapping of belts, Partially damaged belt in operation, Smoldering fire in bunkers, Jamming of idlers and pulleys,

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Fire Hazards In Power Plants

Cables in cable galleries and on trays in all plant sections, Coal dust deposited on cable trays in mill area Fuel oil handling and oil tanks (HSD, HFO, Naphtha, Petrol ) Transformer oil, turbine oil, control fluid, seal oil, Natural gas Electrical system Heat path damaged insulation Grass Accumulation of waste material etc.

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Explosion Hazard In Power Plant

Hydrogen plant Turbo generators where hydrogen is used for cooling of TG. Transformer (oil cooled). Boiler (Coal/Oil fired).

Coal dust in Mills and Boilers.

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Bursting of Pipe Lines, Vessels

Water / Steam pipes due to high pressure/ temperature

H2 Gas lines and Acid lines.

Acid/Alkali tanks H2 Gas Cylinders

Compressed air header.

Compressed air receivers. H2 Gas Holder.

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Release of Gases / Dust

Chlorine in water treatment plant Hydrogen in turbo generator area of main plant Pulverised coal dust from mills and associated piping Fly ash from chimneys and ash ponds, ESP hoppers and bottom ash system Coal dust in transfer points, CHP, Crusher & mill area. Flue gas from the ducts

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Release Of Liquid

Acid and alkali tanks in water treatment plants Chlorine toners in WTPs Fuel oil tanks in fuel oil handling section Naphtha handling and storage Ash dyke Control fluid in 500 MW turbine system Turbine oil and seal oil leakage

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Floods

Breach of balancing reservoir. Breach of ash dykes

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Potential Major Emergency

A major emergency is one that effect several departments within the factory or may cause serious injuries, loss of life extensive damage to property or serious disruption of works which require the involvement of several resources to handle it effectively.

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Sections Which Are Prone to Such Emergencies 1. Coal handling plant 2. Main plant 3. Water treatment plant 4. Hydrogen generation plant 5. MGR transportation system

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Common elements of a model On/Off-site Emergency Management Plan

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Components of On-site Emergency Plan

Plant emergency organization Plant & Area risk evaluation

Notification procedures & communication systems

Emergency equipment and facilities Procedure for returning to normal operations

Training and drills for specialized services

Regular tests procedures Plan updates Emergency response procedures Detailed operating manual
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of

emergency

organization

and

General Risk Evaluation

Consists of the following components: Maximum quantitative and qualitative assessment of of hazards at any given point of time Location of hazardous systems Properties of hazardous systems (MSDS) Location of isolation systems Special fire-fighting procedures Special handling requirements.

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Notification procedures & communication systems Alarm systems Communication equipment (radio, hot lines) Plant management, Local Officials, Response Agencies, Neighbouring industries, Neighbourhood population Names and telephone #s of the designated officials and their alternates Designated persons for media contacts Procedures for notifying families of injured employees Central reporting office.

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Emergency equipment, facilities & procedure for returning to normal operations

Fire-fighting equipment Emergency medical supplies Toxic gas detectors Wind direction/speed indicators Self-contained breathing apparatus Protective clothing Other on-site equipment to be specified according to the local conditions Containment facilities around tanks/vessels Interfaces & lines of communication with off-site officials, neighbouring industries.

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Training & Drills

Knowledge of chemicals (properties, toxicity, etc.) and procedures for reporting emergencies

Alarm systems and communication network

Location of fire-fighting/first-aid equipment Use of fire-fighting/first-aid equipment Use of protective equipment(respirators, breathing apparatus, clothing, etc.) Decontamination procedure for protective clothing and equipment; demolition and repair Evaluation procedures and rescue services Records of documented simulated emergencies which should be conducted frequently. Transportation and public relations
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Training & Drills

Training and drills for specialized services Regular tests of emergency organization and procedures Plan updates Emergency response procedures

Detailed operating manual

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Emergency Preparedness
Testing and evaluating are an integral part of emergency preparedness Objectives:
o Assessment of effectiveness of the plan and response capability and identify whole elements in the plan o Establish criteria for corrective actions o Test knowledge/skill of the participating personnel o Serve as continuing training tool for response personnel, provide an opportunity to practice skills under realistic condition o Test communication network & co-operative response skills, educate the personnel and all other concerned.

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Legal requirement: The concerned authority shall be duty-bound to prepare and keep up-to-date an off-site emergency plan containing the specified details as to
How to deal with an emergency relating to a possible major accident While preparing the plan the Authority shall consult the Occupier The Occupier shall assist the Authority in preparation of the plan

Off-site Emergency Plan

The Authority shall prepare the plan in association with the plant management actively participating in the process,

in case of a new industry before the activity commences, and in case of an existing one within six months of these Rules coming into force

The Authority shall ensure that a rehearsal of the plan is conducted at least once in a year.
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DIZASTER MAGMT.ORGN.

First Information

Emergency Control Room Chief Incident Controller Emergency plan Each section will be headed by Works incident controller reporting to the chief incident controller Details in next slide Safety Module: Disaster Management Plan, Rev 0.0, Mar 2007 Work Incident Controller

DIZASTER MAGMT.ORGN. Chief Incident Controller Task Force Team HR Team Matls Mgmt. Team Autobase Team
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Support Team

Work Incident Controller

Support Team

Communication team

Rescue Team

Maint Team

Medical team
Security Team

Disaster Management Organisation

OCCUPIER WHO HAS THE ULTIMATE CONTROL OVER THE AFFAIRS OF FACTORY Occupier in relation to NTPC plant is Head of the plant i.e., Plant General Manager. The GM of the plant will be CIC. In the absence of GM whoever is in-charge GM will be CIC Head of O&M will be WIC. In the absence of Head of O&M, in-charge O&M on that day will be WIC. Shift Charge Engineer will be the Incident Controller
Public Relation Officer(PRO) will be the ECO The personnel who will have key role to play in providing advice and in implementing the decisions made by the CIC

CHIEF INCIDENT CONTROLLER(CIC)

WORKS INCIDENT CONTROLLER(WIC) INCIDENT CONTROLLER (IC) EMERGENCY COMMUNICATION OFFICER(ECO) KEY PERSONNEL

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Works Incident Controller (WIC)

The main task to WIC is to visit the scene of the emergency, assessment of the situation and decide whether a major emergency exists or likely. WIC is responsible for implementing the disaster plan to control the emergency. The Sr. Manager of the section concerned shall be WIC and name of all WIC shall be identified.

The unit controller / shift in charge engineers shall assume the responsibility of WIC, when he is not available at station.
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Responsibilities of WIC
The WIC shall identify; All probable emergency causing situations and take proper precautionary measures to prevent / control such situations; Ensure that all emergency team under him are informed about their functions before and during emergency; Direct all operations with in the affected area with the following priority; 1. Secure the safety of personnel 2. Minimise damage to plant & environment 3. Minimise loss of material

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Responsibilities WIC
Ensure that all non-essential workers in the affected areas are evacuated to appropriate assembly point.

Set up communication contact through telephone / messenger etc. With emergency control centre.
Report significant developments to the chief incident controller. Assume duties of chief incident controller pending his arrival and in particular;
1. Direct the shut down and evacuation of plant and affected areas likely to be threatened by the emergency. 2. Ensure key personnel are informed and they are called in

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Chief Incident Controller(CIC)

The General Manager /Head of Project shall be the Chief Incident Controller (CIC). The O&M in-charge on duty shall assume responsibility of CIC in the absence of GM/HoP.

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Functions of CIC
1. 2. Relieve the works incidence controller from the responsibility of over all main control. Declare major emergency, if considered necessary and ensure out side emergency services are called in and near by industries are informed.

3. Ensure key personnel are called in to exercise, direct operation control.

4. Directing shutting down and evacuation of plant, establish liaison with head of fire, safety, medical, HR, security and local police.

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Functions Of CIC

5. 6. 7.

Arrange for relief of personnel and catering facilities for affected in emergency. Issue authorised statements to news media. Ensure information / reporting to Corporate Office and Statutory authorities as per provisions of state Factory rules and Factory Act 1948.

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Emergency Control Centre (ECC)

Emergency control centre will be established and equipped with adequate means of communication to areas inside and outside. The emergency control room will be manned by the Chief Incident Controller and key personnel and Sr.Officers of out side services called for assistance. No other personnel shall have access to the ECC.

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Emergency Control Centre (ECC)

ECC must contain the following information: 1. 2. 3. Safety data pertaining to all hazardous materials likely to cause emergency. Procedure of major and special fire fighting, rescue operations, first aid etc. Emergency call out list of persons drafted for emergency control eg key personnel from fire, safety, medical, HR, security, local police and District admn. Authorities.

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Evacuation And Assembly Points

In an emergency, it will almost certainly be necessary to evacuate personnel from affected areas. On evacuation, employees shall assemble at assembly point.

Assembly point must be given in disaster plan.

Assembly points

1. Main gate ( security gate no.1) 2. Industrial canteen 3. Administrative building

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Key Personnel
Apart from WIC and CIC, other works personnel will have key role to play in providing advice and in implementing the decisions made by CIC. Key personnel includes 1. Incharge of generation, electrical & mechanical maintenance, C&I, Chemistry (& WTP) 2. Head of HR, safety, autobase, PR, Medical, Security & fire.

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Mutual Aid
An understanding for mutual aid between nearby industries to send assistance to each other in case of an emergency; Details of facilities offered by the mutual aid partners should be mention in the plan;

Details of contact phone nos. of officers responsible for emergency action of mutual aid partners should be mention in the plan

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First Information
The first person who observes / identifies the emergencies shall inform by shouting and by telephone to the shift engineer / emergency control room and fire station about the hazard. The shift engineer will inform to Work Incident Controller, Chief Incident Controller and also telephone operator, who shall communicate it to all key offices about the emergency.

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Key personnel
Apart from WIC and CIC, other works personnel will have key role to play in providing advice and in implementing the decisions made by the chief incident controller. The key personnel include: Engineer-in-charge responsible for Operation Electrical, Mechanical, C&I maintenance each Chemical IT Head of HR and officers connected with IR and labour welfare. Head of Tech. Services Head of Safety Chief medical officer. Commandant/ Dy.Commandant (CISF) Asst. Commandant (fire) Transport (auto base) engineer-in-charge
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Responsibilities of Task Force Team

To identify source of hazard and try to neutralize / contain it. To isolate remaining plant and keep that in safe condition. To organise safe shutdown of plant, if necessary. To organise all support services ie operation of fire pumps, sprinkler system etc.

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Responsibilities of Maintenance Team

Attend all emergency maintenance jobs on top priority. To take steps to contain or reduce the level of hazard created due to disaster. To organise additional facilities as desired.

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Responsibilities of Fire Fighting Team

In case of fire emergencies, fire team is responsible, To rush to fire spot and extinguish fire. To seek help from out side fire fighting agencies.

To evacuate persons affected due to what ever reasons

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Responsibilities of Communication Team

To maintain the communication network in working condition

To attend urgent repairs in the communication system if required. To arrange messengers for conveying urgent messages when needed so.

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Responsibilities of Security Team

To man all gates. To bar entry of unauthorised persons. To permit with minimum delay the entry of authorised personnel and out side agencies, vehicles etc, who have come for help To allow the ambulance / evacuation vehicles etc., to go through the gates without normal checks.

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Responsibilities of HR team
To rescue the causalities on priority basis. To transport casualties to first aid post, safe places, or medical centres. To account the personnel. To pass information to the kith and kin of fatal or serious injured persons.

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Responsibilities of Safety team

To arrange required safety equipment. To measure gas concentrations, in case of gas leakage, at various places. To record accidents. To collect and preserve evidences in connection with accident inquiries. To guide authorities on all safety related issues.

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Responsibilities of medical team

To arrange first aid material / stretchers immediately and reach to site of incident. To arrange for immediate medical attention. To arrange for sending the casualties to various hospitals and nursing homes.

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Support team to CIC & WIC

In addition to the teams already mentioned there will be one additional team known as support team. This team will assist CIC & WIC during an emergency. The responsibilities of the team given below; Contacting statutory authorities. Arranging for relievers and catering facilities. Giving information to media.

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Responsibilities Of Support Team

Arranging shelters for affected persons. Contacting medical centres and nursing homes. Providing all other support, as necessary. Arranging for urgently required materials through cash purchase or whatever means. Arranging funds for various relief measures as emergency purchase of materials.

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Responsibilities of key personnel: Departmental heads:

The departmental heads will provide assistance as required by the works incident controller. They will decide which members of their departments are required at the incident site.

Head of Tech. Services

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On knowing the major emergency, he will proceed to the site and report to CIC. He will provide technical information as required to CIC/WIC. Head of Safety: On knowing the emergency, he will immediately report to site and keep in touch with CIC He will make sure the all safety equipments are made available to the emergency teams. Participate in rescue operations. Maintain inventory of items in ECC.

Responsibilities of key personnel:Commandant (CISF):

Proceed to main entrance/main gate Arrange to control the traffic at the gate and the incident area. Direct the security staff to the incident site to take part in the emergency operations under his guidance and supervision. Arrange for rescue and evacuation of the people in the plant or in the nearby areas as advised by work incident controller after arranging the transport through transport in-charge. Allow only those people who are associated with handling emergency. Maintain law and order in the area, if necessary seek the help of police. Maintain communication with chief incident controller, works incident controller.

On knowing the emergency, he will

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Responsibilities of key personnel: Asst. Commandant (Fire) On knowing the emergency, he will Reach the fire station and arrange to sound the alarm as per the type of emergency. Guide the fire fighting crew ie. Firemen and trained plant personnel and shift the fire fighting facilities to the emergency site. Adequate facilities will be made available. Take guidance of the Works Incident Controller for fire fighting as well as assessing the requirement of outside help. Maintain communication with Works Incident Controller, Chief Incident Controller and Emergency Communication Officer. Seek outside help from other near by Fire Stations.

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Responsibilities of key personnel:

TRANSPORT (AUTOBASE) ENGINEER-I/c

On knowing the emergency he will immediately report to Works Incident Controller. During emergency situations, all company vehicles and hired vehicles should be surrendered automatically and shall be under the control of auto base in-charge to facilitate availability of all vehicles with administration team. The responsibilities of Auto Base In-charge are : Make all the auto base vehicles ready to proceed for evacuation or other duties, when asked for. Make all arrangements regarding transportation.

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Responsibilities of key personnel:

TRANSPORT (AUTOBASE) ENGINEER-I/c

The responsibilities of Auto Base In-charge are: [contd.] To send at least one mechanic at the site of incident where he may help in attending minor defects in ambulance, fire tenders or other vehicles To arrange Petrol /diesel supply List of all NTPC vehicles and hired vehicles with contact telephone numbers to be made available in Auto Base. Addresses of NTPC drivers and hired vehicles to be made available in Auto Base. Liaison to be developed by the Auto Base in-charge with neighbouring travelling agencies, transport agencies etc. Contact telephone numbers of private ambulance agencies. The above arrangements helps the auto base in-charge to contact immediately for requesting the services during major emergencies without any time delay.
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Mock Drill
Mock-drills are effectiveness of preparedness. conducted to action plan/ test the emergency

Periodicity of mock drill is at least once in every six months. Deficiencies found are to be recorded and corrective actions are to be taken for effectiveness of the plan.

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Action Plan
Emergency siren
--------------------------------------------------------------Type Duration ---------------------------------------------------------------

In case of fire

5 seconds on 2 seconds off, 3 times 20 seconds on, 10 seconds off, 5 times.

Emergency siren for Heavy chlorine leak All clear signal

Continuous siren for 3 min, only once. -------------------------------------------------------Safety Module: Disaster Management Plan, Rev 0.0, Mar 2007

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