1. On-site Emergency Preparedness
National Workshop on Disaster Management
24-26 Sept 08 at Secunderabad, A.P.
A.Y. Sundkar
NATIONAL SAFETY COUNCIL
As compared to natural disasters, industrial disasters represent a relatively new threat. Sine 1974 (Feixbrough Explosion) indl. Accidents have been increasingly in the news. The Itali, Seveso Dioxine leakale in 1976 concern the EC authorities leading to first Directive on MAHC
For the first time, the focus of protection was made comprehensive to include community, env. and property instead of narrow focus on employees.
In India the MAHC remained un-knwon concept till the Bhopal Disaster
Bhopal Disaster – A Turning Point
Rapid growth in use of Hazardous Chemicals leads to accidents, results in loss of life, property and damage to environment.

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 52
Mexico, 1985 2

3. EXPLOSION Sl. No Name of Chemical Involved Death Injury Place & Year 1
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. Typical Layers of Protection
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)
Fire in LPG fired oven
Anil Enterprises, Zakhira, Rohtak 8. 5 8
Explosion
IDL Gulf Oil,
Kukkatpally, Hyderabad 7. 19
Toluene
Ranbaxy Lab Ltd., Mohali, Punjab 4. -
LPG leak - Tank lorry
BPCL Bottling Plant, Dhar 5. 88
Liquid Chlorine
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
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

7. Chemical Accidents in India (2002-06)
Sl. No.
Industry
Date
Source
Impact
Death
Injury
10.
Shyamlal Industries, Vatva, Ahmedabad
Benzene fire - -
11.
Chemplast, Metture, TN
Chlorine leak - 27
12.
Chemical Factory, Dombivilli, Maharashtra
Hexane release & fire 1 8
13.
Gujrat Refinery, Vadodara
Explosion in slurry settler 2 13
14.
Ranbaxy Laboratories Ltd., Mohali, Punjab
Fire in Dryer room 1 2
15.
Kekule Pharma Ltd.
Explosion 1 -
16.
PWD premises
Chlorine release - 20
17.
Gujrat Refinery
Fire - -
18.
Coromondal Fertiliser, Ltd., Ennore
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
20.
Orchid Chemicals & pharmaceuticals Ltd, TN
Explosion 1 4 21
IOCL, Mathura
Fire 1 - 22
Kanoria Chemicals & Industries Ltd , UP
Cl release 6 23 23
Anjana Explosives Ltd, AP
Spillage of haz chemical 5 - 24
Ravi Organics Ltd , UP.
Gas Release 1 - 25
RIL, Jamnagar
Fire 2 -

9. MSIHC Guidelines by MoEF, 1996
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
Natural Calamity – Orissa Super cyclone in 1999 damaged Phosphoric Acid Sludge containment
Bhuj earthquake in 2001 leads release of acrylonitrile from tank

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
Efforts to reduce the scale and frequency of hazards
Emergency Planning integral part of safety

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 : T T
LPG : T 50 T
CHLORINE : 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)
Elements are given in 11 broad headings
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 Basis of the Plan Purpose and objective
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
This chapter suggests organisation for emergency preparedness.
No Plan succeed without Emergency Organisation
Key Personnel to combat emergency to be nominated with specific responsibilities according to set procedure – Incident Controller, Site Main Controller, other key personnel and essential workers

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
This chapter suggests organisation for emergency preparedness.
No Plan succeed without Emergency Organisation
Key Personnel to combat emergency to be nominated with specific responsibilities according to set procedure – Incident Controller, Site Main Controller, other key personnel and essential workers

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
Identification, analysis and assessment of hazards and risks provide vital information to risk management that what should be the type and capacity of its on-site and off-site emergency plan and what type of safety measures and maintenance are required.
Listing of Hazardous materials – Raw material, finished, intermediate and bye products
Process and vessel hazards and controls
Hazards which are not classified as storage, process and vessels then hazards due to boilers, non-chemical pressure vessels, spills from pipeline or vessels, structural collapse, bad housekeeping

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
MSIHC Rule 14(2) – Occupier can seek any information from the Off-site Emergency Plan for preparing the on-site.

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
MSIHC Rule 13(4) – Mock drill of the on-site emergency plan conduced every six months

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 Security Gate No.2 or Security Gate No.4
Works Main Controller (WMC)
Security Gate No.2 or Security Gate No.4
Support Team to WMC
Logistics Team
Leader -
Traffic Control Team
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
Corporate Office at”

39. Cinema Hall
Hospital
Facility where Accident Take Place
School

40. Alarm/communication System
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 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. ON-SITE EMERGENCY PLANS
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
1. Rightly & legally preparation of OEP is the responsibility of the Occupier as he has necessary knowledge & expertise
2. Well developed and tested (rehearsed for its effectiveness, the OEP constitutes a good foundutaion for the Off-site Plan
3.Responsibility lies on Occupier
4.Responibility to submit information to authorities
5. On-site emergency lead to off-site

44. For scrutinising the OEPs checklist developed
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. In Plant Emergency Organization following were missing
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. quantity, type of storages and locations of hazardous materials
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
Listing of Hazardous materials – Raw material, finished, intermediate and bye products
Process and vessel hazards and controls
Hazards which are not classified as storage, process and vessels then hazards due to boilers, non-chemical pressure vessels, spills from pipeline or vessels, structural collapse, bad housekeeping

47. Consideration of Natural calamites triggering on-site emergencies
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.)
i) Identification, analysis and assessment of hazards and risks provide vital information to risk management – process (vessel hazards), storage, or any other
ii) Mass of release – Range for evacuation – Time required for contaminated air to reach

48. Notification Procedures and Communication System
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. Assessment of the resources by the Plant Management
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
Arrangement with organisations :

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

51. Simulated emergencies Testing and Documentation of alarm system
Gaps observed in OEPs
Regular tests of emergency organization/ procedures – Information not available
Types vis-à-vis target groups, frequency, documentation, methodology of Drills
Simulated emergencies
Testing and Documentation of alarm system
Frequent tests of fire fighting equipment
Evacuation practice
MSIHC Rule 13 (4) – Mock Drill every six months

52. In general there is no coverage of plan updates. In specific :
Gaps observed in OEPs
Plan Updates
In general there is no coverage of plan updates.
In specific :
Frequency
Reflect results of drills and tests
History Sheets giving details of updates/revisions including date of Preparation of the Plan
Responsibility on a person to update the Plan
MSIHC Rule 13 (4) – Mock Drill every six months

53. Medical response procedure for handling multiple injuries
Gaps observed in OEPs
Emergency Response Procedures
Not mention about
Medical response procedure for handling multiple injuries
Procedure for arrangement in case of utility failure
Bomb threat procedures
Location of Assembly Points and marking on the Layout Plan
Escape routes

54. General Pages not numbered Absence of contents page
Gaps observed in OEPs contd….
General
Pages not numbered
Absence of contents page
Some cases the content does not match with the matter in the plan