Chemical (Industrial)

Disasters : On-Site
Emergency
Response

Surendra Kumar
Consultant, FICCI and Core Group Member-
National Disaster Management Guidelines :
Chemical (Industrial) Disasters
Framework

Objectives and Legal Framework

Building Blocks of On-Site Response
Dynamic On Site Emergency Plans
Training, Testing, Analysis and
Improvement. NDMG- CDM
Recommendations
Framework

Objectives and Legal Framework

Building Blocks of On-Site Response
Dynamic On Site Emergency Plans
Training, Testing, Analysis and
Improvement. NDMG- CDM
Recommendations
Objectives
On-Site Response : Most important component of CDM
Spells out industry initiatives and policy decisions on
safety tolerances striving for zero accident
Prepared with the help of hazard and operability studies
for design, technology, siting process, P&I and other
safety enumerates
To carve out measures and steps for continued safety
and security of all stakeholders including employees
and neighborhood
Response should deliver on prevention, preparedness
and mitigation as management ethos to contain all toxic
releases within controllable approaches
Shift in Approach
(Prior to NDMG- CDM)

On-Site Plan

On- Site
On-Site On-Site
Emergency Plan
Plan Plan (Transportation /
(Preventive) (Preparedness) Piping )

Designs/ Security Emergency On-site Plan -

Measures Response (including transported hazchem
(from a day of thought) Medical Response) emergencies

Main Priority- Emergency Response

Shift in Approach
(After NDMG- CDM)

On-Site Plan

On- Site
On-Site On-Site
Emergency Plan
Plan Plan (Transportation /
(Preventive) (Preparedness) Piping )

Designs/ Security Emergency On-site Plan -

Measures Response (including transported hazchem
(from a day of thought) Medical Response) emergencies

Main Priority- Prevention / Preparedness Zero Tolerance

Legal Framework
Environment Protection Act 1986
MSIHC Rules 1989
On-Site Plan
Off-Site Plan

CA (EPPR) Rules 1996

Mock Drills Mandatory at defined interval

Factory Act and Rules

Compliance : On Site plans in place of only 1628 MAH
Units/ 1666 MAH units . 38 MAH Units not even have On Site
Plans
Framework

Objectives and Legal Framework

Building Blocks of On-Site Response
Dynamic On Site Emergency Plans-
Training, Testing, Analysis and
Improvement. NDMG- CDM
Recommendations
Building Blocks for On-Site
Response Plans Dissemination of
Information- Press
and Electronic
Medias
Emergency
Functionaries -District,
Fire , Police, Health,
Transportation

Communication- PA,
Walkie/talkie, Mobiles
Safety Auditing- Monthly, Yearly,
Daily Exception
Testing/ Auditing: Radiography,
Hydraulic Testing and Thickness Survey
Post Commissioning HAZOP/HAZAN
Pre Commissioning HAZOP/HAZAN
 DISPERSION CONTOUR
SUPERIMPOSITION ON LOCATION MAP

Without Plant Safety / Neutralization Measures

Tank rupture release
Releases in vapour or liquid form
Corresponding IDLH / STEL Distances
Expected Population Affected
With Plant Safety / Neutralization Measures
Tank rupture release
Releases in vapour or liquid form
Neutralization Measures
Corresponding IDLH / STEL Distances - NIL
Expected Population Affected -NIL
Emergency Control Plan- On-Site
Emergency Situation- Leak (Detectors)
Alarms (Level 1, 2 and 3)
All Clear Signal
Meteorological Situation (wind socks, anemometer)
Emergency Control Centers (2 in perpendicular directions)
Ambulance Routes for Medical Aids (2 (in perpendicular
section)
Safe Assembly Points (at different locations based on
micrometeorology with emergency exits)
Transportation and evacuation system in place
Framework

Objectives and Legal Framework

Building Blocks of On-Site Response
Dynamic On Site Emergency Plans
Training, Testing, Analysis and
Improvement. NDMG- CDM
Recommendations
 Dynamic On Site Emergency Plans- .
NDMG- CDM
Plant Emergency Organisation
Designated person in charge/alternates.
Functions of each key individual and group.
Telephone numbers (office and home) for key people/alternates.
Plant Risk Evaluation/Information on Preliminary Hazard
Analysis
Quantity of HAZMATs.
Location of HAZMATs.
Properties of each (MSDS sheets).
Location of isolation valves.
Special fire-fighting procedures (if any).
Special handling requirements.
Type of accidents.
System elements or events that can lead to a MAH
Safety relevant components.
Dynamic On Site Emergency Plans- .
NDMG- CDM
Details about the site
Location of dangerous substances.
Seat of key personnel.
Emergency control room.
Description of HAZCHEM at the plant site
Chemicals (quantities and toxicological data).
Transformation if any, which could occur.
Purity of HAZCHEM.
Likely dangers to the plant
Enumerate effects of
Stress and strain caused during normal operation.
Fire and explosion inside the plant and effect if any, of fire and
explosion outside.
 Dynamic On Site Emergency Plans- .
NDMG- CDM
Details regarding
Warning alarm and safety and security.
Alarm and hazard control plans in line with disaster control planning, ensuring
the necessary technical and organisational precautions.
Reliable measuring instruments, control units and servicing of such
equipment.
Precautions in designing of the foundation and load bearing parts of the
building.
Continuous surveillance of operations.
Maintenance and repair work according to the generally recognised rules of
good engineering practises.
Details of communication facilities available during emergency and those
required for an Off-Site emergency.
Details of fire fighting and other facilities available and those required for an
Off-Site emergency.
Details of first aid and hospital services available and its adequacy.
External organisation if involved in assisting during an On-Site
emergency
Type of accidents.
Responsibility assigned.
 Dynamic On Site Emergency Plans- .
NDMG- CDM
Area Risk Evaluation
Properties of HAZMAT at nearby plants.
Population clusters nearby.
Contacts (names, telephone numbers) at other sites.
Established procedures for notification of chemical release at other
sites in area.
Notification Procedures and Communication Systems
Alarm systems.
Communication equipment (radios, hot lines, etc.) plant
management, local officials and response agencies, neighbouring
industries, nearby residents.
Names and telephone numbers (with alternates) list.
Designated person for media contacts.
Procedure for notifying families of injured employees.
Central reporting office.
 Dynamic On Site Emergency Plans- .
NDMG- CDM
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.
Dynamic On Site Emergency Plans- .
NDMG- CDM
Training and Drills
Knowledge of chemicals (properties, toxicity, etc.).
Procedures for reporting emergencies.
Knowledge of alarm systems.
Location of fire-fighting equipment.
Use of fire-fighting equipment.
Use of protective equipment (respirators, breathing air,
clothing, etc.).
Decontamination procedures for protective clothing and
equipment.
Evacuation procedures.
Frequent, documented simulated emergencies.
 Dynamic On Site Emergency Plans- .
NDMG- CDM
Regular Tests of Emergency Organisation/Procedures
Simulated emergencies.
Documented, frequent alarm system.
Frequent tests of fire-fighting equipment.
Evacuation practice.
On-going emergency preparedness committee.
Plan Updates
Annual or more frequent if needed.
Reflect results of drills and tests.
Dynamic On Site Emergency Plans- .
NDMG- CDM
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 area only).
Utility failure procedures.
Individual unit emergency procedures.
Bomb threat procedures.
Detailed Operating Manuals (for each process unit and utility
system)
Start-up/shutdown emergency procedures.
Analysis of potential incidents.
Emergency response and action to be taken for each incident.
 Dynamic On Site Emergency Plans- .
NDMG- CDM
Established Emergency Response Durations
Sounding of alert level III (for Off-Site emergency).
Communication to control roomwind speed and direction and for recorded
message transmission to nearby community through public address system.
Actuation of stand-by systems.
Hotline/communication to first respondersthe police and fire brigade.
Mobilisation of internal resources.
Affected plant/system stoppage.
Replacement of operation staff with other plant/unit personnel.
Fire tender/ambulance.
Employees and visitors shifting to assembly points.
Energising fire hydrant/foam or other specified protection system.
Isolating the leaky area.
Emergency crew repairing/isolating leakages.
Procedure for Returning to Normal Operations
Interface and lines of communications with Off-Site officials.
All clear siren or in case of aggravation of emergencyinitiation of full scale Off-Site measures including
broadcast, evacuation, diversion of all types of traffic etc. and full scale operation of medical emergency system
 Information for use in the Off-site Emergency Plan
This is a section in the On-Site emergency plan 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
and prompt full scale availability (establishment of response
time), route/alternate route clearance, diversion/stoppage of
traffic on mobilisation routes.
If own resources (such as equipment, trained man-power,
medical help etc.) are not adequate to meet such off-site
emergencies, to clarify the arrangement (formal or informal)
made to obtain the additional resources (e.g., mutual aid or
arrangement with the public response agencies) mentioning the
salient terms of such arrangements.
 Information for use in the Off-site Emergency Plan
This is a section in the On-Site emergency plan for use in the Off-Site emergency plan.

Organisations involved (including key personnel) and responsibilities and

liaison arrangements between them.
Information about the site including likely locations of dangerous substances,
personnel and emergency control rooms.
Technical information such as chemical and physical characteristics and dangers of
the substances and plant.
Identify the facilities and transport routes.
Contact for further advice e.g., meteorological information, transport, temporary food
and accommodation, first aid and hospital services, water and agricultural
authorities.
Communication links including telephones, radios and standby methods.
Special equipment including fire-fighting materials, damage control and repair items.
Details of emergency response procedures.
Notify the public.
Evacuation arrangements.
Arrangements for dealing with the press and other media interests.
Longer term clean up.
 Information for use in the Off-site Emergency Plan
This is a section in the On-Site emergency plan for use in the Off-Site emergency plan

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 has the community awareness programme been planned?
How has the community been identified (from which zone/part
or full vulnerability zone based on well established wind-
roses)? Have the key opinion makers who can play an active
role been identified? (Give list along with their contact details).
Has the selection of the community or that of key persons in
the community beendone in consultation with the district
authority, etc.?
 Information for use in the Off-site Emergency Plan
This is a section in the On-Site emergency plan for use in the Off-Site emergency plan

Has insurance under the Public Liability

Insurance Act been obtained? Give summary.
Designate a contact person who would be
authorised to coordinate for the Off-Site plan
and his contact details.
Technical team (chemical-wise) in case of an Off-Site
emergency that has taken place due to escalation of an On-
Site incident, contact details of its members.
Structuring of On/Off-Site Planning

Prob of leak

Overlapping
Zone

INDUSTRY System needs

Stakeholder/ to be
Existing On-Site added/up
system graded

Safe Zone Off-Site

WORKING AREA
To make this area less
hazardous
Coordination between blue dots
Capacity Building of violet dots
Safety of both zones
Pooling of resources from safe zone to vulnerable
zone
Education, Training for all
Building up an Institutional and Infrastructural Frame
work
Structuring of On/Off-Site Planning

Coordination

Strengthened
Area

INDUSTRY
Pooling of
On-Site Resources

Safe Zone Off-Site

Strengthened Area during long- term plan Less Hazardous AREA

Framework

Objectives and Legal Framework

Building Blocks of On-Site Response
Dynamic On Site Emergency Plans
Training, Testing, Analysis and
Improvement. NDMG- CDM
Recommendations
Recommendations
Re-update your On-Site plans based on the National Disaster
Management Guidelines- Chemical (Industrial) Disaster
Management
Revisit the worst case scenarios in the presence of increased
threats include security aspects also
Development of effective linkages with Off-Site Plans and
Responders
Conduction of regular mock drills in the presence of neutral
observers and regular reporting of the implementation of lessons
learnt from these drills to the respective authorities constituted in the
aftermath of Disaster Management Act, 2005
Proactive involvement of Industry to validate the practical
applicability of their On-Site Plans by different management
authorities or neutral consultants/ organization involved in this
task.. Accreditation mechanism