EMERGENCY RESPONSE & DISASTER CONTROLByAsghar Naveed;Safety Unit Manager.

Haider I Chaudhry;Safety Engineer.

Engro Fertilizers LimitedVision Statement

To be the premier Pakistani enterprise with a global reach, passionately pursuing value creation for all stake holders.

Company Profile

Engro Fertilizer Ltd. urea manufacturing site is located at Daharki, 600 km north of Karachi-Pakistan. The site produces about 2850 MeT/day urea.

Consumption of fertilizers increased in Pakistan, paving the way for the company called Engro, an acronym for energy for growth.

BackgroundEngro Fertilizers Limited gives the highest importance to safe operations, safe work practices, and protection of the environment and the health of its employees in the conduct of its business.In an endeavor to keep it abreast with the World Class Safety Standards, Engro Fertilizers Limited has aligned safety management systems with Dupont Emergency Response & Disaster ControlNo Major EmergencySince 1968

What is Emergency Response [ER]Design ConsiderationInformation PackageMutual AssistanceCommunity Awareness for Emergency ResponseConsolidated ER Plan & ManualActivate ER PlanINPUTSOUTCOMEEmergency Response & Disaster ControlEmergencyHandlingTraining & Stewardship

Design ConsiderationsEmergency Response & Disaster ControlLayers of Protection

Layers of ProtectionThe current site has the gadgets and documented procedures which entails and governs all the existing reviews and new facilities.

Inherently Safe Process DesignPHACAManagement of Change ApprovalPSSR

Process Design Basis:

P&IDs, PFDs, I&E Diagrams;Process description;Standard operating guidelines & conditions;Maximum intended Inventories;Data history & references;Revisions & new process technologiesInformation PackagePSI (Process Safety Information) package for each operating unit

Equipment Design Basis:

Safety critical componentsControl of vendor manualPSI PackageHazards of Materials:123

Two-fold action plan.Written comprehensive emergency preparedness plan.Separate emergency plan for each hazard/threat, including plans for flood, sabotage & war emergency etc.

ER StructureEmergency Response & Disaster ControlConsolidated ER Plan & Manual

Core Contents (ER Manual)

Role statements.Assembly locations.Emergency Shutdown Procedures.Fire fighting & Toxic Release handling techniques.Emergency Handling TechniquesRescue Plans (Medical Assistance, etc.)Layout of Emergency & Safety EquipmentMisc information (Population around, typical Wind reference diagram, etc.)Critical Equipments and latest communication devices;

Part I

EmergencyHandlingDisaster OccursSS or SIC & Sounds AlarmSquadSecurity Guard (Plant)Area Unit ManagerSafety AdvisorChief Medical AdvisorSecurity InchargeSecurity Guard (Colony)Responds to EmergencyAlertsRelevant ManagementPA & Services InchargeSurrounding CommunityGovernment & Public AuthoritiesNDMAMediaCommunity Emergency ResponseMutual AssistanceCMT formedGuides the Squad for rescue and containment & Communicates with the authorities and Gov agenciesSquad consists of 14 membersControl and Containment of LeakageFire FightingConduct Rescue Operation

Communication Channel Detection, Declaration and CommunicationPart IIEmergency Response & Disaster Control

TrainingTraining of employees for all possible emergencies :Skill certification system;Weekly & Quarterly simulated exercises;Involvement of ES, employees & contract employees and community;Skill certification of ES;Emergency Shutdown procedure.

Training & StewardshipEmergency Response & Disaster Control

Mutual AssistanceSurvival Chances improve

Pool knowledge, equipment & personnel with neighbors.

Procedures developed.Emergency Response & Disaster Control

CAER program has been prepared in conjunction with local community.

Training/ coordination with community

Involvement of local government functionaries

Program structure compliments DuPont

Benchmarked with TATA & GNFC

Emergency Response & Disaster ControlBridging GapsCAER

Ariel ViewPopulationLegendEmergency Response & Disaster Control

Kalo BureroBago BhuttoKotla Mirza

Area (Covered by this Program)HighwayMetalled RoadJeepable Track/ TrailRailway LineTaluka BoundaryCanalsSettlementGraveyardSettlement Within 2 km of FacilitySettlement Outside 2 km of Facility

Emergency Response & Disaster ControlVillagesDeveloped by International Council of Chemical AssociationThe goal is to assure emergency preparedness and to foster community right-to-know. It demands a commitment to openness and community dialogue. The code has two major componentsTo initiate and maintain a community outreach programAssuring that each facility has an emergency response programA socio economic survey was done in 2007 to ascertain social & economic needs of locals. 11 villages (in 2 km radius) covered.

Bago BhuttoKotla MirzaJhando BughioJan Mohammad BughioKalo BureroJhungSajan MalikShahnawaz BureroNathu BhuttoNur Hassan Shah

Community Engagement ModelPhase IPhase IIICommunity Awareness & Emergency Response 2010

Aug, 2009Emergency Organization Table developed. Assignments given: Leader, Deputy Leader & Street Social Workers assigned at Kalo Burero.First Aid & Fire Fighting Trainings for volunteering Social Workers of Kalo Burero.

Nov, 2009Thursday Drill Exercise observed by Social Workers of Kalo Burero.First Aid & CPR Training was conducted for Kalo Burero social workers at EFert.Gadgets for emergency communication in villages approved & order placed at Kalo Burero

CurrentPopulation ready to be engaged in the Quarterly Drills.Nov, 2007Lunch for Kalo Burero at Manufacturing Division Canteen.May, 2008Engro Visit Boys and Girls from Kalo Burero Schools .Oct, 2008Quiz Competition Kalo Burero Boys School.Nov, 2008Quiz Competition Kalo Burero Girls School.TA 09(Apr)People trained & appointed as Safety Facilitator and Scaffolding InspectorKalo BureroCommunity needs: Hospital, Water supply, Gas, Drainage, Vocational Institute.Kalo BureroFeb, 2009Infrastructure Development(drains, bricks soling) & adoption of boys school.Community Awareness & Emergency Response 2010CAER Timeline

Population1500Source of IncomeAgricultureServicesOthers % ageLiteracy RateMaleFemale % ageAccess to Media (TV)60%SchoolsBoys & Girls Primary School

1st National Mock DrillConducted by EFERT & NDMAWorking and coaching the nearby populations for more than two years has led us to a position where we involved the local and nation-wide authorities and Engro along with NDMA (National disaster management authority) conducted the first ever Mock Emergency Drill earlier this year. Preparedness level of nearby village in a large scale Mock Exercise in which ammonia leakage and fire at the manufacturing facility was simulated. Participation by DDMA, DESTO and Urban Search & Rescue Team. Outcomes of the drill: Consolidation of ER Plans of nearby Industries located at the Fertilizer Belt in Sindh.Emergency Response & Disaster Control

VIDEO: ndma.videoDuration: 05 min

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