I/EC A
SAFETY
W O R K B O O K
F E A T U R E
by S. M. MacCutcheon,Dow Chemical Co.
Chemical Plant Emergency Planning — II This over-all plan for preparedness could be a plant saver in an industrial emergency | Ν OUR last safety workbook feature [I&EC 49, No. 6, 77 A (1957) J, we reviewed the philosophy leading to the establishment of an emergency plan, the functional organization of the plan, and six of the major factors to consider in developing the plan. Each factor is a subject in itself and should be carefully considered in developing the over-all emergency program. It is our purpose here to develop this thought and to outline
in more detail the planning that needs to go into each of the six areas. Unit Emergency Plan
As stated previously, the unit plan, as worked out by the individual shop, laboratory, department, or production unit, is the Key to the effectiveness of the over-all emer gency plan organization. Its es tablishment provides the means for
ensuring active employee partici pation, which makes the master plan grow from the ground up rather than being imposed from the top down. Guidance and assistance to re sponsible line personnel should be provided in the form of a guide outline listing topics to be considered in the development of the unit emergency plan. Such an oudine is shown below:
GUIDE FOR DEVELOPMENT OF UNIT EMERGENCY PLAN
I. A.
SCOPE OF UNIT PLAN General Considerations 1.
2.
3.
4.
B.
II.
2. 3. 4. 5.
B.
Product and/or process hazard a. Pressures b. Flammability c. Materials inventory d. Materials toxicity e. Exothermic reactions
C.
A. Sounding alarm Employees and/or supervision Siren signal to conform with standard building alarm Evacuation signal Notification to fire department,plant protection, and adjacent plant units
1.
Order and direction (reference: emergency plan evacuation map showing main routes)
2.
Employees, maintenance personnel, visitors Area check—assign responsibility Assembly location—personnel check-off.
Return and start up
1. 2. 3.
IV.
Estimate of situation, decision to shut down Employee notification Procedure for shutdown (written, essential steps only) Effect on adjacent units (notification) Protective equipment (masks and suits for shutdown personnel)
Evacuation
3. 4.
Fire Explos ion Gas release Spills
RESPONSIBILITY FOR INITIATION OF EMERGENCY ALARM
Shutdown 1.
Building Size Floors Construction Equipment Type Electrical Classification
EMERGENCY PLAN PROCEDURE
A.
Personnel employed Total Per shift
Emergency which might affect unit or adjacent units 1. 2. 3. 4.
III.
All clear signal Inspection of damage Procedure to resume operations
TRIAL RUNS
A.
Periodic tests of alarm system
B.
Simulated shutdowns and trial evacuations
VOL. 49, NO. ·
·
AUGUST 1957
75 A
I/EC
SAFETY ;
A Workbook Feature
Plant emergency services
Direction of Control Measures
Publk and
Maintenance
Industriel Relations
Services
Electrical
Mont Piping
Fire Fighting
Demolition and Shoring
T h e guide outline is offered as a framework around which every unit or d e p a r t m e n t m a y prepare its own plan. Copies of the written plan are turned over to the Emergency Plan W o r k Committee where they are checked for completeness. A periodic review of the unit plan is necessary to keep u p with major process and building changes. Emergency Services Plans Emergency services cover all the departments which swing into action at the time of an emergency. T h e n u m b e r of services used, and the extent to which they are utilized, is dependent upon the severity of the emergency. T h e accompanying chart shows the organization of these emergency services. T h e duties to be carried out by the departments concerned are obviously varied. No write-up or guide outline fits each of the emergency services groups. However, it is particularly important that each of the groups covered have a carefully worked out plan, in writing. I n this way, necessary working relationships between the groups can be established ahead of time. An example of a possible conflict, which can very readily be cleared u p in the planning stage, occurred, in our own case when the public relations written plan listed a particular building as a press headquarters location. T h e medical dep a r t m e n t plan listed the same building as a n auxiliary first aid station. 76 A
Transportation
Public
Medical
Relations
Food Service
Safety
Protection
Personnel
A review of the plans resulted in eliminating this duplication. Communications As pointed out in the previous column, a d e q u a t e and fast communications are extremely important in avoiding panic in any emergency situation. Early control measures, based on proper communications, may keep a fire or explosion within the limits of a n emergency and avoid a major disaster. I n our own experience, when the emergency plan is activated, the plant protection dispatcher's office becomes the center of the emergency communications network. Plantwide communications are handled through short-wave radio-equipped mobile units a n d through a u n i q u e emergency telephone-alert system. Short-wave radio has the obvious advantages of mobility, speed, and immediate tie-in with outside agencies such as local and state police. By using an auxiliary generator, you need not depend on the usual power source. T h e telephone-alert system is an ideal method, in a large installation, of communicating to certain designated " a l e r t " phones the essential information concerning any plant emergency. T h e system overrides any normal telephone conversations and m a y be m a d e selective. By selective we m e a n that one or more zones of the plant m a y be contacted or the entire plant may be covered with the desired one-way communi-
INDUSTRIAL AND ENGINEERING CHEMISTRY
Plant
cation. After necessary information has been received at the individual building, further communication to d e p a r t m e n t personnel is expedited through the building or unit alarm system. Air whistles, horns, or sirens m a y be used, but a standard device should be adopted to ensure recognition by all personnel. Signals, too, should be standardized a n d kept simple. I n our own plant three signals are used: alert, single rise to m a x i m u m pitch; evacuate, continuous; and all clear, two rises to m a x i m u m pitch. T h e alert signal is of particular importance a n d is used t o : 1. Discontinue the use of all flameor spark-producing maintenance equipment. 2. Indicate serious trouble in this or other buildings. 3. Collect employees at building office for instruction regarding shutdown and/or general plant emergency situations. Another phase of communications is the alerting of key personnel at any time of the day or night. This is best handled by the plant protection control center and necessary "call lists" must be established and agreed upon as an important step in planning. Evacuation A traffic control plan is essential, if necessary evacuation is to be car{Continued on page 78 A)
I/EC
SAFETY
;
A Workbook Feature and procedures. Problems which come u p in this connection include provision for ingress routes to allow fire fighting and ambulance vehicles to get to the scene, and the issuance of emergency passes to allow for the clearance of key personnel through road blocks.
EMERGENCY TEST OF (Date) 1.
Did employees gather at a predesignated "safest" area?
Yes
No
per cent accounted
for by check Mobile Control Center
2.
What was the chief problem in carrying out your unit plan?
M a n y plants have equipped a bus, trailer, or station wagon to serve as a field headquarters at the time of a n emergency. E q u i p m e n t may be kept to a minimum, depending on other sources for such items as auxiliary lights, loudspeakers, gas masks, and fire fighting equipment. As a field control center, the unit should have available:
3. Bid your existing unit plan seem adequate? Yes
Needs improvement
Questionnaire for hypothetical emergencies ried out safely and with a m i n i m u m of traffic congestion. T h e establishment of building and plant area evacuation routes is the first step. Education of plant personnel on the routes established is the necessary second step. Evacuation routes should be posted
and personnel assigned to designated control or check points. T h e need for possible evacuation of community population adjacent to the plant area should be studied. Plans m a y be m a d e , with local law enforcement personnel, to coordinate plant a n d town evacuation routes
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1. Radio or phone facilities to establish immediate communications 2. Complete maps covering plant sewer, utility, and process lines 3. Safety equipment, including rescue masks, for personnel working at the headquarters unit Personnel expected to report to the field headquarters include plant protection, fire, maintenance, a n d safety d e p a r t m e n t heads, along with the supervisor of the building involved and a public relations dep a r t m e n t representative. Hypothetical Emergencies T h e proof is in the pudding, but n o one relishes going through an emergency or disaster to prove the strong points or weak points of his emergency program. For this reason, hypothetical emergencies or simulated dry runs are recognized as a very valuable phase in the development of the program. A complete write-up of the problem should be m a d e and sent to all plant supervisors. O u r most recent practice r u n dealt with a tornado going through the plant at a specified time and following a specified route. Production buildings bracketing the p a t h of the storm were listed as well as broken product and power lines. This provided every d e p a r t m e n t with a n opportunity to study its unit emergency plan in the light of the supposed tornado. It was pointed out, of course, that a live
1437 FOURTH STREET (Since 1909) MRKELEY 10, CALIFORNIA
For further information, circle numbers 78 A-1, 71A2 on Readers' Service Card, page 111 A
78 A
INDUSTRIAL AND ENGINEERING CHEMISTRY
(Continued on page 80 A)
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tornado might strike any building on the plant site. Feed-back to all plant personnel of lessons learned and weak points which showed up is especially im portant. This may be carried out by asking each plant department to fill out a questionnaire outlining how its unit emergency plan functioned during the hypothetical emergency. Such a questionnaire is shown on page 78 A. The returned questionnaires are studied by the group responsible for the over-all emergency program, answers are consolidated, and a re port is "fed back" to supervisory personnel. Surprise alerts may also be planned, but thorough education prior to running off the exercise is felt to be advisable for the first few hypo thetical emergencies. Simulating fires, explosions, or releases of toxic gases are other dry runs which will serve to educate personnel in cor recting weak spots in their unit plans. This completes the discussions of the six major factors to consider in establishing chemical plant emer gency planning. Errors of omission are recognized and are primarily due to space and time limitations. The development of mutual aid pacts with nearby industries and civil bodies is one area not touched on. Many such pacts have been organized and details have been out lined in several current publications. A realistic appraisal of the po tential emergencies which might develop within your plant is step one in planning. Assigning responsi bility for emergency planning and the development of unit emergency plans make a logical sequence of steps in further development. With a properly thought out ap proach, the plant is less likely to get into trouble; if trouble arises, the plant is better prepared to cope with the emergency.
Writ· today for Bulletin 2 4 9 · a 3 2 paga npot I en standard* and prie·*.
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SAFETY
INDUSTRIAL AND ENGINEERING CHEMISTRY
Our authors like to hoar from readers. If you have questions or comments, or both, send them via The Editor, l/EC, 1155 16th Street N.W., Washington 6, D.C. Letters will be forwarded and answered promptly.
