Emergency Management and Response Plan

(SANS 1514) FOR MAJOR HAZARDOUS INSTALLATION (MHI)

Aim

The emergency management plan aims to document the predicted emergency scenario and actions that should occur systematically. To ensure that training can be easily understood, and to address quick response actions. The aim of the MHI Emergency Management plan is to effectively respond to and mitigate emergencies in order to ensure the safety and well-being of all individuals within the organization. Form a team with designated roles and responsibilities for managing emergency situations. Identify potential risks and develop comprehensive plans for addressing various types of emergencies. Establish clear communication channels for disseminating information during an emergency, both internally and externally. Provide regular training sessions and conduct drills to ensure that all staff members are prepared to respond effectively during an emergency that necessary resources, such as medical supplies, equipment, and personnel, are readily available for use during emergencies. Establish partnerships with external agencies, such as local emergency services, to facilitate a coordinated response in the event of a large-scale emergency.

Objectives

•   Establish an emergency management team with designated roles and responsibilities;
•   Conduct a risk assessment to identify potential hazards and vulnerabilities;
•   Develop an emergency response plan, including communication protocols and evacuation procedures;
•   Implement training and drills to ensure staff are prepared for emergencies;
•   Coordinate with local authorities and emergency services for additional support as needed;
•   Continuously review and update the emergency management plan based on lessons learned from exercises or real incidents;
•   Establish a system for alerting and notifying staff and stakeholders in the event of an emergency;
•   Create a continuity of operations plan to ensure critical functions can continue during and after an emergency;
•   Secure necessary resources, such as medical supplies, food, water, and shelter, to support individuals affected by the emergency;
•   Develop a process for assessing damage and initiating recovery efforts following an emergency;
•   Establish protocols for providing support to employees and their families during and after emergencies; and
•   Document all actions taken during an emergency for review and improvement purposes.

Location and physical address

The ChemerG site is located in the Cato Ridge industrial area, approximately 6 km northeast of the village of Cato Ridge in KwaZulu-Natal. Figure 2.1.1 is a map of KwaZulu-Natal showing the location of Cato Ridge.
The installation’s physical address is:

53 Drakensberg Street, Harrison, Cato Ridge, KwaZulu-Natal

GPS co-ordinates: 29042’13.20” S 30038’28.47” E

Emergency Coordination and Planning Committee

The committee is appointed according to role and responsibility and company knowledge. The committee is appointed to facilitate, execute and review this plan
1.   The disaster coordinator
2.   The Technical expert
3.   Fire marshal
4.   Fire Fighter
5.   Communication officer
6.   First aider
7.   Any consultant or support co-opted member

The review committee will discuss the plan every 3 months as one part of the safety committee meeting, and the necessary changes must be made and communicated to all.

Authorities

All appropriate authorities must be informed of this emergency plan. The fire department must approve the fire plan. The plan meets SANS requirements.

Review of the plan

•   The plan must be reviewed whenever there is a change;
•   Whenever there is a system or process change; and
•   Whenever there Is a design change.
If none of these happen the plan must be reviewed once in 3 years.

Access Control to Site

All employees, contractors, deliveries, and visitors entering the site must sign in and out on the entry and exit register. This register must be kept at the entrance and exit point. In the event of an emergency, the coordinator must conduct a roll call and notify the marshal and rescue personnel of any missing person immediately.

Induction

All employees, visitors, and contractors shall be inducted before the entrance of the site. The induction should be renewed every year. The induction shall cover the details of this emergency plan.

Process plan Interaction

No	Action	Comments
1	Assess the situation	Gather information about the emergency, including the type, location, and potential impact
2	Notify Emergency Services	Contact local authorities or emergency services to report the situation and request assistance. See contact details on page
3	Alert relevant personnel:	Inform key individuals within your organization or community who need to be involved in the response process
4	Implement safety protocols:	Activate any necessary safety procedures to protect people and property from further harm.
5	Coordinate resources:	Allocate resources such as medical supplies, equipment, and personnel to address the emergency effectively.
6	Communicate with stakeholders:	Keep affected parties informed about the situation, response efforts, and any instructions or updates.
7	Monitor and adapt:	Continuously assess the evolving situation and adjust response strategies as needed to ensure an effective outcome.
8	Debrief and review:	After resolving the emergency, conduct a debriefing session to analyze what worked well and identify areas for improvement in future responses.
9	Support and assist affected individuals:	Provide support to those impacted by the emergency, including medical assistance, counseling, and access to necessary resources.
10	Document the response process:	Record details of the emergency response, including actions taken, decisions made, and outcomes achieved for future reference and analysis.
11	Conduct post-emergency evaluation:	Evaluate the overall effectiveness of the response process, identify any shortcomings or gaps in preparedness, and make recommendations for improvement.
12	Update emergency plans:	Use insights from the response to update emergency plans and procedures to enhance preparedness for future incidents.
13	Train personnel:	Provide training to personnel involved in emergency response to ensure they are well-prepared and competent in executing their roles during emergencies.
14	Engage with community partners:	Collaborate with local agencies, organizations, and community groups to strengthen coordination and cooperation in responding to emergencies
15	Test response protocols:	Conduct drills or simulations to test the effectiveness of emergency response protocols and identify areas that may require refinement or adjustment.
16	Review legal considerations:	Evaluate any legal implications related to the emergency response process, such as liability issues or compliance with regulations.
17	Implement technology solutions:	Explore opportunities for utilizing technology tools or systems that can enhance communication, coordination, and resource management during emergencies

Command Structure Organogram Roles and Responsibility and Identification of Emergency Team

It is essential to ensure that roles and responsibilities are correctly identified and established to activate this emergency plan.
The list of names and appointments appears in designated spots around the plant and as an addendum to this plan.
The following roles and responsibilities were identified.

1. Security

Security is to ensure that all people entering the site, record their details legible. Security must not permit unauthorised visits. Security must ensure that the person entering the site is pointed to the visit register.

2. Fire Marshals- High Viz Red- labelled


	Marshalls shall be established to ensure that employees and visitors are directed to each point as required. The Marshalls are also to ensure that there are no laggers or employees trapped. The marshals must sweep the plane where safe to do so and start a role call immediately

3. Emergency Controller- High Viz Orange Labelled


	The disaster coordinator shall ensure that all appointees are available and exercise the plan accordingly. All appointees shall communicate with the coordinator at all times. The disaster coordinator must communicate with the rescue personnel.

4. Firefighters High Viz -Red labelled


	Firefighters shall take their post if clear and safe to do so and apply their training to the best of their ability. The firefighter shall not place their life in danger at any given time.

5. First aiders- High Viz -Dark Green labelled


	The first aider needs to remove their boxes and be ready and available to address any immediate medical needs. The first aider shall make a diagnosis and report to the disaster coordinator and or liaise with medical personnel until relieved.

6. Technical support- High Viz – Blue labelled


	Technical support must be on standby, to guide the plant, chemicals, what caused the incident, type of material, impact, and health risk of the product. The MSDS and SDS must be available and kept in file for the various departments to look at including the batch sheet in production when the incident occurred. Details of the contact details of the technical support is on the contact list.

7. Communication officers- High Viz labelled


	The communications officer upon given clearance by the disaster coordinator must make the calls to the emergency response teams one after the other. The teams must have the whapp app group call opened and a loud hailer. This allows for communication to be effective.

Emergency Contact Numbers

Placed in the Lab, Offices, entrance and entrances

Department	Location	Phone	email
Fire Department	Catoridge
Disaster Department	Ethekweni
Health Department	Etheweni
EDTEA	KZN provincial
DFFE	National
SAPs	Cartridge
Ambulance services
Cato Hospital

Fire brigade- Please help! We need urgent assistance, we are an MHI. Our address is 53 Drakensberg Street. There was an explosion and there was lots of smoke and fire. The fire is in a certain part of the plant. Follow the instructions of the instructor and communicate with the disaster coordinator.

Ambulance service – explain the same but also give details and the approximate number of people that might need medical conditions.

Disaster unit municipality- Provide the same information and explain the impact or possible impact on public safety and health. No media statement to be made unless the communications officer is the same as the communications officer for Chemerg.

Operations Flow diagram and description

Hazardous Substance Inventory and Location


Flammable store	1
Blending plant
Marpol plant	0.2
Tanks Farm	180
Desludging Plant
Stills	12

Detailed Site Map

Hazard ID and Hazchem table

-	CAS or UN Number	SANS10228 [Ref 2] Classification	SANS10234 [Ref 11&12] Classification	Physical form	Annual Consumption t/y	Inventory t	Largest single container t	Potential MHI Material
FLAMMABLE TANK FARM
Highly flammable materials	Toluene 108-88-3	3	Flam liquid 2	Liquid	5 780	260	72	Possibly
	Acetone 67-64-1		Reprod tox 2
	Butanol 71-36-3		Aspirate haz 1 STOT single 3 (narcotic)
STILLS PLANT
Still Feed (MEK & Acetone)	MEK 78-93-3	3	Flam liquid 2	Liquid	3 000	24	12	Possibly
	Acetone 67-64-1		Eye Irritant 2A STOT single 3 (narcotic)
MARPOL PLANT
Waste foam made from TDI / Methylene chloride / Polyol	TDI 26471-62-5	6.1	Acute tox 2 (inhalation)	Liquid / sludge / foam	24	1	0.02	Unlikely – quantities too small
	MEC 75-09-2		Eye irritant 2A
	Polyol - various		Skin irritant 2
WAREHOUSE PACKAGED STORE
Highly flammable materials	Various	3	Flam Liq 2&3	Liquid	2 400	90	1.2	Possibly
UTILITIES
Fuels (Diesel and HFO)		3	Carcinogen 2	Liquid	150	12	12	Unlikely

Levels and types of emergencies defined

1. Explosion

Two likely events may trigger a major hazardous situation. Initially the explosion due to high pressure built up and second by spontaneous combustion I in zone 1.
Zone one are usually inside a vessel or tank enclosure. Vaporous gas ignites because of the low flash point and due to either static of an ignition source. Lastly high pressure may also be created by chemical reactions.

2. Fire

Zone one has a higher flash point and is not always in a vessel or a tank enclosure.
Zone two is usually a 5 to 10 m sphere around the vessel or tank. This may spark and lead into a vessel or tank and create an explosion scenario. The probability is high as these are fugitive gases that can quickly dissipate into the air.
Zone three is even further away from zone two, this may result as the same in zone two but fugitive releases may dissipate quickly also if caught alight will be at a higher flashpoint but though the probability is higher it may produce the same result.

3. Spill

Spillages may also be a cause for concern and all spillages must be cleaned up quickly and properly as to not allow for the risk of fire from gas releases or flammable liquids on the floor that has the potential to cause fire and trigger a chain response.

4. Leaking tanks and vessels

Leaking tanks and vessels must be sealed immediately by a plug which must be available on site. Vessels must all be in the bund and be able to collect 110% of the tank capacity.

5. Sudden release of pressure

Sudden release of pressure can be hazardous to nearby employees based on the pressure vessel. In the event of a sudden release of pressure. The pressure releases early warning system should have been triggered. If not, the sudden release could be attributed to burst seam or tank or pipe. The ERP must be initiated.

Key stakeholder analysis roles, responsibilities and needs

Interested Parties

Interested Parties	Company	Name
Neighbour	Bass beam
Neighbour	DeAr chemicals
Neighbour	Farmer
Neighbours	Animal food producer
Neighbours	Cement Product
Tenant	Environmental Services	Peter Allen
Affected community leader

Procedure for raising site alarm

The alarms must be sounded, and the sounds of the alarms must be recognized by all employees. Sound and duration for sound are paramount to identifying the type of incident on hand. The sounder/alarm siren must also be in sync with a flashing red strobe light, this is to cater to people who cannot hear or are in a noisy zone.

Upon seeing smoke or fire or hearing distinct explosion, burning smells etc .
The nearest call point alarm must be pressed.

Procedure for receiving and responding to the alarm

When the sound is blown once it is for smaller emergencies- fire, reaction, smoke outside the designated zone.
When it is a continuous blast is a MHI related

Activation of the onsite and off-site plan

The activation of the onsite ERP is only to be initiated once there is a continuous blast

The emergency services will facilitate the offsite plan, noting that neighbours and interested parties are part of the onsite plan though they remain offsite.

Site evacuation and sheltering

Site evacuation must be done efficiently and safely without further compromising someone's safety by tripping or going in the wrong direction. Escape plans are printed and displayed in prominent places indicating safe route passages. All move away from the affected areas as quickly as possible.

See plan...

Control Point for utilities Listing on Map

)

Decontamination following an Incident

a)   Once the appropriate clearance is received from the relevant department.
b)   The situation will be assessed according to the incident
c)   A clean-up company or crew will be appointed
d)   A debriefing of all hazards and methods will be discussed.
e)   The site will be demarcated into different staging areas.
f)   Each unit will be decontaminated separately.
g)   Equipment that requires dismantling will be done systematically
h)   All residue and products that are damaged will be cleaned up and collected into skips provided.
i)   All undamaged products will be separated into a staging area that has a temporary protection safety plan.
j)   All liquids will be pumped into conducive containers for further treatment and disposal by a licensed facility.
k)   Tacks and equipment that need further cleaning will be done and the residue water or cleaners captured.
l)   All drainage and pools will be pumped up and cleaned
m)   The Root cause of incident will be finalised and preventative measures discussed and approved
n)   A revamp plan and project will be drafted for approval

Termination of an Emergency

a)   Once the emergency services provide a clearance
b)   Investigations are completed and RCAT established
c)   Site is made safe and handed over to site manager
d)   The termination of the emergency must be conducted
e)   All stake holders must be informed of the termination of the emergency

Emergency Shutdown Procedures

1.   Tank Farm
PB to include
2.   Distillation Plant
PB to include
3.   Marpol Plant
PB to include
4.   Oil Plant
PB to include
5.   Desludging Plant
Main shut down E stops explained in

Emergency resource, equipment and maintenance plan

Supporting information package – SHE information, Location map, Site layout map, Emergency contact details, other relevant information

Documented evidence of drills/simulations

Documented evidence of ERP audits, reviews and updates

Training – employees

Awareness – neighbour

Tactical -Activation of Emergency

Hear the continuous alarm /siren sound
A continuous sound and blinking strobe light
Shut down the plant or machine and make your way to the assembly point moving away from the source of the incident.
Stay in the assembly area unless instructed to leave.
Don’t leave the site without being signed off from the register
You may leave if you have signed off the roll call sheet
All appointees are to follow through with their responsibilities and take positions and execute training.

Contact List

Contact

Fire station

Ambulance services

Disaster unit

SAPS

Hospital

Management

Technical

Environmental

Firefighter to commence fighting the fire
Fire marshal must rescue and sweep plant
When the coordinator advises to remove stock
FLT must move in and remove stock.
Fire fighting must be strategically controlled covering the base of the fire and creating a curtain to prevent stock from catching alight.

Fire Protection and detection system

It is always better to have a detection system. Huge costs can be saved. Detection systems are more of a proactive system. If the detection system is strategically designed, located, and maintained. It would be an absolute benefit.

Fire Detection

The plant is fitted with the following in different high-risk zones and will set off the alarm when triggered

[ ] Heat sensors
[ ] Smoke sensors
[ ] Infrared
[ ] Pressure sensors

Fail-safe designs

Fail-safe designs is when safety designs built into the system fail. This may not be necessary however it is important to note that of

All the tanks conform to API 650i or 620i. the tanks are all bolted to the grounded
All tanks are above ground and are in bunds
All tanks are earthed to dissipate any static or lightning to the ground.
Monitoring and measurement
Preventative maintenance
- [ ] Pressure valves
- [ ] Overflow switches
- [ ] Tank inspections

Fire protection

Monitors
Hydrants
Hose reels
Sprinklers systems
Foam cannons

The fire protection system is supported by two water tanks and a backup diesel-powered engine fitted with a jockey pump to maintain pressure.
The fire monitors are fitted with foam injectors up to 45m each.

Fire water if overflowed the bunds would move into an attenuation dam. Of which can be sealed off to contain any over spills.

Emergency Exit Points Above
The above plan illustrates the escape routes assembly points and E-stop buttons
The escape routes are dashed green arrows which lead to;

The exit points and assembly point 1
The exit point and assembly point 2

There are two assembly points labelled green

Assembly point 1 is outside the main gate alongside the parking
Assembly point 2 is outside the second exit- not that this exit is only for emergencies

Emergency Stops and Plant Isolation

Each exit point should be fitted with a cut-out emergency switch called E-Stops. Upon emergency, the switch must be pressed. The siren alarm should be connected to every emergency switch. The plant must be isolated from receiving any power. There are three emergency stops located on this plan. Ideally, it would be required that one of the three needs to be depressed. emergency switch must be connected to a siren and strobe light –
Note! The power only is isolated but the process especially chemical-related may continue especially in the distiller. The cooling system may not be disconnected and lights only the plant.

Emergency stops point 1 at exit 1
Emergency stop 2 at exit 2
Emergency stop 3 in between warehouse and boundary fence

Fire Protection System

The schematic below illustrates a simple understandable fire suppression system.

Water supply

The water supply is sufficient to handle a simulated incident. There are two back up water tanks coloured red.
The water tanks are boosted with a basic standard diesel motor and jockey pump. The purpose is to maintain 3000 litre per second.

Monitor valves

The system has 5 monitor valves,
Ladled 1- 5 – each has an 100 mm outlet jet flow system which is capable of letting out 3000 litres per second.

Foam

Each monitor valve carries a 1000lt of synthetic foam connected to each monitor valve.

Fire Fighter

Ther are 6 trained fire fighters- these fighter have been trained on the handling and use of the monitors.
The fire fighters have alid fire training

Emergency Drills

MHI Facilities are required to have an MHI type drill to test the emergency response plan at least once a year and to keep records thereof. Ideally such drills should involve the local emergency services. The drills should test aspects relevant to MHI, e.g. explosion in the stills are, fire in the tank farm or flammable store etc.
ChemerG should ensure that they conduct such drills, even without the presence of the local emergency services, and keep record thereof.

Fire drills are carried out every two weeks.
The site simulates fire /explosion incidents, and the drill begins
The time of response is recorded
The positives and negatives are recorded and corrected
The entire drill is recorded on a emergency drill report

Place fire plan in Here