FFBL Emergency Response Plan - Fire - Ammonia - Chlorine (10-10-2018).pptx

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1. Fauji Fertilizer Bin Qasim Ltd. Emergency Response

2. FFBL management recognizes the significance to conduct its business in a manner which will proactively protect the safety of all employees, the interest of its neighbors, and preservation of the environment along with Company’s own investment. We are therefore determined to maintain an injury free environment by giving safety a priority over all other issues. FFBL SAFETY POLICY

3. .... to minimize the risk to their lives by implementing an effective, well coordinated safety program with proper planning and control. SAFETY “PEOPLE -OUR ASSET” …

4. AMMONIA PLANT UREA PLANT DAP PLANT UTILITIES PLANT PRODUCT HANDLING & SHIPMENT AMMONIA STEAM STEAM AIR UF - 85 CO2 PHOSPHORIC ACID SULPHURIC ACID SAND COATING OIL RAW WATER DEMIN. WATER INSTRUMENT AIR POWER NITROGEN NATURAL GAS NATURAL GAS WASTE WATER TREATMENT “We are the only producer of Granular Urea & DAP in Pakistan having a market share of 10% & 50%, respectively” OVERVIEW – PROCESS PLANTS

5. Definitions Administrative controls Procedures for checking performance of employees on a plant and task e.g. vessels entry, hot work & LOTO etc. Engineering controls Systems or interlocks involving the operation of physical components without human interventions e.g. sensors, transmitters, valves & dykes for containment etc. Consequence Analysis Development of potential scenarios, describing hazardous events due to failure of engineering or administrative controls e.g. Fire scenarios, Ammonia/Chlorine leakage etc. Facility: Physical structure/area within which a process/process segment is operated e.g. FFBL plant, pipelines, warehouse etc.

6. Definitions Fire A combustion process accompanied by heat, flame and light. Hazard Anything that has potential to cause harm to person, property, equipment or environment. Risk Combination of likelihood that a hazard will occur and consequence of the hazard. Explosion: Rapid increase in volume and release of energy in extreme manner, usually with the generation of high temperature and release of gases or A release of energy that causes a blast.

7. Why Emergency plan is necessary? To ensure employees know what to do in emergency. Prevent harm to people Comply with the law Minimise the direct and indirect costs To increase staff morale To promote positive safety culture

8. Safety Critical Equipment Devices, equipment and systems whose failure could result in Serious personal injury or irreversible health effects Significant property loss Environmental impact Safety critical equipment could be Any plant equipment (vessel, pipeline, valve etc.) containing hazardous material in significant amount e.g. Ammonia storage tank. Systems, interlocks, instrument and controls that prevent loss of containment of hazardous materials e.g. interlocking of HVAC and DDEG with release of CO 2 in protected areas. Equipment to mitigate the loss of containment of hazardous materials e.g. firefighting equipment, hoses, hydrants, emergency response communication equipment, safety showers etc.

9. ARE YOU READY ? For Emergency

10. Lagging Indicator Leading Indicator Why Emergency Happened?

11. 11 Emergency – potentially life-threatening situation, usually occurring suddenly and unexpectedly. Immediate response is essential Speed in responding can mean the difference between life and death or between minimal damage and major damage Preparation is planning for emergencies Plan, practice, evaluate, adjust EMERGENCY PREPARATION

12. The 02 most dangerous scenarios which could lead to a disaster in any industry are FIRE CHEMICAL RELEASE

13. Bhopal gas tragedy, India December 2-3, 1984 Estimated loss – Around 15,000 since the tragedy and some 500,000 were exposed to the deadly gases. It is, by far, the worst industrial disaster of recent times What went wrong- Gas leakage Worst Industrial Disasters that Shock the World

14. Chernobyl disaster, Ukraine April 26, 1986 Estimated loss- 50 people were killed in the explosion. Some 4,000 cancer deaths were observed following the disaster What Went Wrong - Reaction going out of control . Worst Industrial Disasters that Shock the World

15. Piper Alpha disaster, North Sea July 6, 1988 Estimated loss- Some 167 men lost their lives with a total loss of US$ 3.4 billion. This makes it one of the worst offshore oil disasters What went wrong- Explosion followed by Fire . Worst Industrial Disasters that Shook the World

16. 2013 Lac- Megantic , Canada Railcar Explosion North Carolina Emergency Management Town of approximately 6,000 people, 47 were killed Credit: The Canadian Press/ Paul Chiasson Credit: The Canadian Press/ Ryan Remiorz

17. FIRE LOSSES

18. 2013 West, Texas North Carolina Emergency Management - Neal Langerman , chemical and health safety officer at the American Chemical Society "The West, Texas, first responders were doing the best they could under the circumstances…The failure was in the community, county, and state leadership to provide emergency planning and implementation guidance… I don't think it's appropriate to beat up on what the first responders did at the time of detonation, but everything that led up to it - preparedness and preparation - was lacking," A fire was reported at 7:19 PM on April 17,2013. Explosion reported 20 mins . after first responders arrived February 2012 Tier II filing did not list ammonium nitrate Apartments and nursing homes within a few hundred yards of the plant Source: Reuters Fertilizer Plant Explosion

19. The world we live in today is an industrial one. All around us people make, move and use products created from chemical that can be hazardous chemical humans. As a result, there is a remote possibility that a hazardous chemical could be spilled during transportation accident or a manufacturing accident. CHEMICAL HAZARDS

20. Main Emergencies in FFBL Fire Chlorine release Ammonia release Flammable gas release and explosion Note: Emergency planning for these hazardous events should be based on worst scenario. Chemical plant blast in China

21. The people who might be at risk Operation staff Process Maintenance staff Lone workers i.e. cleaners Workers in isolated spaces Contractors Visitors Special persons i.e. disabled persons Could be any employee….

22. Training of employees to minimize injury and possible loss of human life & company resources during emergency situation. EMERGENCY PREPAREDNESS

23. FIRE Weekly Fire Drill Live Fire Drill (Monthly) AMMONIA RELEASE Biannual NH3 dry run (Full scale mock drill) Emergency plan ready in place Table drills/ emergency handling discussion in rotating shifts CHLORINE RELEASE Mock drills Emergency plan ready in place Emergency handling discussion in rotating shifts SAFETY TALKS Weekly safety talks in rotating shift groups. Every Monday morning in general shift. EMERGENCY PREPAREDNESS

24. Emergency action plan should be in place. Every individual involved should be trained. HOW TO ACHIEVE

25. OSHA Emergency Action Plan 1910.38 Written and oral emergency action plans Minimum elements of an emergency action plan (Discussed in next slide) Employee alarm system Training Review of emergency action plan

26. Min. Elements for Emergency Action Plan OSHA 1910.38 (c) Procedures for reporting a fire or other emergency; Procedures for emergency evacuation, including type of evacuation and exit route assignments; Procedures to be followed by employees who remain to operate critical plant operations before they evacuate; Procedures to account for all employees after evacuation; Procedures to be followed by employees performing rescue or medical duties; and The name or job title of every employee who may be contacted by employees who need more information about the plan or an explanation of their duties under the plan.

27. EMERGENCY RESPONSE PLAN S S s S s

28. Fire Station 5555 / 5343 Industrial Clinic 5348 Coordination Engineer 5368 Security Gate # 04 5459 EMERGENCY CONTACT NUMBER

29. EMERGENCY SIREN MODE

30. ICC MEMBER Operation Manager Coordination Engineer Shift Engineer Fire Squad Member Manager – E & I Unit Manager S & H Manager Mechanical Concerned Unit Manager Incident Command Center

31. Role Of Incident Command Center (ICC) Role of incident command center is to take immediate action to control emergency condition at the plant. Inform all its activities and receive all guidelines from the back up control center EMERGENCY RESPONSE

32. BCC MEMBER General Manager Resident Manager Admin Manager Security Manager Maintenance Manager Tech. Serv. Manager HSEQ Manager Medical Manager Backup Command Center

33. Role Of Back Up Control Center (BCC) Backup control center is responsible for directing following and planning all activities To keep liaison with OCEA and external agencies (police, fire station hospitals etc ) To order “ Disaster Clear” Alarm To order “Plant Evacuation” (if required) EMERGENCY RESPONSE

34. Fire Alarm System: Manual Pull Station Explosion and Weather Proof Used in open plant areas and Buildings Smoke Detectors & call points Used in covered plant areas and Buildings Used in open plant areas and Buildings Fire Alarm Panels 05 Addressable & 14 Conventional Panels Other Hot line Emergency telephone Radio (Motorola) EMERGENCY COMMUNICATION

35. ROLE OF INDIVIDUAL IN DIFFERENT AREAS PRODUCTIVE PERSONS In affected unit personnel seeing a loss of containment indicent , immediately report to the respective control room & safety unit. Have gas masks and breathing apparatus available for use. Check the wind direction. Keep yourself available for further instructions from your shift engineer. Carefully understand those and question if the instructions are not clear. Isolate the affected equipment if possible from the rest of the plant to prevent further damage or aggravation off the situation. Take only calculated risk Move out of the operating area if asked by the shift engineer and reach the safe assembly area. EMERGENCY RESPONSE

36. Un affected unit persons stay on the job as far as possible. Have gas masks and breathing apparatus available for use. Check the wind direction. Carefully understand supervisor instructions. Question if instructions are not clear. Take only calculated risk to carry out the assigned job. For evacuation, reach the safe assembly Area. EMERGENCY RESPONSE

37. Role of unproductive persons All the outsiders working in open area check wind direction leave area through the safe route & should reached near by shelter. The should used wet cloth to protect breathing Take all measures to stop entry of ammonia gas into your room by closing doors, windows and blocking all openings with wet cloth Close (not lock) all doors, windows etc. Insert wet cloth all openings Breath through a wet cloth in case of difficulty. Store some water Turn off all air conditioners and air handling units Do not leave the room, wait for further instructions. No vehicle movement allowed, park aside vehicle & switched off the engine, leave keys inside and take shelter in nearby building. EMERGENCY RESPONSE

38. FIRE WATER NETWORK Capacity of dedicated firewater reservoir 5000 m 3 Hydrants 72 Nos Monitor 11 Nos Working pressure 10 Bars FIRE WATER PUMPS Jockey (30 m3 / hr) 02 Nos Electrical driven pump (600m3 per hr) 01 No Diesel engine driven pump (600M3 per hr) 01 No FIRE TRUCKS 02 Nos Water 5000 Liters Foam 1000 Liters DCP (Dry chemical powder) 225 Kgs FIRE FIGHTING FACILITIES

39. Chlorine Is used in utilities plant for cooling tower Water treatment in gaseous form and is supplied in 900 kg cylinders, its leakage is localized emergency. In this BCC need not to be established and ICC will serve as control center. CHLORINE RELEASE EMERGENCY HANDLING

40. CHLORINE MSDS PHYSICAL PROPERTIES OTHER CHARACTERISTICS Boiling point  C -34 GREENISH YELLOW GAS, WITH PUNGENT ODOR . The vapour is heavier than air and may travel along the ground. At local heating of steel equipment a chlorine iron fire may develop. Mixtures of hydrogen, acetylene and ammonia are explosive, they can ignite even by the effect intense sunlight. At normal temperatures dry chlorine does not attack steel, copper, bronze etc. Moist chlorine is strongly corrosive. Reacts violently with many organic compounds, phosphorus and (finely dispersed) metals. Attacks all metals in the presence of moisture. The substance is corrosive to the eyes, the skin and the respiratory tract. Inhalation of vapour and/or fumes may cause shortness of breath (lung edema). Serious cases may be fatal. Melting point  C -102 Relative density (water-1) 1.4 Relative vapour density   (air=1) 2.5 Vapour pressure in bar at 20  C 6.8 Solubility in water   g/100 ml at 20  C 0.7 Relative molecular mass 70.9     MAC in ppm MAC in mg/m 3 1 3

41. Leakage from piping control system at Cl 2 skid downstream of cylinder: CHLORINE RELEASE EMERGENCY HANDLING GUIDELINES In case of leakage alarm will sound on DCS in UCR. In case of leakage Area Operator and all other personnel in the vicinity of Cl 2 skid will immediately evacuate the area considering wind direction and inform UCR Utilities Shift Engineer / Panel Operator after confirming the leakage will announce regarding leakage on public address PA system to keep away from affected area. Utilities shift engineer will also inform coordination Engineer and Safety Section about the leakage. Coordination engineer will instruct Ammonia Unit personnel to keep away from affected area. Safety section will reach affected area with Fire Truck / Scott air pack. Coordination Engineer will arrange to cordon off area on Ammonia plant site. Utilities Shift Engineer will arrange to cordon off area of Utilities side. Utilities Shift Engineer will depute one or two persons to wear Scot air pack and isolate Cl 2 cylinder. Safety section / Utilities Operations personnel will rescue any causalities wearing Scott air pack or multipurpose cartridge mask available in UCR.

42. Ammonia is a penetrating, intensely pungent odorous and strongly irritating gas. It is lighter than air and soluble in water. The substance partially absorbs in the human body by inhalation. Chemical Formula is NH 3 Made up of one part nitrogen (N) and three parts hydrogen (H3) One of the most widely used sources of nitrogen for plant growth. Anhydrous means "without water." Because NH3 contains no water, it is attracted to any form of moisture. Most deaths from anhydrous ammonia are caused by severe damage to the throat and lungs from a direct blast to the face. When large amounts are inhaled, the throat swells shut and victims suffocate. Exposure to vapors or liquid also can cause blindness. If exposed to NH3 immediately flush the exposed body area(s) with water for at least 15 minutes Seek medical attention immediately after emergency first aid treatment AMMONIA

43. We insist on safety equipment and strict procedures for everyone follow. Provided leak detectors, warning alarm and automatic shutdown of our leak control. In the unlikely event that and accidental released should occur FFBL employee are trained. Exposure to the liquid ammonia may cause severe burn to skin & damage the eyes. Excessive inhalation of the vapour causes severe damage to the lungs, leading to death. FFBL CONTROL MEASURE FOR AMMONIA RELEASE

44. We want to share with you basic information about a chemical we have on site called anhydrous ammonia. We make it at ammonia plant and used in Urea and DAP for manufacturing of Urea DAP fertilizer WHAT YOU SHOULD KNOW ABOUT AMMONIA

45. Anhyd-06 Caustic (alkali) burns Freezing burns Inhalation danger to lining of mouth, throat and lungs Does not support respiration – suffocation danger Especially dangerous to eyes Agrochemicals and Security: Security and Anhydrous Ammonia AMMONIA HAZARD

46. AMMONIA MSDS PHYSICAL PROPERTIES OTHER CHARACTERISTICS Boiling point  C -33 Ammonia is a colorless, intensely pungent gas (anhydrous ammonia). It can be liquefied under increased pressure. Under normal pressure liquefied ammonia evaporates very rapidly, through it cools considerably down to temperatures of – 33°C Gaseous ammonia is readily absorbed by water. Such solutions contain up to 35% of ammonia. They are called ammonium hydroxide or aqueous ammonia. Liquefied ammonia and highly concentrated ammonium hydroxide have a strongly caustic effect on the skin, the mucous membranes and eyes. Liquefied ammonia can also cause frostbite. Highly concentrated gaseous ammonia can cause severe cauterization. Its pungent smell serves as an early warning and thus prevents in general, serious injuries to health. The real danger lies beyond the limited of tolerance. While actions of gaseous ammonia below the limit of tolerance give no reasons to suspect injuries. Physiological effects of ammonia of various concentrations are described in the table below: Melting point  C -78 Flash point  C flammable gas   Auto ignition temperature  C 650 Relative vapour density   (air=1) 0.6 Vapour pressure in bar at 26  C 10 Solubility in water   G/100 ml at 20  C 53 Explosive limits, vol. % in air 15-29 Relative molecular mass 17.0     MAC in ppm MAC in mg/m 3 25 18

47. AMMONIA THRESHOLD LIMITS FOR HUMAN BEINGS AMMONIA VAPOR PPM EFFECTS ON UNPROTECTED HUMANS EXPOSURE PERIOD < 25 (TLV) No Effect No Limit 50 (TWA) Least Detectable Odor 8 hrs 500 (IDLH) Causes Irritation to Throat 1 hour (Ordinarily No Serious Results Following in Short Exposure i.e. < 1 hrs) 700 Causes Irritation to Eyes -- 1700 Causes Convulsive Coughing No Exposure Permissible (May be Fatal After ½ hrs) 5000 TO 10,000 Causes Respiratory Spasm, Strangulation Asphsic No permissible (Rapidly Fatal) Source = OSHA TLV = Threshold Limit Value TWA = Time Weighted Average IDLH = Immediately Dangerous to Life and Health

48. Source Type Ammonia Storage Tank Dimensions, m D = 25 : H = 16 Holdup, Tons 2,500 Size of Weld Opening 12" x 6" Meteorological Data Wind Speed, m/sec 2.0 Wind Direction NW Stability Class F Ambient Temperature, °C 25 Humidity, % 60 Ground Conditions Open Country INPUT DATA

49. Ammonia Release from Storage Tank Roof due to Weld Failure CASE SCENARIO

50. Emissions Parameters Source Location Source Type / Size Extent of Damage Meteorological Conditions Wind Speed and Direction Atmospheric Turbulence (Stability Class) Ambient Air Temperature / Humidity / Cloud Cover Ground Conditions DISPERSION MODEL - INPUT DATA

51. Mathematical simulation of how air pollutants disperse in the ambient atmosphere Gaussian / Brigg Equations are used DISPERSION MODELING

52. The term Dispersion includes Advection: Moving Downwind Diffusion: Spreading Crosswind DISPERSION

53. Threat Zone NH 3 Conc. Effects Results ERPG-1 < 25 ppm Mild Coughing, Eye Irritation ERPG-2 < 150ppm Reversible Chest Pain, Impaired Vision ERPG-3 > 750 ppm Irreversible Narrowing of Throat, Coma, Death DISPERSION MODEL – OUTPUT

54. Threat Zone Description NH 3 Conc. Effects IDLH Immediate Danger to Life & Health < 300 ppm No reversible effects for < 30 min. exposure TC-50 Toxic Concentration < 1,100 ppm 50% irreversible effects for > 10 min. exposure LC-50 Lethal Concentration > 2,600 ppm 50% deaths for > 10 min. exposure Threat Zones can also be defined manually [ SAIPEM ] DISPERSION MODEL – OUT PUT

55. * Model Run: Gaussian * Threat Zones: LC-50 : 0.7 km [10 min.] TC-50 : 1.1 km [10 min.] IDLH : 2.4 km [30 min.] OUTPUT

56. DISPERSION MODEL ON MAP 2 m/s 1.0 km 2.0 km 2.5 km 2.4 km IDLH 1.1 km TC-50 0.7 km LC-50

57. DISPERSION MODEL ON MAP

58. Means of escape Route that leads to a safe place outdoors Must be properly signed Provided with emergency lighting May be two or more (depending upon the number of people and severity of risk involved) Factors influence the means of escape Travel distance Number of available escape routes Escape routes width Design of any doors in the escape routes Provision of suitable assembly points Building Evacuation