Emergency Response and Control Plan

INDORAMA ELEME FERTILIZER & CHEMICALS LIMITED

(Construction Project)

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Emergency Response and Control Plan

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TABLE OF CONTENTS

1.0 2.0 3.0

4.0

INTRODUCTION OBJECTIVE SCOPE CRIDIBLE EMERGENCY SCENARIOS Explosion Fire Oil Spill Flood Product / Transport emergency Fall from height Suspension trauma. Electrical accidents Serious cut injury- profuse bleeding Collapse of excavation Asphyxiation in confined spaces

5.0

EMERGENCY CONTROL CENTRES

Facilities at Emergency Control Centre

Manning of Emergency Control Centre

6.0

EMERGENCY ALARMS AND COMMUNICATIONS

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7.0

EMERGENCY RESPONSE PLAN General Response

Response of Fire Services Response of Medical Team Response of Security Team

Response of Public Relations Personnel

8.0

EVACUATION & RESCUE PLAN

9.0

STRATEGIES TO COMBAT - EMERGENCY SCENARIOS Explosion Fire Oil Spill Flood Product / Transport emergency Fall from height Suspension trauma. Electric Shock Serious cut injury- profuse bleeding Collapse of excavation Asphyxiation in confined spaces

10.0

EVACUATION PROCEDURE & END OF EMERGENCY

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01

INTRODUCTION

In spite of sound equipment, engineering methods and work by trained and skilled employees incidents leading to emergency situation may take place if there is any deviation from standard practices. Most of the emergency situations can be controlled by careful evaluation of the anticipated possible events and evolving a plan to meet such situations, organize suitable drills or rehearsals for effective implementation at the time of emergency. The Emergency Response and Control Plan (ERCP) of IEFCL is a master plan, which contains the emergency organization structure, responsibilities of key members, communication means and emergency response strategies to control a range of major incidents. This plan has been drafted after a thorough analysis and assessment of various risks associated with each stage of construction work of the project and Simultaneous work of process plant at M/s IEPL as both are in the same precinct. Each key member has his own plan describing detailed activities to function effectively in the emergency management. This plan of action for emergencies will minimize the potential for injury; lose of life and/or property and to define the responsibilities of Managers, Supervisors, Employees and contractor during emergency situations 02 OBJECTIVES

The overall objectives of ERCP are summarized as follows: To establish & define roles of coordinators, plant key personnel & other emergency response personnel.

To establish guidelines for effective response to any emergency.

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 To contain and control emergency incidents. To prevent loss of life and minimize the risk of injuries to people working within the complex.

To minimize damage to company installations and property & environment. To inform employees, public and authorities on the hazards/risks assessed, safeguards provided and the role to be played by M/s IEFCL.

Ensure a smooth interface between various processes of M/s IEPL and M/s IEFCL project construction

03

SCOPE

This plan is applicable to the entire Construction project of fertilizer plant of M/s IEFCL with a view to make all employees aware of the various emergency scenarios and its management
04 EMERGENCY SCENARIOS

Various scenarios that are anticipated to cause major emergencies within our precinct are explosion, fire, flammable release, oil spill, natural calamities like , flood, etc. All these scenarios are discussed in brief in the following text.

4.1

EXPLOSION

Explosion is a major hazard and the quantum of explosion depends on the rate at which energy is released. Explosion can bring in certain effects like blast wave, thermal effects, missile effects, ground shock and injury to personnel. These are not a credible
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scenario for construction site but as IEPL is within the precinct where doing were project construction and these hazards are well taken care of by on site emergency management of IEPL number IEPL-HSE&F-2.111 4.2 FIRE

Fire is also a serious hazard and is normally regarded as having a risk where the potential is of lower magnitude than explosion or flammable gas release that can be controlled at the incipient stage. Certain examples for construction site are fire in acetylene gas cylinder, fire in combustible material due to welding cutting and grinding operation, fire electrical cables and installations etc.

4.3

TOXIC RELEASE

Release of toxic chemicals in the form of gases and vapor can pose major hazards if proper care is not taken. Such hazards presented by a toxic release depend on the duration of exposure and on the chemical itself. It ranges from a sudden brief exposure at high concentration to a prolonged exposure at lower concentration over a working lifetime. Currently no toxic material which causes acute toxicity like chlorine, ammonia, hydrogen sulfide, sulfur-di-oxide are used within the precinct. 4.4 OIL SPILL

Spill may occur on land or on water. Spills on land are relatively simple to handle. They normally require collection and transfer of oil and clean up of oily mud. There is no possibility of oil spill to cause water pollution at construction site.

4.5

FLOOD

The chance of flooding in the complex due to seasonal monsoons is rare. However, with the advance information from the local authorities / meteorological dept. on flood warning, specific actions to be carried out on those occasions are considered in this

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plan. Some of the effects likely during flood are water entering the excavated pits and trenches and affecting the ground level electrical equipment. 4.6 PRODUCT / TRANSPORT EMERGENCY During transportation of the product, emergencies like Explosion, Fire, Leakage, Spillage or flammable release are possible. It may be outside our working precinct, at nearby or far locations. Necessary emergency actions are initiated from internal or external resources as per the level of the emergency. These are covered under on site emergency management of IEPL number IEPL-HSE&F-2.111 4.7 FALL FROM HEIGHT SUSPENSION TRAUMA Workers suspended in their safety harness for long periods may suffer from blood pooling in the lower body and this can result in suspension trauma The worker may have suffered injuries during the fall and may need medical attention. 4.8 ELECTRICAL ACCIDENTS The principal hazards associated with electricity are: electric shock electric burns electrical fires and explosions arcing. 4.9 SERIOUS CUT INJURY- PROFUSE BLEEDING Profuse bleeding if not managed immediately can take life hence treated as an Emergency.

4.10 COLLAPSE OF EXCAVATION Persons get buried in excavation and trenches due to collapsed soil and leads to fatality if not removed out immediately 4.11 ASPHYXIATION IN CONFINED SPACES Persons get asphyxiated in vessels under nitrogen atmosphere or during inert gas purging and if immediate action is not taken may lead to fatality.

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05

EMERGENCY CONTROL CENTRES

At IEFCL, In the event of an emergency PSS-Office is designated as the Emergency Control Center. 5.1 Facilities at Emergency Control Centre

The site incident control room shall be equipped with, but not limited to, the following items: 5.1.1 Facilities Available At ECC Telephones: 4170 Mobile 8053002225 One PC with e-mail, Internet and web site facilities Basic Emergency equipment Inventory of Hazardous materials MSDS of Hazardous Chemicals Drawings showing safe assembly points Emergency Lighting Pre-Incident Plan (PIPA) document (of IEPL) Wireless communication system. Flame Proof Torch Area ownership drawing showing hydrocarbon pipe line entry at battery limit Power supply with emergency DG set/UPS backup

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5.2 Manning of Emergency Control Center Emergency control center is manned round the clock by Plant shift superintendent (PSS) 6.0 EMERGENCY ALARMS & COMMUNICATION

Communication system is very crucial for effective control of any emergency. Any emergency, if detected and communicated to the concerned, timely can be controlled and terminated within shortest possible time without further escalation. At construction site Walkie talkies (Radios) and mobile phone are provided to immediately communicate the emergency to PSS and Emergency Key persons (List Given in Annexure I) 7.0 Emergency Response Plan

7.1 General Response Once emergency is declared, all the personnel inside the construction site including visitors shall respond in the following manner: All the vehicle operators shall pull their vehicle to the left and stop the engines. Engine keys shall be left inside the cabin itself. Visitors shall be necessarily accompanied by the IEFCL employees and guided to a safe location as per the announcements. In case of a Flammable release from IEPL all hot jobs shall be stopped at the prevailing wing direction at construction site on getting communication from PSS or from fire control room. If the situation escalates beyond control, employees shall evacuate the site as per the instructions made PSS / Fire control room through P A System or on radio. All non-essential employees at the incident site shall be moved to a Safe assembly area based on the prevailing wind direction and the level of emergency (based on the announcement made through P.A system or on radio.)

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The respective DNL/ IEFCL construction manager shall assist in conducting head count at the Safe assembly point and arrange for search of missing personnel. Casualties shall be transferred to the OHC and the medical team shall give necessary treatment. Once the event is controlled using various support services, the Fire Manager along with the Safety Manager and DNL/ IEFCL construction manager in consultation with Project Director shall announce all clear to resume normal work at construction site. All persons from the Safe assembly area shall resume their normal duty after getting all clear communication. 7.2 Response of Fire Services The Fire control room operator shall initiate the turnout procedure immediately upon receiving emergency communication. Fire Manager shall take charge immediately at the incident site and coordinate with the DNL/IEFCL construction manager on getting communication of emergency. Fire control room operator shall ensure the continuous fire water availability at emergency site through Utilities.. Fire control room operator shall record all the events / activities in the occurrence book with time against each event.

7.3 Response of Medical Team

The treatment plan of casualties arising out of any injury incidents are as follows: Information about accident will be received through Fire Control Room / Telephone / through DNL/IEFCL employee/PSS. The Medical Officer on duty / Male Nurse initiate the medical response plan and the same is continuously monitored by the Medical Officer. Ambulance with two male nurses (if required along with doctor) shall rush to the incident site to attend the victims. Nurse on duty will inform the duty doctor & simultaneously shift the patient to the treatment room.

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The duty doctor shall evaluate the case. He shall also take on record the personal detailed & history of the case. After initial evaluation and stabilization of the case if specialist opinion is required, patient may be shifted to referral hospital by ambulance or any available vehicle. If the case can be managed at the OHC, the doctor shall give him medication accordingly and if required the patient may be kept under observation. The doctor shall also advise the patient of the precautions and diet to be taken.

7.4 Response of Security Team

The security response plan is to prevent entry of unauthorized persons, while at the same time allowing proper reception, briefing and direction of emergency services and personnel.

After receiving the information at the security control room, from PSS/ Fire Control room the Shift Security officer shall inform the Security Chief or next senior.

The Security Chief shall order one of the Senior Security Managers to assume charge at the security control room and start communicating with the required personnel in an effective manner.

The Security Chief shall report to DNL/IEFCL construction manager at site. The Security Chief shall reinforce the security at strategic locations as the case may be.

Roads & routes around the incident site shall be cordoned off and alternate routes shall be established with the concurrence of the DNL/IEFCL construction manager.

Additional security forces shall be mobilized to take care of the traffic control both inside and near the complex gates.

The security personnel shall accompany all the incoming external emergency services and direct them to the emergency control Centre.
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Additional security forces shall be deployed along with the fire services in rescue operations.

If the situation is likely to escalate beyond the control of the security staff, the local police authorities shall be called in at appropriate time.

A record of all the incoming and outgoing vehicles shall be maintained. The security control room officer shall log all events, the response of various agencies and action taken.

7.5 Response of Corporate Affairs Public Relations

During a major emergency, it is most likely that outside organizations, TV/radio, newspaper reporters, photographers, local residents, neighboring industry etc. will contact the complex soon after the start of an emergency incident. However if these callers are not handled effectively, problems such as unauthorized entry into the complex and inaccurate or even hostile news media reporting would result. Following are some of the actions to be carried out by the corporate affairs personnel.

Arrange to receive and direct news media reporters to the Site Guest House. Build an on-going dialogue with press and media with regard to the incident developed at site.

Organize a meeting with the Project Director to enable him brief the press / media. Prepare press releases in consultation with Project Director. Set up information desk for giving relevant information to the needy employees, their families & relatives

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8.0 EVACUATION & RESCUE PLAN

Based on the magnitude of an emergency, the need for evacuating / rescuing personnel from the complex shall be decided by the Project Director in consultation with Safety Manager. Moving people to Safe assembly points of the respective plant may affect localized evacuation. However, in case of massive release of Flammable, evacuation of people from the complex may be required. Safe Assembly Points Safe assembly points shall be located in a safe place away from process risks and in the least affected downwind direction at all construction plant locations. All the Safe assembly points inside the IEFCL shall be clearly marked by a conspicuous notice and provided with an identified location. Headcount: shall be organized by Security In-charge in consultation with the respective DNL/ IEFCL plant construction head at the Safe assembly point. The names and departments of those reporting there shall be recorded. Before reaching an assembly point or subsequently, if it is required to pass through an affected area or the release of gaseous substance, suitable PPE including respirator, helmets etc should be made available to the people.

Evacuation Procedure The responsibility of evacuating the personnel who are not required at emergency site lies with plant personnel & Security. Security personnel shall shift the Evacuated personnel from assembly point to safe location, if required. The security personnel shall operate from plant battery gate. The actions to be taken by different emergency teams for evacuation are given below:

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( a ) Action to be taken by DNL/ IEFCL construction Personnel Alert all the personnel working in the plant regarding the emergency. Ensure all hot work s / vessel entry jobs are immediately stopped. Shut down welding generators, Close acetylene / oxygen cylinder valves, and switch off electrical supply to electrically operated tools. Guide them to take appropriate escape keeping in mind the prevailing wind direction and assemble at safe assembly point. Provide the list of personnel working in the plant at the time of emergency to security dept to facilitate proper head counting. Ensure all the personnel are evacuated who are not required at emergency site. Inform PSS) / Fire Manager at site for evacuation of any trapped personnel. Keep cool. Do not rush. Assemble at designated safe assembly points as directed by the plant personnel. Inform plant personnel / Security personnels regarding any person is missing or trapped at work site. ( b ) Action to be taken by Fire Service Personnel Rescue personnel trapped in plant, excavation and trenches or elevated platforms. Search for any missing / trapped personnel and rescue. Report to PSS/ Project director/ Safety Manager and appraise regarding the rescue of missing / trapped persons.

( c ) Actions to be taken by Security Personnel Cordon off the area and do not allow any unauthorized persons to enter the emergency site. Keep close liaison with PSS / Project director and take head count of the personnel assembled at safe assembly point. Inform Project director regarding any missing personnel. Evacuate the personnel assembled at assembly points to safer locations on instruction from Project Director.

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9.0 STRATEGIES TO COMBAT VARIOUS EMERGENCY SCENARIOS

Following section describes in brief the general strategies to be taken during various emergency scenarios. These are not sets of detailed procedures for combating emergencies but as guidelines in controlling the emergency.

9.1

Fire & Explosion Initial Operations Response Actions

The DNL/ IEFCL personnel of the respective construction plants being first line respondent at site shall attempt to control the emergency at the initial stage by isolating the fuel, operating the fire protection facilities etc. to minimize the potential effects.

9.2 Release of Flammable Gases IEPL to Take care of this IEFCL will ensure Hot Job is stopped on gas release

9.3 Oil Spill When a liquid or a solid has been discharged onto a land surface, attempt to contain the spilled material and prevent further spread. Dikes or barriers of earth, sand or clay materials can be quickly constructed with bulldozers or similar equipment. Motorized equipment should not be used indiscriminately near

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flammable vapors or gases. Adequate shovels may be arranged for manual cleaning.

Once the spilled material has been contained, the next step is to remove it from the environment. Following methods shall be adopted for gross clean up of contaminated ground surfaces:

- Use of compatible pumps, hoses, tanks, drums, or vacuum trucks to collect pools of accumulated liquids. - Use of soil, sand, clay, straw, saw dust, fly ash, cement powder, vermiculite, or commercially available mineral or plastic sorbing materials to absorb and mop up liquid residues. Dispose off the same as per procedure. Removal of contaminated surface layers (where cleaning in place is not practical) by shovels or mechanical means. - Steam-cleaning or detergent washing of solid surfaces where hydrocarbons have spilled. - Burning of flammable materials in place where it is safe to do so. - Application of special mutant bacterial cultures to contaminated soils and liquids to "digest" contaminants over a period.

9.4 Flood The Project Director will decide and declare to Shut down the construction work and related facilities if the situation demand. Evacuate people from areas, which are likely to be affected. Arrange boats, helicopters and other necessary means to evacuate people from the affected areas. Identify swimming experts to evacuate the trapped personnel. Switch off all electrical supply until the situation comes to normal. Ensure adequate communication facilities are made available. Monitor all open drainage systems for inadvertent entry of water stream. Check that no oil enters the final water stream from the effluent treatment plants and storm water ponds. Ensure adequate de-watering pumps are made readily available.

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Medical team to monitor hygiene and sanitation facilities and take steps to prevent spread of any communicable diseases.

9.5 Product / Transport Emergency Driver of the truck / tanker will inform nearby police station, Fire brigade and then depending upon the distance he will inform the concerned agency This Activity Shall Be mainly Handled by DNL site head.

9.6 Fall from height Suspension trauma Please see Annexure II

9.7 Serious cut injury- profuse bleeding. Stop Bleeding by Pressing pressure point take help of trained first aider call for ambulance immediately.

9.8 Collapse of excavation / Trench Call fire to remove the person, do not use mechanical methods to remove the soil fallen on the person as it could hurt him call ambulance also immediately.

9.9 Asphyxiation in confined spaces Take out the person immediately to fresh air give if required CPR, call for ambulance.

10-END OF EMERGENCY The DNL/IEFCL constructions Manager shall declare the end of emergency after evaluating the situation in consultation with project director.

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ANNEXURE I Emergency Key persons

Note:- Organ gram of DNL & IEFCL not available during drafting the plan

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Annexure II
Procedures for Rescue of a Worker Suspended in a Safety Harness
The rescue of a worker who has fallen and is being suspended in his/her safety harness needs to be undertaken as quickly as possible for several reasons:

1.

The worker may have suffered injuries during the fall and may need medical attention.

2. 3.

Workers suspended in their safety harness for long periods may suffer from blood pooling in the lower body and this can result in suspension trauma. The suspended worker may panic if they are not rescued quickly.

4.

The event that led to the fall may create additional risks that need to be addressed.

General Rescue Procedures:

A.

If Elevating Work Platform is available on site:

Bring it to the site and use it to reach the suspended worker. Ensure that rescue workers are protected against falling. Ensure that the EWP has the load capacity for both the rescuer(s) and the victim. If the victim is not conscious, 2 rescuers will be probably be needed to safely handle the weight of the victim. Position the EWP platform below the worker and disconnect his lanyard when it is safe to do so. Treat the victim for Suspension Trauma and any other injuries. Arrange for transport to nearest hospital.

B.

If no Elevating Work Platform is available:

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Where possible, use ladder(s) to reach the victim. Rig separate lifelines for rescuers to use while carrying out the rescue from the ladder(s). If worker is not conscious or cannot reliably help with his/her own rescue, at least 2 rescuers may be needed. If worker is suspended from a lifeline, where possible, move the suspended victim to an area that can be safely reached by the ladder(s). If victim is suspended directly from his/her lanyard or from a lifeline, securely attach a separate lowering line to the victims harness. Other rescuers should lower the victim while he/she is being guided by the rescuer on the ladder. Once the victim has been brought to a safe location, administer First Aid and treat the person for Suspension Trauma and any other injuries. Arrange for transport to nearest hospital.

C.

If the injured person is suspended near the work area and can be safely reached from the floor below or the area they fell from: Ensure that rescuers are protected against falling. If possible, securely attach a second line to the workers harnesses to assist in pulling them to a safe area. (Note: at least 2 strong workers will be needed to pull someone up.) Ensure that any slack in the retrieving lines is taken up to avoid slippage. Once the victim has been brought to a safe location, administer First Aid and treat the person for Suspension Trauma and any other injuries and arrange for transport to the nearest hospital.

D.

If a person has fallen and is suspended in an inaccessible area (e.g. a tower, against a building or structure that has no openings):

Specialized rescue techniques are needed for this type of situation. It may involve a rescuer rappelling or being lowered down to the victim, it may involve using the lifeline to retrieve the fallen worker, or the use of high-reach emergency equipment. Due to the inherent risk to the rescuers and/or the victim, this type of rescue should not be undertaken by people without specialized training and experience.

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