Pakistan Petroleum Limited Emergency Planning & Response

DOCUMENT CHANGE RECORD

ISSUE
REV. # PAGE(S) BRIEF DESCRIPTION OF CHANGE(S)
DATE
Procedure for Emergency Planning &
Response, PPL-HSE / PR / 06 Rev: 00, issued
in Jan. ’09 by HSE Dept. and withdrawn with the
All merger of HSE and M&I Dept. Procedure for
Emergency Planning Response, PR204 was
issued under revised number scheme of QHSE
PPL-QHSE /
Dept.
PR / 204 Rev: Mar. ‘17
00
Emergency Level III and Pre-Fire Plans
introduced. Requirements related to Emergency
Response Equipment, Local Emergency
18 & 19
Response Team, Simulation exercises aligned
with the Assets / Dept. past feedback and
industry best practices.

Emergency Drill frequency revised (Section 4.4)

01 Dec. ‘22 15 & 17 and requirement for review of Emergency
Response procedure amended. (Section 4.7

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Pakistan Petroleum Limited Emergency Planning & Response

TABLE OF CONTENTS

S. # CONTENTS PAGE #

Terms and Definitions 04

List of Abbreviations 05

1. Purpose 06

2. Scope 06

3. Responsibilities 06

4. Procedure 07

4.1 General 07

4.2 Emergency Response Planning 08

4.2.1 Brainstorming Sessions 08

4.2.2 Evaluation of Existing Controls 08

4.2.3 Evaluation of Potential Disasters 09

4.2.4 Emergency Criterion 09

4.3 Developing Site Emergency Response Procedure 11

4.3.1 Fire Pre-Plans 12

4.3.2 Elements of Fire Pre-Plan 13

4.4 Simulation Exercises 15

4.5 Local Emergency Response Team 16

4.6 Emergency Response Equipment 16

4.7 Review of Site Emergency Response Procedure 17

4.8 Emergency Medical Plan 18

5. Training & Program Evaluation 19

6. Related Documents & Records 19

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Pakistan Petroleum Limited Emergency Planning & Response

DISTRIBUTION LIST

This procedure is available on PPL portal and accessible to all the employees of PPL.

TERMS AND DEFINITIONS

TERM DEFINITION

An unplanned event resulting in an injury, illness or damage to

Accident
property and environment or PPL’s reputation.

A safe place preferably out of operations area for employees

Assembly Point
gathering in case of any emergency situation.

The explosively rapid vaporization and corresponding release of

energy of a liquid, flammable or otherwise, upon its sudden release
from containment under greater-than-atmospheric pressure at a
Boiling Liquid,
temperature above its atmospheric boiling point. A BLEVE is often
Expanding Vapor
accompanied by a fireball if the suddenly depressurized liquid is
Explosion (BLEVE)
flammable and its release results from vessel failure caused by an
external fire. The energy released during flashing vaporization may
contribute to a shock wave.

An event or situation that has the potential to significantly affect

Crisis business operations and services, which need urgent and
coordinated action to cater for disruption.

An undesired condition requiring immediate response to safeguard

Emergency
human life and Company’s assets.

A scenario based plan, specific to a particular process area or

equipment item describing how the fire protection and emergency
response systems are to be used in specified fire scenarios. It takes
Fire Pre-Plan into account the nature and likely effects of the fire scenario, the
materials involved (process materials and plant construction
materials), the surrounding environment, including plant layout, any
special hazards pertaining to that area, and the resources available.

Functional Head Direct reportee of Managing Director

A condition or practice with the potential to cause harm to people,

the environment, property or PPL’s reputation. Hazard is also used
Hazard in the meaning of environmental aspect. Environmental aspect is an
element of an organizational activities or product or services that
may interact with the surrounding environment.

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PCBs are a family of substances which are good electrical

insulators. They are found as dielectric filler liquids in some types of
Polychlorinated
electrical equipment such as transformers, switchgear, capacitors
Biphenyls (PCBs)
and in the starter units of fluorescent lights. Exposure to PCBs can
cause various health related problems.

Combination of the likelihood of an occurrence of a hazardous event

or exposure and the severity of injury or ill health or harm to the
Risk
environment, property damage or PPL’s reputation, that can be
caused by event or exposure(s).

Process of evaluating the risk arising from a hazard taking into

Risk Assessment account the adequacy of any existing controls, and deciding
whether the risk is acceptable or not. Risk assessment can be
quantitative and qualitative.

The explosion resulting from the ignition of a cloud of flammable

Vapor Cloud
vapor, gas, or mist in which flame speeds accelerate to sufficiently
Explosion (VCE)
high velocities to produce significant overpressure.

LIST OF ABBREVIATIONS

BLEVE Boiling Liquid Expanding Vapor Explosion

ERT Emergency Response Team

ERP Emergency Response Procedure

HO Head Office

LTII Lost Time Injury & Illness

PCB Polychlorinated Biphenyls

VCE Vapor Cloud Explosion

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Pakistan Petroleum Limited Emergency Planning & Response

1. PURPOSE:

The purpose of this procedure is to layout a mechanism for managing emergencies

such as medical, fire, explosion, natural disasters, hazardous material release and
similar situations at PPL Assets / Locations / Offices. This procedure will also deal with
the system for defining roles & responsibilities of individuals / concerned to minimize
the potential for injury, illness & property damages together with the impact on
environment and community.

In-depth planning for potential emergencies is essential for an effective response by

site personnel working in close conjunction with supporting community emergency
response organizations. The important products of these are mitigation of impacts on
personnel, environment and facilities as well as prompt control of the emergency.

Key requirements of this procedure are:

▪ Emergency Response Planning

▪ Training
▪ Review of Emergency Response Plan

2. SCOPE:

This procedure is applicable to all PPL operated Hydrocarbon Storage / Processing

Plants / Facilities (inclusive of supplementary equipment’s hired under contract),
offices, exploration, drilling and project sites.

3. RESPONSIBILITIES:

Asset / Field / Dept. Head is responsible for:

▪ Identification and monitoring of all situations which can create a potential hazard
and cause an emergency.
▪ Developing and implementing Emergency Response procedure for his respective
Asset / Dept. / Location in line with this procedure.
▪ Ensuring that all identified Legal and Regulatory requirements are considered /
complied in the location specific Emergency Response procedure.
▪ Ensuring that the effective communication system is in place for managing
emergencies.
▪ Declaring Level of Emergencies after assessing the situation on ground and
notifying High Level Emergency Management Team (IMT) at Head Office in case of
crisis / Level-3 Emergency (Ref. Internal Office Memorandum # MD/ON/CIR-
70/2015).
▪ Liaison with Management at HO for advice on internal and external communication
e.g., media, community, concerned Government Authorities etc. in an event of
emergency.

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▪ Notifying all Concerned Depts. including QHSE Dept. HO for any changes made in
location specific Emergency Planning & Response procedure.
▪ Arranging necessary training for Emergency Response Teams in view of their role
and responsibilities.
▪ Arranging Emergency Drills once in every two months (as minimum) to train the
personnel for handling any emergency situations and record findings of the drill and
forward it to QHSE Dept. HO for review, comments and any suggestions for
improvement.
▪ Reviewing the Asset / Dept. / Location specific Emergency Response Procedure on
defined timelines or has there been any changes in plant / operations / legal
requirement affecting the functioning of existing Emergency Response procedure
and keeping it updated.
▪ Ensuring all reporting requirements set under of Incident Reporting & Investigation
procedure are compiled (Ref. PPL – QHSE / PR / 206).

QHSE Dept. HO is responsible for:

▪ Identifying the requirements raised by Regulatory & Government Authorities and

Industry Best Practices pertaining to Emergency Planning to Assets / Depts. /
Locations for necessary incorporation and implementation in their respective Plans.
▪ Reviewing emergency drill plan submitted by Assets / Depts. / Locations for
adequacy, completeness and comments prior to approval and implementation by
respective Asset / Field / Dept. Head.

4. PROCEDURE:

4.1 General:

This procedure covers different potential emergency situations that will be

identified and evaluated at the various Assets / Dept. / Locations. This procedure
provides the specific decisions to:

▪ Activate the location specific Emergency Response procedure.

▪ Establish communication centers / control rooms where Emergency
Response Team Members shall locate to manage onsite emergency
activities.
▪ Undertake actions such as isolating and evacuating the hazardous
area, plant shutdown, firefighting, community evacuation, intimating facility
neighbors and provision of medical aid to affected etc. in order to prevent /
reduce harm to the employees, community, environment and company
assets.

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4.2 Emergency Response Planning:

Asset / Field / Dept. Head, shall nominate an emergency planning and response
team comprising of experts from all involved and affected groups and disciplines
– particularly the operations teams to review the site operations and to identify
potential hazards / disastrous situations that present an emergency risk to
employees, contractors, visitors, company assets and the risks associated to
nearby facility (ies) and community from PPL operations.

Their scope of review would include but not limited to:

4.2.1 Brain Storming Sessions:

The joint tour / visit of the facility to identify possible causes of major
incidents related to:
▪ Processing of Hydrocarbons

▪ Storage of Crude Oil / Condensate

▪ Loading / filling operation of Crude & Condensate / LPG bowsers

▪ Storage of flammable / corrosive chemicals

▪ Flare stack area for liquid carryovers

▪ Proximity of building to hazards

▪ Storage areas for spillages etc.

Consideration should also be given to past accidents / emergencies that

had occurred within PPL or in the industry.

4.2.2 Evaluation of Existing Controls:

The team will evaluate the availability of existing controls e.g.:

▪ Adequacy of bunding to contain accidental spillages

▪ Adequacy of process control equipment

▪ Adequacy of escape routes

▪ Establishment of emergency control rooms with provision of firefighting

& spillage clean up equipment.

▪ Provision of first aid & site medical centre

▪ Training of staff on handling Emergencies

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The evaluation process will also include the identification of hazards and
the severity of potential consequences on which Asset / Dept. / Location
specific Emergency Response procedure will be based upon. The team
will also recommend any improvements necessary to reduce the risk of an
incident or improve the management of incident handling.

4.2.3 Evaluation of Potential Disasters:

In addition to hazards arising directly from site activities, the team will also
consider the possible effects of natural disasters or unexpected events e.g.

▪ Injuries to personnel as result of accident

▪ Fire / Explosion

▪ Gas leaks, oil and chemical spills, accidental releases or loss of

materials and substances (including radioactive isotopes) etc.
▪ Well blow out and loss of well control
▪ Structural collapse
▪ Power / utilities failure
▪ Natural Disasters such as Earthquakes, flooding due to heavy storm,
Lightening etc.
▪ Exposure from incidents at neighbouring areas
▪ Terrorist activities
▪ Aircraft related emergencies

4.2.4 Emergency Criterion:

Following Emergency criteria shall be followed to deal with the potential

emergency conditions / situations based on the severity and requirement of
resource to handle the emergency.

4.2.4.1 Level – 1 Emergency:

Emergency state in which an incident or series of incidents with no

immediate potential threat to the Health & Safety of Personnel,
Contractor, Community, Environment, PPL Operation and
Equipment. Emergency Response Team and equipment available
on Site can control the situation.

Following conditions define Level-1 Emergency (but not limited to):

▪ An injury or illness without LTII

▪ Minor Spill Chemical / Oil spills

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▪ Small contained Fire or Explosion

4.2.4.2 Level – 2 Emergency:

Emergency state that may cause the normal operations to be

temporarily suspended or shut down. This state may pose a threat
to the Health & Safety of Personnel, Contractor, Community,
Environment, PPL Operations and Equipment. Emergency
Response Team and equipment available on Site can control the
situation through external support.

Following conditions define Level-2 Emergency (but not limited to):

▪ An injury or illness that may result in LTII or poses a health threat
to personnel

▪ Minor Property or Equipment damage due to Fire or Explosion.

▪ Large Chemical / Oil spills.

▪ Electrocution

▪ Natural Disaster

4.2.4.3 Level – 3 Emergency:

Emergency state / crisis which poses serious threat to the Health &
Safety of Personnel, Contractor, Community, Environment, PPL
Operations and Equipment. This state of emergency requires
involvement of Head Office and additional resources to manage the
situation.

Following conditions define Level-3 Emergency (but not limited to):

▪ Multiple LTIIs or Fatality.

▪ Major Property or Equipment damaged due to significant Fire or

Explosion.

▪ Excessive H2S emission.

▪ Aviation related accident.

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4.3 Developing Site Emergency Response Procedure:

On the basis of review by the emergency planning team, Asset / Dept. / Location
specific Emergency Response procedure will be developed, communicated to all
concerned for implementation and tested for verification of actions as defined in
the procedure. This procedure shall address the following subject areas:
▪ Emergency shutdown procedures, including isolation, emptying, venting, or
purging as appropriate.

▪ Acceptable emergency repair procedure and / or service

▪ Procedure to be followed by personnel who remain to operate critical plant

operations before they evacuate

▪ Shutdown of adjacent facilities, as appropriate

▪ Activation of community emergency response plan / necessary actions

▪ Barricading affected facilities

▪ Activation of spill clean-up procedures

▪ Provision of First Aid and Medical Treatment to the affected

▪ Activation of site fire brigade or notification to local authority brigade

▪ Use of fire pre-plans i.e. use of fire protection and emergency response
systems in specific fire case scenarios

In case, the Asset / Site / Location is operated by the Contractor, concerned Asset
/ Dept. / Location Incharge shall ensure that Emergency Response planning and
response requirement is complied so that it meets requirement set under this
procedure.

While developing Emergency Response procedure, special consideration should

be made to ensure that plant control systems or inbuilt layers of protection are
capable enough for tackling process related emergencies and shutdown plant to
prevent human error.

In case of Process Plants, Plant Shift Incharge(s) is delegated absolute authority

to shutdown process plants after necessary verification(s) to prevent / curtail
damages in case of emergencies and informs the site Management. Flow Charts
may be incorporated in Asset / Dept. / Location specific Emergency Response
procedure for clarity on actions, roles, responsibilities and authorities for effective
Emergency Management.

4.3.1 Fire Pre-Plans:

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Fire pre-plan shall act as an aide-memoire in crisis situations where rational

thinking time could be limited. The development of a Fire Pre-plan shall also
aid in highlighting deficiencies in response capability or particular problems
with the emergency scenario. These plans shall serves as a guide and
needs to be adjusted to suit local factors, e.g. weather conditions, actual
process conditions.

The emergency planning team shall evaluate all conditions that could lead
to fires or explosions which may include but not limited to:

▪ Vapor clouds resulting from release of flammable liquids or gases

▪ Spill releases of flammable liquids (including tank or vessel overfill)

▪ Pressure increase in vessels beyond their design

▪ Increase in temperatures due to unstable conditions

▪ Formation of flammable mixtures inside equipment

▪ Mixing of incompatible materials

▪ Undue vibration and shock from process conditions

The location specific emergency response procedure may include fire pre-
plans for the following but not limited to:

▪ Each major storage tank and each bund area

▪ Each pressurized storage vessel and containment area, including

protection of the run-off and impounding area, and key steps to avoid a
BLEVE

▪ Hydrocarbon loading gantry

▪ Each defined “fire area” of the unit e.g. as limited by layout / drainage
where this is practical / meaningful. At least the two or three most severe
fire cases for each process unit should be defined.

▪ Any other specific cases equivalent to one of the above.

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4.3.2 Elements of Fire Pre-Plan:

Fire pre-plans are developed against possible emergency scenarios and

made part of Asset / Dept. / Location specific emergency procedure. Fire
pre-plans should be based on qualitative assessment as minimum and are
made as comprehensive as time and resource permits through quantitative
assessments. Fire pre-plan should include the following information (but not
limited to):

(a) Emergency Description

(b) Equipment, Contents Description and Risk:

▪ Size: Volume, Diameter, Height or Length

▪ Contents: Quantity, Chemical Description and Properties, e.g. Flash

Point, Auto Ignition Temperature

▪ Toxic Risk – including carcinogens

▪ Explosion Risk e.g., VCE, BLEVE etc.

▪ Environmental Impact & Odour Risk

▪ Boil-over Risk

▪ Dispersion and Cloud Characteristics

▪ Equipment and other units also at risk

▪ Third Party Locations at risk e.g., Contractor Operated Oil Heater,

Nearby LPG Bottling Plant etc.

(c) Special Hazards:

▪ Location of radioactive instrumentation elements

▪ Location of electrical equipment with PCB

▪ Location of equipment with water reactive chemicals

▪ High pressure gas cylinders

(d) Key operations response actions, e.g., shutdown,

depressurization and isolation, evacuations, remote activation of
deluge / monitors etc.

(e) Key tactical emergency response actions, e.g., activation of fixed

protection if not automatic, deployment and position of mobile
equipment, target areas for firewater and foam (cooling /

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extinguishment / precautionary), evacuation requirements and

procedures (facility personnel, contractors, community), major medical
response for multiple injury situations.

(f) Measure to Protect Adjacent Equipment:

▪ Identification of other key equipment and hazard arising.

▪ Cooling requirements developed from radiation studies.

(g) Required Manpower:

▪ Level of initial response, e.g. shift first-line response, site brigade,
local authority brigade, mutual aid partners (including their
capabilities, resources and anticipated response time).

▪ Minimum initial response numbers.

▪ Approach direction for various response teams, including entry

point for non-site response, relative to specific and detailed wind /
weather conditions.

(h) Required Equipment:

▪ Fixed & mobile equipment response, equipment type & capacity

e.g., deluge system, fire knock off system, foam trolleys etc.

▪ Limitations, e.g., quantity available firefighting consumables at site

and sources of back-up, max. holding capacity of surrounding
bunds and blocked routes due to equipment congestion etc.

(i) Diagrams:
▪ Scenario plot plan showing position of fixed equipment including
activation panels or valve stations, hydrants, monitors, foam tanks
and likely position of mobile equipment etc.

▪ Radiation contour diagram for human and equipment exposure.

▪ BLEVE profile, consequence and radiation contour diagram.

▪ Dispersion and toxicity diagram.

(j) Maximum Foam and Water Requirements:
The maximum quantities of foam and fire water required to control and
extinguish the fire. This should be based on likely duration and
intensity and the attack strategy.

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4.4 Simulation Exercises:

Training is an essential component of Emergency Planning and Response

programs. The Concerned Asset / Field / Dept. Head will ensure to:

▪ Develop Annual Scenario Based Emergency Drill Plan for his / her respective
area. Annual Drill Plan shall include following scenarios (as minimum):

- Level-3 Drill on annual basis (one per Field / Location)

- Level-2 Drill on biannual basis
- Level-1 Drill on quarterly basis
Drill plan shall be developed such that the drills are scheduled throughout the
year and scenarios are not repeated during the year. Level-3 drill shall involve
IMT Chairman or at least Functional / Asset Head.

▪ Nominate independent observer(s) to help in ensuring correct response during

the emergency drills and identify gaps (if any) during the drills / exercises for
improvement.

▪ Document the findings of drill, initiate corrective action to reduce the gaps and
reporting to QHSE Dept. HO on template Emergency Drill Report (Ref. PPL-
QHSE / PR 204 / FM / 001) for information and review within 5 working days.

▪ Communicate the results of emergency drill exercise to appropriate personnel,

including employees / contractors from the affected area.

▪ Asset / Field / Dept. Head with the assistance of QHSE Representative will
ensure that action completion status is reviewed upon completion of due target
dates for satisfactory accomplishment of actions defined in action plan for
closure (Ref. PPL-QHSE / PR 204 / FM / 001). In case the actions are not
satisfactorily closed by the planned target date, a fresh target date may be
acquired from concerned person(s) and “Action Review” section shall be
updated accordingly. Resolution of drill recommendations shall be
documented and maintained along with the Emergency Drill Report.

▪ Arrange appropriate training to Emergency Response Team Member on

Process Operating & Control Procedures, Fire Fighting, First Aid, Spillage
Control, Emergency Evacuation and Activation of the Site ERP & Employees’
Responsibilities during Emergencies, Use of appropriate PPE & Confined
Space Rescue Equipment.

Where the external / local authority fire brigade plays a significant part in the
emergency response, they shall be made familiar with the Site’s Emergency
Response procedure.

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4.5 Local Emergency Response Team:

The concerned Asset / Field / Dept. Head will select / nominate Local Emergency
Response Team to undertake emergency work such as Alarming, Plant
Shutdown, Isolations, Evacuation, Head Count, Fire Fighting and Provision of
Medical Aid etc. The team will be lead by the Incident Controller i.e. Asset / Field
/ Dept. Head during the emergencies. For each ERT role, consideration should
be given on nominating a primary ERT member and his / her backup. Dedicated
room(s) shall be established and maintained for the purpose of gathering Local
ERT and oversee emergency handling. Due consideration shall be given to site
specific process hazards / emergency situations, provision of necessary
resources, evacuation of local ERT etc. while designating this room.

ERTM(s) name with their roles are displayed at prominent locations on template
List of Emergency Response Team Members (PPL – QHSE / PR 204 / FM / 002).

4.6 Emergency Response Equipment:

To meet emergency requirements, Asset / Dept. / Location is provided with

sufficient emergency response equipment to respond adverse emergency
situation. The requirement of equipment is evaluated during the review / hazard
assessments by the emergency planning team. These equipment should be
placed at prominent location in order to minimize the response time and reduce
the potential impacts of incidents.

The emergency alarm / notification mechanism shall be capable of being

perceived above ambient noise or light levels by all employees in the affected
portions of the workplace. Assembly Point(s) and Emergency Exits shall be well
lit for visibility under normal / emergency situations, kept free from obstructions
at all times and clearly marked with the appropriate signage for guidance and
Emergency Exit doors shall open toward egress side.

Assembly Point (s) shall be designated considering wind direction, distance,

persons on board etc. shall be considered. Head Count should be carried out at
Assembly Point during real emergencies as well as during the mock drills.

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4.7 Review of Site Emergency Response Procedure:

The Emergency Response procedure is reviewed for incorporating necessary

changes / modifications on annual basis but in case of any significant change to
operational activities or materials will require review of Emergency Response
procedure earlier than the set timelines. The procedure shall also be reviewed
after an emergency event or based on the observations noted during simulation
exercise for addressing areas for improvement. The review will be done through
the team comprising of QHSE Representative, personnel from Operations,
Maintenance and other related depts. and shall be headed by Asset / Field / Dept.
Head.

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4.8 Emergency Medical Plan:

Following flow chart to be followed for managing the Injury or illness during
emergency situation:

Injury or Illness

Provide First Aid

Go to Site Clinic

Provided First Aid and sent

Serious back to Work / Home
No
Inform IMT and Yes
Asset / Functional
Head
Provide Medical Aid
and move casualty to
nearby Hospital to
receive further
treatment

No
QHSE Dept. Transfer Casualty to
Head Office Recover another Hospitals
y recommended by Doctor
Yes

Release Information

End

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5. TRAINING & PROGRAM EVALUATION:

For effective implementation of this procedure:

▪ Concerned Asset / Field / Dept. Head in coordination with QHSE Representative will
ensure necessary training to staff, making them fully aware of the requirements of this
procedure, keeping in view their role, responsibilities, and competence.

▪ Concerned Asset / Field / Dept. Head in coordination with QHSE Dept. HO will evaluate
the overall effectiveness of this procedure on periodic basis.

6. RELATED DOCUMENTS & RECORDS:

▪ Emergency Drill Report PPL-QHSE / PR204 / FM / 001

▪ List of Emergency Response Team Members PPL-QHSE / PR204 / FM / 002

▪ Internal Office Memorandum MD/ON/CIR-70/2015

▪ API Recommended Practice 2001

▪ Risk Engineering Position Paper on Fire Pre-

Plans by Marsh, March 2011

▪ OSHA 3132, Standard on Process Safety Management

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