PFL EMERGENCY MANAGEMENT PLAN

Objectives of Today’s Session

• Scope of Emergency Management Plan
• key elements of Emergency Management
Plan.
• Major changes incorporated in this plan.
• To get clarity on this plan so that PFL
employees response must be sharp and any
emergent scenario must be effectively
handled.
 SCOPE
• This procedure is applicable to all personnel at the plant and
resident of Township. It supports the OSHA Guidelines {(Process
Safety Management 29.CFR.1910.119(n)) & Emergency Action
Plans 29.CFR.1910.38} which requires that management should
have systems in place for effective handling of all foreseeable
emergencies in a way so that personnel, plant and Environment
are protected from the possible effects of all foreseeable
emergencies.

• In responding to major emergencies priority will always be

placed on preventing or minimizing harm or injury to individuals
and minimizing adverse effects of emergency to PFL company
personnel, contractors, the environment, surrounding
communities and assets and restoring normal operations in the
safe and shortest possible time
 TYPES OF EMERGENCIES
• There are several types of emergencies that can
occur at the plant. Most emergencies arising out
of process upsets or equipment failure can be
handled by quick localized action of the
operating staff.
• In other instances, the emergency may be
beyond the handling capability of the immediate
operating staff and/or could endanger human
life, plant equipment or the environment unless
proper precautionary steps are taken on time.
•
Contd.
 TYPES OF EMERGENCIES
• Such emergencies can occur either as a result of
fire / explosion or due to leakage of ammonia /
chlorine in high concentration to the atmosphere.
• Fire (in some cases, explosion) can occur due to
ignition of combustible materials such as natural gas,
synthesis gas, oil spills etc. Large ammonia leakages
can occur due to equipment failure e.g. cracks in
vessels or pipes, plunger or gasket blowouts etc.
Chlorine leakages can occur due to failure of fusible
plug of cylinders or thru tubes, valves and fittings
 Emergency Level - I:
(May affect all the personnel within plant premises)

• Unsafe conditions at the plant which cannot be quickly

corrected by the immediate operating staff and which
cause or have the potential of causing injury to personnel,
damaging equipment and / or the environment within the
plant premises, fall in this category. Fires, explosions, and
sizable ammonia releases from flanges, pipes, GLGs,
cracks in vessels, plunger blowout or chlorine leakages
etc. that can be contained within the plant premises are
typical examples of Level-I emergencies.
• Level-I emergency may be converted into Level-II emergency as the
situation worsen and uncontrolled beyond plant site.
 Emergency Level - II
(May affects the personnel / Environment within & outside plant premises)

• Unsafe conditions at the plant that pose a serious

threat not only to the people / equipment /
environment within the plant premises but also to the
township and other neighboring communities outside
the plant premises.
• Large liquid ammonia release from ammonia spheres
(Urea), Urea reactor, Ammonia Storage tank,
Refrigeration loops (Ammonia, NP, CAN plants),
Leakage from main Ammonia Production line, Rupture
of high pressure vessels or instantaneous release of the
entire content of ammonia receivers and evaporators
etc.
Detection & Reporting of Emergency
• Anyone at the PFL site, who sees a fire, hears an
explosion or notices an uncontrolled release of
ammonia or chlorine or Nitric Acid etc. must take the
following actions:
– Informs the Fire Station on 3333 or intercom 333 to give
the following information:
– His/her name and designation.
– Exact type & location of the incident.
– Its magnitude or range.
– Prevailing wind direction, (if known) It should be narrated
with reference point NAST to defined plant or building
i.e., from NAST towards Ammonia plant, Admin building,
CAN plant or Colony Jamia Mosque.
 Detection & Reporting of Emergency

• Then immediately calls respective control room via

radio / intercom system or moves to the control
room and again gives the above details.
• Safety Head Operator on receiving information about
emergency will immediately inform to Coordination
Engineer on Hotline regarding nature and location of
emergency and rush to emergency site.
• Respective Boardman or panel operator in control
room shall immediately inform Coordination
Engineer and Shift Engineer respectively.
 Declaration of Emergency:
• Coordination Engineer, on being informed will
assess and consider the followings
• The nature and type of emergency
• Is there a fire, a spill or a leak of hazardous gases
• What are the weather conditions?
• Who / what is at risk: people, property or
environment?
• What actions should be taken: Is diking necessary?
What resources (Human and equipment) required
and readily available? Is an evacuation necessary?
• What can be done immediately?
• Instruct Urea Plant Shift Incharge / Boardman to
activate appropriate siren.
• Urea Plant Shift Incharge / Boardman will
activate siren according to the instructions of
Coordination Engineer and will immediately
inform to Check Post at Factory Gate for
sounding of colony siren. He must recheck that
the siren at the colony gate has been sounded.
While asking to sound the siren, he will use the
same protocol of communication as has been
mentioned in .
• NAST WILL BE REFERENCE POINT FOR
NARRATION OF WIND DIRECTION
 Emergency Siren Codes
• Emergency will be declared by any one
sequence (Level-1 or Level-II) of the sirens.
When emergency Level-I or Level-II is
declared, all personnel other than operations
staff will assemble, keeping in view the wind
direction, at their safe assembly points.
• Evacuation of plant operators shall be done as
per the nature of emergency determined by
the FCC Leader.
 Emergency Level-1:
• Five blasts of seven seconds with five seconds
interval between the blasts.

Emergency Level-2:

• Ten blasts of fifteen seconds with ten seconds

interval between the blasts.
 Front Line Leadership Organization

• The Coordination engineer plays a critical role in the event of an

emergency. His responsibilities include:
• Prompt verification of the unsafe conditions reported/observed.
• Declaring emergency by authorizing/sounding of appropriate
emergency siren.
• Immediate isolation/depressurization or de-energizing of the problem
area.
• Authorizing partial or total shutdown of plant as required by
conditions.
• Initiating the internal communication process.
• Leading the emergency Squad and carrying out rescue.
• The concerned area supervisor and the Boardman will play a key
supporting role and will execute the instructions of the Coordination
engineer.
contd.
 Front Line Leadership Organization

• The Coordination Engineer will have at his disposal an

Emergency Squad consists of 8-10 emergency squad members
comprising of Shift workers from different plants and 4
members {02 Fire operators (01 safety+01 Lab) + 1 Fire truck
operator + 1 Head operator} from safety and Laboratory. So a
total of 12 – 14 members will be available and led by
Coordination Engr. / Shift Engr. to respond the emergency
situation and paramedic staff with ambulance as well.
• In case of Emergency Level-I or Level-II, All employees excluding
operation staff from his affected or other units would be
available at assembly locations equipped with walkie-talkies &
SCBA and will seek further instructions from their units or FCC.
 FCC Organization
• In case of emergency Level-I and Level-II FCC
will be established in dedicated offices keeping in
view wind direction.
• On hearing the emergency siren Level-I / Level -II or on
being informed by telephone, All FCC members will rush
to FCC, which will be established in the dedicated Office
as mentioned in FCC location.
• All Production departments UM/SH will reach FCC as
soon as possible on hearing about the emergency. They
will seek guidance and instruction from FCC leader about
operational strategy for handling the emergency. The FCC
leader can overrule decisions of the Coordination
engineer.
 FCC Organization

• Coordination Engineer will be assisted by the Front Control

Center (FCC) situated at location declared by FCC leader.
Members of the FCC will be equipped with Self Contained
Breathing Apparatus to enter the plant or reach the control
room if conditions permit and warrant such action. In either
case, members of the FCC will stay in close contact with the
Coordination Engineer and/or the all control rooms.
Note:
• Level-I emergency may be converted into Level-II
emergency as the situation worsen and uncontrolled
beyond plant site, In this case Emergency Level-II siren will
be activated.
 Front Control Center (FCC)
Front Control Centre comprises of the following:

1. Senior Production Manager (FCC Leader)

2. Training Manager
3. Asstt. Production Manager
4. Unit Manager Safety
5. Coordination Engineer (works as ESL)
6. Concerned Shift Engineer (works as ESL till Coordination Engr. arrives)
7. Unit Manager Ammonia
8. Unit Manager Utilities
9. Unit Manager Nitric Acid
10. Unit Manager Urea
11. Unit Manager CAN
12. Unit Manager NP
13. Unit Manger PH & S
14. Unit Manager L.CO2
 FCC ROLE STATEMENT DURING EMERGENCY

Front Control Center will be established in case of emergency

level-I / II emergency. FCC is responsible for directing all field
activities to contain the emergency including rescue operation
and making the plant safe. Specific responsibilities of FCC are as
follows:
1. Actively attempts to stay in close touch with Coordination
engineer and respective area Shift engineer and Control
Room, to direct all emergency handling activities in the field.
2. Guides Emergency Squad in all matters including rescuing the
affected people.
3. Guides Shift Incharges and Unit Managers / SHs on shutdown
of various operating facilities to make the Plant safe.
4. Ensures evacuation of all non-essential personnel.
 FCC ROLE STATEMENT DURING EMERGENCY
5. Keeps head count of plant personnel.
6. Instructs security for road blocks within PFL premises.
7. Keeps Rear Control Center fully updated on status of
emergency situation.
8. Requests for help from RCC, if required.
9. Be prepared to send extra persons to the plant
premises/control room (s) if needed and conditions
permit.
10. After emergency is over, declare end of Level-I
emergency.
11. In case of Level-II emergency, seeks RCC permission
to declare end of Level-II emergency.
 FCC Locations
• Following are the preferable locations for establishing Front
Control Centre
• Uhde Building (APM Office)
• In case of wind direction from NAST to Ammonia plant, FCC will
be established in Uhde Building (APM Office)
• KIC Building (UM Ammonia Office)
• In case of wind direction from NAST to Admin. Building, CAN
plant or Colony Jamia mosque, FCC will be established in KIC
building (UM Ammonia office).
NOTE:
• FCC leader has the authority to relocate FCC if warranted by
conditions at that time.
• FCC may be reestablished at any suitable location near
declared emergency area on FCC Leader disposal as required
by the situation after reaching dedicated FCC locations.
 RCC Organization
• In case of emergency Level-I and Level-II RCC will be
established in dedicated offices keeping in view wind
direction. On hearing the emergency siren Level-I /
Level -II or being informed by telephone, All RCC
members will rush to RCC, which will be established
in the dedicated Office as mentioned in RCC location.
• RCC will be led by Director Operations or his
designate. RCC will be on backup support to
assist/guide FCC management in handling of the
emergency. The prime responsibility of RCC will be to
take necessary measures to protect the community
outside the plant premises.
 Rear Control Center (RCC)

The members of RCC are:

1. Director Operations (Leader)

2. General Manager Admin.
3. General Manager Projects
4. Technical Services Manager
5. E & I Manager
6. Maintenance Manager
7. Manager Civil Colony Projects
8. Staff Engineer Safety
9. Senior Executive Administration
10. Senior Executive Security
11. Chief Medical Officer (stationed at Clinic)
 RCC ROLE STATEMENT DURING EMERGENCY
Rear Control Center will be formed in case of Level-I / Level-II emergency.
RCC is responsible for providing guidance / assistance on emergency
response actions within and outside the plant premises. Guidelines on
specific responsibilities of RCC for the emergencies are as follows;
1. Guide FCC or affected Plant Control Room management on handling
of emergency by taking the appropriate actions.
2. Inform CEO or his designate and Advisor fertilizers division about the
emergency and requests for
help, if required.
3. Sets-up medical aid through PFL Medical Centre and outside
hospitals as required.
4. Inform CEO or his designate and Advisor fertilizers division when the
emergency is over.
5. Respond to queries from employees, their families and third parties.
6. Alert nearby community and businesses to take necessary action
steps as per Emergency handling tips.
 RCC ROLE STATEMENT DURING EMERGENCY
7. Inform SNGPL and other businesses when the emergency is
over.
8. Alert Government/Civil authorities to initiate community
emergency response actions.
9. Provides resources for evacuation of personnel from plant
site.
10. Provides ambulances for transportation of causalities if
required.
11. Initiate necessary actions in the township for evacuation if
required.
12. Take over function of FCC in case it is inoperative.
13. Guide to declare the end of emergency.
 RCC Locations
Preferable locations are given as under depending upon location of
emergency and wind direction;

L.CO2 Plant (UM Office)

• In case of wind direction from NAST to Admin building, RCC will be
established in L.CO2 Plant UM Office.

Admin Conference Room No-1 (Opposite DO’s Office)

• In case of wind direction from NAST to Colony Jamia mosque, CAN plant
or Ammonia plant, RCC will be established in Admin Conference Room
No-1.

NOTE:
• RCC leader has the authority to relocate RCC if warranted by
conditions at that time.
 Role Statement of Emergency Squad
• The Emergency Squad is responsible to assist the
coordination engineer in controlling emergency situations
and rescuing people who may get trapped or injured in
the Plant. The squad is trained to respond quickly and is
equipped with safety gear to approach the location of the
incident under instructions from the Shift Coordinator.
The membership of the Squad is as follows:
• Emergency squad Members
• It comprises 8-10 shift employees from All plants
• East side plants NP, CAN, Nitric Acid Line-C, Old cooling
tower, effluent plant
• West side plants Ammonia, Utilities, Urea, Nitric acid
Line-A & B, LCO2 Plant
 Role Statement of Emergency Squad
SAFETY UNIT:
• One head Operator.
• Two Fire Operators. (1 safety unit + 1 Lab)
• One Fire truck driver.
• Specific responsibilities of the Emergency Squad as a team are as follows:
1. Control and contain spreading of ammonia or chlorine vapors cloud,
forming as a result of Level-I or Level-II emergency.
2. Fight fires resulting from Level-I emergency.
3. Rescue of personnel trapped in an ammonia or chlorine cloud or in a fire
area.
4. Any other job that may be assigned by the Coordination Engineer during
level-I or level-II emergency.
• The emergency squad will approach the emergency site using the safest
route communicated by the coordination engineer to all Control rooms.
 Role Statement of Emergency Squad
NOTE:
• On hearing the emergency siren (Level-I/II) in
colony, the emergency squad members in the
colonies should call / report to UM Safety so
that their services can be utilized in
emergency response if deemed necessary by
RCC.
 FIRE FIGHTING AND EMERGENCY
HANDLING PROCEDURES
This section covers the basic fire fighting techniques that
are generally applicable to typical emergency scenarios at
PFL plant site. These include emergencies like:
• Accidental Ammonia release, which may lead to vapor
cloud explosion, fire and/or personnel exposure.
• Accidental Natural Gas release, which may lead to vapor
cloud explosion and/or fire.
• Process plant fires.
• Electrical fires.
 Accidental Ammonia Gas Release

Actions:
1. SMALL LEAK/SPILL (single drum, cylinder, small containers) - ISOLATE 25
METERS in all directions and restrict entry to emergency response
personnel.
2. LARGE LEAK/SPILL (many drums, cylinders, or large tank)-ISOLATE 50
METERS in all directions and restrict entry to emergency response
personnel, then EVACUATE IN A DOWN WIND DIRECTION AN AREA OF .5
KILOMETER WIDE AND 1 KILOMETER LONG.
3. These are approximations: conditions change, requiring constant
reassessment & good judgment.

Spill Control:
4. Prevent entry to sewers and water courses.
5. Cover liquid spill with foam to minimize gas release.
6. Use water spray downwind of spill to reduce gas.
7. Water should not contact pools of liquid NH3 as this will increase gas
vaporization.
 Critical Exposure Levels:

Concentration / Time Effect

1.5ppm Odor threshold

ACGIH threshold limit value (TLV);

25 ppm
generally irritating to unconditioned
persons.

100 ppm for 120 min or less
1000 ppm for 120 min or
less
5000-10,000 ppm
Extreme respiratory discomfort. Life
Threatening or serious injury likely.
IMMEDIATELY FATAL.

(ppm = Parts per million; 10,000 ppm = 1% in air).

 Water Fogging

• A certain percentage of ammonia or chlorine will vaporize

when released to the atmosphere. Depending on the release
rate, there may be some opportunity for suppressing further
vapour cloud resulting from the liquid spill.
• Water curtains, if promptly used, have helped in reducing the
size of the vapour cloud. One of the techniques to knock
down or dissipate vapour clouds is to use a finely divided
water spray. Water sprays are effective in dispersing vapours
from chlorine and ammonia spill by inspirating air in the
cloud. in the case of ammonia, sprays provide the added
advantage of absorbing ammonia in the water.
• Water sprays can be applied by putting the fog nozzle on fog
so that a water curtain falls in the path of the vapour cloud.
Water Fogging
 Accidental Chlorine Gas Release
• Key Hazards
• High acute toxicity by inhalation
• Corrosive to skin and eyes
• Strong oxidizer; combustible materials will
• Burn In Chlorine.
• Reacts explosively with flammable gases,
Vapors, liquids and finely divided metals.
• Warning Properties:
• Irritating odor
• Smells like bleach.
 Critical Exposure Levels

Concentration/Time Effect

0.01 -0.03 ppm Odor threshold ACGIH

1 ppm Threshold Limit Value (TLV)

3 ppm for 15 min. or less or Extreme respiratory

2ppm for up to 120 min. discomfort.

10ppm for 15 min. or less or Life threatening or serious

5 ppm for upto 120 min. injury likely.

500-1000 ppm FATAL FOR SHORT EXPOSURE

 Cloud Formation and Behavior
• Chlorine can be released in two fashions. The first is the
release of gas or liquid in a continuous emission over a
finite period of time. The second is the instantaneous or
slug release in which the material is released in a very
short period of time. as for example, the catastrophic
failure of a cylinder.
• The failure of a valve or other fitting on a chlorine cylinder
usually results in a continuous release, and the downwind
hazard continues as long as the emission continues and
will extend to the point where the concentration falls
below the safe level. When such a failure is associated
with a cylinder, the rate of emission will steadily decrease
as the pressure within the vessel decreases.
 Emergency Response to Contain Chlorine Leakages

1. Remove affected person(s)

2. Cordon off the area
3. Water curtain to contain chlorine from spreading
4. Installation of chlorine kits

Mitigation Actions:
5. Initiate appropriate siren.
6. Install chlorine kit.
7. Start continuous dosing for 24 hours. A full cylinder will be consumed
within 7 days in Utilities Old and at Utilities New in 4 days based on the
capacity of the chlorinators.
8. Wearing necessary protective (SCBA etc.) carefully approach the area
from upwind. Put Lime (use approximately 1 Kg of lime powder + 0.32
Kg of water) on leaking cylinder using lime powder available at the site.
(For this as per standing instructions, two Shovel loaders of lime
powder should always be available in Lime Section)
 DISASTER MANAGEMENT

• Natural disasters like earthquake, floods,

thunder storms, lightning etc. can adversely
affect a process plant. They may cause
structural damaged, vessels or equipment
damages leading to damage to plant
equipment vessels.
 MEDICAL EMERGENCY PLAN
• Providing safe and healthy working environment to its
employees is one of the top priorities of the company. For this
purpose personal protective and training is given to all
employees. However, in spite of all these efforts an accidents
leading to injuries may occur. In addition to this an employee
may suffer from an attack of angina, asthmas, high blood
pressure stroke etc. To deal with such type of emergencies, a
qualified doctor (GP) is available from (08:00 - 22:00 hrs.) on all
weekdays and paramedical staff (on 8 hrs. shift) is available
round the clock. Main objective of this plan is to set up a line of
action against all type of emergencies in a manner that injured
person / patient gets proper medical treatment well in time.
COMMUNITY AWARENESS PROGRAM
• At PFL, Ammonia gas is stored and processed for
manufacturing of Fertilizers. Any un-controllable
accidental release of the gas can lead to explosion,
fire and exposure of the people. The Ammonia
cloud produced due to any uncontrollable accidental
release, in some situations, may also affect township
and surrounding community. Purpose of this
document is to ensure that township and
surrounding community are kept updated on the
hazards of Ammonia gas, and be informed of their
roles in the event of any untoward incident.
 Liaison with the Neighbors
• It is the responsibility of the GM Admin. / SE
Admin and Technical Services Manager to maintain
liaison with the organizations formally every 2
years. A documented package will be issued to all
such organizations which may be affected by any
emergency at our site. Package will contain:
• Introduction to PFL
• Material Safety Data Sheet for Ammonia
• Plant Emergency Contact Numbers
• Possible help/action required from an organization
in case of an eventuality.
 RELEASE OF INFORMATION
• It must be clearly understood that other employees are not authorized
to interface with the media, if approached; media personnel are to be
redirected to the positions stated above.

• During or after an emergency, no media related external

communication required & none to be made voluntarily for Level-I
emergencies. For a Level-II incident, press communication to be
released only upon being approached or if Company Management
deems fit.
• Employees authorized to represent the Company in such instances to
include:
• 1. Director Operations
• 2. GM Admin
• 3. Technical services manager
• In disaster situation, when & where ever possible, media interface is
to be handled in & by the hierarchy stated above.
 ASSEMBLY POINTS HEAD COUNT LEADERS
ASSEMBLY POINT GROUP A GROUP B GROUP C GROUP D
SL AP NO. ASSEMBLY LEADERS PLANT / AREAS
LOCATION NAME & P.No NAME & P.No NAME & P.No NAME & P.No

Nitric Acid (New), Cooling Tower (New), UT-West SUPERVISOR

IN FRONT OF CDM UM CDM Asim Imam SUPERVISOR: SUPERVISOR
Control Room, Ammonia Control Room, F/M UT-West, SUPERVISOR
1 AP-1 PLANT SH (F-MAINT.) UTY P.No.209 Mubshar Hussain P.No. Shzad Anwar
Co-Generation Plant, Electrical West (Sub-Station Abid Zahoor P.No.4277
LINE "B WEST & NITRIC ACID 205 P.No.207
2202-K), CDM Plant, KIC Offices. CO2 Plant

Ammonia, UT-West Control Room, Ammonia Control

Room, KIC Offices, Canteen, Projects & Planning
SUPERVISOR SUPERVISOR
I.C PROJECT ENGG. Offices, Account Offices, All Stores, All Ware Houses, SUPERVISOR SUPERVISOR
2 AP-2 IN FRONT OF CANTEEN M.Naveed Jaleel Ahmed
SH PLANNING Admin. Offices, Main Workshop, Laboratory, Cooling Attaullah P.No.1479 Nasir Iqbal P.No.1163
P.No.200 P.No.1109
Tower (New), Electrical West (Sub-Station 2202-K),
Nitric Acid (New), CDM Plant. CO2 Plant

Fire Safety Section, Canteen Laboratory, Admin.

Offices, All Ware Houses, Account Offices, Main
IN FRONT OF FIRE UM (MACH. & WS) SUPERVISOR SUPERVISOR SEPERVISOR SUPERVISOR
3 AP-3 Workshop, Projects & Planning Offices, Urea, Effluent
STATION SR. CHEMIST (LAB) Ch.Saleem P.No.1505 Javed Iqbal P.No.1516 Abdul Rauf P.No.1540 Arshad Butt P.No.1512
Treatment Plant, F/M Ammonia, Craft, F/M Urea,
Machinery. NAST

EAST SIDE OF BALKIE Fire Safety Section, Nitric Acid (Old), CAN/CN,
SUPERVISOR
COOLING TOWER, NEAR SH ELECT. (EAST) Effluent Treatment Plant, Urea Handling, F/M CAN, SUPERVISOR SUPERVISOR SUPERVISOR
4 AP-4 Muhammad.Ijaz
HYDRANT NO.39, AE (F MAINT.) CAN Electrical East (Sub-Station 2204-K), F/M UT-East, M.Rizwan P.No.4500 Mujtaba Gul P.No.204 Shukat Hussain P.No.210
P.No1155.
ALONGSIDE ROAD - 23 UT-East.

Urea, UT-East, UT-West, Nitric Acid (Old), Lime Store,

SUPERVISOR SUPERVISOR SUPERVISOR
NEAR TECHNICAL UM TTC Technical Training Center, CAN Bulk Store, Machinery, SUPERVISOR
5 AP-5 Muhammad Asim Ghulam Muhammad Muhammad Afzal
TRAINING CENTRE AE (F-MAINT.) UREA F/M UT-East, F/M Ammonia, F/M Urea, F/M UT-West, IrfanMunawar P.No.4726
P.No.119 P.No.493 P.No.2045
Co-Generation Plant, Craft, AN Crystal Plant & Store.

Technical Training Center, CAN Handling, Lime Store,

AREA BETWEEN CAN CAN/CN, CAN Bulk Store, New CAN Bag Store, Udhe SUPERVISOR SUPERVISOR
SR. (F-MAINT.) NP SUPERVISOR SUPERVISOR
6 AP-6 PRILLING TOWER AND Offices, NP Handling, NP Bulk Store, NP Line Store, Muhammad Altaf TahirMehmood
AE (F-MAINT.) CAN M.Nadeem P.No.1447 Adnan Ali P.No.1335
CAN HANDLING NP Plant, F/M NP, F/M CAN, AN Crystal Plant & Store. P.No.191 P.No.1334
Coating Agent Store, New Canteen.

CAN Handling, New CAN Bag Store, Udhe Office, NP

SH INSTRUMENT SUPERVISOR SUPERVISOR SUPERVISOR SUPERVISOR
IN FRONT OF UDHE Handling, NP Bulk Store, NP Liner Store, NP Plant,
7 AP-7 (EAST) Allah Diwaya Muhammad Riaz Bahadur Shah Muhammad Sabbir
OFFICE Electrical East (Sub-Station 2204-K), New Canteen,
DAY ENGR. (PH & S) P.No.462 P.No.469 P.No.461 P.No.450
F/M NP, Coating Agent Store.
 Evacuation and Personnel Head Count
Types of Evacuation Warnings
There are several types of evacuation warnings at PFL including:
1. Emergency Siren (Level-I / Level-II)
2. Public Address System
3. Telephone
4. Word of mouth
5. Announcement on speakers in mosques for township
• If an evacuation warning is issued, all employees will secure
their work places, turn off lights, close doors and immediately
proceed to the appropriate assembly area.
• Employees will stay assembled at nearest upwind assembly
points until either the all clear siren is given and employees
can re-enter the Plant / building, or they have been directed to
another location by a representative of the RCC.
 Personnel Head Count
• Assembly leaders will be responsible for checking
their work area for employees prior to exiting the
building if it is safe to do so. Sr. Executive Admin or
his designees will be responsible for documenting
about personnel and evacuations.
• Personnel must report to the Assembly Area in an
orderly and calm manner. Personnel shall report to
their supervisor for accountability. The Assembly
Leaders shall report accountability of their personnel
to the Sr. Executive Admin. The Sr. Executive Admin
shall then report plant accountability to the RCC.
 Area Barricading and Traffic Control:

• In the event of Emergency, chaos / panic is

expected which reiterates the need to control
the situation for smooth exit of all to a safer
place including evacuation of casualties. The
same will be possible only if the security staff
is alert and exercises its control to handle the
situation.
• For area barricading and traffic control, the
placement of security staff shall depend upon
the location of Emergency declared and
direction of wind.
Executive Security Remains in Communication with Security Staff on Wireless
set Throughout the Emergency and Directly Controls / Monitors the Operation:

• A total of 9 x Walkie Talkie sets will be used for

wireless communication during the operation.
Each point, where a security guard is stationed
to control the traffic / block the road, will be
equipped with a Walkie Talkie set (Head /
senior watchman) at each point to operate the
Walkie Talkie).
 The details are as follows:

No. of Walkie
Sr # Appointment Strength Location Call Sign
Talkie
a Executive Security 1 RCC 1 Control
b Security Supervisor 1 Factory Gate 1 1
c Head Watchman 1 1 2
Lab Road
d Watchman 1 1 3
Planning & Projects Building
e Watchman 1 1 4
(At Road Junction)
Near Effluent Plant
f Watchman 1 1 5
(Road End)
g Watchman 2 NLC Bypass 1 6
h Head Watchman 1 Link Road near ‘Multan
Wazan Kanta’ & 1 7
i Watchman 1
CNG Station
Near Flyover at Chowk
j Watchman 2 1 8
Kumharan
ADMIN. BUILDING EVACUATION PLAN
 Resumption of Operations
• When it is determined that an emergency no longer
exists, the FCC Leader shall notify all concerned to
begin preparation to return to normal operations.
• All equipment that has been or could have been
affected by the emergency conditions shall be
inspected thoroughly to be sure it can be safely
returned to service.
• Decontamination and/or chemical cleanup
procedures for personnel or equipment shall be
carried out by Plant supervision under the direction
of the SPM and Technical Services manager or their
designee
 FCC & RCC ORGANIZATION
• ERP • EMP
No clarity on FCC and FCC and RCC organization
RCC organization will be established in both
case of Emergency Level-I
and Level-II
 LOCATION OF FCC AND RCC
ERP EMP
FCC Location FCC Location
• Uhde Building (APM Office)
• Udhe Building
In case of wind direction from NAST to
• Ammonia Conference Room Ammonia plant
• KIC Building • KIC Building (UM Ammonia Office)
In case of wind direction from NAST to Admin.
Building, CAN plant or Colony Jamia mosque

RCC Location
• Admin Conference Room No-1
RCC Location
In case of wind direction from NAST to
• Director Operations Office Colony Jamia mosque, CAN plant or
(DO) Ammonia plant,
• VIP Guest House (House # C- • L.CO2 Plant (UM Office)
13) In case of wind direction from NAST to
Admin building
 Clarity on Following Points

ERP EMP
Not fixed reference Wind directions narration
points guidance regarding with reference point New
wind direction. Ammonia Storage Tank
(NAST)
Security actions not clearly Details provided on ;
defined.
• Area Barricading and Traffic
Control
• Executive Security Takes
Necessary Actions.
• Walkie Talkie Networking pict.
• Evacuation details
 TRAINING ON EMERGENCY PREPAREDNESS

• Weekly Simulated Exercises

Weekly simulated exercises are conducted on Wednesday at 11:00
hours for the training of emergency squad. In this regard, training
matrix covering all possible emergencies at the site is prepared &
followed. Level-I siren is sounded during these exercises to create
awareness among Plant site as well as township personnel .
• Quarterly Simulated Exercises
A comprehensive program for quarterly simulated exercises has
been implemented involving all the employees & contractor work
force. Moreover, surrounding Community may be involved if
possible in the simulations once a year. The recommendations of
quarterly simulated exercises critique sessions are stewarded in SOC.
 Yearly Training
• All the clinic staff, doctor, emergency squad
members and other interfaces are involved in
relevant trainings on an yearly basis. Class
room/practical training for the following topics to
be carried out:
• Fire Fighting which briefly covers fire chemistry,
classes of fires & use of portable fire extinguishers.
• Hose handling & making of water curtain.
• SCBA Donning
• 1st-aid training.
 MOVING FORWARD….
• TRAINING - Please ensure the training of your
100% staff for Emergency Management Plan
and send a copy of attendance sheet to safety
unit (target 29feb, 2012)
• QUARTERLY EMERGENCY DRILL – FIRST
EMERGENY DRILL ON THIS PROCEDURE SHALL
BE DONE IN MARCH, 2012.
THANK YOU