Emergency Planning for Seveso II.pdf

BASF Aktiengesellschaft Works Fire Service Emergency planning in line with Seveso-II-guideline / example BASF

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Presentation Emergency planning in line with Seveso-II-guideline / example BASF

Wolfgang Suckfll, BASF Works Fire Service, Ludwigshafen

+49/621/6023310 [email protected]


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1 Introduction The SEVESO_II_guideline requires an internal emergency plan for upper tiers establishments. The purpose of hazard prevention planning which is required by the SEVESO_II_guideline is to avoid large scale accidents, to minimize the major incidents effects on the people and environment by

providing a rapid emergency response and rapid warning systems to optimize the company safety organization in terms of the organization structure

and technical outlay, The basis of the planning is a safety analysis, in which the hazards involved in a factory have to be compared to the corresponding safety measures. As an overall concept comprising a large number of building blocks which is to be used to protect the employees and other people involved, the hazard prevention planning extends all the way from operating instructions or alarm arrangements through major incident alarm planning. The following text provides an explanation of the general WORKS-ALARM-AND-HAZARD-DEFENCE-PLAN in particular of the major incident alarm planning with reference to the example of the BASF Ludwigshafen site, and provides an indication of where these interact with official authority hazard prevention planning. 2 Works Alarm an Hazard Defence Plan (WAGAP)

(in German: Werks-Alarm- und Gefahrenabwehr-Plan WAGAP)

The BASF site in Ludwigshafen enclose 350 factories on an area of 7,2 km. There are a lot of upper-tier and lower-tier establishments. According to Seveso-II-guideline a general Works Alarm an Hazard Defence Plan for the entire site have to be drawn up. The following list shows the index of this plan: 0 Application Area for Works Alarm and Hazard Defense Plans 1 Details of Works and Surroundings

1.1 Regional overview plan 1.2 Local overview plan 1.3 Overview plan of BASF at Ludwigshafen

2 Adresses of Public Buildings (Nurseries, schools, hospitals etc.) 3 Alarmplan for Major Incidents 4 Agreements related to Major Incidents

4.1 BASF Town of Ludwigshafen 4.2 BASF Town of Mannheim 4.3 BASF - Town of Frankenthal

5 Organisation of Works Hazard Defence Personel 5.1 Industrial Fire Department 5.2 Organisation work security DP/W 5.3 Medical Department 5.4 Press 5.5 Fault clearing sevice file

6 Alarmplans (Infrastructure) 6.1 Floods


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6.2 Energy (Electricity, pressured air, nitrogen, steam) 6.3 Pipelines 6.4 Product- und run-off water recontainment

(purification plant and non-purification plant sewer plans) 6.5 Quench water supply (hydrant plans)

6.6 Harbour

7 Alarmplans (special mediums) 7.1 Natural gas within site 7.2 Ammunition discovery 7.3 PCB (clophene-transformers)

8 Catastrophy Protection Plans Towns of Ludwigshafen and Mannheim 9 Comunication Structure on Site (Emergency lines, SOS Pilars, Hazard detection systems) 10 Information and Warning of Plants

10.1 Central Warning System 10.2 Direct Announcment (Buildings with direct PA-connection to Fire

Department) 10.3 PA-Vehicle (Information / Warning for Sub-Contractors) 10.4 Warning and Information System for Plants

(Warn- Alarm- and Emergency Signals) 11 Information for Authorities (Special Notification form) 12 BASF-Guidelines and BASF-Regulations Guidelines / general Regulations for Safety, Health and Environment

protection 13 Plant fault Practice Exercises The WAGAP is the result of an emergency planning system which have a logical structure. 3 Structure of the Company Hazard Prevention Planning A hazard analysis in the works/factory must be a first step taken in drawing up the alarm and deployment plan. In this context, it is necessary essentially to answer two questions: 1. Could an incident arise in the factory/works? 2. What should be the procedure if the incident occurs? In consequence of answering these questions regulations and alarm plans for the employees and for the inhabitants outside have to be drawn up. In principle, all the plans in the factory/works should be of uniform composition and should clearly demonstrate a logically recognizable sequence of actions. The same structure should be sought for all instructions in a factory/works. In this connection, the following hierarchies can form the basis of the planning: Operating instructions for an alarm or hazard incident Alarm or fire precaution regulation according to DIN 14 096


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Fire fighting plans according to DIN 14095 Alarm plan or alarm-raising plan according to German state fire precaution

legislation Organizational plan for major incidents Works-alarm-and hazard defense plan A feature of incidents of all kinds is that measures and decisions (who is informed; by what means) have to be taken quickly under time pressure and under the cloud of what has happened. Therefore, all plans have to be of brief and precise structure in order to be sufficiently comprehensible even to constantly changing personnel, for example, such as manual workers and employees of other companies. The plans are to be drawn up, presented to and practiced with those potentially involved, for example for the following incidents: Fire Explosion Product leak Accidents with many injured/dead Technical assistance Emissions Floods Extreme weather conditions Discovery of a bomb Bomb threats. The structure of the hazard prevention plan thus offers the advantages of a concluded arrangement, the individual stages (plans) of which are to be brought into play by the factory or, for example, the works fire service depending on the extent and nature of the incident. 3 Alarm-raising Plans / Alarm Plans Building on the factory instructions for the event of an alarm, the alarm-raising or alarm plans define the notification and alarm sequence in the event of incidents in the factory. The form of these plans which is customary at BASF includes a list of telephone numbers of specialist bodies or specialist staff which are competent to deal with the incident. The factory incident reports are made to the responsible locations (works fire service headquarters) via the stipulated central alarm point of the site/factory. From there, the authorities, institutions, works specialist departments and staff who have to be warned are notified immediately on the basis of the alarm plan. (see Appendix 1)


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The following principles are to be employed when drawing up an alarm plan at BASF Aktiengesellschaft: 1. The alarm plans are to be worked out by the factories in cooperation with the fire

service and the working safety department. The validity and completeness of the information is to be checked twice a year by the factory.

2. The possible incident site is to be surrounded by a circle which encompasses the

hazardous area. This area is the "Red Zone" or "Core zone". 3. The factory operations in the "Red Zone" which are affected by the alarm are to

be informed verbally of the nature and extent of possible danger, in an information conference.

4. Factories in the Red Zone must compile directions (factory directives) for the

protection of their employees in the event of an alarm and have to work through these directions in regular instruction sessions.

5. The factories and employees outside the building are warned together by a loud

horn (typhoon system). Long 7 sec. blast .......... .......... .......... 2 sec. pause - Auditory warning systems according to DIN 33404 -.

6. The fire service warns other affected factories by an electronical Central Warning

System (CWS) and informs people outside, for example by means of loudspeakers.

7. Where necessary, factories in the Red Zone install alarm systems in the building

in order to warn the employees, as well as wind direction indicators (wind socks) at clearly visible points.

The basic principle is to attempt to draw up all the alarm plans in the works according to a uniform, predefined model. This has the advantage that in the event of a serious incident, irrespective of the cause, the alarm-raising procedure does not differ, or only differs to an insignificant extent. The alarm plan of a factory should include the following compulsory stipulations: who raises the alarm how the alarm is raised to whom the alarm is raised if appropriate, who has to be warned.


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4 Major Incident Alarm Planning On the basis of an agreement between BASF and the city of Ludwigshafen which was first made as early as 1980, major incidents within BASF are dealt with according to an organizational plan which was drawn up for this purpose. These major incidents are characterized by extensive repercussions inside and/or outside the works site. These include in particular events which require the population and the public bodies to be warned or informed. The organizational plan provides a number of committees for combating damage in the works and coordinating the BASF units involved. In the event of an incident, according to the organizational plan, the Hazard Prevention Steering Committee (LAG) and the Technical Operations Management (TEL) assume responsibility for the tasks which are incumbent on BASF. 4.1 Alarm Stages The BASF hazard prevention system works on the basis of a four-stage alarm system. Specifically, a distinction is drawn between the following alarm stages: 1. Plant alarm (PA) 2. Minor alarm (MIA) 3. Major alarm (MAJA) 4. Major incident alarm (MAJACCA). (see Appendix 2) A matrix which specifies the following parameters: number of people hurt extent of the damage whether or not it is known which BASF factory has caused the incident disruption or hazards for people affected and effect in the factory, in the works or outside the works is used to classify the different alarm stages. (see Appendix 3) Factory alarms according to this matrix are characterized by minor damage, a small number of injured and disruption to people affected in the factory. In the event of a factory alarm, the incident is dealt with by the factory affected. In the event of incidents of this nature, the works fire service is not called out. Minor alarms are required if there is danger in a factory affected and if there is disruption to people in the associated Red Zone (zone, 150 m diameter, around the factory which is stipulated in the factory alarm plan). In the event of alarms of this


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nature, the works fire service is deployed and will carry out the damage prevention measures in the factory and the Red Zone. The major alarms stage involves a large number of injured, danger in the works or disruption outside the works site. At this alarm stage, a Technical Operations Management coordinates the damage prevention measures, this operations management being composed of the BASF units which are required depending on the damage situation, for example the environmental protection department, the ambulance service, the medical service, site protection, and if necessary representatives of the public fire service, and is headed by the works fire service. The term major incident alarm encompasses incidents which: 1. in the event of a large number of injured cause a hazard within the

works or disruption outside the works or

2. cause danger outside the works.

The structure and organization of the BASF units responsible for these alarms is stipulated by the alarm plan for major incidents. 4.2 Alarm Plan for Major Incidents The Major Incident Alarm Plan builds the most important part of our WAGAP, because it describes the internal emergency responds management system an the interaction with authorities and very important- with the local press. (see Appendix 4) The BASF works fire service is responsible for designing the contents of and continuously updating the alarm plan for major incidents. An Organizational Plan for Major Incidents forms the core of this alarm plan and is used to arrange cooperation between the BASF committees involved and the responsible authorities of the city of Ludwigshafen. In the event of a major incident alarm, the plan provides for a Technical Operations Management and a Steering Committee to be convened. The membership and tasks of the Steering Committee and its individual members are listed under classification points 2 and 3. The information contained in these sections of the alarm plan (telephone numbers, addresses of the members of the Steering Committee) are used by the works fire service in order to summon the Steering Committee immediately in the event of an incident. On the other hand, Section 3 (tasks of the Steering Committee) provides each member of the Steering Committee with instructions concerning the tasks which he/she is to carry out (check lists). The members who are to be summoned to the Steering Committee also include the heads of the divisions affected by the events of an incident. For this purpose, the alarm plan includes a constantly updated list of the heads of the Operating Divisions


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(including the necessary information, such as for example telephone numbers, private addresses, etc.). The Steering Committee uses a series of working parties, to which BASF technical staff and specialists are summoned on request of the Steering Committee, in order to clarify particular specialist matters or in order to deal with particular tasks. The membership of these working parties is given in Section 5 of the alarm plan, together with the supplementary information required (how the people involved can be reached). In addition to these sections, the alarm plan includes important information for the members of the Steering Committee, in the form of: telephone and fax numbers of the official public authorities

responsible for damage prevention technical facilities of the control room

(permanent meeting venue for the Steering Committee) and important internal telephone and fax numbers. Finally, the composition of the Technical Operations Management which is designed according to the nature of the incidents is appended to the alarm plan in Section 9. The annexes to the alarm plan contain further information for the members of the Steering Committee, such as for example the emissions notification plans which have been agreed with the responsible authorities for incidents which involve airborne or waterborne emissions. 4.3 Organizational Plan for Major Incidents (see Appendix 5) The organizational plan for major incidents constitutes the basis for cooperation between the individual BASF committees in the event of a major incident. In the event of a major incident alarm, the head of the works fire service is initially responsible for coordinating the first hazard prevention measures. As the operations manager in accordance with 25, Section 4 of the Land Protection, Firefighting and Disaster Prevention Act (LBKG), he/she makes use of a Technical Operations Management which, in addition to the specialist BASF units (e.g. works medical service, air/water emissions monitoring department, work safety department, waste disposal department), additionally may also (for example in the event of the public fire service being deployed on the BASF works site) include representatives of the public fire service. The BASF units which are required to prevent hazards and to combat damage are subordinate to the head of the works fire service or the operations manager, who is thus responsible for combating damage on site and for providing information to the responsible authorities of the city of Ludwigshafen. According to the statutory provisions and the agreement between BASF and the city of Ludwigshafen, overall management of hazard prevention may be transferred to the Mayor of the city of Ludwigshafen (overall responsibility of the city of Ludwigshafen). In these situations, the operational measures, for example, at the BASF works site are carried out under the direction of the BASF operational


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manager under instructions from the overall management of the city of Ludwigshafen. On the basis of the organizational plan, the head of the works fire service is obliged to inform the head of the Environment, Safety & Energy Functional Division as soon as he/she is aware of the extent of the incident. In the event of major incidents, the head of the Environment, Safety & Energy Functional Division will notify the head of the Steering Committee of the incident, and the latter will decide whether the Hazard Prevention Steering Committee is to be convened on the basis of the information to which he/she has access. 5.4 Hazard Prevention Steering Committee On the basis of the decision of the head of the Steering Committee, the Hazard Prevention Steering Committee will meet in the steering room (meeting room in the Environmental Monitoring department building) after it has been summoned. In addition to the head of the Steering Committee, who in principle is the member of the Board of Executive Directors who is responsible for the Ludwigshafen works, the members of the Steering Committee include the following functional representatives: the Head of the Environment, Safety & Energy division the Head of the BASF AG Human Resources division the Head of the Works Engineering division the Head of the Operating Division affected by the incident the Head of the Industrial Medicine department the Head of the Emissions Monitoring department and the Head of the Public Relations department. Furthermore, the Chairman of the Works Counsel participates in the meetings of the Steering Committee as a personal member. The fundamental task of the Steering Committee consists in the coordination of all the units involved in an incident both with one another and with the works fire service operations management. Furthermore, it ensures that normal operating conditions are restored as quickly as possible. It is also responsible for providing ongoing information to internal and external agencies. Furthermore, the Steering Committee makes the decisions which are required for production at the Ludwigshafen site and which may be necessary in the context of a major incident (e.g. to shut down production processes or installations, to close down energy supply grids). To carry out these tasks, the Steering Committee uses various Working Parties which it summons according to the particular situation of the incident. These working parties operate under the management of a Coordinator for Working Parties.


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The following working parties (WP), among others, may be activated: Informing authorities and external agencies WP Determination of the extent of damage/settlement of claims WP Clearance and disposal WP Toxicology WP Ecology WP Determination of the cause of damage WP Law WP Air/water WP and Industrial safety WP. These working parties are made up of the experts and specialists working in the BASF specialist bodies. By way of example, in previous incidents, the toxicology and ecology working parties have been convened in order to provide further information to the Steering Committee relating to the environmental relevance of products which have been released. The tasks within the Steering Committee are coordinated on the basis of a detailed distribution of tasks in the alarm plan for major incidents. This alarm plan assigns each member of the Steering Committee tasks according to his/her functional area. For example, the head of the public affairs division has to carry out the following tasks: 1. Information for the works personnel through telex to the board of directors through the BASF Aktuell info bulletin available at the works gates through ZWS central warning system

2. Dealing with representatives from the media set-up a meeting point outside the works grounds escort the media representatives to view the incident scene (after the agreement from the emergency board has been given)

3. Information to the emergency control and guidance board over the questions asked by the press and reports in the news in radio and TV The Steering Committee works in continuous contact with the Technical Operations Management which has been set up by the works fire service. At specific intervals of time, the head of the works fire service informs the head of the Steering Committee of the current damage situation on site.


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4.5 Technical Operations Management The Steering Committee mentioned above, the Technical Operations Management is composed of: the operations manager the heads of the functional divisions S1 - S4 (Technical Operations

Management staff) one advisor from each of the authorities, services, factories, public and

private organizations directly involved in the hazard prevention and auxiliary personnel. The Technical Operations Management Staff is adapted to the requirements of function-oriented operations management depending on the particular incident involved. In principle, the staff is divided into the following supervisory areas: S 1 Personnel supervision, internal supervision, press and public

relations work S 2 Establishing the position S 3 Tactical planning, provision of orders

(where not provided by the operations manager), communications supervision

and S 4 Supplies. The secondment of employees of the works fire service and representatives of the public fire service of the city of Ludwigshafen to the staff depends on the following deployment incident classifications: 1. Incidents without external effects 2. Incidents without external effects but with deployment of the public fire

services 3. Incidents with external effects but without the deployment of the public

fire services in the works and 4. Incidents with external effects and with deployment of the public fire

services in the works. The Operations Manager, when working in the Technical Operations Management, is assisted by employees of the Operating Divisions affected by the incident and, if appropriate, of the factories affected. This ensures that information which is specific to the product, process or factory is available to the Operations Manager immediately and at any time.


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4.6 Procedural Plan for Hazard Prevention (see appendix 6) The organizational units and committees which have been described above and become active in the event of a major incident alarm are classified, at BASF, into a Procedural Plan for Hazard Prevention which is valid for all the alarm stages. On the basis of this procedural plan, incident reports are passed by external agencies, BASF employees, the Environmental Monitoring department or the factory (if the alarm is not a factory alarm) to the existing notification points of the works fire service, the ambulance service or the Environmental Monitoring department. In the headquarters of these units, the matrix which has been explained above is used to make a decision concerning the classification of the hazard prevention into the alarm stages. At the same time, the head of the Environment, Safety and Energy division is informed, who in the event of a major incident alarm will notify the head of the Steering Committee. If the damage situation demands, this decision-making process can be shortened by the head of the works fire service summoning the Steering Committee directly or by informing the head of the Steering Committee. While initial measures for combating the damage are being introduced, the notification points of the authorities responsible for hazard prevention are informed immediately on the instructions of the operations manager of the works fire service. On the basis of the immediate notification received, these authorities decide whether to activate the official hazard prevention measures (e.g. information or warning for the population) and inform the head of the official hazard prevention department (under the overall management of the city of Ludwigshafen). If necessary, it is the responsibility of the head of the official hazard prevention department to decide whether to introduce measures in accordance with the disaster prevention plan. 5 Trainings The paper of all these emergency plans is not worth to be written, if there are no practical trainings and regular drills. The problem is, that in case of an accident, you have .... lack of time, ... .lack of equipment, .....lack of something else ......... But on the other hand, ...rapid response, ...professional handling and ...optimum effects of measures are expected. So it is necessary to organize and train as much as possible in advance. The aim is, that every employee knows exactly what to do in the case of a minor or major incident.


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For practical drills we have got several levels of exercises for the employees: exercise

level Action / Scenary Participants

1 alert exercise to train the plants own technical an organisational procedures.

plants employees

2 Emergency shut down of the production

plants employees, monitored by fire brigade or safety department

3 Alert training (Fire, leakage etc)

employees ,fire brigade (Minor or Major alarm) and the others standard emergenca abating unites.(medical, security,environmental)

4 Major accident alert training (Fire, leakage, explosion etc)

employees, fire brigade and technical operations management. Many injured people (extra players), external forces

5 Steering commitee exercise

Emergency response steering commitee, working groups, other specialists, technical operations mangagement

Every year the BASF carries out 2 exercises level 5 2 exercises level 4 approx 90 exercises level 3 4 to 6 evacuation exercises monitored by our Fire Brigade. Weekly testing of the alarm signals, public address systems and central warning

system. 6 Communication with the neighbours A further major component of incident management is communication between the operating company and the autorities and to the public. By giving information in advance about your plants and your emergency response measures to the residents builds a confidential relationship between the Chemical industry site and the neighbourhoud. In an event of a major accident alarm situation you need this confidence. Together with the cities of Ludwigshafen and Mannheim BASF and other chemical companies in produced an incident booklet Major incident - what now, which is distributed to all residents. The companies describes their factories and give information about the names and dangerous properties of their products. In addition, an information sheet (in several languages) outlines protective measures and action to be taken in the event of an incident in the chemical industry.


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If necessary the city of Ludwigshafen warns the inhabitants with sirens around the BASF information from local radio stations announcements by loudspeaker In agreement with the operating divisions and the Environment, Safety an Energy Division the the Public Realations and Market Communications Department provides press realeases helplines BASF TV Videotext Internet 7 Summary The emergency management system described in this presentation with reference to the example of the BASF site in Ludwigshafen, as well as the content and structure of the plans, committees and staffs mentioned, have proven successful in the past when used inside and outside the works site. The clear definition of areas of interaction with those authorities of the city of Ludwigshafen which are responsible for hazard prevention has allowed measures to be stipulated and carried out quickly and correctly in the event of incidents arising.

Documents

Emergency Planning for Seveso II.pdf