Industrial Emergency procedures: An introduction

Emergency

An emergency is a serious , unexpected, and dangerous situation that poses an immediate risk to health, life, property, and the environment.

An emergency plan is a formal, written document designed to assist management with the control of specific hazards or incidents.

It aims to minimize negative impacts on the organization (such as injury, property damage, disruption to normal operations, and poor public image and reputation) and aid rapid post-incident recovery.

Refer HSG 191 - Emergency planning for major accidents: Control of Major Accident Hazards Regulations 1999 (COMAH), www.hse.gov.uk

Example of some foreseeable events.

(MORE COMMON INDUSTRIAL EMERGENCY)

Fire (Major Industrial Fire)
Release of Radioactivity /Radiation (Chernobyl , Russia)
Explosion (e.g. Gas explosion, Boiler or Pressure Vessels blast/rupture)
Collapse of Building /Structure ( e.g. Rana Plaza Accident, Bangladesh) (Scaffolding collapse, Soil Collapse, Tunnel, Mine Collapse, Cranes topple over)
spillage of hazardous chemical. ( e.g. Outflow of molten metal)
Release of toxic gases /fumes(e.g. MIC-Methyl Isocyanates , H2S-Hydrogen Sulphide )
Multiple causalities
Large Vehicle crashing into the premises
Aircraft crash
Poisoning (e.g. Food Poisoning)
Outbreak of highly infectious diseases.- COVID-19
Medical Emergency ( For 1 worker, individual medical emergency)
Electrocution ( Electrical burn Emergency)

(All emergencies may lead to multiple causalities if not controlled IMMEDIATELY.)

Some industries develop emergency plans under the guidance of a disaster or crisis management team .

NATURAL EMERGENCY:

FLOOD
EARTHQUAKE
TSUNAMI
HIGH WIND CONDITION, TORNADO, HURRICANE
AVALANCHE,
CLOUD BURST,
LAND SLIDES,
VOLCANO RUPTURE
ETC.

MAN MADE EMERGENCY

BOMB THREAT/WARNING,
SABOTAGE,
AGITATION
TERRORIST ATTACK

Why emergency Procedure /plan need to be developed?

Emergencies can occur any time without warning.

In an emergency situation, people react differently to normal yet rapid decisions will have to be made in a short period of time.

The stress of the situation can lead to poor judgement, panic and confusion and the inability to think clearly and logically.

Normal channels of authority and communication also break down.
So pre-planning is essential in order to enable people to act to prevent disaster.
It will also highlight any deficiencies or lack of resources, which can then be addressed before an actual emergency occurs.
The emergency plan should be familiar to all, outline clear roles and responsibilities and be regularly reviewed and rehearsed.
Legal compliance (ILO, MHSWR 1999)

Activity 1 : Group Discussion

What emergency situations would the following organisations have to consider when developing emergency procedures?

A primary school.
A chemical-manufacturing plant.
A Multi-story shopping centre.

Activity 1: Possible Responses

Primary school:

Fire, bomb threat (possibly), severe weather, outbreak of disease, collapse of building, Electrocution , Electrical Fire , Food Poisoning , Outbreak of disease, Medical Emergency, individual medical emergency like unconsciousness including all Natural Emergency etc. .

Chemical-manufacturing plant:

Fire (including multiple-casualty incident), Explosion (Blast) -Pressure vessels, outbreak of disease, gas release, spillage of chemicals , toxic chemical exposure, Structure collapse, Electrical-Electrocution , Electrical Fire , Boiler Blast, Burn from Chemicals, Medical Emergency like unconsciousness due to inhaling of vapour etc.

Cloth Shopping Centre:

Fire, terrorist threats including bomb and/or suspect packages, multiple-casualty incident, crowd panic /stampede, Lift Failure, Electrocution, Electrical Short Circuit, Escalator failure, structure collapse, suffocation-HVAC stopped working-overcrowding , Medical emergency unconsciousness, Slip hazard lead to Individual fracture etc.

Emergency procedures and first aid as per ILO

Refer : https://www.ilo.org/legacy/english/protection/safework/cis/products/safetytm/chemcode/14.htm

14. Emergency procedures and first aid

14.1 Emergency procedures

14.1.1. Arrangements should be made to deal at all times, and in accordance with any requirements laid down by the competent authority or as advised by the assessment of risks, with emergencies and accidents which might arise from the use of hazardous chemicals at work.

14.1.2. These arrangements, including the procedures to be followed, should be kept up to date in the light of new information such as that provided in chemical safety data sheets, experience with the chemicals and any changes in the work activity.

14.1.3. Workers should be trained in the relevant procedures. These should describe:

(a) arrangements for raising the alarm;

(b) arrangements for calling for appropriate emergency assistance, whether in plant or off site, e.g. fire-fighting services in the event of a fire and emergency medical services;

(d) the evacuation of the work area, premises or establishment and the location of emergency exits and escape routes;

(e) action to minimise the incident, e.g. tackling the fire, controlling leaks and spills, emergency shut-down, removal of portable pressure vessels in case of fire, and action specifically prohibited if persons are put at risk;

(f) the evacuation of nearby premises.

14.1.4. In ,some cases it will be necessary to provide for emergency procedures in the event of a foreseeable incident from adjacent work activities or adjacent establishments, which may affect safety during the use of chemicals. Examples might include arrangements:

(a) to cool vessels or other containers from overpressurisation in the event of a fire nearby;

(b) to stop processes and leave plant and equipment in a safe condition in the event of a chemical release from an adjacent plant or site.

14.1.5. Where an incident may affect people or property outside the establishment in which the work activity takes place, appropriate procedures should be developed in consultation with the national authorities or services that may have relevant responsibilities, e.g. external emergency services and local authorities. Guidelines on preparing an emergency response plan in the event of such an incident can be found in the ILO code of practice, Prevention of major industrial accidents (Geneva, 1991), and in the UNEP handbook, Awareness and preparedness for emergencies at local level (APELL): A process for responding to technological accidents (Paris, 1988).

14.2 First aid

14.2.1. Adequate first-aid arrangements should be provided. These arrangements should take account of the hazardous chemicals used at work, ease of communications, and the emergency services and facilities available. They should be in accordance with any requirements laid down by the competent authority.

14.2.2. As far as is practicable, appropriate means and trained personnel for rendering first aid should be readily available at all times during the use of hazardous chemicals at work. The term "trained personnel" includes persons trained in first aid, registered nurses or medical practitioners, for example.

14.2.3. Where hazardous chemicals are used, first-aiders should be trained as regards:

(a) the hazards associated with the chemicals and how to protect themselves from these hazards;

(b) how to take effective action immediately;

14.2.4. An assessment of the first-aid needs should be made by the employer. The reasonable practicability of having trained personnel readily available will depend on:

(a) the number of employees;

(b) the nature of the work activity;

(d) the situation of the work activity in relation to the nearest hospital or other emergency medical services that may be required.

14.2.5. The first-aid equipment and facilities should be appropriate for dealing with the hazards to be encountered in the use of chemicals at work. Suitable facilities should be available for workers to use themselves, e.g. emergency showers or eyewash stations. These should be strategically placed to allow for their immediate use in the event of an emergency.

14.2.6. There should be ready access at all times to first- aid equipment and to the facilities provided.

14.2.7. Properly equipped first-aid rooms should be provided in accordance with national laws or standards. In general, these should be provided in all establishments:

(a) where there are significant acute hazards to health from the use of chemicals at work; and

(b) taking into account the factors outlined in paragraph 14.2.4 (assessment of first-aid needs).

Importance / benefits/Objectives for an organisation to develop emergency procedures/plan.

Q: Why do emergency procedures need to be developed?

The objective is to be prepared emergency procedures to:

Prevent fatalities and injuries. (Keep employees and responders free from harm)
Reduce/ minimize damage to buildings, stock, tools, machinery and equipment.
Protect the environment and the community (MoP-Member of Public).
Minimize downtime - Accelerate the resumption of normal operations.
Legal compliance and meeting regulations.
Reduction in the threat of prosecution.
A clearer understanding of roles and responsibilities
Increasing levels of competency and on-site / off-site skills at the time of emergency.
Sustained high standards of H&S at work
Ensure business continuity

Why is it important to have emergency procedures for the evacuation of people from the workplace?

To reduce the severity, prevent fatalities and injuries of an event affecting a workplace.
To mitigate the adverse effects on people by evacuating from workplace due to dangers inside the building, from fire to a toxic chemical spill/explosion/toxic gas release.
To assess the number of causalities trapped inside the building/site/plant like New Employees, Vendors, clients, and other visitors who are not familiar with emergency procedures, need to evacuate from the site/ building safely.
To start the restoration activity at workplace to normal scale ( to re-make safe place to work like fire extinguishing, to make workplace toxic free , defusing the bomb) –so emergency services can perform their activities smoothly.

What to include in an Emergency Procedure?

Factors for Emergency Procedures

They should ensure that the following precautions are taken:

Emergency procedure to be implemented by organization for foreseeable event.
Nature of emergency ( e.g. Fire or Chemical spillage)- Decide on the possible nature of any emergency that might occur and the potential consequences to the organization;
Degree of emergency ( e.g. High level of emergency due to activities carried out, 50000 Litre Petrol/Diesel Stored, )
Shift patterns (day & night) including working on holidays. This may be particularly important when the organization is closed at weekends or holiday times;
Physical layout of the premises.
Size of organization. (number of workers including vulnerable groups- more workers)
location of site & location relative to hospitals/emergency services ( Immediacy of outside aid)
Capabilities of the organization in an emergency situation.( e.g. Fire Hydrant system, Fire Tenders)
Common elements to be considered in all emergencies include pre-emergency preparation
Provisions for alerting (alarming) - Consider how the alarm will be raised.
Decide on how the emergency services will be contacted—
Decide on an emergency assembly point for staff (Muster Point);
Ensure enough emergency exits (Escape route) ,
Emergency lighting, for everyone to escape quickly,
Emergency signages etc. for everyone to escape quickly,
Nominate competent people
Decide which other key people are needed, such as activators of emergency equipment,
a nominated incident controller,
First-aiders;
How to contain the hazards & risk . - - Plan essential actions such as emergency plant shutdown, isolation or making processes safe.
Ensure that everyone is included in emergency procedures including people with disabilities and vulnerable workers;
Handling casualties (victims)
Decide on the arrangements for liaising with the media during and after the event
Legal requirements

Role of Supervisory/Manager (Event controller / Incident controller ) duties in the event of Emergency Procedure

They should ensure that the following precautions are taken:

Everyone on site can be alerted to an emergency.
Everyone on site knows what signal will be given for an emergency and knows what to do.
Someone who has been trained in what to do is on site and ready to coordinate activities.
Emergency routes are kept clear, signed and adequately lit.
There are arrangements for calling the fire and rescue services and to give them special information about high hazard work, for example in tunnels or confined spaces.
There is adequate access to the site for the emergency services and this is always kept clear.
Suitable arrangements for treating and recovering injured people are set up.
Someone is posted to the site entrance to receive and direct the emergency services.

Emergency Procedures -How going to implemented

Key steps to implement the Emergency planning

Emergency procedure to be implemented by organization for foreseeable event.

Establish the planning team: -- - - representatives from all departments and level, with support from senior management, is most effective.
Assess the Risk/emergency and company capabilities: Scope and outline potential emergencies
Develop the Emergency response plan : - - -Provision of Suitable emergency equipment. (Resources, e.g. Fire Fighting Equipment , Fire tender etc. ) , Nomination of Responsible staff ( Competent), Provision of Training and information needs. ( IITS+ monitoring), Communication systems
Implement the Emergency Plan: Obtain & install equipment , IITS, Procedures to be implemented.
Test the plan : by Mock Drills / Drills and simulation exercises.
Improve the plan continuously – by regular review due to changes in workplaces, vulnerable groups , processes , equipment , hazardous activities, Legal requirement etc.

Arrangement for Contacting Emergency Services

Emergency Communication Protocol will be followed:

Communication equipment: Alarms, Hooters, Land lines, Mobile Phones, radios, etc.
Contact details: Emergency Contact Lists : National and local emergency numbers (display on the site) ( Local Authority contact details , Company Internal contact details etc.). (India - 100/101/102-PFA) (108-A) (UK -999 /112)
Responsible individuals: Command structure , Roles & Responsibilities
ESSENTIAL to understand whose responsibility it is. (ERT-Emergency & Rescue Team)
Must be competent staff specially trained .

Why people need training in emergency procedures

The primary aim of emergency training is to prepare responders to follow the set emergency plan protocol.

This is beneficial as the plans or protocol are designed to reduce physical injuries of people and the building, as well as potential fatalities of staff members.

Familiarity through training and exercises can combat the natural effects of stress in tense /Panic situations.

Having a well-rehearsed emergency plan enables efficient and effective response coordination, reduces losses, and can limit the impact to employees, the environment, and surrounding community.

Training plan spelling out what you should do in an emergency situation. It helps to efficiently and safely get people away from an area where there is an imminent threat, ongoing threat, or a hazard to lives or property.

An Emergency training including evacuation plan forces employees to walk along their route of escape in a calm, and measured manner.

Employers who take the time to thoroughly develop an evacuation plan provide their employees with a safer workplace, and may even save lives.

Emergency Response Training Is An Investment In Your Employees

When your staff is competent with the right emergency response training, they will be able to perform their work more safely and easily. This is important to boost employee morale and improve the productivity of your company. It will definitely help save money in the long run. On the other hand, emergency response training is a great investment in employee retention.

When you give your staff an emergency response training, you are saying to them that you are confident in them and they are a valuable asset to your organization.

Reduces Absenteeism

You reduce responder absence due to injuries and illness with the right kind of emergency response training. That way you will save a lot of time and money in recruiting and training new employees for your organization. You can easily retain your staff with the company when you give them the necessary emergency response training.

This will improve their confidence in performing their jobs, and improve the productivity of your organization.

The Training Will Help The Responders Follow The Emergency Plan In Your Organization

An emergency plan is designed to reduce fatalities and injuries. It will also help reduce damages to the building, machinery, and environment. An emergency plan to offer the guidelines for the responders to act during an emergency situation.

In fact, emergency response training empowers the staff to accurately follow the specified emergency procedures and deal with unexpected situations in the organization.

Emergency Response Training Empowers The Responders To Use Safety Equipment

Most responders won’t know how to handle safety equipment such as fire extinguishers, hose reels, blankets, and other items without the proper emergency response training. This could have serious consequences for your organization. In fact, different fire extinguishers are used for different types of fires. The responder should know how to use a water extinguisher and dry powder extinguisher. The equipment should be regularly maintained and serviced by an approved service provider in order to keep them optimally functional at all times.

A fully trained workforce can deal with any type of emergency situation in your organization. That is why you should be investing in a program of emergency response training for your staff.

Good Reputation For Your Company

The right health and safety measures are important for any organization. It will help your brand to build a positive reputation with your customers, staff, friends, and community.

The good public relations will help increase the visibility of your brand as well as sales and profits of the company. That is why you should be investing in emergency response training for your staff members.

Workplace emergencies can happen at any time. Your company should be able to quickly respond to such emergencies. That is where an emergency response plan is essential for your company. Emergency response training comes in handy under such circumstances. There are many advantages in investing in emergency response training for your staff members. It will safeguard them and improve the productivity and profits of your company. The aforementioned article provides information on the benefits of emergency response training.

Why emergency procedures need to be tested ?

Objective of testing

The objective of testing the emergency plan should be to give confidence in the following constituents of the plan:

(a) the completeness, consistency and accuracy of the emergency plan and other documentation used by organisations responding to an emergency;

(b) the adequacy of the equipment and facilities, and their operability, especially under emergency conditions; and

(c) the competence of staff to carry out the duties identified for them in the plan, and their use of the equipment and facilities.

The overall testing regime for on-site and off-site emergency plans would be expected to examine the following aspects of the emergency response:

(a) activating the emergency plan and notifying the participants:

(i) alerting emergency services;

(ii) sounding alarms; and

(iii) mobilising establishment personnel identified in the emergency plan as having a role to play in the event of an emergency.

(b) establishing an on-site emergency control centre (ECC)

establishing a suitable place from where the on-site response to the emergency can be directed and co-ordinated as required by the on-site emergency plan, within a suitable time. (Also considering the ability to establish an alternative on-site ECC in some tests, to demonstrate the ability to operate when the designated on-site ECC is untenable.)

establishing a suitable place from where the off-site response to the emergency can be directed and co-ordinated, which may be through a strategic co-ordinating group.

(d) supplying information to the ECC (emergency control centre)

demonstrating that information from the participating organisations can be supplied promptly and accurately to the ECC, so that those at the centre have access to an up-to-date picture of the emergency and the response to it, and from which they can base their decision making.

(e) communicating within the ECC (emergency control centre)

demonstrating that the necessary information is exchanged and disseminated among all the parties with a role to play at the ECC, and is in a form that can be understood and assimilated.

(f) team working

demonstrating the ability of participating organisations to work together, using the available information to develop the response to the emergency.

(g) decision making

demonstrating that advice is provided by all participating organisations to allow rational decisions to be made, which can be implemented.

(h) communication and public information

(i) demonstrating that information on the emergency, and the response to it, is passed to all participating organisations and to the appropriate media;

(ii) the demonstration should include preparing briefs for the media and should sometimes include establishing a media briefing centre. In addition, consideration should be given as to the effect of the media in the event of an emergency, and the ability of the ECC to make information available for handling their enquiries.

(i) equipment and facilities

demonstrating that the equipment identified as having a role in the response to an emergency is operational, and that participants are able to use it. Also, demonstrating the operability of the ECC and the equipment associated with it.

Why emergency procedures need to be tested?

This testing is carried out to give confidence that the Emergency plans are accurate, complete and practicable.
It should be able to show that people following the emergency plan could cope up with the range of accidents that could occur.
The testing should give an indication of the conditions that may exist on and off the establishment in the event of an emergency.
It should also show that the plan would work as proposed: controlling and mitigating the effects of an accident;
- - - -communicating the necessary information;
- - - - and initiating the measures which should lead to the necessary restoration of the environment.
Therefore, this is where a detailed understanding of the likely sequence of events
- - and appropriate countermeasures is of great benefit.
There is a Legal requirement to test the emergency procedure.

Methods of training and testing

Exercises to test on-site and off-site emergency plans, and which form part of the ongoing training of key personnel in preparation for dealing with an emergency, can take a number of forms.

These will fulfil different functions within the overall requirements. These exercises include:

(a) drills testing a specific and relatively simple aspect of the emergency plan in isolation.

Examples are:

fire drills;
alarm testing;
evacuation;
roll call and searching;
cascade telephone calls;
spillage control and recovery;

(b) seminar exercises training staff and developing emergency plans.

They facilitate discussion about the different organisations’ responses in particular circumstances during an emergency; Emergency planning for major accidents

(c) walk-through exercises training staff or developing emergency plans. The emergency response is ‘walked through’, including visiting appropriate facilities such as ECCs;

(d) table-top exercises allowing information exchange and dissemination between organisations at the ECC, together with decision making, to be tested.

They are carried out in relation to a model, plans or photographs to depict the establishment. They could involve using information technology or virtual reality systems;

(e) control post exercises testing the communication arrangements during an emergency, with participating organisations located where they would be during an emergency;

(f) live exercises fully testing some or all aspects of the emergency plan for the on-site and offsite response.

Post-incident critiques often confirm that experience gained during exercises was the best way to prepare teams to respond effectively to an emergency.
Exercises should be designed to engage team members and get them working together to manage the response to a hypothetical incident.
Exercises enhance knowledge of plans, allow members to improve their own performance and identify opportunities to improve capabilities to respond to real events.

Exercises are a great method to:

(Refer : https://www.ready.gov/program-improvement )

Evaluate the preparedness program
Identify planning and procedural deficiencies
Test or validate recently changed procedures or plans
Clarify roles and responsibilities
Obtain participant feedback and recommendations for program improvement
Measure improvement compared to performance objectives
Improve coordination between internal and external teams, organizations and entities
Validate training and education
Increase awareness and understanding of hazards and the potential impacts of hazards.
Assess the capabilities of existing resources and identify needed resources

Types of Exercises for emergency

There are different types of exercises that can be used to evaluate program plans, procedures and capabilities.

Walkthroughs, workshops or orientation seminars
Tabletop exercises
Functional exercises
Full-scale exercises

Walkthroughs, workshops or orientation seminars

Walkthroughs, workshops and orientation seminars are basic training for team members. They are designed to familiarize team members with emergency response, business continuity and crisis communications plans and their roles and responsibilities as defined in the plans.

Tabletop exercises

Tabletop exercises are discussion-based sessions where team members meet in an informal, classroom setting to discuss their roles during an emergency and their responses to a particular emergency situation. A facilitator guides participants through a discussion of one or more scenarios. The duration of a tabletop exercise depends on the audience, the topic being exercised and the exercise objectives. Many tabletop exercises can be conducted in a few hours, so they are cost-effective tools to validate plans and capabilities.

Functional exercises

Functional exercises allow personnel to validate plans and readiness by performing their duties in a simulated operational environment. Activities for a functional exercise are scenario-driven, such as the failure of a critical business function or a specific hazard scenario. Functional exercises are designed to exercise specific team members, procedures and resources (e.g. communications, warning, notifications and equipment set-up).

Full-scale exercises

A full-scale exercise is as close to the real thing as possible. It is a lengthy exercise which takes place on location using, as much as possible, the equipment and personnel that would be called upon in a real event. Full-scale exercises are conducted by public agencies. They often include participation from local businesses.

Specific duties, responsibilities, authority, and resources must be clearly defined to handle the emergencies.

Among the responsibilities that must be assigned are:

Reporting the emergency.
Activating the emergency plan.
Assuming overall command.
Establishing communication.
Providing medical aid.
Alerting staff.
Ordering response, including evacuation.
Alerting external agencies, as necessary.
Confirming evacuation is complete.
Alerting outside population of possible risk, as necessary.
Requesting external aid.
Coordinating activities of various groups.
Advising relatives of casualties.
Providing medical aid.
Ensuring emergency shut offs are closed.
Sounding the all-clear.
Advising media.

External organizations that may be available to assist (with varying response times)

Which external agencies are consulted on emergency planning?

Pre-planned coordination is necessary to avoid conflicting responsibilities. For example, the police, fire department, ambulance service, rescue squad, company fire brigade, and the first aid team may be on the scene simultaneously.
A pre-determined chain of command in such a situation is required to avoid organizational difficulties. Under certain circumstances, an outside agency may assume command.
Fire departments.
Mobile rescue squads.
Ambulance services.
Police departments. ( Crowd controls, Traffic Control etc.)
Telephone companies. ( Additional communication channels like Railway Accidents)
Hospitals.
Utility companies. ( Extra water sources, Lighting arrangement –Portable Generator)
Industrial neighbours. ( Big organization take care of small organisation emergency needs)
Government agencies. (e.g. National Disaster Team, State Disaster Team )

These organizations should be contacted in the planning stages to discuss each of their roles during an emergency. Mutual aid with other industrial facilities in the area should be explored.

Question : As part of the on-site emergency planning process, a large manufacturing site intends to provide information to the external emergency services. (Refer : HSG 191, www.hse.gov.uk)

What are the types of information that the site should consider providing to the ambulance service.

Answer:

Establishment information required by the ambulance service:

(a) Identify the location and access points - with alternatives.

(b) Confirm the commercial operation - what the establishment does.

(d) Identify the main hazard - eg fire, explosion or toxic release.

(e) Provide details of the establishment medical personnel and facilities.

(f) Confirm the number of staff on site - day and night.

(g) Identify the location of the ECC(s).

(h) Identify the key personnel (names and/or posts) and contact details.

(i) Provide access to establishment plans showing the layout of the site.

(j) Provide information to allow the ambulance service to carry out a risk assessment to determine the requirement for PPE due to chemicals used on the establishment.

(k) Detail the designated safe areas for decontamination.

(l) Identify the location of any landing zone for a helicopter air ambulance.

Group Discussion:

Q- Justify the reasons why workplace emergency procedures should be developed and practised.

Q- Explain why visitors to a workplace should be informed of the emergency procedures.

Q- Who is responsible for emergency planning?

(Hint- Employer- On-site , Local Authority- Off-site)

Q- How are the emergency plans produced?

Q- When should emergency plans be prepared?

Q- What is the use of emergency plans?

Q- What are the information required for emergency plans?

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