EMERGENCY

RESPONSE &
DISASTER CONTROL
By
Asghar Naveed;
Safety Unit Manager.

Haider I
Chaudhry;
Safety Engineer.

Engro Fertilizers
Limited

Vision
Statement

To be the premier
Pakistani
enterprise with a
global reach,
passionately
pursuing value
creation for all
stake holders.

Company Profile

Engro Fertilizer Ltd. urea manufacturing site is located at

Daharki, 600 km north of Karachi-Pakistan. The site
produces about 2850 MeT/day urea.
Consumption of fertilizers increased in Pakistan, paving the
way for the company called Engro, an acronym for
energy for growth.

Backgrou
nd

Engro Fertilizers Limited gives the highest importance to safe operations, safe work
practices, and protection of the environment and the health of its employees in the conduct
of its business.
In an endeavor to keep it abreast with the World Class Safety Standards, Engro Fertilizers
Limited has aligned safety management systems with Dupont

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Emergency Response & Disaster

What is Emergency
Response [ER]
INPUTS

Design
Consideration
Information
Package

Consolidated
ER Plan &
Manual

Emergency
Handling

Activate
ER Plan

Training &
Stewardship

Mutual
Assistance

Community Awareness for

Emergency Response

OUTCOME
Emergency Response & Disaster

Design
Considerations

Inherently
Safe
Process
Design

Layers
of
Protectio
n

PHA

CA

Management
of Change
Approval

PSSR

Layers of
Protection
The current site has the
gadgets and documented
procedures which entails
and governs all the
existing reviews and new
facilities.

Emergency Response & Disaster

Process Design Basis:

2

Information Package
PSI (Process
Safety
Information)
package for
each
operating unit

P&IDs, PFDs, I&E Diagrams;

Process description;
Standard operating guidelines &
conditions;
Maximum intended Inventories;
Data history & references;
Revisions & new process
technologies

PSI
Package
3
1
Equipment Design Basis:
Hazards of Materials:

Safety critical components

Control of vendor manual

ER
Structure
Core Contents (ER Manual)
Role statements.
Assembly locations.
Emergency Shutdown Procedures.
Fire fighting & Toxic Release
handling techniques.
Emergency Handling Techniques
Rescue Plans (Medical Assistance,
etc.)
Layout of Emergency & Safety
Equipment
Misc information (Population around,
typical Wind reference diagram, etc.)
Critical Equipments and latest
communication devices;

Consolidated ER
Plan & Manual
Two-fold action plan.
Written comprehensive
emergency preparedness
plan.
Separate emergency plan
for each hazard/threat,
including plans for flood,
sabotage & war
emergency etc.

Part I
Emergency Response & Disaster

Emergen
cy
Communication Channel
Handling

Mutual
Assistance

Community
Emergency
Response

Surrounding
Community

Detection, Declaration and

Communication

Guides the Squad for rescue and

containment & Communicates with the
authorities and Gov agencies

Government & Public

Authorities
NDMA
Media

CMT
formed

Relevant Management
Area Unit Manager
Safety Advisor
Chief Medical Advisor
Security Incharge

PA & Services Incharge

Security Guard
(Colony)

Disaster
Occurs
Squad

Responds to
Emergency

Security Guard
(Plant)

Senior VP & CEO

General Manager
Production
Manager

Squad consists of 14 members

Control and Containment of Leakage
Fire Fighting
Conduct Rescue Operation

Alerts
SS or SIC
& Sounds
Alarm

Part II
Emergency Response & Disaster

Training &
Stewardship
Training

Training of employees for all

possible emergencies :
Skill certification system;
Weekly & Quarterly simulated
exercises;
Involvement of ES, employees &
contract employees and
community;
Skill certification of ES;
Emergency Shutdown procedure.

Emergency Response & Disaster

Mutual
Assistance

Survival Chances improve

Pool knowledge, equipment & personnel with neighbors.

Procedures developed.

Emergency Response & Disaster

CAER
CAER program has
been prepared in
conjunction with
local community.

Bridging
Gaps

Training/
coordination with
community
Involvement of local
government
functionaries
Program structure
compliments DuPont
Benchmarked with
TATA & GNFC

Emergency Response & Disaster

Legend
Area

(Covered by this Program)

Highway
Metalled Road
Jeepable Track/ Trail
Railway Line
Taluka Boundary
Canals
Settlement
Graveyard
Settlement Within 2 km of Facility
Settlement Outside 2Facility
km of

Ariel
View
Populatio
n

Kalo Burero
Bago Bhutto
Kotla Mirza

Emergency Response & Disaster

Developed by International Council of Chemical

Association
The goal is to assure emergency preparedness and
to foster community right-to-know.
It demands a commitment to openness and
community dialogue. The code has two major
components
To initiate and maintain a community outreach
program
Assuring that each facility has an emergency
response program
A socio economic survey was done in 2007 to
ascertain social & economic needs of locals. 11
villages (in 2 km radius) covered.

Villages

Bago Bhutto
Kotla Mirza
Jhando Bughio
Jan
Mohammad
Bughio
Kalo Burero
Jhung
Sajan Malik
Shahnawaz Burero
Nathu Bhutto
Nur Hassan Shah

Emergency Response & Disaster

 Identify social workers

(volunteers) for Civil Defense.
Conduct training on (First Aid,
Fire fighting, Home safety,
electrical safety) of social
workers with help of Civil
Defense & Engro.
Initiate infrastructure
improvement/ social projects,
schools up lifts (through school
adoption program), mosques,
drinking water, sewage system.
Career Counseling Workshops
Develop organization of social
workers.
Quiz competitions in boys/girls
school First Aid, Fire, Traffic.
Involve Agri business to help the
agricultures.

Phase III

Visit Village community

Identify notables
Invite notable to dinner
at Plant Canteen
Identify & shortlist social
projects for village
Plant visit by boy school
students & teachers
Plant visit by girls school
students & teachers
Quiz competitions of
boys/girls school on Fire,
Traffic (Engro will
develop/ provide the
quiz

Phase II

Phase I

Community Engagement
Model
Conduct Fire drills.
Lectures in schools on First
Aid training/ environmental
awareness.
Complementation of social
projects
Grant scholarships to
students
Invite notable to dinner at
Plant Canteen.
Community Engagement
thru Volunteers with
quarterly drill.

Community Awareness & Emergency Response

Current
Population ready to be
engaged in the Quarterly
Drills.

2009

Kalo
Population
Burero1500

2008

Source of Income
Agriculture
Services
Others

% age

Literacy Rate
Male
Female

% age

Access to Media
(TV)
Schools

Nov,
2007
Lunch for
Kalo Burero
at
Manufacturi
ng Division
Canteen.

May,
2008
Engro Visit
Boys and
Girls from
Kalo Burero
Schools .

Oct,
2008

Nov, Feb,
2008 2009

Infrastructure
Quiz
Quiz
Competitio CompetitioDevelopment
(drains,
n Kalo Bureron Kalo Burero
Boys School. Girls School.bricks soling)
& adoption of
boys school.

TA 09 Aug, 2009

60%
Boys &
Girls
Primary
School

Nov, 2009

Thursday Drill
Exercise observed by
Social Workers of Kalo
Burero.
First Aid & CPR
Training was
conducted for Kalo
Burero social workers at
EFert.
Gadgets for
emergency
communication in
Community Awareness & Emergency
Response &
villages approved

Emergency
Organization Table
People
developed. Assignments
trained &
given: Leader, Deputy
appointed as
Leader & Street Social
Safety
Workers assigned at Kalo
Facilitator
Burero.
and
First Aid & Fire
Scaffolding
Fighting Trainings for
Inspector
volunteering Social
Workers of Kalo Burero.

(Apr)

100
%

Community needs: Hospital, Water

supply, Gas, Drainage, Vocational
Institute.

100
%

CAER Timeline
Kalo
Burer
o

2010

1st National Mock Drill

Conducted by EFERT &
NDMA

Working and coaching the nearby populations for more than two
years has led us to a position where we involved the local and nationwide authorities and Engro along with NDMA (National disaster
management authority) conducted the first ever Mock Emergency
Drill earlier this year.
Preparedness level of nearby village in a large scale Mock Exercise in
which ammonia leakage and fire at the manufacturing facility was
simulated.
Participation by DDMA, DESTO and Urban Search & Rescue Team.
Outcomes of the drill: Consolidation of ER Plans of nearby Industries
located at the Fertilizer Belt in Sindh.

Emergency Response & Disaster

VIDEO: ndma.video
Duration: 05 min