BASF AktiengesellschaftWorks Fire Service Emergency planning in line with Seveso-II-guideline / example BASF Presentation Emergency planning in line with Seveso-II-guideline / example BASF Wolfgang Suckfüll, BASF Works Fire Service, Ludwigshafen +49/621/6023310 [email protected] Suckfüll Page 1 BASF Aktiengesellschaft Works Fire Service Emergency planning in line with Seveso-II-guideline / example BASF 1 Introduction The SEVESO_II_guideline requires an internal emergency plan for upper tiers establishments.1 Industrial Fire Department 5.und Gefahrenabwehr-Plan WAGAP) The BASF site in Ludwigshafen enclose 350 factories on an area of 7.2 Local overview plan 1. 2 Works Alarm an Hazard Defence Plan (WAGAP) (in German: Werks-Alarm.2 Organisation work security DP/W 5. According to Seveso-II-guideline a general Works Alarm an Hazard Defence Plan for the entire site have to be drawn up. The basis of the planning is a safety analysis.2 km². The purpose of hazard prevention planning which is required by the SEVESO_II_guideline is • to avoid large scale accidents. the hazard prevention planning extends all the way from operating instructions or alarm arrangements through major incident alarm planning.Town of Frankenthal Organisation of Works Hazard Defence Personel 5. The following text provides an explanation of the general WORKS-ALARM-ANDHAZARD-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.3 BASF . There are a lot of upper-tier and lower-tier establishments.) Alarmplan for Major Incidents Agreements related to Major Incidents 4.3 Medical Department 5. hospitals etc. As an overall concept comprising a large number of building blocks which is to be used to protect the employees and other people involved. schools.3 Overview plan of BASF at Ludwigshafen Adresses of Public Buildings (Nurseries. in which the hazards involved in a factory have to be compared to the corresponding safety measures. The following list shows the index of this plan: 0 1 2 3 4 5 6 Application Area for Works Alarm and Hazard Defense Plans Details of Works and Surroundings 1.1 BASF – Town of Ludwigshafen 4.5 Fault clearing sevice file Alarmplans (Infrastructure) 6.2 BASF – Town of Mannheim 4.4 Press 5.1 Regional overview plan 1.1 Floods Suckfüll Page 2 . • to minimize the major incident’s 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. 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.2 6. pressured air.5 6. The same structure should be sought for all instructions in a factory/works. Hazard detection systems) Information and Warning of Plants 10.4 6.und run-off water recontainment (purification plant and non-purification plant sewer plans) Quench water supply (hydrant plans) Harbour Alarmplans (special mediums) 7.1 Natural gas within site 7. 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 Suckfüll Page 3 . all the plans in the factory/works should be of uniform composition and should clearly demonstrate a logically recognizable sequence of actions.6 7 8 9 10 11 12 13 Energy (Electricity.and Emergency Signals) Information for Authorities (Special Notification form) BASF-Guidelines and BASF-Regulations Guidelines / general Regulations for Safety. SOS Pilars.Alarm.1 Central Warning System 10.2 Direct Announcment (Buildings with direct PA-connection to Fire Department) 10.BASF Aktiengesellschaft Works Fire Service Emergency planning in line with Seveso-II-guideline / example BASF 6. steam) Pipelines Product.2 Ammunition discovery 7. Could an incident arise in the factory/works? 2.3 PCB (clophene-transformers) Catastrophy Protection Plans Towns of Ludwigshafen and Mannheim Comunication Structure on Site (Emergency lines. In principle.4 Warning and Information System for Plants (Warn. Health and Environment protection Plant fault Practice Exercises The WAGAP is the result of an emergency planning system which have a logical structure.3 PA-Vehicle (Information / Warning for Sub-Contractors) 10. In this context. 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 this connection. nitrogen.3 6. it is necessary essentially to answer two questions: 1. 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. such as manual workers and employees of other companies. for example. for example. presented to and practiced with those potentially involved. The structure of the hazard prevention plan thus offers the advantages of a concluded arrangement. 3 Alarm-raising Plans / Alarm Plans Building on the factory instructions for the event of an alarm. (see Appendix 1) Suckfüll Page 4 . 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. works specialist departments and staff who have to be warned are notified immediately on the basis of the alarm plan. The plans are to be drawn up. From there. by what means) have to be taken quickly under time pressure and under the cloud of what has happened. the alarm-raising or alarm plans define the notification and alarm sequence in the event of incidents in the factory. all plans have to be of brief and precise structure in order to be sufficiently comprehensible even to constantly changing personnel. The factory incident reports are made to the responsible locations (works fire service headquarters) via the stipulated central alarm point of the site/factory. institutions. the individual stages (plans) of which are to be brought into play by the factory or.BASF Aktiengesellschaft Works Fire Service Emergency planning in line with Seveso-II-guideline / example BASF • • • • 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. the authorities. the works fire service depending on the extent and nature of the incident. Therefore. The validity and completeness of the information is to be checked twice a year by the factory... This has the advantage that in the event of a serious incident. who has to be warned. 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... The possible incident site is to be surrounded by a circle which encompasses the hazardous area. or only differs to an insignificant extent.. Suckfüll Page 5 .BASF Aktiengesellschaft Works Fire Service Emergency planning in line with Seveso-II-guideline / example BASF The following principles are to be employed when drawing up an alarm plan at BASF Aktiengesellschaft: 1. for example by means of loudspeakers. 2 sec.. 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.. 3.. 4.. ... The fire service warns other affected factories by an electronical Central Warning System (CWS) and informs people outside. as well as wind direction indicators (wind socks) at clearly visible points. blast . 5. in an information conference. 2.... pause . 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. factories in the Red Zone install alarm systems in the building in order to warn the employees. Where necessary..... ..Auditory warning systems according to DIN 33404 -... The basic principle is to attempt to draw up all the alarm plans in the works according to a uniform.. the alarm-raising procedure does not differ. 7. irrespective of the cause. The factories and employees outside the building are warned together by a loud horn (typhoon system). The alarm plans are to be worked out by the factories in cooperation with the fire service and the working safety department... 6... Long 7 sec. predefined model.. This area is the "Red Zone" or "Core zone". around the factory which is stipulated in the factory alarm plan).BASF Aktiengesellschaft Works Fire Service Emergency planning in line with Seveso-II-guideline / example BASF 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. These include in particular events which require the population and the public bodies to be warned or informed. 2.1 Alarm Stages The BASF hazard prevention system works on the basis of a four-stage alarm system. 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. (see Appendix 2) A matrix which specifies the following parameters: and − − − − − 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 effect in the factory. the incident is dealt with by the factory affected. These major incidents are characterized by extensive repercussions inside and/or outside the works site. In the event of incidents of this nature. Specifically. The organizational plan provides a number of committees for combating damage in the works and coordinating the BASF units involved. a distinction is drawn between the following alarm stages: 1. (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. the works fire service is not called out. 4. In the event of a factory alarm. 150 m diameter. 4. the Hazard Prevention Steering Committee (LAG) and the Technical Operations Management (TEL) assume responsibility for the tasks which are incumbent on BASF. major incidents within BASF are dealt with according to an organizational plan which was drawn up for this purpose. according to the organizational plan. In the event of an incident. Plant alarm Minor alarm Major alarm Major incident alarm (PA) (MIA) (MAJA) (MAJACCA). 3. in the works or outside the works is used to classify the different alarm stages. In the event of alarms of this Suckfüll Page 6 . For this purpose. and if necessary representatives of the public fire service. and is headed by the works fire service.2 Alarm Plan for Major Incidents The Major Incident Alarm Plan builds the most important part of our WAGAP. The term major incident alarm encompasses incidents which: or 1. At this alarm stage. for example the environmental protection department. a Technical Operations Management coordinates the damage prevention measures. because it describes the internal emergency responds management system an the interaction with authorities and –very important. this operations management being composed of the BASF units which are required depending on the damage situation. site protection. The membership and tasks of the Steering Committee and its individual members are listed under classification points 2 and 3. 4. the works fire service is deployed and will carry out the damage prevention measures in the factory and the Red Zone. The information contained in these sections of the alarm plan (telephone numbers. the medical service. the plan provides for a Technical Operations Management and a Steering Committee to be convened.with the local press. 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. 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. In the event of a major incident alarm. 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).BASF Aktiengesellschaft Works Fire Service Emergency planning in line with Seveso-II-guideline / example BASF nature. the ambulance service. The structure and organization of the BASF units responsible for these alarms is stipulated by the alarm plan for major incidents. in the event of a large number of injured cause a hazard within the works or disruption outside the works 2. The major alarms stage involves a large number of injured. cause danger outside the works. danger in the works or disruption outside the works site. (see Appendix 4) The BASF works fire service is responsible for designing the contents of and continuously updating the alarm plan for major incidents. 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. the alarm plan includes a constantly updated list of the heads of the Operating Divisions Suckfüll Page 7 . in order to clarify particular specialist matters or in order to deal with particular tasks. 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. private addresses. The membership of these working parties is given in Section 5 of the alarm plan. in addition to the specialist BASF units (e. such as for example the emissions notification plans which have been agreed with the responsible authorities for incidents which involve airborne or waterborne emissions. As the operations manager in accordance with § 25. Firefighting and Disaster Prevention Act (LBKG). overall management of hazard prevention may be transferred to the Mayor of the city of Ludwigshafen (overall responsibility of the city of Ludwigshafen). he/she makes use of a Technical Operations Management which. who is thus responsible for combating damage on site and for providing information to the responsible authorities of the city of Ludwigshafen.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. the head of the works fire service is initially responsible for coordinating the first hazard prevention measures. waste disposal department).BASF Aktiengesellschaft Works Fire Service Emergency planning in line with Seveso-II-guideline / example BASF (including the necessary information. etc. for example. The Steering Committee uses a series of working parties. the alarm plan includes important information for the members of the Steering Committee. 4. to which BASF technical staff and specialists are summoned on request of the Steering Committee. According to the statutory provisions and the agreement between BASF and the city of Ludwigshafen. together with the supplementary information required (how the people involved can be reached). In the event of a major incident alarm. works medical 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. In addition to these sections. in the form of: and − 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) − important internal telephone and fax numbers. 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 annexes to the alarm plan contain further information for the members of the Steering Committee. Section 4 of the Land Protection. work safety department.g. at the BASF works site are carried out under the direction of the BASF operational Suckfüll Page 8 . the operational measures. Finally. such as for example telephone numbers. air/water emissions monitoring department. In these situations.). BASF Aktiengesellschaft Works Fire Service Emergency planning in line with Seveso-II-guideline / example BASF manager under instructions from the overall management of the city of Ludwigshafen. 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. Suckfüll Page 9 . the Chairman of the Works Counsel participates in the meetings of the Steering Committee as a personal member.4 Hazard Prevention Steering Committee On the basis of the decision of the head of the Steering Committee. On the basis of the organizational plan. Furthermore. In the event of major incidents. It is also responsible for providing ongoing information to internal and external agencies. To carry out these tasks. These working parties operate under the management of a Coordinator for Working Parties. 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 the Head of the Public Relations department. Safety & Energy Functional Division as soon as he/she is aware of the extent of the incident. the Steering Committee uses various Working Parties which it summons according to the particular situation 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. Furthermore. to close down energy supply grids). the head of the works fire service is obliged to inform the head of the Environment. the Hazard Prevention Steering Committee will meet in the steering room (meeting room in the Environmental Monitoring department building) after it has been summoned. it ensures that normal operating conditions are restored as quickly as possible. the head of the Environment. 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. Furthermore. the members of the Steering Committee include the following functional representatives: and − − − − − − − the Head of the Environment. In addition to the head of the Steering Committee. to shut down production processes or installations. who in principle is the member of the Board of Executive Directors who is responsible for the Ludwigshafen works. 5.g. Safety & Energy Functional Division will notify the head of the Steering Committee of the incident. the head of the public affairs division has to carry out the following tasks: 1. For example. in previous incidents. 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. Dealing with representatives from the media z set-up a meeting point outside the works grounds z escort the media representatives to view the incident scene (after the agreement from the emergency board has been given) 3. These working parties are made up of the experts and specialists working in the BASF specialist bodies. By way of example. Suckfüll Page 10 . The tasks within the Steering Committee are coordinated on the basis of a detailed distribution of tasks in the alarm plan for major incidents. At specific intervals of time. This alarm plan assigns each member of the Steering Committee tasks according to his/her functional area. among others. 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.BASF Aktiengesellschaft Works Fire Service Emergency planning in line with Seveso-II-guideline / example BASF The following working parties (WP). Information for the works personnel z through telex to the board of directors z through the „BASF Aktuell“ info bulletin available at the works gates z through „ZWS“ central warning system 2. the head of the works fire service informs the head of the Steering Committee of the current damage situation on site. may be activated: − − − − − − − − − and 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 Industrial safety WP. BASF Aktiengesellschaft Works Fire Service Emergency planning in line with Seveso-II-guideline / example BASF 4. Incidents without external effects 2. This ensures that information which is specific to the product. the Technical Operations Management is composed of: and − the operations manager − the heads of the functional divisions S1 . communications supervision Supplies. In principle. press and public relations work Establishing the position Tactical planning. factories. Incidents without external effects but with deployment of the public fire services 3.S4 (Technical Operations Management staff) − one advisor from each of the authorities. services. The Technical Operations Management Staff is adapted to the requirements of function-oriented operations management depending on the particular incident involved. if appropriate. Suckfüll Page 11 . process or factory is available to the Operations Manager immediately and at any time. provision of orders (where not provided by the operations manager). 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: and 1. the staff is divided into the following supervisory areas: S1 S2 S3 and S4 Personnel supervision.5 Technical Operations Management The Steering Committee mentioned above. Incidents with external effects but without the deployment of the public fire services in the works 4. internal supervision. The Operations Manager. of the factories affected. public and private organizations directly involved in the hazard prevention − auxiliary personnel. Incidents with external effects and with deployment of the public fire services in the works. when working in the Technical Operations Management. is assisted by employees of the Operating Divisions affected by the incident and. .. On the basis of the immediate notification received. So it is necessary to organize and train as much as possible in advance.g. If necessary. . BASF employees. Suckfüll Page 12 . incident reports are passed by external agencies.. if there are no practical trainings and regular drills. But on the other hand... The aim is.. 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). that in case of an accident. 5 Trainings The paper of all these emergency plans is not worth to be written.rapid response. 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.professional handling and .. . the ambulance service or the Environmental Monitoring department.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. these authorities decide whether to activate the official hazard prevention measures (e....lack of equipment.. On the basis of this procedural plan.lack of something else .. you have .BASF Aktiengesellschaft Works Fire Service Emergency planning in line with Seveso-II-guideline / example BASF 4. the matrix which has been explained above is used to make a decision concerning the classification of the hazard prevention into the alarm stages.. In the headquarters of these units. 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.. . 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. who in the event of a major incident alarm will notify the head of the Steering Committee.. While initial measures for combating the damage are being introduced. lack of time.. into a Procedural Plan for Hazard Prevention which is valid for all the alarm stages.optimum effects of measures are expected. Safety and Energy division is informed. . that every employee knows exactly what to do in the case of a minor or major incident.. . The problem is. the head of the Environment..... 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. If the damage situation demands. at BASF.. At the same time.. what now”. 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 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.(medical. explosion operations management. • 6 Weekly testing of the alarm signals. public address systems and central warning system. monitored by fire brigade the production or safety department 3 Alert training employees . 2 Emergency shut down of plant’s employees. Together with the cities of Ludwigshafen and Mannheim BASF and other chemical companies in produced an incident booklet “Major incident . other specialists.BASF Aktiengesellschaft Works Fire Service Emergency planning in line with Seveso-II-guideline / example BASF For practical drills we have got several levels of exercises for the employees: • exercise Action / Scenary Participants level 1 alert exercise to train the plant’s employees plants own technical an organisational procedures. In an event of a major accident alarm situation you need this confidence. external forces 5 Steering commitee Emergency response steering commitee.environmental) 4 Major accident alert training employees. which is distributed to all residents. security. leakage. Communication with the neighbours A further major component of incident management is communication between the operating company and the autorities and to the public.fire brigade (Minor or Major (Fire. exercise working groups. leakage etc) alarm) and the others standard emergenca abating unites. The companies describes their factories and give information about the names and dangerous properties of their products. Suckfüll Page 13 . 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. Many injured etc) people (extra players). fire brigade and technical (Fire. BASF Aktiengesellschaft Works Fire Service Emergency planning in line with Seveso-II-guideline / example BASF 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. Suckfüll Page 14 . 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. committees and staffs mentioned. as well as the content and structure of the plans. have proven successful in the past when used inside and outside the works site. 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.