New disaster rules for post-lockout business | Economic Times

NEW DELHI: In wake Vishakapatnam incidents where gas leak at an LG polymer plant led to death of 12 persons, the National Disaster Management Authority (NDMA) came out with precautions to be observed while starting the manufacturing units.While reiterating its guidelines, NDMA said, “When Lockout/Tagout procedures are not in place, many energy sources can prove to be hazardous to operators/supervisors who are servicing or maintaining electrical, mechanical or chemical equipment."The authority also added, “When heavy machinery and equipment are not maintained periodically, they can become dangerous for the operators/engineers. Combustible liquids, contained gaseous substances, open wires, conveyor belts and automated vehicles make manufacturing facilities a high-risk environment. Improper enforcement of safety codes and improperly labelled chemicals can further pose serious health hazards."The authority further asserted that “While restarting the unit, consider the first week as the trial or test run period; ensure all safety protocols; and not try to achieve high production targets."“To minimize the risk it is important that employees who work on specific equipment are sensitized and made aware of the need to identify abnormalities like strange sounds or smell, exposed wires, vibrations, leaks, smoke, abnormal wobbling, irregular grinding or other potentially hazardous signs which indicate the need for an immediate maintenance or if required shutdown," the NDMA added.While factories have also been instructed by the Union home ministry to exercise due precaution and social distancing measures to combat the spread of covid-19, the NDMA added, “Especially during the Covid-19 times, ensure all lockout and tagout procedures are in place on a daily basis; Inspection of all equipment as per the safety protocols during the restart phase. In case the industry has any difficulty in managing crucial backward linkages that may be critical for their safe functioning, they should approach the local district administration for specific assistance."At the same time, the Centre and District Magistrates have also tied up to ensure that in such instances, the industrial unit may be facilitated to run their end to end operations, in the overall interests of industrial security.Guidelines for restarting manufacturing industries after lockdownIn early response to COVID-19, nationwide lockdown was ordered with effect from 25thMarch. As the lockdown is being gradually released in some zones, certain economic activities arebeing permitted as per NDMA orders No.1-29/2020-PP dated 1st May 2020 and MHA order No. 40-3/2020-DM-I(A) dated 1st May 2020.Due to several weeks of lockdown and the closure of industrial units during the lockdownperiod, it is possible that some of the operators might nothave followed the established SOP. As aresult, some of the manufacturing facilities, pipelines, valves, etc. may have residual chemicals, whichmay pose risk. The same is true for the storage facilities with hazardous chemicals and flammablematerials.National Disaster Management Authority has issued 1. Guidelines on Chemical Disasters, 20072. Guidelines on Management of Chemical (Terrorism) Disasters, 2009 and 3. Strengthening of Safetyand Security For Transportation of POL Tankers,2010, which are relevant for chemical industries. TheManufacture, Storage and Import of Hazardous Chemical Rules, 1989 under Environment ProtectionAct, 1086 provide the statutory requirements for these industries.When Lockout/Tagout procedures are not in place, many energy sources can prove to behazardous to operators/supervisors who are servicing or maintaining electrical, mechanical orchemical equipment. When heavy machinery and equipment are not maintained periodically, theycan become dangerous for the operators/engineers.Combustible liquids, contained gaseous substances, open wires, conveyor belts andautomated vehicles make manufacturing facilities a high-risk environment. Improper enforcement ofsafety codes and improperly labelled chemicals can further pose serious health hazards.When an unexpected event occurs, managing rapid response becomes challenging. In orderto minimise the risk and to encourage a successful restart of the industrial units, the followingguidelines are being issued.State Governments shall also ensure that the off-site disaster management plan of therespective Major Accidental Hazard (MAH) units are up to date and preparedness to implement themis high. It is also advised that all the responsible officers of the district shall ensure the the IndustrialOn-Site Disaster Management Plans are also in place and cover Standard Operating Procedures forsafe re-starting of the industries during & after COVID 19 lock down.Generic guidelines:1. While restarting the unit, consider the first week as the trial or test run period; ensure all safetyprotocols; and not try to achieve high production targets.2. To minimize the risk it is important that employees who work on specific equipment are sensitizedand madeaware of the need toidentify abnormalities like strange sounds or smell, exposed wires,vibrations, leaks, smoke, abnormal wobbling, irregular grinding or other potentially hazardoussigns which indicate the need for an immediate maintenance or if required shutdown.3. Especially during the Covid-19 times, ensure all lockout and tagout procedures are in place on adaily basis (not applicable for units running 24hrs).4. Inspection of all equipment as per the safety protocols duringthe restart phase5. In case the industry has any difficulty in managing crucial bakcward linkages that may be criticalfor their safe functioning, they should approach the local district administration for specificassistance. District Magistrates may be instructed to ensure that in such instances, the industrial unit may be fcilitated to run their end to end operations, in the overall interests of industrialsecurity.For specific industrial processes:1. Storage of raw materiala. Inspect the storage facilities for any signs of spills, wear and tear during the lockdown.b. Check for already opened storage vessels/containers/bags/silos for possibleoxidation/chemical reaction/ rusting/ rotting etc.c. HAZMAT Chemicals in the storage need to be checked for chemical stability beforeusing for any processesd. Ensure ventilation and proper lighting before entering the storage arease. Sense for abnormalities like strange sounds or smell, exposed wires, leaks and smokef. Check supply pipelines/valves/conveyor belts for any signs of damage/wear & tearg. Check the storage building for any signs of distress and damage to the roof.2. Manufacturing Processesa. Carry out a complete SafetyAudit of the entire unit before taking up starting activitiesb. Cleaning of pipelines, equipment and discharge lines: Mechanical cleaning followedby air /water flushing and chemical cleaning based on the type of the processequipmentc. Run-in of rotatory equipment under supervisiond. Boilers/ furnaces/ heat exchangers to be checked for lining and signs of wear and teare. Check supply pipelines/valves/conveyor belts for any residual material and wear andtear. Also check all the pipelines / valves for obstructions/ pressure levels.f. Ensure all pressure, temperature gauges are functionalg. Tightness test:Many process units handle combustibles or toxic substances (or both),the leakage of which could result in disaster, damage, or economic loss. To preventthe occurrence of such incidents, it is necessary to confirm that the plant complieswith the required tightness before start-up.h. Service test need to be performed for all water, compressed air, and steam piping andequipment with normal operating fluids. The system is first pressurized with operatingfluids and then checked for leakage. For air lines, leaks can be found using soapsolution. For water and condensate lines, the leakage can be observed visually.Leakage points found during the test are retightened. The test is deemed successfulif no foam is observed from soap solution, or if no water or condensate is observedvisually.i. Vacuum hold test: All vacuum systems must be leak tested. Air inside the system isfirst evacuated to attain the required vacuum. The best way is to start at one end ofthe section and work through to the other end, checking flanges, valves, fittings,instruments, and other equipment. Each leak is tagged, making it easy for themaintenance team and personnel of the next shift to continue with the work.j. Trial testing be carried out before the full-fledged production is initiated with fullhuman resourcesk. Ensure the arrangement for round-the-clock emergency crews/ professional technicalteams provided with MAH and cluster of MAH should have an extended coverage of200 km to reach transport accident spots for help3. Storage of productsa. Check the storage facilities / silos for any damage or wear and tear4. Guidelines for the workers1. Ensure 24 -hour sanitisation of the factory premises.a. Factories need to maintain a sanitisation routine every two-three hours especially inthe common areas that include lunch rooms and common tables which will have tobe wiped clean with disinfectants after every single use.b. For accommodation, sanitisation needs to be performed regularly to ensure workersafety and reduce spread of contamination.2. Entrance health checksa. Temperature checks of all employees to be done twice a day.b. Workers showing symptoms should not report to work.3. Provisions of hand sanitisers and mask to all employers.a. Providing gloves, masks and hand sanitisers to be done at all factories andmanufacturing units.4. COVID 19 health and prevention staff educationa. Education on safety steps to take from entry to exit in the factoryb. Measures to take precautions at personal level5. Quarantine measures for supply and storage of goodsa. Sterilise boxes and wrapping brought into factory premisesb. Isolate and sanitise finished goods as appropriatec. Delivery of goods in shifts6. Physical distancing measuresa. Create physical barriers to ensure the physical distance within the work floor anddining facilitiesb. Provide face protection shields along with masks and PPEs.7. Working in shiftsa. Factories that work 24 hours at full production capacity should consider one hour gapbetween shifts, except factories/plants requiring continuous operations.b. Managerial and administrative staff should work one shift at 33 per cent capacity asper MHA guidelines; but while deciding which particular person to be included in 33%at any given point of time, overriding priority should be given to personnel dealingwith safety.c. Ensure no sharing of tools or workstations to the extent possible. Provide additionalsets of tools if needed.8. Scenario plan on discovering a positive casea. Factories have to prepare accommodation to isolate workers, if needed.b. HR has to help manage the whole process for individual, all travelling employees alsoto undergo a mandatory14-day quarantine9. Presence of skilled workers Workers involved in dealing with hazardous material must be skilled and experienced inthe field. No compromise on deployment of such workers should be permitted when anindustrial unit is opened up.