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Personal Introduction

Personal Introduction. Klaus Jödden, Chemist Professional Background: 1977 - 1985 Hoechst Research and Development 1986 - 1993 Plant Manager of Chlorine Electrolysis Plant (Knapsack Site of Hoechst, near Cologne) 1993 - 1995 Occupational and Process Safety

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Personal Introduction

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  1. Personal Introduction Klaus Jödden, Chemist Professional Background: 1977 - 1985 Hoechst Research and Development 1986 - 1993 Plant Manager of Chlorine Electrolysis Plant (Knapsack Site of Hoechst, near Cologne) 1993 - 1995 Occupational and Process Safety 1996 - 2003 Head of Safety Department, (since 1998 InfraServ Knapsack)

  2. Chemical Region Rhineland Düsseldorf l l Universität / FH Chemiepark Dormagen Leverkusen Chemiepark Leverkusen (Bayer AG) (Bayer AG) Industriepark Köln Nord A. Nattermann & Cie. Akzo Nobel Deco Köln DuPont Aachen l Universität / FH l Technische Hochschule / FH Degussa RWE Rheinbraun Chemiepark Knapsack Basell Shell & DEA Oil (InfraServ Knapsack) Degussa RWE Umwelt l Wesseling HT Troplast l Universität / FH lChemcal Park KnapsacklChemical industry, Petro-chemistrylPower plant lDumping ground l Universities Bonn l l

  3. Areas of options Free areas Open Enterprise Structures

  4. Infrastructure Site area 160 ha developed 140 ha undeveloped 20 ha Road network 40 km Railway network 22 km Overhead pipelines 138 km Pipeline network 153 km Sewer pipeline 41 km Employees InfraServ Knapsack 850 Production companies 1510 Trainees 140 Partner companies 500 Chemical Park Knapsack total 3.000 Characteristics

  5. Basell Elenac , Targor / CABB Vinnolit Kunststoffe PE / PP Clariannt / Advent Vinnolit Clariant Spezialchemiekalien Kunststoff PVC Celanese Chemiepark Knapsack Sonstige Chlor / VC Celanese / Vinnolit InfraServ Knapsack Vintron Essigsäure / - Pflanzenschutz AgrEvo CS Acetaldehyd anhydrid Celanese , Aventis Bayer CS Phosphor GmbH AG Celanese Thermphos NewCompaniesand a Local Site Operator

  6. Producer goods

  7. Responsibility • Basic Principle of Responsibility: • The Chemical Park Knapsack is characterized by a lot of users: • Bayer CropScience • Basell • CABB • Clariant • Nexans • Vinnolit • Thermphos • others • and by the • Operator of the Chemical Park: InfraServ Knapsack. • The operator of an establishment is responsible for major accident prevention and mitigation. Obligations cannot be delegated. • Tasks which result from the Seveso II Directive obligations may be delegated for instance to a service company such as the operator of the chemical park.

  8. Areas of option Free areas A Community of International Companies Limitid partners Basell 37 % Clariant 21 % Celanese GmbH 5 % Celanese AG 22 % Vinnolit 15 %

  9. Coordination Function • InfraServ has in many respects overtaken a coordination function for the users of the site: • Conference of the Site • Obligatory site rules • Information of persons possibly affected by major accidents • Complaints of the neighbourhood • Information of external maintenance personnel • Authority Management • Information exchange of major accident prevention managers • Prevention and mitigation • Emergency Plan of the Site • Documentation of alerts • Safety Guidelines

  10. Knapsack Site Rules Common site rules with respect to order and safety have been worked out. They are obligatory to any present and future user. Back to coordination function

  11. Information of the Neighbourhood Every three years neighbours are informed by means of our leaflet how to behave if the alarm devices of the chemical park alert them. This booklet is created by InfraServ Knapsack as a service to the operators of establishments which are responsible for this way of communication. Back to coordination function

  12. Check-in Test External maintenance personnel are tested by InfraServ Knapsack before they are allowed to work in the chemical park. They have to answer 12 questions about safety and correct behaviour in the chemical park asked in the computer aided test “Checkin”.

  13. Check-in Back to coordination function

  14. Authority Management • Authority Management • By order of the establishment operators • change of installations • Notification • Application • Information of exchange of appointed experts in charge of accident prevention Back to coordination function

  15. Coordination Function • InfraServ has in many respects overtaken a coordination function for the users of the site: • Conference of the Site • Obliging site rules • Information of persons possibly affected by major accidents • Information of external maintenance personnel • Complaints of the neighbourhood • Authority Management • Information exchange of major accident prevention managers • Safety Reports according to Seveso II • Safety Guidelines • Emergency Plan of the Site • Documentation of alerts

  16. Prevention and Mitigation • Prevention and mitigation of severe accidents • Professional full time fire brigade, run by InfraServ Basic legal obligations: • Fighting fire and substance releases • Rescue work in case of accidents • Responsible of technical equipment and performance: InfraServ Knapsack • Periodical test of performance by the competent authority Back to coordination function

  17. Prevention and Mitigation • Prevention and mitigation of severe accidents • Professional full time fire brigade, run by ISK • Responsible for water supply and water pressure: InfraServ (1000 m³/h, 2.400 m³/h max.) • In case of failure: elevated reservoir of 1000 m³ and Supply by cooling water • Start of damage fighting within 5 minutes • Retaining of contaminated water from fire fighting: 32.000 m³ waste water or contaminated water can be retained.

  18. Assigning of Risk Points The number of risk points depends on the quantity and quality of hazardous chemicals in an establishment. Costs of the fire brigade are assigned to the operating companies by the amount of risk points.

  19. Site Security • Site security • The first barrier in prevention of unauthorised access to safety relevant installations • Access of persons and vehicles • Integrity of fence and wall • Control of areas within the chemical park, which are not part of an establishment • Closing of areas in case of an accident

  20. Hazard Analysis Example: Railway vehicles

  21. Hazard Analysis

  22. Emergency Plan EmergencyPlan Chemical Park Knapsack Emergency Plan of Plants Emergency Plan of Task Forces

  23. give information to plant management Emergency Plan site first: Fire Accident Damage emergency call 1 1 2 - what is your name? - what accident has occurred where? fire alarm - what help is needed? - wait for assistance - give instructions afterwards: Call numbers plant supervisor - or deputy - or safety service plant engineer

  24. Emergency Plan • Emergency organisation • Central emergency call 112 • Alert centre of the fire brigade • Fire brigade • Emergency manager • Central emergency management team (CEMT)

  25. Emergency Manager • 24 hours present in the chemical park • Contact to the neighbours • high qualification (chemist or engineer) • highly authorized in case of an incident • alerts the neighbourhood and the public authorities without delay

  26. Emergency Manager • Emergency Manager • Categorises accidents according to alert classes • Notifies alert to authorities immediately • Issues immediate warnings to persons who may be concerned via sirens and information of the main district control centre • Activates the Central Emergency Management Team • Supports the head of the fire brigade at the scene • Assesses risks caused by release of dangerous substances • Covers communication with the Central Emergency Management Team

  27. Sirens of the Chemical Park • 9 sirens available in case of incidents • Warning of people in the neighbourhood and people inside the chemical park • Start of the sirens by the emergency manager of the chemical park • You have to do first: Take shelter ina building! • Information about sirens: • - Brochure for people in the neighbour-hood, visitors and employees of the companies • - Leaflets for all visitors of the chemical park Warning signal No danger

  28. D-Announcement to Authorities

  29. Observer Plant Personnel Medical Department Central Emergency Management Team Communication to the Public in Case of Major Accidents Information of the Public Fire Accident Damage Alert of Authorities Auskünfte an Presse/ Oberkreisdirektor Funk/Fernsehen Leitstelle Edwin Inquiries Measurements Warnmeldung/ Entwarnung WDR 2 Reg.-Präsident Köln Control centres of neighbour districts Emergenccy call Main Control Centre of the District 1 1 2 Sirenensignal/ Lautsprecher- Local fire brigade Fire brigade / Rescue durchsagen Patrols in the vicinity Broadcasting/Television Security Emergency Manager Leitstation Ville weiträumige Absperrung der Polizei polizeiliche Maßnahmen Katastrophenwarnung Katastrophenschutz- Katastrophenalarm leitung Erftkreis Stand-by service of establishments Evakuierungsmaßnahmen Rettungsdienst Erftkreis Stand-by service Environmental protection Measures in the vicinity Communication to Media Competent Authorities / Police Stand-by service Energy Engineering Head of company involved Werksgrenze

  30. Time Management presence 100 Heads of the company Central Emergency Management Team Emergency Manager Fire Brigade 0 5 min 1h 6h Assessment of incidents Start of sirens First information of public authorities Further information of public authorities and the press Organizes the damage limiting Information of the company Further crisis management

  31. Access-Database “Einsatz” characteristic data of the incident such as date, time, company, plant incident category kind of emission kind of alert Neighbour questions and complaints Description of incident by a group leader of the fire brigade Description of incident by the emergency manager on duty

  32. Protect • online information system • always up to date • information about emergency calls • collection of important data for the central emergency management team PROTECT

  33. Persons in Charge of Operation A special container of the fire brigade is the Communication centre at the site of damage. The emergency manager has to assess the incident and has to decide about the first communication. He triggers the sirens of the chemical park and informs the Central Emergence Manage-ment Team. The group leader of the fire brigade is responsible for all actions of the firemen at the site of damage The plant manager is responsible for damage-limiting measures inside the plant

  34. Conclusions • Reliable Structures • Operation activities at the Knapsack Chemical Park are based with respect to safety issues on the reliable order and guidelines of the former Hoechst group. • All users of the site agree to basic guidelines of the site and to a common emergency management. • No major accident in the Chemical Park up to now. • Commitments and rules are transparent to every participant; this is also valid for authorities. • Safety policy has not been neglected, on the contrary: Implementation of safety guidelines is subject to policies more than ever.

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