Guide to Manufacturing Plant Hurricane Preparation

Elizabeth Ruiz, Editor, Maintenance World, Content Marketing Coordinator, IDCON INC & TRM

Posted 9/18/2024

Hurricane Season 2024

It’s a highly active hurricane season, and the manufacturing industry is feeling the effects. Adverse weather can cause issues in plants, mills, and mines related to everything from worker safety to electrical problems to flooding – all potentially causing production loss and interruption of the supply chain. Manufacturing plant hurricane preparation needs to be a top priority.

This year has already experienced six hurricanes affecting countries all around the world. Most recently, Hurricane Francine left around 450,000 homes and businesses without power, and many communities are under tornado watches as of the date of this publication. (1) The storm hit the energy and oil & gas industries the hardest, and caused chemical plants in Louisiana to shut down in precautionary action. (2) (3)

Manufacturing Plant Hurricane Preparation

Plants, mills, and mines that prepare properly for high winds, floods, power and raw material loss, infrastructure issues, and other problems can minimize downtime, make restarts easier, reduce property loss, lessen damage to assets and records, and most importantly, possibly save lives. So, what can you do to make sure your plant is ready for a hurricane? (5)

According to the Office of Energy Efficiency and Renewable Energy (EERE), the first step in hurricane planning is to identify vulnerabilities and figure out how to reduce them. Know your insurance coverage. Then, start preparing the facility, carrying out tasks such as ensuring there is emergency backup power, supplies, parts, plan evacuation procedures, and shutdown and restart operations. Research government resources that can help you plan and prepare, like the guide below from FEMA summarized by the EERE.

1. Establish a planning team.

Choose a leader and staff based on their skills and capabilities.
Assign specific tasks to either individuals or teams.

2. Analyze capabilities and hazards.

Assess current preparations, potential risks, impacts of power failures and structural damage, and ways to mitigate damage.
To prepare for flooding, contact your local floodplain manager or other official to learn your risk; use flood-resistant building materials; erect physical barriers; anchor tanks and other structures.
To prepare for high winds, reinforce roof and sliding panels; cover windows and doors; anchor tanks; remove loose objects from your site.
Have emergency backup power – e.g., a generator, battery storge, or combined heat and power (CHP) system; obtain utility contact information for power outages.

3. Develop your plan.

Plan for before, during, and after an emergency; establish protocols for employees’ safety and site readiness.
Prioritize a list of site preparations; update emergency power and supply options.
Establish emergency communication systems and backups.
Establish staff responsibilities and procedures for a shutdown, recovery, and restart.
Develop an evacuation plan, including support for employees.
Establish procedures to shut down utility and process operations safely.
Find ways to protect business records, materials, inventory.
Update your list of contacts for before, during, and after the emergency.

4. Implement your plan for manufacturing plant hurricane preparation.

Track the storm’s path and intensity through the National Hurricane Center.
Stay in touch with your state’s emergency operations center.
Stay in touch with corporate headquarters, other plants, employees, customers, and suppliers.
Carry out procedures for site preparation, emergency backup, shutdown, and evacuation.

Other essential tips include:

Be prepared to quickly shut down key utility supplies such as air, oxygen, and nitrogen, as well as other raw material feeds.
Maintain good internal contact lists so you can communicate with and locate employees quickly if needed.
Figure out how to provide temporary housing, basic needs, and medical services to your team if it becomes necessary. (4)
Keep commonly used spare parts in the storeroom. Parts suppliers may be unable to deliver necessary parts if the weather won’t permit it, so keeping the essentials in stock at all times can be beneficial. (5)

*Ida’s aftermath shows the risks of petrochemical production in a hurricane zone. Image courtesy Grist.*

Be Prepared

The 2024 hurricane season has already shown its capacity for widespread disruption, making it essential for all industries to take proactive steps to safeguard operations. Plants, mills, and mines must prioritize hurricane preparedness to reduce risks like power outages, flooding, and structural damage. By identifying vulnerabilities, implementing comprehensive emergency plans, and ensuring proper communication procedures are in place, companies can protect both their assets and employees.

As we continue through this highly active season, manufacturing plant hurricane preparation is not just about reducing downtime—it’s about securing your operations and keeping your team safe.

Sources

1. 2024 Atlantic Hurricane Season. Last updated September 12, 2024, as of this publication. Online resource. https://disasterphilanthropy.org/disasters/2024-atlantic-hurricane-season/

2. Louisiana chemical plants shut down as Hurricane Francine nears landfall, major capacities at risk. Chang, Joseph. September 11, 2024. Published online by Independent Commodity Intelligence Services. https://www.icis.com/explore/resources/news/2024/09/11/11031389/louisiana-chemical-plants-shut-down-as-hurricane-francine-nears-landfall-major-capacities-at-risk/

3. US offshore oil industry reawakens after Francine shut-ins. Parraga, Marianna and McCartney, Georgia. September 13, 2024. Published online by Reuters. https://www.reuters.com/markets/commodities/louisiana-ports-reopen-following-francine-vessels-dock-texas-terminals-2024-09-13/

4. Is Your Plant Prepared for a Hurricane? Industrial Technologies Program. U.S. Department of Energy, Office of Energy Efficiency and Renewable Energy. July, 2006. Pamphlet. https://www.nrel.gov/docs/fy06osti/40324.pdf

5. Hurricane Season 2024: How to Prepare Your Supply Chain. April 30, 2024. Resilinc Editorial Team. Published online in Resilinc blog. https://www.resilinc.com/blog/hurricane-season-2024-how-to-prepare-your-supply-chain/

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Guide to Manufacturing Plant Hurricane Preparation