Physical Security Risk Assessment (PSRA)

DRASInt® Risk Alliance
2 days ago
13 min read

Updated: 23 hours ago

Chemical Manufacturing Facility, Industrial Zone, Western India

This Use Case has been prepared by DRASInt Risk for professional reference and training purposes. All identifying credentials, including company name, geographic location, specific addresses, personnel names and contact details, have been anonymised or replaced with generic descriptors. All technical findings, vulnerability scores, threat assessments and recommendations are preserved in their original form to maintain the educational and professional value of this document. TABLE OF CONTENTS

1. INTRODUCTION

The subject facility is a well established chemical manufacturing enterprise that has emerged as a significant player in the chemical manufacturing sector, with operations spanning several decades since its founding in the late 20th century. The company is known for its commitment to excellence, innovation and sustainability in industrial chemical production.

Located within an integrated industrial zone in a mid sized city in western India, the facility operates in a dynamic environment, facing challenges such as water scarcity, environmental sustainability and industrial safety. The surrounding district is characterised by a mixed industrial and semi urban landscape.

Recognising the importance of security in safeguarding its operations, the facility management commissioned a Security Risk Assessment (SRA) conducted by an independent professional security consulting firm. The assessment was aligned with global security standards and drew upon best practices endorsed by leading international security agencies.

The assessment identified key areas for enhancement and provided actionable recommendations to fortify the facility's security infrastructure. In addition to perimeter integrity and access control measures, the assessment also put forth the importance of implementing best weighbridge practices to ensure the accurate monitoring and management of inbound and outbound material flows.

Executive Summary of Findings

Observation	Risk Level	Recommendation	Priority
Security perimeter is not contiguous and is open from three sides with multiple breaches	High	Ensure continuity of the perimeter and maintain it to prevent exploitation by intruders	Immediate
Boundary wall on western side requires immediate repairs	High	Repair the west wall to prevent breaches	Immediate
Perimeter wall height is less than 6 ft at places	Medium	Increase height to prevent unaided climbing	High
Barbed wires around the perimeter are damaged or incomplete	Medium	Repair and complete barbed wire installation	High
Functional lighting with many blind spots	Medium	Maintain and regularly assess perimeter lighting	High
Guard posts are poorly maintained	Medium	Regularly inspect and maintain guard posts	High
List of personnel with access to critical areas not reviewed	Medium	Regularly review access list	High
No intrusion detection system at critical locations	High	Install intrusion sensors	Immediate
CCTV system not integrated with alarm system	Medium	Integrate CCTV with alarm system	High
Sparse and non-functional CCTV cameras	High	Repair/replace CCTV cameras and improve infrastructure	Immediate
Poor lighting in specific plant areas at night	High	Upgrade lighting infrastructure	Immediate
No designated officer for managing intelligence and liaison activities	High	Designate an officer with defined roles and responsibilities	Immediate
Unauthorized encroachment within plant premises	High	Address encroachment with local authorities and increase surveillance	Immediate
Poor coordination with local law enforcement agency	High	Establish protocols for coordination with local authorities	Immediate
Lack of incident documentation for post incident analysis	High	Enhance incident documentation protocols	Immediate
Loose scrap and low walls in scrapyard posing theft risk	High	Implement continuous visits and vigilant measures	Immediate
Untreated water discharge and poorly maintained water points	High	Address untreated water discharge and improve maintenance	Immediate
All weighbridges being operated manually	High	Complete automation recommended to mitigate potential losses	Immediate

2. ASSETS CHARACTERISATION

Particular	Details
Facility Type	Integrated Chemical Manufacturing Plant with Satellite Salt Works Site
Location	Industrial Zone, Mid-sized City, Western India
Plot Area	Approx. 767,600 sq. meters
Built-up Area	Approx. 41,176 sq. meters
Total Employees (Main Plant)	Approx. 700 permanent + 314 contractual
Total Employees (Satellite Site)	11 (including weighbridge operators, watchmen, clerks, supervisors, testers)
Total Security Personnel	41 (21 Day shift, 20 Night shift; includes 5 Supervisors, 1 Computer Operator, 35 Guards)
Total CCTV Cameras	51 with Security Office, 08 with Sales, 04 with Utility Department
Licensed Weapons	02
Weighbridges	03 total, 02 at main plant (60 MT and 100 MT capacity), 01 at satellite site (60 MT capacity)

3. THREAT ASSESSMENT, Macro View

3.1 Introduction

The district in which the facility is located spans approximately 10,000+ sq. km. and is bounded by several other administrative districts. Its topography relies primarily on seasonal rainfall for agriculture, with limited irrigation potential. The climate is subtropical, characterised by hot summers and cold winters, with annual rainfall averaging between 760mm to 967mm, leading to drought conditions in alternate years.

The district possesses significant mineral wealth, including fire clay, silica sand, black stone and sandstone. It has a forest area exceeding 500 sq. km. The industrial landscape includes multiple industrial areas housing diverse sectors, with over 1,400 registered industrial units, predominantly comprising micro and small enterprises. Key sectors include agro based industries, textiles, chemicals, rubber & plastics and metal-based manufacturing.

The region faces several industrial challenges including high electricity rates, irregular power supply, shortage of working capital, scarcity of raw materials and skilled labour. Government agencies provide support in project registration, financial aid and technical know how, facilitating establishment and growth of MSMEs.

The district is strategically located within a broader industrial belt and presents both opportunities and risks for facility management. Its diverse terrain encompasses plains, hills and water bodies, supporting agricultural ventures while demanding astute risk management, particularly around climate variability and market fluctuations.

Industrial development, particularly in chemicals, engineering and ceramics, marks the district as a hub of manufacturing. The ceramic industry, with production specialising in tiles, sanitaryware and related products, presents significant economic activity alongside inherent supply chain risks and regulatory challenges.

The district also encompasses ecologically significant areas including salt harvesting zones and wildlife sanctuaries, which have historical and economic importance. Balancing industrial activity with environmental preservation is a key regional imperative, emphasising the need for sustainable practices.

3.2 Immediate Responders

The following emergency response infrastructure was identified in proximity to the facility:-

Police Station

*Institute*	*Approximate Distance*	*Remarks*
Local Police Station	Approx. 2 km	Primary law enforcement response

Fire Stations

*Institute*	*Approximate Distance*	*Remarks*
District Fire Station (Primary)	Approx. 2.5 km	Nearest fire response unit
Regional Fire Station	Approx. 35 km	Secondary fire response support

Hospitals

*Institute*	*Approximate Distance*	*Remarks*
Government Hospital (District)	Approx. 2 km	Primary emergency medical care
ESI/Occupational Health Hospital	Approx. 2.3 km	Workers' health care
Tertiary Medical College & Hospital	Approx. 35 km	Advanced medical care

Emergency Helpline Contacts

*Service*	*Contact Type*
District Administration / Collector Office	Emergency Coordination
District Emergency Helpline	General Emergencies
Women Helpline	National, 1091
Child Helpline	National, 1098
Fire and Rescue	National, 101
Disaster Relief Commissioner	National, 1070

3.3 Crime

The district exhibits a complex crime profile encompassing various forms of criminal activities:-

Crimes against marginalised communities (particularly lower-caste population) are prevalent, with a disturbingly low conviction rate. Over a seven-year period, thousands of cases were reported. Despite an increase in reported cases, the conviction rate remains low, indicating systemic challenges in achieving justice for victims.
Intercommunity conflicts and disputes, often resulting in violence, are evident. Instances including disputes over land and property highlight underlying tensions within the community.
Traditional crimes such as murder, sexual violence and atrocities against women are persistent issues. There is a concerning trend of sexual violence against women and girls, with a significant proportion experiencing harassment and assault in public spaces.
Road accidents are a significant concern, attributed to high traffic density, poor road conditions and inadequate infrastructure maintenance.

3.4 Unrest

The district experiences occasional unrest, driven by various factors including ethnic and communal tensions, political developments and economic disparities. These issues contribute to a volatile environment, sometimes resulting in civil disturbances:-

Religious protests, particularly those related to sensitive social issues, have the potential to escalate into violence, leading to vandalism and property damage.
Socio political unrest may cause localised disruptions, although workers' strikes are less likely to significantly impact operational activities.
Clashes between communities have occasionally resulted in injuries to law enforcement personnel, highlighting susceptibility to communal tensions.

3.5 Terrorism / Insurgency

The district has not experienced widely reported incidents of terrorism. However, regional law enforcement agencies have uncovered illegal arms networks in the broader Saurashtra region. This indicates a background presence of illegal arms activities. While there is no explicit terrorism-related incident recorded at or near the facility, vigilance and cooperation with law enforcement agencies remain crucial in addressing any potential future threats.

3.6 Natural Disasters

Hazard	Description	Recent Events
Earthquakes	The district lies in Moderate Seismic Zone III, adjacent to Zone IV, making it susceptible to seismic activity. Historical earthquakes in the broader region, including major events, highlight the seismic risk.	Multiple low to moderate magnitude earthquakes recorded in the region in recent years, with no significant casualties.
Urban Flooding	Flooding occurs due to heavy seasonal rainfall, compounded by flat terrain and inadequate drainage infrastructure.	Heavy rainfall caused floods in low lying areas of the region, with severe waterlogging in nearby urban centres.
Extreme Heat	The district faces extreme heat conditions, exacerbated by the urban heat island effect. High temperatures contribute to heat-related illnesses.	Maximum temperatures recorded at 46°C, with heatwave conditions prevailing across the region.
Drought	Recurrent droughts stem from uncertain and insufficient rainfall, impacting water availability and agriculture. Groundwater exploitation exacerbates drought threats.	The region faces drought conditions almost every third year, with significant variability in rainfall patterns.

3.7 External Infrastructure

The district faces several challenges in external infrastructure that significantly impact daily operations and the broader functioning of the region:-

Significant congestion occurs due to inadequate traffic management systems, high vehicular density, ongoing construction, encroachment by street vendors and driving rule violations.
Encroachment poses a significant challenge, with concerns raised about encroachment on ecologically sensitive areas. Encroachments also contribute to road accidents and environmental pollution.
The district frequently experiences disruptions in power supply due to cyclones and infrastructure failures. These disruptions cause industrial setbacks, public suffering and broader economic impact.

3.8 Environment, Health and Safety

The district grapples with severe environmental pollution affecting both air and water quality. Air pollution, particularly from particulate matter (PM2.5) and ozone, poses significant health risks. PM2.5 levels are alarmingly high, exceeding WHO guidelines by several times. Water pollution is also a pressing issue, with alkaline groundwater and elevated levels of Total Dissolved Solids (TDS) and Chloride in many locations.

The district's public health sector requires urgent attention and investment. Outbreaks of diseases among livestock highlight the need for better disease control measures. Non-communicable diseases (NCDs) are prevalent among the elderly population, emphasising the importance of improved health care resources.

3.9 Overall Risk Level

The following table presents the overall risk level posed by each identified threat, considering both capability and intent of threat actors:-

Issue	Threat Category	Capability	Intent	Ranking
Disputes arising between different communities, often fuelled by ethnic, religious, or cultural differences	Inter community Conflicts	Medium	High	High
Social disorder or dissatisfaction manifesting as protests or strikes	Unrest
Catastrophic events from natural phenomena, earthquakes, floods, wildfires	Natural Disasters
Environmental degradation, public health crises, industrial accidents	Environment, Health & Safety
Crimes targeting individuals belonging to marginalised communities	Crime against Marginalised Groups
Conventional criminal activities, theft, robbery, assault, vandalism	Traditional Crimes
Vehicle collisions and traffic-related incidents	Road Accidents
Threats to infrastructure from external sources, cyberattacks, sabotage	External Infrastructure
Illicit narcotics production, distribution and consumption	Drug Abuse & Trafficking
Demonstrations driven by religious grievances or disputes	Religious Protests
Social or political unrest including governance and inequality issues	Socio-political Unrest
Acts of violence by non-state actors with political/ideological motivations	Terrorism / Insurgency

4. VULNERABILITY ASSESSMENT AND RECOMMENDATIONS, Micro View

The following scoring guide was applied to assess the security posture of each domain:-

Score	Interpretation
0	Process not yet initiated / Not in place / Lack of awareness. No effective protective measures in place; an adversary would have no difficulty exploiting the asset. No response measures are in place.
1	Security policies/systems not uniformly implemented, initial stage only. Very few effective protective measures; an adversary would have few difficulties exploiting the asset. Limited response measures in place.
2	Security policies/systems not uniformly implemented, though implementation is in progress. Some protective measures exist but are incomplete; an adversary would have little difficulty exploiting the asset.
3	Security policies formally implemented and appropriate to most situations; process measured and controlled. Protective measures in place with some weaknesses that a determined adversary could exploit.
4	Mature security posture with focus on continual improvement and permanent implementation. Effective measures in place that would defeat all but the most determined aggressor.
5	Fully implemented best practices; no deviation recorded for the past 12 months; permanent monitoring in place. Multiple layers of protective security to eliminate adversary exploitation.

4.1 Perimeter

#	Score	Observation	Recommendation
1	0	The security perimeter is not contiguous, open from three sides and broken at various places.	Ensure continuity of the perimeter and keep it well maintained to prevent exploitation of gaps by intruders.
2
3
4
5
6
7

4.2 Perimeter Access Points (Gates 1, 2 and 3)

#	Score	Observation	Recommendation
8	3	No space has been catered for vehicle screening at the perimeter gates. No screening equipment (Under Vehicle Screening Mirror/Wireless Handset) is held.	Implement provision of sufficient space for vehicle screening at the perimeter level to enhance security measures through thorough checks.
9

4.3 Guard Posts

#	Score	Observation	Recommendation
10	2	Security guard posts are not available for all static duties. Standardisation of guard posts is required, they should support stationing of guards, provide protection from external threat and incorporate alternate communication devices and panic buttons.	Ensure consistent availability, maintenance and equipped readiness of proper security duty posts for all static duties.
11

4.4 Screening

#	Score	Observation	Recommendation
12	2	No space has been catered for personnel screening at the perimeter level. No Hand Held Metal Detectors (HHMDs) are held.	Allocate and maintain sufficient space for personnel screening at the perimeter level to ensure no personnel enters the facility without screening.
13
14

4.5 Personnel Control

#	Score	Observation	Recommendation
15	3	Police verification is conducted for all employees including contractual staff.	Ensure background checks are consistently and uniformly conducted.
16
17
18
19
20

4.6 Intrusion Detection

#	Score	Observation	Recommendation
21	0	No intrusion detection system exists for critical locations.	Install intrusion sensors at critical locations to deter intrusion attempts and enhance security infrastructure.

4.7 Vehicle Control

#	Score	Observation	Recommendation
22	3	All vehicle entry is based on manual intervention.	Implement electronic documentation measures such as electronically generated gate passes to improve record-keeping.
23

4.8 Access Control

#	Score	Observation	Recommendation
24	3	Biometric authentication is done through personnel barriers installed at the main gate. Multiple lanes are present, dedicated to contractual labour and employees respectively. However, wage sheets are not being generated using biometric attendance data.	Biometric attendance should always be used for the generation of wage sheets.
25
26

4.9 Video Surveillance

#	Score	Observation	Recommendation
27	3	Video surveillance system is equipped with video storage capacity. Main security office: 64-channel NVR, 51 cameras, 32TB storage (20 days). Sales office: 32-channel DVR, 15 cameras, 32TB storage (60 days). Power control room: 16-channel DVR, 4 cameras, 8TB storage (30 days).	Maintain and regularly verify a minimum of 30 days storage capacity for the video surveillance system in compliance with retention requirements.
28
29
30
31

4.10 Security Lighting

#	Score	Observation	Recommendation
32	2	Lux levels are not well defined in most areas and are severely inadequate.	Regularly assess and adjust lux levels for security related locations, including perimeter, gates, common areas and critical locations, to ensure optimal visibility and surveillance effectiveness.
33
34
35

4.11 Security Operations Centre (SoC)

#	Score	Observation	Recommendation
36	0	An integrated SoC does not exist. An onsite emergency plan exists, which is only one component of a complete SoC.	Establish a SoC as part of an overall Security Management Plan (SMP) to actively monitor security activities, flag suspicious activities and record incidents in a log for effective response.
37
38
39
40
41
42
43

4.12 Security Manpower

#	Score	Observation	Recommendation
44	3	Inadequate deployment of supervisors and guards during night shifts on the three open sides of the perimeter.	Establish and regularly review actual deployment in pairs along the open perimeter to eliminate gaps and enhance the effectiveness of security measures.
45
46
47

4.13 Security Procedures

#	Score	Observation	Recommendation
48	2	Absence of documented procedures for biometric access control systems.	Regularly review and update written procedures for the access control system, adherence to SOPs for issuing, withdrawing, reconciling and reporting deviations, while ensuring all site personnel are issued distinctive photo ID badges.
49
50
51
52
53
54

4.14 Intelligence, Vigilance and Liaison

#	Score	Observation	Recommendation
55	2	Limited mechanism is available for the receipt of alerts and advisories.	Build intelligence and vigilance mechanism for receiving alerts and advisories, ensuring timely response and effective utilisation of intelligence to enhance security measures.
56
57
58
59
60

4.15 Incident and Emergency Management

#	Score	Observation	Recommendation
61	4	The process for coordination with local law enforcement agencies and emergency services is well-defined.	Regularly review protocols for coordination with local law enforcement agencies and emergency services to ensure effective collaboration and support during incidents and emergencies.
62
63
64
65

4.16 Security Governance and Sustainability

#	Score	Observation	Recommendation
66	0	The mechanism for periodic review of the security framework and protocols is absent, leading to gaps in compliance and effectiveness.	Establish and consistently conduct periodic reviews of the security framework and protocols to identify gaps, ensure compliance and enhance effectiveness.
67
68
69
70
71
72
73
74
75

4.17 Weighbridge Management, Main Plant

Two weighbridges, one with a capacity of 100 MT and the other with a capacity of 60 MT, are located at the main plant. The company conducts quarterly checks and calibrations. The following procedure outlines the calibration process for both weighbridges:-

Check the power supply and grounding of the entire system.
Verify platform alignment and ensure free movement. If any part of the platform is found to be in contact with the bridge, adjust accordingly.
Inspect load cell and junction box (JB) wiring for any loose connections.
Perform a corner test by placing a standard weight on each corner of the platform. If corrections are needed, adjust from the PCB inside the JB.
Conduct zero and full calibration using standard weights.
Review calibration records, no abnormalities were detected during most recent checks.

4.17.1 Validation of Calibrations by Tare Weight (TW) Observations, By Sampling

Sample tare weight variations were noted to be large. This could be attributable to weighbridge calibration drift or other operational variables.

Sample #	Vehicle Ref.	TW Variation (Kg)	Remarks
1	Ref. A	N/A (outlier: 13,090 kg reading noted)	Aberrant reading observed
2	Ref. B	Within normal range	Requires investigation
3	Ref. C	Elevated variation	Requires investigation
4	Ref. D	Elevated variation	Requires investigation
5	Ref. E	Elevated variation	Requires investigation

#	Score	Observation	Recommendation
77	3	Weighbridge access control is managed by a dedicated team of weighbridge personnel from the stores department.	Implement an automated weighbridge system to enhance efficiency and accuracy.
78
79
80
81
82
83
84
85
86

4.18 Weighbridge Management, Satellite Site

A weighbridge with a capacity of 60 MT is located at the satellite production/storage site. The company conducts quarterly checks and calibrations, with no abnormalities detected in the most recent calibration record.

4.18.1 Validation of Calibrations by TW Observations, Satellite Site

Sample tare weight are presented below. Variations are significant and warrant investigation to determine whether the weighbridge or operational variables are responsible:

Sample #	Date (First)	Date (Second)	Variation (Kg)	Assessment
1st Sample	Early in period	Mid period	820 kg	Significant, investigate
2nd Sample
3rd Sample
4th Sample
5th Sample

#	Score	Observation	Recommendation
93	3	Weighbridge access control is managed by a dedicated team of weighbridge personnel from the stores department.	Implement an automated access control system to enhance efficiency and reduce dependency on dedicated personnel.
94
95
96
97
98
99
100

4.19 Threat Risk Assessment Matrix (TRAM)

The TRAM maps identified vulnerabilities across two dimensions, likelihood of occurrence and potential impact. This provides a prioritisation framework for remediation efforts.

END OF DOCUMENT

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