Beruflich Dokumente
Kultur Dokumente
0 INTRODUCTION
Safety Audit is an important part of Companys control system. The techniques of safety
audit of a companys activity are a systematic critical examination with the object of
minimizing losses. Every component of the total system e.g. Management Policy,
Attitude, Training & Retraining, Features of the process and of design, Layout &
Construction of the plant, Operating Procedures, Emergency Plan & Preparedness,
Protection Standards, Examinations of the pressure Vessels, and Accident Analysis,
Records & Reporting Procedures etc. are included in the Safety Auditing System.
Safety Audit covers all aspects of safety of the undertaking including compliance with
statutory rules, organisation and administration, general hazard control, process hazard
control, training and motivation, accident investigation and cause analysis etc.
A Safety Audit examines and assesses in details the standards of all facts of a particular
activity. It extends from complex technical operations and emergency procedures to
clearance certificate, job descriptions, housekeeping and attitudes. It also involves labour
relations since people are asked about their training, their understanding of works policy
and whether they think they are making their contribution in the right way.
The safety audit has been carried out as per the guidelines given in the Indian Standard
Code of Practice on Occupational Safety and Health Audit (BIS-14489-1998).
The Audit findings and recommendations are based on the background information &
process data and discussions held with the plant personnel during onsite audit activities.
2.0 OBJECTIVES
The purpose of conducting Safety Audit is that a systematic critical appraisal of all
potential hazards involved, plant personnel, plant, services and operation methods to
ensure that occupational health and safety standards fully satisfy the legal requirements
and those of the companys written safety policies, objectives and programmes.
The specific objectives of safety audit are: -
To study existing systems, procedures, plants and programme on safety and health.
3.0 METHODOLOGY
The methodology of conducting safety audit is as follows:
-
Pre-audit activities
Post-audit activities
Asses strength and weaknesses, Internal Risks And Internal Control Measures
Evaluate audit findings, summarize it, and work-out exceptions and observations
Post audit
Prepare Draft Report, which must include Environmental affairs, Legal affairs
along with the recommendation for each findings
Outcome of audit surveys is/was discussed with Plant's Management and all
findings were communicated to them.
Follow-up
Organization &
Project
Designation
PDIS student batch 2015-16
Designation
Safety officer
Safety officer
Engineer
Signature
GENERAL
Indian Farmers Fertilizer Cooperative Limited (IFFCO) Aonla operates fertilizer plant
for manufacturing Urea at P.O. IFFCO Township, Aonla, Distt. Bareilly (U.P.). It
comprises of two Ammonia Plant of 1520 MT per day and four streams of Urea plant
each of capacity 1310 MT per day and a captive power plant of 2 X 18.0 MW. Urea silo,
bagging plant and other related offsite facilities like - water treatment plant, effluent
treatment plant, inert gas plant, cooling towers, naphtha. Ammonia storage and supply of
utilities like compressed air, water etc. also exists for smooth operation of plant.
IFFCO, Aonla Unit has installed and commissioned Carbon Dioxide Recovery (CDR)
Plant for recovery of CO2 from Primary Reformer Flue Gases based on the technology
from M/s Mitsubishi Heavy Industries (MHI) Limited, Japan and Detailed Engineering
from M/s Tecnimont ICB (TICB) Private Limited, Mumbai. It reduces CO 2 emissions
(Green house gas) to atmosphere, contributes to cleaner environment, conserves carbon
intensive fossil fuels like Naphtha and thus has a great potential to be covered under
Clean Development Mechanism (CDM) of UNFCCC. The trading of certified emission
reductions (CERs) through CDM generates additional revenues & increases the viability
of the CDR Project. Production of additional CO2 from CDR unit in place of costlier
Naphtha feed, shall decrease cost of production of Urea and hence shall reduce
Government of Indias annual subsidy outgo, reduce the inventory of Ammonia and it
has become a viable CDM .
8.2 MANPOWER AND SHIFT TIMING
The plant is in operation on continuous basis. The plant operates in four shifts namely A,
B, C & G shift. The timing of shifts and manpower in the plant is as under:
SN.
Shifts
Timings
General Shift
A- shift
B-shift
C-shift
Total employees number of employees in the plant is 1016 apart from them plant also has
214 numbers of security personnel from different contrators and approximate 900
numbers of contract labour.
8.3 RAW MATERIAL, PRODUCTS AND BY-PRODUCTS
The list of raw materials and products used and handled in Fertilizer Plant is as given
below:
S N Name
A. Raw Material
1.
Natural gas
2.
Naphtha
3.
Liquid Nitrogen
4.
Chlorine
B. Products
1.
Urea (main product)
2.
Ammonia
3.
Power
4.
DM water
Requirement/ production
Inventory
Continuous flow
3 nos. of storage
tanks
60 KL
12 Tonners
1310 X 4 MTPD
1520 X 2 MTPD
18 X 2 MW
140 X 6 M3/hr
10000 X 2 MT
8000 M3
Desulphurization.
ii)
iii)
iv)
v)
Methanation.
vi)
Ammonia Synthesis
vii) Refrigeration.
Urea plant
i.
ii.
iii.
Urea Concentration
iv.
Urea Prilling
v.
Desulphurization.
ii.
iii.
iv.
v.
Methanation.
vi.
Ammonia Synthesis
vii.
Refrigeration.
Natural gas is supplied to the plant at a pressure of 40 kg/cm 2g from GAIL station inside
plant battery limit. The gas contains sulphur compounds in small quantities, which are
removed by passing the gas through desulphrization unit.
The gas is mixed with recycle hydrogen from 1st stage discharge of syn. Gas compressor
and preheated to 3900 C. Heated gas mixture is then passed over a Nickel Molybedenum
catalyst and the sulphur gets hydrogenated. Hydrogen sulphide formed is absorbed in a
zinc oxide bed and sulphur free gas is then sent to reforming section. In high-pressure
reforming section, gas mixture from desulphrisation section is mixed with superheated
medium pressure steam and passed through nickel catalyst packed in tubes. Primary
reformer is a balance draft furnace. Here the reforming reaction takes place, which is
endothermic. Heat is supplied by side-fired burners.
recovered by waste heat boiler, producing steam and gas is cooled to 3600 C.
Shift conversion takes place in two temperature level high temperature shift reaction &
low temperature shift reaction. At the high temperature level the shift reaction rate
increases where as at lower temperature, conversion is more. The gas at 360 0 C passes
through high temperature shift converter containing iron-based catalyst. The exit gas is
cooled down by waste heat boiler, trim heater and BFW pre heater to a temperature of
2000 C. It passes through Low temperature Shift Converter containing zinc copper
catalyst. In both these reactors carbon monoxide is converted to carbon dioxide and
hydrogen. The exit gas from low temperature shift converter contains mainly Hydrogen,
Nitrogen, Carbon-Di-Oxide and small quantities of Methane, Carbon Monoxide and
Argon.
Shift converter exit gas is sent to carbon di oxide absorber where the gas is scrubbed
with hot aqueous GV solution containing 27% by wt potassium carbonate, 1% diethanol
amine, 1.2% glycine and 0.4% vanadium pentaoxide for absorbing carbon dioxide. After
absorbing carbon-di-oxide the GV solution is stripped at low pressure in the GV
regenerator. Here carbon-di-oxide is liberated which is then cooled and sent to urea
plant. Stripped solution is circulated back for absorbing carbon di oxide again.
The gas leaving the absorber contains small amount of carbon monoxide and carbon
dioxide. These oxides are poisonous to synthesis catalyst. Hence these oxides are
converted into methane in methanator to reduce them to very low levels. In metahnator
the oxides of carbon reacts with hydrogen at 320-340 0 C over nickel catalyst to form
methane. Methane is inert to the synthesis catalyst. After methanation gas is cooled
down to 380 C and sent to synthesis compressor.
Purified synthesis gas is compressed in three stages of syn. gas compressor. The recycle
gas for hydrogenation is taken from first stage discharge. Syn. gas is cooled after every
stage and condensate is separated out. Final discharge pressure of syn.gas compressor is
220 kg/cm2g compressed gas is cooled in water cooler, in make up gas chiller and is then
mixed with cooled converter outlet gas. The mixture of make up gas and recycle gas is
finally cooled to 120 C in ammonia chillers.
Ammonia gets condensed and is separated in Ammonia separator. The liquid thus
separated is the product ammonia. Uncondensed gases that come out of the separator
(also known as recycle gas) is then warmed in heat exchanger, compressed in recycle
stage of the syn.gas compressor and sent to ammonia converter containing iron catalyst
after getting heated by converter outlet gases. About 30% conversion takes place in the
converter. The Ammonia converter is Haldor Topsoe radial flow converter.
Product Ammonia is let down from the high-pressure separator to the let down vessel.
Liquid Ammonia from the let down vessel is sent to Urea Plant. Ammonia chillers
operate at different pressure levels. Pressure in each chiller is maintained by booster and
refrigeration compressors in series. The discharge of the refrigeration compressor is
cooled in cooling water-cooled condenser and collected in Ammonia accumulator. From
here it is distributed to various chillers. Whenever Urea Plant is shutdown product
Ammonia is taken to flash drum and the Ammonia is pumped to atmospheric pressure
tank at 330 C. Although the percentage of methane and argon in the make up gas is
small, during recirculation, the percentage goes up and to keep the inert level below a
particular value in the synthesis loop, part of the gas is purged from the converter exit
gases. It is cooled down in chillers and Ammonia is separated out and then sent to a
water wash unit. In this unit final trace of Ammonia is removed from the purge gas by
washing it with water before it is mixed with the fuel gas.
coils situated in convection section of the Primary Reformer and in a NG fired steam
superheater (Auxiliary superheater).
Most of the HP steam goes directly to synthesis gas compressor back pressure turbine
(extraction cum condensing type). When the back end of Ammonia Plant is not running
a let down station lets down the full quantity of high-pressure steam to MP steam header
and maintains 37-kg/cm2g pressures in the header. Out of three let down stations
commonly known as PRDS (pressure reducing and De superheating station) two are
hydraulically operated & are of 300 tones capacity.
Brief Process Description of Ammonia-II
Natural gas is supplied to the plant at a pressure of 40 kg/cm 2g. The gas contains sulphur
compounds in small quantities, which are removed by passing the gas through
desulpharization unit. The gas is mixed with recycle hydrogen and preheated to 390 0 C.
Heated gas mixture is then passed over a Nickel Molybdenum catalyst and the sulphur gets
hydrogenated. Hydrogen sulphide formed is absorbed in a zinc oxide bed and sulphur free
gas is then sent to reforming section. In case of short supply of Natural gas the hydro carbon
feed can be supplemented by Naphtha after heating it to 380 0 C in Naphtha preheater and
Naphtha superheater and then passing this through Naphtha desulpheriser containing cobalt
molybedenum catalyst to convert sulphur to hydrogen sulphide. This hydrogenated Naphtha
is mixed with the hydrogenated Natural gas feed before entering the zinc absorber. Naphtha
is supplied to the plant through rail tankers and stored in Naphtha tanks.
In reforming section, gas mixture from desulpherisation section is mixed with superheated
medium pressure steam and passed through nickel catalyst packed in tubes in Primary
reformer. Here the reforming reaction takes place, which is endothermic. Heat is supplied by
side-fired burners.
carbon monoxide, methane, and steam at a temperature of 800 0 C. The gas is then sent to
secondary reformer and part of this mixture is burnt with measured quantity of air supplied
by air compressor. The gas product at elevated temperature is passed through nickel catalyst
and the reforming reaction is completed. As the secondary reformer exit temperature is high,
(9900 C) heat is recovered in RG waste heat boiler, producing steam and then in process gas
superheater where steam is superheated and gas gets cooled to 3500 C.
The gas at 3500 C passes through high temperature shift converter containing copper
promoted iron based catalyst. The exit gas is cooled down by shift waste heat boiler, trim
heater and BFW pre heater to a temperature of 200 0 C. It passes through Low temperature
Shift Converter containing zinc copper catalyst. In both these reactors carbon monoxide is
converted to carbon dioxide and hydrogen. The exit gas from low temperature shift converter
contains mainly hydrogen, nitrogen, carbon di oxide and small quantities of methane, carbon
monoxide and argon.
Shift converter exit gas is sent to carbon di oxide absorber where the gas is scrubbed with
hot aqueous GV solution containing 27% by wt potassium carbonate, 1% diethanol amine,
1.2 % glycine and 0.4% vanadium pentaoxide for absorbing carbon dioxide. After absorbing
carbon-di-oxide the GV solution is stripped at low pressure in two GV regenerators. Here
carbon-di-oxide is liberated which is then cooled and sent to urea plant. Stripped solution is
circulated back for absorbing carbon di oxide again.
The gas leaving the absorber contains small amount of carbon monoxide and carbon dioxide.
These Oxides are poisonous to synthesis catalyst. Hence these oxides are converted into
methane in methanator to reduce them to very low levels. In metahnator the oxides of
carbon react with hydrogen at 320-3400 C over nickel catalyst to form methane. Methane is
inert to the synthesis catalyst. After methanation, gas is cooled down to 38 0 C and sent to
synthesis gas compressor.
Purified synthesis gas is compressed in three stages of syn. gas compressor. The recycle gas
for hydrogenation is taken from first stage discharge. Synthesis gas is cooled after every
stage and condensate is separated out. Final discharge pressure of synthesis gas compressor
is 220 kg/cm2g. Compressed gas is cooled in water cooler, in make up gas chiller and is then
mixed with cooled converter outlet gas. The mixture of make up gas and recycle gas is
finally cooled to 120 C in Ammonia chillers.
Ammonia gets condensed and is separated in H.P. Ammonia separator. The liquid thus
separated is the product Ammonia. Uncondensed gas that comes out of the separator also
known as recycle gas, is then warmed in heat exchangers, compressed in recycle stage of the
syn.gas compressor and sent to Ammonia converter containing promoted iron catalyst after
getting heated by converter outlet gases. About 30% conversion takes place in the converter.
Product Ammonia is let down from the ammonia separator to the let down vessel, from
where liquid Ammonia is sent to Urea Plant. Ammonia Chillers in synthesis loop operate at
different pressure levels. Pressure in each chiller is maintained by refrigeration compressor.
The discharge of the refrigeration is cooled in water-cooled ammonia condensers and
collected in Ammonia accumulator.
Whenever Urea Plant is shutdown product Ammonia is taken to flash vessel and the
Ammonia is pumped to atmospheric pressure tank at 33 0 C. Although the percentage of
methane and argon in the make up gas is small, during re-circulation, the percentage goes up
and for maintaining the inert level below a particular value in the synthesis loop, part of the
gas is purged from the converter exit gases. The purge gas is cooled down in the chiller
partly Ammonia is separated out and then purge gas is sent to purge gas recovery unit in
Aonla-I. The tail gas after separation of Ammonia and hydrogen is sent back to Ammonia
Expansion Plant to be used as fuel gas in Primary Reformer.
Boiler Feed Water, Steam and Condensate System
Demineralised water supplied from water treatment plant in the steam condensate is stored in
a DM water tank located in Ammonia Plant. DM water is pumped from DM water tank by
pumps to top of the deaerator. Boiler feed water is pumped to RG waste heat Boiler, Loop
waste heat Boiler and the heat recovery unit at gas turbine exhaust. En-route to these
consumers, feed water gets preheated after passing through different BFW preheaters. BFW
preheaters are located after HT shift converter, LT shift converter and Loop waste heat Boiler
in synthesis loop. Preheated water goes to Loop waste heat boiler and to steam drum which
supplies water to waste heat boilers in the front end.
The boiler water flows from steam drum to H.P. waste heat boilers after secondary reformer
and HP waste heat boiler after HT shift converter and back by natural circulation. Steam
gets separated in steam drum. Steam generated in loop waste heat boiler joins the steam
outlet of steam drum. There are three pressure levels of steam in Ammonia plant viz. High
pressure (105 kg/cm2g), Medium pressure (37 kg/cm2g) and low pressure (3.5 kg/cm2g).
High pressure steam is produced in waste heat boilers in the front end and synthesis loop and
is super heated first in H.P. superheater from 320 0 C to 3950 C and then in two superheater
coils situated in convection section of the Primary Reformer to 515 0 C. About 120 t/hr of HP
superheated steam at 5150 C is produced in Heat Recovery Unit of Gas Turbine.
The HP steam produced in HRU of gas turbine is sent to Urea Plant for CO 2 compressor
turbine drive. Most of the HP steam produced in Ammonia Plant goes directly to synthesis
gas compressor turbine. When the back end of Ammonia Plant is not running a let down
station lets down the full quantity of high-pressure steam to MP steam header and maintains
37-kg/cm2g pressures in the header. MP steam header pressure is controlled by the control
valve, which vents excess steam to atmosphere.
Brief process description of Urea Plants
Aonla unit is having two Urea plants. Each Urea Plant consists of two streams of 1100
MT/day each with a single urea prilling tower of 2200 MT/day capacity. The urea
technology is from Snamprogetti, Italy. The manufacture of Urea involves following
operations/process.
-
Urea Concentration
Urea Prilling
The reaction of NH3 and CO2 to produce Urea takes place in 2 stages at elevated pressure
and temperature.
(1) 2NH3 + CO2
The liquid Ammonia is pumped at high pressure (240 kg/cm 2) through an ejector which
drives the carbamate from carbamate Separator into the reactor. Carbon-di-oxide, mixed
with a small measured quantity of air (for passivation) is compressed in a four stage
carbon-di-oxide compressor and is also fed to the reactor (at 160 kg/cm 2). The liquid
Ammonia and Carbon-di-oxide react together here. A high mole ratio of 3.6:1 of NH 3 &
CO2 is maintained. The product formed is carbamate which dehydrates, in the Reactor
itself, to form Urea and water. The oxygen in the air forms a passive oxide layer on the
insides of vessels surfaces to prevent corrosion by carbamate and Urea.
The reaction products from the Reactor containing 33.8% Urea overflow the HP stripper
where the unconverted carbamate is decomposed back into Ammonia and carbon-dioxide. Heat of decomposition is supplied by MS steam, admitted in Stripper shell side
(at 24 kg/cm2). The condensate obtained is sent to MP Decomposer shell side. Urea
solution thus obtained flows out to the MP section through a level control valve
(containing 45.9% urea).
The vapours produced on decomposition in HP stripper enter the HP carbamate
condenser through a mixer, along with weak carbamate solution from MP section. Here
they condense to form carbamate again and flow to the HP Carbamate Separator. During
this condensation, LP steam is generated in the HP carbamate condenser shell side.
Vapours mostly inerts, from carbamate separator are sent to the bottom of MP
decomposer to passivate the MP section. The pressure of HP section is 145 kg/cm2.
Urea-Purification and low pressure recovery
Medium Pressure section
Urea solution from the bottom of the HP stripper now enters the MP decomposer after
pressure reduction through a level control valve (pressure of MP section-18 kg/cm 2).
During expansion and further heating in decomposer much of the remaining carbamate
flashes forming NH3 and CO2 vapours, thereby concentrating urea in the solution. This
urea solution is further let down in pressure by a level control valve and enters the LP
section (at 3.5 kg/cm2).
concentrated and is then sent to the vacuum section through a level control valve.
The vapours enter the LP condenser shell and get absorbed in an aqueous carbamate
solution from wastewater section. LP condenser has cooling water in tube side. The
liquid thus formed goes to the carbonate solution tank from where it is recycled back to
MP condenser.
The inert gases from the Tank containing Ammonia is absorbed in cooled condensate in
LP Ammonia Absorber, washed in inert washing Tower and sent to vent stack. The
liquid flows down to the tank.
The liquid from the bottom of LP decomposer is further concentrated in two Vacuum
concentrators in series. Here with the help of low-pressure steam, urea solution is
concentrated from 72% to 99.8 by wt. The vacuum is created and maintained by a set of
steam ejectors and condensers.
Urea melt thus obtained is then pumped to the prilling section. The vapours from both
the concentrators are condensed in the cooling water condensers and sent to the
wastewater tank.
Urea Prilling
The molten urea thus obtained from the 2nd vacuum concentrators is pumped to the top of
a Common Prill Tower, into a Prill Bucket. The Urea comes out of the holes in the
rotating Prill Bucket and fall down the Prill Tower. Air, by natural draught, flows
upwards counter current to the Urea droplets & cools and solidifies the prills. The solid
prills thus formed fall to the bottom and sent on to a Belt Conveyor by means of rotating
scrapper. They are then transported to Bagging Plant.
Waste Water Treatment
The vapours containing water and a little NH3 and CO2 from process and condensate of
ejectors in the concentration section are condensed and collected in a wastewater tank.
From here it is pumped to a Buffer Waste Water Tank and then to a Distillation Tower.
After first stripping of Ammonia in the upper part, the solution contaminated with urea is
sent to Hydrolyser (at 35 kg/cm2). Here urea is decomposed by means of saturated high
pressure steam and the vapours are sent to the distillation Tower over head condenser.
The solution from the Hydrolyser goes back to the distillation Tower for further removal
of Ammonia. Vapours from the top of the Tower go to the overhead condenser and are
condensed along with vapours from the Hydrolyser. One part of this solution is recycled
back to the distillation tower top as reflux and the remaining portion to the LP condenser
of both units.
The solution from the bottom of the Distillation Tower called the effluent or purified
wastewater is sent to the cooling tower as make-up (containing 5 ppm Urea, 30 ppm
Ammonia).
9.0 ELEMENTS OF OCCUPATIONAL SAFETY AND HEALTH (OS&H)
SYSTEM COVERED IN THE AUDIT
AREAS COVERED
The Safety Audit of Indian Farmers Fertilizer Cooperative Limited (IFFCO), Aonla Unit
as mentioned earlier is being carried out as per the guide notes mentioned in IS-144891998. The areas of Occupation Safety and Health System covered in this audit are as
follows:
1. Occupational Health and Safety Policy
2. OS&H Organizational set up
3. Safety related education and training
4. Employees participation in OS&H Management
5. Motivational and promotional measures for OS & H
6. Safety manual and rules
7. Compliance of the statutory requirements
8. New equipment review/inspection
9. Accident reporting, analysis, investigation and implementation of recommendations
10. Risk assessment including hazard identification
11. Safety inspections
12. Health and safety improvement plan / target
13. First aid facilities
14. Personal protective equipment
15. Good house keeping
16. Machine and general area guarding
17. Materials handling equipment
18. Electrical and personal safeguarding
19. Ventilation, illumination and noise
20. Work environment monitoring system
21. Prevention of occupational diseases including periodic medical examination
22. Safe operating procedure/system
23. Work permit system
24. Fire prevention, protection and fighting system
25. Emergency preparedness plans
26. Process/plant modification procedure
27. Transportation of hazardous substances
28. Hazardous waste treatment and disposal
29. Safety in storage and warehousing
30. Contractor safety system
31. Safety for customers.
10. OBSERVATIONS
10.1 OCCUPATIONAL HEALTH AND SAFETY POLICY
As per the legal requirement of section 7-A (3) and 41-B (2) of Factories Act 1948
(as amended to date). Plant has a written Safety, Health and environment policy,
which is signed by Senior General Manager, the official Occupier of the plant. The
copy of the policy enclosed as Annexure-2 for ready reference.
Plant also has a Corporate Safety, Health and environment Policy, which is prepared
in 1999 and signed by Managing Director. The copy of the corporate policy enclosed
as Annexure-3 for ready reference.
The policy has been prepared as per the guidelines of the statuary requirement.
The policy was time to time updated and scrutinized by U.P. Factory Inspectorate and
safety consultants, the last updation made in year 2003.
The content of the declared policy includes the commitment of top management to
health, safety and environment and compliance with the entire relevant statuary
requirement.
IFFCO has a well-defined Fire & Safety Department headed by Joint General
Manager (Env., Fire & Safety)/Chief Manager (F&S). Plant also has well-qualified
Safety Officer, as per the requirement under U. P. Factories (Safety Officers) Rule1984. The details of safety officer in the plant is as follows:
Name
Designation
Qualification
Experience
:
:
:
:
Shri. A. K. Pandey
Dy. Manager (F&S)/ designated factory Safety officer.
M.Sc., Post Diploma in Industrial Safety from RLI
21 years
The strength of safety & fire department is 27 in number, which includes officers and
staff.
The Head of Safety Department reports to Chief Executive of the plant through
General Manager (Tech).
Safety officer has exclusively responsibility for safety & fire service. No other
responsibility has been given to safety officer, which are inconsistent with or
detrimental to the performance of his duties.
At the time of any emergency, safety officer reports to the top management, who
have the power of shut down the plant. Safety officer may stop the work in any
emergency condition until hazards is rectified but before shutting down the plant he
must inform/discuss with concerned top management/production manager/in-charge
because the process in the plant are mostly continuous and thus can not be abruptly
stopped.
The Plant Level Safety Committees as well as Central Safety Committee meeting is
held once in every three months.
At meeting overall assessment is being done and various problems as per the
requirement are discussed in the meeting such as prevailing unsafe condition and
practices, incidents, financial sanctions, review of the points of the last meeting and
any points with the permission of the chairman.
Before the next meeting, safety officer and members of safety committee follow up
the implementation. In next meeting progress of implementation is reviewed.
The minutes of the safety committee meetings are circulated among the members
both management representatives and workers representatives as well as and top
management.
The minutes of the meeting sent to chief executives of the plant and Trade Union
through the workers representatives.
Both management and union actively participate in HSE activities, and the
recommendations of the safety committees well accepted.
The safety committee members are apprised of the latest development through
discussion in safety committee meeting and through attending in-house training
program arranged by fire & safety department as well as out side training programs.
Top management is kept updated with literature posed by safety department on LAN.
Plant has approximate 30 lakhs annual safety budget, which is .05 % of the total turn
over of the plant.
80% of approved budget has been utilized till date in maintenance contracts, fire &
safety appliances, PPE, consumables, safety day celebration, safety audits,
implementation of safety committee recommendations.
Safety budget not specially reflected in the annual report of the company. It is
included in the general expenditure.
The new recruitment attains the induction training (comprising of plant information
and safety aspects).
The facilities such as audio visual aids, overhead projector, white board, conference
hall, classroom, are available for conducting training.
The training programmes cover general safety topics and aspects related to chemicals
and hazards, specific to the plants.
The training programs are imparted both in English as well as in Hindi. Safety & Fire
department personnel are sent to NSC (Mumbai), RLI (Kanpur) and NFSC (Nagpur).
The senior management personnel get safety training by attending training program,
seminars, conferences etc.
The employees trained in safety and health in the last five years are as under:
2002 - 2003
478
2003 - 2004
830
2004 - 2005
1698
2005 - 2006
1611
2006 - 2007
1813
2007 2008
2200
In 2007 2008, 1100 man-days were used for training all employees.
Training record such as training need identification, analysis of feed back of training,
pre and post program skill evaluation, internal & external training is maintained.
The company actively participates in national award schemes and got the prizes.
These are as under:
SN
1.
Award Name
NSCI -2006 SAFETY AWARD-
Foundation Name
National Safety Council of India,
2.
Prashansha Patra
ICQESMS-2007, Excellence Award
3.
4.
5.
Management-2006
Second Prize for the Energy onservation
NSCI -2004 SAFETY AWARD-
6.
Prashansha Patra
ICQESMS-2005
7.
Excellence Award
NSA-2004 Runner Up Award for
8.
9.
TERI
Environmental Awards-2002/03
Awards
Corporate
Environmental
10.
The safety contest such as Slogan and Cartoons Competition, Safety Quiz
Competition, Safest Shop Competition are organized in the plant for the motivations
of the employees.
The plant has two in house the publications viz. IFFCO magazine and IFFCO News
contain health & safety topics.
The information regarding safety and health is publicized through bulletin boards,
posters, wall writing etc. On 4th to 12th March-2015 plant celebrated National Safety
week.
Details of inspections
01
Statutory
requirements
Status in Plant
of -
Controller of Explosives
02
Statutory
requirements
of -
03
The management of IFFCO has a tendency of reviewing and inspecting the efficacy
of all new equipment and ensures all safety requirements for any change in the
process, equipment or facility.
All the engineering work requisition (EWR) is sent to Technical services department
for detailed analysis. After obtaining the comments from all concerned departments,
the modification is processed for approval by the competent authority.
All major scheme involving process changes are carried out in consultation with the
process licensor/equipment manufacturer.
Drawings are available in the plant for all modifications and new schemes and
updating of P & I diagrams to incorporate the modification is completed.
10.9 ACCIDENT
REPORTING,
ANALYSIS,
INVESTIGATION
AND
IMPLEMENTATION OF RECOMMENDATIONS
All accidents are generally classified. These accidents are to be classified under the
categories agency, plant/ section, machinery, material, part of body, etc. All the
accidents resulting in either minor or major injuries which have the potential of
causing human injury and/or property damage are reported and investigated as per
the specified procedures framed based on U.P. Factories Act and Rules & record is
maintained.
The investigation report of accident retained at more than ten years. The safety
officer maintains accident statistics and data on computer and as well as in hard copy.
The near miss accidents are also investigated promptly and recommendations are
given to concerned department for implementation to prevent recurrence of such
incidents/accidents.
Last five years accident data is available in the plant. Year wise details is as under:
Year
Fatal
Injury
Non-Fatal
Injury
2003-04
Nil
Nil
2004-05
Nil
02
2005-06
Nil
Nil
2006-07
Nil
Nil
2007-08
Nil
Nil
Nature of Injury
Man-day Lost
Nil
Cold burn
20
Nil
Nil
Hot Burns
113
The plant has identified the hazards, which may arise in the factory, on the basis of
the chemicals being handled and any deviation in operational conditions.
The identified hazards in the plant are Noise, heat, toxic release, fire & explosion.
Following steps have been taken to prevent these hazards:
-
The quantitative risk assessment, vulnerable analysis of the plant is done, based on
the on-site and off-site losses.
Continuous monitoring will be done for gas leak detectors for ammonia
and chlorine. LEL indicators are also installed for hydrogen and other flammable
gases.
Ambient air monitoring stations with high volume samplers are installed
in four locations around the plants.
The plant runs continuously round the clock in three shifts. Therefore, most of the
areas normally remain occupied and none of the accidents is likely to remain
unnoticed for a long duration.
The pressure vessels are provided with pressure gauge and pressure rupture and
pressure safety valves, which keep the pressure below the maximum working
pressure.
All the Factory Rules are followed in operation and maintenance of pressure vessels.
The pressure vessels are subjected to hydraulic and ultrasonic testing by competent
person and record is maintained.
IFFCO has the medical and health center in the plant, which conforms the provision
of Factory Rules. Apart from them plant also has own hospital in our town ship,
which is with in 1 km from the plant.
The doctor and attendant are available round the clock in the center/hospital. The
medical center/hospital is equipped with various facilities for treatment of plant
personnel in case of emergency arising in the plant. These facilities are described
below:
i. Ambulance: There are four ambulance van, which remains available in the
hospital to transfer the injured/affected persons.
ii. Emergency medicines: Various emergency medicines/oxygen facilities/life
saving drugs required for the treatment of the persons affected by the exposure to
hazardous chemicals being used in the plant are kept readily available in the
medical center/hospital.All necessary life saving medicines are maintained in
sufficient quantities.
iii. Stretchers: There are 8 Stretchers. Plant medical center/hospital is provided with
stretchers.
iv. Suction apparatus: There are 6 (six) Nos. Suction apparatus.
v. Bandages/Dressing Material: These are found in sufficient quantities.
vi. Decontamination Facilities: Water (Eye,face & bath) showers and istalled at
crucial location in all the plants, where hazardous chemicals are handled.
vii. Strength and status of medical staff:
1. Permanent Doctors
-4
2. Visiting Doctors
- 3+2*
-5
-3
5. Chief Pharmacist
-2
-1
7. Record Keeper
-4
Plant has Liaison with 20 hospitals in Bareilly for specialist medical treatment.
The first-aid boxes available in each section of the plant, which are periodically
checked by the medical department and record is maintained.
At present, about 20% of the employees in each section are trained in first aid.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
Safety Helmet
Chemical Goggles
Dust Goggles
Ear Muff
Ear Plugs
Dust Masks
Leather Apron
PVC Apron
PVC Suit
Asbestos Suit
Aluminized Suit
Chemical Gas Tight Suit
Leather Hand Gloves
Asbestos Hand Gloves
Rubber Hand Gloves
Cotton Hand Gloves
Blue Overall (Dangree)
Ammonia Gas Mask
Spare Canister for Ammonia Gas
Chlorine Gas Mask
Spare Canister for Chlorine Gas
Carbon Monoxide Gas Mask
Spare Canister for CO2 Gas
Leslico Air Lines Mask
Spare Mask Assembly for Air Line Set
26.
27.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
42.
43.
44.
45.
28.
29.
30.
Selection of PPEs was done after the consultation of safety department as well as
workers.
The PPE are selected as per BIS or the best available standards.
Cup boards in the plant/ selection for general equipment and lockers are provided for
all the workers to safely place the PPEs after use.
Plant personnel and safety department regularly check PPEs. Safety department
arranges any maintenance of the equipment.
Necessary PPE for contract workers are issued under the responsibility of the
respective section-in-charge. These include helmets, gloves, gumboots, earplugs,
masks, and safety belts.
Plant has well-developed drainage system all over the plant with pits/sump, pumps
are provided for up lifting of drained materials.
The sufficient numbers of disposable bins are provided. Where required dip tray are
provided all over the plant.
It was observed that Extraction and scrubbing system is provided for urea dust.
Housekeeping competition is conducted with 4 planned visits and one surprise visit.
There are 2 groups. Shields are awarded to winners and runners-up in both the groups
and a token gift for individuals of that plant.
Specific standards have been developed for housekeeping. However, concepts for
cleanliness and Plant-inside-Garden have been well developed.
In product handling area, spillage of urea on epoxy painted floor causes slippery
surface. To prevent any mishaps due to slippery surface prompt cleaning of floors
and spillage control are practiced.
All roads inside the plant are concreted/ bituminized and maintained clean. There is
no dust evolution.
As per section 21, 22, 26 of The Factories Act and rules made thereunder in respect
of safeguarding of dangerous parts of machinery is a measure in accident prevention,
which receives considerable attention. The high severity rate of accidents caused by
dangerous parts of machinery justifies the importance attached to machine guarding.
While taking the audit round, it was observed that most of the moving parts of the
machines and storage area of hazardous chemicals are well guarded/fenced in the
plant.
The processes and equipments capable of generating and accumulate static charge
motors, transformer etc and record are maintained. Electrical department also has
equipment history of all equipment on a pre-designed format.
Adequate earthing arrangements are made at the terminal points where hazardous
chemicals are used through pipe.
Complete lists of pressure vessels in the plant are available in the inspection
department and respective units such as ammonia, urea, captive power and utility
plants.
Pressure is controlled with pressure transmitters, controllers and control valves for
1. Lifting machines
All lifting machines are marked with their SWL. SWL is marked on almost all EOT
Urea dust is generated in the bagging plant, for the controlling of urea dust in
bagging plant scrubbers is provided.
Preventive maintenance is carried out as and when required and records are
maintained by Mechanical Section.
All electrical sub-stations are equipped by the blower system. The work environment
is assessed and monitored.
The personal protective equipments are given to the workers such as Dust/Cloth
Masks, Safety Goggles etc.
Illumination
All work environments are found adequately illuminated. Sufficient and suitable
lighting, natural or artificial or both have been provided. Lux meter is available in the
plant monitoring is carried out when required.
All light fittings and lamps are periodically checked and cleaned.
Annual optometry tests are conducted for all drivers and employees above 35 years.
Noise
The noisy equipment in the plant is identified these are Compressors, turbines & DG
sets and noise monitoring is done at every 6 months.
The high noise level areas in the plant are near some machines (mainly compressors)
is in the range 88 92 db. However, personnel are required to be near the machines
only for short periods during operation wear ear muff/plug.
Soundproof control rooms and acoustic enclosures will be installed to reduce noise
exposure and in high noisy area Ear muffs and plugs are provided to the employees.
Audiometric test will be done of the employees working in the high noisy area.
Caution boards are displayed in high noise areas. Hazards of noise are highlighted to
the employees.
employment medical examination and is recruited only when he has been declared
medically fit by the competent Medical Authority.
Every employee declared medically fit would conform to the medical fitness norms
All the employees are encouraged to report any adverse symptoms immediately to
Work instructions and operation manuals with the safe operating process are
updated.
All workers engaged in process operation know the failure consequences of safe
operating procedure.
No contractor workers are deployed in process/ operation although contractor
In some places portable platforms are used to access valves and some instruments.
These are well maintained.
Oiling and greasing points are located at safe places not liable to drip into walkways.
Such workers were trained and they are provided with fitting clothing and registered
is maintained.
All drains in the work place are covered and in good condition However, the covers
are not flushed with floor in some places.
A written permit to work system is in place. Two types of safety permits are used i.e.
cold & hot work permits. Vessel entry is included in Hot work permit. Electrical
isolation is included in both the permits.
The hazardous chemicals, handled in the plant Natural gas, CO, CO 2, hydrogen,
ammonia, chlorine, sulphuric acid, hydrochloric acid, caustic lye, hydrazine,
potassium carbonate, monoethanolamine, vanadium pentoxide.
Tag out procedure is used for electrical isolation and locks are not used. Electrical
isolation is ensured by removing the power & control fuses, and/ or racking out the
switch gear.
IFFCO has a well-organized fire & safety department within the plant.
The entire fire & safety provisions made available in the plant such as hydrant lines,
fire extinguishers, fire tender etc. All the fire fighting system and equipment are TAC
approved and the equipment conform to BIS.
One DCP tender with 2 nos. 1000 kg (each) DCP vessels and Nitrogen
Cylinders for propellant
b.
c.
d.
12nos.
b. Foam Extinguishers
45 ltr. capacity
04 nos.
c. Foam Generator
02 nos.
d. Foam Extinguishers
09 ltr. capacity
09 nos.
c. DCP Extinguishers
02 kgs
18 nos.
d. DCP Extinguishers
05 kgs
205 nos.
e. DCP Extinguishers
10 kgs
37 nos.
f. DCP Extinguishers
22.5 kgs
09 nos.
g. DCP Extinguishers
70 kgs
01no.
h. DCP trailer
75x2 kgs
03 nos.
i. CO2 Extinguishers
02 kgs.
36 nos.
j. CO2 Extinguishers
6.8 kgs
129 nos
k. CO2 Extinguishers
09 kgs
12 nos.
l. CO2 Extinguishers
22.5 kgs.
40 nos.
51 nos.
05 nos.
50 ltrs.
Apart from the above facilities plant provides automatic acting foam pourer system is
provided on each Naphtha Storage Tanks. M.V. water spray system also installed on
Naphtha Tank.
Smoke detectors and heat detectors are provided on all the important buildings,
transformer & houses of the plant.
Manual Brake Glass calls points also installed in the plant at strategic location.
All extinguishers are checked once in three months, by fire service department and
record is maintained.
The fire hydrant network covers all the plant areas. Pressure of the network is
maintained by running a fire pump. Auto start system is provided for firewater
pumps.
The power is supply to the fire hydranth pump ensured by captive power plant with
gas turbine generator.
Fire alarm system is available in some plants. The system is under revamp.
Name of Items
Yard Hydrant Post
Hydrant Post on Landing
Water Monitors
Total Pipe length of closed loop system
Pressure in hydranth system
Dia of Hydrant pipe
Single Headed Ground
Double Header ground hydrants
Internal hydrants points
Water Jet monitors
Quantity
419 Nos
117 Nos.
27
Nos.
20 Km Approx
8.8 Kg/cm2
500 mm to 80
mm
389 Nos.
18 Nos.
123 Nos.
25 Nos.
5 Nos.
3 Nos.
2 Nos.
2 Nos.
Foam Pumps
Foam monitors
2 Nos.
08 Nos.
Ionization Detectors
Optical Detectors
Heat Detectors
Manual Call Point
754 Nos.
234 Nos.
71 Nos.
122 Nos.
Plant has water reservoir of capacity 14400 m 3. Water is received from 16 nos. of
bore well.
The plant has own Captive power plant with gas turbine generator. Alternative source
of power is UPPSEB grid supply.
The plant has well established fire department, the details are as under:
Joint General Manager (E&S)
: 01
: 01
Manager (F&S)
: 01
: 03
Fire Inspector
: 17
Apart from them all the plant personnel are trained in fire prevention and protection
measures.
Fire resistant doors are installed in Bagging plant as per TAC requirement.
There is no major fire incident occurred in the recent past. Only minor grass fires
have occurred in factory and township. Action taken for removing grass regularly.
The system is On-site emergency mock drills are conducted once in 6 (six) months.
There is no large industry around 50 km radius. The company has understanding with
Bareilly fire brigade and air force station for the help during emergencies.
The mock drills are conducted once in six month as per DCMP and record is maintained.
Last drill was conducted on 24/12/2015
Two Emergency Control Center (ECC) is located in the plant (1) Near fire station (2)
Township Guest House. There are ten 14 assembly points and many of them are airtight rooms.
The emergency team and key personnel have been identified in the On Site
Emergency Plan.
Two numbers of emergency sirens are available in the plant; (1) At Fire Station & (2)
At Power Plant.
First Aid Centre is in the plant with trained medical staff & township hospital within
1 km. Understanding with 20 hospitals in Bareilly for specialized treatment.
In case of any modification, the detail of estimated expenditure and audited benefits
are highlighted and the proposal is rooted through different departments such as
safety, maintenance and other concerned departments for their comments and finally
put to Plant Head for his comments.
In Ammonia-I, fuel gas preheat coils have been installed in primary reformer for
energy saving. This was carried out with technical consultancy from Topsoe, the
original process designer. Other modification was done in the plant like LTSGUARD, CDR UNIT, S-50 Convertor in Ammonia I & II, CT-1 expansion with the
approval of competent concerned authority.
Hazardous materials transported to or from the plant, which are either raw material,
product or waste are Naphtha, ammonia, HSD furnace oil, sulfuric acid, hydrochloric
acid, caustic, chlorine tonners.
Sulphuric acid, hydrochloric acid, caustic, chlorine tonners, ammonia & HSD are
transported by road and Naphtha, furnace oil, ammonia is transported by rail and
only natural gas transported by pipe line.
Outside vehicles are used for road tankers and chlorine tonners. Naphtha & furnace
oil tankers are owned by others. Ammonia rail tankers are owned by IFFCO.
The loading /unloading procedures and safety precautions of hazardous chemicals are
displayed.
Separate parking yard for loaded tankers or trucks is available near the material gate.
All the truck and tanker drivers carry TREM cards or instruction booklet.
Pipelines are over ground in the plant. All the over ground pipelines are painted by
Anti corrosion paint periodically to avoid any rusting. Cathodic protection system is
provided for underground piping for firewater and cooling water.
The pipelines are protected by safety valves, Remote shut off valves are provided
for ammonia and NG pipes. Written procedure for tackling leakage in pipelines is
available.
The pipeline regularly checks with explosimeter for leaks from flanges, valves.
Inspection of pipeline will be done during plant turnaround. NDT is carried out for
selected critical pipelines.
Anti corrosion painting for above ground pipeline & cathodic protection in the under
ground pipelines are provided for the protection of corrosion.
The NG & Ammonia pipelines are protected by safety valves & remote shut off
valves.
The manufacturing process yields variety of waste. The waste generated at IFFCO in
the form solid, liquid as well as gaseous viz. spent catalysts, spent lube oil spent acid
& alkali, heavy metals, used lead acid batteries etc.
For the effluent treatment, the industry has a well efficient Effluent Treatment Plant
and domestic wastewater from the plant as well as township is treated in the sewage
treatment plant. Treated water is used in plantation.
All the hazardous waste being only sold to the authorized vendor of the
pollution control board and other treated waste dumped at authorized sites provided
with impervious lining.
The management has adequate facilities for storing of materials in the plant.
The storage areas are clearly marked/ defined. All the tanks are not found marked by
name of the content in side the tank.
The plant has adequate equipment for material handling such as Trolleys, forklifts,
battery operated mini trucks.
The workers, handling the material, are acquainted with the hazardous associated
with the material. Also, they are trained in safe procedure of handling the material
and they are also practiced this. The workers follow safe procedures for storage of
materials.
Separate training classes in safety are conducted for contact workers before engaging
them for the job. The system for the handling over plant to the maintenance
department and receiving back is maintenance work requisition and safety work
permits (Hazards/Non Hazards). The system is consistently applied.
The system for the preventive and predictive maintenance is on-line monitoring
instruments for vibration/ axial displacement and bearing temperature for large
compressors and turbines, remote temperature monitors for refractory lined
equipment & reformer tubes, ultrasonic test for wall thickness. Specialist outside
agencies for inspection of critical items such as reformer tubes, stripper etc.
Only Liquid Ammonia storage tank is cryogenic pressure vessel in the plant and
other tanks are atmospheric storage.
Ammonia storage tanks and Naphtha storage tanks are the storage vessels/tanks in
the plant have exceeding threshold quantities of hazardous material as specified in
MSIHC Rules, 1989. The sizes and capacity in tones of these tanks is as under:
S.N.
Tank
Capacity
Ammonia tank
2 x 10000 MT
Naphtha tank
2 x 6000KL
Naphtha tank
1X10000 KL
The material of construction of Ammonia tank is low temperature carbon steel and
Naphtha tank is carbon steel.
All these tanks are above ground and provided with flameproof electrical fittings.
Plot plan indicating the locations of the tank is available. The earthing resistance is
checked periodically and records maintained.
Naphtha tanks have dyke wall. The dyke capacity is more than 110% of the tank
capacity. The installation is approved by CCE. Ammonia tanks are double wall
double integrity type. The earthing resistance is checked periodically and records
maintained.
Remote operated valves are provided at ammonia tanks. Manual isolation valves are
provided for Naphtha tank. The vessels are fitted with remotely controlled isolation
valves.
All necessary instrumentation and safety devices are provided such as emergency
vents, relief valve, bursting disc, level indicator, pressure gauge and over flow line.
High level, high temperature and high-pressure alarm system is provided in storage
tanks.
Stand by empty tanks are provided for emptying material in case of emergency.
Fire hydrants with Water monitors, automatic fixed foam system is provided in
Naphtha storage tanks and Ammonia storage tanks provided with Firewater hydrants
and monitors.
The approved component persons are certifies tests and log sheets are filled up on
daily basis for recording the permanent of these vessels.
Both ammonia tanks have been thoroughly inspected during 2001-2002 by expert
agency (PDIL) and Naphtha tanks are also hydro tested.
Fire hydrants and portable fire extinguishers are the measures taken to cambat any
emergency in the cylinder storage area.
Valid licenses have been obtained in storing these cylinders and chlorine tonners.
The integrity test certificate has been obtained from the supplier of these cylinders.
11.0 RECOMMENDATIONS
15.We suggest that make a proper railing on stair of the dyked area of
naphtha storage tank and also suggest increasing the width of stair.
18.
19.
20.
21.
22.
Other recommendations
23.
24.
26.
27.
28.
29.