Upload
lytu
View
226
Download
5
Embed Size (px)
Citation preview
INTRODUCTION
Gujarat Narmada Valley Fertilizers & Chemicals
Limited came into existence on May 10, 1976 with
single stream Urea & Ammonia plant. 1985 onwards
it has been diversified into Industrial Chemicals.
In 1992, promoted NCPL jointly with Chematur
Engineering AB, Sweden and IBI Chematur Ltd.,
India to manufacture Aniline and Toluene Di-
Isocynate (TDI). It has been merged with GNFC in
2007.
2
Plant Capacity(MTPD) Date of Commissioning Technology Suppliers
AMMONIA 1350 DECEMBER 6, 1981 LINDE & BASF
UREA 1927.27 DECEMBER 13, 1981
SNAMPROGETTI-ITALY
SGGU 612 KNM^3 FEBRUARY 13, 1998 H&G –
MUMBAI
METHANOL-I 150 AUGUST 10, 1985 ICI-U.K./LINDE-
GERMANY
MSU 90 JULY 16, 2006 IN-HOUSE
METHANOL-II 300 DECEMBER 31, 1990 ICI-U.K./TOYO-
JAPAN
FORMIC ACID 33 FEBRUARY 22, 1989 KEMIRA-FINLAND
ACETIC ACID 300 SEPTEMBER 13, 1995 B.P. CHEMICALS-
U.K.
WNA (I+II) 1050 MARCH 25, 1990 UHDE-GERMANY
CNA-(I+II+III) 300 OCTOBER 2,1989 &
JANUARY 24,1999 PLINKE-GERMANY
ANP 475 SEPTEMBER 12, 1990 BASF-GERMANY
CAN 475 AUGUST 02, 1990 UHDE-
GERMANY
GNFC’S PLANTS
3
4
Ammonia In the manufacture of Urea, Ammonium Nitro phosphate
Methanol In the manufacture of Acetic Acid, Formaldehyde, DMT, Pentaerithritol, pharmaceuticals and other intermediates
Formic Acid Coagulant for getting rubber from latex, dye fixing in textile & leather industries, intermediates in basic drugs.
Acetic Acid In the manufacture of Acetic Anhydride, MCA, Acetates, Di ketone Derivatives.
Concentrated Nitric Acid
In the manufacture of dyes, dye intermediates, drugs, NB, Aniline, Nitro Chlorobenzene, TDI & nitro derivative.
Weak Nitric Acid
In the manufacture of fertilizers, Ammonium Nitrate, & other explosive, glyoxalin, sodium nitrate, H-Acid, NB etc.
Products & Uses
5
Aniline In the manufacture of dyes, dye intermediates, rubber chemicals, pesticides, pharmaceutical, insecticide etc.
Toluene Di Isocynate (TDI)
Raw Materials for flexible Polyurethane, foam.
Nitrobenzene Dyes & Dye intermediates, pharmaceuticals pesticides
Urea Fertilizer effective for all kinds of soils & crops
Ammonium Nitro phosphate (ANP)
Fertilizer for basic application during sowing time.
Calcium Amm.
Nitrate (CAN)
Fertilizer suitable in all upland crops. For
avoiding soil acidity & alkalinity.
Ethyl Acetate Printing inks, Flexible packaging,Pharmaceuticals , paints etc.
Products & Uses
A ‘Twenty Two Points Programme’ to
manage the safety is given as follow :
6
It covers various kinds of
innovative practices to control the
hazards and to reduce the number
of accidents.
1. MANAGEMENT INVOLVEMENT
In daily production meetings which are headed by
chief executive, report from Safety department is
presented. In this report, all the abnormalities,
incidences or any other information is discussed
and suitable actions are immediately taken.
7
2. SAFETY SURVEY
In the plants, everyday some or other activities isalways going on. There are many maintenanceactivities which requires constant monitoring.Though Safety permits are issued for each activity,there may be shortfalls in following safetyinstructions:
Sometimes, the condition of the workplace mayalso be unsafe. Besides plant personnels, safetypersonnels take rounds of the plants everyday.They record any kind of unsafe condition and actto convey to concerned plant heads. The receivercomplies with the requirement of doing the jobsafely.
In the year 2013, there were 218 no. ofobservations recorded by safety personnel.
8
3. SAFETY ROUND BY SENIORS
To check the plant condition and abnormalities, Sr.
personnels of the company take round of the plants
during day. In the night hours also, a schedule is
prepared for them to take rounds of the plant.
The abnormalities are reported to higher
management.
9
4. HAZOP & RISK ANALYSIS
o In the plant, modification is a continuous process.
These modifications are done to improve the plant
productivity or to improve safety.
o The modifications proposed in the form of schemes
after the design HAZOP study takes place which
is attended by safety representative also.
o HAZOP is done to identify the hazards and they
are evaluated for risk and corrective measures.
o Risk analysis is carried out for the whole complex.
10
5. SAFETY PERMITS
o In a chemical plant various maintenance activities
goes on throughout the year. Similarly, modification
schemes are implemented. These activities requires
hot work in the running plant.
o There is a system that before starting any new
activity , the concerned group will take permit from
the plant in charge.
o There are two kinds of permit viz. Cold work permit,
Hot work permit. Both the permits are issued by
plant in charge.
o Hot work permit is counter signed by Safety officer
after checking all the safety requirements.
o Besides hot work, safety officers also counter sign
permits for work at height, vessel entry and
radiography activity.
11
6. MONITORING OF CRITICAL
ACTIVITIES
In a chemical plant, regular as well as newactivities are always going on.
For critical activities safety officers are discussingwith the plant personnels about the activitiesinvolved in the job.
The criticality of the activities with respect tohazard is discussed. Necessary guidelines forsafety observations and emergency needs areprovided.
Besides this, continuous monitoring of the activityis also carried out. 12
7. TRAINING
Since education is most important tool for safety,more thrust is given on training of the people. Thereare various modules on safety training planned fordifferent categories of employees and workers.
The safety training is given to following category of persons:
i. Employees
ii. Contract workers
iii. Trainees
iv. Hazardous material handling Drivers
v. Family members
vi. Executives
vii. Community 13
CONTD.
o Annual schedule for safety training of employees is
prepared. Class room as well as field training is
imparted by Safety personnel.
o Each contract worker is compulsorily given safety
training before he starts the job. “Safety Gate”
concept is followed to give safety training to every
worker entering into the premises of the Company.
o Trainees: All the trainees viz. GETs, DETs, are
imparted safety training on various models. For this,
every month four days compulsory training is
arranged wherein all the trainees take part.
Trainees are also given fire fighting practical
training. 14
CONTD.
o Family members, ladies and children of the
Company are given training on Road and Home
safety once in a year.
o Executives: Special trainings on subjects like BBS
and Safety audit are kept for senior executives.
o Community: Once in a year, safety awareness
programmes are kept for nearby communities
wherein they are told about the chemicals, hazards
and emergency preparedness.
15
SAFETY TRAINING TO DRIVERS
Every day there are movements trucks and tankersfor delivery and dispatch of chemicals and fertilizersin the Company. The chemicals transported are ofhazardous nature. If any incidence occurs, it mayresult into a big mishap. Hence it is highly requiredthat the vehicle condition should be very good. Thedrivers should have valid license. The driver shouldbe able to deal any emergency occurred due to anymishap. Every month the drivers in a group aregiven hazardous material handling training as wellas other traits of the business.
Drivers of the vehicles transporting material are alsogiven TREM card training.
16
CONTD.
8. INVESTIGATIONS BY HIGHER
AUTHORITY
Every critical incident is investigated by a team of
senior persons of the Company.
The causes of accident and the recommendations are
sent to the management. The modus operands is that
during investigation, head of the department should
remain present along with all the persons of various
disciplines. Similarly, safety department team also
gathers.
On the spot investigation involving the affected
person is done. Various solutions are also discussed
and suggestions are sought from the affected persons.
The final recommendation is prepared by Safety
department which is circulated to all the Heads.17
9. SAFETY COMMITTEE
o A Safety Committee consisting of representativesfrom various disciplines is formed byManagement.
o This is chaired by Sr. Executive. It also consistsof members from the workers.
o The Committee meets quarterly to discuss theissues related with safety.
o The outcome of the committee is presented beforethe management and action plan is prepared tocomply the unsafe conditions.
o Instructions for following safety precautions toemployees is also conveyed through the safetycommittee members.
18
10. SAFETY SUB-COMMITTEES
In addition to Safety Committee, there are safety
committees at plant levels. The committees
consist of members of different disciplines.
They meet every month.
They move around the plant and record all the
abnormalities. These are sent to respective
groups for compliance.
19
11. INVOLVEMENT OF WORK
FORCE
Periodical meetings are organized with contractors tomake them aware about safety.
Contractors safety code is issued to all the contractors.Violations of safety code invites fine to the contractors.
There are various projects going on in the Companywherein many contractors are involved. All the contractorsare made aware about the safety requirement.
Special training is imparted to supervisors and theirworkers on safety aspects like importance of PPEs,working at height, emergency preparedness etc. They arealso given first aid fire fighting training.
If any worker is found violating the safety norms, thecontractor is penalized monitorily. This is also recorded intheir performance evaluation.
20
12. TESTING OF MATERIAL
LIFTING EQUIPMENTS
In the chemical plant, there are various kinds of
material handling equipments, cranes, EOTs and
other lifting machines.
These all machines are tested by third party and
representatives from Inspection, Maintenance
and Safety deptt.
The records are submitted to the Director of
Industrial Safety & Health.
All the lifts of the plants are also tested and the
testing is witnessed by Safety deptt. 21
13. VEHICLE INSPECTION
Although vehicles which are transporting chemicals from
the Company are inspected before the entry into the
factory, there is a check list which ensures that the tanker
is suitable for loading a particular chemical and will be
dispatched safely at the consumers site.
Besides the tanker’s quality, legal papers for
transportation as well as RTO license for the driver are
also checked.
There are chemicals which are incompatible with other
chemicals. There may be dangerous occurrence if
incompatible materials react together.
The quality of the product should also be as per
specifications.
In addition to this, the body of the tanker is also inspected
and the worthiness certificate is also sought from the
driver.
22
14. MOCK DRILLS
There are continuous activities going on in the plant.
To check the readiness of tackling any emergencysituation, regular mock drills are conductedperiodically.
In a year, around 7 to 8 surprise mock drills areorganized. These are conducted in the plant to judgethe effectiveness of the system.
Abnormalities are recorded and noted bymanagement.
Observers are senior executives of the Company. Themock drill reports are discussed in Chief Executivesmeeting and before the Board of Directors.
The feed back report of the mock drill is sent toconcerned groups for compliance.
23
15. EMERGENCY
COMMUNICATION
During the emergency, communication among the
plant persons and the executives of the company
becomes very much essential. Since in case of crisis,
telephone lines becomes busy, it becomes very
difficult for the plant people to talk with their
superiors.
To tackle this problem, we have made a system
wherein automatic SMS message is generated in
the cell phones of Executives whenever an accident
occurs.
Besides this, Pop-up messages are also generated on
the office computers for emergency communication.
24
16. RESCUE TEAM
o A team of around 150 persons is trained for rescue
purpose during the emergency.
o They are given special training to rescue persons
in case of occurrence of disaster.
o They are given training for physical fitness, fire
fighting and rescue tool operation.
o The team members are selected from different
groups representing various areas.
o The list of the trained persons is available at fire
department as well as with individual plant
control rooms. The team members are also given
refresher training. 25
17. CONTRACTOR’S SAFETY
o There are many non-continuous activities go on in theplant. To tackle the need, there are many contractorsworking in the plant.
o The unsafe activity / occurrence of the contractors isrecorded.
o The safety performance of the contractor is judged onthis regard and while awarding new contract to them,they are warned to improve the safety standards.
o Repetition and insincerity in following safety norms isseriously viewed. The violation in wearing PPEs isseriously viewed and contractors are fined for non-compliance.
o The statistics of observation and accidents arerecorded for each contractor and are sent to all HOD’s.
26
18. TRANSPORTS &
CONTRACTORS MEET
To impart knowledge about safe operation, safe
transportation, chemicals, their hazards and
emergency preparedness plan to contractors and
transporters, every year, Transporters and
Contractors Meet is organized.
The safety awareness massage is communicated
by them to their employees.
This way they are also involved in the safety
practices which are required by the workers to
follow. 27
19. CONTRACTOR LABOUR
COMMITTEE
o The committee discusses the matter relatedwith safety practices followed by contractors.
o Due weightage is given for their safetyperformance for issuing new contracts.
o The record of the observations and incidences ofall the contractors is prepared and they arewarned if the occurrences are more.
o Serious violations of safety observations reflectsin awarding the contracts.
28
20. SAFETY DAY
4th March is celebrated as ‘National Safety Day’.
Various activities are planned for safety awareness.
The groups which are included in the programmes
are employees of the Company, contract workers,
drivers, family members and surrounding
community.
Exhibitions and various competitions, talks and
practical training are kept for all.
29
21. MUTUAL AID SYSTEM
o The district is having many big and small industries.
o All the industries representative meet periodically
and discuss about the hazards at their place and the
facilities available.
o The meeting is conducted by the officials from local
authority. This body is named as ‘Local Crisis Group’.
o The group companies are helping each other by
providing the help needed in case of emergency.
30
22. FOUR WAY TEST OF
SAFETY
31
o 1. Is the person skilled for the job?
o 2. Is work place Safe to do the job?
o 3. Are all the necessary PPE’s required for thejob available?
o 4. Are all the tools perfect?
CONCLUSION
At our company, we have adopted various ideas suiting to
the needs of Fire and Safety. Our policy is based on
following guidelines.
Proactive actions to control the hazards and reduce
incidences.
“Fire Fighting” readiness in case of any eventuality.
Fast Communication.
Systematic Analysis of the event.
Recommendations for improvement.
32