Defensive Training for 2W/4W – Train the Master

Trainer, Office Auditing& proactive measures for

Material handling equipment’s& HAZOP.

A mini project submitted in partial fulfillment for the award of degree

of

MASTERS OF TECHNOLOGY

IN

HEALTH, SAFETY & ENVIRONMENT

Submitted By
E.Sathwik Reddy
R080218009

[M. Tech- Health, Safety& Environment]

UNIVERSITY OF PETROLEUM AND ENERGY STUDIES, DEHRADUN

Under the guidance of

Mr. Bhaskar Kundharaju & Mr.Sreehari
Associate Director-Corp SHE, Director-Corp SHE
Dr.Reddy’s Laboratories Limited.
Bachupally, Hyderabad.
 ACKNOWLEDGEMENT

It gives me immense pleasure to express my gratitude to everyone who has helped me in the
successful completion of the project title “Defensive Training for 2W/4W – Train the
Master Trainer, Office Auditing& proactive measures for Material handling
equipment’s& HAZOP”.

I have taken efforts in this project. However, it would not have been possible without the kind
support and help of my guide ‘M.SREEHARI (Corp-SHE Director) & KV.BHASKER (Corp-
SHE Associate Director)’. And I am grateful to the technical inputs given by ‘Appa Rao’
during the project. I would like to extend my sincere thanks to him.

I particularly thankful to Dr. Nihal Anwar Siddiqui, Head of Health and Safety Department
of University of Petroleum and Energy Studies and also the Internship program guide Dr.
Bikrama Prasad Yadav for providing me support & guidance throughout the internship.

I am also thankful to ‘Thakur Perwani’, Global Head SHE, Dr.Reddy’s for providing me good
opportunity to work in live project. Special Thanks to J. P. Kaushik (UPES) and B. Sharika
(UPES) for their helping hand during the project. I thank all the faculty and staff of the
department and our colleagues for their useful suggestions and contribution.

E.SATHWIK REDDY
ABSTRACT:

Over a million people lose their lives due to road accidents in India every year. There were four
fatalities of Dr.Reddy’s employees due to these accidents. As the number of vehicle users is increasing
rapidly the no. of accidents are also increasing. So as to reduce the number of causalities and
incidents, Dr. Reddy’s is planning to implement some of the best Road Safety Practices inside the
campus, and took the initiative to train the employees on Defensive driving for two wheelers & four
wheelers. A process note that has been developed for scheduling, and execution of the defensive
driving program to train the master trainer will be discussed. As a proactive measure the company has
taken an initiative of installation of biometric sensors for all the Material Handling Equipment (MHE)
in order to avoid unauthorized personnel from handling the MHE & also to avoid the occurrence of
incidents in future. A detailed description of installation procedure will be discussed. Similarly,
Defensive training will be also given to MHE operators through virtual reality to Prevent mishaps. A
theoretical session followed by a practical session will be organized to know the progress of the
operators. Office Auditing which was carried out at few sites (GGI, Corporate office, lake shore towers,
cyber spanzo, and jupally) located at Hyderabad were also discussed. HAZOP has been carried out for
Diesel storage tank and will be discussed.

KEYWORDS: Defensive driving, Material handling equipment, Auditing, HAZOP.

 CONTENTS

Contents
1 INTRODUCTION .................................................................................................................................... 5
1.1 BACKGROUND: ........................................................................................................................ 5
1.2 OBJECTIVE OF WORK .............................................................................................................. 5
1.3 ABOUT THE COMPANY:........................................................................................................... 6
2 PROJECT DESCRIPTION .................................................................................................................... 7
2.1 Capability Building on Defensive Driving: ............................................................................... 7
2.1.1 Defensive Driver Methods: ............................................................................................. 7
2.1.2 Identification: .................................................................................................................. 8
2.1.3 Program Designing: ...................................................................................................... 9
2.1.4 Training: ..................................................................................................................... 10
2.1.5 ACTIVITY CHART: ........................................................................................................... 11
2.2 Calculation of Net book values for the existing MHE’s: ........................................................ 11
2.3 Biometric installation for the MHE: ...................................................................................... 12
2.4 Office Auditing ...................................................................................................................... 13
2.5 HAZOP FOR DIESEL STORAGE TANK: ..................................................................................... 18
2.5.1 Recommendations: ....................................................................................................... 22
3 PROGRESS TILL NOW & FUTURE WORK: ........................................................................................ 23

LIST OF FIGURES
FIGURE 2.1:1 -- STRATEGY FOR TRAINING ........................................................................................................................ 8
FIGURE 2.1:1 -- STRATEGY FOR TRAINING .......................................................................... ERROR! BOOKMARK NOT DEFINED.
FIGURE 2.1:2 -- PROCESS FLOW ................................................................................................................................ 8
FIGURE 2.3:1 -- INTERLOCK PROCEDURE FOR MHE ......................................................................................................... 13
FIGURE 2.3:2 --OUTLOOK OF FORKLIFT ALONG WITH BIOMETRIC INSTALLATION ..................................................................... 13
FIGURE 2.4:1 -- OFFICE AUDITING ALONG WITH THE RECOMMENDATIONS IMPLEMENTED ....................................................... 18
FIGURE 2.5:1 -- FLOW DIAGRAM OF DIESEL STORAGE TANK AREA ........................................................................................ 19
LIST OF TABLES

TABLE 2.1:1 -- SELECTION OF TRAINERS .......................................................................................................................... 9

TABLE 2.1:2 -- SCOPE OF WORK ..................................................................................................................................... 9
TABLE 2.1:3 -- SCHEDULE OF THREE DAY PROGRAM ......................................................................................................... 10
TABLE 2.1:4 -- ACTIVITY CHART/ GANT CHART ................................................................................................................ 11
TABLE 2.1:5 -- LOCATION OF TRAINING ......................................................................................................................... 11
TABLE 2.2:1 -- DOUBLE DECLINING METHOD................................................................................................................... 12
TABLE 2.2:2 -- EXISTING NBV OF MHE ........................................................................................................................ 12
 1 INTRODUCTION

1.1 BACKGROUND:
Over a million people lose their lives across the globe due to Road accidents[1]. In past even in Dr.
Reddy’s there had been few incidents both inside and outside the Bachupally campus. Few employees
have lost their lives in these incidents. For any situation there must be some measures which need to
be taken that may be proactive or reactive. In a similar way Dr.Reddy’s has taken reactive measures
regarding to reduce these road accidents i.e.by imparting Defensive driving techniques into the
mindset of the employees by proper training for four wheelers and two wheelers. On average 5000
Employees commute to work on their own vehicles all over India located at Hyderabad,
Visakhapatnam, Miryalguda and Baddi. Apart from this we have a vast sales & marketing team of
around 5900 employees spread across India, commuting daily on two wheelers. Thus we have made
a strategy to acknowledge drivers throw all these causes so as to reduce the accidents. Incidents
during material handling has been increasing rapidly due to improper condition of equipment
improper driving, over speeding, unauthorized person access to MHE (Material handling equipments)
etc., As a proactive measure the company has taken an initiative of installation of biometric sensors
for all the Material Handling Equipment (MHE) in order to avoid unauthorized personnel from handling
the MHE & also to avoid the occurrence of incidents in future. Dr.Reddy’s has overall 112 MHE’S out
of which 20 are defective and are not in operation, remaining 92 MHE’s are ready for the biometric
installation. A detailed description of installation procedure will be discussed. Similarly, Defensive
training will be also given to MHE operators through virtual reality to Prevent mishaps. A theoretical
session followed by a practical session will be organized to know the progress of the operators.
Auditing plays a major role in identifying frauds and prevention of errors. It helps to keep the staff
vigilant, as the work done by them eventually for an Audit. Office Auditing which was carried out at
few sites (GGI, Corporate office, lake shore towers, cyber spanzo, and jupally) located at Hyderabad
were also discussed. HAZOP has been carried out for the diesel storage tank, and recommendations
has been given.

1.2 OBJECTIVE OF WORK

 To develop in-house capability and impart Defensive Driver methods to all on our
employees and associates.
 Analyzing from the various resources and asset number are to be assigned for each
Metal Handling Equipment (MHE).
 Installing Biometric sensors for all the MHE’s.
 Replacement of existing MHE with an external agency which will provide new MHE
along with skilled operators who are completely responsible for the operation of
MHE.
 To carry out the Auditing at few sites (GGI, Corporate office, lake shore towers, cyber
spanzo, and jupally).
 To carry out the HAZOP for the diesel storage tank.
1.3 ABOUT THE COMPANY:
Dr.Reddy’s Laboratories Ltd (DRL) is a global pharma company which provides affordable and
innovative medicines to the people[2]. It has three business-pharmaceutical services & Active
ingredients, global generics and proprietary products. Company concentrates on oncology,
cardiovascular, pain management, dermatology, diabetology, gastrointestinal issues[3]. It operates in
markets across the globe. Its major markets are- USA, INDIA, RUSSIA, CIS countries, & Europe.
 2 PROJECT DESCRIPTION

2.1 Capability Building on Defensive Driving:

Our main goal is to make sure that accidents count decrease in the upcoming future.

To achieve this, many measures can be taken such as:

• Surveys has to be conducted to know the important causes which has led to accidents.

• Emergency measures have to be improved so that people who have met with accidents can
be immediately rescued.

• Drivers must be well prepared so that accidents can be avoided. (They must be well
experienced and they must know all the rules and regulations to be followed in traffic)
(Signal jumping)

Among the several measures listed above, we have focused on imparting Defensive Driver Methods.

So the main focus is to develop in-house capability and impart Defensive Driver methods to all on
our employees and associates.

2.1.1 Defensive Driver Methods:

• Checklist: Vehicle condition has to be monitored continuously.

• Ergonomics: Can be included so that drivers feel safe and secure.

• Climate awareness: Driver must be well aware of how to drive the vehicle based on the
environmental conditions like fog, rains etc…

• Ethics/Regulations: Drivers must not use the mobile phones, they should avoid signal
jumping, Drinking and drinking should be avoided, and Traffic signs must be followed.

• Discipline: Over-speed may seem to decrease in time to reach our destination but also may
become the reason for accident.

• Technical improvements :

Use of sensors (Vehicle will not start unless the user puts on Helmet, eye-blink sensors, Bio
metric sensors)

Glasses which improve the vision during night times.

Connected vehicle technology

 The above methods have to be very well injected into driver mindsets.

Thus we have made a strategy to acknowledge drivers throw all these causes so as to reduce the
accidents.

The objective of this program is to develop in-house capability and impart Defensive Driver methods
to all our employees and associates. To achieve this we want to create a pool of certified trainers and
mentors on Defensive Driving & Road Safety across the business and make our employee commute
safer. Our estimate is that we need around 180 master trainers.

Figure 2.1:1 -- Strategy for training Figure 2.1:2 -- PROCESS FLOW

2.1.2 Identification:
The group of trainers will be selected from each site /location based on the locations as per Fig-1. 180
Employees will be nominated from different sites and GGI marketing team. Site Safety head and Site
HR will identify the site teams to be nominated as train the trainers.
 Table 2.1:1 -- Selection of Trainers

2.1.3 Program Designing:

Designing and scheduling the Master train the trainers program

Table 2.1:2 -- Scope of work

 Refer Annexure – 3 for course contents & package for defensive driving master train the trainer
program.

Table 2.1:3 -- Schedule of three day program

2.1.4 Training:
 Three day training session will be delivered to the trainers. Each session has two day of
classroom training and one day of practical demo and drivers’ assessment.
 Total of 12 training sessions will be conducted across India with batch size of 15.
 Using animations, videos and presentation slides to cover all the topics followed by a practical
session.
 The trainers will be provided with entire training material and resource kit along with trainer’s
guide explaining effective use of these resources in training drivers. The coach will Evaluate,
grade, and certify the DRL trainers for competency based on classroom and practical
performance as A,B,C,D based on written/On ground assessment/ presentation.
  The master trainer should conduct at least 6 sessions in a year covering 60 employees. Upon
completion of this target he will be awarded with a gold certification. If any master trainer
failed to conduct 6 sessions in year will be disqualified as master trainer.
 All employees across DRL will be covered in a year under this program against TNI for which a
detailed training schedule will be prepared and deployed by each site safety head.

2.1.5 ACTIVITY CHART:

S.No Activity 19-Apr 19-May 19-Jun 19-Jul 19-Aug 19-Sep 19-Oct 19-Nov
Identifying agency for
1
developing the program
Program Design in
2
consultation with agency
Scheduling the program
3
including making PO

Identification of 250
members from marketing
4
teams and 70 members
from site team.

Organizing the Master

5
train the trainer programs
Master Trainers to train
6 Onwards
the site Teams

Implementation &
Strengthening of
7 Onwards
defensive driving
programs in all sites

Monitoring & Tracking

8 the progress through Onwards
Handholding.

Table 2.1:4 -- Activity chart/ Gant chart[4]

The training sessions at the following locations will be conducted as:

East Region Kolkata -2

North Region Delhi -3 Lucknow-1

South Region Bangalore -1 Chennai -1 Hyderabad -1

West Region Mumbai -2 Pune -1

Table 2.1:5 -- Location of training

2.2 Calculation of Net book values for the existing MHE’s:

Example:

On April 1, 2012, company purchased MHE for Rs. 100,000. Useful life is 5 years. Company X
considers depreciation expense for the nearest whole month. Calculate the depreciation expenses
for 2012, 2013, 2014 using a declining balance method.
Useful life = 5
Straight line depreciation percent = 1/5 = 0.2 or 20% per year
Depreciation rate = 20% * 2 = 40% per year
Depreciation for the year 2012 = Rs. 100,000 * 40% * 9/12 = Rs. 30,000
Depreciation for the year 2013 = (Rs. 100,000-Rs. 30,000) * 40% * 12/12 = Rs. 28,000
Depreciation for the year 2014 = (Rs. 100,000 – Rs. 30,000 – Rs. 28,000) * 40% * 9/12 = Rs. 16,800

Table 2.2:1 -- double declining method

In a similar way we calculated Net book valves for the all MHE, as below:

Table 2.2:2 -- Existing NBV of MHE

The existing NBV (Net book value) of MHE[5] has been given to the vendor for the replacement with
new MHE along the skilled operators[6].

2.3 Biometric installation for the MHE:

As a Proactive measure we have taken an initiative of installing Biometric sensors to prevent mishaps
in the future. We have total of 112 MHE out of which 20 are defective are remaining 92 MHE are ready
for the biometric installation. We have total 16 units, out of which 3 units installation has been
completed and remaining units installation is ongoing.

The procedure for the interlock system of biometric is as follows:

 Figure 2.3:1 -- Interlock procedure for MHE

Figure 2.3:2 --outlook of forklift along with biometric installation

2.4 Office Auditing

A safety audit is a through, critical examination of an organization's safety management systems and
procedures. It is a structured way of assessing the health and safety performance of an organization
by supplying answers to a series of questions and often involves a scoring system so that
improvements can be made. Office Auditing which was carried out at few sites (GGI, Corporate
office, lake shore towers, cyber spanzo, and jupally) located at Hyderabad were also discussed. Few
recommendations has been given.
 Pre Audit Preparation:

Objective:

To identify the gaps in the existing facility and check their compliance with the standard.

Audit Team: Bhaskar KV, J P Kaushik, E Sathwik Reddy.

Information Gathered: Previous audit reports, site layout, and emergency procedures.

Audit Procedure:

Inspection: Office Auditing was carried out at few sites (GGI, Corporate office, lake shore towers, cyber
spanzo, and jupally) located at Hyderabad.

Gaps identified at various locations (Only critical issues are mentioned in the report):
Recommendations were given for the observations and implementation is done and final closed
report has been shown below.

CORPORATE OFFICE:

OBSERVATION RECOMMENDATION POA

 Rotating parts  360 degree guarding  360 degree

are exposed to be provided for Safety
in the all the rotating Guard
Basement-2 parts. provided
STP room.  Conduct a site wide
 Motors are survey of all the
not provided equipment's to
with 360 identify need of
degree proper 360 degree
guarding and machinery guarding,
the rotating prepare a plan to
parts are provide such
accessible guarding, review the
progress in
apex/departmental
meetings.
 Include inspection of
machine guards in
the equipment
preventive
maintenance
checklist
• Dyke wall • Dyke Wall • Overflow
area of the Area of the PVC pipe
diesel tank is diesel tank removed at
not as per the shall be 10 % Diesel day
standard more than tanks. We
Criteria. the volume are replaced
• The Overflow of the Diesel with MS pipe
line if the tank as per
Diesel tank is NBC Part-4.
attached with • The Overflow
a PVC pipe. line shall be
This might extended till
lead to the dyke wall
accumulation area and
of static shall be
charge. grounded
(No PVC shall
be used).

• Housekeeping • All the • Equipment

Equipment equipment Identification
does not have shall be given label
appropriate identification displayed
identification numbers and • All chemicals
number along the same tins position
with the shall be is changed
periodical displayed (Under
inspection with Sprinkler
tag. inspection coverage
details. area)
• Chemicals • Change the •
used for position of
housekeeping the
and other chemicals
purposes such that
were not they are
under the under the
sprinkler sprinkler
coverage. coverage
area
• Periodical • The • Inspection
inspection of contractor tags are
full body tools and evident for
harness was tackles, PPE the power
not evident stored at the tools being
for few contractor used by the
harness. work area to contractors.
• Inspection be inspected However, we
tags are on periodical are providing
evident for basis. Checklist as
the power • Third Party backup
tools being Certification • Request OST
used by the is mandatory to provide
contractors for Full body proper
whereas the harness. guidelines
supporting • A checklist (periodicity /
Checklist is shall be authorized
not evident. followed for vendor) for
• all the Power safety
tools harness third
party
certification
• Emergency • There shall • Displayed in
Contact be a tie-up the
Numbers of with the emergency
the hospitals Nearest contact
are displayed hospital and numbers and
but the Contact distance of
contact numbers of the hospitals
numbers of this Hospital from the
the nearest shall be office
Hospital ( Sky displayed in locations .
Care) which is the • Distance of
300 mtrs emergency Emergency
away from contact contacts
the office is numbers. covered in
not evident. • Distance of above
• Distance of the display
the hospitals Emergency
from the contacts
office shall also be
locations not displayed in
exhibited the
Emergency
Contact
numbers
 MHJ, CS, JUPALLY:

OBSERVATION RECOMMENDATIO POA

N
 Identificati • Identificati • Closed –
on number, on Provided
Inspection number, inspectio
Tags & Inspection n tags &
Checklists Tags & checklists
are not Checklists for
Evident for for the ladders
the ladders • Removed
ladders. shall be ladders
 Metallic establishe from UPS
ladders are d room /
placed in • Ensure the electrical
the UPS metallic rooms
room. ladders are
not stored
in
electrical
and UPS
rooms.

 Type of the • The work • Type of

work done, permit work
Tools used document done will
by the shall have be
operator the details mentione
are not of type of d going-
evident in work done forward
the Work and the • Mock
Permits. tools used Drill
 Detailed by the Report
report of operator in will be
the fire it. updated
mock drill • Fire Mock with
is not Drill report technical
evident. shall details as
Only a contain the suggested
generic technical
report is details of
present the mock
drill.
 Actions are • The • The data
taken as document will be
per the of the entered
thermogra thermogra on the
phic report phic report same day
but the shall be as
documents completed suggested
are not on the day
closed when
action was
taken.

Figure 2.4:1 -- Office Auditing along with the recommendations implemented

2.5 HAZOP FOR DIESEL STORAGE TANK:

The Hazard and Operability Analysis (HAZOP) technique is used to identify and evaluate safety hazards
in a process plant, and to identify operability problems[7]. Use of the HAZOP Analysis technique
requires a detailed source of information concerning the design and operation of a process[8]. It is
most often used to analyze processes during or after the detailed design stage.

The HAZOP analysis is carried out by an interdisciplinary team. A systematic approach is adopted to
identify hazard and operability problems resulting from deviations from the process's design intent
that could lead to undesirable consequences .The team leader systematically guides the team through
the plant design using a fixed set of words, called guide words .The guide words are applied at specific
points or nodes in the plant design and are combined with specific process parameters to identify
potential deviations from the plant's intended operation[9]. material properties must be known
before doing the HAZOP study[10]

Guidewords

 No
 Less
 More
 Part of
 As well as
 Reverse
 Other than
 HAZOP was carried out for the diesel storage tank as below:

Figure 2.5:1 -- flow diagram of diesel storage tank area

Node: Tanker to storage tank

GUIDE PARAMETE POSSIBLE CAUSES POTENTIAL EXISTING RECOMMENDATIONS

WORD R CONSEQUENCES CONTROL
MEASURES

No Flow Inlet valve of the Pump may run dry ,
pump is closed which may lead to rise in
temperature, so there
might be a chance of
explosion
No power supply Pump will not run, which
leads to process delay
Inspection using a Interlocks which automatically
checklist, switch off the pump when no
supervision flow is detected.
Power supply by
DG sets

Cavitation Decrease in efficiency of Reduce the motor RPM if

pump, damage to
impeller.
Less Flow Rupture of pipeline Loss of diesel, which may
due to mechanical lead to explosion and has
damage impact on environment.
Partial opening of Process delay and back
the inlet valve of pressure on the pump
storage tank which may lead to
decrease in the
efficiency of pump.
Cavitation Decrease in efficiency of
pump, damage to
impeller.
possible or use a booster
pump to feed the principal
pump.
Radiography test
is being
conducted to
identify leaks
Inspection using a Diameter of the delivery line
checklist prior should be greater than the
operation. diameter of the suction line.
Reduce the motor RPM if
possible or use a booster
pump to feed the principal
pump.
More Flow Rated capacity of Excess pressure and Orifice plate should be fixed at
the pump is high accumulation of static the delivery of the pump to
charge may lead to regulate flow
explosion
Reverse Flow In correct placing Mechanical seal is Before coupling of motor to
of coupling with destroyed, Casing is pump run a bump test to
pump damaged, Excess ensure shaft is turning in the
pressure and right way.
accumulation of static
charge may lead to
explosion
Part of Flow Not applicable Not applicable

As well as Flow Not applicable Not applicable

Other Flow Not applicable Not applicable

than

GUIDE PARAMETER POSSIBLE CAUSES POTENTIAL EXISTING RECOMMENDATIONS

WORD CONSEQUENCES CONTROL
MEASURES

More Level Failure of level Over flow of the tank Continuous Interlocks which automatically
indicator which leads to loss of monitoring by a switch off the pump when a
diesel and may lead to competent person fixed level is reached.
explosion
Priming of pump Dry run of pump, which Interlocks which automatically
may increase switch off the pump when a
fixed level is reached.

Less Level Inlet flow of Accumulation of static Dip rod is till the
storage tank stops charge which may lead to bottom of the
explosion tank

Leakage of The leaked diesel Reduction of oxygen

storage tank evaporates and the concentration below 5% by
evaporated vapor may having blanketing at the site
ignite and cause with inert gas
explosion.
No Level Not applicable Not applicable

As well Level Not applicable Not applicable

as

Other Level Not applicable Not applicable

than
reverse Level Not applicable Not applicable

Part of Level Not applicable Not applicable

GUIDE PARAMETER POSSIBLE CAUSES POTENTIAL EXISTING RECOMMENDATIONS

WORD CONSEQUENCES CONTROL
MEASURES

More pressure Inappropriate Buildup of pressure in Vent size shall be calculated as

venting of storage storage tank which may per the design volume of
tank lead to explosion storage tank and chemical
used.

Less pressure Leakage of The leaked diesel

pipeline or evaporates and the
storage tank evaporated vapor may
ignite and cause
explosion.
Incidental vacuum Implosion of the tanker Blanketing of Pressure or vacuum
created by pump tanker with conservation vents shall be
suction during nitrogen gas provided for the tankers.
pumping of liquid
from tanker to
storage tank
No pressure Not applicable Not applicable

As well pressure Not applicable Not applicable

as

Other pressure Not applicable Not applicable

than

reverse pressure Not applicable Not applicable

Part of pressure Not applicable Not applicable

GUIDE PARAMETER POSSIBLE CAUSES POTENTIAL EXISTING RECOMMENDATIONS
WORD CONSEQUENCES CONTROL
MEASURES

More Static Un insulated Generation and Critical thickness of the

vessels and accumulation of static Insulated vessels insulation must be considered.
Improper charge which may lead to are present
grounding explosion
arrangements
Splash filling of Rapid Vapor generation Submerged
storage tank which leads to loss of loading using fill
diesel and single spark pipe method
may lead to explosion
Less Static Not applicable Not applicable

No pressure Not applicable Not applicable

As well pressure Not applicable Not applicable

as

Other pressure Not applicable Not applicable

than

reverse pressure Not applicable Not applicable

Part of pressure Not applicable Not applicable

2.5.1 Recommendations:
 Interlocks which automatically switch off the pump when no flow is detected.
 Reduce the motor RPM if possible or use a booster pump to feed the principal pump.
 Diameter of the delivery line should be greater than the diameter of the suction line.
 Orifice plate should be fixed at the delivery of the pump to regulate flow.
 Before coupling of motor to pump run a bump test to ensure shaft is turning in the right way.
 Interlocks which automatically switch off the pump when a fixed level is reached.
 Reduction of oxygen concentration below 5% by having blanketing at the site with inert gas.
 Vent size shall be calculated as per the design volume of storage tank and chemical used.
 Pressure or vacuum conservation vents shall be provided for the tankers.
 Critical thickness of the insulation must be considered.
3 PROGRESS TILL NOW & FUTURE WORK:
 Defensive Driving- two wheeler/four wheeler – A survey was taken and the number of 2 & 4
wheeler users was identified. Then we shortlisted 180 master trainers who will be trained by
the External agency on Defensive driving. We then designed a 3 day session in consultation
with the external agency. Execution of the scheduled training is going to happen shortly.
 Biometric installation of the MHE – We have identified all the MHE and assigned an Asset
number. We then Calculated the Net book value i.e. the Depreciated cost. As a Proactive
measure we have taken an initiative of installing Biometric sensors to prevent mishaps in the
future. Installation of Biometric sensors is completed in 2 Sites and yet to be completed in the
14 Sites. We’re planning to replace the existing MHE with an external agency which will
provide new MHE along with skilled operators who are completely responsible for the
operation of MHE.
 Office Auditing - We’ve audited few of Dr. Reddy’s sites and suggested certain
recommendations as per the standards.

REFERENCES:

[1] “ROAD SAFETY WEEK.” .

[2] “Dr. Reddy’s at a Glance.”
[3] “Overview of Pharmaceutical Industry Objectives The Playground The Players The
Process Strategy / Trends.”
[4] B. Kv, “Capability Building on Defensive Driving.”
[5] “DRL Forklift data.” .
[6] L. Industrial and E. Solutions, “Comprehensive Study of Material Handling Equipment
Operations Dr . Reddy ’ s Laboratories - A REPORT -.”
[7] “Risk Assessment and Management.”
[8] H. Ibrahim, “Hazard Analysis of Crude Oil Storage Tank Farm Hazard Analysis of Crude Oil
Storage Tank Farm,” no. November 2018, 2019.

[9] M. Kisan, S. Sangathan, J. Nehru, and S. G. Pitroda, “म ा नक,” 2006.

[10] H. S. Diesel, “Material safety data sheet,” no. deg C.