Safety Management in Coromandel Fertilizer

Limited plant, vizag

Abstract:
Safety management and precautions are very important aspects for successful

operation of an industry. In fact safety management determines the fate and fortune of

successful operation of an industry. This is especially applicable to fertilizer producing

industry such as coromandel fertilizer limited plant present in vizag. This industrial plant

mainly concentrates on the production of urea ammonium phosphate 28:28:0, 14:35:14 NPK.

In addition to this CFL has the credit of being the first in India

to import molten sulphur as part of Eco-friendly and energy conservation measure.CFL had

received British safety Council five star rating for health and safety management system

,besides, many national and international awards in the areas of production, safety

management. CFL has taken the initiative to implement Process Safety Management System of

occupational safety and health administration (OSHA), USA to bring company par with

international standards in operating chemical plants.

This paper briefly describes the main ideals of process safety

management system followed in CFL and it also briefly describes the safety rules and

precautions followed in one of the most dangerous plants of the industry i.e. sulphuric acid

production plant shortly abbreviated as (SAP).

KEYWORDS: process safety management, CFL, SAP, NPK, etc.,

Introduction:
The main objective of any industry is to produce products of high quality complying with the
market demands, satisfying the pollution control norms and adopt strictly to environmental

1
friendly production measures. In addition to this it is the basic necessity of any industry to
follow strict safety management procedures for the safety of the workmen and other personnel
involved in the successful operation of an industry. this is applicable to all product producing
industries and is especially applicable to fertilizer producing industries as they involve in
production of acids such as sulphuric acid, phosphoric acid, etc., which are highly dangerous
and if not maintained properly may have devastating effect on the working personnel and may
pollute the environment adversely. So, for any fertilizer producing industry strict safety
measures and procedures must be applied for successful and safe operation of an industry.
One among the main fertilizer producing industries of India is
Coromandel Fertilizer Limited plant present in Visakhapatnam, Andhra Pradesh.
History of the plant:
Coromandel fertilizer plant is spread over 500 acres of land and is at 5km far from
the Visakhapatnam port on the east coast of India. The industry mainly involves in the
production of production of urea ammonium phosphate 28:28:0, 14:35:14 NPK as well as low
analysis fertilizers like 20:20:0:15 under the brand name of ‘gromor’ CFL is originally on
integrated fertilizer complex plant where some the raw materials required such as sulphuric
acid, phosphoric acid etc., are manufactured at high capacity. CFL plant mainly consists of 4
operating plants:
1. Sulphuric acid plant
2. Phosphoric acid plant
3. Complex plant
4. Utility plant
The main raw material such as ammonia is imported from gulf countries and sulphate and
phosphate rocks are being imported from the countries like Japan, Senegal etc., for the
production of sulphuric and phosphoric acid respectively. In addition to these highlights CFL

has the credit of being the first in India to import molten sulphur as part of Eco-friendly and
energy conservation measure.CFL had received British safety Council five stars rating for
health and safety management system, besides, many national and international awards in the
areas of production, safety management. CFL has taken the initiative to implement Process
Safety Management System of occupational safety and health administration (OSHA), USA to
bring company par with international standards in operating chemical plants.
PROCESS SAFETY MANAGEMENT SYSTEM
The main ideals of the process safety management system followed in CFL are:
Objectives:
To proactively avoid incidents that have harmful impact on the employees, community,
environment and facility assets.

Process safety information:

 Process chemistry
 Block flow diagrams
 Safe upper and lower limits of critical parameters
 Material of construction

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  Design codes and standards used.
Operating procedures:
 Up to date set of operating procedures must be readily available.
 Procedures specifying operating limits and consequences of deviating critical
parameters must be updated.
 Following procedures must be mandatorily followed:

 Cold start up of sulphuric plant

 Sulphuric acid truck unloading

 Procedures can be revised and re-issued based on operating experience.

Contractor control:
 To have effective systems for ensuring safe work by contract workmen.
 Safety training to contractor employees before they start working on site.
Pre start up review:
 To prevent process related incidents due to inadequate or incomplete design or
installation.
 Applies to initial start-up of any new additional process equipment
 Also applies to restart of significantly modified equipment
Incident investigation:
 Purpose of this is to ensure that any incident is properly investigated and
recommendation is implemented
 Responsibilities for implementing recommendation assigned
 PIIR: Primary incident report must be prepared and analyzed.
 FIIR: Final investigation report must be prepared and analyzed.

Mechanical integrity:
 List of safety critical equipment
 Pressure vessels/storage tanks/piping systems including valves/relief and vent
systems/emergency shutdown systems/ alarms/interlocks etc.,
 Preparation of safety critical equipment table.
Training:
 Every new employee undergoes process safety related training.
 Refresher training to experienced employees.

Safety work practices:

 Confined space entry
 Lock and tag out of electrical and mechanical energy sources.
 Opening of process equipment
 Working at heights
Emergency Response planning:

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  On site plan, including recovery operations after an incident

Document control system:

Process safety management system follows document control system to ensure latest
procedures to be used and recorded and is properly maintained. They are:
 Master copy
 Controlled copy

Among the four plants sulphuric acid plant is more dangerous and it involves in the
production of sulphuric acid by DCDA(Double Contact Double Absorption process)alongside
it also involves many specific dangers in operation. The main specific dangers and their
prevention and immediate measures are given below:

GENERAL

Reference should be made to the relevant safety requirements under Indian Factory
Regulations as well as other general precautions for handling chemicals.

ACID BURNS:

 In case of an acid burn, the operator should with all possible speed get under a
safety shower and use the full flow of water – the more water the better. A small
amount of water will increase the severity of the burn. Water should be used until
all traces of acid have been washed from the burn. Alkaline solutions are not
needed, if used at all, they should be used only after all acid has been washed
from the burn, it may be treated in the same manner as a heat burn.

 It is considered debatable whether or not a stock of first aid solutions or ointments

should be maintained in acid plant as operators have been known to use them
without first washing the acid from a burn and thus have increased the severity of
the injury.

 A drinking fountain with a liberal upward flow of water is desirable and may be
used advantages for eye burns. If an operator gets a drop of acid in his eye he
place his eye directly over the fountain and thoroughly flush it with water.

 Alkaline neutralising agents should never be used for eye burns. It cannot be more
strongly emphasized that the best first aid measure for an acid burn is “A LOT OF
WATER QUICKLY” and it is better to provide water, which is not excessively
cold.

 When the tests in the acid cooling water show the presence of acid or when any
leaks or drops from valve pickings are suspected, the investigating operator

4
 should approach the area of suspected leak from up wind and preferable from
above.
 Any person entering the acid area or handling acid should at all times wear
goggles and rubber gloves.

REPAIR WORK:

 The examination and repairs of plant and piping where danger from acid, molten
sulphur, steam, hot water, poisonous gases – moving machinery or and other
source is to be expected, should only be done under competent supervision and
after a “permit to work “has been issued.

 As a general rule “permit to work” certificates should always be used where ever
there is a need to coordinate the work of two or more groups of people from the
operating and construction (or maintenance) departments, where the actions or
omissions of one can directly expose the other to hazard. When dealing sulphuric
acid, it should be remembered that the quantity required to cause severe personal
injury is very small. It is there fore recommended that even if lines and vessels are
drained, depressurised and isolated and pumps are stopped and the starters locked
off, rubber gloves and goggles should be worn as a minimum precaution. If any
doubt exists, then full protective clothing including PVC suit, hood and rubber
boots should be worn.

ENTRY INTO TANKS, ETC :

Not withstanding any legislation governing the entry of work men into tanks or other
enclosed vessels, the following are reasonable minimum requirements.

a) The vessel should first be inspected by a competent person who should

certify it as fit for entry and specify and protective clothing etc that may be
required.
b) It is not advisable that spade plates before entry isolate any sources of
dangerous liquid, fume or dust.

Some specific items that should be kept in mind with respect to safety are:

Toxic gases:

Sulphuric dioxide, sulphur trioxide, sulphurous oxides are asphyxiating.

Toxic liquids:

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Sulphuric acid and oleum.

Protective equipments:

Goggles, gloves, aprons, and boots.

Gas masks and breathing apparatus.

Emergency equipments:

Local showers and baths.

Eyewash for acid.

First aid equipment for acid burns.

Danger points:

The worst risks are:

1) Acid pump glands.

2) Acid pipe work.

3) Sulphur burner.

4) Sulphur pit.

Irrelevant personnel should be kept out of these areas.

Conclusion:

In Summary this is brief presentation of safety management ideals followed in

Coromandel Fertilizer Limited Plant, Visakhapatnam .Implementation of the above ideals
and norms, have made CFL one of best industries in India with best safety measures and
procedures and has earned international reputation for the above organization.

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Acknowledgements:
We offer our grateful acknowledgements to Prof.Ch.V.Ramachandra Murthy, Head
of the chemical engg. Department , A.U.C.E for granting us the required permission to undergo
training programme at CFL and we are also grateful to Suresh Betha, Deputy
Manager(training) CFL ,staff and workmen of CFL to grant us the required permission to
undergo the training programme in their organization, and guide us through the training
programme.

Document By
SANTOSH BHARADWAJ REDDY
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