PROJECT REPORT

SAFETY AND HEALTH MANAGEMENT IN CHEMICAL

INDUSTRY

AVG INSTITUTE OF SKILL

V SRINIVASA PRASAD RAO 18/05/2022
DEVELOPMENT
 AVG INSTITUTE OF SKILL DEVELOPMENT
SHARDA EDUCATION SOCIETY
THANE

PROJECT REPORT ON
SAFETY AND HEALTH MANAGEMENT IN CHEMICAL
INDUSTRIES

AT
M/s. SI GROUP INDIA PRIVATE LIMITED
NAVI MUMBAI

SUBMITTED BY
V SRINIVASA PRASAD RAO

PROJECT GUIDE
Mr. AVINASH S KARMARKAR

FOR
ADVANCE DIPLOMA IN INDUSTRIAL SAFETY
ACADEMIC YEAR 2021-2022

COURSE AFFILIATED TO
MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION,
MUMBAI
 ACKNOWLEDGEMENT

I would like to express my appreciation and sincere gratitude to Mr. Avinash

Karmarkar , NSC Expert & ADIS Faculty , Mumbai, for guiding me to complete
the project.

Special thanks to Mr. S.M. Dalvi, Sharda Education Society's - AVG Institute Of
Skill Development" for conducting this course in efficient manner and to all the
faculty members.

V SRINIVASA PRASAD RAO

 PREFACE

The Industrial Revolution that took place in the eighteenth century changed forever the
methods of producing goods. The most important change was the substitution of machines for
people. This resulted in organization of work into large units called "factories", followed by
direct supervision of the manufacturing process and efficient division of work among the labor.
As the industrial revolution continued its rapid growth, unsafe production methods exacted a
heavy toll on the workforce in terms of job-related injuries and deaths (Felton, 1986).

In the twentieth century, as technology grew by leaps and bounds, associated hazards also grew
with it. This resulted in collective efforts and thinking in the direction of controlling work
related hazards and accidents. A group of delegates including safety professionals,
management leaders, public officials and insurance specialists who met in a national safety
meeting in New York in the year 1913, had a desire to attack the problem of occupational health
and safety which most people considered either unimportant or insoluble. This resulted in the
birth of a voluntary organization, named "National Safety Council", which helped to create the
safety movement, as we know it today. Later, similar voluntary organizations such as
International Labor Organization, British Safety Council etc. came up with support from
industries in various parts of the world.

Early legal action in industrial safety took the form of laws to regulate and investigate industry
working conditions, death and injury rates. The next phase was largely concerned with workers'
compensation payments. In subsequent years, governments gradually expanded their roles in
regulating industry on safety matters.

As a result of the above Acts, Safety and health of workers became a major concern and priority
of management. In addition to the losses due to downtime, costs for workers' compensation
insurance, medical and administrative expenses resulting from disability, death and impaired
productivity, they were liable to face serious monetary penalties and criminal sanctions from
the government side, for non-compliance of law. Therefore, safety management became an
important part of industrial management.
 CERTIFICATE

This is to certify that the project report entitled “SAFETY AND HEALTH MANAGEMENT IN

CHEMICAL INDUSTRIES ” submitted by V. Srinivasa Prasad Rao to the Maharashtra State

Board OF Technical Education in partial fulfillment for the award of Advance Diploma In

Industrial Safety is a confide record of the project work carried out by him under my

supervision during the year 2021-2022.

Mr. Avinash S.Karmarkar

Project Guide

Mrs. Mayura Gupte Dr. Harshala Likhite

Co-Ordinator I/C Principal
 SELF DECLARATION

I am pleased to submit a Project report on “Safety in Chemical Industries” on

S I Group India Private Limited-Navi Mumbai as a partial fulfilment of
“Advance Diploma In Industrial Safety” during the year 2021-2022.

V SRINIVASA PRASAD RAO

 EXECUTIVE SUMMARY

I have made an attempt to study Safety & Health Management System status in
Chemical Industry at M/s. S I Group India Private Limited. This being a part of
training for award of Advance Diploma in Industrial Safety, I have carried out
the actual study of safety practices in chemical industry as taught in the syllabus
and under able guidance of my faculties, project guide in ne.

The project includes all the safety practices to which a SI Group follows to avoid
major accidents and I have taken number of photos on various topics. At the end
I have made some recommendations for improvement of plant safety and I am
very thankful to the open hearted management of the company which welcomed
these recommendations and some of these are being are being actually
implemented or in progress.
 INDEX
SR. PAGE
SUBJECT
NO. NO.
1. AIM, OBJECTIVES & METHODOLOGY
1.1 AIM OF THE PROJECT 1
1.2 OBJECTIVE AND METHODOLOGY OF PROJECT ASSIGNED 1

2. INTRODUCTION
2.1 COMPANY PROFILE SI GROUP-INDIA PVT.LTD. 3
2.2 2.2 PRODUCT PROFILE 5
3. MANUFACTURING PROCESS AND ASSOCIATED HAZARDS
3.1 MANUFACTURING PROCESS AND ASSOCIATED HAZARDS 7
3.2 HAZARDOUS PROPERTIES OF CHEMICALS STORED, 15
PROCESSED, HANDLED.
4. SAFETY ORGANISATION
4.1 MANAGMENT COMMITMENT TOWARDS SAFETY 17
4.2 SAFETY ORGANIZATION 19
4.3 MANAGEMENT’S ROLE IN SAFETY 19
4.4 SAFETY POLICY 20
4.5 SAFETY COMMITTEE 21
4.6 TRADE UNION ROLE IN PROMOTING SAFETY 23
4.7 HEALTH & HYGINE 23
4.8 ACCIDENT REPORTING SYSTEM 26
4.9 ACCIDENT INVESTIGATION 27
4.10 SAFETY WORK PERMIT SYSTEM 28
5. PREVENTIVE MEASURES
5.1 PLANT LAYOUT 35
5.2 PERSONAL PROTECTIVE EQUIPMENT 35
5.3 FIRE PREVENTION & PROTECTION 36
5.4 MUTUAL AID SCHEME 42
5.5 INSTRUMENT SAFETY 43
5.6 HOUSEKEEPING 43
SR. PAGE
SUBJECT
NO. NO.
5.7 STORAGE AND HANDLING OF CHEMICALS 44
5.8 SAFETY PRECAUTIONS IN LOADING & UNLOADING 45
5.9 PERIODIC INSPECTION AND TESTING 46
5.10 HAZARD AND RISK ASSESSMENT 48
5.11 WORK PLACE MONITORING OF AIR CONTAMINANTS 50
5.12 OCCUPATIONAL HEALTH HAZARD MONITORING 52
6. SAFETY TRAINING
6.1 INTRODUCTION 56
6.2 CONTINUOUS SAFETY TRAINING PROGRAMES 56
6.3 SAFETY TRAINING FOR CONTRACTOR PERSONNEL 57
6.4 SAFETY TRAINING FOR TANKER DRIVERS AND CLEANERS 57
6.5 SAFETY TRAINING FOR POLICE PERSONNEL 57
6.6 SAFETY AWARENESS FOR SERVICE GROUP 57
6.7 SAFETY EDUCATION AND PROPOGANDA 58
6.8 SAFETY PROMOTING ACTIVITIES 58

7. ONSITE EMERGENCY PLAN

7.1 INTRODUCTION 61
7.2 OBJECTIVES OF EMERGENCY PLAN 61
7.3 THE EMERGENCIES 62
7.4 INTERNAL ASSEMBLY POINTS 62
7.5 EMERGENCY ORGANISATION 62

8. ENVIRONMENTAL CONSERVATION & POLLUTION

CONTROL
8.1 SOURCE OF EFFLUENT AND EMISSION 64
8.2 PREVENTION OF WATER POLLUTION 64
8.3 PREVENTION OF AIR POLLUTION 65
8.4 PREVENTION OF SOUND POLLUTION 67
8.5 ENVIRONMENT MANAGEMENT SYSTEM (ISO 14001) 67
SR. PAGE
SUBJECT
NO. NO.
8.6 ENVIRONMENTAL POLICY 68
8.7 TREE PLANTATION 68
9. MONITORING ENVIRONMENT HEALTH AND SAFETY KEY
PERFORMANCE INDICATORS
9.1 PURPOSE 70
9.2 DEFINITIONS 70
9.3 EHS GOALS 80
10 OBSERVATIONS AND FINDINGS 81
11 RECOMMENDATIONS 83
12 REFERENCES (LIST OF APPLICABLE STANDARDS ) 85

13 MY KEY LEARNING IN INDUSTRIAL SAFETY AFTER PROJECT 86

14 ANNEXURES 87
 CHAPTER-1

1.1 AIM OF THE PROJECT

The main aim of this project is besides being able to complete the Advance Diploma in
Industrial Safety is to increase my knowledge and to improve my performance as a
safety professional.

1.2 OBJECTIVE AND METHODOLOGY OF PROJECT ASSIGNED

 OBJECTIVE:

As a part of curriculum requirement of the “Advanced Diploma in Industrial Safety”

the project work is being undertaken to fulfil the requirement of the topic selected.

 This company is specially chosen for the project because the diversity of hazardous
chemicals handled, stored & processed in company and variety of unit processes
involved in mfg. All these involved variety of hazards that need careful attention.
Secondly the company has well established safety organization and hence interaction
with it is surely productive.

 To identify potential hazards associated with the process and chemicals involved.

 To study safety measures incorporated by management to minimize accidents.

 To collect and analyse the accident data.

 To examine and evaluate the EHS performance of the factory.

 To study statutory requirements.

 To suggest the possible improvements in EHS organization.

 To study about different standards adopted by company.

1
  METHODOLOGY

Following methodology for doing the project was adopted

 Study of process details and plant manuals.

 Study of Safety organization and system of the factory in detail.

 Study of various Fire prevention, protection system, procedures, facilities

 With respect to handling, storage and processing of hazardous chemicals.

 Study of hazards and their control measures.

 Discussion with plant and safety personnel.

 Analyses of overall safety performance of the company using

Accidents, fire and near miss statistics and case studies.

 Data Collection & Analysis

 Conclusion about the Adequacy of Safety, Fire prevention and Protection

System

 Recommendations, if any based on the observations for further Improvement

2
 CHAPTER-2

2.1 INTRODUCTION TO SI GROUP- INDIA PRIVATE LIMITED

SI Group – India Private Limited (formerly known as HERDILLIA CHEMICALS) came

into existence in 1967 as major petrochemical complex and the only company to
manufacture phenol in India. The company is situated as Thane- Belapur belt. The company
is considered as one of the pioneer of petrochemical industries in India, is involved in the
manufacture of Basic Heavy Organic Chemicals. The technologies for plant have been
obtained from reputed International Licensors such as UNIVERSAL OIL PRODUCTS
(U.S.A), SCIENTIFIC DESIGN (U.S.A) and BRITISH PETROLEUM (U.K.)

The product of SI Group India Private Limited serve as raw materials for industries
manufacturing paints, pharmaceuticals, dye, stuff, PVC, synthetic fibres, Heat transfer
media, resins and perfumery.

2.1 COMPANY PROFILE :

The company has present turnover of Rs, 250 crores and has around 425 employees. It has
an installed capacity of 10, 5800 tons per annum, which are continuously being upgraded
using innovative cost saving and debottlenecking technique

3
Over the year the company has made considerable progress in terms of productions volumes,
efficient plants operations, Research and Development, Pollution control, expansion and
diversification. Besides doubling the production capacities of phenol and phthalic anhydride
plants, not only a number of process to minimize and control pollution have been introduced,
but also to convert the waste pollutant effluent streams into value added products

Company is certified to ISO 9001, ISO-14001 and OHSAS -18001 systems and a
Responsible Care signatory company.

Company has been awarded as Best Responsible Care Company in the “Emergency
Response Code” in the year 2008 by Indian Chemical Council.

Photos of awards received

SI Group is a US based having 22 manufacturing sites in the various countries of the world.
SI Group is World leaders in Alkyl phenols. Their major products are based on alkyl
phenols and industrial resins.

In India, SI Group has total four manufacturing sites namely at Navi Mumbai, Rasal (Raigad
district), Lote (Konkan region) and Ranjngaon (Pune) and manufacturing phenol, phenol
based derivatives and industrial resins respectively.

4
2.2 PRODUCT PROFILE

A list of the products manufactured by the SI GROUP –INDIA PVT. LTD, Navi
Mumbai along with installed capacities and uses are given below:

Sr.N Product Capacit Uses

y
(TPA)

1 Cumene 29,800 Intermediate for Phenol, Acetone and

Agrochemical.

2. Phenol 26,000 Intermediate for Phenol. Formaldehyde resins, epoxy

resins lube oil additives, dyes, binders, anti oxidants,
medicines and Alkyl Phenols.

3. Acetone 16,000 Pharmaceuticals, Agro chemicals, surface coatings,

paints, Diacetone Alcohol, MIBK, Isophorone,
Mesityle Oxide, Solvent in printing ink.

4 Diacetone 7,000 Surface coatings, break, fluids, and solvent in Plastic

Alcohol

5. Phthalic 9,000 Plasticizers, paints, dyes, pigments, polyster resins.

Anhydride

6. Isobutyle Benzene 2,000 Intermediate for ibuprofen, perfumery chemicals.

7. Diphenyl Oxide 3,000 Heat Transfer Media, perfumery, and surfactants,

blowing agents, flame retardant

8. Isophorone 3,000 Solvent for decorative coatings, silk screen-printing

and pesticides. Intermediate for Isophorone, Diamine
/ Di Isocyanate, Metaxylenol, Trimethyl Phenol and
perfumery chemicals.

9. **Dodecyl Phenol 6,000 Lube oil additives

10. **Fumaric acid 600 Alkyl resins, polyester, resins, food acidultants,
ferrous fumarate, paper varnish

5
11. Alpha Methyl 900 ABS plastics, Styrene, butadiene rubber, polystyrene,
Styrene styrene, acrylonitrile resins, perfumery chemicals,
poly alpha methyl styrene

12 **Capacitor fluids 2000 Electrical capacitors.

13. Acetophenone 400 Perfumery chemicals / tear gas, intermediate for

pharmaceuticals and resins.

6
 CHAPTER-3

3.1 MANUFACTURING PROCESSES AND ASSOCIATED HAZARDS

CUMENE PLANT:

Process Description:

Cumene is manufactured by the reaction between Propylene and Benzene in the presence
of solid phosphoric acid catalyst at about 35 kg/cm² pressure and 235°C temperature.
C3H6 + C6H6  C9H12
Propylene Benzene Cumene

Propylene is washed with 10% caustic in a caustic wash column and subsequently with
water in a water wash column. Both these columns are operated at around 17.5 kg/cm²
pressure and are provided with safety valves.

The reactants mixture is stored in a vessel at about 17 kg/cm² pressure (fitted with a safety
valve) contains excess Benzene which is recycled in the process. The feed to the reactor is
preheated to the optimum limit to get desired product quality. The reactor effluent contains
Cumene, excess Benzene, Propane and high boilers which is then fed to a series of three
distillation columns to separate Propane, Benzene (to be recycled in the process), product
Cumene and high boilers. The heating media in Cumene plant is hot oil, which is preheated
in a natural draft furnace, which is fired, by furnace oil.

Process Safety:
The catalyst being highly susceptible to absorbing moisture. The moisture level in the
combined feed is analysed every 3 hours to ensure that it remains within the limit of 250
ppm.
High temperature alarm is provided in the reactor with a trip on feed preheater and
Propylene intake.

7
Automatic tripping of the furnace oil (and hence the furnace) when the flow of the hot oil
circulated through the furnace goes below the low flow level.
Safety valves provided on pressurised equipment. Safety exhausts are released to a blow
down tank connected with a vent stack.

PHENOL PLANT:

Process Description:

Manufacture of Phenol involves reaction and distillation. In the reaction section, Cumene
is oxidised to Cumene Hydro peroxide (CHP) by air in a series of four oxidisers. The
strength of CHP leaving the last oxidiser being 20%.

C9H12 + O2  C9H12O2
Cumene Air CHP
The 20% of CHP is concentrated subsequently in a concentrator to about 80% after an
alkali wash. The concentrated CHP of 80% strength (Rest is Cumene and high boilers) is
cleaved in cleavage reactor where controlled quantity of sulphuric acid is added to split
into Phenol and Acetone.

C9H12O2 + C6H5OH  CH3COCH3

CHP Phenol Acetone

The acidic cleavage product containing Acetone, Phenol, Cumene, high boilers is washed
to removed the acidity before pumping to distillation section.

The washed cleavage product is then processed through a series of nine distillation
columns to get pure Phenol and Acetone. Cumene to be recycled to the process. The high
boilers from the crude phenol column are sent to a cracker operated at around 300°C to
recover Cumene, Phenol, crude AMS and crude Acetophenone.

The waste tar form the cracker is then used as a fuel in boiler after blending with waste
hydrocarbon produced in the system.

8
Hazards:
* Fire and explosion
* Uncontrollable escape of flammable and fan toxic liquids
* Uncontrolled reaction in the cleavage reaction or in CHP storage tanks.

Process Safety:
Oxidizers:
* High temperature alarms in all four oxidizers.

PHTHALIC ANHYDRIDE PLANT (PAN):

Process Description:

O-xylene and compressed air having temperature of about 200°C are led to the reactor
having catalyst vanadium pentoxide (V2O5). The reaction being exothermic, tremendous
heat is evolved with the temperature rising to about 465 to 500°C. These reactants are
cooled down in the reactor itself with the help of salt circulation. The heated salt is cooled
by dowtherm circulation which in turn is cooled by boiler feed water producing high
pressure steam.

The reactor gaseous mixture which is coming out of the reactor is cooled by primary gas
cooler with the help of boiler feed water (producing high pressure steam) to 250°C. These
gases are further cooled in secondary gas cooler to 150°C with the help of boiler feed water
producing low pressure steam.

These cooled gases are then passed in switch condensers saving a temperature of about
60°C where Phthalic Anhydride is condensed alongwith low and high boiler impurities.
Some low boiler impurities are allowed to vent to atmosphere.

This condensed PAN is melted and charged in refined steel pot where about 50 MT of
crude PAN is treated to 280°C for 8 hours. During treatment low boiler impurities are
allowed to vent in atmosphere and this treated batch is then distilled under vacuum to
recover pure PAN.

9
 This pure PAN is then flaked and packed in paper bags saving polythen coating.

Hazards:
* Fire and explosion
* Uncontrolled escape of hot dowtherm or flammable liquid.

Process Safety:
* Safety valves on all pressure systems.
* Low and high oxygen alarms for each oxidizer.
* High pressure alarms & low pressure alarms with trip device to stop the air
supply at header.
* Roof over the CHP process tanks with external cooling water spray
arrangement.

Concentrator:
* High temperature alarm.
* High pressure alarm
* Low flow alarm
* High level alarm

Cleavage
* Low / High temperature alarm
* Low feed alarm
* Tripping of the feed of low reflux with alarm device.

HIGH FLOW ALARM ON ACID

In general, where critical flow meter is involved duplicate flow meters are installed
in reaction section.

Distillation:
* High level alarms wherever required.

10
 * Pressure switches to stop the steam input to the reboilers when the overheat pressure
exceeds present valve.

Dowtherm Furnace:
In Phenol plant mainly steam is used to give the heat to the process but cracker is heated
with dowtherm as the temperature involved is around 300°C.

* High dowtherm temperature alarm in the furnace.

* High cracker temperature alarm.
* Automatic cut out device to stop the furnace oil flow to the furnace on high dowtherm
temperature, high surge drum pressure, low flow of dowtherm.

General:
* Safety valves on all pressure equipment including column.
* Low cooling water supply alarm.
* Water spray system on the CHP tanks.

Safety Measures:
Vessels are protected by safety relief valves and other necessary safety devices.

ALPHA METHYL STYRENE (AMS):

Process Description:
Alpha Methyl Styrene is a by-product formed in the Phenol production, which is purified
by fractional distillation.

Safety Measures:
Level and temperature alarms and solenoid operated pressure trips on the heating
medium of the distillation column are provided to protect the plant.

TRANSALKYLATION CUMENE BOTTOMS (TAC):

Process Description:

11
Poly-Iso-Propyl Benzene formed as a by-product in the Cumene manufacturing. They are
treated with excess Benzene in the presence of an alkylation catalyst to form Cumene.

Safety Measures:

Level and temperature alarms and solenoid operated pressure trips on the heating medium
of the distillation columns are provided to protect the plant.

* The catalyst used in the process 'Thorea' is of radioactive nature.

* The safety interlocks are provided which includes tripping of the phenol preheating
furnace in case of low flow of the Phenol or Phenol feed pump trip.

* Provision of dust extraction system comprising of suction hood cyclone separator,

bag filters and blower in order to keep the dust emission levels minimum during
catalyst loading and unloading.

* Personal carrying out the above operations are provided with dust mask. Respirator,
gloves and Apron and also carry personnel monitors to measure radioactive
emissions.

ISOPHORONE:
Process Description:

Isophorone is produced by the condensation reaction of Acetone in the presence of dilute

caustic soda at about 200°C and 32 kg/cm². The condensation reaction is carried out in two
trayed reaction column. The crude reaction product is then passed forward for recovery of
the Isophorone product.

Hazards:

Process is carried out at high temperature and pressure.

12
Safety Measures:

All relevant equipment is protected by safety relief valves and other necessary safety
devices.

DIACETONE ALCOHOL PLANT (DAA):

Process Description:

Diacetone Alcohol is manufactured by liquid phase condensation of acetone using

alcoholic caustic soda as catalyst under low temperature.

2CH3 - CO - CH3 - CH3-CO-CH2-C (OH) - (CH3)2

The reaction is carried out in a series of four reactors provided with cooling arrangement
only part of the acetone is condensed and most of the uncondensed acetone is recycled to
the process.

The alkalinity in DAA is removed through Ion-exchange process before pumping to

distillation stream.

The crude DAA is then processed through a series of three distillation columns to recover
uncondensed acetone for recycling product DAA and some high boilers. A batch kettle
with a fractionating column is provided to recover the acetone from the top stream of the
plant.

Hazards:
* Fire and explosion
* Uncontrolled escape of flammable liquid.

13
 Process Safety:
* Pressure switches provided to stop steam supply when the pressure of the columns
exceeds present valve.
* Safety valves on the evaporator and batch kettle.

ISO-BUTYLE BENZENE (IBB):

Process Description:
IBB is formed by alkylation of Toluene with Propylene. The reaction is carried out at a
temperature of about 180°C and a pressure of 31 kg/cm² over alkali metal catalyst. The
reaction mixture is washed with water to remove the catalyst and distilled to recover
unreacted toluene and obtain pure Iso butyl Benzene. The waste hydrocarbon is burned
in boiler to generate steam.

Hazards:
* Possibility of fire and explosion as Toluene and Propylene, the two main reactants
have flash points well below ambient temperature.
* Alkali metal catalysts are highly reactive with moisture and oxygen in air.
* The reaction temperature is above the critical temperature of Propylene and the
reaction process is carried out at high pressure.
* Hydrogen a highly inflammable gas is evolved in the process distillation is carried
out at reduced pressure.

Safety Measures:

* Safety interlocks and alarms are provided to take care of any sudden rise in
temperature and pressure.
* The entire reaction section is covered with asbestos shed to prevent sodium and NaK
alloys catalysts in coming in contact with moisture and air.
* Appropriate arrangements are made to vent hydrogen evolved in the reaction with
most care.
* Propylene storage area in the plant is provided with water spray systems.

DIPHENYL OXIDE (DPO):

14
Process Description:

The process for manufacture of Diphenyl Oxide involves vapour phase catalytic
dehydration of Phenol over a heterogeneous catalyst Thorea. The active component of
catalyst. Thorium Oxide belongs to radioactive class of materials having low specific
gravity and hence it is mildly radioactive.
2C2H5OH  C6H5OC6H5 + H2O

The reactor outlet passes through four distillation columns to obtain pure DPO.

Hazards:
* Fire and explosion hazard.

3.2 HAZARDOUS PROPERTIES OF CHEMICALS STORED, PROCESSED,

HANDLED.
SR.N MATERIAL FLASH POINT TLV IN PPM CLASS HAZARDOUS
0C PROPERTIES

1 Benzene -11.1 0.5 A Flammable, Toxic,

Carsigenic.
2 Cumene 43.8 50 B Flammable
3 DIPB B Flammable
4 Toulene 4.44 A
5 O-Xylene 14-17 A
6 Cumene Hydro 48.9 --- B Explosive,
Peroxide Reactive, Unstable
7 Cleavage 05 A Toxic, Corrosive
8 Phenol 79 05(Skin) C Toxic, Corrosive,
rapid absorption
through skin
9 Acetone -17.7 A Highly flammable
10 Crude 82 C
Acetophenone

15
11 Alpha Methyl 58 B
Styrene
12 Sulphuric Acid 05 ----- Corrosive
13 Caustic 02 ----- Corrosive
14 Tar blend C
15 Dowtherm Marine pollutant
16 Fuel oil C
17 Hot oil C
18 Propylene -107. --- A Asphyxiant,
flammable,
explosive
19 Propane -104 ---- A Highly flammable
20 LPG -104 A Highly flammable
21 Nitrogen Asphyxiant
22 Hydrogen Flammable/explosi
ve, Asphyxiant.
23 Ammonia 25 Toxic, corrosive
24 Chlorine 1 Highly toxic,
Corrosive

16
 CHAPTER-4

4.1 MANAGEMENT COMMITEMENT TOWARDS SAFETY

It will out of place to mention here that initiative for accident prevention, control of pollution
and enhancement of standard for safety and health at workplace shall be from the top
management. Voluntary and self regulatory measures taken by the management with
cooperation and involvement of their employees are in the long run, more efficient & cost
effective, lead to better and lasting result and contribute to higher moral, motivating and
productivity in its operation.
The management commitment towards safety is visible in the company by way of the
following activities: -

 Commitment of top management is demonstrating by middle

management and staff by ensuring responsibility down the line.

 Safety policy – it compromises of mission statement along with its

implementation.

 Monthly top management safety meeting. - Steering committee

 Department safety committees meeting are conducted monthly.

 Safety competition. Safety quiz, slogan poster competition,

Housekeeping contest are held periodically.

 Safety/productivity suggestion scheme and effective implementation.

 Intra plant safety rounds and survey.

 Fire and safety induction/training programs along with refreshers

training including contractor workmen.

 People audit techniques and zonal head concept.

 Delegating officials to participate in seminars, symposium and

exhibitions.

 Safety management safety audit (internal) based on concept of British

Safety Council five star audits.

17
 External experts audit system.

 Safety week, fire day, environment day celebration.

 Weekly, Monthly and Yearly reports on safety health and environment

performance.

 Tool box talk every day.

 Appraisal system for the assessment of individual’s safety performance.

 Mock drill rehearsal for emergency scenarios.

 Periodic reviews on engineering safety, risk analysis, etc.

 Safety is to driven organization. Responsibilities and authorities are

clearly defined; hence system implementation is effective.

 Communication –safety and a related activity progress is reported to top

management weekly.

 Yearly action plans are prepared by each plant for improvement in safety,
health and environment and are monitored regularly.

 Safety oath is exercised daily as by department which includes contractors

personal also.

 Training is conducted as per schedule. Management ensures

implementation of safety tools/trainings etc. as the on going activity

 It is revealed from the safety performance that the trend is improving and
the accident/incidents are minimized to greater extent.

18
4.2 SAFETY ORGANISATION

INTRODUCTION:

Safety and production are the two sides of a coin. Safety is as important as production and
production can never be at the expense of safety. If production gets precedence over safety
it may succeed for a short period. But sooner or later it is bound to have adverse effects
and a day may come to a total stand still. Hence Safety Department is must to enlist and
maintain the combine efforts of the entire personnel of an establishment in the work of
accident prevention.

Safety organization in M/s SI Group –India Private Limited, Navi Mumbai is a definite,
well planned organized set up (Annexure-1). It consists of two persons. All safety activities
are being looked after Dy. General Manager-EHS (Environment, Health & Safety) whose
commitment and devotion to the safety are beyond words. Functionally he directly reports
to Director –Operations who is overall in charge of the Factory. The Deputy Manager –
EHS is directly in-charge of carrying out all safety related activities. 10 Professional fire
staff are also clubbed to EHS section.

4.3 MANAGEMENT ROLE IN SAFETY:

To co-ordinate with the management and advice the line supervisors by constant vigilance
and inspections for enforcement of safety norms and statutory safety provisions under the
Factories Act 1948.

To ensure safe working conditions by inspecting all work areas, accesses and such places
which are used by the employees.

To conduct periodical plant safety inspections and suggest remedial measures.

To maintain close liaison with Government and non-Government agencies concerned with
safety and fire prevention and ensure that all statutory requirement is adhered to investigate
the accidents and to find out causes and take remedial measures to prevent recurrences.

19
To advise regarding selection of Personal Protective Equipment (PPE).

To maintain safety records and periodical reports to all concerned and forward safety
literature to all concerned.

To advise on any additional safety aspects when major jobs involving hazards are carried
out.

Carry out safety promotional activities for developing the safety culture among employees
by way of training programmes, safety contests are celebrating Safety Week.

Ensuring the safety of contract workers working in the factory by way of providing training
and close monitoring.

4.4 SAFETY POLICY:

As per Section 7A (3), 41B (2) of the Factories Act, 1948 and the Rule 73-L of the
Maharashtra Factories Rules 1963 occupier of every factory shall prepare a written
statement of his policy in respect of health and safety and workers at work.

M/s SI Group –India Private Limited, Navi Mumbai has declared a safety, health and
environment policy with comprises the following (Ref. Annexure 1). It declares the
intention of the company to conduct its business in such a manner that the safety of its
employees and in general the public. Its plants and materials processed in those plants,
the environment of the factory and the surroundings are maintained safe, harmless and
pollution free.

The company assures everybody concerned that it will follow all the statutes relating to
safety, health and environment and will try to remain ahead of them.

It is given that the management and administrative set-up will be utilised to comply with
the objectives. It has set forth to maintain and improve the conditions related to safety,
health and environment.

20
It also gives a detailed description of the responsibilities borne by the Managers,
Supervisors and other employees. The arrangement and facilities available to carry out
such compliance and the support available from the top management to carry out such a
task.

It ensures that safety and related subjects will be given due importance while recruiting
and promoting the employees. It lists various measures taken to maintain the conditions
in a safe manner.

M/s SI Group-India Private Limited., Navi Mumbai, also Follows Corporate

Environment, Health, Safety and Security Policy (EHSS) which signed by President SI
Group of Industries.

4.5 SAFETY COMMITTEES:

Safety Committees do make some useful contribution in a comprehensive safety

programme by the expertise, knowledge and collective thinking of the members, keeping
this in view and to make employees safety conscious. Mainly there are two types of
committees

A. Central EHS Committee

B. Sectional EHS Committee

21
A. CENTRAL SAFETY COMMITTEE:

This committee is the top policy making body on safety matters. The chairman of this
committee is Director –Operations who is the overall in charge inside the factory. The
committee consists of 10 members 5 representing the management and 5 members from
the workers nominated by the Union. These members are nominated for a period of 2
years and they meet once in 2 months. The Dy. General Manager-EHS is the member
Secretary of this committee. This committee is responsible for initiation preparation of
safety rules, safe operating procedures, review of the accidents, fires and near accidents
training objectives or any other policy related matters. The minutes of the meeting are
circulated to all concerned. The Deputy Manager – EHS also attends these meetings by
virtue of his being responsible for safety matters. Decisions are followed up for
implementation by DGM-EHS / Dy. Manager – EHS

B. SECTIONAL SAFETY COMMITTEE:

There are totally 9 Sectional Safety Committees and the respective Sectional Head acts
as the chairman of that committee. In the plants the concerned Senior Plant Manager
functions as the chairman and the head of the maintenance section of that plant as the
Secretary. The committee consists of 5 nominated members taken from various sections
of the plant.
They are nominated for a period of 1 year and related problems in the respective areas
are discussed and the minutes of the meeting are sent to all concerned with the work
completion target date. If any matter arises which is beyond the Sectional Safety
Committee.

22
4.6 TRADE UNION'S ROLE IN PROMOTING SAFETY:

Union does play a positive role in promoting safety, union representatives and leaders
are well educated. This is helpful in good behaviour and better outlook. It is observed
that both management and union leaders are sincere in their desire to co-operate in the
causes of safety and union representative is selected solely from the stand point of his
effective functioning in Joint Management Labour Safety Programmes and for the Safety
Committee Selection of employee as representative of safety committee is based on the
following:

a. Such representative should not be involved in normal union activities such as

bargaining, grievances, settling etc.

b. They should be co-operative minded and sincerely interested in safety activities; their
judgement and knowledge of work methods should be good.

The union participation does help in implementation of safety programmes and in

motivating employees to follow their leaders and their good performance is reflected in
the field of safety. The union leader always encourages the workers, operators to
participate in almost all safety activities that are organized in the factory.

We are proud mention here that most of central EHS committee members nominated by
recognised trade union are safety professionals.

4.7 OCCUPATIONAL HEALTH AND HYGIENE:

M/s SI Group India Private Limited, Navi Mumbai has well-developed Occupational
Health Centre (OHC) with all the necessary infrastructure. Two Factory Medical Officers
(CMO & FMO- and one male nurse are available round the clock. The company has its
own ambulance facility for transporting patient with serious illness from the plant to
Occupational Health Centre or to the nearby hospitals.

PRE-EMPLOYMENT AND PERIODICAL MEDICAL CHECK UP:

23
 All the employees are subjected for a through medical check up by the Factory Medical
Officer before they are enrolled into the service. Thereafter periodical i.e. Annual and
six monthly (for plant personnel) medical check-up is conducted by the Medical
Department for all the employees to detect any abnormalities because of action of any
chemicals at an early stage. The various check-ups also include blood test, urine test,
chest, X-ray and ECG, stress test (need based).

Regular medical checks up is conducted for the employees exposed to toxic chemicals
like Benzene, Phenol etc. Records of the health of each employee is maintained and
monitored. if any employee shows signs and symptoms of toxic chemicals exposure, the
matter is investigated and corrective / preventive measures are taken care accordingly.

MEDICAL FACILITIES:

First Aid Boxes are used and kept in all plants for the immediate rendering of first aid to
personnel injured on duty. First aiders trained by St. John Ambulance Institute are
available round the clock in the shifts to deal with any emergency involving injury to the
plant employees.

OTHER ACTIVITIES OF OHC:

1.First aid training on rendering immediate help to personnel injured on duty is imparted
to the plant employees.
2. The OHC team of Doctors and Nurses conduct blood donation camp in the factory
since last more than 25 yrs.
3. Free medical check up camps like cancer detection, skin diseases or eye sight checking
are conducted in the rural areas like belavali, Panvel and Kopar, Uran etc.
4. Medical check up of Traffic Police personnel are also organized on routine basis, we
are providing disposable dust mask to traffic police.
5. OHC has adopted 5-S housekeeping system in the Occupational health centre.

Photos of Occupational Health Centre with 5 S housekeeping system

24
25
4.8 ACCIDENT REPORTING SYSTEM:

With a view to ensuring timely dissemination of the information or submission of notice

of Accident / Hazardous occurrence to the various Government Authorities within the
stipulated time prescribed under the Factory Act 1948 and the Maharashtra Factories
Rules 1963 the following procedure is being followed.

Whenever an accident takes place involving injuries to an employee or a contract labour,

the concerned section supervisor as soon as he receives the information informs the
medical centre for getting ambulance. The injured person is given first aid treatment with
the help of undergone the first aid training and who are authorised to give first aid
treatment. The supervisor fills up the Occupational injuries and illness form containing
particulars of the accident the type of injury and other relevant factors and sends it along
with the injured person to the medical centre. Then medical officer decides whether
further treatment / action is required, fill up part of the form, the medical authorisation is
then forwarded to the Safety department along with medical authorisation form.
Concerned Supervisor prepares one plus two copies of “INCIDENT FACT SHEET”-
(Annexure-3) and forwards it to Director –Operations. / Department Head, second
copy to the Safety department and retain one copy as section records.

4.9 ACCIDENT INVESTIGATION:

26
Accident investigation is essential to bring out the fact in details to understand the root
cause of the accident so that preventive measures can be taken to prevent the recurrence
of the accident from the similar cause.

From the Heinrich theory of foundation for LTA injuries, in a unit group of 330 accidents
involving the same persons and same condition there are 300 near miss (no injury)
accidents, 29 First Aid (minor injury) accidents and 1 loss time accident injury. Even
though LTA injury is shown at the apex of pyramid. It is not like that it will occur at
330th times but it can occur any time. Therefore, every accident should be investigated.
In SI Group India Private Limited, Navi Mumbai all accidents and near accidents are
investigated by an investigation team. (Pl. refer- INCIDENT FACT SHEET-
Annexure-3)

INVESTIGATION PROCEDURE:

Whenever an accident takes place involving fire or injuries to an employee, the

concerned section supervisor conducts a preliminary investigation of an incident and
prepares the incident occurrence report. This is prepared within a period of 24 hours and
sent to Director Operations. Based on this incidence report further investigation is
carry d out by the concerned department head along with the safety officer. The
investigation report is sent to the area in charge where the accident took place and to all
relevant sectional heads along with the corrective actions to be taken to prevent
recurrence. Follow up actions are taken by the department concerned as per approved
recommendations and subsequent decisions. A copy of this accident report is also sent to
one of the parent company ‘Hercules Incorporated Wilmington’, U.S.A, for their
information and interest.

27
4.10 SAFETY WORK PERMIT SYSTEM:

In order to safeguard men, materials and machinery no maintenance work is performed

on any equipment in the factory premises until an authorisation writing in the form of a
permit is received form to operating department. The permit system has been designed
to provide a close contact and high degree of co-operation between the maintenance and
operating staff. The permit procedure ensures that the area and equipment are made safe
by the operating staff. It also specifies the scope of work and time limit of the job.
The following two types of permits are used in the company.

A. Work permit or cold job permit - Also called as Green Permit. (Annexure 4)

B. Permit for Hazardous Work or Hot Job Permit - Also called as Red Permit.

WORK PERMIT:
All jobs involving cold work should be covered under the work permit. Cold work is a
work that ordinarily does not create enough heat to ignite flammable gas air mixture and
/ or work in restricted area or in equipment where a potential physical hazard exists.
Opening of process or utilities lines, equipment or vessels, hacksaw cutting, blinding
lines, locking out electrical equipment, carrying out normal maintenance of plant
machinery and equipment (without any hot jobs like welding, gas cutting etc.) are
examples of cold jobs.

PERMIT FOR HAZARDOUS WORK:

Basically this can be used for following jobs:

For use of open flame, spark-producing tools, hot metal, heat producing operation in
contraband area like:

28
 Welding
 Soldering
 Gas cutting
 Burning
 Use of flint lighter
 Heating / melting with open flame
 Grinding
 Drilling
 Chipping
 Sand blasting
 Use of Camera / X-ray machine
 Use of non-flame proof equipment
 Use of automobile equipment in plant area
 Use of matchbox etc.

The naked light permit for the work in plant are is limited for a day but valid for a shift
only.

I. For entry in vessel, tank or other confined area:

This procedure is formulated to ensure that any person entering a confined space will not
be subjected to conditions that may cause injury or death. This procedure is applicable
to both Herdillia employees and contractor employees engaged to work in confined
spaces in the company premises. A safety clearance certificate is initiated by the Deputy
Manger - Production or his representative and is approved by the Sr. Plant Manager /
Manager Shift Operations or their representative.

The safety clearance certificate can be issued for 24 hours and can be extended up to 7
days after which a fresh clearance certificate has be prepared.

For excavation inside / outside contraband area guidelines for excavation work. This
procedure applies to all employee’s / contractor’s employees carrying out excavation
in the entire factory.

29
 On a request from the Deputy Manager - Production, Sr. Plant Manager or Area in
charge. The Civil - Engineer and the Electrical Engineer gives the clearances
approval in the hazardous work permit after checking for underground service lines
or cables respectively in that area of work.

For working at height above 3 meters from nearest available platform / landing.
The purpose of this procedure is to avoid fatal accidents due to falling from height.
It is made compulsory in the procedure to wear safety belt when working at height
above 3 meters where no protective railing or guards are provided or even below 3
meters where there is a danger of falling.

COLD JOBS:

The following steps are taken for cold jobs before starting any maintenance work plant
area; it is ensured that adequate safety precautions are to be taken. The operating staff
assesses the conditions in the hazardous area and explosimeter readings are taken to
ensure that the area is free from explosion measures.
The system on which maintenance job is to be undertaken is isolated, depressurised,
washed and/or purged with inert gas/steam / water / air as applicable valves are not to be
trusted upon for holding. Blinds are to be inserted. The necessary electrical
instrumentation / mechanical isolations of the system as applicable are effected and duly
certified on the safety work permit. The concerned unit operator/ supervisor is required
to be present while carrying out the maintenance job. Necessary safety equipment is to
be used while carrying out the job. No flammable / toxic gases and liquid to be left out
into the atmosphere from nearby units. It is ensured that nearest safety shower and
eyewash fountain unit is working all right.

HOT JOBS:

As far as possible hot jobs like cutting, welding, grinding etc, are avoided in the plant
area. Where the plant is running the following safety precautions as applicable are to be
taken in the exigency of such hot jobs. The area in which the hot job is to be carried out

30
is to be cleared off from any flammable or combustible materials such as cotton waste,
jute other papers, oils etc. Over at least 10 meters’ fire department is to be intimated for
inspection of the area and for providing necessary fire fighting equipment before the start
of the hot job.

Wet asbestos sheet or fire proof curtains are used to restrict the spread of sparks a pieces
of hot metals. Firewater should be kept running underneath the spot so that sparks and
molten metal do not fall below or get carried off by wind. Near by electrical cables are
adequately protected from exposure to heat or flame emanating due to the hot job.
Persons working at heights on platforms or scaffolds etc are protected against falling by
the use of railings, safety belts and such other effective safe guards.

Welding cables will have proper earthling connections electric power supply for welding
machines area taken only from prescribed supply points. Damaged welding cables are
not used. Oxygen and acetylene cylinders should not be placed below the cutting area
where sparks and molten metals can fall on the same. They must be placed away from
any hot line or equipment to prevent overheating.

Safety goggles or shields are used when chipping, cutting or grinding is carried out to
protect the eyes from injury due to flying particles.

It is required to clear the area from all scaffolding materials, rods, cables, gas cylinder
etc. which are brought for the job as soon as the job is completed. Till all such materials
are cleared from the area. Safety work permit can not be cancelled.

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CONFINED SPACE ENTRY:

The work at confined spaces include any closed space such as a tank, pit, vessel etc,
where there is a likelihood of atmosphere, dangerous to life being present for entry into
a confined space, whether for inspection or for working a safety clearance certifying
should be issued by a competent person mentioning in it the precautionary measures
taken. Safety equipment that will be work and certifying that the area is safe.

THE SAFETY MEASURES TAKEN:

1. Isolation and Emptying:

Before entry the equipment should be isolated from rest of the system simply closing the
valves is not enough. The flanges are to be blinded and the valves are properly tagged.The
equipment is emptied by drawing out its contents into a safe place. Further precautions
are required in case these vessel tanks originally were charged with toxic or corrosive
chemicals and flammable or explosive materials. All this equipment is purged to remove
their contents.

2. Purging and Ventilation:

The purging can be done either with water, steam or suitable inert gas. A suitable method
of purging should be chosen depending upon the circumstances and resources.

All the manholes and inspection doors are kept open and care is taken that no toxic gases
and vapours enter inside from the adjacent areas. Adequate ventilation is provided inside
during the course of work to safe guard the personnel against harmful concentrations of
poisonous, asphyxiating or explosive gases that are likely to emanate.
After the purging has been completed and equipment has been ventilated it is necessary
that the atmosphere inside the space is tested to ensure that there is no harmful
concentration of gases and vapours. In case hot work has to be done, it should be further
tested to make sure that atmosphere is non-explosive and there is absolutely o danger of
explosion.

3. Special Precautions:

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Portable lamps used inside the confirmed space are operated on 24 volts or less. In case
electrical tools operating on 230 volts are used except for confined space. They will have
proper insulation and effectively earthed. In suspected cases of explosive atmosphere
only flame proof electrical apparatus and non-sparking tools are used. Adequate
precautions are taken to safe guard against harmful concentrations of poisonous
asphyxiating or explosive gases that are likely to emanate during work inside. After the
jobs are completed, it is ensured that everybody has come out from the confined space
and no materials is left inside. then only the covers are closed. The equipment is re
commissioned only after receiving back the safety work permit with the signature of the
person who has executed the job stating the job has been completed satisfactorily.

LOCK OUT TAG OUT SYSYEM (LOTO) FOR ISOLATION:

LOTO System is used for all isolation to ensure Zero residual energy. Physical lock
with specially made Hasps are used for mechanical as well as electrical isolations. The
isolation reference card system is applicable whenever there is a need to isolate a system,
equipment or vessel for repair, maintenance, cleaning or inspection etc. It involves two
types of tags.

Red tags (Annexure-2) to be attached to places where blinding, isolation, breaking is

physically carried out.

Electrical lock out tag (Annexure-2) for locking out electrical equipment connected with
the place of work.

An isolation reference card (Annexure-2) is prepared listing all the isolation points on
the equipment and the concerned employee puts signature on the card when physical
isolation is carried out. When isolation is removed the card is similarly signature is made
by the employee to ensure that none of the points of isolation are missed.

33
 CHAPTER-5
PREVENTING MEASURES

5.1 PLANT LAYOUT:

In M/s SI Group India Private Limited, Navi Mumbai all the plants are open types, which
provides maximum cross ventilation of air. This reduces the concentration of flammable
mixtures in environment reducing fire and explosion hazard and incidentally also helps
in not reaching the TLV limits of those, which are also toxic.

Plot plan of the company shows that the furnaces in Phenol and PAN plants are located
after considering wind directions.

Some other salient features of the plant are as follows:

a. Care is taken that under no circumstances. The entrance and exits of opening of the
plant should be blocked.

b. Fire station is located close to the main gate, which is well away from the plant
operating, storage units.

c. Good illumination is provided everywhere in the factory and particularly in working

area.

d. After every 2 years walls, doors, windows, handrails, stare cases, platforms and
girders are painted with approved colours.

e. Easy accesses are provided to almost all parts of the plants.

5.2 PERSONAL PROTECTIVE EQUIPMENTS (PPE):

Helmet, safety goggles, hand gloves, uniform and safety shoes are issued to all concerned
employees.
Following PPE are kept in the plant control rooms or plant areas within easy reach of the
user in case of any emergency.

* Self-Contained Breathing Apparatus (SCBA).

* Emergency Life Support Apparatus (ELSA) set.
* Safety shower and eye wash fountains.

34
 Other safety equipment mentioned below are available to all employees as per
requirement:

* Ear muff / Ear plug

* Hand gloves - Canvas, Rubber, PVC, Leather, Asbestos

* PVC Apron

* Face shield

* Blow Man’s Apparatus

* Fire suit

* Safety torch

* Dust mask

* Air movers

* Fire fly

* Organic vapour (Ammonia / Chlorine) respirators.

* Multi gas respirators

5.3 FIRE PROTECTION FACILITIES

Fire Protection Training:
1. Basic fire fighting training is given to all employees in the factory. The fire protection
training is conducted by rotation every Wednesday at 3.15 pm.
2. Fire squad drill is conducted for the fire squad members representing different sections
on every Friday between 9.30 Hrs to 11.00 Hrs. The squad consists of around 13 members
in each shifts m representing different sections. The training schedule is made in the
beginning of the year and they are trained in handling all fire fighting equipment s, various
scenarios possible in the plants and their role in an emergency. Tenure of fire squad is Two
years before being replaced by a new team.
Fire squad Members - :
Fire squad members are nominated from each section for the period of two years. They
under gone training in fire fighting & prevention as per the schedule.
Physical fitness of members is examined by CMO once in a year.

35
Role – To assist firemen in Emergency control operation including fire fighting, help to shift
injured person to OHC on stretcher.
Written & practical Evolution of training is done during Safety week celebration every year.
They are provided with blue color safety helmet for easy identification.

Fire Fighting Crew:

We have professionally qualified Managers in charge of the Fire Services Section. There
are Ten qualified and trained Firemen who have necessary experience in respect of handling
fire equipments, and driving licenses to drive fire engine, etc. We also have 13 fully trained
fire squad members in each shift who assist the fireman in fire fighting operations during
an emergency. We have also a well laid out programme for training a number of employees
in fire fighting measures..
a) Foam / Water Tender
b) Multipurpose Fire Tender (Foam, Water and DCP)

Fire Hydrants:

We have 114 double headed fire hydrant posts with wheel valve 63 mm size instaneous
female coupling and 44 internal hydrants in plant area at different locations on multi
storied plant buildings so as to be accessible at all vulnerable sections.

Fire Water Mains & fire pump:-

To ensure that the fire water is available in all the areas of the factory complex, fire water
main is installed in the form of ring main system. The M.S. pipe line of various sizes ranging
from 600 mm to 80 mm laid underground as well as above ground depending upon the
requirement with suitable anticorrosive treatment. Entire ring main is provided with sluice
valves at different branches for isolating particular section of ring for maintenance /
alteration purpose and keep other ring main charged. Water supply to the fire water main is
given through 2 storage tanks (FB-714 & FB-715). For fire fighting total storage capacity
of 7800 cu.m..
Total pumping capacity is 1230 m3./hr. which can give continuous supply of water with
pressure10kg/CM2.for fire fighting for more than 6 hrs. As soon as “1000” is dialled fire
36
water pump gets started. Fire water pump can also be started directly by putting on switch
from Fire Station.

Fixed Water Monitors:

Water monitors are provided on the ring main system at selected locations around process
units and tank farm areas. These monitors installed for cooling and fire fighting operations,
can be put in the operation by one person who need not be skilled in hose handling or other
fire fighting skills. There are 28 Water Monitors provided with locking devices both
horizontal and vertical, capable of discharging 2500-3000 LPM of water at 7 kg/sq.cm. and
has range of around 60 M horizontal and 30 M vertical throw.

Portable Fire Extinguishers:

About 425 fire extinguishers of different types such as foam, carbon dioxide, water, dry
chemicals, ABC type of different capacities are installed in sufficient numbers according to
the type and intensity of fire hazards present in each area. The list of extinguishers with their
name and locations are available with each fireman for their respective area.
Photos of portable fire extinguisher

DCP Trailer :

37
A DCP trailer of 600 kgs. capacity for fighting sodium metal and sodium alloy fire as well
as hydrocarbon spillage fire which has been stationed at Iso Butyl Benzene plant (IBB)
battery limit area.

Fire Alarm System :

A semi-automatic fire alarm system with hooters which can be operated manually or by
electricity installed in all control rooms. Sprinkler system: - Medium velocity spray system
on all storage tanks, six shed in plant & O/S. Automatic delude system at Mounded
propylene bullets & Hydrogen U/L Station at SC-I with H/C detectors & flame detector
semi automatic deluge sprinkler at FB-628 foam pourer to all storage taken O/S.

Foam Compound:

We maintain an adequate stock of foam compound of 12,000 litres at fire station.

Sirens:
a. All the Location sirens are electrically operable from Fire station and kept on maintained
supply.

b. Four manually operated hand sirens are kept in the Contraband area which can be used
to raise fire alarm when electrically operated siren may not work due to power failure.

Fire Station

We have a full fledged Fire Station which is manned round the clock. The fire station control
room has emergency hooters and siren which is actuated in case of an emergency. The fire
station houses Fire tender and multipurpose fire tender and long range Foam trailers. A fire
store is attached to the fire station and all fire extinguishing material and equipment spares
are stored. Fire stationed is manned by ten professional firemen round the clock

Manual Call Points (MCP Panel)

38
The system consist main fire alarm control panel at Fire Station with a MIMIC panel and a
repeater panel in MSO office. Total 64 manual call points are located at strategic location
within the plant which is numbers from 1 to 64. Each MCP has a breakable glass in front.
In case of emergency glass can be broken by hammer provided at MCP. This will activate
the MCP Panel showing location of fire by red LED on the MIMIC panel at Fire station.

Assembly Points

There are 6 assembly points situated at different locations in the factory . The assembly
points are meant for assembling of employees during an emergency whenever they are
required to do so by Chief Controller.

GLIMPSES OF FIRE PREVENTION / PROTECTION & EMERGENCY

MANAGEMENT FACILITIES
1. Full fledged, well equipped Fire Control room manned round the clock.
2. Professional, qualified & trained fire man – 10 Nos.
3. Back up of 13 No. trained Fire Squad members in each shift.
4. Multi purpose fire tender equipped with water, foam and DCP facilities
5. Foam/water fire tender having capacity of 2700 Lts. each
6. Dry Chemical Powder Trailer ( 600kg)
7. Long range (Foam / water) monitor (900ltr.)- with towing arrangement.
8. Fire Water Monitor with Aqua Foam Nozzles arrangements (25 Nos.)
9. Double Headed Hydrants- ( 120 Nos ),
10. Plant wise Internal Hose Boxes - ( 54Nos) equipped with fire hoses and branches
11. Hose Boxes (15Nos ) Hose fully equipped with fire fighting equipment.
12. Hose Reels, fire water hoses (Rubber Hoses –Chemical resistance),
13. Charged Wet riser,
14. Fire doors.
15. Medium velocity sprinkler system ( MVSS ) for all storage tanks
16. Deluge System for isolated storages.
Photos of deluge system

39
17. Fire water Sluice Valve, periodic Loop testing of entire fire water network Lock out
tag out system for fire water system impairment.
18. 1 no. Electrical + 2 nos. Diesel Fire Water pumps (430M3/ hrs. capacity each)
19. Dedicated Fire Water reservoir for 6 hrs. (7800M3 capacity.)
20. Around 450 Nos. Fire Extinguisher ( DCP, CO2, FOAM and ABC Type )
21. DCP stock ( 1000kg ) Foam stock 15000ltr.(25% for Mutual Aid )
22. CO2 flooding system for Gas turbine Generator.
23. FM 200 Flooding system for IT server room
24. Smoke, Flame, Gas detector system (IR/ UV ) for all Control Rooms of plants,
Hydrogen unloading station, Ammonia/chlorine handing area, Propylene storage etc.
25. Adequate nos. of Fire Entry suits, Proximity suits, Fire resistance suits.
26. Self Contained Breathing Apparatus (SCBA) for Long and short duration (ELSA)
with equal nos of spare cylinders.
27. Respiratory Protection: Ammonia, Chlorine, Organic Vapours & Multigas
Respirators, with full face mask, Dual Mask, Disposable dust masks.
28. Communication Aids: Intercom, wireless sets, Public Address system, Manual Call
Points, Emergency Dial facility on 1000 No , Emergency Siren/ Hooters.
29. Emergency staff backup. Dedicated Emergency organization during “Off” hrs
30. Well equipped Occupational Health Centre (OHC) manned round the
clock
31. Ambulance and emergency vehicle.
32. Trained first Aiders-
33. Plant wise Chemical spill Management kits.
Photo of Spill Control Kit

40
34. Well equipped outdoor emergency response kits .
35. Personal Protective Equipments like various types of hand gloves, helmets, safety
shoes, chemical resistant suits, safety goggles, flash goggles, various respirators,
expose meters, LEL and hydrocarbon detectors, vessel entry equipment, safety belts,
full body harness, safety net, fragile roof ladders etc. are available and issued to all
employees including contractors as and when required. Sufficient stocks are
maintained for emergency use/shutdown activities.
36. Specialized Ammonia /Chlorine emergency l kits

5.4 A. Mutual Aid Scheme:

In case of serious gas or fire emergency, the members in the scheme share their resources
and facilities in fire fighting to tackle gas or fire emergency in any one of the affected
participating industry. Presently Fire and Emergency Response Station ( FERS) are the
First Responder in case of Major emergency. Similarly, Civil Fire brigade ( Vashi &
CBD) are also located hardly 5 km away from the factory.

5.4 B Communication Facilities:

The communication facilities available in the factory to deal with any fire emergencies
include:
 Fire emergency dial 1000 using intercom.

41
  Fire hooter and fire siren fixed at plant control rooms and some designated places.
 Public address system installed at different locations inside the factory.
 Wireless sets which include hand sets,( 30 nos) one base station and one mobile
set in the fire tender.
 Smoke detectors installed in the IT server room centre and plant control rooms,
which sound an alarm on detection of smoke , heat & gas

5.5 INSTRUMENT SAFETY:

In any petrochemical process, plant instrumentation plays a major role as far as safety
prevention is concerned. All the parameters like pressure, temperatures, level, flow etc.
are controlled by instrument with the help of remote switches and push buttons provided
in control room. In case of any failure or stoppage of running equipment or if the process
variable crosses the limit an alarm indicates in control room and thus operator can take
corrective action.
Inter locking - The combination circuits in which the contacts of field switches (pressure,
flow, temperatures, levels etc.) are used. If the certain parameters become abnormal,
alarm comes and if any down stream equipment stops, all the equipment on the upstream
also stopped.
5.6 HOUSEKEEPING:

A PLACE FOR EVERYTHING AND EVERYTHING IN ITS PLACE is a golden rule

for good housekeeping. Housekeeping not only has a direct bearing on the number of
accidents and fixes that occur but also on the cost of operation.
Good housekeeping may be defined as safe and orderly conditions of neatness
arrangement, cleanliness and efficiency. It reflects the efficiency of work being done.
General labours and contractor labours are appointed for cleaning the plant area, their
supervisor is accountable for housekeeping. Dustbins of different colours are distributed
for different types of wastes all over the places. The colour code is as following:
RED Drum  Cotton / Paper wastes
BLUE Drum  Plastic wastes
YELLOW Drum  Glass wastes
BLACK Drum  Metal scrap / wastes

42
Scrap material is collected from various plants and stored separately in scrap yard.
Empty drums of used catalyst, oil and other material are stored separately disposed off.
Storage and stacking of materials and finished products, parking of vehicles, forklift,
cranes is done to follow good housekeeping.

In many areas , 5-S housekeeping system is implemented .

5.7 STORAGE AND HANDLING OF CHEMICALS RECEIVING OF

RAW MATERIALS:
On arrival tankers are checked for relevant documents, they are weighed on the weighing
bridge and then moved to the unloading bay. Here the contents are checked for volume,
moisture contents etc. and various samples are sent to laboratory for checking purity and
other specification.

The height of the liquid in the tank is measured by dip tube and volume read off from a
calibration chart. To determine presence of moisture a pink coloured paste is applied on
the dip stack which turns red if any water is present. The material is drawn and sent to
the storage tanks. Colour codes are used to facilitate unloading. For e.g. white for
Benzene, Yellow for O-xylene, etc.
Photos of drums used for handling of lubricant oil to avoid spillage

Dispatch of Finished Products:

The finished products may be dispatched either in the drums or tankers or in the bags. In
case of Phenol, it is diluted with water to about 90% strength before filing in either drums
or tanker in order to prevent solidification.
All dispatch transactions are carried out on weight basis.
43
 Storage & Handling of Chemicals:

Most of the chemicals are stored in the vertical tanks in a specially designed storage area.
Propylene is stored in Mounded bullet installation. Horizontal bullets for Phenol storage
tanks are provided with steam heating coils to maintain temperature at about 50 to 60°C
to prevent solidification. The pumps, pipelines area well insulated from the outside and
are made of stainless steel.

5.8 Safety Precautions in Loading and Unloading (Drums/Carbouys,tankers) :

 The Security Checklist for Vehicles is a document which authorizes stores department
to enter / exit any vehicle (i.e. tanker, truck, tempo, Small vehicles etc) for filling or
Loading / emptying or unloading out materials in plants / storage tanks / Stores or
wherever required inside the Plant premises.
 On duty security in charge of the gate must inform the arrival of any vehicle to Stores
In charge or Concerned Dept. Head before allowing entry of the vehicle
carrying chemicals or goods.
 Security Dept. will check the conditions of the vehicle as per the Checklist.
 If the vehicle does not comply all the point as per the checklist, Security Dept. Will
inform Stores dept. and EHS dept. regarding the same and take approval from EHS
Dept. for entering or exiting the vehicle.
 Once the vehicle enters the Plant area, Store In charge or Concerned Dept. will have to
fill necessary Checklist before loading / Unloading the material if it’s a tanker.
 All the precautions that are stated in the Checklist should be fulfil thoroughly and tick
off when operation is done and write “N.A.” When “Not applicable”. Also refer
hazard symbol shown on tanker.
 No vehicle will be allowed to enter inside the flameproof zone without spark arrester,
muffler.
 While loading / unloading engine must be off.
 Any deficiency observed in Checklist should be brought to the notice of Stores in-
charge & EHS department In-charge.
 Stores In charge will have to ensure all Safety Measures as mentioned in the Checklist.

44
 If any vehicles carrying Engineering goods needs to be Loaded or Unloaded, the lifting
equipment checklist shall be filled separately, and all the legal documents needs to be
checked and cross verified by EHS dept.
 If any of the certificates are not available, Loading or Unloading shall not be allowed
at Site.
 Dept. Head who is authorised to Carry Loading or Unloading of Heavy engineering
Equipment shall ensure that all the safety precaution is taken, and people involved in
the activity are wearing Appropriate PPE’s.
 If any vehicle required to be Loaded or Unloaded with Loose drums / Carboys, it should
be done by trained people only.
 Only Forklift shall be used for Loading and Unloading of Loose Drums / Carboys using
Good Condition Pallets from the vehicle.
 Before Loading or Unloading Loose drums / Carboys by using Forklift all the Drums/
Carboys shall be tied by a belt to avoid fall Hazard.
 Dept. Head Shall ensure Proper supervision before Loading or Unloading Loose drums
/ Carboys by using Forklift.
 All the Loading & Unloading shall be done under Proper Supervision and by
Authorised Persons and trained Persons only.
 In case of spillage of material during loading/unloading, follow emergency procedures
as laid down

 In order to prevent any initiation of fire and handling, processing, storage and
transporting of chemicals following practices are observed.

 Earthing and Bonding - Piping and equipment are grounded to ensure proper earthing
and metallic bonding are provided to prevent accumulation of static charge.
 Photo of Static Discharge Handle

45


 Lightening arresters - At high point lightening arrestors are installed to prevent strike
of lightening.
 Flame arrestors - To avoid fire and explosion hazard.

 Flame proof electrical fittings - All electrical equipment, fixtures, junction boxes and
wiring in the plants are of flame proof type to avoid any sparking.
 Bund or Dyke walls - All the tanks storing hazardous chemicals are protected by
bund or Dyke walls to contain accidental spills.
Photo of Tank farm with sloped dyke wall with NFPA diamond marking

46
 Spark mufflers - The entry of vehicles in the contraband area is restricted. The
vehicles which are required to enter the contraband area are required to fix spark
muffler on their exhaust pipes.

5.9 PERIODIC INSPECTION AND TESTING:

Periodic inspection and testing of equipment is done as per the statutory requirements.
Testing, Inspection of Pressure Vessels (Operating above atmospheric pressure) is done
by M/s Delta Industries, Thane and report of external examination, internal examination,
hydrotesting of pressure vessel is given in Form-13 (as per the Maharashtra Factories
Rule-65 framed under the Factories Act 1948, Section - 31)
1. Schedule of Inspection and Testing:

1. Internal visual inspection - Once in a year.

2. Hydraulic test - Once in 4 years.
3. Hydraulic test (if ‘1’ is not possible) - Once in 2 years
4. Ultrasonic test if ‘ 1 & 2’ not possible - Once in 4 years (With the permission of
Factory
Inspector)
2. Instrument calibration schedule:
Category of Instrument Description
A.- Every Quarter Instrument affecting product quality
B.- “ Instruments effecting plant (Personnel Safety)
C. Six Monthly Monitoring / Control and Environment ( Critical )
D.” Monitoring and Environment ( Non-critical )

Instrument Frequency of testing ( in months )

Category
Transmitter I to P Converter Valve Element
A 12 18 18 36
B 12 24 24 36
C 18 24 24 36
D On break down only

3. Testing and Inspection of other equipment:

47
 a. Eye wash fountain and safety showers Monthly
b. Fire water monitors, hydrants and isolation valves Monthly
c. Safety alarms and interlock Quarterly
d. Safety alarm and interlock bypass removal Half yearly
e. Fire extinguishers Monthly
f. Self Contained Breathing Apparatus (SCBA) set and ELSA set Quarterly
g. Lifting tools and tackles Yearly
h. Testing and overhauling of pressure relief valves Half yearly
I. Testing of safety valves Once in a year

5.10 HAZARD AND RISK ASSESSMENT :

Apart from in-house Process Hazard Analysis (PHA), Fire and explosion index studies
based on Dow and Mond Index methods, Safety audits and consequence analysis from
external agency are carried out on periodic basis.

We have a trained team to carry out Layers of Protection Analysis study ( LOPA) which
is conducted fro 20% of the PHA’s every year.

Transportation of Hazardous Goods Work

SI GROUP is approved institute for conducting drivers training program on” Safe
Transportation of Hazardous Goods” and conducting such programs since 1996.

Transportation of Hazardous goods/ material is done in compliance with The Central Motor
Vehicle Rule- 1989 framed under act- 1988.

TREMCARD, Emergency INFORMATION Panel, Chemical labels & stickers are given to
tanker drivers during transportation.

All essential PPE’s are given to tanker drivers & cleaners in company premises.

Full day training for tanker drivers Is conducted twice in a year on “ Safe handling of
Hazardous Goods” as per Rule- 9 of The Central Motor Vehicle Rule- 1989.

48
Photo of Trem Card

49
Management of Change Procedure(MOC)

HAZOP, PHA( Process Hazards Analysis),HIRA (Hazards Identification Risk Assessments),is

done for any modification, new installation, process changes, change of technology etc.

PMP ( Process Modification Plan) is prepared to address the management of change.

PSSR ( Pre start up Safety Review) is carried out before the actual operation is commence for
new process modification.
5.11 WORK PLACE MONITORING OF AIR CONTAMINANTS

Sulphur Dioxide (SO2), Oxides of Nitrogen as NO2, Respirable Suspended

Particulate Matter (RSPM / PM10) and Fine Particulate Matter (PM2.5) have
been identified for regular monitoring at all the locations. The monitoring of
meteorological parameters such as wind speed and wind direction, relative
humidity (RH) and temperature were also integrated with the monitoring of air
quality. The monitoring of pollutants is carried out for 24 hours (4-hourly
sampling for gaseous pollutants and 8-hourly sampling for particulate matter)
with a frequency of twice a week, to have one hundred and four (104)
observations in a year. Large number of personnel and equipment’s are
involved in the sampling, chemical analyses, data reporting etc.

AIR MONITORING EQUIPMENTS :

At SI Industries , air monitoring instruments used are electronic detectors, available
for discovering hazards in the air and determining the air quality and safety for
people. These instruments fall within the category of Direct-Reading Instruments :

1. Oxygen Availability Monitors ( Oxygen meter)

2. Combustibility Monitors (Combustible Gas Indicators (CGI))
3. Toxic Atmosphere Monitors (Colorimetric Indicator Tubes or aerosol
monitors)

50
 Two sampling methods to test worksite atmosphere—area sampling and
personal sampling.

1. Area sampling is where a particular section or work area of the worksite is

tested for air quality at pre-determined and regular intervals. This helps to
ensure the selected area remains within safe limits or is free from toxicity.

High Volume Sampler

2. Personal sampling is where an individual collects air samples from the

space surround his/her breathing zone.

51
Threshold Limit Values refer to airborne concentrations (typically for inhalation or
skin exposure) of chemical substances and represent conditions under which it is
believed that nearly all workers may be repeatedly exposed, day after day, over a
working lifetime, without adverse health effects. Its units are in parts per million (ppm)
for gases and in milligrams per cubic meter (mg/m³) for particulates such
as dust, smoke and mist.
The Second schedule* of Factory act 1948 gives a list of 116 number of substances with
permissible level of certain chemical substances in work environment
(* for details please refer The Factories Act, 1948)

Categorization of TLVs:
a) Threshold limit value –Time weighted average (TLV- TWA)
It is the average concentration for normal 8 hours work day to which nearly all worker
may be repeatedly exposed without adverse affect.

b) Threshold limit value –Short term exposure limit (TLV- STEL)

It is an allowable average exposure over a short period of time, typically 15 minutes
continuously without suffering from 1) irritation 2) Chronic or irreversible change, 3)
Narcosis and should not be exceeded more than four times in a day as long as the
time weighted average is not exceeded. If the predetermined limit has been exceeded,
the worker must remove him- or herself from the hazard for at least one hour between
exposures.

c) Threshold limit value - Ceiling (TLV –C)

The concentration that should not be exceeded even instantaneously.

5.12 OCCUPATIONAL HEALTH HAZARD MONITORING

Occupational Health monitoring can be: Qualitative meaning that smaller but focused
samples are used. Observing the operation and the employee and noting the potential
hazards. Collecting all the potential hazards through the observation the severity and
probability of negative outcome is estimated, then it will be determined if further

52
evaluation is necessary. Semi-quantitative meaning that assessments involve
mathematical models to predict the exposure. This will also determine if it is necessary
to have quantitative monitoring. Quantitative meaning that an assessment will be done
in a laboratory where the exposure will be tested as if the employee were in the normal
work shift.

Diseases due to Chemical Agents:

 Gases - CO2, H2S, Fuel Gas (Vehicle Emissions)
 Dusts - Pneumoconiosis (Nearby Industries)
 Metals - Lead (Paints)
 Chemicals - Acids, Alkalis , Phenols
 Solvents – Benzene.
 Disease due to dust ( From Catalyst) – Asthma

Health Surveillance :
• Medical examinations : pre-employment, periodic and others
• Supervision of the working environment
• Advice to management and workers
• Health education and training
• Health statistics
• Medical treatment-first aid, emergency and ambulatory treatment
• Health counselling-individual
• Nutrition
• Family planning
• “Well person” screening for early evidence of chronic multifactorial illnesses as
varied as ischemic heart disease, hypertension, diabetes mellitus, etc.
• Health Promotion programs: To prevent employees from falling sick and to
promote the health employees’ health promotion programs are conducted
regularly.
• Glaucoma Screening Program
• Non Communicable Diseases Prevention Program For Employees’ Spouses
• Bone Mineral Density Screening program in 2019
• Development of an efficient data system “health information system” through
computerization for storing and organizing information on Occupational
Hygiene Data; Medical information, Hazard information on each chemical
exposure profile and locations where potential exposure occurred

53
 • Short term practical training of occupational health professionals, doctors,
nurses, and occupational hygienists.
• Hearing conservation program including measurement of noise and audiometry
for measuring acuity of hearing.
• Visual performance screening in order to maintain an individual’s visual
abilities to the highest possible levels of efficiency on the job.
Biological Monitoring :
• Biological monitoring is the measurement and assessment of chemicals or their
metabolites (substances the body converts the chemical into) in exposed
workers.
• These measurements are made on samples of breath, urine or blood, or any
combination of these
• Biological monitoring measurements reflect the total uptake of a chemical by
an individual by all routes (inhalation, ingestion, through the skin or by a
combination of these routes)

54
55
 CHAPTER-6
SAFETY TRAINING

6.1 INTRODUCTION:

M/S SI Group- India Private Limited, Navi Mumbai has evolved a well-planned and co-
ordinated approach to training which is devoted to meet the specific needs of the
employees. Training is an action plan for enriching the job knowledge and sharpening
the skill in particular field and helps in improving the safety performance of each
individual member of organization to get best from everyone and assume succession to
the key jobs. Training not only improves the knowledge, skill but also changes the
attitude and behaviour of the employees and they become more effective in handling
their respective jobs.
Following safety training programmes are conducted.:

a. Induction Training in Safety for all the Newcomers.

b. Safety Procedures Training for All Employees.
c. Refresher Training in Safety for Employees of Different Departments.
d. First Air Training.
e. Fire Fighting Training.
f. Contractor’s Safety Training
g. Tanker Driver’s training on Safe Transportation.
h. Awareness Programme for Different Service Groups.

6.2 CONTINUOUS SAFETY TRAINING PROGRAMME:

A continuous safety training programme for all employees on every Monday is
conducted. It consists of modules on various safety related topics. Demonstration of
safety related appliance, safety film show and plant visit. Modules are changed after
every six months. Those who attend all the modules in the span of six month get
certificate from Safety Department.
Some of the modules are:
a. Safety in Plant Operations
b. Safety in Work Practices
56
c. Safety in Maintenance
d. Onsite Emergency Plan
e. Pollution Control
f. Risk Assessment etc.

6.3 SAFETY TRAINING FOR CONTRACTOR PERSONNEL:

Continuous training programme is conducted for the contractor employees who are
working in the hazardous areas. They are given training on use of personal protective
equipment, plant hazards, permit system, emergency procedure in case of fire or accident
etc. till today almost all the contractor workmen were covered under this safety training.

6.4 SAFETY TRAINING FOR TANKER DRIVERS AND CLEANERS:

A three days training programme is arranged for tanker drivers and cleaners who
transport hazardous chemicals. They are trained to handle any accident or emergency,
action to be taken in case of leakage, spillage of chemicals and guidelines for safe
transportation. After successful completion of training, they get certificate. SI Group –
India Private Limited, Navi Mumbai is an approved and recognised training institute for
safety training of tanker drivers carry hazardous good by ‘Transport Commissioner and
Home Department’ of Gov. of Maharashtra

6.5 SAFETY TRAINING FOR POLICE PERSONNEL:

Herdillia has taken special initiative in training of the Police Personnel in handling
transport emergencies as they are the first persons arriving at the emergency spot. They
are trained on topics like actions to be taken in case of a chemical transport emergency,
hazardous properties of some chemicals, precautions, protection, approaching accident
site, wind direction, evacuation, Trem cards, meaning and use of hazchem codes etc.
(Annexure 5)

6.6. SAFETY AWARENESS FOR SOCIETY REPRESENTATIVES:

In order to create general awareness about chemicals and their importance in day today
life , Hazards and precautions to be taken during emergency situations among the general

57
 public and to remove the misconception about the chemical industries in general , SI
Group – India Private Limited ,Navi Mumbai being a Signatory to Responsible Care
movement has taken some unique initiatives in the form of conducting awareness
programmes for some society representative groups like Doctor, Corporates, Journalists,
Teachers, Traffic Police etc. These professionals are invited to the factory and briefed
about the product manufactured in the company, their hazards and various safety aspects
provided to deal with this, toxic effects of chemicals and treatment for these etc.

6.7 SAFETY EDUCATION AND PROPAGANDA:

Safety education is the process of broadening and adding to one’s safety knowledge for
the purpose of developing the vivid awareness of the importance of eliminating the
accidents and mental alertness recognising and correcting conditions and practices that
might lead to injury. Safety propaganda is a continuous business of the Safety
Department. In view to arouse safety consciousness in all the employees and to reduce
the accidents.
Following are the main activities performed by the safety department toward the safety
awareness.
a. Board showing safety statistics at the entrance of the factory.
b. Display of safety slogan’s, posters, safety rules at various places.
c. Display of boards showing hazardous properties of chemicals and personal protective
equipment recommended.
d. Safety bulletin circulated to all the departments.
e. Publication of various articles regarding safety in the company magazine

6.8 SAFETY PROMOTIONAL ACTIVITIES:

To promote and maintain safety and health awareness and also involve the employees at
work, the following activities are carried out by safety department.

a. National Safety Day and Safety Week Celebration:

Various competitions are held during this celebration. They include safety poster,
safety slogan, safety song, safety talk, safety quiz contest, fire squad, hose drill
contest, good housekeeping, spot the unsafe condition contest etc. Prizes and
certificates are distributed to the winners.

58
b. World Environment Day Celebration:
Environment quiz, essay, slogan contest is conducted as a part of celebrations. Tree
plantations activities are organised during the week.
c. Incentive Scheme:
Management has provided an incentive scheme in the form of safety gift to all its
employees for completion of every year without a lost time injury.
d. Fire Services Week:
Every year “Exhibition of Fire, Safety & Emergency equipment” is organised for the
benefit of company employee as well as employees of various nearby industries.
Similarly, a lecture and demonstration on “Emergency handling of Ammonia” for
ICE manufacturing & cold storage employees is organised. Our fire staff goes to
nearby schools to give training on “Fire safety” for school children.

59
Photos of Safety training classroom as well as practical demonstration

60
 CHAPTER-7
ONSITE EMERGENCY MANAGEMENT PLAN

7.1 INTRODUCTION:

A petrochemical company such as M/S SI Group India Private Ltd., is exposed to risk of
fire, explosion as well as of health hazards. Even though the greatest care has been taken
during the design and construction of the plant and continuous effort is made for careful
inspection and maintenance of the plant to ensure its safe and satisfactory operation.
Company is prepared for any eventuality be it of a minor or major in nature which could
result in danger to personnel or the near by population and in loss of property and
business. In order to meet the above objectives, a detailed ONSITE EMERGENCY
MANAGEMENT PLAN has been prepared. The aim therefore is to evolve such a plan
to meet a disaster and to make personnel, adequately aware of the plan and to discuss and
rehearse it regularly so that the plan is effective. We conduct on site drills every quarter
and “Offsite drill “once in a year

7.2 OBJECTIVES OF EMERGENCY PLAN:

The emergency management plan is a strategy well evolved, organized and rehearsed to
fully utilise the internal resources of the company with the minimum dependence on the
outside agencies for following purposes:
a. Safeguard lives both at site and in the neighbourhood.
b. Contain the incident and bring it under control.
c. Minimise damage to property in the factory in neighbouring habitations and
environment.
d. Rescue and treatment of injured persons.
e. Provide welfare assistance to injured persons.
f. Collect and log information, regarding latest status action etc.
g. Provide relevant information to Police, District Authorities and Industrial Safety
Directorate.

61
7.3 THE EMERGENCIES:
The emergencies in onsite can be classified as:

1. Fire / Explosion:
The fire emergency can be either be handled departmentally or would need help from
other departments at sites. Help from mutual aid scheme or city fire brigade may also
be necessary in serious cases.

2. Leakage /spillage/ Release:

Any leakage or spillage has potential to develop into a fire or explosion after
sometimes.

3. Major Emergency:
Most serious emergency may not only require action as far tackling fire/gas leak but
may also require evacuation of plant site and possibly also the neighbouring areas.

7.4 INTERNAL ASSEMBLY POINTS:

There are seven assembly points. viz.

a. Tank Farm Area

b. Phenol Plant
c. South Gate
d. Speciality Chemical - I
e. Speciality Chemicals - II
f. Boiler House
g. Administrative Building
A board is displayed indicating place of assembly point. After hearing second fluctuating
alarm all persons directly connected with process will take crash shutdown of their plants
and after putting plant in safe condition, assemble on assembly points. At appropriate
time each section supervisor should organise head count of own staff visitors and
contractors.

7.5 EMERGENCY ORGANISATION:

62
 The emergency organization consists of a Chief Controller who is the overall in charge
in carrying out the emergency operations. He controls the entire situation from the
emergency control. Emergency organisation for “Off” hrs is also organised.
All emergency teams are imparted training and they report rotation wise on off days as a
part of “Call duty”.

Photo of ERT on duty (Emergency response team)

63
 CHAPTER-8
ENVIRONMENTAL CONSERVATION & POLLUTION CONTROL

8.1 SOURCE OF EFFLUENT AND EMISSIONS:

a. Effluent Sources:
The aqueous stream discharged from various plants have some quantities of dissolved
hydrocarbons and associated separate phase of hydrocarbon. This effluent is treated in the
Effluent Treatment Plant (ETP). All the plants have their battery limit specification. Liquid
effluent is segregated, settled, sampled and based on the specification sent to Effluent treatment
plant for further treatment n

b. Emission Sources:
The main source of gaseous emission is:
I. The off gases from the oxidisers in Phenol plant.
ii. The off gases from PAN plant.
iii. The flue gases released from the stacks of the furnaces.

8.2 PREVENTION OF WATER POLLUTION:

We have a full fledged ETP plant and final effluents after meeting MPCB specifications
discharged to Common Effluent Treatment Plant (CETP) for further treatment and disposal.
this plan has been set up by our R& AD department. This Bio-degradation plant is also
developed by our own R&D. This plant includes following main sections.

I. Clarifloculator
ii. Aeration Tanks - 2 Nos.
iii. Clarifier
iv. Sludge Drying Beds

Further upgradation of Bio-degradation was carried out by adding Intermediate clarifier,

equalisation for effluent from Phenol plant and Blowers Pump etc.

64
8.3 PREVENTION OF AIR POLLUTION:

SI Group, Navi Mumbai has established and maintained an exquisite record on

environmental protection. The concern for environment has been carefully nurtured into a core
value of the company. Some of the note worthy examples of modifications to existing
processes to effectively curb air pollution are:

1. Numeric acid from PAN plant emission:

The acidic emission form the PAN plant contains Maleic Anhydride along with a
number of other organics. The conventional incineration was ruled out because of high capital
investment and high operating costs. The process was developed through efforts of R&D to
convert Maleic Anhydride into Fumaric acid which is used as a food acidulate and intermediate
for polymers and insecticides.

The benefits of this modification were:

Emission level of PAN plant has been brought down from initial 54 kg/hr. to below 2 kg/hr.
The initial investment was recovered within a short time. The present price of Fumaric acid is
nearly equal to the price of PAN.
Fumaric acid generation serves as an indirect monitor of performance of PAN reactor in
terms of catalyst activity and selectivity.

2. Carbon Bed Adsorption of Cumene:

The emission from oxidizers in Phenol plant contains Cumene. It was not feasible to condense
or scrub Cumene from this stream because of high non-volatile consent. A scheme for recovery
of Cumene from this stream was devised using a twin carbon bed adsorption system with cyclic
adsorption regeneration operations which has paid back the initial investment.

65
3. Steam generation from flue gases of Cumene furnace:

Stack vent of Cumene furnace which is emitting flue gases at the 400°C temperature has been
diverted to waste heat boiler. It reduces the temperature of flue gases and help in reducing
thermal pollution more over add in the steam generation and thus will save energy.

4. Phenol plant improvement:

Some of the modifications carried out in Phenol plant to minimise environmental pollution
problems. Acetone stripper for recovery of Acetone, Dephenolation system for recovery of
Phenol from the aqueous effluent from Phenol plant. Utilisation of phenolic tar by mixing with
waste hydrocarbon and used as fuel for boiler.

5. Compliance to Comprehensive Environment Pollution Index (CEPI)

Initially, Naphtha was being used as fuel in GTG and LSHS is used as a fuel in HRSG for
power and steam generation. Now RLNG supplied by Gail is used for firing in GTG and HRSG
in place of Naphtha and LSHS respectively.

RLNG being a clean fuel gives lower emissions. No corrosion in stack due to low sulphur and
lower stack temperature. No need of soot blowing and good combustion efficiency. Ease of
handling. No storage required.

The use of RLNG has reduced the S02 emissions. SI Group -India Private Limited, Navi
Mumbai has installed new Internal Floating Roof Tank(IFRT) and converted existing fixed
Roof tank to IFRT for benzene storage.

This has resulted in the reduction of Benzene vapour emission from the tank to the extent of
97% as compared to Fixed Roof tank. This benzene emission reduction amounts to- from 52
MT to 02 MT.

66
8.4 PREVENTION OF SOUND POLLUTION:

Vacuum pumps are installed in place of steam ejectors which were previously causing
sound pollution as well as air pollution.

When concentrator section in Phenol plant was not running ENCON-B steam has been vented
causing sound pollution. The diameter of vent pipe is increased and divided into two branches.
Also the vent is diverted to remote place.

8.5 Environment Management System (ISO 14001):

All the organizations are increasingly concerned to achieve and demonstrate sound
environmental performance by controlling the impact of their activities, products or services
on the environment taking into account their environmental policy and objectives. They do so
in the context of:
a. Stringent legislation
b. Development of economic policies and other measures to foster
Environmental protection.
c. General growth of concern from interested parties about environmental
Matters including sustainable development.

Many organizations have under taken environmental reviews or audits on there own to assets
their environmental performance. However, they cannot assure that the performance continues
to meet the legal and policy requirement. To be effective they need to conduct in structured
management system which is nothing but Environmental Management System (EMS). In 1992
it is introduced as BS:7750 (British Standard) then it is revised in 1994 as BS:7750 - 1994.
Further modification of it is knows as Environmental Management System (EMS). ISO 14000
is the standard developed by International Organization for Standardization (ISO) for third
party certification of EMS.

67
Benefits of ISO 14001:

a. Better housekeeping
b. Prevention of pollution
c. Reduction of waste
d. Optimum utilisation of resources
e. Total employee’s involvement
d. Improved image of organization

Core elements of ISO 14001:

a. Environmental Policy
b. Planning
c. Implementation and operations
d. Monitoring and corrective action
e. Management review
f. Continual improvement

8.6 ENVIRONMENTAL POLICY:

The Environmental Policy of the Company is to manufacture and supply products through Eco-
friendly operation of its production facilities, comply with all relevant statutory requirements
and strive to reduce environmental emissions and waste generation through the following
actions:
a. Implementation of EMS to ISO 14001 - 2004
b. Adoption of clean and safe technologies.
c. Conservation of natural resources through innovative modifications in its
production facilities and processes.
d. Conversion of waste streams into value-added products through in-house
R&D.
e. Continuous training and motivation of all concerned.
f. Efforts in maintaining ecological balance by developing green belts

8.7 TREE PLANTATION:

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SI Group –India Private Limited, Navi Mumbai has under taken a massive tree plantation
programme since 1985. So fare more than 30,000 trees have been planted in the vacant land
adjacent to the plant area, housing colony and also in the vacant strip at land west of the plant
adopted from MIDC/CIDCO and all the trees planted are being watered with treated effluent.

Last year we have given consent for 1000 trees plantation on forest land allotted to M/s A.K.
Rural development and MARG, THANE.

Photos of tree plantation inside factory premises

69
 CHAPTER-9

ENVIRONMNET HEALTH SAFETY AND QUALITY KEY PERFORMANCE

INDICATORS- x

 DEFINATIONS

 ACTUAL DATA FOR JAN-NOV.-2012

 GRAPHICAL REPRESENTATION

 ACTION ITEMS FOR EXCEEDING PARAMETERS

EHS Global Reporting- Monthly Metrics/Report

9.1PURPOSE:

SI GROUP RECOGNIZES THE CRITICAL IMPORTANCE OF A STRONG

MANAGEMENT SYSTEM AND THE PERFORMANCE OF OUR
ENVIRONMENTAL, HEALTH, AND SAFETY (EHS) PROGRAMS. EACH
OPERATING LOCATION IS REQUIRED TO PROVIDE A MONTHLY
PERFORMANCE REPORT FOR THE FOLLOWING KEY EHS METRICS TO SI
CORPORATE, BY THE 15TH OF FOLLOWING MONTH. WHERE APPROPRIATE.

9.2 Definitions & Guidance:

Health & Safety

Number of Recordable Injuries:

Report the number of injury or illness cases, recordable by US standards that occurred
during the month. In general, all injuries other than minor injuries requiring only first
aid treatment and which do not involve medical treatment, loss of consciousness,
restriction of work or motion, or transfer to another job are recordable injuries. The

70
TCIR is reported in three ranges on the monthly report; current year-to-date, past 12-
months and past 3-year or 36-months. Click here for Additional Guidance

TCIR = Total Case Incident Rate

Calculation:

# of employee recordable cases/period of time x 200,000 (avg. # of hours US

employee works/year)
Total # of employee man hours worked during the same period of time
Number of Days Away, Restricted, and Work Transfer:

Report the number of injury or illness cases, resulting in lost work days, restricted or
light work duty and/or work transfer during the month. The DART is reported in three
ranges on the monthly report; current year-to-date, past 12-months and past 3-year or
36-months.

DART = Days Away, Restricted & Work Transfer Case Rate

Calculation:

# of employee Days Away, Restricted, & Work Transfer cases for a period of time x
200,000
Total # of employee man hours worked during the same period of time

Man-hours Worked:

Report the total number of employee man hours worked during the month by SI Group
employees and/or permanent contractors. Note: Permanent contractors are employees
under the direct supervision of SI Group management and permanently assigned to a
site (Example: contracted production or laboratory employees). These employees
report and work at the site each day just as an SI Group employee. These permanent
contractors are considered “SI Group employees” for the purposes of EHS reporting.

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Trend Graphs:

Rolling, 36-month TCIR rates are calculated and then plotted on the trend graphs
presented in the Monthly EHS Report. For example, the TCIR from February 2008 –
January 2011 is calculated using the formula below and plotted as the first data point
on the graph. The next data point plotted is the TCIR for the period of March 2008 –
February 2011. As new data is reported, data is rolled or shifted by a month to
incorporate it into the graph. The data is categorized and presented by Region.

Calculation:
# of recordable cases over a 36-month period of time x 200,000
Total # of employee man hours worked over the same 36-month period of time

Number of Contractor Recordable Injuries:

Report the number of injury or illness cases involving Contractors, recordable by US

standards that occurred during the month. In general, all injuries beyond minor injuries
requiring only first aid treatment involving; medical treatment, loss of consciousness,
restriction of work or motion, or transfer to another job are recordable injuries.
Contractor-related events involve persons contracted by SI Group to provide specific,
short-term services. Contractors would not be under the direct supervision of SI Group
management or permanently assigned to a site (Examples: custodial support, worker
from a company hired to repair a boiler). Click here for Additional Guidance

Contractor TCIR = Contractor Total Case Incident Rate

Calculation:
# of Contractor recordable events/period of time x 200,000
Total # of Contractor man hours worked during the same period of time

72
Number of Contractor Days-Away, Restricted and Work Transfer:

Report the number of injury or illness cases involving Contractors, resulting in days-
away, restricted or light duty and/or work transfer during the month. This data is not
presented in the monthly report, but would be calculated as defined below.

Contractor DART = Contractor Days-Away, Restricted & Work Transfer Case Rate

Calculation:

# of Contractor Days-Away, Restricted & Work Transfer cases for a period of

time x 200,000
Total # of Contractor man hours worked during the same period of time

Contractor Man-hours Worked:

Report the total number of man hours worked by Contractor employees during the
month. Contractors are hired by SI Group to provide specific, short-term services.
Contractors would not be under the direct supervision of SI Group management or
permanently assigned to a site (Examples: custodial support, worker from a company
hired to repair a boiler).

First Aid Cases:

Report the number of employee and/or contractor (as defined above) minor
injury/illness cases that occurred during the month involving treatment, but not meeting
the criteria of a Recordable Injury (see above).

First Aid Case Rate Calculation:

# of First Aid Cases reported over a given period x 200,000

Total # of employee + contractor man hours worked during the same period of time

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Near Miss / What If (?):

Report the number of events which underwent an investigation and the establishment
of corrective actions to reduce risk during the month. The intent is to measure proactive
efforts, to identify potential scenarios that could lead to more serious EHS events, and
implement corrective actions toward risk reduction. Events meeting the definition and
reported as injury/illness, spills/releases, High Potential Incidents (HPI), Process Safety
Incidents (PSI), agency reports, or customer complaints should not be included in this
number.

Process Safety

High Potential Incidents:

Report the number of incidents identified as High Potential Incidents (HPI) during the
month. Refer to Attachment A in the Corporate Incident Reporting Procedure (HQ-
EHS-00003)

HPI Rate Calculation:

# of HPI incidents reported over a period of time x 200,000

Total # of employee + contractor man hours worked during the same period of
time

Process Safety Incidents:

Report the number of incidents identified as Process Safety Incidents (PSI) during the
month. Refer to Attachment B in the Corporate Incident Reporting Procedure (HQ-
EHS-00003)

74
Process Safety Incident Severity Score:

Report the sum of all Severity Scores for all PSI events identified and assigned a
Severity Score during the month.

Calculations:

Process Safety Total Incident Rate (PSTIR) Calculation:

# of PSI events reported over a period of time x 200,000

Total # of employee + contractor man hours worked during the same period of
time

Process Safety Incident Severity Rate (PSISR) Calculation:

Sum of all Severity Scores for all PSI events over a period of time x 200,000
Total # of employee + contractor man hours worked during the same period of
time

Reports

Required Agency Reports:

Report the number of events or incidents that required reporting to a government or

regulatory agency during the month. This does not include regular, ongoing reporting
requirements for 'normal' operations. Air emissions or wastewater discharges that
exceed permitted emission limits and other violations of permit conditions that must be
reported to regulatory authorities are to be included in this metric.

75
Photo of Accident statistics board

Note: Corporate EHS will request information from the site to better understand and
document the cause for agency reporting and the magnitude and severity of the
incident or event. Normally this is accomplished by simply providing a copy of
the agency report and/or background information that has already been
developed by the site to Corporate EHS. An Incident Fact Sheet may be
requested if it is determined that knowledge of the event and lessons learned may
benefit other SI Group sites. However, permit conditions are typically site-
specific and have little applicability to other locations. Therefore, Incident Fact
Sheets concerning agency reports are typically not requested.

Environmental Impacts
Finished Products Produced (MT):

Report the total quantity of Finished Product produced during the month, should be
reported in MT.

76
Releases:

Report the total number of spills and releases of material that occurred during the
month. This number should include spills and releases that occur from primary
containment into secondary containment (such as a dyke), as well as process upset
conditions that result in unplanned, non-routine releases to waste water / effluent
treatment plants. Spills and releases should be reported in kilogram (kg) quantity
ranges defined as:

greater than 45 kilograms (100 lbs);

 less than 45 kilograms and greater than 4.5 kilograms; or

 less than 4.5 kilograms.

Waste Shipments (MT):

Report the total quantity of waste materials containing chemical contamination shipped
off-site for treatment and disposal during the month; reported in metric tons (MT). This
number should not include permitted air emissions or wastewater discharges.

Spills/10,000 MT Calculation:

Total # of Spills > 45 kg over a period of time

X 10,000 MT
Total quantity of Finished Product (MT) produced/the same period of time

% Off-Site Waste/Finished Product Calculation:

Total quantity of Off-Site Waste (MT) over a period of time

X 100 %
Total quantity of Finished Product (MT) produced/the same period of time

77
 ACTUAL DATA FOR JAN-NOV.- 2012 AND TREND ANALYSIS

TCI TCIR
TCIR TCIR First first reporti reporta
H R rate DAR SP
2012 PSI Regula rate aid aid ng to ble spill
PI (Cont (Cont T Near
r (Reg) cases rate agency cases I
r) ) miss

0.1
Jan 12 0 0 0 0 0 0 0 0
0 0 0 80 2
0.1
Feb 12 0 0 0 0 0 0 0 1
0 0 0 20 4
0.0
Mar 12 0 0 0 0 0 0 0 0
0 0 0 6 7
0.0
Apr 12
0 0 0 0 0 0 0 0 0.15 0 0 11 6
0.1
May 12
0 0 0 0 0 0 0 3 1.19 0 0 41 2
0.2
June 12
0 0 1 2 0.42 1.23 0 2 1.5 0 1 17 1
0.1
July 12
0 0 0 0 0 0 0 0 0 0 0 96 4
0.1
Aug 12
0 0 0 2 0.32 1.83 0 3 1.2 0 0 26 6
Sept12 0 0 0 0 0.29 1.63 0 0 0 0 0 8 0.1
0.1
Oct 12
0 0 0 0 0 0 0 2 1.5 0 0 50 6
0.1
Nov 12
0 0 0 0 0 0 0 1 1.5 0 0 43 4

78
SAFETY PERFORMANCE INDEX-SPI (Less the better)

79
9.3 EHS GOALS

Following EHS goals are considered and approved in alignment with the CapEx and
Expense Budget planning process and approved along with the 2012 budget – EHS is
fully integrated within our overall business model.

0-0-0

• Ensure no significant process safety, environmental, or negative media events based on

agreed upon CCPS definitions.

Operational – Lagging indicators

• Each site to achieve a three-year recordable injury rate at or below 1.0

• Each site to achieve a loss of containment rate* of less than 0.5

*rate definition = 45+ kg spills / 10,000 MT

Operational – Leading indicators

• Implement Quarterly EHS management reviews.

• Objectives for Functional Safety management systems:

‒ Revalidate 20% of PHA’s including LOPA and SIL analysis (5-year plan to
complete all by 2018)

• Develop inventory and test plan for all safety critical interlocks and components.Each
site to audit another sites safety critical procedures vs. corporate minimum requirements
and /or other key functional safety / process safety management systems and
procedures.

80
 CHAPTER 10

10. OBSERVATIONS & FINDINGS

1. Isophorone plant: -
 Flameproof light fixture filled with water.
 Flameproof junction box cable entry holes found unplugged.
 Impervious flooring found damaged inside plant area.
2. Outside Main work shop:-
 Soft barricading observed for excavation.
 Water accumulation inside the excavated area.
 Excavated soil placed near the edge.
 Soft barricading using red tape done very close to the excavated area.
 Scaffolding erected near the edge of excavated area.
 No shoring done on excavated walls.
3. Benzene Unloading point:-
 Tanker driver found unloading Benzene using a metal bucket without using any
personnel protective equipment.
 No supervision observed while unloading Benzene.
 Filled drum kept without any hazard labeling.
4. Effluent treatment plant:-

 Scaffolding toe boards found missing.

 Scaffolding tag was displayed but not near the access of scaffolding.
 No color coding to scaffolding pipes.
 End caps not provided on scaffolding pipes.

81
  Spigot not provided on base plate.
 Sole plates not provided in unpaved area.
5. All plants:-
 5S technique of housekeeping not implemented in plant area.
 PVC electric cables used in few areas.
 Color coding is provided on pipeline also board displayed for color coding but no
arrow marking and hazard marking was observed.
6. Root cause analysis of near miss reporting is not done.
7. No fire proofing done on plant structure Steel.

82
11 RECOMMENDATIONS

1. Electrical equipment used inside battery limits/ hazardous zones shall be periodically
inspected and maintained in hazardous atmosphere. As per IEC (International Electrical
Commission) 60079 these equipment must be tested for safe operation in hazardous
areas as they may be primary source of fire and explosion. ( Refer IEC 60079 and
IS:2148)
2. Damaged flooring in Isophorone plant needs to be repaired/revamped and maintained
to avoid contamination with soil which may cause soil pollution. Section 114-A
Schedule XII of The Factories Act, 1948 talks about impervious flooring.
3. Hard barricading using scaffolding pipes of 40mm diameter should be provided for
excavation area as people may fall inside excavated area. Water inside excavated area
needs to be removed using ejector pump. Excavated soil shall be placed 1.5 meter away
from the edge of excavated area. Sheathing and shoring shall be provided. Scaffolding
shall be not placed near the excavated place, if placed suitable clearance and supports
needs to be provided to avoid scaffolding collision. (Refer IS:3764 :1992 Excavation
work code for safety)
4. Benzene exposure may cause long term health effects on human body like Decrease in
blood cells, leading to anemia etc Benzene poisoning is also an occupational disease
adequate measures shall be taken to avoid exposure of Benzene. Appropriate Personnel
protective equipment shall be provided for unloading of benzene. Unloading operation
shall be supervised by responsible person. Training frequency of drivers needs to be
increased and during training module trainer must elaborate on loading/ unloading as
well as health effects due to benzene handling and exposure. Hazard identification and
labelling needs to be provided on containers, drums etc..( Please refer Global
harmonised system for labelling of hazardous containers)
5. Scaffolding shall be inspected by responsible person before commencement of the job.
Checklist and work permit needs to be reviewed and add new check point. Scaffolding
and its components shall comply to IS: 3696 part 1 & 2(Code for scaffolding and
ladders, IS: 4014 (code for steel tubular scaffolding), IS: 2750 (Specification for steel

83
 tube scaffolding), BS: 1139 ( Pipe scaffolding and accessories), OSHA 3150 ( Guide
for scaffolding in industry), EN:74 (Scaffolding couplers), IS: 1161 ( Steel tubes for
scaffolding), IS: 5 and IS: 4736 ( Ready mixed paints).
6. 5S technique needs to be adopted in plant area to improve good housekeeping
practise.
7. PVC( Polyvinyl chloride is the second most commonly used plastic in world, which is
harmful to environment and also these cables emit toxic fumes when they caught fire
and heated. Most common cause of fire is electrical cables. Many people have loss their
lives not due to fire but exposed to toxic fumes. Instead of using PVC cables, now days
halogen free cables are available in markets which reduces amount of toxic and
corrosives gases during combustion. Halogen free cables are minimal smoke and
toxicity, environment friendly. Replace old PVC cables with halogen free cables.
8. Many accidents on the pipelines have happened due to mal operation, human error as
we all know the Bhopal disaster. To avoid such kind of incidents direction of flow of
on pipeline and hazard marking needs to be provided. Refer IS: 2379 (Code of practice
for colour coding of pipelines).
9. Near miss reporting to be further expands from disposal to root cause analysis.
10. In the event of fire structural steel loses strength as the temperature increases, so in
order to maintain the structural integrity of the steel frame fire proofing needs to be
done. Fire proofing thickness is based on fire rating duration will depend on applicable
standard.
Refer standard American petroleum institute (API) 2218 Fire proofing practices in
petroleum and petrochemical processing plants.

84
 CHAPTER-12

References (LIST OF APPLICABLE STANDARDS )

1. The Factories Act 1948
2. The Maharashtra Factories Rules1963
3. The Manufacture, Storage Import of Hazardous Chemicals Rules 1989
4. The Bio Medical Waste Rules 2016
5. The Petroleum Act 1934
6. Various standards:- IS:3696, IS: 2309, IS:5572, IS:3521, IS:4014, IS:2379,
API 2000, API 2218, NFPA704, NFC17 102, EN-74, IEC 60079, IS:2148, IS:2190,
IS:2925 IS:6665, OSHA 3150 etc.
7. The Petroleum Rules 2002.
8. Gas cylinder Rules, 2016.
9. Static and Mobile Pressure Vessels Rules , 2016.
10.Fire NOC
11. Hazardous Waste Management Rules, 2016
12. Workmen Compensation Act, 1923.
13. The Environment Act ,1986
14.The Indian Electricity Act, 2003 and The Indian Electricity Rules 1956

15.The Central Motor Vehicles Act 1988 and The Central Motor Vehicles Rules 1989

16.The Indian Boilers Act1923 and The Boilers Regulations 1956

17. The Public Liability Insurance Act 1991

18.The Petroleum Rules 2002

19. The Building and Other Construction Workers (Regulation of Employment &
Conditions of Service ) Central Rules, 1998.

20. Central Electrical Authority Regulations , 2010.

21. Maharashtra State Pollution Control Board – Gazetted Notification , Acts and Rules.

85
 CHAPTER-13

MY KEY LEARNING FROM THIS PROJECT

I got hands on exposure to chemical related safety systems, methods and equipment's.
Whatever I have learned in the class room, practically I got opportunity to see and demonstrate
it. The main goal of safety and health programs is to prevent workplace injuries, illnesses, and
deaths, as well as the suffering and financial hardship these events can cause for workers, their
families, and employers. The recommended practices use a proactive approach to managing
workplace safety and health.Some of the lessons I learnt from this project :

 Prevent workplace injuries and illnesses

 Improve compliance with laws and regulations
 Reduce costs, including significant reductions in workers' compensation
 Engage workers
 Enhance their social responsibility goals
 Increase productivity and enhance overall business operations

86
Annexure 14
(Sample copy)
QEHS POLICY

87
88
 Annexure 2
(Sample copy)
Lock out Tag out tags

89
90
91
 Annexure3.
(Sample copy)

Incident Fact Sheet

Executive Summary

Incident #
Facility Where Event Occurred
Date Event Occurred
Time Event Occurred
Type of Incident
Quantity of Material Spilled if Applicable (kg)
Equipment Damage in US currency
# of Employees Involved/Injured
# of Contractors Involved/Injured
HPI Incident (Yes/No):
PSI Incident (Yes / No):

DESCRIPTION OF INCIDENT:

INVESTIGATION RESULTS:

Root Cause:

Contributing Factor(s):

CORRECTIVE ACTION(S):

Interim/Short-Term Corrective Action(s):

92
 Long-Term Corrective Action(s): Preventive Corrective Action(s):

High Potential Incident (HPI) Analysis:

Credible; Worst-Case Scenario: Permanent injury (i.e. eye injury).
Rating: A4
Severity: Major
Likelihood: < 10-1 per annum - 1/10 years
Severity
Minor Serious Major Extremely Catastrop Major
(6) (5) (4) Serious hic Societal (1)
(3) (2)
-6
< 10 per annum
(F)
1/1,000,000 years
5
< 10- per annum
(E)
1/100,000 years
-4
< 10 per annum
(D)
Likelihood

1/10,000 years
-3
< 10 per annum
(C)
1/1,000 years
-2
< 10 per annum
(B)
1/100 years
-1
< 10 per annum
(A)
1/10 years
Worksite
Permanent Worksite
Fatalities – Worksite
disability to Fatalities –
1 to 5 Fatalities –
worker. 6 - 10
Single OSHA Significant employees / > 10 employees /
Life/Health or employees /
recordable injury to contractors / contractors / on-
Impacts Non- contractors /
injury to worker (non- on-site site vendors
Fatalities permanent on-site
worker. permanent). vendors or
injury to vendors
or Multiple public
member of the or
Permanent fatalities
public. Public fatality
disability to

93
 member of the
public.

Release from Release from

primary secondary Major
Release off-
containment - containment / accident to the
Environmenta site –
exceedance of diversion - environment
l agency
control limits retreatment – with persistent
Damage prosecution /
– formal agency community
fine / penalty
agency actions/warnin impact
notifications gs

Physical $ 10,000 – $ 200,000 –

< $10,000 $ 3 - 20 MM > $ 20 MM
Assets $ 200,000 $ 3 MM

Business $ 10,000 – $ 200,000 –

< $10,000 $ 3 - 20 MM > $ 20 MM
Interruption $ 200,000 $ 3 MM

Process Safety Incident Analysis:

Is incident a Process Safety Incident (Yes or No)? No

If yes, Severity Level Determination:

Severity Points
Level 1 = 27 pts.; Level 2 = 9
Severity Level Assigned
Consequence Category pts.
[1-4]
Level 3 = 3 pts.; Level 4 = 1
pt.
Safety/Human Health
Fire or Explosion
Potential Chemical Impact
Community/Environment Impact
TOTAL:

Severity Level [1-4]: NA

Severity Points [1-108]: NA

94
NOTE: This fact sheet has been developed to provide a snap-shot of a given incident. Please review and distribute this
information, take appropriate action(s) at your location to protect everyone’s health and safety and ensure that this or a
similar event will not occur. For additional information or assistance, please contact the Corporate EHS Department

Annexure 4
(Sample copy)
Cold Work Permit

95
 Annexure 5
(Sample Copy)
Hazchem & community awareness leaflet

96
97
98
MSDS of Phenol :

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102
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