12 Month

Industrial Training Report

Address
Hattar Road Haripur

Submitted to
Sarhad University Peshawar
Department of Electrical EngineerinG

In Partial fulfillment of
The requirements for the degree of
B.Tech. in Electrical Engineering

Submitted by
NAME
REG NMBER
 1

CERTIFICATE

This is to certify that Mr.--------- has partially completed the Industrial Training in our
Organization / Industry during the academic year------. He is trains in the field of
-------His overall performance during the period was Very Good
 Acknowledgement

It is always a pleasure to remind the fine people in the a pvt Ltd for their sincere guidance I

received to uphold my practical as well as Technical skills in Electrical Field. First of all, thanks

to my parent for giving encouragement, enthusiasm and invaluable assistance to me. Without all

this, I might not be able to complete this subject properly. Second, I would like to thanks to

Manager (Electrical, & Technical Section) for give us the opportunity to undergo industrial

training. He also gives me their guidance and support. Thirdly, I also want to express my deepest

thanks to Assistant Manager as industry training advisory for Electrical Department that has

helped me a lot in dealing with industrial training placement. He had supported to me by showing

different method of information collection about the Field. He helped all time when we needed

and he gave right direction toward completion of project. Besides, I would like to thank (Senior

Engineers) for extending their friendship towards me and making a pleasure-training environment

in the Power House. A paper is not enough for me too express the support and guidance I

received from them almost for all the work I did there. Finally I apologize all other unnamed who
helped me in various ways to have a good training.

DEDICATION

To my Parents and Family whose Love and Affection has been

Inspirational throughout my Life

To my Friends who provided help and support whenever needed

To my Teachers whom delivered me everything knowledge about my

Department

&

To all those who in any capacity have been helpful to me in

My Study
 OUR COMPANY
Agritech (Formerly Pak-American Fertilizers LTD) was the first Nitrogenous fertilizer plant built in
Pakistan. It was commissioned in 1958 with production capacity of 50000 MTPA of Ammonium
Sulphate based on indigenous coal & gypsum as raw materials. The capacity was enhanced to 90000
MTPA in 1968.

To meet the power requirement of plant, a Power House comprising two steam turbo generators of
11.5 MW / each capacity was also setup.

In 1973 the plant was converted from coal gasification to Natural Gas process.

BMR of the plant was planned and in the first phase (1982 ~ 84), an 85 MTPH capacity
Demineralized water plant and 85 MTPH capacity new boiler was installed.
Due to aging the Ammonium Sulphate Plant operation became uneconomical, therefore a BMR was
planned and the old Ammonium Sulphate Plant was replaced with new, State of the Art MW
Kellogg’s Process Ammonia & Toyo’s ACES Urea Plants. Designed capacities of the plants are:

Ammonia 600 MTPD

Urea 1050 MTPD

The New Plant was commissioned in September, 1998 and came into commercial production in
November, 1999. At present plant is in production at 104% load.

Old Ammonium Sulphate plant was stopped on June 30, 1997.

The old facilities of Phase-I like boiler house, powerhouse, demin water plant and workshops etc.
were maintained as such for supporting the new plants (Phase-II).
PAFL has achieved distinction of ISO certification for both; Quality Management and Environmental
Management Systems i.e. ISO 9001:2000 and ISO 14001:2004.
 COMPANY PROFILE
Registration No: KAR No. 776 of 1959-60

Company NTN No:  0786771-9

Sales Tax Registration No: 04-09-2800-00137

Incorporation No: 0001061

Our Associated Companies:

 National Bank Of Pakistan

http://www.nbp.com.pk

Contact Us

Head Office
2nd Floor, Asia Centre, 8-Babar Block
New Garden Town, Lahore
Tel: +92 42 35860341-44
Fax: +92 42 35860340

Haripur
Agritech Limited
Hazara Phosphate Business
Hattar Road, Haripur
Distt. Haripur
Fax: 0995616126
PABX: 0095-616124-25

Mianwali
Agritech Limited
Formerly Pak American Fertilizers Ltd.
Iskanderabad, Daudkel
Distt. Mianwali
PABX: 0459:392346-50 | Fax: (92) (459) 392715
 ABOUT US
Agritech plant is located about 50 kilometers toward North of Mianwali city. Its location is
strategically important from marketing point of view. Major portion of production is sold in 150~200
kilometers radius thus giving clear advantage over the competitors. Also it is the closest plant to
fertilizer consuming areas of Khyber Pakhtunkhwa Province.
 

The main business of the company is the manufacturing and marketing of fertilizers. The company
owns and operates the country’s newest and most efficient urea manufacturing plant at
mianwali.The company also manufactures SSP(Single Super Phosphate) at its plant at Haripur
Hazara, which is the largest Single Super Phosphate(SSP) manufacturing plant in the country.
 

Having achieved the company’s strategic goal to become a diversified fertilizer manufactures
producing both nitrogenous and phosphatic fertilizers, the Company’s product are sold under one of
the most celebrated and trusted brand name “Tara” in the fertilizer market.

COMPANY STATEMENT
AGL vision for the 21st Century remains focused on harmonizing the Company with fresh challenges
and encompasses diversification and embarking on ventures within and beyond the territorial limits
of the Country in collaboration with leading business partners.

VISION STATEMENT

Vision:
To be a world class manufacturer of fertilizer and ancillary products, with a focus on safety, quality and positive
contribution to national economic growth and development. We will care for the environment and the communities we
work in while continuing to create shareholders' value.

Mission:
 To be the preferred fertilizer company for farmers, business associates and suppliers by providing quality
products and services.
 To provide employees with an exciting, enabling and supportive environment to excel in, be innovative,
entrepreneurial in an ethical and safe working place based on meritocracy and equal opportunity.
 To be a responsible corporate citizen with a concern for the environment and the communities we deal with.

PRODUCTS

AMMONIA UREA

State : Liquid Type : Prilled

Purity : 99.9 wt% min. Nitrogen : 46% weight min.
Oil Contents : 5ppm wt% max. Biuret : 0.9% by weight max.
Water & Inerts : 0.1 wt% max. Moisture : 0.3% by weight max.
Free Ammonia : 150 ppm max.
Oil : 20 ppm by weight min.
Colour : Hazen 15
Size : 1 ~ 2.5 mm 95% max
 
 FARMERS GUIDE

Maize- Wheat-
Rice-Brochure.pdf
Brochure.pdf Brochure.pdf

Sugarcane- Cotton-
Brochure.pdf Brochure.pdf
 HSE (HEALTH SAFETY & ENVIRONMENT)
Agritech Limited (AGL) is committed to provide healthy and safe workplace for all employees and to
protect the environment in accordance with applicable laws / HSEQ Policy. AGL commitment is
based on the conviction that accidents are preventable and in order to achieve the objective, HSE
risks are identified and mitigated and/or reduced to as low level as is reasonably practicable.

AGL is accredited under the umbrella of Integrated Management System (IMS) for Quality
Management System (ISO9001:2008), Environmental Management System (ISO14001:2004) and
Occupational Health and Safety (OH&S) System (OHSAS18001:2007).The successful implementation
of these systems and compliance with HSE rules and regulations, have imparted continual
improvement in HSE culture, resulted in and improving statistical data of Employees Working Man-
hours without Lost Time Case (LTC) which is compatible with well reputed petrochemical industries.
AGL has always proactive approach towards creating safe working environments and are responsible
for promoting continued Health, Safety education and training for all employees.

AGL is contributing immensely in the realm of Corporate Social Responsibility (CSR) including HSE
awareness and supply of Potable Water to the surrounding community. As per AGL policy,
continuous increasing plantation in the surrounding areas including housing colony is being
implemented to have positive impact on the environment.

1 Fertilizer
Fertilizers are used to provide plants with nutrients, not available with soil. They improve plant health, its
tolerance against pets and enhance appearance. Basic plant needs include:

• Oxygen
• Water
• Sunlight
• Nutrients and
• Growing medium

Plant nutrients are further classified into: macro-nutrients (primary), macro-nutrients (secondary) and
micro-nutrients (minor). Primary macro-nutrients include nitrogen, phosphorous and potassium, while
the secondary include calcium, magnesium and sulfur. Micro-nutrients have a long list including iron,
zinc, manganese, copper, boron, molybdenum, chlorine etc but in very small quantities. Nitrogen is the
key element in plant nutrition. It promotes stem and leaf growth and is an essential component of
chlorophyll molecule. It is also involved in regulating intake of other nutrients.
Fertilizers have been extensively used in agriculture for better growth of food and cash crops. Urea (%
nitrogen) is one of the most used fertilizers in Pakistan. Made from liquid ammonia and carbon dioxide
gas, it has the highest nitrogen content other than ammonia (82%) which extremely disastrous to use
openly.

8.2 Ammonia Manufacture

Ammonia is a colorless gas with a penetrating pungent-sharp odor in small concentration that, in heavy
concentrations produces a smoothing sensation when inhaled. Ammonia is water soluble forming a
strongly alkaline solution of ammonium hydroxide and the aqueous solution is called ammonia water,
aqua ammonia. Ammonia burns with a green yellowish flame.

The first breakthrough in the large scale synthesis of ammonia resulted from development of Haber’s
process in 1913 in which ammonia was produced by direct combination of two elements: nitrogen and
hydrogen, in the presence of a catalyst (iron oxide with small quantities of cerium and chromium) at a
relatively high temperature (550°C) and under a pressure of about 2940 psi (20.3 MPa).

N2 + 3H2 → 2 NH3

FIGURE 1 AMMONIA MANUFACTURE FROM HYDROGEN AND NITROGEN BY HABER PROCESS

In the Haber’s process, the reaction of nitrogen and hydrogen gases is accomplished by feeding the gases
to the reactor at 400 °C to 600 °C. The reactor contains an iron oxide catalyst that reduces to a porous
iron metal in the nitrogen/hydrogen mixture. Exit gases are cooled to – 0 °C to – 20 °C, and part of the
ammonia liquefies; the remaining gases are recycled.

The process varies somewhat with source of hydrogen, but the majority of ammonia plants generate
hydrogen by steam reforming of natural gas or hydrocarbon such as naphtha.

If the hydrogen is made by steam reforming air is introduced at the secondary reformer stage to provide
nitrogen for the ammonia reaction. The oxygen of air reacts with the hydrocarbon feedstock in
combustion and helps to elevate the temperature of reformer. Otherwise nitrogen can be added from
liquefaction of air. In either case a nitrogen-hydrogen mixture is furnished for ammonia manufacture.
(Speight, 2002)

8.3 Urea Manufacture

Urea (carbamide) is a colorless crystalline solid, somewhat hygroscopic, that sublimes unchanged under
vacuum at it melting point and decomposes above the melting point at atmospheric pressure producing
ammonia (NH3), isocyanic acid (HNCO), cyanuric acid (HNCO 3), biuret (H2NHCONHCONH2) and several
other minor products. Urea is very soluble in water (being a component of urine), soluble in alcohol and
slightly soluble in ether. There are several approaches to the manufacture of urea, but the principal
method is that of combining carbon dioxide with ammonia to form ammonium carbamate.

CO2 + 2NH3 → NH2COONH4

The exothermic reaction is followed by an endothermic decomposition of the ammonium carbamate.

 NH2COONH4 →NH2CONH2 + H2O

Both are the equilibrium reactions. The formation reaction goes to virtual completion under usual
reaction condition, but the decomposition reaction is less complete. Unconverted carbon dioxide and
ammonia along with undecomposed carbamate must be recovered and reused.

In the process, a 2:1 molar ratio of the ammonia and carbon dioxide (excess ammonia) are heated in the
reacted for two hours at 190°C and 1500 – 3000 psi (10.3 to 20.6 MPa) to form ammonium carbamate,
with most of the heat of reaction carried away as a useful process stream. The carbamate
decomposition reaction is both slow and endothermic. The mix of unreacted reagents and carbamate
flows to the reactor – decomposer. The reactor must be heated to force the reaction to proceed. For all
the unreacted gases and undecomposed carbamate to be removed from the product, the urea must be
heated at lower pressure (400 kPa). The reagents are reacted and pumped back into the system.
Evaporation and prilling or granulating produce the final product.

FIGURE 2 UREA PRODUCTION FROM AMMONIA AND CARBON DIOXIDE

The mixture formed is approximately 35% urea, 8% ammonium carbamate, 10% water and 47%
ammonia. It is cooled to 15°C and the ammonia is distilled at 60°C. The residue from the ammonia stills
enters the crystallizer vessel at 15°C. More ammonia is removed by vacuum. The resulting slurry is
centrifugal. All excess nitrogenous materials are combined and processed into liquid fertilizer which
contains a mixture of all these materials. (Speight, 2002)

8.4 Industrial Water

Water used in industries comes from natural sources like rivers, lakes and wells. This water is likely to
contain both dissolved and suspended solids even though they may appear perfectly clear. Because
water circulates many times through pipes, exchangers, cooling towers and basins, it picks up more/less
solids. When water evaporates, dissolves solids are left behind, increasing their concentration in the
remaining supply. Solubility of these solids varies with temperature. For example, calcium and
magnesium carbonates are less soluble in hot water than in cold water. When cooling water goes
through a heat exchanger, these become suspended solids. When water containing these salts is boiled
in a vessel, it deposits or scales on the sides and the bottom of the vessel. Scaling decreases the
efficiency of equipments and causes fouling which makes periodic cleaning necessary. Suspended
particles also cause erosion in narrow passages or turns in the flow. Microbiological growth in water can
also plug the narrow passages in the system. Similarly, oxygen content in water can become a cause of
corrosion and reduces equipment life.

In order to secure the equipment and maintain its smooth operation, water is treated and them used by
the plant. Water treatment reduces turbidity, TDS, DS, DO, organic matter, hardness and color of water.
Different unit operations are applied often in series to make water usable by plant.
8.4.1 Problems

8.4.1.1 Hardness

Water becomes hard due to the presence of carbonates, bicarbonates, chlorides and sulfates of metal
ions like calcium, magnesium, iron, manganese, aluminum and barium. The former two cause temporary
hardness and the later two are reason for permanent hardness. . Since the concentration of calcium and
magnesium salts is usually much higher than concentrations of other compounds which impart
hardness, it is customary to consider only the hardness caused by these salts (Utilities Unit, 2009).
Calcium is dissolved as it passes over and through lime stone deposits. Magnesium is dissolved as it
passes over and through dolomite and other Magnesium bearing formations.

Hardness is reason for scaling or deposition of salts inside water pipes, eventually reducing their
capacity. Scaling within appliances, pumps, valves causes wear on moving parts. This also creates
insulation problems inside boilers, water heaters and hot water lines and increases heating cost.
Hardness is expressed in ppm or mg/l.

Since calcium carbonate is one of the most common causes of hardness ,total hardness i.e. usually
reported in terms of calcium carbonate (mg/l as CaCO 3), using either of two methods. a) Ca and Mg
hardness

b) Carbonate and non carbonate hardness

Hardness caused by calcium is called calcium hardness regardless of the salts associated with it similarly
hardness caused by magnesium is called magnesium hardness. Total hardness=carbonate hardness +
non carbonate hardness. The amount of carbonate and non carbonate hardness depends on the
alkalinity of water (Utilities Unit, 2009).

TABLE 1 DEGREE OF HARDNESS

Ppm Hardness
75 Soft
75 – 150 Moderate
150 – 300 Hard
Above Very hard
300
Softening is the term which refers to the process of hardness removal.

8.4.1.2 Alkalinity

Alkalinity is the capacity of water to neutralize acids. This is determined by the content of carbonate,
bicarbonate, and hydroxide. Expressed in ppm of calcium carbonate, it is a measure of how much acid
can be added to a liquid without causing any significant pH change (Utilities Unit, 2009). It has two
types: P – alkalinity and M – alkalinity.

P – value is the measure of hydroxyl and carbonate alkalinity while M-value is the measure of total
alkalinity. Phenolphthalein indicator enables the measurement of alkalinity contributed by hydroxide
ions and half of carbonate ions. Any indicator responding in pH range 4 – 5 can be used to measure the
total M – alkalinity. P – value and M – value determinations are useful for calculations of chemical
dosage required in the treatment of natural water supplies.

TABLE 2 ALKALINITY INDICATION (UTILITIES UNIT, 2009)

Alkalinity Indication
2P=M All alkalinity is due to carbonates.
2P<M Both carbonates and bicarbonates are present.
2P>M Carbonates and hydroxyl are present.
P=M=0 M – Alkalinity id due to bicarbonates only. Carbonates and hydroxyl are not present.
P=0 Carbonates, bicarbonates and hydroxyl all are absent. Hardness is permanent.
8.4.2 Treatment
Water is treated to meet certain specifications before use in equipments. It is obtained from surface and
underground sources. Surface water with a higher turbidity is generally rich in microorganism and
contains fewer dissolved solids. It has high concentrations of oxygen and low concentrations of carbon
dioxide (Utilities Unit, 2009). Whereas the underground water is harder than surface water and contains
more alkalinity and dissolved solids. It is clearer and less sensitive to microbiological contamination than
surface waters.

Canal water is preferred due to low hardness despite of high turbidity. This is because turbidity
reduction is less costly than hardness removal. A mixture of both could also be used to make process
more economical, if one alone does not give desired process optimization. Tube wells are only used
when canal is nonfunctional, due to water shortage in country.

TABLE 3 WATER QUALITY COMPARISON

Surface Water Underground Water
High Turbidity Low Turbidity
Low Hardness High Hardness
High TDS Low TDS
Acidic pH Basic pH
High Dissolved Gases Low Dissolved Gases
8.4.2.1 Clarification

Clarification is carried out in a cone-shaped clarifier that clarifies the source water through the addition
of chemicals like lime, ferrous sulfate, chlorine and polyelectrolyte. Clarifiers purify water by
precipitating and coagulating the impurities and removing them by sedimentation filtration (M. Yaqoob
Ch., 1987). This results in removal of temporary hardness, turbidity and organic matter. It involves three
steps:

1. Coagulation

2. Flocculation

3. Sedimentation

Colloidal particles have large surface area that keeps them in suspension and a negative charge through
which they repel each other and do not form flocs to settle under gravity. Coagulation is the process of
destabilizing the small particles by neutralizing their charge and mixing them thoroughly to enable their
contact. In case of low turbidity, previously settled particles (also referred as sludge) are recycled in
order to increase the number of particle collisions and promote the thickness of sludge. Coagulants (e.g.
ferrous sulfate) are used to destabilize the colloidal particles in waste water so that floc formation can
result. Their dosage varies with respect to turbidity of the source water.

Flocculation is the bridging together of the coagulated particles. Flocculants (e.g.

polyelectrolyte) gathers together floc particles in a net bridging from one surface to another and binding
the individual particles into larger flocs that could settle down under gravity. It is favored by gentle
mixing and a fast pace can destroy the flocs formed. Flocculants work under the principle that a high
molecular wt polymer can attach itself to many suspended particles creating a low density floc with an
increase in the overall size of suspended material.

Sedimentation is the settling of suspended particles to the bottom of the structure leaving behind clear
water.

Chlorine is added to water in order to kill the organic matter and oxidize the iron ions in water enabling
their reaction with lime and settling. Lime removes temporary hardness caused by presence of
bicarbonates salts. Lime reacts with dissolved carbon dioxide soluble bicarbonates to convert them into
carbonates and hydroxyl salts are insoluble and therefore settle at the bottom of the tank.

CO2 + Ca(OH)2 → CaCO3 ↓ + H2O

2 Fe3+ + 3 Ca(OH)2 → 2 Fe(OH)3 ↓ + 3 Ca 2+

Ca(HCO3)2 + Ca(OH)2 → 2CaCO3 ↓ + 2H2O

Mg(HCO3)2 +Ca(OH) 2 → MgCO3 ↓ + CaCO3 ↓ + 2H2O MgCO3 +

Ca(OH)2 → Mg(OH)2 ↓ + CaCO3 ↓

 FIGURE 3 CLARIFICATIONTANK

8.4.2.2 Filtration

Suspended solids are removed from water by filtering the solids in gravity or pressure filter.
These filters have sand and gravel for limiting the flow of suspended particles. Installed in batteries of
two or more, these filters are often backwashed by forcing water in reverse direction. This flushes the
solids trapped in and on the filter bed into waste disposal system. The flow of other cells is continued
through when one cell of the filter is being backwashed.

Gravity Filter Pressure Filter

FIGURE 4 SAND FILTERS

8.4.2.3 Ion Exchange

Demineralization is based on ion exchange process. Ion exchange is the displacement of one ion by
another. It may also be defined as a reversible exchange of ions between a liquid and a solid phase
(resin). This exchange does not involve any radical change in physical structure of the solid (resin). The
ion exchanger or solid body must have its own ions to exchange for others. In demineralization two
types of exchange take place a cation exchange and anion exchange. Cations like calcium magnesium,
sodium, potassium, aluminum iron etc are removed in cation exchanger. Replacement of these cations
is carried out with hydrogen ions. Anions such as chlorides, nitrates, sulfates, bicarbonates and
carbonates are replaced with hydroxyl ions in the anion exchanger after the water has been treated by
the cation exchanger. Most ion exchange units are simple vessels containing a bed of ion exchange resin
operated down flow on cyclic basis. In demineralization process, there are four different types of ion
exchange resins:

• Strongly acidic cation

• Weakly acidic cation
• Weakly basic anion
 • Strongly basic anion

Strong Acid Cation (SAC) resins are used in softening and demineralization applications. In softening
applications, it is used in the sodium form (regenerated with salt) and in demineralization applications in
the hydrogen form (regenerated with acid). A strong acid cation exchanger will exchange all cations of
both neutral and alkaline salts with the hydrogen ion.

Weak Acid Cation (WAC) resins remove only cations associated with alkalinity. While WAC resins can
remove mono-valent ions such as sodium associated with hydroxide alkalinity, in most water treatment
applications they are used to remove divalent ions such as calcium associated with carbonate alkalinity.
A weak acid cation exchanger will exchange cations of mainly alkaline salts, and to a very small extent,
the cations of neutral salts. Most commercial ion exchange resins are synthetic plastic materials such as
co-polymers of styrene and divinyl benzene.

Strong Basic Anion (SBA) resins have strongly basic ammonium groups as the functional groups either
with tri methylamine {(-CH2N+ (CH3)3)} OH- or with di-methylethanol amine {(-CH2N+ (CH3)2 C2H4OH) OH-)}
Groups both these types of strong base resins are used in the hydroxide form for de-mineralizing
systems. Since strong base resins are highly ionized, they will exchange practically all anions which are
present as both strong and weak acids, e.g. hydrochloric acid, sulfuric acid, nitric acid, carbonic acid and
silicic acid. They will also split salts which remain unconverted in the cation exchanger.

They are of two types of SBA resins: Type I SBA resins are used where low levels of silica leakage are
important operating criteria or in warmer climates where source water temperatures may be quite
warm for a significant part of the year. They operate at improved efficiency when warm caustic (120º F)
is used to regenerate the resin bed; Type II SBA resins have an exchange site that is chemically weaker
than Type I resins. Therefore, they must be regenerated at lower temperatures (95º F.) and normally are
not used in climates where warm water temperatures are experienced for a good part of the year.
However, Type II SBA resins have the advantage of a higher initial exchange capacity. They can be the
resins of choice in applications that do not have heated caustic regenerant or where a low silica level is
not a critical operating specification.

Weak base anion (WBA) resins do not exchange any ions but removes by adsorption only those anions
associated with strong acids like hydrochloric, sulfuric and nitric acids (as shown in the above equation).
These resins do not remove carbon dioxide and silica since carbonic and silicic acids are weak acids.
Therefore, they cannot be used to make de-mineralized water without a SBA resin bed following in the
train to remove the carbonate/bicarbonate and silica. The exhausted resin is when regenerated with any
alkali; this simply neutralizes the adsorbed acid and releases it as a neutral salt. Because the weakly
basic exchanger is regenerated simply by neutralization of the adsorbed mineral acids, so a variety of
alkalies can be used for this purpose. The advantage of using the WBA resin is its efficiency. It is fully
regenerated using only about 120 percent of stoichiometry. Like their WAC counterparts, WBA resins
can be regenerated using the spent caustic from the SBA resin bed making their use very efficient
especially when used on water having a high percentage of anion loading from sulfate, chloride or
nitrate.

Mixed Beds provide optimum conditions for the ion exchange process and produces completeness of
exchange with resultant treated water quality much better than could be realized in a multi bed
deionizer. Polishing is carried out when it is necessary to get on high purity water. Resin structures
classified according to their operating properties are:

• Styrene-divinyl benzene copolymer bead structure.  Acrylic resin structure.

Physical classification of resins is:

• Gel resins; have smaller pores in the resin structure, higher initial exchange capacity and a lower
purchase price
• Macro porous resins; have ability to elute foulants easier due to the larger pore structure, stand
up better in harsher operating environments.

5 Safety
Safety and well being of human and site resource is the paramount concern of any industry. It ensures
maximum production and loss prevention and contributes to the well being of unit. With media being
more alert and alarming, safety has also become a concern of good name and repute for organizations.
Therefore, industry encourages its members to improve safety management and manufacturing
procedures and practices to minimize hazards.

Occupation Health and Safety Management System, OHSAS 18001:1999 regulates an industry to remain
committed to maintain a safe and healthy environment having the same significance as proclivity. It
inculcates safety culture by specific training, incentives and effective control, to ensure a safe and
healthy working environment. It resolves to attain the highest standards of safety and health through
consistent improvements in on-the-job and off-the-job safety and working conditions (FFC Safety
Section, 2004).

Chemical manufacturers are required to follow detailed steps in ensuring adequate training,
comprehensive operating procedures, thorough analysis of processes of hazards and investigations of
accidents, diligent maintenance of facilities, well-developed emergency plans, and self audits for
compliance (Richard W. Prugh, 2006).

Injury to personnel and property damage ask for high price, not the least of which are production break
off and loss of trained man force and equipment. In USA, annual worker fatalities three out of a hundred
thousand employees and annual lost-time disabling injuries are nine hundred (U.S. Bureau of Labor
Statistics). However, annual property losses have increased fourfold from the 1970s to the present
(Marsh & McLennan, Inc., Published Annually). This is probably because of increasing complexity and
productivity of the highly automated chemical plants, where personnel are isolated from processes.

Many changes have occurred in the requirements for safety in the chemical and petrochemical
industries during the period from 1974 (Flixborough) to 1984 (Bhopal) to 1994 (Lodi, N.J.). Some of
these changes were presented as consensus guidelines initiated by industry groups, such as the Centre
for Chemical Process Safety (CCPS), established by the American Institute of
Chemical Engineers, the Chemical Manufacturers Association (CMA, now the American Chemistry
Council); and the American Petroleum Institute (API). The objective of these changes is to raise the
design, operating, and maintenance standards of all members of these industries to as high level as is
economically possible (Richard W. Prugh, 2006).
 Inherent Safety
Engineering
Process Equipment and
Process Safety Control
Conditions
Administrative

F IGURE 5 P ROCESS S AFETY C ONTROL H IERARCHY

8.5.1 Process and Production Safety

Process and production hazards could be minimized through a hierarchy of controls that essentially fall
into two (Prugh, 1992) categories, i.e.

• Engineering Controls
• Administrative Controls

8.5.1.1 Engineering Controls

Engineering controls may be subdivided into those providing inherent safety and those involving process
equipment and conditions.

Those providing inherent safety controls include (Richard W. Prugh, 2006):

i. Intensification: Minimizing the amount of hazardous material or hazardous operations

ii. Substitution: Using inherently safer materials or safer processing or production methods
iii. Isolation: Barricading or distancing to minimize personnel exposure

Design and operating control include (Richard W. Prugh, 2006):

i. Containment: Designing for plant and process integrity

ii. Attenuation: Using less severe operating conditions of pressures and temperatures
iii. Consequence Reduction: designing to minimize accidental release rates and quantities iv.
Simplification: Avoiding complexities in equipment and control systems
v. Safeguards:
a. Passive: Use of explosion vents, rupture disks, relief devices, excess flow valves, and
dikes
b. Active: Use of alarm and interlock systems, scrubbers, and remote-operated valves
vi. Risk Minimizations: Arrangements for ventilation, leak-stopping, dump or drown systems, spill
control, and toxic and flammable –vapor sensors and alerting systems

8.5.1.2 Administrative Controls

The administrative controls include (Richard W. Prugh, 2006):

 1) Operating Procedures; for startup, shut down, response to upsets, and emergencies
2) Maintenance Programs; maintaining program integrity through inspections and testing
3) Process Hazards Analysis; maintaining program integrity
4) Limiting Personnel Exposure; limiting access and proving personal protective equipment 5)
Emergency Procedures; for escape and evacuations

FIGURE 6 EMERGENCY DIRECTION SIGNBOARD (FFC, MM)

The OSHA regulations require that Material Safety Data Sheet (MSDS) be developed for all process
materials, so that the hazard data can be communicated to employees (Occupational Safety and Health
Administration, 1999).

Protection may be ensured against toxic chemicals. Individuals can come in contact with materials by
ingestion, inhalation, skin irritation, skin absorption and subcutaneous injection (National Safety Council,
1988). However effects of acute and chronic exposures vary with chemicals and their concentrations.
Contaminants are physiologically classified (Richard W. Prugh, 2006) as:

i. Irritants; corrosive or vesicant, i.e. cause blisters, and may inflame moist or mucous surfaces.
Example: Ammonia, Acids, Alkalis, Bromine, Chlorine etc
ii. Asphyxiants; prevent blood from transporting oxygen to tissues thus respiratory paralysis.
Example: Hydrogen Sulfide
iii. Anesthetics and Narcotics; depressant action resulting in loose of consciousness without
seriously affecting systemic processes. Example: Acetylenic Hydrocarbons
iv. Systematic Poisons; cause organic injury to one or more of the visceral organs. Example:
Benzene, Phenols, Lead, Mercury etc
v. Particulate Matter; effects varied from minute allergy to cancer. Example: Silica,
Asbestos vi. Carcinogens; cause cancer and have been declared by several authorities.
Example: Nitrogen Mustard

8.5.2 Personal Protection Equipment

Industry provides personal protection equipment to its members working in risky areas. The material
and kit varies with job description and task-type.
Starting in 1994, employers are required by OSHA (Occupational Safety and Health
Administration, 1999), to perform hazards assessments to determine if workplace hazards are present
that require personal protective equipment (PPE). This could include hard hats, safety glasses, respirator
masks, gloves, safety shoes, and also may include long-sleeve shirts, long pants, and nets over long hair.
Also, the hazards assessment may require the removal of wrist watches and rings. If such hazards are
present, the employer is to document the hazards assessment, select appropriate PPE, and require that
employees properly use that PPE and conform to other requirements. The OSHA standard does not
require that the employer purchase and provide employees with the needed PPE, but many employers
have accepted a responsibility for furnishing the PPE to employers. (Richard W. Prugh, 2006)

(a) (c)

(b) (d)
FIGURE 7 INTERNEE PERSONAL PROTECTIVE EQUIPMENT (PPE)

(a) Safety Shoes (b) Hard Hat (c) Half Respiration (d)
Safety Glasses Mask

8.5.3 Design of Facilities

Plant Erection is multi stage process accomplished after millions of considerations and planning
procedures. Safety is the first concern of planning team. Several aspects are many times considered and
reconsidered for designing the facilities of a plant.

8.5.3.1 Plant Site and Layout

The choice of the site of a plant is made after consideration of several factors. Important of which are
assessment of hazards, based on the flammability of materials, reaction energy, and presence of highly
toxic materials (Ludwig, 1979). For instance, FFC MM is located in isolation from city population in order
to avoid any public damage due to ammonia leakage. An adequate water supply for process cooling and
fire fighting is a vital necessity. Prevailing winds are also considered. At FFC MM, Masuwah Canal that
flows from between the plant site and township, acts as an ample water supply source.

Open areas around the operating units of a plant act as buffers within the plant and to the surrounding
community. Sufficient clearance is allowed so that if tall structures collapse, other on-site buildings or
equipment, or off-site properties are not affected. Adequate roadways providing entry to the plant are
extremely important, and multiple entries and exits are advisable. An overcrowded plant can lead to
damage or shutdown of adjacent units and may impede the movement of vehicles and materials in case
of emergency (Industrial Risk Insurers, 1990).

Operations having potential for fire and explosion are segregated from non hazardous operations, such
as offices, cafeterias, laboratories, maintenance shops, and warehouses, to minimize evacuation hazards
and victim toll in a fire or explosion incident. When administrative facilities are located on the periphery
of the plant, visitors are less likely to be exposed to operational dangers. Vehicles loading facilities are
adequately separated from other operating areas as well. Adequate roadways are surrounded every
process unit and principal building, for access of maintenance and construction vehicles and fire-
protection equipment. (Richard W. Prugh, 2006). FFC MM plant site map is attached in Appendix I.

Plant security is an important factor in planning the sites for operating equipment, storage tanks, railcar
holding locations, truck operations vehicle parking locations and office buildings. Access to all parts of a
plant, including office building and operating units could be strictly controlled, with fences, card-access
or guard-controlled gates, photo-ID badges, frequent patrols of all areas of the plant, and closed circuit
television coverage of infrequently occupied areas. (Richard W. Prugh, 2006)

Plant designing in accomplished in such a way that interference or deliberate mis-operation may not
result in a catastrophe. Ability to interact with computer systems within the plant, from outside the
plant, could be prohibited or tightly limited to essential personnel, with a welldevised and secure system
of pathways. At FFC MM, internet access is restricted to management level employees only, as a safety
measure.

8.5.3.2 Utilities

8.5.3.2.1 Services and Facilities

Principal electric power lines are run underground to reduce the probability of damage from exterior
cause like weather and vehicles. Transformer stations and switchgear are accessible to only authorized
personnel. Repair works are carried out after ensured safety of both process and personnel. In order to
secure the stake, FFC MM has regulated a written permit system in production area to ensure that any
sort of work is being done after prior information the concerned authorities and staff. The following
eight types of work permits are issued by shift engineers for repair work at unit:

1. Cold Work Permit; low temperatures are required

2. Hot Work Permit; fire is used during work
3. Instrument Work Permit; instruments are replaced or repaired
4. Electrical Work Permit; electricity supply is to be altered
5. Vehicle Entry Work Permit; vehicle has to be used for assistance
6. Excavation Work Permit; digging is to be done

7. Radiography Work Permit; radiation exposure is expected

8. Vessel Entry Work Permit; vessel or tanks are to be repaired
These permits ensure safety of both plant and personnel. Electrical installations and work are done in
accordance with National Electrical Code (NEC) for the type of hazard and degree of process
containment.

TABLE 4 NATIONAL ELECTRICAL CODE, NEC (NATIONAL FIRE PROTECTION ASSOCIATION, 2002)
Type Of Hazard Degree of Process Containment
Class I: flammable gas and vapor Division I Open Division II
Class II: organic, metallic, or conductive dusts Closed
Class III: combustible fibers
It is more economical to prevent explosive atmospheres in rooms than to provide explosion electrical
equipment. Such areas can be reduced when reliable ventilation is provided. Personnel are also avoided
to work in such areas. If atmosphere cannot be avoided through control of flammable gases or vapors or
combustible dusts, access to the area is limited and the area segregated by walls or other barriers, with
special exhaust ventilation. Electrical equipment on open, outdoor structures more than 8 m (25 ft)
above ground usually is considered free from exposure to more than temporary, local flammable
mixtures near leaks (API, 1987).

8.5.3.2.2 Water

Water mains are connected to plant fire mains at two or more points, so that a sufficient water supply
can be delivered in case of emergencies. The plant loop and its branches are adequately valved so that a
break in any main can be isolated with affecting the principal part of the system. Booster pumps could
also be installed for maintaining adequate pressures. At FFC MM, fire mains, fire pumps, isolation
valves, and fire protection system are tested at 1500 hours on every Wednesday in Fire Drill

Special water mains are used to supply untreated water to large plants located nearby a water source in
case of emergency.

8.5.3.2.3 Safety Showers

Safety showers and eyewash fountains or hoses are installed where corrosive or toxic materials are
handled. The valve handles for all safety showers are at the same height and position, relative to the
shower head, and operate in the same way and direction. Water to outside showers is heated to a
maximum temperature of 27°C by an electric heating cable.

8.5.4 Operation of Facilities

Plant operation could be divided (Richard W. Prugh, 2006) into following types:

1. Start-Up; starting up the plant after erection or plant shutdown

2. Normal Operation; routine work flow of plant
3. Shut down; complete plant shutdown for annual repair work
4. Maintenance; repair or replacement of any plant equipment
 5. Safe Work Practices; methods for secure and efficient work like tagging of equipment, sign
boards, work permits etc

Plant Operation

Start-Up Normal Operation Shutdown Maintenance Safe Work Practice

FIGURE 8 T YPES OF P LANT O PERATION

8.5.5 Human Resource Management

8.5.5.1 Personnel Selection and Training

Abilities of operator and workers are closely related with the plant safe operation. Personnel must be
both physically and mentally sane and sound. Selection of personnel for task specific jobs is done after
taking in perspective, these factors. Medical selection is often mandatory for selection. Medical
screening avoids damaging exposures to susceptible individuals for example people with respiratory
ailments are not employed in areas where corrosive atmosphere could occur.

Training is a significant aspect of any professional organization. At FFC MM, graduate engineers are
inducted as trainee for a minimum duration of one year. Training includes development of
understanding of Standard Operating Procedures (SOP) for each unit or plant and complete adherence
to these procedures. Job-safety analysis is also coming up as practice.

On-the-job training includes (Richard W. Prugh, 2006):

1) Preparing the workers by describing the job and discussing the important points 2)
Presenting the operation, encouraging questions, and stressing key points
3) Working under close supervision, with errors being corrected as they occur; and
4) Working alone with frequent follow-up by supervisory personnel

8.5.5.2 Medical Programs

Large chemical plants have at least one full time physician who works at the plant. Routine check-ups
and free medical packages are often included along with basic salary and other provisions. At FFC MM, a
medical centre and pharmacy (located at township) offers management and staff, an immediate service.

8.5.6 Disaster Planning

Plant managers usually recognize the possibility of natural and industrial emergencies and formulate a
plan of action in case of disaster. The well documented is well circulated and explanatory to all
personnel critical to implementation. A checklist for total emergency planning and guide map in such
situations are developed. In all emergency situations, the fire services, the safety staff, and the medical
organization are of paramount importance for the conservation of life and property (NSC, 1988). These
plans are so formulated to mobilize the off-duty personnel and to bring in outside help for assistance if
needed. At FFC MM, guidelines in case of ammonia release and fire fighting and safety information is
well communicated through brochures, circulars, notices and booklets (FFC Safety Section, 2004) to
both plant personnel and township residents.

8.5.6.1 Fire Fighting

Fire is man’s best friend and worst enemy. Fire Safety, at its most basic, is based upon the principle of
keeping fuel sources and ignition sources separate. Three things must be present at the same time to
produce fire, removal of any of which results in extinguishment:

1. Enough oxygen to sustain combustion

2. Enough heat to reach ignition temperature
3. Some fuel or combustible material together, they produce the chemical reaction that is fire

FIGURE 9 FIRE TRIANGLE

Fires are classified according to the type of fuel that is burning. Use of wrong type of fire extinguisher on
the wrong class of fire, you might make matters worse. Fire classification is given in the table below:

TABLE 5 CLASSIFICATION OF FIRE (OSU, 2005)

Fire Fuel Source Examples
Class A Solid Combustibles Wood, Paper, Cloth, Trash, Plastics
Class B Flammable Liquids and Gases Gasoline, Oil, Grease, Acetone
Class C Electrical Fires Energized Electrical Equipment
Class D Combustible Metals Potassium, Sodium, Aluminum, Magnesium
Extinguishment or control of fire is essential. Exposure of personnel to thermal-radiation hazards must
be minimized and property protected. Extinguishing fire requires cooling below the flashpoint, removing
the oxidant, or reducing the fuel concentration below the lower flammability limits (Richard W. Prugh,
2006).

Most fire extinguishers have a pictograph label telling which types of fire the extinguisher is designed to
fight.

Class A Class B Class C Class D

FIGURE 10 FIRE EXTINGUISHER LABELS

For combustible solids and high flashpoint liquids, water can be used alone to extinguish fire. Water has
an additional benefit as a result of its high specific heat and high latent heat of vaporization. It can be
used to cool equipment, structures, and containers of hazardous materials, even when extinguishing is
difficult. Water is the preferred fire control medium (Richard W. Prugh, 2006).

The extinguishing capability of water can be improved by adding foaming materials. Foam are formed by
addition of proteins and similar synthetic materials and aerating at nozzles to make a blanket which
floats on flammable materials. As foam excludes air, and reduced volatilization, it is used to cover spills
(Richard W. Prugh, 2006).

In some cases, extinguishment of fire by means of oxidant reduction is more effective. These include
inert gases like nitrogen, carbon dioxide, halogenated hydrocarbons, or noble gases (Richard W. Prugh,
2006).

Dry-chemicals like bicarbonates or ammonium phosphate provide a coating that makes the material
suitable for use on fire involving solid combustibles like rubber tires, wood and paper (Richard W. Prugh,
2006)

8.5.6.2 Types of Fire Extinguishers

Fire extinguishers are designed to fight different classes of fire.

Water (APW) Fire Extinguishers: APW’s extinguish fire by taking away the “heat” element of the Fire
Triangle. These are designed for Class A fires i.e. fires that have their origin from wood, paper, cloth.
Using water on a flammable liquid fire could cause the fire to spread. Using water on an electrical fire
increases the risk of electrocution. If there is no choice but to use an APW on an electrical fire, the
electrical equipment should be un-plugged or de-energized.

Carbon Dioxide Fire Extinguishers: Carbon dioxide cylinders are red and black. They range in size from
5 lbs to 100 lbs or larger. On larger sizes, the horn will be at the end of a long, flexible hose. The
pressure in an extinguisher is so great, carbon dioxide will be in liquid form may shoot out of the horn.
These are designed for Class B and C (Flammable Liquids and Electrical Sources) fires only and are placed
in laboratories, mechanical rooms, kitchens, and flammable liquid storage areas.

Carbon dioxide is a non-flammable gas that takes away the oxygen element of the fire triangle. Without
oxygen, there is no fire. Carbon dioxide is very cold as it comes out of the extinguisher, so it cools the
fuel as well. Extinguisher may be ineffective in extinguishing a Class A fire because it may not be able to
displace enough oxygen to successfully put the fire out. Class A materials may also smolder and re-
ignite.

Dry Chemical (ABC) Fire Extinguishers: Dry chemical extinguishers put out fire by coating the fuel with a
thin layer of dust. This separates the fuel from the oxygen in the air. The powder also works to interrupt
the chemical reaction of fire. These extinguishers are very effective at putting out fire.

ABC extinguishers are red and blue. They range in size from 1 kg to 70 kg. The greatest portion of
powder is composed of mono-ammonium phosphate. The extinguishers are pressurized with nitrogen.
9 Safety Section

FFC believes in “safety first”.

FFC Management is committed to cause of safety and believes that it is everyone's responsibly. The
objective is to improve the working culture through effective safety program. Zero lost work days are
the target (FFC Safety Section, 2010).

Details are enclosed in Appendix II (FFC MM Plant Safety Policy) and Appendix III (FFC Plant Safety Rules
and Regulation).

Recognition for safe work is arranged in collaboration with NSC, USA. Till July 2010, 8.3 million safe hour
operations have been carried out, i.e. no Lost Time Accident (LTA) has taken place since last 8.3 million
hours. FFC MM has also received IMS 2009 certification for safe working other than ISO 9001, ISO 14001
and ISO 18001.

Safety Section of FFC MM performs various functions and activities for running an effective safety
program through the following hierarchy of section:

• Section Head (01)

• Engineers (02)

• Safety Sub-Engineer (01)

• Supervisor (01)

• Safety Operators (08)

9.1 Activities

FFC Safety section works in both planning ad execution phases to implement safe work conditions at
plant, with improved working standards and safety. This includes multidimensional efforts team. Key
activities (FFC Safety Section, 2010) of unit are as follows:
Managing Safety Program

Main object is to plan, organize, budget, and track execution of activities to achieve safety
objectives of our plant laid down in FFC MM Safety Policy (Appendix II). Through prudent planning
and effective resource management safety section cater for all the needs of personal and process
safety.

Motivation

Safety section is committed to achieve excellence in the field of safety. All projects related to safety
are given top priority and good safety and housekeeping standards are appreciated through token
rewards. This include slogan of the year, best housekeeping award, safe man of the year award and
safe men hours award.

Hazard Recognition

It ensures the identification of conditions or actions that may cause injury, illness or property
damage, is a routine activity carried out at all levels in plant areas. Plant safety committees are
formed all hazards of the plant are highlighted and engineering solution are evolved. Safety section
also carries out routine audits of the plant and points out hazards to concerned units.

Inspection /Audits

Appraise of safety and health risk is associated with equipment, materials, processes and facilities. It
is monitored through routine audits.

Fire Protection

It reduces fire hazards by inspections of facilities and processes. It arranges all type of fire
extinguishers as per need and facilities requirement. It also oversees the design and operational fire
safety of the complex and suggests and coordinates requirement-based developments.

Regulatory Compliance

It ensures that mandatory plant rules and regulations (Appendix II) and International Safety
standards are satisfied.

Health Hazard Control

 It conducts audit and control hazards such as noise, chemical or radiation exposure.

Hazardous Material Management

It creates awareness that dangerous chemicals and other products are procured, stored and
disposed of in ways that prevent exposure or fire. Display of MSDS in areas to increase
consciousness, are ensured.

Training

Safety Section provides management and employees with the information and skills necessary to
recognize hazards and perform their job effectively and safely. All safety inspectors are trained as
fire fighters and work permit procedure auditors. Section also maintains training record of all
manpower.

Accident and Incident Investigation

It determines the facts related to an accident or incident based on witness interviews, site
inspection and collection of other evidences. The focus of this activity is to stop reoccurrence.

Record Keeping

All data related to accidents/ incidents is recorded and maintained. Safety section reports it to
government and NSC if required. It also maintains safe man-hours data of the company and reports
it to NSC.

Evaluating

It evaluates the effectiveness of our program through various indices like accident/ incident rate,
use of personal protective equipment, quality of job safety. It also considers reporting of near miss
as an effective system to avoid occurrence of a real risk.

9.2 Safety Training

FFC ensures safe work environment by providing safety training to all personnel on plant. As per the
company policy all news personnel on plant receive safety training prior taking charge of their
responsibilities. Safety training was provided to the group comprised of author and two other internee
engineers by Mr. Mushtaq Ahmed (Safety Sub-Engineer) on July 1, 2010 at Safety Section, FFC MM.
Training introduced with the plant safety policy and rules and regulations, while functioning of safety
section was also briefed.
T ABLE 6 S AFETY D ESCRIPTION AS SET BY S AFETY S ECTION , FFC MM

S A F E T Y

Search Analyze Find Eliminate Tell You

for hazard situation causes reasons others are safe

The training comprised of :

• Importance of Safety at Plant

• Use of Personal Protective Equipment

• Use of Fire Extinguishers

• Ammonia Disaster

9.2.1 Importance of Safety at Plant

FFC produces about 60 % of market’s urea production. Not preparing for plant safety may not only
result in decrease of company production and sale but also in shortage of fertilizer in market. This may
affect the country’s agriculture growth and thus shortage of food for public followed by price hiking.

FIGURE 11 EMERGENCY SIREN SEQUENCE (FFC SAFETY SECTION, 2004)

The plant produces ammonia as the raw material for urea production. Ammonia as a hazardous gas
always has a probability of release in case of leakage or disoperation. This may result in ammonia
disaster leading to a catastrophe if not avoided or duly responded.
Safety is therefore an important consideration prior to working on plant.

9.2.2 Use of Personal Protective Equipment

The Personal Protective Equipment provided to internees included safety shoes, hard hat, half face mask
and safety glasses. The training gave an idea to author of when and how to use the equipment especially
half face mask, which aids in breathing where air is slightly rich in ammonia or any other hazardous gas
or during ammonia disaster. Escape mask provides safety in situations where concentration of ammonia
in air is 50 ppm to 60 ppm.

9.2.3 Use of Fire Extinguishers

TABLE 7 STRATEGY IN FIRE INCIDENT (SUGGESTED BY SAFETY SECTION, FFC MM)

• Fire
F
• Inform management
I
• Rescue yourself and others
R
• Extinguish / Escape
E

Fire is the most common form of disaster for any industry but could be dealt, if well prepared. Fire
erupts due to unsafe work, and could be avoided if well planned and followed. In order to avoid any
unpleasant accident, personnel are trained for fire fighting. Internees were told taught to use the fire
extinguishers for self safety. Strategies in fire incidents and emergency response have been both
notified and published (FFC Safety Section, 2004) by Safety Section.
 FIGURE 12 EMERGENCY RESPONSE (FFC SAFETY SECTION, 2004)

Using fire extinguisher was introduced synonymously with an acronym PASS; pull, aim, squeeze and
sweep side by side.

Pull Aim Squeeze Sweep

FIGURE 13 PASS APPROACH FOR USING FIRE EXTINGUISHER

Controlling fire can be dangerous; therefore it was advised by the trainer:

1. Assist any person in immediate danger to safety, if it can be accomplished without risk to you.

2. Call 3222 Safety Section or 3234 Shift coordinator and activate the building fire alarm. The fire
alarm will notify the fire department and other building occupants and shut off the air handling
system to prevent the spread of smoke.

Before using a fire extinguisher, it was suggested to know what is burning. Else, using the extinguisher

would not be a wise decision as it could result in a bigger problem. Even if an ABC fire extinguisher is

available, there is always a possibility that fire may explode or produce toxic fumes. Fire extinguishers
are used to control fire in initial stages (OSU, 2005). If fire is continuously increasing from the source

point, it is wise to immediately evacuate the building.

9.2.4 Ammonia Disaster

Leakage or unwanted release of ammonia from plant has been termed as Ammonia Disaster. Ammonia
being a hazardous gas chokes respiration process resulting in death. Therefore, for safe escape, plant
personnel and township residents are trained for plan of action in case of ammonia disaster. All offices,
buildings and homes are constructed with an ammonia shelter, in case of emergency. Shelter has no
windows and only single door which can be sealed in case of ammonia release. Personnel and families
can remain save in shelter until safety announcement is made.

TABLE 8 EFFECT OF AMMONIA AT DIFFERENCT CONCENTRATIONS IN AIR

Concentration Effect
Below 5 ppm Harmless
200 ppm Etching to eyes and skin
500 ppm Problem in breathing
More than 700 ppm Death
For personnel outside building or on pathways, it is suggested to take protection is ammonia shelter
made outside the buildings. Standing below water shower would also be safe as ammonia gets readily
dissolved in water, reducing its intensity of attack. Using a moist cloth for breathing in case no mask is
available is highly recommended to avoid choking. On hearing the ammonia disaster siren, listener
should see the wind direction through prilling tower emissions or air direction sock and move crossway
from wind direction.