EMS SYSTEM & EMS AUDIT

July 12

2016 This report contains details on EMS audit conducted in Reliance Industries by GPCB and exposure to EMS system implementation in Petrochemical Industry

LIVE PROJECT AT RELIANCE INDUSTRIES FOR EMS SYSTEM

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INDEX

1. Acknowledgement 2

2. EMS Audit 3

3. EMS system at Reliance 4

4. EMS Exposure 4

5. ETP Plant Visit 7

6. Secured Landfill 8

7. Pollution Prevention and Control 8

8. Executive Summary 9

9. References 10

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Acknowledgment

I wish to express my sincere gratitude towards Reliance, VMD for giving me, this

opportunity to explore my practical knowledge in the area of Environment

management system and Environment audit. I wish to express my sincere thanks to

Mr. Sanjay Patel for selecting me to join the team and work effortlessly.

I would also like to thank Ms. Purna Paul for the guidance and support. I also wish

to thank Mr.Das and Mr.Jain and other office colleagues who helped me in this

training period for bringing the best outcome of my project.

I would also like to express my gratitude towards SIIB for giving me the

opportunity to work for Reliance VMD.

Lastly I would also like to express our sincere thanks for showing the beautiful

campus of Reliance and making me part of the family.

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Experience at Reliance VMD

1.EMS AUDIT: According to CEPI notification around 88 clusters all over India are deemed as

critically polluted areas and mandatorily Government has asked to check and

monitor pollutants in these areas. Vadodara Manufacturing Unit of Reliance

Industries being a petrochemical industry the hazardous pollutants needs to be

checked and monitored regularly.

Government of Gujarat has appointed some institutions and consultants as auditors

for Environment Management System to keep a check on level of these emissions.

DDU is a deemed university which is being appointed by GPCB as an external

schedule 1 auditor for Reliance Industries (VMD).

External Schedule 1 and Schedule 2 auditors are assigned the duties by GPCB

according to the polluting and very high polluting industries. Schedule 1 auditors

are 30-35 all over Gujarat who audit environment for very high polluting industries.

Consultants given this duty are around 85-90 all over Gujarat which looks at the

emissions of polluting industries.

This team of DDU consisting of 5 members audited the VMD complex for 2 days and

I had got this prestigious opportunity to be part of the team.

This audit is conducted for 3 seasons and a compiled report is sent to GPCB. The

samples for water, air, solid waste were collected in these two days. The processing

and lab testing of these emissions to be in permissible limits as per the GPCB

guidelines was then carried out.

The air sampling is of two kinds: Ambient Air monitoring and Stack Air monitoring.

Water samples are collected from ETP and solid waste samples are collected from

SLF (secured landfill site).

Ambient Air monitoring is conducted for 8 hours or 24 hours at a stretch for

knowing the emission in ambient atmosphere around the site. This monitoring helps

in knowing levels of emission of pollutants in permissible levels for human air

consumption. These AAQ stations are selected initially during the EIA of the project

and then regular monitoring is carried out on these stations for EMS monitoring

during audit. Forced air sampling is taken for flue gas and process gas from stack

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emissions. These samples were taken for three plants namely GOP, GTPP and

VC/PVC. The stack emission is taken for SOx, NOx and PM of the hydrocarbon for

respective plant. The permissible limits are followed as per the guidelines of GPCB.

The gases are taken from nozzle located at the foothill of stack by drawing it by the

function of vacuum.

Water samples were collected from all stages of ETP and were taken for lab testing.

Digital analyser is available to monitor routine levels of pollutants from treated

water. Solid waste samples are taken from secured landfill site. A new development

which is noted in this audit is that digital monitoring devices will be put up on each

stack for daily monitoring and these readings will be noted in control room as well

as in GPCB office.

2. EMS System at RIL Here at RIL VMD, care for environment is central and is maintained at its fullest

from the inception. State of art equipment and other infrastructure are installed for

effective environmental management system. In 2000 it has earned ISO 14001:2004

certifications from DNV until May 2017. Green card performance monitoring system

is an in house environmental management system of RIL which is implemented at

RIL.

All the plants have their own targets on environmental parameters to be achieved

and this keep them striving towards success.

An excellent tree cover is maintained in and around the premises comprising of

more than 1, 50,000 trees of 145 different species.

3. EMS EXPOSURE Later 5 days were included as a training program to know about the procedure

employed at Reliance VMD complex in Environment management system.

As explained by an employee at Reliance Industries the general system of EMS is

bifurcated into two categories namely internal audit and external audit. External

audit is carried out by DNV by ISO 140001:2015 standard and internal audit is

carried out daily by EMS department at Reliance Industries.

Reliance followed the internal audit procedure for maintaining and monitoring the

environment and as per the legal compliance of GPCB norms. The parameters which

were taken into account for monitoring environment were

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Figure 1: Parameters tested

Like every company following the general procedure of EMS implementation, here

too in Reliance Industries the PDCA cycle was followed wherein Policy of the

company was defined by the chairman and accordingly the objectives were set to

achieve these objectives/targets. A detailed plan was carried out for specific every

plant working. An aspect impact assessment process was followed and risks were

assessed as well for every plant. These decisions were reviewed every day and the

parameters were monitored as per the targets to be achieved. This monitoring for

conducted every day and in a year around 130 reports were sent to GPCB as per the

compliance.

Air monitoring is of two types- AAQ and Stack monitoring, in AAQ monitoring the

stations are fixed and readings are taken of a span of 8 hours or 24 hours. Stack

monitoring is carried out for flue gas and process gas and the standard for these is

given as per EPA act of MOEFCC for specific industries.

Water is monitored for the amount of quantity used by plants in cooling and in

process. The access of water consumed can be a fire alert or issue with efficiency of

process of the plant.

Effluent monitoring is carried out on 24 parameters and here both quality and

quantity of effluent are crucial as per the GPCB norms.

Waste monitoring is a basic part of EMS; this waste is non-hazardous and hazardous

waste. Non-hazardous waste like metal scrap, plastic, wood etc. is sold or trashed

and hazardous waste can be flammable, toxic, inert or reactive. This waste is treated

with a 5 step waste minimization procedure i.e Landsink ladder.

Air

WaterEffluent

Hazardous Waste

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Figure 2: Landsink Ladder

1. At the top of his pyramid is waste minimization; this is the first step which should

be taken in any process. When we reduce wastage the process becomes efficient and

production increases

2. Second step is reduce and reuse level wherein the products are reused or recycled

or are reduced. Example can be taken as lube oil which with a little processing can

be reused in industry.

3. Incineration is the third step where the waste obtained is burnt in controlled

environment to get ash waste which is then dumped into secured landfill location.

4. Co processing is like incineration where the waste is burnt and the energy

obtained during the process is utilized in the plants again. This is used on the waste

which has higher calorific value.

5. The waste which is inert in nature has to be directly taken to secured landfilling

site for disposal.

According to GPCB norms, 90 days is the limit given for the disposal of hazardous

waste by industries.

Minimization

Recycling/Reusing

Incineration

Co-processing

Secured Landfill

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4. ETP Plant Visit A brief visit of two hours increased my awareness about the working and treatment

of Effluents which are harmful to environment if left untreated. Initially the flow

diagram was properly explained point to point by Mr. Das Sir and then the plant

and its actual working was explained in detail by Mr. Jain Sir. Whole and whole how

at every stage the effluent becomes a bit less harmful to environment is what was

learnt in this visit. Moreover the targets set by this industry section were looked at.

ETP is effluent treatment plant which is a plant where effluents from various plants

are collected and effluent is extracted out which is then trashed to secured landfill

and this treated water is used for gardening, washing and other purposes.

The arrangement of processing of this waste is very effective and efficiently made

along with very less amount of power is consumed in whole process as the flow of

effluent is managed by gravity. Only in screw pump energy is consumed in ETP

plant. The sludge reduction and water usage of this treated plant is taken up to 15

per cent.

Oily waste is collected underground and then is transferred by screw pumps to first

level and then by second screw pump to surge pond level. Here the liquid then

passes through screen chamber where waste like plastic wood etc are removed from

the liquid and this liquid passes through grit chamber where sand and other gravels

settle down. Here two more effluents are added which are directly treated partially

at the plant. This all liquid gets accumulated at surge pond whose capacity is

9000meter cube. There are 4 such surge ponds for collection of waste.

This waste the passes through gravity into homogenization tank wherein PH level of

this liquid is maintained and then is passed to flask mixer where alum is added to

remove impurities from the liquid. This water is then processed in API unit which is

a skimmer where oil is removed. Later on it passes into clariflocculator tank where

the sludge molecules are combined to form a larger molecule.

Aeration tank is the heart of this process where this water is made effluent free by

microorganism and air intake. There are two types of aerators available; surface

aeration and diffused aeration. Here in RIL (VMD), surface aeration technique is

used in process. Then water is passed on to final clarifier where sludge is separated

from clean water.

This sludge is taken to the sludge drying beds where sludge is dried and then taken

to secured landfill. Clean water passes through pipeline to VECL point, from where

50 km pipeline is laid which takes this water to Cambay.

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The parameters monitored are PH, COD, BOD, TSS, and NH3 as per the GPCB

guidelines.

5. Secured Landfill Reliance industries have a secured landfill site for dumping treated hazardous

waste. This is first site in Gujarat with secured construction. This is in Nandesari

area around 2 kms from the industry site. This secured landfill site has a double liner

where the leachate is prevented from entering the groundwater.

The operations are carried out as per guidelines and in here spent catalysts, resins,

plastic bags and other wastes are disposed without packing.

This operation is suspended during monsoon season and is transported to central

wastewater treatment plant at the complex for treatment.

6. Pollution Prevention and Control 1) Around 230 audits are conducted every year of which 210 are green card,6

quarterly and 2 by DNV.

2) Spill management plan is put into practice to protect the hazardous spill to be

controlled in the plant itself and to ensure no effluent gets drained through storm

water. Dyes, Sluice gates are used to control this spill.

3) Benchmarking system is used to competitively remain in environmentally efficient

system. This benchmarking is with respect to other plants like hazira, dahej etc.

4) Leak Detection and Repair program is undertaken to map the emission of those

effluents which are of very less ppm. These emissions if combined can contribute to

voluminous emissions as being of big petrochemical industry. Here an instrument

with photo ionization detector is used for detecting and monitoring volatile organic

compounds.

This monitoring of VOC is taken at three levels namely level 1, level 2, level 3.

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Figure 3: LDAR Levels

5) Online effluent monitoring is in place for the parameters like COD, BOD, TSS,

Ammonical Nitrogen etc.

6) Online display of parameters like ambient air, stack monitoring, effluent etc. are

placed at entry gate to monitor the level everyday by which production can be

increased and environment can be effectively monitored.

7) Flare tip is replaced with more efficient flare tip which gives a smokeless flare .

Here the new flare is designed in a manner in which abundant spray of steam on gas

which makes this tip smokeless.

9. Executive Summary The training period of 10 days were composed of various activities around the

petrochemical manufacturing division and the measures taken by this magnanimous

giant in terms of waste treatment and environmental management.

Activity 1 was a two day audit conducted by an external agency as a schedule 1

auditor appointed by GPCB. This team collected samples for air water effluent waste

and ambient air from different plants. These samples were to be tested in laboratory

for the results to be in assigned parameters.

Then activity 2 was a detailed discussion on the implementation system of EMS in

Reliance industries and which are the measures necessary taken for specific plants

and the general procedure which is used by Reliance in Environment Management.

The third activity 3 was reading of Ems audit report of the year 2015-16 which made

me aware of many measures of protecting the environment from hazardous and

Audio Visual Round

Detection by dragger tubes and

soap solution

Photo-ionization detector

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non-hazardous wastes as a precaution and the various actions already in place by

Reliance. Along with this audit report the other details about chemical plants and

process was read.

A visit to ETP was activity 4 which was a detailed learning on working of ETP for

any industry and which are specific precaution measures taken in Reliance for it

,various processes which are used in Reliance for the treatment of wastes and its

disposal and later on plant visit to know the whole process implemented practically.

Later on Activity 5 was a study of waste disposal scheme used in Reliance and on

Secured landfills and what is the purpose and method of making a secured landfill.

Capacity and what exactly is dumped in this landfill was in discussion.

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References:

1. Environment Audit Report 2015-16, Reliance Industries

2. Google

3. Urban and waste management

Thank You