Presentation on

CHEMICAL SAFETY

- V K NEMA

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INTRODUCTION

Gujarat Narmada Valley Fertilizers & Chemicals

Limited came into existence on May 10, 1976 with

single stream Urea & Ammonia plant. 1985 onwards

it has been diversified into Industrial Chemicals.

In 1992, promoted NCPL jointly with Chematur

Engineering AB, Sweden and IBI Chematur Ltd.,

India to manufacture Aniline and Toluene Di-

Isocynate (TDI). It has been merged with GNFC in

2007.

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Plant Capacity(MTPD) Date of Commissioning Technology Suppliers

AMMONIA 1350 DECEMBER 6, 1981 LINDE & BASF

UREA 1927.27 DECEMBER 13, 1981

SNAMPROGETTI-ITALY

SGGU 612 KNM^3 FEBRUARY 13, 1998 H&G –

MUMBAI

METHANOL-I 150 AUGUST 10, 1985 ICI-U.K./LINDE-

GERMANY

MSU 90 JULY 16, 2006 IN-HOUSE

METHANOL-II 300 DECEMBER 31, 1990 ICI-U.K./TOYO-

JAPAN

FORMIC ACID 33 FEBRUARY 22, 1989 KEMIRA-FINLAND

ACETIC ACID 300 SEPTEMBER 13, 1995 B.P. CHEMICALS-

U.K.

WNA (I+II) 1050 MARCH 25, 1990 UHDE-GERMANY

CNA-(I+II+III) 300 OCTOBER 2,1989 &

JANUARY 24,1999 PLINKE-GERMANY

ANP 475 SEPTEMBER 12, 1990 BASF-GERMANY

CAN 475 AUGUST 02, 1990 UHDE-

GERMANY

GNFC’S PLANTS

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Ammonia In the manufacture of Urea, Ammonium Nitro phosphate

Methanol In the manufacture of Acetic Acid, Formaldehyde, DMT, Pentaerithritol, pharmaceuticals and other intermediates

Formic Acid Coagulant for getting rubber from latex, dye fixing in textile & leather industries, intermediates in basic drugs.

Acetic Acid In the manufacture of Acetic Anhydride, MCA, Acetates, Di ketone Derivatives.

Concentrated Nitric Acid

In the manufacture of dyes, dye intermediates, drugs, NB, Aniline, Nitro Chlorobenzene, TDI & nitro derivative.

Weak Nitric Acid

In the manufacture of fertilizers, Ammonium Nitrate, & other explosive, glyoxalin, sodium nitrate, H-Acid, NB etc.

Products & Uses

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Aniline In the manufacture of dyes, dye intermediates, rubber chemicals, pesticides, pharmaceutical, insecticide etc.

Toluene Di Isocynate (TDI)

Raw Materials for flexible Polyurethane, foam.

Nitrobenzene Dyes & Dye intermediates, pharmaceuticals pesticides

Urea Fertilizer effective for all kinds of soils & crops

Ammonium Nitro phosphate (ANP)

Fertilizer for basic application during sowing time.

Calcium Amm.

Nitrate (CAN)

Fertilizer suitable in all upland crops. For

avoiding soil acidity & alkalinity.

Ethyl Acetate Printing inks, Flexible packaging,Pharmaceuticals , paints etc.

Products & Uses

A ‘Twenty Two Points Programme’ to

manage the safety is given as follow :

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It covers various kinds of

innovative practices to control the

hazards and to reduce the number

of accidents.

1. MANAGEMENT INVOLVEMENT

In daily production meetings which are headed by

chief executive, report from Safety department is

presented. In this report, all the abnormalities,

incidences or any other information is discussed

and suitable actions are immediately taken.

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2. SAFETY SURVEY

In the plants, everyday some or other activities isalways going on. There are many maintenanceactivities which requires constant monitoring.Though Safety permits are issued for each activity,there may be shortfalls in following safetyinstructions:

Sometimes, the condition of the workplace mayalso be unsafe. Besides plant personnels, safetypersonnels take rounds of the plants everyday.They record any kind of unsafe condition and actto convey to concerned plant heads. The receivercomplies with the requirement of doing the jobsafely.

In the year 2013, there were 218 no. ofobservations recorded by safety personnel.

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3. SAFETY ROUND BY SENIORS

To check the plant condition and abnormalities, Sr.

personnels of the company take round of the plants

during day. In the night hours also, a schedule is

prepared for them to take rounds of the plant.

The abnormalities are reported to higher

management.

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4. HAZOP & RISK ANALYSIS

o In the plant, modification is a continuous process.

These modifications are done to improve the plant

productivity or to improve safety.

o The modifications proposed in the form of schemes

after the design HAZOP study takes place which

is attended by safety representative also.

o HAZOP is done to identify the hazards and they

are evaluated for risk and corrective measures.

o Risk analysis is carried out for the whole complex.

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5. SAFETY PERMITS

o In a chemical plant various maintenance activities

goes on throughout the year. Similarly, modification

schemes are implemented. These activities requires

hot work in the running plant.

o There is a system that before starting any new

activity , the concerned group will take permit from

the plant in charge.

o There are two kinds of permit viz. Cold work permit,

Hot work permit. Both the permits are issued by

plant in charge.

o Hot work permit is counter signed by Safety officer

after checking all the safety requirements.

o Besides hot work, safety officers also counter sign

permits for work at height, vessel entry and

radiography activity.

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6. MONITORING OF CRITICAL

ACTIVITIES

In a chemical plant, regular as well as newactivities are always going on.

For critical activities safety officers are discussingwith the plant personnels about the activitiesinvolved in the job.

The criticality of the activities with respect tohazard is discussed. Necessary guidelines forsafety observations and emergency needs areprovided.

Besides this, continuous monitoring of the activityis also carried out. 12

7. TRAINING

Since education is most important tool for safety,more thrust is given on training of the people. Thereare various modules on safety training planned fordifferent categories of employees and workers.

The safety training is given to following category of persons:

i. Employees

ii. Contract workers

iii. Trainees

iv. Hazardous material handling Drivers

v. Family members

vi. Executives

vii. Community 13

CONTD.

o Annual schedule for safety training of employees is

prepared. Class room as well as field training is

imparted by Safety personnel.

o Each contract worker is compulsorily given safety

training before he starts the job. “Safety Gate”

concept is followed to give safety training to every

worker entering into the premises of the Company.

o Trainees: All the trainees viz. GETs, DETs, are

imparted safety training on various models. For this,

every month four days compulsory training is

arranged wherein all the trainees take part.

Trainees are also given fire fighting practical

training. 14

CONTD.

o Family members, ladies and children of the

Company are given training on Road and Home

safety once in a year.

o Executives: Special trainings on subjects like BBS

and Safety audit are kept for senior executives.

o Community: Once in a year, safety awareness

programmes are kept for nearby communities

wherein they are told about the chemicals, hazards

and emergency preparedness.

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SAFETY TRAINING TO DRIVERS

Every day there are movements trucks and tankersfor delivery and dispatch of chemicals and fertilizersin the Company. The chemicals transported are ofhazardous nature. If any incidence occurs, it mayresult into a big mishap. Hence it is highly requiredthat the vehicle condition should be very good. Thedrivers should have valid license. The driver shouldbe able to deal any emergency occurred due to anymishap. Every month the drivers in a group aregiven hazardous material handling training as wellas other traits of the business.

Drivers of the vehicles transporting material are alsogiven TREM card training.

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CONTD.

8. INVESTIGATIONS BY HIGHER

AUTHORITY

Every critical incident is investigated by a team of

senior persons of the Company.

The causes of accident and the recommendations are

sent to the management. The modus operands is that

during investigation, head of the department should

remain present along with all the persons of various

disciplines. Similarly, safety department team also

gathers.

On the spot investigation involving the affected

person is done. Various solutions are also discussed

and suggestions are sought from the affected persons.

The final recommendation is prepared by Safety

department which is circulated to all the Heads.17

9. SAFETY COMMITTEE

o A Safety Committee consisting of representativesfrom various disciplines is formed byManagement.

o This is chaired by Sr. Executive. It also consistsof members from the workers.

o The Committee meets quarterly to discuss theissues related with safety.

o The outcome of the committee is presented beforethe management and action plan is prepared tocomply the unsafe conditions.

o Instructions for following safety precautions toemployees is also conveyed through the safetycommittee members.

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10. SAFETY SUB-COMMITTEES

In addition to Safety Committee, there are safety

committees at plant levels. The committees

consist of members of different disciplines.

They meet every month.

They move around the plant and record all the

abnormalities. These are sent to respective

groups for compliance.

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11. INVOLVEMENT OF WORK

FORCE

Periodical meetings are organized with contractors tomake them aware about safety.

Contractors safety code is issued to all the contractors.Violations of safety code invites fine to the contractors.

There are various projects going on in the Companywherein many contractors are involved. All the contractorsare made aware about the safety requirement.

Special training is imparted to supervisors and theirworkers on safety aspects like importance of PPEs,working at height, emergency preparedness etc. They arealso given first aid fire fighting training.

If any worker is found violating the safety norms, thecontractor is penalized monitorily. This is also recorded intheir performance evaluation.

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12. TESTING OF MATERIAL

LIFTING EQUIPMENTS

In the chemical plant, there are various kinds of

material handling equipments, cranes, EOTs and

other lifting machines.

These all machines are tested by third party and

representatives from Inspection, Maintenance

and Safety deptt.

The records are submitted to the Director of

Industrial Safety & Health.

All the lifts of the plants are also tested and the

testing is witnessed by Safety deptt. 21

13. VEHICLE INSPECTION

Although vehicles which are transporting chemicals from

the Company are inspected before the entry into the

factory, there is a check list which ensures that the tanker

is suitable for loading a particular chemical and will be

dispatched safely at the consumers site.

Besides the tanker’s quality, legal papers for

transportation as well as RTO license for the driver are

also checked.

There are chemicals which are incompatible with other

chemicals. There may be dangerous occurrence if

incompatible materials react together.

The quality of the product should also be as per

specifications.

In addition to this, the body of the tanker is also inspected

and the worthiness certificate is also sought from the

driver.

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14. MOCK DRILLS

There are continuous activities going on in the plant.

To check the readiness of tackling any emergencysituation, regular mock drills are conductedperiodically.

In a year, around 7 to 8 surprise mock drills areorganized. These are conducted in the plant to judgethe effectiveness of the system.

Abnormalities are recorded and noted bymanagement.

Observers are senior executives of the Company. Themock drill reports are discussed in Chief Executivesmeeting and before the Board of Directors.

The feed back report of the mock drill is sent toconcerned groups for compliance.

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15. EMERGENCY

COMMUNICATION

During the emergency, communication among the

plant persons and the executives of the company

becomes very much essential. Since in case of crisis,

telephone lines becomes busy, it becomes very

difficult for the plant people to talk with their

superiors.

To tackle this problem, we have made a system

wherein automatic SMS message is generated in

the cell phones of Executives whenever an accident

occurs.

Besides this, Pop-up messages are also generated on

the office computers for emergency communication.

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16. RESCUE TEAM

o A team of around 150 persons is trained for rescue

purpose during the emergency.

o They are given special training to rescue persons

in case of occurrence of disaster.

o They are given training for physical fitness, fire

fighting and rescue tool operation.

o The team members are selected from different

groups representing various areas.

o The list of the trained persons is available at fire

department as well as with individual plant

control rooms. The team members are also given

refresher training. 25

17. CONTRACTOR’S SAFETY

o There are many non-continuous activities go on in theplant. To tackle the need, there are many contractorsworking in the plant.

o The unsafe activity / occurrence of the contractors isrecorded.

o The safety performance of the contractor is judged onthis regard and while awarding new contract to them,they are warned to improve the safety standards.

o Repetition and insincerity in following safety norms isseriously viewed. The violation in wearing PPEs isseriously viewed and contractors are fined for non-compliance.

o The statistics of observation and accidents arerecorded for each contractor and are sent to all HOD’s.

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18. TRANSPORTS &

CONTRACTORS MEET

To impart knowledge about safe operation, safe

transportation, chemicals, their hazards and

emergency preparedness plan to contractors and

transporters, every year, Transporters and

Contractors Meet is organized.

The safety awareness massage is communicated

by them to their employees.

This way they are also involved in the safety

practices which are required by the workers to

follow. 27

19. CONTRACTOR LABOUR

COMMITTEE

o The committee discusses the matter relatedwith safety practices followed by contractors.

o Due weightage is given for their safetyperformance for issuing new contracts.

o The record of the observations and incidences ofall the contractors is prepared and they arewarned if the occurrences are more.

o Serious violations of safety observations reflectsin awarding the contracts.

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20. SAFETY DAY

4th March is celebrated as ‘National Safety Day’.

Various activities are planned for safety awareness.

The groups which are included in the programmes

are employees of the Company, contract workers,

drivers, family members and surrounding

community.

Exhibitions and various competitions, talks and

practical training are kept for all.

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21. MUTUAL AID SYSTEM

o The district is having many big and small industries.

o All the industries representative meet periodically

and discuss about the hazards at their place and the

facilities available.

o The meeting is conducted by the officials from local

authority. This body is named as ‘Local Crisis Group’.

o The group companies are helping each other by

providing the help needed in case of emergency.

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22. FOUR WAY TEST OF

SAFETY

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o 1. Is the person skilled for the job?

o 2. Is work place Safe to do the job?

o 3. Are all the necessary PPE’s required for thejob available?

o 4. Are all the tools perfect?

CONCLUSION

At our company, we have adopted various ideas suiting to

the needs of Fire and Safety. Our policy is based on

following guidelines.

Proactive actions to control the hazards and reduce

incidences.

“Fire Fighting” readiness in case of any eventuality.

Fast Communication.

Systematic Analysis of the event.

Recommendations for improvement.

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THANK YOU

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