A Project Report

On

Safety in Chemical Industry

IN

LUBRIZOL INDIA PVT. LTD.

THANE BELAPUR ROAD,

NAVI MUMBAI.

SUBMITTED BY
Ravindra R. Bhagat

Under The Guidance Of

Prof. A.K. Gupta

SUBMITTED TO

THANE BELAPUR INDUSTRIAL ASSOCIATION

RABALE, NAVI - MUMBAI.

1
 Declaration
I, Ravindra R. Bhagat the under signed that this project report entitled Safety in Chemical
Industry for Lubrizol India Pvt. Ltd. is my original work. The empirical finding in this report
is based upon the information collected by me and not copied from elsewhere. I understand
that the detection of any such copying by me for this report is liable to punished in any way
the institute deems.

[Ravindra R. Bhagat]

2
 ACKNOWLEDGEMENT

No man can live as an island, journey through life alone

These words aptly describe the theme of this short but essential page of the report. In
our highly professional field, we need help from time to time from the people around us. Be it
simple suggestion or little words of encouragement, weird ideas or morale boosting talks.
Through these lines I humbly acknowledge the contribution of all those who have helped me
and to whom I am highly indebted.

I take this opportunity to convey my deep sense of gratitude towards the Factory
Manager S.R.D Narsimhan & Safety Manager S.C. Mulay, Lubrizol India Pvt. Ltd. and Prof.
A.K. Gupta for permitting me to undertake this project.

I am extremely thankful to Manager S.R.D Narsimhan, Safety Manager S.C. Mulay,

Project Guide A.K. Gupta who has extended his full support and co-operation in the
successful accomplishment of the project & for providing me this opportunity for taking up
this challenging project.

I am also thankful to all the employees of Lubrizol India Pvt. Ltd. who have helped us
in completing the project.

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 EXECUTIVE SUMMARY

Man has been handling various hazardous substances and operations since ancient days. The
rapid industrialization and innovations has increased the risk potential of the hazards to man,
material, machinery and to the environment at large. The accidents those are caused by
machinery as well as hazardous substances and more over the acute and chronic health
problems caused by handling of hazardous substances has made man think and act on safety
aspects of those operations. Hence it is clearly indicative that the advances in the field of
Safety and Health were not sufficient to cope up with the advances in the technologies.

Meanwhile the rise in standard of living of the people made more & more demands on the
available goods and services. Therefore the industries started more production for meeting the
growing needs of the society such as consumables, pharmaceuticals, insecticides and host of
other substance including material for construction machinery, scientific research etc. Further
chemicals with known fire & explosion hazards and / or with highly toxic properties very
small quantities or which when released in to atmosphere can render the surrounding areas
for kilometer together unfit for human habitation or for agriculture.

Industries, designed, installed and operated for creating wealth to the society by providing
goods and services at reasonable prices cannot be allowed to turn into a monster of
destruction, but not only ruining the wealth it was intended to create, but also taking away the
life of the very people, whom it was supposed to have served by leading to their agonizing
death after a long illness created by the toxic releases.

Hence, Safety & Health of the employees & the neighboring community and environment
protection should be integral part of any industrial activity.

4
 TABLE OF CONTENTS

Chapters Particulars Page No.

1 Company Profile 6

2 Objectives of the Project 14

3 Research Methodology 15
4 Health and Hygiene 17
5 Working of Processes 20
6 Activities Carried Out by the Safety Dept. 24
7 Potential Hazards 25
8 Statutory Requirement 26
9 Safety Management System 28
10 Accident analysis and reporting 37
11 Good Working Practices/ Work Instruction 40
12 Procedure for Writing SOP 58
13 Hazardous Waste Management 62
14 Safety Instruction for Visitors At LIPL 68
15 Recommendation 70
16 Observations 71

Chapter 1.

Company Profile

Historical Background
The Lubrizol Corporation, a Berkshire Hathaway company, is a specialty chemical
company that produces and supplies technologies, which are designed to improve the quality

5
and performance of products in the global transportation, industrial and consumer markets.
Headquartered in Wickliffe, Ohio, United States, Lubrizol holds a base of approximately
1,600 patents as of October 2011. The corporation is divided into two distinct segments, the
Lubrizol Additives division and the Lubrizol Advanced Materials segment. Lubrizol operates
production facilities in 19 countries, with sales and technical offices throughout the world,
through the efforts of more than 6,900 individuals.

Lubrizol sells more than 12,000 products in over 100 countries. The company has two major
business segments: Lubrizol Additives (LZA), a leading global supplier of fuel and lubricant
additives for transportation and industrial applications; and Lubrizol Advanced Materials
(LZAM), a leading global producer of advanced specialty polymers, polymer-based additives
and chemical additives for a broad range of consumer and industrial applications. The
Lubrizol Corporation is on Fortune magazines list of the 500 largest companies in the U.S.
Based on 2010 revenues, Lubrizol moved up in the ranking order to 423 from 453 the
previous year. On the basis of 2010 profitability metrics, total shareholder return (TSR)
and earnings per share growth, Lubrizol was the top performing company among the 16
chemical companies that are on the Fortune 500.

Lubrizol also moved up in the ranking order in the Forbes magazines Global 2000 to 1,220
from 1,249 the previous year. The company ranked number 20 globally in their industry
sector of specialty chemicals. Unlike the Fortune 500, which is a ranking solely on 2010
revenues, the Forbes Global 2000 ranking is based on a combination of revenues, net income,
assets and market value.

6
History

Lubrizol originated on July 31, 1928 as The Graphite Oil Products Company in Ohio, United
States. The company was founded by Kent Smith (first President), F. Alex Nason (first Vice-
President), Frank A. Nason (first Treasurer), Kelvin Smith (President in 1951), Vincent Smith
(first Secretary) and Tommy James (introduced Lubrizols first gasoline additive). On
September 10, 1929, Lubrizols first product, a graphited lubricant and applicator marketed
under the Lubri-Graph name, was launched. The young company changes its name to The
Lubri-Graph Corporation.

'In 1931,' The Lubri-Graph Corporation moves to the Cleveland suburb of Wickliffe, Ohio.
The location will become the companys corporate headquarters and remains so today. By
1934, sales of Lubri-Zol special motor lubricant begin to soar; the company changes its name
yet again, becoming The Lubri-Zol Corporation. (The hyphen is dropped in the 1940s.)
Lubri-Zol also establishes Anglamol, Ltd.later Lubrizol Great Britain, Ltd.its first
affiliate outside the United States and the beginning of its expansion as a global enterprise.
Zinc dithiophosphate, Lubri-Zols pioneering oxidation and corrosion-inhibiting lubricant
additive chemistry is introduced to the market.

In the 1940s, Lubrizol supports the war effort. Government authorities credit Lubrizol with
producing more than half of all the engine oil additives and about 80% of all the gear

7
lubricant additives required in Allied military operations. During this time period, Lubrizol
researchers develop and introduce the first multipurpose extreme pressure additive for hypoid
gears, along with the first fluid additives for automatic transmissions.

By the 1950s, Lubrizol becomes the first company to manufacture lubricant additives in
France. In 1957, Lubrizol acquired International Rustproof Corporation, a producer of metal
coatings. Lubrizol gained significant technical expertise in coatings technologyexpertise
that will increase over the years through numerous research and development initiatives.

In the 1960's, as well as previously and afterward, Lubrizol's patent program was noted for
oppressive hands-on control by management. It finally fell into the hands of a militaristic
micromanager who drove out, one by one, the patent attorneys reporting to him until none of
the old guard was left.

On August 22, 1966, Lubrizol goes public, with stock offered on the New York Stock
Exchange (NYSE: LZ). Growing concerns about air quality and increasing demand for
improved engine performance, lead Lubrizol to re-energize its efforts in fuel additives. As a
result, new, multifunctional dispersant gasoline additives are introduced to the marketplace.

Before the 1970s, no one thought about fuel economy. That changed with the gas crisis of
1974. Lines at gasoline stations stretched for blocks, and for the first time, Lubrizol turned its
attention to additives to improve total vehicle economy. Lubrizol also introduced super high
performance diesel oil additives and fuel saving multigrade gear oil additives.

The 1980s are a decade of technology firsts for Lubrizol. Innovative new additive chemistries
are introduced in numerous product areas: passenger motor oils, gear oils, hydraulic fluids
and viscosity modifiers. Lubrizol launched high water content fluid microemulsions for use
in hydraulics.

In the 1990s, Lubrizol builds on its long-time presence in Asia Pacific by focusing its efforts
in China. The company begins to supply lubricant additives in China through its joint venture
facilities in Tianjin and Lanzhou. Lubrizol continues to expand its presence in the specialty
chemical marketplace by making significant acquisitions in the areas of performance coatings
and metalworking. In addition, in 1996, the company acquired CPI Engineering Services,
Inc., a formulator of specialty synthetic lubricants used in air and refrigeration compressors.

8
On June 3, 2004, Lubrizol completed the acquisition of Noveon International, Inc.(formerly
BF Goodrich Performance Materials), a specialty chemical company with a strong product
portfolio in additives and ingredients for the personal care, performance coatings and
engineered polymers markets. Noveon was a transformational acquisition that nearly doubled
the size of the company and cemented Lubrizols position as a global specialty chemical
company.

In 2009, Lubrizol overcame the difficulties of the global economic recession to become one
of the few chemical companies to produce record earnings. The results from 2009 contributed
to Lubrizol being named Company of the Year by Chemical & Engineering News in January
2010. Later in 2010, Lubrizol expanded its global footprint by breaking ground on a new
additive manufacturing plant in Zhuhai Gaolan, China.

On March 14, 2011, Berkshire Hathaway Inc. (NYSE: BRK.A, BRK.B) and The Lubrizol
Corporation (NYSE: LZ) announced a definitive agreement for Berkshire Hathaway to
acquire 100% of outstanding Lubrizol shares for $135 per share in an all-cash transaction.
The transaction, which was unanimously approved by the board of directors of each
company, is valued at approximately $9.7 billion, making it one of the largest acquisitions in
Berkshire Hathaway history. This transaction was approved by Lubrizols shareholders on
June 9, 2011. The deal is expected to be finalized in the third quarter of 2011.

On September 16, 2011, Berkshire Hathaway completed the acquisition of Lubrizol.

9
 ORGANIZATION CHART

10
 Plant Layout

LIPL plant layout is a typical one. Plant is having three separate entrances. One is personnel
entry gate, the other one is product gate, and third gate is not used and is usually locaked.
Two sides of the plot are having adjacent MIDC road. The internal roads are made of
reinforced concrete construction and are wide enough for smooth vehicular motion. Each and
every part of company is well connected with internal roads (Annexure - 11)

Salient plant layout features

1. Administration building, crisis control station, warehouses, canteens are well

separated from production units

2. Boiler house and utility station are away from production units

3. Fire hydrant tank and pump station are at up wind direction

4. Wind direction helps is separating plants from rest of facilities

5. Fire tender is stationed away from plant and has got effective access road

6. Natural slope of plot is exploited for gravity transfer of affluent to ETP

7. OHC is situated near the personnel entry gate

CHEMICALS HANDLED AT LIPL:

Some Chemicals used as raw materials and intermediates:

Sr.no Name of Chemical Preventive Action

1. Benzyl Peroxide Safe material handling and storage

procedures. Safety inspections.PHA for
material handling/storage. Mock drill

11
 simulating explosion, fire.

2. Hydroquinone Safe material handling and storage

procedures. Safety inspections. Mock
drill simulating spillage.

3. Liquefied Petroleum Gas Safe handling procedures, in built process

safety, PHA of system, safety

Inspection, Mock drill.

4. Maleic Anhydride Safe handling procedures, in built process

safety, PHA of system, safety

Inspection, Mock drill.

5. Phosphorous Safe handling procedures, in built process

safety, PHA of system, safety
penta-sulphide
Inspection, Mock drill.

6. Methanol Safe handling procedures, in built process

safety, PHA of system, safety

Inspection, Mock drill.

7. Sulphuric Acid Safe handling procedures, in built process

safety, PHA of system, safety

Inspection, Mock drill.

8. Xylene Safe handling procedures, in built process

safety, PHA of system, safety

Inspection, Mock drill.

9. Zinc Oxide Safe handling procedures, in built process

safety, PHA of system, safety

Inspection, Mock drill.

10. Chlorine Safe handling procedures, in built process

safety, PHA of system, safety

Inspection, Mock drill.

12
11. Sulphur Di Chloride Safe handling procedures, in built process
safety, PHA of system, safety

Inspection, Mock drill.

12. Styrene Monomer Safe handling procedures, in built process

safety, PHA of system, safety

Inspection, Mock drill.

13. Methyl Methacrylate Safe handling procedures, in built process

safety, PHA of system, safety

Inspection, Mock drill.

Product of Lubrizol and their application

Sr.No. Product Major Application

1. Antioxidant Additives:

( Zinc Based )

Zinc Di organo Di - To work as anti-oxidant for removal of oxidants

thiophosphate produced from petrol or fuel during continuous
running of engines.

Used in Rail, Road, Aviation engines

2. Detergent Additives:

( Low Base type with low Base

Number )

Calcium Sulphonates types To work as detergents for removal of acidity &

cleaning the same which is produced from petrol

Or fuel during continuous running of engines.

Used in Rail, Road, Aviation engines application

Detergent Additives:

13
 ( High Base type with High --------Do--------
Base Number )

Calcium Phenate type

3. Dispersant Additives: To improve the dispersancy of fuel for better

performance. Used in Rail, Road, Aviation engines
( Succinic Acid type )
application.

4. Crude Oil Flow Improve: To improve the flow of material.

All the products of LIPL are certified by BVQI (Bureau Veritas Quality International) under ISO
9000 Quality system.

Chapter 2.

OBJECTIVES OF THE PROJECT:

14
1. To identify potential hazards in the factory
2. To identify risk of fire hazard and inhalation of gases and fumes and exposure to dusting.
3. To study safety measures incorporated by the factory and to minimize the potential
occupational health and accident hazard.
4. To collect and analysis of accident data.
5. To study and suggest preventive measures / new technology to minimize accidents /
hazards.
6. To study safety organization and methods incorporated.

Chapter 3.

RESEARCH METHODOLOGY

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Research is a systematic method of finding solutions to problems. It is essentially an
investigation, a recording and an analysis of evidence for the purpose of gaining knowledge.
According to Clifford woody, research comprises of defining and redefining problem,
formulating hypothesis or suggested solutions, collecting, organizing and evaluating data,
reaching conclusions, testing conclusions to determine whether they fit the formulated
hypothesis

Sampling Design

A sample design is a finite plan for obtaining a sample from Lubrizol India Pvt. Ltd... Simple
random sampling is used for this study.

Universe

The universe chooses for the research study is the Safety in Chemical Industry

Sampling Procedure

The procedure adopted in the present study is probability sampling, which is also known as
chance sampling. Under this sampling design, every item of the frame has an equal chance of
inclusion in the sample.

Methods of Data Collection

The datas were collected through Primary and secondary sources.

Primary Sources

Primary data are in the form of HSE Dept. to which statistical methods are applied for the
purpose of analysis and interpretations.

The primary sources are discussed with employees.

Secondary Sources

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The secondary data mainly consists of data and information collected from records, company
websites and also discussion with the management of the organization. Secondary data was
also collected from journals, magazines and books.

Nature of Research

Descriptive research, also known as statistical research, describes data and characteristics
about the population or phenomenon being studied. Descriptive research answers the
questions who, what, where, when and how.

Variables of the Study

The direct variable of the study is the working of Safety in Lubrizol India Pvt. Ltd.

Tools and Techniques for Analysis

Correlation is used to test the hypothesis and draw inferences.

Chapter 4.

Health and Hygiene

17
LIPL has shown its commitment to its employees health and welfare. Up to 1995 a Doctor
on part time basis was made available. He was visiting the company twice a week to attend
the employees and Lakshadweep hospital at Vashi was available to the company for treating
hospitalization cases.

In the year 1995 medical services were made available through Occupational Health Centre
(OHC) having a full time medical officer to be in overall in charge of the OHC. OHC is
located near the main gate. It is well isolated from process plant area and is strategically
located at the upwind direction. OHC consisting of two rooms, having smoothed tiled
flooring with adequate illumination and ventilation.

OHC is looked after by one full time medical officer and four male nurses. One of the male
nurses is available in each shift. Doctor is available within general shift. Services of medical
officer during silent hours can be made available within few minutes in the case of an
emergency.

Male nurse attend to minor work injuries, illness and gives the treatment and if any
emergency case approached to OHC possible first aid is provided and the employee is shifted
to Mahatma Gandhi Mission Hospital, Vashi. A company affiliated hospital for further
treatment.

Ambulance Car

A well maintained ambulance car with driver-cum-Mechanic is available within the company
round-o-clock. The ambulance is well equipped to take care of any emergency.

Treatment and Medicines

One male nurse is available round-o-clock in OHC. He gives necessary treatment to

employees, who fell sick or meet with an accident while on duty and the same is being
recorded in their individual files. Safety dept. is also kept informed about the injury
accordingly.

Necessary medicines, injections, intravenous fluid, antidotes are kept ready for any
emergency quantities.

Pre-employment Medical Examination

18
New entrants in the factory and head office are screened for their physical fitness for the
particular job they would be assigned to.

A) General physical examination

B) Pathological examination

* Routine blood examination

* Routine urine examination

* X-Ray Chest

* Electrocardiogram

* Audiometry

These test are carried out and detailed reports are made available with the company.

Periodic / Annual health examination

Periodic / Annual health check up for all regular employees is carried out in the company. A
record is maintained for each individual employee about his health.

Following tests are carried out during periodic / Annual health examination.

A) Physical examination

B) Pathological examination

* Routine blood examination

* Routine urine examination

* X-Ray Chest

* Electrocardiogram

* Audiometry

* Vision test

19
C) Biological monitoring for toluene and xylene is also carried out for the employees who
have exposure to those chemicals. Reports of all examination are given to employees
immediately after the examination.

Chapter 5.
20
 Working of Processes

MANUFACTURING PROCESSES:

For the identification of the potential health hazards and evaluate the risk of chemical hazards
in the company, one must know the manufacturing processes.

Manufacturing processes at LIPL are described in brief as follows:

Anti oxidant ( Zinc Di Organo Di Thiophosphate):

Anti oxidants are basically zinc based products. The final intermediate is called as Zinc Di-
Organo Di-Thiophosphate.

The manufacturing of this product is done as follows:

Phosphorous Penta Sulphide (PS) is conveyed via a PS hopper into an enclosed SS reactor
where different types of organic alcohols such as IBUL+AMOL (Iso butyl alcohol and Amyl
alcohol in 60:40 ratio), IOOL (Iso octanol), 2EHA (2-Ethyl Hexyl Alcohol), MPL (Methyl
Propyl Alcohol), etc. are individually reacted with it on continuous basis at a temperature of
102-107 deg centigrade and atmospheric pressure, to produce different grades of acids.
Hydrogen Sulphide is liberated during the reaction which is scrubbed in two NaOH scrubbers
in series, to form NaHS (Sodium Hydrogen Sulphide) as a valuable bye-product. The acid
produced is then neutralized with zinc oxide to produce zinc salt as final product. Alcohols
remaining in it are stripped out and the zinc impurities are filtered off on a plate and frame
filter press. Stripped alcohols are fractioned on a fractionating column and reused in the
process.

Detergents:

21
Detergents additives are manufactured in two ways:

(a) Sulphonates:

These are manufactured at different Base Numbers (TBN) to suit the final performance in
blended additives which has been established in R&D and Engine Testing Laboratory. The
process involves the initial reaction of Sodium Petroleum Sulphonate with Hydrated

Lime (Calcium Hydroxide) and acetic acid. Methanol is added as a promoter. The mixture is
then carbonated by reacting with Carbon Di-oxide (CO2) at 55-60 degree centigrade
temperature and atmospheric pressure to get the desired Total Base Number (TBN). The
chained calcium sulphonate is produced which is then filtered out on sweat land screen filter
and plate & frame filter to remove the solid impurities. Methanol is stripped by stripping in
heat exchanger. It is further fed to fractionating column for its recovery and then it is reused
in carbonation process.

(b) Phenate:

Low Base type:

These are manufactured by initially reacting the Do-decyl Phenol (DDP) with sulphur
dichloride in an enclosed reactor at a temperature of 60-65 degree centigrade and atmospheric
pressure. Hydrogen Chloride gas is produced during the reaction which is absorbed in water
in a falling film absorber (FFA). This liquid HCL at strength of 30% is sold as a valuable bye-
product.

High Base type:

These are produced by initially reacting DDP, Ethylene glycol (ETG), Decyl alcohol (DEOL)
and hydrated lime and then carbonating with CO2 at 65-71 degree centigrade temperature
and atmospheric pressure to get the desired base number of 250 to 260. ETG and DEOL are
used as promoters. These are stripped out through heat exchanger and further sent to recovery
in a fractionation column. Recovered ETG and DEOL are reused in the process. The stripped
reaction product is filtered out on Niagara screen filter and plate & frame filter to remove

22
solid impurities. In this type of process, hydrogen sulphide gas is produced during reaction.
This H2S gas is scrubbed in two NaOH scrubbers provided in series. It yields NaHS as a
valuable bye product. The entire system is enclosed and H2S detectors are installed at various
locations to detect any leakage and control the same.

Dispersants:
Dispersant additives are manufactured by initially reacting Polybutene and Maleic anhydride
with chlorine gas at a temperature of 185-188 degree centigrade and atmospheric pressure in
a glass lined reactor. The chained succinic acid is produced along with generation of HCL
gas. This HCL is scrubbed in water in FFA (Absorber) to produce 30% liquid HCL as a
valuable bye-product. The chained succinic acid is then neutralized with amine in
neutralization reactor at about 105-110 degree centigrade and atmospheric pressure. After the
neutralization, it is further heated to remove water and then filtered out on plate & frame
press to yield the final product. Chlorine is used from chlorine cylinders after passing through
chlorine vaporiser. Since CL2 is a hazardous gas, detectors are installed at specific locations
for detecting any leakage and also a CL2 emergency kit is available at deck level to face such
situations, operators are well trained for its use.

Crude Oil Flow Improve:

Styrene, Maelic anhydride, Methyl Methacrylate these monomers polymerized in Xylene to

produce ter polymer. These ter Polymer then react with Behynal alcohol to produce Ester
(crude oil flow Improver). After approval the batch is then transferred to Storage.
The reactions are carried out in SS reactors.

Blending Unit N0-I:

The intermediates are mixed in blenders as per the Recipe Formula and then sampled for
Complete Analysis. After approval the batch was drummed off or transferred to storage as per
the Customer requirement.

The blending operation is carried out in SS Blenders.

Blending Unit N0-II:

23
The Solubilised Polymer is added in oil, & after heating and proper mixing sample for
complete Analysis. After approval the batch is then either drummed off or bulk dispatched.

The solubilisation is done in MS vessels.

Chapter 6.
24
 ACTIVITIES CARRIED OUT BY THE SAFETY DEPARTMENT

1. It provides information about safety and conduct safety training programs in

collaboration with training department.
2. To conduct investigation of accident and to suggest preventive measure to avoid
recurrence.
3. To keep record of accident and analyses each accident and group analysis to measure
the safety performance.
4. Procurement, Checking and maintenance of safety appliances in various plants.
5. Monitoring of compliance of statutory requirement.
6. Conducting plant safety inspections, conducting internal safety audit.
7. Advising protective measures against fire and explosion.
8. Arty the various section regarding minimization / elimination of hazard.
9. To check jointly with supervisory staff, the operations carried out in plant and see that
they are carried out with prescribed safety measure.
10. To issue safe working permits to departmental and contractors activity.
11. Delegating special safety problems to working teams with joint venture with
department concerned.
12. Preparing and issuing safety bulletins and safety instructions pamphlets.
13. Co-coordinating various safety awareness programs like arrangement of national safety
day celebration.
14. Monitoring department safety committees to ensure their effective functioning.
15. To conducting mock drills.

Chapter 7.

25
 POTENTIAL HAZARDS:

FIRE & EXPLOSION HAZARDS

Flammable / Combustible materials may be ignited by heat, spark or flames

Vapor explosion and poison hazards indoors, outdoors or in sewers
Vapor may travel to source of ignition and flash back
Container may explode in heat of fire
Runoff to sewer may create fire or explosion

HEALTH HAZARDS

May be poisonous if inhaled or absorbed through skin

Vapor may cause dizziness or suffocation
Contact may irritate or burn skin & eyes
Fire may produce irritating or poisonous gases
Run off from fire control or dilution water may cause pollution

Chapter 8.

26
 STATUTORY REQUIREMENT

Factories Act:-
The management has obtained relevant licenses under various regulations including Factories
act, Explosive Act and Pollution Control Act.
a) Factory license is renewed for the year 2012 from JT. Director Industrial Safety & Health
applied for renewal for the next years.
b) The factory comes under MAH and is governed by rules pertaining to MSICH rules,
1989. Under these rules the unit has to prepare safety report and submitted to Factory -
Inspector's office. Such report for the year 2012 is submitted.
c) It is necessary as per the Rule 65 of MFR, 1963, that each pressure vessel/pipeline is
examined every six month externally, once in a year internally 8s Hydraulic test once in a
period of 4 year such vessels have undergone hydraulic test.
d) Pressure vessel testing records are available at Administration & as well as in the
Technical Service Department.
e) Medical examinations of workers engaged in the hazardous process are carried out at
regular intervals and records are available at OHC. No employee was found to be
suffering from Occupational Health Diseases.

Explosives Act:-
Storage of all explosives and flammable chemicals come under the purview of Explosive Act.
For Methanol, Toluene, etc. appropriate licenses have been obtained from the Controller of
explosive

Pollution Control Act:-

Lubrizol India Private Limited is very conscious about the pollution control and has taken all
the measures to protect the environment. The company has well designed Effluent Treatment
Plant for treatment of industrial effluent.

The company has obtained Consent to operate for its manufacturing activities. The consents
are valid and compliance of the consent conditions monitored regularly. Treated effluent
samples are analyzed regularly at the Company laboratory and also vigilance samples are
taken away by the authorities of MPCB.

27
The plant comprising to primary and secondary treatment facility and operated by trained
staff.

The various pollution control and abatement measures are as under:-

1. Dangerous system in the process / storage vessels is scrubbed by connecting its vent to
scrubbing system.
2. Stack emissions from boilers are monitored regularly.
3. Ambient air quality is measured by using high volume sampler and maintained the record
of the same.
4. Workplace environment monitoring is done for Threshold Limit Value (TLV) at various
locations.
5. Solid waste generated during manufacturing is sent to Mumbai, Waste Management
Limited at Taloja for disposal of waste.

Chapter 9.

28
 SAFETY MANAGEMENT SYSTEM

The need for safety organization is to make the industry as safe as possible by various
systems or methods.
The basic function of Safety Organization is to create and maintain an active interest
in safety and to reduce accident rates, health hazards.
By Safety Organization, it is meant the definite planned and organized set up whose
purpose is to enlist and maintain the combined efforts of entire personnel of
organization in the work of accident prevention.

Safety Policy and Environment Policy:
LIPL has declared Safety Policy and Environment Policy:

Refer Annexure 1

Safety Policy and Environment Policy signed by Managing Director is published in English
and Hindi. The copies of both these policies along with Quality Policy are displayed at all
strategic locations in the company and are also given to each employee in the form of a small
booklet.

The main features of the policy are:

It declares the intention of the company to conduct its activities in such a manner that
safety and health of personnel in direct and indirect employment, the soundness of its
plant and protection of environment from damage, directly attributed to its operation
is given as much importance as its business activities.

The company assumes everybody concerned that, it will follow all the statues relating
to safety, health and environment and will try to remain ahead of other industries.

It is given that all resources will be utilized to comply with the objectives, it has set
forth to maintain and improve the safety, health and environment conditions.

29
 It also gives a detailed description of the responsibilities borne by the management
and the other employees, arrangement and facilities available to carry such

Compliance and the support available from the top management to carry out such compliance
and such work.

It lists various measures taken to maintain the conditions in safe manner.

It ensures that safety and related subjects will be given due importance at all levels.

SAFETY & HEALTH SET UP:

SAFETY DEPATMENT:

The department of LIPL includes Safety Manager, Safety Executive and Firemen staff
working under him. The Safety Manager reports to Managing Director.

The role of safety department is advisory. The safety staff periodically audits selected jobs
from safety and loss control point of view. The department suggests safer methods and
systems, discuss them with sectional heads, departments and senior management and lay
down such procedures in the safe working manuals.

The safety department arranges training programs for concerned staff with in-house and
external expertise and audits effective implementation of such newly laid down procedures.

The safety department maintains and makes available necessary information, standards,
statutory provisions and statistics regarding safe working of the plant to the line managers for
the implementation of safety and environment policy. The departments co-ordinate with
statutory and voluntary agencies for the improvement of safety, environment and health.

The safety department organizes and assists in audits, inspection, investigations and
maintains records of safety related occurrences. These are presented with recommendations
and analysis in quarterly meetings of safety council (At LIPL, safety council is termed as
Plant Safety Committee).

30
Though the role of safety department is advisory, in view of the overall importance of safety,
it has authority to over rule the decisions of the line management and to order stoppage of a
method of working or a machine which the department considers to be unsafe, till such time
as the matter is resolved by the top management.

For the safe implementation of safety, health and environment policy; management of the
company takes all the reasonably practicable measures, compliance of acts, rules and
standards for safety, health and environment protection and improvement wherever possible
by in-house efforts, professional and technical experts and organization.

Periodic review of conditions ensures effectiveness of factory policy related to safety, health
and environment. It keeps the share holders informed about the safety performance of the
factory through the annual report going to share holders. Effective implementation of safety
policy with the factory and area under that control is the responsibility of managers which is
achieved by review of all accidents reports, occurrence report and necessary corrective
actions that have been taken. Safety organisation makes use of all necessary tools of
implementation like safety inspection, safety audit, safety committees, etc.

OCCUPATIONAL HEALTH SERVICES:

LIPL is having OHC in which one doctor and four male nurses are working in Rota shifts
round the clock. In addition to day to day check up and treatment of patients, OHC conducts
following activities:

Blood Donation camp

First Aid Training

Stress Test

Routine medical check up.

The OHC is having a well equipped Ambulance available round the clock. In case of serious
injury, the patient is sent to nearby hospital in Vashi.

31
SAFETY COMMITTEE:

Normally, workers like to participate in decision making concerning their health, safety and
welfare. Although they know that final decision will have to be taken by somebody at top,
they have satisfaction to be a party to the decision making.

That is why workers must have a separate platform for decision on safety. Safety Committee
is the good example of one of the platform available for discussion on safety and health. The
constitution of a safety committee consists of equal representation of the worker and
management.

PLANT SAFETY COMMITTEE:

The safety committee acts as a clearing body for all matters regarding making safety drive
more effective. Under section 41-G of Maharashtra Factory Rules, 1963, formation of safety
committee is one of the effective tool for promotion of safety and making employees safety
conscious. Considering this point, LIPL is having a safety committee which is termed as
Plant Safety Committee. (This is because Lubrizol has already implemented the principles
of Responsible Care Codes at its all worldwide facilities and LIPL has also adopted the
same).

The constitution of Responsible Care Council is: 7 members from worker nominated by the
Union and same nos. of members from management. The chairman of the committee is
Managing Director and the secretary is Safety Manager. Meetings are held once in three
month.

Responsibility of Plant Safety Committee includes:

Being an apex body, it is responsible for maintaining and improving overall safety and
environment standards of the company.

Approves standards and goals set for achieving safety and health.

Reviews Accidents Investigation Reports and formulates strategies for improvements.

32
 Acts as a facilitator to resolve inter-departmental issues for furthering the cause of
safety.

SAFETY AUDIT TEAM:

The function of safety Audit team involves in on- going safety program and also observe the
personnel on the job, detect unsafe acts or conditions to prevent their recurrence.

There are two Audit teams comprising of members from cross sectional areas e.g. Process,
maintenance, QAL, R&D, etc. The senior most members serve as the team leader. Each team
conducts minimum one safety audit every six month of entire LIPL facility. Audit teams
observations are reviewed by Plant Safety Committee at the ensuring meeting for
implementation. Audit is planned in such a way that in each quartet of year, one audit is
completed.

The safety manager organizes it and is overall responsible for implementation.

The responsibility of the safety audit team is to identify unsafe acts and conditions. The team
leaders prepare the audit report and route one copy for safety manager, one copy is retained
by team leader.

SAFETY TRAINING:

Safety training is concerned with man in relationship to his environment, his motivation as
well as his behavior, the hazards that confront him and his ability to shield himself from the
hazards. It is very difficult to determine the most effective remedial action to prevent
accidents as there are many factors. But since human error is probably the outstanding cause
of maximum accidents, training is the best approach to minimizing human errors.

Training is the most effective remedial action for developing safety culture and hence in
LIPL, various training programs are arranged. For new employees, induction training is
conducted while periodic training (Refresher Training) is conducted for all employees. First
Aid training is conducted for all employees. Training for contractors employees and
drivers/cleaners is also arranged.

33
 INDUCTION TRAINING:

In selection of new employees, due consideration is given to their training and background
with respect to their academic carrier and previous employment. Even then, new employees
are given further training.

Their induction training includes familiarization with various statutory rules and regulations
applicable to the factory, companys safety policy, and fire procedures.

Location of fire extinguishers, names and locations of trained first aiders, position of first aid
boxes, use and availability of personnel protective equipment (PPE), general hazards in and
around factory, specific hazards and associated with their jobs, procedures for reporting
accidents and getting medical assistance, procedures included in onsite and offsite emergency
(crisis) control plan, etc.

The induction training is given by in-house experts like safety managers, safety executives,
trained safety fireman, FMO, etc. along with outside experts from various institutions like
LPA, NSC, etc. The methods used for induction training are lectures, discussions, film/slide
shows, practicals, etc.

PERIODIC TRAINING:

LIPL organizes periodic training for all employees both in-house and outside. The topics are
safe plant operations, emergency handling, first aid training, fire fighting and all related
subjects to make their working efficient and safe.

A continuous safety training program for all employees is conducted from Tuesday to Friday
every week by safety department at safety training centre. It consists of lectures on safety
related topics, demonstration of safety related appliances, safety film shows and plant visits,
etc.

34
 TRAINING FOR CONTRACTORS:

Safety training for contractor employees is conducted regularly. The activity is carried out on
daily basis to all new contractor employees before he resumes to his job. Also safety training
for contractors employees engaged in shutdown activities is conducted separately. Topics
covered are:

General safety rules and practices

Use and compulsory wearing of PPEs
Work permit system as applicable in company
Precautions during hazardous work
Housekeeping
Emergency procedures
ESIS, etc

FIRST AID TRAINING:

First Aid training and refresher courses have been conducted with the help of St.John
Ambulance, Thane for various employees. After successful completion of training,
certificates are issued to them. So far, there are more than 120 trained first aiders at LIPL.

MOTIVATION AND PROMOTION IN SAFETY:

Motivation is essential to keep everyones interest in safety. The safety department of LIPL
adopts various methods for motivation and promotion of safety attitude which are as follows:

35
 National Safety Day and LIPL Safety Week:

Every year, LIPL celebrates National Safety Day and followed by safety week during that
period. Various safety competitions and programs are arranged. An exhibition of fire fighting
and safety equipment is organized at fire station. The concluding function is held at the end of
the week. The outstanding performance is rewarded by MD on factory Annual Day. The same
is also reported in annual report of the company and also sent to the parent company, LZ
Corporation, USA. Various competitions held during safety week are listed down:

Safety Posters
Safety talk
Contest for wearing fire fighting equipment in shortest time.

Refer annexure 2

Suggestion Box:

Objective of suggestion box is to encourage the creative ability of employees in organization.

The suggestion box in LIPL is opened at regular intervals. The employees put their
suggestion in writing along with other details like diagram, method, advantages,
disadvantages, etc. The suggestions are handed over to respective department heads for
discussion. If suggestion made by employee is found useful, it is implemented as early as
possible. The appreciation with gift is given to the employee on foundation day.

ACCIDENT REPORING AND INVESTIGATION:

A good and accurate accident record is the foundation for effective safety program.

Accident reporting and investigation enables:

Quantitative evaluation of accident problem.

36
 Measurement of the effectiveness of safety programs.
Identifying problem areas, work processes accident prone work, etc. needing focussed
attention.
Planning future accident prevention programs.
Making comparison of safety performance of different departments or other similar type of
organizations.

4.1 REPROTING:

1) All incidents in the factory which cause or have potential to cause injury to personnel,

Damage to property/ equipment, loss of material, threat to environment is reported.

a) Any incident/accident is reported by the supervisor to respective department head

and safety Manager.

b) The supervisor is responsible to fill up the Supervisory Accident Report Form

Immediately on the same day or before the supervisor leaves the plant after his duty hours.

Refer Annexure 3.

c) The report is prepared in ERP system through computer and the printed copy is forwarded
To unit in charge, who after filling the necessary details forwards the copy to department
head. Department head after filling his responsibility forwards the form to factory manager,
who after his comments allocates the responsibility of investigation to any other department
head or unit in charge in order to have a unbiased inquiry and to ascertain the exact route
cause of the accident/incident to prevent repeatability of such cases. Form is sent to S&EH for
record.

d) The factory manager reports incident of serious nature ( as listed in MFR 1963) to

37
 DISH (Director of Industrial Safety and Health) within the period as specified.

Fire Prevention and Fire Fighting Measures

Fire Hydrant System

The fire hydrant system of LIPL comprises of four fire hydrant pumps, located away from
plant area. Three pumps are electrically driven and one pump is operated on diesel. The
system is capable of supplying water under pressure at 7-8 kg./cm2. The fire water tank is
having capacity of 1900 m3. Under ground network of fire hydrant lines has monitors at
different locations.

The network has 100 jet branch pipes and 15 spray branch pipes. Fire hydrant monitors are
located evenly as to reach every corners of the plant. Fireboxes with hosepipe are fixed near
each monitor. There are 101 fireboxes and 228 hose pipes made available for fire fighting.
Fire hoses are four layered, acid, alkali proof in construction to deal with extreme emergency
conditions.

Fire Detection & Alarm Systems

Modern microprocessor based fire detection and alarm system is installed. The system is
called signature series system. Where, every detector is intelligent and communicates with
panels. The devices used for detection of fire are, detectors and mutual call points.

Detectors are used in closed area and manuals call points are at open manned area like entry
and exit points, staircases and plant area detectors are

1. Smoke detectors

2. Heat sensor detectors

The alarms provided are

1. Hooter for indoor area

2. Local siren for outdoor area

3. Four master sirens to cover the entire plant area

Apart from this system telephone, public address systems and walkie-talkie are used for
communication in case of emergency.
38
Fire Fighting

Fire fighting needs trainees manpower as well as fire fighting equipment. LIPL has got both
of them. LIPL has got both them. LIPL owns foam tender having foam water monitor of 1000
liters capacity is available for fire fighting. One fire service jeep is used to tow the trolley-
mounted. It is operated and maintained by firemen. There are two firemen available in each
shift to deal with emergency. Adequate quantity of portable of portable fire extinguishers is
kept in plant premises. Plant personnel, to extinguish the fire in initial stages effectively use
these. All employees are well trained in handling portable fire extinguishers.

Test and Use of Fire Fighting Equipments

A senior safety officer is responsible for timely testing and examining the fire fighting
equipments. He charts out maintenance schedule for all these equipments. Fire tender, fire
pumps are daily checked for operation by firemen. Portable fire extinguishers are examined
weekly for its operation. Fire alarm system is checked daily for effectively operation of
sirens.

39
 Chapter 10.

Reference Annexure-4 for the Employers Report Form.

Accident involving serious personnel injury within 4 hours,

Accident in which a person is likely to remain or remains absent from work for more than 48
hours within 24 hours
Dangerous Occurrence as described in MFR 1963 within 4 hours
Poisoning Industrial sickness within 4 hours.

In the case of an accident where injured person dies subsequent information of his death whenever
known, is sent by Factory Manager by telephone or telegram within 24 hours of occurrence to the
following:

i) Dy. Collector District

ii) Administration Medical Officer ESIS
iii) The District Magistrate or Sub. Divisional Magistrate
iv) The Officer In Charge of nearest police station

In case of personnel injury/accident, shift supervisor fills authorization slip and sends it with person
to OHC. The male nurse completes the medical authorization slip and forwards his observation
report copy giving the details of treatment given to patient, one copy to respective section and one
copy to safety manager.

INVESTIGATION

Refer Annexure -5 for the schematic diagram.

An accident may take place in any area of the plant which may or may not injure the person. In case
to the injury to the person, his supervisor is responsible for immediate

Reporting of the incident / accident to his departmental head and send the injured person for medical
treatment. The supervisor is responsible to fill up the Supervisor Accident Report Form. The report
is prepared and sent to Factory Manager, safety Manager and the concerned officer.

40
General Manager (Mfg) on his own or in consultation with the department head of S&EH, decides
whether the incident requires further investigation or not. If the incident does not merit further
investigation, the department of S&EH files this report serially. If the incident merit further
investigation, GM (Mfg) appoints a team for thorough investigation of the incident and the team
works as fact finding mission rather than fault finding, and submits their report as per the terms of
reference assigned by GM (Mfg).

Department of S&EH independently investigates the incident. However, whenever GM (Mfg)

constitutes an investigation team, no duplication of work is done. However, whenever the
investigation team has made certain recommendations which are executed by concerned department,
the S&EH department supervises those aspects and ensures that those aspects are implemented and
maintain audit checklist on such matters.

Factory Managers office initiates appropriate actions to fulfill statutory obligations of the organization
arising out of such incidents.

Investigation team functions as per the term of reference of the appointing authority, viz. GM (Mfg).

The concerned department head is responsible to promptly resolve all the recommendations of the
investigating team in order to minimize or prevent such incidents.

S&EH department reviews the audit checklist to effectively implement the recommendations.

S&EH department forwards monthly summary report of accident to the parent company LZ
Corporation, USA.

ACCIDENT ANALYSIS:
Accident analysis using last five years data

Accident analysis is done, to evaluate the relative need for taking accident preventing
measures in different departments of an establishment. It helps in making an appraisal of the
progress of an accident prevention campaign, making people safety conscious and it enables
comparison. Companys safety performance can be evaluated for the year.

IS,3786, prescribes basic methods for recording and recording and classifying industrial
acciedents. It also includes details of work injury and gives the methods for computation of
frequency, severity and incident rate of work injuries in industrial premises. These are
indicator of safety performance of a company.

Various formulas used for talking accident data are.

41
 Lost time injuries

1. Frequency Rate (FR) = ---------------------------

Man hour worked

Man day lost

2. Severity Rate (SR) = -----------------------------

Man hour worked

FR * SR

3. Frequency Severity index (FSI) = -------------------------

100

FR now FR past

4. Safe T Score = ----------------------------------

FR past * 10^6

man hour worked now

If value of safety score is,

Less then -2 then performance is significantly improved.

Less then +2 then performance is significantly deteriorated

Between +2 and -2 then performance has not shown significantly change

42
Performance of LIPL

Accident analysis from year 2007 2011 shows that there is a marked reducing trend in
number of accidents. Safety department has introduced various safety programs to reduce
accidents. Vigorous training activities are conducted and that have paid good dividends.
Contractor employees have not reported any reportable injury in last five years. In the year
2000 there was no reportable injury to regular LIPL employee which is commendable

Accidents analysis shows that frequency rate and severity rate is consistently dropping
in last five years. In the year 2012 only one loss time injury was reported but man days lost
were 46, so severity rate and frequency severity index are showing increased values. The
values of Safe- T-Score are ranging between -2 to +2. This shows that there is no significant
change in the performance within last five years. Safe-T-Score for the year 2012 was not
calculated as loss time injury for the year 2011 was zero.

TYPE OF ACCIDENT

As can be seen from the accompanying charts, numbers of accidents involving corrosive substances,
thermal burns shows marginal rise than previous year (2011). But number of accidents involving
corrosive substance remains same during the last two years, out of this fire resulted due to sudden
splash of trapped chemicals, which should have been anticipated while taking up maintenance jobs.

TYPE OF INJURY

Chemical burns injuries have shown marginal increase. Spray of chemicals and thermal burns cases
are result of unsafe conditions which existed unnoticed. Job safety analysis is the only remedy to
minimize such cases.

PART OF BODY INJURED

The accidents involving leg/hands have shown exceptionally hot tending. Out of fire accidents of such
leg injury, two resulted to ankle. In all cases, the injured person had safety shoes but injury is above

43
the foot, twist of ankle joint and cut injury on ankle resulted in these accidents. The major contributor
is facial area due to spray or splashing of chemicals.

CAUSES OF ACCIDENTS:

Faulty job methods have major share in the causes for accidents. Deficiency in equipment and unsafe
overall safety performance.

Case Rate - (Regular+Contractor Employees)

44
 Chapter 11.

GOOD WORKING PRACTICES/WORK INSTRUCTIONS

The following instructions/practices should be invariably followed in order to ensure

that all operations processes are carried out in an environmentally friendly way with
minimum environmental impact:

LIPL as a matter of safety policy has a mandatory requirement for its employees to wear
PPEs in and around the working area. The operating staff shall use belts, shoes, helmets,
goggles, mask, earplugs etc. in order to conduct all processing/operational steps in a safe and
responsible way to ensure minimum risk to life and health.

Following Good Working Practice should be followed in order to reduce utility

Consumption :
1. Isolate steam supply valve & cooling water supply valve when the unit is down.

In case of any leakage of water, steam, N 2, Air etc. immediately send a memo to
respective mechanic main staff and get it attended. Inform Shift in charge / Unit in
charge if it is major breakdown.

2. Any pump/line/valve/flange leak observed should be reported to the Shift In

charge/Officer. Memo will be issued to MNT dept. to arrest the leakage. Proper
isolation shall be given by operating staff to carry out MNT activity. On completion
of job the concerned officer shall acknowledge and pass on information to the
operating staff to restart the operation after necessary trials etc.

3. While operating the valves, connecting/disconnecting lines, lifting loads (Heavy

Material), working on PC; always takes correct posture.

4. While connecting hose pipes always check for mechanical integrity ( good condition )

5. Undivided attention should be paid while unloading material in multiple tanks.

45
6. Tanker connection coupling and fittings should be inspected, before connecting to
tanker. Before loading the tanker check integrity of bottom valve & in closed
condition.

7. After filling any drum, bung must adequately tightened to avoid detonation of
material stored in drum

8. Ensure Nitrogen supply to the tanks especially during tanker filling or material
transfer.

9. Before starting pumps or electrical equipments check that proper earthling is

provided.

10. Dyke valves of all the tank farms should be always kept closed and to be opened
intermittently only to drain the water accumulated during rain.

11. There exists a policy of work permits for cold as well as hot work. For an extension
or working on holiday/weekends special approval is required from designated
officials. The details are available in SE&H manual .The Shift in charge/Officer shall
ensure that all repairs or maintenance jobs are carried out by competent staff only
after the approval and clearance through cold and hot work permits.

12. The Shift in charge /Officer shall ensure that all operating staff follows SOP to
minimize chemical spillage during sampling, transferring, loading/unloading
activities related with handling of drums, Bulk.

13. All personnel involved with handling and processing of chemical(s) shall be familiar
with safe handling procedures of the material involved.

14. All precautions shall be taken to minimize spillage of PS, ZnO, lime, FA, MgO, SFL,
FO-95, CSB, FOH2 to maintain good housekeeping and prevent valuable loss of raw
materials resources. VIM-41 & VIM-43 recycled in batch Lime, MgO spill will be
collected & recycled in ETP and FA spills will be scooped and reused. BZP-75 &

46
 OIU spills will sent to Mumbai waste management. Everybody will work in such a
direction that waste control procedure will be followed.

15. Always switch off A/C, Fans off while leaving the workplace.

16. Before charging rejected recoverable, slow/Non moving approved material from
drum, it should be checked physically before work-off.

17. Lab retain sample bottles are emptied out in drum labeled as waste oil, empty scrap
bottles, packing material is sent to scrap yard. Removal of used filter pads/Filled cake
bins/empty bottles/Used drums/Used pallets & other Non-hazardous waste from plant
area & shifting it to designated area to maintain good house keeping.

18. The operating staff shall ensure before suspending SWT/Niagara/P & F that the
hopper /tray is empty. In addition precaution will be taken to minimize spillage of
cake/oil during its handling. The respective bin of same product code shall be kept
below SWT/Niagara/P&F to avoid intermixing. Full bins shall be replaced with
empty ones

19. Cake bins containing cake to be tagged, stored and handled carefully with
identification. These are then sent for recovery to Taloja plant.

20. Used filter pads / Filled cake bins / empty bottles / used drums / broken pallets &
other Non-hazardous waste from plant area will be removed & shifted to designated
area to maintain good house keeping.

21. Safe operating practices followed for used filter pads from G-101 & G-101A is as
follows
(a) Do not allow the batch temp beyond 145OC during filtration.

(b) Before opening the filter press, flush P&F with flush oil.

(c) In case of a qualifying batch or when flushing is not possible, ensure sufficient
cooling of filter press before its opening & removing the filter pads & cake.

47
22. Hazardous/Non-hazardous wastes are properly segregated, stored in appropriate
colored plastic bins.

23. Ensure that there is no mix up of process waste & storm water drains through out the
plant area.

24. Ensure minimum generation of empty & dirty oil drums, reuse empty drums
wherever possible.

25. Ensue no spillage occurs through drum emptying pan draining procedure.

26. Before line breaking ensure that lines are properly blown by N 2 to avoid
spillage/wastage of material. While breaking, make sure that residual energy or
material is safely removed before handling it over to MNT (Special care to be taken
while working on steam/condensate line breaking).

27. Material leakage from pipeline/system should be collected to recycle maximum

possible quantity and the contaminated material should be collected as waste oil.
After recovering maximum possible spilled material, floor/area must be cleaned using
absorbent or saw dust. Solid waste thus generated should be collected properly and
disposed to MWML.

28. Thermal fluid spilled shall be collected in dirty oil drums and area will be cleaned
using adsorbent & sent as solid waste.

29. Spills of HCl, HSOM, MMACR will be diverted to ETP & neutralized. In case of
HCl gas leaks plant shut down will be taken & Water sprayed to contain the effect.

30. Ensure Nitrogen supply to the tanks especially during tanker filling or material
transfer.

31. Always wear goggles and appropriate hand gloves while sampling.

48
32. Formula quantity charged will be cross checked during and after every charge to
verify correct quantity charge has gone in to reactor. Concern officer should be
contacted in case of any discrepancy

33. Before making any hose/line connection, the flow path of material should be verified
properly.

34. Provide muffler on the silencer of tanker or forklift to avoid air pollution.

35. In case of CLG leak, stop the chlorination immediately if it is in progress, inform to
Shift in charge & take appropriate action to connect Cl2 hood to divert gas to CSL
Scrubber & follow safe handling of Cl2 procedure. During handling of MAA ensure
that all PPEs prescribed in SOP for MAA handling are used. While handling SDCL
ensure that all PPEs are used as mentioned in SOP for SDCL handling.

36. Inform immediately shift in charge in case of any LPG leakage. Stop the LPG supply,
isolate and empty out line safely and inform MNT to carry out the repairs before
taking it on line.

37. There exists an exhaust system to suck vapors during SWT/Niagara and filter press
opening.

38. All aqueous effluent from CFI plant is diverted to T-719 (effluent pit) from where it is
pumped to ETP plant.

39. The flare unit will be monitored continuously through monitor on panel in ZDDP as
well as in HBP for operation. In case of flare failure, attempt to light the flare. Care
should be taken to ensure that the scrubber(s) are in operation under such
circumstances.

40. Stop the agitator when level in reactor goes below the agitator blade.

41. Attempt should not be made to by pass steam trap.

49
 42. In case of power shutdown or failure, DG supply arrangement is done to provide
power to critical equipments.

43. MUA-R chemist shall flush the seal pot with fresh water before opening it for
cleaning. The flushed solution is transferred to ETP.

44. The stock of BZP should be stored under wet conditions,(<38 deg C) to prevent its
decomposition.

45. SRN drums should be stored in cool dry place. While handling SRN follow the instruction as
given in SOP.( SRN handling instructions are provided near the are of operation in plant)

46. Use appropriate PPEs during handling of HGLY-1.In case of spillage from
pumps/lines etc, flush the area with sufficient amount of water and get the leak
attended immediately. In case of flash fire use extinguishing media CO2, DCP or
foam.

47. While transferring the material to and from storage please check the level/quantity of
destination tank from level measurement system or Tank farm management system to
ensure sufficient space in storage. It is advised to transfer the material upto safe top
of tank. In case, if it is inevitable to accommodate left over quantity of the batch
above safe top of storage, due care must be taken to transfer the material in physical
presence of a person to monitor level continuously from tank top nozzle.

48. Reactor storage cleaning with water. Generated water effluent (Acidic/Basic) raw
effluent will drained to ETP suitably.

WORK INSTRUCTIONS: BLENDING-1

1. Inspect blender area is clean, and free of steam, nitrogen, air leakage.

2. Check list for Blender startup.

a) Ensure blender is empty.

50
 b) Ensure availability of instrument air, nitrogen & steam pressure.

c) Check hopper is empty, if shows level inform to unit in charge/Blending officer.

d) Inspect proper pig position.

3. DHO operation:

a) Check internal area is clean. If there is any spillage inside the DHO, inform unit in
charge/Blending officer.

b) Open the DHO door carefully.

c) Check DHO interlocks are in working condition.

d) Set temperature & start DHO check sound if it is abnormal inform blending
officer.

4. Check antifoam skid area is clean. Leakage if any, attended immediately.

5. Before discharging the batch from blender in hold tank, ensure hold tank is empty &
flushed properl(If necessary)

6. Check area around drum filling point is clean & without any spillage.

7. Check proper stenciling of drum with product code, Lot number & weight.

8. Reused & part drums should be kept separately in designed area with proper
identification

9. While handling KOH and PHL-90 use PVC hand gloves .Any leakages from pump
should be attended immediately.

WORK INSTRUCTIONS:ZDDP PLANT

1. Whenever the empty PS tote bin is removed from the tilt unit, empty out the tray at the
back of the tilt unit into the empty PS tote bin so that no PS is left out in the open for long
time. Whenever any fire occurs in the PS shed. Immediately sand should be dumped on the
fire.

2. All aqueous streams arising out of alcohol water separation is analyzed for % water. If
more than 95%, then it is drained to ETP after informing the ETP chemist.
51
3. Following care should be taken when H2S gas leak occurs.

1. Avoid contact with gas. Keep people away.

2. Wear goggles & breathing apparatus.
3. Shut off the ignition sources, and call up the fire department.
4. Stop flow of gas, if possible.
5. Evacuate the area in case of leakage/discharge.
6. Stay upwind & use water spray to knock down the vapours.
7. Call for medical aid.

STEPS TO BE TAKEN FOR HANDLING ACID DECOMPOSITION (ZDDP Plant)

When decomposition occurs the following steps are taken,

1. Automatically the PS is shut off due to high vent(H2S) flow alarm.

2. Control valve on top of T-214 switches the scrubber solution, (Na2S & NaHS) from
E-220 to E-214. These are done automatically, but the operating chemist should check
for improper functioning of all control valves.

BE-AWARE OF H2S GAS (MSDS)

The steps the operating Chemist should take are as follows;

1. Check for improper valving diverter valves (CV 204,CV 205) switched , PS flow cut
off, alcohol remains feeding.

2. Cool the reactor and continue adding alcohol for 10-15 minutes.

3. Stop PS flow to reactor and isolate receiver pot pump out from decomposing reactor
from other storage tanks.(T-205, T-205A)

4. The caustic soda level in T-208 is always checked in shifts.

5. T-208 agitator is to be turned on.

6. Next the hydro cones should be by-passed and the reactor put on circulation.(Note: it
is probable that

52
 the thick substance formed by the decomposition will not pump with the reaction
circulation pump. Therefore, no time should be wasted trying to get the pump to
circulate.)

7. Open the inlet valve to the PD pump on the reactor and stop the agitator.
8. Begin pumping the decomposed material from the reactor to T - 208

Note: T-208 must contain a minimum of 35.0 RO and a maximum of 62,0 "RO.

9. When the reactor is empty, it must be flushed with 2 dumped tank flushes of
Alcohol and then

pump by the PD pump. N2 blow line from PD pump to T-208

10. Cl2 addition is continued until all obnoxious odors have been oxidized.

11. The treated material in T-208 is then disposed of and the systems returned to their
operating status.

12. A careful check of the reactor and lines should be made before an attempt is made to
start up the

reactor again. (Purge the reactor and open for inspection.)

13. Scrap material that was isolated from the receiver pot.(T-202)

Steps to be taken in case of H2S leak from PS Hopper:

1. Stop PS feed screw from the panel.

2. Keep alcohol on for 5mnts to the reactor.
3. Start cooling of the reactor manually from the panel.
4. Do not go out of the control cabin and monitor the H2S ppm level.
5. Inform Det 1 cabin for not coming towards ZDDP unit.
6. Inform Shift In charge about the H2S leak.
7. Confirm exhaust blower on T201 is ON.
8. If low PS alarm is already activated then run the conveyor to seal the hopper.
9. After half an hour run the feed screw manually to see if PS can be leveled, keeping
a watch on reactor pressure and H2S ppm.

53
 NaHS SCRUBBER CLEANING PROCEDURE: ZDDP UNIT

1. T-220/T-221 NaHS strength to be checked periodically. If NaHS % is 34-37% then T-220,

T-221 is pumped to T-223.

2. To prepare fresh NaOH solution of 33% strength in T-220/T-221 charge the required
amount of water, circulate through spray nozzle to flush the packing and then add NaOH
quantity of required strength.

3. If system found to be getting pressurized, scrubber packing needs to be cleaned.

Following procedure is to be adopted:
4. Open scrubber side manhole and remove packing & fill up in bags.

5. Unload these bags in a tray and wash with water. Drain this water to ETP with at
controlled rate.

6. If there is any sludge at T-220/T-221 bottom it is to be removed & to be disposed off

separately.

7. Refill the cleaned packing in scrubber. After box up prepare fresh solution for next batch.

NaHS TANKER LOADING PROCEDURE FOR ZDDP

1. Keep the NaHS storage tank T-223 under circulation and sample for % NaHS. After
approval from QAL tanker loading should start.

2. Check the tanker is empty & clean. If the tanker is not checked for emptiness & if it is
contaminated by some acidic material it can evolve H2S gas while filling the tanker. &
person may expose with gas so check tanker carefully, use safety belt while checking the
tanker & use full face mask with suitable cartridge.

3. Open bottom valve & check for leakage & start the pump carefully use suitable PPEs
Check the line up & ensure that all valves are open. Close the circulation valve slowly
and raise the pressure slowly.

54
4. Check the integrity of the bottom valve to avoid spillage of NaHS. Use PPE while checking
the valves.

5. Ensure that the hose pipe is tied firmly so that it will not come out of the tanker while
loading. Use full face mask & PVC gloves while loading the tanker.

6. Continuously monitor the level of tank. After completion of loading remove hose
carefully. Check the level of tanker physically counter check the level difference with
weighbridge load slip.

PS CONVEYOR CLEANING AND MAITENANCE IN ZDDP UNIT

1. Before handing over the conveyor for MNT, tote bin screw should be stopped.

2. Keep CO2 padding and run conveyor for 15 to 20 minutes to empty out conveyor.
This will minimize PS spillage.

3. PS tilt unit is cleaned periodically to remove waste PS & spend PS put back in
empty tote bin & sent back to PS supplier for disposal.

4. Disconnect electrical supply of PS feeding system from MCC.

5. During inspection of PS window glass for flight checking uses PPE to avoid PS
contact.

6. Avoid metal contact while working on PS handling system as spark may lead to
fire.

STEPS OF OPERATIONS FOR ODOUR CONTROL EFFECTIVENESS

Odor control units are required for controlling of alcohol/obnoxious odors emitted during the
process. The odors are scrubbed in a water medium by counter current system with the help
of a vent blower.

55
Hence following steps to be taken before starting operation:

1. Ensure scrubbing medium is filled up to required level

2. Start circulation pumps and ensure it is running properly.

3. Start the vent blower and ensure that the standby blower (if available) is also in
working condition.

4. Line up tank processing to odour control unit.. During the course of operation the
scrubbing medium

gets saturated with gaseous emissions and becomes ineffective.

5. The saturated scrubbing medium is emptied out in drums/or pumped for recycling.

6. Refill the odour control system and follow step 1. to 4..In case even after the above
steps are carried out and the scrubbing is not effective then:

7. The vent line at source on the process tank to be cleaned and taken on line or scrubber
packing are taken out for cleaning.

NaHS SCRUBBER CLEANING PROCEDURE: (HBP)

1. T-326/T-326A or T-327 NaHS strength to be checked after sulfurization of every batch.

If NaHS % is >17% then the respective scrubber is pumped to T-337 storage tank.

2 To prepare fresh CSL solution of 20% strength in T-326/T326A/T-327 charge the required
amount of water, circulate through spray nozzle to flush the packing and then add CSL
quantity of required strength.

3. If system found to be getting pressurized, scrubber packing needs to be cleaned.

Following procedure is to be adopted:

a) Empty out the scrubber into T337 storage tank.

b). Flush it with water and empty put to ETP with ETP chemists consent.

c). Open scrubber side manhole and remove packing & fill up in bags.

56
 d) Unload these bags in a tray and wash with water. Drain this water to ETP with at
controlled rate.

e) Remove the sludge from scrubber bottom & dispose off separately.

f). Refill the cleaned packing in scrubber. After box up take pressure leak test and
prepare fresh solution for next batch.

NaHS TANKER LOADING PROCEDURE FOR HBP

1. Keep the NaHS storage tank T-337 under circulation and sample for % NaHS. After
approval from QAL tanker loading should start.

2. Check the tanker is empty & clean. Use safety belt while checking the tanker & use
full face mask with suitable cartridge.

3. Ensure that the hose pipe is tied firmly so that it will not come out of the tanker while
loading. Use full face mask & PVC gloves while loading the tanker.

4. Continuously monitor the level of tank.

5. After completion of loading remove hose carefully from the tanker and close the cap
on the hose pipe to avoid spill.

EMERGENCY SHUTDOWN PROCEDURE IN CASE OF H2S LEAK

(High Base Phenate)

1. If in T-300 sulfurization is in progress, start cooling of the batch immediately.

2. In extreme case of emergency, reaction can be quenched by charging neutral oil in T-

300 (Use standard neutral oil quantity for the batch. Take care not to dilute it)

57
 3. In case of power failure, batch can be cooled. But stop N2 blowing on filtration vent
header side so as reduce the load on flare.

Following actions are recommended.

Stop N2 blowing on filtration vent header side.

Stop CO2/N2 blowing in T-301.
Take immediate action get emergency power on line. Put J-326/J-326A/J327 on
circulation through H2S scrubbers. DG power supply has been provided to J-
326/J326A/J327. It takes 30 sec. For switch over to DG supply.
It is advisable to keep T-300 under agitation and circulation.

4. Care should be taken when H2S gas leak occurs.

Avoid contact with gas. Keep people away.

2 Wear goggles & breathing apparatus.

Shut off the ignition sources, and call up the fire department.

Stop flow of gas, if possible.

.Evacuate the area in case of leakage/discharge.

Stay upwind & use water spray to knock down the vapours.

Call for medical aid.

Please Note: The venting system is designed such that the sources containing significant
quantities of H2S are removed. The vent to the flare stack via flare knock out pot (K.O.
Pot) is almost free of H2S gas.

Ref: Process Manual of HBP(Document no 400-D-009)

58
EMERGENCY SHUTDOWN STEPS IN CFI PLANT:CFI Manufacture:

In case of power failure the following steps should be followed

1. Steam supply to ejector should be shut off.

2. if stripping is on in T-712/T-700 is on, put the tanks in normal vent operating 3 way
valve.
3. Emergency cooling water line valves should be opened.
4. Interlock provision is made for auto change-over from cooling water to raw water in M-
700 & M-712.

START UP PROCEDURE:

1. Start stem to ejector.

2. Stripping to be proceeded after applying vacuum to T-712/T700.
3. Start chiller water pumps.
4. Start J-712/J-700 and establish circulation.

OPERATIONAL CONTROLS

CAUSE EFFECT INTERLOCK/PROCESS

ACTION

CW failure(Ejector of T-700 Poor stripping of batch due Vacuum cut off. Raw water to
or T-712) to low vacuum be started manually.

N2 failure in T-700 Formation of explosive Stop heating, start raw water

mix. of toluene in supply to condenser.
presence of air

Vacuum cut off in T-712 Toluene loss/Poor stripping Stop heating and start raw
during Polymerization water to condenser

High temp. due to vacuum Runaway reaction Provision of external cooler

failure in T-712 during M-727

59
exotherm

High storage temp. of BZP Decomposition Provision of cold storage

room

1. POWER FAILURE
Provision has been made for the following.

Agitator of T-712(Terpolymer reactor) & T-700 (Esterification reactor) are provided with
DG power supply. In T-712, it will help in better dissipation of heat, thus avoiding
chances of localized heating. The vapors evolved shall be condensed & refluxed back to
the reactor, thus maintaining the temp. of the batch. In T-700, it will help to keep the
reaction mass in dispersed condition, in case of power failure before alcohol charging &
subsequent reaction. Since the material transferred from T-712 to T-700 has 88% solvent
(Xylene) and only 12% reaction mass in slurry form, there are chances that in case of
power failure (Immediately on transfer), the slurry may settle down and form sticky
mass

2. COOLING WATER FAILURE

1. In case of cooling water failure there is provision to manually close auto valves located
on CWS & CWR lines and manually open auto valves on PWS &PWR lines in T-712
(Terpolymer reactor) Stop addition of initiator and monomer. Try to maintain the temp.
within the given range.
2. In T-700 (Esterification Reactor), heating should be stopped and restart the reaction
once the supply of cooling water resumes.

Work Instruction for Dispersant Plant:

1. Vent lines of T-119,T-119A,T-119B,T-100 and T-100A must be cleaned minimum

once in a month.
2. Chlorine scrubber system must be monitored for proper level and strength of caustic
solution in tank, operation of pumps and blowers. The strength of caustic solution to
be checked and recorded in a register. Change caustic solution if PH of solution has

60
 come down to less than or equal to 10. Spent solution should be drained to HCL pit
and pumped to ETP with due information and consent from ETP chemist/Incharge.
3. Chlorine FRP hood operation must be checked weekly and status should be recorded
in recorded to ensure smooth operation.
4. HCL seal pot dip pipe will be cleaned after each batch and seal pot will be
cleaned/changeover after three batches to remove accumulated solid MAA/Maelic
acid. Before opening seal pot material will be drained in MUA-R (HCL) pit and it
should be flushed with water to minimize HCL gas emission to the environment. The
recovered waste MAA/Maelic acid will be collected appropriately and disposed off to
MWML.
5. In case of HCL emission from tail tower vent, take corrective actions such as
increasing the fresh water flow rate to tail tower, observe the emission and stop
chlorination if needed.
6. HCL liquid /Gas leak from pipe line must be attended promptly. Stop chlorination,
depressurize the 198.XX system and handover to maintenance to rectify the problem
by issuing work memo.
7. Check the scrubber T-616 solution before filling tankers. Drain the spent acid in
MUA-R (HCL) pit and charge fresh water in needed.
8. Waste MAA/acid recovered from HCL vent line, reactor system, HCL seal pots,
pipelines and MAA storage deposits should be collected properly and disposed off to
MWML.
9. Tank cleaning/flushing water from dispersant and HCL recovery system will be
drained to HCL pit and pumped to ETP with prior information to ETP
chemist/Incharge.
10. Aminators and 198.XX storage vent scrubber water and P&F filter pads sprinkled
water will be drained to MUA-R (HCL) pit from where it will be pumped to ETP.
11. 198_XX tanks will be cleaned as and when required. Solid waste generated will be
collected properly and disposed off to MWML.
12. MAA storage tanks will be cleaned at & when required waste MAA generated will be
collected suitably & disposed off to MWML.

Emergency Response Capabilities

On Site / Off-Site Emergency Plan

61
 Well equipped Crisis control Center
On site and off-site mock-drill.
Trained firemen / 24 hrs.
Well equipped Occupational Health Centre & Ambulance van / 24 hrs.
One Fire Tender and one mobile foam trolley.
Hydrant system covering all corners of the plant.
Fire water tank (1.9 million litres capacity).
Plant-wide availability of Fire extinguishers, SCBA, ELSA, etc.
Fire alarm/smoke detector system
Membership in Mutual Aid Response Group (MARG) of TTC area.
Efficient & effective emergency communication system.
Training of regular & contract employees on emergency handling
Rescue Squad teams trained on first aid and basic fire fighting

Chapter 12.

62
 Procedure for writing SOP

Purpose

Standard Operating Procedures (SOP) are used for carrying out various activities at LIPL.
The purpose of this SOP is to document a standard procedure for creating SOP.

Scope

This SOP applies to LIPLs Turbhe & Taloja plant sites.

Definitions

SOP SOP means Standard Operating Procedure

SOP Writer Need of SOP is visualized by dept head or section head. He appoints a SOP
writer who will be responsible for writing SOP.

Custodian : The dept head or section head.

SOP Review Team : Team constituted by dept head or section head for comments on final
draft.

Roles & Responsibilities

Department head or section head will be the approving authority for the final SOP
document. He will receive the draft SOP from the unit in charges or section in charges
working under him in his area.

The unit In charge or section in charge will prepare draft SOP for the identified jobs in
his section and submit the draft for approval to his department head. He will be called
as SOP Writer. He will be also responsible for updating and revising all SOP in his
area of operation and he will ensure that only valid SOP are available at the place of
use.

Dept head or section head i.e. SOP approving authority will seek respective General
Managers consent if there are any policy matters involved.

63
 The staff working in respective department will be responsible for adopting the SOP
in that department.

SOP Content

SOP Documentation :

The unit In charge or section In charge will write the draft SOP in the format as
attached herewith in Annex-1. This format will clearly indicate the SOP number,
issuing date, revision date, issue no., revision no., issuing authority and approving
authority.

Initial draft will have zero revision no. and issue no. The issue no. will change over to
next number after twenty revisions are completed.

The SOP writer will submit the draft to his department head or section head for his
comments. While writing a SOP, the SOP writer may take help of senior person either
from his department or any other department who had experience in the given job.

Department head/section head will review the draft and give his comment/suggestions
and send back the drafty to SOP writer. Even if the dept head has no comments, he
will send the draft to SOP writer mentioning the same and giving clearance from his
side.

The dept head/section head will also seek comments from Review Team in his area.

The dept head/section head will approve the final draft and send it to the SOP writer
for its final issue.

Training & awareness on approved SOP

The SOP writer will ensure that the working staff using SOP is adequately trained and
made aware about the standard procedure. The training can be in the form of self
study, group discussion, discussion with individuals (on the job / off the job), etc.

The SOP writer will update the training sheet of the staff and include SOP training.

64
 The SOP writer will review the suggestions given by working staff and incorporate it
in SOP if applicable.

SOP Document Control

All SOP will be written in the format attached herewith in Annex-1.

Each approved SOP will have separate identity number. For example

MFG-General-xxxxx

MFG-MNT-xxxxx

MFG-S&EH-xxxxx

MFG-PROD-xxxxx

Once the SOP is approved, the dept head/section head will put them in common folder
for his department/section in which all approved SOP will be filed.

The dept head/section head will also make a folder in PUBLIC FOLDER on desktop
giving identity for his department/section name and post all the soft copies of
approved SOP of his dept/section in this folder.

The dept head/section head will have rights for posting the approved SOP of his
dept/section in PUBLIC FOLDER.

SOP Modification:

No SOP will be modified or changed without written consent/permission of

department head/section head.

The SOP writer will have responsibility for updating the SOP and ensuring that the
current version of SOP is in use at custodian location.

In case of any proposed change or modification in SOP, the SOP writer will discuss
the change with his dept head. He will discuss the detail of required change with
proper justification for the same.

65
 While reviewing the change, the dept head may seek comments from other heads, if
required. If he is satisfied with the justification, he will approve the change and ask
SOP writer to amend the change in current SOP.

Once the change is approved, the SOP writer will incorporate it in the current version.

Revision Log will be maintained as given in Annex-2.

The SOP writer will have responsibility to communicate the change and to train the
user staff as per 5.2 on the amended SOP and its document control.

SOP Auditing

It will be the responsibility of SOP writer to carry out periodic checks (through various audits
or otherwise) to ensure that the requirements of SOP are properly followed in practice by user
staff.

The non conformity noted during such checks will be communicated to the user staff at the
site and rectified accordingly.

Feedback received by the SOP writer from user during such checks will be noted and
discussed with his dept head/section head for correction/amendment of current SOP as
applicable.

Records of such periodic checks will be maintained by the SOP writer.

Records

Approved copy of SOP

Updated training sheet record of all concerned in user staff (incorporating the training
given on SOP)

Record of periodic checks of SOP

Revision Log

66
 Chapter 13.

Hazardous Waste Management

Waste:

Waste means the material which can not be reused, recovered and recycled.

Waste disposal

Handle with care

Dispose off as per statutory requirements.

To be disposed only to Common Hazardous Waste Treatment Storage &

Disposal Facility (CHWTSDF).

Waste oil/used oil must be disposed only to authorized recyclers (approved by

& registered with Central Pollution Control Board (CPCB) / Ministry of
Environment & Forest (MoEF).

Hazardous Waste:

Hazardous Waste & Hazardous material.

Hazardous waste is waste that poses substantial or potential threats to public health or
the environment and generally exhibits one or more of these characteristics:

Ignitable

Oxidizing

Corrosive

Toxic

Radio active

67
Law reference:

The Hazardous Waste (management & Handling) Rules, 1989.

The Hazardous Waste (management, Handling & Transboundary Movement) Rules,

2008.

Importance.

Effectively implemented through local Pollution control board authorities.

Heavy penalty on illegal or improper handling of Hazardous waste.

Cancellation of environment permit given under Hazardous waste rules.

Disposal of Hazardous Waste:

Disposed at MPCB authorized hazardous waste disposal sites.

Mumbai Waste Management Ltd (MWML), Taloja.

Trans Thane Creek Waste Management Association (TTCWMA), Mhape.

Waste is treated to stabilize before disposal

Incineration

Incinerated in incinerators

Ash is land filled.

Landfill sites

Concrete built land fill pits having impermeable coating.

Regular inspection of the area around the site.

Hazardous Waste Disposal:

Records.

Manifest forms to be filled. (Form 13 6 copies)

Form 11 (Transport Emergency (TREM) Card)

68
 Form 12 ( Labeling of Hazardous waste container)

Form 3 ( records of hazardous waste disposal)

Form 4 ( Hazardous waste return to MPCB)

Maintain the approved disposal note for each waste.

Responsibility of disposing department.

Label each hazardous waste container with Form 12

Fill all the above forms appropriately for each disposal trip

Maintain Form 3 for each disposal

Ensure the vehicle is authorized to transport Haz. Waste

Forward the white copy of manifest form to S&EH for submission to MPCB.

Waste Storage:

Waste oil storage is to be done at designated storage area.

Make use of the term Waste Oil which exists in our MPCB consent. Avoid the
nomenclature Dirty oil in records or on drums/container.

No hazardous waste should be stored for more than 90 days. It must be disposed off
before this period.

Disposal to new waste

Will require initial sample to MWML

Based on analysis of sample, MWML will decide pathway for its disposal (i.e.
whether landfill or incineration).

Accordingly the rates for disposal cast are quoted by MWML.

Avoid generation of waste oil.

69
Effluent Monitoring - COD & BOD:-

Emission Trend:-

Waste Oil Collection at ETP:

70
 Waste oil from effluent is separated by continuously running oil skimmer (by
skimming it from surface).

The separated oil (with water) is collected and stored in oil storage tank (FRP tank).

drums/bins containing oil from various areas of plant are also unloaded in Oil storage
tank.

After proper settling, water is drained from bottom and the oil in storage tank is
sampled to QAL for %water.

Once approved by QAL, bulk tanker is arranged for disposal of waste oil to
authorized party.

Disposal note is raised. Manifest forms filled by Stores.

E- Waste:

E-waste refers to any unwanted electronic device or Cathode Ray Tube (CRT) and is
classified as universal waste. E-waste frequently contains hazardous materials, predominantly
lead and mercury, and is produced by households, businesses, governments, and industries.

Source at LIPL

IT department,

Instruments

Disposal

MPCB approved waste operators

Hazardous Wastes at LIPL:

71
 Chapter 14.
72
 Safety Instructions for Visitors at LIPL

General Instructions :

1) Ensure that you are wearing Personal Protective Equipment Safety Helmet,
Safety Goggles and shoes.

2) Watch the instruction boards posted at various areas and act accordingly.
3) Switch off your mobile phones when you are inside the plant area.
3) Smoking is strictly prohibited within the plant premise. Do not carry any spark / flame
generating gadgets, kindly deposit it at security.
4) Preferably keep left while walking in the road area of plant.
5) Beware of moving forklifts & other vehicles / loading & unloading operation.
6) Ensure that you are accompanied by LIPL contact while entering in the manufacturing
areas.

Instructions for Emergency:

1) Follow instruction of your LIPL contact. If you notice any abnormal happenings,
report it to him immediately.
2) Useful intercom numbers during emergency are
500 : (Firemen cabin),

600 : (Emergency Control Centre ECC-1)

421 : (Reception).

427 : Occupational Health Centre (OHC)

743 : Security Gate no.1

744 : Security Gate no.3

3) Listen to all announcements on Public Address System carefully and follow them.
4) Testing/checking of Emergency Siren is done daily at 10:30 am. The testing includes
initial wobbling sound (of emergency) and subsequent continuous sound (of all clear
checking). Except this testing timing, any other siren should be considered as

73
 Emergency. In case of any emergency situation arising during siren testing period,
appropriate announcement will be done on Public Address System.
5) During emergency situations, stay with your LIPL contact and follow instructions
given by him.
6) Area Evacuation will be done only if it is announced on Public Address System. (This
is based on overall assessment of emergency condition at site by the incident
controller). However, you must be alert and keep yourself prepared for such
evacuation.
7) Nominated Assembly Points during emergency are - Security Gate No 1 & 3.
8) Termination of emergency will be sounded by all clear siren and appropriate
announcement will be done on Public Address System guiding you to resume back to
your work.

WISH YOU A SAFE VISIT TO OUR PLANT

74
 Chapter 16.

Emergency Plan

The crisis management plan has been made based on the guideline from Oil Industry safety
Directorate, New Delhi (OISD) and the guidelines given in the manufacture, storage and
import of hazardous chemical (Amendment) rules 1994. The plan has been prepared by the
department of safety and environment hygiene and updated in June 2001.

In view of the potential hazard involved in the manufacturing of various types of chemical
additives for petroleum products. It is essential to evolve crisis management plan. So that if
situation demands, LIPL Personnel can effectively make use of the available resources to
minimize the human suffering and property damage. There would be many outside agencies
involved in the activities for the effective handling of disasters namely fire service, civil
authorities, medical personnel, Police and also personnel for neighboring industries and
voluntary organization. LIPL is member of MUTUAL AID RESPONSE GROUP (MARG).
At that critical juncture, it would require a good co-ordination and organized multi
disciplinary approach to solve the problem.

This crisis management plan presented provides clear organization structure involving a crisis
coordinator and resource mobilization. The plan also elaborates the steps to be implemented
and duties to be performed by each person when the crisis occurs so that the severity of
human suffering and property damage is reduce to bare minimum. The activities include
beside implementation of other immediate step, providing medical attention and life
sustaining requirements.

The crisis management plan has been revised to include the activities both for onsite and
offsite emergency. The enormities of the offsite emergency situation have been arrived at
using the consequence analysis data. The consequence analysis was carried out by the Atomic
Energy Regulatory Broad (AERB), in 1993.

28 emergency situations have been identified for LIPL, which may cause due to one of the
above conditions or in combination of them.

75
 Chapter 15.

Recommendation
House Keeping to be improved in division I,II, and III area. The company can
introduce an award system for the best maintained plant. This will increase motivation
and competitiveness among the worker to keep their plant in good condition.

Contractors need to be given more training to improve their awareness about the
hazards and their preventive actions to reduce accidents and maintain a safe working
condition

Specific routes to be decided for all incoming vehicles and the drivers and cleaners to
be informed about the routes

More Safety awareness to be imparted to employees as well as contractors on use of

PPE

Road signage, Posters are required to be displayed

Location of extinguisher shall be dry, cooled and will ventilated and away from heat
source and acid vapor. The area of fire equipment should be marked so that from a
distant place it can be identify

Fire hydrant should be easily accessible and approach made clear for fire staff use by
removing scarp materials

Chapter 16.

76
 Observations

The organization set up shows a full fledged safety dept. which includes safety and
fire officer along with fire staff

The health and safety policy is available for the organization and is prepared as per
requirement

The organization has on site emergency plan giving detailed responsibilities of all
members. Training on handling emergency situations is given to almost 80% of the
employees and these people are known as emergency crew member. Schedules are
arranged in such a manner that at least 30% of these members are available at any
given shifts

Mock drills are conducted once in every three months without any prior information.
The drilled are witnessed by observers who then give their suggestion, if any for
further improvement. Occasionally the mock drills are also witness by District
Collectors and their suggestion are also taken to improved the safety to standards.

Medical check up is done twice in a year for all employees

House keeping in plant area was found to adequate how ever there is a good scope for
improvement in group III

Ventilation problem in Pigment area particularly batch making Roof height to be

increased and required block arranged to the walls to facilitate cross ventilation and
air circulation.

Acid measuring vessels, no return lines in pigment area. Providing return lines to
measuring vessels to avoid overflowing of acids and spillage.

Use of PPE's in all area PPEs are provided but some of the employees are found
working without PPE's it is unsafe. PPE use should be making compulsory.

Solvent building and storage Provide spark arrestors to solvent pumping and returns
line to isolate fire from plant and storage area and also lightening arrestors to be
provided.

77
 Structural stability of some the building walls, slab and bridges of Pipelines found
racks require repairing.

Safe working arrangement to be provided at the time of repairing/ Replacement of AC

sheets on top of the building.

78