CHAPTER: - 1

1.1 Background of the company

INTRODUCTION

United Phosphorus Ltd. (UPL) was promoted by Mr.R.D.Shroff in the year 1969 to manufacture Phosphorus and its compounds. In the year 1972, the company started by making Red Phosphorus. Having established itself as a leading producer, it subsequently added to its list of products. United Phosphorus Ltd. (UPL) is a leading global producer of generic crop protection Product, intermediates and other industrial chemicals it is one of the largest agro chemical Producers in India with a wide range of Products the includes Fumigants, Fungicides, Insecticides and Herbicides. UPL ranks 4rd amongst the top 8 agrochemical Companies in the World. UPL manufactures and markets both technical and markets both formulations. The companys branded Products are, well recognized and have reputation for Quality. UPL has customer base in 86 countries which makes the global Player of crop Protection Products in the world UPL has a worldwide network of Subsidiaries, affiliate, offices selling branded agrochemicals, bulk pesticides and industry chemicals. The underlying Philosophy of the company is to provide cost effective, quality solution in crop Protection for farmers. UPL has been able to achieve this through managing change and making most of the opportunities that opened up with liberation and globalization. A focus on our Core Competence, a vision of being a global Player and a commitment to provide cost effective quality solution in crop protection for farmers, have been the driving forces of the company. UPL is constantly looking for new ways to improve their products and Services and the efficient synthesis of active ingredients is the core of our success UPL has started Pioneered backward integration in agrochemicals and is one of the worlds few companies to manufactures complex organ phosphorus compounds starting from the basic raw materials, rock phosphate. The strategy has now been extended to other products. Their main aim is to build successful long term relationship with customers to understand their needs and deliver real performance in huge benefits. As a reliable and dynamic partner their
1

area of experience covers registration manufacture and formulation, technical support and marketing. UPL is also concerned with product development and their aim is to accurately meet the needs of their markets across the world through the development and introduction of existing and new products. These products are developing to meet and exceed their customers expectation in the area of quality and performance. The quality control policy of the UPL is based on the clear target of zero Defect. Each stage of production from raw material through manufacturing to postproduction is closely monitored. UPL has also committed substantial investment to maintain and improve high standards of environmental care. This concern is designed in to UPLS process and manufacturing plants at the outset to minimize effluents and energy use. Care is taken to ensure that raw material and energy are used efficiently across the production process. They recognize that their process may have an impact on the environment and as a result they are committed to continuously improving their environmental performance to minimize the effluent. To work closely with the customer in the market place, UPL recognizes the requirement of the support in product research, development and registration. The company has invested in research team, which undertakes extensive filed trials for developing innovative formulations. New products have been introduced every year of the companys history, in response to the specific needs of the changing market. The company is committed to maintaining and expanding its portfolio of registration throughout the world. Considerable investment has been focused on the regularity requirement for registration support. Through acquisition, subsidiaries, UPL has built a network across the globe in Europe, America, Asia-pacific, Africa, Australia with fully owned subsidiaries in Argentina, Bangladesh, china, Cuba, Denmark, Honk Kong, Japan, Mauritius, Mexico, Russia, South Africa, USA, UK, Zimbabwe and representative offices in Sri Lanka and Vietnam. UPL has established a marketing and distribution network, comprising of more than 5000 dealers and 25 offices that works closely with the farmers. UPL has the commitment and capabilities to offer total solution from start to finish in the agriculture sector. All the units of UPL are certified under the ISO 9001 for quality Assurance, 14001 for environment pollution control norms and OSHAS 18001 for health and safety.
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1.2 Form of Organization

UPL is a Public Form of Company. It is a Multi National Corporation with its base in India. That means the company is listed on stock market.

1.3 Vision and Mission Statement

Vision Statement To be world class organization by Enhancing values to our customers and other stakeholders. Caring for employee to work as a motivated team in an open and learning environment. Setting challenging new standards of performance. Focusing on total quality, innovation and responsible care towards the environment.

Mission Statement We are in the business of: Manufacturing and Supplying Crop Protection and Specialty Chemicals Worldwide. Providing solutions to optimize farm productivity for the farmer through innovative and cost effective products to provide the customer better value for money.

1.4 UPL GOALS Provide customers with prime quality products and services, backed by efficient and courteous customer services. Earn enduring respect of customers and the community.

1.4 Plant of UPL In India.

Overview of UPL Plants in India Table: 1 Plant Location of UPL in India. Location Ankleshwar Ankleshwar Ankleshwar Halol Jhagadia Vapi Jammu Haldia Unit No Plant 01 Plant 02 Plant 03 Plant 04 Plant 05 Plant 00 Plant 07 Plant 08

CHAPTER:- 2

COMPANY PROFILE

Business Type Capital in Rupees Primary Competitive Advantages

Exporter , Manufacturer , Service Provider , Trader Rs. 450 Crores

Competitive Prices Premium Quality Products On-Time Delivery Schedules

Year of Establishment OEM Service Provided No of Engineers

1972 Yes 21

Monthly Production Capacity 1,500 Tonnes Memberships Ankleshwar Industrial Association BEAIL G.P.C.B Product Range 1. 2. 3. 4. 5. 6. 7. 8. 9. Mancozeb 75% Acetamiprid 20% Carbendazim 12% + Mancozoleb 63% Sulphur 80% Acephate 75% Metalaxyl 35% Hexaconazole 35% Lambda Cyhalothrin 5% Phorate

CHEPTER 3:-

RAW MATERIALS AND INTERMEDIATES

The various chemicals and intermediates used in thePhorate Plant are as follows along with there basic properties:

PHORATE 3.1 Raw Materials: DETA Ethyl Mercaptan Formaldehyde Caustic Lye Water

PRODUCTs:

PHORATE

3.2 Physical Properties of Phorate:Physical status: Liquid Molecular Formula : C7H17O2PS3 Molecular Weight : 259 Melting Point: Specific Gravity: Vapor Pressure: Stability : Boiling Point : Acute poisoning: 118 0C 1.156 AT 35 0C 8.4* 104 mmHg stability at room temperature 118 ~ 120 C / 106.7Pa short-term exposure (oral, inhalation, skin, mucous membrane) exposure cause acute poisoning. Performance headache, dizziness, anorexia, nausea, vomiting, abdominal pain, diarrhea, salivation, restlessness, increased respiratory secretions, sweating, muscle bundle tremors.

DETA
DETA is the raw material for making Phorate product and it is produced in a company itself.

3.3 Raw material used for DETA

DETA (heel) P2S5 (Phosphorous Penta sulfide) TEA (Tri Ethyl Amine as catalyst) Absolute Alcohol (Ethanol)

3.4 Properties of DETA

DETA is transparent, a slight smell of oily liquid; Vapor Pressure : Boiling Point : Solubility: Density Stability : 112mPa (20 C); -15 C 116 ~ 117 C / 106.7Pa; Do not dissolve in water, soluble in alcohol, ether, acetone, relative 1.167 stability at room temperature, pH 5-7 stable, the acidity (pH <2) or alkaline (pH> 9) media can promote hydrolysis, and the speed depends

on the temperature and acidity; Pathways: Health hazards: Toxicity: Acute toxicity: Fire: Inhaled, ingested, percutaneous absorption. Inhibit cholinesterase activity, causing nerve physiological dysfunction. It is a high drug category. LD503.7mg/kg (rat oral); 70 ~ 300 mg (rats Paper) water, sand, carbon dioxide fire extinguishers, should wear reliable anti-virus, medical supplies and protective gear to prevent physical poisoning.

CHAPTER:-4

PROCESS DESCRIPTION

The process of manufacturing of DETA as given below:-

4.1 The Process of DETA

First of all in a 10 KL reactor R- 5301, some part of DETA is already remaining in the reactor which is called DETA heel which is in liquid form. In this reactor firstly P 2S5 is charged which is in solid form and TEA which is catalyst is also charged in to the reactor. TEA is very necessary to enter in this reactor because it helps to improve the quality, purity and also speed up the production of the product. After the addition of these two raw materials storing process is done so that P2S5 which is solid product and DETA which is liquid product are mixed up properly so it becomes the slurry. After the storing of these products liquid Alcohol is charged in to this reactor. This addition is done for 8 to 10 hours. After the addition of the Alcohol again cooking (stirring) process is done. In this reactor cooking process is done for 2 hours. This process generates H2S gas which is converted into by product i.e. NaSH and also generates DETA in a liquid form. For converting H2S in to NaSH small process is carried out i.e. in a big tank NaOH is filled up than in a big column from one side solution of NaOH is entered and from other side H2S gas is entered than in this column circulation is done and this process gives NaSH which is dispatched by the company to the Dye industry. The reaction mass is cooled for 2 hours at 40 c. Finally DETA is transferred in filter for filtration and to remove the other impurities. Then DETA is transferred into the storage tank and this is in liquid form.

4.2 The process of Phorate

DETA is main raw material for making Phorate product First DETA and water are charged in the reactor than alternative addition of formaldehyde and Ethyl Mercaptan at 34 0C temp is done. In the reactor addition of Ethyl Mercaptan at 340C and atmosphere temp at 300 to 350C generate hit, so it is necessary that reactor has to be cool so 150 to 250C. Cooling is given to reactor. After the addition, this reaction is transferred to the other reactor for cooking process. Here reaction is cooked for 18 hrs at 250C to 300C here reaction is divided under two layers (phase) one is Aqueous phase and other is Organic compound. In this glass port separation is done. In this separation organic part is separated at the bottom and Aqueous is separated at the top. Than Aqueous phase is pumped to different tank and it transferred to ETP and organic phase is pumped to other reactor. In this reactor organic phase is contained Acidity so to neutralize the solution and to remove the acidity, there are two types of washing is done. 1. Caustic wash 2. Water wash

In this reactor first caustic lye is added to remove or control the acidity. After the addition of caustic lye 2 hrs are given for settling. After the addition of the caustic lye again this reaction is divided in two phases. One is Aqueous and anther is organic compound. In this separation caustic lye is removed as a Aqueous and it is transferred to ETP and organic phase is in other reactor. This organic compound is contained Phorate but it id not pure. So after the separation of caustic, to neutralize the solution water washing is done and again this reaction is divided in two phases. One is Aqueous as water is separated in other tank and it is transferred to the ETP plant and organic phase which is phorate is transferred to other reactor. This organic phase which is phorate, it also contained some part of water so to remove the water and impurity stripping is done for 4 hrs. In the stripping process heat is given at 800C temp. So through vapor water and other impurities are removed.

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After this process 90% quality of phorate is obtained. 90% quality of phorate is also dispatched by the company. Than from the striper it is transferred to TFE. To get pure phorate further purification is done in TFE (Thin Film Evaporator by giving 1140C temp. heating. After this process 93% of quality of phorate is obtained which is fixed good of the company.

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CHEPTER:-5

DETAILS OF EQUIPMENTS

In chemical industry, for the manufacturing desired products we have carry out number of chemical reactions. The list of different types of equipments which are using in the manufacturing process of PHORATE in the plant as given below,

5.1 Different types of Equipments:

Table 5.1 Types of Equipments.

EQUIPMENT TYPE
RECTOR

TYPE
STIRRED TANK REACTOR

NO.
6

HEAT EXCHANGER PUMP EVAPORATOR STORAGE TANKS

SHELL AND TUBE TYPE CENTRUFUGAL THIN FILM VERTICAL HORIZONTAL

4 13 1 10 1 1 1

STRIPPER SILO

STEAM STRIPPER

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CHEPTER:-6

ETP Plant

Effluent is nothing but liquid waste produced in the industry. The main sources of effluent in industry are utility plant, canteen, bathrooms, and product manufacturing plants during washing and cleaning of equipments, during leakage through valves, pipes, fittings, spillage, overhauls, operations, material handling, storage, etc. Since this effluent comes from the manufacturing plant it contains mixture of various dangerous, hazardous chemicals. If it is directly discharged to anywhere or to any natural source like river then these chemicals present in effluent may cause various dangerous problems to environment, animals, plants and then to human beings also. Hence it is very necessary to treat this effluent before discharging so as to remove hazardous chemicals from it. This treatment is carried out stepwise in separate plant and that plant is called as effluent treatment plant (ETP).Each and every industry has its own ETP plant in which effluent is treated to remove hazardous chemicals and to avoid pollution. Now days due to continuous increasing pollution it is very important to meet ever stringent emission norms of Gujarat Pollution Control Board (GPCB) which is controlling authority that examines treated discharged effluent. In this plant following treatments to are given to effluent 1. Preliminary Treatment 2. Primary Treatment 3. Secondary Treatment 4. Carbon Treatment

1. Preliminary Treatment
This is the first step of treatment. The effluent coming from plant contains floating matter, oil, grease, lubricant, pieces of rags, papers, plastics wood etc. Hence this must be removed earlier because presence of solid material may choke up the pipeline and causes problems. This treatment is carried out in preliminary tank. This treatment reduces BOD content to 5%

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2. Primary Treatment
An effluent from preliminary tank is fed to equalization tank. From equalization tank effluent is pumped to neutralization tank where acidity of effluent is neutralized by adding lime solution and pH is maintained between 7- 8. This neutral mixture is then pumped to FLOCCULATION UNIT where alum is added as flocculating agent so as to settle inorganic impurities. The residence time of 4-5 hours is to be given. This mixture is then pumped to flash mixer for proper mixing. Then this effluent is pumped to primary settling tank where all inorganic matter is settled down. Here 2-3 hours are given to settle impurities. An effluent is then fed to aeration tank where air is added form bottom of tank through sparer. This aerated effluent is then introduced into secondary settling tank. 30% of BOD is removed here.

3. Secondary Treatment
This is an important treatment which is also called as biological treatment. Due to aeration in aeration tank oxygen is added in to effluent. This causes bacteria to flourish which consumes organic matter present in effluent and by this way all organic matter is consumed by bacteria which agglomerates and finally settle down the tank. The residence time of 4-5 hours is given. An effluent from this tank is pumped to second aeration tank where remaining organic impurities are removed by adding fresh air to tank from bottom of tank through air spurges. In this treatment effluent becomes free from all biological impurities which are then fed to carbon filter through underground tank. In this treatment 80% of BOD is removed. The sludge settled at the bottom of primary settling tank and secondary settling tank is called activated sludge which contains living bacteria. Some of sludge can be used in primary and secondary tank as promoter for biological treatment. The remaining sludge is collected from bottom of both tanks which are then dried on sludge drying beds and send to disposal for land filling.

4. Carbon Treatment
An effluent from secondary treatment is then collected in underground tank and then from this tank it is pumped to carbon filter. The carbon present in the tower adsorbs all kinds of suspended, dissolved impurities and finally clear treated liquid is discharged to G.I.D.C. outlet.

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Various chemicals quantity needed in ETP:1. Lime solution: 2. Alum solution: 3. HCl solution: 4. Poly solution: 5. Citric acid: 200kg in 1000L(pH: 14) 40kg in 1000L(pH:2) 3L in 1000L(pH:2) 850ml in 1000L(pH:7) 75kg in 1000L(pH:2)

6. Sodium Hypochlorite: 5L in 1000L(pH:7)

6.1 Process of ETP plant

Capacity of the ETP plant is 250 MT / day. Effluent come from all the plants like acephate, phorate, devrinol, PD and from the other sources like bathrooms, canteen is fed in the ETP plant for removing the hazardous chemicals from the effluent before discharging outside. These effluents contain oil, grease, paper, plastic, lubricant and other liquid waste. All these effluent fed in to oil separator tank. In this plant treatment is given to the effluent to remove the oil and wastages from the effluent. This separation is done in a oil separator tank. It is necessary to remove the wastages because presence of solid or any liquid wastages may choke up the pipe lines and it create problem. In this oil separator oil, solvent are removed and then effluent is pumped to the equalization tank. In the oil separator only oil, solvent are removed but in the equalization tank all the Hazardous chemical present in the effluent are equalized because all the effluents comes from all the plants are hazardous in nature. They have to be equalize in this tank so all the hazardous are removed from the effluent and from the equalize tank effluent is transferred for neutralization tank. In the neutralization tank acidity of effluent is neutralized by adding lime solution and PH is maintained between 7 to 8. From this tank effluent is transferred to flocculate. In the flocculating process Alum is used to settle the inorganic impurities. The resident time is given for 4 to 5 hours. From the flocculate effluent is pumped to primary settlement tank where all inorganic particles are settled down and resident time is given 2 to 3 hours to settle the impurity. This treatment is known as primary treatment.

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In primary tank all the particles are settled down and clear water is overflowed and it fed to TSDF where water is separated in two layers. First layer is sludge and other layer is clean water. Sludge is settled at the bottom of primary settling tank then is dried and send to disposal for land filling. Then clear water is overflowed in aeration tank. In this tank 1.5 to 3% oxygen is fed in to tank. In this tank living bacteria diets the biomass organic part which is presented in effluent and again clear water is overflowed and aerated effluent is then introduced in to secondary settling tank. From the aeration tank with the clear water, living bacteria is also fed in to secondary settling tank. In this tank bacteria will diet the organic part from the effluent. Similar process is followed in the second aeration tank and secondary settling tank. By this way all organic part is consumed by the bacteria and then an effluent from the second aeration tank is pumped to second secondary tank where remaining organic impurities are removed by adding fresh air to tank from bottom of tank. In this treatment effluent become free from all biological impurities and clear effluent is then fed to carbon filter. In this treatment 80 to 90% of BOD is removed. This treatment is known as secondary treatment. In the carbon filter, carbon is fed in to this filter. In this filter tertiary treatment is given to clear effluent to remove the color from effluent and further purification id done in this filter and finally clear water is discharged to GIDC outlet.

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6.2 Types of material handling equipment used:

There are many equipments are used for handling the material in the plant area. Fork lift Stacker Hand trolley Wooden palate Manually Pipe lines Vapor lines Tanks Pump Cranes For handling the material big reactors are used. In these reactors all the chemical reactions are done. The raw material in the reactors is filled by using the pipe lines.

6.3 Quality of effluent after treatment:

pH: BOD: COD: Ammonical Nitrogen: Phosphate: 4-5 30-50 mg/l 100-200 mg/l <50mg/l <5mg/l

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CHAPTER:-7

INSTRUMENTATION

Thermocouple

The thermocouple instrument is not used equally Temperatures encountered in industrial

for all temperatures, both low and high.

processing are seldom higher than 3000F. and

temperatures ranging from 2000 to 3000F are commonly met, in the steel, glass and ceramic industries. The thermocouple is used for low temperatures as well, temperatures of both liquids and glass as low as -300F are measured. The thermocouple provide an accurate indication of temperature for many kinds of industrial applications. Thermocouple can be interchanged since they are supplied to standard calibration. This is one important reason for their wide adoption for industrial temperature measurement. A Thermocouple is composed of two

dissimilar wires joined together so as to produce a electric emf.Thedesirable properties of thermocouple for indistrial use are 1. Relative large thermal emf 2. Resistance to corrosion and oxidation 3. Produce linear relationship between emf and temperature Thermocouple are made to operate with standard instruments having calibrated charts and scales. Resistance to corrosion, oxidation and contamination should be high in oreder that the thermocouple will have long life.

Thermocouple
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The five most commonly used Thermocouples are 1. Copper-Constantan. 2. Iron-Constantan. 3. Chromel-Alumel. 4. Platinum-Platinum, 13%rhodium. 5. Platinum-Platinum, 10%rhodium.
Pressure gauge

The measurement of pressure and vacuum has always been important in continuous-processing industries.The pressure spring gage employes spiral helix or bourdon tube. A pressure spring Of bronze is used in the pressure range up to about 600 psi , a beryllium copper. Pressure a spring up to about 10,000 psi, and a steel or alloy steel pressure spring Up to 10000 psi and higher. The most common type of the pressure spring gage is The simple dial pressure or vacuums. This type is used literally by the thousands in All industries and may be obtained in sizes from 2 in diameter dial up to 14 in. Diameter in many different indicating styles.

Bourdon tube Pressure Gauge

Flow meters

The flowmeters operate on the principle that the variation in area of the flow stream Required to produce a constant pressure differential at a restriction to find flow is Proportional to the flow rate. The rotameter is one type of area meter. The flowing Fluid enters the bottom, passes upward through, the metering tube and around, the Float , and exits at the top. The metering tube is hollow, usually made of glass, and has Tapered sides so that the cross-section area at the top is greater than at the bottom. Often the mattering tube has protruding vertical ridges at the inside diameter, for Guiding the float in its travel up and down the tube .the tube must be installed
21

Vertically, that is, it must be plumb to within about 2 geometrical degress,because The float must center itself in the fluid stream.

Orifice meter Different Control Systems used in Industrial Process Control 1. Pneumatic control systems. 2. Centerlized computer control system. 3. Microprocessor based single loop electronics controllers. 4. Distributed control systems.

Flow Controlling Elements (Valves) Flow controlling element is used in the process industries for controlling the flow & on off the flow in the plant. Major three types valves are used in the DHT, Butterfly valve, gate valve & glob valves are used. Valves description is given below. Butter fly valve is used in controlling the flow or on-off purpose depending upon the service. This is automatic control valves some reasons people are using them more often as automatic valves can be seen in the following advantages: They are more compact than globe valves of the same size.
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They are less expensive. They have fever parts. They are available in larger sizes than globe valves. They are bubble tight. Actuator sizing is not dependent upon the differential pressure across the system. When size properly, they are capable of actuate control. There are following disadvantages to the butter fly valves: The cavitations potential is grater than with glob valves. They have grater potential for water hammer than glob valves. They have equal percentage-type characteristic not suitable for all application.

The control valves have two major portion first is valves &second is actuator both part are connected to each ether and make the control valve shown in the figure.

Control Valves

Level Indicator This is screw or flange connection, this is used pressure up to 400 bar & temperature 450 C for specific gravity 0.845,Magnetic Level Gauges provide clear, high clarity indication of liquid level. A float containing a magnet rises and falls with the liquid. As the float moves, this information is transferred to the indication rail mounted on the outside of the tube. The white and

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red indication flaps represent air and liquid level respectively. The magnetic level gauge can be mounted in various orientations, typically onto the side of a vessel, however it may be fitted onto the top as required.
QUALITY CONTROL

There are various types of equipments for maintaining quality of products in the quality control laboratory as given below. o TLC (Thin layer chromatography) o Melting point apparatus o LOD (loss of drying) o Gas Chromatography o H.P.L.C. (Hyper Potential Liquid Chromatography)
GAS CHROMATOGRAPHY

A gas chromatograph is a chemical analysis instrument for separating chemicals in a complex sample. A gas chromatograph uses a flow-through narrow tube known as the column, through which different chemical constituents of a sample pass in a gas stream (carrier gas, mobile phase) at different rates depending on their various chemical and physical properties and their interaction with a specific column filling, called the stationary phase. As the chemicals exit the end of the column, they are detected and identified electronically. The function of the stationary phase in the column is to separate different components, causing each one to exit the column at a different time (retention time). Other parameters that can be used to alter the order or time of retention are the carrier gas flow rate, and the temperature.

24

Generally chromatographic data is presented as a graph of detector response (y-axis) against retention time (x-axis), which is called a chromatogram. This provides a spectrum of peaks for a sample representing the analytes present in a sample eluting from the column at different times. Retention time can be used to identify analytes if the method conditions are constant. Also, the pattern of peaks will be constant for a sample under constant conditions and can identify complex mixtures of analytes. In most modern applications however the GC is connected to a mass spectrometer or similar detector that is capable of identifying the analytes represented by the peaks.
T.L.C. (THIN LAYER CHROMATOGRAPHY)

Thin layer chromatography (TLC) is a chromatography technique used to separate mixtures. Thin layer chromatography is performed on a sheet of glass, plastic, or aluminum foil, which is

25

coated with a thin layer of adsorbent material, usually silica gel, aluminum oxide, or cellulose (blotter paper). This layer of adsorbent is known as the stationary phase. Thin layer chromatography can be used to:
o o o

Monitor the progress of a reaction Identify compounds present in a given substance Determine the purity of a substance

ANALYSIS:

As the chemicals being separated may be colorless, several methods exist to visualize the spots:
o

Often a small amount of a fluorescent compound, usually manganese-activated zinc silicate, is added to the adsorbent that allows the visualization of spots under a blacklight (UV254). The adsorbent layer will thus fluoresce light green by itself, but spots of analyte quench this fluorescence.

o o

Iodine vapors are a general unspecific color reagent Specific color reagents exist into which the TLC plate is dipped or which are sprayed onto the plate

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CHAPTER:-8

FIRE & SAFETY

Safety is given the prime importance by the management. There is a separate safety department for the safety of the workers and employees. Safety meetings are held frequently in the organization. Steps are taken to improve the awareness among the workers. Monthly safety committees meetings are held. Mock-drill of an on-site emergency is carried out regularly. Chlorine kit demonstration is done every month. This demonstration helps the workers to take an on-site emergency action in case of chlorine gas leakage. Many banners are kept at various places in the Company regarding the hazardous physical and chemical nature of the chemicals produced and used. These banners also explain the immediate action to be taken in case of an accident. Danger signs are kept at places where there could be possibility of major accident. 8.1 DEPARTMENTAL STRUCTURE
General Manager Works

Manager (Safety, Health, ENV)

Assistant Manager

Factory Medical Officer

Male Nurse and Fire Man

Figure No.8.1 Departmental Structure

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8.2 ACTIVITIES OF THE SAFETY DEPARTMENT

They conduct BCA test (blood cholinesterase activities) of the worker at every week. They check whether BCA of all the employees is in between the range of 62.5% to 75%. If BCA of some worker is not match with this standard, they provide rest to that worker at the company premises itself, till the BCA is match to the standard (75%).

They conduct safety talk every morning to create safety awareness among the employees about the necessity of the safety & safety equipments in the plant area. It is conducted by the different employees of the safety department about various safety talk topics.

They provide the protection equipment to the workers like boiler suit, shoes, helmet, goggles etc

8.3 GENERAL SAFETY RULES Safety spectacles must be worn at all the necessary time. Safety shoes, helmet, suit must be worn at all time. Smoking & carrying match box or cigarette lighter or any other sources which may create a flame is strictly prohibited. Only authorized personnel may operate mobile or camera in the company. For all the employees who are working in the plant area, it is compulsory to wear required PPE like goggles, dust mask, gloves to avoid the eye, hand and head injuries. Know the location of the extinguisher and fire exit. It is compulsory to report about all incidents which are take place in the plant area. Photography is strictly on permission. There are certain site traffic control rules like vehicle entry pass, driver license, speed limit, no smoking in vehicle.

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Function of the Safety Department To highlight unsafe act and unsafe situation To follow legal requirement like Periodically checkup of the employ. Pre-employment checkup of the employ Plan inspection Training to the ERT members Prepare a mock- drill report Factory license

Permit system is followed by safety department that is for any non routine work workers have to take permission from the Assistant manager of the safety department. It includes work permits like: Cold work permits Hot work permits Vessel and confined space entry Temporary electrical connection

To conduct safety committee in every three months To create awareness among the workers, they celebrate fire day, national safety day etc. To create motivation among ERT members (emergency response team) they conduct competition among different ERT of different units of UPL. To create awareness among the workers they provide first aid training to all employees and health related training programmed also held time to time. To provide information regarding the hazards in lab and plant area because of Toxic materials, flammable materials and hazards related communication to onside emergency contractor.

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8.4 PERSONAL PROTECTIVE EQUIPMENTS:The various types of personal protective equipments are: Breathing Apparatus Dust Mass Helmet Face-Seal Safety Goggles Hand Glove Safety Shoes

8.5 FIRE
FIRE EXTINGUISHERS:The following types Of Fire Extinguishers are used: COLOR CODE UPL uses the color system for the supply of the chemical, water, which also helps in safety. Color Blue Green Silver Red Yellow Chemical Raw water Cooling water Steam Hydrant water Vacuum line Dry Chemical Power(DCP) CO2 Water Spray Alcohol Resistance Foam

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8.6 HEALTH, SAFETY AND ENVIRONMENT (H.S.E.) POLICY: UPL Health, Safety and Environment (HSE) policy has been adopted by its Directors and applies to all Employees across the group. It is considered as guide line from leader and always keeps the employee focused on HSE issues. 1. The Management of United Phosphorus Limited is committed to safeguard the Health, Safety and Environment for all by minimizing adverse effect due to its Industrial and Agrochemicals manufacturing and marketing operations. 2. Necessary standards for Occupational Health, Safety and Environmental Performance & Statutory Compliance shall be ensured by adopting suitable proactive steps during operations including those for prevention of injury, ill health and pollution. 3. The Management shall make due arrangement for Information, Education, Training & Retraining to all our employee about Occupational Health, Safety and Environment objectives at different levels and to interested parties & general public whenever & wherever required. 4. The Management is committed for continual improvement in the H.S.E. by carrying out Risk Assessments with involvement of employees, Waste minimization and optimum use of resources through:(a) Source Reduction and/or (b) Recovery/ Recycle/Reuse and/or (c) Suitable treatment for any hazardous /toxic waste arising out of its operations. 5. The Management shall give due importance to H.S.E. aspects in all decisions making including purchase of plant, equipment & machinery, selection of materials and process and individual's performance on H.S.E. in their career advancement. 6. The Management shall ensure monitoring the health of all employees through preemployment and periodical medical check-ups at desired frequency. 7. All Unit Heads shall review their operations for identification of significant H.S.E. aspects & risk levels regularly, prepare and monitor relevant objectives & targets as appropriate. 8. The H.S.E. policy, objectives & targets and performance shall be reviewed periodically and communicated to all employees & interested parties.
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8.7 ERT (EMERGENCY RESPONSE TEAM)

Introduction In the year 2001 there was Ammonia leakage in unit-1 at the loading point & noticed that there is no awareness in the employees how to handle the emergency. So at that it was decided that they should have their own trained person just like common do to act immediately in case of any type of emergency. UPL falls under major accident hazards industry. They are handling hazards chemicals, if it leaks may cause fire and toxic release. So that they have decided for ERT so that in case of any emergency in the company, emergency response team always ready to handle any type of emergency and they try to save the life, material, machine. For this purpose 57 members are selected from the different plants. Selection of ERT members is done by the safety managers as well as plant HOD. ERT members are also given training as per their schedule. Mock drill is also done in the plant area and to motivate the ERT members competition is held in different units. ERT is useful not only to handle inside emergency but also in off side emergency.

Objective To give quick emergency response to all the emergency accidents, incidents inside and outside the factory premises.

Criteria Members need to be selected with individual personnel interviews with criteria that self interested and enthusiastic members to be select. This selection expected from safety officer and head of the plant. Training given to ERT members Following trainings are given practically as well as theoretically. 1. What is Accident types, prevention, precaution, effects, duties and responsibility of ERT members? 2. What is fire causes, types of fire, equipments? 3. Hazardous chemicals handling study of MSDS.
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4. practical fireman ship duties and responsibility of fire man 5. Self RESCUE from height by using Rope ladder, by ladder climbing. 6. Spillage handling & prevention and precautions & control of spillage of various solvent and materials. 7. SBA SET types, uses, practice of wearing equipments. 8. Special fire / leakage risk solvent fire, oil fire and control of leakages of chlorine and Ammonia gas. 9. FIRST- AID Definition, rules, limitation of FIRST AID. 10. Discussion on off side emergency, mock drill 11. Visit to fire station for practical look and study of modern fire fighting equipments available in the fire bridge station. 12. Leakage handling of chlorine.

8.8 PSR (PLANT SAFETY REPRESENTATIVE) There are eight employees are selected as a plant safety representative. These representatives are selected from the different plants and departments, like they are selected from five plants like Acephate, PD, Phorate, Devrinol, ETP & one from electric department, one from store department and one from the QA department. The selection of these representatives is done by plant HOD. Two years contract is given to the representatives. After this contract if HOD feels, then he can change the representative. There are some roles and responsibility performed by the representatives which are defined by the HOD. Following duties are performed by them.

Roles and responsibility of PSR Promoting safety culture in their area including being catalyst in involving employees in safety activities and emphasis zero accident culture. Conducting plant safety committee Meeting as per the guide lines on fortnightly basis. Conducting plant safety inspection once in a month, as per guide lines and submits the report to unit Head by 25th of every month.

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Inspection and maintaining the safety cupboards and ensuring readiness of all safety equipments. Co-ordination safety activities related to their department such as safety Talk and upgrading Area accident statistics board. Continuous interaction / co-ordination with safety department on behalf of the plant. Supporting investigation of accident / incident occurring in their submitting the reports, if required. To compulsorily attend and deliberate the monthly safety meetings to be held in 1st week of every month. PSR is fully responsible of housekeeping in their section.

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