6.1 Introduction To Industrial Safety:
Safety is becoming very important with every management as it has come to play a very vital role in the modern development. Before many years, accidents were considered as acts of God and nature.
Scientific minded people have analyzed accidents and developed a separate engineering branch of accident prevention. This analysis was required due to
Rising trend of accidents Increased use of machinery Increased material handling Lack of safety standard Lack of training
Better reporting of accidents
6.2 Safety:
Safe use of man, material and machine by safe system method of work is to achieve
zero accidents which results in higher productivity.
6.3 Accident:
An accident is unplanned and unexpected events which interfere or interrupts the
planned process of work and results in personal injury.
6.4 Accident Factors:
A personal accident injury occurs as a result of an accident An accident due to unsafe act and/or unsafe condition Unsafe act/unsafe condition exists due to fault of persons Fault of persons are due to negligence.
Thus, if we can remove fault of persons we can prevent 98% accidents.
6.5.1 Respiratory Personal Protective Equipments
Self-contained breathing apparatus sets of 30 minutes and 10 minutes Continuous airline masks.
Trolley mounted self-contained breathing apparatus set 2.5 hours Canister gas mask. Dust mask/cloth mask. (Air purifying respirator)
6.5.2 Non-Respiratory Personal Protective Equipments
Helmet
Ear muff and ear plugs Goggles Face shield Hand gloves Aprons Safety Shoes Suits Safety harness 6.5.3 Warning Instruments
Oxygen, carbon dioxide, chlorine, ammonia indicator with replaceable sensors.
Explosive meters for measuring explosive range.
Fire fly instrument for confined space entry.
6.5.4 Gas Leakage Protection Installation
Safety Showers
Manual water sprinklers Communication systems
6.5.5 First Aid Boxes
IFFCO kalol is maintaining the dispensary around the clock at plant over & above
6.6 Safety Precautions:
When taking samples of anhydrous ammonia and when operating or working on
ammonia valves, equipment containing ammonia such as ammonia feed pumps, operators, laboratory and maintenance personnel must wear overalls, safety goggles and rubber gloves. If any part of the skin has been exposed to ammonia, wash immediately and thoroughly with water.
Work on the ammonia equipment should be done from the upwind side of the
equipment to avoid or minimize contact with escaping ammonia.
The location of fire hydrants, safety showers, eyewash fountains ammonia canisters
gas mask, emergency air breathing apparatus should be well known to all person.
Instruments containing mercury must not be used if ammonia is likely to come in
contact with the mercury.
Heavy leakage of ammonia can be dealt by spraying large quantity of water with
spray nozzles.
6.7 Fire Hazards:
The general types of fire are encountered in the process plants. One involves
common combustible material such as wood, rags, paper, etc. (Class „A‟ fires), the next flammable liquids and gases such as lubrication oils and solvents, ammonia vapors etc. (Class „B‟ fires) and the third involve electrical equipment (Class „C‟ fires).
In general three things are required to make a fire
Something which will burn egg., a combustible material Oxygen-air
A source of ignition or existence of a temperature at or above which a material will
start burning spontaneously.
Fire may be extinguished by withdrawing of flammable contents, interrupting
flammable flow, isolating fuel from air, heat removal to below reaction temperature or by dispersal.
In the event of fire on electrical mains or apparatus, the affected part shall be
immediately isolated from its source of supply of electrical energy.
Carbon tetrachloride extinguishers and Carbon dioxide extinguishers are intended
mostly for use on electrical fires and may be used on energized electrical equipment without danger to operator provides. They are properly maintaining no moisture.
It is dangerous to throw a stream of water, a wet blanket or a stream from an
ordinary soda acid or foam type fire extinguishers on line main apparatus. When found necessary to use them, have all neighboring mains or apparatus made dead.
In case of fire, it is the duty of the operating personnel to protect life and property
and to extinguish the fire as quickly as possible.
The greatest cause of fire is welding which may be required during plant operation.
It should be a stringent rule of the plant that no welding without permission of the supervisor.
Fire and safety equipment, under conditions of extreme exertion provide protection
only for a few minutes. Equipment must be cleaned, replenished and inspected for damage before being returned to service. Equipment should be maintained in excellent condition and inspected frequently so that they are available in case of emergency.
6.9 Color Code For Pipeline:
Green---ordinary hazard Red---high level hazard Black---foam
6.4 Fire Fighting Appliances:
Type of Class A Class B Class C
extinguisher
Carbon Suitable for surface Suitable. Does not Suitable. Non- dioxide fires only leave residue or conductor and
affect equipment or does not damage food stuff. equipment. Dry Suitable for small Suitable. Chemical Suitable. chemical fire releases smothering Chemical is non-
gas and shields conductor or dry operator from heat. chemical shields
operator from heat.
Foam Suitable. Has both Suitable. Unsuitable. Foam smothering effect Smothering blanket being a conductor and wetting action. does not dissipate, should not be
floats on top of used on live spilled liquid. equipment. Water Suitable. Water Unsuitable. Water Unsuitable. Water
saturates material a will spread and not being conductor
6.10 Fire Protection:
Segregation buildings, fire resistant walls, flame arrestor, automatic fire
extinguishers.
Portable extinguishers, hydrants, sprinklers, fire water and trailer pump,
firefighting team and drills.
Safe access for firefighting, protection against lightening and ignition and detailed
provisions of fire exists.
CHAPTER 7 :- BAGGING & MATERIAL HANDELING
Storage silo with a capacity of 30,000 tones urea has been provided to ensure continuous operation in the event of non-availability of wagons or irregular seasonal demand for the fertilizer. Urea is bagged in polyethylene laminated jute bags. Bagging and material handling plant is a section of the production department. This is the plant where packing of urea product is done in bags and then it is loaded in trucks / wagons and sent to the market.
7.1 Types Of Conveyors, Machines, Heavy Equipments In This Plant
1. Product conveyor 2. Silo ingoing conveyor 3. Silo outgoing conveyor 4. Dust conveyor
5. Mini conveyor
6. Bagging plant conveyor 7. Hopper conveyor
8. UBM hopper conveyor.
7.1.1 Conveyors
They are made up of 4 ply Dunlop rubber joined by vulcanization. There are carrying rollers, return rollers, idlers, guide rollers and impact rollers. The conveyors are driven by a motor or gear box. There are rope switches for immediate stopping of the belt. There are skirt guards to prevent spillage and scrappers to clean the conveyor belt.
Product Conveyor:
This conveyor is inclined. It takes material from the urea plant and delivers to silo ingoing conveyor or bagging plant conveyor through a flap valve.
Silo Ingoing Conveyor:
This conveyor receives material from the product conveyor through a flap valve and delivers in silo.
Silo Outgoing Conveyor:
This conveyor is used to transfer reclaimed material from silo to bagging.
plant conveyor through vibrator screens.
Dust Conveyor:
This conveyor is used to deliver dust received from vibrator screen to silo.
Mini Conveyor:
This conveyor is used to feed material on bagging plant conveyor.
Vibrating Screens:
There are 4 screens to carry out screening of reclaimed material. Screen overflow (good material) is fed to bagging plant conveyor. The screens are manufactured by Pennwalt India Ltd. Screen size is 84”. The screens have a capacity of 26 ton per hours.
Transfer Tower:
The area where product conveyor material is delivered on the bagging plant conveyor tail end and the screens are located is called the transfer tower.
Silo:
It is a go down where urea material is stored.
Shape : Parabolic
Purpose : Storage of loose urea prills Capacity : 30000 tons Length : 210 meters Width : 37 meters Height : 18.5 meters 7.2 Detailed Description: 7.2.1 Conveying System:
From prill tower to urea storage building. From urea storage to bagging machines. From prill to bagging machines.
The control circulation for the control gear provides for remote starting of any of
the pre-selected route for prilled urea all the drives of the conveying system are electricity inter locked.
7.2.2 Empty Bag Handling:
Empty bag bales are lifted through two openings in the floor of empty bag store.
Bags with the help of two half tones cranes M-2133 A & B and one crane is second empty bag store. Besides lifting the bag bales, these cranes can be used for stacking empty bag bales in empty bag store.
7.2.3 Reclaim Machine:
This machine is used to reclaim the material from the silo and deliver it to the silo
outgoing conveyor. The main parts of the reclaim machine are the scrapper bottom, bucket elevator and link conveyor. By using scrapper bottom, material is
scrapped and delivered to the buckets from where the material is transferred to the link conveyor from the vertical bucket elevator.
The reclaim machine length of bulk urea storage building. Bulk urea is reclaimed
via scrapper, bucket elevator and belt conveyor and discharge on the reclaim conveyor M-2117.travels along the
Process:
There are 6 packer scale (P/S) or Bagging and Weighing machine along with six hoppers. Each hopper has a capacity of 12 Ton. One new P/S known as UBM (Universal Bagging Machine) which is fully automatic has also been installed.
When the machine is stopped, 45kg material is fed in the bucket through opening of two feed gates. Then one gate is closed which has a hole in the centre through which remaining 5 kg material is fed.
Then the second gate closes. When the bag is applied to the sock gap assembly, the bottom flapper of the bucket opens and the material is fed in the bag. The bag is then
released and it moves on the slat conveyor. Stitching of the bag is done and then the bag falls on the platform through chutes. The bag is then loaded into bucket / wagons or stacked on platform.
Specification Of The Empty Bag
Length : 915 mm
Width : 610 mm
Weight : 130 gm (+ or – 3%)
Material : HDPE
Color : Milky white with blue ton
Lamination : Inside laminations with 100 gauge thick. This is done to protect urea from moisture as it is a
hygroscopic material.
Stitching : stitching thread green in colour
Strength : Width wise
Bottom seam : 32 kgf
Rail tanker loading:
The surplus liquid NH3 from tanks is dispatched to IFFCO (Kandla Unit) through rail
tankers. For loading into rail tankers, five loading points are provided. At a time batch of five tankers wagons, each having capacity of 32 tone can be loaded to NH3 loading pumps each having discharge capacity o f 105 tone/hr at a pressure of 21.00 kg/cm2 are
installed.
Refrigeration system:
The NH3 storage tanks are fully & designed for maximum boil off of 0.04% per day.
Vapor pressure of NH3 is high even at atmospheric condition. To maintain nearly atmospheric pressure in tank, the vapour generated has to be condensed. This is done by taking the generated vapour from storage tank to the refrigeration system where the vapour are compressed, liquefied & returned to the tank in liquid form.
One refrigeration compressor having capacity of 540 kg/hr was installed with 10,000 tone NH3 storage tank. Two more NH3 refrigeration compressors having identical capacity
were added with installation of 5000 tone NH3 storage tank. These three refrigeration compressors are integrated to draw vapour from both the storage tanks. Also 150 mm NB pipe line is provided to take about 200 kg/hr vapour from both the storage tanks to NH3 plant refrigeration system through pressure control valve.
7.3 Effluent Treatment & Disposal:
Approximately 18000m3/day of raw water is utilized at IFFCO kalol mainly for process water & boiler feed water generation. Effluent treatment facilities have been installed to handle the 3500-4000m3/day bulk & 50-600m3/day strong effluent
coming out of various out of various plants every day.
Equipment specification:-
Strong effluent tanks Bulk effluent tanks
Balancing ponds Effluent pit
H2SO4 storage tanks
Effluent treatment system is installed to control the undesirable element in the liquid
effluent before discharging outside IFFCO premises.
Effluent discharge outside IFFCO should statutory requires norms imposed by state &
central pollution control boards.
7.4 Types Of Liquid Effluent:
The total effluent generated within the plants is divided into t wo categories & treated separately
Strong effluent: - Having higher concentration of dissolved compounds.
Bulk effluent: - Having comparatively less amount of concentrated dissolved solids.
This effluent is collected either into strong effluent tanks or bulk effluent tanks. Water from urea plant drains & washing is collected in separate tanks known as balancing ponds diverted to bulk or strong effluent as per its analysis.
Strong effluent & disposal:
The concentrated effluent from water plant is collected in strong effluent tank & discharged to solar evaporation lagoons inside IFFCO premise with the help of strong effluent pumps. Nearly 600m3/day of strong effluent is generated, collected in strong effluent storage tanks, mixed & then pumped to polythene lined solar evaporation lagoons having area about 15 hecters.
Bulk effluent treatment & disposal:
Effluent water containing comparatively very low concentration of pollutant is called bulk effluent. The effluent from following source is collected in bulk effluent storage
tank.
Water treatment plant with low concentration of salts
Cooling water blow down
From hydrolyser system during upset condition Sand filter backwash oil separator
Domestic effluent
HCL fumes scrubber water
Open channels domestic water collected at effluent pit is diverted to bulk effluent. Bulk effluent segregated from the water treatment plant is collected only in bulk effluent tank B & allowed to mix into tank A for better neutralization effect.
Weak effluent collected & mixed in weak effluent storage tanks to form bulk/combined effluent. Bulk effluent elements are controlled by adjusting the dilution water flow in normal operation.
About 3000m3/day combined effluent is pumped outside IFFCO premise. The effluent quality is continuously monitored within plant before final discharge to meet statutory requirement of pollution control board.
CHAPTER 8 :- ENVIROMENT & POLLUTION CONTROL
It accepts its duty to exercise care for health of employees & others which may be affected by operation & pollution. It gives equal importance to pollution control as any other activity.
8.1 Air Pollution:
The main source of air pollution from ammonia plant at IFFCO kalol are emition from stack of furnaces & boiler.
Primary reformer Secondary reformer Boiler
The concentration of sulphur being negligible in the RLNG & associated gas obtained from nearby well & flue gas remains below specified limit. However unit has SO2, NOx, CO analyzer for analyzing flue gas quality of ammonia plant & utility
8.2 Solid Waste:
Waste means any substance which constitute scrap material or an effluent oran other
unwanted surplus sub. arising from app. of any process
In ammonia plant at kalol mainly two types of solid waste are generated Spent catalyst from plant
ETP sludge
8.2.1 Disposal Of Solid Waste:
Spent catalyst are stored in drum & sell too gather company who has GPSB
authorized
ETP sludge collected from strong effluent tank mainly salt of Ca & Mg are filled in
bags & damped in GPSB approved site
Waste can also be removed by other methods like dilution ,incineration,
bioremediation, stabilization
To control the water pollution a centralized effluent treatment plant is installed. All the streams are collected in pond. After treatment & confirming by GPSB norms & s tandards it is discharged outside plant premise this water is utilized by farmers for irrigation
Mainly 18000m3/d Narmada water is utilized in plant for process water & boiler feed water generation. effluent facilities have been installed to handle 3500-4000m3/d bulk & 500-600m3/d strong effluent coming out of various plants every day
ETP contains
Strong effluent tanks Bulk effluent tanks Balancing ponds Effluent pit
H2SO4 storage tanks
ETP is installed to controlled the undesirable element in the liquid effluent before