World Environment Day 2010 Theme - “Biodiversity — Ecosystems Management and the Green Economy”

1350 MTPD X 2 Ammonia Plants, 2300 MTPD X 2 Urea Plants, Off-site facilities, GTs with HRSG, H P Steam Boilers, Water Treatment Plants, Ammonia Storage, Bagging, Compressed Air, Inert gas, Effluent treatment

Management Systems

QUALITY MANAGEMENT SYSTEM (QMS 9001): Current & future needs of the organization, Current product and process performance, Benchmarking, opportunities for improvement, Results of Management Review, Self assessment results, Levels of satisfaction of interested parties, Legal concern in respect of product, Out come of marketing surveys

ENVIRONMENT MANAGEMENT SYSTEM (EMS 14001): Environmental Policy, Legal concern, Technological and Operational feasibility, Financial viability, Significant aspects , Resource Depletion, Interested Party Concern , Results of Management Review

OCCUPATIONAL HEALTH & SAFETY MANAGEMENT SYSTEM (OHSAS 18001): OH & S Policy of the company, Legal and other requirements. Significant Risks, Technological options and feasibility. Financial, Operational and Business requirements. Views of employees and Interested Party Concern. Past accident/ incidents data in the complex as well as in similar organisations, Results of Management Review.

PROCESS SAFETY MANAGENT SYATEM (PSMS): Establishing a Safety culture, Providing management leadership and commitment, implementing a comprehensive PSMS, Achieving operating excellence through operational discipline.

Based on our systems we are continuously giving dedication to all because of all the systems having their own significance.

Responsibility Regarding Systems

Section Head Responsible for implementation and maintenance of Management Systems (ISO 9001,ISO 14001,OHSAS 18001 & PSMS) in the section/area Identification of training needs including QMS, EMS, OHSAS & PSMS competency for personnel reporting to him and maintain competency assessment records Ensure employees in the section are adequately trained and instructed to carry out their assigned duties and responsibilities.

To identify the Aspects/Risks related to various activities in the section/area that can have potential impact on Environment, Health & Safety (EHS) w.r.t EMS,OHSAS and maintain a register and evolve control plans Evaluate the significant Environmental Aspects/OH&S Risks in the section/area and maintain a register, prepare & implement Operation Control Procedures and ensure existing controls are in place.

To propose objectives and targets from time to time and ensure effective implementation w.r.t QMS, EMS, OHSAS & PSMS pertaining to the section and to communicate to the concerned employees in the section.

To conduct communication meetings periodically to disseminate pertinent information required under QMS, EMS, OHSAS & PSMS.

To ensure that the connected Work Instructions & Operation Control Procedures are followed

To ensure the Emergency Preparedness plan is well disseminated and well prepared for meeting any emergency and ensure adequate number of persons are trained in first aid & rescue operations.

To assist HOD in QMS, EMS, OHSAS & PSMS related activities.

To ensure compliance w.r.t all applicable statutory regulations/ standards and also to ensure the requirements of safety & PSMS standards
Consider QMS, EMS & OH&S requirements while placing purchase/ service orders and approving such indents.

To ensure Environment protection & Safety is given due performance while evaluating employees performance Responsible for compliance of Recommendations on various audit observations and maintenance of records Report, investigate all OH&S incidents/ accidents, Environmental incidents or emergencies.

Ensuring maintenance of competency assessment records of contractors.

Shift in Charge
To assist SH in effective implementation of Management Systems in the section
To assist SH in identifying Environmental aspects/OH&S risks, Objectives & Targets for the section
To effectively implement Work Instructions & Operation Control Procedures in the functional area
To assist SH in imparting Management Systems awareness in the section
Provide a suitable level of supervision.

Table here (please visit PDF file attached)

To ensure good work environment in the section
To coordinate with sections concerned during upset conditions to minimize Safety, Health & Environment impacts.
Report all accidents/ incidents/emergencies & near misses and conduct preliminary investigations on such happenings.
Encourage employees to report defects and suggest improvements

Ensure right tool is used for the right job and defective tools/ equipment are taken out of use.
Conduct regular inspections of work sites to eliminate conditions and practices that could lead deviation from Management Systems.
Communicate the unsafe conditions and hazards to all concerned, including contract workmen and ensure timely actions are taken.

Allocate work in accordance with the employees level of competency
Ensure the availability of Personnel Protective equipment (PPE) and use of appropriate PPE by the subordinates.

Conduct regular OHS 5-Minute Safety talks with the staff, explaining the relevant measures and procedures in relation to their work and encourage greater awareness.

Collect feedback from the subordinates for improving Management Systems in the section/plant
Operator
To be aware of the Management System policy
To follow the Work Instructions & Operational procedures appropriate to the job
To assist SIC in improving the management systems performance in the work area.
To report unsafe condition/ act, defective equipment to the immediate Supervisor/ Engineer.
Always use the right tool for the right job
Don’t use defective equipment or misuse the equipment. Use tools which are tested and certified
To follow emergency preparedness plan in case of emergency
To report accidents, incidents, however small, and “near misses” to the supervisor and suggestions for improvement.
To maintain tools and equipment in safe working condition and reporting any defects to the supervisor
To participate in QMS, EMS ,OHSAS &PSMS meetings
To use appropriate PPE.

SUPPORTING STAFF
To follow the Work Instructions & Operational Control Procedures specified for the work area.
To assist SH/SIC/Operators to keep work environment clean

Common aspects of Systems

o Policy development and management commitment.
o Steering committee or management review committee.
o Nominating co-ordinator or management representative.
o Core teams involving sectional heads.
o Field level teams comprising of first line supervisors and workmen.
o Extensive and intensive training for all levels, including contract workmen – awareness programmes, practical training for understanding and implementing procedures and record keeping. Similarity of documentation, measurement, monitoring and control among the systems.
o Motivation through recognition and reward system.

Benefits derived

Process Safety Management System

Focused system approach towards process safety has proactively eliminated potential incidents in hazardous chemical (ammonia) handling and storage.
o Increased participation of employees and ownership of the system.
o Compliance to all safety regulations by contractors and contract employees.
o Changes to process involving hazardous chemicals carried out in a controlled and safe
way.
o Increased preparedness for emergency response.
o Continual improvement in process safety by regular compliance audits & incident investigations.
o Maintaining safety critical equipment in proper condition, thus avoiding incidents. Improved technical awareness of process hazards and safety systems contributing to safe work behavior.

Quality Management System

Focused attention on training and periodical internal audits, generated a sense of importance, which has particularly helped in improving effectiveness in product handling and bagging operations. The results were seen through reduction of off-spec generation and product losses.
o The practice of PDCA (Plan DO Check Act )and preparation of CAPA ( Corrective and Preventive Action) documentation under QMS (Quality Management Systems) has resulted in improving quality of the product and operations.
o Documentation of procedures and maintaining of records though cumbersome and time consuming has given good clarity of job requirements and sense of direction to employees.
The employee suggestion scheme as part of involvement of people brought solutions for chronic problems such as quality of finished products and reduction of losses.
o The sense of purpose programme under customer focus initiated by the organization has given greater scope for understanding customer requirements by the plant personnel, thus resulted in delivering of improved quality of the product to the customer.
o Adhering to schedules for periodic calibration of instruments measuring the quality parameters and conditioning monitoring of the equipment affecting the quality helped he organisation supplying the consistent quality of the product to the customer on sustainable basis.

Environmental Management System

Critical review of the existing systems as part of EMS helped in elimination of wasteful practices, identifying source of hazards and controlling inefficient operations resulting in energy and material conservation.
o Commitment towards statutory compliance and initiatives of better environment and energy management practices are the two major indicators of implementation of the system.
o The Aspect-Impact Analysis under EMS has thrown up the deficiencies in the system and by addressing the same statutory compliance could be ensured.
o Implementation of the systems has brought out cultural transformation amongst the work force including contract workmen, thus facilitating them carrying out the operations in a safe and environmental friendly manner.
o Implementation of EMS in line with ISO 14001 has lifted the organization to a new level of performance, winning many laurels particularly in housekeeping, sustained legal compliance with respect to liquid effluents, material and oil spillage control, hazard waste management and energy conservation.

Conclusion
For sustainability and to derive maximum benefit out of the systems, a holistic approach involving people and processes should be adopted.
o Like any initiative towards improvement, the implementation of the systems requires a cultural change amongst all concerned and the time schedule should allow for this.
o It is also important to explain and convince various operating personnel in the organization, the reasons to go for these systems.
o A team effort and commitment amongst employees including contract workmen, accepting their role in the process is highly desirable for the sustainability of the systems.
o The additional burden of documentation and regimented procedures is more than compensated by the benefits derived in form of organizational effectiveness.

The audit plan covers
a) The audit objectives;
b) The audit criteria and any reference documents;
c) The audit scope, including identification of the organizational and functional units and processes to be audited;
d) The dates and places where the on-site audit activities are to be conducted;
e) The expected time and duration of on-site audit activities, including meetings with the auditee’s management and audit team meetings;
f) The roles and responsibilities of the audit team members and accompanying persons;
g) The allocation of appropriate resources to critical areas of the audit. The audit plan should also cover the following, as appropriate:
h) Identification of the auditee’s representative for the audit;
i) The working and reporting language of the audit where this is different from the language of the auditor and/or the auditee;
j) The audit report topics;
k) Logistic arrangements (travel, on-site facilities, etc.);
l) Matters related to confidentiality;
m) Any audit follow-up actions.

The audit team leader, in consultation with the audit team, should assign to each team member responsibility for auditing specific processes, functions, sites, areas or activities. Such assignments should take into account the need for the independence and competence of auditors and the effective use of resources, as well as different roles and responsibilities of auditors, auditors-in-training and technical experts. Changes to the work assignments may be made as the audit progresses to ensure the achievement of the audit objectives.

Materials Handled: Natural Gas, Naphtha, Hydrogen, Chlorine, Ammonia, Carbamate Soln., Carbon dioxide, Nitrogen, Hydrochloric Acid, HDPE/PP bags, Sodium Hydroxide, Compressed Air

HAZARDS: FIRE, CORROSION, TOXICITY, EXPLOSION
Main Types of Audits: Compliance audit, Pre-acquisition/Due diligence audit. Regulatory compliance audit, Personal Protective Equipment audit, Fire prevention & control audit, Electrical safety audit, Ergonomics audit, Hazardous substances handling audit, Emergency response planning audit,
Audit Process: Audit scope Covers facilities & units, subject areas and criteria, Factors to be considered: Company policies, Regulatory requirements, Resource limitation, Time available, Nature of operation & risks

No single ‘correct’ approach
: Audit objectives, Audit frequency, Audit staffing, Audit techniques, Pre-audit, Audit, Post-audit, Audit reporting Audit follow-up: Internal Auditors: Low cost, Operational familiarity, Less independent Cover all sections, Monitor thoroughly, Train as many as possible, Quality matters not numbers, Choose from middle and senior levels, Conduct periodic refresher courses

Look for: Adequacy, Compliance, Effectiveness
OHSAS: Programs that enhance system performance, (Ex. Audit program, change control, document control), Programs that go beyond the core goals of the system, (Ex. Health promotion, off-the-job safety) Implementation rather than documentation, Has the Company gone beyond Statutory requirements, Conduct Surprise- Mock drills, House Keeping
Auditors to be seen as “Partners” Audit should “add value” and “stimulate progress”, Last word “Organized Commonsense”

Gas based fertilizer unit with high efficiency.
Has thousands of farmers as share holders.
Started production in the year 1992 at Kakinada in Andhra pradesh, India .
Doubled its urea production capacity in 1998, marketing upto 14 lakh tonnes of urea per year.
Urea being even to remote areas through extensive, strong network with more than four thousand dealers.
Commanding 60% market share in Andhra Pradesh, India.
Nagarjuna Urea stands first in Orissa and West Bengal also because of farmers preference due to quality.

Composition and uses of Nagarjuna Urea
Comprises 46 % Nitrogen.
Promotes quick growth of crop.
Pre-cursor for protein development, cell construction in plants.
Promotes lush green growth of crop.
Low cost source of Nitrogen.

Nagarjuna urea special features
Nagarjuna urea is pure and free from dust or impurities. It contains free flowing uniform hard granules. Hence this urea brings more nitrogen availability than any other Urea.
Nagarjuna urea has white granules of accurate weight and uniform size which can be conveniently broadcast in the field.

As the biuret content is less than one percent in Nagarjuna urea it won't harm the crop and makes the nitrogen available easily, quickly to the plants.
As the biuret percentage is low, Nagarjuna urea can be used for foliar spray also.
When Nagarjuna urea is applied to crop it supplies nitrogen for longer time.
Nagarjuna urea is suitable for all types of soils.


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ENVIRONMENT, HEALTH, SAFETY & QUALITY MANAGEMENT FACILITIES AT NFCL, KAKINADA, ANDHRA PRADESH, INDIA
R. RAGHAVAN, K. RAMCAHNDRA RAO, V. APPALA RAJU, *Dr AMAR NATH GIRI