ACKNOWLEDGEMENT

I take great pleasure while presenting this project report entitled as – “SAFETY
IN JUBILANT LIFE SCIENCES LTD”. This project work has been carried out at M/s
Jubilant Life Sciences Ltd. N-34, MIDC, Anand Nagar Add.,Ambernath, Dist : Thane -
421506 in partial fulfillment of the course – “Advanced Diploma In Industrial Safety,
Health & Environment” as requirement of MSBTE, Mumbai.

I am sincerely thankful to Mr. Sunil Nadkarni (V.P. –Operations) for granting me

permission to carry out project work at M/s. Jubilant Life Sciences Ltd, Ambernath. I
take this opportunity to convey my special thanks to Mr. Suhas Tari (Manager EHS) for
the support he has extended during completion of this project.

Lastly, I must place my gratitude to Mr. Rajendra Paynaik & Mr. Bapji Chaudhari for
providing guidance for successful completion of this project.

YOGESH DHEKALE

*****

1
 PREFACE

Chemical industries have grown and continue to grow up all over the world.
Variety of products, medicines / drugs manufactured in Chemical industries is essential
in day to day life.

The no. of chemicals handled during manufacturing are potentially hazardous to

human life and environment. Hence we should try to handle these chemicals in safe way
without damage to environment and ecology. By the days, superior manufacturing
techniques are being developed to achieve maximum production by using various safety
systems.

The main objective of this project is to focus on various activities carried out in
M/s Jubilant Life Sciences Ltd. from Safety, Health and Environment point of view.

*****

INDEX

2
Sr.
Contents Page No.
No.
1 Methodology 4
2 Introduction 5
3 Manufacturing Process 6
4 Process Flow Diagram 7
5 In Built Safety Measures 8
6 Environment, Health And Safety Policy 9
7 Organization chart of Jubilant Life Sciences, Ambernath 11
8 Role of management in promoting safety 13
9 Accident, incident – investigation and reporting 15
10 Accident statistics 17
11 Case study 19
12 Safety Training 24
13 Occupational Health and Hygiene 27
14 Environment conservation and protection 29
15 Safety in storage and handling of chemicals 30
16 Safe operating procedures 32
17 Material Safety data sheet 37
18 Work permit system 35
19 Fire prevention and fire fighting measures 39
20 Housekeeping 44
21 Colour coding 45
22 Personal Protective Equipment 46
23 Safety audit 49
24 Onsite emergency plan 50
25 Findings and recommendations 55

1. Methodology

The objectives of this project are:

 To understand various safety systems in chemical industries.
 To study safety organization and safety procedures.
 To study and prevent accidents at works by improving work atmosphere and
procedures.
 To examine and evaluate safety performance of company.

The following methodology is adopted for completion of this project are:

3
  Study of various unit operations, processes and plant procedures.
 Identification of hazard in manufacturing and handling of chemical products in
factory.
 Safety inspection rounds with EHS officer, EHS Manager.
 Study of safety training, training evaluation and effectiveness.
 Study of various safety systems in the plant.
 Discussion with managers, supervisors, workmen in order to get information on
safety related aspects.
 Study of previous safety performance reports.

*****

2. INTRODUCTION

Jubilant Life Sciences Limited is an integrated Pharmaceutical & Life Sciences

company. As India's largest Custom Research and Manufacturing Services (CRAMS)
player and a leading Drug Discovery and Development Solutions provider out of India,
it is constantly engaged in delivering value to its global customers through innovative
technologies, products and services.

The company is in the area of fine chemicals and intermediates production. It is in the
operation since 2006. Its production units are located in:
1. UNIT-1: Plot No. B-34, Wadolgaon MIDC, AMBERNATH(w)-421 501.
2. UNIT-2: Plot No. N-34, Anandnagar MIDC, Additional Ambernath Industrial
Area, AMBERNATH(E)-4210506

4
Manufacturing facility is located at additional Ambernath industrial area, Anandnagar
MIDC, Ambernath. It is in the state of Maharashtra and is located in approved MIDC
chemical zone. Jubilant Life Sciences Ltd has been manufacturing 2-Chloropyridine and
its derivatives.

Jubilant LifeSciences Ltd current manufacturing capabilities and product range is :

Sr. No. Product Maximum Quantity

MT /Annum
1. 2-ChloroPyridine 2040
2. 2,6-Dichloropyridine and other pyridine 364
Intermediates

As the market for intermediates is continuously growing at an exponential rate, company

has decided to increase its fine chemical and intermediates manufacturing activity.

5
 VISION, VALUES AND PROMISE

3. MANUFACTURING PROCESS

1. 2-Chloropyridine:

Pyridine and chlorine are heated at high temperature in a column and product is
collected. Bisulphite is added in product to prevent evolution of chlorine. Product is then
transferred to reactor, neutralized and distilled. Distillate is treated with acid to proper P H
and aqueous layer is separated.
Organic layer is then treated with alkali and collected for fractionation to get pure 2-
chloropyridine. Aqueous layer is made alkaline and distilled for pyridine recovery.
The residue after steam distillation which is a solution of organic salts is sent to Effluent
Treatment Plant.

2. Symtet :

Residue from 2-chloropyridine production is centrifuged, washed to get 2,6-

Dichloropyridine. 2,6-Dichloropyridine is reacted with chlorine in liquid state at 160-
1700C in presence of anhydrous ferric chloride to produce 2,3,5,6-tetrachloropyridine.
The obtained mixture is fractionally distilled using fractionating column to get pure
Symtet.

3. Other Pyridine Intermediates:

a) 2-Methoxy pyridine: 2-chloropyridine is treated with aq. Methanolic sodium

hydroxide at reflux. At the end of reaction methanol is distilled and recycled.

6
 Product is washed with water and distilled. The effluent is aq. Solution of sodium
chloride.
b) 6-Chloro-2-Hydroxypyridine: 2,6 Dichloropyridine is reacted with Solvent and
Caustic to form 6-Chloro-2-Hydroxypyridine which is then isolated by distilling
out extra tertiary butanol. The product is then acidified and filtered in centrifuge
and dried in tray dryer to receive pure 6-Chloro-2-Hydroxypyridine.

4. PROCESS FLOW DIAGRAM

DISPENSING

BATCH
INITIATION

REACTION

FILTRATION

PURIFICATION

FINAL
DISTILLATION

PACKING

7
 *****

5. IN BUILT SAFETY MEASURES

Different types of hazardous chemicals are handled and produced at M/s Jubilant Life
Sciences Ltd. For that, adequate safety measures have been incorporated in the plant
design. For different preventive measures, good engineering techniques have been
followed in the plant to minimize the hazards.

 Vessels containing hot processes are insulated and pipelines are provided with
flange guards.
 Flammable and toxic chemicals are stored and handled in a closed system to
avoid exposure to employees.
 It is ultimate goal of management to control the process and system safely.

To achieve this following in built control measures have been provided with existing
facilities.

 Rupture Discs, Safety Relief Valves:

In case of emergency or when reaction pressure is not getting controlled through
vents, the rupture disc, which is fitted in large diameter vent line, is useful to
avoid bursting of vessel and subsequent explosion.
Generally rupture disc is fitted prior to safety relief valve to avoid damage,
choking of SRV.

 Flame arrestor:

8
 Flame arrestors are provided in tanks and reactors containing flammable solvents
to avoid fire and explosion emergency. These flame arrestors are installed at the
end of vent line.

*****

6. ENVIRONMENT HEALTH AND SAFETY POLICY

Jubilant Life Sciences is Integrated pharma and life sciences company serving its
customers globally with recognized strengths in innovation, manufacturing and support
services. Jubilant endeavors to go beyond compliance with regulatory standards
achieving Environmental, Health and Safety (EHS).

We shall achieve this by

 Complying with regulatory standards on Environment, Health and Safety
 Optimizing resource utilization for pollution prevention, energy & waste
conservation and reduction of waste & emissions
 Identifying hazards at the design stage of the process & services and build
appropriate measures to mitigate risks.
 Ensuring safe & healthy work environment with necessary infrastructure and
systems
 Reviewing EHS performance for continual improvements
 Promoting EHS performance among key stakeholders
 Imparting training to operating personnel

The policy will be available in public domain and it is applicable to all Indian
operations.

9
October 14, 2010 Shyam Bang
(Executive Director)

Jubilant Lifesciences Ltd. recognizes importance of managing safety health and

environment matters effectively as an integral parts of its business activities.

For successful implementation of this policy the management contains the following –
• Take full cognizance of safety, health and environmental considerations in
project planning, decision making and conducting time to time audits /
inspections programmes.
• Assess and seek to minimize the impact of business activities on the environment
and communities in which its operations are located.
• Provide proactive and effective occupational health and hygiene programmes.
• Seek to achieve continuous improvement in its health, safety and environment.
• Comply with all statutory provisions with regards to health, safety and
environment.
• Investigate all accidents, even of near miss or minor nature and implement the
recommendations to avoid reoccurrence.
• Develop & maintain appropriate emergency response procedures and
contingency plans.
• Inform, educate, train & retrain the employees and contractors.
• Motivate employees to participate in safety, health & environment related
activities with the objective of achieving the highest standards in safety, health
and environment.
• All contractors, subcontractors, and transporters are responsible for maintaining
same standards of safety, health & environment as of Jubilant lifescience

10
 UNIT HEAD

HOD ENGG. HOD SAFETY HOD P & A HOD QC HOD R & D HOD SUPPLY
CHAIN

SAFETY SUB SAFETY SAFETY SUB SAFETY SUB SAFETY SUB SAFETY SUB
COMMITTEE OFFICER COMMITTEE COMMITTEE COMMITTEE COMMITTEE

11
*****

OCCUPATIONAL SECURITY
HEALTH CENTER DEPARTMENT

7. ORGANISATION CHART OF JUBILANT, AMBERNATH

DOMBIVILI
 PRODUCTION

COMMITTEE
SAFETY SUB
HOD

Comments and recommendations:

1. Organizational set up in Jubilant Lifesciences ltd. is very good.

2. The members of safety sub committee are directly reporting to HOD of the
concerned dept. Hence, this will be helpful for other employees to forward their
requirements in the work area regarding their safety and health.
3. Manager Safety is directly reporting to Location Head of the company.
4. The frequency of conducting Safety sub committee meeting is once in quarter
.The meeting starts with review of the earlier meeting minutes.

*****

12
 8. ROLE OF MANAGEMENT IN PROMOTING SAFETY

The management of company is highly conscious about safety, health and environment
and have provided an excellent facilities. The details about facilities are as –

1. Quality control department:

Quality control department is engaged with continuous monitoring of various organic
and inorganic chemicals in and around the factory. This laboratory is well equipped with
latest equipment in the field of pollution control monitoring appliances.
Instruments like gas chromatograph, thermal desorption system, spectrophotometer,
portable meters, sensors, detector tubes are routinely used for analyzing different types
of pollutants in the factory premises. Time weighted average monitoring is being carried
out with the help of gas chromatography coupled with thermal desorption system. With
the help of analytical data, control measures are adopted in the plants to reduce pollution
level. Highly qualified scientific officers and technicians personnel are deployed to carry
out the analysis.

2. Occupational Health Center:

Occupational health center facilities are made available in Canteen building .On regular
interval qualified doctor carry out annual & pre employment medical check up of
employees. Also visiting part time medical officer, MBBS, AFIH is visited at regular
interval .

13
In case of any emergency, the victims are shifted immediately to nearest M/s Chaudhary
Hospital, which is 5 km away from site.

3. Effluent Treatment Plant:

M/s JUBILANT has well established pollution control facility. The effluent is collected
& pre-chlorinated to reduce the COD. After chlorination the effluent is filtered and
filtrate is passed through Multi Effect Evaporator. The concentrated effluent is
centrifuged and the solid is disposed to CHWTSDF at Taloja.

4. EHS Department:
Safety department is equipped with all sorts of Safety , fire fighting equipments. The
maintenance of emergency equipment is the responsibility of safety department. Safety
Manager, safety officer conducts training programmes at different levels of employees to
eliminate accidents and to overcome emergency.
1. In house safety audit of process and storage units.
2. Personal protective equipments including respiratory and non-respiratory types
are provided.
3. Management has provided printed safety manuals, safety instruction board
regarding safety rules and safety policy.

5. Safety Competition:
Safety competitions are held at regular intervals on the eve of following days. Various
competitions like fire fighting, SCBA wearing, first aid treatment, housekeeping
competition, safety poem, written test etc.
 National safety day / week on 04th March of every year.
 World health day – 08th April
 Fire service day – 14th April
 World Environment Day – 05th June
Different activities of management to promote safety are as –
1. Safety Inspection.
2. Safety Audit.

14
 3. Safety in Process Training.
4. Accident, Incident investigation.
5. Maintaining of health and hygiene.
6. Conducting of Mock Drill – once in three months.
7. Formation of safety committee.
8. Housekeeping rounds.
9. Development of accident statistics.
*****

9. ACCIDENT, INCIDENT – INVESTIGATION AND REPORTING

Accident: Any unexpected or unintended event, which is having high potential to cause
damage to human being, property, or environment, is called as an accident.

The injured employee gets first aid treatment from first aid box provided at prominent
places inside the factory premises. If extent of injury is more, then concern employee is
send to nearest M/s Choudhary Hospital in company vehicle on priority basis. Further
medical treatment is given in M/s Choudhary Hospital as per the nature and requirement
of injury.

Accident reporting system:

1. Whenever any accident / incident took place inside factory premises, shift
Incharge attends victim and gives him / her first aid treatment. If required, he /
she is sent to hospital as per severity of injury.
2. Shift In charge does primary investigation and submits report to Plant Manager.
While carrying out analysis, following procedure is adopted –
a. To visit the accident site immediately.
b. Examination of site for noticing of any evidence.
c. Personal interview of injured person or any other eyewitness to find out
route cause of accident, incident.

15
 3. Concerned Plant manager starts further investigation immediately and send the
report to HOD Production and Safety dept, unit head.
4. Reportable accident as per Rule 115 of Maharashtra Factories Rules, 1963 is
reported to Authority in prescribed form (Form no. 24) by Factory Manager.
5. Safety department completes investigation and submits report to Location Head.

Accident Report:
Final accident report is made after investigation by joint team of safety officer,
production officer, and maintenance engineer. Help of QC or R & D is also taken in
absence of any member. Report consist of brief description of accident / incident, time
and place of accident / incident, cause of accident / incident, corrective and preventive
action taken, recommendations made by investigation team. All these points are
discussed with Director. Approved recommendations are implemented in plants through
project department.

Accident report to Government Agencies:

As per Maharashtra Factories Rule, 1963, Rule 115 form no. 24 and 24A are used to
send report of accident and dangerous occurrence to Factory Inspector respectively.
Depending upon source of injury, electrical or Boiler Inspector are also informed about
the accident. Explosion and fatal accidents are reported to Factories Inspector, Police
Inspector, Directorate Of Industrial Safety, Health & Environment (DISH), State
Pollution Control Board.

Accident Records:
Safety department maintains records of all accidents in the register as required under
Rule 123 of The Maharashtra Factories Rules, 1963. Safety department maintains

16
accidents and investigation reports. Location Head maintains an inspection book as per
rule no. 124 in form no. 31.

*****

10. ACCIDENT STATISTICS

M/s JUBILANT LIFESCIENCES LTD has developed accident statistics to serve as a

guideline for further accident prevention considering following points –
 To learn and know accident causes so that improving work conditions can
prevent similar accident in future, appropriate precautionary measures and
effective supervision.
 To attract the attention of management, supervisors, and workers towards hazards
involved in various processes.
 To find out actual facts to determine the legal liability and further information.
 Determination of injury rate for evaluation of safety performance.
 Use of fact-finding records for the purpose of safety analysis.
 Preparation of records for safety meetings, training and motivation to employees.
 To assist in evaluating the cost of an accident.
 For the determination of areas and operations most prone to accident, so as help
in accident prevention.

17
Comparison of Accident Rates:

Incidents 2011-2012 2012-2013

First aid cases 17 20
Non Reportable 1 1
Loss Time Injury
Total Incidents 18 21

Observations:

In year 2011-12, 17 first aid cases are noted while he number goes to 20 in 2012-13.
Non Reportable Loss Time Injury cases remain one.
Most of the first aid cases are due to splashing of residue while dechoking, minor burns
due to hot copper tubing.
Non Reportable Loss Time Injury in year 2011-12 was due to damage of catch pot where
the loss time of 5 hrs is recorded.
In year 2012-13, Non Reportable Loss Time Injury was due to splashing of acid droplets
on fore head. Loss time was 4 hrs.

Comments:

18
Safety performance of the Jubilant Life sciences is very good. (Frequency rate is 1.85
and 1.66 respectively in 2011-12 and 2012-13).
Most of the incidents were due to lack of communication and non compliances of PPE.

11. CASE STUDY

Case No. 01

Date: 05/09/2012

Location: 2-CP Plant

Accident details in brief:

Reactor R-207 bottom line shut down was taken for Tank Reactor R-210 line hook
up. After completing the line job near the reactor. Mr. Atul Singh opened the same
line flange some distance away from the shut down area for adjusting the line
tension, Mean while Production Officer Mr. Shinde who was not aware of the above
joint opening job started transferring of reactor R-210 assuming that job is
completed. Residue came out from the loose joint and splashed on the face & eyes
of Mr. Atul.

Type of accident:
Residue splashed in both eyes.

Underlying cause:
1. Lack of communication between Production Officer, operator & contract
workmen.
2. Improper shut down was given for R-210 line hook up.
3. Non compliance of PPE's & work permit system.

19
Recommendations:
1. Pump isolation should be done while giving the shut down at the discharge end of
the pump.
2. Tagging should be done strictly with safety work permit.
3. Face shield should be used while opening the pipelines carrying hazardous
chemicals.
4. Poor supervision.

Case No. 02

Date: 09/11/2012

Location: 2-CP plant

Accident details in brief:

Mr. Raju Shastri (Production Officer) was opening organic layer transferring valve from
tank T-7006 to tank T-7008 containing Pyridine. Mean the time. Mr. Sinha (Production
Officer) started transferring from the line which was opened from where pyridine got
splashed in left eye & face of Mr. Raju Shastri.

Type of accident:
Pyridine spillage on left eye & face.

Underlying cause:
1. Lack of communication between Production Officer Mr. Sinha & Mr. Raju
Shastri.
2. Tagging was not done to open line.

Recommendations:
1. Tagging should be done while doing the maintenance of piplines.

20
2. Counseling done for poor communication.

21
Case No. 03

Date: 12/08/2012

Location: Symtet Plant

Accident details in brief:

Mr. Kamble (Process Workman) was tightening the hand hole of filter SF-60 with the
help of spanners. While doing so, one of the spanners slipped from hand hole & hit
on right ear of Mr. Kamble causing injury. At that time, he was wearing pressure suit.

Ty p e of accident:
Cut Lascerated Wound to right ear inner laps.

Underlying causes:
1. Mr. Kambale applied excess force & lost his balance while tightening of hand
hole.
2. Lack of knowledge.

Recommendations:
1. On the job training should be given to Mr. Kamble.
2. Competent supervision is must in such type of cases.

22
Case No. 04

Date: 31/12/2011

Location: Tank Farm area.

Accident details in brief:

Tanker Driver Mr. Ramesh was bringing tanker (TN-31 M 6002) containing Caustic
solution at unloading point at non-explosive tank farm. Mr. Vishnu (Tanker
Cleaner) was giving signal to the tanker. Tanker driver applied breaks suddenly to
stop the truck & caustic solution came out through the manhole of the tanker.

Type of accident:
Caustic splashed in right eye of Mr. Vishnu.

Underlying cause:
1. Tank Farm operator did not do proper tightening of manhole after completing
the sampling work.
2. Improper work method adopted.

Recommendations:
1. After completing the sampling at tank farm, proper gasket & tightening should
be checked & confirmed by TF operator.
2. Personal Protective Equipment should be provided to tanker or truck Driver &
Cleaner during sampling activities on returnable basis.

23
Case No. 05

Date: 07/11/2012

Location: 2-CP

Accident details in brief:

Mr. Katkar along with Mr. Shinde (Fitter) was dechoking the mechanical seal of reactor
R-531 by purging steam. While doing so; steam hose joint broken & caused minor steam
burn on left side forehead of Mr. Katkar.

Type of accident:
Steam burn to left side of forehead.

Underlying cause:
1. Improper work method adopted by Mr. Shinde (Fitter).
2. Rubber hose was of insufficient length.
3. The rubber hose was connected with another hose to steam line.

Recommendations:
1. Alternative method is to be suggested by Engineering while de-
choking the mechanical seal rather than steam. so that burn injuries could be
prevented.
2. Sufficient length SS breaded hose (as per need) should be used.
3. PPE's like face shield should be used while handling steam - lines.
4. Counseling was done to Mr. Shinde (Fitter) & Mr. Katkar.

*****

24
 12. SAFETY TRAINING

Safety department for different categories of employees regularly imparts training.

The safety department prepares yearly plan for different training sessions. Seminars
& special training are conducted regularly in company on regular basis.

Seminar and workshops are conducted in the company on a regular basis for specific
subjects. Special training programs have been organized for middle management and
for engineering department officers. During the training, special attention is given on
work permit system. For the motivation and to assess the knowledge, they have
gained during the training; a written test is also conducted alter the completion of
training.

Company has trained staff to meet all kind of emergency. They have been trained in
different disciplines from Outside agencies. During the training, emphasis is given on
the properties of chemicals, its safe handling and effects on health. The importance of
good housekeeping is also taught.

Training need identification:

Whenever new employee joins a company, safety department took induction training
Same thing is applicable with the process workmen and contract employees.

Training tools:
1. Audio and videocassettes, CD's on various topics are available with safety
department. Modules are prepared on computer.

25
1. Process Workmen:
Training of Process Workmen is conducted as and when required. Following
topics are conducted during the training -
 General Safety Rules.
 Personal Protective Equipment demonstration.
 On the job training – sampling from reactor or drum, drum sucking,
handling of drum trolley and pellet trolley, solid and liquid material
charging, housekeeping.
 Operation of fire hydrant, fire extinguishers & safety shower.
 Learn First Aid, health awareness - CD show on television.

2. Contract Workmen :
Training for contract workmen is conducted as and when required.
Following topics are conducted during the training -
 General Safety Rules.
 Personal Protective Equipment demonstration.
 Work permit system.
 Safety precautions during – welding, gas cutting, painting, work at
height, etc.
 Operation of fire extinguisher, fire hydrant and safety shower.

3. New joining and Permanent Employees:

Training of new joining or permanent employees is conducted as and when
required. Following topics are conducted during the training -
 General safety rules.
 Safety in chemical laboratory.
 Personal Protective Equipment.
 Work permit system.
 Material Safety Data Sheet.
 On Site Emergency plan.
 Fire fighting training & demonstration.

26
  Operation of fire hydrant, fire extinguishers & safety shower.
 Accident, Incident - Causes and prevention of accidents, incidents.
 Operation of self - contained Breathing Apparatus.
 Written test & personal interview of the candidate

Comments and recommendations:

1. The training effectiveness is required to be evaluating as numbers of employees
are covered under safety training.
2. Training on Emergency Preparedness – frequency of training is to be increased.
3. Company is having good training program with excellent modules prepared by
safety department. Library contains lot of' hooks on the chemical process, safety
and occupational health.

*****

27
 13. OCCUPATIONAL HEALTH AND HYGIENE

Occupational health is responsible for recognition, evaluation and Control of hazards

in workplace. Both disciplines arc interdependent.
Occupational health management of any organization arises from following needs –

1. Treatment to the injured person on emergency basis. Providing first aid treatment to
all plant employees including their training in the same. To make provision of first
aid boxes in the plants with adequate medicines.
2. Pre-employment and post employment medical check up of employees.
3. Protect worker from occupational diseases or work related diseases.
4. Promote effectiveness of hygiene.
5. Maintenance of detail medical records of each employee from the date of joining
till retirement. These medical records should be attested by certifying surgeon.

The main objective of periodical check up is to detect abnormalities at earlier stages

and to find out adverse effect of chemicals on workmen. Depending upon the effects
and symptoms, special treatment is given if required. Each worker is subjected to do
thorough Medical check up at a fix interval of time depending upon the place of
work. The findings of medical check up are tabulated for individual.

 Details of first aid and hospital services available, its adequacy:

A) Treatment in occupational health center (OHC):
The employees who got minor / major injury during the all stages of manufacturing,
these are treated in OHC which is just 05 km away from company.
Doctors: Dr. Anuja Bhise is visiting to factory once in a week.

28
Communication - Telephone intercoms (4857).
Material Safety Data Sheet of chemicals handled in Jubilant is available of
Local Area Network (LAN).

B] Stretchers:
For quick rescue of the injured. Stretchers arc available in OHC.
C] First aid boxes:
First aid boxes are available in all manufacturing plants and other areas. These
boxes are checked periodically and consumed items are promptly replaced.
Following are the contents of first aid box provided in the various departments.

Sr.
Items Quantity
No.
1. Cotton wool 50 Gm
2. Roller Bandage 10 nos.
3. Dettol or Savlon 100 ml
4. Burnol ointment 01 no.
5. Adhesive plaster 1'' 01 role
6. Medicated dressing plaster 10 nos.
7. Tab – Paracetamol 500 mg 10 tablets
8. Nebasulf powder 01 bottle

14. ENVIRONMENT CONSERVATION AND PROTECTION

29
Industrial wastewater treatment and air pollution control are main areas concern
with health of workers. Due to various manufacturing processes, large quantities of'
wastewater, effluent and gases are emitted to the atmosphere; JUBILANT
LIFESCIENCES LTD has established pollution control facilities inside the factory
premises. All types of effluent is collected and sent to effluent treatment plant after
primary treatment for Multiple Effect Evaporter (MEE). Different types of control
measures have been taken to minimize emission of various gases to the atmosphere.
1. Air Pollution Measures:
Air pollutants mainly consist of toxic and poisonous gases like Sulfur dioxide,
Chlorine etc. To control air pollution, JUBILANT Lifesciences Ltd has provided
following facilities
a) Scrubbers for process reactor.
b) Dust Collectors for Boiler chimney
c) Portable and online Gas detectors.

Water pollution control measures:

M/s JUBILANT has well established pollution control facility. The effluent is collected
& neutralized. Neutral effluent is filtered and filtrate is passed through multi effect
evaporator. The concentrated effluent is centrifuged and the solid is disposed to
CHWTSDF for direct landfilling.

*****

15. SAFETY IN STORAGE & HANDLING OF CHEMICALS

JUBILANT handles, manufactures and stores huge quantities of various raw

chemicals like Chlorine, Pyridine , Sulphuric acid etc. In any type of chemical

30
industry taking utmost care does storage and handling of chemicals. This is the area
where possibility of' Untrained people meets chemical hazard.

Storage of chemicals:
Most of the raw materials, solvents used during manufacturing stages are stored at
atmospheric pressure and pipeline storing and carrying the chemicals arc fitted with
appropriate valves and fittings of standard specification. Tanks are fitted with vents
and flame arrestor, which are useful during loading and unloading operation. All
tanks are provided with earthing and are bonded on flange joints. Different types of
level indicators have been fixed on each tank. Each tank is surrounded by bund wall
and dyke wall. The connection of pumps for loading and unloading are kept away
from vicinity of the tank to avoid electrical hazards.
Every tank is provided with adequate fire fighting appliances. Also portable monitor
is provided in explosive tank farm. These tank farms are declared as prohibited area
and it is fenced from all sides. The operations of tank farm are done by skilled
persons and managed by a person with the rank of manager.

For storage handling and transporting of these chemicals following guideline are
used:
 Entry of unauthorized person in storage tank area is prohibited.
 As per Factories Act, 1948 all storage tanks are labeled with chemical name,
capacity and class of chemical.
 Competent person checks each storage tank within stipulated period.
 Dyke walls are provided to storage tanks, which are maintained carefully.

 Wherever required an effective neutralizing, arrangement is made with proper

drainage arrangement.
 Precautionary boards are displayed in storage area of chemicals.
 At overflow points, storage tanks are interconnected.
 Level indicators are provided to each tank.
 Earthing and Bonding is provided to each storage tank.

31
Company has well designed pipeline network from plant to plant, raw material
storage to plant and tank farm to plant. Maximum care has been taken to avoid
leakage from pipelines. Flange guards are provided to all flange joints. Pipelines
transport the chemical within the factory. The out side transport is done by tankers
and trucks through transporters. TREM cards are provided to transporters, which is
helpful to give information about the chemical and hazards associated it. It also tells
emergency handling procedure along with local police no. and information about the
manufacturer.

Comments and recommendations:

1. At some of places, continuity jumpers to flammable solvents carrying lines are
missing. Jumpers should be provided to each and every joint.
2. Flame arrestor inspection and cleaning should be done regularly.

*****

32
 16. SAFE OPERATING PROCEDURE

Safe operating procedure (SOP) is a important key of any process without which
one can't go ahead. It is a written document or manual, which contains various
process checks from safety point of view.

Availability of safe operating procedure:

One can refer safe operating procedures of various equipment operation and
processes, as these are under custody of HOD. These SOP's are containing various
checklists during or before starting any process or equipment. Safe operating
procedure is controlled document.

Safe operating procedure covers following points –

 Start up of plant.
 Steps to be taken for planned shut down and emergency shutdown.
 Preventive maintenance system from safety point of view.
 Personal protective equipment to be used for various type of operation.
 Safe handling and hazards associated with different chemicals.
 Information about the various interlocks & parameters to be monitored.
 Action to be taken in case of an emergency.

Comments and recommendations:

1. All types of safe operating procedures should be made available in the
operational area instead of keeping in the HOD cabin.
2. Concern HOD should impart training on sale operating procedures at regular
intervals.

*****

33
 17. MATERIAL SAFETY DATA SHEET

As per the manufacture, storage and import of' hazardous chemicals rules, 1989
rule 17(2) An occupier who has control of an industrial activity shall arrange to
obtain or develop information in the form of Material Safety Data Sheet. The
information shall be accessible upon request for reference.
As per the Maharashtra Factories Rule, 1963 rule 73(m), the occupier of every
factory carrying on a hazardous process shall arrange to obtain or develop
information in the form of Material Safety Data Sheet in respect of every such
substance or material handled in the factory.

Contents of MSDS:
1. Material identification & Use:
Chemical name, trade name, Synonyms, Chemical formula, Class of chemical.

2. Hazardous ingredient of Material:

Hazardous ingredient, approximate concentration, UN number, LD50, LC50.

3. Physical Properties of material:

State, odor. Colour, specific gravity, vapor pressure, vapor density, Boiling
Point, Melting Point, Solubility.

4. Fire & Explosion Hazard of material:

Flammability, LEL (Lower explosive limit), UEL (Upper explosive limit), Flash
Point, Auto ignition temperature.

5. Reactivity Data:
Chemical stability, Incompatibility, Hazardous decomposition product.

34
6. Toxicological properties of Material:
Routes of entry, Effect of acute & chronic exposure.

7. Preventive measures:
PPE to be used, leak & spill control. Handling procedure & Equipments to be
used.

8. Emergency & First aid measures:

9. Material handling and storage.

10. Additional Information / References:

11. Manufactures & supplier’s data:

In Jubilant Lifesciences, Material Safety Data Sheet of all chemicals used,
manufactured arc made available and accessible to all employees on local area
network (LAN). Material Safely Data Sheet of chemicals are also displayed on
board in Marathi and English in every plant building.

Comments and recommendations:

Translation of MSDS in to local language will be helpful to understand the terms and
conditions mentioned in the MSDS.

*****

35
 18. WORK PERMIT SYSTEM

Work permit is a statutory requirement under section 36 (1 and 2) of The Factories Act.
1949, The Maharashtra Factories Rule, 1963, The petroleum Rules 1976 (rule 172).

In JUBILANT list of person who is authorized to issue work permit of different

types is prepared and circulated to all departments.

 Usefulness of Permit system:

 Work permit provides -
 Written information oil the prevalent hazards connected with the job
performance.
 It spells out the Suitable remedial measures to be adopted to encounter
hazardous condition that are prevailing or that can be encountered while
performing the job.
 It indicates various PPE required to be used.
 It serves as a predetermined checklist for various safety precautions to be
taken.
 It also serves media of information to all concerned in advance.
 It provides written record of the operation including the personnel who are
involved in Authorizing & carrying Out the operation.

 Work permit is essentially a document that categorically spells out -

The task, equipment involved and its location, persons involved, time limitations and
precautionary measures to be adopted to encounter the hazardous condition effectively
that can arise while performing the job.

Work permit is consisting of various checklists filled by different departments.

36
1. Permitter Dept. checklist:
The department who grants permission to carry out certain job on particular
equipment or system is called as permitter department.

2. Permittee Dept. checklist:

The department who actually does the job on particular equipment or system is
called as permittee department.

 Types of work permits in Jubilant Lifesciences Ltd., are –

Type Name of Work Permit

Safety Work Permit for Entry in to Confined Space, hot work,
A working on Height, Excavation, demolition (major and
minor)
Safety Work Permit for work on machinery, electrical work, work
B
on pipeline, maintenance.

 Recommended guidelines for Entry into Confined Space:

 Blinding at nearest flange of equipment, tank, etc.
 Bottom line to be disconnected & open ends to be blinded.
 Vessel should be clean.
 Vessel should be smell free.
 Vessel should be cooled to Room temp.
 Dead blinds at the bottom should be removed.
 Wooden logs should be fixed for Reactor Filter.
 Manhole size should be proper.
 No Line connection should be done alter permit is issued.
 Lifeline holder should be present all the time when vessel entry is in
progress.
 Safety belt/Rope ladder / 24 volts lamp should be provided.
 Electrical isolation of accessories associated with tank, vessel should be
done.
 Permit hand over procedure should be followed.

37
 Recommended guidelines for Hot Work:
 Lines isolation from reactor / tank- for hot work inside vessel.
 Open tapping / pipe in area should be blinded.
 Equipment should be clean properly.
 Steaming should be done so as to make it smell free.
 Vessel, lank cooling should be done.
 Area around should be free from flammable material, atmosphere.
 Fire Fighter should be present during hot work.
 Fire fighting arrangement: Pr. water hose, Hydrant connection, Extinguisher
 Drain & gutter should be blocked
 Areas covering by flameproof clothes.
 Protection of cable tray/HDPE line.
 Electrical clearance of welding machine.
 Blower for Hot work inside the vessel should be made available.
 Permit hand over procedure should be followed.

 Recommended guidelines for Work at height permit:

 Healthy Scaffolding should be used.
 Working platform with railing at 1.5ft & 2.5ft height.
 Safe access to working platform should be provided.
 Provision of Roof ladder.
 Body safety belt with anchoring facility.
 Required PPF provision to workmen.
 Cordoning of work area.
 Hot surfaces to be covered.
 Another work permit with respect to job should be taken.

38
 Recommended guidelines for Permit for Excavation -
 Area should be cordoned.
 Isolate Moving machinery in & around the work.
 Open-end tapings should be blinded.
 Loose chemical streams around the work area to be removed.
 Underground pipelines, cables are isolate before starting excavation.

Validity of work permit:

All work permits are carried out only in daytime i.e. from 9:30 am to 17:30 pm.

Other requirements:
1. Entry into Confined Space & Hot Work Permits is filled in triplicate. In that,
Permittee Dept. will retain white copy. Safety dept. will retain pink copy &
permitter dept. will retain green copy.
2. For this permit, responsibility of permitter dept. / job initiator is more.
Initiator should ensure clearing , of vessel. tank & equipment. Initiator should
remove all flammable material from the surrounding area where hot work is to
be carried out. In case of hot work inside the vessel, exhaust blower should be
fixed for proper ventilation inside the vessel.
3. Work permit is required when working height is more than 3meter, roof ladder
is used while working on fragile roof. Metal scaffolding is used for making
temporary platform. The scaffoldings material selection and erection is done
as per IS-2750 of 1964.

Comments and recommendations:

1. Many of times, it is observed that pump isolation (removal of Fuses) is not
done in case of maintenance work at discharge end of pump or pipeline.
2. While erecting the scaffolding, metal hollow pipes should be used instead of'
bamboo and shall conform to IS standards.
*****

39
 19. FIRE PREVENTION AND FIRE FIGHTING MEASURES

JUBILANT handles processes and stores flammable, toxic chemicals. Therefore,

degree of potential for fire, explosion and health hazard is very much. Emphasis has
been placed on fire prevention including minimizing acts and conditions that may
result in a Fire or explosion. In addition to this, there are several natural and man
made causes of fire like - lightning, earthquake, heat radiation from Sun, cyclone,
chemical fire, electrical spark & short circuit, smoking in prohibited area, hot work,
ignition, mechanical and frictional heat, etc.

To meet these emergencies, JUBILANT has maintained all necessary equipment

required for fire prevention.

Hydrant System (Fixed Installations):

A) Details Water Reservoirs:
l. Fire Water Tank:
Water for Hydrant service is stored in 02 nos. of compartments of
underground Water tank, which feeds the fire fighting pumps through negative
suction.
The tank is located adjacent to fire Pump House.
Water Capacity reserved in Compartment No.100 M 3

Hydrant Water Pumps:

Two dedicated hydrant water pumps have been provided for Protection against the
fire. These pumps are mounted in pump house on fire hydrant storage tank. All
two Pumps are directly coupled to motors with non-corrosive body parts.

Jockey Pump:

It is designed to deliver the water at rate of 11 M 3/hr. It is always kept in auto

mode so that it always maintains the pressure in the system in between 7 to 8
kg/cm2.

40
Main Hydrant Pump:

The main hydrant pump is designed to deliver water at a rate of 135 M 3/hr. at a
pressure of 7 to 8 kg/cm 2. Whenever any hydrant point is opened, the pressure
of jockey pump came down to 4.5 kg/cm 2 and automatically main hydrant
pump starts.

Hydrant Circuit:

The hydrant system consists of tile underground Mains; single headed risers.
The system is maintained at 7.0 to 8.00 Kg/Cm 2 pressure by the pumps. Ring
main type i.e. each point gets water from two or more routes.

41
Extinguishers (Portable Fire Appliances)
A] Specifications

1] Carbon Dioxide Type:

1. 2 kg capacity Carbon DI Oxide fire extinguisher, fitted with horn and

locking pin, duly charged, along with fixing brackets and Screws, as
per IS 2878 bearing ISI mark. Manufacture's and CCE certificate is
must.
2. 5 kg & 9 kg capacity Carbon Dl Oxide lire extinguisher, fitted with
1M high-pressure hose and horn, duly charged, along with fixing
brackets and screws as per IS 2878 hearing ISI mark. Manufacture's
and CCE certificate is must.

 Operating procedure of Carbon Dioxide Extinguisher :

1. Remove the safety clip.

2. Hold the discharge horn.
3. Open the valve in anti-clockwise direction.
4. Direct the CO, let towards fire with sweeping action.

 Precautions:

1. Do not operate the extinguisher up side down.

2. Do not touch any metal part. It may cause cold burns.

42
2] Dry Chemical Powder (DCP) Type:

1. 10 kg capacity DCP fire extinguisher fitted with high-pressure

discharge hose, nozzle and G. M. cap. Complete with 1 set of refill,
CO2 cartridge, fixing brackets and screws. As per IS 2171 bearing,
ISI mark. Manufacture’s certificate is must.

 Operating procedure of Dry Chemical Powder Extinguisher:

1. Extinguishing material is sodium bicarbonate powder. Extinguishes fire by

smothering principle.
2. Remove the safety clip.
3. Hold the discharge tube and press squiz grip.
4. Strike the plunger.
5. Direct the DCP jet towards fire with sweeping action.

 Precautions :

1. Do not operate the extinguisher up side down.

2. Do not lean on extinguisher. Hold the extinguisher side by.

43
3] Chemical Foam Type Extinguisher:

9 lit. Capacity chemical foam fire extinguisher fitted with G. M. cap,

complete with 1 set of refill fixing brackets and screws, as per IS 933 bearing
ISI mark. Manufacture's certificate is must.

 Operating procedure of Chemical Foam Extinguisher :

l. Extinguishing, material is Aluminum Sulphate & Sodium Bicarbonate

solution. Extinguishes fire by smothering principle.
2. Lock the plunger.
3. Invert the fire extinguisher and mix two chemical solutions by tilting
extinguisher 2-3 times.
4. Direct the foam towards lire.

 Precautions:
1. Do not revert the extinguisher until it gets emptied or in operation.

4] Aqueous Film Forming Foam solution (AFFF):

These are excellent foam maker when mixed with water, helps to cease the
tire in least time. AFFF solution is very much useful in case of flammable
liquid or solvent fire.

Comments and recommendation:

1. Chemical foam extinguisher should be replaced with DCP extinguisher as it is
banned.
2. In Jubilant Lifesciences, good thing observed is that, fire fighter are well
trained and can handle fire emergency at any time.

*****

44
 20. HOUSEKEEPING

It respective of all preventive measures incorporated in the plant layout design,

good housekeeping is very much essential to have accident free and healthy
environment in the factory. Housekeeping is on top priority of JUBILANT. To
achieve this, following steps have been taken and implemented in entire factory.

1. Hazardous Solid waste is properly segregated and then sent for

incineration to Mumbai Waste Management Ltd, Taloja.
2. Factory has well equipped engineering department to look after the maintenance
of various plant. The different tools used by them are stored in tool racks. The
maintenance staff is also instructed to clean up the workplace after completion
of the job.
3. Dust beans are provided on each & every floor.
4. Good drainage systems are provided in the factory to avoid blockage. All these
lines are connected with effluent treatment system.
5. Latrines & urinals cleaning in all plants is done in every shift by housekeeping
personnel.
6. Sweeping is done once in a day in all plants.
7. Concrete road sweeping is done once in a week.

*****

45
 21. COLOUR CODING

JUBILANT LIFESCIENCES LTD has developed standard method of colour coding

of all the pipe lines and tanks carrying, storing hazardous chemicals. Because of
this, it is possible to identify the contents of pipeline when more than one pipe line
is passing from pipe rack or crossing over each other. Also company has provided
standard color-coding chart for different gas cylinders in every plant as per IS
standard 4739.

Direction of flow of chemical is also painted on most of the lines, which indicated
from where pipeline is coming and where it is going. These arrows are in either
black or white color in contrast with pipeline color.

All the storage tanks are marked with

1. Name of chemical.

2. Capacity of the tank.

3. Quantity of chemical filled or to be maintains in the tank.

4. Class material.

Comments and recommendations:

1. Colored signboards or pictures should be used to indicate about the hazards

associated in the work area. Because colored signboards or pictures attract
attention of human being due t which appropriate message will he sent to
workmen.

2. Weatherproof paints should be used while painting the structures inside the
factory premises.

*****

46
 22. PERSONAL PROTECTIVE EQUIPMENT

The Factories Act, 1948 has special provision (section 35, 36) of providing
Personal Protective Equipment to the workers who are exposed to unsafe and
unhealthy Environment.
The provision of law relating to use Personal protective Equipment in different
operation is formed in such a spirit that workmen on the operation and in the
process arc protected against all possible hazards.
Personal protective Equipment acts as a barrier and prevents accidental injury
but does not stop accidents. They are second lines of defense. When engineering
controls are failed then this line of defense comes to help. Although in plant
design and production we take all adequate care, we could not eliminate all
hazards. Personal protective Equipment protects us from injury due to dust,
fumes, noise, hot surface etc.
At Jubilant Life Sciences Ltd, all Personal Protective Equipments are provided
to all employees and to the contract workmen too. All Personal Protective
Equipment’s are purchased as per safety department recommendation. They are
purchased from approved supplier.
These personal protective Equipment are classified in to two categories based on
their use.
A) Non - Respiratory Personal Protective Equipment;
Following are the examples of non–respiratory protective equipment.
1. Helmets.
2. Ear Plugs and Ear Muffs.
3. Safety Goggle and Face Shield.
4. Hand Gloves (Acid alkali proof. Leather Gloves, Asbestos Gloves,
Electrical Gloves Cotton gloves).
5. Safety Shoes
6. PVC Apron.
7. Safety Belt.

47
B) Respiratory Personal Protective Equipment:
The respiratory system consisting of some vital organs of the body is very core of
human being. If it collapses, life itself is extinguished; hence proper protection
against these hazards is to be applied. The hazards can be classified as –

1. Oxygen deficiency -

a) Due to decayed organic matter.

b) Due to chemical reaction.
c) While working in confined space.
2. Gaseous and vapor contaminants:
Toxic gases may produce harmful effect.
Would endanger life of a person and inert.
3. Particulate contaminants:
Dust, fumes, smoke, mist and fog cab also damage respiratory system of
human being.
Following are personal protective equipment used as respiratory PPE's.
1. Dust Mask.
2. Airline respirator.
3. Self-contained Breathing Apparatus.
4. Canister Mask / organic vapor mask.

Quality of Personal Protective Equipment:

 Personal protective equipment received in the company are tested for its quality
rather than quantity. The frequency of inspection of personal protective
equipment is once in a month.
 If poor quality personal protective equipment arc observed, immediately they arc
rejected and feedback is Sent to the supplier.
 Before issuing any personal protective equipment From stores, it is inspected
thoroughly for its quality by store, EHS department.

48
Stock of Personal Protective Equipment:

Stores department maintains the stock of personal protective equipment.

Comments and recommendations:

1. If we will see the accident statistics in the previous chapter, we will come to
know that maximum accidents are caused due to non-compliance of PPE. It
is recommended that employees are to insist to wear PPE during working.
2. As lot liquid and solid hazardous are handled which can generate gases,
multi gas cartridge is required in canister mask.

*****

49
 23. SAFETY AUDIT

In JUBILANT LIFESCIENCES LTD has two types of audits are carried out. One is
internal and second is external. Safety department of company, once in a year
carries out internal safety audit. External audit is carried out once in a three year,
under MSIHC Rules 1989, safety audit is mandatory.
Safety audit is an important tool for identifying areas of risk, potential hazard in
plant.
In safety audit following things are seen.
 Identification of Hazards
 Site operations.
 Occupational Health and safety standard.
 Pollution control facilities.

There are three stages of safety audit

 Pre audit.
 On site activities.
 Post audit activities.
In first stage questionnaire are given to departmental heads and data is collected.
The visits of different plants are arranged, where compliance of parameters, data
collected from questionnaire is crosschecked. Auditor may ask some relevant
questions to workmen or departmental head. Based on this, report is prepared in
which strength or weakness of system is highlighted. Recommendations are also
given in this report. In post audit activities or action plan is prepared on
recommendations of auditor.

For internal safety audit, checklist is used for different departments while doing the
audit. It is attached as an annexure.
*****

50
 24. ON - SITE EMERGENCY PLAN

The Emergency could be as a result of abnormal functioning within the facility or

caused by third parties (tanker driver or others) or by natural factors. If the
implication of emergency remains within the boundary of the factory, it is called as
"ON-SITE EMERGENCY". If the implication of emergency crosses the boundary
and leads to damage to life and property of its neighborhood, it is called as "OFF-
SITE EMERGENCY". The main objective of the plan is to contain the emergency
within and to prevent off site implication.

The objectives in brief are follows:

1. To control the emergency, localizing the emergency and removing hazard.
2. Welfare of the employees managing emergency.
3. Head-count and rescue operation.
4. Treatment to injured.
5. Safeguarding others by timely evacuation.
6. Minimizing damage to the property and environment.
7. Informing and assisting relatives of victims.
8. Informing and collaborating, with statutory authorities.
9. Informing the news media.
10. Preserving records and organizing investigation.
11. Ensuring of the works before personnel re-enters and resumes work.
12. All clear siren.

Main Features of “ON SITE EMERGENCY CONTROL PLAN" JUBILANT LIFE

SCIENCES LTD is as –

First action plan:

Actions to identify, an emergency at am location in the factory premises and to
communicate the same to all those present in the factors premises and to the
concerned is the First Action plan.

51
A) Initial emergency communication:
 Person who observes an emergency [toxic gas leakage, lire, explosion, and heavy
leak spill of flammable-toxic liquids] is known as FIRST OBSERVER. He will
try to handle the situation at his own level; if condition goes out of his control
then he has to assess the same [whether to alert everybody within dept. / plant or
in vicinity area].
 After assessing the emergency, he has to break manual call point, provided on
each floor in plants and at various locations in the factory premises.
 At the same time a hooter provided at Panel Board will be sounded. The Assistant
Security Officer himself or through his security guard will get information about
Plant / Dept. and location [floor] of the emergency aroused. At this moment the
officer is knowing about the location of the emergency but he is so far not aware
about the type of emergency so he wait for emergency phone call to get further
information on emergency intercom no. 4815.
 After hearing the emergency hooter all people working in the plant will start bringing
the operations / activities in sale mode.
 The first observer will try to approach his superior to convey about his
emergency. But if he could not locate anybody then he can directly phone to
security on phone no.4815 and inform as per following guidelines :
o Observer's Name.
o Dept. Location of the emergency.
o Nature of the emergency.
 Once the Security Officer gets information on phone, he will reset the hooter
and sound the siren [Alert Mode]

B) Emergency handling procedure:

 On hearing ALERT siren and announcement on Public Address System,
all key personnel, controllers and team members will rush to their
nominated locations and take position for further actions.
 The Incident controller will remain at the spot of emergency.

52
 The Main controller will rush to the site. He will take his position close
to the site but not on the spot of emergency and take further steps
accordingly.
 The security guard will rush with Main controller's helmet and PPE’s and
will hand over to main controller, incident controller and the advisory
team members.
 The communication team members will take their positions in security
office at tile main gate.
 The nominated key person will rush to the spot of emergency and assist
the Incident controller.
 All first aiders, fire fighters and technical team members will delegate
the job to their co-workers, which they were doing at the time of
emergency. They will rush to the spot of emergency and report to the
incident controller.
 All other employees of the plant will stop their activities and bring the all
operations in shut down mode. They are not required to vacate the plant
unless the Incident Controller/Main controller instructs or condition has
become unbearable.
 The advisory team members and communication team members will
inform to main controller about their locations on walkie-talkie.
 The Main controller will continuously assess the situation by taking feed
back from the incident controller. Accordingly he will instruct
communication team members. He will contact advisory team members to
Let essential information if he is required but if he does not require taking
help from advisory team. he can assign other jobs to advisory team. The
option is completely left to the main controller.
 Once the emergency is brought under control, main controller will inform
to communication team to sound 'ALI. CLEAR' siren and announce on
PAS about completion of emergency.

53
D) Evacuation Procedure:
Once the main controller realises that the emergency is not controllable easily, he
will instruct communication team to sound siren (waning and waxing) and
subsequently announcement for evacuation on Public Address System.

On hearing evacuation message on Public Address System. Evacuation Team

will guide personnel towards assembly point.

After guiding the personnel to assembly point learn will physically confirm
evacuation then only they will leave for assembly point. At the assembly point
they will carry out HEAD COUNT (attendance) to ensure complete
evacuation. It is essential that they should know number of persons present in
that area prior to the emergency.

Assembly points:
In the premises three assembly points are identified and declared as follows –

ASSEMBLY LOCATION

ASSEMBLY POINT 1 Near canteen

ASSEMBLY POINT 2 Main Security Gate

54
Salvage operation:

Procedure of salvage operation:

The salvage operation will be carried out under guidance of salvage committee
consisting of advisory team members and headed by main controller.
The committee will conduct accident investigation, assessment of damage / losses.
The committee will hold a meeting and schedule a time bound programme for
salvage operation. The committee will form various groups to carry out the operation.
The brief information is as follows:

Details of Communication facilities available during Emergency and those

required for an Off - Site Emergency:

List of facilities:

Facility Purpose

Emergency Hooter system in the To alert plant personnel and security

Plants
To inform all in the factory premises
Manual Call Point about fire & gas leak
For main controller, outside people in
Telephone the vicinity

*****

55
 25. FINDINGS AND RECOMMENDATIONS

1. Unwanted lines shall be removed so as to avoid congestion in the

process area.
2. The safety policy of company comprising of responsibility of
individual employee at different levels.
3. Organisation set up in M/s JUBILANT LIFE SCIENCES LTD is very
good.
4. EHS Manager is directly reporting to factory manager. Hence
suggestions raised in safety meeting are directly communicated to higher management
through safety manager. This is helpful to make compliance of such points at the
earliest.
5. Frequency of conduction of safety meeting shall be revised, as it is not
conducted regularly.
6. It is observed that most of first aid cases, incidents are caused due to
following reasons –
a) Non-compliance of PPE.
b) Improper work method adopted.
c) Poor supervision
7. Name of safety defaulter shall be displayed in each department;
counseling is also to be done.
8. The safety training effectiveness is to be evaluated.
9. First aid training frequency shall be increased. Contract employees can
be trained in first aid.
10. The pipelines, equipments, systems containing flammable liquids, gases
shall be provided with continuity jumpers so as to avoid risk of fire.
11. Frequency of inspection of flame arrestor shall be carried out once in a
year.
12. Bamboo shall not be used while erecting scaffolding. Standard
scaffolding pipes shall be used.
13. Fire fighting training frequency shall be increased so as to cover all
employees.
14. Emergency lighting shall be provided in case of power failure.

56
15. Minimum PPE”s shall be provided in cupboard so that can used in
emergency.
16. Drainage system shall be improved inside as well as outside process
area.

*****

57