20904081 century rayon
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CENTURY RAYONEnvironmental and Occupational Health & Safety Policy
Century Rayon is the leading manufacturer of Viscose Filament Yarn and Chemicals. The company is committed to the protection of the environment and the health and safety of its employees, customers and community.In this vein the company shall:Regularly review objectives for attaining continual improvement in environmental and occupational health and safety performance.Be committed to prevention of pollution. Implement continual improvement in resource conservation i.e.: Raw Materials and utilities like Energy and Water.Take measures and ensure safe work environment towards reduction of accidents. Monitor and control work place hazards.Train and involve company's employees and contractor's workmen in Environmental and Occupational health and Safety performance.Ensure compliance of legal and other requirements and strive for further improvement.Century Rayon is committed for a cleaner and healthier environment.The Environmental and Safety Policy shall be communicated to all persons working for or on behalf of the organization and is available to the public on request.
Date: 28.2.2007 President
CENTURY RAYONEnvironmental & Occupational Health & Safety Management SystemEnvironmental & Occupational Health & Safety Management System
ISO-14000 is a series of international, voluntary environmental management standards for better environment management.
OHSAS-18000 is a set of authorities through which an organization maintains awareness & control over its interactions with worker health & safety.
Interfaces directly with business objectivesInterfaces directly with business objectives
OverviewOverview
CENTURY RAYON
Environmental Aspect: Element of organizational activities or products or services that can interact with the environment.Environmental Impact: Any change to the environment whether adverse or beneficial wholly or partially resulting from an organization’s environmental aspects.Hazard: Source or situation with a potential for harm.Risk: Combination of the likelihood & consequences of a specified hazardous event.SSPD Score: Product of individual weightages of scale, severity, probability & duration.EMP: Environmental & Occupational Health & Safety management program includes objectives, targets & action plan.EPR: Emergency preparedness & response for potential emergency situation & accident.M&M: Monitoring & measurement of key characteristics that can have significant impact / harm.
DefinationsDefinations
CENTURY RAYON
Sr. No.
Particulars Remarks
1 Process flow sheet – aspects to be linked to process flow
activity. A. / H. no. included
2 Cross Reference for aspects / significant aspects & objects/ targets / programs
Implemented
3 Aspect of contributing factor to be rated Implemented
4 Procedure for issue, distribution & maintenance of PPE Implemented
5 External origin documents to be identified & records to be maintained.
Implemented
6 Objectives to be displayed and communicated through training.
Implemented
7 Incident report, Frequency Report, Severity Report, Trend charts of near misses , incidents & accidents
Implemented
Pre-audit Observations of M/s TUVPre-audit Observations of M/s TUV
CENTURY RAYON
Sr. No.
Particulars Remarks
8 Toe Guard for stair cases. Implemented
9 OCP to be modified as per clause 4.4.6. Implemented
10 Environmental program - procedure to be modified for review, changes, benefits & closure of EMP
Implemented
11 ETP - control measures to be provided for fall hazards.
Plan for DO probe in aeration tank. Aspect & impact evaluation of foam suppression
Implemented
12 Basic risk, residual risk with existing control, risk classification & corresponding control plan to be included in the procedure.
New format for Evaluation
13 M & M plan with frequency & for Key Environmental performance Indicators (Water, power & Air etc.)
Implemented
Pre-audit Observations of M/s TUVPre-audit Observations of M/s TUV
CENTURY RAYON
Sr. No.
Particulars Remarks
14 Companywide power consumption. 1% Reduction taken as an objective.
15 Trend of Environmental performance improvement. Implemented
16 Procedure for legal requirement to include updating, responsibility for liaison with statutory bodies, M & M etc.
Implemented
17 Evaluation of compliance- Legal / Statutory regulatory requirement. (PCB Act, Bio medical waste, MV Act, Battery Rules etc.)
Implemented
18 M & M (Legal) to be maintained at one defined department.
Implemented
Pre-audit Observations of M/s TUVPre-audit Observations of M/s TUV
CENTURY RAYON
Sr. No.
Particulars Remarks
19 M & M for maximum permissible discharge limit of sewage - evidence to be provided.
Implemented
20 Management programs for sewage treatment with defined action plan.
Not Required
21 Recycling of treated water & discharge of excess quantity through Waldhuni nallah - evidence to be provided.
Implemented
22 The quality & quantity of treated effluent discharged to ulhas river thru waldhuni nallah - evidence to be provided.
Implemented
23 The quality & quantity of effluent from each plant to ETP to be measured and monitored - plan to be defined against set norms.
Under Progress
Pre-audit Observations of M/s TUVPre-audit Observations of M/s TUV
CENTURY RAYON
Sr. No.
Particulars Remarks
24 Water consent order Form No. 5 - consumption for Industrial cooling - evidence to be provided.
Implemented
25 License for sulphur storage - evidence to be provided. Available
26 Monthly Form 3 of PCB to be filled for inventory / stocks of hazardous waste.
Not Required
27 Non-ferrous metal waste - to be included in form 13. Implemented
28 Investigation format for incident/ accident to include 4.5.2 clause of OHSAS 18001.
Implemented
29 Water Budget, Water balance as per permitted quantities by MPCB - evidence to be provided.
Implemented
30 Chlorine leaks , CS2 leaks , fire due to inflammable material to be included in onsite emergency plan.
Implemented
Pre-audit Observations of M/s TUVPre-audit Observations of M/s TUV
CENTURY RAYON
Sr. No.
Particulars Remarks
31 Management programs for storage of waste oil. Under progress
32 Hazards during cement unloading. Implemented
33 Identification of hazardous waste chemical containers. Implemented
34 Compressed gas cylinder - legal requirement for capping, color coding & safety distance, test date and due dates to be displayed on cylinders.
Being taken as EMP
35 Housekeeping in scrap yards. Implemented
36 Procedure for maintenance including plant - dust collectors, scrubbers, blowers, ETP equipment - records to be maintained. Test records from external agency for chain pulley blocks & EOT Cranes.
Implemented
Pre-audit Observations of M/s TUVPre-audit Observations of M/s TUV
CENTURY RAYON
Sr. No.
Particulars Remarks
37 Training - Contractors, material movers, sub-contractors & transporters - for outside & inside people.
Under Progress
38 Training Calendar to be made Implemented
39 Policy & Compliance with legal requirements to be displayed outside.
Under progress
40 Receiving, documenting and responding to communication from public to be updated & recorded
Implemented
41 ISI marking on First aid & Fire fighting equipments Implemented
42 Canteen – Aspects & Hazards due to LPG leaks, fire due to diesel storage, OCP for pest control, license for LPG cylinder storage
Implemented
Pre-audit Observations of M/s TUVPre-audit Observations of M/s TUV
CENTURY RAYON
Sr. No.
Particulars Remarks
43 Dust collectors - OCP for downtime analysis, PM schedules, spare parts & efficiency measurements
Implemented
44 List of E & S critical equipments – down time analysis of ETP, dust monitors,& efficiency measurements – records to be maintained.
Implemented
45 Drawing/Plot plan indicating domestic sewage lines, process waste lines, storm water drains, septic tank locations, ETP location, ambient air monitoring station, noise monitoring stations, hazardous storages, evacuation routes, entry, exits & assembly points. Sign boards at emergency exits to be provided
Implemented
46 Management Review – Agenda to be reviewed to include clauses
Implemented
Pre-audit Observations of M/s TUVPre-audit Observations of M/s TUV
CENTURY RAYON
Sr. No.
Particulars Remarks
47 Documentation System , Levels of Documentation, Review, Approval & Issue matrix.
Implemented
48 Master List of Documents & records. Implemented
49 Drinking water analysis – Chemical & Bacteriological – As per ISI Standards.
Implemented
50 Laboratory – Hazardous chemicals to be considered for Aspects / Impacts.
Implemented
51 Overall Roles & Responsibility – As per the Clause Implemented
Pre-audit Observations of M/s TUVPre-audit Observations of M/s TUV
CENTURY RAYON
1. Rayon Viscose (Production)
In GCF section no SSPD analysis carried out and aspects /hazards are made significant without analysis.
2. Century Chemicals Laboratory
Temperature is abnormal in chemical laboratory. It is unhygienic for staff and workmen especially during summer.
DETAILS OF NON-CONFORMITIES – CLOSED (ROUND NO. 1)
CENTURY RAYONTyre Cord Plant
Pulp Ratio – Apr ’05 to Mar.’07
1.028 1.026
1.026
1.026
1.026
1.0261.026
1.0231.025
1.025
1.035
1.028
1.031
1.022
1.024
1.026
1.028
1.030
1.032
1.034
1.036A
pr'
05-
Mar
'06
Ap
r '0
6
May
'06
Jun
e '0
6
July
'06
Au
g.'0
6
Sep
t. '0
6
Oct
.'06
Nov
. '06
Dec
. '06
Jan
.'07
Feb
.'07
Mar
.'07
Year
PU
LP
(K
g./ K
g. Y
arn
)
CENTURY RAYONTyre Cord Plant
Power Ratio – Apr ’05 to Mar.’07
3.273.4
3.77
3.58
3.23.43
3.673.62
3.31
3.39
2.92
3.12
2.82.7002.8002.9003.0003.1003.2003.3003.4003.5003.6003.7003.800
Ap
r'05
- M
ar'0
6
Ap
r '0
6
May
'06
Jun
e '0
6
July
'06
Au
g.'0
6
Sep
t. '0
6
Oct
.'06
Nov
. '06
Dec
. '06
Jan
.'07
Feb
.'07
Mar
.'07
Year
PO
WE
R (
KW
H /K
g. Y
arn
)
CENTURY RAYONTyre Cord Plant
Caustic Ratio – Apr ’05 to Mar.’07
0.706
0.7110.7140.720
0.730
0.747
0.730
0.717
0.725
0.760
0.7480.746
0.717
0.705
0.715
0.725
0.735
0.745
0.755
0.765A
pr'
05-
Mar
'06
Ap
r '0
6
May
'06
Jun
e '0
6
July
'06
Au
g.'0
6
Sep
t. '0
6
Oct
.'06
Nov
. '06
Dec
. '06
Jan
.'07
Feb
.'07
Mar
.'07
Year
CA
US
TIC
(K
g./ K
g. Y
arn
)
CENTURY RAYONTyre Cord Plant
Water Consumption – Apr ’05 to Mar.’07
33
38
32
28
3939
36 3737
38
28
30 32
242628303234363840
Ap
r'05
- M
ar'0
6
Ap
r '0
6
May
'06
Jun
e '0
6
July
'06
Au
g.'0
6
Sep
t. '0
6
Oct
.'06
Nov
. '06
Dec
. '06
Jan
.'07
Feb
.'07
Mar
.'07
Year
WA
TE
R (
Gal
lon
s)
CENTURY RAYONTyre Cord Plant
Steam Ratio – Apr ’05 to Mar.’07
19.77
20.35
19.58
20.77
21.47
20.52
18.21
21.53
20.66
21.07
22.31
20.73
21.51
18.0018.5019.0019.5020.0020.5021.0021.5022.0022.50
Apr
'05-
Mar
'06
Apr
'06
May
'06
June
'06
July
'06
Aug
.'06
Sept
. '06
Oct
.'06
Nov
. '06
Dec
. '06
Jan.
'07
Feb
.'07
Mar
.'07
Year
STE
AM
(K
g./ K
g. Y
arn)
CENTURY RAYONCSY Plant
Pulp Ratio – Apr ’05 to Mar.’07
1.115
1.044
1.1001.095
1.075
1.060
1.080
1.065
1.105
1.075
1.0671.065
1.059
1.0401.0501.0601.0701.0801.0901.1001.1101.120
Ap
r'05
- M
ar'0
6
Ap
r '0
6
May
'06
Jun
e '0
6
July
'06
Au
g.'0
6
Sep
t. '0
6
Oct
.'06
Nov
. '06
Dec
. '06
Jan
.'07
Feb
.'07
Mar
.'07
Year
PU
LP
(K
g./ K
g. Y
arn
)
CENTURY RAYONCSY Plant
Power Ratio – Apr ’05 to Mar.’07
4.534.46
4.053.94
3.83 4.16
4.74
5.11 5.27
5.48
5.435.74
5.86
3.500
3.800
4.100
4.400
4.700
5.000
5.300
5.600
5.900
6.200A
pr'
05-
Mar
'06
Ap
r '0
6
May
'06
Jun
e '0
6
July
'06
Au
g.'0
6
Sep
t. '0
6
Oct
.'06
Nov
. '06
Dec
. '06
Jan
.'07
Feb
.'07
Mar
.'07
Year
PO
WE
R (
KW
H /K
g. Y
arn
)
CENTURY RAYONCSY Plant
Caustic Ratio – Apr ’05 to Mar.’07
0.6300.630
0.630
0.630
0.640
0.650
0.625
0.620
0.625
0.6300.630
0.630
0.625
0.615
0.625
0.635
0.645
0.655A
pr'
05-
Mar
'06
Ap
r '0
6
May
'06
Jun
e '0
6
July
'06
Au
g.'0
6
Sep
t. '0
6
Oct
.'06
Nov
. '06
Dec
. '06
Jan
.'07
Feb
.'07
Mar
.'07
Year
CA
US
TIC
(K
g./ K
g. Y
arn
)
CENTURY RAYONCSY Plant
Water Consumption – Apr ’05 to Mar.’07
4948
42
39
42
47
50
5456
6061
56
39
38404244464850525456586062
Apr
'05-
Mar
'06
Apr
'06
May
'06
June
'06
July
'06
Aug
.'06
Sept
. '06
Oct
.'06
Nov
. '06
Dec
. '06
Jan.
'07
Feb
.'07
Mar
.'07
Year
WA
TE
R (
Gal
lons
/ Kg.
Yar
n)
CENTURY RAYONCSY Plant
Steam Ratio – Apr ’05 to Mar.’0743.69
34.81
36.02
28.63 28.26
41.19
43.2941.62
39.56
37.01
32.09
30.87
35.29
28.00
30.00
32.00
34.0036.00
38.00
40.00
42.00
44.00A
pr'0
5- M
ar'0
6
Apr
'06
May
'06
June
'06
July
'06
Aug
.'06
Sept
. '06
Oct
.'06
Nov
. '06
Dec
. '06
Jan.
'07
Feb
.'07
Mar
.'07
Year
STE
AM
(K
g./ K
g. Y
arn)
CENTURY RAYONACCIDENTS IN TYRE CORD PLANT
( Including Contract Workers )
3 3
5
4
2
3
2
4 4
2 2
1
5
1
1
4
0
1
2
3
4
5
6
Avg
. (20
05)
Jan
'06
Feb
. '06
Mar
.'06
Ap
r. '0
6
May
'06
Jun
e '0
6
July
'06
Au
g. '0
6
Sep
t. '0
6
Oct
. '06
Nov
. '06
Dec
. '06
Jan
. '07
Feb
. '07
Mar
.'07
Year
No.
of
Acc
iden
ts
CENTURY RAYONMaster List of Objectives & Targets
Tyrecord
Viscose (P)
To reduce CSY pulp ratio From 1.080 to 1.070
To reduce the total Energy consumption From 12000 kwh to 11880 kwh
Spinbath (P)
To reduce Steam consumption of Tyre Yarn From 20 Tons/Ton of yarn to 19.5 Tons/Ton of yarn
To reduce Filtered water consumption From 350000 gallons/day to 300000 gallons/day
Spinning (P)To reduce water consumption By 5%
To minimise viscose waste due to idle positions By 5%
Textile (P) To reduce the Mandays loss due to accidents to nil
MaintenanceTo reduce the total Energy consumption From 1.5 KW to 1.1 KW
To reduce the water pollution