Health and Safety

Health of the employees is given utmost importance in KRIBHCO. Due care has been taken to ensure that health of the employees and of contract workers are not affected due to its business activities. Health care facilities are available round the clock for the employees and their dependent family members, contract workers, resident of neighboring villages. Hospital’s Integrated Management System (IMS) is certified by M/s Indian Register Quality System, Mumbai in line with international standard ISO-14001 and OHSAS 18001. Kribhco hospital is 30 bedded with all infrastructure and medical facilities providing medical care round the clock. Four ambulances fully equipped with oxygen cylinders, foot operated suction machine and portable vital sign monitors are available to cater any emergency situation. Due care has been taken for Bio-Medical Waste (BMW) being generated at hospital and disposal of BMW is being carried out as per statutory norms.

HEALTH CARE ACTIVITIES AND SERVICES PROVIDED

1. Out- Patient Care
2. In Patient Care
3. CARE Accident and Emergency
4. Medical Surveillance
5. Health Education
6. School Health Program
7. Health Awareness Camps
8. Blood Donation Camps
9. Occupational Health Services
10. Free Medical Camps for Under Privileged

NATIONAL HEALTH PROGRAMMES

1. Universal Immunization Program
2. Pulse Polio Immunization Program
3. National Malaria Control and Eradication
4. RNTCP
5. Filaria Eradication Program

Specialists in various fields of medical science are appointed as visiting doctors in the hospital. Annual medical examination is conducted for all the employees to keep track of their health records. The first aid centre at KRIBHCO Fertilizer complex is operational round the clock and is integrated with KRIBHCO hospital situated in the township premises. Regular first aid training and occupational health awareness programs are being conducted at HRD. Public health awareness programs are conducted in township by experts on different health related issues. CDs on health related topics are displayed on cable TV.

KRIBHCO Hazira plant is one of the largest fertilizer plants of India.  Understanding its social responsibility, KRIBHCO is fully committed towards continual improvements in the fields of safety, health and environment (SHE). In this direction, KRIBHCO has not only incorporated ISO 9001-2008, and integrated ISO 14001& ISO 18000 Management Systems as an integral part of its operations, but is also improving upon them continuously.

KRIBHCO has separate departments to look into the safety, health and the environment aspects respectively.

The safety setup of KRIBHCO Hazira Plant has been established with a vision to achieve its slogan of “SAFETY FIRST; PRODUCTION MUST.”

1. Safety objectives of the Hazira plant have been derived from following VALUES of KRIBHCO:
2. Creation of safe, efficient and pleasant working environment in the plant
3. Continual Enrichment of Safety culture of the plant.
4. High level of emergency preparedness at all the time
5. Extending support to the neighbouring villages, industries and government agencies for any emergency mitigation beyond plant boundaries.

To achieve the above, following systems following systems and infrastructures have been set up, maintained and continually improved upon.

1.SAFETY IN PROCESS:

The safety aspects of each department monitored by top management in regular weekly / monthly meeting held for each plant / department separately.

2.SAFETY IN MAINTENANCE:

Effective Safety work permit system.

Jobs of hazardous nature carried out under the supervision of Fire and Safety personnel.

3.SAFETY INSPECTIONS:

Following types of safety inspections are conducted at regular intervals. The recommendations of these inspections are incorporated in the existing system for continual improvement in the OHS environment of the plant. In each shift by Fire & Safety personnel.

1. Daily Rounds
2. Periodical plant safety inspections by Safety managers along with the production & maintenance engineers.
3. Periodical audits by internal & External Auditors of ISO 9001 & ISO 14000-18000 integrated management systems.
4. Specialized Third party Safety Audit, Risk Assessment, and Hazard and Operability analysis are conducted at regular intervals.

4.ACCIDENT INVESTIGATION SYSTEM :

There is an established system for investigation of any injuries / dangerous occurrences with a view to find out the facts and to implement the corrective and preventive actions

5.SAFETY COMMITTEES:

Two tier safety committees are operational in KRIBHCO

1. Plant Safety Committees
2. Central Safety committee

6.SAFETY DURING ADDITIONS / MODIFICATIONS:

When any modification is planned or any new equipmet / structure is installed in plant, it is ensured that no safety aspects are compromised.

7.SAFETY AWARENESS:

1. Boards and hoardings have been displayed at various locations to create safety awareness amongst the employees.
2. Safety pamphlet is given to all the visitors coming into the plant. This covers relevant safety and emergency response information of the plant.
3. KRIBHCO Safety manual has been issued to all employees of the plant. Nearby villagers and KRIBHCO Township residents are made aware of the action to be taken in case of Ammonia leakage.
4. Safety video films are screened on cable TV in township from time to time.
5. Safety related competitions are organized for permanent and contract workers (and their families) every year.

8.EMPHASIS ON TRAINING:

In KRIBHCO training on Safety takes the top priority. The safety training includes safe behaviour and conduct in the plant, general safety rules, hazards in the plant, use of personal protective equipment, basic fire fighting, response to various emergency conditions etc.

1. On joining, all employees are given induction training on safety. No worker or labour is permitted to work in plant without the induction safety training.
2. Refresher safety training is imparted from time to time.
3. Training sessions on First-Aid are conducted by internal and external doctors.
4. At shop-floor level also, safety related lectures and fire fighting practicals are conducted regularly.
5. Practical fire fighting training is imparted to various categories of employees at the KRIBHCO Fire and Rescue training ground.

Fire and Safety personnel are periodically sent to reputed professional Institutes like CLI, Mumbai; GSC, Vadodara; NFC, Nagpur; NCDC, Nagpur etc. for up-gradation of their skills awareness and knowledge.

9.FIRE ALARM AND GAS DETECTION SYSTEM:

The entire plant area is covered by state of the art automatic and manual fire and toxic gas alarm system. The system consists of various types of modern generation detectors suitable to the nature and location of the hazard.

10.FIRE PROTECTION AND FIRE FIGHTING SYSTEM:

The fire protection systems have been designed on the basis of TAC guidelines. KRIBHCO has a full fledged Fire Station equipped with three major fire tenders, one DCP tender, one emergency/rescue tender, speed boats, an ambulance  and other auxiliary vehicles & equipment.

The entire plant is served by Firewater ring main (Approx. 30 Km) and maintained at around 8.8 Kg/cm2 pressure with the help of two jockey,  pumps, two engine driven pumps and four electric motor driven pumps. The automatic pump switching system and sufficient quantity of raw water ensures total reliability of the fire hydrant system at all the times.

State of art fire suppression system such as sprinkler system, CO2 flooding, FM200, FE227, Foam system etc are suitably provided in appropriate quantity to protect delicate and critical equipment like turbo generators, computer rooms, DCS panels, Fuel tanks, transformers, lube oil console etc,

Special water diffuser nozzles and water curtains are provided for knocking down the escaping ammonia vapours at critical locations like Ammonia storage loading area, Ammonia pumps, control rooms etc.

Around 1000 portable fire extinguishers of various capacities and types are provided to cover the entire plant for first-aid fire fighting purpose

11.EMERGENCY PLANNING AND PREPAREDNESS:

KRIBHCO has established procedures to identify potential accidents and emergency situations in the plant. These emergency situations, all the aspects for mitigation  are documented in the form of an “ON SITE EMERGENCY PLAN” (OSEP) of KRIBHCO. The “OSEP” has been made available to all concerned through hard and soft copies.

To check the effectiveness of the emergency plan, mock drills are carried out at regular intervals. On Site Emergency Plan is reviewed and updated regularly.

12.SAFETY EQUIPMENT :

Around 100 Breathing Apparatus Sets including full duration SCBA, Escape sets, Air line sets, Fire entry suits, Chemical entry total encapsulating suits etc. have been provided at various locations in the plant

13.INSPECTION, TESTING AND MAINTENANCE OF SAFETY EQUIPMENT:

Fire and Safety personnel carry out routine inspection and testing of all safety & emergency equipment in three shifts.

In addition to the routine maintenance, periodical testing and maintenance of Gas alarms, fire alarms, air liners, BA Sets, Gas canisters, Hydrant systems etc is also carried out by the teams consisting of professionals from Fire & Safety, Maintenance and production departments.

Comprehensive records of all testing and maintenance activities are such  maintained

Safety checks are also carried out for the empty ammonia tankers entering the plant

14.MUTUAL AID SCHEME:

To cope with any major emergency, a mutual aid scheme has been developed amongst nearby industries – ONGC, RIL & NTPC. Major emergency exercises are carried out once in a year involving on site resources and the nearby industrial fire services & Surat Municipal Corporation Fire Services.

15.EMERGENCY COMUNICATION SYSTEM:

Direct communication system from all the emergency vehicles to fire control room

Emergency phone numbers displayed at various locations in plant and township.

Direct communication system with fire control rooms of neighbouring industries and Surat Municipal Corporation.

ACHIEVEMENT – HONOURS & AWARDS:

With the combined efforts of the one and all, KRIBHCO has been recognized by several prestigious national (e.g. GSC & NSC) and international safety organisations (e.g. National Safety Council - USA , ROSPA - UK & Greentech Foundation- New Delhi).

CONCLUSION:

Due to its social values and powerful safety programme KRIBHCO has been on the forefront of  Firstly Protecting the human life at any cost by ensuring utmost safety in all of its processes; Secondly being fully prepared for any type of emergency so that the losses, in respect of life and plant property, are  kept at bare minimum; and Thirdly to strengthen the confidence of its employees for working in the plant with high dedication & morale . Accordingly, KRIBHCO has successfully spread the message to one and all that,

“SAFETY IS AN INTEGRAL PART OF ITS BUSINESS PROCESS”.