century rayon

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


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


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


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


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


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


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


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


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

)


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

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

PO

WE

R (

KW

H /K

g. Y

arn)


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'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

CA

UST

IC (K

g./ K

g. Y

arn)


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)


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

)


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

)


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'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

CA

UST

IC (K

g./ K

g. Y

arn)


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)


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

(Kg.

/ Kg.

Yar

n)

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