10 Introduce a system of ensuring the commencement preparedness’ at the beginning of each batch of production of each product by including appropriate endorsement by shift in charge in BMR of each batch. This shall necessarily cover relevant safety precautions like PPE, Training, Pep Talks, raw material labeling, equipment readiness etc.. P. Fire Safety 1. Replace the existing plastic pipes with electrically conductive pipes for transferring of chemicals from reactors to centrifuges etc. 3 Extend the vents of centrifuges, reactor condensers, tray driers extended to outside the building as they were found terminated inside (vents are inside in PB-III) 4 Provide earthling to GLRs by using tantalum plugs and furnish the design data of the same. 10 Maintain the record for the periodical measurement for earthing and bonding continuity 11 Provide a Nitrogen generation plant in the factory arrange for Vacuum breaking with Nitrogen, Nitrogen blanketing centrifuges, filters and storage tanks etc 13 Provide flash back arresters to the vents of condensers, centrifuges, storage tanks, charging tanks, Dump tanks etc 17 Ensure the wheels of the trolleys , ladders etc are of conductive and anti friction type 20 Provide fire/smoke detection arrangements at all strategic locations and connect them with alarm systems. 21 Identify all process in total range of products mentioned in CFO where in serious explosion and flash fire hazards are present and propose them only in a segregated buildings 22 The equipment having serious fire hazard like reactors, centrifuges etc shall be isolated from rest of the work place. 23 Provide electrical interlocking to the dampers in ventilation with smoke/ heat detection system 31 Provide roof mounted hydrant rings over the equipment with flammable materials or DCP flooding systems if water is not recommended and connect them to fire/ heat detection systems in order to get automatically pressed into service in case of a fire. (Provide water sprinkling system to reactors in PB-II and PB-III, and also to the remaining two bays in the ware house) 34 The fire fighting systems in the factory are not in proportion to the fire load potential in the factory thereby the factory is not self sufficient. Get the fire safety audit done through an expert third party and submit the compliance report Q. Storage and Handling 3 Provide properly anchored & independently (without resting on the tanks) supported access and working platforms to PPFRP and HDPE storage tanks (non-metallic material)
4 Provide the bund walls independently to each of the Bulk storage tanks, process storage tanks, receivers containing flammable, toxic and corrosive chemicals (instead of common bund walls) 5 Provide substantial wire mesh covering all glass vessels, vents of glass vessels, flow meters etc to protect persons working nearby in the event of breakage of glass 9 Arrange for examination of the pipelines carrying flammable materials by a responsible person once in a week to detect any defect or accumulation of material and maintain the record 14 The existing body showers and eyewash fountains always be maintained in good condition. R. Equipment Safety 3 Get the doors of the cages of the material lift electrically interlocked to the operation of the lift / hoist itself so as to ensure the lift / hoist shall not move unless the gates are closed. 4 Provide interlocking to covers of centrifuges with their power supply 6 Provide for quick isolation with appropriate indication, to the plant or part of the plant or equipment, in case of an emergency 7 Centrifuges: Provide electrical interlocking to the lids of all the centrifuges Provide vibration sensors S. Electrical Safety 3 Provide Earth Leak Circuit Breakers in all the electrical circuits for human protection in case of electrocutions. 6 Provide rubber mats at all panel/switch boards b) The rubber mats should be examined periodically by an authorized person and record of such examinations shall be maintained and made available during inspection. 7 Arrange for the display of instructions, both in English and Telugu towards treatment of persons in case of an electrical shock at all important & conspicuous locations 8 Fume extractors (localized) should be provided, to extract fumes during welding, gas cutting operations. T. Personal Protective Appliances 3 Except the location specific PPE, wearing all PPE by workers like Safety shoes, helmets and goggles shall be ensured at the security gate as well as before commencement of work at the beginning of each shift. 5 Provide lockers to all workers including contract workers for storing their PPE, clothing etc., U. Additional Recommendations If Any: No Subject Recommendations 1 Standard Guidelines for Scrubbing Arrange for properly and suitably designed scrubbing system for gases generated during the processes & submit a note on this.