EXECUTIVE SUMMARY & RECOMMENDATIONS

The audit team of M/s ABC Engineers (P) Ltd., Meerut visited the 160 KLPD distillery of
Amba Sugar Limited, Mawana, Dist. Meerut on 28.12.2017 for carrying out the
Occupational Safety & Health Audit as per IS:14489. The general comments and
recommendations are given below:

1. Plant housekeeping was found to be very good.

2. Pollution Air consent of the factory is valid upto 31.12.2017. It is recommended

to follow-up with concerned authorities for its further renewal.

3. It is recommended to have hand siren near alcohol processing/ storage areas

for faster communication during emergency.

4. SOPs are displayed at few operating points at the distillery. It is recommended to

cover all major points and display standard operating procedures.

5. It was observed that though the security staff was found alert on duty but the
physical frisking is not 100%. There is scope for improvement and it should be
ensured to record and physically check every person entering the premises.

6. Loose cables were observed at the MCC as shown and there is need to review
same at all electric control rooms and corrective action may be taken.

7. Auditors were informed about the many recent improvements in fire fighting
arrangements at the factory. It is further recommended to upgrade these
arrangements as per the item “Part B- General Recommendations“ mentioned at
page 3 of HAZOP study of the plant already conducted.

8. Distillery has an ON-site Emergency Plan. It is recommended that everyone at

the distillery should be suitably informed of its various provisions either during
training or otherwise.

Date: 15.1.2018

(Er.SK GUPTA)

---------------------------------------------------------

(Signature of authorized rep. of the distillery)

 CHAPTER-1

INRODUCTION

1.1 PREAMBLE

Amba SugarSugar Limited (BHSL) was incorporated on 23rd November, 1931 under
the name - The Hindusthan Sugar Mills Limited – on the initiative of Jamnalal Bajaj - a
businessman, confidante, disciple and adopted son of Mahatma Gandhi. He sought
Gandhiji's blessings in this new venture, which, apart from being a sound commercial
proposition would also meet a national need. Till then, there were barely thirty sugar
factories in the country.

In the year 1988, The Hindusthan Sugar Mills Limited was renamed as Amba
SugarSugar Limited and shortly thereafter in 1990, Sharda Sugar & Industries Limited
was amalgamated with Amba SugarSugar Limited.

The Company embarked on an aggressive Greenfield expansion drive in 2003-2007,

starting with a plant at Mawana, near Meerut (UP), which was completed in a record
time of just seven months as against the industry norm of 18-24 months. This facility
commenced commercial production in November 2004.

Amba Sugar Limited (Distillery Unit), Mawana, Meerut was established in 2006 and
commenced production in the same year itself..

Amba Sugar Limited, Distillery Unit, Mawana, Dist. Meerut being a prestigious unit of
Amba Sugargroup, needs a well planned strategy for the smooth functioning of the
plant. For the successful Implementation of any plan related to the safety of the plant it
is essential that the various departments and every component of the total system
should be examined critically , this systematic critical examination with the aim of
minimizing loss to organization is termed as “ SAFETY AUDIT ‘’. In safety audit every
component is included e.g. Management policy, attitude to training, features of the
process and of design, emergency plans, personal protection, accident records, medical
& first aid facilities etc. An Audit (as in the field of accountancy) subjects to discuss the
strength and weakness and vulnerability of risk.

The Safety Audit for M/s Amba Sugar Limited, Distillery Unit, Mawana, Dist. Meerut has
been carried out as per the guide notes given in the “Indian Standard code of practice
on Occupational Safety & Health Audit (IS -14489, 1998)’’. The audit research and
recommendations are based on the process data, background information and
discussion held with plant personnel during audit activities. Besides, the auditors have
exercised all reasonable skills and care in carrying out the study.
“ABC ENGINEERS (P) LTD.’’ conducted a safety audit of M/s Amba Sugar Limited,
Distillery Unit, Mawana, Dist. Meerut. The study was conducted as per guidelines
formulated in IS 14489-1998.

1.2 Location:

The plant site is situated at Mawana, Dist Meerut. The site is fairly flat. The site is more
than 550 m away from the railway line and still further from highway and hence meets
the requirements of Department of Environment with respect to its distance from railway
line and highway. There are no archeological monuments, reserved forests, or
sanctuaries in study area. Mawana is about 33 Km from Meerut. Plant is easily
accessible by road.

1.3 No. of Workers and shift Timings:

The Plant is manned on continuous basis the Plant operates in four shifts namely A, B,
C and G Shift. Plant has an approximate strength of 118 employees including 30
contract workers. The shift timings are as under:

Shift –A - 06:00 am to 02:00 pm

Shift –B - 02:00 pm to 10:00 pm

Shift –C - 10:00 pm to 06:00 am

General shift - 09:00 am to 06:00 pm

1.4 Scope of Study:

As per statutory requirement of “Rule -10 Manufacture, Storage and Import of

Hazardous Chemical Rules, 1989”, the Safety Audit of a plant storing or handling the
hazardous substance equal to or more than the quantity specified in schedule -2, has to
carry out the external Safety Audit of the plant every year.

The Amba Sugar Limited, Distillery Unit, Mawana, Dist. Meerut is engaged in
manufacturing and storage of chemicals having inflammable characteristics in
appreciable quantities as per the criterion mentioned above. The plant therefore
qualifies for current study under above mentioned rule. While conducting the Safety
Audit, the norms and procedures mentioned in IS – 14489- 1998 were given due
consideration. The scope of study is as under.

1. Hazard Identification: Identification of potential hazards which could trigger

loss by causing events like fire explosions, fatalities, work injuries, etc. in
process, storage and loading/unloading areas.
 2. Prevention of fire and toxicity hazards: Critical examination of all areas and
activities that involve fire and explosion hazards and submit recommendations
wherever required, with object of minimizing losses.

3. Fire Detection and Protection Arrangements: Providing comments on

adequacy of existing fire detection and protection arrangements (portable and
fixed both) in the plant premises and suggest improvements wherever required.

4. Emergency Preparedness: Assessment of the adequacy of available facilities

like first aid, security, fire fighting, communication etc. in view of effective
handling of possible emergencies at the plant.

1.5 Methodology: The activities carried out in conducting the Safety Audit and
implementing the audit recommendations are given below:

Activities before audit

Audit: on site activities

Activities after audit

Activities before audit:

Pre- audit session includes gathering all background information and process data
on Pre – designed questionnaire.

Audit: on site activities:

This includes the inspection of areas and activities being carried out in the plant;
discussions with the plant engineers and workmen and checking all the necessary
records with the object of identifying status and effectiveness of the safety systems,
procedures and emergency preparedness at the plant.

After Audit Activities:

The post audit session includes the evaluation of the audit research and observation
and evidences gathered. Findings are discussed with plant management and then
summarized in the form of Audit Report is submitted to Chief Executive of the unit.

1.6 Team Visit:

Er. SK Gupta, Director M/S ABC Engineers (P) Ltd, a senior HSE consultant visited the
plant to undertake the audit.
 CHAPTER -2

PLANT AND PROCESS DESCRIPTION & FACILITIES

2.1 Manufacturing facilities:

Mawana distillery capacity is 160 KLPD. The plant is divided into various blocks with
adequate separation distances. The office block is a building of class “A” construction
with RCC columns 4 slabs and brick masonry walls. The plant has following sections
viz.

 Fermentation section
 Distillation section
 Receiver and bulk storage section
 Cooling Tower and water treatment plant
 Raw Molasses tank
 Molasses unloading pit
 Biogas plant
 Boiler House
 D.M. Plant/ Mechanical workshop
 Power House
 Bagasse yard
 Lagoon for spent wash
 Bulk and storage tank
 PCC Room
 CO2 Recovery Plant
 ETP
 Etc.

These sections have RCC structure and/or MS columns and ACC sheet roofing. All the
manufacturing sections are of non-combustible construction and fire accident in one of
the manufacturing blocks is not likely to have any impact on the other block.
M/S Amba Sugar Limited, Distillery Unit, Mawana, Dist. Meerut have the approved
building plan from the Directorate of Factories, U.P. and Certificate of Stability of the
entire building from the competent person approved by Directorate of Factories U.P.

Product carrying equipment, pipe-work and valves of the plant are made of standard
materials.

List of major equipment: The details are as under

 Molasses tank
 Fermenter
 Analyzer
 Pre rectifier
 Rectifier
 Purifier
 Simmering
 Condenser
 Alcohol storage tank
 Boiler
 Turbine
 Power house
 DM RO Bio-digester
 ETP (RO)

2.2 Protection zones. Explosion protection.:

All the manufacturing sections are located with adequate separation distances to ensure
that a fire in one section does not affect the neighboring section.
The manufacturing/storage areas identified as flame proof zones are provided flame
proof type electric fittings to ensure absence of a source of ignition in the plant.

2.3 Raw Materials, Main Products, Intermediate Products and By-Products:

The details of storage tanks storing various chemicals at the distillery are given below
with their maximum storage quantity.

S.No. Tank Nos. Unit Capacity each tank

FERMENTATION HOUSE
1 Culture vessel 1 2 Liter 150
2 Culture vessel 2 2 Liter 960
3 Culture vessel 3 2 Liter 6000
4 Culture vessel 4 2 Liter 30000
5 Pre fermenter 2 Liter 160000
6 Fermenter 4 Liter 1000000
7 Wash holding tank 1 Liter 1000000
8 H2SO4 Tank 1 MT 90
9 Molasses 1 MT 150
10 H2SO4 dosing tank 1 Liter 1000
11 Antifoam dosing tank 1 Liter 1000
12 Nutrient dosing tank 1 Liter 2400
13 CIP Tank 1 Liter 20000
MOLASSES
14 Molasses Tank 2 Qntls 1.04 Lacs
WARE HOUSE
15 Rectified Spirit tank 5 Liter 17.5 Lacs
16 ENA 5 Liter 17.5 Lacs
17 Impure 2 Liter 2.9 Lacs
18 SDS 2 Liter 0.96 Lacs
19 2 Liter 0.20 Lacs
20 Issue vat 2 Liter 2.9 Lacs
21 2 Liter 2.9 Lacs
22 Daily Receiver 3 Liter 1.7 Lacs
23 3 Liter 1.7 Lacs
24 3 Liter 0.20 Lacs
DM PLANT
25 Raw water 1 KL 120
26 DM Water 2 KL 600
27 HCl 1 KL 12
ETP (RO)
28 H2SO4 1 MT 25
BIOGAS
29 Bio-digester 2 M3 19200

2.4 Process Description:

In the manufacturing of Alcohol, by Fermentation & Distillation, provides a means for

separating the Ethyl Alcohol from the fermented wash. The raw material for the process
is Molasses which is left over after sugar recovery from sugar cane in sugar industry.

In Distillery, molasses is used as a raw material, which is the by- product of sugar mills
obtained by final extraction of sugar.
FERMENTATION

“Fermentation is a biochemical reaction in which the conversion of one compound to

another takes place by the action of microorganism, such as Yeast.”

Yeast is a microorganism which is used in fermentation to produce alcohol from sugar

content present in molasses

In Aerobic fermentation, oxygen is basic requirement, supplied for growth of yeast.

Maximum yeast biomass is formed during this process.

In Anaerobic stage the conversion of sugar in to ethyl alcohol and carbon dioxide takes
place. -

INVERTASE

C12H22O11 +H2O -------------------> C6H12O6 + C6H12O6

(sucrose) (Glucose) (Fructose)

ZYMASE

C6H12O6 -------------------- > 2C2H5OH + 2CO2+Heat

(Mono saccharides) (Rectified Spirit)

DISTILLATION

“Distillation is a physical process in which the various components of a mixture are

separated by virtue of their difference in boiling points. “

In distillation process the fermented wash from fermentation is distilled in different

columns at different pressure for the separation of alcohol. This alcohol has a purity of
95%v/v which is called RECTIFIED SPIRIT .This rectified spirit is further distilled for the
purification. The purified spirit is called as ENA which also has alcohol concentration
95%v/v. The alcohol is stored in storage tanks, from where it is sent to the buyers
through the tankers.

Process Flow diagram:

 LAB FERMENTATIONHOUSE
LAB YEASTTRANSFERTO
YEASTPROPAGATION
UPTO5LITFLASK. YEAST VESSEL C V - 1

DISTILLATIONSECTION
Y E A S T V E S S E L

TESTTUBE 3 0 0 L I T

WASH
ANALYSER COLUM FOCCOLUMN ATM RECEIVER IMPURE
CONICAL VACUME SPIRIT

C V - 2 Y E A S T W A S H C L E A R T A N K

RS ENA SDS
1LIT. V E S S E L 8 0 0 L I T 1 0 . 0 L A C

SPENTWASH
L I T

COUNTRY IMFL CHEMICALS

5LIT LIQUOR
PRERECTIFICATION S I M M E R I G C O L U M RECEIVER ENA STORAGEVATS
COLUM VACUME ( E N A ) A T M IMPURESPIRIT SDS

C V - 3 Y E A S T F E R M E N T O R RUM
V E S S E L 8 0 0 0 1 0 . 0 L A C L I T

L I T

RECTIFIERCUM S T O R A G E V A T S DENATURENTVATS DAA

EXHAUSTCOLUMNRS E N A

DMWATER / ENA PRESSURE MIXINGIN

PETROL
C V - 4 Y E A S T P R E - F E R M E N T O R

MOLASSES V E S S E L 3 2 0 0 0 1 . 6 0 L A C L I T

L I T

P U R I F I E R C O L U M N RECEIVER RS
F O R E N A A T M

WATER
SALE
STORAGEVATS RS
 CHAPTER -3

Elements of Occupational Safety and Health (OS & H) System

3.1 Areas covered:

The Safety Audit was conducted as per standards and procedures as well as area of
concern laid down in the IS – 14489-98 “CODE OF PRACTIE ON OCCUPTATIONAL
SAFETY AND HEALTH’’. The areas of occupational safety and health system covered
in audit are as follows:

3.2 Safety, Environment & Health Policy:

M/s Amba Sugar Limited, Distillery Unit, Mawana have enunciated an integrated
Environmental, Occupational Health & Safety Policy which indicates company’s total
commitment towards preservation of environment and ensuring occupational health and
safety of company’s employees, plant and who so ever visits the plant.

The policy has been prepared as per guidelines of the statutory requirement.

3.3 Safety Department:

Plant has a Safety Officer. The details of the Safety Officer are as follows:

Name : Mr. R.K. Mishra

Designation : Manager (EHS)

Experience: 20 years

Safety Officer reports to Unit Head.

Plant has a Fire Safety department. Mr. Beer Singh Choudhary is the Head of the
department and the total strength is 5.

3.4 Safety Committee:

Plant management has a Safety Committee.

- The tenure of the committee is 2 years

- The safety committee meets as often as necessary but at least once in six
months.

- The minutes are recorded and circulated to all concerned members .

- Safety committee has the right to be adequately and suitable informed of:

(a) Potential safety and health hazards to which the workers may be exposed at
work place.

(b) Data on accident as well as data resulting from surveillance of the working
environment and of the health of the workers exposed to hazardous substances so
far as the factory is concerned.

(c) All the accidents occurred in previous 15 days and analyzed suggested remedial
measures are implemented or not.

(d) The latest status of the implementation of the safety jobs.

(e) Report of plant safety inspections.

(f) Safety points pertaining to individual areas are discussed and plan of action is
framed or not

Functions and duties of the Safety Committee

- Formulation/review of safety Policy, various statutory requirements, safety

aspects in design and planning of the projects and plants shutdown needs,
developing Safety/Organization.
 - Assisting and cooperating with the management in achieving the aims and
objectives outlined in the ‘Health and safety Policy’ of the factory.

- Dealing with all matters concerning health, safety and environment and to arrive
at practicable solution to problems encountered.

- Creating Safety Awareness amongst all workers.

- Undertaking educational, training and promotional activities.

- To organize safety inspections with connected members to upgrade safety

aspect.

- Discussing reports on safety, Environment and Occupational health surveys,

safety audits, risk assessment, emergency and disaster management plans and
implementation of recommendations made in the reports.

- Carrying out health and safety survey and identifying causes of accidents.

- Looking into any complaint made on the likelihood of an imminent danger to the
safety and health of the workers and suggesting corrective measures; and

- Reviewing the implementation of the recommendation made by it.

- The safety Committee has the right to be adequately informed of:

- To investigate accidents and their preventive measures are well explained

- Saving as a means of safety communications.

3.5 Safety Budget:

There is no separate Safety budget. Suitable expenditures under this head is made at
the unit level as per the need. Any major expenditure on this account is made as per the
recommendations made by the Safety Officer and other officers of the unit and/or
review/decision taken by Unit Head and at regional/ head office level.

3.6. Safety Related Education and Training:

There is no separate training department but internal training in basic safety is imparted
BY Safety Officer at the plant to all employees including new entrants. All the facilities
like projector, video, TV and computer etc are available.

3.7 Employees participation in OS + H Management:

The management has involved the participation of employees in Plant Safety
Committee meetings.

3.8 Motivational and Promotional Measures for OS + H:

 Plant management encourages safety suggestions from employees and any one
can give suggestion in written form to the section incharge or Safety Officer.
 The safety contest such as Safety Essay, Slogan and Poetry Competition etc.,
are organized in the plant for the motivations of the employees. The information
regarding safety and health is publicized through bulletin boards, post serious
accident board, posters, wall writing etc. Plant also celebrates Safety Week every
year.

3.9 Safety Manuals and Rules:

 Plant has a comprehensive Distillery Safety Manual.
 Copies of various acts like Petroleum Rules 2002, MSIHC Rule 1989, The UP
Factories Rules 1950, Air & Water (Prevention & Control of Pollution) Act-
1981/1974 etc. are available at the plant.
 Operations and maintenance manuals of various equipment are available in
respective sections.

3.10 Compliance with Statutory Requirements:

The management was found committed to comply with all statutory requirements
as per the respective Acts and Rules made there under of the concerned
authorities. A brief assessment report of the same is as under:

S Statutory license name Present Status

No.
02 Statutory requirements of U.P. - Air consent valid up to 31-12-2017.
Pollution Control board.
- Water consent valid up to 31-12-2018..

03 Statutory requirements of U.P. Factory License valid up to 31-12-2017. As

Factories Rule – 1950 informed it has been further renewed upto
31.12.2018
04 Statutory requirements of U.P. Certificate from Fire Department valid Upto
fire Prevention & Fire Safety 14.2.2018
Act -2005

05 Statutory Requirements of The Public Liability insurance is valid upto 12.6.2018

Public Liability Insurance
Rules, 1991

3.11 New Equipment Review/ Inspection:

The management of plant has a tendency of reviewing and inspecting of the efficiency
of all new equipment and ensures all safety requirements for any change in the process,
equipment or facility.

3.12 Accident Reporting Investigation and Analysis:

 All the accidents resulting in either minor or major injuries which have the
potential causing human injury and / or property damage or fatality are reported
and investigated as per the specified procedures.
 Remedial measures, if needed are taken to prevent similar accidents/incidents in
future.
 The near miss accidents are also investigated promptly and recommendations
are given to concerned department for implementation to prevent recurrence of
such incidents/ accidents.
 Plant has accident data as NIL.
 The Safety Officer & HR department maintain accident statistics and data.

3.13 Risk Assessment including Hazard Assessment:

  The plant has identified the hazards, which may arise in the factory, on the basis
of the chemicals being handled and produced and any deviation in operational
conditions.
 Plant has also conducted a HAZOP Study during 2017.
 Alcohol is the hazardous chemical manufactured and stored in the plant which is
flammable in nature. The major hazard involved is fire in an Alcohol facility.
 Adequate control measures have been taken by the plant to effectively control
and manage the hazard by proper and safe plant design, in built safety
measures; operational safety measures etc.. The details of safety features are
given in the existing On Site Emergency Plan.
 Plant has many interlocks and trip system in the plant to trip the system/process
in case of deviation of parameters beyond acceptable limits.

3.14 Safety inspection and maintenance schedule:

Plant has regular plant safety inspections schedule covering all departments/sections.
Dy. Manager EHS has a daily safety round of the plant. In addition monthly Internal
safety inspection/audit is also carried out. Preventive and shutdown maintenance is
also in practice for all plant equipments, safety and fire fighting equipments/personal
protective equipments / pressure vessels and lifting tools etc.

3.15 Health and Safety Improvement Plan:

 Plant has a well maintained occupational Health Center.

 OHC is headed by a qualified doctor.

 The medical attendants are available round the clock in the center. One
ambulance is available round the clock.

 The plant also has liaison with following nearby hospitals:

- JP Hospital, Rohta Road, Meerut

- Kailashi Super-speciality Hospital, Meerut

- SDS Global Hospital, Meerut

3.16 First Aid Facilities:

Distillery has provided the necessary first aid facilities throughout the plant. The first aid
boxes are being controlled by trained persons in the first aid.

Distillery has the occupational safety and health center that conforms to the provision of
Factories Act, 1948. The medical attendant is available round the clock in the OHC.
One ambulance is available round the clock in the plant.

3.17 Personal protective equipment (PPE)

The factory has made the provision for the personnel protective equipment within the
plant, which are regularly used by the workers and these can be useful in case of
emergency are as under:

 Breathing apparatus set – 01 no.,

 Safety Helmets,

 Rubber gloves,

 Asbestos gloves,

 canvas gloves,

 Safety Belts,

 Ear plugs,

 Dust masks,

 Safety goggles,

 Gum boots,

 Ear mufs,

 Face Sheilds,

 PVC Suit,

 PVC Apron

 Etc.

3.18 House Keeping:

 Plant housekeeping was found to be excellent.

 Plant has well-developed drainage system all over the plant.

  The sufficient number of disposable bins are provided. Where required dip tray
are provided..

 In the process plant all processes are closed type so there is no chance of
fumes/gases present within the plant during normal plant operation but the fumes
may be generated in the plant due to leakage in vessels/pipelines and during the
collection of samples.

 No dusty process is carried out in the process plant. However bagasse is used
in boilers as fuel and bagasse dust is observed at bagasse storage. Bagasse
dust is controlled by sprinkling water using water monitors. Workers also use
appropriate PPEs in this area.

 The walkways are clearly marked and free from obstruction.

3.19 Machine and general area guarding:

All the moving machines and storage areas of hazardous chemicals are well guarded/
fenced in the plant. Plant is also guarded round the clock by the security staff.

3.20 Electrical and personal guarding:

The process and equipments capable of generating and accumulating static charge
have been identified. All such equipments are properly bonded and earthed. Electrical
earth resistance measurement and continuity tests are carried out periodically and test
record is maintained in plant- Annexure 10.

3.21 Materials handling equipment:

A. Lifting machines

 Most of the lifting machines are marked with their SWL.

 All the examination and test document of the lifting machine, ropes and lifting
tackles are maintained in the Register as per ‘The U.P. factories Rule, 1950’.

 Competent person certifies the lifting tools and tackles.

 Adequate lifting tackles are provided at all places where it is required and are
maintained in good conditions.

 Only trained operators are engaged for operating the equipment.

 The training of operators is done in supervision of plant management.

B. Mobile equipment and vehicular traffic

 Plant has hand trolleys; tractor trolleys as well as fork lift for transportation of
materials. All the mobile equipment is in good condition & installed with muffler .

 Only trained drivers are engaged for forklift trucks.

 Adequate number of warning signs/signals is displayed at vulnerable points

3.22 Ventilation, Illumination, Noise:

Ventilation:

Effective ventilation system is provided in the working area. Almost in all working areas,
natural ventilation system is provided.

Illuminations:

Effective illumination system (natural and electric lighting) system is provided in working
areas, the employees do not feel any discomfort conditions of darkness.

Noise:

There is no objectionable noise in plant premises. Noise monitoring is regularly carried

out at the distillery and the noise level is always found to be below acceptable limit. A
copy of Noise Monitoring Report is enclosed as Annexure 12.

3.23 Work environment monitoring system:

The management has a system to conduct work place monitoring in plant area to
assess contents of chemical escaping into atmosphere.

3.24 Prevention of occupational diseases:

Every employee of the company at the time of recruitment is subjected to pre -

employment medical examination and recruited only when he has been declared
medically fit by the competent medical authority.

Every employee so declared medically fit would conform to the medical fitness norms in
accordance with the rules standards prescribed by the company.

All employees are also medically examined every 6 months by the Factory Medical
Officer.

All health screening examinations aim evaluation of general as well as occupational

health status of employees. These examinations include screening and diagnostic tests
as may be deemed necessary from the occupational exposure point of view. All the
 employees are encouraged to report any adverse symptoms immediately to their
manager/Safety Officer/ OHC.

3.25 Safe operating procedures:

Technical aspects:

The written safe procedures of various equipments installed in plant are available at
plant. The safety procedures for plant operation and maintenance highlights need of
work permit requirement, training in use of personal, protective equipment, preparation
for maintenance work, release of plant and equipment, preparation for maintenance
work, release of plant and equipment pressure, opening of malfunctioning equipment,
entry into equipment. No contractor workers are deployed on any main stream process/
operation.

Access:

All accesses are maintained in sound condition. Oiling and greasing points are located
at safe places not liable to drip into walk ways.

3.26 Work permit system: A written permit to work system for hot work, working at
height, Rigging, vessel/tank entry, digging/excavation and cold work exists in the plant

3.27 Safety and Fire fighting arrangements/facilities:

The Safety and fire fighting arrangement available within the plant is as under:

S.N. Facility Description

1. Water collection facility Tubewell- 270 M3/hr.

2. Water reservoir Under ground water reservoir of capacity 3240

m3

3. Fire hydrant system Almost entire plant is covered by the hydrant

system by means of total 61 numbers of hydrant
points. Besides, Water Monitors (9 nos.), Fire
hoses, jet nozzles, and foam branch pipes etc.
are also provided. Sufficient quantity of foam is
also provided.
4. Water supply system Fire pumps (Each capacity- 100 M3/hr.) -2 nos.

5. Electrical back-up system Sugar Factory Power and a DG set is provided

for emergency power back-up.

6. Fire alarm Provided

7 Portable fire extinguishers The plant has provided total 72 nos. of portable
fire extinguishers all around the plant to cover
entire plant area.

Fire extinguishers/ hydrants/ water monitors/hose boxes/ nozzles etc are regularly
checked/ tested. The plant has full-fledged trained fire fighting staff under direct control
of Safety officer. These employees are selected from various departments ensuring that
these are uniformly distributed in all shifts. Apart from them, all the security guards are
also trained in fire fighting.

Note- Fire protection system is under up-gradation for betterment.

3.28 Emergency preparedness plan:

 Plant has a detailed On Site Emergency Plan, and mock drill is conducted once
in three month as per On Site Emergency Plan.

 The office of the Unit Head in the distillery is the emergency control center and
plant has two numbers of assembly points, these are located at the distillery
administrative building and near distillery main gate.

 The emergency team and key personnel have been identified in the On Site
Emergency Plan.

 Suitable numbers of adequate protective and rescue equipment are available.

 The fixed line telephone and mobile phone is the primary mode of
communication service at the distillery. Electric siren is available for sounding
emergency. Email and fax is available.

 Distillery has mutual aid available through the Amba Sugar group Sugar Plant.

3.29 Process / Plant modification procedure:

The modification is defined as change in equipment of process, temporary or
permanent, which may affect the safety of the process or integrity of the plant. The need
of such change/modifications may come out at various times during the plant life due to
a need based change or as a statutory requirement. The plant has a formalized
procedure for modification in process as well as in the plant. Any proposal for plant
modification is also scrutinized from safety angle.

3.30 Transportation of hazardous substances:

 Only road transportation is used in the transportation of hazardous materials by
the plant. Via rail or pipeline no hazardous materials are transported to or from
the plant.
 The pipelines are used for transportation of chemicals with in the plant.
 All pipelines are over ground in the plant & all pipelines are painted periodically to
avoid any rusting.
 Excise department Color code system is followed to differentiate the pipelines .
 Forklift are used for transportation of materials from stores to workplace. Only
trained operators are engaged to drive these vehicles in the plant.
 The loaded trucks and tankers are parked in a specific area on site.

3.31 Hazardous waste treatment and disposal:

Mawana distillery has installed a well maintained ETP Plant. The total effluent is being
treated by bio-gas plant and concentrated through RO Plant. After that concentrated
effluent is being gainfully utilized in Bio- composting. Distillery has also upgraded
treatment system by installing a new 6 stage multi Effect Evaporator System.

3.32 Safety in storage and ware housing General/ Central Store:-

 The management has adequate facilities for storing of raw materials as well as of
final product.

 All the tanks are clearly marked by name of the content inside the tank. The
storage areas are clearly/ marked / defined.

 In stores all the racks and steel cages are kept in good condition.

 The plant has adequate equipment for material handling.

 As informed the workers, handling the material, are acquainted with the hazards
associated with the material. Also, they are trained in safe procedure of handling
the material.
  All the electrical installation in the tanks, process section where flammable
materials handled or stored are flames proof and which can generate static
charge are earthed and bonded.

 All the tanks are provided with Air-vacuum vents.

 Vents are discharged in to ambient air.

 All the storage areas are provided with hydrants system.

 The fire extinguishers and/ or water monitors are provided in these areas.

3.33 Contractor safety system:

 No Contract workers are involved in plant operations. The contractor workers are
hired for other variety of jobs.

 The responsibilities of contract labours, transporters are as follows :

- All contractors/ sub contractors labours and transporters engaged in all kinds of
jobs are directed to follow safe and healthy work practices as described by the
company from time to time.

- The contractors/subcontractors and transporters are made responsible for the

safe working and safety of their employees. They maintain regular liaison with
Safety Officer.

- Training on safety is imparted to the contractor labor by the company.

3.34 Safety for customers (including material safety data sheet)

The material data sheets of all the hazardous materials are available at the plant,