INTERNSHIP AT ONERIO LIFECARE

An Internship Report

Submitted by

PATEL DEVANSHI

In Partial Fulfillment of the award of the degree of

BACHELOR OF TECHNOLOGY

In

Chemical Engineering

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 DHARMSINH DESAI UNIVERSITY
Nadiad, Gujarat

DECLARATION

We hereby declare that the Internship report submitted along

with the Internship project entitled internship at ONERIO
LIFE CARE PVT Ltd. Submitted in partial fulfillment for the
degree of Bachelor of Engineering in Chemical Engineering
Dharmsinh Desai University, Nadiad, is a bonafied record of
original Internship carried out by me at ONERIO LIFE CARE.
Under the supervision of Ankit patel and that no part of this
report has been directly copied from any student’s reports or
taken from any other source , without providing due reference.

Name of the Student

PATEL DEVANSHI
21CHUOS028

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 ACKNOWLEDGEMENT
It is my great pleasure to record profound gratitude to my
ONERIO LIFE CARE for their constant inspiration and
invaluable guidance throughout the course of summer
internship from 06/05/2024 Monday to 08/06/2024 Saturday.
I extend special gratitude to all of the esteemed staff of
ONERIO as well as other colleagues in our department, who
were so easily approachable, helpful and a source of
encouragement during this span of work.
I would like to take this opportunity to thank, Mr. Ankit
Patel(HR Head) for their guidance.
Success of any training depends on the dedication and
sincere hard work. It also requires some essentials like
motivation, guidelines, encouragement, positive attitude, good
observation and time. We express our sincere gratitude to our
Guide. We would like to thanks to the department of chemical
engineering for their constant support and valuable suggestion
without which the successful completion of this training
would not have been possible.

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 ABSTRACT

This internship report serves the purpose to record the

details of my industrial training which was conducted in the
ONERIO LIFE CARE PVT LTD the times span of 4 weeks
starting from 6th May, 2024 to 8th June, 2024.
The main aim of the internship was to gain as much experience
and knowledge as about various aspects used in Chemical
Industries from on-field experts. This opportunity provided us
with an insight on the practical work done in corporate
environment.
This report holds all the details regarding the training starting
from safety measures to the whole process description of
Different kinds of raw materials, many reaction processes and
unit operations are involved to finally obtain

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TABLE OF CONTENT

Chapter 1 Overview of the company............................................................. 7

Company History .............................................................................................................7

Environment, Health and Safety ....................................................................................8
Infrastructure ……………………………………………………………………………………………………….

Chapter 2 Introduction to Products ............................................................... 9

Product Information ....................................................................................................9

Product Basic Information...........................................................................................9
Product Price..............................................................................................................10
Applications................................................................................................................10
Material and Safety Data Sheet ................................................................................12

Chapter 3 Process Analysis ........................................................................ 20

Process Description ........................................................................................................... 20

Chapter 4 Introduction to Energy Balance .................................................. 21

Chapter 5 Plant Utilities ............................................................................. 22

Type of Utilities .................................................................................................................. 22

Chapter 6 Safety, Health and Environment ................................................. 23

Introduction......................................................................................................................... 23
Basic Rules Followed ............................................................................................................ 62
Safety Training ..................................................................................................................... 24
Safety Vision of Safety.......................................................................................................... 24
Types of Incident / Cases… ....................................................................................................25
Safety Management System of UPL ....................................................................................... 28

Emergency Siren Codes ........................................................................................................ 28

Management System ........................................................................................................... 29
Process Hazard Analysis......................................................................................................... 29
Work Permit System ............................................................................................................ 30

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 Fire and Explosion .................................................................................................................33
Plant Safety.......................................................................................................................... 38

CONCLUSION ......................................................................................... 44

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 CHAPTER 1: OVERVIEW OF THE COMPANY

About Company
A young company that is steadily making it's dynamic presence known on the occupier of map, Oneiro
Lifecare is a quality name in the pharmaceutical industry. Established in 2004, today Oneiro has developed
a creditable countrywide and international network by a comprehensive product range and innovative
solutions.

An ISO 9001:2000 certified organization, we are involved in the manufacturing of a range of pharmaceutical
intermediates/ingredients that are used as raw materials for a spectrum of functions in the pharmaceutical
industry. Oneiro’s strengths comprising research and innovation, update manufacturing capabilities, human
resources and effective implementation of quality management system, have helped the company to scale
up and establish an identity in the industry in a short time...

We believe that our futuristic outlook and incessant drive to be globally competitive will help us to
continually learn and evolve towards becoming a leading name in the near future

Environment, Health and Safety

In my capacity as the occupier of M/S ONEIRO LIFECARE declare the company’s commitment,
that Environment, Health and Safety of the employees and is a matter of prime concern to the company.

To comply with the statutory and non statutory provisions by ensuring following high priority to
Environment, Health and Safety control program and integrate the Environment, health and safety aspect in
all decisions.

To ensure that technology absorbed, assimilated, upgraded and developed by the company lays emphasis on
Environment, Health and Safety aspects in and around the work place.

To ensure continuous improvement in Environment, Health and Safety aspects by carrying out safety Audit,
Risk assessment, Hazop studies and providing resume in annual report.

Organize training program on regular basis to educate employees (including contractor employees), contract
workers and contractor, sub contractor, transporter, as they are responsible for Environment, Health and
Safety aspect.

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 Infrastructure
Total Land Area
 42000 Sq. Mtr

Total Plant Area

 Plant 1: 400 Sq. Mtr
 Plant 2: 300 Sq. Mtr
 Plant 3: 350 Sq. MtrETP
 Plant 4: 400 Sq. Mtr

List of Utilities
 Boiler
 Brine Unit
 Soft Water Plant
 RO Plant
 Chilled Water Plant
 Cooling Tower
 DM Water Plant
 N2 Plant
 Evaporator
 Effluent Treatment Plant

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 CHAPTER 2: INTRODUCTION OF PRODUCTS

Product information:

 Active Pharmaceutical Ingredients

Antigastro
* Omeprazole
* Esomeprazole
Antidiabetic
* Sitagliptin Phosphate Monohydrate
* Linagliptin
* Dapagliflozin propanediol monohydrate Empagliflozin
Antihistamine
* Bilastine
Antitussives
* Dextromethorphan Hydrobromide
Anti-inflammatory
* Celecoxib
* Allopurinol
Antiarrhythmic
* Sacubitril valsartan sodium salt
* Sacubitril Valsartan Trisodium Hemi Pentahydrate
Antiviral
* Molnupiravir
Vitamin Complex
* Folic Acid
Antiplatelet
* Ticagrelor
Anti-hyperglycemic
Vildagliptin

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 Vildagliptin
Structure

Molecular Formula C17H25N3O2

IUPAC Name  (2R)-1-[2-[(3-Hydroxytricyclo[3.3.1.1(3,7)]dec-1-

yl)amino]acetyl]-2-pyrrolidinecarbonitrile

Regular Name Vildagliptin

Molecular weight 303.4 g/mol

Product price:

Vildagliptin costs around 6500 Rs/Kg in Indian market.

Applications:
Vildagliptin is a once-daily dipeptidyl peptidase 4 (DPP-4) inhibitor used in the management of type
2 diabetes mellitus.
Vildagliptin (LAF237) is an orally active antihyperglycemic agent that selectively inhibits the
dipeptidyl peptidase-4 (DPP-4) enzyme. It is used to manage type II diabetes mellitus, where GLP-1
secretion and insulinotropic effects are impaired.2 By inhibiting DPP-4, vildagliptin prevents the degradation
of glucagon-like peptide 1 (GLP-1) and glucose-dependent insulinotropic polypeptide (GIP), which are
incretin hormones that promote insulin secretion and regulate blood glucose levels. Elevated levels of GLP-
1 and GIP consequently results in improved glycemic control.6 In clinical trials, vildagliptin has a relatively
low risk of hypoglycemia.

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 Folic acid
Structure

Molecular Formula C19H19N7O6

IUPAC Name 2S)-2-[(4-{[(2-amino-4-hydroxypteridin-6-

yl)methyl]amino}phenyl)formamido]pentanedioic acid
Regular Name Folic Acid

Molecular weight 441.4 g/mol

Product price:

Folic Acid costs around 2900 Rs/Kg in Indian market.

Applications:

Folic acid is used for preventing and treating low blood levels of folate (folate deficiency) and
high blood levels of homocysteine (hyperhomocysteinemia). People who are pregnant or might become
pregnant take folic acid to prevent serious birth defects such as spina bifida. Folic acid is also used for
many other condition including depression, stroke, decline in memory and thinking skills, and many
others.

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Sitagliptin Phosphate Monohydrate
Structure

Molecular Formula C16H20F6N5O6P

IUPAC Name (3 R)-3-amino-1-[3-(trifluoromethyl)-6,8-dihydro-5 H-

[1,2,4]triazolo[4,3-a]pyrazin-7-yl]-4-(2,4,5-
trifluorophenyl)butan-1-one;phosphoric acid; hydrate
Regular Name Sitagliptin Phosphate Monohydrate

Molecular weight 523.32g/mol

Product price:
Sitagliptin Phosphate Monohydrate costs around 9100 Rs/Kg in Indian market.

Applications:

Sitagliptin is used with a proper diet and exercise program and possibly with other medications to
control high blood sugar. It is used in people with type 2 diabetes. Controlling high blood sugar helps
prevent kidney damage, blindness, nerve problems, loss of limbs, and sexual function problems. Proper control
of diabetes may also lessen your risk of a heart attack or stroke.Sitagliptin is a diabetes drug that works by
increasing levels of natural substances called incretins. Incretins help to control blood sugar by
increasing insulin release, especially after a meal. They also decrease the amount of sugar your liver makes.

MSDS (Material Safety Data Sheet) For Sitagliptin

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 1 Identification
Product identifier
Trade name: (–)-Sitagliptin (phosphate)
Article number: 13252
CAS Number:
654671-78-0
Application of the substance / the mixture
This product is for research use - Not for human or veterinary diagnostic or therapeutic use.

2 Hazard(s) identification
Classification of the substance or mixture

Acute Tox. 4 H302 Harmful if swallowed.

Skin Irrit. 2 H315 Causes skin irritation.
Eye Irrit. 2A H319 Causes serious eye irritation.
STOT SE 3 H335 Maycause respiratoryirritation.
Label elements
GHS label elements
The substance is classified and labeled according to the Globally Harmonized System (GHS).

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 · Hazard pictograms

!
~
GHS07

· Signal word Warning

· Hazard statements
H302 Harmful if swallowed.H315
Causes skin irritation.
H319 Causes serious eye irritation. H335 May
cause respiratory irritation.
· Precautionary statements
P261 Avoid breathing dust/fume/gas/mist/vapors/spray
P264 Wash thoroughly after handling.
P270 Do not eat, drink or smoke when using this product.P271
Use only outdoors or in a well-ventilated area.
P280 Wear protective gloves / eye protection / face protection.
P301+P312 If swallowed: Call a poison center/doctor if you feel unwell.
P330 Rinse mouth.
P302+P352 If on skin: Wash with plenty of water.
P321 Specific treatment (see on this label).
P304+P340 IF INHALED: Remove person to fresh air and keep comfortable for breathing.
P305+P351+P338 If in eyes: Rinse cautiously with water for several minutes. Remove contact lenses, ifpresent and easy to do.
Continue rinsing.
P332+P313 If skin irritation occurs: Get medical advice/attention.
P362+P364 Take off contaminated clothing and wash it before reuse.
P337+P313 If eye irritation persists: Get medical advice/attention.
P403+P233 Store in a well-ventilated place. Keep container tightly closed.P405
Store locked up.
P501 Dispose of contents/container in accordance with local/regional/national/international
regulations.
· Classification system:
· NFPA ratings (scale 0 - 4)
Health = 2
Fire = 0
2 0 Reactivity = 0

· HMIS-ratings (scale 0 - 4)
HEALTH 2
Health = 2
FIRE Fire = 0
REACTIVITY 0 Reactivity = 0
· Other hazards
· Results of PBT and vPvB assessment
· PBT: Not applicable.
· vPvB: Not applicable.

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 3 Composition/information on ingredients

Chemical characterization: Substances

CAS No. Description
654671-78-0 (–)-Sitagliptin (phosphate)

4 First-aid measures
Description of first aid measures
General information:
Symptoms of poisoning may even occur after several hours; therefore medical observation for at least48 hours after
the accident.
After inhalation: In case of unconsciousness place patient stablyin side position for transportation.
After skin contact: Immediately wash with water and soap and rinse thoroughly.
After eye contact:
Rinse opened eye for several minutes under running water. If symptoms persist, consult a doctor.
After swallowing: Immediately call a doctor.
Information for doctor:
Most important symptoms and effects, both acute and delayed
Maycause anemia, cough, CNS depression, drowsiness, headache, heart damage, lassitude(weakness, exhaustion), liver
damage, narcosis, reproductive effects, teratogenic effects.
No further relevant information available.
Indication of any immediate medical attention and special treatment needed
No further relevant information available.

5 Fire-fighting measures
Extinguishing media
Suitable extinguishing agents:
Use fire fighting measures that suit the environment.A solid
water stream may be inefficient.
Special hazards arising from the substance or mixture No further relevant information available.
Advice for firefighters
Protective equipment: No special measures required.

6 Accidental release measures

Personal precautions, protective equipment and emergency procedures Not required.
Environmental precautions: Do not allow to enter sewers/ surface or ground water.
Methods and material for containment and cleaning up: Ensure adequate ventilation.
Reference to other sections
See Section 7 for information on safe handling.
See Section 8 for information on personal protection equipment.See Section 13
for disposal information.
Protective Action Criteria for Chemicals
PAC-1: Substance is not listed.
PAC-2: Substance is not listed.

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 7 Handling and storage
Handling:
Precautions for safe handling
No special precautions are necessary if used correctly.Avoid breathing
dust/fume/gas/mist/vapours/spray.
Avoid prolonged or repeated exposure.Keep
away from sources of ignition.
Take precautionary measures against static discharge.re.
Information about protection against explosions and fires: No special measures required.
Conditions for safe storage, including any incompatibilities
Storage: Store in accordance with information listed on the product insert.
Requirements to be met by storerooms and receptacles: No special requirements.
Information about storage in one common storage facility: Not required.
Further information about storage conditions: Keep receptacle tightly sealed.
Specific end use(s) No further relevant information available.

8 Exposure controls/personal protection

· Additional information about design of technical systems: No further data; see item 7.
· Control parameters
· Components with limit values that require monitoring at the workplace: Not required.
· Additional information: The lists that were valid during the creation were used as basis.
· Exposure controls
· Personal protective equipment:
· General protective and hygienic measures:
Keep away from foodstuffs, beverages and feed. Immediately remove all
soiled and contaminated clothing.Wash hands before breaks and at the end
of work.
Avoid contact with the eyes and skin.
· Breathing equipment:
In case of brief exposure or low pollution use respiratory filter device. In case of intensive or longerexposure use
respiratoryprotective device that is independent of circulating air.
· Protection of hands:

S Protective gloves

The glove material has to be impermeable and resistant to the product/ the substance/ the preparation. Due to missing
tests no recommendation to the glove material can be given for the product/ thepreparation/ the chemical mixture.
Selection of the glove material on consideration of the penetration times, rates of diffusion and the degradation
· Material of gloves
The selection of the suitable gloves does not only depend on the material, but also on further marks ofquality and varies from
manufacturer to manufacturer.

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 · Penetration time of glove material
The exact break through time has to be found out by the manufacturer of the protective gloves and has
to be observed.
· Eye protection:

R Tightly sealed goggles

9 Physical and chemical properties

· Information on basic physical and chemical properties
· General Information
· Appearance:
Form: Solid
Color: Not determined.
· Odor: Characteristic
· Structural Formula C16H15F6N5O • H3PO4
· Molecular Weight 505.3 g/mol
· Odor threshold: Not determined.
· pH-value: Not applicable.
· Change in condition
Melting point/Melting range: Undetermined.
Boiling point/Boiling range: Undetermined.
· Flash point: Not applicable.
· Flammability (solid, gaseous): Product is not flammable.
· Decomposition temperature: Not determined.
· Auto igniting: Not determined.
· Danger of explosion: Product does not present an explosion hazard.
· Explosion limits:
Lower: Not determined.
Upper: Not determined.
· Vapor pressure: Not applicable.
· Density: Not determined.
· Relative density Not determined.
· Vapor density Not applicable.
· Evaporation rate Not applicable.
· Solubility in / Miscibility with
Water: Not determined.
· Partition coefficient (n-octanol/water): Not determined.
· Viscosity:
Dynamic: Not applicable.
Kinematic: Not applicable.
SOLUBILITY DMF: 0.25 mg/ml; DMSO: 5 mg/ml; PBS (pH 7.2): 5 mg/ml
(Contd. on page 6)
US

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10 Stability and reactivity
Reactivity No further relevant information available.
Chemical stability
Thermal decomposition / conditions to be avoided:
No decomposition if used according to specifications.
Possibility of hazardous reactions No dangerous reactions known.
Conditions to avoid No further relevant information available.
Incompatible materials: strong oxidizing agents
Hazardous decomposition products:
carbon dioxide, carbon monoxide, hydrogen fluoride,nitrogen oxides

11 Toxicological information
Information on toxicological effects
Acute toxicity:
Primary irritant effect:
on the skin: Irritant to skin and mucous membranes.
on the eye: Irritating effect.
Sensitization: No sensitizing effects known.
Additional toxicological information:
Carcinogenic categories
IARC (International Agency for Research on Cancer) Substance is not listed.
NTP (National Toxicology Program) Substance is not listed.
OSHA-Ca (Occupational Safety & Health Administration) Substance is not listed.

12 Ecological information
Toxicity
Aquatic toxicity: No further relevant information available.
Persistence and degradability No further relevant information available.
Behavior in environmental systems:
Bioaccumulative potential No further relevant information available.
Mobility in soil No further relevant information available.
Additional ecological information:
General notes:
Water hazard class 1 (Self-assessment): slightly hazardous for water
Do not allow undiluted product or large quantities of it to reach ground water, water course or sewagesystem.
Results of PBT and vPvB assessment
PBT: Not applicable.
vPvB: Not applicable.
Other adverse effects No further relevant information available.
US

(Contd. on page 7)

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 (Contd. from page 6)

13 Disposal considerations
Waste treatment methods
Recommendation:
Must not be disposed of together with household garbage. Do not allow product to reach sewagesystem.
Uncleaned packagings:
Recommendation: Disposal must be made according to official regulations.

14 Transport information
· UN-Number
· DOT, IMDG, IATA not regulated
· UN proper shipping name
· DOT, IMDG, IATA not regulated
· Transport hazard class(es)
· DOT, ADN, IMDG, IATA
· Class not regulated
· Packing group
· DOT, IMDG, IATA not regulated
· Environmental hazards: Not applicable.
· Special precautions for user Not applicable.
· Transport in bulk according to Annex II of MARPOL73/78 and
the IBC Code Not applicable.
· UN "Model Regulation": not regulated

15 Regulatory information
Safety, health and environmental regulations/legislation specific for the substance or mixture
No further relevant information available.
Sara
Section 355 (extremely hazardous substances): Substance is not listed.
Section 313 (Specific toxic chemical listings): Substance is not listed.
TSCA (Toxic Substances Control Act): Substance is not listed.
Hazardous Air Pollutants Substance is not listed.
Proposition 65
Chemicals known to cause cancer: Substance is not listed.
Chemicals known to cause reproductive toxicity for females: Substance is not listed.
Chemicals known to cause reproductive toxicity for males: Substance is not listed.
Chemicals known to cause developmental toxicity: Substance is not listed.
Carcinogenic categories
EPA (Environmental Protection Agency) Substance is not listed.
TLV (Threshold Limit Value) Substance is not listed.
NIOSH-Ca (National Institute for Occupational Safety and Health) Substance is not listed.

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 CHAPTER 3 PROCESS ANALYSIS

4.1 Process Description of Sitagliptine:

Two effective processes have been developed for the preparation of sitagliptin phosphate. The
approach of chemical resolution obtained R-sitagliptin in five steps from commercially available starting
materials using the inexpensive NaBH 4 to reduce the enamine and then using (−)-di-p-toluoyl-L-tartaric
acid to resolve racemates in 11% yield overall. The route successfully avoids the use of expensive noble
metal as catalysts compared with traditional synthesis methods, resulting in greatly redu ced costs and
simplified synthetic routes. Other alternative asymmetric hydrogenation of β-ketomide routes for the
synthesis of sitagliptin were found, two of the intermediates were synthesized for the first time.

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 CHAPTER 4: ENERGY BALANCE

Sitagliptin (SG) increases serum GLP-1 (Glucagon-like peptide-1) through inhibition of the
hormone degradation. Resistant starch (RS) induces GLP-1 expression by stimulating L-cells in the intestine.
Sitagliptin and resistant starch may have a synergistic interaction in the induction of GLP-1. This possibility
was tested in current study in a mouse model of type 2 diabetes. Hyperglycemia was induced in the diet -
induced obese mice by a signal injection of streptozotocin (STZ). Sitagliptin (0.4g/100g diet) was tested in
the mice (n = 55) with dietary RS (HAM-RS2) at three dosages (0, 15, or 28g/100g diet). Energy and glucose
metabolism were monitored in the evaluation of synergistic activity, and GLP-1 activity was determined in
the GLP-1 receptor knockout (KO) mice. In the wild type mice, body weight and adiposity were reduced by
sitagliptin, which was enhanced by RS (28g). Serum GLP-1 was induced and energy expenditure was
enhanced by sitagliptin. Fasting glucose, insulin, and leptin levels were decreased by sitagliptin. The
sitagliptin effects were lost in the KO mice (n = 25) although induction of serum GLP-1 by sitagliptin was
even stronger in KO mice. The data suggests that sitagliptin is able to reduce adiposity and insulin resistance
through induction of energy expenditure. The effect of sitagliptin is partially enhanced by RS. GLP -1
receptor may regulate serum GLP-1 by facilitating the hormone clearance.

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 CHAPTER 5: PLANT UTILITIES

8.1 Introduction
● Utilities, something that is very necessary for the proper functioning of a process plant.
Something that plays a role of a back bone in a chemical process plant. Utilities are
many; ranging from water to electricity everything that is necessary for the operation
of the plant is a utility.

List of Utilities

 Boiler
 Brine Unit
 Soft Water Plant
 RO Plant
 Chilled Water Plant
 Cooling Tower
 DM Water Plant
 N2 Plant
 Evaporator
 Effluent Treatment Plant

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CHAPTER 6: SAFETY, HEALTH AND ENVIRONMENT

Introduction
● Safety is the state of being "safe", the condition of being protected against physical,
social, spiritual, financial, political, emotional, occupational, psychological,
educational or other types of consequences of failure, damage, error, accidents, harm
or any other event which could be considered non-desirable. This can take the form of
being protected from the event or from exposure to something that causes health or
economical loss. It can include protection of people or of possessions.
● No industry can afford to neglect the fundamentals of safety in design and operation of
its plant and machinery. It is important that all the people responsible for management
and operation of any industry should have a good knowledge of industrial safety.
● “Safe uses of man, material and machine by safe systems and method of work so as to
achieve zero accidents which results in higher productivity.”
● Accident: An accident is unplanned/ unexpected events which interfere or interrupts
with the planned process of work and results in personal injury.

Basic rules to be followed:

● No smoking
● No electronic items allowed in the industry without special permission
● Photography is strictly prohibited
● Personal protective equipments (PPE) are compulsory.
● Only walk on the showed footpath.
● Watch out for big vehicles in the blind spot convex mirrors. Let them pass and then
cross the road.
● Speed limit 10km/hr.
● Do not enter in restricted area.

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 Safety Training:
An Initiative to ensure proper safety while working in the industry.
Basic rules to be followed:
1. No smoking
2. No electronic items allowed in the industry without special permission
3. Photography is strictly prohibited
4. Personal protective equipments (PPE) are compulsory.
5. Only walk on the showed footpath.
6. Watch out for big vehicles in the blind spot convex mirrors. Let them pass and
then cross the road.
7. Speed limit 10km/hr.
8. Do not enter in restricted area.
9. Don’t touch any equipments.
10. Hold the handrail while climbing on stairs.
11. If any abnormality takes place in the industry then firstly inform the respective
authorized person of the section.
12. In cases of emergencies use emergency exit and gather at the assembly point as
soon as you hear panic siren and stay there until clear siren.
13. Always ensure checking of the siren once in a week.
14. Take care of gate pass and ID card given to you.
15. Before you go, inform your host and then leave the plant.

Benchmarking Parameters for safety:

● TRFR (Total Recordable Frequency Rate) <0.4

TRFR = (number of injuries*200000) / (total manhours worked)

● Severity index (SI) <10

SI = man days lost*1000000 / total manhours worked.

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 Different unplanned activities occurring in an industry
● Incident: It may cause harm at a minor scale to plant property or employee.
● Accident: it causes harm to plant property or employee.
● Dangerous Occurrence: It causes harm only to plant property.
● Near miss: The incident happened doesn’t result in any loss or injury

10.2 Types of INCIDENTS / CASES :

● First Aid Case (FAC): person may resume his/her work after taking medicine from
health center.

● Medical treatment case (MTC): A medical treatment case is any injury sustained on
the job by an employee which requires medical treatment from a professional
physician or qualified paramedic.

● Restricted working day (RWC): In such kind of injuries person should immediately
be taken to the hospital and to be kept there until he/she gets fit for the work.

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● Loss time incident (LTI): An LTI is an injury sustained by an employee that leads to
loss of productive work in the form of absenteeism or delays.

● LTIFR(Loss time incident)

● Dangerous occurrence (DO): These are incidents with a high potential to cause death
or serious injury, but which happen relatively.

● Major process safety incident (MPSI): An event that is potentially catastrophic, i.e.,
an event involving the release/loss of containment of hazardous materials that can result
in large-scale health and environmental consequences.

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 Safety management system :
● Daily safety talk
● Training & Performance
● Contractor safety management
● Incident Investigation & report
● Change management
● PHA (Process Hazard Analysis)
● BBS (Behavior based safety)
● PSSR (Pre-Start-up Safety Review)
● PSR (Plant Safety Representative)
● Work Permit system
● Health monitoring (Occupational Health Center)
● Emergency Preparedness and Response
● Second Party Audit (from other units)
● Safety control Points
● Preliminary LOPA & Risk Assessment
● Workplace monitoring
● Construction safety
● Safety Self-Recognition Program
● War Against Hazard

Figure Safety Management Model

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 Emergency siren codes:

Testing Siren rings till 1 min continuously

Plant alert Siren rings until Plant safety Representative

arrives on the place

On site emergency Siren rings sinus odiously 10s on and 5s off 3

times

Off-site emergency Siren rings sinus odiously 10s on and 5s off for
15 min continuously

All clear (On site) Siren rings continuously for 2 minutes.

All clear (Off site) Siren rings continuously for 3 minutes.

Management System :

Change Management:-

Whenever amendments are to be made in a particular plant or industry then

change management committee is required. It generally consists of persons from:

● Instrumentation Dept.
● Safety dept.
● Human resources (HR) dept.
● Electrical dept.
● Mechanical dept.
● Research and development (R&D) dept.

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 Figure Change Management Diagram

 Change management is of 3 types:

● Change to technology: if any advancements are to be done in process of manufacturing
then change to technology is required
● Change to personnel: if man power is more or less inside the plant or else the authorized
person is not working properly then change to personnel is required.
● Change to facility: Industry provides many facilities to the employee that works over
there. If there is any flaw in facilities then a change to facility is required.

Process Hazard Analysis:

Figure Steps of Hazard Handling

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 Hazard: A danger or risk That may take place.
Several reactions are taking place inside the industry at a same time. Some examples of
hazardous reactions are:
a) Isomerization
b) Perkow reaction
c) Oxidation
d) Nitration
e) Increase of pressure in the equipment
f) Chlorine storage
 Process hazard analysis should be done once in every 3 years.
 It generally requires the following documents:
a) “What if” analysis
b) Block flow diagram of system (BFD)
c) Process flow diagram of the system (PFD)
d) Piping and instrument diagram of the system (P&ID)
e) HAZOP analysis

Pre start-up safety review (PSSR):

● One of the fundamental tools for managing change is the Pre-Startup Safety Review
(PSSR). A PSSR consists of a checklist of items to be thoroughly verified before a
process begins or restarts in order to ensure that potential hazards have been properly
addressed.
● The aim of PSSR is to prevent serious injury from the hazard of stored energy (pressure)
as a result of the failure of a pressure system or one of its component parts.
● Team required for pre startup safety review consists of representatives from the
following departments:
a) Process
b) Mechanical
c) Electrical
d) Project
e) Instrumentation
f) Safety

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● It consists of verification of:
a) Fire and explosion safety
b) Electrical safety
c) Machine and equipment safety
d) Industrial hygiene
e) Safety training
f) Interlocks and alarms
g) Field safety
h) Relief devices

Layer of protection analysis (LOPA):

Figure LOPA

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● Layers of Protection Analysis (LOPA) is a method used to evaluate high-consequence
scenarios determining if the combination of probability of occurrence and severity of
consequences meets a company’s risk tolerance.
● Managing process safety means understanding the many factors that contribute to risk
and establishing appropriate measures for risk mitigation. LOPA addresses the key
questions: “how safe is safe enough?”; “how many independent protection layers are
needed?”; and “how much risk reduction should each layer provide?
● The layers of protection are;
a) Process design and control
b) Critical alarms and operator response
c) Instrumentation safety (ISS)
d) Physical protection (pressure relief devices)
e) Plant emergency response
f) Community emerging response

Work permit system:

● To do any kind of work in industry permission is required. The necessary things to be
kept in mind to get work permit are:
a) Details of necessary work to be done
b) Clear responsibility of authorized person
c) Appropriate training should be given to workers
d) Each worker should wear necessary safety equipment.

● Work permit is taken for 2 objectives:

a) For non-routine events
b) For hazardous works.

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Types of work permit

Table Types of Work Permit

Work Color of work permit

Hot work Pink

Confined space work Yellow

Cold work White

Electrical work Light blue

Line breaking Pink

Temp maintain in electrical Light blue

connection

Crane operation Orange border

Work at height Gray

Fire and Explosion:

● Generally, in industries explosions and fires have more possibility to happen because
sometimes untrained workers are allowed to operate or else the event is simultaneous
like increase of pressure inside the boiler.
● Before going further let’s understand some important terminologies:

a) Flash point: The minimum temperature at which fluid gets converted to vapor is called
flash point.
b) Lower explosive limit: The Lower Explosive Limit (LEL) is the lowest concentration
of a gas or vapor that will burn in air.

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c) Upper explosive limit: The highest concentration of a gas or vapor (percentage by
volume in air) above which a flame will not spread in the presence of an ignition source.
d) Flammable range: the concentration of gas between lower and upper explosive limit.
e) Permissible exposure limit (PEL): Permissible exposure limit (PEL) is a regulatory
limit on the amount or concentration of a substance in the air.
f) Threshold limit value (TLV): Permissible exposure limit (PEL) is a regulatory limit
on the amount or concentration of a substance in the air. (ppm)
g) Short term exposure limit (STEL): A short-term exposure limit (STEL) is the
acceptable average exposure over a short period of time, usually 15 minutes as long as
the time-weighted average is not exceeded.
h) Acute toxicity: Acute toxicity describes the adverse effects of a substance that result
either from a single exposure or from multiple exposures in a short period of time
(usually less than 24 hours).
i) Chronic toxicity: Chronic toxicity is the development of adverse effects as the result
of long-term exposure to a toxicant or other stressor.
j) Excursion limit: The OSHA standard fibre per cubic centimetre (f/cc) worker exposure
limit to asbestos, averaged over a sampling period of thirty minutes (currently 1.0 f/cc).

The Fire triangle:

Figure Fire Triangle

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● The fire triangle or combustion triangle is a simple model for understanding the
necessary ingredients for most fires

● The triangle illustrates the three elements a fire needs to ignite: heat, fuel and
an oxidizing agent (usually oxygen). A fire naturally occurs when the elements are
present and combined in the right mixture. A fire can be prevented or extinguished by
removing any one of the elements in the fire triangle. For example, covering a fire with
a fire blanket blocks oxygen and can extinguish a fire. In large fires where firefighters
are called in, decreasing the amount of oxygen is not usually an option because there is
no effective way to make that happen in an extended area.

Types of fires:

Table Types of Fires

CLASS MATERIALS EXTINGUISHERS

A Wood, Paper, fabric Water

B Flammable liquids Foam

C Burning gases Carbon dioxide

D Combustible metal Dry chemical powder (Soda

bicarbonate)

E Electrical equipment Carbon dioxide

F Unsaturated cooling Oil Carbon Dioxide

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❖ HAZCHEM CODE:

Figure Hazchem Code

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 NFPA Diamond:

NFPA: National Fire Protection Association

Figure NFPA Diamond

Techniques to stop fire:

a. Cooling: By reducing temperature of surroundings.
b. Smothering: By removing oxygen from fire
c. Starving: By removing the fuel in the vicinity of fire.

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Plant Safety
 Electrical safety: High voltage electricity is required to automize a chemical plant. So
electrical safety should be given priority.
● Some methods of shock protection are:
a) Isolation: To limit the forces transmitted to the surroundings of the equipment in which
shock originates.
b) Limitation: To stop providing power to the origin of shock.
c) Low voltage: Use earth leakage circuit breakers to avoid high voltage.
d) Double insulation: For thick wires use highly durable insulation material.
e) Earthing: Earthing is used to protect you from an electric shock. It does this by
providing a path (a protective conductor) for a fault current to flow to earth.

● Behavior Based Safety:

● Safety can always be made a way of life.
● So, while working in the plant the employees and workers are given safety training and
are suggested for not performing any unsafe act as it can cost their lives.
● So, a safety self-recognition program is organized to ensure everyone is working safely.
● 3 types of tokens are given to each plant head:

a) Blue token: if everyone works safely without instructing then plant head puts one blue
token inside the box that is installed at each plant.

b) Green token: this is a bonus token. If everyone works safely for a whole month then
plant head puts 5 blue tokens inside the box.

c) Red token: that’s the danger one. If safety is not ensured inside the plant then the plant
head puts a red token which means -5 blue tokens and immediate actions should be
taken.

 At the end of 3-4 months the plant with a greater number of green tokens is specially
rewarded.

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● Personal protective equipments (PPE):

Figure PPE

● Personal protective equipment, commonly referred to as "PPE", is equipment worn to

minimize exposure to hazards that cause serious workplace injuries and illnesses. These
injuries and illnesses may result from contact with chemical, radiological, physical,
electrical, mechanical, or other workplace hazards. Personal protective equipment may
include items such as gloves, safety glasses and shoes, earplugs or muffs, hard hats,
respirators, or coveralls.

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 ● Personal Protective Equipments:
Table PPE

Non-Respiratory Respiratory

Safety Helmet Dust Mask

Safety goggles ½ mask

Ear plug Full mask

Hand gloves: Powdered Air Purifying Respirator

Sharp object-Kevlar gloves

Solvent Handling- Neoprene gloves

Normal work-Rubber gloves

Hot work-Leather gloves

Safety shoes Supplied Airline Respirator

Safety Harness Self-controlled breathing apparatus

(SCBA):

a. Open circuit
b. Closed circuit
Protective Clothes

❖ Quality checks and further Expansion

Ambient Air Quality - The Ambient Air quality was monitored for PM10, PM2.5, NOx,
SO2, CO, NH3, HC (Methane and Non-methane), C6H6, HCl, Cl2, H2S, HBr and VOCs at
nine (9) locations in the study area.

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In general, the ambient air quality is satisfactory with respect to all major pollutants except
particulate matter at a few locations. Non-Methane HCs, VOC, C6H6, H2S, HCl, HBr and Cl2
were found below their respective detection limits.
❖ Water Quality - Surface water samples were collected once during the study period
at four (4) locations. The pH varied from 6.5 to 8.3 while dissolved oxygen varied from
5.8 mg/l to 7.1 mg/l. The results also showed presence of total coliform. The suface
water quality conformed to CPCB D criteria (propagation of wildlife and fisheries) as
per CPCB standards. Ground water samples were collected from eight (08) locations to
assess the existing groundwater quality of the study area during the study period. The
samples compared as per the requirements of IS10500:2012 standards. The pH varied
from 7.4 to 8.3 showing it slightly to moderately alkaline with total dissolved solids
ranged from 821 mg/l to 1,395 mg/l. Total hardness ranged from 323.2 mg/l to 888.8
mg/l and total alkalinity ranged from 285.0 mg/l to 606.9 mg/l. Sulphates varied from
21 mg/l to 128 mg/l. Heavy metals viz. Cd, Cr, Cu, Pb, Hg were found in concentrations
below detection limits.

❖ Plant Expansion :-The net water demand after proposed Project expansion will be
4,751.7 m3/day, out of which ~1,030.5 m3/day is existing and ~3,721.7 m3/day is
proposed. The water requirement for the proposed expansion shall be met from the
existing GIDC water supply. No ground water is/shall be used. The wastewater
generated from process, boiler, cooling tower etc. is and will continue to be treated in

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existing effluent treatment plant (ETP) of capacity 550 m3/day having primary,
secondary & tertiary treatment. The unit is Zero Liquid Discharge (ZLD) since May-
2014 and will continue as ZLD. Moreover, the Unit has also installed online CCTV
camera and magnetic flow meter at ETP outlet line and online CCTV footage is being
transmitted to CPCB website. The Treated domestic waste water from proposed sewage
treatment plant will be recycled/ reused in toilet flushing / green belt and there will not
be any discharge from UPL Unit 2. The Unit 2 will be maintained as ZLD even after
proposed expansion. UPL proposes to install additional Reverse Osmosis (RO) plant of
capacity 650 m3/day, Multiple Effect Evaporator (MEE) of capacity 450 m3/day and a
sewage treatment plant (STP) of capacity 40 m3/day to maintain zero liquid discharge.

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References:

1. https://www.oneirolifecare.com/infrastructure.aspx

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 CONCLUSION:

● For a technical student it’s very important for the one to get the practical knowledge
which he can correlates with the theoretical knowledge he learned during his
curriculum. I applied for the summer internship at ONERIO LIFE CARE. I gained all
theknowledge about the working of the plant with all the safety at the prior.
● Here I understood working of all the reactors their types and scrubber. I also learned
about many unit operations happening here like Distillation, crystallization, filtration
etc.
● At last I would like to conclude that my summer internship at ONERIO LIFE CARE
provided me the amount of industrial knowledge which would be helpful to me in my
future endeavours in this field.

THANK YOU…!!!

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