Checkpoints for Process Plant and Equipment

1. Selection of proper material of construction for a new vessel/reactor, and modification.
2. Proper design and fitting of vessel/reactor as per standard codes. Small bath size desirable.
3. Operating conditions at less pressure, temperature, flow, slow reaction rate and less hazards desirable.
4. Condition monitoring and pressure testing of vessels and equipment.
5. Safety fittings like Pressure gauge, Temperature gauge, Rupture disc, Level indicator, Non return valve, Excess flow valve, interlocks, alarm and trips. Flameproof fitting where required.
6. Safe operating procedure and safe close down procedure displayed for operator.
7. Batch sheet design and full filling with details.
8. Fire fighting equipment.
9. Use of personal protective equipment.
10. Open space maintenance space and leakage checking.
11. Scrubber connections and scrubber working.
12. Safe columns, condensers, receivers and vent and safety valve for distillation process.
13. Auto and manual devices to stop heating, charging etc, and quenching or safe transfer of material in case of emergency.
14. Close transfer/charging of hazardous material.
15. Local exhaust ventilation on toxic material charging, transfer and filling/packing.
16. Double earthing and static charge eliminator where required viz. Solvent in a glasslined vessel.
17. Proper piping and colour code.
18. Checking of proper O2/N2 lines and cylinders to avoid accident.
19. Use of safety work permit.
20. Machine guarding for drives, pumps etc.

Checkpoints for Pollution Control

(A) Effluent Treatment Plant (ETP)

1. NOC and comment from Pollution control board.
2. Norms suggested by Pollution control board like pH, BOD, COD, Oil & grease, Colour odour, suspended solid, total dissolved solid, heavy metals etc. Fill the format of logbook.
3. Norms prescribed under the Factories Act (Schedule-2). Fill the format.
4. Drawing approval of ETP.
5. Continuous operation of ETP.
6. Primary and secondary treatment plants.
7. Continuous monitoring of parameters for final discharge from factory premises.
8. Whether pollutant being discharged above prescribed limit?

(B) Gas Emission/Leak Control

1. NOC and consent from Pollution control board.
2. List emission/leaking points, pollutants and their prescribed limits.
3. Selection of proper scrubbing media.
4. Proper design and continuous working of scrubbers/flare/incinerator etc.
5. Final vent gas detector with alarm and discharge valve.
6. Whether pollutant being discharged.