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INDEX
1. Acknowledgement 2
2. EMS Audit 3
3. EMS system at Reliance 4
4. EMS Exposure 4
5. ETP Plant Visit 7
6. Secured Landfill 8
7. Pollution Prevention and Control 8
8. Executive Summary 9
9. References 10
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Acknowledgment
I wish to express my sincere gratitude towards Reliance, VMD for giving me, this
opportunity to explore my practical knowledge in the area of Environment
management system and Environment audit. I wish to express my sincere thanks to
Mr. Sanjay Patel for selecting me to join the team and work effortlessly.
I would also like to thank Ms. Purna Paul for the guidance and support. I also wish
to thank Mr.Das and Mr.Jain and other office colleagues who helped me in this
training period for bringing the best outcome of my project.
I would also like to express my gratitude towards SIIB for giving me the
opportunity to work for Reliance VMD.
Lastly I would also like to express our sincere thanks for showing the beautiful
campus of Reliance and making me part of the family.
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Experience at Reliance VMD
1.EMS AUDIT:
According to CEPI notification around 88 clusters all over India are deemed as
critically polluted areas and mandatorily Government has asked to check and
monitor pollutants in these areas. Vadodara Manufacturing Unit of Reliance
Industries being a petrochemical industry the hazardous pollutants needs to be
checked and monitored regularly.
Government of Gujarat has appointed some institutions and consultants as auditors
for Environment Management System to keep a check on level of these emissions.
DDU is a deemed university which is being appointed by GPCB as an external
schedule 1 auditor for Reliance Industries (VMD).
External Schedule 1 and Schedule 2 auditors are assigned the duties by GPCB
according to the polluting and very high polluting industries. Schedule 1 auditors
are 30-35 all over Gujarat who audit environment for very high polluting industries.
Consultants given this duty are around 85-90 all over Gujarat which looks at the
emissions of polluting industries.
This team of DDU consisting of 5 members audited the VMD complex for 2 days and
I had got this prestigious opportunity to be part of the team.
This audit is conducted for 3 seasons and a compiled report is sent to GPCB. The
samples for water, air, solid waste were collected in these two days. The processing
and lab testing of these emissions to be in permissible limits as per the GPCB
guidelines was then carried out.
The air sampling is of two kinds: Ambient Air monitoring and Stack Air monitoring.
Water samples are collected from ETP and solid waste samples are collected from
SLF (secured landfill site).
Ambient Air monitoring is conducted for 8 hours or 24 hours at a stretch for
knowing the emission in ambient atmosphere around the site. This monitoring helps
in knowing levels of emission of pollutants in permissible levels for human air
consumption. These AAQ stations are selected initially during the EIA of the project
and then regular monitoring is carried out on these stations for EMS monitoring
during audit. Forced air sampling is taken for flue gas and process gas from stack
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emissions. These samples were taken for three plants namely GOP, GTPP and
VC/PVC. The stack emission is taken for SOx, NOx and PM of the hydrocarbon for
respective plant. The permissible limits are followed as per the guidelines of GPCB.
The gases are taken from nozzle located at the foothill of stack by drawing it by the
function of vacuum.
Water samples were collected from all stages of ETP and were taken for lab testing.
Digital analyser is available to monitor routine levels of pollutants from treated
water. Solid waste samples are taken from secured landfill site. A new development
which is noted in this audit is that digital monitoring devices will be put up on each
stack for daily monitoring and these readings will be noted in control room as well
as in GPCB office.
2. EMS System at RIL
Here at RIL VMD, care for environment is central and is maintained at its fullest
from the inception. State of art equipment and other infrastructure are installed for
effective environmental management system. In 2000 it has earned ISO 14001:2004
certifications from DNV until May 2017. Green card performance monitoring system
is an in house environmental management system of RIL which is implemented at
RIL.
All the plants have their own targets on environmental parameters to be achieved
and this keep them striving towards success.
An excellent tree cover is maintained in and around the premises comprising of
more than 1, 50,000 trees of 145 different species.
3. EMS EXPOSURE
Later 5 days were included as a training program to know about the procedure
employed at Reliance VMD complex in Environment management system.
As explained by an employee at Reliance Industries the general system of EMS is
bifurcated into two categories namely internal audit and external audit. External
audit is carried out by DNV by ISO 140001:2015 standard and internal audit is
carried out daily by EMS department at Reliance Industries.
Reliance followed the internal audit procedure for maintaining and monitoring the
environment and as per the legal compliance of GPCB norms. The parameters which
were taken into account for monitoring environment were
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Figure1: Parameters tested
Like every company following the general procedure of EMS implementation, here
too in Reliance Industries the PDCA cycle was followed wherein Policy of the
company was defined by the chairman and accordingly the objectives were set to
achieve these objectives/targets. A detailed plan was carried out for specific every
plant working. An aspect impact assessment process was followed and risks were
assessed as well for every plant. These decisions were reviewed every day and the
parameters were monitored as per the targets to be achieved. This monitoring for
conducted every day and in a year around 130 reports were sent to GPCB as per the
compliance.
Air monitoring is of two types- AAQ and Stack monitoring, in AAQ monitoring the
stations are fixed and readings are taken of a span of 8 hours or 24 hours. Stack
monitoring is carried out for flue gas and process gas and the standard for these is
given as per EPA act of MOEFCC for specific industries.
Water is monitored for the amount of quantity used by plants in cooling and in
process. The access of water consumed can be a fire alert or issue with efficiency of
process of the plant.
Effluent monitoring is carried out on 24 parameters and here both quality and
quantity of effluent are crucial as per the GPCB norms.
Waste monitoring is a basic part of EMS; this waste is non-hazardous and hazardous
waste. Non-hazardous waste like metal scrap, plastic, wood etc. is sold or trashed
and hazardous waste can be flammable, toxic, inert or reactive. This waste is treated
with a 5 step waste minimization procedure i.e Landsink ladder.
Air
WaterEffluent
Hazardous
Waste
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Figure2: LandsinkLadder
1. At the top of his pyramid is waste minimization; this is the first step which should
be taken in any process. When we reduce wastage the process becomes efficient and
production increases
2. Second step is reduce and reuse level wherein the products are reused or recycled
or are reduced. Example can be taken as lube oil which with a little processing can
be reused in industry.
3. Incineration is the third step where the waste obtained is burnt in controlled
environment to get ash waste which is then dumped into secured landfill location.
4. Co processing is like incineration where the waste is burnt and the energy
obtained during the process is utilized in the plants again. This is used on the waste
which has higher calorific value.
5. The waste which is inert in nature has to be directly taken to secured landfilling
site for disposal.
According to GPCB norms, 90 days is the limit given for the disposal of hazardous
waste by industries.
Minimization
Recycling/Reusing
Incineration
Co-processing
Secured Landfill
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4. ETP Plant Visit
A brief visit of two hours increased my awareness about the working and treatment
of Effluents which are harmful to environment if left untreated. Initially the flow
diagram was properly explained point to point by Mr. Das Sir and then the plant
and its actual working was explained in detail by Mr. Jain Sir. Whole and whole how
at every stage the effluent becomes a bit less harmful to environment is what was
learnt in this visit. Moreover the targets set by this industry section were looked at.
ETP is effluent treatment plant which is a plant where effluents from various plants
are collected and effluent is extracted out which is then trashed to secured landfill
and this treated water is used for gardening, washing and other purposes.
The arrangement of processing of this waste is very effective and efficiently made
along with very less amount of power is consumed in whole process as the flow of
effluent is managed by gravity. Only in screw pump energy is consumed in ETP
plant. The sludge reduction and water usage of this treated plant is taken up to 15
per cent.
Oily waste is collected underground and then is transferred by screw pumps to first
level and then by second screw pump to surge pond level. Here the liquid then
passes through screen chamber where waste like plastic wood etc are removed from
the liquid and this liquid passes through grit chamber where sand and other gravels
settle down. Here two more effluents are added which are directly treated partially
at the plant. This all liquid gets accumulated at surge pond whose capacity is
9000meter cube. There are 4 such surge ponds for collection of waste.
This waste the passes through gravity into homogenization tank wherein PH level of
this liquid is maintained and then is passed to flask mixer where alum is added to
remove impurities from the liquid. This water is then processed in API unit which is
a skimmer where oil is removed. Later on it passes into clariflocculator tank where
the sludge molecules are combined to form a larger molecule.
Aeration tank is the heart of this process where this water is made effluent free by
microorganism and air intake. There are two types of aerators available; surface
aeration and diffused aeration. Here in RIL (VMD), surface aeration technique is
used in process. Then water is passed on to final clarifier where sludge is separated
from clean water.
This sludge is taken to the sludge drying beds where sludge is dried and then taken
to secured landfill. Clean water passes through pipeline to VECL point, from where
50 km pipeline is laid which takes this water to Cambay.
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The parameters monitored are PH, COD, BOD, TSS, and NH3 as per the GPCB
guidelines.
5. SecuredLandfill
Reliance industries have a secured landfill site for dumping treated hazardous
waste. This is first site in Gujarat with secured construction. This is in Nandesari
area around 2 kms from the industry site. This secured landfill site has a double liner
where the leachate is prevented from entering the groundwater.
The operations are carried out as per guidelines and in here spent catalysts, resins,
plastic bags and other wastes are disposed without packing.
This operation is suspended during monsoon season and is transported to central
wastewater treatment plant at the complex for treatment.
6. PollutionPrevention andControl
1) Around 230 audits are conducted every year of which 210 are green card,6
quarterly and 2 by DNV.
2) Spill management plan is put into practice to protect the hazardous spill to be
controlled in the plant itself and to ensure no effluent gets drained through storm
water. Dyes, Sluice gates are used to control this spill.
3) Benchmarking system is used to competitively remain in environmentally efficient
system. This benchmarking is with respect to other plants like hazira, dahej etc.
4) Leak Detection and Repair program is undertaken to map the emission of those
effluents which are of very less ppm. These emissions if combined can contribute to
voluminous emissions as being of big petrochemical industry. Here an instrument
with photo ionization detector is used for detecting and monitoring volatile organic
compounds.
This monitoring of VOC is taken at three levels namely level 1, level 2, level 3.
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Figure3: LDAR Levels
5) Online effluent monitoring is in place for the parameters like COD, BOD, TSS,
Ammonical Nitrogen etc.
6) Online display of parameters like ambient air, stack monitoring, effluent etc. are
placed at entry gate to monitor the level everyday by which production can be
increased and environment can be effectively monitored.
7) Flare tip is replaced with more efficient flare tip which gives a smokeless flare.
Here the new flare is designed in a manner in which abundant spray of steam on gas
which makes this tip smokeless.
9. Executive Summary
The training period of 10 days were composed of various activities around the
petrochemical manufacturing division and the measures taken by this magnanimous
giant in terms of waste treatment and environmental management.
Activity 1 was a two day audit conducted by an external agency as a schedule 1
auditor appointed by GPCB. This team collected samples for air water effluent waste
and ambient air from different plants. These samples were to be tested in laboratory
for the results to be in assigned parameters.
Then activity 2 was a detailed discussion on the implementation system of EMS in
Reliance industries and which are the measures necessary taken for specific plants
and the general procedure which is used by Reliance in Environment Management.
The third activity 3 was reading of Ems audit report of the year 2015-16 which made
me aware of many measures of protecting the environment from hazardous and
Audio Visual
Round
Detection by
dragger tubes and
soap solution
Photo-ionization
detector
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non-hazardous wastes as a precaution and the various actions already in place by
Reliance. Along with this audit report the other details about chemical plants and
process was read.
A visit to ETP was activity 4 which was a detailed learning on working of ETP for
any industry and which are specific precaution measures taken in Reliance for it
,various processes which are used in Reliance for the treatment of wastes and its
disposal and later on plant visit to know the whole process implemented practically.
Later on Activity 5 was a study of waste disposal scheme used in Reliance and on
Secured landfills and what is the purpose and method of making a secured landfill.
Capacity and what exactly is dumped in this landfill was in discussion.
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References:
1. Environment Audit Report 2015-16, Reliance Industries
2. Google
3. Urban and waste management
Thank You
