Internship project

1. REDUCE THE RISK AND TO IMPLEMENT THE
SAFETY PROCEDURE IN THE
FERTILIZER INDUSTRY
Submitted by
PRINCEDANIEL.I
Reg.No. 920120423014
A INTERNSHIP REPORT
Submitted to the
FACULTY OF MECHANICAL ENGINEERING
In partial fulfilment of the requirements for the award of the degree
Of
MASTER OF ENGINEERING IN
INDUSTRIAL SAFETY ENGINEERING
BHARATH NIKETAN ENGINEERINGCOLLEGE
AUNDIPATTY-625 536
ANNA UNIVERSITY CHENNAI:: 620 025
JANUARY :: 2022

2. I
ANNA UNIVERSITY, CHENNAI
BONAFIDE CERTIFICATE
Certified that this thesis titled “REDUCE THE RISK AND TO IMPLEMENT
THE SAFETY PROCEDURE IN THE FERTILIZER INDUSTRY” Is the bonafide
Work of PRINCEDANIEL.I (ROLL No: 920120423014) who carried out the work
under my supervision. Certified further, that to the best of my knowledge the
work reported here in does not form part of any other project report or dissertation
on the basis of which a degree or award was conferred on an earlier occasion on
this or any other candidate.
Submitted for the viva-voce examination held at Bharath Niketan Engineering College,
Aundipatty on ……
INTERNAL EXAMINAR EXTERNAL EXAMINAR
Signature of the HOD
Dr P.V.ARUL KUMAR M.E,M.B.A, Ph.D
HEAD OF THE DEPARTMENT
Department of Mechanical Engineering,
Bharath Niketan Engineering College,
Aundipatty.
Signature of the Supervisor
R.RAJASEKARAN .,M.E
ASSISTANT PROFESSOR,
Department of Mechanical Engineering,
Bharath Niketan Engineering College,
Aundipatty.

3. II
DECLARATION
We affirm that the Project Report titled REDUCE THE RISK AND TO IMPLEMENT
THESAFETY PROCEDURE IN THE FERTILIZER INDUSTRY being submitted in
partial fulfillment of the requirements for the award of Master of Business Administration
is the original work carried out by us. It has not formed the part of any other project
report or dissertation on the basis of which a degree or award was conferred on an earlier
occasionon this or any other candidate.
DATE: (SIGNATURE OF THE CANDIDATE)
(PRINCEDANIEL.I)

4. III
ABSTRACT
Today agriculture is the back bone of our country in that to boost up the production we
tend to use of fertilizer ,so due demand of natural fertilizer ,weswitch over to chemical
fertilizer and simultaneously depend our country GDP.In that process also we can find
out the so many technique used on it in that we preferred HABER –BOSCH PROCESS
We preferred to take NEW UREA POLICY ,WHISTLEBLOWER POLICY and for the
bettermentof soil and yield production My project is also deal with find out the hazard
and risk present in the manufacture process and provide with practical implementation of
control risk and determine a certain and appropriate awareness ,SOP ,training provide
with proper PPE, policy ,code of conducton it
KEYWORDS:
PPE, HABER–BOSCH SOP ,TOTAL-RECYCLE
PROCESS,TRANING.

5. IV
ACKNOWLEDGEMENT
I am very much grateful to our Managing Chairman Shri. S. MOHAN for enabling me
to complete this work successful.
I am thankful to Dr. P.V. ARUL KUMAR, M.E., M.B.A., Ph.D., Principal, Bharath
Niketan Engineering College for his support and encouragement to complete my project
.
I extend my thanks to Dr. P.V. ARUL KUMAR, M.E., M.B.A., Ph.D., Head,
Department of Mechanical Engineering for his/her motivation and suggestion
which improved the quality of project work.
I wish to express my sincere thanks to my Supervisor Mr R.RAJASEKARAN M.E,
Assistant Professor, Department of Mechanical Engineering for his/her able guidance
and support rendered to me during the semester successful completion of project work.
Finally, I express my hearty thanks to my Parents for their moral support.
PRINCEDANIEL.I

6. V
TABLE OF CONTENTS
CHAPTERS CONTENTS PAGE
NUMBER
ABSTRACT (iii)
LIST OF FIGURE (VI)
1 INTRODUCTION 1
2 LITERATURE 2
3 PROCESS FLOW DIAGRAM 4
3.1 UREA PROCESS 4
5
3.2 AMMONIA PROCESS
4 LIST OF HAZARD IN FERTILIZER INDUSTRY 6
5 LIST OF MAIN HAZARD
5.1 CAKE FORMATION
7
5.2 ELECTROCUTION
8
9
5.3 COINFINED SPACE
5.4 POOR POSTURE
10
5.5 GAS EMISSION 11
5.6 CARBAMYLUREA
FORMATION
12
5.7 NOISE
13
14
5.8 VIBRATION
6 SAFETY ALERT 15
7 CONCLUSION 18
8 REFERENCE 19

7. VI
LIST OF FIGURE
CHAPTERS TITLE PAGE NO
3 3.1 UREA PRODUCTION 4
3.1.1 UREA 4
3.2 AMMONIA PRODUCTION 5
3.2.1 AMMONIA 5
4 HAZARD LISTED 6
5 5.1 CAKE FORMATION 7
5.1.1 HARDERNCAKE 7
5.2 PASS OVER HT LINE 8
5.2.1CONTACT WITH LIVE WIRE 8
5.2.2 STAMPING IN LIVE WIRE 8
5.3.1ENTRY OF WORK) CONFINED SPACE WORK 9
5.3.2TESTING DONE IN CONFINED SPACE 9
5.4 SIGN FORPOOR POSTURE 9
5.4.1DISC PROBLEM 10
5.4.2 LIGAMENT DAMAGE 10
5.5 (GAS EMISSION)
11
5.5.1BLURRY VISION
11
5.5.2 LUNG DISORDER 11
5.6 BIURET 12
5.6.1 AQUEROUS SOLUTION BIURET 12
5.6.2 PROTEIN TEST 12
5.7 RINGING 13
5.7.1 TEMPORARY LOSS OF HEARING 13
5.7.2 SHOUTING 13
5.8.1 MSD 14
5.8.2 WHITE FINGER 14
5.8.3 DISC PROBLEM 14
6 6.1 FIRE ON GAS CYCLINDER 17
6.2 TRAINING AND DEMONSTRATION 17
6.3 CLOSING POINT 17

8. 1
CHAPTER 1
INTRODUCTION
 Fertilizer, natural or artificial substance containing the chemical elements that
improve growth and productiveness of plants.Fertilizers enhance the natural
fertility of the soil or replace the chemical elementstaken from the soil by
previous crops The use of manure and composts as fertilizers is probably almost
as old as agriculture. Modern chemical fertilizers include one or more of the
three elements that are most important in plant nutrition: nitrogen, phosphorus,
and potassium. Of secondary importance are the elements
sulfur, magnesium, and calcium
 Urea is the world's most commonly used nitrogen fertilizer and indeedmore urea is
manufactured by mass than any other organic chemical
 Containing 46% N It is the most concentrated nitrogen fertilizer, and is readily
available as free-flowing prills (granules).
 It is the cheapest form of nitrogen fertilizer to transport and it is also the least
likely to 'cake'.
 It is therefore favored in developing countries.
 While over 90% of urea produced is used as a fertilizer
 Globally, approximately 88% of ammonia is used as fertilizers eitheras its salts,
solutions or anhydrously.
 When applied to soil, it helps provide increased yields of crops such asmaize and
wheat.

9. 2
CHAPTER 2
LITERATURE
 Fertilizers are widely used in agriculture to maintain soil fertility and toincrease crop yields.
 Fertilizer is any organic or inorganic material of natural or synthetic origin that is applied
through soil or leaves to the plants to supply nutrients
 It is essential to the growth and productivity. Before the Green Revolution, natural
and traditional farming methods were adopted for cultivation, which involved
natural methods of maintaining soil fertility and controlling crop pests
 .Consequently, upon Green Revolution commendable agricultural production has
been achieved mainly due to increased use of chemical fertilizers, pesticides and
farm machinery.
 Fertilizers facilitated higher yields on less crop area than without the use of
fertilizers;
 Therefore, they are considered important elements in worldwide foodproduction.
 As the population continues to grow, more and more agricultural output
will be required, and fertilizers will play a vital role (Clark and Kelly, 2004).
 Soil is vital natural resource on which life supporting system of a country and the
socio- economic development of its people depends.
 Soils provide food, fodder and fuel to meet the basic needs of human and animal.
 India is the seventh largest nation in the world with a geographical area of 328.7
million hectare and more than1000 million people
 Agriculture is the foundation of the Indian economy, which contributesabout 22
percent of gross domestic product from 141 million hectare cultivated area
 .Rapid increase in population of India has necessitated parallel increase in food
grain production.
 Out of total geographical area of the India, about 50% is already undercultivation
(which is about five times more than the international average of 11%).
 This indicates that in India, there is no more land to bring under cultivation and the
capacity of the Indian soil to produce is limited because of intrinsic
characteristics of soil and soil management.

10. 3
 Food-grain production in India more than doubled itself during the post- Green
Revolution.
 However, overuse of chemical fertilizers, pesticides, especially invegetables and
fruit plants, resulted in residues above safety levels (Agnihotri, 1999)and showed
ill-effects; even drinking water is not spared (Anonymous, 2004)These ill effects
of modern agriculture forced people,
 Especially in countries with high-income economies to demand food grown
without chemical l fertilizers and pesticides.
 Growing awareness of health and environmental issues in agriculture has
demanded production of organic food, which is emerging as an attractive source
of rural income generation, and this paved the way for organic farming (Prasad,
2005).
 Use of fertilizers and manures is a key factor to sustain fertility of the soil.
 Fertilizers being a costly input, the scientific approach towards the profitable
agriculture would imply the supplemental use of plant nutrients according to the
actual need of the situation (Agboola and Ray, 1994)
 On the other hand, foliar fertilizers as chelate should be easily absorbed by plants;
rapidly transported and should easily releasetheir ions to affect the plant growth
(Larue and Hohnson, 1989).
 Amino acids are moderately strong chelating absorbed by plants agents,
micronutrients chelated using amino acids remain in solubleforms

11. 4
FEED( + + ₂ )
CHAPTER 3
PROCESS FLOW DIAGRAM
UREA PRODUCTION:
FIG :3.1.1
(UREA)
PUMP
PRILLING TOWER
PRODUCT
(UREA)
FIG 3.1 PROCESS FLOW DIAGRAM FOR UREA PRODUCTION
TANK OF MOLTEN MASS
EVAPORATOR
DISTILLATION TOWER
SYNTHESIS TOWER

12. 5
PRIMARY REFORMER
DESULPHURISATION
SHIFT CONVERSION
SECONDART REFORMER
METHANATION
CO₂ REMOVAL
AMMONIAPRODUCTION:
ZNO ZNS
H₂O FLUEGAS
AIR HEAT FIG 3.2.2
(AMMONIA)
HEAT
HEAT CONDENSATE CO₂
POWER
HEAT POWER/HEAT PURGE
FIG 3.2 PROCESS FLOW DIAGRAM FOR AMMONIA
PRODUCTION
COMPRESSION
AMMONIA SYNTHESIS

13. 6
CHAPTER 4
LIST OF HAZARD IN FERTILIZER INDUSTRY
 Noise  Cake formation
 Vibration  Electrocution
 Spill  Prills formation
 Feed rate  Work at height
 Poor posture  Un guarded machinery
 Gas emission  High exposure to sunlight
 Decrease in reflux rate  Frequent lifting
 Confined space  Carbamylurea formation
 Work place violence
FIG 4 HAZARD LISTED

14. 7
CHAPTER 5
LIST OF MAIN HAZARD
CAKE FORMATION :
 Due to increase the load in the prilling tower can been negativeconsequences of
the prill quality
 High moisture content and high temperature and increase the likelihoodof caking
problem
 While caking which leads to decrease the quality of urea and alsoformation
of rusting develop inside the chamber
FIG 5.1(CAKING SAMPLE)
FIG 5.1.1(HARDERN CAKING)

15. 8
ELECTROCUTION:
 Direct worker contact with energized equipment can occur in a varietyof
ways. Maintenance technicians might inadvertently contact overhead crane
runway conductors
 Mostly electrocution which lead to Stopping the heart beating properly
Preventing the person from breathing
 Causing muscle spasmsAnd leads to electrical burns , loss of muscle control, thermal
burns too
FIG 5.2 (PASS OVER HT LINE)
FIG 5.2.1(CONTACTWITH
LIVE WIRE)
FIG 5.2.2 (STAMPING IN LIVE WIRE)

16. 9
CONFINED SPACE :
 A person carry out the work in the confined space ,without proper
measure should have taken means serious consequences should be
delivered to them
 A toxic atmosphere may cause various acute effects, A toxic
atmosphere may occur due to the presence or ingress
of hazardous substances
 The enclosed nature of a confined space can increase the risk of heat
stroke or collapse from heat stress, if conditions are excessively hot.
FIG 5.3(SIGH FOR FIG 5.3.1(ENTRY OF WORK)
CONFINED SPACE WORK)
FIG 5.3.2(TESTING DONE IN CONFINEDSPACE)

17. 10
POOR POSTURE:
 Workers usually often done the work under pressure only so that they
much not consider about the posture of work
 Their moto and organization vision towards the completing of
assignment duties only
 They may not having adequate training towards the poor posture and
the exposure of work handling towards in works place
 This may further attract your disc cord, muscular skeleton
disorder,work related upper limb disorder, ligament damage
FIG 5.4 (SIGN FOR FIG 5.4.1(DISC PROBLEM)POOR
POSTURE)
FIG 5.4.2 (LIGAMENT DAMAGE

18. 11
GAS EMISSION :
 In the prill tower is the major of emission ,in the urea plant the
large volume of discharge of untreated cooling air contain
particular urea dust as well as NHз
 And also seen in ammonia process we can obtained through it,
 Gas emission must be covered in to toxic environment
around ,unlesswe take them in a careless way it will cause
several consequence should be face it
 So that it can damage our liver and lung disorder and may it
even blurryvision
FIG 5.5 (GAS EMISSION) FIG 5.5.1(BLURRY VISION)
FIG 5.5.2 (LUNG DISORDER)

19. 12
CARBAMYLUREA FORMATION:
 In the present in the urea in high concentration has a poisonous effecton
plant
 Rate of which the biuret produced in the molten urea and in the conc.
Aqueous urea solution has been measured as the function of ammonia
concentration
 Biuret is produced is mainly by a reversible reaction between the ureaand
iso cyanides
 Biuret in the urea may decreases the high ammonia concentration
FIG 5.6 (BIUERT) FIG 5.6.1(AQUEOUS SOLN BIURET)
FIG 5.6.2 (PROTEIN TEST)

20. 13
workplace
NOISE:
 In the fertilizer industry we can often predominantly occur loud noise
occur in the machinery section
 Noise is realize only through repeated exposure to that area so that
when we exceed the limit of occurrence we can see the consequences
 In ammonia production we can able to see in the shift
conversionprocess and the pump section we seen the loud noise occurrence
 They should be experience in temporary hearing loss after leaving your
FIG 5.7(RINGING ) FIG 5.7.1(TEMPORARYLOSS
OF HEARING)
FIG 5.7.2(SHOUTING)

21. 14
VIBRATION:
 The vibration is most common and dangerous hazard occur in the
manufacturing industry
 In vibration we can obtain while doing repair and renovate works
undergoes we can seen it
 In these also we can feel the effect only the continuous exposure and
frequent movement takes place through it
 In these we can results we can feel our disc cord depreciation ,andalso
the feels vibration white finger
FIG 5.8.1 (MSD)
FIG 5.8.2(DISC PROBLEM)
FIG 5.8.3 WHITE FINGER

22. 15
CHAPTER 6
SAFETY ALERT
INCIDENT DESCRIPTION
A worker has been carried out gusset plate modification work on the ground to
erect bracing pipes , after completion of his job it was noticed a fire caught on the
Dissolved Acetylene Cylinder which he was worked with 30 minutes ago, Immediately
people near by has extinguished the fire using foam fire extinguishers ,wet fire blankets
and wet gunny bags
OBSERVATIONS DURING INVESTIGATION:
 Hose got completely damaged from the fire
 Evidenced both cylinders Oxy & DA knobs were not turned off to release the
pressure which was in the hose
 No suitable fire extinguisher sighted nearby
 Torch was not placed in the torch pocket
ROOT CAUSE
 Worker not turned the torch nob completely off after completion of his job and line
pressure was not drained off from the hose
 Hot surface torch was placed on the hose
 Hose rolled to the pressurized cylinders
 Leather hand gloves placed on the cylinders
 Gas leak has been evidenced from the valve surface
CONTROL MEASURE
 Gas nob and cylinder nob to be turned off after job completion, Line pressure
should be drained immediately
 Torch to be placed in separate pocket after the job
 Separate hose hangers provision to be provided to roll and hang the hoses
 Do not place any kind of PPEs on the cylinders
 Gas leakage test to be done before and after completion of job

23. 16
RECOMMENDATIONS
 Daily inspections to be carried out
 Fire blanket to be ready in place during gas cutting activities
 After completion of work, inspection to be carried out for spark spatters in the
vicinity
 Leakage test to be done by using soap solution, before and after the job
 Safety awareness campaigns and mass TBT's to be organised to workers who ever
dealing with gas cylinders,
 Fabrication works strictly not allowed except it is specific to the job , especially in
hand overed areas
 Cylinders should be in upright position and secured to trolley with chains
 LN key should be available with trolley to attempt any adjustments and secure to
valve
 Pressure gauges should be in working condition
 Cylinder and torches to be provided with working flash back arrestors
 Sufficient and suitable fire extinguishers to be in place
 Only standard hoses to be supplied and should be free from damage
 Always use trolleys to shift cylinders from one place to another place
 Fire watch to be in place all the time, and should inspect the job prior , during and
after

24. 17
ACCIDENT PHOTO CORRECTIVE ACTION
FIG 6.1 (FIRE IN GAS CYLINDER)
FIG 6.2( TRAINING AND DEMONSTRATION)
FIG 6.3 (CLOSURE POINT)

25. 18
CHAPTER 7
CONCLUSION:
 In these we can come to end as mostly hazard where involved with lack of
awareness and not given adequate training needed to them in the fertilizer
industry and also use of appropriate PPE’s
 In Overall ratio, majority of the workers files their report on adverse effect on
health problems which can evidence by significant, in the blood immunization
level of the workers in fertilizer industry should compare their health with
general population
 Planning and preparedness is the key to reduce the risk of injury and illness of
workers in this industry ,there should be prepare a framework ,thatignition for the
developing safety regulation and fixing prepared guides to the fertilizer industry
 Also, fertilizer industry workers were increased risk of several physical and
mental problems ,they should often to be minor level and they should prefer
proper safety measures and should excel knowledge in the fertilizer industry,
strictly followed the laws and regulation and also acceptable safety practicesinside
the campus

26. 19
CHAPTER 8
REFERENCE
 Heinrich W. Scherer. "Fertilizers" in Ullman’s Encyclopedia of Industrial
Chemistry. 2000, Wiley-VCH, Wenham.
Jump up to:Dittmar, Heinrich; Drachm, Manfred; Voss Kamp, Ralf;
Trenkel, Martin E.; Gutser, Reinhold; Steffens, Günter(2009). "Fertilizers,
2. Types". Ullmann's Encyclopedia of Industrial Chemistry..
 "AESL Plant Analysis Handbook – Nutrient Content of Plant".
Aesl.ces.uga.edu. Retrieved 11 September 2015.
 H.A. Mills; J.B. Jones Jr. (1996). Plant Analysis Handbook II: A practical
Sampling, Preparation, Analysis, and InterpretationGuide.
 J. Benton Jones, Jr. "Inorganic Chemical Fertilizers and Their Properties"
in Plant Nutrition and Soil Fertility Manual, Second Edition. CRC Press,
2012. .
 Jump up to Smil, Vaclav (2004). Enriching the Earth.
Massachusetts Institute of Technology.
 "Summary of State Fertilizer Laws"(PDF). EPA. Retrieved 14 March
2013.