in-plant training report of ipca ratlam

2011

Institute of Chemical Technology, Mumbai

IN-PLANT TRAINING REPORT

Subimitte in partial fulfillment of Master ofChemical engineering.

Under the guidance of

Mr. M K MittalMr. Lokesh Khandelwal andMr. Promod Trivedi,Departmant of Environmental Health and Safety,IPCA, Ratlam

IPCA Laboratories Limited, Ratlam

ACKNOWLEDGEMENT

With a deep sense of gratitude, I, Inderdip Shere, am very thankful to my guides form the departments of Environmental

Health and Safety, Ipca, Ratlam, Mr. M. Mitthal, Mr. Lokesh Khandelwal and Mr. Promod Trivedi for their valuable guidance, suggestions and timely encouragement throughout the course

of this in-plant training. And providing me an opportunity to present the report on project Topic entitled as;

“Assessment of compliance of consent conditions, stipulation of environmental clearance and condition of

authorization under HSMD rule, 2008 for Ipca laboratories limited, Ratlam”

The completion of project would not be possible without the graceful help from all the members of EHS department in

several situations, Mr. Piyush Raj Purohit, Mr. Raj Kumar, Mr. Ravi Khelkar. There has been direct and indirect help form all

the peoples working in the industry.I would also like to thank my all colleague who have helped me to understand the subject better, without whom this work could

not have been a reality.

Date:15 June 2011Inderdip P. Shere

Final year, M. Chem. Engg.Department of chemical engineering

ICT, Mumbai

In-plant training, IPCA, Ratlam Page | 2


INTRODUCTIO

NIPCA Laboratories Limited, Ratlam

Introduction

Ipca is a fully integrated, rapidly growing

Indian pharmaceutical company with a strong thrust

on exports. Ipca's APIs and Formulations produced

at world class manufacturing facilities are approved

by leading drug regulatory authorities including the

US-Food and Drug Administration (FDA), UK-Medicines and Healthcare products

Regulatory Agency (MHRA), South Africa-Medicines Control Council (MCC), Brazil-

Brazilian National Health Vigilance Agency (ANVISA) and Australia-Therapeutic Goods

Administration (TGA). With operations in over 100 countries, exports account for over

52% of the company's income.

Forbes, a leading US business magazine, selected Ipca in 2003 among its top 200

successful, rising companies outside USA, with sales under USD 1 Billion. Over 19,000

companies were considered by Forbes, and of the 18 companies from India that figured in

this list, only four were from the 'Indian Pharmaceutical Sector'. Ipca happens to be one of

them. Subsequently, Ipca was selected by FORBES in this prestigious list for two

consecutive years; 2004 and 2005. From a modest income of Rs. 0.54 crores in 1975-76, the

net income has soared to Rs. 753.30 crores in 2005-06 with exports accounting for Rs.

401.83 crores. The net profit for the year ending 31st March, 2006 stood at Rs. 63.98 crores.

Formulations constitute 67 percent of the total income for 2005-06. Today, Ipca is one of

the biggest manufacturers in the world of APIs Atenolol (Antihypertensive), Chloroquine

Phosphate (Antimalarial), Furosemide (Diuretic) and Pyrantel Salts (Anthelmintic) right

from the basic stage. Ipca is also one of the largest suppliers of these APIs and their

intermediates world over.

M/s. Ipca Laboratories Ltd. is a reputed name in the Indian pharmaceutical & Health

care industry. It is a public limited organization engaged in manufacturing pharmaceutical

products since 1975 in various plants located in India. The products made by the company

have been well received both by the national & foreign users, thereby leading to further


expansions & developments M/s. Ipca Laboratories Ltd. had contemplated a major

expansion of its products & production capacity of the plant at Ratlam. The company has

been pioneers in development & market headers in most of the products made by them. The

plant at present manufactures 62 Bulk Drugs & is having formulation. The Existing

Production capacity of Bulk Drug is 2551.5 MT/year this consists of,

Tablet : 800 Million nos. /year

Injection : 20 Million nos. /year

Liquid orals : 2500 KL/year

Table 1: Plant over view


Company Back Ground

One of the first modern Pharma factories of yesteryears was commissioned by IPCA

at Mumbai in 1969. The company was originally promoted by a group of medical

professionals and businessmen and was incorporated as ‘The Indian Pharmaceutical

Combine Association Limited’ in October 1949. The present management took over in

November 1975 when the total turnover of the company was just Rs. 0.54 corers. Currently,

this premise where IPCA started its operations, houses the registered office of the company,

key departments like international marketing, R&D (formulations) and analytical

development lab are located here.

IPCA is a fully integrated, rapidly growing Indian pharmaceutical company with a

strong thrust on exports. IPCA’s APIs and formulations produced at world class

manufacturing facilities are approved by leading drug regulatory authorities including the

US- food and drug administration (FDA), UK- medicines and healthcare products

regulatory agency (MHRA), south Africa – medicines control council (MCC) , brazil-

Brazilian national health vigilance agency (ANVISA) and Australia- therapeutic goods

administration (TGA). With operations in over 100 countries, exports account for over 52%

of the company’s incomes. Forbes, a leading us business magazine selected IPCA in 2003

amount its top 200 successful, rising companies outside USA, with sales under USD 1

Billion. Over 19,000 companies were considered by Forbes, and of the 18 companies form

India that figured in this list, only four were form the Indian pharmaceutical sector. IPCA

happens to be one of them. Subsequently, IPCA was selected by Forbes in this prestigious

list for two consecutive years. 2004 and 2005. Form a modest income of Rupees 0.54 cores

in 1975-76, the net income has soared to Rupees 753.30 cores in 2005-06 with exports

accounting for Rupees 401.83 cores. The net profit for the year ending 31 st march 2006

stood at Rupees 63.98 cores. Formulations constitute 67 % of the total income for 2005-06.

Today, IPCA is one of the biggest manufacturers in the world of APIs atenolol (anti

hypertensive), chloroquine phosphate (anti malarial), furosemide (diuretic) and pyrantel


salts (anthelmintic) right form the basic stage. IPCA is also one of the largest suppliers of

these APIs and their intermediates world over.

M/s IPCA laboratories ltd, Ratlam a public limited company with share capital of

Rupees 1100 cores was established in 1984 India’s first APIs plant commissioned at Ratlam

and IPCA’s second formulations plant commissioned at Ratlam.

M/s IPCA laboratories ltd. having its registered office in Mumbai, came into

existence originally in the 1975, with a pharmaceutical manufacturing activity in Mumbai,

and gradually grown up as a large pharmaceutical corporation in coming years.

All the manufacturing operations are conducted strictly adhering to GMP norms. The

production is licensed by FDA. Batch to batch production quality control is maintained as

per he FDA rules which are the most stringent and strict amongst all the government

regulations concerning the industrial manufacturing activities.

Mission

1. Enhance continuously the total quality of life of its employees and help them realize

their potentials by

Providing opportunity to grow and realize full potential.

Improving their quality of life

Improving their skills and character

Giving joy in work / camaraderie

2. Become a key player world – wide in chosen areas of business.

3. Customer satisfaction of a high level and standards higher than that of competitors by

providing :

Quality, transparency, reliability, flexibility, cost competitiveness and enjoyable

relationship

Provide good returns to its share holders by giving

Good profitability, above average return on net worth.

Regular dividend market appreciation.


Courteous and reliable service.

Vision

Emerge as world class player in all its chosen business areas in 5-7 years.

Achieve global standards in quality, cost, service and the scale of its operations.

Become world class in the way we thing, manage and do things using principles, methods,

systems and tools of total quality management (TQM).

The Ipca Laboratories Ltd. plant is situated in North -East direction of village

Sejavta which is approximately 7 km away from Ratlam district headquarter on the Madhya

Pradesh National Highway No. 79 connecting Mhow & Neemuch. The city of Ratlam is

situated on the main broad gauge rail route of western railway connecting Mumbai & Delhi.

It is also connected to state capital Bhopal and Rajasthan by rail. Mumbai & Kandla are the

nearest sea ports. Both are connected with rail route from Ratlam. Indore is the nearest

airport & domestic flights for Ahmedabad, Mumbai & Delhi are available from here.


Plant Layout

Figure 1: Site Layout Plant


Energy Consumption

With the implementation of Energy conservation measures, Ipca could still maintain

the consumption pattern, even after its expansion of production facility almost at the same

level. The energy cost as percentage of manufacturing cost has shown the decline, for year

2006-07 it was 23.69%. Which depicts the continual reduction in energy consumption due

to sustain efforts to conserve it by implementation of various energy measure and ideas to

increase efficiency of equipments. The Table below gives the comparative figure of energy

consumption of last three years.

Ipca has Energy conservational cell headed by D.G.M. assisted by Asst. Manager &

supported by 2 engineers. This team identifies various energy saving potential in different

working areas. This team makes the proposal after a brain storming session and after

evaluating its feasibility, a report is made and submitted to management for approval.

Table 2: Energy consumption


Manufacturing process

IntroductionTo assess the possible impact of the pollutants on the environmental component, it is essential to understand the manufacturing process of the products, raw material used and nature and quantum of pollutants released during the curse of manufacturing. One may co-relate the volume and concentration of the pollutants, which is suppose to be given the treatment at pollution control facilities available at premises.

Project dataMost of the project data are process and operation related data. Project data are distinguished into project description, resources requirement (water, power, etc), technology and chemicals used, land required, and resource recovery (water, solid waste, energy, etc)

Project description

General M/s IPCA laboratories lid, located at Sejavta industrial area, Ratlam made a change in their product mix and discontinued / reduced production of certain bulk drugs and intermediates and added / increased production of certain bulk drugs and intermediates, tablets, injections and liquid orals. Total production capacity of plant is 1202 MT / year of bulk drugs, 800 millions no per year of tablets, 20 millions no/ year of injections and 2500 KL/year of liquid orals.name of product and product capacity given in Table no

S. No ProductsExisting Capacity

Additional Capacity

Total

Bulk Drugs

1. Synthetic Drug API (MTPA) 2551.5 59 2610.5

Formulations

2. Tablets (Million Nos./Year) 800 1300 2100

3. Injections (Million Nos./Year) 20 Nil 20

4. Orals (KL/Year) 2500 800 3300


5. Dry Syrup (Million nos./year) Nil 1.5 1.5

6. Ointment (MTPA) Nil 150 150

R&D Products

7. R & D Products (MTPA) Nil 05 MT 05

Steroids & Hormones

8. Steroid & Hormonal products (MTPA)

Nil 41.391 41.391


RESEARCH AND DEVELOPMENT

Located at Mumbai, Ipca’s research center is focused on generics in regulated

markets, specifically in Europe and USA. The center has expertise in Active

Pharmaceutical Ingredients, Drug Intermediates and Formulation Development which

includes NDDS and ANDA. Ipca’s Research and Development comprises of two sections:

1 Active Pharmaceutical Ingredient and Drug Intermediates

2. Formulation Development

Both the departments are supported by the Analytical Development cells which are

fully equipped with all modern instruments (like NMR, LC-MSMS, GCMS etc) required to

carry out research on day-to-day basis. Units are geared to continuously innovate and

remain competitive by developing/acquiring abilities to find simple and effective solutions

to practical problems, solutions which are free from Patent Infringement issues.

1. Active Pharmaceutical Ingredients/Drug Intermediates

The Active Pharmaceutical Ingredients/Drug Intermediates Research and

Development department at Mumbai is supported by two more units located at Ratlam and

Indore. All the R&D units are recognized by the Department of Science and Industrial

Research, Government of India.

Research & Development units at Ratlam and Indore are also supported by facilities

required for scale up of the processes from grams to kilo as well as to Pilot level.

Strengths:

Innovative chemistry-driven process research leading to the generation of non-

infringing routes for APIs/Drug Intermediates and Intellectual Property. Ipca has highly

qualified and experienced groups of people capable of handling patent-related issues, which

includes various aspects of patenting and patent evaluations.

Impurity Profiling of APIs:


This includes identification and characterization as well as structural elucidation of

unknown impurities (present in APIs), followed by their synthesis.

Analytical developments:

New method developments.

Method validations for getting products registered in Regulated Markets.

Process Research:

Process development/improvements to make products competitive and profitable in

the long run by giving major emphasis on:

Non-infringing processes

Alternative cost effective routes

Increasing plant friendliness.

Improving selectivity/reducing impurity levels by sensitive chemistry inputs.

Reducing effluent generation.

2. Formulation Development

Our Formulation Development Laboratory located at Mumbai has been gearing up

for a state-of-the-art R&D facility (in line with the US-FDA requirements). The current

R&D activities are also approved by the Department of Science and Technology,

Government of India. The laboratory is well equipped with various ultramodern equipments

and technologies required for conducting high quality research activities.

Some of the equipments available in the R&D are:

High Sheer Mixer (GMP model)

Fluid Bed Drier

Fluid Bed Processor

Ganscoata

Walk-in Stability Chambers

Dissolution Apparatus with intrinsic dissolution


Assembly

Bilayer Tablet Compression Machine

Equipments for liquid orals and semi-solid

Hard gel capsule facility

Blister packing machine with Alu-Alu facility

Press-cota

Roll compactor

Pelletisation facility

Facility for Effervescent tablets (low RH area)

Reverse laminar flow

The key activities of R&D-Formulations are:

Novel Drug Delivery System (NDDS):

R&D in this area attempts to improve the efficiency with which the medicine is absorbed in

the body. Novel

Drug Delivery Systems (NDDS) efforts are directed towards:

1. Controlled Release:

Ipca’s Research concentrates on sustained, delayed and pulsatile release. The company

introduced a novel

bilayer tablet for an antidiabetic combination.

2. Novel Dosage Formulations:

In the novel dosage form, the company concentrates on the following therapeutic segments.

Cardiac Care

Anti-infective

Anti diabetics


Ipca’s R & D laboratory has filed patents across the world for products based on the

NDDS. Ipca’s strength in this segment of R&D puts the company in an excellent position to

compete in the growing markets for generic drugs in Europe and USA.

Abbreviated New Drug Application (ANDA):

The filing of ANDAs received a major boost after Ipca opened its wholly owned subsidiary

in New Jersey, USA. The company will now be working on ANDAs to address the growing

opportunity in USA. Ipca’s research endeavors are well supported by world class

infrastructure comprising:

Analytical Research

Clinical Research

International Regulatory Affairs

Corporate Quality Assurance

Intellectual Property Cell

Manufacturing of generic products for registration in UK/EU/South Africa/Brazil and many

other countries

At present, pollution and its abatement are a concern at every level. It is essential to

understand the magnitude of the task confronting the developing world to maintain the

cleanliness of its environment while keeping up the pace of industrialization.

While the industrial revolution brought comforts to the making in abundance, it also

brought with in miseries and discomforts, the degradation of environment, due to

industrialization, has been at an alarming pace, the increasing urban and sub –urban

population, which needed the goods in large quantities, brought with it industries in large

numbers, the Ganges of yesteryears is not the Ganges of today. The country has to cleanse


the Ganges which was supposed to be purest in the world. As a matter of fact, not only the

Ganges, but most of the available water in the country is polluted, in addition to the

pollution of water the pollution of the air is also on rise.

Keeping the above facts in view, manufactures and entrepreneurs have no longer the

freedom to disregard to environment and they have to take every precaution to see that the

environment s not exploited in any manner. The enlightened management of the industries

has every reason to put all its might to keep the environment as pure as possible.

Communities all over the world, including India, have introduced legislations. In India, the

water (prevention and control of pollution) act was promulgated in 1974.

The other act, namely, air (prevention and control of pollution) act followed in 1981. These

tow acts aim at controlling pollution at source. The central government also promulgated a

comprehensive umbrella act, namely, environment (protection) act in 1986.


Treatment and evaluation of the waste water management

IntroductionPrediction of impacts is the process of determining the nature and extent of the environmental changes that may result form proposed activity. The predicted value for environmental variables from the objective basis for the assessment of the environmental feasibility of the proposed activity and for evolution of the effectiveness of mitigating measures.

The management of M/s IPCA laboratories Ltd., Ratlam has decided to carry out an evaluation and performance study of exiting ETP. The study was conducted by setting up field stations for measurement of ambient air quality, meteorology, analysis of water and soil, collection demographical and other relevant data.

Table 3: pollutant sources and characteristics

S no

Activity Pollutant Pollutants characteristics

Frequency

Construction phase

1 Ground working and leveling

Air emissions –SPM, PM10, CO,NOx,SO2

Dust form construction activities and excavation. Particulates, NOx and Co form vehicles exhaust

Temporary during construction phase only- bulk of the emissions are expected from ground working and leveling activities

Earth/ solid waste

Solid waste form construction activity and excavation

Periodic

Noise Noise generated form construction equipment and machinery

Temporary during initial construction phase

2 Labor camps Sewage Sewage generated form temporary labor camps on site

Temporary- during the initial construction phase

Operation phase

1 Vehicular movement

Air emissions and noise

Vehicle exhaust emissions

Continuous / periodic

2 Diesel power generators

Air emissions SO2,NOx, SPM , CO form fuel burning

If power cut from MPSEB


Noise Noise due to running of equipment

Continuous

3 Sewage treatment plant

Solid waste Settled and stabilized sludge

Continuous

Treated water Treated sewage used for horticulture

Continuous

4 Diesel storage Solid waste Settled sludge during tank cleaning

Occasional

Oil Oil spillage- accidental large spills due to pipe rupture oil spillage – small quantities due to small pipe leaks

Accidental / only due to poor housekeeping

5 Hydrogen bullets

Thermal / blast effect

Accidental explosion due to hydrogen leaks and fire

Accidental

6 Maintenance housekeeping

Waste water Floor washing Continuous

Solid waste Used equipment parts and garden waste

Continuous

7 Air conditioners

Air emission Ozone depleting substance release

Continuous

8 Vehicle parking area

Oil spills Minor oil leaks in parking lot

Continuous- small quantities

Water environment As stated, during operation phase, the total quantity of water is required per day for

exiting project is about 622 m3/day (622KLPD) which includes 150 KLPD of water for

utility, 250 KLPD for cooling purposes, 100 KLPD for domestic and 122 KLPD for process

purpose. Therefore total fresh water needs to be pumped is about 622 KLPD for

consumption of domestic and industrial purpose. Discharge of domestic/industrial waste

water is 350 m3/day form the exiting project, form which domestic/industrial waste waster

shall be treated in well designed effluent treatment plant. The entire volume of treated water

shall be recycled again for different uses. Part of the treated water will cover the

requirement of the cooling tower and fan coil units, which is basically the HVAC

requirement and balance water will be used for green belt development. Thus there will be


no adverse impact over the water environment. Detail of water balance is given below in

table

Table: details of water consumption per day

1 Domestic 100 m3/day

2 Industrial a. Process 122

m3/dayb. Cooling 250

m3/dayc. Utility 150

m3/dayTotal 622

m3/day

Table: details of waste water generation per day

1 Domestic 95 m3/day

2 Industrial a. Process 122

m3/dayb. Cooling 58

m3/dayc. Utility 75

m3/dayTotal 350

m3/day

Exiting effluent treatment plant The facility has a full fledged effluent treatment plant designed for a hydraulic flow

of 500 m3/day. (Flow diagram attached)

All the effluent generated form the process plants and utilities are led to ETP through “impervious” drainage system/ the waste water form various units and streams of the plant are finally mixed together in the equalization chamber and then the composite effluent is collected into a holding tank no 1

The present effluent generation quantity is around 280m3/day

Therefore the present effluent treatment plant is adequate enough to treat the hydraulic load of waste water as per given below in table.


Methodology of treatmentThe existing treatment process comprises of the three stages;

Primary treatment Secondary treatment Tertiary treatment

The effluent treatment is carried out in three stages

1. Primary treatment to reduce the suspended solids and BOD/COD2. Secondary treatment which is a two stage biological treatment to reduce BOD/COD3. Tertiary treatments consisting of pressure sand filter and activated carbon filter to

polish the effluent


Primary treatmentThe composite effluent form the plant is passed through oil and grease trap to

separate the oily matter. The oil layer is periodically removed form the oil and grease trap / chamberThe oil collected in drums and incinerated in the incinerator.

The effluent is then collected in tow nos. of holding tanks operating in series. The first tank is of 300 m3 holding capacity with 3 nos. of 5 HP floating aerators, followed by another tank of 150 m3 capacity with 2 nos. of 5 HP floating aerators. The total retention time is about 22 hours. On average flow.

These tanks serve the purpose ofa. Equalization of effluent feed stream.b. Stripping of volatile organicsc. Mixing of neutralizing chemicals

The neutralized effluent is then pumped to the chemical treatment tank where a coagulant dose, alum or PAC or ferric chloride is added. It is then passed into a primary clarifier to facilitate settlement of flocculated mass for better flocculation polyelectrolyte is also added. The primary sludge settled at the bottom of clarifier is taken into sludge drying beds for drying, while the clarified effluent is further subjected to biological treatment.

Secondary treatmentThe biological treatment provided is a tow stage extended aeration activated

sludge process. The residence period in the total system is 3 days and oxygen supplied is 2400 kg/day by means of 98 HP surface aerators.

The clarified effluent form the 1at stage clarifier is taken to an intermediated sump for pumping to the 2nd stage aeration tank. In the secondary aeration tank BOD and COD is further reduced.

The secondary sludge form both the secondary clarifiers is recycled in their respective aeration tanks or taken to the sludge drying beds for drying.

Tertiary treatmentTertiary treatment facility at the plant comprises of following units

I. Pressure sand filterII. Activated carbon filter.

The clarified effluent form second stage secondary clarifier passes through pressure sand filter. In the sand filter fine suspended matters and colloidal matters are removed.

The quality of the biological oxidized effluent is slightly higher the standards prescribed. Hence it is further taken for tertiary treatment by passing through


activated carbon to remove traces of organics. This will act as a polishing treatment to the biologically oxidized effluent.

Further carbon adsorption helps in removal of the refractory organic compounds in the waste water.

Effluent the tertiary treatment, the effluent passes through a holding sump provided with V- notch. It is then pumped to the holding lagoon located at the dairy farm through a closed pope line for final disposal. Ultimately the treated effluent is disposed off either by solar evaporation or use for irrigation purposes.Form quality of treated waste water it is observed that it is meeting the discharge norms of MPPXB for treated effluent. Even the yield of the various crops like maze, wheat and sugarcane etc. taken form this water is quite good.

Table 4: details of units of effluent treatment plant

S no

Unit Size (m)

Volume (m3)

Hydraulic retention time

1 Oil separator (2 no) 5 *1.2*1(SWD)

6 1 hours on average flow

2 Holding point (2no0 with floating aerators / mixers

12.5(D)*2.5 (SWD) *3

300/150 22hours

3. Chemical treatment tank with slow mixer

2.5 *2.5M*2.0M SWD *3 nos.

12.5 0.5hours

4 Primary clarifier 7 (diameter) *2.6 (SWD)

100 4hours

5 Bio reactor no 1 with surface aerators

9.25 *18.5 *3(SWD) +1.0

1000 1.5 days

6 Bio reactor no 2 with surface aerators

18.5 *18.5*3(SWD) +1.0

500 1.5 days

7 Secondary clarifiers 1 and 2 7 (diameter) *2.6 (SWD)

100(each) 4 hours

8 Intermediate effluent 2.6(diameter) *2 (SWD)

10 -

9 Sludge drying beds 10 *10*3 300 6 days10 v-notch chamber 1.55 *0.8*0.8 0.96 -11 Lagoon Bottom

(71.5*49.2)Top (85*62.5*4.3)

- -

12 Sand filter 0.3 *1.5*3nos 13 Activated carbon filter


Table 5: details of the mechanical equipments

S no

Equipment Hp Make Purpose

1 Intermediate effluent pump

5 KIRLOSKAR Pumping effluent form intake well to oil separator

2 Return sludge pump

5 CROMPTOM GREAVES/RADICON

3 Floating aerator 5 CROMPTOM GREAVES/RADICON

Attaching to holding tank

4 Mixer 3 KIRLOSKAR Chemical treatment tank

5 Surface aerator (4 no)

15 KIRLOSKAR Bioreactor tank

6 Primary clarifier 2 CROMPTOM GREAVES/RADICON

7 Secondary clarifier 2 CROMPTOM GREAVES/RADICON

Sewage treatment plant All the sanitary discharges are diverged to STP via drains and sewage discharges are collected into a septic tank. Septic tank overflow is transferred to the bio reactors where it acts as a nutrient for bio mass development. There is no direct discharge of sanitary and sewage waste water on surface water bodies of possibility ground water contamination.

Waste water characterization To carry out a systematic performance analysis of the existing effluent treatment plant, it was decided to collect the samples from all the units of the plant.All the results are complied in enclosed table and are as follow.

Sampling date Following are the average analysis data of the samples.


Table 6: average analysis data of the samples

Parameter

Outlet of equalization tank (holding tank)

Outlet of chemical treatment tank

Outlet of primary clarifier

Secondary clarifier 1

Final tank

Bioreactor

1 2pH 7.5 8.53 7.44 7.405 8.52BOD 1660 1660 8.42COD 5110 5110 3057 1318 32.38

5TS 4931 4931 0TDS 4678 4678 0TSS 253 253 56.2 0MLSS 337

53626.77

Design basis and details of the exist ion ETP1. Raw waste waster characteristic:- the average characteristics of the raw waste

water has been found as below:

Flow 500 m3/daypH 6.5-10.5BOD 800-2000COD 2300-5000TS 1200-9800TDS 1000-9000TSS 200-800O&G 20-40

2. The effluent treatment plant consists of the following units

Oil and grease trap

No of traps 2 nosDimensions 5M*1.2M*1M SWD

*2nosMaterial of construction

RCC tank with polyurethane coating

Retention time 1 hour on average flowVolume 6m3(each)


Holding pond

Holding ponds 2 no’sMaterial of construction

it is RCC tank provided with polyurethane coating

Volume 150 m3/300 m3Dimensions 12.5 m diameter *2.5 MSWD*3NosRetention time 22hours on average flow

These tanks are be provided with floating aerators / mixers for mixing and equalization of effluent

Chemical treatment tank

Volume 12.5m3

Material of construction

RCC tank with polyurethane coating

Retention time 0.5 hour on average flowDimensions 2.5M*2.5M*2.0M SWD

*3nosThe tank provided with slow speed mixer. These mixers are also help in effective neutralization of effluent during addition of neutralizing chemicals.

Primary clarifier

Volume 100 m3

Dimensions 7M diameter *2.6M SWD

Retention time 4 hour on average flow (20 hours)

Material of construction RCC tank

Sludge drying beds

Chemical sludge 200 kg/dayDrying period 6 days


Produce per day % consistency

2.0%

Material of construction

brick masonry construction provided with 600 mm height filter media

Volume 12.5m3

Drying bed area 200 m2

Dimensions 10 M*10*2 no’s

Bio reactorTotal BOD load 1500 kg/dayBOD load after primary treatmentBOD loading (F/M)I stage 0.3II stage 0.15MLSS concentration 4000-4500 PPMOxygen requirement 2.0 kg of O2 / Kg of BOD appliedVolume of bio reactorI stage 1000m3

II stage 500 m3

Retention time (overall) 3.0 days (approx)DimensionsBio reactor no I 9.25 M*18.5 M*3.0M SWD +1.0 MBio reactor no II 18.5 M*18.5 M*3.0M SWD +1.0 MHP required for oxygenation90 HPMaterial of construction these are RCC tank, provided with RCC Bridge for installation of surface aerators.

Secondary clarifiersNo of tanks 2 no’sVolume 100 m3 (each)Retention time 4 hours on average flowDimensions 7M diameter *2.6 M SWDMaterial of construction RCC tank

Intermediate effluent sump


Function to pump the 1st stage clarified effluent to 2nd stage aeration tank

Volume 10 m3

Dimensions 2.6 M diameter *2.0 M SWDMaterial of construction RCC tank

Sludge drying beds% consistency 1.0%Drying period 6 daysDrying bed area 300 m2

Dimensions 10 M*10*3 no’sMaterial of construction brick masonry construction provided with 600 mm height filter media

V-notch chamberThis chamber is provided with a V- notch to measure the out going flowDimensions 1.5 M*0.8 M * 0.8 M Material of construction brick masonry /RCC

Lagoon The effluent water is being stored in the lagoon is given appropriate physical and chemical treatmentDimensions bottom diameter 71.5 M* 49.2 M

Top diameter 85 M* 62.5 M *4.3 MMaterial of construction brick masonry /PCC lining

Sand filterNo 1 Size 0.3 M * 1.5 M * 3Capacity for 80 m3/day is sufficient for sand filter and activated carbon filter

Activated carbon filterNo 1Size 0.3 M * 1.5 M * 3Capacity for 80 m3/day is sufficient for sand filter and activated carbon filter

Analysis and observation of the existing ETPDesign basis


Supplier has taken the values at higher side considering the changes that may occur with the time span

Flow 350 m3/day

pH 6.5-10.5BOD 1500COD 5000TS 5000TDS 4500TSS 500O&G 50

Considering is to be continuous process has been applied 1. Oil separator

Design flow taken as 6.0 m3/dayRetention time then 1 hour (remark) (OK)

2. Holding pond

Design flow taken as 150 m3/day

Retention time then 22 hours (remark) (ok)

3. Chemical treatment tankDesign flow taken as 12.5 m3/dayRetention time then 0.5 hours (remark) (OK)

4. Primary clarifierDesign flow taken as 100 m3/dayRetention time then 4 hours (remark) (OK)

5. Bio reactorBOD load 1500kg/dayBOD loading (F/M)

I stage 0.3II stage 0.15

MLSS concentration 4000-4500 PPMOxygen requirement 2.0 kg of O2 / kg of BOD applied (remark) (OK)For tank volume of 1000/500 m3 the MLSS and F/M ratio is within design parameter

6. Secondary clarifierDesign flow with 100% re-circulation 100 m3/dayOver flow rate 16m3/m2/dayRetention time 4 hours


The oil and greases content has reduced form 130 – 150 mg/l to 16 -20 mg/l at primary oil separatorsThe effluent equalizes over the organic load due to proper mixing and the volatile matter is also removed by stripping of solvent traces giving substantial reduction in COD levels reveals proper functioning of aeration grid and sprinkler nozzles in equalization tank Introduction of more effective coagulants like FeSo4 and poly electrolyte in neutralization tank The reduction in the COD concentration in the primary stage has been observed as 35- 40 %Better bacterial grow this observed and the DO levels have increasedThere is no accumulation of the activated biomass and the entire bio mass is available for recirculation in secondary settling tank Pressure sand filter and activated carbon filter has helped in the tertiary treatment in maintaining the outlet norms

Suggestion and recommendation on performance of existing ETP The existing ETP at EPCA, Ratlam has been over designed. The parameters as analyzed before treatment is of very high concentration but after treatment at the ETP all the parameters falls within the prescribed limits of MPPCB. For better functioning of the ETP, the following suggestions are advisable1. Dosing at neutralization tank can be minimized, if proper dosing calculation

can be done.2. Oil removal system can be made more effective if proper skimming of the

floating oil is made from time to time3. Quantity of lime dosing to be properly calibrated to reduce lime sludge4. Design MLSS to be maintained at the aeration tank 5. DO level to be monitored at the aeration tank \sludge level to be monitored at

the secondary settling tank 6. Proper backwashing of the PSF and ACF to be done to obtain maximum

efficiency.7. RO treatment can be used for reduction of TDS of the final treatment effluent

for further use.


PERFORMANCE EVALUATION OF THE INCINERATOR

INTRODUCTION

Prediction of impacts is the process of determining the nature and extent of the environmental changes that

may result from proposed activity. The predicted values for environmental variables from the objective

basis for the assessment of the environmental feasibility of the proposed activity and for evaluation of the

effectiveness of mitigating measures.

DESIGN BASIS AND DETAILS OF INCINERATORS

1. Waste Data

Composition Solid ( % by weight) Liquid ( % by weight)

Chlorides 1.6 6.3

Phosphorous 1.7 6.9

Carbon 32.1 33.03

Hydrogen 5.06 5.16

Sulphur 0.23 0.40

Oxygen 35.88 60.2

Nitrogen Traces Traces

Ash 26.73 1.21

Calorific value ( Kcal/kg) 1817 9664

2. Area Classification : Non Hazardous


Duration for operation : 20 hrs per day

3. Utility Specification

Fuel LDO

Instrument air 6-7 kg/cm3 9g) dry, oil and dust free

Process Water 2 kg/cm2 (g) at ambient

Alkali Solution 5% NaOH

Power

Motor

Instrumentation & Control

440 V, 3 phase, 50 Hz

230V, 3 phase, 50 Hz

4. System Parameters

A. Solid waste Incinerator

Type Pyrolytic with primary and secondary

chambers

Thermal Capacity 710000 Kcal/Hr

Operating Temperature

Primary

Secondary

750-850 oC

950-1150 o C

Operating Pressure -5 to -15 mm WG

Auxiliary Fuel LDO


Firing Rates (Kg/Hr) 100 (Kg/Hr) solid waste

Mixing Firing 50 (Kg/Hr) liquid waste

Duration 10 hrs/day

B. Quench

Type Open Spray type

MCC Acid resistant refractory

Flue gas inlet temp 500 oC

Flue gas outlet temp. 50oC

Quench Field Water

C. Absorption Tower ( Packed Coloum)

Type Vertical Cylindrical randomly packed

MCC MSRL

Type of Packings PP Intallox sadddie

Scrubbing Media 5% Alkali Solution

D. Stacks

Type Self Supported

Diameter 400 mm at top

Height 30 mtrs

MOC MSRL

E. Combustion cum Dilution Air Fan

Type Centrifugal

MOC MS

Capacity 6000 M3/hr


Head 150 mm WG

Motor 7.5 HP

F. I/D Fan

Type Centrifugal

MOC MS

Capacity 7500 M3/hr

Head 400 mm WG

Motor 25 HP

G. Fuel Oil Tank

Type Horizontal Cylindrical

MOC MS

Capacity 1 M3

H. Recirculation Pumps

Type Centrifugal

MOC UHMW

Capacity 25 M3/hr

Head 3 kg/cm2 (g)

Motor 10 HP

I. Plate Heat Exchanger

Type Plate type

MOC Titanium

Thermal capacity 5,30,000 Kcal/hr


Cooling Water Inlet temp – 32 0C

Outlet temp – 38 0C

PERFORMANCE EVLUATION FOR INCINERATOR

1. Burner installed on the unit is of pre jet type with following specification:

Capacity : 3.00 LKcal/Hr X 2 nos.

Fuel : LDO

Comment (A) Both the burners are found in working condition with satisfactory performance.

(B) Combustion Was Colourless

(C) Sensor working properly

2. Stack Temperature found to be in range of 60-80OC, which is as per recommended practice.

3. Refractory lining checked and found to be OK

4. Fuel filter and pressure gauge were working properly.

5. ID fan and FD fan is working properly.

6. Safeties & Control of the unit(A) Bypass Damper opening in case of power failure(B) Combustion parameters at the outlet of the unit were checked & found OK


7. Client has installed and Heat recovery unit at the flue gas outlet of the incinerator, which shows the concern of the user to prevent the losses & save the environment.

8. Performance of Incinerator is 99%.

SUGGESTION & RECOMMENDATION1. Timely overhauling and replacement of burner is needed attention.

2. Regular maintenance is to be scheduled for refractory lining.

3. Confirmation required with the design parameters towards the pressure drop across the heat exchanger is in

line with the safety limits of the fans.

4. Further safety devices like flame failure, auto ignition, fuel pump for low and high pressure, charging door

open interlocking are recommended of better performance of the incinerator.


Environment health and Safety

EHS Management system

Environment, Health, Safety (EHS) program is managed according to the framework that sets out consistent standards of employee health and safety, environmental protection and sustainability. This framework acts as an internal regulatory system that reflects our understanding of risks to ensure our operations comply with laws and regulations. Our integrated EHS management system is further evaluated on a regular basis to identify areas for continual improvement.

By thoroughly tracking our performance, we are able to spotlight our successes in eliminating or reducing our EHS impacts, quickly and responsibly handle any EHS issues, and identify key areas where we need to focus on improving our performance.

During the past few years, Ipca has improved energy efficiency and reduced the emissions in various operations. Our strategy is to focus on continuous improvement by striving to learn from our experience and those of others, and to apply scientific, economic and technical analysis to adopt best practices.

Environment management system

To achieve sound environmental performance, organizational commitment towards a systematic approach and continual improvement of its all aspects arising out of all its activities is a pre- requisite.

They have made an inventory of all activities, which are interfacing with environment and have positive of negative impact. To mitigate the adverse effect of all such activities documented procedures are implemented by trained persons. Wherever required “environment management procedures” are made to mollify the adverse effects of the industrial activities. Management review is done periodically of EMS and preventive measures are decided and implemented

Experience of last few months after implementation of EMS cam be narrated in the following few words.


Environment policy

IPCA laboratories Ltd .Ratlam is committed to create and maintain clean, safe and pleasant working environment. They used to do continual improvement for pollution control over and above abiding all environmental legislation and regulations.

They have taken initiation for energy and water conservation, waste reduction and other objectives, keeping in view the interest of employs and associates. They give averseness training to employs, contractors and the concerned vendors.

What is pollution?

The air, water, soil, plants and animals – all constitute the environment. These constituents keep on interaction with each other to maintain a mutual balance, called ‘ecological balance’. Man, using nature in the process of development does cause certain changes in environment. It these changes are not fully orchestrated to preserve the harmony of nature and the ecological balance, he runs the risk not only of increasing the costs of development but also of imbalances which may be so serous as to reduce his living conditions instead of enriching them. It is this imbalance which creates pollution.

Industrialization and pollution

Industries have often been called “the big polluter”. The impact on human environment is not restricted to highly industrialized countries only. India also has severed pollution problems of its own. Improper location of industries, the use of ‘polluting’ technologies, and inadequate waste treatment facilities are mainly responsible for deterioration of air and water quality in industrialized cities of our country.

There is a growing need for industrialization and more important is to preserve and world for improvement of environment and ecology. IPCA laboratories ltd. Ratlam has given equal importance to both

Following steps have been taking to preserve and enrich the environment and ecology at IPCA laboratories lid, Ratlam 1. Technology selected which is less pollution.2. Training people and creating full awareness in this direction.3. pollution controls considered a social need in place of legal requirement 4. Integrated facility for effluent treatment and incinerator and its monitoring 5. Extensive tress plantation.


Formulation of check list as per concerning environmental acts

Hazardous Waste (Management and Handling) Rules, 1989Order Rules Rules

citationChecked

1 Responsibilities of the occupier for handling of Hazardous wastes

4

1.1 Is Hazardous wastes generated is sent or sold to a recycler of re-processor or re-user registered or authorized?

Sub rule 2 Yes/ No

1.2 Is hazardous wastes transported in accordance with the provisions of these rules

Sub rule 3 Yes/ No

1.3 Is facility to the treater provided as per state pollution control board? Sub rule4 Yes/ No

2 Grant of authorization for handling hazardous wastes 52.1 Is it authorization from the State pollution control board? Sub rule 1 Yes/ No2.2 Is application in Form 1 made to state pollution control board for

authorization?Sub rule 3 Yes/ No

2.3 Is authorization in Form 2 obtained from State pollution control board?

Sub rule 4 Yes/ No

2.4 Whether authorized person who is handling Hazardous wastes maintaining record in Form 3?

Sub rule6 Yes/ No

2.5 Is prepared record is submitted to State pollution control board as specified in Form 4, before 30th of June?

Sub rule6 Yes/ No

2.6 Is application for renewal of an authorization in made in Form 1? Sub rule7 Yes/ No

3 Storage of hazardous waste 73.1 Is record of sale, transfer, storage, recycling and reprocessing of

Hazardous waste is maintained?Sub rule1 Yes/ No

4 Procedure for grant of registration 84.1 Is application in Form 5 for recycling or reprocessing of hazardous

waste is made?Sub rule1 Yes/ No

4.2 Is consent to establish granted by the State pollution control board attached?

Sub rule1 (a) Yes/ No

4.3 Is certificate of registration issued by the district industries center or any other government authorized agency, attached?

Sub rule 1 (b) Yes/ No

4.4 Proof of installed capacity of plant and machinery is attached? Sub rule 1 (c) Yes/ No4.5 Is certificate for compliance of effluent, emissions standards and

treatment and disposal of hazardous wastes, is attached for renewal?Sub rule 1 (d) Yes/ No

4.6 Is records of hazardous wastes purchased and processed is maintained?

Sub rule 2 Yes/ No

4.7 Is the records is filed in annual return of its activities to state pollution control board on 30th June of every year?

Sub rule 7 Yes/ No

5 Do we sell hazardous wastes to the occupier having valid registration from central pollution control board for recycling or recovery?

9 Yes/ No

6 Is utilization of hazardous wastes is processes is approved by central pollution control board?

11 Yes/ No

7 Treatment, storage and disposal facility for hazardous wastes 187.1 Is the design and setup of treatment storage and disposal facility as

per technical guidelines issued by the central pollution control Sub rule 2 Yes/ No


board?7.2 Is the storage and disposal facility is operated as per the guidelines

issued by the central pollution control board?Sub rule 4 Yes/ No

7.3 Is record for treatment, storage and disposal facility of hazardous wastes is maintained?

Sub rule 5 Yes/ No

8 Packaging and labeling 198.1 Is packaging and labeling for safer handling, storage and transport is

as per the guidelines issued by the central pollution control board?Sub rule 1 Yes/ No

8.2 Is labeling and packaging is easily visible and could sustain physical conditions and climatic factors?

Sub rule2 Yes/ No

9 Transportation of hazardous waste 209.1 Is transportation of hazardous wastes as per rules of motor vehicles

act, 1988?Sub rule1 Yes/ No

9.2 Is in formation regarding hazardous wastes and an emergency measure is provided to the transporter in Form 11?

Sub rule2 Yes/ No

9.3 Is hazardous waste containers are marked as per Form 12? Sub rule2 Yes/ No9.4 Whether the ‘No objection certificate’ from State Pollution Control

Board of both the states (from and to) is obtained?Sub rule3 Yes/ No

10 Manifest system (movement of document to be used within the country only)

21

10.1 Is 6 copies of manifest in Form 13 prepared as per the rule Sub rule 1 Yes/ No10.2 Is copy 1 (white) is forwarded to state pollution control board? Sub rule 2 Yes/ No10.3 Is copy (blue) is received from operator on completion of treatment? Sub rule 5 Yes/ No

11 Records and returns 2211.1 Is a record of operations of facility for disposal of hazardous waste is

maintained in Form 3?Sub rule 1 Yes/ No

11.2 Is annual returns is sent to state pollution con troll board in Form 4? Sub rule 2 Yes/ No

12 Accident reporting and follow up 2412.1 Is report of accident dealing with hazardous wastes, if any, is

submitted to state pollution control board in Form 14?24 Yes/ No


The manufacture, storage and import of Hazardous chemical rules, 1989Order

Rules Rules citation Checked

1 Approval and notification of sites 71.1 Is it approved for undertaking of industrial activity? Sub rule 1 Yes/

No1.2 If any changes are made in the activity, has it been reported to

concerned authority?Sub rule 2 Yes/

No

2 Safety reports and safety and reports 102.1 Has safety report on the industrial activity in concern of authority is

submitted to concerned authority?Sub rule 3 Yes/

No2.2 Has safety audit with the help of an expert is performed? Sub rule 4 Yes/

No2.3 Is auditor’s report is been forwarded with comments to concerned

authority, with in 30 days after completion of audit?Sub rule5 Yes/

No2.4 Is the safety audit is updated every year and same is submitted with

comments to concerned authority?Sub rule 6 Yes/

No

3 Updating of reports under rule 10 113.1 Whether the modification to the industrial activity is made to which

safety report is applicable, if so, modification in the report is sent to concerned authority, before 90 days of modification?

Sub rule1 Yes/ No

3.2 If industrial activities are unchanged with respect to the safety report, then, has further report is being send within 3 years?

Sub rule 2 Yes/ No

4 Preparation to on-site emergency plan by the occupier 134.1 Is up-to date emergency plan is made to deal with major on site

accidents as per schedule II?Sub rule1 Yes/

No4.2 Whether plan includes the name of the persons who are responsible

for safety?Sub rule1 Yes/

No4.3 Whether changes in plans are being informed to relevant provisions? Sub rule 2 Yes/

No4.4 Whether mock drill on the on-site emergency plan is conducted every

6 months?Sub rule4 Yes/

No4.5 Is detailed report of the mock drill conducted is made available to the

concerned authority?Sub rule5 Yes/

No

5 Information to be given to persons liable to be affected by a major accident

15

5.1 Whether appropriate steps are taken to inform persons who are likely to be affecting by the major accident?

Sub rule1 Yes/ No

6 Collection, development and dissemination of information 176.1 Whether safety data sheet is developed as specified in schedule 9 and

could be accessible upon request?Sub rule 2 Yes/

No


6.2 Whether safety a data sheet includes accurate information related to hazardous wastes and added to material safety data sheet as specified in schedule 9?

Sub rule 3 Yes/ No

6.2 Whether every container of a hazardous chemical is labeled or marked as per the rule?

Sub rule 4 Yes/ No


The Hazardous wastes (management, handling and Trans boundary movement) rules, 2008

Order


1 Responsibilities of the occupier for handling of hazardous wastes

4

1.1 Whether the hazardous wastes are sent to an authorized re- processor? Sub rule 2 Yes/ No

1.2 Whether the waste sent for reprocessing or recycle thing is being transported accordance with the provisions of the rules?

Sub rule3 Yes/ No

1.3 Whether all adequate steps are taken while handling hazardous wastes as per the rule?

Sub rule Yes/ No

2 Grant of authorization for handling hazardous waste 52.1 Do we have obtained an authorization from the state pollution control

board for handling hazardous wastes?Sub rule1 Yes/

No2.2 Are the handling of hazardous wastes is done in the facilities, which

are authorized by the state pollution control board?Sub rule 2 Yes/

No2.3 Whether the application in Form 1 to the state pollution control board

is made for the authorization?Sub rule3 Yes/

No2.4 Whether the record of waste handled by each authorized personal

made in Form 3?Sub rule4 Yes/

No2.5 Whether the annual return is submitted to state pollution control

board containing the details specified in Form 4 on or before 30th of June?

Sub rule4 Yes/ No

2.6 For renewal of authorization whether application is made in Form 1? Sub rule7 Yes/ No

2.7 Whether all the possible steps take to reduce and prevent waste generation with condition specified in the authorization?

Sub rule8 Yes/ No

3 Storage of hazardous waste 73.1 Whether the record is maintained for storage of hazardous waste as

per the rules?Sub rule1 Yes/

No3.2 Whether the storage time is as per rules Sub rule1 Yes/

No

4 Procedure for grant registration 84.1 Whether the application in Form 5 made for recycling or

reprocessing the hazardous waste as per Schedule IV?Sub rule1 Yes/

No4.2 Whether the application is accompanied by the copies of documents

listed in the rules for grant or renewal of registration?Sub rule1 Yes/

No4.3 Whether the record of re-processed is maintain in Form 6? Sub rule7 Yes/

No4.4 Whether annual return of the activities of previous year is made to

state pollution control boards or pollution control committees?Sub rule7 Yes/

No


5 Whether hazardous wastes are sold to recycler having a valid registration from the central pollution control board for recycling or recovery?

9 Yes/ No

6 Whether the recycling, if any, is as per guidelines issued by the central government and central pollution control board?

10 Yes/ No

7 Treatment, storage and disposal facility for hazardous waste 187.1 Whether the treatment storage and disposal facility is as per technical

guidelines issued by the central pollution control board?Sub rule2 Yes/

No7.2 Whether storage and disposal facility and its closure and post closure

phase are as per guidelines issued by the central pollution control board?

Sub rule4 Yes/ No

7.3 Whether the records of hazardous wastes handled is maintained in Form 3?

Sub rule5 Yes/ No

8 Packaging and labeling 198.1 Whether the package and labeling is as per the guidelines issued by

the Central pollution control board?Sub rule1 Yes/

No8.2 Is labeling and packaging is easily visible and would be able to

withstand physical condition and climatic factors?Sub rule2 Yes/

No

9 Transportation of hazardous waste 209.1 Is transportation of wastes is as per the provisions of the rules made

by the central government under the motor vehicles act, 1988?Sub rule1 Yes/

No9.2 Whether the relevant information in Form 11 is provided to the

transporter?Sub rule2 Yes/

No9.3 Whether the container is marked the hazardous wastes as per Form

12Sub rule2 Yes/

No9.4 Whether ‘No Objection Certificate’ is obtained from the state

pollution control board?Sub rule3 Yes/

No

10 Manifest system (movement of document to be used within the country only)

21

10.1 Is 6 copies of manifest in Form 13 prepared as per the rule Sub rule 1 Yes/ No

10.2 Is copy 1 (white) is forwarded to state pollution control board? Sub rule 2 Yes/ No

10.3 Is copy (blue) is received from operator on completion of treatment? Sub rule 5 Yes/ No

11 Records and returns 2211.1 Is a record of operations of facility for disposal of hazardous waste is

maintained in Form 3?Sub rule 1 Yes/

No11.2 Is annual returns is sent to state pollution con troll board in Form 4? Sub rule 2 Yes/

No

12 Accident reporting and follow up 2412.1 Is report of accident dealing with hazardous wastes, is any, is

submitted to state pollution control board in Form 14?24 Yes/

No


The Noise Pollution (Regulation and Control) Rules, 2000Order


1 Ambient air quality standards in respect of noise fro different areas/ zones

3

1.1 Whether the ambient air quality with respect to noise is as per schedule?

Sub rule 1 Yes/ No


The Bio Medical Waste (Management and Handling) Rules, 1998Order


1 Duty of occupier 41.1 Whether all steps are taken to ensure that such waste is handled

without any adverse effect to human health and the environment?4 Yes/

No

2 Treatment and disposal 52.1 Whether the treatment and disposal of the waste is as per schedule I

and with compliance with the standards prescribed in schedule V?Sub rule1 Yes/

No2.2 Whether a waste treatment facility is set up in accordance with the

Schedule VI?Sub rule2 Yes/

No

3 Segregation, packing, transportation and storage 63.1 Whether the bio medical waster is collected separately? Sub rule1 Yes/

No3.2 Whether the bio medical waste is segregated into the containers/ bags

in accordance with Schedule II?Sub rule2 Yes/

No3.3 Are the container labeled according to Schedule III? Sub rule2 Yes/

No3.4 Is all of the bio medical waste is treated before the period of 48 hours,

or permission is taken from the authorized person, subjected it does not affect the human health and environment?

Sub rule 5 Yes/ No

4 Authorization 84.1 Is application in Form 1 for grant of authorization is made? Sub rule 2 Yes/

No4.2 Whether the application is accompanied by a fee as prescribed by the

government of the state?Sub rule3 Yes/

No

5 Annual report 105.1 Whether the annual report is submitted to the authority in Form 2 by

31st of Jan?10 Yes/

No

6 Maintenance of records 116.1 Whether the records related to the generation, collection, reception,

storage, transportations, treatment, disposal or handling is maintained?

Sub rule 1 Yes/ No

6.2 Are records are ready for inspection and verification by the authority at any time?

Sub rule2 Yes/ No

7 Accident reporting 127.1 Whether the report in Form 3 for accident is submitted to the

concerned authority?12 Yes/

No


The Air (Prevention and Control of Pollution) Act, 1981(Act No. 14 Of 1981)

Order

Acts Acts citation Checked

1 Restrictions on use of certain industrial plants 211.1 Whether the establishment of operation of an industrial plant is with

the consent of the state government, in an air pollution area?Sub act 1 Yes/

No1.2 Whether the application for consent of the state board is accompanied

by fees?Sub act 2 Yes/

No

The Air (Prevention and Control of Pollution) Rules, 1982The Air (Prevention and Control of Pollution) (Union Territories) Rules, 1982

Order


1 Form of application for consent and fees 9 (chapter IV)

1.1 Whether the application for consent is made in Form 1? Sub rule 1 Yes/ No

1.2 Whether the prescribed application fee is paid as per the rule? Sub rule 1 Yes/ No

2 Manner of taking samples 12Yes/ No

2.1 Whether the required facilities are provided for taking samples of air or emission as may required by the board or empowered officer?

Sub rule 1 Yes/ No

3 Form of appeal and manner of preference 17Yes/ No

3.1 Is appeal under section 31 against an order passed by the board, if any, is filled in the Form 7?

Sub rule 1 Yes/ No

3.2 Is appeal is as per the rule? Sub rule 3 Yes/ No


The Water (Prevention and Control of Pollution) Act, 1974Act No 6 Of 1974

The Water (Prevention and Control of Pollution) Rules, 1975Order


1 Application for consent 321.1 Is application of consent in Form 13 made to central board? 32 Yes/

No

2 Directions 342.1 Whether all direction issued in writing, if any, have been followed in

time span of 15 days?Sub rule 3 Yes/

No

The Waste (Prevention and Control of Pollution) Cess Act, 1977(Act No. 36 Of 1977)

Order

Acts Acts citation Checked

1 Levy and collection of Cess 31.1 Is levy and collection of Cess is as per Schedule II? Sub Act2 Yes/

No1.2 Is levy and collection of Cess applicable to us? Sub Act 2 Yes/

No

2 Whether the meters are affixed as per the act? 4

3 Furnishing of returns 53.1 Whether returns are being furnished? Sub Act 1 Yes/

No

4 Rebate 74.1 Whether we are entitle for the rebate of Cess as per Act? 7 Yes/

No

The Water (Prevention and Control of Pollution) Cess Rules, 1978Order


1 Standards of the meters and places where they are to be affixed

3

1.1 Are Vee notches are permitted from authority? Sub rule 2 Yes/ No

1.2 Is separate meter is affixed to measure the purpose as per Schedule II Sub rule 3 Yes/


No1.3 Are meters approved by the assessing authority and is as per the rule? Sub rule 4 Yes/

No

2 Furnishing of returns 42.1 Is the return is furnish in Form I on or before 5th of every month? Sub rule 1 Yes/

No

3 Manner of payment of the Cess to the central government and the time within which it shall be paid

5

3.1 Is Cess amount remitted in bank draft as per mentioned rules? Sub rule 2 Yes/ No

4 Appeal 94.1 Whether aggrieved by an order of assessment under section 6 or order

imposing penalty under section 11?Sub rule1 Yes/

No4.2 Whether the appeal in Form II made, as per the rules? Sub rule 1 Yes/

No4.3 Is appeal accompanied by the fee of 50 Rs? Sub rule 4 Yes/

No


Conclusion

Visit to IPCA, laboratories, Ratlam has been pleasant and

knowledgeable experience in term of both theoretical and practical

knowledge. This golden opportunity to have a close view to processes

involved in the effluent treatment plant have enriched my knowledge

regarding environmental hazardous and safety related matters. . I have

gathered brief information about manufacturing processes. Learning

over here was worth attaining any vocational training. This tour also

tackled me with interaction with other departmental employees. It also

taught me to be responsible towards ones environment, rule books have

set of guidelines but how to concern for ones environment was learnt

over here. Managing environment is worth praising. The hygiene and

safety is as per the standards not only pertaining to Indian norm but

global norms.

I hope company shall maintain its standards in futures, and one day

must evolve as leading global pharmaceutical industry.


in-plant training report of ipca ratlam

Documents