CENTURY RAYON

Environmental and Occupational Health & Safety Policy

Century Rayon is the leading manufacturer of Viscose Filament Yarn and Chemicals. The company is committed to the protection of the environment and the health and safety of its employees, customers and community. In this vein the company shall: Regularly review objectives for attaining continual improvement in environmental and occupational health and safety performance. Be committed to prevention of pollution. Implement continual improvement in resource conservation i.e.: Raw Materials and utilities like Energy and Water. Take measures and ensure safe work environment towards reduction of accidents. Monitor and control work place hazards. Train and involve company's employees and contractor's workmen in Environmental and Occupational health and Safety performance. Ensure compliance of legal and other requirements and strive for further improvement. Century Rayon is committed for a cleaner and healthier environment. The Environmental and Safety Policy shall be communicated to all persons working for or on behalf of the organization and is available to the public on request. Date: 28.2.2007 President

CENTURY RAYON
Environmental & Occupational Health & Safety Management System

Overview

ISO-14000 is a series of international, voluntary environmental management standards for better environment management.
OHSAS-18000 is a set of authorities through which an organization maintains awareness & control over its interactions with worker health & safety. Interfaces directly with business objectives

CENTURY RAYON
Definations
Environmental Aspect: Element of organizational activities or products or services that can interact with the environment. Environmental Impact: Any change to the environment whether adverse or beneficial wholly or partially resulting from an organizations environmental aspects. Hazard: Source or situation with a potential for harm. Risk: Combination of the likelihood & consequences of a specified hazardous event. SSPD Score: Product of individual weightages of scale, severity, probability & duration. EMP: Environmental & Occupational Health & Safety management program includes objectives, targets & action plan. EPR: Emergency preparedness & response for potential emergency situation & accident. M&M: Monitoring & measurement of key characteristics that can have significant impact / harm.

CENTURY RAYON
Pre-audit Observations of M/s TUV
Sr. No. 1 2 Particulars Remarks Process flow sheet aspects to be linked to process flow A. / H. no. included activity. Cross Reference for aspects / significant aspects & Implemented objects/ targets / programs

3
4 5 6 7

Aspect of contributing factor to be rated

Procedure for issue, distribution & maintenance of PPE

Implemented
Implemented

External origin documents to be identified & records to Implemented be maintained. Objectives to be displayed and communicated through Implemented training. Incident report, Frequency Report, Severity Report, Implemented Trend charts of near misses , incidents & accidents

CENTURY RAYON
Pre-audit Observations of M/s TUV
Sr. No. 8 9 10 11 Particulars Toe Guard for stair cases. OCP to be modified as per clause 4.4.6. Remarks Implemented Implemented

Environmental program - procedure to be modified for Implemented review, changes, benefits & closure of EMP ETP - control measures to be provided for fall hazards. Implemented Plan for DO probe in aeration tank. Aspect & impact evaluation of foam suppression

12

Basic risk, residual risk with existing control, risk New format classification & corresponding control plan to be for included in the procedure. Evaluation
M & M plan with frequency & for Key Environmental Implemented performance Indicators (Water, power & Air etc.)

13

CENTURY RAYON
Pre-audit Observations of M/s TUV
Sr. No. 14 Particulars Companywide power consumption. Remarks 1% Reduction taken as an objective.

15
16

Trend of Environmental performance improvement.

Implemented

Procedure for legal requirement to include updating, Implemented responsibility for liaison with statutory bodies, M & M etc. Evaluation of compliance- Legal / Statutory regulatory Implemented requirement. (PCB Act, Bio medical waste, MV Act, Battery Rules etc.) M & M (Legal) to be maintained at one defined Implemented department.

17

18

CENTURY RAYON
Pre-audit Observations of M/s TUV
Sr. No. 19 20 21 Particulars Remarks M & M for maximum permissible discharge limit of Implemented sewage - evidence to be provided. Management programs for sewage treatment with Not Required defined action plan. Recycling of treated water & discharge of excess Implemented quantity through Waldhuni nallah - evidence to be provided. The quality & quantity of treated effluent discharged to Implemented ulhas river thru waldhuni nallah - evidence to be provided. The quality & quantity of effluent from each plant to Under ETP to be measured and monitored - plan to be defined Progress against set norms.

22

23

CENTURY RAYON
Pre-audit Observations of M/s TUV
Sr. No. 24 25 26 27 28 29 30 Particulars Remarks Water consent order Form No. 5 - consumption for Implemented Industrial cooling - evidence to be provided. License for sulphur storage - evidence to be provided. Available Monthly Form 3 of PCB to be filled for inventory / Not Required stocks of hazardous waste. Non-ferrous metal waste - to be included in form 13. Implemented Investigation format for incident/ accident to include Implemented 4.5.2 clause of OHSAS 18001. Water Budget, Water balance as per permitted Implemented quantities by MPCB - evidence to be provided. Chlorine leaks , CS2 leaks , fire due to inflammable Implemented material to be included in onsite emergency plan.

CENTURY RAYON
Pre-audit Observations of M/s TUV
Sr. No. 31 32 33 Particulars Management programs for storage of waste oil. Hazards during cement unloading. Identification of hazardous waste chemical containers. Remarks Under progress Implemented Implemented

34

Compressed gas cylinder - legal requirement for Being taken capping, color coding & safety distance, test date and as EMP due dates to be displayed on cylinders.
Housekeeping in scrap yards. Implemented

35

36

Procedure for maintenance including plant - dust Implemented collectors, scrubbers, blowers, ETP equipment - records to be maintained. Test records from external agency for chain pulley blocks & EOT Cranes.

CENTURY RAYON
Pre-audit Observations of M/s TUV
Sr. No. 37 38 39 40 41 42 Particulars Remarks Training - Contractors, material movers, sub- Under contractors & transporters - for outside & inside people. Progress Training Calendar to be made Implemented Policy & Compliance with legal requirements to be Under displayed outside. progress Receiving, documenting and responding to Implemented communication from public to be updated & recorded ISI marking on First aid & Fire fighting equipments Implemented Canteen Aspects & Hazards due to LPG leaks, fire due Implemented to diesel storage, OCP for pest control, license for LPG cylinder storage

CENTURY RAYON
Pre-audit Observations of M/s TUV
Sr. No. 43 44 Particulars Remarks Dust collectors - OCP for downtime analysis, PM Implemented schedules, spare parts & efficiency measurements List of E & S critical equipments down time analysis of Implemented ETP, dust monitors,& efficiency measurements records to be maintained. Drawing/Plot plan indicating domestic sewage lines, Implemented process waste lines, storm water drains, septic tank locations, ETP location, ambient air monitoring station, noise monitoring stations, hazardous storages, evacuation routes, entry, exits & assembly points. Sign boards at emergency exits to be provided Management Review Agenda to be reviewed to include Implemented clauses

45

46

CENTURY RAYON
Pre-audit Observations of M/s TUV
Sr. No. 47 48 49 Particulars Remarks Documentation System , Levels of Documentation, Implemented Review, Approval & Issue matrix. Master List of Documents & records. Implemented Drinking water analysis Chemical & Bacteriological Implemented As per ISI Standards.

50
51

Laboratory Hazardous chemicals to be considered for Implemented Aspects / Impacts.

Overall Roles & Responsibility As per the Clause Implemented

CENTURY RAYON
DETAILS OF NON-CONFORMITIES CLOSED (ROUND NO. 1)
1. Rayon Viscose (Production) In GCF section no SSPD analysis carried out and aspects /hazards are made significant without analysis. 2. Century Chemicals Laboratory

Temperature is abnormal in chemical laboratory. It is unhygienic for staff and workmen especially during summer.

CENTURY RAYON
Tyre Cord Plant
PULP (Kg./ Kg. Yarn)
1.036 1.034 1.032 1.030 1.028 1.026 1.024 1.022
1.028 1.028 1.025 1.025 1.023 1.026 1.026 1.026 1.026 1.026 1.026 1.031

Pulp Ratio Apr 05 to Mar.07 1.035

May '06

Nov. '06

Apr'05- Mar'06

June '06

Sept. '06

Year

Mar.'07

July '06

Apr '06

Dec. '06

Aug.'06

Jan.'07

Oct.'06

Feb.'07

CENTURY RAYON
Tyre Cord Plant
3.800 3.700 3.600 3.500 3.400 3.300 3.200 3.100 3.000 2.900 2.800 2.700

POWER (KWH /Kg. Yarn)

Power Ratio Apr 05 to Mar.07

3.77 3.58 3.4 3.27 3.2 3.43 3.31 3.12 2.92 2.8 3.39 3.67 3.62

July '06

Apr '06

Aug.'06

Nov. '06

May '06

Apr'05- Mar'06

Jan.'07

June '06

Sept. '06

Year

Mar.'07

Oct.'06

Dec. '06

Feb.'07

CENTURY RAYON
Tyre Cord Plant
CAUSTIC (Kg./ Kg. Yarn)

Caustic Ratio Apr 05 to Mar.07

0.765 0.755 0.745 0.735 0.725
0.717 0.748 0.746 0.747 0.760

0.725

0.730 0.730 0.7140.720 0.717 0.711

0.715 0.705

July '06

Apr '06

Aug.'06

Nov. '06

Apr'05- Mar'06

May '06

Jan.'07

Oct.'06

June '06

Sept. '06

Year

Mar.'07

Dec. '06

Feb.'07

0.706

WATER (Gallons)

40 38 36 34 32 30 28 26 24

30

Apr'05- Mar'06 Apr '06

32

May '06

33

June '06 July '06 Aug.'06

38 32 28 36

Tyre Cord Plant

CENTURY RAYON

Water Consumption Apr 05 to Mar.07

Year

Sept. '06 Oct.'06 Nov. '06 Dec. '06 Jan.'07 Feb.'07

39 37 37 38 39

28
Mar.'07

CENTURY RAYON
Tyre Cord Plant
22.50 22.00 21.50 21.00 20.50 20.00 19.50 19.00 18.50 18.00

STEAM (Kg./ Kg. Yarn)

Steam Ratio Apr 05 to Mar.07

22.31 21.51 21.47 20.77 20.73 19.58 19.77 20.66 21.07 20.52 20.35 21.53

18.21

Nov. '06

Aug.'06

Apr '06

Dec. '06

May '06

Jan.'07

Feb.'07

Oct.'06

June '06

Apr'05- Mar'06

Year

Sept. '06

Mar.'07

July '06

CENTURY RAYON
CSY Plant Pulp Ratio Apr 05 to Mar.07
1.120 1.110 1.100 1.090 1.080 1.070 1.060 1.050 1.040
PULP (Kg./ Kg. Yarn)
1.115 1.105 1.080 1.075 1.065 1.059 1.067 1.065 1.060 1.044 1.075 1.095 1.100

May '06

Nov. '06

Apr'05- Mar'06

June '06

Sept. '06

Year

Mar.'07

July '06

Apr '06

Dec. '06

Aug.'06

Jan.'07

Oct.'06

Feb.'07

CENTURY RAYON
CSY Plant
6.200 5.900 5.600 5.300 5.000 4.700 4.400 4.100 3.800 3.500

POWER (KWH /Kg. Yarn)

Power Ratio Apr 05 to Mar.07

5.86 5.74 5.43 5.48 5.11 4.74 4.53 4.46 4.05 3.94 3.83 4.16 5.27

July '06

Apr '06

Aug.'06

Nov. '06

May '06

Apr'05- Mar'06

Jan.'07

June '06

Sept. '06

Year

Mar.'07

Oct.'06

Dec. '06

Feb.'07

CENTURY RAYON
CSY Plant
CAUSTIC (Kg./ Kg. Yarn)

Caustic Ratio Apr 05 to Mar.07

0.655
0.650

0.645
0.640

0.635
0.630

0.630 0.630 0.625 0.630 0.625 0.620

0.630 0.630 0.630

0.625
0.625

0.615

July '06

Apr '06

Aug.'06

Nov. '06

Apr'05- Mar'06

May '06

Jan.'07

Oct.'06

June '06

Sept. '06

Year

Mar.'07

Dec. '06

Feb.'07

WATER (Gallons/ Kg. Yarn)

62 60 58 56 54 52 50 48 46 44 42 40 38
Apr'05- Mar'06
49

Apr '06
48

May '06
42

June '06
39 39 42

July '06 Aug.'06

CSY Plant

CENTURY RAYON

Water Consumption Apr 05 to Mar.07

Year
Sept. '06 Oct.'06 Nov. '06 Dec. '06 Jan.'07 Feb.'07 Mar.'07

47 50 54 56 56 60 61

CENTURY RAYON
CSY Plant
44.00 42.00 40.00 38.00 36.00 34.00 32.00 30.00 28.00

Steam Ratio Apr 05 to Mar.07

43.69 41.62 41.19 39.56 36.02 35.29 32.09 30.87 28.63 28.26 37.01 34.81 43.29

STEAM (Kg./ Kg. Yarn)

Nov. '06

Aug.'06

Apr '06

Dec. '06

May '06

Jan.'07

Feb.'07

Oct.'06

June '06

Apr'05- Mar'06

Year

Sept. '06

Mar.'07

July '06

No. of Accidents
0 1 2 3 4 5 6

Avg. (2005)

Jan '06

Feb. '06

Mar.'06 Apr. '06 May '06

5 4 2

June '06 July '06 Aug. '06 Sept. '06 Oct. '06 Nov. '06 Dec. '06 Jan. '07

3 2

( Including Contract Workers )

CENTURY RAYON

ACCIDENTS IN TYRE CORD PLANT

Year

4 4 2 2 1 5 1

Feb. '07 Mar.'07

CENTURY RAYON
Master List of Objectives & Targets Tyrecord To reduce CSY pulp ratio From 1.080 to 1.070 Viscose (P) To reduce the total Energy consumption From 12000 kwh to 11880 kwh To reduce Steam consumption of Tyre 20 Tons/Ton of yarn to 19.5 Tons/Ton of yarn To reduce Filtered water consumption gallons/day to 300000 gallons/day Spinning (P) Yarn From From 350000

Spinbath (P)

To reduce water consumption By 5%

To minimise viscose waste due to idle positions By 5%

Textile (P)
Maintenance

To reduce the Mandays loss due to accidents to nil

To reduce the total Energy consumption From 1.5 KW to 1.1 KW To reduce the water pollution