environment_2009%20.pdf

7/29/2019 Environment_2009%20.pdf

http://slidepdf.com/reader/full/environment200920pdf 1/48

A brief on

Environment, Health and Safety

in Siemens Pakistan

2009 China / Asia Environmental Health & Safety

Conference,

Xian, October 21-22, 2009

Mansoor Iqbal Khan



22009 China / Asia Environmental, Health & Safety Conference, China , October 21-22 2009 Mansoor I Khan Company Confidential

Contents

¾ Pakistan at a glance

¾ Siemens Pakistan at a glance

¾ Organization of EHS function

¾ Achievements till 2008

¾ Objectives - Fit4 2010

¾ Selected Experience in Environmental Projects

(Two Case Studies)

¾ Occupational Health & Safety – Salient Features

¾ Fire Safety- Selected Example

¾ Last Word




Pakistan at a glance –Key Indicators

GDP1

(August 2009) 159 (US$ billions)

GDP growth rate1

(August 2009) 2%

Population

1(est. July 2008)

172 millions

Energy gap (b/w demand and supply)2

~3000 MW

Decrease in Water Per capita availability from 5300m3/p/y in 1951

(limit for water stressed country = 1000 m3/p/y) Æ to 1100m3/p/y in 2007

Ranked on EPI3index 124 (score 58.7)

Total CO2 emission in 20064

142.60 million tons

• Emission from energy sources causing

5

100.00 million tons(46%-oil related, 45%-gas and 9%-coal.)

Pakistan contribution to global CO2 emission. 0.5% (2006)

Environment degradation cost in 20066

6% of GDP

(~ Rs. 365 b/year)1. State Bank of Pakistan Data2. Government of Pakistan

3. Environmental Performance Index – developed by Yale University.

4. United Nations Statistics Division- Environmental Statistics

5. Asian Development Bank-Country Analysis Report

6. World-Bank - Pakistan-Strategic Country Environmental Assessment (August 2006).


http://slidepdf.com/reader/full/environment200920pdf 4/4842009 China / Asia Environmental, Health & Safety Conference, China , October 21-22 2009 Mansoor I Khan Company Confidential

Environmental Protection Agency (EPA) under

the Ministry of Environment governs this function in Pakistan

Pakistan Environmental Protection Act as a legal frame work.

Mandatory National Environmental Quality Standards (NEQS)

Effluents :32 parameters (3 industrial categories)

Gaseous emissions:16 parameters (2 industrial categories)

Weak implementation : EPA Survey report of 150 industries.

GOP orders rigorous implementation.

2009 declared as

“Year of the Environment”



T e x t i

l e i n d

u s t r y

Textile industry

T e x t i l e

i n d u s t r y

T e x t i

l e i n d

u s t r y

Our Main Septic TankCommunity Discharge line

Location of Siemens Pakistan Industrial Complex

Locaion

Siemens Pakistan



Siemens Pakistan Industrial Complex



Siemens Pakistan

Power

Transmission &Distribution

Projects

Power


Projects

Power

Generation &Services

Power

Generation &Services

Industrial

Solutions

Industrial

Solutions

The Company operates in following areas:The Company operates in following areas:

ProjectsProjectsManufacturingManufacturing ServicesServicesSales &Marketing

Sales &

Marketing

Main ActivitiesMain Activities

EnergyEnergy

IndustryIndustry

HealthcareHealthcare

Drive Technology /

IndustrialAutomation

Drive Technology /

Industrial

Automation

Power


Products / Systems

Power


Products / Systems



Siemens Pakistan

HealthcareIndustry Energy

Power Generation and

Services, Oil and Gas

- Fossil Power Generation

- Renewable Energy

- Service Rotating Eqp.

- Oil & Gas

T&D Projects Pak & Dubai

- Power Transmission

- Power Distribution

Human Resources

Corporate Communication

Industrial Relations

Business Development

Iraq, Iran and Afghanistan

SG&A Project

Healthcare Sales and

Services

- Imaging & IT

- Workflow & Solutions

Corporate Quality andProcess Excellence Mgt.

Strategic Business

Development / top+

Export Control & Customs

Real Estate / Security

/Shared Service

Company Secretary /

Accounting

Sector Controller

Corporate Financial

Functions Legal

Corporate InformationTechnology

Regional Branch Mgt.

Corporate functions

Sector Controller Sector Controller Regional Compliance

T&D Products/Systems

- Power Transmission

- Power Distribution

GS / DX / XP / OEM-Diagnostics

(under development)

Business Development

Industry Solutions

Building Technology

Industry Automation /

Drive Technology

Mobility

Siemens in Pakistan - Organization



To be the enabling force for the company in

achieving leadership in market & technology and

retaining its prominent local presence through

sustainable excellence

support the organization in embedding a high level

of quality in all spheres of its operations through

professional tools and methodologies enhancinghigh performance culture, safety, environmentalpreservations while ensuring applicable statutory &

regulatory compliance.

with a mission to …

Departmental Vision and Mission



EHS ab-initio …in line with our vision and mission



EHS Policy



Topics of Environmental relevance in Siemens Pakistan

Effluent

Waste management

Emissions

Energy Consumption.




Environmental Activities till 2008

Established EHS Organization up to BU level.

Environmental Action Group - Members from BUs /

Depts. for Synergy & Buy-in.

Promoting Awareness

Monitoring compliance of EPA regulations and NEQS.

Relevant Corrective and Preventive Actions.

• Oil usage Control & Inventory in Production

Departments

• Medical Waste Management of Plant Dispensary.

• Database & Profiling of Hazardous Chemicals usedand MSDS Web based Library.

Contd…




(…..Contd)

Environmental Activities till 2008

Elimination of Asbestos from the Industrial Complex.

Campaign against Polythene bags < 30 microns.

Mandatory Lead Free Paints.

Purchase authorization required from CQPE for

Hazardous Chemicals. (as defined in SN 36350 part 2)

Suppliers’ declaration of Hazardous Chemical use.

VOC issues identified and mitigation plan developed.

Disciplinary action against violations of Environmental

Guideline.

Systematic SESIS reporting process.




Data received from BUs

and Depts. on

quarterly basis

Compilation of Data

for annual reporting

Review and Assessment of

Data by CQPE Specialists

Discrepancy &

DataIntegrity

check

Initial entry in SESIS Tool

Quality Check

Correction Required

Correction Required

Review by Director CQPE

Signed and Delivered

Refer to BU / Dept.for Correction

Not

accepted

Accepted

Yes

No

No

Yes

SESIS Reporting Process

Inform BU/Dept. about results

for corrective actions and

Future Environmental Objectives




Internal Recognition

……




External Recognition

Environmental Excellence Awards

Year 2006 Year 2007

Year 2008 Year 2009 ……




2008 Onwards….

Objectives based on Target

values

Base year

2006

Activities & Status

01 Setup organization for implementation

-

Oct-08 Environmental Action group

reformed as EnvironmentalCommittee.

02 Third party certification under ISO 14001:2004 Dec-09 Audit conducted in Sep 09.

Result awaited

03 For Production Facilities

Decrease in consumption of Electrical Energy 20% • Study conducted to establishpattern of energy consumption .

• Action plans drawn

• Result to be evaluated by Dec-

09

- Annual decrease in emission by 2011 15% VOC reduction project in progress

- Annual efficiency gains in the emission reduction of CO2

from energy use- by 2011

20% Under consideration.

04 - Implementation of SN-36350 part 1

- Implementation of SN-36350 part 2

Implemented with limited

application in Siemens Pakistan.

Part 2 implemented.




Objective -2

ISO 14001 Certification Challenges

We believed that

Our system is ISO 14001 complaint.

We know aspect and impacts of our processes.

People are aware of environmental problems.

When we went for external certification we realized that

“We are a bit far from Reality”

Gaps in our system were:

Systematic documentation

Commitment intensity

Monitoring of Environmental targets




Corrective Actions taken:

Extended QMS to incorporate EMS requirements

EMS process documentation reviewed and modified.

Extensive Trainings conducted at all functional levels.

Roadmap for certification agreed with stakeholder and implemented on

time.

Result:

Successful audit --- No major Non-Conformity identified so far




Lessons Learnt

Don’t take anything for granted.

Buy-in of all Stakeholders should be acquired.




Study of plant machinery e.g. winding, core cutting machines

and cranes established high consumption pattern.

Conventional clutch system replaced with inverter drive

All machines gradually being upgraded

Gain :

Example of Coil Winding machine

Before modification: Standby 7.2 kWh

Running 32 kWh

Total 39.2 kWh (per day)

After modification: Standby 0 kWh

Running 19.2 kWh

Total 19.2 kWh (per day)

Accumulated Savings ~50%

Objective -3 – (Selected Examples

Decrease Consumption of Electrical Energy

Project 1: Inverter drive system for Production Machines in Trafo.




•Phase-1 Minimizing Heat Losses

• Initially temperature acheived in 10 hours due to

high heat losses

• After insulation and cladding losses reduced and

temperature achieved in 8 hours.

•Gains

•Before 250 kWh / After 200 kWh (per annum)

•Savings ~20%

•Phase-2 – Modifying heating system –electric to gas

•Presently electric heating system in place•Converting into gas fired hot oil circulaiton system

(Scheduled for Q2 FY10)

•Gains

•Before 200 kWh / After 75 kWh (per annum)

•Savings ~62%

Objective -3 – (Selected Examples)


Project 2: Minimizing Energy Consumptions in Vacuum Drying Ovens




Project 3:Optimized use of Production Hall lights

Conventional control is replaced by PLC giving flexibility to program according to the working hours, breaks with

motion sensors

Provision for Natural Light by installing transparent plastic sheets in the Production Hall’s ceiling reducing energy load.

Phase 1: Manufacturing Area of Power Trafo

Phase 2: Manufacturing Area of Distribution Trafo

Phase 3: Manufacturing Area of Steel Fabrication

Gain (for Phase 1):

Installed – Final Commissioning by Nov 09

Total units consumed/ annum: 97,843 kWh (before)

Units/ annum: 68,490 kWh (after ) results so far.

Saving:~30%

Objective -3 – (Selected Examples)





Case Study - I

Control of VOC Emissions

VOC emission identified during SESIS reporting

= 153t ( 80 + 73)*

Major contributor Trafo Paint Shop

Two specific areas of Paint Shop focused.

1. Flood painting for DT 2. Spray painting for PT

Risk Assessment identified areas of concern:

Uncontrolled VOC emissions

Fire Hazard

Human Safety

* Direct use and 50% from oil based paints.

Surface

CleaningPainting Drying

63tons

65tons

Contd…




Case Study - I


Containment of VOC emissions.

Option 1: Outsourcing Painting Facility: Not Feasible

Environmental Degradation remainsQuality of workmanship

questionable

Option 2: Water Based Paint Viable but not immediately feasible

Not locally available

Process Change Required

Customer’s Approval Required

Contd…




Case Study - I


Option3: Modify Existing Process

Focus 1 – Surface Cleaning Process (DT)

Non-VOC cleaning agents to be used. Several chemical tested (e.g.

OCD-4 Heavy Duty Carbon Remover)

no feasible solution found yet.

Problem faced: surface

become reactive and got rustedin short period of time.

Alternate :

Changed process from highpressure air cleaning to pressurized rinsing.

Contd…




Case Study - I

Control of VOC Emissions - Situation Before

Contd…




Case Study - I

Control of VOC Emissions - Modified Cleaning Process

• Pressurized rinsing in a

closed loop system

• Further Study Continued….

Contd…

Case Study - I




FY MVA Thinner (kg) Ratio kg/MVA % reduction

2006-07 2601 63666 24.48

2007-08 2525 40345 15.98 36.63%2008-09 2585 33064 12.79 18.04%

Case Study I


Savings of VOC- From Cleaning Process.

Beginning of Project

Contd…

C S d I




Focus 2 – Painting Process

Vapors Collection for DT Paint Area

– Under Study

Collection of vapors by

generating negative air

pressure

Passing vapors through Activated Charcoal Filter

Collection for disposal

….Further processing “On Hold”

Case Study - I


Contd…

C St d I




Focus-3 – Reduction of Emission

to Air in PT Paint Area

Enclosed chamber developed

VOC vapors passed through

water curtain before discharging

into air. Contaminated water

disposed through Hazardous

Waste Disposal process.

Environmental contamination

reduced.

Further study in progress.

Case Study - I


Contd…

C St d I




Focus-4 – Air Less Painting

System

Under study

Equipment trial foreseen in

current FY.

Comparison with Oil based

paints will be made

Case Study - I


Contd…

Case Study I




Case Study - I


Fire Hazard

Fire Load -Paint storage was reduced in paint shop

and a separate central chemical store constructed.

Thermography carried out to identify Hot Spots

Electrical Wiring was redone

Electrical Lighting and Appliances -

Explosion proof Lights were installed

Sprinkler System installed.

Contd…

Case Study I




Case Study - I


Human Safety

Toluene and Xylene contents in air measured

through Diffusion Monitor by 3M and found to be

within permissible limits.

Use of special safety masks were introduced as

recommended by 3M.

3M diffusion monitor

Personal Monitoring members

Area monitoring STA Temperature readings

Contd…

Case Study I




Case Study - I


Entry restricted to paint shop workers

only

Job rotation for paint shop workers

(Reducing exposure to same persons)

Operational and Visual Management

enhanced. Awareness campaign

Emission limits for VOC are notprescribed as yet under Pakistan’s

Environmental laws.

Contd…

Case Study II




Case Study II

Effluent Investigation

Result of parameters were noted to have haphazard pattern

• TSS, BOD, COD, Oil & Grease Causes Known

• Pb, Cd, Ni, Zn, Fe, Cr (III, VI) Causes not Known

Contd…

Case Study II




Case Study II


Paints, water softening chemicals, cleaning bleach, used transformer oil, hand washing detergent,

acid cleaning detergent, used cutting oil, used engine oil etc. were analyzed at various points within

the complex to identify possible sources.

Old Sewage Line

New Sewage Line

NEQS Limit Parameters 2nd Exit Point ` TR Point TR-DT Phosphator

10 Oil & Grease 2189 1995 Not Tested

2.0 Iron (Fe) 12.08 Not Tested 15.5

0.1 Cadmium (Cd) 1.13 Not Tested 0.52

1.0 Chromium (Cr) 4.98 4.06 3.99

1.0 Nickle (Ni) 4.28 3.97 3.58

0.5 Lead (Pb) 2.89 2.02 2.24

5.0 Zinc (Zn) 10.89 11.69 10.00

NEQS Limit Parameters Main Septic Tank Worker’s Canteen Switchboard Motor & Alternators

10 Oil & Grease 2480 2085 180 6920

2.0 Iron (Fe) 11.98 Not Tested Below Detection Limit 14.70

0.1 Cadmium (Cd) 1.29 Not Tested 0.08 1.09

1.0 Chromium (Cr) 5.98 Not Tested Below Detection Limit 6.08

1.0 Nickle (Ni) 4.31 Not Tested 0.48 4.97

0.5 Lead (Pb) 2.21 Not Tested Below Detection Limit 2.01

5.0 Zinc (Zn0 11.01 Not Tested 0.26 10.01

H

D

K

H

K

E MBC

A

SR

N

Q

P

L

JW

F

m 3m 2m 1

4

65

7

2 3

1

8

Contd…

Case Study II




Case Study II


No significant process / chemical identified except Surface Treatment Plant

but not in significant quantities and pattern of discharge.

Suspected backflow or seepage of neighboring waste water.

Thorough cleaning of septic tank was done. Back flow observed and blocked.

Sample showed drastic reduction in heavy metal in waste water results which

indicates high probability of infiltration from municipal sewerage.

Further work on.

Objectives drawn as a part of EMS to control the effluent results.

(controlling backflow, Surface Treatment waste water disposal etc.)




Occupational Health & Safety – Salient Features

Service Engineers dealing with X-rays /Radio Active material are

monitored for Radiation Exposure

Bi Yearly Hepatitis Screening of Canteen Staff

Hepatitis Vaccination of Staff – Safe Water

Epidemic Emergency Response Committee – in house provision of

Vaccines – Emergency Response Drawn.

Ergonomic training by Company Doctor. Company Doctor part of the

Corporate Management Team – Presents Pattern of Diseases and

Medical Issues and Cost in Quarterly Management Meeting.

Accidents/Incidents /LTIR/Investigation Report of Accidents and

Safety Issues presented to Management Monthly, Discussed

Quarterly in Management Meeting

Safety Talks at Shop Floor level jointly by EHS Manager andCompany Doctor




Occupational Health & Safety

Siemens Sustainability Report 2008




Fire Safety

A Fire erupted in a Paint factory in the

vicinity of Siemens Industrial Complex

in Jan 08.

Availability of Municipal Fire support

found weak.

Long response time of Fire Dept .

It took about 18 hours to extinguish

this fire

This forced us to re-evaluate

consequences and response in

case of Emergency in our complex.

Contd…

(…Contd)




( )

Fire Safety

Decided to purchase own Fire Tender

and related appliances.

Training conducted on Fire fighting and

rescue operation with these equipment.

Contd…

(…Contd)




Fire Safety

Regular trainings of

Fire fighting equipment

for staff.

Evacuation drills.

Average

evacuation time for

last drill ~ 4 mins

Contd…




LAST WORDS

AUT INVENIAM - AUT FACIAM




Thank You for Your Attention

environment_2009%20.pdf

Documents