ALUMINA PLANT REFINERY PROCESS

Introduction:
Bauxite is the raw material from which alumina is extracted by alkali
process. Invented by Austrian Scientist Karl.Josheph Bayer, in nineteenth
century, it is the only process available for commercial extraction of
Alumina hydrate. he bauxite is mixed with hot sodium hydroxide solution
to dissolve alumina present in it. !sin" various techni#ues such as cyclonic
separation, settlin", and filtration separates the non$reactive part consistin"
mostly iron oxide. he soda solution havin" dissolved alumina in it is then
precipitated out at low temperature to "et alumina hydrate as intermediate
product. his is calcined at about %&&&
'
( to "et alumina.
Bauxite excavation capacity) *+lakh tones,year
Alumina production capacity) -lines. /.0/lakhtons,year1%/.2/lakh
tones,year
BAUXITE
he ore for alumina is present in different form and composition. he
tropical bauxite present in the hills of 3anchapatmali of 4aman5odi has
followin" components.
6 Al
0
'
-
,-70' 8IBBSI9
6 Al
0
'
-
, 70' B'79:I9
6 ;e
0
'
-
79:AI9
6 Al
0
'
-
,0Si'
0
,<'7=
*
KA'>I?I9
6 Si'
0
@!AABI9
6 7
0
' ;A99 :'IS!A9
6 C
0
'
/
CA?A4I!: 39?'DI49
6 i'0 IA?I!: 4I'DI49
6 8a
0
'
-
8A>I!: 'DI49
he components are expressed in more useful terms and approximate
composition is as follows
6 Al
0
'
-
*/E
6 ;e
0
'
-
0/E
6 Si'
0
F %.2 E
6 Si'
0
0.- E
6 >'I 0-E
6 i'
0
0E
6 C
0
'
/
%E
6 3
0
'
/
AA(9S
6 8a
0
'
-
AA(9S
At minin" site, after removin" the overburden, holes are drilled and
trinitrotoluene is used as explosive for breakin" the deposit. hen rock$
breakin" machines are used to reduce the siGe of ore to below +&&mm. he
material is then transported by dumpers to crusher house and crushed to
below %/&mm siGe by two numbers of toothed double roll crushers also
called as primary crusher. he crushed bauxite is then transported to alumina
plant by a special conveyor called as cable belt. he specialty of cable belt is
that it not only has vertical curves like conventional belt conveyors but also
has several horiGontal turnin"s to meet the re#uirement of hilly terrain. he
sin"le fli"ht %*.Hkm lon" conveyor is supported on a rope, which is driven
by a synchronous motor.
At alumina plant, the bauxite is stored in open yard stack piles and
reclaimed at specified rate by two numbers of bucket wheel reclaimers. he
material is then crushed by three numbers of hammer crushers to siGe below
-&mm and stored in stora"e tanks called as silo.
BALL MILL
Because the process of alumina processin" involves solid bauxite and li#uid
sodium hydroxide reaction, fine siGe of solid is necessary to have better
reaction and hi"her yield. he bauxite from silo is extracted at measured rate
and fed to ball mill, which "rinds the material to about H-micron siGe. he
"rindin" process is accelerated by addition of dilute caustic soda solution at
%/&"m,lit soda concentration. 9ach of the four ball mills has "rindin"
capacity of 0&&tons,hr. 9ach ball mill is loaded with about %&&tons of hyper$
steel spherical balls and rotates at %/A3:. hree streams of the plant
operate with four ball mills. he "round bauxite in caustic soda solution is
called as mill slurry is pumped to subse#uent process called as pre$
desilication.
IMPORTANT TERMS
Soda concentration) expressed in "rams of soda present in the li#uor in the
form of sodium hydroxide and sodium meta aluminate and expressed as
?a
0
'.
RP) this is the ratio between alumina present in sodium :eta aluminate
form, expressed as Al
0
'
-
and the soda present in the form of sodium
hydroxide I sodium :eta aluminate expressed as ?a
0
'.
Al0'-, -70') alumina tri$hydrate
Al
0
'
-)
Alumina or calcined alumina
PRE-ESILICATION
he silica present in bauxite in the form of kaolinite is called as reactive
silica, since it reacts with sodium hydroxide easily to form sodium silicate.
his sodium silicate deposits as scale on the wall of the vessels and heat
exchan"ers resultin" in reduced process efficiency. hatJs why pre$
desilication process is desi"ned to convert harmful reactive silica to non$
reactive sodium aluminium silicate. he mill slurry is heated with steam to
react kaolinite with sodium hydroxide to form sodium silicate. After that, the
slurry is passed in tanks where sodium silicate is converted to sodium
aluminium silicate or sodalite. Sodalite is a hi"hly stable compound and not
reactive with sodium hydroxide any more.
Al0,0Si'
0
,<'7=
*
K?a'7$$$$$$$$$$$$$$$$ ?aAl'
0
K?a
0
Si'
-
K 70'
?aAl'
0
K ?a
0
Si'
-
K7
0
'$$$$$$$$$$$$$$ ?a
0
', Al
0
'
-
, 0Si'
0
, n7
0
'K?a'7
Sodalite
he slurry is then mixed with concentrated caustic soda solution and
pumped to cyclones for classification. he particles havin" bi""er siGe than
H-micron are recycled back to ball mill for further "rindin". he fine
particle slurry proceeds to di"estion process.
I!ESTION
7ere the fine bauxite slurry in caustic soda solution is heated in tanks to
achieve %&/
'
(. Sodium hydroxide reacts with alumina tri$hydrate to form
sodium meta$aluminate. he non reactive components such as iron oxide,
bohemite and silicon dioxide remain in suspended form in the slurry. Supply
steam for heatin" the slurry is at Lbar and 0%&
'
(.
Al
0
'
-
, -7
0
'K?a'7$$$$$$$$$$$$$$$$$$$$$$ ?aAl'
0
K7
0
'
4i"estion tanks are provided with a"itators to prevent settlin" and increase
speed of reaction. he slurry remains for about 0hrs and -&minutes in
di"estion tanks and then pumped to sand separatin" cyclones for removal of
coarse particles called as sand.
SAN SEPARATION
4i"ested slurry havin" about %&&"m,lit solid is fed tan"entially to small
conical tanks called as cyclones. 4ue to tan"ential feedin", the particles
experience centrifu"al force and are thrown towards periphery and collide
on the wall of the cyclone. 7eavier particles then fall under "ravity and "et
separated from bottom. he slurry havin" very small particles come out
from top of the cyclone and come to a tank called as dilution tank. he
separated sand is washed with water to extract soda from it and the washed
li#uor is fed to dilution tank. he slurry here also contain solid and separated
in subse#uent sta"es and washed with water for soda recovery. he wash
li#uor derived from there is partly mixed in dilution tank to "et desired soda
concentration of %H2"m,lit.4iluted slurry has about H&"m,lit of solid and at
%&0
'
(. 4iluted slurry is pumped to post desilication tanks.
POST ESILICATION
Aemainin" amount of reactive silica, which could not react with soda in
3redesilication, reacts in di"estion and forms sodium silicate. his sodium
silicate has to be converted to non$reactive sodalite in precipitation. ;or this
purpose, diluted slurry is heated in post desilication tanks up to %&/
'
( and
retained for about +hrs.the slurry is slowly a"itated in post desilication tanks
to 5ust avoid settlin" and facilitate sodalite formation. ;avorable condition is
hi"h temperature and low concentration. 'utlet of this process is pumped to
settler for solid waste separation.
SETTLER
hese are bi" tanks havin" diameter of *&m and hei"ht Hm. 4esilicated
slurry is fed at the centre and the mud settles down and clear li#uor remains
at the top. Slow speed rake mechanism drives the settled mud from centre to
periphery. Synthetic flocculant is dosed to the settler feed to enhance rate of
settlin". Settler overflow containin" about *&&m",lit of solid and %H/"m,lit
soda is collected in an overflow tank. he underflow of settler containin"
/&&"m,lit of settled mud is washed in six sta"es with water to recover
maximum amount of soda. 3art of that wash li#uor is mixed with settler
overflow li#uor to attain %*+"m,lit of soda concentration i.e. favorable
condition for alumina precipitation. he li#uor thus achieved is pumped to
security filter feed tanks for third and last sta"e of solid impurity removal.
SECURITY FILTRATION
Since *&&m",lit of solid impurity in the li#uor will make the alumina impure
in precipitation up to unacceptable limit, further separation of solid is done
by means of filtration. ;or this purpose, settler overflow li#uor is filtered in
security filter or Kelly filter to brin" down the solid from *&&m",lit to below
-&m",lit. Kelly filters are pressure leaf filters bein" operated at -ata
pressure. @uick lime solution is used as filter aid to help in filtration. he
li#uor there after is called as aluminate li#uor and is ready for of alumina
production by precipitation. he soda concentration here remains at %*2"pl,
A3 at %.&H.
PRECIPITATION
Aluminate li#uor is cooled down to about H/
'
( in plate heat exchan"ers to
achieve better precipitation. As per #uality demand of precipitated products
"rain siGe is most si"nificant and in order to achieve bi""er particles, small
hydrate particles are mixed with aluminate li#uor so that alumina hydrate
precipitation takes place on those particles and their siGe increases. At the
end of precipitation process, the particles are classified as per siGe and
coarse particles are taken out as final product hydrated alumina. he fine
particles are mixed with fresh aluminate li#uor to allow precipitation on the
surface to make them "row further. In this manner the coarse products are
taken out and fines are recycled to precipitator after mixin" with aluminate
li#uor. After classification of the precipitated products, slurry containin"
coarse particles is filtered in product filter to remove the mother li#uor
called spent li#uor. he fine particles slurry is filtered in seed filters to
separate the mother li#uor called as spent li#uor. he spent li#uor received
from both product and seed filters is heated up in plate heat exchan"ers
while coolin" aluminate li#uor and dispatched to evaporation area.
he seed hydrate is not only put in aluminate li#uor for particle "rowth but
also for increasin" the rate of precipitation as auto precipitation rate of
aluminate li#uor is very low. >ow concentration of soda in aluminate li#uor,
low precipitation temperature, hi"h surface area of seed hydrate, hi"h
amount of seed hydrate are favorin" factors for better precipitation.
Aluminate li#uor mixed with seed is kept in precipitators for about *&hrs to
achieve substantial production. here are %H precipitators of *0&&m
-
effective volume each in each stream. he precipitators are also cooled in
between to decrease the temperature to "et more yields.
he spent li#uor at concentration of %/&"pl soda is pumped to evaporation
area and product hydrate proceeds to calcinations area.
E"APORATION
he spent li#uor at +&
'
( is stored in spent li#uor tanks. 3art of the li#uor is
pumped to ball mill to help in wet "rindin" and 3redesilication. :a5or
portion of the li#uor is concentrated in evaporators and used for di"estion.
here are six evaporator batteries, each have six effects. Any one of the first
five effects can be bypassed for maintenance purpose. hese are fallin" film,
backward feed evaporators. Steam is used for heatin" the spent li#uor and
boil to "et vapor, so that the li#uor "ets concentrated.
Ae#uired evaporation ) +&&tons,hr of water
Steam used ) 0H&tons,hr
he steam condensate from these multiple effect evaporators is sent back to
steam plant. 8enerated vapor is condensed in different effect and the
condensate is used in different area as sodic condensate. o enhance
capacity of evaporation battery, last effect is operated under vacuum and
sprayin" coolin" water to the "enerated vapor "enerates the vacuum. he
product of evaporation battery is called as "reen li#uor as it is capable of
"ivin" productionM the temperature is %&/
'
( and concentration is 00/"pl.
CALCINATION
he hydrated alumina received from precipitation is washed in drum filters
to reduce impre"nated soda. In order to remove bound or chemically
combined moisture i.e. -7
0
' from the hydrate it is sub5ected to temperature
of %&&&
'
( furnace. he temperature is achieved by burnin" fuel oil with air.
here are three fluid bed calciners which have rated capacity of //&& tons
alumina ,day.
he alumina is transported to silos by belt conveyors and from there by
railway wa"ons to An"ul and CiGa".
#UALITY OF ALUMINA
6 37NSI(A> @!A>IN
6 $*/ %0Emax
6 K%0/ %/Emax
6 B9 Area H&$+&:0,8:
6 >oss on i"nition %E:AD
6 content %&E:AD
6 (79:II(A> 3A'39AN
6 Al
0
'
-
<3urity= L+./E:I?
Impurity
6 ?a
0
' &./E:AD
6 (a' &.&/E:AD
6 Si'
0
&.&0E:AD
6 ;e
0
'
-
&.&%/E:AD
SPECIFIC CONSUMPTION OF RA$ MATERIALS
6 BA!DI9 0.H/'? <4AN=
6 (A!SI( S'4A 2&K8
6 3'O9A 02/KO7
6 ('A> &.2/'?
6 ;!9> 'I> +&K8
6 >I:9 *&K8
6 (N9( -&&8:
6 BAA? *K8
6 (8: %K8
6 OA9A *'?S
U%e o& a'u(ina:
%. :ainly for manufacture of aluminium
0. In ceramic industries for manufacture of refractory
-. ;or manufacture of tooth powder, tooth paste
STEAM AN PO$ER PLANT
?alco is a purpose utility. he main purpose is the production of
Alumina from bauxite. In this process of conversion of bauxite into
Alumina, steam is a ma5or prere#uisite, which is used in various unit
operations.
he unit operations where steam is re#uired are as follows)
4i"estion
3redesilication
4esilication
(lassification
9vaporation
(alcinations
;locculation
Keepin" in view the re#uirements of steam in the process of the plant,
durin" the time of installation a boiler was set up which would boil water
usin" oil and coal to heat water to steam. But with time it was seen that the
plant could produce more steam then was re#uired i.e. only a part of it was
utiliGed. It was only then proposed to use this steam in power "eneration in
addition to itJs utiliGation in unit processes. his led to establishment of a
steam a power plant unit <S33= in ?A>(' 4aman5odi. S33 is called a
co"eneration plant because it helps in the production of both steam and
power. his steam is "enerated from the boiler and the power is "enerated
usin" this steam in a turbo "enerator. A turbine and a "enerator set up are
used for the production of power usin" steam.
here are various units, which are included under the steam and power
plant at ?A>(' 4aman5odi. All these units are interconnected and affect
each otherJs performance. he units are as listed below
4: 3lant
;uel 'il 7andlin" plant
(oal 7andlin" 3lant
Boiler
urbo "enerator
Ash 7andlin" 3lant
All the units were studied in the above order every section has an
intricate use of pro"rammable lo"ic control system <3>(= makin" the
whole plant an automated unit. ?alco is further focusin" on convertin"
this whole 3>( system to a 4istributed (ontrol System <4(S=.
M $ATER PLANT
he 4e$:ineraliGed water plantJs aim, the plant is basically desi"ned
to demineralise the water, which is in turn fed in to the boiler for the
"eneration of steam. 7ence the name demineralised water plant.
he purpose of the plant is to free water froPm all kind of impurities,
includin" suspended particles, cations, anions, undesired "ases like ('
0
hence demineralised water is free from all kinds of
impurities. Its importance arises when water is needed in the
boiler for the production of steam. Water in the boiler must
be demineralised because, mineralized water in the boiler
results formation of scales. Hence hindering the production
of steam in the boiler. Scaling has the following
disadvantages.
Results in the formation of holes in the water tubes of
the boiler.
Aesults in leaka"e of water in the core of the boiler
Coal burning is left incomplete
his steam is further utilized in the processes involving
the production of alumina. Hence serving the core purpose
of the plant.
he dm plant consists of ! streams having a "ow rate of
#$ m
!
,hr of water feedin" to the three workin" boilers. he streams of the
4: plant are Identical and are made up of the followin" sta"es)
Acti)ated car*on &i'ter: - this is the first sta"e to which the
stream is made to flow. It is sub5ected to an A(; whose main
function is the absorption of the suspended impurities.
Acce+tance 'i(it:$
P, )a'ue -./$+.0
Tur*idit0 )a'ue /-0&ntu
Strong acid cations:- resins present in the S%C
are sub&ected to passage of water b' common ion
e(ect help in removal of cations
Degasser tank:) undesirable gases like carbon
dio*ide are removed in the tank b' passing through
the degasser tower which contains + huge air
blowers.
Strong Basic Anion:) the water free of suspended
particles cations and undesirable gases is passed
through the S,% tank to remove anions.
Mixed Bed:) then the water is passed thru a mi*ed
bed containing boot cationic and anionic resins for
further purit' from ionic impurities
Fuel Oil Handling
;uel oil is procured in oil tankers into the plant premises. his fuel oil
is fundamentally of two types li"ht diesel oil and heavy fuel oil. here are
two separate oil tanks for storin" the oil procured from the oil tankers. here
are specialiGed unloadin" oil pumps which help in unloadin" the oil from the
oil tankers to the oil tanks. he capacity of the 7;' tank is %&& m
-
and that
of >4' tank is 0/m
3
.All the three tanks have an earth "rid resistance of
&.%2H ohm.
here are specialiGed suction pups for drawin" oil from 7;' and >4'
tanks there are three >4' suction pumps and three separate 7;' pumps.
hese pumps are used dependin" on the re#uirement in the boilers. If the
re#uirement is less one of the pumps is used as a standby. hese pumps
pump oil from the tank and direct it towards the strainer. hese strainers are
two in number and they are aimed at filtration of the oil in order to remove
the oil sediments. he filtered oil from the strainer is sent to the oil heater.
hese are also two in number, one standby and one inline. his oil heater is
used to reduce the viscosity of oil so as to make the oil suitable for boiler
operation. his oil is heated by interactin" it with steam at a pressure of %%
ata and temperature of 00& de"ree (elsius
his oil is channeliGed into the oil "uns where it is used for li"htin" up
the boiler.
;uel oil >i"ht density
oil<>4'=
7eavy fuel oil
Standard ISI *H&,%L2* ISI %/L-,%L2%
3our point <max= %0 Q %+ Rc -+ Rc
;lash point <min= HH Rc HH Rc
Ciscosity <max= 0./ Q %/.2 (.S. at
-&Rc
+& Q -2& (.S. at
/& Rc
(arbon
dioxide< max=
%./E by mass $$$$$$$$$$$$$$$$
otal sulphur
<max=
%./ Eby mass -./E $ *./E by
wei"ht
A3I "ravity
<typical=
-/ sp 8r.&.+/ at %/
Rc
%& sp. 8r. &.L-* at
%/& Rc
(ross heatin"
valve
%& Q 0&E Kcal,k" %&02 Kcal,k"

COAL 1ANLIN! PLANT
(oal is used as a primary fuel in the boiler. his coal is used in the
production of steam by heatin" water inside the boiler. hus coal forms a
ma5or re#uirement in S33. his steam is used for carryin" out the various
unit processes. he coal is bou"ht from alcher coal mines, by wa"ons. his
coal used in the boiler is known as B$ "rade coal, i.e. bituminous variety of
coal. he coal is now made to under"o a series of processes before bein" fed
to the boiler. he processed coal is sent to the coal handlin" plant. And then
it is used up by the coal feedin" plant.
Coa' un'oadin2 %0%te(: - the coal from wa"ons is fed to a hopper by
means of a rotaside wa"on tippler. he coal from hopper is fed to the
vibratin" feeder. By means of vibratin" action it is made to pass into the
techno chute by means of a conveyor and flap "ate arran"ement. his coal is
stocked in the techno chute.
Coa' &eedin2 %0%te(: - this system has been so desi"ned to separate
the iron components in the coal stock. his is done because iron presence
hinders steam formation. A (B: is installed for this purpose <(ross Belt
:a"net=. his ma"net attracts the iron pieces and separates them. But there
is possibility of some iron particles "ettin" missed out. So a ma"netic pulley
I fitted at the end of the conveyor. hen the coal is fed into the crusher
where it is reduced to $0/ mm. two crushers <% acts as standby=. ;rom the
crushers the coal is made to pass throu"h a series of two conveyors and a
flap "ate mechanism to enter the coal bunkers. A (B: is a"ain used alon"
with a ma"netic pulley so that iron particles donJt enter the bunker. (oal is
conveyed to the bunkers by means of a travelin" tipper. :etal detectors help
in avoidin" presence of metal in the boilers.
Rota %ide 3a2on ti++'er: - tips the wa"ons so that coal is collected in
the coal hopper.
Coa' (i'': - the function of the coal mill is to reduce the siGe by
"rindin" the crushed pieces of coal to 0&& mesh siGe. his reduction of siGe
due to "rindin" increases the surface area of coal to enhance combustion of
coal.
Sea' air &an: - In the coal mill there is "ap in the rotatin" and static
part of the mill. his may lead to loss of coal by flyaway, due to intense
pressure prevailin" in the coal mill. o avoid this seal air fan is provided at
the outlet which sucks in cold air from the atmosphere and pumps it into the
coal mill where the "ap is created. 7ence the pressure of the air pumped in
is always more than pressure inside the coal mill. It avoids leaka"e of coal to
the atmosphere.
AS1 1ANLIN! PLANT
Ash produced due to combustion in the boiler needs to be disposed off
safely so that it does not have an adverse effect on the environment or the
people.
his function is carried out by the ash handlin" plant. 'ut of the total
ash produced 0& Eis known as bottom ash which is collected in the water
impounded furnace <bottom hopper=. he rest is conveyed out by flue "as
and is collected mainly in the 9S3. the fly ash is collected in three parts, the
ma5or amount is collected in 93 hoppers, small amount of fly ash is
accumulated in the economiGer and air pre heater hoppers. he scrapper
conveyor located below the bottom ash hopper carries the ash fallin" on it
and delivers it to the clinker "rinder where clinkers are flushed away by low
pressure ash water into the trenches below the "rinder. he ash water from
the trenches is collected in an ash pit, from where it is pumped to the ash
pond usin" slurry pumps.
E'ectro%tatic +reci+itator: - these are widely used for industrial
purposes of dust collection and cleanin". hese are very reliable because of
the followin" reasons)
7i"h precipitation efficiency
'perational reliable units
'ptimiGation in unit siGes
Suitability for hi"h resistively dust application
Aeduction in operation and maintenance cost
his is a set up for collection of ash particles from flue "as produced in
the boiler core. hese precipitators have very hi"h efficiency of LL.LE. he
rest &.%E is lost to the atmosphere. here are two passes for a boiler S 3ass
AT and S3ass BT. 9ach pass in a boiler has seven feedersM the fourth unit has
0+ feeders.
An 9S3 consists of a ne"atively char"ed dischar"e electrode, which is
hun" between to earthed metal plates called collectin" electrodes. Ohen a
hi"h dc volta"e is supplied to the dischar"e electrode an electric field is
produced which ioniGes the "as around the dischar"e electrode. his
phenomenon of dischar"e is called S(orona 4ischar"eT. After char"in" the
particles start mi"ratin" towards the earthed electrodes. 'n reachin" the
opposite collectin" plates these ash particles loose their char"e and "et
deposited there. his deposited dust layer is removed by Srappin"T at fixed
intervals. his dust then falls into hoppers and ash$handlin" process is
carried out.
Boi'er
he boilers set up in ?alco 4aman5odi at its steam and power "eneration
plant <spp= have the followin" specifications)
C! type, natural circulation
(apacity) uses 0&&tonnes,hours
;uel in5ection type, tan"ential fixed corner type fuel firin",
Bidrum,
Steam pressure) H2 K",cm
0
Steam temperature) *+/ Rc
In+ut%: -
here are three basic needs which a boiler re#uires)
water to "enerate steam
fuel to heat the water
1P a%, 3ater
+u(+:-
(apacity) 0L/ m
-
,hr
7eat) +/ :O(
:otor ratin") ?89;,
*%/C,
/& 7G, %&/ KO
Speed) %/&& rpm
9fficiency) 2+E
A%, %'urr0 +u(+: -
Speed) +0/ rpm
motor ratin") %/& kw
pump capacity)H-/
m
-
,hr
rain +u(+: -
(apacity) %&& m
-
,hr
otal head) %/ mts
Speed) %&*& rpm
motor ratin") %/ kw
air to support combustion
Out+ut%: -
initially the steam "enerated by the boiler was used to meet the
re#uirements of the plant i.e. he process of alumina refinin" but "radually
it was seen that steam produced could be further utiliGed to "enerate power
as a by product. hus the outputs of the boiler now are
steam for the process of alumina refinin"
power as a by product
residual products <waste products=
Con%truction: -
i(en%ion%:-
(uboidal in shape
7ei"ht Q %/& ft
he inner walls of the boiler entirely comprises of vertical water tubes with
a bore diameter of 2/ mm each. hese vertical tubes are called as steam
"eneratin" tubes. he water tubes a re separated by thin vertical tubes of
metal called fins. o ensure safety of maintenance workers the boiler is
insulated from the outside. ;urther description is done takin" into account
the various paths of the inputs
$ater:
he water from the dm plant output is stored in the 4: tank. ;rom the
dm tank the water is taken to the make up water tank <:!O=. Oater from
the :!O is pumped to the deaerator chamberM wherein the dissolved
oxy"en is removed from the dm water by usin" steam. his oxy"en free
water is stored in the deaerator tank, which is below the deaerator chamber.
he water is now pumped to the steam drum throu"h the boiler feed pump
arran"ement.
Before bein" sent to the feed pump it is first set to the feed station <level
control= and then to the economiGer <preheatin"= and then to the steam drum.
?ow the water from the steam drum is fed to the mud drum by means of
bank tubes. ?ow from the mud drum water moves to the rin" header via
down comers.
he steam "eneratin" tubes inside the boiler are connected to the rin"
header. And as the water in the boiler heats up it passes in to the rin" header,
resultin" in natural circulation.
his saturated steam is now fed into the super heater placed inside at
the top of the boiler
;inally the super heated steam at *+/ Rc is fed into the main streamline.
his is the main steam header. his header is now the input to the turbines
hence aidin" in power "eneration.
Air +at,: -
?ow any fuel in any form is brin" in5ected in to the boiler chamber it
catches fire or under"oes combustion instantaneously.
hus in order to control this combustion there are some very elaborate
arran"ements
Boiler is always kept at a ne"ative pressure, so that pressure does not
increase to an explosive value.
3roducin" a forced air draft does this.
Fue' +at,: -
he fuel used in the boiler is of two types. 'ne is the fuel oil and the
other is the pulveriGed coal. (oal is used as a fuel as it is less costly
compared to fuel oil. But the fuel oil has its own si"nificance. Since the coal
cannot be used for combustion as it will result in improper combustion. So
7;' is first used to attain a necessary temperature in the boiler of about H&&
Rc and then coal dust of 0&& mesh siGe is in5ected into the boiler after this
temperature is attained. Initially >4' was used to attain i"nition
temperature in the boiler for firin" 7;' and then coal.
"ariou% co(+onent% and t,eir &unction%: -
Econo(i4er: preheats the water before sendin" to the boiler drum.
Stea( dru(: contains both steam and water pumped in there by the
boiler feed pump.
Ban5 tu*e%: connect the steam drum and the mud drum
Mud dru(: It is preheated by flue "ases and contains water at very
hi"h pressure.
eaerator c,a(*er: - it dissolves the oxy"en present in the
demineraliGed water comin" from the 4: plant
eaerator tan5: water from the deaerator chamber is stored in the
deaerator tank
Ma5e u+ 3ater tan5: it is filled with condensed steam from the return
steam line received throu"h the return steam lines. It also receives A( from
condensate extraction pumps
$ind *o6) contains heated air from the air pre heater. It provides air in
the proper proportion for complete combustion in the boiler.
Air +re ,eater: it is a heat exchan"er in which air temperature is
raised by transferrin" heat from flue "ases.
Scanner: to check whether the fireball has been established or not we
need to constantly monitor the interior of the boilers. thus scanners have
been installed in order to check the temperature and pressure
Scanner air &an%: in order to keep the scanners cool and clean the
"lass surface is blown by blasts of cold air continuously. hus for coolin"
and pur"in" scanner air fans are used
Tur*ine
he workin" steam flows axially throu"h the sin"le casin" extraction
back pressure. he emer"ency stop valves are arran"ed on the casin" at the
inlet, their purpose bein" to shut off the total steam flow, the boiler to the
turbine in the shortest possible time. he live steam flows trou"h the
emer"ency stop valve housin"s, which are welded on to the side of the
turbine casin", to the hp control valve chest. he control valves re"ulate the
steam flow throu"h the turbine accordin" to the load demand.
he bladin" both in the hi"h pressure and low pressure parts of the
turbine is of the impulse type with hi"h reaction. hese parts serve as
re"ulatin" sta"es.
After expansion throu"h the hp part some of the steam is let off
throu"h the two extraction steam mains. ;or isolatin" the turbine from the
mains an extraction stop valve is provided which operates in the same way
as the live steam emer"ency stop valves. ItJs purpose is to isolate the turbine
from the extraction steam mains in the case of shutdown and thereby avoid
steam flowin" back into the turbine
he pressure at the point of extraction is "overned by the >3 control
valves. he steam flow throu"h the >3 part is related to the extraction steam
#uantity in such a way that the pressure at the extraction point is kept
constant within the desi"n ran"e. he hp and >3 control valves are each
positioned by a hydraulically operated relay cylinder via linka"e system.
he turbine outer casin" is horiGontally split. he hp and lp steam
chests are cast inte"ral with the top half. hese cylindrical steam chests are
arran"ed transversely with two side assembly openin"s. In the hp steam
chest these openin"s also connect with the emer"ency stop valves. wo
further top openin"s allow further installation of the two valve spindles.
he steam passes via the diffusers and the hp inner casin" noGGle
bowls to the re"ulatin" sta"e. he inner casin" is not horiGontally split
thereby allowin" optimum dimensions with approximately constant wall
thickness. Besides the noGGle rin" and its lockin" rin" for the mountin" of
the diaphra"ms is built into the hp inner casin". hese diaphra"ms are split
horiGontally and are fixed to the lockin" rin" by radial bolts. hereby free
thermal expansion with exact centerin" is allowed. he axial steam forces on
the diaphra"ms are carried by the inner casin" via the lockin" rin" and its
bayonet lock. he centerin" of this lockin" rin" in the inner casin" is
achieved by axial keys arran"ed around the circumference
he steam pressure downstream of the hp inner casin" is
simultaneously the pressure on the outside of the inner casin" caused by
pressure difference are relatively small, no appreciable thermal stresses
occur throu"h temp differences in the inner casin" as it is surrounded by
steam comin" out of the labyrinth at approximately the live steam
temperature
he hp inner casin" is radially and axially located so as to follow free
thermal expansion in all directions. It is supported and located axially and
vertically in the outer casin" near the horiGontal 5oint, for sideways
displacement is prevented by top and bottom fit bolts. he connection to
inlet steam chest is achieved by steam ti"ht flexible rin"s which allow
expansion
he use of the hp inner casin" severely reduces the internal pressure
actin" on the outer casin" therefore the outer casin" flan"es and bolts can be
reasonably dimensioned
he lp inner casin" is arran"ed downstream of the hp inner casin", the
lower steam conditions allowin" it to be horiGontally split.
A collar in the outer casin" retains it in the axial direction almost
without play.
ItJs centerin" relative to the rotor and the outer casin" is achieved by
horiGontal and vertical keys and centerin" bolts
he diffuser for the low$pressure valves which are necessary for
maintainin" the extraction pressure and for controllin" the lp steam flow are
screwed into and locked in the inner casin". he noGGles which are attached
to two half rin"s are inserted direct in the inner casin" halves. he
diaphra"ms are located I the inner casin" by radial centerin" bolts and
vertical bolts t horiGontal 5oint thereby "uaranteein" free thermal expansion.
In order to eliminate steam leaka"e between the rotor and inner casin"
with closed lp control valves a labyrinth seal is provided which operates as a
shaft "land.
As the turbine rotor and outer casin" are independently supported by
the bearin" pedestals an exact ali"nment of both elements is necessary. Since
the rotor position is determined by the bearin"s the thermal expansion must
be taken into account when supportin" the outer casin". he vertical position
of the casin" is determined by paw supports, the play under the heads of the
bolts holdin" the paws to the bearin" pedestals allows transverse expansion
of the outer casin" relative to the bearin" pedestals. he ali"nment of the
outer casin" in the horiGontal plane is achieved by lower casin" "uides
which are so constructed that the outer casin" can freely move up and down
he exhaust and bearin" pedestal is fixed to the sole plates since the
lower casin" and the bearin" pedestal do not allow for axial movements
between casin"s and bearin" pedestals, thermal expansion of the casin"
pushes the front bearin" pedestal forward, sideways movement of the
bearin" pedestal is prevented by axial "uide keys. he bearin" pedestals
cannot twist tip or lift.
he turbine rotor is manufactured from an alloy steel for"in". he
formation of the blades direct from the rotor material allows for hi"h blade
loadin". he 5ournal bearin"s for the rotor are located in the bearin"
pedestals. Oith the front allocated in the bearin" pedestal also contains the
thrust bearin" which rotates the turbine rotor axially and absorbs axial thrust
A tooth couplin" connects the turbine rotor to the driven machine and
prevents carry over of axial thrust and bendin" moments.
he balance piston partially compensates the axial thrust as the axial
thrust also depends on the turbine load the remainin" thrust is taken by the
thrust bearin" at the same time the balance piston labyrinth seals the
pressure in the wheel chamber a"ainst the "land steam pressure.
he bladin" consists of a hp and lp impulse sta"e which allows partial
arc admission fro "ood flow re"ulation, the remainin" sta"es and impulse
sta"es. he radial and axial clearances are so dimensioned that add hi"h
reliability in service with best utiliGation of the available heat drop is
achieved
he turbine is hydraulically "overned
he over speed trip is to interrupt steam admission to the turbine as
soon as the speed becomes excessive.
3ressure measurin" points on the various steam spaces are provide for
supervision, thermometers on the bearin" oil return lines allow for re"ular
bearin" checks.
Lu*rication %0%te(: - the lubrication system is desi"ned to reduce the
frictional losses and provide ade#uate coolin" arran"ement to the bearin"s
of the turbine and "enerator, couplin" and "earboxes. It furnishes "overnor
and control oil re#uirement s also
he ma5or parts "overnin" the lubrication system are as follows)
:ain oil tank
:ain oil pump
Auxiliary oil pump
9mer"ency oil pump
Jack oil pump
'il coolers
'il filters , centrifu"e
TURBO!ENERATOR
INTROUCTION
In the recent years many basic industries could not meet their
production tar"ets because of lack of availability of power in ade#uate
#uantity. ?on$availability of power has affected production as well as safety
of some of the core industries. >ookin" from this an"le and based upon the
steam re#uirement of alumina extraction process, detailed study was
conducted for suitable selection of !AB' 89?9AA'AS.
(o"eneration increases the cycle efficiency of the power plant.
AnalyGin" the steam and electrical load pattern of the entire plant, three %+./
:O extraction <*/ tph= back pressure <%%& tph= !AB' 89?9AA'AS of
backpressure type with the uni#ue feature of controlled extraction. 4esi"n of
turbines was done so that after expansion in 8 steam parameters at turbine
outlet are at compatible level as per the re#uirement of alumina refinery.
Superheated steam is "enerated in the boilers by combustion of fuel.
his superheated steam is expanded in turbines,pressure temperature and
pressure 3ower is co$"enerated by means of 9xtraction Back pressure
!AB' 89?9AA'AS.
It essentially consists of two components$the turbine and the "enerator.
he turbine is a steam turbine and is basically an extraction
backpressure type. he steam is fed at a temperature of *+/ de"ree
centi"rade and at a pressure of H+ K",S# cm and is fed to the alumina
process as well as to take care of the auxiliary consumption with in the
steam power plant. Balance #uantity of steam from the 73 sta"e is fed to
the >3 sta"e and from the exhaust of this sta"e at a pressure of H k",S# cm is
fed to the alumina process as per re#uirement. he 3$C expansion of the
steam inside the turbine determines the work done by the turbine. In turbine
the thermal ener"y of the steam is converted into mechanical motion of the
turbine.
he mechanical ener"y of the turbine is used to drive a cylindrical pole
-&&&$rpm "enerator throu"h a "earbox of /-&&,-&&&. he stator consists of
the stationary hi"h volta"e circuit and the rotor forms the low volta"e
excitation or the field circuit.
;or an 9:;,volta"e to be induced in a conductor as per faradays laws of
electroma"netic induction$ i.e. if the flux linkin" with a conductor chan"es
an 9:; is induced in the conductor and ma"nitude of the induced 9:;
depends on the rate of chan"e of flux linka"es.
he stator consists of the windin"s constitutin" the conductor portion, a flux
has to be induced by the rotor circuit, where as the rate of chan"e is taken
care of by the turbine motion.
;or creatin" a flux by the rotor circuit a volta"e has be applied to this
rotatin" windin" throu"h slip rin"s and carbon brushes. 7ence when the
turbine is runnin" at almost constant speed the "enerated volta"e output is
dependant on the field,rotor input supply.
he Active power output "enerated is dependant on the steam input supplied
to turbine, by varyin" steam input the :O output "enerated by the "enerator
can be varied.
he Aeactive power output "enerated is entirely dependent on the field
supply, by increasin" the excitation the :CAA output inductive can be
increased and by decreasin" the excitation the :CAA output (apacity can
be increased.
7ence to maintain constant "enerator output volta"e it is necessary to
maintain the excitation supply constant. o take care of the excitation
re#uirements an Automatic volta"e re"ulator is provided in the excitation
system. he automatic volta"e re"ulator shall be discussed in a little while
SYSTEM ESCRIPTION:
here are three %+./ :O extraction and back pressure turbines in
?A>(' Alumina Aefinery at 4aman5odi. A tunin" 3A4S system alon" with
4ump (ondenser and Cent system makes the "eneratin" facility capable of
island operation isolatin" the plant from power cuts.
Steam flow throu"h the turbines is in axial direction. o shut off the total
steam supply from Boiler to urbine in the shortest possible time 9mer"ency
Stop Calve <9SC= is arran"ed at the turbine inlet. he live steam flows
throu"h 9SC to the valve chest of 73 (ontrol valves which re"ulate the
steam flow throu"h the turbine accordin" to the load demand.
hey are bladed both in the hi"h pressure and low pressure parts of the
turbine is of the impulse type with hi"h reaction. he 73 and >3 parts serve
as re"ulatin" sta"es. ;or 98 type of turbine, part of the steam is bled from
the turbine at the extraction branch behind the 73 drum bladed and fed to
extraction steam. 9xtraction stop valve is provided in the same way as live
steam emer"ency stop valve to isolate the turbine from extraction mains,
thereby avoidin" steam flowin" back to the turbines causin" over speedin"
of the turbine due to reverse flow.
he >3 control valve controls the backpressure at the extraction
branch. he steam rate throu"h the >3 steam is matched to the extraction
rate in such a way that the pressure is kept constant within the desi"ned data.
A hydraulically operated relay cylinder positions the 73 and >3 control
valves and a labyrinth "land separates both the drum bleedin"s. he turbine
rotor is manufactured from an alloy steel for"in". he formation of the
blades direct from the rotor material allows for hi"h blade loadin". he
Journal bearin"s for the rotor are located in the bearin" pedestals. he front
bearin" pedestal also contains the thrust bearin" which locates the turbine.
A tooth couplin" connects the turbine rotor to the driven machine and
prevents carry over of axial thrusts and bendin" moments.
TURBINE !O"ERNIN! SYSTEM
urbo "enerator is e#uipped with hydraulic "overnin" system. his is
desi"ned to control the speed of urbo "enerator set at varyin" electrical
loads and extraction steam #uantities.
;or control purpose sin"le casin" backpressure turbine with one
controlled extraction has been divided internally with steam "lands into two
parts hi"h$pressure part and low$pressure part. In each part of the turbine
steam flow is re"ulated by a set of steam control valves. he amount of
openin" of each valve is controlled by the hydraulic si"nal <secondary oil
pressure= "enerated by speed "overnor <back pressure controller= and
extraction pressure controller.
Speed "overnor "enerates the secondary oil pressure for control valve
actuators <servomotors= in such a way that the chan"e in amount of steam
flow throu"h 73 and >3 parts of the turbine is the same he SAC IC
"overnor controls the turbine speed and maintains it at a constant value in
accordance with the functional relationship represented by its characteristic
line. he pressure of the secondary oil dischar"ed at the "overnor output side
forms the input si"nal that acts on the control piston of the servomotor.
he followin" mechanical protections are inbuilt into the "overnin" system.
%. 'ver speed protection. Q Set between + to %&E above the rated
speed.
0. >ow lube oil pressure protection. Set at &.2k",cm
0
".
-. 7i"h back pressure protection. Q Set at 2.0 k",cm
0
".
*. 7i"h extraction pressure protection. Q Set at %0.0 k",cm
0
".
/. 9mer"ency hand trip device. o trip the set locally in emer"ency.
LUBRICATION SYSTEM
he lubrication system delivers clean, filtered 'il at the specified
pressure to the bearin"s of the "enerator, turbine, couplin" and "earboxes. It
furnishes "overnor and control oil re#uirements also.
he main oil tank has a capacity of %%&&& ltr. he tank is provided
with a level si"ht "au"e "lass, a low$level alarm switch. It has the facility of
a centrifu"e e#uipped with a heater, fillin", drainin" and ventin".
4urin" normal operation of the turbine total oil re#uirement is met by
:ain 'il 3ump<:'3= which is turbine driven. 4urin" start up Auxiliary 'il
3ump<A'3= meets the oil re#uirement which is powered from A( source .
In addition an 9mer"ency 'il 3ump<9'3= powered from 4( source caters
to the bearin" lubrication and subse#uent coolin" down of the set durin"
power failure.
wo oil coolers are provided, each servin" as a standby to the other to
cool the total oil flow used for the set.
he oil after leavin" the cooler "oes to the filter. 3aper
cartrid"es<disposable= are used in this<in filter unit, each servin" as a
standby to the other. 7i"h differential pressure across the filter calls for a
chan"e of cartrid"es.
T1E CENTRIFU!E
he centrifu"e is a machine, which applies centrifu"e force to a li#uid.
he rotor, called a bowl has an openin" in the bottom to allow the fluid to
enter, and openin" in the top of the bowl to allow the li#uid or fluids to
dischar"e. he fluid enterin" the rotatin" bowl is caused to rotate with the
bowl. (entrifu"al force is "enerated by the rapid rotation. he li#uid, as it
passes from the bottom to the top of the bowl, is acted upon by the
centrifu"al force "enerated the separation of li#uids is thus effected and the
removal of solids also accomplished separatin" it into its various parts
accordin" to their relative wei"ht. he heavier parts <Such as solids and
slud"es=, are forced throu"h the li#uid and form a layer on the inside wall of
the bowl. he heavier li#uid forms a cylindrical layer upon which floats a
cylindrical layer of the li"hter li#uid. he li"ht li#uid is assumed to be oil,
and the heavy li#uid water.
C'ari&ication:
he term SclarificationT is used to describe a separation of solids from
a li#uid. A clarifier is a centrifu"e ad5usted to dischar"e a sin"le li#uid from
which the solids have been removed by centrifu"al force. If oil contains no
moisture, the use of a clarifier is all that is necessary to purify. If, however,
the oil contains some moisture, this will settle to the bottom of the "ravity
throu"h, to"ether with the solids. As additional wet oil is flowed throu"h the
trou"h, the layer of water in the bottom will build up until eventually the
trou"h will be full of water. If wet oil is still fed to the trou"h, it will merely
flow across the top of the water layer and the oil will dischar"e without the
water havin" separated from the oil.
Se+aration:
he term SseparationT is used to describe the result of "ravity or
centrifu"al force actin" on two li#uids, such as oil and water. A centrifu"al
separator is one that is ad5usted to continuously separate and dischar"e these
li#uids. Since this force is also actin" on any solids present, clarification
takes place at the same time throu"h the deposit of these solids present
clarification takes place at the same time throu"h the deposit of these solids
a"ainst the wall of the bowl. Oater is fed first when the machine <bowl=
reaches its full speed to the "ravity throu"h or to the centrifu"e bowl. he
bowl will be filled up with water and the excess water will overflow throu"h
the water drain passa"e. his is followed by oil enterin" the bowl. If,
however, oil is first fed, the trou"h or the bowl will fill up until water drain
port hei"ht is reached and the oil will then overflow, dischar"in" throu"h the
water drain. his means that the oil is delivered at the outlet normally
intended for water, because there is not water in the bowl to seal off this
outlet and thus cause the oil to overflow. In any oil and water separation,
water must first be fed to the bowl in order to create this seal. his operation
is known as Sprimin"T.
EXCITATION SYSTEM:
he excitation transformer, connected to the "enerator stator terminals
throu"h a tap off bus duct feeds to the thyristor converter. he output of
these thyristor brid"es is connected to the "enerator field throu"h field
breaker. he automatic volta"e re"ulator controls the output from thyristor
converters by ad5ustin" firin" an"le dependin" on the "enerator volta"e. he
field flashin" circuit facilitates initial build up of "enerator volta"e from 4(
power supply.
he excitation system comprises of$
$ An excitation transformer fed from the "enerator output
terminals and its associated protections.
$ A thruster converter used in - sections for redundancy to convert
the A( to 4( for feedin" the rotor circuit alon" with all
associated protection, coolin" and control systems
$ A field breaker for switchin" on the excitation supply on 4( side
with field dischar"e resistor to avoid over volta"es when field
breaker opens, it is a make before break contact
$ A field flashin" contactor to provide the initial excitation system
re#uirements throu"h a station battery which automatically
switches off as soon as the "enerator output volta"e reaches 2&E
of the rated volta"e.
$ A series compoundin" transformer alon" with rectifier circuits to
provide -&E of the excitation re#uirement durin" normal
operation and to provide additional excitation re#uirements for a
few seconds in case of a fault in the system i.e. to enable the
"enerator to sustain if the fault is cleared instantaneously. he
ma"nitude of the supportin" excitation in case of a fault supplied
by the S( is proportional to the ma"nitude of the fault current
fed by the "enerator it self, it is a basic re#uirement in case of
isolated networks and in systems operatin" in island condition.
$ An Automatic volta"e re"ulator to control the excitation circuits
to maintain the output volta"e constant at set reference value.
AUTOMATIC "OLTA!E RE!ULATOR
he automatic volta"e re"ulatorUs functions are carried out by the
different modules that have been built into it circuitry. he functions of these
modules and their operation mechanisms are discussed briefly below.
he ACA is desi"ned to control the output volta"e of the "enerator at
set value throu"h a closed loop control comprisin" of inputs from the 3, (
of the "enerator
It has various limiter circuits that override the ACA si"nal to ensure stable
performance of the "enerator .
hey are rotor current limiter, limitin" the rotor current to a set value if
brin"in" irrespective of the ACA si"nal exceeds the set value and ACA
can take over only when the current has come down below the set
value of the rotor current limiter.
Stator current limiter to limit the "enerator output current to set value
overridin" the ACA increasin" error si"nal and ACA can take over only
when the current has come down below the set value
Aotor An"le limiter to prevent the rotor fallin" out of step overridin"
the ACA increasin" error si"nal and ACA can take over only when the
current has come down below the set value
?$0 limiter to limit the rotor current in case of failure of O' thyristor
brid"es
79 ACA IS 4ICI494 I?' O' S9(I'?S '?9 $$A!'
(7A??9> ;'A ?'A:A> '39AAI'? A?4 A :A?!A> (7A??9>
;'A 9SI?8 3!A3'S9 A?4 ;'A 9:9A89?(N '39AAI'?.
here is a provision for automatic chan"eover from A!' to :A?!A>
channel in case of any problem in the excitation circuits and in such a case
to ensure sur"e free operation durin" chan"eover the :anual channel
reference is made to automatically follow the auto channel reference
throu"h a follow up circuits, pulse comparison circuits
he :anual channel functions in an open loop control throu"h a manual
limiter and field current re"ulator
he 3ulse "enerator, intermediate pulse amplifiers are duplicated one each
for A!' I :A?!A> channel
'ther important cards like pulse supervision module, pulse distribution
board and necessary power supply modules, transformers, filters, Colta"e
relays, Auto potentiometers and manual reference potentiometers, :atchin"
and feed back modules, (ards for >o"ic circuits and annunciations, fault
indications, timers etc are provided to ensure fool proof operation and
dynamic stability of the re"ulator
he pulse final sta"e and its power supply, thruster and its coolin"
circuitry, pulse transformers etc are in - different and independent sections
FUNCTIONS OF A"R MOULES IN AUTO 7 MANUAL
C1ANNELS
Matc,in2 7 Feed*ac5 Modu'e:
It is used in both :A?!A> and A!' mode
It is used for matchin" the :A?!A> reference to the runnin"
A!' 3' reference, when 8 is runnin" on A!' mode, on a
continuous basis. his is necessary for sur"e free operation of 8
when a chan"eover takes place from A!' to :A?!A> due to
any reason.
he input is used for matchin" the :A?!A> reference to the
runnin" A!' 3' reference, when 8 is runnin" on A!'
mode, on a continuous basis, i.e. with 3% relay ener"iGed. Ohen 8
is runnin" in :A?!A> this input is inverted and si"nal is fed to
ACA i.e. with 30 relay ener"iGed.
It has an sin"le input which is available at test point / of A! &/
'utput for ?ull balance voltmeter is available at test point * of A!
&/.
Bero volt reference available at test point -& of A! &/.
Fo''o3 u+ contro':
It functions only when ACA is in A!' mode
It is employed everywhere one must influence a controlled variable with
discontinuous final control elements. 7ere it is utiliGed to "ive si"nals to
raise ,lower the :A?!A> reference to follow the A!' 3' reference.
And thereby ensurin" sur"e free operation in case of chan"e over from
Auto o manual channel
It has an electrical interlockin" so that both raise I lower si"nals are not
available at the outputs simultaneously.
'utput raise ,lower is available at test point 0/ ,0* of A! &/.
Stator current 'i(iter8 Inte2rator:
It controls the ACA in A!' mode
>imits stator current in synchronous "enerators.
It has a I sin <phi= detector circuit which distin"uishes between
inductive I capacitate current. Also a volta"e input is necessary for
this circuit.
If capacitate current is exceeded immediately the stator current is
brou"ht back to set value by immediately "ivin" a command to ACA to
increase the excitation current, this is prevent out of step failure of
"enerator. 'utput is available at terminal *L of A! %&.
If inductive current is exceeded it is brou"ht down to set value thru. An
inte"rator ckt. . his is necessary for ensurin" the dynamic stability of
the system. 'utput is available at terminal /% of A! %&
he action is instantaneous for capacitate current by increasin" field
current
he action is time delayed for inductive current by decreasin" field
current
his unit has its power supply in built
Rotor current 'i(iter:
It controls the ACA in A!' mode
>imits rotor current in synchronous "enerators.
?ormally limits the current to set value, but in case of ?$0 in
auto,manual it is brou"ht down to a set value <ref= from manual limiter,
at this point rotor current limiter is ineffective.
'nly Ie% is effective. Ie0 is not in ckt.
his has a priority over rotor an"le limiter.
It has a provision for switchin" ';; the output.
Initially this limits the current to Ie max I then it is slowly brou"ht
down to Ie%
4ecreases field current throu"h delay
Load An2'e 'i(iter
It functions in both :A?!A> and A!' mode
In A!' its output is delivered to ACA throu"h a contact in manual
limiter
In :A?!A> mode output is delivered to manual limiter which in turn
controls the field current, but the priority of field current is there over
this in both :A?!A> and A!' mode .
>imits electrically the an"le between the stator I rotor. It has a
provision for switchin" ';; the output.
Instantaneous action and increases field current t to keep the machine
fallin" out of step
Manua' 'i(iter
It is used in both :A?!A> and A!' mode
>imits rotor current in <?$0= operation in both A!',:A?!A>
akes an input from load an"le limiter to control the field current
VVsed on the existin" load an"le to prevent out of step operation of
"enerator, in case of chan"eover from A!' to :A?!A>.
It is an open loop operation.
>imits the rotor current to a set value in <?$0= operation in A!'.
Aotor an"le limiter overrides the manual reference.
3riority of ?$0 over rotor current limitation.
Fie'd current re2u'ator
It is used in :A?!A> mode
o limit the rotor current , re"ulate the field current.
his is used to re"ulate current to set value especially when the
excitation system has a series compoundin" transformer.
e' a'+,a 8 Pu'%e Co(+ari%on Unit
It is used for comparison of firin" pulses Auto and :anual (hannels
!sed for pulse comparison to compare the output pulses of both Auto
I manual channel in order top keep the manual channel analo" output
e#ual to the Auto channel analo" output so that sur"e free chan"e over
from Auto to :anual is ensured in case of any abnormality, this is
achieved throu"h :atchin" I ;eedback :odule and follow up
control.
Pu'%e %u+er)i%ion unit
It is used in A!' mode
3icks up after set delay in case of missin" pulses, asynchronous pulses
with an >94 indication, and in turn blocks the pulses of the
intermediate pulse sta"e or and cause protective chan"eover to :anual
(hannel
(han"e over to :anual channel disables this unit
Contro' A(+'i&ier 8 A"R
It re"ulates the output volta"e of the "enerator and keeps it constant as
per the set value if all parameters are with in limit
4oes not have any internal power supply
Aeceives input from reference circuit, limiters, actual value circuit
comprisin" of sensed 3 and ( input values and delivers an output
volta"e proportional to the difference of actual value and reference
value to "rid control unit after considerin" the inputs from limiters.
It has a provision for reactive power compensation to take care of the
drop in the unit transformer.
It has a fre#uency dependent circuit to control the output volta"es
proportional to fre#uency when the "enerator is runnin" at fre#uencies
lesser than the rated value.
It has "ain reducin" circuitry to minimise the oscillations in output
Con)erter
;or the purpose of redundancy, it is split into - sections, each havin"
its own pulse out put final sta"e with built in power supply, pulse
transformers, thyristor, coolin" fans, monitorin" unit for air.
;ailure of one section leads to Alarm.
;ailure of wo sections lead to limitation in output
;ailure of all the three sections to trippin" of field breaker
Li(iter%
All the limiters namely $ Stator current limiter, rotor current limiter,
inte"rator, Aotor an"le limiter operates in parallel with the reference
value of the ACA at input.
!rid Contro' Unit 7 Pu'%e Inter(ediate Sta2e
(onverts the Analo" output si"nal of the ACA <for Auto channel= or
the ;ield current re"ulator <of he :anual (hannel= into a row of
tri""er pulses of appropriate phase position for the power output sta"e
It works on the principle of vertical control by intersection with the
sinusoidal volta"e obtained throu"h synchronous transformer
It has an advanta"e of self$re"ulation of supply volta"e variations
he control characteristics is linear ensurin" optimum dynamic
performance
he intermediate pulse sta"e amplifies the pulses "enerated by the
8rid control !nit
he intermediate pulse sta"e has its inbuilt 4( power supply source
i.e. converts A( input Available into 4( for its functionin" as well as
provides the power supply for 8rid control !nit
4uplicated one for the :anual channel and one for the Auto channel
Auto channel 8(! I 3IS is controlled by ACA
:anual (hannel 8(! I 3IS is controlled by ;ield current Ae"ulator
Pu'%e i%tri*ution Board
(ommon to both Auto I :anual channel
Aeceives the pulses from the intermediate pulse sta"e of the channel in
operation i.e either from Auto or :anual, the pulses of the channel not
in service are blocked electronically at the intermediate pulse sta"e

C,anne' c,an2eo)er &ro( AUTO to Manua'
It takes place automatically as a result of 3rotective chan"eover si"nal
due to any abnormal operation of the excitation system , the re"ulator
as sensed by the lo"ic circuitry
(han"e over carried out from the control desk or re"ulator
intentionally
4urin" chan"eover the pulses of the unused channel are blocked
electronically and for the channel comin" into service the pulses are
released electronically
In :anual channel the Aotor current limiter, Stator current limiter,
inte"rator are not effective
'nly the load an"le limiter is effective in addition to :anual limiter
when the re"ulator is operatin" in manual channel.
Po3er %u++'0
he power supply for the electronics is obtained from the excitation
transformer throu"h a re"ulation supply transformer after rectification,
re"ulation , stabilisation in the power supply :odules
;or Auto channel O' power packs !? 0&&2 and !?0&&* are
provided. !? 0&&% and !? 0&&* are functional upto minimum of -&
E &f the rated supply volta"e
!? 0&&2 is functional upto K,$ -& E of the rated supply volta"es and
supplies K,$ %/ C) K/C) K0* C stabilised power supply for limiters,
Slip stabilisation circuits, Supervision modules. It is provided with an
input :(B to open in case of 'ver Colta"e , 'ver (urrent. It has an
circuit to monitor output under volta"e and indication by an >94
which does not "low in case of under volta"e and in case of output
under volta"e causes chan"e over to manual channel
;or :anual (hannel only power pack is provided namely !? 0&&*
9ach 3ulse output Sta"e has its own power pack !? 0&&%
Synchronous Colta"e for pulse "eneration is obtained from a
Synchronous transformer,of ratio %*&,-+& C A( whose primary is
connected to the excitation transformer secondary a filter. A Colta"e
relay supervises the synchronous volta"e
;or the purpose of testin" the re"ulator, an Auxiliary supply is
provided throu"h a Auxiliary transformer of ratio *%/ C, -+&CA(
from an external source
he supply for coolin" fans of the thyristor cubicle is obtained from
the excitation transformer throu"h a fan supply transformer of ratio
%*&,-+&C A(
*+ Colt 4( is obtained throu"h a= %%& C4( , *+C 4( 4( $4(
converter KxL%2%a, and b= %*& C A( , *+C 4( throu"h an A(, 4(
converter KxL%2%a. All the 0 outputs are connected in parallel And
are used for ! trippin"M !c for "eneral control circuitsM !s for
si"nalisation
0* Colt 4( is obtained throu"h a= %%& C4( , 0*C 4( 4( $4(
converter KxL%2&a, and b= %*& C A( , 0*C 4( throu"h an A( , 4(
converter KxL%2%a. c= 0* C A($4( linear power supply. All the -
outputs are connected in parallel and are used for lo"ic cards
"o'ta2e Re'a0 UN 99:9
:onitors the output "enerator volta"e
8ives si"nal for blockin" the pulses of the 8AI4 control unit if the o,p
volta"e is less than -&E of the rated system volta"e
Switches ';; the field flashin" e#uipment if the ',p volta"e is more
the n 2&E of the rated system volta"e
Pu'%e &ina' Sta2e UN ;99:
7as its own supply unit
Supplies the pulses to the thyristor throu"h pulse transformers
Serie% co(+oundin2 tran%&or(er
It is basically a current transformer
he output of the secondary of this is rectified and the volta"e so
obtained is used in series additive mode to the out put from the
converter to supply to the field circuitry
It is basically desi"ned for use with an isolated network system with
the excitation system drawin" power from the "enerator terminals to
prevent the "enerator from trippin" for a small period <in sec= in case
of startin" of heavy motors , faults which result in under volta"e of the
"enerator out put
It basically supplies an additional field volta"e durin" startin" of heavy
motors , faults by usin" the hi"h current drawn from the "enerator it
self to au"ment the field volta"e as the excitation transformer cannot
meet the field re#uirements at that moment.
If the under volta"e sustains for more than few seconds the "enerator
under volta"e protection takes care of the system and isolates the
"enerator
It is best suited for networks which do not have any transformer
connected between load distribution point and the "enerator terminals
It does not have any effect on the ACA controls
It "enerally caters -&$*& E of the excitation re#uirement and the
balance is taken care of by excitation transformer.

TEC1 ATA:
Tec,nica' ata o& Tur*o2enerator:
ype $83 00*0*&,0 S:Apparent output $0-%0/kva
Active output $%+/&&kO Aated power factor $
&.+ la"
Aated volta"e $%%&&& volt Aated current
$%0%* Amp
Aated speed $-&&& rpm Aated fre#uency /& 7G
Short ckt.ratio $&./2* 8ener.field resistance
$&.%L0+ ohm
(ritical speed of "en. $%L*& rpm :oment of inertia of rotor $
-.0+0
8enerator phase $star connected (arbon brushes $+ per rin"
<0 rin"s=
(arbon brush siGe $-0D-0mm (arbon brush "rade
$7:HA
In%u'ation:
Stator $(lass B Aotor
$(lass B
9xcitation re#uirement) Amp Colt
3ower
At no load$ 0&/ *&
+.0kO
At full load$ /-H %*/
22.20kO
Tec,nica' ata o& T! Au6i'iarie%:
A'3)
;rame $K34 'A&0H :''A $
KO$2./
otal head $+L./H mm. A3: $0+2&
A3: $0L2& Colta"e $*%/ C
Aatin" $2/ KO (urrent $0+ Amp
9'3)
8$% I 0 <:otor= KO Q2./ 8$-KO $
2./
A3: $-&&& A3: $0+&&
(urrent $%&- Amp. (urrent $%&-Amp
Colta"e $%%&, Colta"e $%%&C
:otor br". $SK;$H-%0 Br". $
SK;H-&H0
(3)
:''A) Induction motor 3ump) yoe$'3K$H$-0$
0/&
KO$2./, Colta"e Q *%/ C. (apacity$*./ m
-
,hr.
A3:$0+/&, (urrent$%*.& Amp Near Q %L+L, A3:$0L&&
<OP:
C AC: Induction :otor
KO$-.2,A3:$%**&, Colta"e$*%/ C, (urrent$
2.H Amp.
Colta"e$%%& C, (urrent Q*% Amp. KO Q -.2, A3: Q %**&
Br". (e) skf H-&HB, (onnection 4elta
8land Steam (ondenser
@ty. of "land steam at inlet %**+ k",hr<max=,
3r and temp of "land steam at inlet &.L+ata , -%&
&
c
@uantity of coolin" water %/& m-,hr.
(O temp. At inlet , outlet -/,*0&c
Surface area *& m0
SiGe of tubes <'dx hkWW.= %/x%x0/&&mm
?o of tubes -/0
Meta''ur20 o& !SC
ubes Ad. Brass, SB III (
**-&&
Shell, (hannel, covers I tube plates (S, SA /%H 8r H&
;lan"es (arbon steel
Support plates (S, IS 0&H0
Oater I,>, ',> I steam I,> pipes (S, SA %&H 8r B
Impin"ement plate SS, SA 0*& 3 -&*
Stea( =et e=ector &or !SC
Oorkin" steam pr.,temp %%ata,0H*
&
c
Steam consumption %/H k",hr.
Suction pr. &.+/ ata
Suction moisture 0/& k",hr
Oi' Coo'er
@ty. of oil H+.%0 m
-
,hr.
'il I,> and ',> temp /L.L,*/
&
c
3r. 4rop in oil side %.- k",cm0
@ty. of coolin" water %&& m
-
,hr.
(O I,> and ',> temp -H,*&.%
&
c
(oolin" surface %&& m
0
ube siGe <'dx hk.xl."th.= %/x%x0H%& mm
?o. 'f water passes *
:etallur"y of tubes Adm. Brass, SB III ($
**-&&
Tec,nica' ata o& Tur*ine:
:. T0+e : E! >99-; ;. S+eed :
/?99r+(
-. Speed reduction "ear )-&&&rpm *. Inlet pr.
)H+k",cm
0
abs.
At output shaft /. Inlet temp )
*+/
&
(
H. 9xtrn.pres. ) %%k" ,cm0 abs. 2. 9xtrn. emp. ) 0H*(
+. 9xtrn.flow )*/tph L. 9xhst.pres
) 2k".,cm
0
abs.
%&. 9xhst temp. ) 0%2
&
( %%. 9xhst. ;low ) %%&tph
COOLIN! TO$ER SYSTEMS:
SYSTEM ESCRIPTION:
Oith three 8s and dump condenser the re#uirement of coolin" water
increased and hence (oolin" ower Q III was established. It caters to the
re#uirement of hu"e amount of coolin" water for dump condenser, "enerator
coolers, turbine lubrication oil coolers and "land steam condensers. here
are three coolin" water pumps <(O3=, three auxiliary coolin" water pumps
<A(O3= and four induced draft coolin" tower fans <(;= in (oolin" ower
Q III. Suction pipes of (O3s and A(O3s are connected to common water
sump. he sump level is made up with addition of filtered water. 4ischar"es
of A(O3s are connected to a common to a common header and the water is
supplied to 8 auxiliaries coolin" system i.e., "enerator coolers, lubrication
oil coolers and "land steam condensers. 4ischar"es of (O3s are connected
to a common header and the water is circulated throu"h the dump condenser.
he (O outlet lines from 8 auxiliaries and dump condenser are connected
to a common header and re$circulated back to (oolin" ower. he hot water
is sprayed in the hot basins in the form of fine spray throu"h noGGles. Oater
"ets cooled by comin" in contact with the air circulated due to induced draft
created by coolin" tower fans. he cold water is collected in the cold$water
basin from where it flows to the coolin" water sump throu"h strainers. o
control internal corrosion and scale formation on the inner surface of the
circulatin" pipes, corrosion inhibitors like Binc Sulphate and Sodium 7exa
:eta 3hosphate are dosed, in the coolin" water sump. (hlorine is also
added to control the "rowth of al"ae, fun"i and other bacteria. (ycle of
concentration <ratio between the 4S of circulatin" water and the fresh
make up water= is maintained normally within -. Ohen it increases the
water from the cold$water basin is drained and the loss in made up with
fresh floodwater to reduce the cycle of concentration.
Conc'u%ion
he steam and power plant was essentially commissioned to increase
the economic viability of the steam production at the refinery complex. he
power plant was commissioned later to efficiently utiliGe the steam bein"
produced at the refinery complex. It ensures an uninterrupted power supply
to the refinery.
An essential piece of e#uipment for the power plant is the turbo$
"enerator. he different departments of the power plant function to ensure
the smooth functionin" of the 8.
he basic function of an Automatic Colta"e Ae"ulator and the series
compounded transformer is to increase the efficiency of the turbine and to
prevent trippin" of the turbine durin" minor malfunctions in the "rid.
SAFETY
In todayJs world Safety, 7ealth and environmental issues have become a
matter of serious concern for all societies, which no country can afford to
disre"ard in the process of development. As industry has evolved, si"nificant
advances have been made in overcomin" many of the challen"es to the
safety, health and well bein" of the workin" people. Net it is estimated by
I>' that more than two lakh work related death occur each year all over the
world. In addition, a lar"e number of workers are victims of work related
accidents and occupational diseases. 9stimate also indicates that the
economic conse#uences of accidents and diseases at work represent at least
%E of the 8?3 of our nation. It is therefore necessary that Safety, 7ealth
and 9nvironmental consciousness become intrinsic to our thinkin" and
development process. 3reventin" or minimiGin" accidents, ill health and
pollution, avoidin" wasta"e and conservin" no$renewable resources must
become our personal and public "oals.
'bservance of safety norms is of vital importance as any lapse on this
account many not only result in loss of e#uipments and machinery but also
loss of precious human life. Safety must therefore be "iven utmost priority
in every sphere of our life, be it in work place or at home.
?alco bein" an inte"rated pro5ect involvin" minin", chemical processin",
smeltin" and power "eneration, a hi"h de"ree of awareness re"ardin" safety,
health and environmental is must at all levels. :ore so, at this particular
5uncture, when we are "oin" to commission a massive expansion almost
doublin" our activities, the pressure to achieve hi"her efficiency on order to
remain afloat in the "lobal market would certainly brin" about increased
exposure of our people to industrial haGards.
MEASUREMENT TA@EN OUR PLANT
%. INSPECTION OF PLANT 7 E#UIPMENT: Safety inspection of
3lant and 9#uipment are carried out re"ularly to identify unsafe
practices and usa"e of safety appliance.
0. INSPAECTION OF EFERENT AREAS: 3eriodic inspections of
different areas are bein" conducted and the defects which are noticed
durin" inspections are hi"hli"hted, action plan and are rectified within
the time bound plan.
-. ELIMINATION OF UNSAFE CONITION: he systematic way
of identifyin" unsafe conditions and makin" time bound action plans
for eliminatin" them has been "iven top priority to provide a safe and
haGard free environment. A lar"e number of various modification 5obs,
rectification of unsafe conditions, safety committee recommendations
are bein" undertaken durin" this period.
*. SAFETY APPLIANCES: sincere efforts are made in different
4epartments at the time of re"ular inspection t motivate and enhance
the use of personal protective 9#uipment by safety committee
:embers and Safety 4epartment.
/. ISTRIBUTION OF FIRST AI BOXES: ;irst Aid Boxes alon"
with necessary contents were issued to -+ <hirty$ei"ht= locations
identified for the purpose inside our plant and inspection is done on a
re"ular basis to ensure the availability of all its contents always.
Besides, all the contractors maintain first aid box at their respective
worksites.
H. EMER!ENCY EYE $AS1 S1O$ER: 9mer"ency 9ye wash
shower$cum$;ountain is provided at various strate"ic locations and
re"ular inspection is done on a #uarterly basis to ensure its proper
functionin".
2. TESTIN! OF 1OISTS 7 LIFTS: the competent person as
prescribe under the 'rissa factories rules includin" the (ontractor
establishment conducts estin" of 7oists and >ifts.
NEE FOR SAFETY
IndustrialiGation has brou"ht within its wake several problems. 'ne such
is industrial accident. Oith rapid advances in industrial processes, newer
types of dan"ers to life, limb and health are bein" increasin"ly
introduced. :echanical, 9lectrical, (hemical and Aadiation haGards be
set us on all sides. Nearly, several lakhs of employees are in5ured in
factories due to accidents. Annexure % "ives the details of accidents in
India durin" %L2+ to %L+%.
hese accidents represent a social loss of "reat ma"nitude in the form of
pain, loss of earnin" capacity and cost due to disturbance to economic
efficiency. he painted sufferin" of the in5ured as well as the emotional
loss to the victims of the fatalities and accidents causin" permanent
disfi"urements or disabilities are impossible to be summed, throu"h
partially, no fi"ures are available in terms of the total cost of accidents in
our factories. o the mana"ement, it is the direct costs for meetin"
medical expenses, compensation of disablement benefits to the in5ured or
their families and also the various other indirect costs due to the
interference caused by accidents, which are "enerally taken rou"hly as for
items the direct costs. o the society, the economic cost is in terms of loss
of productive capacity and the cost of maintenance of the in5ured and
their families throu"h social security schemes or throu"h public or private
charities.

In the absence of date relatin" to total economic losses due to accidents,
makin" use of the fi"ure published by the >abour Bureau can have a very
approximate idea. Simla of claims paid by the employees of State
Insurance (orporation in respect of establishments covered by the
employees sate Insurance Act. he total cost of payments for temporary,
and permanent disablements and dependants benefits paid by the
(orporation durin" the years %L2+ to +% in accident cases covered by the
Scheme was on an avera"e As. 0& crores. his forms only one part of the
direct costs. In as much as the cost of providin" medical care has not been
included. ?o fi"ures are available in respect of the latter. All the same, for
our purpose., it can be indicated by usin" the multiplication factor
su""ested by 7einrich <Indirect costs 1 * times direct costs=.
CLAUSES OF ISO A99: : :AAB
*.% :A?A89:9? A9S3'SIBI>IN
*.0 @!A>IN SNS9:S
*.- ('?AA( A9CI9O
*.* 49SI8? ('?A'>
*./ 4'(!:9? A?4 4AA ('?A'>
*.H 3!A(7ASI?8
*.2 ('?A'> '; (!S':9A Q S!33>I94 3A'4!(
*.+ 3A'4!( I49?I;I(AI'? A?4 AA(9ABI>IN
*.L 3A'(9SS ('?A'>
*.%& I?S39(I'? A?4 9SI?8
*.%% ('?A'> '; I?S39(I'?, :9SA!AI?8 A?4 9S
9@!I3:9?
*.%0 I?S39(I'? A?4 9S SA!S
*.%- ('?A'> '; ?'?$('?;'A:I?8 3A'4!(
*.%* ('AA9(IC9 A?4 3A9C9?IC9 A(I'?
*.%/ 7A?4>I?8, S'AA89, 3A(KA8I?8, 3A9S9AACI'? A?4
49>IC9AN
*.%H ('?A'> '; @!A>IN A9('A4S
*.%2 I?9A?A> @!A>IN A!4IS
*.%+ AAI?I?8
*.%L S9ACI(I?8
*.0& SAISI(A> 9(7?I@!9S
ISO A99: : ;999
CLAUSES
%.& S('39
%.% ?'A:AIC9 A9;9A9?(9S
%.0 @!A>IN :A?A89:9? SNS9:
%.- A9S'!A(9 :A?A89:9?
%.* 3A'4!( A9A>ISAI'?
%./ :9AS!A9:9?, A?A>NSIS A?4 I:3A'C9:9?
ISO A99: : ;999
#UALITY MANA!EMENT SYSTEM RE#UIREMENTS
%.H @!A>IN :A?A89:9? SNS9:
%.2 89?9AA> A9@!IA9:9?S
%.+ 4'(!9:?AI'? A9@!IA9:9?S
%.L 89?9AA>
%.%& @!A>IN :A?!A>
%.%% ('?A'> '; 4'(!:9?S
%.%0 ('?A'> '; @!A>IN A9('A4S
ISO A99: : ;999
#UALITY MANA!EMENT SYSTEM RE#UIREMENTS
%.%- :A?A89:9? A9S3'?SIBI>IN
%.%* :A?A89:9? ('::I:9?
%.%/ (!S':9A ;'(!S
%.%H @!A>IN 3'>I(N
%.%2 3>A??I?8
%.%+ @!A>IN 'BJ9(IC9S
%.%L @!AKIN :A?A89:? SNS9: 3>A??I?8
%.0& A9S3'?SIBI>IN, A!7'AIN I ('::!?I(AI'?
%.0% A9S3'?SIBI>IN A?4 A!7'AIN
%.00 :A?A89:? A93A9S9?IC9
%.0- :A?A89:9? A9CI9O
%.0* 89?9AA>
%.0/ A9CI9O I?3!
%.0H A9CI9O '!3!
ISO A99: : ;999
#UALITY MANA!EMENT SYSTEM - RE#UIREMENTS
%.02 A9S'!A(9 :A?A89:9?
%.0+ 3A'CISI'? '; A9S'!A(9S
%.0L 7!:A? A9S'!A(9S
%.-& 89?9AA>
%.-% (':399?(9, AOAA9?9SS A?4 AAI?I?8
%.-0 I?;AASA!(!A9
%.-- O'AK 9?CIA'?:9?
ISO A99: : ;999
#UALITY MANA!EMENT SYSTEM RE#UIREMENTS
%.-* 3A'4!( A9A>ISAI'?
%.-/ 3>A??I?8 '; 3A'4!( A9A>ISAI'?
%.-H (!S':9A A9>A94 3A'(9SS9S
%.-2 499A:I?AI'? '; A9@!IA9:9?S A9>A94 ' 79
3A'4!(
%.-+ A9CI9O '; A9@!IA9:9?S A9>A94 ' 79 3A'4!(
%.-L (!S':9A ('::!?I(AI'?
%.*& 49SI8? A?4 49C9>'3:9?
%.*% 3!A(7ASI?8
%.*0 3!A(7ASI?8 3A'(9SS
%.*- 3!A(7ASI?8 I?;'A:AI'?
%.** C9AI;I(AI'? '; 3!A(7ASI?94 3A'4!(
%.*/ ('?A'> '; 3A'4!(I'? A?4 S9ACI(9 3A'CISI'?
%.*H CA>I4AI'? '; 3A'(99S9 ;'A 3A'4!(I'? A?4 S9ACI(9
3A'CISI'?
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#UALITY MANA!EMENT SYSTEM RE#UIREMENTS
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#UALITY MANA!EMENT PRICIPLES
CAOPTE FOR ISO A999 : ;999D
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CONTINUAL IMPRO"EMENT
Improvement means settin" hi"her standards and achievin" the same.
(ontinual improvement refers to on"oin" efforts for improvement. !sually
what is understood is improvement involvin" everyone in the or"aniGation.
(ontinual improvement is also know as kaiGen.
KAI 1 Improvement
B9? 1 8ood, for the better
7ow can you contribute to continual improvement)$ hrou"h individual
su""estions or by "roup activity like #uality circles.
;or improvement in the followin" areas.
:akin" the 5ob easier i.e. Aeduction in man hours.
Aemovin" drud"ery from the 5ob.
Aemovin" nuisance from the 5ob.
:akin" the 5ob safe.
:akin" the 5ob more productive.
Savin" in time I cost.
7ow can continual improvement be achieved ) $ By settin" hi"her standards
of work, achievin" the same, maintainin" it and improvin" standards.
Aesult )$ Safe, Aeliable processes that runs automatically or in a
standardiGed why without intervention by people.
O"ER "IE$ OF MINES
INTROUCTION
3anchapatmali bauxite deposits have an indicated reserve of -%2
million tones. It is divided into three blocks. hey are north block and
central block. he present minin" is concerned with sector % of central
block. he annual production of bauxite is 0.* million tones per annum .A
downhill cable belt system is established to carry one to the stockpile at
alumina plant.
SALIENT FEATURES OF MINES
>en"th of conveyor %*.HH%km
Oidth of conveyor belt %.%-2mm
;all of conveyor belt -*&mts
Aated capacity of conveyor belt %+&&tph
3ercenta"e of Alumina *0./E
3ercenta"e of silica 0.-E
ype of crusher 4ouble ooth roll crusher
>ump siGe before crushin" +&&mm
>ump siGe after crushin" %/&mm
MININ! MOEL
;or drawin" up annual production pro"ramme, indicatin" the #ualities
and #uantities and for studyin" in advance the various overburden and
bauxite faces, a numerical minin" model is made by transformation of
information obtained from the deposit model in the 8eostatistical studies. It
consists in a breakdown of the deposit to a %&&mD%&&m kri""ed "rid. 9ach
of such panel is further divided to a block of over burden a block of bauxite
to be mined in first phase and thick block of bauxite to be mined in second
phase. After allowin" for unminable areas locked up in minin" infrastructure
and peripheral barriers and Applin" the loss and dilution factors for each
such panel the followin" parameters are determined.
onna"e of overburden to be removed.
onna"e of minable ore in each phase with Al0'- and Si'0 content
showin" of minable bauxite between the two phases is done keepin" in
view mass minin" in firs phase <with nominal dilution= and selective
minin" in the second phase.
MININ! TEC1NI#UE:
he morpholo"y of the bauxite deposit, the irre"ular roof and floor makes it
impossible to adopt conventional XBenchin" :ethodJ of open pit minin" at
3anchapatmali, Instead , a modified Xrench :ethodJ, consistin" of
development of rou"hly parallel trenches with sta""ered faces, form initial
main track has been adopted. his techni#ue facility minin" of different
Gones of a deposit, featurin" different thickness, independent of one another,
thereby simplifyin" mechaniGed minin" within individual trenches with
minimum loss and dilution.
In the trenches, bauxite is extracted in two distinct. he first phase
consistin" of a slice of around +$%0 mts. hickness usin" normal drillin" and
blastin" procedures, while in the second phase, the bauxite is extracted in
selectively in * mtr thick slices. 'n of the lar"e siGe wheel loader of
hydraulic excavators has been found suitable for loadin" operations in first
phase. he second phase re#uires backhoe hydraulic excavators for selective
minin".
?ormally the width of the trenches are kept more than *& mts for efficient
use of heavy machineries and the level differences between ad5acent
trenches, is kept less than *mts. he faces of the trenches are systematically
advanced to maintain a XSaw ooth (onfi"urationJ of work sites, which
ensure ade#uate flexibility in minin" operations and safety to the e#uipment
deployed.
A %/ mt wide peripheral barrier around the deposit on the ed"e of plate is
left to constitute a safety barrier for the machines. his also serves to locate
the peripheral road and helps in containin" most of the rainwater with in the
mine. It provide a natural curtain for the mine excavators form surroundin",
which help preservin" the natural beauty of the re"ion apart from
minimiGin" the possible dust storms in the minin" area.
he modified trench method of minin" has the followin" advanta"es)
%. Cersatility Q :inin" faces are separated and interchan"eable. hey
are numerous and can be worked continently for effective "rade
control of A.'.:. feed.
0. Adaptability to 8eolo"ical disturbances on the deposit results in low
loss and dilution factors.
-. (onvenient work site dimensions permit concentration of minin"
e#uipment and minimiGed travel.
he minin" area is divided into trenches in a alphabetical order from A to
@. Aocks containin" Alumina less than -/E or Silica more than /E are
left. It is proper blendin" that the re#uired percenta"e of *0./E Alumina
and 0.-E silica is obtained.
CRUS1ER AN CON"EYOR SYSTEM
he bauxite after minin" is fed to the crusher the main purpose
is to reduce the siGe ran"e from +&& mm to %/& mm. he avera"e
moisture content of bauxite is +./E
PRIMARY CRUS1ER
he bauxite is fed to the hopper by dumper either from the stockpile
or directly from the mines. ;rom hopper the material is transformed to
crusher throu"h Appron ;eeder %. It is driven by a //kw dc motor. he
crusher is a double tooth roll crusher and it has an crushin" capacity of
L&& tph from +&& mm fed siGe to %/& mm product siGe. his is powered
by 0D0&& KO A( motors .he tow rollers run at different speed <2& rpm
and %&& rpm= and crush the material by the process of compaction and
shearin". >ow and differential peripheral speeds minimiGe wear and
further help takin" up or more plastic part of lar"er siGe between the rolls.
he crusher is e#uipped with anti$clo""in" devices formed by series of
cleanin" scrappers. Ohich help in complete cleanin" of rolls.
Below the crusher output a feeder conveyor is present which is
driven by a /& KO 4( motor. ;rom feeder conveyor the material "oes to
another where a trip switch is present. Ohenever this hopper is filled
with excess material this switch trip and apron feeder % stops. ;rom
hopper material is fed to apron feeder 0 which is driven by // KO 4(
motor. 'n this feeder a metal detector is present which detects any metal
present in the one. Ohen a metal is detected it automatically switches
on the ma"netic separator. he function of the ma"netic separator is to
separate out any iron particle present in the material. It is now fed to an
Acceleratin" conveyor from which it is finally transformed to a %*,HH-
K: lon" cable conveyor belt.
CABLE BELT
he cable belt is driven by 0 D %&H2 KO synchroniGed motor. he
cable belt system consists of 0 endless /% mm diameter steel wire ropes. A
%%-2 mm wide belt with special shoe forms sits on the drivin" steel ropes
<cables= which carrier the material to be transported. he cable and the belt
run over specially desi"ned pulleys which are mounted on linestands and are
supported by them. In strai"ht Gones the linestands are placed.
he ali"nment of the system and positionin" of the pulleys are done
throu"h computeriGed desi"n calculations. he system is desi"ned to carry
L&& tph it a belt speed of 0.0/ m,s and will carry %+&& tph by doublin" the
belt speed.
o ne"otiate the sleep escarpments between the loadin" and dischar"e points
the cable belt transforms it selfs into a series of hyperbolic curves both
horiGontal and vertical limited to %+ and -& respectively. he conveyor is
covered all alon" the len"th for protection of belt from weather and sun rays.
he conveyor system is e#uipped with various safety devices for safe and
efficient operation.
$ORL BAUXITE RESOURCES
%. otal Oorld Bauxite Aesource Q -+ Billion on
0. :a5or 4istribution of Bauxite Aesources
(ountry Bauxite Aesource in Billion on
%. 8uinea L.*
0. Australia H.%
-. BraGil -.-
*. Jamaica -.&
/. India 0.//
A>!:I?A
Oorld (apacity $ -+ : , Near
IndiaJs (apacity $ %.*2 : , Near
Aank of India $ 2
th
A>!:I?I!:
Oorld (apacity $ %+ : , Near
IndiaJs (apacity $ &./+ : , Near
Aank of India $ 2
th
MA<OR BAUXITE MINES OF $ORL
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A>!:I?I!: Q 79 O7I9 8'>4
Abundantly available in nature.
+E of 9arthJs crust comprises Alumimium.
:ost widely used metal in the world after steel.
!ni#ue properties, a versatile metal.
:ost friendly metal Q technolo"ically, economically and ecolo"ically.
3A'39AI9S '; A>!:I?I!:
Y 8as Aesistance Y Aeflectivity Y Stron" Y Anodisable
Y 4uctile Y 3rintable Y 9mmisivity Y :alleable
Y Aecyclable Y ?on$permeable Y >i"ht wei"ht Y
7y"ienic
Y asteless Y 'dorless Y?o sparkin" Y Oorkability
Y (apacity Y ?ontoxicity Y (orrosion resistance
Y :oisture$vapour resistance Y 8rease and 'il resistance
Y 7eat I ;lame resistance Y hermal (onductivity.
A33>I(AI'?S '; A>!:I?I!:.
ransport Q >and, Sea, air, Space
Buildin"
4efence
3ower transmission
;ood processin"
3harmaceuticals$tables, 'intments
:ilk 3roducts$yo"hurt, curd, cheese, butter, steriliGed milk.
Sweets Q (hocolates bars, boxes of chocolates, ice creams, chewin"
"um.
7ousehold aluminium foil.
(offee, ea$ vacuum packa"in".
4ried food ) Soups, (ereals, 3otato puree, baby food.
Instant foods.
4rinks Q Aefreshments, Beer, ;ruit 5uice.
obacco
3et ;ood.
(osmetics
8lues, 3aints, Inkcatrid"es.
AREAS OF USA!E OF ALUMINIUM PAC@A!IN!
3acka"in",;ood 3rocessin" is an important application sector of
aluminium directly involvin" the human society.
Oithstands both heat and cold.
9asy to steriliGe for food and medical applications.
9xcellent barrier a"ainst li#uids, vapours and li"ht.
>i"ht wei"ht, hy"ienic and non$contamination$lon"er shelf life of end
products.
>ac#uer able and printable.
In soft temper has full dead fold properties and ease of shapin".
?ontoxic, 'dorless, tasteless, colourless and hy"ienic.
8ood heat reflectivity <li"ht I !C Aays= and conductivity.
?on$permeable
>aminatable.
>i"htwei"ht
(orrosion Aesistant.
Aecyclable I Biode"radable.
O7N A>!:I?I!: 3A(KA8I?8
9ver thinner :aterial, 9ver stron"er in function.
:aximum results from minimal material investment.
!nlike plastics totally recyclable I Biode"radable.
7i"h recovery rate with reduced emission of pollutants.
9ner"y and material savin".
9nsure fuel economy in transportation.
Aepeated use without loss in #uality.
7ealth Q Safe I 9co$friendly.
A>!:I?I!: I? 79 7!:A? B'4N
;ound naturally Q approx. -/m". $ /&E in the laun"s
0./E in the soft tissue
0./E in the bones.
Impossible to avoid exposure.
Body ad5usted well to the exposure.
3lays no physical role
ypes of exposure )
?atural content, throu"h diet, dependin" on "eo"raphical
area, <0$%&=m".
Intentional additive$preservatives leavenin" a"ent. 9tc. <0$
/&=m".
!nintentional additives packa"in" I cookin" in aluminium
utensils <up to -./=m".
4ru"s and medicines </& $%&&=m".
he human body strives to maintain an effective balance of all
materials. :ost of the aluminium enterin" the human body throu"h
whatever source is thrown out as #uickly as possible.
O7N A>!:I?I!: ;'A (''KOAA9Z.
9xcellent conductor of heat.
ransfers heat very effectively and evenly.
Aluminium cookware is li"ht, stron" and durable.
9asily recyclable with extremely hi"h recovery rate <L/$L+E=, with
small ener"y re#uirement </E of ener"y re#uired to produce vir"in
metal=, without loss in #uality.
(onducts heat more efficiently than stainless steel, losses only 2E heat
it receives
Aluminium has excellent cookin" characteristics.
Aluminium cookware dose not impact any taste or odor to food.
Aluminium is safe cookware and a "ood container of food.
It is very easy to fabricate.
It take very "ood surface finish.
Aluminium is #uite neutral. 4oes not "et leached or corroded on
contact with food.
(an be easily lac#uered, anodiGed, plated, enameled prevent attack by
acids.
7i"h ener"y savin".
A>!:I?I!: A?4 79A>7
AlGheimerJs disease is pro"ressive, de"enerative disease that attacks
the brain and results in impaired memory, thinkin" and behaviour.
9xtensive investi"ations for H& years by reputed health a"encies and
AI4 establishments have clearly shown that the amount of aluminium
in"ested throu"h cookin" in aluminium utensils is very small and
harmless.
Investi"ations conducted directly on the human brain could not
establish that aluminium causes AlGheimerJs disease. Ohat Oorld
7ealth 'r"anisation <O7'= say<%LL/=.
Aluminium has not been demonstrated to pose a health risk to healthy,
non$occupationally exposed humans.
here is no evidence that aluminium causes any brain disorder
<AlGheimerJs disease=.
4ata are inade#uate to support the hypothesis that exposures to
aluminium in drinkin" water accelerate AlGheimerJs disease or that
exposures. 9ither occupationally or via drinkin" water, impair
co"nitive function.
here is insufficient health related evidence to 5ustify alterin" existin"
O7' 8uidelines for aluminium exposure in healthy, non$
occupationally exposed humans.
'rdinary environmental exposure to aluminium is safe.
Intake of aluminium throu"h cookware, packa"in" etc. is ne"li"ible
and harmless.
he amount of aluminium in"ested throu"h cookin" in aluminium
vessels is very small.
7as not been demonstrated to pose a health risk to humans.
Any intake of aluminium is promptly excreted.
O7A 79 ;''4 A?4 4A!8 A4:I?ISAAI'? <;4A=, !SA SANS
he cause , causes of AlGheimerJs disease <Brain 4isorder= is not
know.
he biolo"ical si"nificance of aluminium in the brain is not
understood.
Aluminium is poorly absorbed in the body.
'rdinary environmental exposure to alumina is safe.
4r. Jacob Aoy and his collea"ues throu"h their extensive research work on
AlGheimerJs disease have also rules out that there is not even casual
connection between aluminium and AlGheimerJs disease and that the
evidence for the linka"e has never been more than circumstantial. As already
mentioned, they report that the incidence of AlGheimerJs disease could be
attributed to a number of factors, from emotional stresses to an interruption
of the brainJs blood supply and the "enetic risk factors.
CONCLUSION
9ven throu"h aluminium has a hi"h environmental cost in the primary
sta"e, it is very well compensated for by its environmental and
resource friendly characteristics, durin" its use and reuse phases.
Aluminium fits perfectly in to the future scenario where the parameters
will the technolo"y, economy and ecolo"y.
Aluminium has the advanta"e of bein" available abundantly in our
country as opposed to tin, which is imported.
Aluminium is tottaly recyclable with no loss in #uality, hence hi"hly
eco$friendly and safe as opposed to plastic, which is not biode"radable.
Aluminium is safe, the most environment friendly and a hi"hly useful
material.
All accusation,criticisms a"ainst aluminium with respect to health are
hearsay, lackin" any scientific and clinical evidence.
EN"IRONMENT MANA!ENT
Since inception ?A>(' has taken ade#uate steps for pollution control
and environment mana"ement by selectin" eco$technolo"y process and
e#uipment on the advise of :,S Aluminum 3echiney <A3= the
consultants, who have "ood experience in marinatin" strin"ent pollution
control standards of 9urope.
;urther, the company has adopted a detailed environment
mana"ement plan <9:3=, which was prepared after extensive studies on
environment impact assessment .his 9:3 has the approval of orissa
state pollution control Board <'S3(B= and ministry of environment and
forests <:'9;= "overnment of India.
Implementation of adopted environment policy in all units and
constant monitorin" has helped the company to achieve considerable
success in the filed of environment mana"ement. he company maintains
a track record of meetin" statutory "uidelines in existin" plants as well as
on"oin" pro5ects.
CORPORATE EN"IRONMENT POLICY
In reco"nition of the interests of the society in securin"
sustainable industrial "rowth compatible with a wholesome environment,
?A>(' attmns that it assi"ns hi"h importance to promotion and
maintenance of pollution tree environment in all its activities.
'b5ectives)
o use non$pollutin" and environment friendly technolo"y.
o monitor re"ularly air, land, water, noise and other environment
parameters.
o constantly improve upon the standards of pollution control and
previde a leadership in environment mana"ement.
o develop employees awareness on environmental responsibilities
and encoura"e adherence to sound environmental practices.
o work closely with "overnment I local authorties to prevent or
minimiGe adverse conse#uences of the industrial activities on the
environment.
o comply with all applicable laws "overnin" environment protection
throu"h appropriate mechanisms.
o actively participate in social welfare and environmental
development activities of the locality around its units.
Co((it(ent:
Oe dedicate ourselves to ensure a "reen and wholesome environment in
all areas of our operation for sustainable industrial "rowth and to set
standards in environmental mana"ement.

Mea%ure% ta5en:
:easures taken by the company in all its units for environment
mana"ement are as follows.
Mine%
3eriphery barrier of %/m width havin" "reen cover around mines.
8arland drains I draina"e control within mines.
4ust suppression at source and sprinklin" of water
otal overburden excavated with topsoil is used for reclamation and
rehabilitation of mines our areas with ve"etation cover.
Alumina Aefinery)
7i"hly efficient 9S3 s at calciners and steam "eneration plant.
:ulti$ sta"e washin" of red mud I linin" of red mud pond to
impound hi"hly alkaline waste.
!se of dust collectors in alumina transport and handin" areas I stack
emission control at steain "eneration plant.
Aecyclin" of waste water.
S(e'ter
7oodin" of pots and absorption of "as by dry scrubbin" with alumina
in fume treatment plant.
4elluoridation to reduce fluonne level of contaminated surface water
I recyclin" it to achieve Gero dischar"e.
Specially desi"ned preservation system for spent pot lines.
(aptive power plant
9lectrostatic precipitators with advanced intelli"ent controllers and
effective stack emission control.
9fficient burner mana"ement to reduce emission of carbon monoxide.
Ash pond with Gero dischar"e and recyclin" of wastewater.
Co((on (ea%ure% ta5en in a'' unit%
reatment and recyclin" of process wastewater and sewa"e.
Ae"ular monitorin" of air, water and noise pollution.
Ae"ular safety and fire audits mock drills etc.
'ccupational health surveys and periodical medical check$up of all
employees.
3romotin" and executin" pro"rammes for socio$economic
development in peripheral areas such as housin", electricity and water
supply, sanitation, road I communication, health, education,
a"riculture, vocational trainin", sports I cultural activities.
ISO :B999
In its #uest for excellence in environmental care the company crossed
a milestone when :IA complex was certified under IS' %*&&%. Alumina
refinery of the company is the first chemical plant in the country to be
certified under IS' %*&&%.
oday all the four units of the company have achieved IS' %*&&%
certification as detailed below.
Unit ate o& certi&ication certi&0in2 a2enc0
:ines June 0*, %LLH :,s Aspects moody
certification, !k
Aelinery ;ebruary %&, %LL2 $do$
(pp 4ecember %L, %LL2 :,s AOI!C, 8ermany
Smelter :ay 0/, %LL+ $do$
;rom ;ebruary 0&&& onwards re$certification of mines I refinery by :,s
AO!C, 8ermany.
he IS' %*&&& certification has not only helped to improve the
ima"e as an eco$friendly company but has also "iven si"nificant financial
benefits. hese benefits have come mostly due to better house keepin"
reduction in waste "eneration and systematic collection for disposal of
wastes and improvement in performance particularly with respect to
consumption norms.
9nvironment mana"ement must be an inte"ral part of every level of
business enterprise successful mana"ement will have to expand its sphere of
influence to embrace a considerably wider concept have environment. he
"rowin" compulsions on account of the environment awareness have forced
the industries to a provocative retrospection of their processes to ensure
compliance of specific emission standards and assure the public that their
product,process are more eco$friendly.
he 9nvironment mana"ement system <9:S= is an emer"in"
environmental imperative. It is a comprehensive mana"ement tool to brin"
in substantial improvements in any industry in overall environment
mana"ement. he 9:S certification enables companies to ac#uire the label
of environmentally sound enterprise and also accrue the benefits of benefits
of improved economic performance.
(onsiderin" the importance and re#uirement mines I refinery
units has been certified with IS' %*&&& since %LLH I %LL2 respectively I
recently we have switched over to AO!C as our certifyin" a"ency since
%%.&2.0&&& for compatibility with IS'$ L&&& system also.

COMMITMENT
Oe dedicate ourselves to total environmental mana"ement system for
prevention of pollution and continual improvement for achievin" our
ob5ectives.
he policy and the information on environment protection efforts shall be
shared with public and all interested parties throu"h periodical publications,
booklets, pamphlets posters etc.
(>A!S9S '; BS 22/&, %LL*
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EN"IRONMENTAL POLICY
Ohile committin" to the corporate environmental policy of ?A>('
Alumina refinery, 4aman5odi, resolves to protect and maintain a "reen
and clean environment while contributin" to sustainable socio$economic
development of the re"ion throu"h its activities.
.IS' %*&&% is an internationally accepted standard that lays down the
re#uirements for establishin" implementin" and operatin" an environment
mana"ement system. IS' %*&&%)0&&* has been published on %/th
?ovember 0&&*. It features clarification of re#uirements, ali"nment with
IS' L&&%)0&&& and chan"es to the text to make it more user$friendly. Some
chan"es are likely to re#uire or"aniGations to review or perhaps amend their
system to ensure conformance with the final version of the new standard.
;or or"aniGations usin" IS' %*&&% for their 9:S and accredited to IS'
%*&&%)%LLH a summary of the key chan"es is provided below.
Co(+ari%on c,art
ISO :B99:::AA- ISO :B99::;99B
% scope % Scope
0 ?ormative references 0 ?ormative Aeferences
- 4efinitions - erms and 4efinition
*.% 8eneral Ae#uirements *.% 8eneral Ae#uirements
*.0 9nvironmental policy *.0 9nvironmental 3olicy
*.- plannin" *.- 3lannin"
*.-.% 9nvironmental Aspects *.-.% 9nvironmental Aspects
*.-.0 >e"al I other Ae#uirements *.-.0 >e"al and other
Ae#uirements
*.-.- 'b5ectives I ar"ets *.-.- 'b5ectives ar"ets I
pro"ramme<s=
*.-.* 9nvironmental mana"ement
3ro"ramme <s=

*.* Implementation and operation
*.* Implementation and operation
*.*.% Structure I Aesponsibility *.*.% Aesources Aoles
Aesponsibility I Authority
*.*.0 rainin" Awareness I
competence
*.*.0 (ompetence rainin" I
Awareness
*.*.- (ommunication *.*.- (ommunication
*.*.* 9nvironmental mana"ement
system
4ocumentation
*.*.* 4ocumentation
*.*./ 4ocument control *.*./ (ontrol of 4ocuments
*.*.H 'perational control *.*.H 'perational (ontrol
*.*.2 9mer"ency preparedness I *.*.2 9mer"ency preparedness
Aesponse and Aespones
*./ (heckin" and corrective
action
*./ (heckin"
*./.% :onitorin" and
measurement
*./.% :onitorin" and
measurement
*./.0 ?onconformance and
corrective I preventive action
*./.0 9valuation and compliance
*./.- Aecords *./.- ?onconformity corrective
action I preventive action
*./.* 9nvironmental mana"ement
system audit
*./.* (ontrol of records
*././ Internal Audit
*.H :ana"ement review *.H :ana"ement review
C'au%e :: Sco+e
he scope of the standard has been expanded to include new application in
the 0&&* version of the standard. hey include options to demonstrate
conformity by )
:akin" a self$determination or self$declaration
Seekin" confirmation from parties who have an interest in the
or"aniGation, for instance, customers
Seekin" certification or re"istration of the 9:S by an external
or"aniGation
I(+'ication
An or"aniGation is now re#uired to define the scope of its 9:S. his
scope directly links the mana"ement system with the or"aniGationJs
activities products and services. he word and determine how it fulfils these
re#uirements related to re#uirements in IS' %*&&% have been added to the
clause *.%. wo thin"s need to be done in this re"ard. ;irstly, define the
scope of the or"aniGationJs 9:S includin" what activities, operations,
services and products are included with it. he scope needs to be
documented one possibility could be in the environmental policy. Secondly,
there is a need to evaluate and document how an or"aniGationJs 9:S fulfils
the re#uirements of IS' %*&&%. his could be done as part of the internal
audit or as part of mana"ement review, as lon" as it is traceable.
C'au%e ?: Ter(% and e&inition%
IS' %*&&%)0&&% includes some definitions not included in the %LLH version.
Some of the definitions in IS' %*&&%)%LLH have also been revise to ensure
they are more consistent with terminolo"y in IS' L&&%)0&&&.
he followin" are the new terms and definitions introduced in IS'
%*&&%)0&&*)
-.% Auditor $ person with the competence to conduct an audit
-.- Correcti)e Action$ Action to eliminate the cause of a detected
nonconformity
-.* ocu(ent$ Information and its supportin" medium
-.%* Interna' Audit$Systematic independent and documented process for
obtainin" audit evidence and evaluatin" it ob5ectively to determine the
extent to which the environmental mana"ement system audit criteria set
by the or"aniGation are fulfilled.
-.%/ Noncon&or(it0$ ?on$;ulfillment of a re#uirement
-.%2 Pre)enti)e Action$Action to eliminate the cause of a potential
nonconformity
-.%L Procedure $ Specified way to carry out an activity or a process
-.0& Record $ 4ocument statin" results achieved or providin" evidence
of activities performed
he followin" are terms and definitions that have been modified in the
new version of IS' %*&&%)0&&*)
-.0 Continua' i(+ro)e(ent $ Aecurrin" process of enhancin" the
environmental mana"ement system in order to achieve improvements
in overall environmental performance consistent <SconsistentT in place
of Sin lineT= with the or"aniGationJs environmental policy.
-.2 En)iron(enta' i(+act$ Any chan"e to the environment whether
adverse or beneficial wholly or partially resultin" from an or"aniGationJs
environmental aspects <Senvironmental aspectsTin place of an
or"aniGationJs activities products or servicesT=
-.+ En)iron(enta' (ana2e(ent %0%te( CEMSD $ 3art of an
or"aniGationJs mana"ement system used to develop and implement its
environmental policy and mana"e its environmental aspects. <In place of
She part of an or"aniGationJs mana"ement system that includes
or"aniGational structure plannin" activities responsibilities practices
procedures processes and resources for developin" implementin"
achievin" reviewin" and maintainin" the environmental policyT=
-.L En)iron(enta' o*=ecti)e $ overall environmental "oal consistent
with the environmental policy that an or"aniGation sets itself to achieve.
In place of Soverall environmental "oal arisin" from the environmental
policy consistent with the environmental policy that an or"aniGation sets
itself to achieve and which is #uantified where practicableT.
-.%& En)iron(enta' +er&or(ance $ :easurable results of an
or"aniGationJs mana"ement of its environmental aspects. In place of
S:easurable results of the environmental mana"ement system related to
an or"aniGationJs control of its environmental aspects based on its
environmental policy ob5ectives and tar"etsT
-.%% En)iron(enta' +o'ic0 $ 'verall intentions and direction of an
or"aniGation related to its environmental performance as formally
expressed by top mana"ement. In place of Sstatement by the or"aniGation
of its intentions and principles in relation to its overall environmental
performance which provides a framework for action and for the settin" of
its environmental ob5ectives and tar"etsT
-.%0 En)iron(enta' Tar2et $ 4etailed performance re#uirement
applicable to the or"aniGation or parts there of that arises from the
environmental ob5ectives and that needs to be set and met in order to
achieve those ob5ectives <in place of detailed performance re#uirement
#uantified where practicable , applicable to the or"aniGation or parts there
of that arises from the environmental ob5ectives and that needs to be set
and met in order to achieve those ob5ectives=
-.%+ Pre)ention o& +o''ution $ !se of processes practices techni#ues
material products services or ener"y to avoid reduce or control <separately
or in combination= the creation emission or dischar"e of any type of
pollutant or use of processes parcties material products that avoid reduce
or control pollution which may include recyclin" treatment process
chan"es control mechanisms ,efficient use of resources and material
substation.
I(+'ication
here are chan"es to several of the definitions which impact on an
or"aniGationJs system the implication of the key chan"es are hi"hli"ht
below.
Auditor $ his definition is new and is taken from IS' L&&%)0&&& and links
to demonstrate that its internal auditors are competent and auditor
competence must be defined in the or"aniGationJs 9:S
Interna' audit $ Internal audit has replaced the term environmental
mana"ement system audit partly to avoid confusion by users of the standard
with external <certification= audits. he wordin" of the definition has been
amended to emphasiGe that internal audits must be independent. he focus
of the internal audit has chan"ed from one of determinin" conformance of
the 9:S to determination of conformance with the 9:S audit criteria.
Continua' i(+ro)e(ent $ he definition of continual improvement has
been amended with an additional emphasis that the continual improvement
process is recurrin" and is not a one$off event. he definition also is more
definitive by linkin" it to environmental performance rather than
improvement of the mana"ement system. 'r"aniGations will need to ensure
that they have clearly defined audit criteria.
En)iron(enta' +er&or(ance $ he definition environmental performance
has chan"ed in focus from the mana"ement system to the or"aniGationJs
mana"ement of its environmental aspects. 'r"aniGations will need to ensure
that the evidence they use to demonstrate environmental performance
improvement is in accordance with the revised definition.
Pre)ention o& +o''ution $ he definition of prevention of pollution has been
clarified to reflect methods and options for the prevention of pollution. An
or"aniGation will need to examine how it defines prevention of pollution
<and its scope= to ensure that it covers new concepts of creation emission or
dischar"e of any type of pollutant or waste.
En)iron(enta' +o'ic0 $ Several chan"es now re#uire an or"aniGation to
review its environmental policy. he or"aniGation needs to ensure that its
policy.
Is developed by top mana"ement
(overs the scope of your 9:S and does not imply a wider scope than
that
(overs all activity products and services within the scope of than 9:S
?otes chan"e to terminolo"y related to le"islative and re"ulatory
re#uirements
Aeflects other environmental re#uirements the or"aniGation may have
subscribed to
Is distributed to everyone workin" for or on behalf of the or"aniGation
such as sub$contractors, contractors, temporary staff, and remote
workers.
B.: !enera' reEuire(ent%
Re)i%ion
his clause of the standard now re#uires the or"aniGation to establish
document implement and maintain an 9:S as previously, but also
continually improve the 9:S and determine how it will fulfill the IS'
%*&&% re#uirements. A sentence has been added to the revised standard
which re#uires the or"aniGation to define and document the scope of its
9:S.
I(+'ication
his addition of determine how it will fulfill these re#uirements to
clause *.% re#uires the or"aniGation to state how the 9:S fulfill the
re#uirements of IS' %*&&%. he process will need to be traceable. It
will be insufficient to claim that the internal audit cycle covers all
clauses of the standard and therefore or"aniGation is able to
demonstrate that the 9:S fulfill the re#uirements of IS' %*&&%.
9nsure that the scope of the 9:S is clearly defined and documented
includin" what activitiesM operations, services and products are
included within the scope. ;or or"aniGations seekin" accredited
C'au%e B: En)iron(enta' (ana2e(ent %0%te(
reEuire(ent%
certification, the 9:S scope must a"ree with the re#uirements laid
down by accreditation rules. hese preclude or"aniGations from Xrin"
fencin"J their 9:S scope to exclude difficult areas or areas that are
part of their site.
B.; En)iron(enta' +o'ic0
Re)i%ion
he environmental policy now must be defined within the scope of the
9:S. he policy must also be communicated to all persons workin" for or
on behalf of the or"aniGation.
he wordin" under policy with re"ard to le"al compliance has chan"ed. he
phrase Sapplicable le"al re#uirements and with other re#uirements to which
the or"aniGation sub$scribes which relate to its environmental aspectsT
replaces the text in IS' %*&&%)%LLH, which referred to Srelevant
environmental le"islationWT
I(+'ication
o o comply with re#uirement for the environmental policy to be
consistent with the scope of the 9:S the environmental policy must
not cover issues that are wider, narrower or different from that the
9:S scope.
o o demonstrate compliance with the new re#uirements the
environmental policy must)
Be developed by top mana"ement
(over the scope of the 9:S
(over all activities, products and services within the scope of the
9:S
Aeflect the amended terminolo"y with re"ard to applicable le"al
and other re#uirementsM and
Be communicated to everyone workin" for or on behalf of the
or"aniGation. his includes contractors, subcontractors,
temporary staff and remote workers.
B.?.: En)iron(enta' A%+ect%
Re)i%ion:
he or"aniGation is re#uired to establish and maintain a procedure to
identify environmental aspects of its activities, products and services
within the scope of the 9:S.
he re#uirement to take account of the environmental aspects it can
control and over which it can be expected to have an influence has
been chan"e to take account of the environmental aspects it can control
and those that it can influence. Additionally text that used to be in
section on environmental pro"rammes relatin" to Splanned or new
developments, or new or modified activities, products and servicesT
has been move to the aspects sectionM hence, movin" the re#uirements
to start earlier at the aspect identification state for new pro5ects.
Si"nificant environment aspects must be considered when developin",
implementin" and maintainin" the 9:S, rather than in settin"
environmental ob5ectives as is re#uired in IS' %*&&% ) %LLH.
I(+'ication
Activities, products, or services have been replaced with activities,
products, and services within the scope of the or"aniGationJs 9:S.
he re#uirement has been chan"ed to those activities, products, and
services that it can influence. his means there is now a clear
re#uirement to determine those aspects that an or"aniGation can
influence in addition to those it can control. he procedure for
identifyin" aspects and impacts needs to be revised to ensure that it
incorporates activities, products, and services that can be influenced
within the scope of its 9:S.
he aspect identification procedure needs to cover planned or new
developments, or new or modified activities, products and services.
'r"aniGations are re#uired to document the whole process of
identifyin" their environmental aspects and determine which are
si"nificant.
B.?.; Le2a' and ot,er reEuire(ent%
Re)i%ion:
he first point to note is the "eneral chan"e from the confusin" usa"e
of le"islative, re"ulatory and le"al re#uirements to Xle"al
re#uirementsJ. he world Xle"islativeJ is chan"ed to Xle"alJ. his
differentiates between Xle"islativeJ, which refers to a law passed by
"overnment, and Xle"alJ which is much broader and covers re"ulatory,
court decisions and others. his does not mean that because a piece of
le"islation is not in the environmental 3rotection Act it is not relevant
to the 9:S.
Amendment has been made to the wordin" on le"al and other
re#uirements <in line with the revised wordin" in environmental
3olicy=. he phrase Sapplicable le"al re#uirements and other
re#uirements to which the or"aniGation subscribes related to its
environmental aspectsT is included.
An additional point has been added that specifies that the or"aniGation
needs to determine how the re#uirements <le"al and other
re#uirements= apply to its environmental aspects.
As for *.-.% above, le"al and other re#uirements must be considered in
developin", implementin" and maintainin" the or"aniGationJs 9:S.
I(+'ication:
he chan"es in the wordin" of the re#uirement <in this clause and in
environmental policy= means that or"aniGations will have take account of all
le"al re#uirements that relate to their environmental aspects. his means that
not only the aspects related le"islation. 'r"aniGations will need to determine
how the le"al and other re#uirements apply to their environmental aspects,
ensurin" that these are reflected in the 9:S overall.
B.?.? O*=ecti)e%F Tar2et% and Pro2ra((e%
Re)i%ion:
(lause *.-.- of IS' %*&&%)0&&* mer"es clause *.-.-, S'b5ectives and
ar"etsT, and clause *.-.*, S9nvironmental :ana"ement 3ro"ram<s=T, of
IS' %*&&%)%LLH. revisions include an additional re#uirement that ob5ectives
and tar"ets be measurable, consistent with le"al and other re#uirements, and
committed to continual improvement.
'b5ectives and tar"ets are re#uired to be measurable where practicable.
In addition to the re#uirements in IS' %*&&%)%LLH, ob5ectives and
tar"ets must be consistent with the commitment to compliance with
le"al and other re#uirements and continual improvement.
I(+'ication:
'r"aniGations need to demonstrate throu"h the 9:S that the ob5ectives are
consistent with the above.
B.B.: Re%ource%F Ro'e%F Re%+on%i*i'it0 and Aut,orit0
Re)i%ion:
:ana"ement is now tasked to ensure the availability of resources. he
list of necessary resources has been expanded to include or"aniGational
infrastructure. here is also the re#uirement that the mana"ement
representative provide top mana"ement with recommendations for
improvement to the 9:S.
I(+'ication:
he revised clause incorporates resources, roles and authority, in
addition to responsibility, which need to be reflected in the 9:S and
4ocumented procedures.
'r"aniGations are now re#uired to Sensure the availabilityT of
resources rather than SprovideT as was in IS' %*&&%)%LLH. his will
mean. ;or example, that or"aniGation will need to demonstrate that
there are contin"ency plans in place to ensure that competent people
are able to fulfill specific 9:S roles.
B.B.; Co(+etenceF Trainin2F and A3arene%%
Re)i%ion:
he or"aniGation is re#uired to identify trainin" needs associated with
its environmental aspects and its 9:S and the or"aniGation shall
provide trainin" or take other action to meet establish needs.
'r"aniGations must establish and maintain procedure to make people
performin" tasks for it, or on its behalf, aware of *.*.0 a Q d <as
re#uired by IS' %*&&%)%LLH but a broader scope=.
IS' %*&&%)0&&* states that in an or"aniGation, Sany person<s=
performin" tasks for it or on its behalfT must be identified by the
or"aniGations as competent if their activities have the potential to cause
a si"nificant environmental impact. his has been chan"ed from Sall
personnelT to include contractorJs onsite and other persons not
employed by the or"aniGation who mi"ht perform an activity that
mi"ht cause a si"nificant impact.
I(+'ication:
he re#uirement for competence, trainin" and awareness has been
extended to incorporate all persons performin" tasks for or on behalf
of the or"aniGation. he or"aniGation will need to review all people
workin" for or on behalf of it to ensure they are competent to fulfill
their role in the 9:S. Aecords must be retained by the or"aniGation
that demonstrate competence <on the basis of education, trainin" or
experience= of people performin" tasks that have the potential to cause
a si"nificant environmental impact.
he or"aniGation will need to ensure that all people performin" tasks
for or on behalf of the or"aniGation, which includes contractors, sub$
contractors, temporary staff and remote workers, have had an
appropriate assessment for their potential to cause a si"nificant
environmental impact and the associated competence re#uired.
he revised wordin" in para"raph two allows flexibility for the
or"aniGation to develop the skills and competence to fulfill 9:S
functions, rather than simply re#uirin" trainin".
B.B.? Co((unication
Re)i%ion:
he re#uirement now is for an or"aniGation to decide whether or not
to communicate externally about its si"nificant environmental aspects
and to document its decision. If the decision is to communicate, the
or"aniGation shall establish and implement a method<s= instead of
SprocessesT as re#uired by the %LLH standard for this external
communication.
I(+'ication:
If the or"aniGation decides to communicate about its environmental
aspects it needs to establish methods of communication in its 9:S.
he decision re"ardin" this matter must be documented by the
or"aniGation. :ost or"aniGations do communicate about their
environmental aspects) sometimes actively to all the public, e.".
throu"h an environmental report or by the use of an environmental
mark,lo"o on their productM sometimes selectively re#uirements, e.".
monitorin" returns to environmental re"ulators. In all these cases the
or"aniGation will need to establish its methods for communicatin". It
is probable that only very few or"aniGations do not communicate in
some way and hence do not need a method of communication.
B.B.B ocu(entation
Re)i%ion:
his clause has not chan"ed in intent but has been updated to ali"n it more
with IS' L&&%)0&&&.
he listed 9:S documentation now includes the environmental policy,
ob5ectives and tar"ets, a description of the scope of the 9:S, a description
of the main elements of the 9:S and their interaction and reference to
related documents, documents and records re#uired by the standard,
documents and plannin", operation and control of processes that relate to the
si"nificant environmental aspects.
Implication)
he or"aniGation will be re#uired to demonstrate that the above documents
are in place to ensure the effective plannin", operation and control of
processes, which relate to si"nificant environmental aspects. he extended
re#uirements are in accordance with the re#uirement of IS' L&&&)0&&&.
ISO :B99::;99B reEuire% docu(entation to inc'ude:
he environmental policy, ob5ectives, and tar"ets
he scope of the 9:S
A description of the main elements of the 9:S, their interaction, and
reference to related documents
4ocuments, includin" records, re#uired by IS' %*&&0)0&&*
4ocuments, includin" records, determined as necessary by the
or"aniGation to its si"nificant environmental aspects
B.B./ Contro' o& docu(ent%
Re)i%ion:
;ormattin" chan"es help ali"n this cause of IS' %*&&%)0&&* with IS'
L&&%)0&&&. An additional clarification has been made to define records
as a special type of document re#uirin" control. A new addition to the
re#uirements aims to ensure documents of external ori"in, <i.e. :S4S,
3ermits= that are necessary to the system, are identified and their
distribution controlled.
he revised standard re#uires documents re#uired by the 9:S and
the standard to be controlled. 4ocuments must be controlled in
accordance with the re#uirements in *./.*.
'r"aniGations will need to establish and maintain procedures to
approve documents for ade#uacy prior to issue, review and update
as necessary and re$approve documents, ensure that documents
remain le"ible, ensure that documents of external ori"in determined
by the or"aniGation to be necessary for plannin" and operation of
the 9:S are identified and their distribution controlled <and
prevent the unintended use of obsolete documents, and apply
suitable identification to them if they are retained for any purpose=.
I(+'ication:
itle and wordin" has been chan"ed to a"ain with IS' L&&%)0&&&.
he or"aniGation will need to demonstrate, in addition to the existin"
re#uirements, how documents are approved for ade#uacy prior to issue
and how documents of external ori"in, such as licenses, are identified
and their distribution is controlled.
B.B.- O+erationa' Contro'
Re)i%ion:
?o si"nificant chan"es have been made to this clause. As in many other
cases, Simplementin"T has been added to establishin" and maintainin"
procedures to clarify actions re#uired for conformance with IS'
%*&&%)0&&%.
he or"aniGation needs to identify and plan those operations associated
with identified si"nificant environmental aspects and ensure that they
are consistent with the environmental policy, ob5ectives and tar"ets. o
ensure operations are carried out under specified conditions, the
additional re#uirements are to establish and maintain documented
procedures to control situations where absence of documented
procedures could lead to deviations from the environmental policy,
ob5ectives and tar"ets.
B.B.G E(er2enc0 Pre+aredne%% and Re%+on%e
Re)i%ion:
?o si"nificant chan"es have been made to this clause. he revised standard
clarifies one re#uirement by statin" that in the actual event of an emer"ency,
the or"aniGation shall respond in such a way to prevent or miti"ate
associated adverse environmental impacts.
he re#uirements have been re$specified, statin" explicitly that the
or"aniGation shall establish and maintain procedures to identify
potential emer"ency situation and potential accidents that can have an
impacts on the environment.
In addition, procedures must be established and maintained to respond
to actual emer"ency situation and accidents.
he or"aniGation is re#uired to periodically review and, where
necessary, revise its emer"ency preparedness and response procedures.
I(+'ication:
'r"aniGation should check that their existin" procedure covers the
Xidentification of potential emer"ency situations and potential
accidents that can have an impact on the environment and how it will
respond to themJ.
3rocedures must also cover actual emer"ency situations.
'r"aniGations will also be re#uired to demonstrated that the procedure
have been periodically reviewed.
B./.: Monitorin2 and Mea%ure(ent
Re)i%ion:
his clause does not include any substantial additional re#uirements. he
re#uirement to ensure that calibrated monitorin" and measurement
e#uipment is used and maintained has been extended to include calibrated or
SverifiedT monitorin" and measurement e#uipment.
he re#uirements for periodic evaluations of le"al compliance have
been moved from section *./.% IS' %*&&%)%LLH and form the basis of
new clause <*./.0 see below=. he additional re#uirement for this
clause is for the monitorin" and measurement procedure to include a
re#uirement to document information to monitor performance and
applicable operational controls.
ReEuire(ent%:
A++'ica*'e has replaced relevant when referrin" to operational
controls. 'r"aniGations will need to update their procedures to reflect
this chan"e.
B./.; E)a'uation o& Co(+'iance
Re)i%ion:
his clause has been separated from *./.% to become its own clause. his
achieves clarification, while addin" additional re#uirements. Included in
*./.% of IS' %*&&%)%LLH was a re#uirement for the or"aniGation to
periodically evaluate compliance with relevant environmental le"islation
and re"ulations. his re#uirement has become sub clause *./.0.% in the 0&&*
standard. Sub clause *./.0.0 of the 0&&* standard calls for evaluation of
compliance with other re#uirements to which it subscribes. A new
re#uirement has been added that re#uires an or"aniGation to keep records of
periodic evaluations of compliance.
his is new section and is split into two parts <*./.0.% and *./.0.0=
*./.0.% re#uires the or"aniGation to establish, implement and maintain
a procedure<s= for periodically evaluation compliance with applicable
le"al re#uirements and keep records.
*./.0.0 re#uires the or"aniGation to evaluate compliance with other
re#uirements to which it subscribes and keep records. his can be
combined with the evaluation of le"al compliance noted above.
'r"aniGation must record the results <and maintain the records= of the
periodic evaluation of compliance and these will need to be considered at
the mana"ement review.
I(+'ication:
'r"aniGations will be re#uired to retain records of the periodic
evaluation of le"al compliance undertaken. ?ote should be made that
this clause re#uires or"aniGations to undertaken an evaluation of
compliance a"ainst all le"al and other re#uirements and that this will
be a pre$re#uisite of accredited certification. his means that
compliance a"ainst each and every piece of le"islation,re"ulation
relatin" to an or"aniGationJs environmental aspects will need to be
evaluated before it can be considered to be in conformity with IS'
%*&&%)0&&*. It will not be acceptable for or"aniGations to claim that
the periodic evaluation will be covered by their internal 9:S audit
pro"ramme at some future date.
B./.? Noncon&or(it0F Correcti)e action and Pre)entati)e action
Re)i%ion:
he revision to this clause ali"ns the re#uirements for identifyin" and
correctin" ?onconformity with similar re#uirements in IS' L&&%)0&&&.
(learer definations are provided for actions needed to prevent, investi"ate,
identify, evaluate, review and record ?onconformity, corrective actions and
preventive actions.
he re#uirement is for or"aniGations to establish, implement and
maintain a procedure<s= for dealin" with actual and potential ?on$
conformities and for takin" corrective and preventative action.
he procedure needs to define re#uirements for identifyin" and
correctin" ?on$conformities and takin" actions to miti"ate their
environmental impacts. Investi"ate ?on$conformities, determine their
cause and take actions<s= to avoid their recurrence. 9valuated the need
for actions to prevent ?on$conformities and implement appropriate
actions desi"ned to avoid their occurrence. Aecord the results of
corrective and preventative actions taken, and review the effectiveness
of corrective and preventative actions take.
Actions taken need to be appropriate to the ma"nitude of the problem
and environmental impact encountered and ensure that any necessary
chan"es to the 9:S documentation are made.
I(+'ication:
'r"aniGation need to review and update their procedures as appropriate
and ensure that they incorporate, in particular, the prevent of re$
occurrence of ?on$conformities and the prevention of potential ?on$
conformities.
he or"aniGations processes must also be reviewed to ensure that it
evaluates the need for action to prevent ?on$conformities and
implement appropriate actions to avoid their occurrence.
B./.B Contro' o& record%
Re)i%ion:
(ontrol of records has been simplified, reworded, and reformatted to
ali"n its content with IS' L&&%)0&&&. Aecord must demonstrate
conformity to the 9:S. In keepin" with the focus on continual
improvement, a new re#uirement has been added for records to
demonstrate Sresults achievedT. Aesults are understood to mean outcomes
of audits, corrective actions, operation control, pro"rams to achieve
ob5ectives, and monitorin".
he or"aniGation shall establish and maintain records as necessary
to demonstrate conformity to the re#uirements of the 9:S and the
standard.
A procedure must be implemented for the identification, stora"e,
protection, retrieval, retention and disposal of records.
Aecords must remain le"ible identifiable and traceable.
I(+'ication:
'r"aniGations need to ensure that all records used to support the
9:S and the standard, demonstrate compliance with the 9:S,
procedures and results.
Aecord retention times are no lon"er re#uired by the standard,
althou"h record retention is still re#uired.
B././ Interna' audit
Re)i%ion:
here are two key additions to this clause. ;irst, the revision adds that the
internal audit process must address the retention of associated records.
Second, the revision considers the selection of auditors and states that the
selected auditors shall ensure ob5ectivity and impartiality in the audit
process. his statement is important when choosin" an internal auditor. he
or"aniGation must ensure that the auditor has freedom from bias or other
influences that could affect their ob5ectivity.
he or"aniGation is re#uired to conduct 9:S audits at planned
intervals and the audit pro"ramme shall be planned.
he revised standard re#uires the audit procedures to address retainin"
associated records from audits. his was in the records clause in the
%LLH edition.
he selection of auditors and the conduct of audits must be ob5ective
and impartial.
I(+'ication:
he or"aniGation will need to demonstrate that audits have been
planned and an audit pro"ramme is in place$ this may be done throu"h
the or"aniGationJs audit procedure.
'r"aniGations must also retain records from audits and provision for
this must be included in the procedure.
B.- Mana2e(ent re)ie3
Re)i%ion:
(lause *.H in IS' %*&&%)0&&* includes some important chan"es that ali"n it
closer to IS' L&&%)0&&&. he aim of the clause is the same, but the revision
is more prescriptive. he prescriptive lan"ua"e details inputs to the
mana"ement review process <not all of which are in IS' %*&&%)%LLH=
includin")
Aesults of internal audits and evaluations of compliance with le"al
and other re#uirements
(ommunication from external interested parties includin" complaints
he environmental performance of the or"aniGation
he extent to which ob5ectives and the tar"ets have been met
he status of preventive and corrective actions
;ollow$up actions from previous mana"ement reviews
(han"in" circumstances includin" developments le"al and other
re#uirements
Aecommendations for improvement
Specific outputs of the mana"ement review include continual improvement
and decisions and actions for possible chan"es to)
he environmental policy
'b5ectives
ar"ets
'ther elements of the system
he key chan"es can be summariGed as
he top mana"ement of the or"aniGation is re#uired to the 9:S at
planned intervals.
he results of the mana"ement review must be documented
he review must also include assi"n opportunities for improvement
he input into the mana"ement review will additionally include
communications from external parties, performance of the 9:S, extent
to which ob5ectives and tar"ets have been met, status of corrective and
preventative actions, follow$up actions from previous mana"ement
reviews, chan"in" circumstances includin" developments in le"al and
other re#uirements related to its environmental aspects and
recommendations for improvement.
he outputs from the mana"ement review shall include any decisions
and actions related to possible chan"es to environmental policy,
ob5ectives, tar"ets and other elements of the 9:S, consistent with the
commitment to continual improvement.
I(+'ication:
he input and output of the mana"ement review is now prescribed in
detail <as listed above= and each of the identified inputs, outputs will
need to be incorporated into the or"aniGationJs mana"ement review
processes. ?ote that the mana"ement review is not limited to the of
items and may cover other issues as well as reach decisions and
recommendations beyond the listed items but which are of relevance to
the 9:S
As with audits, mana"ement reviews must be conducted at planned
intervals, rather than intervals the or"aniGation determines.
9xplicitly document decisions from the mana"ement review.
IAF Tran%ition +'an &or Accredited EMS certi&ication &ro( ISO
:B99:::AA- to ISO :B99::;99B
:. Pre+aration ti(e Cu+ to - (ont,% a&ter t,e +u*'ication o& t,e ne3
%tandardD
Ohen the certification, re"istration bodies <(ABs= a"ree with the
existin" and new client or"aniGations on whether IS' %*&&%)%LLH or
IS' %*&&%)0&&* is to be used as the audit criteria, the standard bein"
used shall be identified in the audit plan for initial audit, surveillance
or reassessment. If IS' %*&&%)0&&* is to be used, the (ABs shall
ensure that procedures for assessment and certification to the new
9:S standard are in place.
0. I(+'e(entation date C&ro( - (ont,% a&ter t,e +u*'ication o& t,e
ne3 %tandardD
;rom six months after the publication of the new standard, all audit
plans prepared for existin" and new client or"aniGations should include
IS' %*&&%)0&&*
?. E6tra )i%it% *0 t,e CRB%
Additional visits by (ABs to assess solely a"ainst revision to the
standard are not re#uired.
B. Noncon&or(itie% Cdurin2 a &urt,er :; (ont,% a&ter t,e
i(+'e(entation date de&ined in c'au%e ;D
;or existin" or"aniGations that are certified, re"istered to IS'
%*&&%)%LLH, nonconformities a"ainst chan"es made in the new 9:S
standard may be raised. hese nonconformities will not adversely
affect certification until the end of the transition period.
/. Certi&icate%
he 9:S standard indicated on any certificate shall be consistent with
the standard identified on the audit plan. ;or existin" or"aniGations it is
expected that 9:S certificates will be renewed based on the outcome
of the periodic visit in applyin" the new standard. his renewal should
not chan"e the previous certification cycle unless a complete
reassessment audit takes place. All existin" certificates shall be
renewed as conformin" to the new 9:S standard before the end of
transition <see clause H=.
-. End o& tran%ition C:> (ont, a&ter +u*'ication o& t,e ne3 %tandardD
9i"hteen months after publication of the standard, any existin"
accredited certificates issued to IS' %*&&%)%LLH will become active
and will affect certification, Ae"istration.
G. Accreditation *od0 a%%e%%(ent
Accreditation body assessment visits will cover the (AB plans for
effectively mana"in" the transition.

TOTAL PROUCTI"E MAINTENANCE
CTPMD
Pur+o%e:
3: is promoted by Japan Institute of 3lant :aintenance <JI3:= with
followin" aims)
8et the maximum production from the plant by maximiGin" overall
e#uipment effectiveness <'99=
3revent every kind of loss, mainly throu"h Bero Breakdown, Bero
4efect and Bero Accident.
Involvement of all functions and all levels.
Aeduce cost and time of production.
TPM POLICY:
In our pursuit towards 'r"aniGational 9xcellence throu"h practice of Sotal
3roductive :aintenanceT, we are committed to
:aximiGe 'verall 3lant 9ffectivenessM
Achieve Bero Breakdown, Bero 4efect and Bero AccidentM
Involve all employees in Systems and 3rocess ImprovementsM
(reate a (lean and >ively Oorkin" 9nvironment.
EI!1T PILARS OF TPM
>osses are eliminated by actions under + heads, called pillars of 3:
Autono(ou% Maintenance
4evelop e#uipment competent operators to maintain basic
conditions of e#uipment I shop floor and eliminate forced deterioration.
P'anned Maintenance
Improve Aeliability I :aintainability of e#uipments.
Focu%ed I(+ro)e(ent
Improve overall plant effectiveness by systematic elimination of
losses throu"h KaiGens.
Education and Trainin2
4evelop operation and maintenance skills for Bero Breakdown,
Bero 4efect and Bero Accident.
#ua'it0 Maintenance
4evelop perfect e#uipments to ensure perfect #uality of outputs.
Sa&et0F 1ea't, and En)iron(ent
:aintain Bero pollution and achieve Bero Breakdown, Bero 4efect
and Bero Accident.
O&&ice TPM
Improve efficiency of office activities to provide excellent support
for manufacturin".
e)e'o+(ent Mana2e(ent
Aedesi"n and,or select e#uipments for Shi"h e#uipment
effectivenessT.
:- MA<OR LOSSES
3: aims for SBero >ossT. 'verall 3lant effectiveness can be improved by
eliminatin" %H ma5or losses described below)
Lo%%e% a&&ectin2 EEui+(ent E&&ecti)ene%%
%. 9#uipment failure loss
0. Start$up loss i.e. loss incurred till process stabiliGes.
-. Set$up and ad5ustment loss.
*. ool chan"e loss.
/. :inor stoppa"e I idlin" loss.
H. Speed loss i.e. operation less than rated capacity.
2. Shutdown loss.
+. 4efects and rework loss.
Lo%%e% a&&ectin2 3or5er e&&icienc0
L. :ana"ement loss i.e. waitin" for instructions, materials.
%&. Idle time losses due to unbalanced work.
%%. >o"istics loss i.e. material transfers delay etc.
%0. >ow speed operation due to difference in skills.
%-. >oss due to fre#uent measurement and ad5ustment.
Lo%%e% a&&ectin2 re%ource%
%*. Nield loss i.e. material loss.
%/. 9ner"y loss i.e. poor utiliGation of ener"y.
%H. ool loss i.e. losses due to dama"e to tools.