PROCESS PLANT MANAGER’S

READY RECKONER
BY
D.K.JOSHI
1988 (UPDATED 2019)
 FOREWORD
• This presentation is part of the booklet with the same title. This
booklet “PROCESS PLANT MANAGER’S READY RECKONER” is prepared
more as a self learning tool than a conventional training tool. It is
something which every plant manager should prepare for himself and
regularly update.

• I first prepared it for myself in year 1988 when I became Production

Manager for Agrochemicals at BASF India. I found this ready reckoner
very useful in my career and hence thought of sharing with Plant
Managers at MOL / MFL. I suggest it be shared to all those who are
already In-charges of a plant or section of the plant. It will be also very
useful for those who have just taken the charge or budding to do so.

• D.K.Joshi
4 March 2019
 INDEX
SUBJECT SLIDE
No.
List of Products, Intermediates and Byproducts
List of Raw Materials and Packing Material (Along with
Major Specifications)
Process Knowledge
Chemistry Practiced in the Plant
SOP of each step of operation
Log sheets or Batch Report and other Records
Block Diagrams
Process Flow Diagram
P & ID
What can go wrong? Possible Deviations
 INDEX
SUBJECT SLIDE
No.
Plant Manpower
Company Employees (Category wise)
Contractual Employees
Major Equipment List as per sheet prescribed
Yield calculations / RM Consumption norms and scope of
Improvisation
Capacity Calculations including bottlenecks to capacity and tips.
Costs under various Heads and Process of Cost Reduction
MIS Report
Instrumentation in the plant with special emphasis on Relef
Systems, Controllers and Safety Interlocks.
 INDEX
SUBJECT SLIDE
No
Important Statutory Rules for EHS as well as product related.
EHS Related Information: Building Up a Safety Culture:
SAFETY
Building Up a Safety Culture
MSDS (For RM, Intermediates, FG and By-products.
Major Hazards Identified and its Communication
Process related Hazards
Emergency Management
Essential PPEs.
Permit Systems
Reporting Near Misses
Signage related to Safety
ENVIRONMENT
Material Balance and Water Balance for the Plant
Quality of Waste water at source
 LIST OF RM, FG etc.
• To Prepare List of Materials as per below format. This applies
to Raw Materials, Intermediates, Finished Goods and By-
products: (Example given)

Name of Important Packaging Specifications Principle of

Material Properties Details Analysis
Tri ethyl Flammable 200 Litre MS BP
amine liquid, BP 65, drum Purity GC
Amine smell
Cypermet Liquid to 200 L Purity :96% GC (
hrin molten mass, lacquered min
Technical irritating to skin MS drum
and eyes, toxic
nonflammable
 PROCESS KNOWLEDGE
• As part of Process Knowledge, Following Information must be with Plant
Manager:
Chemistry Practiced in the Plant
Chemical reaction / equation with Mol wt of each including the by-product. The information
should be in quantity ( kilo ) basis as well as mole basis.

SOP of each step of operation

SOP should clearly state each step of operation in orderly manner. All operating parameters
like temperature, pressure, rate of addition, time periods etc. should be specified. SOP
should also include sampling procedure. From safety point of view, PPEs to be warn and any
other precaution to be taken needs to be mentioned. Trouble shooting guidelines as well as
emergency shut down and non routine start up should be also included.
Log sheets or Batch Report and other Records
Log sheets are important record for the batch history. Firstly, it should be in line with SOP.
Plant name, Date and shift, Equipment (s) involved should be entered.
As a good practise, there should be a section where All RM used are recorded along with
quantity, supplier ‘s B.No, purity etc. Sampling procedure, sampling sequence, action based
on sample results be recorded.
At the end, when product is packed, a correct label (Product name, B. NO. DOM and DOE are
a must. Depending on legal requirement additional data may be mentioned on label.
Packaging is as per customer’s requirement or as per SOP.
• Information as above should be prepared for Unit
Operations also. Logsheets SOPs should be prepared
for these as well.
• Like mentioned earlier; the SOPs for reactions as well
as unit operations should clearly deal on what can go
wrong and trouble shooting for the same. Wrong can
be quality, quantity, uncontrolled reaction exothermic.
Liberation of toxic material, fire explosion or whatever.
• Also separate SOPs be prepared for normal start of the
batch and normal stoppage; non routine start up as
well as emergency stoppage. Handling emergency
should be well thought of in advance proactively.
• Yield calculations / RM Consumption norms
and scope of Improvisation
• Capacity Calculations including bottlenecks to
capacity and tips.
 EQUIPMENT INFORMATION &
DIAGRAMS
• Production Manger should have with him
following diagrams:
– Block Diagrams with Material Balance
– PFD Process Flow Diagrams: All equipment as well as
material flow including utilities are shown.
– P & I Diagrams: Include detailed information on
equipment, piping (including design parameters, ), as
well details of instrumentation is shown in this.
• List of Important equipment should be prepared
in following format:
• Eqpt Operation MOC Capacity Max Max Process Mitigation
no Temp Pressure Hazard Means
 IMPORTANT RULES FROM
FACTORIES ACT
• Factories Act / Gujarat Factory Rules: (Summarised and
relevent info only)
• Petroleum and Explosives storage (PESO)
• Indian Petroleum Act
• Boiler Act and Rules / Indian Boiler Regulation
• Static and Mobile Pressure Vessels
• Poison Act
• Insecticide Act (For Agrochemical Units only)
• Pollution Related Rules Waste water, gasses and
Hazardous Waste (Summarised and relevent info only)