Technical safety

 In accordance with requirements of the Russian Federation Labour code, Federal law «On In-dustrial Safety of Hazardous Production Facilities», other regulatory legal acts and normative techni-cal documentation, JSC «Kazanorgsintez» has industrial safety department, the main purpose of which is monitoring of compliance with the industrial safety requirements on hazardous production facilities of the Company and labour safety.

Measures aimed to minimization of production potential hazards:

1. Production control execution in accordance with «Regulation on production control over compli-ance with the industrial safety requirements on hazardous production facilities of JSC “Ka-zanorgsintez” (as approved by the Company General Director and agreed by Deputy Director of Privolzhsky Rostekhnadzor Administration) by implementation of complex of measures aimed to or-ganization of hazardous production facilities safety operation.

Parameters of production control (2009):
- Number of performed examinations and inspections of equipment - 4482;
- Number of preventive inspections performed by production control department - 824;
- Number of proposals made by production control departments to the Company management regard-ing organization of industrial safety - 414;
- Number of work stoppage in hazardous conditions (as per production control results) - 47.

2. Industrial safety inspection on hazardous production facilities of the Company in accordance with annually elaborated «Summary plan on labour safety, industrial and environment safety, production control on JSC “Kazanorgsintez”, approved by the Company General Director, plan of the Company department’s activities.

3. Special-purpose inspections (condition of chloride, methanol, flare systems, execution of hazard-ous works and other) of the department’s industrial safety conditions with issuing the binding im-provement notice.

4. Weekly operational inspections with the use of photographic technique under the supervision of deputy chief engineer on industrial safety with participation of certified specialists of technological supervision department (Electric Inspection Service Bureau, technological supervision department, division on technological supervision and upkeep of buildings, facilities and roads), Automatic Proc-ess Control System and metrology division, labour safety division, environment division, Tatar Re-gional Gas Resque Squad, State Instituition “5-Squad Federal Fire-Fighting Service of the Republic of Tatarstan (contractual)”.
Subsequent to the results of operational inspections every week the heads of checking divisions take the floor at the meetings on production plan holding under the supervision of Deputy General director - chief engineer of the Company with participation of directors, chief specialists of the Company and plants on issues related to detected breaches and division’s industrial safety condition in general.

5. Industrial safety service jointly with the Company’s specialists have developed and executed Pro-gram to bring up fire explosive divisions of the Company, regulated by Privolzhsky Rostekhnadzor Administration, to the industrial safety rules and regulations requirements. Programs include 227 technical measures.


Technical measures in 2009 aimed to industrial safety upgrade on JSC
(Program to bring up divisions of the Company, regulated by Privolzhsky Rostekhnadzor Ad-ministration, to the industrial safety rules and regulations requirements)

- In shop 0402-0409: erection of emergency discharge system of the II category blocks was per-formed with installation of remote-operated stop valves on emergency discharge lines of the fol-lowing devices No. 121,2, 2;
- In shop 0310-0352-0353: the enclosure was lifted up to 2m from the side end (building 312);
- Stop valves for high pressure spring gauges were installed at Low Density Polyethylene Plant;
- In shop 2021-2045: purging gas supply system with blocking, providing inert gas supply in case of stopping of purging gas supply to the flare system have been mounted; erection and hook up works of Ð-132 Pump from V-169 Vessel have been performed with max. and min. level inter-locks (Instrument works are completed);
- In shop 0771-0776: devices, registering all cases of protection parameters shutdown for B-5 turbo-compressor ethylene supercharger, have been mounted in ESD (emergency shutdown) sys-tems;
- In shop 0403-0406: emergency discharge systems with high-response stop valves have been mounted in 141-3 Columns;
- In shop 0401: 72 item of pump have been replaced.

Technical measures in 2009 aimed to industrial safety upgrade on JSC
 (Outside the program to bring up divisions of the Company to the industrial safety rules and regulations requirements)

Ethylene Plant:
- Actuation of Â-401À/Â compressor polymerization inhibition system (shop No. 65-76);
- Actuation of Â-3 compressor polymerization inhibition system (shop No. 771-776);
- Conversion of oil-quenching unit control system to the upper level (shop No. 2021-2045);
- Conversion of feed unit, flue gas waste-heat recovery unit control systems to the upper level con-trol (shop No. 771-776);
- Commissioning of light resin separation system from quench water in Å-203 Settler using phase separation level gauge (shop No. 58-68);
- Installation of wafer pack in Å-203 Settler for enhancement of heavy resin separation efficiency from quench water (shop No. 58-68);
- Conversion of depropanization and secondary deethanization units control systems to the upper level control (shop No. 2021-2045);
- Replacement of internals for Ê-303 finished ethylene separation column (shop No. 65-76);
- Modernization of substation No.54 (shop No. 58-68, 65-76).

Low Density Polyethylene Plant:
- Replacement of worked-out autoclave reactor on one process line (shop No. 2002-2004);
- Implementation of process data collection and transmission station to JSC information network (shop No. 2002-2004) – 400 Thousand Roubles (2009).

Organic products Plant:
- Replacement of hermetic magnetic drive on reactor of item 7 (shop No. 41-52);
- Replacement of gland sealing by mechanical seal on pumps of the following items 13, 20, 59, 65 (shop No. 41-52);
- Replacement of mechanical seal on agitator of 7II-1 item (shop No.41-52);
- Installation of high-response valves on the agitators pumping line 1041,2 (shop No. 41-52);
- Replacement of 2à item heat exchanger (shop No. 310-352,353).

Nitrogen, Oxygen and Air production Plant:
- Civil and erection works on air separation units of «Linde» Company, Germany with capacity of 14 000 m3 /hr for nitrogen gas, as well as with output of liquid cryogenic products have been com-pleted
- The nitrogen booster piston compressor of ZW-8,6/2-70 type with capacity of 1500 m3/hr  have been mounted and brought into operation in building 0890 of nitrogen and air shop;
- In Neutralization and Treatment of Industrial Effluent Shop the following programs have been exe-cuted: new pumping station for industrial effluent pumping have been accepted for operation, with installation of 5 submerged pumps of “KSB” Company with double mechanical seals and other ex-plosion-proof electrical equipment; sulfuric acid vapor gas analyzer of “DACH” type has been mounted on sulfuric acid discharge rack.


Technical diagnostics and industrial safety expert review of the following items were performed: 730 vessels, 61,8 km of process pipes, 17 compressors, 205 pumps, 18,4 km of steam pipes, 79 lifting de-vices, 843 m of crane ways, 12 projects.


Computer (training) classroom was organized. Training-supervisory systems “OLYMP:OKC” were purchased, which allow to carry out pre-examination preparation and certification of the Company’s management and specialist in the field of industrial safety.


Within recent years in accordance with requirements of General Rules on Explosive Safety, computer emergency simulators have been developed and implemented in the following divisions of the Com-pany: shop No. 65-76, shop No. 754,762, shop No. 301-304-310, shop No. 201-203, shop No. 152.