CHAPTER 01

INTRODUCTION
1.1 Introduction
Supreme Petrochem Ltd (SPL) was promoted jointly by The Supreme Industries Ltd, and
established, highly diversified Rajah Raheja Group. The former is among India’s largest plastics
processors and an acknowledged leader in the industry, with 28 advanced plants that manufacture the
country’s most comprehensive plastic products portfolio. The latter is a well-established, highly
diversified group with interests in cement, ceramic tiles, automotive batteries, construction, retail
superstores, and more’s owns and operates India’s first & only international scale Styrenics complex
at Amdoshi (Nagothane), 120 km from Mumbai. The complex hosts a Polystyrene (PS) plant using
technology from Huntsman Chemical Corporation, USA, an Expandable Polystyrene (EPS) plant
using latest technology, a Compounding unit producing a variety of high quality polymer
compounds, and an Extruded Polystyrene (XPS) insulation board plant. The SPL Nagothane plant is
an imposing 337 acres facility which features 4 lines of high technology Polystyrene capable of
producing consistent grades of GPPS and HIPS. This site also hosts an EPS plant, XPS plant, SPC
plant and a state-of-the-art laboratory for quality control and development catering to all the above
plants.The plant also has a full-fledged effluent treatment facility with automatic control and
monitoring. In order to provide a green cover around the plants SPL has planted more than 100,000
trees. We have installed a Zero Liquid Discharge (ZLD) plant to recycle water used at the facility for
horticulture purposes as well as process needs. Health safety and environmental protection are given
highest priority in all our operations. Training on fire fighting is given regularly to keep the premises
safe and secure resulting in more than 22 years of accident free operations’ housing colony with
requisite facilities is constructed for key personnel manning the plants.
1.2 Supreme petrochem LTD (SPL)
Supreme Petrochem Ltd. Is promoted jointly by The Supreme Industries Ltd., India’s largest plastics
processor, and the well diversified R. Raheja Investments Pvt Ltd. The Supreme Industries Limited,
founded in 1942 has been relevant with the changing times and continues to be a household name
solely because of the core values that they uphold.Raheja Group has multifarious business interests
covering cement, ceramic tiles, automotive batteries, cable TV, retail superstores, construction,
etc.Supreme Petrochem Ltd commenced operations in 1995, with a modest polystyrene plant of
66,000 TPA capacity. Yet , in less than a decade and a half, the company became the undisputed
leader in polystyrene in India, with a market share exceeding 50%.Its installed capacity has grown to
300,000 TPA effectively making SPL one of the largest single location PS producer in Asia. Exports

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havegrown considerably too. Today the company proudly serves customers in more than 100
countries worldwide. To widen its Styrenics spectrum, SPL forayed into production of EPS at
multiple locations. The current installed capacity of EPS stands at 118,000 TPA.From being a large
commodity player, SPL is now increasingly operating as a supplier of value added products.It has
broken new grounds by developing specialty PP compounds for Appliances and Automotive
applications. SPL expanded its masterbatch range to include White, Black, Colour, Filler and UV
variants with various carrier resins. Simultaneously SPL in 2007 started India’s first and only
integrated plant of XPS (Extruded Polystyrene) Insulation foam boards to support and promote
Green Building movement in India and are registered with IGBC and GRIHA.

1.3.1 GGPS (General purpose Polystyrene)

General Purpose Polystyrene? Today, polystyrene polymer is one of the most widely used polymers
in the world after polyethylene. The main advantage of this product, in addition to high transparency,
is that it can be easily converted into efficient products by molding. One of the most widely used
grades of this material, which is used for general purposes, is General Purpose Polystyrene (GPPS),
which is also known as Crystal. Properties of natural polystyrene such as heat resistance, operating
temperature, flow and fluidity properties, dielectric and strength properties, and impact resistance of
general purpose polystyrene product (GPPS) are optimized. It is widely used to make disposable
tableware, electronics such as televisions and radios, sports equipment, toys, and household
appliances.Advantages of general purpose polystyrene (GPPS)Advantages of general purpose
polystyrene (GPPS) include transparency, high rigidity, good dimensional stability, good electrical
properties, gamma-ray resistance, and low price. In addition to these advantages, this product also
has disadvantages and limitations.The most important disadvantages are fragility at ambient
temperature, poor mechanical properties at temperatures above 70 ° C, high flammability, poor
chemical resistance, especially against organic solvents, and sensitivity to ultraviolet radiation.

Figure 1.1 (GGPS)

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1.3.2 (HIPS) (High Impact Polystyrene)
High Impact Polystyrene also known as PS (Polystyrene), is an amorphous thermoplastic material,
used in lower heat applications. It is categorized as a standard material, and offers ease of processing,
high impact strength, and stiffness.HIPS is a versatile cost-effective material engineered from tough
polystyrene resins. It is often specified for low strength structural applications when impact
resistance, machinability, and low cost are required. It has excellent dimensional stability and is easy
to fabricate – it can be guillotine cut, die-cut, punched, and also painted and glued, properties that
make it a popular option for machining pre-production prototypes. Natural (translucent white) HIPS
is FDA compliant for use in food processing applications.Styrene sheets are extensively utilized for
crafting a broad spectrum of everyday items, including displays, signs, and various other fixtures.
Renowned for its superior dimensional stability and robustness, styrene emerges as the premier
choice for the precise crafting of a diverse array of prototypes and models. This adaptable material is
integral in the production of numerous daily-use products, such as bike helmets, car body parts,
compact appliances, and much more, owing to its versatility. The sheets of styrene are both non-toxic
and devoid of any odor, ensuring their safe and appropriate use across a multitude of applications.
Moreover, the ease with which styrene sheets can be molded and joined using adhesives or solvents
highlights its practicality for manufacturing processes.High Impact Polystyrene (HIPS) can be
assembled with mechanical fasteners, solvents, or adhesives. Printable grades of styrene sheets can
be decorated using a variety of printing methods including offset lithography, screen-printing, and
digital printing. It is also used as a substrate to mount graphics such as plotter vinyls/films.HIPS is
ideal for producing signs and displays; it is one of the lower cost materials available and contains
many of the properties desired by lithographic, screen and digital printers.

Figure 1.2 ( HIPS)

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1.4 Injection moulding machine

Figure : 1.3 Injection moulding machine

Injection moulding (U.S. spelling: injection molding) is a manufacturing process forproducing parts
by injecting molten material into a mould, or mold. Injection moulding can beperformed with a host
of materials mainly including metals (for which the process is called die- casting), glasses,
elastomers, confections,andmostcommonly thermoplastic and thermosetting polymers. Material for
the part is fed into a heated barrel, mixed (using a helical screw), and injected intoa mould cavity,
where it cools and hardens to the configuration of the cavity. After a product isdesigned, usually by
an industrial designer or an engineer, moulds are made by a mould-maker (ortoolmaker) from metal,
usually either steel or aluminium, and precision-machined to form thefeatures of the desired part.
Injection moulding is widely used for manufacturing a variety of parts, from the smallest
components to entire body panels of cars. Advances in 3D printing technology, using photopolymers
that do not melt during the injection moulding of some lower-temperaturethermoplastics, can be used
for some simple injection moulds. Injection moulding uses a special- purpose machine that has three
parts: the injection unit, the mould and the clamp. Parts to beinjection-moulded must be very
carefully designed to facilitate the moulding process; the materialused for the part, the desired shape
and features of the part, the material of the mould, and theproperties of the moulding machine must

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all be taken into account. The versatility of injectionmoulding is facilitated by this breadth of design
considerations andpossibilities
1.5 HSE Department
HSE DepartmentSafety Training For the first week in SPL I was posted to HSE department. There I
learned about fire and environment safety. The officials took the introductory lecture and the safety
manual containing the safety policies and company policy was given to me. The manual contained
the company rules and various methods and safety precautions. It consisted of various chemicals
being used in the vicinity of their specifications and precautions against them. While going through
training sessions main points covered were:
● Hazard and Hazard identification techniques
● Material Safety Data Sheet (MSDS)
● Personal Protective Equipment
● First Aid
● Work Permit
● Methods of Fire Extinguishment
● Classes of Fire etc.

1.6 Safety for industry

10 Easy Ways to Improve Safety in a Manufacturing Work Environment
1) Inform Supervisors of Unsafe Conditions. …
2) Use Equipment, Machines, and Tools Properly.
3) Wear Safety Equipment (PPE) …
4) Prevent Slips and Trips. …
5) Keep Work Areas and Emergency Exits Clear.
6) Eliminate Fire Hazards.
…7) Avoid Tracking Hazardous Materials
.8) Prevent objects of falling
9) Use correct posture when lifting
10) Take works breaks from time to time

 Personal protective equipment

Personal protective equipment, commonly referred to as PPE, is the equipment worn to minimize
exposure to a variety of hazards that cause injuries or illnesses.o The purpose of PPE is to provide a

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barrier between a hazard and the body of a person working in a hazardous environment. PPE is
needed for the safety of workers.

 Apron:
Protection of Bodyo An apron is body protective clothing it is used for the protection of the body
from heat, chemical or metal splashes, spray from pressure leaks and impact and is to be worn over
normal clothing’s.

 Face Shield: Protection of Faceo It is used to protect the wearer’s face and eyes from impact
hazards such as flying objects, splashes or sprays of hazardous chemicals, radiation, etc.

 Splash Goggle: Protection of Eyeso It Is a tight-fitting eye protection that covers the eyes, eye
sockets and facial area surrounding the eyes.

 Ear Plug: Protection of Ear (Protection against Noise)o Ear plugs used for hearing protection
(protection from noise). Ear plugs directly into the ear canal and offer greater protection that
ear muffs and thus are used during long hours of exposure to a high dthus are used during
long hours of exposure to a high decibel sound

 Helmet Protection of Heado Helmet is used in every industry to protect head from injury due
to falling objects Impact with other objects and chemical drips. It is also used in areas of
restricted head space.

 Hand Gloves: For Hand Protection Hand gloves are used for the protection of hand and worn
while handling hazardous materials biological agents, very hot or cold liquids, corrosive
materials, hot objects, rough and sharp edges objects, prolonged immersion in water, etc.

1.7 MSDS (Material Safety Data Sheet)

Safety data 1.HSE Department Safety Training For the first week in SPL I was posted to HSE
department. There I learned about fire and environment safety. The officials took the introductory
lecture and the safety manual containing the safety policies and company policy was given to me.
The manual contained the company rules and various methods and safety precautions. It consisted of
various chemicals being used in the vicinity of their specifications and precautions against them.
While going through training sessions main points covered were: Classes of Fire etc. (SDS) material

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safety data sheet (MSDS), or product safety data sheet (PSDS) is a document that lists information
relating to occupational safety and health for the use of various substances and products. SDSs are a
widely used system for cataloguing information on chemical species including chemical compounds
and chemical mixtures. SDS information may include instructions for the safe use and potential
hazards associated with a particular material or product, along with spill-handling procedures. The
older MSDS formats could vary from source to source within a country depending on national
requirements; however, the newer SDS format is internationally standardized.

MSDS (Material Safety Data Sheet) typically contains 16 sections, each providing essential
information about the safe handling, storage, and potential hazards of a chemical substance.

1. Product and Company Identification

2. Hazards Identification
3. Composition, Information on Ingredients
4. First Aid Measures
5. Fire Fighting Measures
6. Accidental Release Measures
7. Handling And Storage
8. Exposure Controls, Personal Protection
9. Physical And Chemical Properties
10. Stability And Reactivity
11. Toxicological Information
12. Ecological Information
13. Disposal Considerations
14. Transport Information
15. Regulatory Information
16. Other Information

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 CHAPTER 02
2.1 INTRODUCTION
We Learn about safety Overview in all industry MCP. DY System water monitor, Grain diversity,
Pumps house fire extinguisher class and contact we study about SPL permit system we see in spl
terms of product capacity Utilities power water supply and we studied about plant line colour code
We attend workshop lecture we got vist in plants like SPS. XPS.GGPS.HIPS

2.2 WEEKLY JOB SUMMARY

2.2.1 FIRST WEEK

Day ActiveesCarried out

1 We Learn about Safety

2 Overview in all industries MCP.water monitor.Drain diversion

3 Fire extinguisher class and contact

Key personal and their responsibility

Phase1: Up to first 20 minutes after the occurrence
4
Phase2: from 20 minutes to 45 min of the occurrence
Phase3 : from 45 minutes onwards

5 We study about SPl Permit system

We see in spl termss of product

6
Capacity utilizes (Power water supply P

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2.2.2. SECOND WEEK

Day Activities Carried out

1 We studied about Plauw Line Colour Code

2 Incident Leaning Farana erame fatal inddent Excavation pipeline

3 We attend workshop Lecture

We attend lecture in training room about : 1 hazard identification risk

4
assessment & determing control 2 legal &other requirements

5 We go to plant (SP.XPS)

6 We attend the lecture fire prevention and fire protection

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2.2.3WEEK THIRD

Day Activities Carried out

1 We Studied about water block capacity 7654

We Studied about jack well Pump, Pump type-multistage, pump Vertical

2
centrifugal, pump submersible.

3 We Studied about DMF

We learned about Drinking

4
Water treatment in details

5 We study about RD plant

6 We learn about MSDs (material safety data sheet)

2.2.4WEEK FOURTH

Day Activities Carried out

We Study about CPR

1
( Cardio plumomary Resuscitation)

We learn about Electrical safety

2 Hazard to electricity
Human resistance to electric

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 3 We Studied about safety colour and sign

4 We learn about fire alarm

5 We Studied about ZLD plants

6 We Studied about ETD

2.2.5 WEEK FIFTH

Day Activities Carried out

1 ETP ( Efficient treatment plant)

Drilling, thank foam vist

2

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 Learn about lathe machine hydraulic press
3

EOT machine to lift the load 5000kgs

4
To the heavy machine

5 Pumps Maintenance centrifugal pump.

6 We see a teaching machine we used for packing bags

2.2.6 WEEK SIXTH

Day Activities Carried out

1 We Study the manual of health safety and environment in the

manual study safety and plant

2 We study about hazards quality technique

Quative technique

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 3 We learned about safety in welding and gas cutting operation
Safety in sea folding
Safety in hand tools
4 We Studied maintanence of following register in Manual we
Weekly checked carried out confirming the effectiveness of the
interlock
Weekly check confirming that all accessories
Are in good state of repair
5 We study about plant maintenance
Types of plant maintenance
Breakdown,preventive ,predective
6 We study produce and plant for safety plant operation
Shut down maintenance
Procedure forshut down maintenance
Emergency shut down

CHAPTER 3
CONCLUSION

It was a great of internship in SUPREME PETEOCHEM LTD and full of knowledge. I really
enjoyed the training period. I have learnt about HIPS and theta provide a relevant conclusion about
Supreme Petrochem Ltd., it would help to know the specific aspect you’re interested in, such as
financial performance, market position, or strategic initiatives. However, ageneral conclusion about a
company like Supreme PetrochemLtd. . Most of the time I used to see how the polystyrene is done

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and . I also seen that how an organization work under extreme pressure and how to handle it like
when so much work in the limited time it is really a very big task. Overall it was a good experience
and it increases my interest in the Chemical industry, now I am planning to enhance my skills in this
field.

REFERENCES
Supreme Petrochem Limited (SPL) has multiple reference numbers, including:Corporate
Identification Number (CIN): L23200MH1989PLC054633Registration number: 054633BSE Script
Code: 500405Symbol: SUPPETROISIN Number: INE663A01017

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