lafarge hs pictorial guide
TRANSCRIPT
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Safety Pictorial Guide: East & South West Asia Region Cement Audits
Audit Elements
East and SouthEast and South -- West Asia RegionsWest Asia RegionsVersion 1: Dated 25th Jan 2010Version 1: Dated 25th Jan 2010
H&S Pictorial GuideH&S Pictorial Guide
Chapter 1/5: Group StandardsChapter 1/5: Group Standards
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Group StandardGroup Standard Work At HeightsWork At HeightsScaffoldingPlatforms
StairwaysFalling Objects
Portable LaddersFall Protection Equipments Harness etc.
Gaps, Holes on platformsWAH Permits
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Safety Pictorial Guide: East & South West Asia Region Cement Audits WorkingWorking -- At At --HeightsHeights ScaffoldsScaffolds
Fatality - A contractor in Fumin project in YunNan (China) got killed in a 14-meters fall when climbingdown the scaffolding.
Access to landing
platform is restricted
Ladder not extended 1meter from platform
Base to height ratio of4:1 not followed
height
b a s e
Bracings not up tostandard
Illustration of a standard scaffold
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Safety Pictorial Guide: East & South West Asia Region Cement Audits WorkingWorking -- At At --HeightsHeights ScaffoldsScaffolds
Scaffolding tag Green scaff tag denotedthat Scaffold is Fit To Use
FHRA displayed at the various work locations.
Fatality - A contractor in Fumin project in YunNan (China) got killed in a 14-meters fall when climbingdown the scaffolding.
Scaffolds being usedwithout inspection(no inspection tag)
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Scaffolding inspection training program conducted
WorkingWorking -- At At --HeightsHeights -- ScaffoldsScaffolds
Fatality: In Saudi Arabia, while working inside the main chimney on a hanging platform, 2 contractorsdied when the platform tipped over, provoking a fall from 95 meters.
Trained & certified team of scaffolders
Fatality:Substandardplatform gaveaway & theperson fell allthe way to theground & died.
Broken woodplanks
Gap at platform
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Safety Pictorial Guide: East & South West Asia Region Cement Audits WorkingWorking -- At At --HeightsHeights -- ScaffoldsScaffolds
Fatality: A Sub Contract Concrete Pumping Supervisor died after being struck on the head by a fallingwooden scaffold pole
Gaps betweenplanks
Planks not tied toledgers and
transoms
Improper crossbracing
Using planks withvarious shapes and
sizes
Rough edges ofscaffolding pipes
Tubes protrusionnot less than 4
inches from clamp
braces properlyspaced and rigid
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Safety Pictorial Guide: East & South West Asia Region Cement Audits WorkingWorking -- At At --HeightsHeights -- ScaffoldsScaffolds
Fatality: In Malawi, an artisan welder was hit by a falling pipe while he was leading dismantling worksat the decommissioned Changalume plant.
Self-closing door at accessplatform of a scaffold
Access ladder extended up to 1meter from the access platform
A-frame scaffolding used for a heightmore than 1.5 meter
1
2
3
No top rail, toe board and access ladder
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Safety Pictorial Guide: East & South West Asia Region Cement Audits WorkingWorking -- At At --HeightsHeights -- PlatformsPlatforms
Inside silo, a temporary platformfound without railings.
A rope used for Edgeprotection
Missing toe boardMissing toe board
Fatality: In Algeria, the victim (Guerine) was at the very top of the installation, the structural fixings of the access stairwaygave way. Guerine fell from a height of 30 meters and died instantly.
Toe board on workingplatform
Rails in place
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Toe board with large opening
An example of how an object (ironbar), can slip through an opening& fall
Big gap between toeboard and floor
Standard toe board onworking platform
Standard railings andaccess stairs
WorkingWorking -- At At --HeightsHeights -- PlatformsPlatforms
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Safety Pictorial Guide: East & South West Asia Region Cement Audits WorkingWorking -- At At --HeightsHeights -- StairwaysStairways
Missing handrail
Fatality : In Algeria, a contractor felt from 30 meters when the structural fixing of the access ladder hewas climbing on (for an unknown reason) gave away.
Accumulated materials onstairways
Heavy materials storedon working platform
Access stairs free fromtrip hazards
Standard railings andaccess stairs
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Use of safety net during construction activity,to reduce the risk exposure of any fallingobject.
WorkingWorking -- At At --HeightsHeights Falling objectFalling object
3 fatalities happened in 2009, as a result of objects falling from height - Morocco, Malawi, Malaysia.
No safety signage toalert people of men
working at height
No established DropZone. Workers can
access below thesuspended load
Drop zone clearly identifiedbelow the area, where WAHactivity is taking place.Inspectiontags
men working below
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Safety Pictorial Guide: East & South West Asia Region Cement Audits WorkingWorking -- At At --HeightsHeights Falling objectFalling object
3 fatalities happened in 2009, as a result of objects falling from height - Morocco, Malawi, Malaysia.
Only 1 bulldoggrip installed
Wire rope with Bulldog clamping grips as perstandard.
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Safety Pictorial Guide: East & South West Asia Region Cement Audits WorkingWorking -- At At --HeightsHeights Portable LaddersPortable Ladders
Portable ladders are inspected before useDamaged or defective ladders are removed fromservice Tagging system in place.Ladders are used properly: one person on aladder at a time, 3 feet extension above theroof.Angle of the ladder at least 4:1 (length of the
ladder against base distance from the wall).
Steel ladder not properlystored
Portable ladder used aspermanent access way
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Safety Pictorial Guide: East & South West Asia Region Cement Audits WorkingWorking -- At At --HeightsHeights Portable LaddersPortable Ladders
Portable ladder left lyingon operation site.
Metallic ladder being usedin electrical substation
Portable ladder properly stored and secured
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Safety Pictorial Guide: East & South West Asia Region Cement Audits WorkingWorking -- At At --HeightsHeights Portable LaddersPortable Ladders
Using portable ladder withoutconsidering other hazards
Uneven footingHeight ~ 5meters
mobile elevated working platform
Use of appropriate working platform
mobile scaffolds
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Safety Pictorial Guide: East & South West Asia Region Cement Audits WorkingWorking -- At At --HeightsHeights Fixed LaddersFixed Ladders
Monkey ladderwithout cage
Cage installed onmonkey ladder
7 feetfrom the
ground
Lockable barrierto regulate
access
Monkey ladderwithout cage
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Bag handler using fall protection equipment(retractable lanyard anchored unto lifeline)during WAH.
WorkingWorking -- At At --HeightsHeights General RequirementsGeneral Requirements
Cement bagloader withoutfall protection
Height ~2.5 meters
Cement bagloader with fall
protection
worker using retractablelanyard
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Safety Pictorial Guide: East & South West Asia Region Cement Audits WorkingWorking -- At At --HeightsHeights General RequirementsGeneral Requirements
Bulk loading facility with access way and fall protectionClimbing up the bulk tanker without
proper access and fall protection
Truck loading facilitywithout proper access
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Safety Pictorial Guide: East & South West Asia Region Cement Audits
Proper donning of fall protection equipment
WorkingWorking -- At At --HeightsHeights General RequirementsGeneral Requirements
Employees are properly trained in WAH,including rescue & suspension trauma.
Harness not secured properly
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Safety Pictorial Guide: East & South West Asia Region Cement Audits WorkingWorking -- At At --HeightsHeights General RequirementsGeneral Requirements
Fall arrest and fall restrain equipment are ingood conditionInspection tags showing the date ofinspection and the date of next inspection.
Fatalities: In Egypt, a contractor employee died while using substandard fall arrest equipment. In Nigeria, a Lafarge employee died after
falling from the top of a kiln shell. He was using a defective safety harness. In India, a mechanical erection contractor employee fell fromthe platform inside the cyclone under construction 14 meters to his death. He was not using the harness.
Use of rope grab fall arrestor
Inspectiontags
Worn out lanyard protectionagainst metal edges
Repaired safety harness
(using rivets on sewedportion) highly
prohibited!
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Large openings around the working platform,which increases the exposure of fall risk.
WorkingWorking -- At At --HeightsHeights General RequirementsGeneral Requirements
Fatalities : In India, a contractor fell to his death through a hole while trying to lift a metal sheet tocover another hole on the roof of the cement mill.
Floor openings observed ontemporary installations
Uncovered portion of ducts
Typical cover of ducts
Typical covering of ducts (with allowable gap for metal expansion)
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Safety Pictorial Guide: East & South West Asia Region Cement Audits
Group StandardGroup Standard Energy IsolationEnergy IsolationUnexpected energization, start-up, or release of hazardousenergy when performing tasks on machines, equipment and
process (MEP).LOTOTO Lock Out Tag Out Try OutEnergy Isolation MatrixConveyor Safety Guarding & Pull Cords
Spillages around ConveyorsInspection & Clean out doorsPressurized Tanks & Vessels
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Energy Isolation and LOTOTO sequencecomplied
Energy IsolationEnergy Isolation General RequirementsGeneral Requirements
Permitshows 2personsworking
Only onepadlock atthe LOTOTO
box
Worker stillwith padlockon his waist
while workingon machine
Multi-haspwith
personalpadlocks
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Energy Isolation and LOTOTO devices
available at site
Energy IsolationEnergy Isolation General RequirementsGeneral Requirements
Display of isolation matrix and wellmaintained individual lockout box.
EI Matrix
Dusty LOTOTOboxes
LOTOTO boxeswithout label
Broken glass ofLOTOTO box
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Safety Pictorial Guide: East & South West Asia Region Cement Audits Energy IsolationEnergy Isolation Lockout/Tagout/TryoutLockout/Tagout/Tryout
Energy isolation devices installed on allsources of hazardous energy
Ball valve withoutenergy isolation device
An electrical panel which can beopen even while energized
Ball valve with energy isolatingdevices
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Safety Pictorial Guide: East & South West Asia Region Cement Audits Energy IsolationEnergy Isolation Lockout/Tagout/TryoutLockout/Tagout/Tryout
Energy isolation devices installed & used priorto doing any task on MEP.
VCS (visible cutoff switch)Is locked
Fatality: Hasim Yozgat was asked to clean alone the area near the conveyor belt that is bringing recycling waste to the drier. He was used to dothis operation. His right arm was caught between the running conveyor belt and the counter belt that bring the material up. He died after beingcrushed by the conveyor belt. In Sichuan (China), an experienced contractor died while cleaning a conveyor belt in the quarry.
Compromising LOTOTO procedure with the urgency ofcompleting task.
Workers habitually work on running conveyors,such as to take out jammed bags in packing plant
Fatality happened here
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Personnel padlock with employee identification,and information tag
No proper identification of authorized individualdoing the LOTOTO procedure.
Energy IsolationEnergy Isolation Lockout/Tagout/TryoutLockout/Tagout/Tryout
Isolation box without label
Padlocks without owners identification
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Safety Pictorial Guide: East & South West Asia Region Cement Audits Energy IsolationEnergy Isolation Lockout/Tagout/TryoutLockout/Tagout/Tryout
Inspection door secured with metalwedge and welding electrode
Non-lockableinspection door
Inspection door securedwith poking bar, worn outtool and leftover metallic
materials
Inspection doorwith lock
Visible safety signof the hazard
S f Pi i l G id E & S h W A i R i C A di
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Safety Pictorial Guide: East & South West Asia Region Cement Audits Energy IsolationEnergy Isolation Conveyor SafetyConveyor Safety
Defective pull switch
Cut off emergency pull cord
Pull rope with builtup materials
Operational pullswitch
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Pull cord is installed 100mm 200mm
above the level of the conveyor belt
Energy IsolationEnergy Isolation Conveyor SafetyConveyor Safety
Sagging pull rope along thebelt conveyor
Properly tensioned pull rope
Pull rope installed at 100 200 mmabove the conveyor belt
Safety Pictorial Guide: East & South West Asia Region Cement Audits E I l iE I l ti C S fC S f t
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Safety Pictorial Guide: East & South West Asia Region Cement Audits Energy IsolationEnergy Isolation Conveyor SafetyConveyor Safety
Fatality: In South Africa, a general worker died after being caught in the tail pulley of the conveyer belt
extracting rock from the primary stockpile of the granular plant of the quarry.
Conveyors without audible or visual start up warningsystem
Belt conveyor with audible and /or visible start up warning system
Safety Pictorial Guide: East & South West Asia Region Cement Audits E g I l tiEnergy Isolation C S f tConveyor Safety
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y g Energy IsolationEnergy Isolation Conveyor SafetyConveyor Safety
Fatality: In South Africa, a general worker died after being caught in the tail pulley of the conveyer belt
extracting rock from the primary stockpile of the granular plant of the quarry.
Conveyors with gaps along the access wayand nip points not guarded
Belt conveyor with properguarding at nip points
Safety Pictorial Guide: East & South West Asia Region Cement Audits Energy IsolationEnergy Isolation Conveyor SafetyConveyor Safety
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Energy IsolationEnergy Isolation Conveyor SafetyConveyor Safety
Gravity Tensional Unit (GTU)not properly isolated
Barrier not locked
No restriction for entry Fully enclosed Gravity Tensioning Unit
Safety Pictorial Guide: East & South West Asia Region Cement Audits Energy IsolationEnergy Isolation Conveyor SafetyConveyor Safety
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Energy IsolationEnergy Isolation Conveyor SafetyConveyor Safety
Machine guard not re-installed after repair
Machine guard not re-installed after repair
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Safety Pictorial Guide: East & South West Asia Region Cement Audits Energy IsolationEnergy Isolation Conveyor SafetyConveyor Safety
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Energy IsolationEnergy Isolation Conveyor SafetyConveyor Safety
Proper machine guarding
Fatality: A contractor in Sichuan died after he was caught by a conveyor while cleaning theunguarded portion of the return rollers.
No guards at the dischargepoints of belt conveyor
Nip point can beaccessed from here
Nip point can beaccessed from here
Machine guard at tail end of conveyor
Adjusting bolts outside of machine guard of conveyor
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gygy y yy y
Safety communication campaign is conducted
to raise awareness regarding conveyor safety.
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Guarded transfer point
gygy pp
Transfer point inspectionhole with defective cover
Transfer point withunsecured door
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Safety Pictorial Guide: East & South West Asia Region Cement Audits Energy IsolationEnergy Isolation Inspection and Clean out DoorsInspection and Clean out Doors
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Inspection doorwith no locking
provision
Inspection door
with no lockingprovision
Poke holes providedwith hinge type cover
Inspection doorwith lock
Safety Pictorial Guide: East & South West Asia Region Cement Audits Energy IsolationEnergy Isolation Pressurized tanks & vesselsPressurized tanks & vessels
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Fatality: In Brazil, a death of a mechanic occurred, following the accidental explosion of a pressurized
valve.
Corrodedpressure vessel
Pressure vessels withoutinspection tag indicating test
date and condition
Pressure vessels wit inspectiontag indicating test date and
condition
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Safety Pictorial Guide: East & South West Asia Region Cement Audits Energy IsolationEnergy Isolation Pressurized tanks & vesselsPressurized tanks & vessels
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RECOMMENDATIONS FOR INSTALLATION, OPERATIONAND MAINTENANCE OF AIR CANNONS
Initiate or verify the LOTOTO procedure for air cannons Read entire Manufacturers installation manual before
beginning any work and check for compliance Initiate inspection and maintenance program as per
Manufacturers recommendation (monthly and yearly) Inspect all discharge valves and remove cracked valves
out of service immediately Initiate replacement of all old-design discharge valves
with re-enforced valves, and use the latter in any newinstallation.
Limit the stress on the valve by mounting the tanks inthe most vertical position with short extensions
On hot application air cannons, install Air CannonThermo Safety Shields
Inspect all restraining cables and replace if worn orincorrectly installed. Check cable sizing with air cannonmanufacturer.
Minimize compressed CO2 blasts in the direct vicinity of
air cannons If compressed CO2 blasts are used near air cannons,
slide gates must be installed to isolate the air cannonsfrom CO2 blast
Establish a safety zone and route around operating aircannons
Train ALL employees on the hazards of air cannonsand these types of failures
Revise site-specific training to ensure this training is
provided to visitors and contractors
Maximum stress atmounting flange
Minimum stress onthe valve flange
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Safety Pictorial Guide: East & South West Asia Region Cement Audits Energy IsolationEnergy Isolation Pressurized tanks & vesselsPressurized tanks & vessels
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Locking device to prevent snaking of High pressure hose, installed here
Pressurized hoses tiedwith G.I. wire
Pressurized hoses tied with G.I. wire can snapand cause whipping action or snaking of
hose that can hit anybody nearby
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Punctured pressurizedhose
High pressure hose withoutpunctures and with standard
hose clip
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Personal Protective EquipmentPersonal Protective EquipmentSelection, issuance, use, maintenance and replacement ofPersonal Protective Equipment (PPE).
General PPE Requirements.Site Specific & Task Specific PPE.Quality of PPE.
Safety Pictorial Guide: East & South West Asia Region Cement Audits PPEPPE General RequirementsGeneral Requirements
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Cloth, instead of dust mask tocover the nose
No fire resistant protection
Different types of masks
Standard dust masks /respirators are used at site
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Safety Pictorial Guide: East & South West Asia Region Cement Audits PPEPPE General RequirementsGeneral Requirements
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Helmet made ofsoft material
Painted helmet
Additional features like reflective strips
Standard safety helmet (EN397 compliant)
Safety Pictorial Guide: East & South West Asia Region Cement Audits PPEPPE General RequirementsGeneral Requirements
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Safety shoes laced with nylon rope
Worn out safety shoes
Standard safety shoes (EN345-1 compliant)
Safety Pictorial Guide: East & South West Asia Region Cement Audits PPEPPE General RequirementsGeneral Requirements
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Standard ear protection
Chin strap on safety helmet
Poorly maintained earplug
Chin strap not properly mounted
Safety Pictorial Guide: East & South West Asia Region Cement Audits PPEPPE General RequirementsGeneral Requirements
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Very specific PPE requirements forhazards on siteWorking without the right PPE
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Very specific PPE requirements forhazards on site
Workers taking off their PPE at PPE Zone
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Insufficient PPE for electrical works
Wooden fabricated stoolfor HV panel works
Purely manual rackingmechanism for HV panels
Having only one pair of HVgloves in the substation
Properly insulated stool for electrical works
Sufficient electrical tools atthe substation
Safety Pictorial Guide: East & South West Asia Region Cement Audits
Audit Elements
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East and SouthEast and South -- West Asia RegionsWest Asia RegionsVersion 1: Dated 25th Jan 2010Version 1: Dated 25th Jan 2010
H&S Pictorial GuideH&S Pictorial GuideChapter 2/5: GroupChapter 2/5: Group AdvisoriesAdvisories
Safety Pictorial Guide: East & South West Asia Region Cement Audits
Table of Content
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1. Group StandardsWorking at Height (WAH)Energy Isolation (includes conveyor &LOTOTO advisories)
PPE
2. Group AdvisoriesMobile EquipmentStockpile & Surge PileConfined Space
3. Systems & ProcessesRisk AssessmentInspectionsTrainingEmergency Preparedness & Response
4. Site StandardsHousekeepingSafety in DesignIlluminationLifting equipment & HoistsCompressed Gases and Hoses
LaboratoryHarbourCoal Shop
5. ManagementLeadership & AdministrationCommunication Signs
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Group AdvisoryGroup Advisory Mobile EquipmentMobile EquipmentAssessing the Risks.Circulation Plan Edge protection, Speed Limit, Parking
Safe Zone Pedestrian walkway, visibility, Gradient, Sand TrapsReversing of vehicles Alarm, Light, Camera, IlluminationMotor BoysOverloading
Seat Belts & Cell Phone Extra pasengersEnergy working under power linesDrugs & AlcoholMobile Equipment Condition - Inspections
Qualification & Training of DriverBehavior of DriversJourney Management Assessing the risks
Safety Pictorial Guide: East & South West Asia Region Cement Audits Mobile Equipment SafetyMobile Equipment Safety Circulation PlanCirculation Plan
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Proper berm wall at quarry access road.Insufficient berm wall or edge protection
Slightly graded haul road with sufficient widthand high berm with interval luminous marking
Fatality: A quarry contractor died after his dump truck transporting limestone fell off a ramp and crashed 9
meters to a lower bench, due to insufficient edge protection.
Using boulders as edge protection Edge protect ion < 1.5 meters
Edge protection with strips
Edge protection > 1.5 metershigh
Safety Pictorial Guide: East & South West Asia Region Cement Audits Mobile Equipment SafetyMobile Equipment Safety Circulation PlanCirculation Plan
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Fatalities: In Cameroon, a driver employed by our transport contractor, his motor-boy and two
unknown passengers were killed in a road accident while delivering clinker to the plant.
Tractor with operator w/o seatbelt and ferrying passengers.
No safety / warning signsa l o n g t h e q u a r r y r o a d
Safety sign and speed limit along the quarry road
Safety Pictorial Guide: East & South West Asia Region Cement Audits Mobile Equipment SafetyMobile Equipment Safety Circulation PlanCirculation Plan
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Trucks left by drivers with engine still ON.Reverse parking system in place
No system of parking (reverse parking? Forward parking?
Safety Pictorial Guide: East & South West Asia Region Cement Audits Mobile Equipment SafetyMobile Equipment Safety Circulation PlanCirculation Plan
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Safety sign at parking area
Safety Pictorial Guide: East & South West Asia Region Cement Audits Mobile Equipment SafetyMobile Equipment Safety Safe ZoneSafe Zone
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Vehicles Smaller vehicles may be at risk of being crushed. Like pedestrians they should be kept away from areas where largevehicles operate. If this cannot be achieved: i) smaller vehicles should operate with headlights on at all times; ii) fitted with flashing
lights (i.e. strobe lights) and flags (i.e. buggy whips) or otherwise made readily visible to the operators of large vehicles.
Revolving light forsmaller vehicles
Smaller vehicles follow the
same route as larger vehiclewithout sufficient visibility
Safety Pictorial Guide: East & South West Asia Region Cement Audits Mobile Equipment SafetyMobile Equipment Safety Safe ZoneSafe Zone
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Fatalities: In Sichuan (China), a contractor got run over by an excavator while he was conductingmaintenance works on a temporary access road.
Smaller vehicles follow the same route as largervehicle without sufficient visibility
Revolving light and flagfor smaller vehicles
Detachable magneticrevolving light
Safety Pictorial Guide: East & South West Asia Region Cement Audits Mobile Equipment SafetyMobile Equipment Safety Safe ZoneSafe Zone
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Undersizedwheel stopper
Typical design of an effective wheel stopper,painted with light color
Worn out tires
Good tire
Stone used as wheel block
Safety Pictorial Guide: East & South West Asia Region Cement Audits Mobile Equipment SafetyMobile Equipment Safety Safe ZoneSafe Zone
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Personnel walking outside of the pedestrian lane
No designated pedestrian lane on plant site
Personnel walking along thedesignated pedestrian lane
Safety Pictorial Guide: East & South West Asia Region Cement Audits Mobile Equipment SafetyMobile Equipment Safety Safe ZoneSafe Zone
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Pedestrian lane not respectedat process line
Very narrowpedestrian lane
Designated pedestrian lane inside the process line
Well established pedestrian lane
Safety Pictorial Guide: East & South West Asia Region Cement Audits Mobile Equipment SafetyMobile Equipment Safety Safe ZoneSafe Zone
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Fatality: In Wapco (Nigeria), a driver working with one of our contracted transporters died after havingbeen run over by his own truck driven by his assistant at the plant entrance
Unstable structure
No clear separation of pedestrian & trucks
Established circulation Plan at plant site
Established circulation Plan at quarry site
P e d e s t r i a n r o u t e
T r u c k r o u t e
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Safety Pictorial Guide: East & South West Asia Region Cement Audits Mobile Equipment SafetyMobile Equipment Safety Safe ZoneSafe Zone
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Sand trap provided on high gradient quarry road, to facilitateemergency stop in case of brake or equipment failure
High gradient road with no facility for emergency stopsin case of brake failure
Safety Pictorial Guide: East & South West Asia Region Cement Audits Mobile Equipment SafetyMobile Equipment Safety -- ReversingReversing
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Motor boys commonly entering at sites
Fatalities: In Egypt, a motor boy employed by a transport contractor was killed after being run overby his own truck. In India, a motor boy was crushed under the truck, during the reversing process.
CameraBehind thetruck
TV Screen on
dash board
Contractor driver Shi Rui was crushed under the wheelsof his truck while attempting a rolling start using asecond truck/ Fumin Project in Yunnan.
Towing process not regulated in the site Camera installed behind all tippers operating in the quarryfor safe reversing
Safety Pictorial Guide: East & South West Asia Region Cement Audits Mobile Equipment SafetyMobile Equipment Safety Equipment ConditionEquipment Condition
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Fatalities: In 2009, a Lafarge employee was run over by a reversing wheel loader which did not have areversing alarm installed.
Payloader operating without reversing alarm andrevolving light
Payloader with reversing alarm, revolving light andreflective paints
Poorly maintained equipment operating at our site Mobile equipment not allowed to operate in the site unlessinspected for fitness
Safety Pictorial Guide: East & South West Asia Region Cement Audits
Defensive Driving Training for drivers include a
Mobile Equipment SafetyMobile Equipment Safety -- DrivingDriving
Drivers not resting properly sleepy while driving
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Defensive Driving Training for drivers, include a
specific module for trailer truck safety focusing onreactions to accident situations (with simulations).
Drivers not resting properly sleepy while driving.
Excessive overloading of vehicles.
Fatalities: In Spain, a driver employed by a contractor died in a collision on his way from Sagunto todeliver clinker to the Cementos Esfera grinding plant.
Diver was feelingsleepy while driving
The tipper had get outfrom material gate atmorning 2.30 AM. Driverlost h is contro l overs t e e r i n g a s he fee lsleepy at round 4:00AM resulting tipper tomove to extreme end ofthe road & toppled ont h e w a y .Driver sustained bruiseand strain on his head.Driver & motor boy bothwere not wear safetyb e l t .
A tipper trolley carryingcoal, was toppled insidec o a l y a r d w h i l eunloading the coal. Theunloading cylinder wasfound bend and it wasfound the tripper wasoverloaded & the driverhad not rested properly.
Nothing happened toany body. But it had thepotentia l for ser iousInjury. The entire truckc a r r y i n g c o a l g o ttoppled on one side.
Overloading prohibited & adhered to for all mobileequipments.
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Safety Pictorial Guide: East & South West Asia Region Cement Audits
Alcohol Tester for mobile equipment operators
Mobile Equipment SafetyMobile Equipment Safety Drugs and AlcoholDrugs and Alcohol
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Alcohol Tester for mobile equipment operators
Site do not have clear guidelines onalcohol and drug testing for operatorsand driversNo instrument to monitor level ofalcohol operators and drivers enteringthe site
Drivers training, motivation &engagement issues (over speeding,non use of stoppers, PPEs noncompliances observed).
Safety Pictorial Guide: East & South West Asia Region Cement Audits Mobile Equipment SafetyMobile Equipment Safety SeatbeltsSeatbelts
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Fatalities: In Pakistan, a driver died in a tragic road accident while trying to stop his truck whose brakeswere not working.
Driver wearing a non-functioning seatbelt
Delivery truck without seatbeltinstalled for driver and passenger
Truck driver wearing a functioning seatbelt.
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Safety Pictorial Guide: East & South West Asia Region Cement Audits Mobile Equipment SafetyMobile Equipment Safety Seatbelts / Reverse alarmSeatbelts / Reverse alarm
No reversing alarm
Forklift with reversing alarm and revolving light. Operator iswearing seatbelt.
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SER: This case is demonstrating the need of wearing seat belt in forklift...even for short / limited operations. Approximately 20 buckets (20kg) of wetmix productfell on top of a forklift truck while being driven by an operator at the Frampton site. The buckets were on a pallet on the top shelf of storage racking. The operatorwas removing a pallet from the shelf below and as he was reversing the top of the vertical back rest on the fork lift truck lifted the cross bar of the storage shelf.The shear bolt activated allowing the wooden shelf to drop causing the top two layers of buckets to topple downwards onto the roof of the FLT. The drivers immediate reaction was to get out of the FLT, but as he was wearing his seatbelt he remained in the cab. The driver was unhurt due to the protective cage.
Operators must remain inside the cab withinoperating areas.
Working without seatbelt
No reversing alarmand revolving light
Safety Pictorial Guide: East & South West Asia Region Cement Audits Mobile Equipment SafetyMobile Equipment Safety ReversingReversing
Stopper arrangement to prevent fall during reversing
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Tyres for buffering any impact during reversal of vehicleMissing edge protection. Trucks reversing during operations
Safety Pictorial Guide: East & South West Asia Region Cement Audits Mobile Equipment SafetyMobile Equipment Safety Vehicle InspectionVehicle Inspection
Daily inspection of mobile equipment and records are maintained forreference.
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Fatalities: In Pakistan, a driver died in a tragic road accident while trying to stop his truck whose brakeswere not working.
Ignition key left in the switch
No reversing alarm Broken rear light
Worn out tire
Inspection tag forevery vehicle
Safety Pictorial Guide: East & South West Asia Region Cement Audits
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Group AdvisoryGroup Advisory -- Working SafelyWorking Safely Around Stockpiles and Surge piles Around Stockpiles and Surge pilesAngle of Repose.
Pedestrian Access - Barricading.
Safety Pictorial Guide: East & South West Asia Region Cement Audits Working Safely AroundWorking Safely Around SurgepileSurgepile and Stockpilesand Stockpiles
Unstable stockpile Typical angle of repose for this type of stockpile
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Stable stockpile, with concrete barrier and isolated frompedestrians
40 deg
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Safety Pictorial Guide: East & South West Asia Region Cement Audits Working Safely AroundWorking Safely Around SurgepileSurgepile and Stockpilesand Stockpiles
Stable stockpile, with covers (tarpaulin) and isolated from
d
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No Retainer for loose stockpile resulting in spreading ofmaterials which could cause skidding of heavy vehicles
Alternative fuel not properly barricadedpedestrians
Safety Pictorial Guide: East & South West Asia Region Cement Audits Working Safely Around Surge pile and StockpilesWorking Safely Around Surge pile and Stockpiles
W k t di g t l
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SER: The Event - A Caterpillar D9T dozer rolled of a turn down the slope of a stockpile. The operator was pushing limestone as required on the top of asecondary surge pile. In the process of backing up, the dozer went too close to the piles outer edge and could not recover, it lost traction and slid down the edge ofthe pile. The operator was wearing his seatbelt and the dozer was equipped with a Roll Over Protection Structure (ROPS). The operator was not injured. He stayedinside the enclosed cab until help arrived. The dozer sustained limited damage. The repair cost was approximately $35,000 resulting in 3 weeks of downtime.
Worker standing too closeto the moving equipment
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Group AdvisoryGroup Advisory -- Confined Space EntryConfined Space EntryConfined Space Entry Permit.Visible Signage on Entry Door.Secure & Lock Entry Doors.Emergency Rescue System in Place.Well Laid out Procedures.Activity performed only by Trained Persons.Clear Identification Outside on who is Inside the Confined Space.
Safety Pictorial Guide: East & South West Asia Region Cement Audits Safe Work SystemsSafe Work Systems Confined Space EntryConfined Space Entry
Confined spaces are clearly identified and controls are inplace prior to entry
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Fatality: In China, the victim entered into a hopper and the head has been caught by the breakerdevice, apparently causing immediate death.
Some areas (such as this ball mill) is not considered aconfined space, thus no control measures for CSE isimplemented
place prior to entryUse of unprotected lighting fixtureinside a confined space
Safety Pictorial Guide: East & South West Asia Region Cement Audits
Clear identification and tagging done at the entrance of aconfined space
Safe Work SystemsSafe Work Systems Confined Space EntryConfined Space Entry
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Fatality: Two workers entered the bin through manhole to clean the blockage. Coal sticking on the wallsdetached and engulfed both the worker. One of the worker managed to get out and rushed to bringrescue, victim was dragged out from the chute but died while transporting to hospital.
Confined space with noaccess door to regulate entry
confined space
CSE tag placed at the entranceof a confined space
Safety Pictorial Guide: East & South West Asia Region Cement Audits
All confined space activities are performed bytrained persons, after duly taking the permit
for working in a confined spaceDoing confined space entry without any permitprocedure
Safe Work SystemsSafe Work Systems Confined Space EntryConfined Space Entry
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for working in a confined space.
Fatality: To check the stock of additive in the silo, the victim went alone at the silo top, removed thegrill & while introducing the measuring tape, fell in side the silo & died.
Entrant should be above the top of materialbuildup!
p
Person inside a CSE without a designated Entrant /Watchman !
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Safety Pictorial Guide: East & South West Asia Region Cement Audits
1. Group StandardsWorking at Height (WAH)
4. Site StandardsHousekeeping
Table of Content
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Working at Height (WAH)Energy Isolation (includes conveyor &LOTOTO advisories)
PPE
2. Group AdvisoriesMobile EquipmentStockpile & Surge PileConfined Space
3. Systems & ProcessesRisk AssessmentInspectionsTraining
Emergency Preparedness & Response
HousekeepingSafety in DesignIllumination
Lifting equipment & HoistsCompressed Gases and Hoses
LaboratoryHarbourCoal Shop
5. ManagementLeadership & AdministrationCommunication Signs
Safety Pictorial Guide: East & South West Asia Region Cement Audits
Risk AssessmentRisk Assessment
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Risk AssessmentRisk AssessmentRisks adequately identified, controlled and managed for All Tasks.Risk Assessment done on Site (not in office).
Participation of all involved in task.Refresher Training on Risk Assessment & Hazard Identification.Monitoring and alert system.Review & Audit of Risk Assessment process.
Tool Box Meeting.Management of Risks through Hierarchy of Controls.
Safety Pictorial Guide: East & South West Asia Region Cement Audits
Risk Assessments are done based on sequence of
activities.Hazards are identified based on job steps
Risk AssessmentRisk Assessment
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Hazards are identified based on job steps.Risk level are evaluated based on probability ofoccurrence and severitySpecific control measures are evaluated based onhierarchy of control, i.e. elimination, substitution /isolation, engineering and administrative controls. PPE isthe last control identified.
Drop Zone ??? Watcher???Safety Latch??? Trailing Rope
Entering into the manhole ???
Safety Pictorial Guide: East & South West Asia Region Cement Audits
Control measures are clear and specific to thehazard and consequence identified in theassessment
Risk AssessmentRisk Assessment
Generic control measures
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assessment.
Lafarge standard, advisories and controlmeasures are the basis of control measures.
Safety Pictorial Guide: East & South West Asia Region Cement Audits Risk AssessmentRisk Assessment
Poor system of Hazard Identification andControl
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Standing tooclose to unstableload
Work at heights
No PPE
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Safety Pictorial Guide: East & South West Asia Region Cement Audits
No visible evidence to show that toolbox
meetings are being held regularly.
10 risk assessments are selected per month & is reviewedby a taskforce team (comprising representatives from
maintenance, production, safety, etc.) to brainstorm andenhance the quality of those risk assessments.
Risk AssessmentRisk Assessment
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Toolbox meeting held regularlyRisk assessment being done only forselect major jobs, not for all tasks(regardless of routine, non-routine, majorand minor).
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Safety Pictorial Guide: East & South West Asia Region Cement Audits InspectionsInspections ToolsTools
Gas regulator ind d
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Substandard clip used forpressurized hose
Broken glass of oxy-
acetylene regulator
Crimped type fitting usedfor pressurized hose
good condition
Safety Pictorial Guide: East & South West Asia Region Cement Audits InspectionsInspections ToolsTools
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Broken tools still used onsite
Broken handle ofa sledge hammer
Safe and standard tools
Safety Pictorial Guide: East & South West Asia Region Cement Audits InspectionsInspections ToolsTools
Contractor tools and equipment pass through safetyinspection, prior to use.
Broken lanyard
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Verified by safety
Lever block withoutsafety latch
Safety Pictorial Guide: East & South West Asia Region Cement Audits InspectionsInspections Tools & TacklesTools & Tackles
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Fatality: electrocution
Unreliable grounding tool for welding machine
Standard grounding clampfor welding works
Safety Pictorial Guide: East & South West Asia Region Cement Audits
Inspections are noted and reviewed bythe team for proper action
InspectionInspection Safety ObservationSafety Observation
Supervisors not fully participating in H&SinspectionSenior management not consistently doing
Nov '07 Dec '07 Jan '08 Feb '08 Mar '08 Apr '08
MONTHKPI
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Senior management not consistently doingH&S observations.Inspections are focused on operations issues. Safety & improvement of sitestandards gets a lower priority.
No periodic safety specific patrol, tocapture issues like house keeping,spillages, missing railings & guarding, looseelectrical wiring, unsafe behaviors.No proper tracking/Monitoring ofobservation result per Department /section of the plant.
No. of Audits Made 63 33 61 37 107 89
No. of audit findings 179 30 73 225 198 138
UA per man-hour 0.7811 0.7814 0.3347 0.4157 0.3536 0.4662
No. of auditors with 2or more audits
conducted
17 11 14 29 28 21
Safety Main t Product ion Admin-Gen Finance Opt i -Envi TotalNb of actions 36 43 46 7 4 7 143Nb of actions completed 35 31 40 6 4 7 86%Nb of actions not starte 0 5 2 0 0 0 5%Nb of actions on going( < 50% completed ) 0 3 4 0 0 0 5%
Nb of actions on going(> 50% to < 100 %
completed )
1 4 0 1 0 0 4%
Safety Pictorial Guide: East & South West Asia Region Cement Audits
Inspections are noted and reviewed by the team forproper action
InspectionInspection Work Area InspectionWork Area Inspection
Inspection Log without entry
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Inspection not consistently done
Inspection record
Safety Pictorial Guide: East & South West Asia Region Cement Audits InspectionInspection Work Area InspectionWork Area Inspection
Inspections are noted and reviewed by the team forproper action
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Inspection record
Safety Pictorial Guide: East & South West Asia Region Cement Audits
Inspections are noted and reviewed by the teamfor proper action
InspectionInspection Preventive Maintenance and TestingPreventive Maintenance and Testing
Poor system of area inspection
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Deteriorating equipment condition not acted upon
Broken pull switch handle not reported for correction
Oil leaks trip hazard
Safety Pictorial Guide: East & South West Asia Region Cement Audits
TrainingTrainingTraining Matrix Who needs training on what!
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Training Matrix Who needs training on what!Tracking system for training undergone by people.Use of Good & Effective training tools & material.
Specific Focus on Contractor safety Training.
Safety Pictorial Guide: East & South West Asia Region Cement Audits
Systematic tracking system of trainingundergone for specific mobile equipments.
TrainingTraining TrainingTraining ScheduleSchedule
No structured training matrix for all level
of staffs (including what is mandatory,compulsory and optional for a specificrole).
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No systematic tracking system of trainingundergone for specific mobile equipments.
Safety Pictorial Guide: East & South West Asia Region Cement Audits
Systematic tracking system of trainingundergone for specific mobile equipments.
TrainingTraining TrainingTraining ScheduleSchedule
No system of training for contractors and
visitorsSite- specific training for new facilities notbeing done
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being donefire alarm system in not fullyunderstood
Training on use of Mobile ElevatedWorking Platform (MEWP) not done
Safety Pictorial Guide: East & South West Asia Region Cement Audits
Use of training tools for easy awareness andunderstanding
TrainingTraining
One size Fits all training program No specific training / coaching based onindividuals profile (do competencemapping & then design which training for
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mapping & then design which training forwhom!!).
Need to plan the refresher trainings &higher frequency for some of the plantpopulation (contractor workers, payloader operators, lab team, guards,dispatchers, packers/loaders etc.).
No effective training program for supervisors.
Use of magnetic
pieces of PPE ,used as a trainingtools for easyawareness andunderstanding.
Safety Pictorial Guide: East & South West Asia Region Cement Audits
Use of training tools for easy awareness andunderstanding
TrainingTraining
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Safety Pictorial Guide: East & South West Asia Region Cement Audits CSMCSM Roles and Responsibili tiesRoles and Responsibili ties
Contractor Safety Management standard is not
well communicated to regular employees.Roles of management and contractors are notclearly identified.
Contractor Safety Training is conducted beforecontractor personnel are allowed to work inany Lafarge site.
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No formal training of contractors regardingCSM and the Lafarge HS standard andadvisories.
Safety Pictorial Guide: East & South West Asia Region Cement Audits CSMCSM Roles and Responsibili tiesRoles and Responsibili ties
Contract Management procedure is in place.
BU HS Coordinator is a signing authority of POfor CAPEX items.
Plant feedback is not duly considered beforefinalization of contract.
Contractors were found doing unsafeoperations, but no clear penalty clause existsfor contracts.
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Penal action, against safety non compliance, isdefined in the Purchase Order.
Safety Pictorial Guide: East & South West Asia Region Cement Audits
Emergency PreparednessEmergency PreparednessEstablished Emergency Response Plan.
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Fire Suppression system Extinguishers, Hydrants.Quality & Condition of equipments Inspections.
Periodic Review, Mock Drills, Testing.Electrical Safe Work Practices.Restricted Entry in Risky Areas.
Emergency Exit Doors.First Aid, Ambulance, Medical Support.
Labeling & Signage.
Safety Pictorial Guide: East & South West Asia Region Cement Audits Emergency PreparednessEmergency Preparedness Emergency Response PlanEmergency Response Plan
Inadequate site emergency response plan, that include:
not updated telephone numbers, contact personsand emergency response team membershipnot addressing all types of emergencies thathave a high probability of occurring
Emergency Preparedness and Response procedureclearly posted on prominent locations and wellcommunicated
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g p y glimited Assembly Areas
Unclear notification procedure (areas of the emergencyand containment of emergency or re-entry plan)
Not updated emergency telephone numbers
Safety Pictorial Guide: East & South West Asia Region Cement Audits Emergency PreparednessEmergency Preparedness Fire ExtinguishersFire Extinguishers
Missing fire extinguisher
Fire extinguisher mounted on
site and periodically inspected
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Poorly maintained fire extinguisher lever filled with dust
Safety Pictorial Guide: East & South West Asia Region Cement Audits Emergency PreparednessEmergency Preparedness Water Storage and Hose SystemsWater Storage and Hose Systems
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Poorly maintained fire hydrant system
Well maintained fire fighting facility
Periodic inspection being done for all fire fightingequipment
Safety Pictorial Guide: East & South West Asia Region Cement Audits Emergency PreparednessEmergency Preparedness Water Storage and Hose SystemsWater Storage and Hose Systems
Hydrant hose not properly rolled trapped water can cause deterioration
Properly rolled hydrant hose in cabinet
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Hydrant valve without cover
Deteriorated hydrant hose
Hydrant valve with cover
Safety Pictorial Guide: East & South West Asia Region Cement Audits Emergency PreparednessEmergency Preparedness Water Storage and Hose SystemsWater Storage and Hose Systems
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Non-operational fire fighting equipment
Periodic testing of fire fighting equipment
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Safety Pictorial Guide: East & South West Asia Region Cement Audits Safe Work SystemsSafe Work Systems Electrical Safe Work PracticeElectrical Safe Work Practice
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Substation door with luminous EXIT sign butno emergency panic bar
Substation door without luminous EXIT sign and emergency panic bar
Substation door with luminous EXIT sign and emergency panic bar
Panic bar
Panic bar
Safety Pictorial Guide: East & South West Asia Region Cement Audits
Substation used as storage/ parking area Electrical substation restricted for entry
Safe Work SystemsSafe Work Systems Electrical Safe Work PracticeElectrical Safe Work Practice
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Substation used as dwelling area
Safety Pictorial Guide: East & South West Asia Region Cement Audits
Un insulated floors of motor control center
Safe Work SystemsSafe Work Systems Electrical Safe Work PracticeElectrical Safe Work Practice
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Tools are kept besideHV panels
Insulation mats are provided at front and rear of MCCs
Safety Pictorial Guide: East & South West Asia Region Cement Audits
No warning sign or lock installed. Free accessto high tension cables.
Restricted access to risky areas.
Properly locked / secured entrance door ofelectrical room
Safe Work SystemsSafe Work Systems Electrical Safe Work PracticeElectrical Safe Work Practice
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Fatalities: In Cameroon, an operator in a subcontracting civil engineering company, died fromelectrocution.
Unlocked access door of electrical room
Safety Pictorial Guide: East & South West Asia Region Cement Audits
Properly labeled electrical panelElectrical panels without label
Safe Work SystemsSafe Work Systems Electrical Safe Work PracticeElectrical Safe Work Practice
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SER: A serious explosion occurred & section stoppage happened, when an electrician mistakenly drew out an energizedvacuum circuit breaker. This could have been avoided if all VCB (visible circuit boards) in the substation had proper labels onthem.
Safety Pictorial Guide: East & South West Asia Region Cement Audits
Properly labeled electrical panelElectrical panels without label
Safe Work SystemsSafe Work Systems Electrical Safe Work PracticeElectrical Safe Work Practice
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SER: A serious explosion occurred & section stoppage happened, when an electrician mistakenly drew out an energizedvacuum circuit breaker. This could have been avoided if all VCB (visible circuit boards) in the substation had proper labels onthem.
Safety Pictorial Guide: East & South West Asia Region Cement Audits Health, Safety and Environmental ControlsHealth, Safety and Environmental Controls
First Aid kits available on all areas
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Ambulance with designated drivers
Safety Pictorial Guide: East & South West Asia Region Cement Audits Health, Safety and Environmental ControlsHealth, Safety and Environmental Controls
Hazardous areas are labeled andsafety instructions are clearly posted
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Noise level determined and measuresare posted to control the hazard
Safety Pictorial Guide: East & South West Asia Region Cement Audits
Audit Elements
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/asa
East and SouthEast and South -- West Asia RegionsWest Asia RegionsVersion 1: Dated 25th Jan 2010Version 1: Dated 25th Jan 2010
H&S Pictorial GuideH&S Pictorial Guide
Chapter 4/5: Site StandardsChapter 4/5: Site Standards
Safety Pictorial Guide: East & South West Asia Region Cement Audits
1. Group Standards
Working at Height (WAH)Energy Isolation (includes conveyor &LOTOTO advisories)
PPE
4. Site Standards
HousekeepingSafety in DesignIlluminationLifting equipment & Hoists
Table of Content
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/asa
2. Group Advisories
Mobile EquipmentStockpile & Surge PileConfined Space
3. Systems & ProcessesRisk AssessmentInspectionsTrainingEmergency Preparedness & Response
Compressed Gases and HosesLaboratory
HarbourCoal Shop
5. ManagementLeadership & AdministrationCommunication Signs
Safety Pictorial Guide: East & South West Asia Region Cement Audits
HousekeepingHousekeepingKey Priority.Managing Scrap & Unusable Items.
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Storage Facilities.
5S Housekeeping Process.Clean walkways Trip Hazards.
Safety Pictorial Guide: East & South West Asia Region Cement Audits Site StandardsSite Standards Storage Facili tiesStorage Facili ties
Poor system of managing scrap & usable items.
Storage area for usable and scrap itemsshould be fenced and entry shall beregulatedThere should be two entry/exit points in astorage area.
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/asa
The area should be located such that theuse of cranes are possible without creatingany hazard to personnel.Storage area shall be designated far fromany overhead electrical lines, HV lines andoverhead installations.
No segregation of larger, heavier items andlight materials
Storage area can be accessed by unauthorizedpersonnel
1. Seiri : Sorting / Segregating
2. Seiton : Self arrangement
3. Seiso : Spic & Span
4. Seiketsu : Standardization
5. Shitsuke : Self Discipline
5 S for Good Housekeeping
Safety Pictorial Guide: East & South West Asia Region Cement Audits
Poor system of managing scrap & unused items.
Site StandardsSite Standards Storage Facili tiesStorage Facili ties
Usable items mixed with scraps
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Usable items are kept in racks
Items are segregated according to size and weight
Safety Pictorial Guide: East & South West Asia Region Cement Audits
Pipes stored in a enclosed section
Site StandardsSite Standards Storage Facili tiesStorage Facili ties
Scraps are dumped in various locations
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Bins placed to dump the items
Post-shutdown materials are left at site
Safety Pictorial Guide: East & South West Asia Region Cement Audits Site StandardsSite Standards Walkways / HousekeepingWalkways / Housekeeping
Clean walkway without obstruction
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Cables are laid out along the walkway
Hoses and welding cables laid out along the stairway
Clear stairway free from trip hazards
Safety Pictorial Guide: East & South West Asia Region Cement Audits Site StandardsSite Standards Walkways / Housekeeping SafetyWalkways / Housekeeping Safety
Material spillagesalong access way
Access way free from materialbuild ups and accumulation
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Safety Pictorial Guide: East & South West Asia Region Cement Audits
Safety in DesignSafety in DesignSafety in Design (e.g. Face Shields, Guards, Barriers) .Restricted Access.St F iliti
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Storage Facilities.
Blasting Shelter
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Safety Pictorial Guide: East & South West Asia Region Cement Audits Site StandardsSite Standards Access ways Access ways
Mill with no barrier around and no proper accessplatform for entering into into manhole
Ball mill complete with barriers and accessplatform
No fall protection above the mill
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Unsecured fence around the ball mill
No platform above the mill
Unsecured landing area
Safety Pictorial Guide: East & South West Asia Region Cement Audits Specific ShopsSpecific Shops Explosives and ChargingExplosives and Charging
There is an existing procedure to limit the
quantity if explosives available in the area.Storage for explosives are gazetted asrestricted area whereby proper separation isdoneThere is an established procedure for securing
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the quarry before any blasting operation isinitiated.
Vegetation within the vicinity of explosive magazine
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Safety Pictorial Guide: East & South West Asia Region Cement Audits Site StandardsSite Standards Storage Facili tiesStorage Facili ties
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No secondary containment in case of leaks or spillsFuel storage with secondary containment and isolated fromother structures
Safety Pictorial Guide: East & South West Asia Region Cement Audits Specific ShopsSpecific Shops Explosives and ChargingExplosives and Charging
Person B
Person A
Blasting shelter provided on siteduring blasting activities
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Fatality: In Nigeria, Ewekoro quarry (Wapco), an employee was killed while attempting to perform ablast in the quarry.
Person A
Persons C,D
People within close vicinity from theblasting site without protection
Safety Pictorial Guide: East & South West Asia Region Cement Audits
Illumination, Rest Rooms, Shelter Illumination, Rest Rooms, Shelter Proper Lighting & Illumination at site.Testing & monitoring Illumination Levels.Mobile Lighting.
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g g
Proper & Sanitized Resting Facilities for Workers.
Safety Pictorial Guide: East & South West Asia Region Cement Audits Site StandardsSite Standards -- IlluminationIllumination
Good illumination in the process linePoor illumination in the process line
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Inadequate lighting system inthe process line
Storage area with non-explosion proof lighting above
flammable liquids
Inadequate lighting system in the process line
Proper lighting system provided in the process line
Illumination level tested in the process line
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Safety Pictorial Guide: East & South West Asia Region Cement Audits Site StandardsSite Standards IlluminationIllumination
Poorly maintained lighting fixtures Proper lighting system provided in the process line
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Cobwebs covering the florescent tube Blurred floodlight glass
Hardened cement dust on floodlight Hanging cover of florescent fixture
lighting fixtures provided inevery level of pre-heater tower
Safety Pictorial Guide: East & South West Asia Region Cement Audits Site StandardsSite Standards Restrooms, Lunchrooms and LockersRestrooms, Lunchrooms and Lockers
Substandard resting facilities
Makeshift restroom with defective chairs in untidy area
Good resting facility for workers
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Makeshift restroom beside charged electrical panels Sanitary toilet and wash room
Safety Pictorial Guide: East & South West Asia Region Cement Audits Site StandardsSite Standards Restrooms, Lunchrooms and LockersRestrooms, Lunchrooms and Lockers
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Workmen sleeping at site and the cable drumkept very near to them in unstable condition.
No proper resting shelter at site.Proper resting shelter at site.
Safety Pictorial Guide: East & South West Asia Region Cement Audits
Lifting Equipment & HoistLifting Equipment & HoistSafety Latch & Limiting Switch.P ki f H i & P d S i h
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Parking of Hoist & Pendant Switch.Storage & Inspection of Hoists & Lifting Devices.Quality & Inspection of Lifting Ropes Inspection Tags.Proper Mounting of Lifting Devices.
Free Movement of Hoisting Equipment.
Safety Pictorial Guide: East & South West Asia Region Cement Audits Site StandardsSite Standards Lift ing DevicesLift ing Devices
Chain block withdefective safety
latch
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Chain block withoutsafety latch
Chain blockwith good
safety latch
Safety Pictorial Guide: East & South West Asia Region Cement Audits Site StandardsSite Standards Lift ing DevicesLift ing Devices
Hoist pendant switch is locked whereby the key iskept by a certified hoist operator or Area Owner.
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Fatalities: A contractor in Malaysia died after the hook block of an overhead crane fell and hit him.The hook was suspended above a working area.
Hoist pendant switchunsecured and lying on
the platform
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Safety Pictorial Guide: East & South West Asia Region Cement Audits
Hoists and lifting devices not properly stored Hoists and lifting devices properly stored &inspected. Visible inspection tags in place.
Site StandardsSite Standards Lift ing DevicesLift ing Devices
Unused hoist not properly stored
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Usable lifting cables mixed with defective ones, notproperly stored
Safety Pictorial Guide: East & South West Asia Region Cement Audits
Hoists and lifting devices not properly stored Hoists and lifting devices properly stored &inspected. Visible inspection tags in place.
Site StandardsSite Standards Lift ing DevicesLift ing Devices
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Usable lifting cables mixed with defective ones, notproperly stored
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Safety Pictorial Guide: East & South West Asia Region Cement Audits
Poor procedure to mount lifting devices..
Site StandardsSite Standards Lift ing DevicesLift ing Devices
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Fatalities: In Morocco, a mechanic working at the extension site of the Ttouan plant killed by a fallingcrane block.
Lifting device mounted on aframe latch become useless
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Safety Pictorial Guide: East & South West Asia Region Cement Audits
Compressed Gases & HosesCompressed Gases & HosesSecured Cylinder Bottles (e.g., proper parking, segregation, stored awayfrom heat sources..) .
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Labeling & Signage.Quality of Rubber Hose.Quality of Cylinders (e.g., free of dents, corrosion..).
Safety Pictorial Guide: East & South West Asia Region Cement Audits
Unsecured cylinder bottles. Secured cylinder bottles
Site StandardsSite Standards Compressed GasesCompressed Gases
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Proper segregation of filled and emptycylinders, chained and gated.
Free-standing cylinders
Safety Pictorial Guide: East & South West Asia Region Cement Audits
Poor quality of rubber hoses. .
Site StandardsSite Standards Hoses and CablesHoses and Cables
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Safety Pictorial Guide: East & South West Asia Region Cement Audits
LaboratoryLaboratory
Restricted Access.Storage of Hazardous Chemicals.Emergency Eye Wash & Body Shower.
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Safety Equipments For Hot Material, Fume Hood.Radiation & X-Ray Protection.Secured Gas Cylinder.
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Safety Pictorial Guide: East & South West Asia Region Cement Audits
Chemical bottles properly segregated,labeled and stored in a safe place.
Specific ShopsSpecific Shops LaboratoryLaboratory Storage & labellingStorage & labelling
Unlabeled chemical bottles
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All bottles are labeled, even if it contains justwater.
Dangerous chemicalsstored in a safe cabin
Safety Pictorial Guide: East & South West Asia Region Cement Audits
Well maintained eye wash station with reliablewater supply
Specific ShopsSpecific Shops Laboratory Eye Washer Laboratory Eye Washer
Laboratory eye wash station withoutwater supply
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Safety Pictorial Guide: East & South West Asia Region Cement Audits Specific ShopsSpecific Shops Laboratory EquipmentLaboratory Equipment
Safety equipment to handle Hot material in thelaboratory
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Well maintained Fume Hood.
Safety Pictorial Guide: East & South West Asia Region Cement Audits Specific ShopsSpecific Shops Laboratory XLaboratory X --ray radiationray radiation
Radiation Dosi-badge are available tolaboratory personnel
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Safety Pictorial Guide: East & South West Asia Region Cement Audits
Harbour Harbour
Edge Protection Guarded Jetty.Emergency Safety Equipments (e.g. Life Rings, ropes, ladders) .Site Specific PPEs Life Vests.
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Safety Pictorial Guide: East & South West Asia Region Cement Audits
Well guarded jetty
Specific ShopsSpecific Shops Harbour Harbour
Inadequate barrier at jetty. People workingtoo close to the edges.
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Safety Pictorial Guide: East & South West Asia Region Cement Audits Specific ShopsSpecific Shops Harbour Harbour
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Substandard gang plank without railing
Standard gang plank with railing and toe board
No edge protection. Risk for moving & reversingvehicles falling, due to narrow roadway.
Safety Pictorial Guide: East & South West Asia Region Cement Audits
Emergency equipment are readily available.
Specific ShopsSpecific Shops Harbour Harbour
Lack of emergency equipment available in the jetty area
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Corroded emergency ladder
Missing emergency ladder
Life rings
Safety Pictorial Guide: East & South West Asia Region Cement Audits
Emergency equipment are readily available.
Specific ShopsSpecific Shops Harbour Harbour
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Near Miss:One of ship crew fell into the sea while hewas holding the rope during ship berthing
Life vestscompulsoryin Jetty area
No Life vest. Working close to edge of the jetty
Safety Pictorial Guide: East & South West Asia Region Cement Audits
Coal Shop & Burning ShopCoal Shop & Burning Shop
Restricted Access.Fire Safety (e.g., Fire Extinguishers, Hydrants, Explosion proof installations,wooden & plastic showels etc.) .
Explosion Vents
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Explosion Vents.Site Specific PPEs.Warning Signs & Start Up Sign for Cyclone un blocking activity.Emergency Eye Wash & Body Shower Facility.
Safety Pictorial Guide: East & South West Asia Region Cement Audits
Plastic and wooden shovels used at the coal shop
Specific ShopsSpecific Shops Coal ShopCoal Shop
Metallic shovel used at the coal shop
Plastic shovelused in coalshop
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Wooden shovelused in coalshop
Safety Pictorial Guide: East & South West Asia Region Cement Audits Specific ShopsSpecific Shops Coal ShopCoal Shop
N2 suppression system for coal mill
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Fire hydrants available at coal shop area
Safety Pictorial Guide: East & South West Asia Region Cement Audits Specific ShopsSpecific Shops Coal ShopCoal Shop
EXPLOSION flaps facing the access way andinside the building
EXPLOSION flaps facing the atmosphereand away from the building
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Safety Pictorial Guide: East & South West Asia Region Cement Audits Specific ShopsSpecific Shops Coal ShopCoal Shop
Coal Shop without entry restriction Coal Shop building is for authorizedentry only
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Faded warning sign
Safety Pictorial Guide: East & South West Asia Region Cement Audits Specific ShopsSpecific Shops Burning ShopBurning Shop
Personnel not fully protected for hotmeal activities
Heat resistant suit used at the burning shop
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No heat resistant suit /apron and face shield
Safety Pictorial Guide: East & South West Asia Region Cement Audits Specific ShopsSpecific Shops Burning ShopBurning Shop
Personnel not fully protected for kilnactivities
Personnel fully protected for kiln hot works
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Fabricated heat resistant shield
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Safety Pictorial Guide: East & South West Asia Region Cement Audits
Specific ShopsSpecific Shops Burning ShopBurning Shop
Emergency showers at the pre-heater Area
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