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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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    Safety Pictorial Guide: East & South West Asia Region Cement Audits

    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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    Safety Pictorial Guide: East & South West Asia Region Cement Audits

    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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    Safety Pictorial Guide: East & South West Asia Region Cement Audits

    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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    Safety Pictorial Guide: East & South West Asia Region Cement Audits

    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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    Safety Pictorial Guide: East & South West Asia Region Cement Audits

    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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    Safety Pictorial Guide: East & South West Asia Region Cement Audits

    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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    Safety Pictorial Guide: East & South West Asia Region Cement Audits

    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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    Safety Pictorial Guide: East & South West Asia Region Cement Audits

    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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    Safety Pictorial Guide: East & South West Asia Region Cement Audits

    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

    Safety Pictorial Guide: East & South West Asia Region Cement Audits lE I l i fC S f

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    Safety Pictorial Guide: East & South West Asia Region Cement Audits

    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

    Safety Pictorial Guide: East & South West Asia Region Cement Audits Energy IsolationEnergy Isolation Conveyor SafetyConveyor Safety

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    gygy y yy y

    Safety communication campaign is conducted

    to raise awareness regarding conveyor safety.

    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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    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

    Safety Pictorial Guide: East & South West Asia Region Cement Audits Energy IsolationEnergy Isolation Pressurized tanks & vesselsPressurized tanks & vessels

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    Punctured pressurizedhose

    High pressure hose withoutpunctures and with standard

    hose clip

    Safety Pictorial Guide: East & South West Asia Region Cement Audits

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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

    Safety Pictorial Guide: East & South West Asia Region Cement Audits PPEPPE General RequirementsGeneral Requirements

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    Very specific PPE requirements forhazards on site

    Workers taking off their PPE at PPE Zone

    Safety Pictorial Guide: East & South West Asia Region Cement Audits PPEPPE General RequirementsGeneral Requirements

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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

    Safety Pictorial Guide: East & South West Asia Region Cement Audits

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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

    Safety Pictorial Guide: East & South West Asia Region Cement Audits

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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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    /asa

    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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    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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