Safety Audit Report 12020 Chettinad Cement Corporation Pvt

Safety Audit Report – 2020 1

M/s. Chettinad Cement Corporation Private Limited

INTERNAL SAFETY AUDIT REPORT - 2020

Audit Team Members:

1. Mr. A. Narender Reddy, HOD-Mech.

2. Mr. U.P.B Sai Ram, HOD – Process

3. Mr. R. Sreenivasa Babu, HOD – Elect.

4. Mr. R. Laxman Rao, HOD – Inst.

5. Mr. G. Selvam, HOD – Civil

6. Mr. D. M. Subhani, Dy. Manager – Safety.

Other concerned section heads from various departments have also been participated

during internal safety audit in June – 2020.

Chettinad Cement Corporation Pvt. Ltd. Dachepalli Works



CONTENTS

Sec No. Description Page No.

1.0 OBJECTIVE OF SAFETY AUDIT

3

2.0 SAFETY MANAGEMENT SYSTEM 4

3.0 SITE SPECIFIC OBSERVATIONS

& RECOMMENDATIONS

7

4.0 CONCLUSION 13

5.0 ANNEXURES

Safety organization chart

Constitution of Safety Committee

Recent copy of minutes of safety committee

14



1. OBJECTIVE OF SAFETY AUDIT:

The objective of the safety audit is to evaluate the effectiveness of the

company’s safety effort and make recommendations which lead to a reduction in

accidents and minimization of loss potential.

Safety audits are an important part of a company’s control system and these

checks ensure that deteriorating standards are detected. Examination of the

defects exposed in this review results in hazardous conditions and potential

accidents being avoided.

Regular audits should be based on the premise that resources should be made

available to identify and eliminate hazards before accidents occur, rather than

use the resource of manpower and materials only after injuries and damage to

equipment have resulted in human suffering, significant monetary loss which, in

certain circumstances, affect the profitability severely.

Mistaken belief is that, management and sites are operating satisfactorily within

the requirements of appropriate legislation / regulations and standards / codes of

practice is eradicated, and the direct contact with individual workers has as its

aim the resultant change in attitude and commitment to the use of safe working

practices, which continual involvement and education.



2.0. SAFETY MANAGEMENT SYSTEMS

The following are the OH & S management systems implemented at CCCPL,

Dachepalli works.

2.1 OS & H ORGANISATIONAL SETUP:

Organization Chart for OH & S department has been set up and enclosed in the annexure - 5

2.2 SAFETY EDUCATION AND TRAINING:

Awareness program on Work at height, Hot works, Lifting safety, First Aid, Electrical Safety, Machinery Guarding are periodically being conducted and records are available.

Induction training program is being conducted for all new Contractor

workers before entering the plant.

2.3 EMPLOYEES PARTICIPATION IN OS & H MANAGEMENT:

Safety Committee consisting equal participation from workmen and

management meets once in every month, to discuss occupational health

and safety issues. The deliberations of the Safety committee meetings are

minuted and circulated to all concerned for follow up actions.

2.4 MOTIVATIONAL AND PROMOTIONAL MEASURES FOR OS&H:

The following motivational and promotional measures are being practiced, like;

Display of safety posters

Safety week celebrations on the occasion of National safety day and

conducting competitions such as elocution, essay writing, Posters, Slogans,

quiz on safety & health is being held for all the employees and winners are

awarded with prizes.

2.5 COMPLIANCE WITH STATUTORY REQUIREMENTS:

From the company’s records and documents, it was observed that all the

relevant statutory compliances are being met timely.



2.6 SAFETY INSPECTION:

It is observed that periodical safety inspections are being carried out by the

safety team during plant visits.

2.7 FIRST AID FACILITIES – OCCUPATIONAL HEALTH CENTRE : OHC with medical officer & Compounders are available.

2.8 WORK PERMIT SYSTEM

Work permits for 1. Work at heights, 2. Electrical Work, 3.Hot work 4.

Confined space entry 5. Excavation 6. Lifting Plan for lifting activities are

existing and being implemented in daily maintenance works.

2.9 FIRE PREVENTION, PROTECTION AND FIGHTING SYSTEMS: Fire

extinguishers are in place at site locations, however installation of fire-fighting equipment is in progress.

2.10 EMERGENCY PREPAREDNESS PLANS (ON-SITE) :

On-site Emergency Plan is prepared for attending emergencies effectively.

Mock drills being conducted quarterly for the awareness of the workers

and also getting familiar, how to act at emergencies.

2.11 CONTRACTOR SAFETY SYSTEMS: CSS are in place and all the workers are undergoing medical health checkups before their entry and undergoing safety induction before being deployed at site.

2.12 MACHINE& GENERAL AREA GUARDING

It was observed that for all the rotating equipment, guarding has been

provided.



2.13. PERSONAL PROTECTIVE EQUIPMENT:

It was observed that the organization is supplying the primary PPE such as

helmets, safety shoes, High Visibility Reflective Jackets (HVRJ) and other

required respiratory & non respiratory PPE as per the work requirement.

However usage of personal protective equipment by employees is evident.

2.14 SAFETY BUDGET: It is to be appreciated that Organization has allocated the required funds

for the safety provisions and can be used for improving the safety systems



3.0 SITE SPECIFIC OBSERVATIONS & RECOMMENDATIONS

3.1 MINES & EXPLOSIVE MAGAZINE: 1. A stand by Emergency vehicle like Ambulance at mines is recommended.

2. Risk assessment for explosives to be prepared for better threat zones

identification.

3. Reverse horn is to be made mandatory and Rear view camera is

recommended for heavy vehicles in mines.

4. It is suggested that Gate can be Earthed for discharging of Static electricity, date of testing and values are mentioned on the earth pits.

5. PESO license was renewed and updated on display board at Mines

entrance.

6. Recommended study on provision of lightening protection at explosive

storage area.

7. Do’s and don’ts at Explosive Magazine to be displayed in local language

to educate/worn local Village people.

8. As dipping system is in practice it is still recommended to install Earth

dissipating pads before entering the explosive room.

9. Explosive Magazine/stores should be covered under surveillance

cameras.



3.2 ELECTRICAL PANEL ROOMS :

10. Rubber Mats have been provided

11. Double Earthing for the HT / LT panels is visible

12. Fire extinguishers and sand are in place

13. Earth Discharge rods are facilitated in MCCs

14. Earth pits at all areas to be mentioned with Date of inspection, Due-date

and Resistivity values as per IE rules

15. First Aid for electrical shock chart was displayed.

3.3 Lifting Machineries/ Lifting Tools & Tackles/ Air Blasters & Air Receivers All the Lifting Machineries/ Lifting Tools & Tackles/ Air Blasters & Air Receivers have been tested, certified, visibly marked at site for easy identification.





3.4 STORES:

1. Safety posters and Signages could be displayed

2. Safe Exit routes to be displayed inside the stores to escape at earlier time

3. Smoke detectors with alarm system to be installed to identify the fire in no

time

4. According to NFPA rules Fire Extinguishers should be placed 1.5mts

above the ground, it is maintained.

3.5 FLY ASH:

Tanker test certificate and also PRV test certificate to be verified at gate

to know the integrity of the tank.

All Pressure parts like hoses and pipe lines to be tested and certified.

3.6 PACKING PLANT:

High priority to be given for secondary method of loading bags as Human

interface during loading of bags is at very high risk

Occupational Health conditions to be monitored as the staff at packing plant

are being exposed to cement dust for long hours

Vehicle moving forward during loading to be studied and better techniques

to be followed to avoid incidents at loading bay.

Control gun to be installed at the end of the pressure air line which was

being used for cleaning purpose bag loading area.

Good Manual handling techniques are to be covered in the training needs

of the staff working at packing plant.

3.7 CHEMICAL LAB:

All Cylinders to be dragged out from lab and to be stored outside

as it is a high risk to store Explosive cylinders inside the labs



LPG and Solvents usage area to be equipped with Flame proof

fittings to avoid the ignition point and also Oxygen analyzer is

required to identify the oxygen levels at all times

Usage of PPE for handling acids and solvents should be made

mandatory at Labs.

Compatibility charts to be displayed for all chemicals being used in the Lab

All MSDS important points to be displayed at labs for easy

understanding about the Chemical

3.8 NITROGEN TANKS AND PIPE LINES

Nitrogen Tanks and Pipelines are identified with color coding but

flow directions has to be given as it is a harmful if inhaled.

Nitrogen Lines to be pressure tested to know the integrity before

giving chance for an incident to happen

Nitrogen tanks are tested & certified by the competent person as

per statutory requirement.

3.9 OCCUPATIONAL HEALTH CENTER:

Taking Plant Manpower into consideration, OHC facility is

arranged.

Female Nurse/ Compounder can be recruited.



3.10 AMBULANCE:

1) Ambulance is facilitated at site.

3.11 ELECTRICAL DOCUMENTATION:

1) Earth pit records are being maintained and also resistivity values for

lighting arrestors (Earth Pits) are being recorded and maintained.

2) Earth pit values for Lightening arrestors are being recorded.

3) Electrical Calibrations to be done under NABL accreditation.

4) As it is mentioned by Director of Factories an Electrical Safety Officer is to

be appointed.

5) Electrical Job-Oriented trainings frequency is to be increased



4.0 CONCLUSION

It is well-known fact that incidents do happen when huge activity goes on in any

massive production unit based on man-machinery interface. The management

should implement appropriate methods to avoid / reduce the severity of the

incidents. This is only possible by opting well-accepted safe operation

philosophy, by imparting training, improvement of workmen attitudes, behavior

and proactive approach of Senior and Middle management. As a whole, it is

inculcating the safety culture among the employees of the organization.

The Management of CHETTINAD CEMENT CORPORATION PRIVATE

LIMITED at Dachepalli works has implemented good safety health and

environment and other management systems. They have developed and

implemented safe and environmental friendly practices.

In order to maintain the HSE system with achievements made in the past, extra

efforts are needed on the part of the area managers. They should lead their

people, working under them, to be vigilant all the time and their behaviors should

be reinforced again and again to achieve the desired goal of zero incidents.



5.0. ANNEXURES

Page 1 of 4

Chettinad Cement Corporation Private Limited Dachepalli Works

Minutes of Safety Committee Meeting held on 27th

June 2020

Attendees of the Meeting :

S. No Name of the Member Designation & Department

Organization

1 K Chandrasekhar Vice President - Projects CCCPL

2 G. Selvam AVP - Civil CCCPL

3 A. Narender Reddy Sr. GM - Projects CCCPL

4 V. Chandra Sekar Rao GM - QUAS CCCPL

5 R. Laxman Rao GM - Instrumentation CCCPL

6 Sreenivasa Babu. B R GM - Electrical CCCPL

7 H. Sai Prasad GM – HR & Admin CCCPL

8 R.Ravichandran DGM - WHR CCCPL

9 C Phanidhar AGM Mines CCCPL

10 Sri Rama Chandra Murthy Chief Security Officer CCCPL

11 D Mahaboob Subhani Dy. Manager - Safety CCCPL

12 Balivendar Singh Foreman – Mech. ESPEETECH

13 Venkata Krishna Technician – Elect. CCCPL

14 Hasan Babu Technician – inst. SLE

15 Manikanta Sample Boy – QUAS Uma Maheshwara Reddy

16 D Rajesh Kumar Officer - Safety ESPEETECH

Page 2 of 4


Substitutes in place of Absentees :

S. No Name of the Employees/ Worker

Designation & Department

Organization

1 A Ramesh Sr. Manager - Operations

CCCPL

2 G Sreenivasulu Manager - HR CCCPL

3 S Gopi Krishna Project Manager ESPEETECH

4 A Ramesh Ex. Operator - Mines Laxmi Earth Movers

5 P Naga Maheswara Rao Attendant - Opearations Vasu Technical Services

Agenda Of the Meeting :

Safety Statistics for Previous & Current Months.

Near Miss Reporting

Safety Developments

Observations during Internal Safety Audit

Previous meeting pending/on going points

New observations/ points raised.

Path Forward.

Page 3 of 4


Points Raised during Safety Committee Meeting:

Sl. No

ISSUES Issue Raised by

Responsibility

Target Date Priority

MECHANICAL DEPARTMENT

1

At the side of Mines weigh

bridge, hand railing has to be

provided. Girders can also be

provided at all the four cornors

of entrance & exit

C.

Phanidha

r Mines

ANR 20.07.2020 Medium

2

A stair case can be provided for

approaching top for stack

monitoring.

Hasan

Babu –

Inst.

ANR Planning for

Spiral type

stair case.

Medium

3

Preheater: An approach platform

can be provided for thermo

couples for safe maintenance

during operation.

Hasan

Babu ANR 31.07.2020 Medium

Civil Department

1

Speed breakers between main gate

& project office have been

damaged, to be re constructed.

Rajesh -

Safety GS 30.07.2020 Low

2

Children park in colony: Gorund

can be filled with more sand to

avoid injuries to children.

C.

Phanidhar -

Mines

Welfare 25.07.2020 Medium

Electrical Department

1 All the electrical connections can

be reouted through ELCBs/ RCCBs. RLR SBR 31.07.2020 Medium

2

All the welding Machines and

portable electrical equipment can

be checked and provided with a

inspection sticker periodically.

ANR SBR For

Information Medium

Safety Department

Page 4 of 4


1 Electrical Safety Audit can be

conducted as per corporate format.

SBR Safety /

Elect.

25.07.2020

Medium

2

Road side reflectors are not

working, at steep turnings of road

(From plant gate –

Tummalacheruvu road) blinkers/

amber lights can be provided for

cautioning the drivers.

SBR Safety /

Elect.

31.07.2020

Medium

3 Safety Signages has to be

displayed at approach to Main gate.

GS - HR Safety 30.07.2020

Low

Security Department

1.

Security Guard deputed at

dachepalli road in our mines can be

instructed to ensure safe crossing

of tippers with signal lights.

C

Phanidhar

Mines

CSO 05.07.2020

Medium

Miscellaneous

1. Best Safety Suggestion will be

awarded.

VP -

Projects

All

For Information

2 Gate Meeting can be conducted on

first Monday of the month.

VP -

Projects

All

For Information

3.

All buildings: Housekeeping can be

done, unnecessary materials have

to be removed.

GS All

concern

ed

For

Information Low

5.

Cross Department housekeeping to

be done every fortnightly, weekday

will be intimated accordingly.

HSP All

departm

ents

20.07.2020

Low

D Mahaboob Subhani Dy. Mgr Safety & Convener – Safety Committee Meeting.

Documents

Safety Audit Report 12020 Chettinad Cement Corporation Pvt