Safety Audit Report – 2020 1

Chettinad Cement Corporation Pvt. Ltd.

Dachepalli Works

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.

M/s. Chettinad Cement Corporation Private Limited

 Safety Audit Report – 2020 2

CONTENTS

Sec No. Description Page No.

1.0 OBJECTIVE OF SAFETY AUDIT

3

2.0 SAFETY MANAGEMENT SYSTEM 4

3.0 SITE SPECIFIC OBSERVATIONS 7

& RECOMMENDATIONS

4.0 CONCLUSION 13

5.0 ANNEXURES 14
 Safety organization chart
 Constitution of Safety Committee
 Recent copy of minutes of safety committee

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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.

M/s. Chettinad Cement Corporation Private Limited

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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.

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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.

 
M/s. Chettinad Cement Corporation Private Limited
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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

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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.

M/s. Chettinad Cement Corporation Private Limited

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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.

M/s. Chettinad Cement Corporation Private Limited

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M/s. Chettinad Cement Corporation Private Limited

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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

M/s. Chettinad Cement Corporation Private Limited

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 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.
M/s. Chettinad Cement Corporation Private Limited
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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

M/s. Chettinad Cement Corporation Private Limited

 Safety Audit Report – 2020 13

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.

M/s. Chettinad Cement Corporation Private Limited

Safety Audit Report – 2020 14

5.0. ANNEXURES

M/s. Chettinad Cement Corporation Private Limited

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 & Organization
Department
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

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Chettinad Cement Corporation Private Limited
Dachepalli Works

Substitutes in place of Absentees :

S. No Name of the Designation & Organization
Employees/ Worker Department
1 A Ramesh Sr. Manager - CCCPL
Operations
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.

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Chettinad Cement Corporation Private Limited
Dachepalli Works

Points Raised during Safety Committee Meeting:

Sl. Issue Respons Priority
ISSUES Target Date
No Raised by ibility

MECHANICAL DEPARTMENT
At the side of Mines weigh
bridge, hand railing has to be C.
1 provided. Girders can also be Phanidha ANR 20.07.2020 Medium
provided at all the four cornors r Mines
of entrance & exit
A stair case can be provided for Hasan ANR Planning for
2 approaching top for stack Babu – Spiral type Medium
monitoring. Inst. stair case.
Preheater: An approach platform
can be provided for thermo Hasan
3 ANR 31.07.2020 Medium
couples for safe maintenance Babu
during operation.

Civil Department
Speed breakers between main gate
Rajesh -
1 & project office have been GS 30.07.2020 Low
Safety
damaged, to be re constructed.
Children park in colony: Gorund C.
2 can be filled with more sand to Phanidhar - Welfare 25.07.2020 Medium
avoid injuries to children. Mines

Electrical Department
All the electrical connections can
1 RLR SBR 31.07.2020 Medium
be reouted through ELCBs/ RCCBs.

All the welding Machines and

portable electrical equipment can For
2 ANR SBR Medium
be checked and provided with a Information
inspection sticker periodically.

Safety Department
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Chettinad Cement Corporation Private Limited
Dachepalli Works
SBR Safety / 25.07.2020
Electrical Safety Audit can be Elect.
1 Medium
conducted as per corporate format.

Road side reflectors are not SBR Safety / 31.07.2020

working, at steep turnings of road Elect.
(From plant gate –
2 Medium
Tummalacheruvu road) blinkers/
amber lights can be provided for
cautioning the drivers.
GS - HR Safety 30.07.2020
Safety Signages has to be
3 Low
displayed at approach to Main gate.

Security Department
C CSO 05.07.2020
Security Guard deputed at Phanidhar
dachepalli road in our mines can be Mines
1. Medium
instructed to ensure safe crossing
of tippers with signal lights.

Miscellaneous
VP - All
Best Safety Suggestion will be Projects
1. For Information
awarded.

VP - All
Gate Meeting can be conducted on Projects
2 For Information
first Monday of the month.

All buildings: Housekeeping can be GS All For

3. done, unnecessary materials have concern Information Low
to be removed. ed
Cross Department housekeeping to HSP All 20.07.2020
5. be done every fortnightly, weekday departm Low
will be intimated accordingly. ents

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

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