Sonadih Cement Plant CII -SHE Award Sonadih.pdf · Overview A S J Lafarge, Arasmeta M J J Lafarge,...

Sonadih Cement Plant

CII - SHE Award

28th February 2014

Overview

AS

J

Lafarge, Arasmeta

MJ

J

Lafarge,Chittaurgarh

Lafarge, Bhiwani

� Sonadih Cement Plant is having two

Clinkerisation lines.

� Commercial Production of Line 1 started in

1993.

� Initial Installed Capacity 1 Million Ton.

� Taken over by Lafarge in 1999.

� Commercial Production of Line 2 started in

2009.

� Present Production Capacity:


AS

Lafarge,Jojobera

Lafarge, Sonadih

Lafarge, Mejia

� Present Production Capacity:

1. Clinker – 3 Million Tons (Line 1: 1.4 Million

ton & Line 2: 1.6 Million ton)

2. Cement – 0.5 Million Tons PPC

� Main raw materials:

1. Lime Stone, Iron Ore, River Sand, Fly

ash, Gypsum, Flue Dust, Coal, Liquid

solvents and other alternate fuels.

� ISO 9001, 14001 & OHSAS Certified Plant.

Health & Safety Policy


SCP Vision, Objectives & Target 2014


Engagements

Monthly

� Gate Meeting

� Logistic Meeting

� Plant Safety Committee Meeting

� Departmental Safety Committee Meeting

Yearly Celebrations:

� Road Safety Week

� Fire Safety Week

� Safety Month Celebration

� Safety Week

� Transporters Meeting

� World Environment day

� Earth Day etc.


Safety Initiatives: Participation in Safety Management System

Plant Manager addressing the Highest Engagements TrophyPlant Manager addressing the

Gate Meeting

Highest Engagements Trophy

Housekeeping Trophy Health and Safety Nukkad


Safety Initiatives: Reward and Recognition Schemes

Plant Manager distributing prize

for safety person of the month Maintenance Manager distributing

the prizes for Near Miss Reporting


for safety person of the month the prizes for Near Miss Reporting

Conducting Quiz Competition at

gate meeting

Plant Manager distributing prize for

Best Nukkad at gate meeting

SCP Safety Statistics

2011 2012 Dec-13 YTD 2013 YTD 2013 Dec-13 2012 2011

0 0 0 0 Fatality 0 0 0 1

1 0 0 0 LTI 0 0 1 0

0 1 0 0 Medical Injury 2 0 2 6

3 3 0 4 First Aid Injury 15 1 18 30

1.1 0 0 0 Frequency Rate 0.00 0 0.55 0.47

Lafarge EmployeesDescription

Contractor Employees


� Increasing trend in HS Training Man-Hrs, Safety Engagement & Unsafe condition reporting.

1.1 0 0 0 Frequency Rate 0.00 0 0.55 0.47

4494 4580 208 5806 Total HS Training Man-Hrs 26175 1578 21141 24029

334 271 28 308 Training hours spend 2504 191 1749 1650

2772 4589 1581 8093 Total Safety Engagement NA NA NA NA

268 197 47 207 Nearmiss 80 13 84 125

3957 4438 1228 7408 Unsafe Condition 4 0 51 142

44 8 0 20 Unsafe Action 124 5 72 250

Health and Safety Initiatives - 2013

� Process Owners pro-actively implementing H&S Standards and Advisories and it has

been translated in Hindi for easy understanding.

� Started bottom up approach by involving people from shop floor to lead training on all

H&S Standards & Advisories: Completed 80% - OPR, 54% - NOPR, 58% - Contract

workmen.

� Upgraded water filtration system to improve the drinking water quality - turbidity less

than 5.

� In-house heath checkup for employees and shutdown contract workmen.

� Ladies Club organized health check up camp for detection of Osteoporosis & Obesity.

� Improved Road Signage throughout Plant, Colony and Mines.

� Able to retain 60-70% shutdown contractor population in last two consecutive Kiln

shutdown.

� Contractor's initiative to provide standard PPEs - T Shirt and Safety GKB Specs.

� Installation of CO2 system in Line 2.

� Stopped using stick at packer discharge end at packing plant and resolved a long

pending safety issue.

� Several initiatives taken to involve all the stakeholders including family, to improve the

quality of Logistics Gate Meeting.


A. Governance Standard - 3

� Contractor Safety Management

� Risk Management

� Reporting & Investigation

B. Operational Standard - 9

� Working at Height

Health & Safety - Standards & Advisories

C. Safety Advisories - 9

� People Road Transport

� Mobile & Lifting equipment for

WAH task

� Stock pile & Surge pile

� Conveyor belt safety

� Demolition Advisory

� Energy Isolation (EI) Standard

� Confined Space

� Personal Protective Equipment

� Respirable Crystalline Silica and Total Dust

� Workplace Noise Standard

� Ergonomics

� Whole Body Vibration (WBV) Standard

� Hand Arm Vibration (HAV)


� Logistics Advisory

� Mobile Equipment

� Workforce Accommodation

� LOTOTO

Safety Initiatives: Bottom Up Approach Champions

Conveyor Safety Champion Demolition Safety Champion WAH Safety Champion

EI Safety Champion Stock Pile Safety Champion MEA Safety Champion


PRTA Safety Champion Logistic Safety Champion CSE Safety Champion

Verification of Driver’s

License, Age: Min 25 Yrs

& Experience : Min 2 Yrs

Appointment form

Safety Training by Plant

Logistics Safety Officer

(half day session)

Medical Test to ensure

fitness

Driver Selection Process

Defensive Driving Training by

Skilled Trainer (appointed for

training only) - Theory & Practical

Award to best driver after the

completion of DDT

Written Test after

Training


Refresher Training to all the drivers (half

yearly)

Vehicle ChecklistVehicle checking by

Safety Supervisor

Alcohol testing by

transport supervisor at

Transporter Office

Safety Induction to the

Market Vehicle’s drivers

Procedure for entry of Vehicle inside Plant

Signature on Pratigaya

Patra by drivers

Cross checking by

security guard at material

gate

Compulsory use of 3

point retractable Seat

Belt

Random Alcohol checking

at material gate by

security guard


Counselling of all the drivers by the

Skilled Counselors after every trip

Road Safety Movies on various topics

to increase road safety awarenessDMC started for drivers

on 19th August’13

Driver Management Center

Stress Management clasess through

professionals on regular intervals

Extra curricular activities for Driver

(physical exercise classes, drawing

competition, etc)

Entertainment Programs for Drivers


Monthly award of Rs Five Hundred to the

drivers, who did zero safety violations

Every month award to one driver of

each transporter as the safest driver

Framed photograph to the safest drivers, who

are coming with the family in gate meeting

Building Relationship….

Safety Mega Award function by

transporters quarterly.

Gift to every pass port holder driver , during

the safety month for increasing their morale

Dinner for 10 best drivers along with their

family, with Plant Management Team


Daily safety engagement with Drivers

to increase safety awareness

Weekly Chaupal with Drivers & Helpers

separately to resolve their issues

Monthly Logistic Gate Meeting for drivers in

presence of Plant Management Team

Spot checking of vehicles outside plant

on the routes in regular intervals

Safety Mentors selected among the

drivers to spread safety in all the drivers

Frequent visit to drivers home & engagement

with family for appreciation.


Logistics Safety

Declining trend in the number of

violation by drivers for

transporting clinker.

# We do similar tracking for Raw

Material & Cement.

11 9 1017

33

21 22

10

2 27 7

0 0 0 005101520253035

Nov 12

Dec 12

Jan 13

Feb 13

Mar 13

Apr-13

May-13

Jun-13

Jul-13

Aug-13

Sep-13

Oct-13

Nov-13

Dec-13

Jan-14

Feb-14N

o. of Speed Violations

Months

Speed Violation Outside Plant Year Till Date 2013-14More than 45 KM

75150

200

250

300

No. of Speed Violations

Speed Violation Inside Plant Year Till Date 2013-14More than 25 KM


Awarded for Achieving Zero

Violation in Clinker, Cement &

Raw Material Transportation

(consistently for 3 Months).

Zero Violation Award

74 74

93

26 21

410

3 1 2 0 0 0 0 00102030405060708090100

Dec 12

Jan 13

Feb 13

Mar 13

Apr-13

May-13

June-13

July-13

Aug-13

Sep-13

Oct-13

Nov-13

Dec-13

Jan-14

Feb-14

No. of Violations

Months

1-4 AM Violation Year Till Date -2013-14

750 6 7 12 11 6 4 4 0 0 0 0 0 0 0

0

50

100

150

Nov 12

Dec 12

Jan 13

Feb 13

Mar 13

Apr-13

May-13

Jun-13

Jul-13

Aug-13

Sep-13

Oct-13

Nov-13

Dec-13

Jan-14

Feb-14

No. of Speed Violations

Months

Violation Matrix

Penalty against different type of violation to

the Transporters

Four Corner violation Gate Pass


Safety Initiatives: Management Visible Leadership

Daily High Risk Activities on W:Drive Daily HOD Safety rounds and discussion on the points in the meeting

Daily High Risk Activities on W:Driveon the points in the meeting

Authorization Matrix


SOTSYS

Risk Management

Fall Hazard Risk Assessment 3 Column JSA

HIRA: Hazard Identification Risk AssessmentPermit to Work


Safety Initiatives: Hierarchy of Control

Insertion of Beams inside the cyclone door level Separate Pedestrian Walkway

ELCB HT Line Protection + Road Signage


ELCB

Insertion of Beams inside the cyclone door level Separate Pedestrian Walkway

Certification & Awards

Mines Environment & Mineral Conservation, 2012

SHE Award by CII 2010-2011 FICCI Safety Excellence Award 2011

Safety Awards by DGMS - 2012Energy Conservation Award by CREDA


Safety Awards by DGMS - 2012

Mines Environment & Mineral Conservation, 2013

ASC Awards 2013

Learning from Events

Fatality Flash SER FlashFatality Flash SER Flash

Near Miss Report Sharing Medical & First Aid injury Report Sharing


Safe Operating Procedures Instructions for Safe Usage of Machinery

Safety Initiatives: General Safety

Safe Operating Procedures

Signage's provided for all Hazards


VCS

Safety Initiatives: General Safety

Guarding for all Rotating PartsOrganic Vapour Mask: Protective Equipment

Heat Resistant Suit: Protective Clothing


Mandatory PPE’s

Belt Conveyor Safety


Confined Space: Silo Cleaning Initiatives

Conventional Method of Silo Cleaning


Conventional Method of Silo Cleaning

Cardox Method of Silo Cleaning

Safety Initiatives: Energy Isolation / LOTOTO

LOTOTO Box Pneumatic Valve Locking Arrangement


LOTOTO Box Pneumatic Valve Locking Arrangement

Arc Flash Boundary Identification Multiple Earthing Points

Safety Initiatives: Working at Height

Cuplok Scaffolding Inside Cyclones Cherry Picker used to eliminate WAH risks

Pictorial Depiction of Rescue PlansPictorial SOP’s


Vertical Stretcher for Rescue in

Confined Spaces

Safety Initiatives: Working at Height

Retractable fall Arrestor

With Winch Provision

Confined Spaces

Tagging System in Scaffolds along with checklist


Fire Control, Emergency Plan & First Aid

Smoke Detectors are Provided in all MCC

& Cellar

Emergency Preparedness Mock Drills conducted regularly & Cellar

Emergency Number displayed Display of First Aider’s & Rescuer’s contact details


conducted regularly

Health Initiatives

Occupational Health CentreSonadih Cement Plant

Glimpse of Liquid Hazardous Waste System

Key Features : System can handle

• Gross CV - 4600 to 5600 kcal/kg;

• Fire point - 85-88ºC;

• Moisture content -15-20% ; Ash content - 15%;

• Chloride content - 1-1.2%

• Viscosity ~ 55 centipoise

• Maximum substitution of fossil fuel up to 7%.


Unloading 100% covered Shed

To Kiln Burner

Glimpse of Solid Hazardous Waste SystemKey Features :Key Features :Key Features :Key Features :

� New alternate feeding systemcomprising of bucket elevator &weigh feeder was commissionedon 1st Nov 2013.

� Enhanced AF substitution in Line2 in a mechanized way.

� Maximum substitution capacityhas now increased to 8%.

� Capable of handling wide varietyof alternate fuels.

� Well covered storage yard for

2.2

3.9

1.0

8.1

0.0

1.0

2.0

3.0

4.0

5.0

6.0

7.0

8.0

9.0

Alternate Fuel SubstitutionAlternate Fuel SubstitutionAlternate Fuel SubstitutionAlternate Fuel Substitution

� Well covered storage yard forhazardous waste.

0.0

Sept 13 Oct 13 Nov 13 Dec 13


Energy Saving Initiatives


PAT Target & Action PlanBack Ground :

The average total energy consumption for the period of 2007-

08, 2008-09 and 2009-10 is 177731.2 MTOE. LIPL – Sonadih

Cement Plant is a Designated Consumer.

The baseline production for the year 2009-10 in terms of total

major equivalent product (PPC cement) is 30.07 Lakh MT.

The average SEC for the baseline period is 721.49 kcal / kg

cement. Based on this PAT target for Sonadih is 692.3

kcal/kg cem, which is equivalent to 7134 MTOE.

Actions to reduce the Gate to Gate SEC & to achieve the PAT

targets within given time Span are being carried out.targets within given time Span are being carried out.

Way Forward

� Maximizing the usage of alternate fuels.

� Installation of WHR for both manufacturing lines

� Improving C/K ratio.

� Improving the cooler performance by enhancing the

recovery ratio & thus reducing the overall heat

consumption.

� Carrying out energy saving projects by identifying the

impact on the SEC.

� Improving the RF of both lines to reduce the SEC.

Action Plan for Year 2012-13-14

Action Plan


Environment Initiatives

Rain water harvesting pit : 2.3 Million M3 Specific Water Consumption

0.4416

0.4214

0.3743

0.34

0.36

0.38

0.4

0.42

0.44

0.46

2011 2012 2013

Water M3/Ton Clinker

Plantation all around the premises Specific CO2 Emission

517

516

513

511

512

513

514

515

516

517

518

2011 2012 2013

CO2 Kg/Ton Cement

2011 2012 2013


(CO2 emission level is much better than industrial norm)

Environment Initiatives

Installation of Continuous Emission Monitoring System (CEMS) at all major

Stacks (Make - Durag) for Particulate Matter, SOx & NOx (Make - ABB) at

Kiln Stack for On-Line Monitoring.


Standard Stack Emission (PM) : 50 mg/Nm3 (Lafarge Target – 30 mg /Nm3)

Sonadih Stack Emission (PM) : 20-25 mg/Nm3

Health, Safety & Environment Initiatives


Key CSR ProgramsCSR Categories

Safety

EmployabilityEducation

Health


Vehicle checkup Safety round for village ladies Safety wall paintings

Glimpses of CSR Programs

Sonadih Community Health CenterEye checkup camp Health checkup for children

Women Education Computer Education for Children Computer Education for Ladies


Skill Development Training Hand Pump Repair TrainingSewing Training

Glimpses of CSR Programs

Training for hand pump repair

Hand pump installation Concretization of village roads School boundary wall construction

Rural toilets Pond deepening activities Community centers


People Road Transport Advisory


Training Programs for Children & Colony Ladies

44Sonadih Cement Plant

Defensive Driving Training for School Children Fire Fighting training to colony ladies

-

10

20

30

40

50

20

26

36

42

Ongoing Expenditure (Safety + Environment)Ongoing Expenditure (Safety + Environment)Ongoing Expenditure (Safety + Environment)Ongoing Expenditure (Safety + Environment)

Safety & Environment Expenditure (MINR)


2011 2012 2013 2014 BUD

-

10

20

30

40

50

60

2011 2012 2013 2014 BUD

12 16

28

55

Capex Expenditure (Safety + Environment)Capex Expenditure (Safety + Environment)Capex Expenditure (Safety + Environment)Capex Expenditure (Safety + Environment)

80.6

88.9

95.6

90

100

RF

LINE 2 RF

114.8

90

110

130

Hrs.

LINE 2 MTBF

335340

352

340

350

360

TPH

RAW MILL 2 TPH

158.5

89.1

251.1

50

100

150

200

250

300

2011 2012 2013

Hrs.

LINE 1 MTBF

308

305

319

300

305

310

315

320

325

2011 2012 2013

TPH

RAW MILL 1 TPH

95.9

93.6

97.6

85

90

95

100

2011 2012 2013

%

LINE 1 RF

Performance


80.6

70

80

2011 2012 2013

RF

795

767 764

750

765

780

795

810

2011 2012 2013

Kcal/kg clk

LINE 2 SHC

53.061.4

30

50

70

2011 2012 2013

Hrs.

54.9

64.5

71.5

40

50

60

70

80

2011 2012 2013%

CHEMICAL GYPSUM USAGE

80.3

76.7

75.5

74

76

78

80

82

2011 2012 2013

kWh/T clk

LINE 2 SPC

310

320

330

2011 2012 2013

TPH

Issues 2013 2014 2015 2016

L2 RF:

Reliability issues with control cards of PH fan, cooler fan VSD

failures, vibration in raw mill, cooler boulder/snow man

formation, frequent Mech failures & high winding temp RM main

motor.

L2 PF :

Low stock capacity of raw meal & break downs in raw mill circuit.

L2 SHC : Poor cooler efficiency.

L2 : Low MTBF.

Performance Roadmap


L2 : Low MTBF.

L1 RF:

Break down in cooler, raw mill separator, coal mill separator and

kiln roller bearing temp high.

Alternate Fuel :

Storage and feeding arrangement for various alternate fuels.

RM Storage and Handling : Open Yard and Manual Handling

Clinker storage and handling to loading silo.

Quality of lime stone with limited mines life.

Infrastructure : Colony & Plant.

Thanks

Issues Action Plan

L2 RF:

Reliability issues with control cards of PH fan,

cooler fan VSD failures, vibration in raw mill, cooler

boulder/snow man formation, frequent Mech

failures & high winding temp RM main motor.

• Control card and VSD are being upgraded.

• Screening of coal char and flue dust.

• Better raw mix control and high pressure jet pump

procured.

• Cooling tower efficiency being studied.

L2 PF :

Low stock capacity of raw meal & break downs

in raw mill circuit.

• Inter connection of Line 1 and Line 2 raw meal silo.

• 5 nos. of cooler fans will be changed in next KSD but

Current Issues & Action Plan


L2 SHC : Poor cooler efficiency.

• 5 nos. of cooler fans will be changed in next KSD but

mechanical condition of cooler to be strengthened (to be

studied further).

L2 : Low MTBF – Problem in pan conveyor, cooler

plates, cooler hydraulics, PH fan cards, Kiln main

drive cooling fan, cooler fans, all VFD, ball and

snowman formation.

• Reasons for failure studied, few actions done and few

initiated.

L1 RF:

Break down in cooler, raw mill separator, coal

mill separator and kiln roller bearing temp

high.

• Cooler first grate static and movable beams are being

changed

• Raw mill separator is being replaced

• Coal mill separator GB is procured

• Kiln roller no 9 and 11 bearing are being replaced.

Issues Action Plan

Alternate Fuel :

Storage and feeding arrangement for various

alternate fuels

• Storage and feeding arrangement of SHW is under

construction but we need to have storage and handling

arrangement of various other low density AF (our

vision).

RM Storage and Handling :

Open Yard and Manual Handling.

• Raw materials are stored in open and are getting wet

during rainy season and material loss is happening.

• Covered storage along with mechanized storage and

feeding arrangement is proposed (our vision).

Current Issues & Action Plan


Clinker storage and handling to loading silo.• Mechanized storage at L&T yard and transporting

arrangement to loading silo.

Quality of lime stone with limited mines life.

• Current mines life is approx 6 years with lot of high iron

patches, new mining area procurement is to be speeded

up.

Infrastructure of Colony & Plant needs improvement.

• Plant - Crane, material handling equipment and storage

sheds.

• Colony - Condition of Floors, Kitchen, Washroom ,

accommodation for shutdown workers etc.

Safety Statistics


Driving License for Ladies

� Training and Distribution of 27 Permanent Driving License to

Colony Ladies.


Incident Reporting

0

20

40

60

80

100

120

High Medium Low

Carelessness

Electrical

Fall Of Object

House Keeping

Illumination

Lack Of Co-OrdinationLifting Tools & TacklesMaintenance

Road Safety0

1

2

3

4

5

6

7Carelessness

Caught in

Communication

Fall of Material

Improper PositionInspection

Slip of Tools

Medical & First Aid ReportNear Miss Reporting


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Sonadih Cement Plant CII -SHE Award Sonadih.pdf · Overview A S J Lafarge, Arasmeta M J J Lafarge,...

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