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training manual for risk assessment in the cement industry
Contents
1. FUEL STORAGE 01 03 2 DESCRIPTION OF THE MAIN HAZARDS AND THE CORRESPONDING PREVENTION MEASURES AREA HAZARDS QUARRYING Drilling 9 Fall from height 9 Hurling of material Movement of heavy goods vehicles e The collapse of a floor level e Mechanical movement of the drill e Exposure to noise and dust Charging and ignition Inappropriate use of explosives Fall from height The collapse of a floor level Hurling of material Exposure to noise and dust and vibration Movement of heavy goods vehicles PREVENTION MEASURES VISUAL APPRECIATION The moving parts of the bore holing machinery Falls from height Material falling from height Crushing of quarry table Hurling of material Presence of dust and noise Movement of earth moving equipment Job safety analysis and work permit Isolation of the charging and ignition area Use of minimum explosives Authorised person in charge Pre approved explosion plan Safety signage safety warnings No smoking CRUSHER AREA RAW MATERIAL SIORAGE Loading Unloading Track movement reversing Load displacement Reversing into hopper Falling rocks during unloading Absence of reversing barrier Crusher Operation Stacking of hopper Accidental start up of crusher Hazards during unplanned maintenance Electrical hazards Work inside the crusher control room e Airborne dust Uniformly distributed load Worker movement segregation areas Existence of safety signag
2. Check The welding machine electricity supply lead are protected from chemicals mechanical trapping or water on the ground M01 EN 2 15 USE OF MANUAL HAND TOOLS MO01 EN 2 15 1 1 Hazards from the use of manual hand tools The moving parts of manual hand tools must be guarded or equipped with safety devices 1n case they are hazardous The safety devices should never be removed unless required for their maintenance In such cases all necessary measures must be taken so that the risk of accident 1s reduced All guards or other safety devices must be replaced as soon as maintenance intervention has been carried out The general protection measures are e never operate a manual hand tool if the worker 15 not competent in its use or authorised to do so To always make sure that the hand tools are appropriate for the intended use and are correctly applied e never interfere with the hand tools electrical wiring unless you are competent to do SO e To always plan your activities before using a hand tool e never touch its moving parts or try to stop it using your hands e Never were loose or unbuttoned work wear or hanging sleeves rings or ties because there 1s a serious risk of trapping For the same reason any long hair must be contained within a hat e never approach any machine parts or the cutting area without the use of appropriate PPEs e never leave the manual hand tool unattended and in
3. Check the existence of collective protection measures such as barriers guards or access doors for the inspection of the preheater the kiln and the cooler Check the existence and use of operating procedures for gaining access to the preheater the kiln and the cooler Check that all operators in the clinker production area use the appropriate PPEs Maintenance MM 4 Check that all maintenance activity 1n the preheater the kiln and the cooler 15 properly planned in advance Check the use of pre maintenance inspection Authorised technicians Into the preheater the kiln and the cooler j prior to entry Check the condition of the inside of the the preheater the kiln and the cooler prior to entry The existence of material temperature inside Check the existence of the necessary safety signage Check the condition of the PPEs safety belt harness Ventilation mask Work ware safety shoes Special helmet equipped with eye protector ree 1 manual work equipment L carried out under constant supervision M01 EN 2 7 THE FILTERING PLANT In the cement industry there are 2 types of filters used for the collection of the dust produced the electrostatic filters and the bag filters The hazards associated with the normal operation as well as the maintenance of both types of filters are very similar In the following analysis the hazards for both are described and the
4. Area used by WV Area used by personnel Check the area used by WV Sharp upwards or downwards inclination Uneven floor ll Soe instructions during the refilling of fuel Check the adherence to the safety instructions during the charging of the batteries If applicable Check that there is a documented method of reporting and following up on breakdowns 12 Check the use of the appropriate PPEs by the WV driver M01 02 01 jpg 47 M01 EN 2 14 METAL WELDING AND CUTTING OPERATIONS MOI EN 2 14 1 1 Hazards in the Welding and Cutting Operations The welding and cutting operations entail hazards such as Hurling of hot particles Burns and fires Explosion Electrocution Exposure to hot and radiating sources Smoke and dangerous gases In such activities the main protection and prevention measures are The personnel undertaking these activities must have the necessary competence and authorisation The welding work areas must be 1solated with the use of appropriate barriers so that glaring and hurling of hot particles to other areas 1s eliminated When welding 1s carried out at higher levels all the necessary measures must be undertaken so that other operatives working below are protected from hot particles It is the responsibility of the welder to implement such protection Remove all flammable material and waste material If this 1s not possible then protective barriers must be used During the weldi
5. USE OF THE GRAPHICAL METHOD 1 THROUGH THE USE OF REAL EXAMPLES IN THE FORM OF ACTUAL PHOTOGRAPHS THE PARTICIPANTS IDENTIFY THE HAZARDS 2 RISK ASSESSMENT OF THE IDENTIFIED HAZARDS USING THE RISK ASSESSMENT TABLES PROVIDED 01 04 1 TEST 1 RISK ASSESSMENT USING THE GRAPHICAL METHOD PICTURE OF A WORK AREA 76 IDENTIFYING THE HAZARDS IDENTIFICATION OF HAZARDS WORK AREA WITHOUT BARRIER ABSENCE OF GUARD ELECTRICAL HAZARD INAPPROPRIATE PPE WORKING NEAR MACHINERY INSUFFICIENT MAINTENANCE BAD HOUSEKEEPING 79 01 04 2 TEST 2 RISK ASSESSMENT USING THE GRAPHICAL METHOD PICTURE OF A WORK AREA 80 IDENTIFYING THE HAZARDS UNGUARDED ROTATING MECHANISM HAND TOO CLOSE TO MOVING PART NO USE OF PROTECTIVE GLOVE BAD HOUSEKEEPING OF WIRING AND CABLING 81 01 04 3 TEST 3 RISK ASSESSMENT USING THE GRAPHICAL PICTURE OF WORK AREA H s TAA ut 52 IDENTIFYING THE HAZARDS NOT WEARING THE APPROPRIATE PPE HELMET AND MASK TRANSPORTING HOSE PIPE ON THE MOTORCYCLE TRAVELLING IN THE MIDDLE OF ROAD ALSO USED BY HEAVY GOODS VEHICLES 83
6. operating procedures dictating the method of cleaning and unblocking P ansa carried out during operation during the removal of material Check the existence and adequacy of safety signage and restricted passageways use of PPEs Check 1f the use and maintenance of the approved PPEs 7 Check the passageways used by all personnel Check the proper labelling of each passageway Check the noise 1solation of the homogenisation rooms by securing the doors Milmaintnane Check the securing procedures before and after the maintenance of equipment including the guarding 10 Check that all maintenance activity in the mills 15 carried out by Authorised technicians and that there 1s continuous supervision by a third person Check the internal condition of the mill prior to entry for absence of material and absence of thermal load Check the condition of the PPEs that must be used Safety belt harness Ventilation mask Work ware Safety shoes Special helmet equipped with eye protector Positioning of the mill at stop 14 Checkthesecuringoftheaccessdoor f 4 4 4 15 Check the proper use ofthe PPEs 22 M01 EN 2 5 SILO CLEANING OPERATIONS RAW MATERIAL AND CEMENT MO1 EN 2 5 1 Hazards The internal cleaning of silos 1s high ris
7. 5 guards or access doors at the top of the silo ss ae instructions for accessing the silo Check condition of the staircase inside the silo 4 Check the existence of the necessary safety signage for the use of PPEs and restriction for i ss ss authorised personnel only During cleaning inside the silo Check the condition and use of the manual work 25 equpmen L o 6 Check for the continuous supervision of work noe R spiral manner manholes Check the securing of the side manhole following the completion of cleaning Check the use of the PPEs Check the condition of the PPEs Safety belt Ventilation mask Safety work ware Safety shoes Special helmet with eye protection MO0I EN 2 6 THE CLINKER PRODUCTION PROCESS The clinker production facility includes the rotating furnace the preheating cyclones the clinker cooler the clinker filters and the work vehicles M01 EN 2 6 1 Hazards The main hazards are focussed on the following e Use of fuels Xphon e Contact with superheated material e Exposure to heat e Exposure to noise e Fall from height e Mechanical hazards The hazards due to the maintenance activities inside the clinker furnace may involve e Taking down and repairing of the composite inner lining e Taking down material that adhered to the inner walls In such activities other additional hazards must be included such as e Fall
8. AND MATERIAL TRANSPORTATION SYSTEMS M01 EN 2 3 1 Hazards and protection measures The main hazards during the transportation and storing of material are e The airborne dust created during the storage of material e The conveyor belts during their normal operation as well as during their maintenance In order to reduce the risk from airborne dust Material should not be stored at unacceptable heights To use dust suction systems To implement the necessary procedures for the routine cleaning of the settled dust In material transport systems there are moving parts that are a constant source of hazard for any person working near these conveyors during normal operation or during the maintenance activities For the safe operation of material transportation systems all the necessary guards are applied to 1solate the moving parts Additionally where personnel 1s working at a short distance from the guards emergency stops are provided within short distance of these operators During the normal operation of the transportation systems The removal of guards by unauthorised personnel must be prevented e Any maintenance work during the operation of the transportation systems must be avoided e Removing material during the operation of the conveyors must be avoided e The cleaning of overflows during operation must be avoided unless the cleaning is done by the conveyor operative e The use of unauthorised passageways either over or under the transpor
9. Atmospheric discharge during 1 discharge unstable weather personnel procedures of the antidischarge facilities 8 M01 EN 2 9 3 Accident Prevention Check List Fuel storage Control Points S US Fuel and Gas storage facilities Check the safety signage E d _ 2 Check the current protection measures as well as the Emergency preparedness and response plans and evacuation procedures 3 Check the existence of work instructions for work on and around the storage facilities l 4 Check the existence and use of maintenance planning procedures for work on the storage tanks 38 Inspection of work prior to execution A Authorised technicians authorisation for carrying out maintenance Check the condition and use of the 12 Check the maintenance of the high pressure relief valves 16 Check the condition of automatic shat of valves 19 Check the condition of the coal transportation facilities 20 in the storage facilities area appropriate PPEs Check the condition of earthing facilities __ Coal Storage s 17 Check the existence of records proving that the storage temperature 15 routinely checked 5 Check the equipment for executing maintenance work in the fuel storage area 7 Check the prevention measures prior to carrying out the work 10 Check the appropriateness and use of the manual work equipment 0 14 Check the condition of th
10. Check that the scaffolding 15 not loaded with material since there 1s the possibility of moving the centre of gravity upwards with increased possibility of tripping 17 Check that the scaffolding is not moved while it 1s used by operatives or contains materials 18 Check that that the climbing up or down the scaffolding 15 carried out from the inside of the scaffolding only Check that approaching naked or isolated 44 electrical supply lines either during assembly or the movement of the scaffolding 1s avoided M01 EN 2 12 USE OF FORK LIFTS Fork lifts are used in all cases when there 15 a need to move and lift up materials finished goods and equipment since the use of such vehicles 1s necessary there 1s a need for all personnel involved to be careful for proper use paying attention to both the driver as well as the employees working in the vicinity The use of fork lifts 1s associated with a number of accidents mainly due to the fact that there are hazards linked to their use M01 EN 2 12 1 Hazards from the use of Fork Lifts The more frequently reported accidents linked to the use of fork lifts are Tilting of the fork lift e Tilting of the load e Hitting of goods or people The main reasons for the increased risk when using fork lifts are e Lack of basic training e Insufficient maintenance e Insufficient visibility e Inappropriate load e In appropriate po
11. If the cleaning operation takes more than one day then it 1s the responsibility of the supervisor to inform daily the silo operators about the start and finish times 24 M01 EN 2 5 2 Risk assessment Cleaning of storage silos 1 Hazard 2 3 4 5 Specific Hazard Area Hazard Description Person Harm Current safety measures Cleaning of storage silos Falling of Falling of operatives during Operators Serious injury PEs Approved and tested personnel accessing the work area or death lifting device platform when using the lifting platform Serious injury PPEs Supervision death Operators PPEs Dust suction system leaners problems Airborne dust Airborne dust inside the silo Falling of Falling of material during Dperators Serious injury PPEs Cleaning from top to material cleaning of the silo walls leaners Falling of Falling of material during the Operators Serious injury PPEs Approved and tested cleaning of the silo walls due to cleaners lifting device platform insufficient securing of the safety devices Use of hand held work Operators Serious injury PPEs equipment during the cleaning operation Gradual hearing PPEs impairment MO01 EN 2 5 3 Accident Prevention Check List Cleaning of storage silos Control Points S US Observations Silo operation Check the existence of collective protection 2 measures such as
12. operative s neck and face The electrical connections as well as their condition on the welding machine should be checked on a daily basis Additionally the condition of the electrodes and the welding pliers must be checked routinely The pliers that provide the contact should be connected on the body to be welded near the welding area When welding on trucks with rubber wheels the truck should be earthed and extra care should be taken due to the existence of fuel and lubricants The welding machine electricity supply lead should be protected from chemicals mechanical trapping or water on the ground During the arc welding operation the appropriate PPEs should be used that must include welding gloves apron shin protectors and safety shoes MO01 EN 2 14 2 Accident Prevention Check List Welding and metal cutting operations Control Points S US Check that the personnel undertaking these activities have the necessary competence and authorisation Check that the welding work areas are isolated with the use of appropriate barriers so that glaring and hurling of hot particles to other areas 1s eliminated 3 Check that when weldingiscarriedoutat 50 higher levels overhead all the necessary measures are undertaken so that other operatives working below are protected from hot particles It 15 the responsibility of the welder to implement such protection 3 Check the existence and compliance with the welding opera
13. or under the silo side door e Afterwards the cleaning of the walls from above is carried out using the Givonet system which 1s done with the use of connecting the necessary piping without having to enter the silo e The next step 15 to open carefully the side door The door and the area around the door 1s cleaned using a dust suction system DISAB and with the use of aluminium piping with the operatives staying out side the silo Once the supervisor has inspected and made sure that he has seen the bottom of the silo near the door and that no material masses are hang from the silo walls then he gives the necessary instructions to start the Filter funs All personnel entering the silo must be equipped with the following o Dust mask type P2 or P3 due to the small size of dust particles inside the silo 23 o Safety shoes o Safety glasses o Helmet o Safety belt and harness connected to an appropriate rope leading outside of the silo There must be at least two operatives outside the silo who case of emergency will pool out the operative inside the silo The supervisor 15 always nearby throughout the cleaning activity The cleaning of the silo 1s done either manually or using the suction system DISAB In both cases the cleaning 15 done peripherally In a downward spiral direction using the work platform The operator inside the silo must pay constant attention to the fact that he must step only on the clean bottom surface
14. peculiarities of each type are identified 28 M01 EN 2 7 1 Hazards and protection measures during normal operation During the normal operation the main hazards associated with filters Falling of material on operatives due to blockage of the transportation system Operatives falling from height Exposure to dust Asphyxiation of operatives when inside the filters Electrical hazards for electrostatic filters Explosion due to the existence of increased concentration of CO in the case of coal dust The main protective measures are Never remove all the necessary safety devises such as barriers guards security of access doors etc The use of authorised personnel Always to follow the operating procedure for securing the electrostatic filter To follow the special operating instructions given for a particular type of work To with the safety instruction available at the work place To use the appropriate PPEs assigned to each operative M01 EN 2 7 1 Hazards and protection measures during Filter maintenance During the maintenance activities inside of the filter the following additional risks must be added such as Dusty environment Accumulated material Insufficient ventilation High temperature Staggering and falling of operators static electricity electrostatic filters The main preventive measures necessary include The removal all the accumulated material from the filter prior to entry The cleaning of
15. the liftine mechanism onto operatives Fall of the load to be lifted due to the failure of the lifting gear Insufficient or inappropriate securing of the load Tilting of the load during its transportation Crashing of the load on the building Electrocution as a result of lifting mechanism contacting o h lines Use of authorised and trained personnel Existence and compliance with work instructions Safe operation of the stopping mechanism the breaks and the lifting lines Check on a routine basis the hook mechanism Always secure the load using the approved straps Always avoid the lifting of loads overhead from working operatives 01 03 3 SUMMARY OF USE OF PERSONAL PROTECTIVE EQUIPMENT PPE PER AREA AREA SOURCE PPE QUARRING DUST MASK GOGGLES UNIFORMS NOISE EAR PROTECTORS gt 80db FALLING MATERIAL HELMET SAFETY BOOTS CRUSHING STORAGE OF MATERIAL DUST MASK GOGGLES UNIFORMS FALLING MATERIAL HELMET SAFETY BOOTS NOISE EAR PROTECTORS gt 80db LIGHT PORTABLE LIGHT 24v HOT ENVIRONMENT HEAT RESISTING OVERALLS 600 C CLINKER PRODUCTION MASKS FOR PROTECTION AGAINST ULTRAVIOLET RADIATION HEAT RESISTING GLOVES LIGHT PORTABLE LIGHT 24v HOT MATERIAL HEAT RESISTING GLOVES AREA SOURCE PPE PACKING AND PREPARATION DUST MASK GOGGLES UNIFORMS FOR DELIVERY HIGH TEMPERATURE HEAT PROTECTION GLOVES 300 C WELDING WELDING MASK WELDING APRON 01 04 ASSESSMENT TEST
16. 16 LIFTING EQUIPMENT MOI EN 3 RISK ASSESSMENT IN THE CEMENT INDUSTRY GENERAL INFORMATION MOI EN 3 SUMMARY OF HAZARDS PER WORK AREA MOI EN 3 2 DESCRIPTION OF THE MAIN HAZARDS AND THE CORRESPONDING PREVENTION MEASURES MOI EN 5 2 SUMMARISED LIST OF PPE PER WORK AREA M01 EN 4 ASSESSMENT TEST M01 EN 4 1 TEST 1 RISK ASSESSMENT USING THE GRAPHICAL METHOD PICTURE OF A WORK AREA M01 EN 4 2 TEST 2 RISK ASSESSMENT USING THE GRAPHICAL METHOD PICTURE OF A WORK AREA M01 EN 4 3 TEST 3 RISK ASSESSMENT USING THE GRAPHICAL METHOD PICTURE OF A WORK AREA M01 EN 1 INTRODUCTION TO THE MODULE M01 EN 1 1 SCOPE OF THE MODULE This training Module aims to present the main hazards that are embedded in the Cement production processes as well as the risk assessment including the management of the corresponding risk The basic principles and the risk assessment methodology are described in training module MO EN within which the risk assessment form used in this module is provided For every production process a representative Risk Assessment Table has been prepared while for all the supporting processes there is a description of the hazards as well as an indicative Check List for managing the identified hazards MOI EN 1 2 PURPOSE OF THE TRAINING MODULE The goal of the module 1s for the participants to have by the end of the course to have basic realisation of all the main hazards in the cement industry basic knowledge and e
17. Accident on personnel The inappropriate loading of material onto the heavy goods vehicles with the result that material 1s hurled from the vehicle as the material 1s transported 13 M01 EN 2 2 2 Risk Assessment table Protection measures Hazard 2 Specific H Hazard Description with people During the maintenance of the electrical parts there 15 hazard from the electric cables Necessary Interaction with the machinery Inappropriate Inappropriate loading can loading of cause the shifting of the load material on with the result that rocks and 1 4 heavy vehiclematerial is flung in the area of the hopper him fall in the hopper During unloading dust is Operators Breathing UseofPPE dust 1s flung i in the air Excessive Necessary work in the hopper for the purpose of unblocking the mouth of the insi Injury opper 3 4 5 Harm Current safety measures se of Guards Use Authorised personnel Maintenanceserious injury se of PPE Gradual hearing impairment Operators Authorised personnel MaintenanceSerious injury raining of personnel onstruction of a ontrol room made Serious injury Death Operators Operators Breathing problems trom concrete to ithstand possible rushing personnel se of PPE personnel heck the stability of rocks inside the Adequat
18. Marking certificate including the lifting gear Fm Check that all protective measures are in place Check that Hfting equipment operator 15 trained and authorised to use the equipment 5 Check the existence and use of the work instructions for the particular lifting ul Check the level of maintenance and the existence of operational integrity certificates or certificates of test for Transmission system Breaking and isolation Lifting lines Load limiting device Hook Check that the loads are properly secured prior to lifting Check that the loads are properly lifted slow upward movement slow side ways movement with no operatives underneath Check that above the lifting area there are electricity supply lines Use of hoists j 10 Check the use of safety operating Instructions Gradual tensioning of load Gradual unwinding of rope from pulley Appropriate connection tying up to the load 11 Checktheintegrity ofthehook C 12 Check the use of suppliers instructions Check the existence of a valid CE Marking certificate and labelling 13 Always be aware of the load you are lifting and assess the lifting capabilities of the hoist and the lifting gear 14 Useoflifts and elevators O J o Check the existence of the necessary safety EE labelling on the lifting equipment 16 Check that the moving parts of the lifting device 1s appropriately guarded Check the ex
19. RN old bore hole iE s an unexploded bore hole MF drilling rig and the table edge Check that drilling rig has been transported to the quarry table according to the operational procedures Drilingproeess O O Tooo S e s process e In position Check that everybody stays clear of the E moving parts of the drilling rig during operation 8 Check the existence of operational procedures in case the drilling element is stack Maintenance and checking of the drilling rig 49 Check that the routine maintenance on the drilling rig has been carried out Check the condition of the hydraulic system for possible leakages 50 Check the protective measures during the maintenance activity Check the use of appropriate PE and the use of the manufacturers operating manual 12 M01 EN 2 2 CRUSHING M01 EN 2 2 1 Hazards The hazards In the Crushing department focus on The rotational movement and the movement of the parts of the crusher The exposure to noise and dust of the personnel responsible for the continuous control of the crusher The maintenance activities inside the crushing chamber The electrical problems The activities inside the hopper due to o The operation of the feeder o The possible crushing of material o The approach of heavy goods vehicles for unloading material The movement of heavy goods vehicles o Reversing of the vehicle into the hopper o
20. ards are due to e The fact that coal can easily self ignite when exposed to the air 36 The explosive characteristics of coal dust The production of highly toxic CO as a result of slow and incomplete combustion In order to manage the risks with the above hazards it 1s necessary to Avoid the storage of coal in enclosed areas or silos for a long time Control the temperature as well as the CO concentrations Inspect the outdoor storage facilities Make sure that the coal transportation pipes are always earthed so that any excess charges do not create an explosive condition Maintain the fire fighting neutralisation equipment in good order Use of Fuel oil During the use of Fuel Oil the main hazard is its flash point combustion temperature gt 65C which 15 relatively low In order to manage the risks associated with the use of fuel oil it 1s essential to Ensure that the storage tanks are properly earthed and are equipped with the necessary facilities for use against atmospheric discharge Avoid fuel leaks during maintenance or unloading and to remove any possible discharges Make sure that the fire fighting and neutralisation facilities are properly maintained and in good operating condition Avoid the direct contact of fuel oil with human skin Use of fuel gas During the use of Gas the main hazard 15 its very low combustion temperature as well as the fact that the gas 1s transported under pressure In order to manage the
21. ast as follows e Falls from height from the mill platforms e Hurling of metallic fragments from the mills shell Work in confined spaces with insufficient ventilation e Exposure to dust e Exposure to High temperatures Due to the nature of the hazards involved such high risk operations must necessarily be planned so that all the following preventive measures are adhered to Securing of the plant in a place where there 15 easy access of the maintenance technician into the mill e maintenance activity must be conducted by authorised personnel e work must be carried out under continuous supervision e Adherence to documented operating preventive procedures e Assure the necessary ventilation of the work space e Assure the reduction of temperature prior to access to the space 19 The use of the appropriate PPEs that must Include O O O Special helmet equipped with eye protector Safety belt connected to a tying rope Special work ware and foot ware able to withstand thermal load Heat retarding gloves Special mask equipped with ventilating fun or connected to a central ventilation system Portable torchlight RCD 15A 20 M01 EN 2 4 3 Risk Assessment in milling operations Milling Homogenisation Storage Raw material and cement mills IInyn Hazard 2 3 4 5 Specific Hazard Area 2 Person Harm Current safety measures Risk Assessment in milling oper
22. at all work at height 1s done safely and that all safety measures are in place existence of the necessary safety measures Check all the safety measures that are In place for the safe movement of operatives and goods transportation vehicles r m safety signage MN RR by all personnel activities ee equipment 5 during the maintenance activity LONE procedures are followed Check that the appropriate are used M01 EN 2 9 FUEL STORAGE FACILITIES During the production of cement the drying of raw materials and the production of clinker there 15 a need to consume large quantities of fuel that can be solid coal and pet coke liquid heavy fuel oil or gas For combustion fire to take place there 1s a need for three conditions to coexist e Presence of fuel 35 Presence of oxygen Presence of thermal energy heat If any one of the above three conditions is absent then the combustion does not take place stops or does not start The start up of an unwanted fire may be due to employees not adhering to the company s operating procedures or due to the inappropriate maintenance of the fuel storage facilities The main hazards associated with the storage and use of fuel are e Explosion e Fire Asphyxiation e Creation of toxic waste eg VOCs The basic sources of ignition are e The use of open flames near the storage areas e The creation
23. ations Raw material and cement mills Airborne dust PPEs Dust suction systems Operators Serious injury roper guarding Safety signage a Mechanical Contact with moving parts moving parts N Falling During transportation there a risk material from falling material 1 Increased risk if carried out by Serious injury unauthorised personnel PPEs Supervised work Exposed to Exposed to excessive noise levels Operators Gradual hearing Minimise noise at source or excessive in the milling areas due to the Maintenance impairment isolate noise PPEs Secure noise levels crushing of material inside the Technicians he doors of the imill and due to the operation of homogenisation rooms the homogenisation blowers Work in confined spaces during Operators Seriousinjury PPEs Supervised work the repair of the mill inner walls Maintenance or the replacement of the milling Technicians balls Hot gases returning back due toOperators Serious injury se of an automatic fuel insufficient respiration of the Maintenance from burns interruption system fusible link Death 21 M01 EN 2 4 4 Accident Prevention Check List No Control Points S US Observations 1 Check the existence of collective protection measures such as barriers guards or access doors and the machinery guards 2 Check the existence and adherence to
24. ble leaks using soap solution 18 Check that it is forbidden to grease valve part and that the valves are operated using the appropriate tools provided Useofeylinders O 0 L 19 Check that the cylinders are always held upright and Ata safe distance from the work area in a position that In case of emergency the operative can have unobstructed and quick access to the cut off valves 20 Check that the operating instructions regarding the following items are followed Burner ignition Gas cut off Positioning of a lit burner At the end of the cylinders use the valves are cut off and the remaining gas in the piping 15 let out 2 Check so that during the assembly of the piping to the cylinders and the burner the pipe colours are not confused Areweldingoperation 22 Check that During the arc welding operation the appropriate PPEs are used that must include welding gloves apron shin protectors and safety shoes 23 The electrical connections as well as their condition on the welding machine 1s checked on a daily basis Additionally the condition of the electrodes and the welding pliers 1s checked routinely 24 The pliers that provide the contact should be connected on the body to be welded near the welding area 25 When welding on trucks with rubber wheels the truck should be earthed and extra care should be taken due to the existence of fuel 53
25. e Implementation of approved codes of practice Install proper guards and barriers Guards to isolate mechanical hazards Maintenance by approved technicians under supervision Work inside the hopper only under supervision Concrete walls for the control room Use of the stacker and reclaimer system to collect dust Routine cleaning of the area Good housekeeping RAW MATERIAL Back firing of the furnace Use of fuel safety device fusible link MILLS Noi n HOMOGENISATIO 0156 01 a tag 18 out system during N AND RAW Dust maintenance Foroteciive Use of a closed circuit surveillance system STORAGE sence of protective barrier f Di Absence of guards Use of a dust suction system Disab Electrocution Hot material THE CLINKER PRODUCTION e High temperatures Useofa safe system of work no accidental PROCESS Superheated material particles operation tag 1n tag out procedures PREHEATING OF MATERIAL KILN OPERATION Back firing of burner e Use ofa closed circuit surveillance system 9 Working near hot surfaces e Use 01 8 safe system of work no accidental Working in a hot environment operation tag 1n tag out procedures COOLING SYSTEM CEMENT AND RAW MATERIAL SIORAGE SILO CLEANING Dusty environment Accidental hurling of hot material Use of a high pressure pump to clean the area Noise during the cleaning operation Falling material from the silo wall
26. e facilities against atmospheric discharge Check the existence and use of documented instructions and criteria for the storage of coal open spaces M01 EN 2 10 ENVIRONMENT WORK AREAS AND PASSAGEWAYS Check the existence and use of written Check the cut off of the electricity supply Check the level of supervision of work D 15 Check the maintenance and condition of the fire fighting equipment Check the adherence to instructions The work areas must be constructed and adjusted according to the following parameters e The provision of adequate space for the activities carried out and the existence of entrances and exits e The operational ergonomic and safe positioning of work places and equipment The environmental conditions Ventilation air conditioning and light e The protection against physicochemical agents such as Noise Dust VOCs toxic substances etc The safe keeping of the work place contributes greatly towards the prevention of accidents and work diseases 39 For this to be achieved there 15 a need to e Keep the passageways floors and emergency exits free of any obstacles To remove presently any material spilt on floors and escalators If this 1s not possible the spillage area must be correctly labelled and protected e remove and sharp corners or edges present either as a result of the building or the equipment and furniture e To close any permanent or temporary floor openin
27. e light 14 MO01 EN 2 2 3 Accident Prevention Check List No Control Points S US Observations EM Area of Hopper 1 Check that the material 1s correctly loaded on the vehicle 2 Check the existence of a hopper guard and that 1s In good condition Check that in the hopper area there 1s the correct signage specifying the necessary PPE 4 Check that the correct PPEs are used 5 Check that during reversing the are the necessary sound warnings so that no operative 15 at the back of the vehicle Check that no work 1s carried out 1n the hopper unless there 15 continual supervision that there 1s no risk from crushing rocks and that the feeder 1s secured 7 Check that there 1s the necessary lighting in the crusher area M 8 888 RR In place Ee 15 carried out by the supervisor parts ll Check that the work clothing 15 not loose with the possibility of coming into contact with the rotating part 12 Check that no maintenance work is carried out on working machinery without the supervision and written consent from the Supervisor sss EE Check that all maintenance work 1s carried out by authorised personnel Crusher chamber 14 Check the existence of written procedures for the stopping of the crusher and that these procedures are adhered to 15 Check that all work 1n the crusher chamber 15 carried out under supervision 15 M01 EN 2 3 STORAGE
28. e used so that accidental displacement 1s avoided Following the use of the welding cylinders these are not be left unattended but placed in a predefined and safe area and not in the area of the rotary kiln The cylinders are labelled according to an international labelling system If the cylinders provided do not conform to the labelling these should be removed and returned to the supplier It 15 forbidden to write on the cylinders The oxygen cylinders are stored separately from the other cylinders Also empty and full cylinders are stored separately During storage the cylinders are safely secured in order to avoid their displacement and fall They are not exposed to the sun or other sources of heat Smoking and the use of open flames in the cylinders storage area 15 strictly prohibited The area must be well ventilated Prior to using the welding equipment this 1s checked thoroughly namely the valve the piping and the burner All piping must be equipped with a non return valve The piping connections must be checked on a daily basis On a routine basis the piping 1s checked for possible leaks using soap solution No valve part 1s greased Valves are operated using the appropriate tools provided B Use of cylinders The operatives must make sure that The cylinders are always held upright and at a safe distance from the work area in a position that in case of emergency the operative can have unobstructed and quick access to the cut
29. ery For the purpose of supervising the mills the operators are having to walk on specific platforms equipped with protective railing so that falls from height are prevented Due to the excess kinetic energy of material as 1t rotates and the continuous pounding of the material inside the mill there 1s a serious hazard from the frequent hurling of mill nuts In order to minimise the risk of accidents it 15 necessary to wear the appropriate helmet as well as the periodic tightening of the of the nuts Within the milling area and the blowers homogenising area storage the employees are exposed to noise and dust The sound level must be assessed and if In doubt it must be measured The resulting corrective action first of all must involve the reduction of noise at source then the isolation of noise and if then this is not possible to use the necessary and appropriate PPEs Due to the nature of work there 1s risk of dust being released to the atmosphere and if the dust stays airborne for a long time it creates short and long term breathing problems to the employees dust collection system must be used and employees must use the appropriate PPEs M01 EN 2 4 2 Hazards and protective measures during maintenance The maintenance activities 1n the inside of the mills include e The maintenance of mill linings The replacement of the milling balls As a result of the above activities a number of serious hazards are created for the workers at le
30. gs To replace any barriers or guards when removed e To place the manual equipment and hand tools in safe place and out of the way In work areas where there is a risk of explosion or fire it is forbidden e smoke or use of open flame e use tools and equipment that may create sparks or overheating MO01 EN 2 10 2 Accident Prevention Check List Environment Work areas and Passageways No Control Points Passageways G RN Existence and labelling of emergency exits Check that the passageways and corridors have no obstacles Work place floors Passageway floors Emergency exits Check the existence of cleaning instructions in case of spillage of slippery substances on the floors Check the existence of sharp or protruding edges in the work place Check the existence of floor openings and the existence of protection Check the good housekeeping of the work place Check the work place layout Safe positioning Work places Equipment Check the following environmental 40 Check the adequacy of the stable barriers to protect openings Barriers Guard plates conditions for adequacy Ventilation number of air changes per hour Air conditioning Maximum and minimum work place temperature Lighting Adequate lighting for the work being carried out Check the protection measures against physiochemical factors Check the noise level assessment of le
31. he batteries EM the FL driver M01 EN 2 13 USE OF WORK VEHICLES WV MO1 EN 2 13 1 Hazards from the use of work vehicles Other work vehicles are vehicles that are used to carry out other support activities within the cement factory Such vehicles are earth moving equipment loading trucks mechanised broom etc Hazards can be generated from the use of such vehicles due to bad visibility lack of training not adhering to policies and instructions As a result of the above a number of accidents may arise that may involve the hitting or stepping of personnel hitting other vehicles hitting the buildings or facilities or the tilting of the vehicle itself due to inclined surfaces 46 M01 EN 2 13 2 Accident Prevention Check List Use of Work Vehicles WV Control Points S US BE Check the authorisation given to the WV driver by management Check compliance of the preventive maintenance instructions both from the driver and the maintenance technician Brakes Steering wheel Lifting devices Tire condition Alarm systems documented work instructions devices the WV Check the use of instructions for the safe parking of the WV Inclined level Forks down Keys Use of hand break Check the existence and use of the instructions for the safe use of the WV Carrying of personnel Securing of the load Visibility Unknown load Check the existence of safety signage
32. imit Safety measures for movable scaffolding Avoid going beyond the accepted height Make sure that the wheels are blocked when stationary and secure the structure from possible tripping or movement Do not overload the scaffolding with material since there is the possibility of moving the centre of gravity upwards with increased possibility of tripping Do not move the scaffolding while it is used by operatives or contains materials e Climb up or down the scaffolding from the inside of the scaffolding only e Avoid approaching naked or isolated electrical supply lines either during assembly or the movement of the scaffolding MO01 EN 2 11 2 Accident Prevention Check List Use of Ladders and Scaffolding Control Points S US 1 Check forthe appropriate safety labelling 0 f O 2 Check the maintenance and condition of ladders Use of antl slip steps 3 Check that 1f the ground 15 unstable all the necessary protection measures are applied at the foot of the ladder Check the proper use of the ladder Climb up and down the ladder with the face facing the ladder moving slowly and steadily holding the ladder with both hands Avoid moving the body on the sides order to reach away from the ladder or step further than the third step from the top Check the implementation of the appropriate work instructions Always use the helmet either on the ladder or working near Avoid moving the ladder with a pe
33. ing of material e Insufficient ventilation 9 Working in a confined space e Thermal load e Saturation of space with dust Moving part of transport machinery Use of high pressure pumps With regards to the hazards of the operation and maintenance of the filters please refer to chapter 2 7 26 M01 EN 2 6 2 Risk assessment in clinker production 1 Hazard 2 3 4 Specific No Hazard Hazard Description Person Harm Area Clinker production Falling of operatives during echnicians Serious injury gaining access inside the furnace Work in confined spaces inside Technicians Serious injury the furnace and the preheater Airborne dust inside the clinker Technicians Breathing furnace the preheater and the problems cooler echnicians Serious injury echnicians Serious injury Falling of material Use of the high pressure water pump to clean the linings WOMA S Current safety measures PPEs Checked lifting devices PPEs Supervision PPEs Dust suction system entilation system PPEs Supervision PPEs Supervision PEs Supervision x echnicians Serious injury Maintenance and check of the high pressure line Use of PPEs PPEs Supervision 27 M01 EN 2 6 3 Accident Prevention Check List Clinker production No Control Points S US Observations Om 1
34. ing so that RR 51 10 flexible piping 15 not pulled or bent violently It is placed away from passageways and protected from damage from overstepping hurled particles hot surfaces or sharp edges The stability means provided are used so that accidental displacement 1s avoided Check that cylinder are stored so that Following the use of the welding cylinders they are not left unattended but placed in a predefined and safe area and not in the area of the rotary kiln Check so that The cylinders are labelled according to an international labelling system If the cylinders provided do not conform to the labelling these are removed and returned to the supplier Check so that The oxygen cylinders are stored separately from the other cylinders Empty and full cylinders are stored separately During storage the cylinders are safely secured in order to avoid their displacement and fall They are not exposed to the sun or other sources of heat Smoking and the use of open flames in the cylinders storage area 1s strictly prohibited The area 1s well ventilated Pr wedmgehek __ O 16 Check that prior to using the welding equipment This 1s thoroughly checked namely the valve the piping and the burner All piping 1s equipped with non return valve The piping connections are checked on a daily basis Check a routine basis the piping for 52 _ possi
35. ised and can be a source of ignition rained personnel M01 EN 2 7 3 Accident Prevention Check List Filter operation Control Points S US 1 Check the existence of collective protection measures such as barriers guards or access doors and access passageways 3 Check the existence of operating instructions for accessing the filters 3 Check that all maintenance activity 1n the filters area 1s properly planned in advance Check the use of pre maintenance inspection Authorised technicians 4 Check the appropriateness of the access equipment Maintenance activities 3l Check the activities prior to entering the filters Check of the filter condition Check the securing of the filters Check for the existence and adequacy of the safety signage Check the use of the PPEs Check the condition of the PPEs safety belt harness Ventilation mask Work ware safety shoes Special helmet equipped with eye protector 8 Check the condition of the work equipment Check that the maintenance activity 15 supervised Check that the filters are cleaned using the operating procedures and that the area 1s well ventilated and there 1s proper use of PPEs through the appropriate access doors il NN NN NR following the maintenance activity M01 EN 2 8 LOADING AND DELIVERY OF PRODUCTS The loading and delivery equipment used includes the bag filling machine the palletiser the packing material warehouse the fi
36. istence of a valid CE Marking certificate including the lifting gear 17 Always be aware of the load you are lifting and assess the lifting capabilities of the hoist and the lifting gear pese poo to lifting NETT the use of operating instructions Use Use of crane bridge crane bridge labelling in the crane bridge area 21 Check the rout of the load to be moved a p arrangements prior to moving the load Always be aware of the load you are lifting and assess the lifting capabilities of the hoist and the lifting gear The operator responsible should know at all times 24 Check the existence and use of the suppliers operation and maintenance instructions Check the existence of a valid CE Marking certificate 25 Check that the all operators make use of the appropriate PPEs Lifting equipment at the cement siloM01 02 02 jpg 59 01 03 RISK ASSESSMENT IN THE INDUSTRY GENERAL INFORMATION 01 03 1 SUMMARY OF MAJOR HAZARDS PER AREA OF OPERATION ELECTRICITY MECHANICAL FALLING MOVEMENT OF AREA OF NOISE DUST HAZARDS MATERIAL TRUCKS ACTIVITY QUARRYING CRUSHING SIORAGE AND MATERIAL MOVEMENT GRINDING AND MILLING SILO CLEAN CLINKER PRODUCTION FILTERING PROCESS LOADING AND DELIVERY EE EEE f f EI 1
37. k and relatively frequent operation In the cement industry and for this reason all necessary preventive measures must be taken The cleaning of the silo takes place whenever there 15 a problem in the extraction of material due to the blocking of the outlets from solidified material In addition this happens when there 15 a problem with the ventilators and a result there 1s insufficient ventilation or homogenisation of the material in the Blending Sib The main hazards are focused in the following Work In confined spaces Falling of personnel from the working platform Falling of material Exposure to dust Use of lifting equipment Preventive safety measures For such a high risk operation there must be a responsible supervisor for the silo cleaning He 15 responsible to ensure that the following steps are followed Firstly he must notify the silo operatives about the impending cleaning and to make sure that the feeding of material to the silo 1s stopped This 15 done by decommissioning the relevant electrical motors closing the silo inlet valves and by placing blind flanges for additional safety Before the start of any cleaning activity the silo must be inspected from above using light 15A which 15 lowered gradually downwards in order to observe o are conglomerated masses of material on the silo walls and at what height o The quantity and distribution of material o To identify whether the level of material is over
38. kers it is necessary to Always place and remove the socket while the supply switch is off Always make sure that the socket is appropriate for use and that the earth leads are properly connected e Never use equipment for which the electrical characteristics are not known or they do not carry a label form the manufacturer 9 Make sure that all moving or hazardous parts are equipped with the necessary guards Beaware about where the supply lead 15 placed It should not be placed on hot surfaces or sharp edges e Always check the integrity of the electrical connections when supply leads are extended Always use sockets equipped with RCDs e Always grab the tools from the handle in order to avoid accidental start up of the tool Never lay down the supply leads since there is an increased risk of trips and falls Always use the appropriate PPEs Incase the hand tool 15 not operating properly then it must be submitted for repair to the competent technicians rather than attempt to repair it yourself M01 EN 2 15 1 3 Hazards from the use of hand tools driven using compressed air The main hazards are created from 55 The use of compressed air e The use of flexible piping e The hurling of particles and cut parts during operation For the safe use of hand tools driven using compressed air it is necessary to e Make sure that all moving parts are equipped with the necessary guards and other safety devices e Check the i
39. mperatures eriodic vehicle checks se of appropriate signage during transport Existence of operational procedures for the ransportation of explosives during unstable weather 4 during unstable weather 1 Hazard 2 3 4 5 iN Hazard Area Use of I I I plosives 1 Specific Hazard Description Person Harm Current safety measures i 3 ignorance of special instructions Periodic checks and stock ontrol 3 Failure to In case of untriggered People Death from Existence of written comply with theexplosives there will be orking in nexpected instructions of the charging explosion plan iconfusion he area explosion of and triggering process 2 ntriggered raining of personnel explosive involved Periodic implementation audits 3 ntriggered Work near untriggered bore Death from raining and retraining of bore holes ing 1 nexpected personnel 3 explosion of eriodic audits of operational ntriggered instructions 3 Failure to Failing to implement the ransportation of the company rules and regulations ing 1 explosives to be used only The use of unauthorised rotection of the explosives procedures explosives from high temperatures Failing to use the approved Forbid use of mobiles explosion plan Ireless near the explosives The existence of unexploded Isolation of area from boreholes nauthorised personnel Failing to prevent unauthori
40. nd authorised Check the availability of certificates Check the use of the Regulations for the use of explosives Check that the documented procedures are available 0 24 Check that the procedure for issuing the explosive out of the warehouse 15 followed Check the documentation and records used 7 explosion plan 26 Check that the transportation method 15 carried out according to the operational procedures and the method of protection from heat and humidity unauthorised people approach the area opening the hole on the dynamite stick 29 Check the method of communication during the transportation and use of explosives x Charging and triggering are cleared from the explosion area 31 Check the warning procedures J _ ME communication of the explosion plan changes to the explosion plan p explosion a unexploded bore hole EY Check the existence of operational Instructions for the case of electric triggering MO01 EN 2 1 4 3 Accident Prevention Check List The drilling process EMI Control Points KG During the During the preparation for drilling for drilling Check the existence of a drilling plan prior to the operation surface cracks Make sure that no quarrying or material transportation work 15 carried at a quarry table situated above s sss
41. ng or cutting operation there must be a fire extinguisher at hand and the operative must be competent in their use Make sure that in case where welding 15 carried out indoors then a smoke suction system must be used appropriately placed Prior to leaving the welding area the operative must check if as a result of the operation a hot spot has been created superheated welded areas must be protected so that they do not accidentally come in contact with skin Welding cannot take place In areas where there 15 storage of flammable liquids such as petrol and paint Always use the appropriate PPEs provided M01 EN 2 14 1 2 Hazards from the use of Oxygen Acetylene in welding and cutting operations A General care of the cylinders The operatives must make sure that Oxygen or acetylene cylinders are handled with care whether full or empty and should not be thrown down rolled or hit Prior to their transportation valve caps must be used 48 The cylinders placed In special cylinder trolley In upright position and tight up using chains or other strong means The cylinders should not be transported with any other means other than the trolley provided The use of magnetic lifting devices must be avoided The flexible piping 1s not pulled or bent violently and should be placed away from passageways and protected from damage from overstepping hurled particles hot surfaces or sharp edges The stability means provided ar
42. nished goods warehouse and the truck silo filling facility The main hazards associated with this area are e Mechanical hazards associated with the moving parts of machinery The movement of heavy lorries and goods transporting equipment fork lifts delivery lorries silo trucks etc e Fire in the packing material area or the wooden pallets e Falls from height either material or people e The hurling of dust or coming into contact with hot material e Manual handling of loads e Exposure to noise The basic preventive measures for the reduction of the reduction of the consequences from the above hazards are e That guards or other collective safety barriers should never be removed barriers access doors e The adherence to the special operating instructions 32 The adherence to the limited access rules as well as the road safety signage The use of the appropriate PPEs provided During maintenance activities the following hazards are added to the above list e Getting hit by compressed air or other hydraulic fluids e Getting hit crushed or trapped by machinery e Dusty environment The basic preventive measures for the reduction of these additional associated risks are e The adherence to the standard operating procedures for the securing of the machinery prior to any maintenance activity e adherence any additional special instructions provided The use all the necessary PPEs provided 33 M01 EN 2 8 2 Risk a
43. ntegrity of the flexible hoses the pressure level as well as the connections to be safe and dry e Make sure that the piping does not impose an increased risk to the others e Never bend the pipes in order to stop the flow of air or use the pipes as a puling rope to pull the tools e Always use the supply valve whenever there is a need for die change or at the end of the e Always remove the air from the supply line at the end of operation e Always use the appropriate PPEs MO1 EN 2 15 2 Accident Prevention Check List Use of Manual Tools Control Points S US Manual hand tools Check the existence of safety labelling on Check that the moving parts are adequately guarded Check the existence of CE marking Ml place eee T 1 authorised to use the particular tool work instructions the level of housekeeping measures are at hand and that the operative Check that the necessary fire fighting 15 trained in their use Check that the operative uses the PPEs provided and that his work ware 15 not loose with the possibility of entanglement in the tool Check that the operative 1s aware of the use of appropriate PPEs for each type of work pM Manual hand tools with electrical supply Check that the appropriate work instructions are followed with respect to 56 working in the open Appropriate voltage Wet work area Portable lights Method of connection to supply source Protection measures for passer
44. of hot spots during operation or maintenance of the tanks e The self ignition of hot material e The electrical discharge thunderbolt electrostatic charges short circuits The basic preventive and protective measures for the reduction risks associated with the above are aimed towards the isolation or quick reduction of one of the three sources that create or cause the combustion namely the fuel quantity or oxygen or the presence of heat For this reason it 15 necessary e To adhere to the special safety operational instructions that specify that no smoking is allowed nor the use of open flames near that fuel tanks and the distribution facilities comply with the safety signage e To make sure that the supply of electricity is switched off prior to any maintenance work e To make sure that the conditions for creating an explosive is removed prior to entering an empty tank or storage silo that previously contained fuel To routinely maintain all the storage facility s health and safety equipment such as high pressure relief valves the control valves the equipment for protection against atmospheric discharge the earthing equipment the fire fighting and or neutralisation as well as the pipe isolation valves e To always use the appropriate PPEs All hot working activities near the tanks should not be carried out unless authorised using the documented operational procedures Use of Coal During the use of coal the main haz
45. off valves The burner 15 lit using a steady flame or a lighter without delaying especially indoors The burner 15 cut off during momentary breaks in operation either to clean the burner or any other reason The flame can be on only for short durations The burner is placed in a predetermined position so that it does not come accidentally into contact with the piping the cylinders or other operatives In case the burner catches fire the valves must be cut off readily For this reason the appropriate key must be on the valve at all times The flame 15 cut off by cutting the acetylene valve first and then the oxygen valve At the end of the cylinders use the valves are cut off and the remaining gas in the piping should be let out 49 In case of cylinders overheating or ignition the emergency procedures are followed The approved pressure settings are always used During the assembly of the piping to the cylinders and the burner the pipe colours are not confused M01 EN 2 14 1 3 Arc welding operations The welding and cutting operations can be a source of hazards such as Hurling of hot particles Burns and fires Explosion Electrocution Exposure to hot and radiating sources Smoke and dangerous gases The additional protection measures during arc welding operations are The use of the protective arc welding mask provided to protect the eyes from the flash as well from ultra violet rays The cover should be able to protect the
46. operation e To secure the hand tool before its cleaning or maintenance e To never clean the work benches by using o compressed air or by blowing or by using bare hands Use the appropriate brooms and spades provided The grinding pieces may cause an accident e To never talk to the operator during the use of hand tools To always use the appropriate PPEs for each type of operation 54 M01 EN 2 15 1 2 Hazards from the use of hand tools with electrical supply The basic hazards are Coming into contact with electricity Coming into contact with its moving parts The use of inappropriate parts and consumables The hurled particles parts or machined parts During the use of electrical hand tools such as drills and grinding wheels it 1s necessary to always check the environmental conditions such as The working voltage and well as the supply sockets The supply must correspond to the one labelled on the tool itself If the work area is wet or there 15 possibility of the tool coming into contact with metallic masses the voltage should not be more than 50V Portable light must carry an appropriate RCD 15A Hand tools with double insulation must be preferred since they are safer Hand tools with power greater or equal to 1000W must be connected on the supply using a socket equipped with an RCD safety device The area must be appropriately lit and the passageways must be protected For the safe use of portable electrical tools by the wor
47. or inappropriate securing of the load e Tilting of the load during its transportation 37 e Crashing of the load on the building and as a result the tilting release and crushing down of the load e Electrocution as a result of lifting mechanism contacting overhead electricity supply lines In general for the safe use of lifting equipment it 15 necessary To allow their operation only by authorised and trained personnel having all necessary licenses e To make sure that the operators comply with the necessary work instructions e make sure their safe operation and in particular the stopping mechanism the breaks and the lifting lines check on a routine basis the hook mechanism To always secure the load using the approved straps e To always lift the load slowly upwards for several cm in order to make sure that the load 1s balanced and stable prior to its lifting e To always avoid the lifting of loads overhead from working personnel For this reason the lifting equipment must be equipped with a warning sound signal so that all persons are withdrawn from the area under the load 01 2 16 2 Accident Prevention Check List Use of Lifting equipment Control Points S US BE General protective measures 1 Check the existence of the necessary safety labelling on the lifting equipment Check that the moving parts of the lifting device 1s appropriately guarded Check the existence of a valid CE
48. over and under ofthe technicians death appropriate safety signage transportation system Risk when carried out by Serious injury se of authorised personnel unauthorised personnel death a Supervision Unauthorised tampering Serious injury se of authorised personnel death Supervision Unclean platforms can cause Fall from height Implementation of the dust staggering and falls Serious injury cleaning schedule platforms death M01 EN 4 3 3 Accident Prevention Check List Material Storage and Transportation Control Points S US swaga 1 Check the existence of a general cleaning programme for the systematic cleaning the settled dust Wy the dust sources 3 Check the proper operation and maintenance condition of the dust suction systems __ Material transportation systems J f y O guards the transportation systems 17 Check the protection measures in case maintenance activity 1s carried out during the operation of the transportation system Check the protection measures taken during the removal of material from the conveyor belts Check the protection measures taken during the overflowing of the transportation system health and safety signage by the operatives in the area e transportation system 15 carried out Check that there the appropriate labelling of approved passageways __ Maintenance of transportation s
49. r 5 Current safety measures Severe harm Training of personnel Periodic check of protective measures of the bore holing Material falling from height Personin Severeharm Checks of the quarry table quarry table Existence of a drilling plan Never drill on an older bore i Severe harm Implementation of operational procedures including checks prior to working on a quarry able Make sure that 15 dequate space between the bore holing machinery and the ____ U 1 quamytableedge O heck prior 10 working quarry table for possible cracks and drops Training of personnel se of PPEs raining of personnel se of PPE Implementation of operational directives relating to the movement of transportation equipment and personnel in he quarry Implementation of operational directives relating to the securing of machinery for the execution of maintenance ork reparation of the temporary measures Use of PPE MO1 EN 2 1 4 Accident Prevention Check List M01 EN 2 1 4 1 Accident Prevention Check List Storing and Transportation of Explosives Control Points Warehouse External signage outside the explosives warehouse there Ese necessary PPE are prescribed 4 Check the adequacy of the housekeeping outside the warehouse Are there other materials that are a source of hazard Check the maintenance condition of
50. rage facilities MO01 EN 2 1 1 Hazards as a result of the Storage Transport and Use of explosives The explosives are stored only in approved sites that have to comply with the requirements of relevant legislation During explosives storage the main hazards are the following e Storing explosives and capsules in the same area e Entry of unauthorised persons in the area e Smoking or use of naked flame in the storage area e Storage of other goods and equipment housekeeping in and out of the warehouse e Inadequate distance lt 10cm between the containers and the warehouse wall e Absence of boundaries and labelling e Insufficient building maintenance lighting ventilation with the possibility of concentration of humidity 1n the warehouse e Execution of non approved maintenance work on the warehouse electrical wiring e Insufficient warehouse security Not following the FIFO First In First Out in the management of explosive stocks Using work or personal equipment that can create sparks eg wireless mobile phones Hazards during the transport of the explosives are e The use of unauthorised vehicles e The transport of explosives together with capsules as well as not keeping the necessary labelling during transport e The carrying of passengers e The unplanned stoppage e The transport of explosives during unstable weather Hazards during the use of explosives are e The Failure to implement the company rules and reg
51. risks associated with the use of gas 1t 1s necessary to Routinely check the integrity of the gas distribution network and always follow the special safety instructions 1n case of maintenance on the electrical safety devices Make sure that all authorised personnel involved know and operate the emergency gas cut off shat down procedures The storage tanks and distribution network are properly earthed and are equipped with the necessary facilities for use against atmospheric discharge 2 M01 EN 2 9 2 Risk Assessment at the Fuel Storage Facilities 1 Hazard 2 3 4 5 Specific Hazard Area Hazard Description Person Harm Current safety measures Fuel Storage of open flame create ATI Hot working operating accidental ignition personnel Instructions n s Hot spots are created during Hot working operating imaintenance activities which can personnel instructions be a source of ignition ATI Hot working operating particles other fire source in the area personnel instructions Emergency response plan in case of another fire source in he area Electrical Electrical spark during Authorisation procedures for maintenance work on the coal orking on the coal dust piping system ransportation system S 42 I High temperatures created within Coal storage Inspection the coal storage stock piles procedures ES EN Atmospheric
52. rson on it Use of an assistant to help the movement of people and vehicles whenever he ladder has to be placed in a passageway Avoid letting two operatives on the same ladder Never leave tools on the top step jaane Is carried out by competent people Check that prior to the assembly of the scaffolding all parts and equipment are thoroughly checked of a double ladder Never use the ladder as a scaffolding piece Never work on metal ladders when the distance between the top of the ladder and the electricity supply lines 1s less than 5 meters EN Eg Check that the scaffolding complies with the legal requirements relating to the structure assembly use the stability characteristics the strength the adequacy of the levels and floors the access to the levels etc Check that the floor levels are at least 0 6m and that the barrier 15 at least Im high 10 Check that the metallic scaffolding 15 protected against atmospheric discharges by having earthing every 20m along the perimeter ll Check that the maximum scaffolding load is known and documented 12 Check the stable tying up on the building to effectively secure the scaffolding from horizontal or seismic movements on a stable ground Movable scaffolding i s the accepted height 15 Check that the wheels are blocked when stationary and that the structure 1s secured from possible tripping or movement 16
53. s Dusty environment Operator getting overcome by material at the base of the silo Use of authorised personnel Use of a dust suction system Disab Use of a safe system of work no accidental operation tag in tag out procedures Use of dust suction system Floor preparation Use of safety signage Use of tag in tag out procedures Use of blind flanges Continual supervision Provision of adequate lighting Provision of sufficient ventilation using bag filters PACKAGING LOADING AND UNLOADING Dusty environment Falling material Moving parts of packaging machinery Movement of heavy trucks Existence of third parties truck drivers in the area Overhead loads Use of lifting equipment Falling of loads Dusty environment Use of a dust suction system Use of appropriate PPEs Training of personnel Adequate machine guarding Use of safety signage Use of authorised personnel Provision of appropriate maintenance to the lifting equipment Use of load limiting devices Routine cleaning of the area MAINTENANCE DEPARTMENT FUEL STORAGE Toxic fumes from welding operations Insufficient tag 10 tag out procedures during maintenance Manual handling causing Musculoskeletal problems High temperatures Electricity Use of hand tools Bad housekeeping Use of naked flames near fuel storage The creation of hot spots during maintenance activities The hurling of hot material in the f
54. s by Check that the manufacturers instructions are followed Check for CE Marking labelling connections connections Check the work area housekeeping paying EM particular attention to the supply lead Check the use of appropriate PPEs Hand tools driven using compressed air _ ball cl labelling on the tools Check that the moving parts are adequately guarded Check the existence of CE marking ID place Check the work area housekeeping paying particular attention to the flexible air supply hoses 19 Checktheuseofapproprate PPEs M01 EN 2 16 LIFTING MACHINES AND EQUIPMENT The usual lifting machines devices and equipment used in the cement industry are cranes elevators lifts hoists the crane bridge and hydraulic jacks Due to the nature of operation of these machines any misuse failure to comply with instructions any lack of planning or coordination careless action inappropriate stand or positioning of body insufficient maintenance etc can be serious sources of hazards in the work place M01 EN 2 16 1 1 General hazards in the use of Lifting equipment The main sources of hazards from the use of lifting equipment are e Crashing of the load or the lifting mechanism onto employees or operators within the working range of the lifting equipment e Fall of the load to be lifted due to the failure of the lifting gear e Fall of the load to be lifted due to insufficient
55. sed Existence of written person to approach the regulations for the connection 4 explosives area and electrical triggering Allowing the transport of more than required explosives quantity Leaving the explosives unprotected from excessive temperature or near flame Using mobile telephony or wireless near explosives Using unauthorised equipment during bore holing 3 nplanned Triggering the explosives by Death from Existence and communication riggering unauthorised personnel or Ing 1 nexpected of the triggering plan outside the agreed timetable explosion of se of trained personnel Not giving the necessary and ork audits timely warning prior to triggering M01 EL 2 1 3 2 The bore holing process 1 Hazard 2 No Specific Hazard Area Hazard Description 0 Bore holing he bore 1709 moving parts of the bore holing machinery Failure of a instability following the pos explosion Blasing of material during 5 bore holing Presence of dust and noise Pemonin Gradual hearing Training of personnel of dust and noise during the operation of the drilling machinery Crushing of employees working on the quarry tables NES Maintenance of Failure to secure the he bore holing machinery Maintenance by unauthorised personnel 3 Person Maintenance echnician 4 Harm Severe harm Severe harm impairment problems Severe harm or Severe harm o
56. sitioning of the load on the forks e Excessive speed and negligent road safety culture The fork lift drivers have the direct responsibility for the safe use of the vehicle It 1s also the responsibility of the maintenance personnel to assure the reliable and proper functioning of the vehicle M01 EN 2 12 2 Accident Prevention Check List Use of Fork lifts FL Control Points S US Check the authorisation given to the FL driver by management Check compliance of the preventive maintenance instructions both from the driver and the maintenance technician Brakes Steering wheel Lifting devices Tire condition Alarm systems Check for existence andcomplianceto J 45 __ documented work instructions 4 Check the existence of the necessary Mm Mm Check the use of instructions for the safe parking of the FL Inclined level Forks down Keys Use of hand break Check the existence and use of the instructions for the safe use of the FL Carrying of personnel Appropriate forks Securing of the load Visibility Forks down Unknown load Inappropriate pallets Check the existence of safety signage Area used by FL Area used by personnel Check the area used by FL Sharp upwards or downwards inclination Uneven floor rE T instructions during the refilling of fuel Check the adherence to the safety instructions during the charging of t
57. ssembly instructions of the scaffolding manufacturer Prior to the assembly of the scaffolding all parts and equipment are thoroughly checked For scaffolding of more than 10m high they must be made of metallic piping The scaffolding must comply with the legal requirements relating to the structure assembly use the stability characteristics the strength the adequacy of the levels and floors the access to the levels etc The floor levels should be at least 0 6m There 15 also a need for a barrier of at least 1m height Metallic scaffolding must be protected against atmospheric discharges by having earthing every 20m along the perimeter The maximum scaffolding load must be known and documented The stable tying up on the building effectively secures the scaffolding from horizontal or seismic movements Additionally it must be made sure that the scaffolding base 15 situated on a stable ground When working on scaffolding it is necessary to e Carry the hand tools only in special toolboxes and belts e ift material using appropriate lifting devices e Avoid throwing tools and materials from height but by using the appropriate containers e Avoid leaving unsecured planks e Secure safely the floor planks e Avoid blocking the passageways with material e Move from one level to the other using the appropriate ladders 42 e Avoid running or jumping on the level floors Avoid overloading the floors beyond the approved loading l
58. ssessment Bagging and loading for delivery of goods Hazard 2 3 4 5 Specific Hazard Description Person Harm Current safety measures Hazard Area Operators hazard particularly when the operatives work near the machine Dusty environment in the bagging Operators Breathing problems Safety labelling Restricted area access areas Use of PPEs Movement of Movement of heavy goods Operators Serious injury Existence of the necessary heavy goods transportation vehicles death guards Safety labelling ransportation Restricted access areas Use of ehicles PPEs Maintenance Getting hit by compressed area or Technicians Serious injury Existence of the necessary of machinery hydraulic fluids guards Safety labelling estricted access areas Use of Falling of Hurling of material material form Exposure to Dusty environment i 34 M01 EN 2 8 3 Accident Prevention Check List Loading for delivery of goods Check the existence of collective protection measures such as barriers guards or access doors Check the existence and use of operating procedures for gaining access to the bagging area Check that all maintenance activity 1n the bagging area 1s properly planned in advance Check the use of pre maintenance inspection Authorised technicians Check that the bagging equipment operates properly and that all moving parts are isolated or are far away from the operative Check th
59. tation systems must be avoided because there 15 the risk of personnel getting trapped by the conveyor or overflowing material can fall from height e The overhead bridges must be clean in order to minimise the possibility of the tripping and falling of the personnel performing the checks on the conveyor belts e Any intervention on the conveyor belt overload systems must be done by authorised personnel During the maintenance activities of the material conveyor belts it 15 necessary e For the transportation systems to be secured so that accidental start ups are eliminated e To check that all guards have been put in place prior to commissioning and Check that the maintenance work is completed and that all maintenance personnel have left the vicinity of the equipment 16 M01 EN 2 3 2 Risk assessment in the material storage and material transportation systems 1 Hazard 2 3 4 5 No PPE ce Hazard Description Person Harm Current safety measures Hazard Area 2 Material storage and material _ transportation systems Airborne dust Airborne dust in the storage area Operatives Breathing PPEs Dust suction systems problems Contact with moving parts the Operatives Serious injury Guarding risk of entrapment Contact with moving parts the Operatives Serious injury Side guarding risk of entrapment Use of unauthorised passages Operatives Serious injury estricted entry Use of Travelling
60. the 5 i building The condition of the roof the door the walls 1ntegrity and humidity Check the position of overhead electricity supply cables so that in case of electric discharge there 1s no explosion hazard Warehouse Internal Check the adequacy of internal housekeeping waste material specified corridors Check the existence of materials other than explosives Check the place where the capsules are stored 7 Check the adequacy of the space between the explosives boxes and the wall There should be a space of at least 10 20 10 Check for the existence of humidity on the floor and the walls Are there adequate ventilation measures electrical wiring ll kept by the storekeeper physically checking the explosives batches lll E warehouse Transport of explosives 0 of explosives E the transport of explosives s ais RN vehicles Check the use of the necessary signage 10 during the transportation of explosives 18 Check the procedure for transporting explosives and capsules Check the procedure for avoiding of an unplanned stop 20 Check the procedure for the transport of explosives during unstable weather 2 Check the arrangements for the transport of passengers Control Points S US EN Use of explosives 22 Check that all personnel involved with the use of explosives are approved a
61. the filter in a well ventilated environment The adequate earthing of the electrostatic filter The interruption of the compressed air supply bag filters The isolation of the mechanical movement of the filter as well as the material transportation system The review the dust levels prior to entry into the filter Opening the side doors so that the filter 1s cooled prior to entry 29 e The presence of supervisors outside the filter side doors so that they act In case of an emergency e The use the appropriate PPEs 30 M01 EN 2 7 3 Risk assessment in filtering operations 1 Hazard 2 3 4 5 Specific Hazard Area Hazard Description Person Harm Current safety measures uarding Barriers and other collective safety measures uarding Barriers and during maintenance and operation l echnicians other collective safety measures Operating procedures Exposure to dust during normal Operatives Serious injury A dequate securing of the filters prior to any operation and maintenance echnicians maintenance work Use of Work in confined space inside theOperatives Breathing problems Adequate securing of the onfined spaceelectrostatic filters echnicians asphyxiation filters Use of PPEs authorised and trained personnel Static electricity can be created if Operatives Serious injury A dequate securing of the the filter is not earthed properly Technicians filters Author
62. the steps In case that the floor surface 1s unstable or uneven there 15 a need to take the necessary measures that the ladder legs are stabled e Climb up and down the ladder with the face facing the ladder moving slowly and steadily holding the ladder with both hands Avoid moving the body on the sides in order to reach away from the ladder or step further than the third step from the top e Handle only light tools always properly on a special belt so that the hands are always free to move up and down 4 Always use the helmet etther the ladder or working near Avoid moving the ladder with a person on it Have a colleague at hand to help the movement of people and vehicles whenever he ladder has to be placed in a passageway Avoid letting two operators on the same ladder Never leave tools on the top step of a double ladder Never use the ladder as a scaffolding piece Never work on metal ladders when the distance between the top of the ladder and the electricity supply lines 15 less than 5 meters MO01 EN 2 11 1 2 Scaffolding hazards For the execution of work at a height of more than 2m the scaffolding 1s the best method for managing the risk of falling from height The use scaffolding itself on the other hand has the following hazards The assembly and taking down of the scaffolding must be carried out by competent people equipped with the necessary harness and under the direction of a supervisor and according to the a
63. ting instructions 4 Check the good housekeeping of the work area Check that all flammable material and waste material 1s removed If this 1s not possible then protective barriers must be used 5 Check that during the welding or cutting operation there 15 a fire extinguisher at hand and the operative 15 competent In their use Check that the appropriate PPEs are used Welder must know the eye protection measures to be used for each type of welding technique used J Check that in case where welding is carried out indoors a smoke suction system is used appropriately placed Check that prior to leaving the welding area the operative checks if as a result of the operation a hot spot has been created Check that the superheated welded areas are protected so that they do not accidentally come in contact with skin Check that no welding takes place 1n areas where there 1s storage of flammable liquids such as petrol and paint __ Transportation and use of cylinders 11 Check that oxygen or acetylene cylinders are handled with care whether full or empty so that They are not thrown down rolled or hit Prior to their transportation valve caps are used The cylinders are placed in a special cylinder trolley in the upright position and tight up using chains or other strong means The cylinders are not transported with any other means other than the trolley provided The use of magnetic lifting devices are avoided Check flexible pip
64. uel area Electrical discharges Thunderbolt electrostatic charges during refuelling short circuits Use of a fumes suction system Trained personnel Use of hoists Use of approved and maintained metering devices RCD s 30 mA Routine cleaning goog housekeeping practices Use of approved and well maintained hand tools USE Existence of a work permit system for working near the fuel storage Maintenance and control of the anti discharge system USE OF ALTERNATIVE FUELS WORK ENVIRONMENT WORK AREAS AND PASSAGEWAYS USE OF WORK VEHICLES FORK LIFTS LOADERS UNLOADERS Disab Biological hazards from the use of bone meal used rubber tyres olive seats RDF and other solid waste Absence of safety signage Obstructions in the passageways Inadequate environmental conditions Insufficient protection from physiochemical factors Insufficient training Insufficient maintenance Inappropriate securing of the load Speeding Insufficient visibility Routine cleaning of the area Use of appropriate PPEs Use of appropriate safety signage indicating the passageways and emergency exits Good house keeping of the area Assessment of the environmental conditions and provision of adequate protection Authorisation and training of personnel Routine maintenance of the work vehicles Provision of work instructions Labelling of the vehicle movement area LIFTING EQUIPMENT Crush of the load or
65. ulations e The use of unauthorised explosives e The Failure to use the approved explosion plan e The existence of unexploded boreholes The Failure to prevent unauthorised person to approach the explosives area The transport of more than required explosives quantity The temporary storage of explosives at excessive temperatures greater than 65 degrees C or near naked flame The use of mobile telephony or wireless near explosives The use of unauthorised equipment when opening a hole in the explosives During the filling up and triggering the explosives the main hazards are The triggering the explosives by unauthorised personnel or outside the agreed timetable The insufficient warning prior to triggering The approach of other persons other than the person in charge near the explosion area following the triggering The failure to comply with the company procedures in case of untriggered explosives The failure to comply with the connecting procedures in case of electrical triggering M01 EN 2 1 2 Hazards during the Bore holing process During the bore holing process the basic hazards are The moving parts of the bore holing machinery Falls from height Material falling from height Crushing of quarry table Hurling of material Presence of dust and noise Movement of earth moving equipment M01 EN 2 1 3 Quarrying Operations Risk Assessment Protection Measures M01 EN 2 1 3 1 Storage and transport of explosives Ha
66. vel Check the dust level take dust measurements Check the VOCs levels Check the existence of toxic substances in the work place M01 EN 2 11 LADDERS AND SCAFFOLDING MO01 EN 2 11 1 1 Hazards from the use of ladders The common movable ladders must be made from strong material equivalent to its use with strong beams and non slippery steps A ladder that is not functioning properly must be removed from use Another main hazard 1s the inherent instability of the ladder and for this reason the ladder must be stabilised appropriately or held down by personnel The ladders must be fit for use The ladder must be at least 1 m higher than the work level The ladders must have the right inclination so that they are not too inclined or unstable The inclination angle should be between 68 to 75 or inclination base to 4 height The double movable ladders should be less than 5 meters high and should have a solid method of restrain so that they do not open beyond the accepted limit For ladders equipped with extensions the full length of which reaches a maximum length of 12 meters must be stabilised at the top and the operative on the ladder must be supervised by a colleague at the ladder base The operatives using such types of ladder must be trained and authorised in their use For the safe use of ladders it 1s necessary to e Check the condition of the ladders as well as the presence and adequacy of the anti slip material on
67. xperience of the ways in which accidents be prevented basic knowledge for managing risk MOI EN 1 3 CLASSIFICATION OF THE HAZARDS IN THE CEMENT INDUSTRY In all the cement production processes there are hazards that can be classed in e Routine and general hazards such as o Safe behaviour o Environment work and passage areas o Work equipment o Safety labelling o Personal Protective Equipment PPE o Manual load handling e Special hazards during the cement production phases such as o Quarrying o Crushing o Clinker production o Milling processes at raw mill cement milling and coal milling o Material transport o Hitering o Storage o Loading and delivery of final products o Fuel storage activities o Use of hazardous material o Generating units e Special hazards as a result of the work environment o Dust o Noise o Fire o Emergency response M01 EN 1 4 CEMENT MANUFACTURE PROCESS FLOW The following diagram shows the process flow of a typical cement factory 01 0 M01 EN 2 HAZARDS AND THEIR SOURCES IN THE CEMENT INDUSTRY M01 EN 2 1 QUARRYING The quarrying activity includes the drilling of bore holes the filling up of explosives and the triggering of the explosives Once this happens then the material 1s loaded and transported either to open storage piles or to the crushing area During the process of charging and ignition the explosives are transported to the explosion area from the explosive sto
68. xz Education and Culture Leonardo da Vinci This document does not necessarily represent the Commission s official position CEMENT INDUSTRY Coordinator Cyprus Workers Confederation SEK Participants Department of Labor Inspection CY Cyprus Safety and Health Association CY Cyprus Employers amp Industrialists Federation CY Arbeit und Leben D Odense Techniske Skole DK Hellenic Institute for Occupational Health and Safety EL Kauno Kolegija LT Confederatia National A Sindicatelor Libere din Romania FRATIA RO Center for Advanced Technologies Politechnic University of Bucharest RO TABLE OF CONTENTS M01 EN 1 INTRODUCTION TO THE SUBJECT MOI EN 1 1 SCOPE OF THE MODULE MOI EN 1 2 LEARNING OBJECTIVES MOI EN 1 3 CLASSIFICATION OF HAZARDS IN THE CEMENT INDUSTRY MOI EN 1 4 PROCESS FLOW DIAGRAM MOI EN 2 SPECIFIC HAZARDS AND THEIR RISKS IN THE CEMENT INDUSTRY MOI EN 2 1 QUARRYING OPERATIONS MOI EN 2 2 CRUSHING MOI EN 2 3 STORAGE AND MATERIAL MOVEMENT MO1 EN 2 4 GRINDING AND MILLING OF RAW MATERIALS AND CEMENT MOI EN 2 5 SILO CLEANING MOI EN 2 6 CLINKER PRODUCTION MOI EN 2 7 FILTERING PROCESSES MOI EN 2 8 LOADING AND DELIVERY OF FINAL PRODUCTS MOI EN 2 9 FUEL STORAGE FACILITIES MOI EN 2 10 WORK ENVIRONMENT PASSAGE WAYS MOI EN 2 11 LADDERS AND SCAFFOLDING MOI EN 2 12 FORK LIFTS MOI EN 2 13 WORK VEHICLES MOI EN 2 14 WELDING AND CUTTING ACTIVITIES MOI EN 2 15 WORK EQUIPMENT MOI EN 2
69. ystems 12 Check the securing procedures before and after the maintenance of transportation systems including the guards 13 Check the electrical panels so that all electrical circuits are properly labelled MO01 EN 2 4 THE MILLING PROCESSES MILLING HOMOGENISATION STORING RAW MATERIAL AND CEMENT MILLS The milling plant consists of e The mill cylindrical with ball bearings and the separator e The filters The hazards and protection measures are described in chapter MO1 EN 2 6 e The furnace for the production of hot gases for drying for the hazards and protection measures please see the Chapter on fuels e The blowers for mixing the material after milling and before storage e exhaust blowers at the storage silos M01 EN 2 4 1 Hazards and Protection measures during normal operation The main hazards during normal operation of the mills mainly concern The movement parts of machinery e The falling of personnel from height of material e The falling of material from height in case the protection ducting is blocked The hurling of mill parts e The exposure to noise e The exposure to dust 18 For the safe operation of the mills all the necessary guards must in place in order to isolate the mechanical movement from contact with the operators Additionally where operatives need to be near moving parts of machinery the necessary emergency batons must exist In case there 15 for to stop the machin
70. zard 2 Specific Hazard Area Storage and 1 ransport of explosives Includes Storing of explosives with triggers Storage of other goods Bad housekeeping Bordering and labelling Failing to comply with the FIFO Use of work or personal Hazard Description 3 4 Person Harm Multiple deaths 5 Current safety measures Existence of operational procedures equipment that create sparks Multiple deaths Existence of operational procedures erlodic checks Trained personnel Insufficient Entry of unauthorised persons Storekeeper Ity 1 Failing to comply with the EM gt safe keeping and securing ing 1 iprocedures Insufficient maintenance the possibility of entry of 1101 humidity 1 3 Unauthorised maintenance of electrical wiring The use of unauthorised i vehicles The transport of explosives i together with capsules as well as not keeping the necessary labelling during transport The carrying of passengers The unplanned stoppage The transport of explosives Multiple deaths from explosion due to wiring he area failure or from Maintenance personnel Multiple deaths passengers due to explosion Inhabitants reventive maintenance of the building check for humidity on walls and floors electrical iring eriodic checks Trained maintenance personnel se of approved vehicles rotection of explosives from high te
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