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Sonadih Cement Plant
CII - SHE Award
28th February 2014
Overview
AS
J
Lafarge, Arasmeta
MJ
J
Lafarge,Chittaurgarh
Lafarge, Bhiwani
� Sonadih Cement Plant is having two
Clinkerisation lines.
� Commercial Production of Line 1 started in
1993.
� Initial Installed Capacity 1 Million Ton.
� Taken over by Lafarge in 1999.
� Commercial Production of Line 2 started in
2009.
� Present Production Capacity:
Sonadih Cement Plant
AS
Lafarge,Jojobera
Lafarge, Sonadih
Lafarge, Mejia
� Present Production Capacity:
1. Clinker – 3 Million Tons (Line 1: 1.4 Million
ton & Line 2: 1.6 Million ton)
2. Cement – 0.5 Million Tons PPC
� Main raw materials:
1. Lime Stone, Iron Ore, River Sand, Fly
ash, Gypsum, Flue Dust, Coal, Liquid
solvents and other alternate fuels.
� ISO 9001, 14001 & OHSAS Certified Plant.
Health & Safety Policy
Sonadih Cement Plant
SCP Vision, Objectives & Target 2014
Sonadih Cement Plant
Engagements
Monthly
� Gate Meeting
� Logistic Meeting
� Plant Safety Committee Meeting
� Departmental Safety Committee Meeting
Yearly Celebrations:
� Road Safety Week
� Fire Safety Week
� Safety Month Celebration
� Safety Week
� Transporters Meeting
� World Environment day
� Earth Day etc.
Sonadih Cement Plant
Safety Initiatives: Participation in Safety Management System
Plant Manager addressing the Highest Engagements TrophyPlant Manager addressing the
Gate Meeting
Highest Engagements Trophy
Housekeeping Trophy Health and Safety Nukkad
Sonadih Cement Plant
Safety Initiatives: Reward and Recognition Schemes
Plant Manager distributing prize
for safety person of the month Maintenance Manager distributing
the prizes for Near Miss Reporting
Sonadih Cement Plant
for safety person of the month the prizes for Near Miss Reporting
Conducting Quiz Competition at
gate meeting
Plant Manager distributing prize for
Best Nukkad at gate meeting
SCP Safety Statistics
2011 2012 Dec-13 YTD 2013 YTD 2013 Dec-13 2012 2011
0 0 0 0 Fatality 0 0 0 1
1 0 0 0 LTI 0 0 1 0
0 1 0 0 Medical Injury 2 0 2 6
3 3 0 4 First Aid Injury 15 1 18 30
1.1 0 0 0 Frequency Rate 0.00 0 0.55 0.47
Lafarge EmployeesDescription
Contractor Employees
Sonadih Cement Plant
� Increasing trend in HS Training Man-Hrs, Safety Engagement & Unsafe condition reporting.
1.1 0 0 0 Frequency Rate 0.00 0 0.55 0.47
4494 4580 208 5806 Total HS Training Man-Hrs 26175 1578 21141 24029
334 271 28 308 Training hours spend 2504 191 1749 1650
2772 4589 1581 8093 Total Safety Engagement NA NA NA NA
268 197 47 207 Nearmiss 80 13 84 125
3957 4438 1228 7408 Unsafe Condition 4 0 51 142
44 8 0 20 Unsafe Action 124 5 72 250
Health and Safety Initiatives - 2013
� Process Owners pro-actively implementing H&S Standards and Advisories and it has
been translated in Hindi for easy understanding.
� Started bottom up approach by involving people from shop floor to lead training on all
H&S Standards & Advisories: Completed 80% - OPR, 54% - NOPR, 58% - Contract
workmen.
� Upgraded water filtration system to improve the drinking water quality - turbidity less
than 5.
� In-house heath checkup for employees and shutdown contract workmen.
� Ladies Club organized health check up camp for detection of Osteoporosis & Obesity.
� Improved Road Signage throughout Plant, Colony and Mines.
� Able to retain 60-70% shutdown contractor population in last two consecutive Kiln
shutdown.
� Contractor's initiative to provide standard PPEs - T Shirt and Safety GKB Specs.
� Installation of CO2 system in Line 2.
� Stopped using stick at packer discharge end at packing plant and resolved a long
pending safety issue.
� Several initiatives taken to involve all the stakeholders including family, to improve the
quality of Logistics Gate Meeting.
Sonadih Cement Plant
A. Governance Standard - 3
� Contractor Safety Management
� Risk Management
� Reporting & Investigation
B. Operational Standard - 9
� Working at Height
Health & Safety - Standards & Advisories
C. Safety Advisories - 9
� People Road Transport
� Mobile & Lifting equipment for
WAH task
� Stock pile & Surge pile
� Conveyor belt safety
� Demolition Advisory
� Energy Isolation (EI) Standard
� Confined Space
� Personal Protective Equipment
� Respirable Crystalline Silica and Total Dust
� Workplace Noise Standard
� Ergonomics
� Whole Body Vibration (WBV) Standard
� Hand Arm Vibration (HAV)
Sonadih Cement Plant
� Logistics Advisory
� Mobile Equipment
� Workforce Accommodation
� LOTOTO
Safety Initiatives: Bottom Up Approach Champions
Conveyor Safety Champion Demolition Safety Champion WAH Safety Champion
EI Safety Champion Stock Pile Safety Champion MEA Safety Champion
Sonadih Cement Plant
PRTA Safety Champion Logistic Safety Champion CSE Safety Champion
Verification of Driver’s
License, Age: Min 25 Yrs
& Experience : Min 2 Yrs
Appointment form
Safety Training by Plant
Logistics Safety Officer
(half day session)
Medical Test to ensure
fitness
Driver Selection Process
Defensive Driving Training by
Skilled Trainer (appointed for
training only) - Theory & Practical
Award to best driver after the
completion of DDT
Written Test after
Training
Sonadih Cement Plant
Refresher Training to all the drivers (half
yearly)
Vehicle ChecklistVehicle checking by
Safety Supervisor
Alcohol testing by
transport supervisor at
Transporter Office
Safety Induction to the
Market Vehicle’s drivers
Procedure for entry of Vehicle inside Plant
Signature on Pratigaya
Patra by drivers
Cross checking by
security guard at material
gate
Compulsory use of 3
point retractable Seat
Belt
Random Alcohol checking
at material gate by
security guard
Sonadih Cement Plant
Counselling of all the drivers by the
Skilled Counselors after every trip
Road Safety Movies on various topics
to increase road safety awarenessDMC started for drivers
on 19th August’13
Driver Management Center
Stress Management clasess through
professionals on regular intervals
Extra curricular activities for Driver
(physical exercise classes, drawing
competition, etc)
Entertainment Programs for Drivers
Sonadih Cement Plant
Monthly award of Rs Five Hundred to the
drivers, who did zero safety violations
Every month award to one driver of
each transporter as the safest driver
Framed photograph to the safest drivers, who
are coming with the family in gate meeting
Building Relationship….
Safety Mega Award function by
transporters quarterly.
Gift to every pass port holder driver , during
the safety month for increasing their morale
Dinner for 10 best drivers along with their
family, with Plant Management Team
Sonadih Cement Plant
Daily safety engagement with Drivers
to increase safety awareness
Weekly Chaupal with Drivers & Helpers
separately to resolve their issues
Monthly Logistic Gate Meeting for drivers in
presence of Plant Management Team
Spot checking of vehicles outside plant
on the routes in regular intervals
Safety Mentors selected among the
drivers to spread safety in all the drivers
Frequent visit to drivers home & engagement
with family for appreciation.
Sonadih Cement Plant
Logistics Safety
Declining trend in the number of
violation by drivers for
transporting clinker.
# We do similar tracking for Raw
Material & Cement.
11 9 1017
33
21 22
10
2 27 7
0 0 0 005101520253035
Nov 12
Dec 12
Jan 13
Feb 13
Mar 13
Apr-13
May-13
Jun-13
Jul-13
Aug-13
Sep-13
Oct-13
Nov-13
Dec-13
Jan-14
Feb-14N
o. of Speed Violations
Months
Speed Violation Outside Plant Year Till Date 2013-14More than 45 KM
75150
200
250
300
No. of Speed Violations
Speed Violation Inside Plant Year Till Date 2013-14More than 25 KM
Sonadih Cement Plant
Awarded for Achieving Zero
Violation in Clinker, Cement &
Raw Material Transportation
(consistently for 3 Months).
Zero Violation Award
74 74
93
26 21
410
3 1 2 0 0 0 0 00102030405060708090100
Dec 12
Jan 13
Feb 13
Mar 13
Apr-13
May-13
June-13
July-13
Aug-13
Sep-13
Oct-13
Nov-13
Dec-13
Jan-14
Feb-14
No. of Violations
Months
1-4 AM Violation Year Till Date -2013-14
750 6 7 12 11 6 4 4 0 0 0 0 0 0 0
0
50
100
150
Nov 12
Dec 12
Jan 13
Feb 13
Mar 13
Apr-13
May-13
Jun-13
Jul-13
Aug-13
Sep-13
Oct-13
Nov-13
Dec-13
Jan-14
Feb-14
No. of Speed Violations
Months
Violation Matrix
Penalty against different type of violation to
the Transporters
Four Corner violation Gate Pass
Sonadih Cement Plant
Safety Initiatives: Management Visible Leadership
Daily High Risk Activities on W:Drive Daily HOD Safety rounds and discussion on the points in the meeting
Daily High Risk Activities on W:Driveon the points in the meeting
Authorization Matrix
Sonadih Cement Plant
SOTSYS
Risk Management
Fall Hazard Risk Assessment 3 Column JSA
HIRA: Hazard Identification Risk AssessmentPermit to Work
Sonadih Cement Plant
Safety Initiatives: Hierarchy of Control
Insertion of Beams inside the cyclone door level Separate Pedestrian Walkway
ELCB HT Line Protection + Road Signage
Sonadih Cement Plant
ELCB
Insertion of Beams inside the cyclone door level Separate Pedestrian Walkway
Certification & Awards
Mines Environment & Mineral Conservation, 2012
SHE Award by CII 2010-2011 FICCI Safety Excellence Award 2011
Safety Awards by DGMS - 2012Energy Conservation Award by CREDA
Sonadih Cement Plant
Safety Awards by DGMS - 2012
Mines Environment & Mineral Conservation, 2013
ASC Awards 2013
Learning from Events
Fatality Flash SER FlashFatality Flash SER Flash
Near Miss Report Sharing Medical & First Aid injury Report Sharing
Sonadih Cement Plant
Safe Operating Procedures Instructions for Safe Usage of Machinery
Safety Initiatives: General Safety
Safe Operating Procedures
Signage's provided for all Hazards
Sonadih Cement Plant
VCS
Safety Initiatives: General Safety
Guarding for all Rotating PartsOrganic Vapour Mask: Protective Equipment
Heat Resistant Suit: Protective Clothing
Sonadih Cement Plant
Mandatory PPE’s
Belt Conveyor Safety
Sonadih Cement Plant
Confined Space: Silo Cleaning Initiatives
Conventional Method of Silo Cleaning
Sonadih Cement Plant
Conventional Method of Silo Cleaning
Cardox Method of Silo Cleaning
Safety Initiatives: Energy Isolation / LOTOTO
LOTOTO Box Pneumatic Valve Locking Arrangement
Sonadih Cement Plant
LOTOTO Box Pneumatic Valve Locking Arrangement
Arc Flash Boundary Identification Multiple Earthing Points
Safety Initiatives: Working at Height
Cuplok Scaffolding Inside Cyclones Cherry Picker used to eliminate WAH risks
Pictorial Depiction of Rescue PlansPictorial SOP’s
Sonadih Cement Plant
Vertical Stretcher for Rescue in
Confined Spaces
Safety Initiatives: Working at Height
Retractable fall Arrestor
With Winch Provision
Confined Spaces
Tagging System in Scaffolds along with checklist
Sonadih Cement Plant
Fire Control, Emergency Plan & First Aid
Smoke Detectors are Provided in all MCC
& Cellar
Emergency Preparedness Mock Drills conducted regularly & Cellar
Emergency Number displayed Display of First Aider’s & Rescuer’s contact details
Sonadih Cement Plant
conducted regularly
Health Initiatives
Occupational Health CentreSonadih Cement Plant
Glimpse of Liquid Hazardous Waste System
Key Features : System can handle
• Gross CV - 4600 to 5600 kcal/kg;
• Fire point - 85-88ºC;
• Moisture content -15-20% ; Ash content - 15%;
• Chloride content - 1-1.2%
• Viscosity ~ 55 centipoise
• Maximum substitution of fossil fuel up to 7%.
Sonadih Cement Plant
Unloading 100% covered Shed
To Kiln Burner
Glimpse of Solid Hazardous Waste SystemKey Features :Key Features :Key Features :Key Features :
� New alternate feeding systemcomprising of bucket elevator &weigh feeder was commissionedon 1st Nov 2013.
� Enhanced AF substitution in Line2 in a mechanized way.
� Maximum substitution capacityhas now increased to 8%.
� Capable of handling wide varietyof alternate fuels.
� Well covered storage yard for
2.2
3.9
1.0
8.1
0.0
1.0
2.0
3.0
4.0
5.0
6.0
7.0
8.0
9.0
Alternate Fuel SubstitutionAlternate Fuel SubstitutionAlternate Fuel SubstitutionAlternate Fuel Substitution
� Well covered storage yard forhazardous waste.
0.0
Sept 13 Oct 13 Nov 13 Dec 13
Sonadih Cement Plant
Energy Saving Initiatives
Sonadih Cement Plant
PAT Target & Action PlanBack Ground :
The average total energy consumption for the period of 2007-
08, 2008-09 and 2009-10 is 177731.2 MTOE. LIPL – Sonadih
Cement Plant is a Designated Consumer.
The baseline production for the year 2009-10 in terms of total
major equivalent product (PPC cement) is 30.07 Lakh MT.
The average SEC for the baseline period is 721.49 kcal / kg
cement. Based on this PAT target for Sonadih is 692.3
kcal/kg cem, which is equivalent to 7134 MTOE.
Actions to reduce the Gate to Gate SEC & to achieve the PAT
targets within given time Span are being carried out.targets within given time Span are being carried out.
Way Forward
� Maximizing the usage of alternate fuels.
� Installation of WHR for both manufacturing lines
� Improving C/K ratio.
� Improving the cooler performance by enhancing the
recovery ratio & thus reducing the overall heat
consumption.
� Carrying out energy saving projects by identifying the
impact on the SEC.
� Improving the RF of both lines to reduce the SEC.
Action Plan for Year 2012-13-14
Action Plan
Sonadih Cement Plant
Environment Initiatives
Rain water harvesting pit : 2.3 Million M3 Specific Water Consumption
0.4416
0.4214
0.3743
0.34
0.36
0.38
0.4
0.42
0.44
0.46
2011 2012 2013
Water M3/Ton Clinker
Plantation all around the premises Specific CO2 Emission
517
516
513
511
512
513
514
515
516
517
518
2011 2012 2013
CO2 Kg/Ton Cement
2011 2012 2013
Sonadih Cement Plant
(CO2 emission level is much better than industrial norm)
Environment Initiatives
Installation of Continuous Emission Monitoring System (CEMS) at all major
Stacks (Make - Durag) for Particulate Matter, SOx & NOx (Make - ABB) at
Kiln Stack for On-Line Monitoring.
Sonadih Cement Plant
Standard Stack Emission (PM) : 50 mg/Nm3 (Lafarge Target – 30 mg /Nm3)
Sonadih Stack Emission (PM) : 20-25 mg/Nm3
Health, Safety & Environment Initiatives
Sonadih Cement Plant
Key CSR ProgramsCSR Categories
Safety
EmployabilityEducation
Health
Sonadih Cement Plant
Vehicle checkup Safety round for village ladies Safety wall paintings
Glimpses of CSR Programs
Sonadih Community Health CenterEye checkup camp Health checkup for children
Women Education Computer Education for Children Computer Education for Ladies
Sonadih Cement Plant
Skill Development Training Hand Pump Repair TrainingSewing Training
Glimpses of CSR Programs
Training for hand pump repair
Hand pump installation Concretization of village roads School boundary wall construction
Rural toilets Pond deepening activities Community centers
Sonadih Cement Plant
People Road Transport Advisory
Sonadih Cement Plant
Training Programs for Children & Colony Ladies
44Sonadih Cement Plant
Defensive Driving Training for School Children Fire Fighting training to colony ladies
-
10
20
30
40
50
20
26
36
42
Ongoing Expenditure (Safety + Environment)Ongoing Expenditure (Safety + Environment)Ongoing Expenditure (Safety + Environment)Ongoing Expenditure (Safety + Environment)
Safety & Environment Expenditure (MINR)
Sonadih Cement Plant
2011 2012 2013 2014 BUD
-
10
20
30
40
50
60
2011 2012 2013 2014 BUD
12 16
28
55
Capex Expenditure (Safety + Environment)Capex Expenditure (Safety + Environment)Capex Expenditure (Safety + Environment)Capex Expenditure (Safety + Environment)
80.6
88.9
95.6
90
100
RF
LINE 2 RF
114.8
90
110
130
Hrs.
LINE 2 MTBF
335340
352
340
350
360
TPH
RAW MILL 2 TPH
158.5
89.1
251.1
50
100
150
200
250
300
2011 2012 2013
Hrs.
LINE 1 MTBF
308
305
319
300
305
310
315
320
325
2011 2012 2013
TPH
RAW MILL 1 TPH
95.9
93.6
97.6
85
90
95
100
2011 2012 2013
%
LINE 1 RF
Performance
Sonadih Cement Plant
80.6
70
80
2011 2012 2013
RF
795
767 764
750
765
780
795
810
2011 2012 2013
Kcal/kg clk
LINE 2 SHC
53.061.4
30
50
70
2011 2012 2013
Hrs.
54.9
64.5
71.5
40
50
60
70
80
2011 2012 2013%
CHEMICAL GYPSUM USAGE
80.3
76.7
75.5
74
76
78
80
82
2011 2012 2013
kWh/T clk
LINE 2 SPC
310
320
330
2011 2012 2013
TPH
Issues 2013 2014 2015 2016
L2 RF:
Reliability issues with control cards of PH fan, cooler fan VSD
failures, vibration in raw mill, cooler boulder/snow man
formation, frequent Mech failures & high winding temp RM main
motor.
L2 PF :
Low stock capacity of raw meal & break downs in raw mill circuit.
L2 SHC : Poor cooler efficiency.
L2 : Low MTBF.
Performance Roadmap
Sonadih Cement Plant
L2 : Low MTBF.
L1 RF:
Break down in cooler, raw mill separator, coal mill separator and
kiln roller bearing temp high.
Alternate Fuel :
Storage and feeding arrangement for various alternate fuels.
RM Storage and Handling : Open Yard and Manual Handling
Clinker storage and handling to loading silo.
Quality of lime stone with limited mines life.
Infrastructure : Colony & Plant.
Thanks
Issues Action Plan
L2 RF:
Reliability issues with control cards of PH fan,
cooler fan VSD failures, vibration in raw mill, cooler
boulder/snow man formation, frequent Mech
failures & high winding temp RM main motor.
• Control card and VSD are being upgraded.
• Screening of coal char and flue dust.
• Better raw mix control and high pressure jet pump
procured.
• Cooling tower efficiency being studied.
L2 PF :
Low stock capacity of raw meal & break downs
in raw mill circuit.
• Inter connection of Line 1 and Line 2 raw meal silo.
• 5 nos. of cooler fans will be changed in next KSD but
Current Issues & Action Plan
Sonadih Cement Plant
L2 SHC : Poor cooler efficiency.
• 5 nos. of cooler fans will be changed in next KSD but
mechanical condition of cooler to be strengthened (to be
studied further).
L2 : Low MTBF – Problem in pan conveyor, cooler
plates, cooler hydraulics, PH fan cards, Kiln main
drive cooling fan, cooler fans, all VFD, ball and
snowman formation.
• Reasons for failure studied, few actions done and few
initiated.
L1 RF:
Break down in cooler, raw mill separator, coal
mill separator and kiln roller bearing temp
high.
• Cooler first grate static and movable beams are being
changed
• Raw mill separator is being replaced
• Coal mill separator GB is procured
• Kiln roller no 9 and 11 bearing are being replaced.
Issues Action Plan
Alternate Fuel :
Storage and feeding arrangement for various
alternate fuels
• Storage and feeding arrangement of SHW is under
construction but we need to have storage and handling
arrangement of various other low density AF (our
vision).
RM Storage and Handling :
Open Yard and Manual Handling.
• Raw materials are stored in open and are getting wet
during rainy season and material loss is happening.
• Covered storage along with mechanized storage and
feeding arrangement is proposed (our vision).
Current Issues & Action Plan
Sonadih Cement Plant
Clinker storage and handling to loading silo.• Mechanized storage at L&T yard and transporting
arrangement to loading silo.
Quality of lime stone with limited mines life.
• Current mines life is approx 6 years with lot of high iron
patches, new mining area procurement is to be speeded
up.
Infrastructure of Colony & Plant needs improvement.
• Plant - Crane, material handling equipment and storage
sheds.
• Colony - Condition of Floors, Kitchen, Washroom ,
accommodation for shutdown workers etc.
Safety Statistics
Sonadih Cement Plant
Driving License for Ladies
� Training and Distribution of 27 Permanent Driving License to
Colony Ladies.
Sonadih Cement Plant
Incident Reporting
0
20
40
60
80
100
120
High Medium Low
Carelessness
Electrical
Fall Of Object
House Keeping
Illumination
Lack Of Co-OrdinationLifting Tools & TacklesMaintenance
Road Safety0
1
2
3
4
5
6
7Carelessness
Caught in
Communication
Fall of Material
Improper PositionInspection
Slip of Tools
Medical & First Aid ReportNear Miss Reporting
Sonadih Cement Plant