C E M E N T A D D I T I V E S

CEMENT PLANT CEMENT PLANT

SAFETY SAFETY
C E M E N T A D D I T I V E S
Safety - Introduction
Comply with Grace Safety Policy and Procedures
Comply with Customer Safety Policy and Procedures
Unsafe practices could disadvantage Grace and the Customer
Remember - Safety BEFORE Sales!
C E M E N T A D D I T I V E S
General Rules
DO
Consider the safety implications of what you are doing and
where you are working
Consider the changes in weather and daylight when driving and
working
Be confident enough to say No if asked to participate in unsafe
acts
Only use equipment you have been trained to use
Only use equipment for the purpose it has been designed for
Remain aware of your surroundings - conditions relating to your
safety are constantly changing
Obey your customers site safety rules
Report incidents/near misses immediately to your site host and
your supervisor/manager
C E M E N T A D D I T I V E S
General Rules
DO NOT
DO NOT go to a plant site without the correct PPE
DO NOT work beyond your capabilities - lifting, training,
understanding, etc.
DO NOT use customer equipment that you are not trained to use
DO NOT use equipment that is damaged or obviously unsafe, e.g.
bare wires, exposed blades/sharp edges, etc.
DO NOT adopt bad and unsafe practice to fit in with others
DO NOT start work without using the appropriate safety controls
including personal protective equipment
DO NOT be afraid to report incidents and near misses
C E M E N T A D D I T I V E S
CLINKER COOLING CLINKER COOLING
RAW MATERIALS RAW MATERIALS
GRIND GRIND
BLEND BLEND
DRY DRY
PREHEAT PREHEAT
CALCINE CALCINE
SINTER SINTER
CEMENT GRINDING CEMENT GRINDING
Limestone or Chalk or Clay Shale
Remove H
2
O
100
o
C
700
o
C
Fuel + Air
1000
o
C
CO
2
1450
o
C
Fuel + Air
~150
o
C
Gypsum
Cement
C E M E N T A D D I T I V E S
Cement Process
Potential Hazards
Large Equipment
Hot Materials & Surfaces
Moving Machinery and Parts
Noise
Dust
Heavy Items
Mobile Plant
Electrical Equipment
Compressed Gas and Air
...
C E M E N T A D D I T I V E S
Access to Cement Plant
Comply with Local Site Regulations and Instructions
Sign In and Sign Out as required
Respect car access and site car parking regulations
Know who to Contact
Satisfy Local Safety Policy Requirements
Wear Visitors Badge as required
Obtain permission before working
USE PPE As Required/Instructed
Comply with No Smoking Policy
C E M E N T A D D I T I V E S
STOP!
STOP at the beginning of every job/activity
THINK what could go wrong and take Precautions
OBSERVE safety Regulations - ALWAYS
PROCEED with care at all times
C E M E N T A D D I T I V E S
Housekeeping
Slips, Trips and Falls are the most frequent causes of accidents
Clean as You Go. DO NOT drop litter.
Keep access clear
Always report spillages and follow relevant procedures
Take Rubbish away or use designated bins provided
Do Not leave equipment out or unattended
Take care of trailing wires and tubing
C E M E N T A D D I T I V E S
Access/Egress
Keep walkways and gangways clear
Keep to designated areas, do not enter restricted areas
Obey Local Site Regulations
Cross roadways and rail tracks at designated crossings only
Avoid confined spaces
Avoid working alone, ensure your whereabouts are known
Comply with local Permit to Work & Tag Out procedures
C E M E N T A D D I T I V E S
Personal Protective Equipment
PPE
Hard Hat - MANDATORY
Protective Footwear - MANDATORY
Eye Protection - MANDATORY
High Visibility Overalls or Jacket - MANDATORY
Dust Mask - as needed/indicated
Hearing Protection - MANDATORY in Mill Building
Gloves - as needed/indicated
C E M E N T A D D I T I V E S
Personal Protective Equipment
Hard Hat Life
C E M E N T A D D I T I V E S
Noise
Hearing Protection is MANDATORY where there is a noise
level of 90db(A) or above
Crushers, Raw Mills, Cement Mills
Hearing protection is advised where there is a noise level
above 85db(A)
Hearing protection is MANDATORY in Cement Mill House
Must be compatible with other PPE
C E M E N T A D D I T I V E S
Moving/Rotating Machinery
Know where the Emergency STOP is located
All Dangerous Parts should be Guarded
Belt Conveyors, Screw Conveyors, Elevators, Mills, Valves
Never climb on to Conveyors
Always follow Isolation Procedure and Permit to Work
Follow Instructions
DO NOT work around unguarded equipment
C E M E N T A D D I T I V E S
Mobile Plant
Be Aware of Mobile Plant and Equipment
Trucks, Cars, Vans
Trains, Wagons, Railcars
Tippers, Front-End Loaders
Fork Lifts
Cleaners, Sweepers
Bicycles
Give right of way
Lookout for reversing mobile plant
..
C E M E N T A D D I T I V E S
Manual Handling
Avoid manual handling if there is an alternative
Assess task before starting
Assess Risks
Get assistance
Get as close to the object as possible
Wear Gloves
Bend your knees, NOT your back!
Lift using your legs, NOT your back!
C E M E N T A D D I T I V E S
Electrical Equipment
Only used approved equipment
Verify voltage requirement/regulations (can be
110v only for portable equipment).
Obey local site regulations
Get permission before using site electricity
Test BEFORE touching
Sub-Station - Authorised access only
C E M E N T A D D I T I V E S
Compressed Air/Gases
Be aware of compressed air lines
Be aware of gas cylinders
C E M E N T A D D I T I V E S
Working at Heights
Carry out a risk assessment before working at height
Look for BOTH Fall Hazard
AND objects falling from height
Use safety harness, where there is possible fall of >2m
C E M E N T A D D I T I V E S
Cement Additives
Know and carry the MSDS
Rinse equipment and dispose of wash water into the mill
NEVER pour additive down the drain
Know how to deal with spillages
Know spill reporting procedures
C E M E N T A D D I T I V E S
Sampling Procedures
Know the Sampling Points before sampling is needed
Only those agreed/directed by customer
Know the locations (e.g. product, circuit samples)
Verify access for sufficient size (and sampler)
Assess Safety for access (heights, steps, guard rails, etc)
Check for exposure risk to pressure/suction, heat, dust, etc
Have suitable equipment (PPE, containers, sample devices, etc)
Be aware of moving parts (e.g. rotary valves, screw conveyors)
If in Doubt - ASK
C E M E N T A D D I T I V E S
Fire Precautions/Procedures
DO NOT Obstruct Fire Exits
DO NOT prop open Fire Doors
Be Familiar with the local Emergency Procedures
Know the Assembly Points
Know what the local Fire Alarm sounds like
DO NOT remove fire extinguishers
C E M E N T A D D I T I V E S
First Aid Procedures
Know where, who and how First Aid help can be sought
Know where there is a First Aid Room
C E M E N T A D D I T I V E S
Accidents & near Misses
Every accident MUST be reported (to Cement Plant and to Grace)
Obey both the Local Site and Grace Regulations
Correct reporting will allow proper investigation and action to
prevent recurrence
C E M E N T A D D I T I V E S
CEMENT PLANT CEMENT PLANT
SAFETY SAFETY
If in Doubt, STOP, and ASK
STOP at the beginning of every job/activity
THINK what could go wrong and take Precautions
OBSERVE safety Regulations - ALWAYS
PROCEED with care at all times