SN Standards Observations Level Unit Responsibility Corrective Action Target Date Status Remarks

Site subcommittees functioning needs to be focused in terms of objective,

assessing whether it could achieve expected outcome from meeting and also 1. Objectives are to be defined with roles Roles and responsibilities are defined for
1 Safety Management locally brain storming on doing something more other than direction LEVEL-1 RDM/ SKM Ram Murari and responsibilities. 5/10/2019 Completed the individual
Systems coming from top committees specifically on issues related to local site 2. Brain Storming session with site Brain storming session is organised
experiences person will be orgnised
conditions and standard implementation.

Safety Management The site should Fix Roles and responsibilities wrt to All deliverables in SI, IM All Commitees will be again revised and
2 Systems and SRP Committee, it has been partially being done but all items must be LEVEL-1 Common Ram Murari same shall be executed immediately 5/15/2019 Completed
assigned individual responsibilities

The SI committee needs to focus on developing action plan for reporting Unsafe Meeting is called for the key persons Meeting done with all shift Foremen as well
Safety Management
3 Systems Acts 74% to more than 90%, people needs to focus in reducing the unsafe LEVEL-1 Common Ram Murari regarding the observation and will be 7-May-19 Completed as shift Incharges & other HOD's on 10th
conditions 30 % as SI is a behavioral observation tour improved immediately withing a week. May regarding the SI issues

SI schedule is circulated for the month of

4 Safety Management All leadership must conduct SI on weekly basis, it has been observed that few LEVEL-1 Common Ram Murari May and Defaulter List will be extracted Completed Completed
Systems people have carried out SI either in last week or more SIs in a particular week
and action will be taken

SI committee to track the list of defaulter and must establish feedback process
5 Safety Management in site Apex LEVEL-1 Common Ram Murari Immediately defaulters list is extracted 4-May-19 Completed All the defaulters identified and warning
Systems Committee and warning letter to be issued. leeter issued individually

Safety Management As a sample the SI categories were analyzed for 03 months & found reporting Meeting with all the key persons is
6 Systems under procedures head as 42%, PPE 12% & tools 9% S ite to refocus efforts in LEVEL-2 Common Ram Murari planned and other area's will be focussed 10-May-19 Completed Detailed deliberation will to all enginners
reducing PPEs observations
The frequency of safety observation i.e. 4 nos./month should be ideally
distributed 1 no./week. Gap between two consecutive observation rounds
should be uniformly distributed across stipulated period. In case of specific case SI schedule is circulated for the month of
7 Safety Management i.e. leave/ Official Duty to non-business LEVEL-2 Common Ram Murari May and Defaulter List will be extracted 10-May-19 Completed Defaulter list is identified and warning has
Systems Cement Unit, an individual can schedule safety observation at a frequency 2 and action will be taken been given
nos. per week with a minimum gap of three days between consecutive two
observations.
15 % of scheduled total observations should be done in non-office working
8 Safety Management time. The nonoffice working time shall be considered as night hours (8.00 PM to LEVEL-2 Common Ram Murari Schedule is to be prepared 20.05.2019 Completed
Systems 06.00 AM) and all holidays/Off days

special schedule for safety observation round should be prepared for shutdown
9 Safety Management and critical LEVEL-2 Common Ram Murari Preparation of schedule is to be done 20.05.2019 Completed
Systems activities.

Safety Management FLEs ( Front Line Executives) must conduct observation in presence of mentor MM program is shall be started and
10 Systems (Mentor – Mentee programme is LEVEL-2 Common Ram Murari records shall be completed Completed
required)
Safety Observation and Audit’s functioning was reviewed, following gaps were
observed;
1. It only reviews basic requirement like compliance to schedule and category of
11 Safety Management observation. LEVEL-2 Common Ram Murari Further discussion shall be done with the 20.05.2019 In Progress
Systems 2. Inter linkag e with other sub committees were not focused. (A structured team to get aligned with the observation
process of interlinkage is required between SI, CSM, SI & SRP committee is
required)
Safety Management A special schedule for safety observation round should be prepared for
12 Systems shutdown and critical activities LEVEL-2 Common Ram Murari Schedule is to be prepared 20.05.2019 In Progress

13 Safety Management The last 03 months’ data of SI there are approximately 1286 observation in V&d LEVEL-2 Common Ram Murari Necessary actions is to be taken in the 20.05.2019 In Progress
Systems & whereas no action plan has been developed in line with observation trend context as per the observation
The minutes of review meeting has not been effectively documented and
Safety Management discussed points MOM of the review meeting shall be
14 Systems are not reviewed in subsequent months as R1R2&R3, so how effective the LEVEL-2 Common Ram Murari documented 20.05.2019 In Progress
committee in
holding people responsible for completion of assigned tasks is difficult to gauge.
15 Safety Management Trade Tests are not being done at many places LEVEL-2 SKM Ram Murari Pending
Systems

16 Safety Management Quarterly HSE audits, as per annexure 13 of the CSM procedure, are not being LEVEL-2 Common Ram Murari HSE audits are to be schedules and 20.05.2019 In Progress
Systems conducted circulated

17 Safety Management Regular inspection of tools / tackles and PPEs are not being done LEVEL-2 Common Shikhar Gupta Inspection of tools will be done regularly 31.05.2019 Completed
Systems and records will be documented

During interaction with Incident Investigation subcommittee following gaps

observed,
 Detail incidents with respect to eight step process (WHY- WHY) was not Incident investigated at RDM has proper
18 Safety Management evident.
Systems  Quality check mechanism to check Incident investigation report, root causes & LEVEL-3 Common Ram Murari why Why tree and same shall be ensured Immediate Completed
corrective and preventive action need to be strengthen. further
 Effective analysis of incident and correlation with other work process were not
evident. Site has made attempt to analyze few incident data for last quarter.

19 Safety Management site has not developed the charter of IM committee for FY 19. LEVEL-3 Common Ram Murari IM charter will be finalised by site afetr 30-Jun-19 In Progress
Systems finalising from the corporate IM team

Safety Management
20 Systems The linkage of deliverable and Agenda items was found missing. LEVEL-3 SKM Pending

21 Safety Management HIPO recommendations completion pendency from 01st march 2018 to 1st LEVEL-3 Common Ram Murari Completion of HIPO recommendations Immediate Completed All the HIPO's reviewed and Complinces are
Systems April 2019 is 21.74% and review implemented

Four samples HIPOs were analyzed and it has been found that All HIPO's will be submitted after why-why
22 Safety Management  The WHY tree has not been developed for HIPOs happening in RDM LEVEL-3 Common Ram Murari tree preparation and implementation of Immediate Completed HIPO's happening have proper why-why
Systems  The recommendation of any incident must emerge from WHY tree, this is a tree
common observation across Zone the same

Safety Management The Site Safety Head or chairman of IM committee must have authorization to IM chairman will be authorized to open IM chairman is authosized to AAROHAN
23 Systems open the completion status of any recommendation if found noncompliant in LEVEL-3 Common Ram Murari the completion status of any Immediate Completed ADMIN
field recommendation

The IM committee must link each failure to work stream standards, that data
24 Safety Management must be a feedback loop to SRP committee for standards reviews and local rules LEVEL-3 Common Ram Murari Pending
Systems
upgradation

25 Safety Management Attendance of each committee has not be monitored (only KPI of attendance is LEVEL-3 Common Ram Murari Monitoring of all attendance of the shall Immediate In Progress
Systems maintained) be kept

26 Safety Management Standard,

SRP Committ RuleeeandmeeProcedure:
ting Site happened
has not has made attempt
sinceand to track
Jan 2019and monitor 1.
At Site
RDMspecific procedure is in place and is Immediate
Systems progress on enforced standard but its effectiveness holistic approach was LEVEL-3 Common Ram Murari signed meeting
off. was concuted Monthly Completed Last Meeting done in May 2019
missing. Following gaps were observed, 2. The standard content is already been
 Site specific procedures are available but cross references, HOW & WHO part modified with site specific details and
27 Safety Management not LEVEL-3 Common Ram Murari incorporated in SOP which is already 25-May-19 Completed
Systems
addressed in site procedure. Currently standard content are directly copied as signed off.
procedure. 3. Activitywise SOP alond with JCC is
Safety Management  Development,
Service providersdeployment
are unawareand enforcement
of the of site specific
six steps process rules procedure.
of HZ L CSM were not already developed
Training andto
shall be given timely
ensureJCC
6 audit
step is 31-May-19
28 Systems evident
They (listhave
don’t of site specific
even rulesprocedure
the CSM to be developed and maintained)
with them LEVEL-3 Common Ram Murari being carried
process of CSM out for health check. In Progress Training has been started

Review of PQ score is being done on the basis of documentation, that too found Review of PQ score shall be done
29 Safety Management inadequate, LEVEL-3 Common Ram Murari 10-Jun-19 In Progress
Systems & close room discussion. Site verification of PQ points are not in practice. PQ positively. Also close room discussions
shall be started.
scorecard shall be prepared on the basis of site verification only.

30 Safety Management Pre bid & post bid meetings are not effective LEVEL-3 Common Ram Murari Pending
Systems

CSM awareness to contractor is lacking at ground. One of major O&M

31 Safety Management contractor Site In charge don’t have clarity about CAM; CCM; CM & CS of his LEVEL-3 Common Ram Murari CSM refresher training shall be done for 10-Jun-19 In Progress CSM training is in progress
Systems all persons
contract indicates the interaction of CSM team with contractor is not adequate.

32 Safety Management CFSA training effectiveness and its quality needs improvement. LEVEL-3 Common Ram Murari CFSA training is scheduled for the training 31-May-19 In Progress Refresher training is under progress.
Systems of the employees

Safety Management Contractor employee wise tracking of Training on standards are not in place. Training documents will be maintained in Training documents are there for the
33 Systems Due to the same, few critical persons are left out from critical training needs. LEVEL-3 Common Ram Murari very strutured Manner Immediate Completed operators and other contractor employees

PTW (General: 177855) SK Mine HEMM work shop: Personnel lock mentioned in
34 Permit to work isolation Level 1 SKM S Praveen PTW
Clause. Master isolation key is with co-permitte rather than in Box

PTW: SK Mill: noncompliance to LOTO standard practice. No foolproof isolation

35 Permit to work at energy Level 1 SKM
source. Master isolation can be defeated.

SK Mill phase-3: Safety belt with shock absorber used for working height of
36 Permit to work 2.5mts. Person Level 1 SKM
unaware of usage. Permit non availability at site.

SK Mill Phase-3 (GPTW: 172856, W@H53245) Rescue method and approach for
37 Permit to work rescue Level 1 SKM
crew nowhere mentioned.
All Permits formats are not aligned with corporate standard approved document
39 Permit to work dated Level 2 SKM
13.04.2018.
40 Permit to work Custodian review which is critical in permit flow not adhered. LEVEL-2 Common Ashish Mishra/ Kamlesh Awareness will be given to all the Immediate Completed
Bhandari custodian
41 Permit to work Site specific procedure for Zone-1 produced for Zone-1S. But need to relook at LEVEL-2 Common Ashish Mishra/ Kamlesh Will be discussed with zone champion and 10-May-19 In Progress
overall Zone. Bhandari will be concluded

42 Permit to work
43 Permit to work
46 Permit to work
Process isolation requirement considerations not so evident in mining Level 2 SKM
GPTW: 10995 issued on 03.04.2019, whereas L&S Permit: 10067 issued on
04.04.2019. Ashish Mishra/ Kamlesh
LEVEL-2 Common Bhandari Awareness training to shop floor people Immediate Completed
Which is not as per standard procedure. will be given
Rescue plan in CSE and W@H permit needs to be prepared by joint visit of
rescue team and Ashish Mishra/ Kamlesh
LEVEL-3 Common Bhandari Already discussed with rescue team, will Immediate In Progress
be implemented immediately
plant team sign off must be done.

47 Permit to work Work at Height permit check points compliance I not up to the mark LEVEL-3 Common Ashish Mishra/ Kamlesh All the special permit requirement will be 30-Jun-19 In Progress
Bhandari covered in refresher trg

48 Permit to work Non availability of work permits at site in Mill project Level 3 SKM

Lifting and shifting of

49 load PMI and minor Maintenance of the lifting equipment SOP not evident Level 1 SKM

Lifting and shifting of

52 load RJ 09EA 3596 operator awareness about the signal and about standard is not up Level 1 SKM
to mark Inspection date and Due date not mentioned on project sany crane.

53 Lifting and shifting of Area demarcated for minor Maintenance of the equipment but PTW or SOP not Level 1 SKM
load evident

54 Lifting and shifting of Competent authority certificate LIC number not mention on Certificate Level 1 SKM
load

55 Lifting and shifting of Pick and carry no RJ 30 EA 1833 document not evident Level 1 SKM
load

Training to be provided by the Crane

Lifting and shifting of
56 load
Awareness level of the EOT operator is very poor Shashank Shekhar/ A. Jain/ Champion on EOT Crane Operation,
LEVEL-1 Common Jayam 5/15/2019 Completed Training session is completed by the site
further training to be provided by Crane lifting & shifting champion
OEM

Visual display for lifting and shifting and EOT operation should be increased at Yuvraj S ingh, Shashank Visual display completed and training given
57 Lifting and shifting of M/s Normet Visual display to be increased in all the
LEVEL-1 RDM/ SKM Shekhar, R.L Saini, Anup Das, areas 5/31/2019 Completed to all the persons and authorisation done.
load of EOT Crane Operation
and M/s Epirock work shop and also awareness level is very low. Kamlesh Bhandari 05.05.2019

58 Lifting and shifting of List of authorized people has been displayed but Training record not available LEVEL-1 RDM/ SKM Shashank Shekhar/ A. Jain/ Refresher training of the authorised 30-Jun-19 Completed Records are there
load Jayam persons to be completed

59 Lifting
load
and shifting of Jib crane use at sites but Lifting certificate not available and awareness is very
poor LEVEL-1 SKM Shashank Shekhar/ A. Jain/
Jayam

Lifting and shifting of Shashank Shekhar/ A. Jain/ Warning signs to be displayed on the Pick warning sign are fixed at pick and carry
60 load Warning signs not Displayed at back and front site of the Pick and carry crane LEVEL-2 Common Jayam and Carry Crane 20-May-19 Completed cranes. 13 May 2019

Frequent chang e in operator was found and has resulted in non- compliance of
61 Lifting and shifting of relevant pick Level 2 SKM
load and carry documents.
Lifting and shifting of
62 load Competent authority certificate LICENCE number not mentioned in Certificate Level 2 SKM
Colour coding is done and circulated over
64 Lifting and shifting of Color coding for the lifting tools and tackle has not been followed as per the LEVEL-2 Common Shashank Shekhar/ A. Jain/ Colour coding of the lifting tools to be 31-May-19 Completed mail. Also awareness is given and all
load standard Jayam completed as per the quarter necessary testing are done by third party.
07 May 2019
SKM: Very less alarm sound and no visual warning light during crane movement
65 Lifting and shifting of at Epiroc Level 2 SKM
load and Sandvik workshop.
Lifting and shifting of Shashank Shekhar/ A. Jain/ Material keeping to be improved for Material are kept in sepated manner and at
66 load Poor Material keeping at site store LEVEL-3 Common Jayam Monomark Store 10-May-19 Completed the designated places
Lifting and shifting of
67 load Pre-operational checklist was found in non- standardized format as per standard Level 3 SKM

68 Lifting and shifting of General checklist is not matching with standard annexure Shashank Shekhar/ A. Jain/
LEVEL-3 Common Jayam Pending
load

SK Mill – confined space entry in Mill found open unattended without warning
70 Confined Space Entry signage Level 1 SKM
where shutdown work was taken up

71 Confined Space Entry Paste fill – tank CSE permit was not shown for work taken up in past for rubber Level 1 SKM
lining
At SK Mill for rotor stator replacement work General work permit was issued
and CSE
72 Confined Space Entry permit was not issued though the entry was found open and cell looked Level 1 SKM
cleaned. The
opening (grating ) was also not barricaded
74 Confined Space Entry At SK Mill for CSE work in the Cell Dart valve box the entry ladder in use without Level 2 SKM
Safe tag

76 Confined Space Entry At SK Mill CSE warning signage was missing on one mill. Level 3 SKM

For providing forced ventilation requirement use of man cooler and exhaust fan
was found
77 Confined Space Entry at site. For any localized ventilation arising, ventilation fan with flexible ducts Level 3 SKM
were not
available. To be provided
SK Mill-2/DSC Zn: Non-compliance has been found with respect to earthing of
78 Electrical Safety various small Level 1 SKM
field DBs like lighting, welding etc

83 Electrical Safety
84 Electrical Safety
85 Electrical Safety
86 Electrical Safety
90 Electrical Safety
Common: Back door interlock compliance has to be verified once again at all 1. Back Door interlock is provided in HV
the sites. Every Roopesh Mehta/ Dev Kishan Incomers.
feeder rear door having potential energy (charged through cables) shall have LEVEL-1 Common Sharma 2. Rear Door of all new HV breaker are Completed Completed
interlocked.
interlock.
1. Arc Flash study conducted.
Common: Awareness on arc flash boundaries and accordingly selection of PPE’s 2. Arc Flash awareness and use of Arc 30.05.2019
to be LEVEL-1 Common Roopesh Mehta/ Dev Kishan Flash PPE's traning given to all Completed 10.05.2019 completed
improved among electrical community Sharma Electricicans.
3. Arc Flash standarization done in
Electrical Community meet
Arc Flash Boundary: The boundary within which arc flash PPE is required to be Arc Flash Boundary diaplayed upto all
displayed Roopesh Mehta/ Dev Kishan MCC & PCC's.
LEVEL-1 Common Sharma 30.09.2019 Completed
Incident Energy
1. VRD under procurement.
Voltage Reducing devices to be installed in welding machines Roopesh Mehta/ Dev Kishan 2. New Welding Machines are procured
LEVEL-1 Common Sharma 30.08.2019 In Progress Under procurement
with VRD
SK: Buried cable drawing was available but not updated fully Level 2 SKM

Common: Implementation of voltage reducing device (VRD) in all welding Roopesh Mehta/ Dev Kishan Stanadards to be amended by Corp.
92 Electrical Safety machines to be LEVEL-2 Common Sharma Champ and Implementation will be done In Progress Under procurement
targeted.

Common: Rescue hook location shall be easily accessible in case of emergency.

93 Electrical Safety
94 Electrical Safety
97 Electrical Safety
Also it LEVEL-2 Common Roopesh Mehta/ Dev Kishan 2-May-19 Completed
should not be kept with earthing rods and other electrical tools. Sharma
Each hoist must have electro-mechanical motor and mechanical load or
equivalent braking Roopesh Mehta/ Dev Kishan
system. A totally redundant holding brake means is required. Each brake must LEVEL-2 Common Sharma 2-May-19 Completed Thruster brakes available
be “fail-safe"
SKM: Plunger type fire extinguisher shall be replaced with squeeze type Level 2 SKM

98 Electrical Safety SKM: HEMM workshops: ELCB test due date expired in the month of Nov`18 Level 2 SKM

SKM Mill: Welding machine leads – Electrode holder to be replaced if insulation

99 Electrical Safety gets Level 2 SKM
damage
SKM Mill Area: Road not barricaded; welding machine leads crossing the road
100 Electrical Safety and Level 2 SKm
welding
SK machine
Mill: SOPs not placed
are available butnear to workplace
some SOPs need (Close proximity)
updation w.r.t isolations for
101 Electrical Safety VFD/SS Level 3 SKM
feeders, usage of fuse puller etc
102 Electrical Safety SK PF-1: Lot of places outdoor lights were found in ‘ON’ condition in day time Level 3 SKM
103 Electrical Safety Zn CH: Standby person list to be provided in substation. LEVEL-3 DSC Pending

104 Electrical Safety CPP/Common: Entry/Exit of AHP MCC to be made obstruction free LEVEL-3 DSC Pending

Common: Common S OPs to be made for all mills like all SK mills as well as RD.
105 Electrical Safety Team Roopesh Mehta/ Dev Kishan Under Discussion
LEVEL-3 Common Sharma 30.08.2019 Pending
to sit together and review all available SOPs

Common: Similar electrical permit(DGMS) issuing method to be followed. Both

106 Electrical Safety SK & RD Level 3 SKM
are having different method of making electrical permits

Common: Common maintenance schedule to be followed in electrical as per

GESM
107 Electrical Safety Roopesh Mehta/ Dev Kishan completed
standard. e.g . ELCB testing to be done in six months not 2months, relay testing LEVEL-3 Common Sharma Immediate Completed Inside unit RDM, it is common
in 3 years
not 1 year etc.

Common: Possibility of fire stop barriers at the entry/exit and panel entry/exit
108 Electrical Safety to be looked Roopesh Mehta/ Dev Kishan Explorattion is under progress for the
LEVEL-3 Common Sharma 30.07.2019 In Progress
possibility
into and implemented in phased manner.

109 Electrical Safety Operating instructions of co2 Fire extinguisher must be displayed LEVEL-3 Common Roopesh Mehta/ Dev Kishan Display printing is to be done 15.05.2019 Completed Displayed
Sharma

110 Electrical Safety List of authorized persons should be displayed at the gate. License numbers Roopesh Mehta/ Dev Kishan Will be done
LEVEL-3 Common Sharma 10.05.2019 Completed Displayed at all prominent places. Name,
shall be included in the list of persons Mob. No, & photo of the persons

labeling on electrical DB/Panel can be done in black colour with yellow

111 Electrical Safety background & LEVEL-3 Common Roopesh Mehta/ Dev Kishan Will be done as per recommendation 30.07.2019 In Progress In Progress
black border Sharma

112 Electrical Safety Labelling to done on rear side if panel can be opened – CEA 2010 LEVEL-3 Common Roopesh Mehta/ Dev Kishan Will be done 30.05.2019 In Progress For Htpanels done, for LT panels in progress
Sharma

113 Electrical Safety Earthing conductor should be green IS 3043 LEVEL-3 Common Roopesh Mehta/ Dev Kishan Completed
Sharma

SK Mill-1 & DSC Zn: MLB were found in control room having locks on MLB with
keys.
115 LOTOTO Also there are more than two locks were found on MLB, however as per Level 1 SKM
standardVF
SK it should
be PF-1:
only twoDlocks
practice
doors arepermit
i.e. gettingrequester
opened and
with permit
LOTO provided.
issuer. Also, as a standard
116 LOTOTO isolation for VFD feeders shall be taken from source i.e. from MCC end and not Level 1 SKM
from
VFD panels.
SK Mill-2: Although door locking provision was available on MCC feeder but only
117 LOTOTO MCCB/MPCB LOTO has been provided. Level 1 SKm

Common: Compliance of LOTO for mobile heavy equipment’s to be made (e.g. All Persons are having personel and access
122 LOTOTO manlifter LEVEL-2 Common Ravi Goyal In Progress 20-May-19 Completed
machines etc.) control locks who are involved

123 LOTOTO Glove ball Lock out device has been used for Electrical Lock out LEVEL-2 Common Ravi Goyal Instructed not to be used Completed Completed

125 LOTOTO Common: Record has to be maintained and cable to be disconnected for long LEVEL-3 Common Ravi Goyal In Progress 10-May-19 Completed Ensured
period LOTO

126 Excavation Zone-1 to declare the excavation champion and respective UIC members LEVEL-1 Common Unit Champion is declared: Subham Completed Completed
Bharadwaj

127 Excavation Site to develop site specific procedure LEVEL-1 Common Subham Bharadwaj Completed

128 Excavation Training on excavation standard is not yet started to be started. LEVEL-1 Common Subham Bharadwaj Training by Site Champion 5/31/2019 In Progress

129 Excavation Excavated material was found lying on the edge of the pit LEVEL-1 Common Subham Bharadwaj removal to be done Immediate Completed Removed and all such pits are fenced

130 Excavation Excavated site was not found hard barricaded meeting the requirement of LEVEL-2 Common Subham Bharadwaj Barrication to be done Immediate Completed
standard

131 Excavation No Safe access and egress was provided in the excavated pit of ME project site LEVEL-2 DSC Pending

132 Excavation Excavations should be barricaded to prevent employees and others falling into LEVEL-2 Common Subham Bharadwaj Barrication to be done Immediate Completed
them

133 Excavation Display of warning signboard in Hindi/English/regional language at conspicuous LEVEL-2 Common Subham Bharadwaj Signboards to be fixed Immediate Completed
locations

A minimum clearance of one meter between the storage and walls shall be for alum room, construction and renovation
134 Excavation provided LEVEL-2 Common Subham Bharadwaj Proper arrangement is to be done 30.06.2019 In Progress done and stacking is in progress

135 Excavation Signage board for excavation and work in progress was not there LEVEL-3 Common Subham Bharadwaj Signboards to be fixed Immediate Completed signboards is to be fixed

Fluorescent net and 2 level barricading (i.e. 21” and 42”) height from the
136 Excavation ground LEVEL-3 Common Subham Bharadwaj arrangement is to be done Immediate Completed arrangement done
was not found in plant
Excavation approved plan was missing in plant and at project site found Plan is already prepared and to be kept
137 Excavation however to be LEVEL-3 Common Subham Bharadwaj Immediate Completed Plan is filed and kept for records
attached with the excavation permit along with permit no on plan filed

Lock of Sodium Cyanide store at central store chemical godown is kept open.
140 Chemical handling and Once any one Level 1 SKM
storage enter to chemical godown he can enter to sodium cyanide store room as well.

141 Chemical handling and Fire suppression system not installed at central store where MIBC is stored in Level 1 SKM
storage RDM & S KM.

Chemical handling and

143 storage Nitrogen gas not included in chemical list in RDM & SKM Level 1 SKM

144 Chemical
storage
handling and Tailing slurry not identified as hazardous chemical in RDM & SKM. Level 1 SKM

145 Chemical handling and Chlorine tonner storage room was open, thus deluge system in case of release is Level 1 SKM
storage not effective.

146 Chemical handling and Understanding of Chemical Handling Standard is low at shop floor Level 2 SKM
storage
CH&S Corporate Champion and his Input not visible. No corporate meeting
151 Chemical handling and happening for Level 2 SKM
storage standard and hence no input and knowledge with other zones.
NFPA 704 diamond apart from fire, health and flammability, specific hazard
153 Chemical handling and rating should Level 2 SKM
storage also be mentioned (DSC smelter). NFPA 704 to be implemented at RDM & SKM.
Loading & Unloading check list for most of the chemicals is not available or not
157 Chemical handling and being filled Level 2 SKM
storage at site.

Chemical handling and Handling of MIBC drum to unload at site at SK Mill 2 is being done manually.
158 storage Some pump Level 2 SKM
can be used to avoid manual activity.

The Chemical handling and Storage Standard team to work closely with PSM
159 Chemical handling and team. There is Level 3 SKM
storage mismatch in chemical list available with CHS team &PT Packages

160 Chemical handling and Awareness of exclusion within team is low LEVEL-3 Common Sanjay Kumar Barnwal In Progress 31-May-19 Pending
storage

161 Chemical handling and Packaging and procurement part of chemical standard yet to be implemented LEVEL-3 Common Sanjay Kumar Barnwal In Progress 30-Jun-19 Pending
storage
171 Vehicle and driving Preventive maintenance schedule of vehicles not prepared and maintained. LEVEL-2 Common Vishwadeep/ BM Rathore Pending
Safety:
172 Vehicle and driving Fire extinguisher not available at ore transporting Dumpers. LEVEL-2 Common Vishwadeep/ BM Rathore Pending
Safety:

Vehicle and driving Refresher training schedule not prepared and followed for Comprehensive and
174 Safety: awareness LEVEL-3 Common Vishwadeep/ BM Rathore Pending
training on VDSS standard.
 All vehicles should carry one set of complete documents pertaining to vehicle &
175 Vehicle and driving driver for LEVEL-3 Common Vishwadeep/ BM Rathore Pending
Safety: verification by plant people. Gate pass also not available with the Operator and
Drivers.

176 Vehicle and driving Very Poor Road condition and No traffic signage’s find at Ore shifting road. LEVEL-3 Common Vishwadeep/ BM Rathore Pending
Safety:
Short ladder used at the Deep cone thickener @ Paste fill plant project. Ladder Material keeping to be improved for
197 Work @ Height shall extend Level 3 SKM
be at least 3 rungs above the landing. To be replaced. Monomark Store

201 Work @ Height Monkey ladders at few places found short of landing in mill LEVEL-3 RDM/ SKM Anshul Khandelwal/ Anup Das Inspection Immediate Completed All monkey ladders are OK at RDM

Toe guards are not as per standard and are being replaced but not in structured
manner. In Standard Toeguard will be fixed on
202 Work @ Height one of the tanks in Mill the toe guard height found equal to the gratings LEVEL-3 RDM/ SKM Anshul Khandelwal/ Anup Das Reagent tank top 30.06.2019 In Progress Toe Guard replacement started
thickness. Needs
additional toe g uard.
Deck plates at SK Mill found at few places (3) not properly placed on supports
204 Scaffold and poses Level 1 SKM
fall hazard. To be removed. Interaction was given to the team for the same.
At one place scaffold was supported cantilever type and getting partially
205 Scaffold supported on Level 1 SKM
handrail.

206 Scaffold At few places the decking of the scaffold work places were found incomplete LEVEL-2 Common Subham Bharadwaj Immediate Completed
with gaps

207 Scaffold Access ladder found short on one case LEVEL-2 Common Subham Bharadwaj Immediate Completed

208 PPE Common: Zone-1 (PPE`s procedure shall be prepared) LEVEL-2 Common Murli Bingi Procedure Prepared 5-May-19 Completed

Common: Respirator cartridge replacement frequency to be fixed same shall be

209 PPE incorporated LEVEL-2 Common Murli Bingi Procedure to be prepared 31-May-19 Completed
in Zone procedure

Common: Personal dust monitoring and other monitoring completed at SKM

210 PPE but CAPA to LEVEL-2 SKM
be prepared and action to be taken; DSC yet to check report and action plan

211 PPE Common: PPE`s fit test to be conducted for ear plug, dust mask and respirators. LEVEL-2 Common Murli Bingi Procedure Prepared 5-May-19 Completed

Common: Trend analysis presently not available due to change in employee

212 PPE number of LEVEL-3 Common Murli Bingi Pending
contract workers

SKM: Color coding & helmet sticker shall have following details Name, Emp.no,
213 PPE Blood Level 3 SKM
Group to improve 100% standard compliance.

215 Machine Guarding Guards shall prevent access to the space directly below the counter-weight Level 1 SKM 12/31/2019

Side guarding of the conveyors on the For Mill areas idlers are in progress. After
217 Machine Guarding Guarding is required on carrying idlers as per ISO 13857 & HZL standard LEVEL-1 Common Shashank Shekhar/ PS carrying idler side and return idlers side 8/31/2019 In Progress that mine area conveyor idlers guarding
Dhabaria to be completed will be started

219 Machine Guarding Paint the Guard as Yellow and surfaces behind guard as red LEVEL-1 Common Shashank Shekhar/ PS Painting of the surfaces behind the 6/30/2019 In Progress
Dhabaria guard as red to be completed

All Pull chords switches to be rechecked,

220 Machine Guarding Emergency pull cord wires must terminate at switches on both sides LEVEL-1 Common Shashank Shekhar/ PS and wires on both the sides to be 5/31/2019 In Progress BC1
Dhabaria checked

221 Machine Guarding Return idlers guarding should extend to atleast 01 meter on both ends Shashank Shekhar/ PS
LEVEL-1 Common Dhabaria Return idlers guarding to be completed 8/31/2019 In Progress
for all the conveyors

222 Machine Guarding Provide distance guard so as to prevent any touch to counter weight wire rope Level 1 SKM All Pull chord wire to be checked 5/20/2019
Machine Safety Hazard Risk Assessment for machinery - HZL operations
shall also
consider other hazards associated with machinery that are not covered
224 Machine Guarding under this standard LEVEL-1 Common Shashank Shekhar/ PS To be considered and amendment in 5/31/2019 In Progress Conveyor guarding started and is in
such as: electrical; thermal; noise; vibration; radiation; hazardous materials Dhabaria standard. progress
and substances;
slipping, tripping
Counterweight and falling;
tension devicesenvironmental
shall be guardedhazards
up to a or a combination
height of 2.5 m at of
225 Machine Guarding these hazards.
points accessible Level 2 SKM
to personnel – CPP – Level 2

230 Machine Guarding Any removal, breaking, slacking of pull cord wire should activate the machine LEVEL-2 Common Shashank Shekhar/ PS To be discussed 5/30/2019 Pending Detailed deliberation is required
Dhabaria

List of human machine Interactions inventory tasks for safeguarding tasks

related to
abnormal or non-routine human-machine interactions, including, but not Human Machine Interaction Inventory
231 Machine Guarding limited to LEVEL-2 Common Shashank Shekhar/ PS tasks to be listed and control measures to 5/31/2019 In Progress
troubleshooting , process upset, equipment malfunction, power interruption, Dhabaria be defined.
un-jamming,
and adjusting.

232 Machine Guarding Annual Machine improvement plan is missing as per standard. Shashank Shekhar/ PS
LEVEL-2 Common Dhabaria Annual machine improvement plan to be 5/20/2019 Completed
made.

SKM: Crusher conveyors found with multiple openings, access to rotating

233 Machine Guarding elements, Nonstandard Level 2 SKM
guards
SKM: Crusher conveyors found with carryback, non-standard pull cord wires &
234 Machine Guarding damaged Level 2 SKM
deck plate.
236 Machine Guarding Use Pull cord wire in Emergency to be displayed in local language LEVEL-3 Common Shashank Shekhar/ PS Display for Use Pull Chord Wire in 6/30/2019 Pending
Dhabaria Emergency to be done

Shashank Shekhar/ PS Primary and secondary cleaner of all the

239 Machine Guarding Carry back issues found on the return side and deck plate has given away. LEVEL-3 Common Dhabaria conveyors to be checked and to be 5/20/2019 Pending
resetted

SSR is g enerally followed, however many rock bolts are dumped forward (floor Separate store for all items in UG are to be 31.05.2019 Stores are already marked and prepared for
245 Ground Control: of drives LEVEL-3 Common Ambareesh Jha In Progress
is not properly cleaned prior to Jumbo positioning for drilling). made LL and for NL & VRM section are in progress

246 Ground Control: SSP plans are not available with Jumbo operators. LEVEL-3 Common Ambareesh Jha SSR plans are to be fixed in all jumbos Immediate Completed SSR plans are given to all jumbo operators
and also pasted in the jumbos

247 Tailing Dam: Perimeter toe ditch is missing or blocked in several sections of the TSF. LEVEL-2 SKM Pending

248 Tailing Dam: Seepage of water from the TSF is not measured LEVEL-2 SKM Pending

Only a limited number of instruments (piezometers and inclinometers) are

installed. No
data is recorded since Feb 28, 2019. The instruments shall be fixed immediately.
Also,
249 Tailing Dam: no critical level has been defined for the instruments. An instrumentation plan LEVEL-2 SKM Pending
shall be
developed and more instruments shall be installed. Critical levels for each
instrument
shall be defined.
250 Tailing Dam: TSF Risk Assessment is not carried out yet. LEVEL-2 SKM Pending

Training is lacking on the OMS Manual and Emergency Response Plan (ERP). A
251 Tailing Dam: muck LEVEL-2 SKM Pending
drill on the ERP shall be carried out.

252 Tailing Dam: Tailings Dashboard is not available yet. This is a Group Level requirement. LEVEL-2 SKM Pending

253 Tailing Dam: Capacity is available until Feb 2020. Land acquisition and design of raising the LEVEL-2 SKM Pending
embankment are critical. These issues shall be addressed on priority.

254 Tailing Dam: Some areas of the downstream slopes are too steep due to land availability LEVEL-2 SKM Pending
issues.

Common: Critical Flammable areas to be tagged / barricaded & to be

displayed along with 1. Identify the flammable areas. Displayed in all diesel bowsers &
255 HOT WORK the details of the flammable material, MSDS, Quantity, Volume. (EXPLOSION LEVEL-1 Common Anup Das/ Yuvraj 2. Tagging & Barricading area 6/30/2019 In Progress Explosive Van
& FIRE
HAZARD).

SKM: In diesel storage/ filling yard: Behind the diesel tanker vehicle two drums
256 HOT WORK of Level 1 SKM
kerosene/ diesel stored (FIRE HAZARD).

2. Tagging and barricating area

Common: Filled / Empty cylinders were found mostly stacked together without
257 HOT WORK MSDS LEVEL-2 Common Anup Das/ Yuvraj 1-May-19 Completed Completed
displayed
1. Identify all the storage area for
DA/Oxygen
2. Audit the as per Stand.

Common: Found damaged Pressure regulators, hoses, flashback arrestors,

torches, 1. Numbering of all Gauges with all
258 HOT WORK holders, lugs & PPEs at sites, to be replaced immediately & records to be LEVEL-2 Common Anup Das/ Yuvraj vendore of RDM (Mill /Mine) 15-May-19 In Progress
maintained for Periodic Checking of Gauges
the same.

266 HOT WORK SKM: Fire extinguishers in Mill -1 found with no test & due dates Level 2 SKM
2. Periodic checking of Gauges

267 HOT WORK SKM: Oxygen & Acetylene cylinders were tied with ropes instead of chains. Level 2 SKM

SKM : Workers carrying mobile phone inside the area where it is prohibited
268 HOT WORK (Diesel Level 2 SKM
filling station)

Identification of PSM critical equipment and PSM critical piping not done or
269 PT Package not done as per LEVEL-1 Common Vekesh Chittora Is in progress 5/31/2019 In Progress
guidance note for “Identification of PSM Critical equipment

AT RDM and SKM facilities like Nitrogen production, storage and usages, fire
hydrant
271 PT Package system, HEMM repair shop, Utilities, tailing slurry handling system is not LEVEL-1 RDM/ SKM Vekesh Chittora Is in progress 31-May-19 In Progress
covered in PT
Package.

If storage and handling of highly hazardous or inflammable materials are done

272 PT Package in central store, Level 1 SK
the facility should also be included in PT package.

There is miss match in list of chemicals identified in CHS standard and PT

package. In short
273 PT Package all raw materials, input chemicals, intermediate products, by products, waste LEVEL-2 Common Vekesh Chittora Pending
generated and
finished g oods should be identified.

Various items like zinc & lead concentrate, zinc sulphate, nitrogen gas, tailing
274 PT Package slurry etc. are LEVEL-2 Common Vekesh Chittora Pending
missing from “Hazards of Material section.

275 PT Package Hazards not mentioned in form 1d and 1e LEVEL-2 Common Vekesh Chittora Pending

276 PT Package SOPs available at SK Mill2 control room are not revised after 2017 Level 2 SKM

At SK Mill 2 HHP & LHO identification is not as defined in PSM standard, this will
277 PT Package further Level 2 SKM
affect PHA

Process description should be in details describing each and every step of

278 PT Package operation. LEVEL-2 Common Vekesh Chittora Pending

All PFD and P&ID drawings should be listed in PT package and updated drawings
279 PT Package with LEVEL-2 Common Vekesh Chittora Pending
revision no. and date should be kept in a folder for usages as and when
required.
Details of all safety devices like fire extinguishers, fire hydrant points, wind
socks, smoke
280 PT Package detectors, emergency exits, eye washer & body showers, lightening arrestors, LEVEL-2 Common Vekesh Chittora Pending
earth pits etc
should be part of PT package.

281 PT Package All SOPs in PT package should be kept updated with revision no. and date LEVEL-2 Common Vekesh Chittora Pending

In “Standard Operation Conditions – Deviation” section it should be mentioned

that how
282 PT Package process will be brought back to normal operation (guidance for operator). Here LEVEL-2 Common Vekesh Chittora Pending
reference of
SOP no. can also be given.

283 PT Package PT Champion at RDM & SK newly appointed, hence awareness is low LEVEL-2 RDM/ SKM Vekesh Chittora Pending

284 PT Package Training required regarding PT package in most of the sections LEVEL-2 Common Vekesh Chittora Pending

PT standard and PT package (either in soft or hard) not available in all control
285 PT Package rooms LEVEL-2 Common Vekesh Chittora Pending

SOP, MOC and Process safety incident section should be regularly update as per
286 PT Package changes LEVEL-2 Common Vekesh Chittora Pending
done in field.

SKM: All scraps stored together (including batteries) near oil storage area (near
287 Hot Work Epiroc level 1 SKM
and Sandvik workshops)

Common: Standard Checklist for Inspection of Welding Machine & Oxy-

Acetylene Yet Standared not receved , As soon as
288 HOT WORK Cutting sets to be maintained across site. Not available for most of the locations LEVEL-3 Common Anup Das/ Yuvraj standared receved will follow the same 31.08.2019 In Progress Checklist shared. filling to be started.
except
DSC . Appendix H available in Hot Work Standard)

289 Hot Work SKM: Color coding for Oxygen & Acetylene cylinders to be strictly followed (Not Level -3 SKM
found at many locations on site)

Interaction with Shop floor people revealed their knowledge about the standard 1. Identify the person who require the
290 HOT WORK but LEVEL-3 Common Anup Das/ Yuvraj training . 30-Jul-19 In Progress Training to be started.
needs more training & knowledge enhancement. 2. Training Calender to be made
3. Training Will be imparted

291 MOC No MOC is being raised for Kaizen in RDM. In SKM, only one MOC for Kaizen is LEVEL-1 RDM/ SKM Rakesh Khurana 15-May-19 In Progress Training calender is rolled out and MOC
evidenced. As per standard, any not in kind change calls for MOC. prep. In progress
Training calender to made

292 MOC No MOC for subtle changes has been raised in RDM and SKM so far. LEVEL-1 RDM/ SKM Rakesh Khurana In Progress
Training will be imparted
Total 17 MOC's were documented and
293 MOC Very few MOC is being raised in RDM and SKM. In SKM only 7 MOCs have been LEVEL-1 RDM/ SKM Rakesh Khurana also we will cover all the Kaizen's in MOC's 31-May-19 In Progress
raised.
as suggested in second party audit
No PSSR report evidenced in Conveyor Guarding MOC though recommended by
295 MOC RC Level -1 SK
(SKM).

Understanding regarding requirement of PHA in MOC to be strengthen in Mines

a. MOC for N2 plant for tyre inflation (RDM)recommended for PHA, but no PHA
300 MOC report evidenced. LEVEL-2 RDM/ SKM Rakesh Khurana Pending status from vishu
b. PHA recommended in MOC for conveyor guard locking (in SKM), but not
evidenced.

Proper Risk Analysis through PHI checklist

a. N2 plant for tyre inflation: Hazard identified, but mitigation plan is not
301 MOC mentioned. LEVEL-2 RDM/ SKM Rakesh Khurana Pending
b. EOT crane installation: Hazard identified, but mitigation plan is not
mentioned.

Training schedule is to be prepared to train all employees at site. At present no Training schedule is to be prepared and
309 MOC training LEVEL-3 Common Rakesh Khurana traing will be imaparted 15.06.2019 Pending
schedule is available.

310 MOC Meeting of RC in each plant is to be conducted every week as per MOC LEVEL-3 Common Rakesh Khurana MOM will be recorded as per the MOC continue In Progress
procedure. formats

312 MOC MOM of RC meeting must be recorded as per format specified in MOC LEVEL-3 Common Rakesh Khurana It will be continued from the Next RC continue In progress
procedure.

Closure Form of MOC (Form #4) evidenced was blank: Conveyor Guarding in
313 MOC SKM. It Level 3 SK
should be properly filled up and resubmitted.

No dedicated Pedestrian walkway is visible at the entrance of SKM gate area

315 PHA creating Level 1 SKM
“Man-Machine Interaction” situation.

Provide access control at MIBC Day Tank area along with, gas, Fire detection
316 PHA system and Level 1 SKM
the Auto Fire Suppression system as like in S KM

Consequence Analysis Done considering worst case scenario of MIBC (Methyl

Iso Butyl
317 PHA Carbonyl) ½ inch line rupture creating liquid pool fire, flash fire, vapor cloud LEVEL-2 SKM Sunil Sampla 31-May-19 Pending
explosion,
liquid pool toxic evaporation. But No recommendation against the CA.

318 PHA 1st party audit for PHA not conducted both in SKM and RDM. LEVEL-2 RDM/ SKM Krishna Vyas/ Anup Das Pending

319 PHA Evaluation of Inherent safer process is not evident in any of the PHA LEVEL-2 Common Krishna Vyas/ Anup Das 31-May-19 Pending

320 PHA Team member’s qualification, discipline and experience not documented LEVEL-2 Common Krishna Vyas/ Anup Das 31-May-19 Pending

321 PHA PHA team members PHA training record was not found. LEVEL-2 Common Krishna Vyas/ Anup Das 31-May-19 Pending

Most of the Recommendations against Hazard Evaluation were of

322 PHA Administrative control, LEVEL-2 Common Krishna Vyas/ Anup Das 31-May-19 Pending
only few engineering control recommended

323 PHA Across the site the standard format for PHA document is not available. LEVEL-3 Common NS Choudhary/ Sunil S ampla Standarization of the document in 10-May-19 In Progress
progress

324 PHA The Membership signature not available in most of the PHA documents LEVEL-3 Common NS Choudhary/ Sunil S ampla Document verification & signature Immediate Completed

325 PHA Training record of the member not available. LEVEL-2 Common Krishna Vyas/ Anup Das PHA refresher training is to be given 31-May-19 In progress Refresher training to be given

At SKM the ERCP manual is specifying training of rescue and firefighting team
329 ERCP only. Level 2 SKM
The training & refresher training for all the working personnel is not mentioned.

The training & refresher training for the Emergency coordinators are not
330 ERCP mentioned in Level 2 SKM
the ERCP site specific Procedure

Conduct Table top exercise on Mock drill on the identified scenario once in a
331 ERCP year. Level 2 SKM
 Increase the number of Wind sock at mine & mills site. At SKM only one wind
332 ERCP sock Level 2 SKM
observed during site round whereas at RDM no wind sock found.

Mock drill done on “Fire in Chemical at SKM” in the month of Oct’19. The
333 ERCP medical Level 2 SKM
team was not informed & also the ambulance was not arrived at incident site.

As per recommendation of Mock-drill conducted in the Month of Oct’19 at SKM

the
334 ERCP New Fire tender to be made available and New Fire Hydrant line to be laid. Level 2 SKM
These two
recommendations need to be expedite

336 ERCP Start Use of Mock drill software for better follow up of all the LEVEL-3 Common Sanjay Kumar Will be done as per recommendation 31.08.2019 Pending
recommendations.

360 PSSR Post and pre PSSR Recommendation details were not available Level -3 SKM
 CAPA Dash Board- Second Party Audit

Observation Level Observation Completed In Progress

LEVEL-1 31 17 14
LEVEL-2 62 27 13
LEVEL-3 54 21 15
Total Observations 147 65 42

Implementation of voltage reducing device (VRD) in all welding machines to be

1 targeted.
Standard Checklist for Inspection of Welding Machine & Oxy-Acetylene
Cutting sets to be maintained across site. Not available for most of the locations
DSC . Appendix H available in Hot Work Standard)
2
Dash Board- Second Party Audit

Completed In Progress Pending

Pending Compliance % Compliance % Compliance %
0 54.8% 45.2% 0.0%
22 43.5% 21.0% 35.5%
17 38.9% 27.8% 31.5%
39 44.2% 28.6% 26.5%

) in all welding machines to be

chine & Oxy-Acetylene

ailable for most of the locations except
)
 Level I findings Level II findings

Identified for Identified for Total Identified for Identified for

the Quarter the year (YTD) closed
(YTD) the Quarter the year (YTD)
DSC
RDM 24 31 14
SKM
CLZS
RAM
ZM
 Level III findings
Total Identified for Identified for Total
closed the Quarter the year (YTD) closed
(YTD) (YTD)