INFORMATION on typical violations in the field of industrial safety identified during supervisory and preventive measures

INFORMATION

on typical violations in the field of industrial safety identified during supervisory and preventive measures:

absence of a license (or no contract concluded with a specialized organization);

no changes are made to the information contained in the state register of hazardous production facilities, in case of changes in the name and legal address of the entity, taxpayer identification number, composition of the hazardous production facility (hereinafter - HPO), technical characteristics of the potentially hazardous facility (hereinafter - PHO), their registration numbers, etc.;

absence of the Regulation on the procedure for organizing and implementing industrial control;

workers are not tested on knowledge of local legal acts defining industrial safety requirements, the compliance with which is part of their job responsibilities, taking into account the specifics of technological processes;

persons responsible for safe operation have not passed an industrial safety knowledge test;

persons responsible for safe operation have not undergone industrial safety training;

technical inspection (hereinafter - TI) and technical diagnostics (hereinafter - TD) of PHO are not carried out within the established deadlines;

staff of employees engaged in the operation of HPO (PHO) and ensuring industrial safety are not fully staffed;

persons responsible for the implementation of industrial control have not been appointed;

persons responsible for the proper condition and safe operation of PHO have not been appointed;

persons responsible for the proper condition and safe operation of PHO are not trained before their initial knowledge test and at the periodicity established by the rules;

a commission for testing knowledge on industrial safety has not been created, or the composition of such a commission does not comply with the requirements of the legislation;

employees (chairman of the commission for checking knowledge of industrial safety, specialist responsible for industrial control) have not passed the unscheduled check of knowledge of industrial safety in connection with changes in legislative acts in the field of industrial safety, the observance of which is their duty;

not all sections in the certificates for the right to operate lifting equipment are filled in (photograph, qualification category by job title, name and number of the education document, etc. are missing);

an employee has not been appointed to replace the person responsible for industrial control (in case of illness, business trip, vacation, and other cases), who has passed the knowledge check in the established manner;

an employee has not been appointed to replace the person responsible for the safe operation of lifting equipment (in case of illness, business trip, vacation, and other cases), who has passed the knowledge check in the established manner;

employees have not been trained in actions in case of an accident or incident: there is no plan for localization and elimination of accidents and incidents, documents confirming the conduct of training alarms, educational and training sessions are not provided;

there is no logbook for recording accidents and incidents.

We draw attention to the violations identified during supervisory and preventive measures regarding:

LIFTING CRANES:

metal structures of lifting cranes are not protected from corrosion, there are local delaminations of protective paintwork and local corrosion damage;

after the repair of a lifting crane, information about the nature of the repair and the replaced components of the lifting crane is not entered into the passport of the lifting crane, indicating the manufacturer's document confirming the quality of manufacture, and information about the acceptance of the lifting crane from repair;

lifting hooks of a 4-leg sling lack safety latches that prevent the accidental release of lifting accessories;

the length of the free end of the auxiliary hoist rope of the lifting crane from the last clamp on the drum is less than two rope diameters;

the registration number of the lifting crane to which voltage is supplied is not indicated on the housing of the voltage supply switch;

the light signaling of voltage presence on the main trolleys is not working;

the input devices of the tower crane are not equipped with a device for locking them when de-energized, and the registration numbers of the cranes are not indicated;

the limit switch for operating movements for automatic stopping of the lifting crane's travel mechanism is faulty;

there is no sun visor in the cabin of the lifting crane;

the lifting crane operating outdoors lacks

a device for locking the door from the outside when the crane operator leaves the lifting crane;

there are no (not appointed) employees for carrying out work and servicing the lifting crane who have the relevant occupational qualifications (crane operator, rigger);

the procedure for taking lifting cranes out for repair and putting them into operation after maintenance or repair is not observed (appropriate entries are not regularly made in the duty logs indicating the date and time, as well as records prohibiting crane operation during maintenance or repair and authorizing their commissioning after scheduled work);

a procedure for periodic inspection of lifting devices and containers has not been established;

instructions for persons responsible for the safe operation of lifting cranes have not been developed;

instructions for safe work practices (operating instructions) for employees with occupational qualifications have not been developed;

employees who do not have the occupational qualification relevant to the work performed, have not passed an industrial safety knowledge test and a medical examination are allowed to operate and service lifting cranes and rig loads; a duty log is not kept (is missing);

measures for the preservation of a motor crane not used for its intended purpose have not been developed;

employees not among those responsible for maintaining lifting cranes in good working order, and (or) persons responsible for the safe operation of lifting cranes have been appointed to inspect removable lifting devices and containers;

safety latches are missing from the hooks of rope slings used during work;

the crane lacks a plate indicating the registration number, rated capacity, date of next maintenance, and annual technical condition inspection;

the inscriptions on the plate indicating the registration number, rated capacity, date of next maintenance, and annual technical condition inspection of the lifting crane are not readable from floor level, and the indicated information does not correspond to the actual data;

defective, unmarked containers and removable lifting devices are present at the site of operation of the lifting crane;

regular visual and (or) instrumental inspection of the condition of lifting crane ropes is not ensured, with inspection results recorded in logbooks;

a list of main loads moved by the lifting crane, indicating their mass and rigging diagrams, is not posted at the work site;

the load testing of the lifting crane's load limiter is not carried out within the deadlines specified in the operating manual and the load limiter's passport;

crane operators and riggers at the construction site have not been familiarized with the work production project;

the procedure for working near power lines, issuing work permits, and conducting briefings for employees has not been established by a local legal act of the lifting crane owner;

the crane runway does not comply with the requirements of the design and operating documentation;

brake linings on the auxiliary hoist mechanism have defects exceeding rejection standards (cracks approaching rivet holes);

protective grounding is damaged; safety devices and equipment are faulty;

the lifting crane is not equipped with the required number of wooden pads for the outriggers of mobile cranes;

the high-pressure hoses of the hydraulic system of the mobile crane outriggers have defects;

AMUSEMENT RIDES:

the rules for using the amusement ride do not comply with the requirements and rules for use specified in the manufacturer's operating documents;

the instruction for safe work practices (operation instructions) for the amusement ride attendant does not contain instructions on actions in non-standard or emergency situations, and lacks a description of emergency passenger evacuation procedures, including evacuation in case of power failure;

regular maintenance and repair logs for amusement rides, and amusement ride forms are not kept;

technical measures to prevent a large number of users from being at the start of a water slide have not been implemented;

the amusement ride is operated with a faulty access control system for passengers and users; partial damage to critical components subject to daily inspection (the passenger module has chips and nicks on the plastic seat parts);

there is no information stand at the starting platform of the water slide;

ELEVATORS, CONSTRUCTION PASSENGER HOISTS, ESCALATORS, CONVEYORS

an instruction for the person responsible for the operation of the lifting equipment has not been developed;

an instruction for safe work practices for maintenance personnel has not been developed;

the elevator maintenance log does not contain entries from the person supervising the completed work;

the inspection log for elevators, construction passenger hoists, escalators, and passenger conveyors does not comply with the form established by the Rules;

the passport of the elevator does not contain information about the position of the employee, surname, first name, patronymic (if any), and signature of the person responsible for the safe operation of the elevator, as well as the date and number of the local legal act on his appointment and assignment to the elevator;

the Emergency and Incident Response Plan does not specify the main technological parameters and characteristics of elevators, freight elevators, escalators, passenger conveyors;

the Emergency and Incident Response Plan does not include a list of persons and performers responsible for carrying out the measures provided for in the operational part of the plan, indicating their home addresses and phone numbers;

the contract between the owner and the specialized organization does not define the rights, obligations, and responsibilities of the specialized organization for ensuring the safe operation of elevators;

there are no rules for using the elevator at the main landing platform/in the car/near each control station;

elevator operation is permitted with an unsealed elevator speed limiter/without indicating the direction of rotation of the speed limiter corresponding to the engagement of the safeties/without installed protection against access to the rotating elements of the elevator winch (drive);

foreign objects not related to elevator operation are stored in the elevator machine room;

there are no inscriptions (plates) on the doors of the elevator machine room indicating the registration number and the date of the scheduled maintenance;

elevator maintenance is not carried out (presence of dust and dirt, insufficient lighting in the shaft, oil leaks from elevator equipment, emergency lighting in the car is not working);

the maintenance personnel do not carry out a shift inspection of the elevator (the approach to the machine room is not illuminated, the machine room is not illuminated);

there are no inscriptions on the doors of the freight elevator shafts

regarding the elevator's lifting capacity and the prohibition of transporting people;

OBJECTS AND PRODUCTION FACILITIES WITH CHEMICAL, PHYSICO-CHEMICAL, PHYSICAL PROCESSES WHERE IT IS POSSIBLE

FORMATION OF EXPLOSIVE ENVIRONMENTS CONTAINING EXPLOSIVE TECHNOLOGICAL UNITS WITH A RELATIVE ENERGY POTENTIAL QВ GREATER THAN 9:

changes to the design documentation are made by an organization that does not have a permit for the development of projects for technological processes and production, where explosive environments may form;

a list of parameters determining the explosiveness of the process is not compiled, indicating their maximum permissible and critical values;

analysis of the compliance of parameters determining the explosiveness of the process is not organized;

shut-off valves used for emergency shutdown of units are not identified on the technological diagram;

numbers according to the technological diagram are not applied (marked) on technological equipment, technical devices, shut-off (shut-off and control, shut-off) valves (valves);

the direction of substance movement is not indicated on technological pipelines;

numbers according to the block diagrams in the PL are not applied (marked) on control valves, shut-off valves, shut-off devices, manual shut-off valves involved in shutting off the installation (unit).

sections of inter-shop pipelines with an indication of the arrangement level, pipeline diameters, and the names of transported substances are not available on technological facilities;

documented results of checking the response time of inter-unit shut-off devices before each start-up of the technological system (technological unit) after scheduled shutdown maintenance are not prepared;

the frequency, methods of control and permissible values of high-temperature organic heat transfer fluid indicators are not established in the technological regulations / the frequency, methods of cleaning and control of spent drying agent from the dust of the dried product are not determined / methods and means of supplying inert gases to technological systems are not determined;

technical documentation regulating the procedure for shutting down and starting up technological equipment does not define methods for purging it with inert gas, as well as indicators and methods for monitoring the effectiveness of purging (by oxygen and (or) combustible substances content in exhaust gases);

the technological regulations and instructions do not reflect the frequency, methods, and means of cleaning the internal surfaces of pipelines and apparatus from deposits of resinification, polymerization, and polycondensation products;

technological documentation does not define the frequency of control and the permissible content of combustible impurities in non-combustible liquid to be discharged into the sewer system;

the procedure for short-term disabling of individual protection parameters for repair or verification in regulation, control, signaling systems, as well as emergency protection systems, is not observed;

the list of officials authorized to issue orders for disabling protection means is not defined by order;

instruments of control, management and emergency protection systems, as well as communication and notification systems, located on the control panel, do not have appropriate labels clearly reflecting their functional purpose and protection settings;

technological documentation does not specify process stages or individual parameters that are not allowed to be controlled manually / the frequency of compressed air quality analysis for instrumentation and automation needs is not defined / the procedure for testing and monitoring the condition of heat exchange elements of technological equipment is not defined;

a reserve of measuring instruments in the amount of at least 10% of each type (range) is missing;

shut-off (inter-unit, regulating) valves, actuators involved in the control, management and emergency protection systems schemes

of technological processes, after repair and before installation, are not tested for strength and tightness of closure with the issuance of acts or with a record in the passport, in the log;

technological regulations and measurement procedures do not undergo metrological expertise;

technological instructions do not outline the methods and procedures for the safe performance of operations for emergency release of faulty tank railway cars, tanks (vessels);

quality of repair is not assessed for each piece of equipment;

results of control and testing are not reflected in the relevant as-built documents during the repair of main equipment of technological units of all categories;

when assembling flange connections of technological pipelines, the following requirements are not met: bolt nuts must be located on one side of the flange connection, bolts and studs must be lubricated;

ventilation system air ducts lack markings indicating the direction of airflow;

measures and means to ensure the safe conduct of the process in manual mode during the replacement of control or automation system elements are not provided;

changes to industrial technological regulations are not made in a timely manner;

manufacturer's certificates are missing for safety valves;

sensors for explosive and maximum permissible concentrations are not fixed in their design positions;

the implementation of the schedule for replacing measuring instruments of control, monitoring, and safety automation systems is not ensured;

discrepancies with regulated values are present in the inspection reports on the response time of inter-unit shut-off valves;

the response time (opening) of valves does not comply with regulatory parameters;

devices for protection against static electricity on the protective coating of equipment insulation and technological pipelines are faulty;

AMMONIA REFRIGERATION UNITS:

changes to ARU pipeline diagrams are not made in a timely manner during the installation of new equipment or changes to the ARU refrigeration supply scheme;

an instruction for testing equipment operating under excess pressure and ammonia pipelines has not been developed, which should outline safety measures during the testing of vessels (apparatus, pipelines);

results of pneumatic testing of a vessel (apparatus, pipeline) with indication of initial and final pressures, temperatures, and test duration are not documented by a special act;

safety valves of AHU vessels are not adjusted to start opening at a pressure of 1.7 MPa on the discharge side;

acts containing information on the adjustment of safety valves are not drawn up;

responsible AHU specialist does not issue written orders for taking equipment out of service for repair, indicating safety measures in accordance with regulatory legal acts / AHU equipment is not handed over for repair indicating: completeness and sufficiency of emptying from ammonia, oil, water and coolant, as well as isolation of the section from the rest of the refrigeration unit; measures for complete de-energization of the refrigeration equipment under repair; date and time of handover for repair, indicating the position, name and signature of the person handing over and accepting / for starting up equipment after repair and shutdowns;

acts for admitting equipment to operation after AHU repair are not drawn up, with an assessment of the repair quality;

blanks used during preparation for maintenance of vessels, repair of AHU technical devices, do not have a visible tail painted red, on which their number, pressure, and diameter are stamped;

instrumentation and automation fitter does not participate in checking the operability of AHU compressor protection devices, the serviceability of level protection relays on AHU vessels;

AHU is not provided with tools made of materials that prevent sparking during maintenance and repair of equipment;

no instructions have been developed on the procedure for safe performance of AHU repair work;

safety valves installed

on AHU discharge pipelines are not sealed;

there are no thermometers for monitoring the temperature of cooling water at the outlet from the compressor cylinder jackets;

technological pipelines are not registered; passports for technological

pipelines: operating parameters, service life, no records of conducted inspections (results of technical condition assessment) are made;

fittings are not numbered according to technological diagrams, the direction of rotation for opening and closing is not indicated on the fitting handwheels;

ammonia refrigeration chambers are not equipped with warning light and sound alarms for possible ammonia leakage;

the service life of filters for individual filtering gas masks intended for protection against ammonia exposure has expired;

the service life of regenerative cartridges for IP-4 insulating gas masks has expired;

freezing of thermal insulation of technological ammonia pipelines (more than 20% of its area);

the direction of movement of ammonia, brine, and water in pipes is not indicated by arrows of contrasting paint (black or white) in visible places near each valve and gate;

periodic checks of the "man in the chamber" system's operability by persons responsible for chamber operation are not carried out;

checks of the operability of automatic protection devices of AHU compressors and the serviceability of protective level relays on apparatuses (vessels) are not carried out. The results of the protection automation check are not recorded in the daily log of the compressor shop;

portable ammonia leak detectors ready for operation are missing;

calibration of ammonia leak detection devices is not carried out in a timely manner;

the signal from the "Man in the chamber" button does not reach the room with permanent staff duty;

EXPLOSIVE PRODUCTION FACILITIES AND GRAIN STORAGE AND PROCESSING FACILITIES:

workers servicing technical devices do not have instructions (an instruction) for the operation of technical devices;

the technological regulations do not contain information on the equipment specification, the list of journals in which the results of laboratory and industrial control of the technological process, raw materials, finished products are recorded, the list of current NPA, TNPA;

Technological diagrams are not updated in terms of displaying technical devices with models (technological numbers, types, brands) and their main characteristics, as well as other technical means ensuring interlocks, control, and emergency protection of the facilities;

Explosion safety regulations, technological instructions defining the procedure for carrying out technological processes, and equipment operation in accordance with passport data on performance, load, etc. are missing;

Personnel actions according to the emergency response plan during drills are not verified, and documents confirming the drills are absent;

Monthly monitoring of explosion prevention means is not carried out with records in the log;

Technical devices at the facilities are not marked in accordance with the technological diagram;

Labels indicating the purpose of the control elements of technical devices are missing in accordance with the requirements of regulatory technical documents;

Moving parts of equipment (protruding shaft ends, open gears (pulleys, belts), conveyor tension drums, etc.) are not guarded;

Stationary belt conveyors for bulk materials lack a device for cleaning the return strand of the belt;

Dust is present on the equipment, and dust cleaning schedules for the facilities are not observed;

Explosion relief devices do not have passports of the established form;

Explosion relief devices installed on bucket elevators are not marked, lack identification tags with numbers, and explosion relief devices are not sealed;

Replacement of the membrane of the explosion relief device made of polyethylene film after one year of operation is not performed;

Aspiration systems are not checked for actual operating parameters against design values in cases specified by regulatory technical documents;

The technical operation manual for aspiration systems does not define the procedure for periodic inspections of aspiration systems, filling out a defect report, does not specify types of repairs, and does not define the procedure for repair, adjustment, and instrumental testing of the efficiency of aspiration systems;

the passports of aspiration units do not reflect the results of checking the efficiency of aspiration units, there are no defect statements, lubrication charts;

lubrication charts indicating lubrication points, method and frequency, name, brand and consumption rates of lubricating material are missing;

planar diagrams of aspiration units in the passports of aspiration units indicate equipment positions that do not comply with the technological regulations and technological diagram;

burlap, rubber inserts installed on aspiration air ducts lack wire or cable jumpers (protection against static electricity);

there is no operation log for aspiration units; the tightness of air ducts and material pipelines, technical devices and technological lines of production premises is violated;

chain conveyor chain break control devices are not installed; bucket elevators are not fully equipped with braking devices and bucket elevator belt slippage control devices;

protective grids for lighting fixtures at heights up to 2.5 meters are missing; a complete set of V-belts for the fan drive is missing; timely control of explosion prevention means with log entries is not carried out;

level sensors (detectors) on hoppers are missing/faulty; loading and manhole hatches are not equipped with safety grilles locked with a padlock;

there are no "Information on Silos (Hoppers)" of POO, and where available, a number of data are not agreed with the production technical laboratory;

information on the temperature of grain, feed raw materials in grain storage facilities, silo-type warehouses and elevators is not stored for the calendar year;

the design of underground galleries of silo-type warehouses and elevators does not prevent water from entering them;

active ventilation systems for metal silos

grain storage facilities are in disrepair (corrugations of ventilation ducts with visible tears);

grain receiving points are not equipped with magnetic protection;

OBJECTS OF THE GAS DISTRIBUTION SYSTEM

AND GAS CONSUMPTION:

technological and labor protection instructions for persons engaged in the technical operation of gas distribution system and gas consumption facilities are absent;

requirements for the composition of crews performing hazardous gas operations are not met;

analysis of the gas content of the working area during hazardous gas operations is not carried out;

route maps of underground gas pipelines are absent; approved schedules for the maintenance of gas distribution system and gas consumption facilities are absent;

current repair of gas pipelines and gas equipment is not carried out, or the deadlines for its implementation are not observed.

operation of faulty pressure gauges (with broken glass, with no red line indicating the value corresponding to the maximum working pressure) and those that have not passed state verification is allowed;

warning rings, marking plates, or arrows indicating the direction of gas flow are not applied to the gas pipelines;

the numbering on the tags of shut-off valves is not readable,

in accordance with the technological diagram of the gas pipelines of the facilities

of gas consumption;

there is no indication of the direction of rotation for opening and closing on the valve body.

OPEN PIT MINING FACILITIES:

entries in the machine serviceability check logs are irregularly kept by operators, mechanics, and chief mechanics;

vehicles awaiting loading are supplied for loading without a permissive signal from the excavator operator;

development of working ledges and dumping of spoil banks are carried out in violation of the project and the face passport;

stripping operations are carried out with deviations from the development project and the annual mining development plan (there is no planned lead of stripping operations over extraction operations);

the height of the extraction ledge does not comply with the requirements of the development project, as well as the technical characteristics of the equipment used;

heavy-duty trucks are not equipped with mirrors that provide a view of the front, non-visible area (blind spot) of the vehicle;

the width of the roadway of the in-pit road does not comply with the development project, taking into account the dimensions of the vehicles;

the limiting slopes of the non-working ledges (stability angles) do not comply with the development project;

UNDERGROUND MINING FACILITIES:

safe passage along the conveyor is not ensured due to existing washouts in the soil;

there are breaks in the grounding conductor of the winch brake;

there is no plug on the unused cable entry of the indicator;

operation of the shearer does not comply with the requirements of the manufacturer's technical documentation:

there is a working fluid leak through the hydraulic unit seals; the handle of the cutting element engagement clutch of the shearer is broken off; operation of the conveyor does not comply with the requirements of the manufacturer's technical documentation:

the covering device of the indicator housing is missing; the idle roller of the belt is missing;

connecting pins of the guide board of the face conveyor are missing in places;

the indicator mounting is missing; there are non-rotating rollers on the working belt strand; individual bolts for fastening the transfer node to the conveyor frame are missing;

DRILLING OPERATIONS FACILITIES:

the industrial safety entity carrying out drilling operations does not have a permit from the State Industrial Supervision;

operating documentation for drilling rigs is missing; the industrial safety entity does not have maintenance and repair schedules for drilling equipment;

the industrial safety entity does not have logs for checking drilling equipment and protective devices;

measuring instruments used on drilling rigs do not undergo state verification;

FACILITIES WHERE MOLTEN FERROUS AND (OR) NON-FERROUS METALS AND ALLOYS BASED ON THESE MOLTEN METALS ARE OBTAINED, TRANSPORTED, USED:

technical and technological documentation is missing at the workplaces;

the repair work area is not fenced and not equipped with safety signs, posters, and signaling devices; pouring ladles do not undergo technical documentation checks;

There is no design documentation for the tools and devices used in the maintenance of POL (production of oil and gas);

the results of checking POL and technical conditions during shift changes are not fully recorded in the shift acceptance and handover log;

periodic verification of control and measuring instruments has not been carried out;

warning posters and safety signs are not displayed in high-risk areas;

repair work (replacement of lining) of the rotary flame furnace was carried out by an organization that does not have a license for industrial safety activities;

there is no sound and light signaling to warn workers about upcoming operations: charging, purging (mixing melts, adding additives, and other operations), casting;

moisture was detected on the working platforms of melting furnaces; the temperature of the outer surfaces of melting furnaces exceeds 45 ^oC;

EXPLOSIVE OBJECTS:

before starting work with electric detonators (during the preparation of the primer for charging), the blaster does not discharge static electricity;

the blaster (master blaster) is not familiar with the user manual for the industrial explosive substance used in the work;

the form of the work order for carrying out blasting operations does not comply with the established requirements;

personnel carrying out drilling and blasting operations are not familiar with the work project (passport);

the conductivity of the electric blasting network is not checked; specialists without a certificate of qualification for managing blasting operations are allowed to supervise blasting operations.

PRESSURE EQUIPMENT:

the commissioning of equipment is not formalized by an order of the operating organization.

there are no markings indicating the direction of rotation on the handwheels of fittings; the operating manual for pressure equipment does not comply with the requirements of the Rules;

a red line is not marked on the manometer scale at the division corresponding to the working pressure;

information on the number, month, and year of the next maintenance is not updated on the nameplate of equipment operating under pressure;

pressure measuring devices (pressure gauges) installed on equipment operating under pressure are operated with an expired calibration period;

chemical control over the quality of feed, network, and makeup water of boilers is not ensured.