FACILITY INFORMATION
Name of the Facility
Kabir
Steel
Limited
Shitalpur, Shitakunda
Chattogram, Bangladesh
Chattogram, Bangladesh
Name of the Facility
KHAWAJA
SHIP BREAKING
Limited
Madambibirhat, Bhatiary Shitakunda
Chattogram, Bangladesh
Registered Address
KABIR MANZIL
SK. MUJIB ROAD, AGRABAD C/A
CHATTOGRAM-4100
Representative
MOHD. MEHRUL KARIM
Number of Employee
(Approximately)
(Approximately)
100 (Permanent)
300- 400 (Contracted)
Contact Information
- +880-1713 187263
- +880-31-710542
- info@kabirshiprecycling.com
- https://www.kabirshiprecycling.com
Working
Language
Language
BENGALI
& ENGLISH
FACILITY FACTS
Capable to recycle
08
08
SHIPS
SIMULTANEOUSLY
04 ships in each yards
Vertually
NO
RESTRICTION
on vassel size
(Length, Breath, Draft and LDT)
Approx.
300000
MT LDT & ABOVE
the facilities have capacity to
recycle 12 ships / year
Equipment & Machinery
Crawler
Crane
200 Tons x 2
250 Ton x 1
80 Tons x 2
JIB CRANE
45 Tons x 02
WINCH
45 Tons, 6 NOS
Weighbridge
Dump
Truck
Rescue
Boat
Barge mounted crane
Load cell
GENERATOR
MAGNET
CRANE: 2 Tons x 3, 1 Ton x 4
Excavator : 5 TONS x18
Oily Water SeparatION TANKS
Oily Water Separator
Incinerator
Sheering
Machine
Bale
compactor
Dust
Collecting
Machine
Water
Spray
Car
Lux
Meter
Multi Gas
Detector
dB
METER
Ship Recycling Process FLOW
Ship pre-arrival management
- MOA between yard and owner
- NOC for LC Opening from MOI, LC Opening
- Collection of documents, records, declarations, certificates etc.
Preparation
of SRP (Rev 0)
- Collection of IHM report from ship (if available) .
- Analysis of ship structure.
- Preliminary SRP prepared by SRF.
Ship arrival
management
- Vessel arrival at anchorage
- Appointment of safety agency
- Inspection & visit by authorities
- Issuance of Safe for Entry Permit by authority
- Signing of Protocol of Delivery & Acceptance (PODA)
Landing of
Vessel
- Landing approval from authority
- Appointment of approved beaching master
- Landing preparation at facility
- Landing of the vessel
After landing
management
- Second inspection by authorities
- Ensuring safe access to the ship
- Appointment of safety team
- Sharing workers list with authority
Issuance of
vendor challan
- Inspection by Govt. approved & appointed safety agency
- Issuance of vendor challan by safety agency as proof of oil removal
Issuance of Permits
by authority
- Submission of SRP to authority by safety agency
- Verification of SRP, Vendor Challan & others reports by MOI
- Issuance of Hot Work & Safe for Entry Permit by authority
- Issuance of cutting permission by MOI
IHM Report
- Update IHM report for Part II & III (if available in ship)
- If IHM report is not available:
- Prepare VSCP
- Collect hazmat sample
- Send sample to accredited lab for testing
- Prepare final IHM report
Preparation of
SRP final version
- Collect hazmat details (identification & quantification) from final IHM report
- Analyze the actual ship structure
- Prepare final version of IHM
Management of
hazmat
- IHM Part-I: Collect & storage within facility designated area
- IHM Part-II: Transfer to DOE approved vendor
- IHM Part- III: Re-use or recycle within our running vessel, works shop, sister concerns
Dismantling of ship ( excluding Engine and Pump Room)
- Finding out the confined spaces
- Dismantling of clean blocks (cargo tank, WBT, wing tanks etc.)
- Ensure proper use of barge mounted and shore/ fixed cranes
Issuance of Hot Work Permit for Oil Tanks, Engine and Pump Room
- Cleaning of all oil FO, LO, DO & others oil tanks
- Removal of engine room oily items (equipment and accessories)
- Cleaning of engine room sump & pump room
- Inspection and confirmation by authority
- Issuance of hot work permit for engine and pump room by authority
Handling of Oily Blocks & Equipments
- Ensure proper cleaning of oily blocks on board
- Keep the oily equipment inside oily block handling area in yard
- Use OWS to treat the oily water
Completion of recycling
- Declaration completion by SRF
- Issuance of completion certificate by safety agency
- Final calculation of material by SRF
Review of The SRFP as Applicable
- Compilation of all reports, records, monitoring etc. of the entire project
- Evaluation of recycling process against SRP and SRFP
- Review and update the SRFP as necessary
Maintenance & Workshop
The maintenance department of a ship recycling facility plays a critical role in ensuring that the facilities and equipment are kept in good working condition to facilitate efficient and safe recycling activities. The department is responsible for the maintenance, repair, and replacement of all equipment, tools, and facilities used in the yard.
The primary objective of the maintenance department is to prevent breakdowns, reduce downtime, and ensure that all equipment and facilities are functioning optimally. To achieve this, the department carries out routine maintenance checks, repairs, and replacements of parts as necessary. They also conduct regular inspections and testing of equipment and facilities to identify potential problems before they occur.
In addition, the maintenance department is responsible for ensuring compliance with safety regulations and guidelines. They conduct safety audits and inspections, ensure that all safety equipment is in good working condition, and enforce safety protocols and procedures in the yard.
The maintenance department of a ship recycling yard consists of skilled technicians, mechanics, electricians, welders, and other specialized personnel. These professionals work together to ensure that the yard’s equipment, tools, and facilities are maintained to the highest standards.
Some of the key tasks performed by the maintenance department include:
1. Conducting routine maintenance checks on all equipment, tools and facilities following the preventive maintenance plan
2. Repairing or replacing parts as necessary
3. Conducting regular inspections and testing of equipment and facilities
4. Ensuring compliance with safety regulations and guidelines
5. Conducting safety audits and inspections
6. Enforcing safety protocols and procedures in the yard
7. Maintaining a detailed maintenance and repair log for all equipment and facilities
training
KSL is committed to continually improve the competency of all workers working under the facility by properly identifying the training need and conducting training accordingly as per the annual training plan. The effectiveness of the training is monitored by the competent person regularly.
All workers are provided with the appropriate training by Govt. Approved Trainer and/or by Bangladesh Ship Breakers & Recycler Association (BSBRA) prior to performing any ship recycling activity.
Internal Training:
The in house training program are conducted by the Govt. approved ToT trainers. The purpose of this training program is to enable all the facility workers to safely undertake all operations that they are tasked to do and ensures that all workers at the SRF are familiar with their job. There are mainly 04 types of internal trainings are being conducted for the workers:- Familiarisation: This is a mandatory training for all workers conducted by yard people.
- Internal training- conducted by the internal experts and ToT trainers following the facility developed training modules.
- Special training- conducted by specialised organisation such as Red Crescent, Fire Service & Civil Defense etc.
- Misc. Training- as and when identified by safety department for any individual worker or if there is any changes in internal process or equipment, these training is conducted internally.
External Training:
The external training is always approved by the authority and/or the facility Top management.- Conducted by Govt. approved agencies and as identified by top management.
- 03 days basic safety training on ship recycling by Govt. approved training institution for unskilled works
- 07 days basic safety training on ship recycling by Govt. approved training institution for skilled works
– Hazmat expert training by DNV-GL
– ToT by SENSREC
– General worker training by SENSREC
– Ship recycling workers training by BSBRA
– Firefighting, rescue and first aid training by Bangladesh Fire Service and Civil Defense
– IHM & SRP awareness course by Bureau Veritas
– Arranging regular workshop on Hazmat, Circular Economy, Carbon Foot Print, Environment & Labor Issues etc. for the senior management from Litehauz/ CTD
– Basic first aid training by Bangladesh Red Crescent Society
– Internal auditor training by DNV-GL
OCCUPATIONAL HEALTH & ENVIRONMENT (OH&E) MONITORING
Occupational Health & Safety Monitoring:
Ship recycling facilities are hazardous workplaces and the health and safety of workers in such facilities must be closely monitored to prevent accidents and injuries. The following key steps are followed to ensure occupational health and safety monitoring of workers in our ship recycling facilities:- Conduct health risk assessment: A comprehensive risk assessment is conducted to identify potential hazards and risks of the workers. This assessment includes an evaluation of the physical, chemical, and biological hazards that workers may be exposed to, such as noise, heat, dust, asbestos, and chemicals.
- Implement engineering controls: Once potential hazards are identified, engineering controls put in place to minimize the risks to workers
- Provide Personal Protective Equipment (PPE): Workers in the ship recycling yard are provided with appropriate PPE such as boiler suit, gum boot, gloves, hard hats, safety goggles, respirators etc.
- Conduct regular health screenings: Regular health screenings are conducted to detect any signs of work-related illnesses or injuries. This includes hearing tests, lung function tests, blood & urine tests, ECG, skin assessments etc.
- Train workers: Workers are trained on the potential hazards they may encounter in the ship recycling yard and how to use the PPE and engineering controls provided to them. The training also covers emergency procedures and first aid.
- Implement a safety management system: A safety management system is in place to ensure that all workers are following the proper safety procedures and that any incidents or injuries are promptly reported and addressed.
- Monitor and evaluate the effectiveness of the safety program: Regular monitoring and evaluation of the safety program are conducted to ensure that it is effective in protecting workers and preventing accidents and injuries.
Environment Monitoring:
Facility understands the environmental risks associated with ship recycling and is implementing the environmental requirements imposed by the legal regulations. The monitoring plan is facility specific, taking into account the plots and land-sea interface soil, noise and air monitoring are applied for identification of features with regular chemical, biological and physical changes in the environment surrounding the facility. Regular monitoring reported to The Department of Environment as per requirement. SRF understands the environmental risks associated with ship recycling and is implementing the environmental requirements imposed by legal register regulations. Environmental monitoring is performed as per Environmental Monitoring Programme. These monitoring reports are maintained and archived by the HSE Department in a separate folder. In case any negative changes are identified specialists / concern authority will be contracted for identification of the causes, evaluation of risks and development of counter measures. Department of Environment (DOE) is taking sample for exhaust gas emission, air quality, sea water quality and soil quality and conduct the test accordingly.
Incident Monitoring of Occupational Health & Environment
At our facilities, we place the highest importance on the well-being of our employees, the communities we operate in, and the environment. Our commitment to safety and environmental stewardship is underpinned by our rigorous incident monitoring and management practices.
Our Approach:
- Incident Prevention: Our foremost goal is to prevent incidents that could impact health and the environment. We invest in robust safety measures, training and sustainable practices to minimize risks.
- Incident Monitoring: We maintain a vigilant monitoring system that tracks and assesses potential health and environmental incidents in real-time. This includes regular inspections, record keepings for both yard & vessel and analysis of the incidents accordingly.
- Timely Response: In the event of an incident, we are committed to a swift and efficient response. Our emergency response teams are well-prepared and have access to the necessary resources to mitigate any potential harm.
Key Aspects of Our Incident Monitoring:
- Data Collection: Our HSE Inspectors are trained to capture the incident data on daily basis to continuously monitor key environmental and health parameters, allowing us to detect and respond to incidents promptly.
- Reporting: Incidents are promptly reported and documented to ensure transparency and accountability. We maintain detailed records of each incident and our response actions.
- Risk Assessment: Our team of experts conducts risk assessments to understand the potential impacts of incidents and determine appropriate response strategies.
- Stakeholder Engagement: We maintain open lines of communication with our employees, nearby communities and regulatory authorities to keep them informed about incident monitoring and response efforts.
- Continual Improvement: We believe in the principle of continual improvement. After each incident, we conduct a thorough analysis to identify root causes and implement preventive measures.
Environmental Stewardship:
Our commitment to environmental protection goes beyond compliance with regulations. We actively work to reduce our environmental footprint, conserve resources and minimize the impact of our operations on the planet.
Transparency and Accountability:
We are dedicated to transparency in all aspects of our incident monitoring and response efforts. Our stakeholders can trust that we take their well-being and environmental concerns seriously.