Joint SOP-Ferro, Flux & Refractory

STANDARD OPERATING PROCEDURE
Form No.: F/SAFETY/05 Form Rev. No.: 00 Effective date: 20.10.2021

SOP No. TSLPL/ STORE/JSOP/01 Effective Date 20.10.2021 Revision No. 00
SOP Description JOINT SOP: Ferro, Refractory & Flux Handling Section Material receiving & Issue section
DEPARTMENT STORES/SECURITY/QA/SMS Page 1 of 14
Step Activity Associated Responsibility Process / Tools / PPEs (HOW) Remarks /

No. (WHAT) Requirements/Hazards/Impacts (WHO) Reference
Safety Hazard: Security & Driver Safety:
1. Road Accident due to faulty brakes, faulty light, of the Truck 1. Vehicle should have complied following road worthiness condition: a. Working hand brake, b. Horn, c.
and horn Head light d. Rear view mirror e. Reversing Horn, f. Dala Hinge and pin lock, g. Front wind glass, h. Main
2. Road Accident due to untrained driver or brake, i. Wiper blade assembly, j. Self-starter, k. Blinker light with audible buzzer, l. brake and parking light,
alcoholic driver. m. Footrest.
3. Road accident due to rolling of vehicle on 2. Driver and khalasi should not be under alcohol influence
inclined surface 3. All truck should have at least two pieces of scotch block
4. Falling of material during movement of truck 4. No trucks should be allowed inside which is overloaded and not permitted by law.
due to improper stacking 4. Driver and khalasi should have Face mask, Safety helmet, hand gloves, safety shoe, fluorescent jacket and
6. Hazard related to noncompliance of statutory they should wear shirt/T shirt & full pant
norms i.e. driving license, vehicle fitness, and 6. Vehicle reporting at gate should have following papers before being allowed for gate entry: a. Valid RC, b.
insurance. Insurance certificate, c. PUC, d. Fitness certificate issued by RTO, e. Road permit f. Driving License
7. Improper/Unauthorized parking of truck 7. Vehicle should enter from gate no.1 unless directed otherwise. After weighment at the weigh bridge,
Gate Entry 8. Accident due to over speed security guard should direct the vehicle to the designated place and ensure that vehicle engine is stopped,
and parking brake is applied, truck is in geared position and scotch block is applied in the wheels before driver
1 goes to stores for paper verification.
weighment
8. Speed of the vehicle should not be more than 16 Km per hour.
of Vehicle Health:
Health Hazard: 1. All trucks should have hand sanitizer. Every driver and khalasi to be check by infrared thermometer and if
1. Hazards of Covid infection Covid symptoms like high temperature, dry cough etc are found, matter needs to refer to OHC for further
advise.
Environment:
Environment Impact: 1. Vehicle should have valid PUC
1. Pollution due to high vehicular emission 2. Material should be proper packaging and covered with tarpaulin
2. Environmental hazard due to fines release in air.
Quality Requirements: Quality:
1. Quality deterioration due to rain 1. Material should be covered with tarpaulin and should not be wet.
Prepared By Checked By Approved By Approved By Approved By Approved By

Name & Designation: Debabrata Name & Designation: Saikat Roy Name & Designation: Sarbani Name & Designation: P Name & Designation: Dr. Name & Designation: S C
Routray (Manager, Warehouse & (Divisional Manager, Warehouse & Jha (Sr. Divisional Head, S Jha (HOD, Security) T Bhaskar (HOD, QA) Shrivastava (HOD SMS)
Delivery) Delivery) Procurement)
Sign with date: Sign with date: Sign with date: Sign with date: Sign with date:
Activity Associated Responsibility Process / Tools / PPEs (HOW) Remarks /

Step (WHAT) Requirements/Hazards/Impacts (WHO) Reference
No.
Safety Hazard: Security / Store Safety:
1. Driver goes to stores without PPE i.e. 1. Stores to accept papers when drivers come with full PPE i.e. Face Mask, Safety Shoe
Face Mask, Safety Shoe and Hand Gloves and Hand Gloves.
2. Driver crosses the road from 2. Pedestrian movement to be made through defined walkway
unauthorized place
Driver report to Health Hazard:
Central Store 1. Lack of hygiene which increases the Health:
2
office for Store chances of Covid infection. 1. Hand sanitizer to be kept outside store for use by the drivers.
In Environment Impact:
NA Environment:
Quality Requirement: NA
NA Quality:
NA
Safety Hazard: Store Safety:
1. Truck can move to unauthorized area 1. Receiving officer will ensure that one stores person escorts the vehicle to warehouse
2. Truck can overspeed in case driver is not aware about the location of unloading area.
3. Khalasi can drive the truck resulting into 2. Escorting employee to ensure that vehicle is driven by the driver only and does not
Movement of serious accident cross the speed limit.
truck from 4. Congestion of truck in unloading area 3. If one truck is already unloading/loading in the warehouse then the vehicle to be kept
Health Hazard: waiting in the designated area and to be released only when first vehicle is moved out of
3 central store to NA the unloading area.
Ferro Alloys Environment Impact: Health Hazard:
warehouse NA NA
Quality Requirement: Environment Impact:
NA NA
Quality Requirement:
NA


Safety: Store Safety:
1. Truck may be parked at a place which 1. Truck should be parked in a designated area which surface is flat
is the safety hazard. 2. Driver should switch off the engine, keep the truck in geared position and hand brake
2. Truck may move from its position should be applied before driver gets off the truck.Driver should apply scotch block in
while unloading of material diagonally opposite wheels.
3. While removing the Tarpaulin 3. Driver Should wear all PPEs including Hand Gloves (to be provided by TSLPL)
driver/khalasi may fall down from the while he is outside the truck cabin.While opening the rope and tarpaulin, truck driver
height should use hand gloves (to be provided by TSLPL) and should use platform type
4. Tarpaulin may be kept in unauthorised ladder.While opening the dala truck driver must use hand gloves and step ladder to go
area creating a slip trip hazard up.
5. Truck operator may be roaming around 4. Tarpaulin and rope to be kept on truck hood using the ladder.
Parking of during unloading creating chances of 5. After opening the tarpaulin and dala, truck driver and khalasi should sit in cabin.
Vehicle in accident Truck should be barricated which is at list six feet distance from the truck.
4
warehouse
area Health Hazard: Health Hazard:
NA NA
Environment Impact: Environment Impact:
NA NA
Quality Requirement: Quality Requirement:
NA NA


No. (WHAT) Requirements/Hazards/Impa (WHO) Reference
cts
Safety: Store Safety:
1. Bags position has changed in a 1. Stores supervisor use the step ladder to climb up on the truck and visually inspect the material.
dangerous manner due to movement of 2. Barricading done entire unloading area i.e. From loaded truck to material stacking area. Store officer/supervisor
the vehicle. shall present during unloading and ensure the stoppage of any other man/machine movement
2. Unauthorized entry of people in 3. Rigger should climb on the truck with the help of step ladder and get down from the truck before load is lifted by
unloading area as well as movement path crane.
of F15 crane. 4. Only nylon belt (cut resistance) of a load carrying capacity of 6 MT should be used for lifting the bag.
3. Fall hazard during climbing up of 5. Rigger climb down from the truck, then flag man should give the signal to the FX15 operator to lift the material.
rigger (currently rigger training is not 6. Two belt slings to be used to lift the bag, so that even if one fails, other belt carries the material safely
given to these employees) for hooking of 7. Everyday morning before start of the job warehouse incharge should check the belts and maintain daily record in a
bag with crane. predefined format.
4. Hazard of hit to rigger at the time of 8. In case any belt is damaged due to cut/crush then it should immediately be changed, and record of change should be
lifting the bag due hanging load. maintained.
Unloading 5. Hazards related to lifting the bag 9. If one belt fails then other belt should also be checked for potential damage and record should be maintained.
5
of Material without clearance from rigger 10. In no case, more than 4 bags should be lifted at one time.
6. While lifting the bag and transporting it 11. Hydra rope sling should also be checked visually on daily basis and record should be maintained.
to stacking area, sling breaks and bag 12. Load test certificate of all F15 should be maintained and crane should not be used if load test certificate has
falls down on the ground. expires.
7. Accidental chances of collision of 13. Once the load is lifted from the truck, it should be kept hanging in the air in still position for 60 seconds before F15
working employee with moving load/F15. starts moving.
8. Crane operator performs its action on 14. During F15 marching flagman must be in front of the F15 with whistling and signaling. Flagman should maintain
instruction of Rigger/warehouse in the safe distance from F15 and should always have eye contact with crane operator. Flagman should ensure that
charge/other persons present. nobody should enter in to barricaded area.
15. Crane operator should take instruction only from flagman. In case flagman is not present then warehouse incharge
will designate one person as flagman for the day and maintain the record in the register.
16. F15 crane should unload the bag and stack at designated place.


Safety: Store 1. Materials should be stack only at earmark designated place.
1. Slip, Trip & Fall during stacking 2. Vertical height of stacking should be maximum up to 6 feet.
2. Fall of Bag from height 3. To prevent slip, trip and fall six directional safety hazards to be ensured along with
3. Fall of Person from height while use of all mandatory PPEs.
removing sling 4. Vertical height of maximum 3 bags (in case of Aluminum Cube/shots only two bags
4. Stacking above man Height allowed)
Stacking of 5. Rigger engaged in removing the sling should not land his feet on any adjacent bag for
6
Bags Health Hazard: taking support, nor should he climb on top of bag in order to remove the sling.
1. Toe getting entangled in torn bag 6. No torn bag should be kept in stacking area, if any torned bag found it should be
resulting in fall immediately removed from the stacking area and kept separately.
Environment Impact: 7. Periodic dust cleaning of entire area.
7. Hazard from small dust particles 8. Person should always use goggles, safety helmet, hand gloves and nose mask.
Quality Requirement:
1. Improper Stacking
1. Fall of Bag Store/QA 1. Before lifting bag check the condition of bag physically if found OK then only lift
2. Fall of material the bag.
3. Sling Broken 2. Do not come under the lifting load directly
4. Belt of Bag getting broken 3. Never cut the bag for sample collection while it is in lifted position.
Health Hazard: 4. Cut the bag through bag cutting arrangement.
Sampling of 1. Cut injury while bag cutting 5. While cutting the bag nobody should be within 6 feet of the bag.
7 Environment Impact: 6. The persons taking the sample should wear nose mask apart from the PPEs.
Ferro Alloys 1. Hazard from small dust particles 7. The crane should go away from sampling after cutting the bag.
Quality Requirement: 8. At the time of sieving and sample collection the workman should wear nose mask,
hand gloves and goggles mandatorily.


1. Fall of Bag Store 1. Before lifting bag check the condition of bag physically if found OK then only lift
2. Fall of material the bag.
3. Sling Broken 2. Do not come under the lifting load directly
4. Belt of Bag getting broken 3. Never cut the bag for sample collection while it is in lifted position.
5. Hazard from small dust particles 4. Cut the bag through bag cutting arrangement.
6. Cut injury while bag cutting 5. While cutting the bag nobody should be within 6 feet of the bag.
6. The persons taking the sample should wear nose mask apart from the PPEs.
7. The crane should go away from sampling after cutting the bag.
8. At the time of packeting the workman should wear nose mask, hand gloves and
goggles mandatorily.
Packeting of
8
Ferro Alloys


1. Bags position has changed in a dangerous Store/SMS 1. Barricading done entire loading area i.e. from truck to material stacking area. Store officer/supervisor shall
manner due to stacking for long time. present during loading and ensure the stoppage of any other man/machine movement
2. Unauthorized entry of people in loading 2. The bag should be lifted by overhead crane and keep it on designated place from where hydra will lift it for
area as well as movement path of F15 crane. loading on truck.
3. Fall hazard during climbing up of rigger 3. Rigger should climb on the truck with the help of step ladder and get down from the truck before load is kept by
(currently rigger training is not given to these crane.
employees) for unhooking of bag with crane 4. Rigger climbs down from the truck, then flag man should give the signal to the FX15 operator to keep the
on the truck. material.
4. Hazard of hit to rigger at the time of lifting 5. Only nylon belt (cut resistance) of a load carrying capacity of 6 MT should be used for lifting the bag.
the bag due to hanging load. 6. Two belt slings to be used to lift the bag, so that even if one fails, other belt carries the material safely
5. Hazards related to lifting the bag without 7. Everyday morning before start of the job warehouse incharge should check the belts and maintain daily record in
clearance from rigger a predefined format.
6. While lifting the bag and transporting it to 8. In case any belt is damaged due to cut/crush then it should immediately be changed, and record of change should
Issue of loading area, sling breaks and bag falls down be maintained.
9 Ferro Alloys on the ground. 9. If one belt fails then other belt should also be checked for potential damage and record should be maintained.
7. Accidental chances of collision of working 10. In no case, more than 4 bags should be lifted at one time.
(1MT Bag) employee with moving load/F15. 11. Hydra rope sling should also be checked visually on daily basis and record should be maintained.
8. Crane operator performs its action on 12. Load test certificate of all F15 should be maintained and crane should not be used if load test certificate has
instruction of Rigger/warehouse expired.
incharge/other persons present. 13. Once the load is lifted from the stacking area, it should be kept hanging in the air in still position for 60
9. Bags are kept on the truck in overload seconds before F15 starts moving.
condition 14. During F15 marching flagman must be in front of the F15 with whistling and signaling. Flagman should
10. Hazard of hit to rigger at the time of maintain the safe distance from F15 and should always have eye contact with crane operator. Flagman should
loading the bag on the truck due to hanging ensure that nobody should enter in to barricaded area.
load. 15. Crane operator should take instruction only from flagman. In case flagman is not present then warehouse
11. Hazards of unloading the bag at SMS incharge will designate one person as flagman for the day and maintain the record in the register.
floor. 16. F15 crane should unload the bag and stack at designated place.
17. Unloading at SMS floor to be done only in presence and supervision of SMS authorized person.


1. While transporting the Iron Bin it can hit the Store/SMS 1. Iron Bin should be placed near the packets
human beings. 2. At the time of placement of bin, no workman should be within its vicinity till the time it is kept on the ground.
2. Bin position have changed in a dangerous 3. For lifting the bin, Sling and D-Shackle should be used in place of nylon belt/chain.
manner due to stacking for long time. 4. The bin should be lifted by overhead crane and keep it on designated place from where hydra will lift it for loading on truck.
3. Unauthorized entry of people in loading area 5. Maximum 3 bins can be loaded in the truck.
as well as movement path of F15 crane. 6. No person should be on the truck at the time of loading.
4. Fall hazard during climbing up of rigger 7. Barricading done entire loading area i.e. from truck to material stacking area. Store officer/supervisor shall present during
(currently rigger training is not given to these loading and ensure the stoppage of any other man/machine movement
employees) for unhooking of bag with crane on 8. Rigger should climb on the truck with the help of step ladder and get down from the truck before load is kept by crane.
the truck. 9. Rigger climbs down from the truck, and then flag man should give the signal to the FX15 operator to keep the material.
5. Hazard of hit to rigger at the time of lifting the 10. Only nylon belt (cut resistance) of a load carrying capacity of 6 MT should be used for lifting the bag.
bag due to hanging load. 11. Two belt slings to be used to lift the bag, so that even if one fails, other belt carries the material safely
Issue of 6. Hazards related to lifting the bag without 12. Everyday morning before start of the job warehouse in charge should check the belts and maintain daily record in a
Ferro clearance from rigger predefined format.
7. While lifting the bag and transporting it to 13. In case any belt is damaged due to cut/crush then it should immediately be changed, and record of change should be
10 Alloys loading area, sling breaks and bag falls down on maintain.
(20Kg the ground. 14. If one belt fails then other belt should also be checked for potential damage and record should be maintained.
8. Accidental chances of collision of working 15. In no case, more than 4 bags should be lifted at one time.
Bag) employee with moving load/F15. 16. Hydra rope sling should also be checked visually on daily basis and record should be maintained.
9. Crane operator performs its action on 17. Load test certificate of all F15 should be maintained and crane should not be used if load test certificate has expired.
instruction of Rigger/warehouse incharge/other 18. Once the load is lifted from the stacking area, it should be kept hanging in the air in still position for 60 seconds before F15
persons present. starts moving.
10. Bags are kept on the truck in overload 19. During F15 marching flagman must be in front of the F15 with whistling and signaling. Flagman should maintain the safe
condition distance from F15 and should always have eye contact with crane operator. Flagman should ensure that nobody should enter in
11. Hazard of hit to rigger at the time of loading to barricaded area.
the bag on the truck due to hanging load. 20. Crane operator should take instruction only from flagman. In case flagman is not present then warehouse in charge will
12. Hazards of unloading the bag at SMS floor. designate one person as flagman for the day and maintain the record in the register.
13. Bins topple down on the road during 21. F15 crane should unload the bag and stack at designated place.
transporting. 22. Unloading at SMS floor to be done only in presence and supervision of SMS authorized person.


1. Nylon belt is worn-out or cut due to sharp edge Store 1. Daily check of Nylon belt sling and D Shackle and sling at the start of the shift.
2. Sling and D shackle are damaged 2. Crane hook should always move from the side where bag is kept.
3. Overhead crane moves over a person and its 3. All the persons working inside the warehouse should mandatorily wear helmet.
hook hit the person 4. Hydra should lift the bag -----feet from the ground
4. Person gets injured from bag cutting device by 5. After cutting the bag, the bag cutting device should immediately be shifted at a
accidentally falling over it. designated place and be properly covered from top as it has sharp edge.
5. Hydra lift the bag either too high or too low 6. If a bag is kept in the stock for more than two months, extra care needs to be
6. The bag has been damaged due to ageing taken while handling it.
7. Any overhead item falls on a person from 7. All floors to be repaired and make plain.
height. 8. Drain cover to be immediately covered.
8. Due to uneven surface, person slips on the 9. Before monsoon, roof to be clean every year.
floor
11 Others 9. Open drain cover resulting in accidental fall
inside.
10. Live high voltage cable passing through open
drain cover.
11. During monsoon rainwater comes from roof
top making it a slip hazard. Wet material can
create hazard in SMS operation also.


Joint SOP-Ferro, Flux & Refractory

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Joint SOP-Ferro, Flux & Refractory

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STANDARD OPERATING PROCEDURE

Form No.: F/SAFETY/05 Form Rev. No.: 00 Effective date: 20.10.2021

Step Activity Associated Responsibility Process / Tools / PPEs (HOW) Remarks /

Prepared By Checked By Approved By Approved By Approved By Approved By

Activity Associated Responsibility Process / Tools / PPEs (HOW) Remarks /

Prepared By Checked By Approved By Approved By Approved By Approved By

Step Activity Associated Responsibility Process / Tools / PPEs (HOW) Remarks /

Prepared By Checked By Approved By Approved By Approved By Approved By

Step Activity Associated Responsibility Process / Tools / PPEs (HOW) Remarks /

Prepared By Checked By Approved By Approved By Approved By Approved By

Step Activity Associated Responsibility Process / Tools / PPEs (HOW) Remarks /

Prepared By Checked By Approved By Approved By Approved By Approved By

Step Activity Associated Responsibility Process / Tools / PPEs (HOW) Remarks /

Prepared By Checked By Approved By Approved By Approved By Approved By

Step Activity Associated Responsibility Process / Tools / PPEs (HOW) Remarks /

Prepared By Checked By Approved By Approved By Approved By Approved By

Step Activity Associated Responsibility Process / Tools / PPEs (HOW) Remarks /

Prepared By Checked By Approved By Approved By Approved By Approved By

Step Activity Associated Responsibility Process / Tools / PPEs (HOW) Remarks /

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Joint SOP-Ferro, Flux &amp; Refractory

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Joint SOP-Ferro, Flux &amp; Refractory

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STANDARD OPERATING PROCEDURE

Form No.: F/SAFETY/05 Form Rev. No.: 00 Effective date: 20.10.2021

Step Activity Associated Responsibility Process / Tools / PPEs (HOW) Remarks /

Prepared By Checked By Approved By Approved By Approved By Approved By

Activity Associated Responsibility Process / Tools / PPEs (HOW) Remarks /

Prepared By Checked By Approved By Approved By Approved By Approved By

Step Activity Associated Responsibility Process / Tools / PPEs (HOW) Remarks /

Prepared By Checked By Approved By Approved By Approved By Approved By

Step Activity Associated Responsibility Process / Tools / PPEs (HOW) Remarks /

Prepared By Checked By Approved By Approved By Approved By Approved By

Step Activity Associated Responsibility Process / Tools / PPEs (HOW) Remarks /

Prepared By Checked By Approved By Approved By Approved By Approved By

Step Activity Associated Responsibility Process / Tools / PPEs (HOW) Remarks /

Prepared By Checked By Approved By Approved By Approved By Approved By

Step Activity Associated Responsibility Process / Tools / PPEs (HOW) Remarks /

Prepared By Checked By Approved By Approved By Approved By Approved By

Step Activity Associated Responsibility Process / Tools / PPEs (HOW) Remarks /

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Step Activity Associated Responsibility Process / Tools / PPEs (HOW) Remarks /

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