[

Survey conducted
by
th
4 4 SEPTEMBER
TH
Arvind September
Industrial Hygiene
2023
Consultancy
2023
Raipur
]
C0MPREHENSIVE INDUSTRIAL HYGIENE SURVEY
AT
MIVAAN STEELS LIMITED.
UNIT: MANDIR HASAUD

[
Survey conducted
By
Arvind Industrial Hygiene
Consultancy
Raipur.
]
[ 1
Contents Page

Introduction 0f the study …………………………… 04-07

Technical information………………………………………………… 08-09

Material Method …………………………………………………… 09-12

Observations …………………………………………………. 12-14

Result & Discussion …………………………………………… 14-15

Recommendations & Conclusion ………………………………… 16

Survey Photographs ……………………………………… 17-18

Lab Report ………………………………………………………. 19-23

Calibration & Certificate’s …………………………………… 24-30

2
Ref:No. – Arv/2023-24/ 34 Dated: 12/09/2023

To,
Head, Safety & Fire Services
Mivaan Steels Limited
Mandir Hasaud, Raipur.

Ref –Work order no. – MSL-WOR23-00353 / 29-08-2023

Subject – Comprehensive Industrial Hygiene Survey of Works Area.

Dear Sir,

With reference to the above order an extensive industrial

hygiene survey had been conducted by our team at different locations of Ferro Alloy Sponge
Iron, Power plant, SMS and Rolling Mill (Steel 2) area of Mivaan steels Ltd. on 4 th September
2023 during General shift hours. The survey work was coordinated by Mr. Rabindra Bhowmik &
Mr. Navneet Mishra from Safety department. Please find below the report for your requirement
to take necessary action towards safety.

Dr. Avinash Kumar Verma,

Director & Competent Person, Under CG Govt.
Arvind Industrial Hygiene Consultancy, Raipur.

3
 INDUSTRIAL HYGIENE SURVEY REPORT OF MIVAN STEELS LTD.

INTRODUCTION: Mivaan Steels Limited is one of the leading producers of Sponge Iron, Ferro Alloy,
Structural material & Power in the state of Chhattisgarh. The company was commissioned in the year
1992 since then with further expansion and capacity addition over a period of years. With the
work force of 720 regular employees and 800 contract workers the plant is engaged in the
production of Sponge Iron DRI (300000 TPA), Steel MS Billet (250000 TPA), Power (60MW),
Ferro alloy – Silico Manganese (44000 TPA) & Structural Stee (150000 TPA). The plant has 60
MW coal-based power plant to fulfill in-house requirement of power. Most of the process are
carried out at high temperature that give rise to emission of air borne contaminants such as
manganese fumes, dust and other common metallic fumes, excessive heat stress and Noise in
various process areas. Process involves melting and handling of molten metal at high
temperature using electric arc and Induction furnaces. The alloying agent are added in different
stages of melting process.

The employees working near SAF are exposed to Heat stress, Noise and oxides of
Manganese, silica and iron. The furnaces have the top charging facility which uses raw
materials like Manganese, iron ore, dolomite, and quartz and coal fines. The process takes
about 3 hours and tapping is done to produce ferro alloy like Silico-manganese and ferro
manganese, which is crushed and stored in the metal yard. The whole process is controlled
from the 3 nos. of central control room.

Industrial hygiene survey plays a significant role in recognizing assessing and control of
adverse factors in the working environment and thus making the workplace congenial and
conducive to health. The main legislation governing safety health and welfare of persons
employed in factories in India is the Factory act 1948, which underwent a major amendment
called act 20 of [Link] amendment include increased responsibility of occupier, designer,
engineer, manufacturer, and product safety, provision relating to hazardous process, workers
participation in safety management, increased power of safety inspectors and inclusion of new
schedule. (Refer FA book, chapter 9 special provision sec.91 A), the new National policy on
safety health and environment published in Feb. 2009 by the Government of India has made the
legislation more stringent and transparent

4
DUST EFFECT ON HEALTH – The important group of occupational diseases in the iron ore
processing unit are the result of airborne dust and the effect of macroclimatic and micro
climatic conditions in the workplace environment. Chronic bronchitis associated with
emphysema has been reported as the most frequent respiratory diseases in the iron ore
processing unit. Fine dust exposure causes pneumoconiosis is which has been described as
a benign pin head or reticular pneumoconiosis, which may appear after prolonged exposure
and present a very slow progression. The exposure to dust which uses iron oxide, silica and
manganese often causes skin lesion and eczematous lesions among workers of material
handling yard. The adverse effect of dust depends on its chemical composition, size of the
dust particles, duration of exposure, personal hygiene and general health conditions of the
individual.

The Industrial hygiene survey was conducted at the various identified locations of the plant.
This survey provides input for the assessment of occupational health risk among the
workers, which may help subsequently for taking control measures in the work place. The
data collected is useful to co-relate the health of employees with their occupation,
improvement of working environment and work to become conducive to safety and health.

5
6
OBJECTIVE: The objective of this study was to monitor and assess the Respirable dust
concentration, Manganese content in respirable dust, coal dust, heat-stress, Noise level,
Gas-chemical & illumination in the working environment, and to identify the potential hazard
and risk arising from the workplace, comparing with permissible exposure limits (TLV) and to
suggest remedial measures to make the environment congenial and conducive.

Manganese Toxicity-

Manganese is used in the production of steel, as a reagent to reduce oxygen and sulfur and
as an alloying agent for production of special steel. Manganese is a hard, brittle metallic
element with a melting point of 1244oC. It is brilliant white in color with are dish tinge.
Manganese dioxide and other manganese compounds are practically insoluble in water.
Only manganese compounds of particle size 0.1 - 5 micron are respirable (small enough to
reach alveoli) eventually to be absorbed into the blood. Large manganese compound
particles may cleared from the respiratory tract and swallowed. Manganese may also enter
the gastro intestinal tract with contaminated food and water. Manganese can exist in eight
oxidation states, out of which manganese dioxide is the most stable oxide (Patty 1985;
Plunkett 1987;Stellman1998).While small manganese compound particles of 0.1-5 microns
are respirable and eventually get absorbed into the blood, large manganese compound
particles may be cleared from the respiratory tract and swallowed (Stellman 1998). The rate
of gastro intestinal absorption can be influenced by the dietary level of manganese and iron,
the type of manganese compound, iron deficiency, and age. The risk of intoxication through
natural ingestion has not been established. Absorption of manganese through the skin is
negligible (Chandra 1981; Chandra & Seth 1974; Saric 1978). The total body burden for
manganese is between 10-20 mg for a 70 Kg male. The biological half-life for manganese is
between 36 to 41days (Plunkett 1987; World Health Organization [WHO] 1981). The
permissible exposure limits for manganese in work-zone respirable dust is
5000μg/m3,the recommended manganese level in blood (MnB) is 4.2--16.5 μg/l, and in
urine (MnU) 0.9-9.80 μg/las WHO recommended norms given by the Advisory
Committee on Toxic Substances (ACTS)(WHO 2000). The normal range of manganese
refers to a background level of manganese present in the healthy human body. The two
target organs affected by chronic exposure to manganese are the lungs and the central
nervous system. The central nervous system has clinical manifestations similar to
Parkinson’s disease (Bowler & Roles 2007; Elder & Gelein 2006; Koller& Lyons 2004;
Racette2001; Sadek et al. 2004). Long term exposure to manganese dust may lead to
impairment of ventilator lung function, alteration of neurofunctional performances (slowed 7
visual reaction time, impaired audio verbal short-term memory, decreased hand steadiness
and impaired eye hand coordination).
TECHNICAL INFORMATIONS

(a) Threshold limit value – TLVs refers to airborne concentration of substances for 8
hrs. Work days to which nearby all workers may be repeatedly exposed day after day
without having any adverse health effect.

(b) TWA– The time weighted average concentration permit excursions above the limits,
provided they are compensated by equivalent excursion below the limit during the
workday.

(c) Decibel db- A unit used to express sound intensity. Minimum difference in loudness
that is usually perceptible. The general relationship is L=10q/qo(dB)
One decibel is one tenth of able and it is the preferred unit for noise measurement.

(d) Sound pressure level Spl– The level in decibel of a sound is 20 times the logarithm
to the base 10 of the ratio of the pressure of this sound to the reference sound
pressure. The unit gives idea about the effect of noise on ear drum.

(e) Equivalent noise exposure Leq– Equivalent exposure for extended period of time
provided there is no change in the noise because of the interference. It gives the
assessment of noise dose as per ISO -1999 for hearing conservation purpose. Useful
for calculating TLV/TWA for noise dose of exposed employees.

(f) Sound emission level SEL–The unit gives the assessment of noise intensity
generating from the source or machine. The parameter is useful for adopting
engineering control measures in the workplace.

(g) Area Monitoring– Sampling of the working environment pollutants at the workplace.

(h) Personal monitoring – Sampling of employees exposed to various pollutants by

fixing sampler in the breathing zone.

(i) Exposure Time– The length of individual employee’s exposure may be limited as
administrative control. There is shorter exposure time for higher sound levels.
Permitted noise exposure time or PT can be calculated for the measured sound level
8
and it may be used as an administrative control measure to minimize the exposure
level. PT can be calculated from the following formula
 PT=8/2(L-90)/5
(j) Wet Bulb Globe Temperature (WBGT)–It is the recognized index for monitoring
dry& hot atmosphere in industry in compliance with ISO standard.

(k) Respirable Dust (0.1 -5 micron) – The dust of the above size suspended in the air
for prolonged period of time and has a tendency to deposit in the alveoli chamber of
the lungs. From naked eye one can see only the dust size of above 7 microns.

MATERIAL & METHODS- Monitoring of various health hazards were carried out by
measuring the factors present in the environment through sampling. The survey was
conducted at various locations identified after interaction with the safety officers of the plant.
The instruments used were portable and battery operated with direct reading LCD display
type. Different physical hazards were monitored by using area sampling and personal
sampling techniques. The identification of the exposed employees was done on the basis of
data collection, its analysis and comparison with threshold limit values of respective hazards.
All the measurements were taken by following the calibration schedule of each instrument.
The instruments were properly calibrated before sampling.

RESPIRABLE DUST -The respirable dust concentration was monitored with the help of
Personal air sampler (Apex – II, Casella London Make). The instrument was attached to the
workers in the identified locations of the plant. Air containing respirable dust was drawn
through the sampling head (Cyclone 225-8-01) at the rate of 1.9 ltr./mts. Suction is provided
by a pump driven by aD.C. Motor rom a rechargeable NiMH battery which lasts up to 10 hrs.
The breathing zone samples were collected during the normal working hours. of the
individual. The instrument was removed after 8 hrs. And dust concentration was calculated
on the basis of weight difference of the filter paper (PVC –Membrane 37 mm dia).

NOISE:

Noise level measurement was done with the help of sound level meter type 2231,
B&K(Denmark) make. Parameters like Spl, Leq and SEL were recorded near the different
machines following the OSHA guidelines for noise sampling (1 mtr. away from the machine
and at the place where worker is sitting during the duty hrs.) Area of maximum noise and
safe zone were identified using noise mapping technique.

9
ILLUMINATION

Illumination measurement was done with lux meter which gives assessment of brightness in
the unit area of work place in lux. The degree of safety with which a task is performed
depends in large part on the quality of illumination and on visual capacities. Human eye can
accommodate wave length of 380-760 nm. The illumination data collected was compared
with the reference values adopted by ACGIH.

Manganese Estimation in Dust

samples –Respirable dust sample

The dust sample was collected in a cellulose ester filter type AAWP03700® placed in the
filter box of Personal Air Sampler, AFC 124 Casella London Make. The filter was stored at
room temperature +27oC in a desiccator before its analysis. The filter paper was cut into
small pieces and placed for 30 minutes in 100 ml HCl (1+1 deionized water) on low heat.
The extra solution was removed and the solid was extracted with water. Again 10 ml of HCL
was added in the extract, and evaporated nearly to dryness. The remaining was again re-
dissolved in 10 ml HCl and 10 drops of concentrated HN0 3 was added. The solution was
transferred toa50 ml volumetric flask and diluted up to the mark with de ionized water. The
solution was filtered through an S & S # 589 blue ribbon® filter paper and aspirated into the
flame. The concentration of manganese was determined using AAS–ICE3000 analytical
method USEPA1311B.

HEAT STRESS

WBGT Index – Wet bulb globe temperature is an agreed international standard (ISO-7243)
on heat stress which was published in 1982, and accepted by most of the countries in the
world. Its TLVs have been established by American Conference of Government and
Industrial Hygienist (ACGIH).This index is being used for judgment of the severity of thermal
environment and the risk for heat causalities. The combination that was best related to the
human response was found to be: WBGT=0.7tnw+0.2tg+0.1tdb
tnw –Natural wet bulb temp, tg–Globe temp, tdb –Dry bulb temp. This is the best index to be
used in conjunction with Air velocity and Relative humidity(RH%) or vapor pressure at NTP.

What is HEAT STRESS - Heat may occur in environment with high air temperature,
high dermal radiations like Foundries, Smelter, refineries, Steel plant, Ceramic factories
& high level of humidity for example Rotary kiln, boiler, turbines & laundries or at work 10
place where high activity level (Increasing metabolic rate) are needed. When heat stress
from the thermal environment is imposed on the human body, there will be resulting
strain in the body. This may result in physiological reactions such as increased skin
temperature, sweat productions, increased heart rate and higher core temperature.
Under severe conditions the strain may attain such a magnitude as to cause health
impairment & death.

The heat stress imposed on the body by a certain environment is often evaluated by a
heat stress index” which by a single value combines the influence of one or more of the
environmental factors as air temperature, mean radiant temperature, air velocity, relative
humidity, activity & clothing. WBGT index is the most commonly used internationally
standardized index for monitoring heat stress in hot & dry environment. Some other
index is CET, P4SR, ET etc. In India although there is a reference of many studies
mentioned above on measurement of Heat Stress in various Industries, but there are a
few (finger counted) studies published on the health effect of heat stress (heat strain).
National Institute of OH, Ahmedabad Anjali Nag [Link] have published a study on effect of
heat stress in [Link].

Heat Exchange &Heat Balance–

The heat stress on the human body results from two types of heat load

1. External Heat– Environmental

heat 2. Internal Heat– Metabolic

heat

External heat load results basically from Mechanism of conduction, convection and
radiation. Internal heat generated from human body due to intra cellular oxidative
process (metabolism) which is combination of heat generated by the basal metabolism
and resulting from physical activity. In order to maintain the internal thermal balance, the
metabolic heat load must be dissipated and this can be achieved through conduction,
convections & radiation, (depending on the environment conditions) the body may gain
or loss heat through this mechanism. The evaporation of 1 ltr of sweat removes 580 kcal
heat from the body, to the surrounding environment

Heat Balance – Heat exchanges between the human body & its environment follow
certain physical laws & can be expressed by the following equation.

Heat Gain= Heat loss

M+W+Cd+Cv+R –E=0
M –Metabolic rate, W – Heat gains due to work, Cd Conduction 11
Cv– Convections, R-Radiation, E-Evaporation
QUESTIONNAIRE SURVEY - The status of the working environment & Occupational health
conditions was also checked by conducting structured questionnaire survey, specially prepared for
this purpose. The personal interview was conducted for 28 no. of employees including contractor
workers, working in different hazardous locations of the plant. The status of First Aid Boxes,
drinking water facilities, Provision of toilet for male and female employees, Periodical medical
examination status for the current year were also recorded during the survey. The data collected
were analyzed statistically to evaluate the findings.

OBSERVATIONS –

Table-1
Respirable Dust Personal
S.N Name Location Contami Dust TLV
Designation nant Mg/m3 Mg/m3

1. Ritesh Cont. worker Coal handling Coal 2.80 2

Nirmalkar plant. dust
2. Bajrang Cont. Worker Ash Silo Ash dust 2.23 3
Yadav
3. Rohit Verma Cont. Worker RMP – 2 Ore mix 1.94 3
dust
4. Gajendra Cont. Worket
Ferro alloy Metal Mn Dust
2.73 3
Sahu yard
5. Shivnarayan
Cont. Worker Submerged Arc Ore mix 1.65 3
Yadav Furnace ferro dust
plant
TLV/TWA–Mn RD work zone air– 5Mg/[Link] Respirable Dust–3 Mg/m3,
Coal Dust - 2Mg/m3, Manganese as fume – 1 Mg/m3, Metal fume – 5 Mg/m3.

Table -2
Noise level survey (Area sampling)

S.N Location Noise Noise Noise TLV

dB(A)S dB(A) dB(A) dB(A)
pL Leq SEL
1. Submerged arc furnace floor
84.2 82.5 88.6 85
near fur.1
2. TG Floor Power Plant 83.7 82.6 87.2 85
3. Kiln Platform 84.2 84.2 90 85
4. Rolling Mill - Workshop 89.8 87.6 93.2 85
5. Main Workshop. 75.8 73.9 79.2 85 12
 Table- 3
Heat Stress Measurement (Time 11.30 AM to 1.30PM)

S.N Location D W RadiantH Mean % TLV

eat0C WBGT Excess 0
C

1. Submerged Arc Furnace 33 26 39 29.9 11.9 26.7

2. Kiln Area 32 26 38 29.6 10.8 26.7

3. Induction furnace floor 30 25 34 27.3 2.2 26.7

4. Continuous casting m/c 33 29 41 32.6 22.09 26.7

Air velocity 0.5 to 1.7 Mtr/sec, RH 78 to 84 % at different locations.

Table- 4
Illumination Level (Lux)

Location Illumination, Requirement

[Link] (Indoor/outdoor) lux (Day/Night)

1. Induction Furnace 120 100

2 CCM Hot Saw 110 100
3. Rolling Mill (Near motor no.-1) 130 100
4. Lathe Machine 320 150
(RM Workshop)
5. HT Room 165 100
6. Main Workshop 180 150
7. Ground Floor TG building 120 100
8. First Floor TG building 110 100
9. Operation Auxillary Station 250 150
10. Boiler Area (BC15) 184 100
11. Road between power plant 95 20
WHRB2 (outdoor)
12. Day-Bin (outdoor) 60 20
13. Casting making area 110 100
14. Ferro raw material feed area 70 20
(Outdoor)
15. First Floor (Ferro plant) 98 100

16. Near Product hopper 58 20

(Outdoor)
13
17. Kiln Platform (outdoor) 68 20
Required Lux 50 to 300 Lux as per IS 6665 – 1972 for different category of work. > 20 Lux IFA
for Outdoor. Refer Annexure II Illumination Guideline Illumination engineering society USA.

Table - 5
Analysis of Questionnaire on Occupational Health symptoms
(Subjective Response n = 28)

[Link]. Symptoms % Response Yes % Response No

1. Environmental Factors Heat,

Dust, Noise, at the work place 20 80

2 Ventilation system efficiency is

Good? 90 10

3. Use of Dust Mask 90 10

4. Use of Ear plugs in Noisy area 80 20

5. Health Symptoms

(a) Headache 10 90
(b) Giddiness 00 100
(c) Nausea 00 100
(d) Vomiting 00 100
(e) Breathing difficulty 03 97
(f) Uncomfortable work place 05 95
(g) Drinking water, Toilet 95 05
facilities, FA Box

* Feedback response on environment, and use of PPEs were found to be in proper use.

RESULTS & DISCUSSION –

Mivaan Steels Ltd. is a modern plant with state-of-the-art technology. The plant having
all the pollution control system working properly on the place. The process of various
section is being controlled from centralized control room. Worker’s exposure was found
to be negligible except in the metal yard, which involves manual process of breaking
the alloys and packing in the bags. Total 28 samples for dust, noise, heat stress &
illumination Gas were collected from the work place out of that 3 samples (10 %) have
deviated from the TLV norms. These Data are shown in the observation table1to 5.

Respirable Dust Personal– Respirable dust at personal level was measured at 5

locations of the plant using personal samplers. Quantitative estimation of respirable
dust was done for manganese, nuisance, coal and fly ash dust. Manganese content in
the respirable dust sample of metal yard and electric arc furnace were found to be
within the norms. Coal dust exposure at CHP area was observed above the
permissible limit. Free silica content in coal dust was found < 5 % as reported by
14
laboratory. Extensive water spray was found in the RMP yard and approach road
towards power plant CHP area.
Noise –

Noise level survey was conducted at 5 locations of the plant. Parameters like SpL,
Leqand SEL were recorded, shown in table 2. All the three parameters have significant
role in controlling the occupational noise hazard in the work place. Out of 5 samples,
noise level was observed exceeding at 1 location of Rolling mill area. (Table 2)
At rest of the locations noise intensity was observed within TLV.

Heat Stress -

Heat stress was measured in terms of wet bulb globe temperature (W.B.G.T.). Mean
WBGT is reported in table No.- 3. Out of 4 locations surveyed, heat stress in terms of
radiant heat and WBGT was found above the norms at C C M c u t t i n g a r e a . In
CCM area one person has to remain there near the machine to observe the billets
rolling and cutting process. At rest of the surveyed locations heat was observed within
norms. Air velocity and relative humidity was also measured and found to be in the
comfortable range. Prolong exposure to radiant heat was not observed at any of the
mentioned locations except near CCM machine. Over all mean WBGT was observed
varying from 2 to 22 % excess at different locations.

Heat related precautions such as use of relevant PPEs, facility of cool drinking water,
AC and work rest schedule were also found in place and accordingly ensured. (Table
3).

ILLUMINATION – Illumination survey was conducted at 17 locations, out of that light

intensity at all the locations were found to be as per the requirement. Light intensity
was found adequate in all the locations, high mast light in metal yard, CHP and Rolling
mill yard and white LED lights were found glowing at all the surveyed locations.
General illumination in entire plant were found to be very good and up to the mark.
(Table 4)

QUESTIONNAIRE SURVEY - Status of personal hygiene, ventilation and ergonomic

issue were assessed using a structured questionnaire. The consent of the participants
was obtained before filling the forms. Total 28 participants have included in the study
from various locations. Their subjective response was recorded on various issues like
health problems, availabilities of PPEs, Drinking water, Availabilities of FA box
presence of environmental factors, ergonomic issues like work place design, Comfort,
Postural problem, in the work place. The data collected were analyzed. Out of 28,
most of the participants have given favorable opinion about the various issues. Rest 15
have given their opinion for improvement in the work place (table 5).
 RECOMMENDATIONS – On the basis of the above extensive survey of the works
area, following recommendations have been suggested which will help to improve the
working environment conditions of the plant:
1. Use of HEPA filter to be ensured in coal handling plant to reduce coal dust
exposure Water spray to be continued in coal yard and approach road.
2. Manganese has a tendency get absorbed 75 % through inhalation therefore half
face
fume cartridge may be used in furnace platform of EAF, metal yard and Induction
furnace.
3. Noise exposure in Rolling mill is high, so use of ear muff should be made
compulsory
and job rotation could be implemented for the employees accordingly.
4. Workshop and lathe machines are very close to rolling mill area; hence turners are
exposed to high noise, audiometry of these employees must be monitored via
doctor and use of ear plug/muff should be made mandatory.
5. Heat protective apron may be used in the tapping side of electric arc furnace &
CCM floor.

CONCLUSION

The above study reveals the general assessment of the working environment on
one sample one time basis. Positive inference could be drawn only after replicate
measurements, collecting adequate samples and analyzing the data at regular time
interval may be on yearly basis. This study may be of significant importance for
implementation of IMS Policy, rationalize distribution of PPEs and effective control
measures in the works.

[Link], [Link]. PhD.

Director, Lead Auditor, ISO - 45001
Arvind Industrial Hygiene Consultancy
16
Raipur (C.G.)
 SURVEY PHOTOGRAPHS

QUESTIONAIRE SURVEY AREA NOISE MONITORING

ILLUMINATION AT HT ROOM HEAT STRESS AT SAF FLOOR

 SURVEY PHOTOGRAPHS

PERSONAL DUST MONITORING HUMIDITY MONITORING

AREA NOISE AT RM-WORKSHOP PERSONAL DUST MONITORING

(For Manganese)