ISSHR2015 - Bio-data of speaker

Rajendra Kumar Singh

Name:

General Manager ( Safety & Fire Services)

Designation:

JSW Steel Ltd. Vijayanagar

Organisation:

27 years
Work Experience: Previously worked at Reliance Industries Ltd, JSPL, Angul, Vedanta
group

Recognition from Director of Factories , Boilers and Health in 2013,2014

Awards/ Achievements: in Odisha and Karnataka, BSC Five Star at Reliance 2010, Award on
Safety Excellence at Vedanta
Lead auditor of ISO 9001:2008, ISO 14001:2004 and OHSAS
18001:2007
Chemical Safety , Risk assessment, Behaviour based safety – Need of
Papers published/ today, PSSR –Important tool of Process Safety, Employee involvement
RISK ASSESSMENT, SAFETY OBSERVATION AND JCC

Application for Safety Excellence

By R K Singh ( JSW Steel Ltd) Vijayanagar

 Safety Iceberg
Fatality REACTIVE
Lost Time
Medical Treatment Incident Investigation
First Aid Incident Analysis
INCIDENTS

UNSAFE
PROACTIVE CONDITIONS PROACTIVE

JCC & HIRA

Safety Observations
UNSAFE
ACTS
 Hazard Identification & Risk Assessment
It includes
Identification of Hazards

Evaluation of risks with existing control measures in place (taking into account exposure

to specific hazards, the likelihood of failure of control measures & potential severity of

consequences of injury or damage.

Evaluation of acceptability of residual risk

Identification of any additional risk control measures needed

Evaluation of whether the risk control measures are sufficient to reduce the risk to a

acceptable level
 Review of Risk Assessment

The Hazard Identification, Risk Assessment & Risk control process should be reviewed at a
predetermined time or period as set out in OH&S policy or at a time predetermined by the
management. This period can vary depending on the following considerations:

The magnitude of the Risk.

Changes from normal operations

Changes in feedstock, raw materials, chemicals etc.

 Process of Risk Assessment
Identify likely hazards
at all locations

HAZARD
Ensure compliance and IDENTIFICATION Analyse hazard severity
improve system
and likelihood of occurrence

AUDIT AND RISK

REVIEW ANALYSIS

Evaluate results.
Determine acceptability

MODIFICATION AND RISK RISK

CHANGE CONTROL MANAGEMENT ASSESSMENT

Assess all changes

and modifications

RISK
MONITORING
CONTROL

Eliminate or
Ensure controls are
reduce risks
effectively maintained
COMMUNICATION

Keep personnel informed of

all risks and controls
 Types of Hazards
Occupational Safety hazards Occupational Health hazards
 Contact with electricity  Physical Hazards
 Hit by moving object/equipment  Noise
 Entanglement with rotating parts/equipment  Vibration
 Manual handling of Machinery parts, loads  Pressure
 Fall from height  Radiation
 Fall of objects  Heat / Cold
 Use of hand tools / pneumatic  Chemical Hazards
 Splash of liquid/material  Dusts
 Contact with hot materials  Fumes
 Contact with hazardous chemicals  Vapours
 Contact with hazardous waste  Liquids
 Confined space  Gases
 Slip & trip  Ergonomics
How To Assess The Risks In Your Workplace

Step 1
Identify the hazards

Step 2
Decide who might be harmed and how

Step 3
Evaluate the risks and decide on precautions

Step 4
Record your findings and implement them

Step 5
Review your assessment and update if necessary
 Risk Classification - Using The Risk Matrix Table
CONSEQUENCE INCREASING PROBABILITY

S 1 2 3 4 5
E
V
E Incident Incident
People Assets Work Reputation Never Incident Incident
R happened happened
Environment Happened at Happened at Happened in
I Several Several
T any plant Other plants our
Times in Times in
Y Plant
Our plant Our Dept
No No No No
0 Damage
Injury Impact Impact
First Aid Slight Slight
1 Slight
Injury Impact Impact
Damage
Minor Limited
MTC / Minor
2 Impact Impact
RWC Damage
Local Localized Considerable
3 LTI Damage Impact Impact

Single Major Major Major

4
Fatality Damage Impact National

Multiple Extensive Massive Major

5
Fatalities Damage Impact International
 Risk Classification - Using The Risk Matrix Table
Risk Factor Classification Risk Level
"Unacceptable Risk"
It would be appropriate to prohibit the activity until suitable
20 to 25 Very High
improvements have been implemented to reduce the level
of risk to an acceptable level
"Substantial Risk"
15 to 19 High Hazards within this range should be proactively managed
to reduce risk to acceptable;
"Adequate" Risk"
Identified hazards within this range should be actively
9 to 14 Medium
managed with efforts to bring down risk level to
acceptable;
"Acceptable Risk" and therefore no further action would
0 to 8 Low be necessary. However it would still be important to
ensure that any existing controls are maintained.
 Job Cycle Check

Job cycle check is a process to identify the gaps in the existing operational control
and modify Risk Assessment

It also helps in reviewing the implementation of system.

Steps in Job Cycle Check

Reviewers Preparation (Line Manager/Supervisors)

Pre-Job Evaluation

On the Job Evaluation

Final Evaluation

Reporting
 Reviewer’s Preparation

• As per schedule the Review Team Leader makes an appointment with Area of the job
as to time and location of the preview and execution of the job.

• The Reviewers, optionally make a photocopy of the procedure to be reviewed for use
as a working copy or alternatively and in addition, use a checklist.
 Pre-job Evaluation

• The Review team and Work executor sit down before job execution and review the job
preparation along with HIRA.

Key questions to be asked :

 What protective equipment is required? Is it in good shape?
 What tools are required? Are they provided in good condition?
 Is the procedure up-to-date?
 Can the job be done safely and efficiently by following this procedure?
 Other activities going on in the area, that may interfere (an other contractor job)?
 Direction check and other position/ location
 issues – what risks are there from all directions?
 On-the-Job Evaluation

• After the off-the-job discussion, the Review team and Work executor will go into the
area.

• Work executor will perform the job as described by procedure.

• Gaps / Deviations are observed

Note: Use HIRA as reference, but observe beyond

 On-the-Job Evaluation… cont’d
Use the Safety Observation Categories

1. Reaction
In JCC, not specifically evaporative behaviors but rather attitude, mind-set of the work executor
observed.
2. Position
Ergonomics & Risks from all directions
3. PPE
4. Tools & Equipment
5. Procedures
6. Housekeeping/ orderliness
 On-the-Job Evaluation (cont’d…)

Identify and document the following key items:

• Gaps/Deviations.
• Other check points:
 Striking hazards,
 Defective equipment/ tools and tackles.
 Any additional equipment needed.
 Emergency Preparedness.
 Any parts of the job that are not covered.
 Position, ergonomic aspects, location etc.
 4. Final Evaluation

• After the pre- and on-the-job evaluations:

 Review of team and work executor
 Review their initial findings and on- the-job evaluation.
 The Reviewer asks suggestions/opinion from the Work executor.
• Job cycle check form is then completed
 Do’s and Don'ts of JCC
DO’s:
 Have preview with whole team/
work-party
 Observe, 360° around
 Get workers’ confidence
 Strive for “real life” work situation
 JCC team leader interacts with
supervisor/ work execution leader
 Stop immediate hazards safely
 Time out at proper moment
 Have workers’ involvement and
allow for their suggestions
 Have review with whole team
Don'ts :
 Have preview with supervisor/
work execution leader only
 Inspect, use mobile
 Not “us” and “them”
 Interfere directly and
individually with work execution
members
 Interrupt at improper moment
and create unsafe situations
 Have review with supervisor/
work execution leader only
 Example of HIRA
Activity : C4&C5 conyeours junction house jam cleaning
Severity Rating

Probability
Potential Current control Required control
SN Basic Job Steps Consequence Risk
Hazard measures P E A R measures

Shoes and hands shall be

Suffering Lost Time
Slip & Fall free greese, oil or any 1 0 0 0 2 2
Person climbing the Skirt Injury
1 slippery material
board of C5 conveyor
Suffering Lost Time
Sliding of Ladder Tying the ladder firmly 0 0 0 0 2 0
Injury
Suffering Lost Time Full body harness to be
Fall from Height 1 0 0 0 4 4
Injury used while working
Suffering Lost Time Isolation of C 5 conveyor
Start of Conveyor 0 0 0 0 2 0
Injury and applying LOTO
2 Open the inspection door
Using right tools for right
Suffering Medical job & tools should be free
Hit by objects 1 0 0 0 4 4
Treatment case from slippery material like
greese or oil
Sudden discharge of Suffering Medical Maintaining a distance
1 0 0 1 4 4
coal from the chute Treatment case from the inspection door
Clearing the coal jam
3
from the chute Isolation of material
Start of Material Suffering Lost Time
feeding conveyor and 0 0 0 0 2 0
Feeding Conveyor Injury
applying LOTO
 Example of HIRA

Suffering Lost Time Full body harness to be

Fall from Height 1 0 0 0 4 4
Injury used while working
Suffering Lost Time Isolation of C 5 conveyor
Start of Conveyor 0 0 0 0 2 0
Closing the inspection Injury and applying LOTO
4
door Using right tools for right
Suffering Medical job & tools should be free
Hit by objects 1 0 0 0 4 4
Treatment case from slippery material like
greese or oil
Shoes and hands shall be
Suffering Lost Time
Person getting down the Slip & Fall free greese, oil or any 1 0 0 0 2 2
Injury
5 Skirt board of C5 slippery material
conveyor Suffering Lost Time
Sliding of Ladder Tying the ladder firmly 0 0 0 0 2 0
Injury
 JCC Evaluation Form
TO : Sectional Head Date 8.10.15
From : Mr. Venkata Seshaiah, Dy. ,Mgr
Supervisor
Activity: Chute Jam Cleaning

Names of other Employees who participated in the process of JCC -

1. Mr. Venkata Seshaiah, Dy. Mgr Operations
2. Mr. Jayanand S, Asst. Mgr Operations
3. Mr. Sunil Panday, Jr. Mgr Maintenance

Condition of Housekeeping : Found Satisfactory

`
Unsafe Acts, Practices & Conditions observed: Yes No
Describe - Skirt board on which person was standing was not adequate to do the the jam cleaning

PPEs: Adequate YES NO

Worn YES NO

Tools & Tackles : Available Readily Good Condition

Replaced
 JCC Evaluation Form

Other Hazards Noted : No

Hazard Identification & Risk Assessment:

UP to Date YES Known YES Followed YES
NO NO NO

What is needed to make this operation safer, more efficient, to improve quality; or to change
standard practice or safety rules ?
Inspection door position to be changed and additional platform with proper
Employee's Comments acces is to be made for work execution

Employee's Signatures - (All who haveparticipated in the JCC need to sign)

1. Mr. Venkata Seshaiah, Dy. Mgr Operations
2. Mr. Jayanand S, Asst. Mgr Operations
3. Mr. Sunil Panday, Jr. Mgr Maintenance
 JCC Evaluation Form

Supervisor's Signature with Comments -

Above suggestion helps us to do the job more safely and confidently

Signature and comments from Area In-charge (Expert)

Above said suggestion is practically implementable

Comments of the HOD with signature. Guideline for incorporation of the suggestion -
Implement the suggestion YES NO
Comments, justification if decision is 'NO' - Not Applicable

Forwarded to the Writer of the HIRA -

Recommendations incorporated YES NO
No recommendations - Numbered & Filed YES
Communicated to R&P SC representative for considering change in the Standard -
YES NO

Reference number : BF4/Mill4/2 Signature with Date (Writer of HIRA)

DSC - Blast Furnace - 4
Implementation

Before After
 Conclusion

• Improves quality of Risk Assessment development process

• Means to analyze employees performance on the job.
• Means to assess the effectiveness/ skills of supervision
• Requires cooperation, openness between the work party and review team.
• Helps discover hidden hazards.
• Tool for verifying adequacy and effectiveness of training method Input for training
• Way to improve observation skills: “Seeing and seeing beyond rather than Looking”
• Tool to change mindset of employees/contractors and all involved
THANK YOU