A Presentation by –

SHAILESH KUMAR (Asst. Mgr/SAFETY)

SAIL-ISP ,BURNPUR
 WHAT IS SAFETY ?

Freedom from unacceptable risk or harm

 Safety & Occupational Health –An
inevitable aspect of an industry

Total Loss Prevention

The first duty of any business is to survive and the guiding principal
of business economics is not the maximization of profit but the
avoidance of loss.

Peter Drucker

Present scenario demands a highly safe work place with a symbiosis of ease of
facilities and to achieve production targets.
Statistics reveals that the most successful companies are also the safest one.
 Domino Theory
1932 First Scientific Approach to
Accident/Prevention - H.W. Heinrich.

Social Fault of the Unsafe Act

Environment Person or Accident Injury
and Ancestry (Carelessness) Condition

MISTAKES OF PEOPLE
 SAFETY as a business risk
• An accident is a failure of a successful operation
• Major accidents generally result from a combination of minor problems or
errors
• Safety performance recognised as a key element in maintaining
reputation
• Contributes to positive Company culture and values
• There is a direct linkage between business objectives and sound Safety
performance
Investment in the reduction of losses contributes directly to profit
 Ban
k
(Ov ruptcy
e
HSE rspend
) in g on

Cata
st
(No f rophe
oc
HSE) us on Running a Business
is “steering a boat
Ope With out hitting either bank”.
ratin
g Li
m it s
 Job safety analysis
(JSA)
Job safety analysis (JSA), is a qualitative risk
assessment method; it is a tool to manage workplace
hazard by taking adequate control measures to make
the work-environment safe.
JSA gives us insight about the process hazard
associated while carrying out the job and the
opportunity to use control measures for continual
improvement in workplace safety for making the
process accident free.
 JSA : Consisting of five steps as follows:

1. Breaking down the job activity

2. Identification of Hazard in each job

activity

3. Determining control measures

4. Implementation of suggested
control measures

5. Monitoring and review for

continual improvement
 Relevance of JSA in Steel
Manufacturing
Steel making process is considered as one of the most hazardous
processes.
The steel manufacturing process starts with the handling of raw
materials. These raw materials are processed in different
stages. Each stage requires different equipments and process
handling skills.
A Steel Manufacturing Process may be divided into 3 zones:- Iron
Making Zone ( Consisting of Raw Material/Ore Handling, Coke
Making Plant/ Coke Ovens, Sintering Plant), Steel Zone ( Basic
Oxygen Furnace, Continuous Casting Shop, Mills) and Utilities
(Oxygen Plant, Power Plant, Gas Holder, Process Gas Handling
etc.)
 Major hazards associated with
steel making
• Exposure of Toxic ,Inflammable and explosive gas
• Exposure to hot metal
• Hit by Object
• Caught in between moving objects / machines
• Fall from height
• Rail- Road/Traffic accident
 Recommendations to Improve the
Safe Work Environment
Potential Hazard Recommendations for safe working
Gas exposure 1. Fixed CO monitors with sensors at different critical locations to be provided
with interface in the control rooms. These monitors are to be calibrated
periodically.
2. Health assessment of utility pipelines (Fuel gases/ steam) to be done through
periodic NDT (Non destructive testing) / RLA (Residual Life assessment) with
proper record keeping.
3. Adequate training programs on gas safety for regular & contract workers are to
be organized. Periodic mock drill as per emergency plan to be arranged to
ascertain the readiness to deal with emergency situations.
4. Actions required for emergency situations, SOP, contact nos. etc. must be
displayed in control room & gas prone locations. Adequate system of
communication to be provided between important agencies like BF, GCP, Gas
Safety etc. in emergency situations.
5. Rest shelters, shift rooms etc. to be located at a distance from gas prone areas.
 Recommendations to Improve the
Safe Work Environment
Potential Hazard Recommendations for safe working
Hit by Object & Hit by Object:-
Caught in between i). Tested tools & tackles like slings, chain pulley blocks, winches etc. are to be used for
moving objects / material handling.
machines ii). The associated person to maintain a safe distance from crane / other lifting machine
during lifting / transportation of load.
iii). Persons should not be allowed to stand in wagons / trucks during material loading /
unloading job.

Caught in between moving objects / machines:

i).“System of Permit to Work” during various maintenance / repair/ cleaning jobs on the
conveyor belt, pulley, idlers etc. are to be implemented.
ii). Interlocks for sequential starting of conveyors and safety devices like Pull chord
switches, zero speed switches, belt sway switches etc. along the length of the conveyor
to be checked and maintained properly.
iii). Adequate guards over drive end & tail end drum side of conveyors, coupling
guards, V-belt guard, Hydra wheel guards & other exposed area with chances of
entanglement with moving part must be provided and maintained.
 Recommendations to Improve the
Safe Work Environment
Potential Hazard Recommendations for safe working

Exposure to hot metal / 1.Load testing of all hot metal cranes to be done as per factory act / rules & records to be
slag splashes maintained.
2. Audio visual alarm during movement of hot metal cranes, scrap charging crane, ladle &
slag transfer cars etc. to caution the surrounding persons must be provided and maintained.
3.Simultaneous operation of crane CT/LT/ Hoist etc. to be avoided during transfer of hot
metal.
4.Strict adherence to applicable SOPs/ SMPs by working crew must be ensured.
Fall from Height 1. Provision of handrails with top rail, middle rail and toe guard on the working platform
with a system of regular inspection should be in place.
2. Provision of anchoring the full body harness with lifelines / fixed structure to be made
prior to start of work & all persons at height must safely anchor their Full Body
Harness.
3. Usage of mobile phone during height jobs must be banned.
4. Permit to work at height signed by all agencies involved in the job should be ensured
Rail - Road/Traffic 1. All rail- road crossings must be provided with blinkers, audio alarms & caution boards.
accidents 2. Speed limit caution boards to be prominently displayed.
3. System of inspection of locos, rail – road crossing, Illumination etc must be followed.
4. Monitoring of Non-usage of Crash Helmet by Two wheeler riders, non-fastening of
seat belt by four wheeler drivers, Safety at Rail-Road crossings etc. by schedule/
surprise checking.
 Conclusion
•For effective implementation of safety system at workplace particularly
for steel manufacturing the areas to be stressed upon:-
a). Job Specific Safety Training to all employees ranging from managers,
supervisors and workers. Critical aspects of JSA of each job must be
made known to the concern workmen.
b). Extensive Behavioural based safety management needs to be carried
out to change the mindset of the people towards safe working. c). The
management of a steel plant must evolve a suitable system which will
encourage the workers participation in the safety culture transformation
journey by way of reward, appreciation to the individual or group.
This will ultimately inculcate the deep sense of accountability of each
worker to promote safety culture at workplace.
•
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Thank You
 Hierarchy of Risk Control measures

ELIMINATION
SUBSTITUTION

ENGINEERING

ADMINSTRATION

PPE

Increase Effectiveness Increase Participation &

and Sustainability Supervision needed
 Types of Controls and their effectiveness

 
Type of Controls Effectiveness
1. Eliminate the hazard completely. 100%

2. Engineering Controls: Create a barrier between the  40–99%

person and the hazard.

3. Administrative Controls: by use & implementation  20–40%

of regulation, law, SOP/SMP/WI/OCP, safety
procedures, etc.

4. Provide personal protective equipment (PPE). 1- 20%

 
JSA Methodology