HAZARD IDENTIFICATION

IN VARIOUS DIVISIONS
AND RISK ASSESSMENT
USING HIRAC TOOL IN
NEW METAL
GRANULATION UNIT

SUBMITTED BY - SARATH KRISHNAN U

M Tech (HSE)
UPES Dehradun

HAZARD IDENTIFICATION IN VARIOUS DIVISIONS AND RISK

ASSESSMENT USING HIRAC TOOL IN NEW METAL
GRANULATION PLANT

INTERNSHIP PROJECT
AT

JINDAL STEEL LTD, BELLARY

SUBMITTED BY
SARATH KRISHNAN
R080215055
[M.TECH HSE ENGINEERING]
Under the guidance of
FARHAN AHMED
DEPUTY MANAGER
(FIRE & SAFETY SERVICE)

UNIVERSITY OF PETROLEUM AND ENERGY STUDIES

INDEX

CERTIFICATE

ACKNOWLEDGEMENT

1. SECTION: BRIEF INTRODUCTION ABOUT JSW GROUP

JSW SAFETY POLICY

1.1 OP JINDAL GROUP

8
9

1,2 JSW OVERVIEW

10

1.3 JSW STEEL & EXPLANSION PLANS

13

1.3.1 JSW EXPANSION PLANS

1.4 JSW STEEL PRODUCTS
2. SECTION: JSW STEEL PRODUCTION PROCESS
2.1 STEEL PRODUCTION PROCESS FLOWCHART

14
15
16
18

2.1.1 RAW MATERIA HANDLING

20

2.1.2 PELLET AND SINTER PLANT

22

2.1.3 MAKING OF IRON

27

2.1.4 STEEL MELTING SHOP

32

2.1.5 CONTINOUS CASTING SHOP

35

2.1.6 HOT STRIP MILL

35

2.1.7 COLD STRIP MILL

36

2.1.8 LONG PRODUCT MILL

39

3. SECTION : HAZARD IDENTIFICATION OF VARIOUS DIVISION

40

3.1 OBJECTIVE

41

3.2 METHODOLOGY

41

UNIVERSITY OF PETROLEUM AND ENERGY STUDIES

3.3 HAZARD IDENTIFICATION

42

3.3.1 HAZARD IDENTIFICATION IN COREX PLANT

45

3.3.2 HAZARD IDENTIFICATION IN SMS

46

3.3.3 HAZRD IDENTIFICATION IN CRM

3.3.4 HAZARD IDENTIFICATION IN HSM
4. SECTION: RISK ASSESSMENT OF MGP USING HIRAC TOOL

48
50
51

4.1 OBJECTIVE

52

4.2 HIRAC FLOW DIAG

52

4.3 BASIC CONCEPT

53

4.4 ANALSIS

57

4.5 HIRAC REPORT

61

4.6 RESULT

63

RE
CONCLUSION

64

REFERENCE

65

PICTURE
INDEX

JSW STEELS LIMITED

16

JSW STEEL MAKING PROCESS

18

FIGURE 1 RAW MATERIALHANDLING SYSTEM

20

FIGURE 2 PELLET AND SINTER PLANT

22

FIGURE 3 PELLET FLOW DIAGRAM

24

FIGURE 4 SINTER PLANT FLOW DIAGRAM

25

FIGURE 5 COMBINATION DIAG OF MOLTERN IRON MAKING

27

FIGURE 6 COREX PLANT 1 & 2

27

FIGURE 7 COREX PLANT WORKING FLOW DIAGRAM

28

FIGURE 8 BLAST FURNACE

29

FIGURE 9 BLAST FURNACE WORKING DIAGRAM

30

FIGURE 10 COMBI NATION DIAGRAM OF SMS

32

FIGURE 11 STEEL MELTING PROCESS FLOW DIAGRAM

33

FIGURE 12 JSW STEEL MELTING SHOP

33

FIGURE 13 CONTROL ROOM & CONVERTER IN SMS

34

FIGURE 14 CPL & ECL

37

FIGURE 15 CRM WORKING FLOW CHART

37

FIGURE 16 SMS 2 & 3

47

FIGURE17 COLD ROLLING MILL

49

CERTIFICATE
This is to certify that the Project Work entitled HAZARD IDENTIFICATION IN VARIOUS
DIVISIONS AND RISK ASSESSMENT USING HIRAC TOOL IN NEW METAL GRANULATION
UNIT and submitted by SARATH KRISHNAN U, Roll No. R080215055 for the Summer Internship
(2016-17), embodies the bona fide work done by him under my supervision

Date: 25-06-2016
Place: Toranagallu

..

UNIVERSITY OF PETROLEUM AND ENERGY STUDIES

Signature of mentor

ACKNOWLEDGEMENT
I am very much thankful to almighty GOD that he has given me the opportunity to
stand here. I am also very much thankful to my respected teachers and parent for
their support, without their cooperation this training would not have been possible.
I would like to express deep gratitude to my esteemed guide Mr.FARHAN
AHMED, Deputy Manager Safety and Fire Services dept. for offering me an
opportunity to carry internship project at JSW Steel ltd from 1st JUNE 2016 to 30th
JUNE 2016 for their continuous support to complete the project successfully. And
also providing different ways to approach the project and for giving constructive
criticism in each and every Stage of the Project to accomplish my goal.

I am extremely glad to express my sincere gratitude to Dr. NIHAL ANWAR

SIDDIQUI, H.O.D Health safety Environment Dept., UPES for guiding us with his
valuable advice and assistance throughout the project.

Last, but not the least, I thank all Safety Engineers and other employees of JSW,
Bellary for their constant support.

SECTION: 1
BRIEF INTRODUCTION
ABOUT JSW GROUP

Health and S a f e t y Policy

JSW Steel shall provide safe and healthy working environment to all its
employees, associates and other interested parties as an integral part of
business.
We are committed to:
Improve H ea Ith & Safety in and around our operations proacti vel y
Impart continuous training and education to employees, and associates to
prevent injuries and occupational illness
Implement effective occupational health
practices of international standards

and safety

management

Comply to the standards, statutory requirements through the line

management
Provide plant, equipment, machinery, material and personnel meeting
the requirements ofhealth & safety standards
Ensure the safety and health of associates who are entering into the plant
premises by fixing the responsibility unambiguously
Conduct safety and risk assessment
environment

for health, safety of works

Present a resume of health & safety performance of the plant

annual report

Date: 9'" Nov 2011

in

our

Dr Vinod Nowal
Director & Chief Executive Officer

Steel Limited, VIJayanagar Works

1. O.P JINDAL GROUP

The Jindal Group is currently valued to be a US$ 18 Billion conglomerate, which over the last
three years has emerged as one of the most dynamic business organizations in the country.
Founded in 1952 by visionary Late Mr. O.P Jindal, it has expanded its operations to become a
multi-national and multi-product steel conglomerate with business interests spanning various
sectors such as steel, energy, minerals and mining, aluminum, infrastructure, logistics, cement
and information technology. Presently the group has manufacturing outfits across India, US, UK
and Indonesia; mining concession in Chile, Indonesia and Mozambique and marketing
representatives offices across the globe.
In its appetite for continuous growth and commitment towards sustainable development, the
group has already announced its intention to set up Greenfield steel plants and power plants in
the state of West Bengal, Jharkhand, Chhattisgarh, Odisha, Rajasthan, Maharashtra and
Karnataka. It continuously looks out for various acquiring various Iron Ore and Coal Mines and
other critical inputs to steel making. The group currently employs over 50,700 people across the
globe.

1.2 JSW GROUP OVERVIEW

JSW group is one of Indias largest business conglomerates, with a strong presence in the core
economic presence in the core economic sector based in Mumbai. It is currently led by Mr.
Sajjan Jindal and is a part of the US$ 18 billion O.P. Jindal Group. JSW steel is currently one of
the largest producers of steel in the industry with an annual capacity of 14.3 million tons. The
JSW group comprises of the following:

JSW ENERGY LIMITED

It was one of the first movers into the power sectors after the liberalization in the early 1990s.
JSW energy currently produces 3140 MW of power, with another 8630 MW capacity under
implementation and development. By managing its operations, enhancing social and economic
benefits, minimizing environmental impact and employing innovative technologies, it has
become a leading full-service integrated power company in the Indian Power Sector with its
presence across several states.

JSW INFRASTRUCTURE AND LOGISTICS LIMITED

It is one of the leading private infrastructure companies in the country. It started its operations in
1999 and currently has employee strength of over 1200. It is dedicated to developing world class
airports, shipyards, townships, roads, and rail connectivity, inland waterways, water treatment
plants, SEZs, and other infrastructural facilities.

JSW HOLDINGS LIMITED

It is the investment arm of the JSW group. It was incorporated in 2001 as a public limited
company registered with the Reserve Bank of India and listed under BSE, NSE and Delhi Stock
Exchange. Its main business activities include management of consultancy services and also take

care of investments in shares, stocks and other securities in India and abroad.

JSW CEMENT

JSW cement utilizes the industrial by-products such as slag to make eco-friendly cement.
Focusing on its goal to make India self-reliant and considering the unprecedented growth in
infrastructure, JSW cement was established in 2009. Even after being one of the late entrants to
the industry, it has a total capacity to produce over 5.4 million tons per year and is in plans to
expand further. Its flagship plant in Nandyal uses world class technology to manufacture cement.
JSW cement produces three types of products: Portland Slag Cement (PSC), Ordinary Portland
Cement (OPC), and Ground Granulated Blast Furnace Slag Cement (GGBFS). Its major sales
areas are Andhra Pradesh, Karnataka, Tamil Nadu, Kerala, Maharashtra and Goa.

JSW STEELS

As part of the US $18 billion O. P. Jindal Group, JSW Group has diversified interests in steel,
energy, minerals and mining, infrastructure, cement and information technology.[4] JSW's history
can be traced back to 1982, when the Jindal Group acquired Piramal Steel Limited, which
operated a mini steel mill at Tarapur in Maharashtra and renamed it as Jindal Iron and Steel
Company
The Group set up its first steel plant in 1982 at Vasind near Mumbai. Soon after, it acquired
Piramal Steel Ltd., which operated a mini steel mill at Tarapur in Maharashtra. The Jindals, who
had wide experience in the steel industry, renamed it as Jindal Iron and Steel Co. Ltd. (JISCO).
Jindal Vijayanagar Steel Ltd. (JVSL) was set up in 1994, with its plant located at Toranagallu in
the Bellary-Hoped area of Karnataka, the heart of the high-grade iron ore belt and spread over
3,700 acres (15 km2) of land. It is just 340 kilometres (210 mi) from Bangalore, and is well
connected with both the Goa and Chennai Port. In 2005, JISCO and JVSL merged to form JSW
Steel Ltd.

1.3 JSW STEEL LMITED AND THEIR EXPANSIOIN PLANS

JSW Groups foray into steel manufacturing began in 1982, when it set up the Jindal Iron and
Steel Company with its first steel plant at Vasind near Mumbai. The next two decades saw
significant expansion and several acquisitions, following the merger of Jindal Iron and Steel Co
(JISCO) and Jindal Vijayanagar Steel Ltd (JVSL) in 2005. Headed by Mr. Sajjan Jindal, it is the
largest private sector steel manufacturer in terms of installed capacity of 14.3 Million tons per
annum (MTPA). It is also one of the lowest cost steel producers in the world.
It has established a strong presence in the global value-added steel segment with the recent
acquisitions of steel mills in US and service center in the UK. Partnerships with global sector
leaders such as JFE Steel, Marubeni Itochu Steel, Praxair and Sever field Rowen Plc. has
allowed it to become one of the lowest cost steel producers in the world. It has also tied up with
JFE Steel Corp, Japan for manufacturing high grade automotive steel. It produces and entire
gamut of steel products: Hot Rolled, Cold Rolled, Galvanized, Galvalume, Pre Painted
Galvanized, Pre painted Galvalume, TMT Rebars, Wire Rods and special steel bars, rounds and
blooms.
Other locations where JSW Steel operates in are:

SALEM (TAMIL NADU)

Indias largest producer of special steel in the long products category, JSW Steel Salem plant
mainly caters to the automotive sector. It is an environment friendly, zero effluent plant. JSW
acquired SISCOL in the year 2004, a sick unit at that time. Quick turnaround of the plant was
achieved by expanding capacity from 0.3 Mt to 1 Mt and switching over to value added products.
Located advantageously at just about 350 km from Chennai, the Salem plant has emerged as a
global steel hub for automobiles and auto components.

DOLVI (MAHARASHTRA)

The 3.3 MTPA integrated steel plant at Dolvi, Maharashtra majority stake acquired in 2010, is an
inherent part of JSW Steel. Located on the west coast of India, the plant has a jetty with a
capacity of 10 million tonnes per annum. This provides the unit with logistical advantages in
importing raw materials and savings on freight cost. The unit is well connected through rail, road

and sea and has given the JSW Steel a strategic presence in western India. The Dolvi plant caters
to several industries including automotive, projects and construction, machinery, LPG cylindermakers, cold rollers, oil and gas sector and consumer durables.

VASIND (MAHARASHTRA)

The Vasind plant focuses on JSW- branded high-end steel products. It sources HR Steel coils
from the Dolvi and Vijayanagar plants to manufacture value-added, branded steel products such
as galvanised steel, plain and corrugated products as well as colour-coated products. Started in
1982 with the commissioning of a 20 high cold rolling mill, it has now turned into a full-fledged
complex with cold rolling, hot rolling, galvanizing and colour coating facilities. Galvanised steel
from Vasind is a market leader in both domestic and international markets. The unit exports
mainly to the USA, Europe and Middle East Asia and South African Continent.The plant has a
total capacity of 0.45 MTPA in galvanised and cold-rolled products, 0.225 MTPA colour coated
products and hot-rolled plates manufacturing facility.

KALMESHWAR (MAHARASHTRA)

One of the downstream operations of JSW Steel is executed from Kalmeshwar. The plant
produces several branded products including JSW Vishwas, JSW Vishwas Plus, JSW Colouron
and JSW Colouron Plus. The products are sold to leading OEMs including Whirlpool, Haier,
Blue Star, Kirby, Pennar, Metal Kraft, Solidus, Tata BlueScope, Tata International, Fowler, BG
Shirke, Tata Marcopolo, BHEL, NTPC and Tiger Steel. It is also engaged in retail sales and
exports. A new cold rolling mill is being added to raise the existing production level to 0.60
MTPA.

1.3.1 EXPANSION PLANS

The company plans to expand its total capacity to 34 MTPA by the year 2020 and touching 40
million tons in the next decade, it is expanding capacities at their existing sites and setting up
plants in new locations. On the anvil, are two 10 million tons Greenfield facilities in West
Bengal and Jharkhand. The Vijayanagar plant capacity is planned to increase to 12 MTPA by
2016 and up to 16 MTPA by 2020.

SALEM

The Salem plant aims to develop the Kanjamalai, Kavuthimalai and Vediappanmalai iron ore
mines in Tamil Nadu on receipt of requisite approvals to improve raw material security. This will
facilitate expansion of production capacity to 2 MTPA. It will also allow the unit to diversify
into the production of value-added products such as annealed, drawn and peeled steel. The plant
is continuously working to develop special grades for critical automotive applications.

DOLVI

The Dolvi unit aims to increase its upstream capacities. Expansion projects include a 1 million
tons coke oven plant and, 4 million tons pellet plant. In the second phase, the unit will be
expanded by an additional 4 million tons capacity, which will include a sinter plant, a blast
furnace, slab caster, a hot strip mill, a coke oven and two power plants of 300 MW each.

1.4 JSW STEEL PRODUCTS

Vijaynagar unit of JSW steel offers a wide variety of products to cater to its large number of
customers from various industry segments. It offers products to industry segments like
Automobile, Consumer goods, General Engineering, Energy, Machinery, Pressure vessels,
construction projects etc.
The current total capacity of the Vijaynagar unit stands at 10.0 MTPA. The basic product that is
created is the Slab, which is further used for generating other value added products such as Coils,
Wire Rods, Bar rods, and Cold rolled coils. The total capacity of individual products is as shown:
Product
Hot Rolled Coils/Sheet
Cold Rolled Coil/Sheet
Wire Rod Coils
TMT Bars
Total

Capacity(MTPA)
8.5
0.9
0.6
1
10

Cold Rolled Coils: 0.9 MTPA

Hot Rolled Coils: 0.9 MTPA

Slab: 10 MTPA

SECTION : 2
JSW STEEL PRODUCTION
PROCESS

JSW STEELS
UNIVERSITY OF PETROLEUM AND ENERGY STUDIES

2.1 STEEL PRODUCTION PROCESS FLOW CHART

Fig : Jsw steel making

UNIVERSITY OF PETROLEUM AND ENERGY STUDIES

Raw materials are received at north yard and south yard through rail and road
transport. After that it is stored at raw material handling plant. According to the
requirement raw material goes to further processing departments like coke oven, pellet
plant, sinter plant to prepare burden for blast furnace and corex for iron making.
Molten iron then goes to steel making shop. Here the carbon content and impurities are
reduced by flux addition and oxygen lancing. Final molten steel goes to casting shop;
here steel is casted into slabs and billets. These slabs and billets either goes to customer
directly or slab goes to strip making (HSM, CRM) and billet goes to wire rod
mill and bar rod mill. From here finished steel goes to
customer.

2.1.1 RAW MATERIAL HANDLING SYSTEM

Fig 1. Raw material handling system

Material flow in steel production starts from RMHS. It receives raw material in adequate
quantity and allocate space for raw material stacking. Materials handled in RMHS are iron ore,
coke, lime-stone and dolomite.
Types of transportation modes:

Rail Wagon

Road trucks

Conveyor Belt

Types of equipment to transfer material from one mode to other:

Wagon tippler:

To unload the rail wagon material. It holds the wagon and inverts it. The material falls on chain
linked conveyor belt and goes to storage area.

Stacker-Reclaimer:

It is a machine which with the help of conveyor belts makes piles of raw material and whenever
needed it reclaim material with the help of buckets attached to conveyor belt. Material falls on
another belt and is send to the other production sections

Twin Boom Stacker:

It also makes stacks of material but does not reclaim.

Barrel Reclaimer:

The piles made by TBS, barrel reclaimer collect it and send the material with the help of
conveyors.

21

UNIVERSITY OF PETROLEUM AND ENERGY STUDIES

2.1.2 PELLET AND SINTER PLANT

Fig 2: pellet & sinter plant

Agglomeration unit consist of the sinter plant and the pellet plant. In these plant
the iron ore fines are agglomerated and theses agglomerated fines are feed to the
BLAST FURNACE and the COREX PLANTS

Agglomeration is the process of converting the fine iron ores to the form of lumps

Benefit of the agglomeration are that the fine materials are most efficient to
use in the corex and the blast furnace plant

This method is used to increase the production of blast furnace and also to
lower the cost of steel making.

Pellets are then fed to the blast furnace and COREX plant. Pellets are made
to give porosity in the burden of COREX and blast furnace

Agglomeration is further classified as the vacuum extrusion, Briquetting etc.

Preparation process:
DRYING OF IRON ORE FINES:
The iron ore fine coming from the RMHS contains the 8-12% moisture. It is dried into the dryer
fired with COREX gas and oxygen. At the one end of the drum COREX gas burner is attached
and at the other end induscive draft fan is attached which creates the negative draft inside the
drum. The dust laden hot air goes to cyclone separator and then to scrubber. Dust obtained from
cyclone goes to ball mill and slurry obtained from scrubber goes to settling tank.

BALL MILLING
The dried ore particle size then reduced by ball milling. In ball milling a drum is rotated at fixed
RPM. Inside the drum high chromium ball are there, due to their attrition the particle got break
and reduced in size. The dust coming from the ball mill is also recovered and scrubbed.

MIXING OF IRON ORE WITH ADDITIVE AND MOISTURE

After ball milling the iron ore is mixed with additives like bentonite, lime stone, coke and ore
slurry obtained from scrubbers for moisture. After this process the mixture is with 8-12%
moisture and ready for pellet making.
BALLING OR PELLETIZING DISK
The mixture is then fed to balling disk which rotates at 8-10 RPM, disk diameter 7.5m and
inclined at 45-48. The standard pellet size 8-12mm. the pellet size depends upon various
parameters like RPM, moisture and feed rate. The pellets produced here are called green pellets
because they contain some moisture and deficient in strength.

SCREENING
Then the pellet are screened with double deck rollers, first with 14mm size and second with 8mm
size. In this way pellet size between 8-14mm size (appropriate for COREX and BF feeding).
Further goes for heat treatment. Under and over sized pellets are send back as the raw for pellet
making.

INDURATION

Now to strengthen the pellets these are introduced to elevated temperature to remove moisture
and to create bonding between particles of raw materials. This section is divided into three parts
1. Drying zone 200-300C
2. Heating zone 300-1300C

3. Cooling zone 1300-100C

SCREENING
Again due to water vaporization and collisions pellet size decreases so screening is done. Under
sized pellets are send back for pelletization.

Fig 3: Pellet flow diagram

SINTER PLANT
Sinter plant is a pre-processing unit for the Blast Furnace. To make ore burning easy and uniform
in BF by converting the rich iron ore fines into sinter.
It is to agglomerate the iron ore fines that have rich Fe content into lumps by adding
agglomerating agents such as dolomite and limestone and making the lumps more permeable.

Flux & Fuel Crushing

Iron Ore Fines
from (SR-7 /
TUS)
BF Return Fines
Eiric
ESP Dust

Proportioning Bins
Calcined Lime

Mixing
Drum

To Micro
Pellet Plant

Sinter Cooler

Screening
Hearth Layer
Return Fines

Product Sinter
to Blast

Fig 4 :Sinter plant flow chart

RETURN FIN

HEARTH LAY

Nodulizi

SINTER MAKING PROCESS

Mixing of raw material with small quantity of water so that the particles of coke, limestone and
dolomite may get stick on the surface of iron ore. This mixing is done into nodulizing and
mixing drum which rotates at its vertical axis at some angle to ground.
Particle size of raw materials,
Iron ore: 1mm to 8mm
Coke, lime stone, dolomite: <= 2.5mm
The nodulised raw material is fed into sintering buckets. Numbers of sintering buckets are
attached on a conveyor and this conveyor travel at very slow speed. The bottom of bucket is
porous made of cast iron thick strips spaced with 1mm distance. Below the bucket air suction
hoppers are attached. For the sintering process the top most layer is made hot by COREX and
LPG gar torch. Once the top most layer attain the 800-900C temperature sintering process starts
By the suction air system the air passes through the space between the nodules so the sintered top
layer cools and the next layer got heated and undergo sintering. In this way the whole material of
bucket got sintered.
The suction air contains raw material fine dust it is collected in to the electrostatic precipitator
and this dust sent to the pellet plant. The air then made clean and then released into the
environment.
After that sintered cake is crushed up to 80 mm size, then it is cooled. The appropriate sized
sinter has sent to the blast furnace by conveyor to the blast furnace. The under sized sinter has
sent as feed for sintering again.

2.1.3 MAKING OF IRON

This is the zone in which the iron is produced from the two process namely the corex and the
blast furnace.

COREX
1&2

BLAST
FURNCE
1&2

BF 3 & 4

MOLTEN IRON
Fig 5 : Combination diagram of molten iron
COREX TECHNOLOGY

Fig 6: corex plant 1&2

The Corex process consists of two main parts a Reduction Shaft and Melter- Gasifier . The
main reagents for the Corex process are iron ore, noncoking coal, and oxygen.Unlike the Blast
furnace the Corex process does not use a hot blast of nitrogen, thereby greatly reducing
NOX gas

emissions, but instead uses oxygen. In addition, the Corex process can use iron

oxides containing up to 80% lump ore and uses non coking coal directly as a reducing agent.
Corex is a smelting reduction process combining a melter gasifier with a reduction shaft. The
process takes lump iron ore or pellets, non-coking coal, and oxygen as main inputs. Similar to
the blast furnace process, the reduction gas moves in counter flow to the descending burden in
the reduction shaft. Then, the reduced iron is discharged from the reduction shaft by
screw conveyors and transported via feed legs into the melter gasifier.

Fig 7: Corex plant working flow

diag
The gas containing mainly of CO and H2, which is produced by the gasification of coal with
pure O2 leaves the melter gasifier at temperatures between 1000 and 1050 C. Undesirable
products of the coal gasification such as tar, phenols, etc. are destroyed and not released to the
atmosphere. The gas is cooled to 800-850C and cleaned from dust particles. After reduction of
the iron ore in
the reduction shaft, the top gas is
cooled.

PROCESS STEPS

The burden first reduced by reducing gases like CO. Here the iron oxide gets changed
into iron but in solid form.

Then this reduced iron ore (sponge iron) is feed to melter gasifier shaft where coal is feed
and this coal produce heat to melt the iron ore.

The molten metal and slag is tapped out periodically. The slag goes to the slag
Granulation plant and molten iron is poured into transferring ladles.

BLAST FURNACE
The Blast Furnace is a huge steel stack lined with refractory bricks. Iron ore, coke and limestone
are into the top and preheated air is blown from the bottom. The blast furnaces reduce and
convert the iron oxides into hot metal.

Fig 8: blast furnace

Fig 9: Blast furnace working diag

Blast furnaces require many auxiliary facilities to support their operations. However, in simplest
terms, the furnace itself is a huge steel shell almost cylindrical in shape and lined with heatresistant brick. Once started, or "blown-in," the furnace operates continuously until the refractory
lining needs renewal or until demand for iron drops to the point where the furnace is closed
down. The duration of furnace operations from start to finish is referred to as a "campaign" and
may last several years.
Iron ore and other iron bearing materials, coke and limestone are charged into the furnace from
the top and work their way down, becoming hotter as they sink in the body of the furnace which
is called the stack. In the top half of the furnace, gas from burning coke removes a great deal of
oxygen from the iron ore. About halfway down, limestone begins to react with impurities in the
ore and the coke to form a slag.
Ash from the coke is absorbed by the slag. Some silica in the ore is reduced to silicon and
dissolves in the iron as does some carbon in the coke. At the bottom of the furnace where
temperatures rise well over 3000 Fahrenheit, molten slag floats on a pool of molten iron which is
four or five feet deep. Because the slag floats on top of the iron it is possible to drain it off
through a slag notch in the furnace. The molten iron is released from the hearth of the furnace

30

UNIVERSITY OF PETROLEUM AND ENERGY STUDIES

through a tap hole. The tapping of iron and slag is the major factor permitting additional
materials to be charged at the furnace top.
This brief summary of the complex operations of a blast furnace is presented here to provide a
point of reference for the actual flow of operations. Very often, several blast furnaces may be
arranged in a single plant so that the most efficient possible use can be made of fuels, internal
rail facilities, etc.
CHARACTERISTIC OF JSW VIJAYANAGAR BLAST FURNANCE
The JSW steel Vijaynagar plant hold the largest blast furnace in India, it has 4 blast furnace which
produce

the molten

iron equipped by Siemens VAI Metals Technologies, was commissioned

successfully. With an internal volume of over 4,019 cubic meters and a nominal annual capacity
of 2.8 million metric tons of iron, it is the largest blast furnace existing in India today. This
increases the production capacity of JSW Steel at Vijayanagar works to around seven million
metric tons of steel per year. A cyclone separator developed by Siemens VAI is being used for
the first time to clean the top gas in Toranagallu. This solution makes it possible to flexibly
control the efficiency of dedusting and, as a result, to maximize the recovery of dust containing
iron and avoid an excessive concentration of zinc or other heavy elements in the recycled dust.

UNIVERSITY OF PETROLEUM AND ENERGY STUDIES

2.1.4 STEEL MELTING SHOP

The molten metal coming from the blast furnace and corex is bearing some impurities like Si, P,
S, and others. To reduce the Carbon percentage. Below 2 wt.%, remove the impurities and
addition of some alloying elements is the function of Steel Making Shop. This is done by various
processes step by step.

SMS 1

STEEL
MAKING
SHOP
SMS 3

SMS 2

Fig 10: Combination diag of SMS

Hot Metal Pre-treatment

In this section the impurities of Si and P is removed. This is done by adding some fluxes and
oxygen gas. Average process time for each stage is 15-20mins 1200-1250o C => HMPT =>
1100-1150o C
Hot Metal De Sulfurization
This process is done to further reduce sulfur S from the hot metal. De-S Agent: Calcium Carbide
The de-sulphurised slag is skimmed off using Slag Raking machine.Mixer maintains
homogenized temperature and chemistry of hot metal from different iron making units. This Hot
Metal from the Mixer is transferred to the converter with the help of a charging ladle

Fig 11: steel making process flow diag

Hot Metal Pre-treatment

In this section the impurities of Si and P is removed. This is done by adding some fluxes and
oxygen gas. Average process time for each stage is 15-20mins 1200-1250o C => HMPT =>
1100-1150o C

Steel Making Shop

Slab Caster

Billet Caster

Fig 12 : Steel melting shop

Hot Metal De Sulfurization

This process is done to further reduce sulfur S from the hot metal. De-S Agent: Calcium

Carbide
The de-sulphurised slag is skimmed off using Slag Raking machine.Mixer maintains
homogenized temperature and chemistry of hot metal from different iron making units. This Hot
Metal from the Mixer is transferred to the converter with the help of a charging ladle

Converting

Converting is the process of reducing the fixed carbon from the molten iron by lancing oxygen
gas. Carbon reacts with the oxygen and makes carbon monoxide and carbon dioxide gas. In this
stage the carbon percentage lowers down up to 0.2% from 0.4%. The convertor used is LD
Convertor named on the name of its inventor. The gas rich in CO gas is called LD gas.

Ladle heating furnace

To increases micro cleanliness and to remove nonmetallic inclusions ladle heating by graphite
electrode arching is done. In addition of it Ferro-alloying is done in this stage.

Fig 13: Control room

Fig 13 : Converter

2.1.5 CONTINOUS CASTING PLANT

The continuous casters produce slabs of the finished steel which are dimensioned to meet
customer requirements. Cut-to-length and slitting lines are available for this processing stage. 18
Casting is the continuous process at one end the molten metal poured into the mould, cooled
from outside with water spray. The mould travel at certain speed and cast moves forward. At the
other end cutting torch cuts the cast into fixed length. Then de-scaling and cooling is done by
water jet.
Casting Speed of Caster 1 and 2 is 1.75Meters/Min.Max. Caster 3 maximum speed is 2
Meters/Minute.

2.1.6 HOT STRIP MILL

In this section the slabs casted in continuous casting section is pressed under two rollers in
heated condition and made into long sheets.

HEATING

Slabs coming from the continuous casting section have to be heated up to 1280C to undergo hot
rolling. For this the slabs are heated into the furnace. This special type of furnace has four
section depending upon temperature.

RECAPORATIVE ZONE

In this section no burners are there some heating of the slab takes place due to the heat of next
zone. This type of heating is the preparation to introduce the slab in next zone at 1150C.

PRE-HEATING ZONE

The temperature of this section is 1150C.This temperature is attained by 12 burners lighted by

COREX Gas or Mixed gas.

HEATING ZONE

The temperature of this zone is 1280C, lighted by 16 burners.

SOAKING ZONE

The temperature of this zone also at 1280C and in this section the slabs are kept to homogenize
the slab temperature.

PRIMARY DE-SCALING

The heated slab come out from the furnace and then through the help of rolling drums it goes
forward and pass through the water spray at 200 bar pressure. This is done to remove the oxide
layer.

ROUGH ROLLING

In this section the de-scaled slab comes and pressed under the rollers. The 220mm slab converted
into 27mm thickness sheet with same width with the help of 5 to 7 passes. At the time and place
of pressing the pressurized water spray is done to remove oxide scaling and to cool the rollers.

COILING BOX

After reducing the thickness the hot sheet is send to the coil box. Here the sheet is coiled. Here
the purpose of coiling is to homogenize the outer and inner temperature of the sheet because it
has to undergo further rolling to reduce the thickness.

FINISHING MILL

Here 6 mills are placed each having the distance between the rolls gradually decreasing one after
another. The sheet passes through these mills and the thickness is reduced up to 1.6 mm
depending on the demand of customer.

DOWN COILER

The final sheet is send to the coiler where it coiled and then placed on the transfer car which
transfers it to the coil yard. In coil yard intermediate storage, cooling, packing and numbering is
done.

2.1.7 COLD ROLLING MILL

After hot strip making the strip goes direct to customer or goes to cold rolling section for further
reduction in thickness and finishing treatments.
CONTINUOUS PICKLING LINE
In the hot strip making the upper layer of the strip get oxidized which is not desirable. For further
reduction and treatment this oxide layer should be removed. This removal is done by
hydrochloric acid treatment. The strip is made to pass through the pickling bath divided into five
parts. The acid concentration and pickled sludge level should be maintained for good
performance. Next is rinsing of strip by DM water to remove all chloride ions from the surface

because in the next step of rolling the chloride ions present on the surface will lead to cracking.

Fig 14: Continuous pickling line

CRM FLOW CHART

Fig 15: Cold rolling mill working flowchart

Fig 14 : Electrolytic cleaning line

COMPACT COLD ROLLING

The clean strip is now subjected to rolling under twin stand 6 HI reversing mill. The thickness is
reduced with the help of continuous supply of emulsion of long chain fatty acids with DM water
(de mineralized water). This emulsion helps in cooling and lubricating of rolling joints.

ELECTROLYTIC CLEANING

In next step electrolytic cleaning is done to remove oil on the surface of the strip because in the
next step of annealing the oil residues will form soot. Electrolyte used is the solution of 2.5-3.5%
sodium hydroxide silicate in DM water. Then again rinsing is done with DM water to eliminate
the residual iron and oil concentration.

BATCH ANNEALING

During rolling crystal deformation and mechanical hardening take place. These reduce the sheets
yield strength and ultimate tensile strength and hence draw ability. To recover these properties
annealing is done on sheet. Annealing is the process to heat the metal below its liquids
temperature and hold it for some time to allow the microstructure reformation. Annealing is done
inside the annealing furnace. Before heating the furnace is purged with nitrogen gas up to
99.99% concentration. Then furnace is purged with hydrogen gas to produce reducing
atmosphere. These purging are done at 40C. After purging the furnace temperature is increased
up to 400C and then it is hold there for some time, it is called HEATING and then again
temperature is increased up to 650-700C and held there for some time this process is called
SOAKING. Then we do furnace cooling

SKIN PASS MILL

In this mill the some mechanical hardening is done on the strip. It is done by subjecting the strip
under elongated condition with the help of rolls. In the rolls wet temper fluid is used which
should possess following qualities like anti-staining, lubrication and detergent effect. This oil is
for only one time use.

RECOILING COIL INSPECTION LINE

After all treatments the sheet is inspected at both sides and then coiled.

AUTO PACKAGING LINE

The coil is packed as a coil roll. Now it is ready to deliver to the customer.

2.1.8 LONG PRODUCT MILL

The billets casted in the continuous casting mill moves forward to long product mill. Here wires
and rods are made by some more specific rolling processes.

WIRE ROD MILL

BAR MILL

Following processes are done to change the shape of billet, reduce the diameter and further
elongation.

FURNACE CHARGING

To increase the temperature of billet for further deformations.

DE-SCALING

To remove the scale of oxides from the surface of billet 230 bar pressurized water spray is
deployed.
ROLLING
According the desired final product subsequent rollings are done

COOLING

Cooling with water spray is done to cool down the work piece and equipments at the rate of 0.61.4C. Water sprays are attached after every rolling station. Sizing and measurement: on line
diameter measuring equipment is attached to the line with digital display boards showing
entering and outgoing diameter of object.

PACKAGING AND WEIGHING OF FINAL PRODUCT

The wire coils in wire mill and bars are cooled down in air and then compacted and packed with
strapping machine. The final weights are measured and then send to the storage yard.

FINAL PRODUCTS

From wire mill: wire diameter range 5.2mm2.2mm Coil outside diameter 1200mm-1250mm
Coil inside diameter 750mm-850mm
from bar mill:
8-40mm TMT bar (structural steel)

SECTION 3
HAZARD
IDENTIFICATION IN
VARIOUS DIVISION

3.1 OBJECTIVE
Objective of project was to get introduced to and learn modern methods and technologies used in
Health Safety and Environment field in JSW Jindal steel
During the internship program I have taken the project to conduct the HAZARD
IDENTIFICATION OF VARIOUS DIVISIONS in the JSW steel plant. The areas visited during
the internship program are COREX, STEEL MAKING SHOP, COLD ROLL MILL, HOT
STRIP MILL.
In the internship program I have also take the risk assessment of the MGP Site using the
HIRAC Tool

3.2 METHODOLOGY
During the internship program the project taken up was having the theoretical methodology type.
It consist of visiting the various divisions in the plant and identifying the hazards associated with
the particular plant. Most of the hazards found in the divisions were having the control measure.
But though theoretical research , interaction and discussion further control measures were wound
which will increase the safety and the hazard.
The second phase of the internship project was the risk assessment using the HIRAC tool and the
division selected for this purpose was the MGP construction site. The risk assessment using
HIRAC was basically proactive approach in which many situations are analyzed and happens the
control measures are evaluated.
Further in the risk assessment also recommendations are provided which will increase the safety
and decrease the accidents.

3.3 HAZARD IDENTIFICATION IN JSW PLANT

STEPS INVOLVED IN THE PROCESS

IDENTIFY THE HAZARDS

Walk around your workplace and look at what could reasonably be expected to cause
harm safety.
Remember to think about long-term hazards to health (e.g. high levels of noise or
exposure to harmful substances) as well as safety hazards.

DECIDE WHO MIGHT BE HARMED AND HOW

Some workers have particular requirements, eg new and young workers, new or
expectant mothers and people with disabilities may be at particular risk. Extra thought
will be needed for some hazards.
Members of the public, if they could be hurt by construction activities.

EVALUATE THE RISKS AND DECIDE ON PRECAUTIONS

Try a less risky option (eg switch to using a less hazardous chemical).
Prevent access to the hazard (eg by guarding.
Issue personal protective equipment (eg clothing, footwear, goggles etc.).

TYPES OF CONTROL THE SOURCE OF THE HAZARD

a. ELIMINATION - Getting rid of a hazardous job, tool, process, machine or substance
is perhaps the best way of protecting workers. For example, a salvage firm might
decide to stop buying and cutting up scrapped bulk fuel tanks due to explosion
hazard.
b. SUBSTITUTION - Sometimes doing the same work in a less hazardous way is possible.
For example, a hazardous chemical can be replaced with a less hazardous one.
Controls must protect workers from any new hazards that are created.
c. ISOLATION-Isolate big machines in another place.
d. ENGINEERING CONTROL
Redesign
Isolation
Automation
Barriers
Absorption
Dilution
e. ADMINISTRATIVE CONTROLS

Safe work procedures

Supervision and
Job rotations
Housekeeping, repair and maintenance programs
Hygiene must

 PERSONAL PROTECTIVE EQUIPMENT (PPE)

Personal protective equipment (PPE) and clothing is used when other controls measures are not
feasible and where additional protection is needed. Workers must be trained to use and maintain
equipment properly. The employer and workers must understand the limitations of the personal
protective equipment. The employer is expected to require workers to use their equipment
whenever it is needed. Care must be taken to ensure that equipment is working properly.
Otherwise, PPE may endanger a workers health by providing an illusion of protection.

3.3.1 HAZARD IDENTIFICATION IN COREX PLANT

S/NO

POTENTIAL
HAZARD

CONCEQUENCE

RISK

CONTROL
MEASURES

a) can cause temporary or

permanent respiratory
problem
1

Dust

b) can cause dust

explosion and eye
irritation

Risk to life

Use appropriate
ppe while
working in the
dusty areas

c) can cause lung cancer

d) can hide valuable
safety signs
a) Risk to ears
a) Can cause threshold
2

Noise

shift either permanent or

temporary hearing loss

Heat stress

a) can cause partial or

complete burning
sensation of skin

b) Risk as per the

level to the
intensity
c) Lack of
concentration
a) Risk to health
b) Risk to
equipment

a) Improper operation of
EOT cranes can result in
Falling of hot materials
on the surface.
4.

Falling of material
a) Risk to the life
b)
Can
cause
explosions
( molten metal and
and property
minute or large depending
slag)
upon the quantity of water
content

Use ear muffs or

ear plugs having
NDR of 28db
minimum
Use heat resistant
jackets and jeans
while working in
these areas and
heat resistant suit
in extreme heat
prone
areas.
a) Use safe &
tested
equipments to
handle and
transport the
material
b)Reduce the
error of spill
during transport

3.3.2 HAZARD IDENTIFICATION IN STEEL MAKING SHOP

S/N

POTENTIAL
HAZARD

CONCEQUENCE

CURRENT
CONTROL
MEASURES

RECOMMENDED
CONTROL MEASURE

a) ambulance
and the medical
assistance.

a) workers should be trained

for these situation and
b) proper resting time
b) first aid other should be given to the
basic medical
worker,
material.

Heat stees,heat
stroke

a) Person losing the

consciousness, tired
ness and nausea

Hot open pit

a) Chances of
workers falling in to
the open hot pit.

a) No control
measures are
adopted in this
hazard

a) Burns, fatality
and injury to the
workers, structures
and the machines
can be damaged

a) Basic
evacuation plan
is present along
with directing
the workers to
assemble in the
safe zone

a) Fatality and
injury

a) Fire
extinguishers
and fire hydrants
are present in
the working site.

proper evacuation plan

should be present, the
emergency exit should lead
to the assembly point, the
fire extinguishers should be
maintained

a) use always
the co personal
monitor

strict rule should be

enforced for the use of ppe,
and before stating of the
work always check the co
level in the area, always
carry the personal co
monitor

Spillage of the
hot metal

Fire hazard

Gas leakage

a) Unconsciousness,
fatality

a) heat resistance
barricading can be used
b) working area can be
continuously supervised
a) Inspection during the
process,
b) Alertness, Regular
maintenance of the
equipment should be
carried out

Fig 16: SMS 2& 3

3.3.3 HAZARD IDENTIFICATION IN COLD ROLL MILL

S/NO

POTENTIAL
HAZARD
Chemical
(Sulphuric Acid,
Hydrochloric
acid,Chlorine,N2
,NaOH, COREX
gas, Carbon
Monoxide)

CONCEQUENCE

RISK

CONTROL
MEASURES

a) Can result in serious

danger to life and
property if not handled
properly

Risk to life

Use appropriate
PPEs like
chemical suit ,
SCBA and gas
monitors while
working

b) If there is a leak,Vapor
cloud explosion & even
death.

a) Risk to ears
a) Can cause threshold
2

Noise

shift either permanent or

temporary hearing loss

4.

Heat stress

a) can cause partial or

complete burning
sensation of skin

Biological ( algae,
bacteria fungi)

a) Can result in skin

disease, odor nuisance of
cooling tower which in
turn effect the odor of
water
b) Minimizing the effect
of coolant inside the
tower

b) Risk as per the

level to the
intensity
c) Lack of
concentration
a) Risk to health
b) Risk to
equipment

a) Risk to life
and property

Use ear muffs or

ear plugs having
NDR of 28db
minimum
Use heat resistant
jackets and jeans
while working in
these areas and
heat resistant suit
in extreme heat
prone
areas.

Use Biocides and

Disinfectants

FIG 17: Cold rolling mill

3.3.4 HAZARD IDENTICATION IN THE HOT STIRP MILL

S/NO

POTENTIAL
HAZARD

Pressurized steam,
Water

CONCEQUENCE

a) Can result in falling

, burning and even
slipping and Tripping.

RISK

Risk to life

CONTROL
MEASURES
a) Use
appropriate
barrier while
working in steam
prone areas
b) Design the
equipment free
from steam
leakage

a) Risk to ears
a) Can cause threshold
2

Noise

shift either permanent or

temporary hearing loss

4.

Heat stress

a) can cause partial or

complete burning
sensation of skin

a) Can result in Vapor

Gas(Corex,
cloud formation,
Carbon Monoxide) Explosion, Suffocation,
Nausea and even death

b) Risk as per the

level to the
intensity
c) Lack of
concentration

a) Risk to health
b) Risk to
equipment

a) Risk to life
and property

a) Use ear muffs

or ear plugs
having NDR of
28db minimum
a) Use heat
resistant jackets
and jeans while
working in these
areas and heat
resistant suit in
extreme heat
prone
areas.
a) Use
appropriate gas
monitors like CO
monitors and
detectors
wherever there is
proximity of CO
gas
b) Proper
training to
worker

SECTION 4
RISK
ASSESMENT
OF NEW
METAL
GRANULE
PLANT
USING
HIRAC
TOOL

4.1 OBJECTIVE
The purpose of risk assessment is to provide a systematic and objective approach to assessing
hazards and their associated risks that will provide an objective measure of an identified hazard as
well as provide a method to control the risk. It is one of the general duties as prescribed under the
Occupational Safety and Health Act 1994 (Act 514) for the employer to provide a safe workplaces
to their employees and other related person.
In the JSW STEEL PLANT the HIRAC is carried out in the under construction metal
granulation plant.The existing control measure is identified and some efficient control measures
which can decrease the risk during the construction is recommended.

4.2 Hazard Identification, Risk Assessment and Control

52

UNIVERSITY OF PETROLEUM AND ENERGY STUDIES

PURPOSE
OF
ASSESMENT

RISK

The purpose of risk assessment is to provide a systematic and objective approach to

assessing hazards and their associated risks that will provide an objective measure of
an identified hazard as well as provide a method to control the risk. It is one of the
general duties as prescribed under the Occupational Safety and Health Act 1994 (Act
514) for the employer to provide a safe workplaces to their employees and other related
person.

4.3BASIC
CONCEPTS

WHAT IS RISK?

Risk is something that we as individuals live with on a daily basis. People are constantly
making decisions based on risk. Simple decision in daily life such as driving,
crossing the road and money investment all imply an acceptance risk. Risk is the
combination of the likelihood and severity of a specified hazardous event occurring. In
mathematical term, risk can be calculated
by the
equatio
n:

Risk
Risk= = Likelihood x Severity
Likelihood*Severity

LIKELIHOOD OF AN OCCURRENCE

This value is based on the likelihood of an event occurring. You may ask the
question How many times has this event happened in the past?:

Assessing likelihood is based worker experience, analysis or measurement. Likelihood levels range from most
likely to inconceivable. For example, a small spill of bleach from a container when filling a spray
bottle is most likely to occur during every shift. Alternatively, a leak of diesel fuel from a secure holding tank
may be less probable. Table A indicates likelihood using the following values

SEVERITY OF HAZARD

Severity can be divided into five categories. Severity is based upon an increasing level of severity to an
individuals health, the environment, or to property. Table B indicates severity by using the following table:

RISK ASSESSMENT

Risk can be presented in variety of ways to communicate the results of analysis to make decision on risk control.
For risk analysis that uses likelihood and severity in qualitative method, presenting result in a risk matrix is a very
effective way of communicating the distribution of the risk throughout a plant and area in a workplace. Risk can be
calculated using the following formula:

L x S = Relative Risk
L = Likelihood
S = Severity

An example of risk matrix (Table C) is shown below:

Table C

To use this matrix, first find the severity column that best describes the outcome of risk. Then follow the likelihood
row to find the description that best suits the likelihood that the severity will occur. The risk level is given in the
box where the row and column meet. The relative risk value can be used to prioritize necessary actions to
effectively manage work place hazards. Table D determines priority based on the following ranges:

Table D
Hazards assessed, as High Risk must have immediate actions, to resolve risk to life safety and or the
environment. Individuals responsible for required action, including follow up must be clearly identified. A further
detail risk assessment method may require such as quantitative risk assessment as means of determine suitable
controls measures.

4.4 HIRAC ANALYSIS

PLANNING AND CONDUCTING OF HIRARC
Purpose of HIRAC
The purposes of HIRAC are as follows:
a. to identify all the factors that may cause harm to employees and others (the hazards);
b. to consider what the chances are of that harm actually be falling anyone in the circumstances of a particular
case and the possible severity that could come from it (the risks); and
c. to enable employers to plan, introduce and monitor preventive measures to ensure that the risks are
adequately controlled at all times.

Planning of HIRAC Activities

HIRAC activities shall be plan and conducted:
a. for situation:
i.

where hazard appear to pose significant threat;

ii.

uncertain whether existing controls are adequate; or/and

iii.

before implementing corrective or preventive measures.

b. by organization intending to continuously improve OSH Management System. It should be the duty of the
employer to assign a trained personnel to lead a team of employees associated with one particular process or
activity to conduct HIRAC.

Process of HIRAC

Process of HIRAC requires 4 simple steps:

a. classify work activities;
b. identify hazard;
c. conduct risk assessment (analyze and estimate risk from each hazard), by calculating or estimating:
i.

likelihood of occurrence, and

ii.

severity of hazard;

iii.

Decide if risk is tolerable and apply control measures (if necessary).

4.5 HIRAC REPORT

LOCATION: PLANT
CONSTRUCTION OF
METAL GRANULATION
AGENCY:GAMMON INDIA
LTD

PREPARED BY:SAFETY TEAM

ACTIVITY / HAZARD
IDENTIFIED
EVENT

DANGER EXISTING
PRESENT CONTROL

Material
Handling

Injuries, cut Bad quality of H

and bruises PPE used

Not wearing
adequate PPE

Workers sitting
on unstable
slopes
Transporting Unergonomic
Raw materials work conditions
Worker
behavior

DEPARTMENT: FIRE & SAFETY

DATE:07/06/2016 to 15/06/2016

Accidental
fall

RISK
RATING

ADDITIONAL
CONTROLS

RISK
RATING

Timely
L
replacement &
Effective monitori
Weekly Training L
and Awareness
program
Automation and L
worker rotation

Ineffective
monitoring

Ergonomic Inadequate
injuries and Devices
diseases
Injuries,
No controls
cuts and
bruises

Training and
Good House
Keeping

Accidental
fall

No warning
signs

Use of Mobile Lose

Accidents
phones while concentration in
working
work

No controls

Setting proper
enclosure and
correct Signs
Strictly Prohibit
use of mobile
phone

Ineffective
Supervision

Supervisors
are less in
number

Awareness
program and
implement
effective
supervision
Proactive
inspection and
maintenance

Incorrect tool No
selection
knowledge
on tool
selection
Improper
Bad method of
enclosure
enclosure

Maintenance
issue

Follow rules
only when
safety officer
present
Poor quality of
equipments
being used

Accidents

Accidents Ineffective
and
inspection
breakdown

4.6. RESULT
From the HIRAC analysis of the MGP Construction site and after calculating the Risk value, it
has been found that the Maintenance issue of the equipments is having the highest risk of
Medium level even after Control measures are implemented
The current control measures may not be sufficient if a major violation occur in the construction
site. If the recommended control measures are in cooperated in the system, accidents can
be prevented to larger extent.
Apart from this workers are to be given realtime hazard based training . Recommended control
measures will decrease the accident and damage.

CONCLUSION

The major hazards in a steel plant are Dust, Noise, Handling hazards of molten metal .But
predominantly the most hazardous of them are the accidents cause due to material handling and
Conveyor belts. In the Steel plant major number of Fatalities is due to working on Conveyor
belts. Working on heights and transfer of Material through equipments like Hydra, Loader JCB
etc.
The best way to reduce these type fatal is by giving proper training prior to the commencing of
the work and also to give defense driving training to the Drivers.
Hazards caused due to Conveyor Belts are the most predominant in the Steel Plants and new and
advance techniques are coming in to force to overcome these hazards in future in a steel Plant.
If the recommendation and the hazards identified in the some of the divisions are rectified the
accidents in the plant can be controlled and it can become the safest steel plant in INDIA to a
greater extent

REFERENCE

Narayanagounder,s and Gurusami,k 2009- A New Approach for Prioritization of Failure

Modes in Design FMEA using ANOVA, Journal of word Academy of science (Engineering
and Technology), Vol.49,2009,pp.524-532.

Hughes, N., Chou, E, Price, C.J and Lee, M.1999, Automating mechanical FMEA using
functional models, Proceeding of the Twelfth international Florida AI Research Society
Conference, (AAAI Press, Melno, CA), pp.394-398.
Shirouyehzad, H, Badakhsian, M, Dabestani, R,
Panjehfoulan, H. 2010 FMEA Analysis for Identification and Control of Failure preferences in
ERP Implementation, The journal of Mathematics and Computer Science, Vol.1 No.4 (2010)
pp.366-376.
Arabian-Hoseynabadi, H, Oraee, H, Tavner, P.j. 2010
Failure Modes and Effect Analysis (FMEA) for Wind Turbines, International Journal of
electrical power and energy system.32 (7), pp-817-824.
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http://esatjournals.org/Volumes/IJRET/2014V03/I23/IJRET20140323007.pdf
http://www.worldstainless.org/Files/issf/non-imagefiles/PDF/ISSF_Good_Safety_Practice_in_Stainless_Steel.pdf
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http://ec.europa.eu/energy/intelligent/projects/sites/iee-projects/files/projects