EMERGENCY SITUATION OF F&D

Sl. no. Description Impact

1.1 Electrocution • Fatal injuries to employee electrocuted.
1.2 Fire in Recoiling & Inspection Line • Man/Machine damage may happen.

CIC : Chief Incident Controller IC : Incident Controller WIC : Work Incident Controller EO : Emergency Officer TSLW : Tata Steel LTD. Work, PMO : Plant
Medical Officer
First Aid post no 29-C near Column M 29 VIP road side
Action:
First aid post no 29-D near Column P66 .
Barricade area
First aid post no 29-E near Central oil storage station,
Inform concerned
Isolation of energy Nature/ Source of Fire Method
Fire in Gas line Mech. Foam, DCP or CO2 type Fire Extinguishers
First aid to victim by trained person Fire in Mech. Eqpts. Water CO2 type Fire Extinguishers.
Inform at single emergency contact 47777 Fire in Elect. Panels, cable & Eqpts. DCP and CO2 type Fire Extinguishers.
Fire in hydraulic Foam type, CO2 type
MAJOR HAZARDS OF F&D
1. HOT COILS 2. COIL HANDLING BY EOT CRANE 3. TRAILER MOVEMENT 4 WAGON MOVEMENT 5. MOVING MACHINERY

HEADER RECALIBRATED RISK MATRIX FOR HAZARD IDENTIFICATION AND RISK MITIGATION
Gross Risk calculation Net (Residual) Risk Calculation

People /
Hazard Consequence Risk description (Only for Probablit Probablit
Asset / Existing Consequ Recomm Consequ
Job Activity Environmental Hazardous Event Cause description C4 & C5 consequence y of y of Likelihoo Resid
Environment Safeguard ences ( Likelihood endation ences (
Aspect Environmental Impact scenarios) failure of Risk failure of d ual
/ Community Severity Severity
safeguar safeguar Risk
Scale) Scale)
d d
 POSITIVE ISOLATION
• Ensure the safety of personnel who will be performing the work
• .Operation and maintenance work shall be done without injury to personnel, equipment damage or causing
environmental damage.
• The primary objective of Positive isolation fulfills the concept of ‘My Life is My Life’.
a) Personal Locks b) System Locks
Exemption: present the Electrical jobs like, all the jobs below and up to 250V AC and 220V DC, Lighting circuit, Electrical
maintenance jobs in buildings; such as jobs on tube lights, fans, PCs. In Case if energy is given to the positively isolated
equipment for performance trial /Testing
Complex Isolation: Complex Isolation is when more than three Isolators or more than two types of Energy Sources are
involved.
Control Stop: Control Stop is a method of stopping Equipment (where Isolation is not used) for the performance of high
frequency, short duration, and low risk routine tasks.

a) Red Colour Lock ---- Self protection Tata Steel Employees Energy Source Identification (ESI)
b) Blue Colour Lock ---- Contractor’s supervisor shall put for
himself & on behalf of his workers Lock out-Tag Out-Try Out (LOTOTO):
c) Black Colour Lock ----- Group lock
d) Yellow colour Lock ----- Equipment Lock
Fatality: Fatality refers to death resulting from a work-related injury, regardless of the time intervening between the injury and
the death.
Lost Time Injury (LTI): LTIs are occupational injuries in the workplace (injury on works) which prevents an employee from
joining duty in the next scheduled shift.
First Aid Case: First Aid cases are occupational injuries for which immediate aid provided to the injured person either at shop
floor or at plant First Aid center/OHS center as applicable and released afterwards as fit for duty.
Injury on duty (IOD): IOD are those occupational injuries which prevents an employee from joining duty in the next
schedule shift if the injury caused due to the incident happened in company premises excluding factory premises or person
is engaged outside company premises for company business.
Ex-Gratia: Injury due to road accident while coming to or returning from duty, provided that such accident takes place
• Within an hour of the beginning or the end of his/her shift.
• On the main/shortest route from employee’s home to his/her workplace.
• The injured persons need to attend authorized TSL Medical Centre within 2 hours of the incident/ injury.
• The injured person needs to report the incident to his/her Superior /Supervisor over phone/ text as soon as possible after the
incident.
Fire Incident: Fire Incident is an unplanned ignition of flammable or combustible material (solid, liquid, or vapor) either
with an open flame or without flame (smoldering). This includes smoldering, charring, smoking, scorching, carbonizing,
uncontained electrical arcing / sparking, or evidence that any of these have occurred.
Process Safety Incident: An unplanned or uncontrolled loss of containment (primary) of any Hazardous material / release of
energy including non-toxic and non-flammable materials (e.g. Steam, Hot condensate, Nitrogen, Compressed CO2 or compressed a
Hydraulic Oil, Water ) from a process or an undesired event or condition that under slightly different circumstances either resulted
could have resulted in a loss of containment (LOC) of hazardous material /release of energy like Fire, Gas release and Explosions o
process interruption.
What is a Hazard?
Hazard – Any Source or Situation Having Potential to Harm
1. People
2. Property
3. Environment

Hazard Identification: Process of recognizing that a hazard exists and defining its characteristics

We can’t do much about the hazards we

don't see!!

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 Classification of Hazard

Workplace Safety

Process Safety Occupational

Work Place Hazard
Hazard Health Hazard

Difference in approaches : Behavioral Safety & Process Safety

LF- Low Frequency

HF- High Frequency
LC- Low consequence
HC- High consequence

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Hazard Groups – Work Place Hazard
Physical Hazards Chemical Hazards
Causes damage to the body, e.g. Able to produce detrimental health
• Working with tools and machinery effects, through ingestion, absorption,
inhalation, skin contact, Injection e.g.
• Working at height
•Dusts and fibres
• Electrical work •Fumes and gases
• Exposure to noise or vibration •Corrosives, poisons

• Fire PHYSICAL ERGONOMIC

CHEMICAL BIOLOGICAL Ergonomic Hazard

Biological Hazards
Harm caused by the relationship
Causes ill health through contact with
between workers and their
biological substances that pose a threat
environments
to human health
•Poor working posture
•Micro-organisms (Bacteria, Viruses,
•Poor workstation layout
Fungi)
•Excessive pulling, lifting, pushing
•Insects (mites, parasites)
•Unsuitable equipment
•Human, animal waste
•Sharps (needles, scalpels)
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 Process Hazards

Process Hazards: A conditions that has the potential to result in a release

of, or exposure to a hazardous substances, which in turn can cause serious
injury to personnel, significant propriety damage , or significant
environmental harm.
Hazards can usually be classified as one of the following generic
potential events:

Explosion Effects
Thermal Exposure
Acute Toxic Exposure

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 Types of Occupational Health Hazards
▪ Heat Radiation
▪ Dust & Fumes
▪ Noise
▪ Vibrations

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 How to Start Hazard Identification
Divide the Formation of Multidisciplinary Understanding of Existing HI
Select the section for
Department in team including shop floor employees Checklist & its requirements
Hazard Identification
various Sections Team for Hazard Identification by experts

Visit of Multidiscipline team to selected area for understanding

of process / equipments/ Input/ output/ facilities

Collection of Data for Hazard Identification

Filling / Update of
Hazard Identification
checklist based on the
information gathers
Elimination / Substitution/ Reduction of Hazard
Comprehensive List of Hazard in that Section
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Study of field Visit findings
& collected information by
team for understanding of
hazards exist in that section
1. Process Flow Diagram with all inputs, outputs, by-products etc
2. Input from Tool Box/ Mass Meeting
3. MOC Record
4. Analysis of Safety Observation ( Unsafe Act , Unsafe Conditions)
5. Various safety Audits
6. Safety Alerts / Red Strip/Orange Strip
7. HIRA / FMEA
8. PSI / PHA / Structure integrity reports
9. Past Incidents ( Injury, PD, NM etc)
10. Leaning's from others
11.Contractro Audit Data
12. PPEs used
12. Emergency Preparedness Doc
13. Mock Drill Reports
14. Process wise skill / competency required for the job
15. Regulatory requirements related to facilities / jobs/ etc
16. Materials used in / kept / stored in that area / process
17. think about long-term hazards exposure to health ( Noise, Fumes,
Dust, temp, vibration etc)
18. Installation of New Facilities / Equipment / etc
19 any changes in facilities / Parameters
What is Risk?
The considered expected loss or damage associated
with the occurrence of a possible undesired event
• Undesired event
• the occurrence of undesired conditions.
• an accident (eg. a failure, a destruction, a disintegration, etc.).
• a particular unfavorable (dangerous, costly) action.

Risk = Consequence resulting from the release

of a hazard
x
Probability of the occurrence of that event

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Risk Management – Why?
“ To prevent accidents by identifying hazards and reducing the risk of injury from those
hazards to as low a level as is reasonably practicable.”
System description

Hazard identification • HIRA

•”What if”
Scenario identification
• Checklists
• HAZOP
• FMEA
Accident Accident
probability consequences • HIRA
•Fault tree analysis
• Event tree analysis
Risk determination • Bowties
•Consequence models

risk &
N
hazard Modify design / Use of Hierarchy of Control
acceptable
?

Accept system 16
The Work Permit System: What is it?

A work permit system consists primarily of a standard procedure

designed to ensure that potentially hazardous routine and non routine
work on industrial installations can be carried out safely.

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 Meaning
Permit requested by: – Permit will be requested by the executing departmental
agency under which job will be carried out in all cases.

Permit Issued by: - Permit will be issued by Owner of the area / equipment in all
cases

Permit taken by: - Permit will be taken by the agency that will perform the job.

In case of central agency ( MSG ,MED,ENGG SERVICES, CONSULTANT ,etc…),permit

will be taken by central agency or permit will be taken by central agency and
contractor under central agency on same form at prescribed area.

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 • SOP should be made in advance, in the prescribed format EHSMSM
/WORKS / 446 / 4013 by the executing department.
• Six directional hazard forms EHSMSM / WORKS / 446 / 4015 should be
filled up before requesting permit to work by executing agency
• Training of SOP should be provided to all Contractors’ Supervisors by
Executing department
• In case of Contractor under central agency, training on the Standard
operating procedure should be done by the central agency.
• Executing Department should ensure that permit should be given only after
verifying the Contract workers are well aware of Standard Operating
Procedure. In case of Contractor under central agency, this verification will
be done by the central agency
• Self certification by contractor should be taken for all tools & PPEs etc.
• Audit should be conducted by executing agency (Permit requested by)
before and during the job to check compliance of SOP ,six directional
hazards ,work permit compliance .
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 Six-directional Hazard Form
It is equally important before start of every job

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 How to check adequacy of SOP

As Mentioned in Management
1. SOPs for all the Job
safety principle Responsibility

2. SOPs Adequate
JOB CYCLE CHECK

3. SOPs Followed

Job Cycle Check is tool to review

1. Adequacy of SOP

2. Competency of Employee

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 Job Cycle Check – Cycle

Plan JCC
for
Identified
SOP

Verify after Do Job Cycle

Confirmation Check

Job Cycle
Check
Confirm Log JCC
Uploading report

Modify SOP

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 What are Slips, Trips & Falls?

Slip
A slip occurs when there is too
little traction or friction
between the shoe and walking Fall
surface.
A fall occurs when you
Trip are too far off balance.

A trip occurs when a person’s foot

contacts an object in their way or
drops to a lower level unexpectedly,
causing them to be thrown off-balance.

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 Common Reason of Slip, Trip, Fall at workplace

➢ Not Paying Attention while

walking
➢ Use of Mobile Phone at workplace
➢ Not Holding Hand rails
➢ Poor House Keeping
➢ Open Pits
➢ Slippery or Damaged Floor
➢ Spillage / seepage on shop floor or
pathways
➢ Poor Illumination
➢ Not secured Ladder
➢ Improper or damaged Barricade at
the platform etc
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 Tips for mitigation of Slip, Trip, Fall Hazard

✓ To ensure Drainage system is well maintained and drain cover is in

place

✓ To Ensue that identified storage place is available to store spares.

✓ To ensure that sufficient working bench and sitting stool, Proper

Access & safe working platform are available to perform job in good
ergo posture

✓ To ensure that handrail is provided in all staircases and working

platforms wherever applicable

✓ To ensure that access to the staircase, entry, exit door , life saving
equipments, First Aid Box, Stretcher, Fire hydrant, Fire extinguishers
and Electrical Switch boards are free from obstruction and safe to
reach/ exit.

✓ To ensure that all the openings are either covered or properly

barricaded in the work area.

✓ You may add many more….

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 Risk control measures as per Hierarchy of Control

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