SAFETY IN IRON AND STEEL INDUSTRIES

SAFETY IN IRON AND STEEL INDUSTRIES

M.TECH(SAFETY ENGG.)

NIT ,ROURKELA

PRESENTED BY:-

SOURAV MOHANTY

LAXMINARAYAN NAYAK

ARIN MANNA

SOURAV PRADHAN

ABINASH MOHANTY

SANIL KURIAKOSE

RAVIKUMAR REDDY

ABISHEK ACHARYA

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INTRODUCTION

Coke ovens and by-product plants

Iron and steel-making

Handling molten metal, dross or slag

Surface preparation

Iron and steel foundries

Rolling mills

Coating lines

Heat treating

Five leaf award

Conclusion

reference

introduction

India the 4th largest producer of crude steel in the world

largest producer of direct reduced iron or sponge iron

Major proposed investments are in the states of Odisha, Jharkhand, Karnataka, Chhattisgarh and West Bengal.

Per capita consumption of steel in the country has risen from 45 kg in 2008-09 to about 60 kg in 2013-14.

The steel sector contributes nearly 2% of the countrys GDP and employs over 6 lakh people.

Deficiency of safety IN INDIAN STEEL INDUSTRIES

63 people died between 2007 and 2010 in the OHSAS 18001-certified plants.

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CSE EVALUATION

Chandra Bhushan: The future road map for the sector is clear.

It will have to reduce its ecological footprints drastically

invest in health and safety of its workers and treat local communities as stakeholders and beneficiaries.

Coke ovens and by-product plants

HEALTH HAZARDS

cancer

polynuclear aromatic hydrocarbons

toxic gases and vapour such as benzene, hydrogen sulphide, carbon monoxide and ammonia

Lung damage

coal dusts

heat stress..

Safety hazards

burns

fire and explosion.

mobile equipment, including larry cars, pusher machines, and door machines.

Coke oven gas is flammable and explosive, as are many of the chemicals collected in by-product plants.

emission

Badly controlled

Visibilty can be poor

Hazard control on by-product coke batteries

Designing and maintainance

A program should be instituted for explosive atmosphere keeping the gas concentration above the UEL.

Sealants for doors, lids and other equipment should be free of asbestos and other hazardous materials

Mobile coke oven machines should be designed for safe entry and exit, and provided with travel alarms and operated from enclosed cab.

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Respiratory program and heat stress program should be instituted.

Walkways should be designed so as not

to cross the path of mobile equipment.

Pyrometer can be used.

Coke shouldnt pushed before compliton of cooking process.

HAZARD CONTROL ON BY-PRODUCT COKE BATTERIES(CONTD)

Hazard control in non-recovery batteries

Uncontrolled beehive ovens should be replaced

the stacks or flues of non-recovery batteries should be equipped with desulphurization systems

The negative pressure system should be maintained

Hazard control in by-product recovery plants

An engineering assessment should be performed

5% Coal tar is carcinogenic

Sumps should be enclosed and blanketed with nitrogen or some other gas to reduce leaks.

Alarms should be installed

Prevention of explosive atmosphere

periodic air monitoring program should be instituted

A respiratory protection program should be instituted

leukaemia and other blood disorders caused by benzene

Iron and steel-making

ergonomic problems.

continous detector should be provided

Furnace may cause glare , that can injury the eyes

PPE

Preventing fires and explosions

water coming into contact with molten metal.

ignition of volatile materials and fuels

The most hazardous procedures are during the firing-up and shutting-down procedures.

The fuel supply to gas- or oil-fired furnaces should be fitted with an automatic shut-off mechanism

The building should be designed to be non-combustible, with automatic fire suppression engineered or designed into the process

Refractories and tools should be preheated and dried

Preventing carbon monoxide poisoning

Blast furnace gas and coke gases containing large concentrations of carbon monoxide

It should be equipped with continuous automatic carbon monoxide sensors and alarms

Continuous monitoring of exposure levels should be carried out by portable gas monitor

Training and gas rescue drill

Preventing steam explosion

Molten slag and metal should be prevented from coming into contact with water, which will cause a steam explosion.

cleaning of Equipment and piping.

Handling molten metal, dross or slag

Burns may occur :-

at the front of the furnace during tapping from molten metal or slag

from spills, spatters or eruptions of hot metal from ladles or vessels during processing, pouring or transporting

from contact with hot metal as it is being formed into a final product.

Tap holes should be checked regularly.

Control strategies

Training

Moulds and tundishes should not be damp and avoid contact with water

The area should be cordoned off prior to the transport of molten metal

Inspection by a competent person

PPE, such as helmets, gloves, aprons and boots should be provided and used.

Injuries caused by molten metal, dross or slag or exposure to alkaline dust should receive immediate medical attention.

Surface preparation

Scarfing may expose workers to metal fumes and dust, noise, and burns from scarfing lances.

Alloying agents in the steel may increase the hazard of the fumes or dust.

Surface grinding also generates dust, and involves machinery hazards.

Degreasing solvents may be toxic. Acids can cause acid burns.

The coiling machinery has many nip points which need to be risk assessed

Hazard control

Scarfing and surface grinding should be done in enclosures, with good exhaust ventilation.

Workers should be provided with respiratory protection and hearing protection.

Workers who handle pickling acids or hydrogen peroxide should be provided with ppe.

Hydrofluoric acid should be handled with extreme care

Acids should not be stored next to solvents or hydrogen peroxide.

Appropriate machine guarding should be provided for coiling apparatus

Iron and steel foundries

Hand-tilted transport ladles should have an integral locking device to prevent accidental tipping.

Large transport ladles (>500kg) should have a self-restraining anti-tipping device

Casting ladles with rigid ladle bails should have safety devices to prevent the bails from swinging or overturning.

The ladle bails should be insulated against radiant heat.

Locking devices on casting and transport ladles should be engaged

Stopper-operating mechanisms on bottom-pouring ladles should be provided

Rolling mills

injuries may be caused by shearing, cropping, trimming

in automated works, accidents occur in

conversion work while changing heavy rollers in the stands.

Cuts may occur when workers contact the edge of thin steel sheets or strip.

Cobbles occur when material catches in a roll and escapes into the work area

When lead-alloyed steel is rolled or cutting-off discs containing lead are used, toxic particles may be inhaled.

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Dust particle

Flying mill scale

glare

Eye may be affected

Control strategies

Nips of rolls and dangerous part should be effectively guarded.

An effective lockout/tag out program should be planned, implemented and monitored for maintenance and repair.

guardrails should be installed and their use enforced.

Gratings, absorbent materials and boots with slip-resistant soles should be provided

Water-based rolling oils, lubricants and coolants should be replaced on a regular basis

Coating lines

Some of the plasticizers are skin sensitizers.

Metal fumes may be toxic.

Control strategies

Guards, railings, enclosures and signs should be used

Workers should be provided with the appropriate PPE.

Msds should be provided for each of the hazardous chemicals.

Areas which have strong electromagnetic fields should have warning signs.

local exhaust ventilation is strategically placed.

Heat treating

hazards

burns and scalding

mechanical hazards from steel handling

annealing gases, including nitrogen,hydrogen and carbon monoxide

Furnace insulation wools can expose workers to hazardous fibres.

Hazard control

minimize the possibility of worker contact with hot steel, or to scalding in the case of quenching operations.

Carbon monoxide should not be used for carburizing

use insulation wools with a low content of respirable fibres silica

Compressed air should never be used

when heated

prevent

Annealing gasses buildup

asphyxiation

prevent

Build up of hydrogen

explosive

transportation

Internal transport, such as road and rail vehicles used in the transport of raw materials, intermediates, products, waste and people, has the potential to cause injuries to workers and other people, as well as damage to the workplace environment.

The hazards can be caused by interaction between vehicles, vehicles and other objects and personnel, or by loads falling off or from the vehicle.

CONTROL STRATEGIES

Training and information

Operators of certain types of vehicles may require regular medical surveillance.

Operators should have the necessary knowledge of the hazards and potential risks concerning the transportation of cargo.

Operators of vehicles should receive and maintain adequate training and the required certification according to the regulations established by the competent authority.

Contractors and other visitors should be appropriately instructed about the hazards and potential risks. They should be instructed about the rules of how to move in the area.

CONTROL STRATEGIES (contd)

Prevention and control

routes should be clear of obstructions

The safe operating speed for vehicles should be posted and enforced.

Loads should be lowered slowly and smoothly.

Vehicles should be equipped with ventilated cabins to protect workers from hazardous materials.

Forklift controls should be designed to stop if released.

Workstations should not be located underneath the path of molten material.

The operator of a vehicle should perform a check on the vehicle at the start of each shift, and a record should be kept.

PPEs

FIVE-LEAF AWARD

conclusion

19/100-average score

the steel sector rating is a reminder of the challenges, but also the enormous potential of bringing about change

Production with safety is a win condition that we must strive towards

REFfERENCE

Code of practice-ILO

Steel.gov.in

Cse

www.cseindia.org/steel

www.worldsteel.org

http://en.wikipedia.org/steel