SAFETY MANAGEMENT SYSTEMAt

T S ALLOYS LIMITED

ABOUT THE PLANT TATA STEEL LTD acquired 100% equity stake of raw

met ferrous industry in the year 2007 thus giving rise to T S ALLOYS LTD.

It is an integrated Ferro alloy plant located at Anatapur village of Athagarh sub-division in the district of Cuttack, Odisha.

The existing production capacity of High carbon Ferro-Chrome is 53481MT/Annum and the Briquetting plant capacity is 100,000MT/Annum.

The current turnover of T S Alloys is 164.7 Crore.

The total manpower of T S Alloys is 800 and more than 95% of the work force comes from the local populace.

SAFETY ACHIEVEMENTS Du-Pont Structure was incorporated under the leadership of Chief of

Corporate Safety on 4th of May 2011.

Certification of ISO 9001: 2008, ISO 14001: 2004, OHSAS 18001: 2007 by Indian Register Quality Systems was attained on 10th November 2011.

Implementation of 5S and Kaizen from 5th September 2012

T S Alloys received Kalinga Safety Award for best practices in Safety, Health and Environment on 14th September 2012.

TSAL received best safety performance in TIS Group award for its best practices in safety from M.D Tata Steel Ltd on 30 November 2012.

implementation of LOTO {lock out tag out} process was initiated from 18th March 2013.

PLANT PROCESS LAYOUT

ORGANIZATIONAL STRUCTURE OF SAFETY

MD GM(Admin & Services)

Asst. Manager(Safety &

Environment)

The Flowchart of safety organizational structure above gives a clear picture of a parallel flow of consulting and reporting for better implementation of safety organization and system in the industry

SAFETY MANAGEMENT SYSTEMA Safety Management System (SMS) is a systematic approach to managing safety, including the necessary organizational structures, accountabilities, policies and procedures.

Need of Safety Management System

To protect human life and environment from industrial Hazards.

to eliminate heavy losses from the direct and indirect cost of

accidents.

For the smooth operation of the Plant thereby benefiting the

society and country as a whole.

To satisfy and attain the legal compliance.

SAFETY MANAGEMENT AT T S ALLOYS LTDT S Alloys management seeks to create and sustain a Company culture in which employees share a commitment to HSE. T S Alloys believes safety is as important as cost, productivity, or employee relations.

T S Alloys follows Du-Pont Structure for safety which says “Safety is a line manager’s function”.

FLOWCHART OF SAFETY MANAGEMENT SYSTEM

Safety Observation SystemIncident Investigation

HIRAC StudySafety Audit

Compliance to legal requirementsOn-site Emergency Plan

Work Permit System

Safety Training System – Induction, Work Specific safety trainings, Mock drills & EAIS (Employees Action in Improving Safety).Safety Events- Safety Quiz, On-site Safety Quiz for contractual employee, Housekeeping audit, Safety Speech, Safety slogan, PPE work shop, etc.Training & Celebration of – Road Safety Week & National Safety Week.

ANALYSIS OF ON-SITE EMERGENCY PLAN

On-site Emergency Plan – “legal Compliance”

Section 41-B(4) of Factories Act 1948 requires that every occupier of a

hazardous factory shall draw up an On-site emergency plan and detailed

disaster control measures for his factory and make it known to the workers

and the general public in the vicinity, the safety measures required to be

taken in the event of an accident taking place.

On-site Emergency

An on-site emergency is caused by an accident that takes place in an

industrial industry and the effects are confined to the factory premises

involving only the people working in the factory.

IDENTIFICATION OF HAZARD Hazard is in fact the characteristics of a system/plant/storage that

has the potential for an accident and risk is the probability of

occurrence of hazard.

Hazard identification is of prime significance for the quantification

of risk and for cost-effective control of accidents in any industrial

installation.

Hazards are mostly manifested in the form of fire / explosion / toxic

release.

HAZARD AND ITS IMPACTSl No

Area/Activity Hazard Impact

1 Furnace Oil Pool fire/fire ball may occur in case of direct

contact with flame.

Fire may propagate to the near-by areas containing furnace oil like Briquette

plant.

2 Liquid Oxygen Leakage to atmosphere May cause damage to equipment if the combustion

mixture is formed.

3 Coal Fire may occur due to spontaneous ignition of

coal

Fire will propagate within the coal storage yard.

HAZARD AND MITIGATION MEASURESFURNACE OIL – Furnace oil is a flammable liquid, having flash point of 66°c and auto ignition temperature of 407° c and explosive limit of 5% volume in air. So it is susceptible to fire hazard.

The pool fire modeling of furnace oil is done for three different situations using fire equation.

LIQUID OXYGENLIQUID OXYGEN – There is a liquid oxygen storage tank. Release of oxygen from pipeline or oxygen storage tank accidentally may pose serious fire hazards (leakage through 25mm diameter hole).

Leakage of liquid oxygen from oxygen storage plant will vigorously accelerate the combustion or explosion of organic or other oxidizable material.

Control measures

The liquid oxygen dispersion model has been prepared on the basis of guassion model.

Emergency procedures are to be prepared including the event of spillage of the cryogenic fluid.

emergency procedures are prepared in conjunction with the emergency services or fire brigade and the local conditions are considered.

The procedures shall be readily available to all personnel involved, regularly practiced and checked periodically.

COAL FIRECOAL FIRE - Self-heating is the process whereby a coal particle undergoes chemical and physical reactions that generate heat within the coal particle.

Control Measure

Coal should not be stacked in the yard more than the process requirement for a stipulated number of days.

As far as possible, coal must not be stored for more than 3 months.

Where it is unavoidable to store it for a longer period, the top and sides of each heap/ stack must be well sealed with oil or other suitable medium.

Coal handling unit/Agency shall provide adequate fire-fighting measure to avoid any fire or related hazards.

T S ALLOYS ON-SITE EMERGENCY FACILITIES Ambulance

One doctor with paramedical staff.

First aid boxes.

Portable fire Extinguishers – total of 75 extinguishers including (ABC, CO₂, DCP & FOAM type)

Fire hydrant points all over the plant – total of 25 hydrant points.

Sand buckets – total of 19 buckets.

Mobile equipment- Front wheel loader.

Transport vehicle – Bus and light vehicles.

Assembly Points.

Security personnel.

Fire ladder – (1nos).

Mutual Aid – Arati steel Ltd (located 6kms away from the plant).

RAISING OF ALARM DURING EMERGENCY & CLOSING PROCEDURE

Raising of Alarm During Emergency

The person noticing the emergency should immediately inform the shift in-charge or the unit head who in turn will inform the combat team leader immediately regarding the hazard.

• Raise the alarm. • Summon help and emergency services. • Notify fire brigade immediately (if necessary). • Evacuate all persons from the immediate danger area and seal it off. Closing procedure

• Works Main Controller shall declare normalcy after full control of the emergency.

• Works Main Controller shall direct the auxiliary team leader (ATL) / security gate to blow,” all clear siren continuously for one minute”.

COMMAND STRUCTURE DURING ON-SITE EMERGENCY

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