1

Final Report Confidential

REPORT

OF

SAFETY AUDIT

CONDUCTED AT

VISHAKHAPATNAM STEEL PLANT,

VISHAKHAPATNAM.

20-26th February, 2019

BY

NATIONAL SAFETY COUNCIL 98-A, Sector 15, Institutional Area,

CBD Belapur, Navi Mumbai-400 614

Tel. 022-27579924/5/6/7, Fax: 022-27577351,

Email: safetyaudit@nsc.org.in, Website: www.nsc.org.in

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ACKNOWLEDGEMENTACKNOWLEDGEMENTACKNOWLEDGEMENTACKNOWLEDGEMENT

We express our sincere thanks to thWe express our sincere thanks to thWe express our sincere thanks to thWe express our sincere thanks to the management and e management and e management and e management and employees ofemployees ofemployees ofemployees of Vishakhapatnam Steel Plant, Vishakhapatnam Steel Plant, Vishakhapatnam Steel Plant, Vishakhapatnam Steel Plant, VishakhapatnamVishakhapatnamVishakhapatnamVishakhapatnam for their cofor their cofor their cofor their co----operation and unstinted operation and unstinted operation and unstinted operation and unstinted help without which the Safety Audit could not have help without which the Safety Audit could not have help without which the Safety Audit could not have help without which the Safety Audit could not have been possible. been possible. been possible. been possible. The courtesy and cordiality extended to the audit team is The courtesy and cordiality extended to the audit team is The courtesy and cordiality extended to the audit team is The courtesy and cordiality extended to the audit team is highly appreciated.highly appreciated.highly appreciated.highly appreciated.

----National Safety CouncilNational Safety CouncilNational Safety CouncilNational Safety Council----

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CONTENTS

Sr. No. TITLE PAGE NO.

PART – 1 GENERAL 1

1.1 Introduction 1 1.2 About the organization 1

1.3 Scope 42 1.4 Objective of Audit 42 1.5 Methodology 42 1.6 Opening Meeting 43

1.7 Study of Document 43 1.8 Closing Meeting 43 1.9 Audit Report 43

1.10 Disclaimer 44 PART – 2 EXECUTIVE SUMMARY 45

PART – 3 HEALTH AND SAFETY MANAGEMENT SYSTEM 56

3.1 Health & Safety Policy 56 3.2 Safety Organization 57 3.3 Safety Committees 58 3.4 Safety Inspection 58 3.5 Accident Reporting, Recording, Investigation & Analysis 60

3.6 Safety Education & Training (Including First Aid Training) 61 3.7 Promotional Activities on Safety & Health (Safety

Competition, Safety Suggestion Scheme, Safety Incentive Scheme)

63

3.8 Identification & Assessment of Hazards 64 3.9 Safety Document (safety Manual, Operating Procedure) 66

3.10 Safety Budget 66 3.11 Safety Audits 67

3.12 First Aid Facilities and OHC 68 3.13 Medical Check Ups of Employees Related To Hazardous

Processes 72

3.14 Compliances with Statutory Requirements (License, Certificates, Authorization etc.)

75

3.15 Emergency Preparedness plan & Mock drill 76

PART – 4 MECHANICAL & PHYSICAL HAZARDS 78

4.1 Testing & Examination of Pressure Vessels/Plants 78 4.2 Testing & Examination of Lifting Machines & Tackles 79 4.3 Manual and mechanical material handling 81 4.4 Handling & Storage of Gas Cylinder 82 4.5 Guarding of Machines & Dangerous Areas 82

4.6 Means of access, platforms & railings 86 4.7 Preventive maintenance system and records 87

4.8 Ventilation, Illumination, Noise 87

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Sr. No. TITLE PAGE NO.

4.9 SOP 88

4.10 MOC/ New Equipment / Review System 89

4.11 Monitoring of Workplace & Stack Emission 89 4.12 Housekeeping 90 4.13 Personnel Protective Equipment 91 4.14 Work Permit System 91 4.15 Statutory warning 92

4.16 Road Safety 92 PART - 5 CHEMICAL & PROCESS SAFETY 94

5.1 Storage & Handling of Hazardous Chemicals & Tank Farm Safety

94

5.2 Chemical Transportation Safety 94 5.3 Material Safety Data Sheet (MSDS) 94

5.4 Laboratory Safety (QATD) 94 5.5 Color Coding of pipelines 96 5.6 Statutory warning & labeling 97

PART - 6 FIRE PREVENTION, PROTECTION AND MITIGATION 98

6.1 Fire Hazard Occupancy 98

6.2 Organizational Set up for Fire Fighting 98 6.3 Fire Station, Tender, Fire Hydrant System 100 6.4 Fire Pump House 100 6.5 Fire Detection & Alarm System 101 6.6 Portable Fire Extinguishers 102 6.7 Up keepment of Fire Fighting Equipments 102

6.8 Fire Incidence Reporting and Recording System 103 6.9 Fire Preventive Measures 103

6.10 Communication System 103 6.11 Fire Fighting Training 103 6.12 Documents Related to Fire Safety 104

PART - 7 ELECTRICAL SAFETY 105

7.1 Compliance with Respective to CEA 2010 105 7.2 Testing and Examination of Electrical Machines &

Equipment 110

7.3 Preventive Maintenance of Electrical System 111 7.4 Electrical Work Permit & LOTO Procedures 111 7.5 Electrical Hand tools- Inspection & record keeping 111

7.6 Safety in Temporary Wiring 112 7.7 Flameproof Electrical Equipments/ Fittings 112 7.8 Lightning Protection System 113 7.9 Earthing System 114

7.10 Emergency Lighting System 115 7.11 Electrical Safety & Personal Safeguarding 115

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Sr. No. TITLE PAGE NO.

7.12 Safety in Temporary Wiring 116

7.13 Safety WRT underground cable work 117

7.14 Contractor Safety 118 7.15 New Equipment Review 118 7.16 Electrical Safety at Receiving station/ sub station 119

PART 8 AREA WISE OBSERVATIONS 123

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PART – 1

GENERAL 1.1 INTRODUCTION

At the request of Vishakhapatnam Steel Plant, National Safety Council (NSC) conducted Safety audit from 20-26th February, 2019 of Vishakhapatnam Steel Plant, Vishakhapatnam.

AUDIT TEAM COMPOSITION

The safety audit was conducted by a 4-member team from 20-26th February, 2019.

i.Shri S. K. Patil, Assistant Director, NSC & Lead auditor ii.Shri. Swapan Bhattacharjee, NSC Expert Panel iii.Shri K. K. Singh, NSC Expert Panel iv.Shri. U. K. Dasgupta, NSC expert panel

1.2 ABOUT THE ORGANIZATION/PLANT

Rashtriya Ispat Nigam Limited (RINL), a Navratna Public Sector Enterprise (PSE) is the corporate entity of Visakhapatnam Steel Plant (VSP). VSP is the India’s first shore-based integrated Steel Plant built with state-of-the-art technology and a prime producer of long steel products in the country having extensive market in infrastructure, construction, automobile, electrical and forging industry. With an annual turnover of over Rs16000 crores, VSP is gearing up production to achieve rated capacity of 7.3 Mtpa liquid steel. The plant is situated in Visakhapatnam, Andhra Pradesh on the coast of Bay of Bengal. The total area of the plant including township is 9219 hectares while the plant built-up area is 2439 hectares. There are about 17,052 regular employees and 16,229 contract workers working in the plant in 04 shifts, one being the General shift. VSP meets its iron ore requirements from Bailadilla mines of National Mineral Development Corporation at Chattisgarh, Coking coal requirements through imports and coal washeries of Coal India Limited, SMS grade limestone through imports, quartzite requirements through purchase and boiler coal from the coal mines of Mahanadi Coal Limited. SMS Lime Stone from Dubai, Boiler Coal from Indonesia, Coking Coal from Australia / US, Medium Coking Coal (MCC) from Kathara / Swang / Rajarappa / Kedla & LAM Coke from China. Iron and steel plant has been notified as an industry with hazardous process and specified in the first schedule of factories act 1948.There are many production operations involving safety and health hazards which include- molten metal handling, storage of toxic and inflammable gas and exposure to dust, fume, noise, heat, radiation etc. Further, there are many operations in the steel plant, such as Grinding, shot blasting, iron making, foundries and handling of corrosive

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substances are declared as dangerous operations as per sec.87 of factories act and state factories rules. The Visakhapatnam Steel Plant essentially consists of the following Departments Major Production Units: i. Raw Material Handling Plant (RMHP) ii. Coke Oven & Coal Chemical Plant (CO&CCP) iii. Sinter Plant (SP) iv. Calcining & Refractory Material Plant (CRMP) v. Blast Furnace (BF) vi. Steel Melting Shop-1 (SMS-1) vii. Steel Melting Shop-2 (SMS-2) viii. Light and Medium Merchant Mill (LMMM) ix. Medium Merchant and Structural Mill (MMSM) x. Wire Rod Mill (WRM) xi. Roll Shop & Repair Shop (RS & RS) xii. Wire Rod Mill-2 (WRM-2) xiii. Structural Mill (STM) xiv. Special Bar Mill (SBM)

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RAW MATERIAL FLOW CHART

Coking coal

PCI coal

Steam coal

Iron ore fines/Limestone/

Sized iron ore/ Mn Lump/ LD Slag

Sized iron ore/ Raw Dolo/ Mn Lump/Coke

Quartzite lump/ PELLETS

RMHP

CO&CCP

SP

TPP

Dolomite/Quartzite & Sand/LD Slag

LD Slag

CHP

OHP

To BF

Power

BF Coke

To SMS

Sinter

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Process flow – Integrated Steel Pant

Blast

Furnace

Converter

Bar Mill

Caster

SBM

SM

Hot Metal Liquid Steel Crude Steel

Oxygen

Slag

Raw materials

Pig Iron

Blooms/Billets

for sale

WRM-1

MMSM

WRM-2

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The brief manufacturing process of steel making is given below. Raw material handling plant (RMHP) is a unit where various raw materials are received. RMHP is covered under QMS, EMS, EnMS and OHSAS. The raw materials in railway wagons are tippled in wagon tipplers and then through a series of conveyors and stacking machines, the raw materials are stacked in the assigned beds. Imported coking coal, imported boiler coal and pulverized coal are predominantly received from Gangavaram port limited in two streams of conveyors. A small tonnage of raw materials is received by road. Depending on the requirements of the consuming departments, various raw materials are sent through a series of reclaiming machines and conveyor systems. The Iron Ore Fines, Iron Ore Lumps, Sized Iron Ore, Limestone (BF& SMS grade), Dolomite (BF & SMS grades), Dolo Chips, Sand, Quartzite, Manganese fines & lumps and Fluorspar are stocked in Ore & Flux Yard and an additional storage facility for stacking Iron ore lumps and sized Iron ore, Iron ore fines (IOSA) is also available. The Imported Coking Coal (ICC), Medium Coking Coal (MCC) and Boiler Coal are stocked in Coal Yard. The boiler coal is sent to Thermal power plant (TPP), the imported coking coal and medium coking coal is processed and sent to coal preparation plant of Coke ovens (COCCP). The Iron ore fines and crushed lump ore (sized iron ore) Limestone (BF), Manganese Lump, Quartzite is sent to Blast furnace (BF). BF grade lime stone, BF grade dolomite, sand, Manganese ore & iron ore fines are sent to Sinter Plant (SP). SMS grade Lime stone and Dolomite, Dolo chips are sent to Calcining plant (CRMP). SMS grade Dolomite, Fluorspar, Sized Iron Ore are sent to SMS. The layout is designed in a spacious area for orderly movement of materials. The raw material like coking coal, boiler coal received is compacted using machinery and stored in various beds to prevent self ignition. Fire hydrant pipeline and landing valves are provided all along the conveyor galleries. Similarly fire hydrant connections are provided by the side of coal yard. Fire detection and alarm systems are provided in all important areas. Emergency filling tanks are provided at coal tipplers and coal junction house no.5. To control the generation of dust, dust suppression (sprinkling water) and dust extraction systems are provided at all the ore and coal tipplers and conveyors. All equipment like tipplers, conveyors, stackers, reclaimers etc. are provided with safety devices and interlocks. Fencing, alarm signaling systems are provided to avoid incidents related to locos & wagons. The dust generated while sizing and at all material transfer points during handling of raw materials is collected by aspiration systems and cleaned in cyclones/bag filters. Water spraying system is provided in the stockyards for dust abatement. Dry fog system is being run in at the ring granulator (RG) building for dust suppression. Also one additional water sprinkling system is provided in boiler coal beds. CO & CCP: COKE OVENS & COAL CHEMICALS PLANT (CCP) can be broadly classified under the following sections: I. COKE OVENS DEPARTMENT

Coal Preparation Plant (CPP) Coke Oven – Batteries Coke Dry Cooling Plant (CDCP) Coke Sorting Plant

II. COAL CHEMICALS PLANT (CCP)

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(A) CCP – RECOVERY (i) Gas Condensation Plant (GCP)

Separators/PGCs/ESP/Exhauster Condensate Pump House (CPH) Condensate Polishing Unit (CPU) Final Gas Coolers (FGC) Benzol Recovery Plant

(ii) Ammonium Sulphate Plant (ASP) (iii) Mechanical, Biological & Chemical Treatment Plant (iv) Reagent Storage Section (RAS) (B) CCP - TAR DISTILLATION PLANT (TDP)

Tar & Oil Storage Tar Distillation Section Pitch Cooling & Loading Area Naphthalene Anthracine Fractional Crystallization

(C) CCP – BENZOL DISTILLATION PLANT i. Benzol Distillation Section (BDS) ii. Hydro-Refining and Extractive Distillation Section(HRED) iii. Crude and Finished Product Storage (CFPS).

There are 4 coke oven batteries with 67 ovens each which receive blended coal from coal preparation plant (CPP) where coal from the storage yard, the coking coal is sent to foreign material removing section and iron traps to remove foreign matters and ferromagnetic particles respectively. For averaging and proportioning of coal, 16 bins each of 800 T capacity are provided along with continuous feeders of 100 TPH. There are two stages of crushing. The primary crushing is carried out by reversible hammer crushers. Then it is fed to pneumatic separation to produce fine and coarse products. The coarse product is sent to secondary crushing in reversible hammer crushers. The crushed and blended coal from pneumatic separation section is conveyed to two coal towers each of 4000 T capacity. Weigh bridges are provided under coal towers to weigh the coal charged. Coal is fed from Coal Tower into the Charging Car which in turn is charged into the Ovens. The primary objective of coke ovens is to produce metallurgical coke by carbonization of coal where coal is heated in the coke ovens in the absence of air to produce coke. CO and BF Gas are used as the fuel energy (mixed gas) for firing the ovens, electrical energy is used for driving various electrical equipments, process steam is used during charging of coal into coke ovens, compressed air is used for gunniting. The coke is then pushed by a pusher car into coke bucket through a Door Extractor cum Guide Car. During the coking process enormous amount of volatile matter/gas (known as CO Gas) is liberated which is collected in a Gas Collecting Main. The collected gas is then cooled with chilled water in primary gas cooler and treated in the Coal chemical plant with Ammonical Liquor Solution, purified and distributed throughout the plant as a fuel. Automatic valves for gas pressure control in gas collecting mains are mounted on the cross over pipe line on the pusher and coke sides and on the common branch pipe. A provision is also made for hydraulic wash out of tar sludge in the gas collecting main. The battery is of under jet compound

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type having twin heating flues and recirculation of waste gases. CO Gas yield from Batteries is 330 NM3/T of Coal with CV of 4250 Kcal/Nm3. The metallurgical coke is cooled in Coke dry cooling plant (CDCP), where the coke from Coke Ovens is pushed into the bucket placed on the coke car and transported by electric loco to the coke dry cooling plant. A hoist lifts the bucket to the chamber top. The bucket is then placed above the charging hopper and the coke is charged into the cooling chamber. The upper part of the chamber serves as a collecting chamber into which the red-hot coke is charged and resides there about two hours. The lower part serves as a chamber where the cooling process is taking place. Cooling of coke is done with circulating (N2) gases. The gas is circulated by smoke fan and flows upwards to counter current to the coke flow and is heated on its way. The hot circulating gas from top of the chamber enters the ring channel from where it is sent to dust catching bunker to waste heat boiler then through cyclones. It is further recycled into the cooling chamber. The waste heat from circulating nitrogen is recovered to produce SH steam (39 ata) and used in two Back pressure type steam turbine station for generation of 2X7.5 MW power and simultaneous generation of process steam extracted from the low pressure outlet of BPTG is used in Coal Chemical Plants. Back pressure steam generated at BPTG is further used in Chilled water plant -1, which operates on the principle of vapor absorption system, for production of chilled water. From the cooling chamber, cooled coke (1.7 T) is discharged continuously onto the conveyor to Coke sorting plant (CSP). Operating conditions of Coke Dry Cooling Plant a) Temperature of Coke charged into the chamber 950-1,050 deg C b) Temperature of Cooled coke 180 - 200 deg C c) Temperature of circulating gases before the waste heat boiler 760-800 deg C d) Temperature of circulating gases before the cooling chamber 180 - 200 deg C e) Steam rising from one chamber 20 - 25 ton/hr f) Steam pressure 39 - 40 atm. g) Temperature of superheated steam 430 - 450 deg At the Coke Sorting Plant coke from the coke dry cooling plant coke is discharged into de-dusting units by conveyors. De-dusting units are provided with equalising bunkers and belt feeders to compensate for irregularity of coke discharge from dry cooling plant. From the de-dusting unit coke is conveyed to crushing section. It is first separated into +70mm and -70mm fractions. The +70 mm fraction is fed to two roller toothed crusher. The crushed product along with -70 mm fraction is conveyed to screening plant where 20 to 70 mm and 0 to 20 mm fractions are separated and 20 to 70 mm coke is conveyed to blast furnaces for use as fuel and reducing agent. Bunkers of 600 T capacities are also provided for loading into wagons/lorries. The 20 mm fraction is fed to vibrating screens to separate into 0 to10 and 10 to 20 mm fractions. Each fraction is stored in bunkers of 160T capacity. These fractions are either conveyed to sinter plant or loaded into wagons/lorries. Separate yards are also provided for storing blast furnace coke and sinter plant coke/fraction. Vibro feeders are replaced in mixing bins of CPP and rotary discharge devices are installed in CDCP chambers for enhanced quality. Coke of various grades is produced at Coke oven is screened and sent to Blast Furnace to meet energy requirements at Blast Furnace, Sinter plant and SMS. Smokeless charging system by steam injection is provided to minimize the emissions during charging of coal into the coke ovens. The dry quenching of coke is adopted (instead of conventional

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wet quenching) to minimize the air pollution. The dry quenching of coke from dry quenching plant also facilitates recovery of waste heat from the red-hot coke to produce steam which is utilized by back pressure turbine station (BPTS) to produce power as the bi-product. The dust laden air from coke crushing and screening plant and material transfer points is aspirated and cleaned in wet scrubbers. The contaminated water from various wet cleaning systems is collected and treated in a sludge treatment plant. The collected sludge is sold out to outside parties. The treated water is recycled into DE system. The main by product in the process of coke making is crude coke oven gas, which has a lot of valuable chemicals in it. These are recovered in coal chemical plant. The primary by-products are cleaned CO gas, Ammonium Sulphate, Benzol and Crude Tar. The tar removed is further processed in tar plant and the following secondary bi-products are obtained, i.e. pitch, anthracene oil, wash oil, hot pressed napthalene, phenol, and pitch creosote mixture. The crude benzol removed is further processed to get products namely benzene, toluene, light solvent naptha, non-aromatics, and high boiling fraction. Coal Chemical plant’s (CCP) the coke oven gas released from coke oven batteries during carbonization of coal is processed in the coal chemical plant. The primary object is to clean coke oven gas released from coke oven batteries and send it back for using it as fuel in batteries and for other consumers. The cleaning of gas is done in recovery unit which is one of the primary units of coal chemicals plant. The CO gas leaves coke oven chambers at a temperature of 800 deg. C and goes to the gas collecting main where it is cooled to 80 deg. C by spraying Ammonical Liquor. In this process, the major part of the tar is condensed and the particulate matter settles as sludge. Tar and sludge is separated and the flushing liquor from the separators goes along with sludge and tar to mechanized decanters of the Tar Distillation Plant. Due to the difference in densities, the flushing liquor clarified from tar and sludge flows out from top continuously by gravity into flushing liquor collecting tanks. From these tanks flushing liquor is pumped to the CO Battery gas collecting mains for spraying again. The tar settled down in the decanters flows continuously through telescopic pipe to tar collecting tank. From tar decanters the tar free sludge and water flows by gravity through the telescopic pipe to collecting tank from where it is sent to startup tank in tar distillation section. Then the tar is pumped to first stage of pipe still furnace along with 8% soda solution to neutralize the tar. Tar is heated to about 130 deg C in the convection zone of the furnace and fed to first stage evaporator, where water and portion of light oil present in tar are evaporated. The water and light oil vapors are condensed and sent to a separator and further to separate tanks for storage. The vapor mixture from the top of the second stage evaporation is fed to the fractionating column. Super heated steam is supplied at the bottom of the fractionating column. Anthracine (II) fraction is drawn off as the bottom product from the fractionating column through a level controller. The next fraction is wash oil drawn between 12th and 20th trays which is cooled and routed to storage tank. The next fraction is naphthalene oil drawn between 24th and 30th trays and it is cooled and sent to storage tank. The next product is phenol fraction drawn from 44th and 48th trays which is cooled and sent to a storage tank. The vapors from the fractionating column top are condensed. These vapors are light oil and phenolic water and in the separator light oil and phenolic water are separated and sent to respective storage tanks. Light oil is pumped as reflux to the top of the fractionating column to control the top temperature. Pitch

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from second stage evaporator is received in over head tanks and taken into still reactors. Softening point of pitch is increased by giving compressed air in the bubbler of still reactor. Air flow is controlled to control the temp of the pitch. The reaction between pitch and air is exothermic. Oil fractions present in pitch are carried away with air and are condensed in vapor washer. Hard pitch from still reactor is drained to horizontal hard pitch tanks which is pumped to over head tanks and loaded in tankers. Naphthalene fraction is received in an over head tank of NAFC section from Tar distillation plant. Naphthalene is fed into a drum crystallizer bath by gravity. The drum is cooled by spray water. Layer of Naphthalene formed on the ribbed surface of the drum is cut off by knives and transported by a screw conveyor to mixer of hydraulic press, through a chute. The Naphthalene generated in the crystallization of pressed oil is pumped to the over head tank and fed to the pressed oil mixer directly. The Naphthalene flakes and molten Naphthalene are kept homogeneous in the mixer and charged into the filter of hydraulic press. The hot pressed Naphthalene cake of 20-40 kgs weight goes to the crushing and bagging section where it is crushed by jaw crusher and bagged in 50 kg. bags. During pressing operation Naphthalene oil is squeezed out and goes to pressed oil tank. The pressed oil containing about 60-70 % Naphthalene is pumped to the over head tank and from there it is charged into scraper crystallizer. Anthracine -I fraction is pumped to over head tank in NAFC section. From the over head tank it is charged into scrapper crystallizer. The crystallized mass after atmospheric cooling upto 55oC is cooled to 35oC by external water and drained to a mixer. The crystal slurry is centrifuged. The oil is separated from crystals and goes to a collecting tank. The crystals fall on to a conveyor which take them to storage bunker. Crystals are bagged and dispatched. The centrifuged oil is pumped to pitch cooling and loading area for making tar. The CO gas is then cooled to 35 deg. C in PGC and the water vapors, the remaining tar and Naphthalene are condensed. Drops of Tar fog left in the gas after PGC are separated in ESP and collected in the seal pots from where it is transferred to gas condensate tank. Then this purified and cooled gas is supplied by exhausters to Ammonium Sulphate Plant at 50 deg.C and 3000 mm W.C Ammonia is recovered in the form of ammonium sulphate in the AMMONIUM SULPHATE PLANT (A S P) where the CO gas after the exhauster enters the saturator where ammonia is almost completely absorbed by sulphuric acid in the form of Ammonium Sulphate according to the following exothermic Reaction: 2NH3 + H2SO4 --> (NH4)2SO4 Crystals of Ammonium Sulphate from the saturator is taken out by centrifugal pump and sent to crystal receiving tank. The mother liquor is freed from Sulphate crystals and sent back into saturator. Ammonium Sulphate crystals from crystal receiving tank are sent to centrifuge for separation of mother liquor while Sulpahte crystals are sent to drier and the dried Sulphate is sent to storage. The CO gas then enters the final gas cooler at 55 deg C. Naphthalene present in CO-gas is scrubbed by water and separated tar is taken out and stored in tanks and sent to Tar Distillation Plant for processing. The coke oven gas is at 35-42 deg C and 600 mm WC after the final gas cooler/pre cooler flows to two Benzol scrubbers (60,000 Nm3/hour capacities) of Benzol Recovery Plant where Benzol is scrubbed using “Solar” oil as scrubbing medium. Benzol hydrocarbon is scrubbed with the circulating

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debenzolised oil flowing in a counter current direction of the gas flow. The temp. of the oil is maintained at 2 to 3 deg C higher than the CO gas to avoid condensation of water vapor in the gas. The benzolised oil is pumped to Benzol Distillation plant. In Benzol distillation Plant, the benzolised oil is preheated in oil dephlegmator with hot Benzol hydrocarbons from Benzolised oil stripping column. The benzolized oil is finally heated to 180 deg C in steam preheater before it enters the stripping column (BT/107). Direct steam is supplied to the Benzol striping column to strip the Benzolvapors from the benzolised oil. The hot debenzolised oil from the bottom of the stripping column passes through heat exchangers and finally through a water cooler and enters an oil decanter (BT/137). A small quantity of makeup water is sprayed in oil decanter to facilitate sludge removal from oil. The debenzolised oil is circulated back to Benzol recovery plant. Sludge is separated out in the form of emulsion and transferred to emulsion breaker (BT/139). Mixture of Benzolvapors and steam from the top of the stripping column (BT/107) enters the dephlegmators (BT.101 & 102) where vapors are partially condensed. The phlegma condensed in the dephlegmators consists of high boiling hydrocarbons along with water. Phlegma is separated from water and the water sent to water settling tank (BT/130) for separation of entrained oil. Naphthalene is also absorbed along with Benzol from CO gas in Benzol scrubbers. Absorbed Naphthalene is removed in Naphthalene stripper. A part of the Phlegma is fed to stripping column (BT/107) as reflux and the rest is fed to Naphthalene stripper. Both direct and indirect steam is used in Naphthalene column for better control of process. Steam along with light boiling fraction from the top of the Naphthalene column enters the stripping column (BT/107) near its top. Naphthalene rich oil from the bottom (BT/111) is routed to collecting tank (BT/128). The crude Benzol is fractionated in to two fractions i.e., Crude Benzol-I (Boiling up to 150 deg C) and crude Benzol-II (boiling above 150 deg. C) in a single steam. The mixture of Benzol and water vapor from dephlegmators (BT-112) is fed to rectification column for crude Benzol I (BT-112). Heat for fractionation is supplied by reboiler (BT/114). The vapors of crude Benzol-I and water from the top of the C.B.I column enter the condenser (BT/116). After separation of water, crude Benzol - I overflows to reflux tank (BT-124). A part of crude Benzol I is pumped as reflux to C.B.I. Column (BT/112) and the balance to crude Benzol-I tank (BT/125). Heavy Benzol leaving as bottoms from C.B-I column (BT/112) enters crude Benzol II column (BT/113). The vapors from the top of the column (BT/113) returns to crude Benzol-I column (BT/112). Crude Benzol-II leaving from the bottom of crude Benzol II column (BT/113) is cooled and sent to collecting tank (BT/126). The crude benzol-1 from crude Benzol-I tank (BT/125) is pumped to crude benzol tank of crude finished product storage area from where it is pumped to intermediate storage tanks of Hydro-refining section. In Hydro refining crude benzol is purified by using pure hydrogen to produce BTXS. This BTXS is distilled in pressure distillation column where BT and XS are separated. The BT fraction is processed in Extractive distillation column by using a solvent NFM to separate pure aromatics and non-aromatics. The NFM absorbs non aromatics from BT fraction. The NFM solvent is recovered from nonaromatics in solvent recovery column and non-aromatics product is pumped to storage tank at CFPS. The pure aromatics with NFM are processed in stripper column where NFM and pure aromatics are separated. The NFM separated is recirculated to extractive distillation column and pure aromatics are sent to B/T separation column where Benzene and Toluene are produced. The

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XS separated in pressure distillation is charged into batch still where light solvent oil is produced by giving indirect steam. The LSO is transferred to CFPS tanks by gravity. All the finished products like Benzene, Toluene, Light solvent oil, Heavy crude benzol, High boiling fraction are stored in CFPS tanks. The cleaned gasses without pollutants are collected from various places of coal chemical plant and discharged into the atmosphere. Stainless steel saturators are installed for better results. The ammonia liquor and water from the coke ovens and coke chemicals plant which is contaminated with chemicals like phenol, cyanides, etc. It is collected and treated in two stages, the “mechanical biological and chemical treatment plant”. The treated effluent is treated further in the effluent treatment plant. The hazardous wastes generated in the coal chemicals plant are mixed with coal and charged into the coke oven batteries. All the liquid and gas products of coal chemicals plant are fire hazardous in nature. In the design of layout of coal chemicals plant care has been taken to maintain sufficient distance between the three sections of CCP, namely recovery, tar plant and benzol plant. This has been done to minimize the effect on other units in case any-On site emergency situation develops in any unit. The following special OH&S facilities are provided in coke ovens in addition to the general safety provisions: - Automatic opening of gas bleeder valves in case of high pressure in gas collecting

mains of battery. - Auto stopping of heating in batteries in case of low inlet gas pressure - The coke oven and mixed gas line network has been provided with seal pots for

condensate removal - Steam and nitrogen purging facility is available in all gas lines - Safety flaps are provided in circulation gas track in CDCP The following OH&S facilities are available in all 3 sections of CCP: A fire station and a first aid station are provided in coal chemicals plant zone. Bund wall is built around the storage tanks. For CO gas line net work isolation valves are provided to isolate CO gas to any section. Provision of steam and nitrogen injection to CO gas lines is available. In reagent storage where sulphuric acid is unloaded and stored, the storage tank and the area are lined with acid proof bricks. The pipelines and pumps handling acid is made of stainless steel. In Ammonium Sulphate unit the saturator handling 5% sulphuric acid are made up of stainless steel. Also the whole unit area flooring is made of acid proof bricks. A separate fire fighting pump house with static water tank exists for fire fighting in tar plant. All overhead pitch tanks and reactor have been provided with nitrogen line. Steam purging facility is available to all tanks and equipments. For furnace, steaming facility is available to smoother the fire which can occur in case of pipeline leak. For NAFC go down, smoke detector and water sprinkler system is available. A dedicated fire fighting pump house with static water tank is available for water shell spray to all tanks and also for foam injection to all vertical storage tanks in CFPS. Benzene monitor is fixed at sensitive location to detect the benzene leak. If in ambient air, benzene content is greater than 20 PPM, siren will blow to alert the employees. In HRED, in case of leak in HP circuit, facility is available to de-pressurize line quickly and feed nitrogen into the circuit. Nitrogen purging facility is available to all equipment of HRED. In Benzol distillation plant, facility is available to empty oil of any equipment to emptying tank in case of emergency.

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Sinter Plants covered under QMS, EMS, EnMS and OHSAS, are units where sinter is produced from Iron Ore fines, Lime stone, Coke, Dolomite and Sand from RMHP and Metallurgical Wastes such as the fine iron dust, metallurgical wastes from the water treatment plants in blast furnaces, steel melting shop & rolling mills, flue dust, mill scales, coke breeze, coke dust, lime dust, Stock House Dust, Cast House Dust, Gas torch sludge, CC Scales, BF Gas Cleaning Sludge, LD Gas Cleaning Sludge etc., etc. collected from various units in the plant are re-used as feed for sinter making. These raw materials are received in Raw Material Bins, raw materials preparation plant for Base Mix preparation: Base mix is a mix of above materials in required proportion to meet the Blast Furnace quality requirement. After proportioning, the raw materials are mixed in the primary mixing drum and stored in base mix yard. Secondary Mixing, Moistening and Palletizing of sinter mix is carried out in the palletizing drum to ensure uniform mix of all the burden components. Then the Sinter Mix is charged on the grating above hearth layer of 60 to 80mm thick .The Sinter mix with coke breeze as solid fuel, is then ignited in the furnace using Mixed Gas. The temperature maintained is in the range of 1150o-1250oC. Sintering is done on the grating of the Sinter machine due to air suction in the downward direction and high temperature created by burning carbon of the sinter mix layers. Hot sinter discharged from sintering machine at 700oC is crushed to 150mm size in a spiked single roll crusher. Unsintered grains are liberated as sinter returns. After crushing, the sinter is screened. The +8mm hot sinter is cooled on straight line circular sinter coolers by forcing atmospheric air through sinter bed. This is further conveyed to Blast Furnace after eliminating -5mm sinter fraction. Electricity is used for operating exhausters for maintaining better vacuum and blowers fan for cooling of sinter. Further, Electricity is also used in for de-dusting, ACP fans, ESPs etc for dust evacuation and reducing dust emissions. In addition to the above, various types of carbonaceous dust is recycled in to sinter machine. Sinter plant is also using lime stone and dolomite as fluxing agents to maintain basicity. Sinter plant recycles the LD slag generated at steel melt shop to replace lime stone. Within the sinter plant, there are a vast network of conveyor systems, equipments, stacking and reclaiming machines and two sinter machines (each with 312 sqm grate area / 276 sqm of sintering area) in SP-1 and one Sinter machine(408m2) in SP-2. The large amount of gases containing particulate matter evolved during the sintering process are collected and cleaned in electrostatic precipitators to reduce the dust content from 3000 mg/Ncum to below 50 mg/Ncum (115 mg/Ncum for SP-1) before letting out to the atmosphere through 120 m tall chimney. The dusty air from various other material transfer points is also collected and cleaned in wet scrubbers and the sludge processed through SDPM (Slime Dewatering Pump House) is reused in SP-1. Blast furnace (BF): There are three blast furnaces. Each blast furnace (each with 3800 cum useful volume) is capable of producing 2.5 MT of hot metal (liquid iron) per year. Blast furnaces are covered under QMS, EMS, EnMS and OHSAS. The burden (raw materials) like-blast furnace coke from CSP, sinter from SP, sized iron ore, limestone, LD-slag and at times additives (Mn ore & quartzite) from RMHP are received through conveyor system in the stock houses through a junction house. These are screened before stock house to remove fines. Each material is fed simultaneously by two hopper scales according to the predetermined furnace charging programme. Automatic system is provided for batching, weighing and feeding of the burden to the furnace top. Paulwurth bell-less top system is installed

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for furnace charging from the top through a conveyor. It consists of two bunkers of 65 M3 capacities each, charging/moving hopper and rotating trough. Semi -cleaned BF gas and Nitrogen are used for pressure equalization in charging bunkers. Nitrogen is also used for cooling rotating trough drive and for blowing off stock twin gates and sealing valves of charging arrangement. One mechanical gauge rod and two ultrasonic probes are provided for measuring stock level. There are four hot blast stoves for BF-1 and BF - 2 and three stoves for BF-3. These are heated by a mixture of BF & CO gas at a pressure of 600 mm W.C. Combustion air is supplied by three fans of 120,000 M3/Hr. The cold blast received from the thermal power plant turbo blowers is heated in the hot blast stoves to 12500C in BF-3 and 9500C in BF-1 before it is sent to the tuyeres via hot blast mains. It is taken out from top as Hot Blast and sent to BF for melting the burden stock. Hot air is blown through tuyeres into the blast furnaces. The blast furnaces produce normally basic grade pig iron suitable for steel making. Each blast furnace has four tap holes and a circular cast house for BF-1 and BF-2, flat cast house for BF-3. Hot metal and liquid slag are tapped through the tap holes. Hot metal is separated from liquid slag at the cast house. The liquid hot metal is collected in the hot metal ladles by rocking runners in cast house. Hot metal ladle cars are moved by a car pusher. There are four railway tracks for hot metal transportation to SMS and PCM. Slag is discharged from the furnace 16 to 20 times a day, duration of each discharge being 60 minutes. The molten slag produced by the furnaces is fed to cast house slag granulation plant (SGP), through the slag runners, for granulation by water jets. Granulated slag is conveyed to slag storage yard from where it is dispatched. Four double strand pig casting machines of 1700TPD capacity are installed to treat off-grade metal and metal diverted due to off-stoppage in SMS. The machine can handle one furnace production. Each PCM is served by a 75T overhead trolley to tilt the 140 T hot metal ladle. Refractory masses required in cast house viz. Runner mass, Mud gun mass, Tap hole frame mass are prepared in Masses and Compound Shop. During Blast Furnace operation, enormous amount of gas is generated and this gas coming out from Blast Furnace at a pressure of 2.5 kg/cm2 and temperature of 170oC, recovered from the furnace top, is first cleaned in the dust catchers which removes major portion of dust particles and thereafter in the scrubbers of the Gas Cleaning Plant, where water is sprayed to further clean the gas from fine Dust particles. From scrubber, the gas is passed to Cyclone Mist Eliminator through an Adjustable Venturi. While passing through the Venturi, the gas pressure is reduced and the differential pressure across the Venturi is always maintained. Any mist present in the gas is separated in the Cyclone Mist Eliminator. Further, it is sent to Gas Expansion Turbine Station (GETS) which generates 12 MW Power. The pressure of gas before GETS is 1.75 KSCG and after GETS is 0.15 KSCG. GETS generates electric power utilizing potential energy (pressure energy) of the compressed BF gas. Part of BF gas generated is also reused in the BF stoves. The GETS operates for 8000 hours/year with annual generation of 123.8 to 184.6 x 106 KWH. The dust level in the gas is thus reduced to 4 mg/N cum and is then sent to the BF Gas Line Network for use as fuel by various consumers in the plant as fuel. The scrubbed water contaminated with dust is sent to water treatment plants TP-1 and TP-2 where the dust particles are separated in the clarifiers and clean water is re-circulated in the gas cleaning plants. The slurry from bottom of clarifiers is sent to a settling pond. The settled sludge, after sun-drying, is sent to sinter plant as feed material. The exhaust fumes generated at the runners and while tapping hot metal into the open hot metal ladles/ torpedo ladles are exhausted and cleaned in electrostatic precipitators before being vented to the

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atmosphere through 100 m tall chimneys. The dust laden air generated at all the transfer points of blast furnace burden handling systems is aspirated, cleaned in electrostatic precipitators and the clean air is vented to the atmosphere through 80 m tall chimneys. The dust content at the outlet of above electrostatic precipitators is limited to 50 mg/Ncum. BF gas flare stacks are provided to flare the excess gas. These Flare Stacks are the heart of the Gas Line Network (GLN) throughout the plant. It is these flare stacks which maintain the network pressure at the desired value. If the pressure anywhere in the GLN increases, the gas is led to atmosphere through these flare stacks by means of automatic control systems. At the top of the stack the let out gases are burnt completely by means of pilot burners. The hot metal is distributed to the steel melting shop and to the pig casting machine (PCM). Pig iron, produced in the pig casting machine is stored in pig storage yard from where it is dispatched to different customers. The following special OH&S features are provided in BF in addition to the general OH&S provisions: The furnaces are equipped with bleeders and relief valves to take care of excess pressure condition. The stoves are operated in a sequence with safety interlocks. Auto isolation schemes are provided in case of power failure, low pressure in gas line etc. The tap hole drilling machines, mud guns, pusher cars and rocking runners are provided for safe handling of liquid metal and slag. The furnace is designed to prevent gas leaking while charging of materials. Emergency water supply tank is provided for the cooling of the furnace in case of power failure. The feeding conveyors to blast furnace area are provided with material tracking system. Failure of nitrogen, hydraulic system for hot blast control valve etc. are monitored with alarms in the control room. The slag granulation plant is provided with safety controls and monitoring of critical items like flooding of pump house, drop in pressure of compressed air, pump tripping, interlocks for dehydrator movement and slag vibrator for dumping. All equipment like conveyors, mud guns, drilling machines, cranes, pusher cars, combustion air fans, furnace top charging system etc. are provided with various safety interlocks and devices. Calcining and refractory material plant (CRMP): The CRMP comprises of two units i) Calcining plant, where it calcines limestone and dolomite into flux which is required mainly for steel making and ii) brick plant, where it undertakes manufacturing of refractory bricks required for lining of converters and ladles in steel melting shop. Calcining Plant of (CRMP), covered under QMS, EMS, EnMS and OHSAS, receives limestone and flux grade dolomite from RMHP through a series of conveyor belts. These raw materials are processed in rotary kilns at 1200 O C - 1300O C by burning coal tar as fuel (CTF)/ pitch creosote mixture fuel (PCM). The resultant product i.e. flux is cooled, screened and stored in the bunkers, and dispatched to SMS as and when required. Electricity is consumed for driving of rotating equipment like ID fans, Primary Air fan, Secondary Air fan, pumps etc. Each rotary kiln is installed with pre-heater where in outgoing flue gases sensible heat is used for preheating of raw material. Process steam is used for atomization of Coal Tar fuel and compressed air is also used for general housekeeping purposes. The flue gasses from each rotary kiln is cleaned in a cyclone and then finally in a pulse jet-type bag house to a dust content of below 50 mg/Ncum before venting to the atmosphere through 60 m tall chimneys.

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Brick plant of CRMP: Brick plant manufactures bricks, bottom jointing mass and back filling mass for lining of the converters and ladles of Steel Melting Shop. The brick plant receives sea water magnesia (SWM) of 0-25 mm size from the refractory stores in polythene bags. The SWM is crushed, screened and the different fractions of SWM obtained are stored in classified bunkers. Pitch is received in tankers from coal chemical plant (CCP) and stored in storage tanks. Predetermined quantities of different size fractions of SWM and pitch are taken and mixed in the mixer, and the mix is charged into the press hopper and pressed into the required shape of bricks as per the settings. Then the bricks are tempered in the tempering kiln after which they are packed and sent to SMS as and when required. The dust generated at the material processing and handling areas in flux storage building, kiln building and brick plant is collected and cleaned in various bag filters and clean air is let out into the atmosphere. The lime fines generated are partly converted into briquettes for charging into converters in steel melting shop and the balance is transported to sinter plant as well as marketed to outside parties. The following special OH&S features are provided in CRMP department in addition to the general provisions: Bund wall around the individual tanks are provided like in CTF/PCM pump house of calcining plant and pitch storage tanks in brick plant pump house. The tanks are provided with interlocks for high level. All the belt conveyors are provided with safety interlocks. In CTF/PCM pump house, all lights and motors are flame proof. Fuel safety shut off valve provided in firing system of flux kiln burner is provided with safety interlocks. The vibro tube mill area is enclosed within sound proof walls. All equipment in calcining plant and brick plant are provided with safety interlocks. Steel melting shop-1 (SMS-1) is covered under QMS, OHSAS, EMS, and EnMS. The liquid metal/ Hot Metal from the blast furnace is taken to SMS in ladles by locos. It is poured into two hot metal mixers (1300 T cap.) for intermediate storage. Hot metal from mixer or torpedo ladles is charged, after adding scrap additives received from scrap salvage department (SSD), into LD converter to make liquid steel in two 133 cum & one 150cum capacity top blown oxygen LD converters. Alloying elements from the metal such as carbon, Silicon, Manganese and Phosphorus are added in proper proportion to produce required grades of steel. Primarily the carbon content of hot metal is reduced by blowing oxygen called lancing operation. The total cycle time for one heat is 50 mins yielding 140 to 150 T of liquid steel. LD converters are equipped with suppressed combustion system to recover the converter LD gas which is used as fuel in the plant, by blowing Oxygen (from Air separation plant) from top lance and simultaneously Nitrogen or Argon are introduced from bottom through tuyers for better slag formation and better process control. Calcined Lime & Dolomite from CRMP are added as flux for facilitating slag formation and ensuring the slag basicity. The gases, CO & CO2 formed and are captured through gas cleaning system. Refining of molten pig iron in LD Converters releases gas rich in carbon monoxide and laden with significant amount of dust. The hot gases are collected above the converter mouth by a skirt, cooled through a hood and tack and cleaned in scrubbing installation in Gas Cleaning Plant. This cleaned gas is either flared in a flare stack or stored in a gas holder for further utilization by means of a Change over Valve (COV) installed at ID fan discharge which ensures the gas switching either to flare stack or to the gas recovery. Gas is

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routed to holder when CO is more than 30% and O2 is less than 2% and is routed to flare stack when the above conditions are not satisfied. The recovered gas is stored in the holder at a pressure of 180 to 250 mm WC. The capacity of the holder is 80000 m3. The stored gas is further cleaned in an Electrostatic Precipitator (ESP) and boosted to a pressure of 1500 mm WC and injected into the BF Gas Main going towards Rolling Mills. The liquid steel at the desired temperature is tapped from converter into steel ladles and taken to Argon Rinsing Station, where IR-UT (injection refining – up temperature) & ladle furnace facilities exist, for equalizing the temperature, averaging chemical composition and for lowering steel temperature, if necessary, by adding small size scrap. The slag retained inConverter is splashed by introducing N2 from top with O2 lance to coat the Converter lining. The treatment time is about 3 to 6 min. There are three argon rinsing stations having facilities for PROCESSES of lance, charging scrap, measuring temperature, charging heat insulating mixture and lance assembly and preparation. Liquid steel after rinsing with argon is cast into blooms of nominal size (250mm x 320mm and 250mm x 250 mm) in six numbers, 4 strands radial type with base radius of 12m, continuous casting machines. One of the machines namely CCM#2 is equipped with Automatic mould level controller and Electromagnetic Stirrer for production of high quality blooms. The tundish capacity is 25T. Cast blooms are cut by flame cutting machines to about 5.8 to 6.1m(M)/ 6.0 to 6.4m(L) length and short length bloom pieces are moved to cooling bed. After cooling to 500oC, they are transferred to racks. This is then lifted by 16 T magnet crane and piled for further cooling and stored in bloom storage yard. During process of steel making, ladles are used for transfer of hot metal, Coke oven gas is used for ladle heating and tundish drying, electricity is consumed at Induced Draft fans for evacuating waste gases from converter, Central ventilation fan systems, IRUT furnaces. Oxygen is blown in to the converter and Nitrogen is used for slag splashing of converter bottom. Compressed air is used for general housekeeping purposes. The converter gas produced during steel making is collected, cooled and then cleaned in wet gas cleaning system consisting of a kinpactor (adjustable throat venturi) and a quencher. The gas is cleaned to 100 mg/Ncum of dust and is either burnt at the outlet of 82 m tall flare stacks or is collected in the gas holder depending on the carbon monoxide and oxygen content in the gas. The gas is further cleaned in electrostatic precipitators to a dust content of maximum 10 mg/Ncum and is then used as fuel in the plant. The dust-laden fumes generated while charging the hot metal into mixers or while pouring hot metal from the mixers into hot metal ladles are exhausted and cleaned in electrostatic precipitator of the central ventilation system and discharged into atmosphere through 80 m tall chimney. The dust-leden air aspirated from material transfer points and screens etc. of the bulk material charging system is also cleaned in the electrostatic precipitator of the central ventilation system. The dust content at the outlet of the chimney is kept below 50 mg/Ncum. The water contaminated with dust from the converter gas cleaning plants is treated in clarifiers of treatment plant (TP-3) and recycled for cooling and cleaning the converter gas. The water contaminated with scale & oil from continuous casting machines is treated in a treatment plant (TP-4) and recycled. The collected sludge from bottom of clarifiers at TP-3 and TP-4 is recovered and used as feed material in sinter plant. The oil collected from scale pit of pump house no.15 is processed in oil reclamation unit. The collected scale from scale pit is transported by wagons to sinter plant for being used as feed material. The steam generated in the secondary cooling chambers of continuous casting machines is vented to atmosphere by exhaust fans. The slag and debris generated

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in steel melting shop are transported to the slag and debris dump located outside the plant boundary after recovery of steel scrap from the slag. The following are few important safety provisions made in steel melting shop (in addition to the general safety provisions). The LD converters and the continuous casting machines are provided with safety interlocks. The oxygen lances are lifted automatically in emergency with the help of battery/pneumatic lifting. The gas cleaning plant is provided with process safety interlocks. Explosion in the system is prevented by suitable process instrumentation. Overhead water tank is provided to supply water to the continuous casting machines in the case of power failure. Special fire fighting systems like CO2 flooding systems, Inergen flooding systems and fire fighting pump house are provided. The slide gate of steel ladle closes automatically in case of power failure. The magnet cranes of bloom storage yard are provided with fingers to prevent falling of blooms in the event of power failure. The hot metal and liquid steel handling cranes are provided with two sets of brakes in the main hoists. Steel melting shop-2(SMS-2) is presently covered under QMS. The liquid metal/ Hot Metal from the blast furnace is taken to SMS in torpedo ladles by locos. Hot metal from torpedo ladles is poured into hot metal ladles for charging, after adding scrap additives received from scrap salvage department (SSD),into LD converter to make liquid steel in two 150 cum capacity top blown oxygen LD converters. Impurities from the metal such as carbon, Silicon, Manganese and Phosphorus are removed & then alloying elements added in proper proportion to produce required grades of steel. Primarily the carbon content of hot metal is reduced by blowing oxygen called lancing operation. The total cycle time for one heat is 50 mins yielding 150 T of liquid steel. LD converters are equipped with suppressed combustion system to recover the converter LD gas which is used as fuel in the plant, by blowing Oxygen (from Air separation plant) from top lance and simultaneously Nitrogen or Argon are introduced from bottom through tuyers for better slag formation and better process control. Calcined Limestone & Dolomite from CRMP are added as flux for facilitating slag formation and ensuring the slag basicity. The gases, CO & CO2 formed and are captured through gas cleaning system. Refining of molten pig iron in LD Converters releases gas rich in carbon monoxide and laden with significant amount of dust. The hot gases are collected above the converter mouth by a skirt, cooled through a hood and stack and cleaned in scrubbing installation in Gas Cleaning Plant. This cleaned gas is either flared in a flare stack or stored in a gas holder for further utilization by means of a Change over Valve (COV) installed at ID fan discharge which ensures the gas switching either to flare stack or to the gas recovery. Gas is routed to holder when CO is more than 30% and O2 is less than 2% and is routed to flare stack when the above conditions are not satisfied. The recovered gas is stored in the holder at a pressure of 180 to 250 mm WC. The capacity of the holder is 80000 m3. The stored gas is further cleaned in an Electrostatic Precipitator (ESP) and boosted to a pressure of 1500 mm WC and injected into the BF Gas Main going towards Rolling Mills. The liquid steel at the desired temperature is tapped from converter into steel ladles and taken to On line Rinsing Station for homogenization, sample & temperature measurement. Then the liquid steel is sent to ladle furnaces for temperature & chemical analysis adjustment. The slag retained in Converter is splashed by introducing N2 from top with O2 lance to coat the Converter lining. The treatment time is about 3 to 6 min. There are three one on line Rinsing Station for each Converter. There are two Ladle Furnaces for temp. & Chemical analysis adjustment for the liquid steel. There is one RH Degasser for removal of hydrogen if required.

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Liquid steel after rinsing with argon is cast into billetsooms of nominal size (150mm x 150mm and 200mm x 200 mm) in two numbers, 6 strands radial type with base radius of 10m, continuous casting machines. One of the machines namely CCM#1 is equipped facility to cast either 150 mmX150 mm square or rounds of sizes 220 mm, 280 mm & 350 mm size. All the caster are equipped with Automatic mould level controller and Electromagnetic Stirrer for production of high quality billets. The tundish capacity is 35T. Cast billets are cut by flame cutting machines to about 12 m length and moved to cooling bed. After cooling to 500oC, they are transferred to racks. This is then lifted by 16 T magnet crane and piled for further cooling and stored in billet storage yard. During process of steel making, ladles are used for transfer of hot metal, Coke oven gas is used for ladle heating and tundish drying, electricity is consumed at Induced Draft fans for evacuating waste gases from converter, Central ventilation fan systems, Ladle furnaces. Oxygen is blown in to the converter and Nitrogen is used for slag splashing of converter bottom. Compressed air is used for general housekeeping purposes. The converter gas produced during steel making is collected, cooled and then cleaned in wet gas cleaning system consisting of a adjustable throat venturi and a quencher. The gas is cleaned to 100 mg/Ncum of dust and is either burnt at the outlet of 82 m tall flare stacks or is collected in the gas holder depending on the carbon monoxide and oxygen content in the gas. The gas is further cleaned in electrostatic precipitators to a dust content of maximum 10 mg/Ncum and is then used as fuel in the plant. The dust-laden fumes generated while charging the hot metal into Converters, while pouring hot metal from torpedo ladles into hot metal ladles & during tapping are exhausted and cleaned in electrostatic precipitator of the Secondary Emission Control System and discharged into atmosphere through 80 m tall chimney. The dust-leden air aspirated from material transfer points and screens etc. of the bulk material charging system is also cleaned in the bag house of MHS Dedusting system. The dust content at the outlet of the chimney is kept below 50 mg/Ncum. The water contaminated with dust from the converter gas cleaning plants is treated in clarifiers of and recycled for cooling and cleaning the converter gas. The water contaminated with scale & oil from continuous casting machines is treated in a treatment plant and recycled. The collected sludge from bottom of clarifiers is recovered and used as feed material in sinter plant. The collected scale from scale pit is transported by dumpers to sinter plant for being used as feed material. The steam generated in the secondary cooling chambers of continuous casting machines is vented to atmosphere by exhaust fans. The slag and debris generated in steel melting shop are transported to the slag and debris dump located outside the plant boundary after recovery of steel scrap from the slag. The following are few important safety provisions made in steel melting shop (in addition to the general safety provisions). The LD converters and the continuous casting machines are provided with safety interlocks. The oxygen lances are lifted automatically in emergency with the help pneumatic system. The gas cleaning plant is provided with process safety interlocks. Explosion in the system is prevented by suitable process instrumentation. Overhead water tank is provided to supply water to the continuous casting machines in the case of power failure. Special fire fighting systems like CO2 flooding systems, Inergen flooding systems and fire fighting pump house are

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provided. The slide gate of steel ladle closes automatically in case of power failure. The hot metal and liquid steel handling cranes are provided with two sets of brakes in the main hoists. The Rolling Mills: Light and medium merchant mill (LMMM), consists of LMMM and Special Bar Mill (SBM), covered under QMS, EMS, EnMS and OHSAS. LMMM is at an elevation of 5m level except the charging grids and consists of a break down mill of seven stands and a Bar mill which is a 2 strand continuous multilane mill consisting of 26 stands. It is a combined billet mill and merchant bar mill. The mill has been envisaged to produce 18,57,000 T of billets, out of which 7,26,000 T for in line bar mill to produce 7,10,000 T of finished bar product, 8,85,000 T for feeding to wire rod mill and 2,49,000 T for sale. The feeding material for the mill is continuous cast blooms of 320 x 250 mm with a nominal length of 6.3 m from SMS Continuous Casting Dept. carried by magnet cranes for charging onto the charging grids of 150 T each. Defective blooms can be sorted out and rejected onto two take-off grids provided along the charging roller table. Blooms from the charging grid are fed into the charging roller table one by one and then elevated to working platform. The cold blooms are charged into a walking beam furnace (2 nos) to heat up to rolling temperature i.e. 1200o C. Normally one furnace is intended to feed hot blooms for production of billets, and depositing on to cooling bed while the other furnace is intended to feed hot blooms for onward transmission of billets to in line bar mill. Billet Mill consumes mixed gas for reheating of blooms in reheating furnace which is equipped with dual firing to attain rolling temperature, Once rolling temperature is achieved, blooms are rolled into billets. The reheating furnace is walking beam type use DM water for cooling of furnace skids and posts. During the cooling of skids and post, the DM water is re-circulated and the furnace is equipped with evaporative cooling system for generation of process steam. The process steam generated can be used for driving steam turbine for running ECS pump incase of emergency and in normal circumstances, the process steam recovered is sent to plant process steam network. The walking beam furnace is equipped with Waste heat recovery system for recovering sensible heat of hot flue gases and air recuperator is installed for recovering waste energy. The bar mill reheating furnace consumes mixed gas and is installed with waste heat recovery system. Billet mill uses electrical energy for stands, combustion air fans and for hydraulics, lubrication, ventilation and lighting system. Bar mill consumes electrical energy for driving of rolling stands, running of blowers, for hydraulic, lubrication, ventilation and lighting system. In addition to the above bar mill consumes various utilities such as oxygen, nitrogen, steam, etc. The hot blooms are rolled into 125 x 125 mm billets in billet mill consisting of 4 horizontal and 3 vertical stands. The billets intended to be sent to wire rod mill or for sale, are cut in to three pieces with head and tail cropped and off loaded on to “turn over type cooling bed”. The billets for bar mill are cut only at head-end and at tail end with a normal length of 31.6 m. Billets get cooled on cooling bed and are lifted by magnetic cranes for stacking in yard and for onward supply to wire rod mill. Saleable billets are loaded onto wagons/trailers by magnetic cranes for dispatch. The billets for bar mill are sent through bar mill reheating furnace and transported with a speed of about 2m/sec to the in-line two strand RH furnace via a switch arranged in front of RH furnace. The bar mill consists of three groups, comprising an eight stand roughing train, 2x5 stand intermediate train, and 2x4 stand finishing train. The output from the finishing

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trains is cut into the cooling bed lengths by rotary shear. The products are cut to required length and are bundled at finishing area of bar mill for shipment. Billets meant for wire rod mill and for sale are taken to billet storage yard through two turn over type cooling beds. The products of bar mill are rounds, reinforcement bars. The mill incorporates Material tracking through online system (SAP/PPC) along with heat identification / colour coding facilitates product identification and traceability, walking beam furnace temperature control facilitates the heating process depending on the grade of the material, rolling process stage wise size control facilitates finished product size control, tempcore process of controlled cooling facilities and quality inspection facilities for the production of quality output and branded reinforcement bars. The MOU’s with EMD, RS&RS, DNW, WMD, L&H etc; controls the quality of Mixed gas, Rolls, Guides, power, water, lub& hydraulics etc; respectively received as input to the mill. The following special safety features are provided in addition to the general safety provisions in LMMM: All normal operations of the mill are done from control pulpits which are enclosed and air conditioned making them free from noise, dust and heat. Concrete barricades are provided near shift office-2, to prevent cobble material reaching the shift office. Furnace gas lines are provided with auto shut off valves, which are closed automatically on emergency. Auto Nitrogen purging is provided in gas line of WBF (Walking Beam Furnace) & RHF(Roller Hearth Furnace) to avoid back firing in the gas lines. Automatic fire fighting system (foam flooding system) is provided for oil cellars. Battery backup for electromagnetic lifting cranes are provided to prevent the falling of material in the case of power failures. Cobble detection schemes are provided to initiate the chopping and closing of snap shear, to avoid spreading of cobble material to more areas. All equipments are provided with various safety interlocks and devices. SBM : SBM is at an elevation of 5 m level except the charging tables and coil line which are at 0 m level, consists of total 21 stands of which 6 are roughing stands, 6 are intermediate stands, 6 are pre-finishing stands and 3 are finishing stands. The mill is envisaged to produce 7,50,000 T of plain rounds of size from 20 mm to 45 mm, with provision to roll 16 mm and 18 mm, both in straight and coil form. The input material is continuous cast blooms of 150 x 150 mm of cross section and 12 m of length, 2.15 T of weight, from SMS-2 Continuous Casting Dept. carried by magnetic cranes and placed on the charging tables of SBM at 0 m level. The blooms are elevated to 5 m level by the elevator equipment and placed on the charging roller tables. The defective blooms can be identified and is ejected from charging roller tables using billet ejector arm. The blooms are charged in to reheating furnace through the charging door by the charging rollers, which are inside the furnace. The reheating furnace is walking beam type and uses mixed gas for fuel and indirect water cooling system for cooling skids, charging rollers and doors. The walking furnace is equipped with air recuperators, for waste gas heat recovery from flue gas, which pre-heats the combustion air from combustion fans before combustion. Inside the furnace the blooms can be heated up to the rolling temperature of around 1200°C. The heated blooms are discharged from furnace through the side discharging door and are send to the roughing train of the mill for rolling process. The blooms are rolled in six roughing strands, six intermediate stands, 6 finishing stands and 3 finishing stands. Head cut of bloom is done in

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pendulum shear if required before entering the stand-1. There are shears installed at entry of first intermediate stand, first pre-finishing stand and first finishing stand for head cutting, if required, chopping in case of emergency and cobbles. The number of intermediate and pre-finishing stands in line varies depending upon final size requirement of the bars. Before the stock is fed into finishing stands, it is passed through PQS cooling stretch 1 & 2, for enabling low temperature rolling in finishing stands. After final rolling the bars are cooled in cooling stretch-3 and are either sent to bar line or coil line. In Bar line, bars are cut in dividing shear and sent to cooling bed for cooling. From cooling bed the bars are shifted to roller table by chain transfer system and then cut to final required size in cold shear. Finally, the bars are bundled together in 2 sets of bar bundling machines and sent to Bar storage yard for stacking and dispatch. In coil line, the bars are coiled in three numbers of garret coilers. The coils are placed on walking beam type coil transfer system in which it is cooled by blower fans. The coils are then tilted and placed on power C- hook conveyors and then finally compacted and strapped in three number of compactor machines after which it is transferred to coil storage yard for storage and dispatch. All control operations are done from control pulpits, which are enclosed and air-conditioned making them free from noise and dust. PLC based control system is provided for reheating furnace with nitrogen purging system and interlocks for closure of shut-off valves in case of emergencies/ interruption. Emergency overhead water tank with diesel pump back-up will cater to furnace cooling and emergency needs in case of power trip and pump house trip. Process control/ PLCs are having inbuilt safety interlocks to prevent damage of equipment and working personnel’s. Area wise loudspeaker announciation and inter-com systems are provided for communication of problems and emergencies. Wide network of fire and drinking water with fire hydrants at various locations are provided in mill and cellars to deal with possible fire accidents. All cranes and other equipments are provided with safety interlocking devices. Wire rod mill consists of WRM & Wire Rod Mill-2 (WMR-2), covered under QMS, EMS, EnMS and OHSAS. Wire Rod Mill (WRM) is a 5.38 m level, high speed, continuous mill designed to produce 850,000 of wire road coils. It consists of 4 strands x 7 stand roughing mill, 4 strands x 6 stand intermediate mill, 4 strands x 2 stand each pre-finishing group and 4 strands x 10 stand each finishing group, total 61 stands. The mill is equipped with pre-finishing blocks, morgan finishing blocks incorporating no twist rolling, stelmor line with controlled cooling and power and free hook conveyors for handling wire rod coils. The mill is designed to produce plain wire rods from 5.5 mm to 14.0 mm. dia in coil form and rebars in 8, 10 and 12 mm dia., from rolled billets of 125 ± 3%mm. x 125± 3% mm. x 98000-104000 mm, rhombodity : 3.5%. The billets received from billet mill (LMMM) are placed at +0.00 level by magnet crane on charging grid I and II through on-line inspection for quality traceability of heat number. The billets deposited are moved towards billet cross transfer which takes over individual billets and carries them to billet elevator. Billets elevator takes the billets one by one to the mill floor situated at +5.350 m level. Billets are transported to the reheating furnace by means of the furnace approach roller table. The walking beam of furnace collects the billets from roller table and charges them into furnace for reheating. The billets are heated as per the grade & size following process parameters document. The reheating furnace at WRM Mill consumes mixed gas for reheating of blooms in reheating furnace. The reheating furnace is walking beam

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type uses indirect cooling water for cooling of furnace skids and posts. During the cooling of skids and post, the indirect cooling water is cooled in cooling tower and returned as cooling water. The walking beam furnace is equipped with Waste heat recovery system for recovering sensible heat of hot flue gases and air recuperartor and gas recuperartor is installed for recovering waste energy, with this, the furnace is supplied with hot air and hot gas. Once rolling temperature is achieved, the billets are discharged into groove of mill stand no.1. A four position shiftable billet switch feeds the billets to the 4 strands of the mill individually. The roughing mill comprises of seven continuous 4 strand horizontal two high stands. The pass design is oval-round sequence. Four rotating crop and cobble shears are provided after stand-7, one for each line. The intermediate group comprises of 6 two high horizontal stands. The stock is reduced to 21-23 mm. round. This is fed to 4 individual finishing lines. The stock is reduced to 17-19 mm. dia in the prefinishing blocks. The stock passes through water cooling stretch for partial cooling before final rolling. Horizontal loopers are provided before prefinishing blocks for tension free rolling. 10 stand no twist finishing blocks are used for final rolling of wire rods. In process checks are carried out for expected stock outputs at various stages and final dimension of wire rods. All the 10 stand finishing blocks are used for 5.5 to 6.5 mm. size wire rod rolling, for 7 to 8 mm only 8 stands are used, for 9 to 10 mm. only 6 stands are used and for 12 and for 14 mm only 2 stands are used. After final rolling, wire rods are cooled in stelmor cooling system by setting cooling parameters as per the supplied grade. The quality of the rolled product depends on the heating, rolling & cooling effects the final mechanical & metallurgical properties of wire rods with respect to their tensile strength, yield point, drawability and the physical properties affects the surface quality of end product. The coils are formed in coil forming chamber. The coils are loaded onto C-hook. A total of 180 hooks are provided for handling the production. The C-hooks are carried by a power and free hook conveyor circuit. The coils are compacted and tied at automatic compacting and tying machines. The size and mechanical properties are tested and the appropriate grade is fed to the production control computer at express lab. Identification labels and colour code are attached to the coils as per declared grade taking reference from production control computer and display units. The coils are stacked with the help of EOT magnet cranes. All controls operations are done from control pulpits, which are enclosed and air-conditioned making them free from noise, heat and dust. Microprocessor based control system is provided for reheating furnace with interlocks for closure of shut off valves in case of emergencies/ interruption. Process control computer/PLCs are having inbuilt safety interlocks to prevent damage of equipment and injuries to working personnel. Area wise annunciation is provided in all control pulpits/ECR to indicate problems/emergencies. Wide network of fire and drinking water system with fire hydrants at various locations are provided in the mill and cellars to deal with possible fire accidents. Automatic fire fighting pump house (foam filing system) is provided for all cellars with back up diesel pumps to deal with power failure situation. Fire detection alarm systems are provided in ECRS and cable tunnels. Fire check doors are provided for cable tunnels. All cranes and other equipment are provided with safety interlocking devices. Wire rod mill-2(WMR-2) is at +5.50 m level, high speed, continuous mill designed to produce 600,000 tons of wire rod coils. It consists of a single strand x 6 stand Fast Roughing mill( both Vertical & horizontal), 2 strands x (6+4) stands intermediate mill, 2 lines of 2 stands each of pre-finishing group, 10 stand each finishing group(

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NTM) & (2+2) stands of each RSM, total 30 stands for each line. The mill is equipped with pre-finishing blocks, finishing blocks incorporating no twist rolling, stelmor line with controlled cooling and power and free hook conveyors for handling wire rod coils. The mill is designed to produce plain wire rods from 5.5 mm to 20.64 mm. dia in coil form, from SMS-2 caster blooms of 150 x 150 x 12000 mm. However, Rolled Billets of 125 mm x 125 mm from Billet Mill (LMMM) square cross section & length ranging from 9.9 m to 10.4 m also can be rolled as per mill builder. The blooms are received from SMS-2 placed at +0.0 level on 3 Nos. of Charging Grids in the BSY by magnetic cranes after inspection for quality & traceability of heat number. The blooms deposited and moved on the Grid towards LLBRT at 0.0 mt level and transferred to it for forwarding them to the Elevator one by one. At the Elevator Blooms are lifted to the +5.7mt level FART. Billets are transported to the reheating furnace by means of the furnace approach roller table (FART). The charging roller table of the furnace collects the blooms from the approach roller table and charges them into furnace for reheating after ensuring measured length of the blooms. The blooms are heated to rolling temperatures of 1050 to 1200° C as per the grade & size of the output as per process parameters. The reheating furnace at WRM-2 consumes in-house generated mixed gas for reheating of blooms. The reheating furnace is walking beam type uses indirect cooling water for cooling of furnace skids and posts. The return indirect cooling water is cooled in cooling tower and recirculated as cooling water in a closed circuit. The walking beam furnace is equipped with Waste heat recovery system for recovering sensible heat of hot flue gases using an air recuperator installed in the flue duct. Thus, the furnace is supplied with hot air and Mixed gas for combustion to achieve rolling temperature. The blooms are discharged using discharging roller tables to Stand no-1 (vertical) of the FRM, through the De-scaler, SSIRT, Pinch roll & pendulum shear. The roughing mill comprises of six continuous vertical & horizontal two high stands alternatively. The pass design is Box-Boxoval- round sequence. The stock size is reduced to 73 round by gradual reduction in the roughing group. A rotating 950mm shear is provided after stand-6 followed by a TSIRT to feed either strands of the two strand, 10 Horizontal stand intermediate mill group. The bar from Intermediate mill is fed to individual lines starting with 2 stand pre-finishing mill, 8 stand no twist mill and four stand reducing and sizing mill (V configuration modules) alternately in line A and line B. The process from intermediate mill is a continuous rolling process with provision for chopping and cropping at shears located in intermediate and no twist mill areas. The process line is also equipped with pinch rolls before pre-finishing, no-twist mill and after reducing sizing mill for rod feeding, complemented by Loopers for tension free rolling. The stock is reduced to 21-23 mm. round after Stand-16. The stock is further reduced to 17-19 mm. dia in the prefinishing blocks. The stock passes through water cooling stretch and covered equalizing troughs for partial cooling & normalizing before final rolling. Water cooling boxes are located between No-twist mill , Reducing sizing mill & Laying Head for controlling the temperature of feed stock during the rolling process. In process checks are carried out for expected stock outputs at various stages and final dimension of wire rods. As per the output size required the stands of the NTM & Intermediate Mill are put into line or bypassed using dummy stands/ inserts. The finished wire rod from reducing & sizing mill is made into coil form at inclined laying heads and further handled on stelmor roller conveyor by setting cooling parameters as per the grade under rolling. The controlled cooling process is achieved by stelmor cooling conveyor where coiled wire rod loops are cooled with air using optiflex system. The coil is formed at the end of the stelmor in coil forming station

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with the support of ring distributor provided in the forming stations. The formed coil in free form is collected at twin mandrel station and is transferred to a waiting hook by a transfer car at the zero level of the mill. The Hook conveyor system is provided for handling the free coils formed at coil forming station passes through various processes like trimming, compacting, weighing and tagging before delivering the finished coils to unloading stations for further handling and shipping. The hooks are driven /carried by three sets of power and free hook conveyor circuits. The quality of the rolled product depends on the heating, rolling & cooling which effects the final mechanical & metallurgical properties of wire rods with respect to their tensile strength, yield point, drawability and the physical properties The size and mechanical properties are tested and the appropriate grade is fed into the system at the metallurgical lab located in finishing area beside Mill bay at the zero level. Identification labels and color code are attached to the coils as per declared grade taking reference from the system/process control computer and display units. 6 Nos. of EOT cranes for carrying out material handling activities are provided in the Mill, Furnace & Roll shop areas. Another 6 Nos. of RT Magnetic cranes are provided for handling of coils for stacking & loading in the shipping bay. Dispatches are coordinated with Traffic, Marketing &PPM for yard management to keep the mill rolling without space constraint. All cranes and other equipment are provided with safety interlocking devices. The Plant is equipped with Roll Shop in a separate bay for turning and grinding of roll grooves, rings & guide rollers. It has facilities & equipment for servicing of stand housings both for housing less stands and high speed areas. A facility for servicing of guides and work shop for carrying out repairs of equipment is also provided. 6 Nos. of lubrication systems, 10 Nos. Hydraulic systems, 4 Nos. of Oil-Air systems, 5 Nos. of Grease Systems & 1 No. Descalar Pump house are located in Cellars provided for various plant equipments located at 0.0mt level & sub-zero level in the main mill bay. Electrical Power & control equipments are provided in Electrical Control Rooms I & II. ECR-I caters to Furnace and Mill equipments and ECR II for Finishing & Dispatch Area Equipments. ECR-I is located outside the Mill bay consisting of four floors along the intermediate & high speed mill area. ECR II is located in finishing area beside Mill bay in Single Floor at the zero level finishing mill area. 3 Nos. of Control Pulpits are provided for the Furnace, Mill and Finishing Areas for various groups of equipments. All controls operations are done from control pulpits, which are enclosed and air-conditioned making them free from noise, heat and dust. PLC based control systems provided for reheating furnace with interlocks for closure of shut off valves in case of emergencies/ interruption. Process control computer/PLCs are having inbuilt safety interlocks to prevent damage of equipment and injuries to working personnel. Area wise annunciation is provided in all control pulpits/ECR to indicate problems/emergencies. Wide network of fire water system with fire hydrants at various locations & portable extinguishers are provided in the mill and cellars to deal with possible fire accidents. Dedicated automatic fire fighting pump house with back up diesel pumps to deal with power failure situation is provided. Fire detection alarm systems & CO2 flooding system are provided for the cellars. Clean Agent flooding system along with Intelligent Addressable Microprocessor based automatic fire detection and alarm system (FDA) with state of art and technology with fire alarm panel (FAP) each in ECR-1 & 2 along with repeater panel has been provided for the ECR’s. The cable tunnels are provided with FDA system along with portable fire extinguishers for fire fighting. Fire check doors are provided at various points for cable tunnels.

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Medium merchant and structural mill consists of MMSM and Structural Mill (STM), covered under QMS, EMS, EnMS and OHSAS. MMSM is a single-strand continuous mill provided with two walking beam type reheating furnaces connected with a chimney, 8 stand roughing mill, 6 stand intermediate mill & 6 stand finishing mill, double sided rake type cooling bed, on line straighteners and cold saws. The mill is envisaged to produce 8,50,000 tons of merchant and structural products. It is capable of rolling medium merchant size rounds, squares, flats, equal angles, unequal angles, T-bars, channels and IPE and HEA beams. The mill incorporates facilities for rolling universal beams. The input for the mill is 250 x 250 mm, continuous cast blooms of 6 m length from SMS-2 are also being used now as an alternate input. In addition to this 200X200mm continuous cast blooms of 12 m length from SMS-1. The cold blooms are charged in walking beam reheating furnace to heat up to the rolling temperature i.e. 1200o C. The reheating furnace consumes mixed gas for reheating of blooms in reheating furnace. The reheating furnace uses DM water for cooling of furnace skids and posts. During the cooling of skids and post, the DM water is recirculated and the furnace is equipped with evaporative cooling system for generation of process steam. The process steam generated can be used for driving steam turbine for running ECS pump in case of emergency and in normal circum stances, the process steam recovered is sent to plant process steam network. The walking beam furnace is equipped with Waste heat recovery system for recovering sensible heat of hot flue gases and air recuperartor and gas recuperartor is installed. The heated blooms are fed into the mill and rolled through roughing mill train (RMT), intermediate mill train (IMT) and finishing mill train (FMT) to get the desired profile as per rolling programme of that particular profile. The maximum speed of mill is 9 m/ sec. The material coming out of exit stand is cut into multiples of 12 m. (customer length in general) and is cooled in cooling bed which is designated as RHS (right hand side) and LHS (left hand side). The cooled material on cooling bed is sent to batching through straightner (for structural’s) and directly in case of merchant products. The finished products are cut into customer length at cold saw and sent to piling in case of structural’s and squares and to bundling in case of rounds. The products are piled / bundled to a maximum weight of 9 tonnes and sent to collecting grid. Color coding is done as per the grades rolled and tags are fixed to identify the material. Then these are lifted by EOT cranes and stacked for shipping and dispatch. Electricity is consumed in running of combustion air fans, rolling mill strands, ventilation systems, hydraulic pumps. Lighting systems. On line PPC system is in place for product identification and traceability of products right from bloom stage to the packing, stacking and dispatch stage. This user friendly system enables data entry in First in First out (FIFO) manner thus helps maintain data integrity and avoid quality mix up. The Implementation of Maintenance Management System (MAMS) ensures availability of equipment through systemization of maintenance planning activities and systematic analysis of breakdowns for avoiding recurrence. Implementation of Strapping of finished products brought in improvement in quality of packaging and dispatching. On-line rolls management system (ROMANS) is installed for On-line information of rolls data, cassettes data to facilitate in strategic decision making related to technological requirement of pass/cassette/section changing. Due to the installation of PLC in furnace control, efficient & uniform heating process in the re-heating furnaces through dynamic air-gas ratio correction system with respect to varying calorific value of mixed gas is achieved. The following special OH&S features are

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provided in MMSM in addition to the general OH&S provisions: CO2 flooding systems 1 and 2 are provided to fight any fires in the oil cellars. High pressure water system is provided for fighting fire in the lub oil enclosures. The furnace is provided with safety interlocks. The mill trips in the case of lubrication oil failure. Interlock is provided for the cooling bed so that in case of any tripping of equipment of cooling bed, further material feeding is stopped (800 KNS goes into chopping mode). The saw areas, batching areas and piling areas are provided with safety interlocks. All cranes and other equipment are provided with safety interlocking devices. Structural mill (STM), is a single-strand continuous mill provided with one walking beam type reheating furnace of capacity 200 Tons/hr, 7 stand roughing mill in H-V configuration, 5 stand intermediate mill & 5 stand finishing mill, with H-V-U configurations each, a double sided rake type cooling bed, on line strengtheners ,cold saws and stackers The mill is envisaged to produce 7,00,000 tons per year of structural Products with a provision to produce 8,50,000 tons per year in future. It is capable of rolling medium merchant size rounds, squares, flats, equal angles, unequal angles, T-bars, channels and IPE and HEA beams. The input for the mill is 200 x 200 mm, continuous cast blooms of 8 to 12 m length from SMS. The billets received from SMS are placed at +0.00 level by magnet crane on the three charging grids.. The blooms deposited are moved towards the elevator. The elevator takes the blooms one by one to the mill floor situated at +5.0 m level. Blooms are transported to the reheating furnace by means of the furnace approach roller table. The cold blooms are charged in walking beam reheating furnace to heat up to the rolling temperature i.e. 1200˙C. The reheating furnace consumes mixed gas for reheating of blooms in reheating furnace. The walking beam furnace is equipped with Waste heat recovery system for recovering sensible heat of hot flue gases and recuperartor is installed. The heated blooms are fed into the mill and rolled through roughing mill train (RMT), intermediate mill train (IMT) and finishing mill train (FMT) to get the desired profile as per rolling programme of that particular profile. The maximum speed of mill is 12 m/ sec. The material coming out of exit stand is cut into multiples of 12 m. (customer length in general) and is cooled in cooling bed which is designated as RHS (right hand side) and LHS (left hand side). The cooled material on cooling bed is sent to batching through straightner (for structural’s) and directly in case of merchant products. The finished products are cut into customer length at cold saw and sent to stacker for stacking. The products are strapped and sent to collecting grid and tags are fixed to identify the material. Then these are lifted by EOT cranes and stacked for shipping and dispatch. Here in STM, the Roll Shop is attached to the Mill. It caters to the requirement of roll pass design, Roll turning, Stand preparation and guide assemblies. It is equipped with sophisticated CNC Lathes, CNC Milling m/c’s, Branding M/c etc. The above mills are provided with reheating furnaces suitable for firing mixed gas (mixture of blast furnace gas, coke oven gas and converter gas). The furnaces in LMMM are also suitable for firing low sulphur heavy stock (LSHS) or furnace oil. The flue gases from the furnaces are let out into the atmosphere through 4 nos chimneys. The direct cooling water used for cooling the rolled products in WRM, LMMM, MMSM, WRM-2 is contaminated with oil / grease / scale and is collected in the scale pit of pump house no.12 where the scales are separated, collected and transported to sinter plant as feed material. The floating oil is skimmed, collected

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and processed in oil reclamation unit. The treated water from the clarifier is cooled and recycled. Roll shop & repair shop (RS&RS) is a prime service department to the Rolling Mills LMMM, WRM & MMSM and is covered under QMS, EMS, EnMS and OHSAS. It caters to the requirement of roll pass design, roll set assemblies, guide assemblies and repairs / manufactures of mechanical spares to all the three rolling mills. It comprises of the following : - Roll shop-I which caters to the requirements of LMMM & WRM - Roll shop-II which caters to the requirements of MMSM - Area repair shop which caters to the spares requirements of all mills. Roll shop & repair shop has been built to exacting international standards in design and engineering with the state of the art technology which includes the following salient technological features : * 12 nos of CNC heavy duty roll turning lathes * CNC Notch milling machine to make notches on rolls for rebar rolling in LMMM * CNC Template milling machine to make accurate templates for final inspection of

roll profiles and mill setting. * Guide rollers grinder to machine the WRM guide rollers with high accuracy. * Two numbers of branding machines to mark VSP logo on rolls of finishing stands

for re-bar rolling in LMMM & for structural rolling in MMSM The different wastes generated during the operations, viz, Ferrous & Non Ferrous scrap, lead acid batteries, used rubber seals, oil soaked cotton waste and used oils are disposed in an environmental friendly manner. Sun light is being used in the shop floor to the maximum extent possible by installation of transparent sheets on the roof top.

Thermal power plant (TPP) and blower house, covered under QMS, EMS, EnMS and OHSAS, produces high pressure steam, electric power and cold blast for the blast furnaces. The estimated power requirement for VSP is 490 MW at 6.3 MT stages, the peak load being 500 MW and essential load being 80 MW. The generating capacity is 520MW, comprising of 315 MW from Main TPP 120MW from PP2, 24MW from gas expansion turbine, 15MW from Back Pressure Turbine Station, 20MW from NEDO, 14 MW from COB4 and 13 MW from TRT. Apart from meeting part of the power requirements, the power plant and blower house supply cold blast air to blast furnaces and steam at 13KSCA and 4KSCA to the plant. TPP has 3 turbo generator units of 60MW each and two units of 67.5MW, 3 turbo blowers each having a capacity of 6067 NM3/min, one turbo blower having a capacity of 7000 NM3/min and 6 boilers each of 330 T/hr capacity at 101 KSCA at 540oC. The steam generating sets are of multi-fuel firing design and the rating of each steam generation while firing various fuels is 100%MCR with pulverized fuel and coke oven gas, 50% MCR with blast furnace gas and 25% MCR with fuel oil. The power produced can be synchronized with the power grid of Andhra Pradesh Transmission Corporation. The unit supplies power to emergency units in case of failure of external power supply. The high pressure steam produced in this unit is for meeting the requirements of turbo blowers and turbo generators as well as for other process requirements in the steel plant. Thermal Power Plant and blower house has six high pressure boilers, five turbo generators and four turbo blowers. The boilers are multi fuel type, suitable for firing with coke oven gas, blast furnace

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gas, furnace oil and coal. A number of other facilities like water system, ash handling system, flue gas handling system etc. are provided. Furnace oil is used for flame stabilization and High Speed Diesel (Diesel) is used during startups of Boilers. Part of the High pressure steam generated at Boilers is sent to Turbo blowers for generation of blast air and remaining steam is sent to Turbo generators for generation of electricity. The Steam Turbines are envisaged with Condensing and Extraction type and process steam of 13 ata and 4 ata is extracted. 13 ata steams extracted from Steam Turbines partially used internally in Power Plant and remaining sent to Plant process steam network to meet requirements at CO, BF, SMS, Mills and ASP. 4 ata Steam extracted from Steam Turbines is used for Demineralised Plant for production of DMDA water for make up in Boiler feed water circuit and CDCP boilers. Chilled water plant -2 operates on vapor absorption system use 4 ata steam extracted from steam turbine for generation of chilled water. Steam is cooled in condenser and Cooling water requirements are met from Pump House-4. Electricity is used for driving of motors of rotating machinery like Boiler feed pump, Primary Air fan, Coal Bowl mills, Induced draft fans, Ash Slurry pumps etc. The auxiliary units comprise of 16 nos of waste heat boilers which produce steam by recovering heat from hot nitrogen in coke dry cooling plant, 2 nos of back pressure turbo-generators and one number condensing type turbo generator generating power from the above and 3 nos of gas expansion turbo-generators generating power by expansion of blast furnace top gas. The boiler quality water is produced in the dematerialized (DM) treatment plant. During the production of DM water, acidic effluents are generated which are collected and neutralized before discharging into the storm water drain. The flue gases from the high pressure boilers are cleaned in electrostatic precipitators to a final dust content of below 50mg/Ncum and vented through a 180 m tall multi-flue chimney. The fly ash and the bottom ash from the thermal power plant and blower house is collected and conveyed through a wet system to the ash slurry pump house from where it is pumped to the ash pond located outside the plant boundary wall. The water so contaminated is about 1500 cum/hr (8 mgd). The clarified water from the ash pond is pumped back to the thermal power plant for ash handling. Power plant 2 consists of two BF gas fired boilers and one condensing type turbo generator of 120 MW along with associated equipment. The following special OH&S features are provided in TPP in addition to the general OH&S provisions: The boilers are provided with safety valves and furnace safe guard supervisory system. The turbines and blowers are provided with over speed and high vibration protection. The generators are provided with automatic CO2 flooding system, differential and earth fault protection systems against fire and short circuits. The lube oil cellars are provided with automatic CO2 flooding system. The cable cellars are provided with water sprinkler system. A separate fire fighting pump house is provided. Fire detection and alarm systems are provided in important areas. All operations are carried out from air conditioned control rooms. Distribution Network Department (DNW), covered under QMS, EMS, EnMS and OHSAS, handles power at 220KV, 33KV and 6.6 KV levels. Power at 220KV level is received from AP TRANSCO at Switching Station of DNW. Power is further extended through three numbers of 220 kV cable feeders to Main Receiving Station (MRS) of DNW and from Thermal Power Plant (TPP) at Load Block Step down

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Substation-5 (LBSS-5). MRS is inter-connected through the Tie Lines with LBSS-5 i.e. TPP switchyard. The power generated in TPP at 11KV level is stepped up at 220KV level and synchronized with AP TRANSCO grid supply. Power is distributed to various plant units at 33KV, 11KV and 6.6KV levels through LBSS-1, LBSS-2, LBSS-3 LBSS-4, LBSS-6 and LBSS-7 by DNW department. Switchgear equipments of 33KV, 11LV and 6.6KV are housed in substation buildings whereas the outdoor equipment of 220KV and 33KV are surrounded with boundary walls to prevent un-authorized entry. All the circuit breakers and isolators are provided with safety interlocks. Fire detection & alarm system is provided in substations. DNW department maintains equipment related to power distribution up to 6.6KV to the plant units in close conjunction with Thermal Power Plant and Andhra Pradesh Eastern Power Distribution Co. Ltd. During the process of maintenance used transformer oil and used lead acid batteries are generated. It collects and stores the used transformer oil and used lead acid batteries for further disposal. Periodic reports are sent to EnMD department as required by the Hazardous Wastes (Management, Handling and Transboundary movement) Rules, 2008, and amendment thereof& Batteries (Management & Handling) rules, 2001. Energy management department (EMD), covered under QMS, EMS, EnMS and OHSAS, undertakes monitoring and distribution of various fuel gases produced in the steel plant as well as various utilities like nitrogen and chilled water through the SCADA system. EMD also operates the BF gas cleaning plants, converter gas recovery plant, CO gas boosting station, gas mixing stations and central fuel oil station. EMD also have the flare stacks for coke oven gas and blast furnace gas under its control. EMD monitors overall Energy consumption of plant and advise all departments on proper course of action on energy conservation. EMD ensures optimum distribution of fuels and utilities and try to minimize fuels and utilities losses. Further, EMD consumes electrical energy in running of booster fans at COGBS and LDGRP and pumping system at GCP-1&2. Electricity is also used in lighting system. The following special OH&S features are provided in energy management department in addition to the general provisions: LD gas recovery plant consists of a gas holder of 80000 m3 capacity, gas boosters and electrostatic precipitators. It is provided with necessary safety features like interlocks for high and very high level and low and very low level and high pressure. The gas boosters are provided with safety features viz., bypass across the booster and tripping of booster in case of abnormal conditions sensed through instrumentation. Similarly the electrostatic precipitators are also provided with safety interlocks for abnormal operating conditions sensed through instruments. The gas mixing station no.5 is also provided with alarms and annunciations. The blast furnace gas cleaning plants BFGCP-1 and BFGCP-2 are provided with various safety signals like failure of water supply, failure of water seal in scrubber and high differential pressure across venturies. The coke oven gas boosting station has low pressure booster and high pressure booster. These are provided with various safety interlocks and alarms for abnormal conditions like low suction pressure, booster vibration high, discharge pressure high and failure of cooling water supply. The energy management department also takes care of gas pipeline network of BF gas line, mixed gas line and coke oven gas line. These lines are provided with drip pots and nitrogen injection facility when the line pressure is low. The pipelines are also connected to BF gas flare stack and coke oven gas flare

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stack. In case of low pressure in the gas line, certain consumers are cut-off automatically. Lubrication and hydraulic department (L&H), covered under QMS, EMS, EnMS and OHSAS, renders service to all the user departments in the plant by arranging supplies of required types, quantity of lubricating/ hydraulic oils, greases, hoses, O-rings & oil seals for effective running of the plant. It stores and issues lubricants and hydraulic oil to consumers (bulk oil management), collects used lubrication and hydraulic oils from various departments, operates and carry’s out reclamation of collected used oils for reuse in various identified units (used oil management) and maintains the oil reclamation unit, various hydraulic equipment & lifts. Checking the correctness of the specification & up gradation of specification in line with technological developments are carried out to procure quality inputs. Centrifuges, oil purification system, on-line contamination checking (6-channel), condition monitoring for all large centralized critical hydraulic systems are employed in reclamation process. It stores the waste lubricants and hydraulic oils, oil sludge, de-toxified empty drums and grease barrels for further disposal in accordance with the hazardous wastes (management & handling) rules, 1989 as amended up to 2003. Utilities department: The utilities department, covered under QMS, EMS, EnMS and OHSAS, operates and maintains the following units: a. Air separation plant: I, II, III, IV for generation and distribution of oxygen, nitrogen

and gaseous argon. b. Compressor house: I, II for supply of compressed air, Instrumentation air & dry

air. c. LPG d. Chilled water plant: III, IV, V, VI &VII for supply of chilled water for air conditioning. It also undertakes filling & issue of gaseous Oxygen, Nitrogen, Argon. It procures LPG as per requirement of CCD and also supplies LPG cylinders to various maintenance sections. The utilities department also controls the consumption / leakages and phasing out of the ozone depleting substance (ODS) and takes necessary action for complying with the ‘Ozone depletion substances (regulation and control) rules, 2000. Air Separation Plants (ASU 1, 2, 3, 4) Atmospheric air is compressed in air compressors to 7.4 Kg/Cm2. Compressed air is pre-cooled to 100c with the help of refrigeration unit and air water tower. The compressed and pre-cooled air is purified to remove traces of moisture and contaminants. It is then cryo cooled using expanders and heat exchangers to the temperature of – 178 deg. C. It is then distilled in the ASP cold box and fractions of liquid nitrogen, liquid oxygen, liquid argon, gaseous oxygen and gaseous nitrogen are produced. The gaseous oxygen and nitrogen are compressed in separate compressors and sent to their consuming sections. Air separation plant uses electricity for rotating machinery like Feed air compressors (air separation), Oxygen compressors, Nitrogen compressors, Pumps, Turbines etc. The Air separation unit -4 employs a similar cryogenic distillation process, but its columns are of structured

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packing type compared to ASU 1, 2, 3 which are of tray type. The process cycle is almost the same. The most significant aspect is that high pressure gaseous oxygen is obtained at the downstream of heat exchanger itself and does not require further compression. Also high pressure gaseous argon (17 kscg ) can be obtained at the downstream of heat exchanger itself which can be used to feed SMS-1 and SMS-2 for combined blowing. PRMS I & II and PRS-III. The oxygen separated at Air separation unit is compressed as per process requirement at SMS for blowing and at BF for enrichment of blast.. In the oxygen pressure reducing and metering stations (PRMS I & II and III), compressed oxygen gas is stored in buffer vessels and also transferred to the utilizing sections through pressure reducing and metering valves. PRMS – I caters to SMS-1 , PRS-III to SMS-2 and PRMS-2 caters to the autogenous needs all over the plant. Oxygen is supplied through pipelines to various consumers to meet process requirements. Oxygen is also supplied to scrap processing yard for cutting of scrap. Similarly, Nitrogen separated is compressed to desired pressure and supplied to Blast Furnace Nitrogen Control station to meet the paul worth gear box cooling requirements, makeup in CDCP chambers, Ammonia Sulphate plant, Slag Splashing system in Steel Melting shop and purging of gas lines. The Liquid Oxygen, Liquid Nitrogen and Liquid Argon are also stored in storage tanks. They are subsequently filled in portable cylinders and sent to various consumers. There are two compressor houses for supplying compressed air and dry air(instrument air). The compressed air is segregated in to various consumers and these are operated at various pressures depending upon the process requirements. Chilled water plants (CWP-3, 4, 5, 6, 7) There are five chilled water plants which operate with vapor compression principle and uses R-134 A as refrigerant. Electricity is used for running of chillers’ and other associated equipment. Chilled water plant -3 meets the cooling requirement of SMS-I, ASP and rolling mills. Chilled water plant -4 meets cooling requirements of central computer centre, energy & telecom building and pay & PF section. Chilled water plant – 5 meets the cooling requirements of SMS-2 and WRM-2 while Chilled water plant – 6 meets that of Blast Furnace – 3 and Chilled water plant -7 that of Sinter plant -3. Water Electrolysis Plant In the water electrolysis plant, de-mineralized water diluted with caustic is electrolyzed in series of electrolytic cells. Gaseous Hydrogen and Oxygen are the products of the electrolytic process. The oxygen produced has no specific utility and hence vented to atmosphere above the building. The hydrogen produced is purified, compressed and sent to consumption in the air separation unit. The Compressed hydrogen is also stored in two buffer vessels. LPG distribution unit LPG cylinders of 49.5 kgs capacity at 5 to 7 kscg pressure are procured from public sector oil companies. These cylinders are connected to manifolds and supplied to

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consumers at a pressure of 0.92 – 0.93 kscg through the Vapour Off Take (VOT) method. Filled Acetylene gas cylinders are also procured from outside and delivered to the various consumers inside the plant on demand. The following special OH&S features are provided in Utilities Department in addition to the general OH&S provisions: As an abundant precaution; reinforced cement concrete walls were constructed around the oxygen pressure reduction stations and oxygen compressors to minimize the effects of explosion caused if any. Safety valves are provided to all the equipment and pipelines to protect them from excess pressurization. The whole complex is fenced with barbed wire and provided with security guard to prevent unauthorized entry. For all the cryogenic liquid storage tanks rupture discs are provided in addition to duplex safety valves. Holding tanks are provided for collecting the leakages of liquid oxygen tanks and liquid nitrogen tanks. Facilities are provided for transfer of liquid from one tank to another in the event of a leakage. All the cryogenic liquid drains of air separation unit are connected to common drain stack. They are vaporized with air before letting out in to atmosphere. Clean rooms are provided for the maintenance of oxygen handling equipments. Any equipment can be approached from two sides minimum for fire fighting in the event of an out-break of fire. In emergencies, oxygen to consumers can be cut off by remotely operated quick shut-off valves. Noise hoods are provided to all compressors to bring down the noise level. Silencers are provided at various gas vents to minimize noise pollution. The following special OH&S features are provided in the LPG distribution unit: Anti spark tools are used. Ventilation is provided at ground and roof level to prevent accumulation of gas.. Nitrogen gas purging facilities for equipments/pipelines are provided. Flash-back arresters are provided at discharge manifolds. LPG pressure and flow rates are monitored carefully. In case of too low a pressure or too high a flow, alarms are generated and follow up action is initiated.RCC walls are provided in between discharge manifold cylinder racks to minimize the effects of fire/explosion. Barbed wire fencing is provided around the plant. In order to avoid rise of pressure in the piping / equipment systems, safety relief valves are provided at manifolds and pipelines. The following EnMS features are provided in the Utilities department: Structured packing columns which consume 15% less energy have been procured in the new units .Variable frequency drives are employed in most of the new equipments. Compact fluorescent lamps which are more energy efficient are used instead of normal fluorescent lamps. Energy efficient screw chillers are used . Operating strategies are tuned to operate the units at their highest efficiency range. Personnel are trained on energy efficient operating practices and energy audits are undertaken frequently. Water management department (WMD), covered under QMS, EMS, EnMS and OHSAS, receives water into the Kanithi balancing reservoir and distributes it as per the requirement to various units of the plant after required chemical treatment. The water in circulation is about 260000 cum/hr which is mainly used for cooling of equipment. The heated water is cooled in 38 nos. of induced draft cooling towers and is recycled. The water used for gas cleaning, dust separation, mill scale / fine

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particle flushing etc. gets contaminated by suspended solids and oil. The waste oil is removed by oil skimmers provided at scale pit pump housees-12,15, SMS 2 and Mills 2 Scale pit PH. The contaminated water is treated in 10 non treatment plants consisting of radial settling tanks, etc; and recycled after removing the contaminated solids. The slurry containing metallurgical wastes from treatment plants TP- 1,2,3,4,7 & 8 is pumped to a Metallurgical pond. The clarified water from the metallurgical pond is being discharged to sea. Water is used for fire fighting, equipment cooling, steam generation, drinking and sanitary use. Water management department has one reservoir for raw water and another for ash (ash pond).is recycled for use through ash pond. It has 47 re-circulating water pump houses, 10 overhead tanks, 38 cooling towers, 10 treatment plants, 13 sewage pump houses, 7 sludge pump houses, 2 nos. of filter press units etc. Plant has also 3 reverse osmosis units to achieve zero discharge goals. These plants are in very advance stage of commissioning. Plant water is treated at raw water treatment plant and is stored in two compartments, which are located at pump house-01. Make up water is supplied to different recirculation water pump houses by makeup water pipeline network. The makeup water is also sent to fire and drinking pumps which are located at pump house-02. It is further treated and stored in overhead tank and on ground reservoir. It is supplied throughout the plant by using fire and drinking water pipe network. In stage 2 waste treated water line network is there for firefighting makeup water which caters to fire fighting pump house built for individual zone. Electricity is used for running rotating machinery like Pumps, Cooling tower fans, and lighting systems. The following special OH&S features are provided in water management department in addition to the general provisions: Fire alarm signal is provided at pump house-02 where emergency fire fighting pumps are available. Chlorine leak detector is available at chlorine dozing points. For chlorine cylinders, neutralization tank is available. Dewatering pumps are installed with alarm and auto operation to take care of flooding. At acid dozing tanks, showers are available. Processes that provide Services Traffic department, covered under QMS, EMS, EnMS and OHSAS, receives raw material rakes from Railways in the pre-tippler lines of Raw material handling plant. After emptying of wagons, the rakes are handed back to Railways within the plant. Traffic also coordinates with Railways for supply of rakes required for the outward dispatch of the products. It also undertakes various rail movements inside the plant including movement of hot metal from Blast furnaces to the Steel melting shops or to the pig casting machines and pig iron from the pig casting machines to the pig storage yard. The diesel locomotives used for hauling the rakes and the captive wagons used for transporting various materials within the plant are maintained in the Loco & wagon repair shop. The installations and machinery of Traffic department are provided with inbuilt safety devices. Route relay interlocking (RRI)/Solid state interlocking (SSI) system is provided in the following areas: Blast furnace yard, Mixed goods marshalling yard, Rolling mills product sorting yard, Raw material unloading yard. All the diesel locomotives are provided with standard safety interlocks. The cranes and machines in the Loco & wagon repair shop are provided with the standard limit switches to prevent over travel. The rail-road

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crossings in the RRI/SSI areas are provided with signal lights and hooters. Diesel is used as fuel in diesel locomotives and Electricity is used in buildings, yards and the Loco & wagon repair shop. Quality assurance and technology development department (QATD), covered under QMS, EMS, EnMS and OHSAS, assures the quality of product by initiating the control activity right from input and continued throughout the process till product is dispatched to the customer for use. QA&TD is equipped with the state- of- the art instruments by which analysis activities and process monitoring is carried out at various stages during production. Quality assurance starts right from monitoring the quality of raw materials for the compliance to the purchase specification and quality of in process materials to adherence of set norms and finally the checking of the products for meeting the specification or customer requirements. Quality Assurance at VSP consists of Quality control, Process control, Failure analysis, Inspection and Testing. Chemical and Physical testing of Raw materials, Slag, Semi-finished & Finished product, and by-products are the main activities of QA&TD. Quality control deals with testing of raw materials, in-process materials and finished / semi-finished products. Process control monitors the salient process parameters to adherence of the set norms at various stages. Inspection and Testing ensures the quality of the products dispatched to the customers. Some specialized studies are carried out in the area of failure analysis, customer complaint samples of our products, input coal used in blend to initiate corrective measures required in the process. Usage and storage of chemicals are standardized in line with 5’S’ practices and ensuring minimum wastage. It also carries out analysis of water, effluents, emissions and solid wastes as per requirement of EnMD. A meteorological station installed at QA&TD monitors the weather data. The QA&TD department operates centrally from a spacious building. It is fully equipped with sophisticated instruments and laboratory rooms. Extensive facilities are provided to handle chemicals carefully. Adequate ventilation systems are provided to remove the fumes. All the instruments and other equipment are provided with safety interlocks. Research & Development department, covered under QMS, identifies, selects and handles R&D projects both internal with inhouse expertise and resources and externally in collaboration with other organizations related to design and development of new steel products. Pilot oven /pot sintering is used for carrying out R&D activities. It is instrumental in improving the process/ product quality and enhancing the brand image of the product. Instrumentation department, covered under QMS, EMS, EnMS and OHSAS, renders the services through procurement, installation and maintenance of process control equipment used in automation & control of various processes throughout the plant. The old outdated technology is upgraded with latest PLC based systems with MMI & HMI units for improvement in productivity, safety of the equipment and employees, cost and energy saving, ease of operation and optimum utilization of resources. It maintains Zonal FDA Systems spread throughout the plant which monitors the safety of the plant and equipments from fire hazards round the clock. It also maintains the weighing systems, ensuring accurate weighment of all incoming raw materials and outgoing products, by road/rail weighbridges, adhering to norms of Weights and Measures department (State Government) and internal weighing systems such as Weigh feeders, Belt Scales, Crane weighing systems and other Static weighing systems. It renders services related to standardization, calibration

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and repair of instruments throughout the plant. It ensures collection and disposal of the electronic wastes. Scrap and salvage department (SSD) covered under QMS, EMS and OHSAS, carries out the collection & processing of various types of iron and steel scrap generated in the plant and makes arrangements for supply of scrap to steel melting shops I & II by SSD as well as disposal to external customers. Different types of refractory bricks are collected by SSD and supplied to DF Bay (SMS-I), Five clay type (SMS for emergency containers) and SMS converters, Mag-carbon for patch work or transported to stores department for disposal. All the debris and solid wastes which could not be recycled or sold are transported to designated slag and debris dump located near Appikonda gate. All the hired vehicles engaged for transportation are ‘PUC’ certified. Refractory engineering department, covered under QMS, EMS, EnMS and OHSAS, helps sinter plant, blast furnace department, steel melting shop, and rolling mills in rendering repair and maintenance of refractory works in various reheating furnaces, converters relining, ladle lining continuously. Capital repair group (CRG), covered under QMS, EMS, EnMS and OHSAS, carries out refractory repair/maintenance of all relevant equipments of CO&CCP including jobs during capital repairs and also mechanical repair/ maintenance of anchorage system, gas withdrawal system, heating system and doors of coke oven batteries. CRG also specializes in providing acid proof lining to protect against corrosion in all relevant installations in coal chemical plant & refractory maintenance of benzol plant, tar distillation unit, Coke dry cooling plant, coke sorting plant etc. It is instrumental in replacing the asbestos rope with environmental friendly ceramic rope and performing effective maintenance and modifications to reduce stack emissions and fugitive emissions in coke ovens. Environment Management Department, covered under QMS, EMS, EnMS and OHSAS, keeps a close watch at the emissions and the effluents from various units. It also coordinates with the state and central pollution control boards. It acts as the nodal centre for all environmental monitoring activities and carries out the following tasks: a. Monitoring of ambient air quality with ambient air quality monitoring system,

water quality, effluent quality, stack emission with Online stack monitoring system , fugitive emissions, effluent quality, waste generation / handling / disposal, ambient noise-level and work-zone environment as per prescribed statutory norms, wherever applicable.

b. Mechanical maintenance of Dust Extraction-systems dry fog systems in various

departments Telecommunication (Works) department, covered under QMS, EMS, EnMS and OHSAS, is involved in providing & maintaining the communication network through different types of communication equipment to meet the needs of various shop floor personnel like operation, electrical, mechanical and other service departments. These communication facilities are categorized as general communication (all types of telephones) through latest OKI plant exchange & electronic EPABX systems,

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shop floor communication (broadcasting systems) and signaling (central fire alarm system), CCTV, wireless systems, central supervisory and data acquisition system and data communication network for central computer system throughout the plant and monitoring (CCVM through CCD device cameras and IP based cameras) facilities. Safety engineering department, covered under QMS, EMS, EnMS and OHSAS, closely monitors actions related to safety of plant, equipment and personnel and coordinates activities with statutory safety authorities. It advises and assists the management in the fulfillment of the obligation concerning prevention of incidents and maintaining a safe working environment. SED imparts safety training as well as refresher safety training to the regular employees as well as contractor workers. SED conducts safety inspections and co-ordinates with the department for corrective actions in respect of unsafe conditions and unsafe actions. SED conducts safety campaigns and competitions amongst the employee to promote safety. SED ensures that high quality safety appliances are procured and issued to the employees. SED has been conducting comprehensive Safety Audit, comprehensive Risk Assessment & Management (HAZOP, HAZAN, Quantitative Risk Assessment, Consequence Analysis, Hazard Analysis & Risk Assessment- HARA, Emergency Action Plan) for entire plant including the newly commissioned units and updating the On-site Emergency Plan SED co-ordinating with departments for updating Work Procedures, Work Instructions, HIRAs, Legal & Other requirements, conducting Internal & External Safety Audits, monitoring NCRs & Observations raised during the audits and follow-up for compliance. SED Conducting regular meetings with the OHSMS Co-ordinators for reviewing the status of implementation of OHSMS. Occupational health services and research centre (OHSRC), Covered under QMS, EMS and OHSAS, offers comprehensive services to all employees complying with the statutory obligations by carrying out man preventive maintenance activities like periodical medical examination of the employees, industrial hygiene surveys & services, toxicological evaluation, noise measurement studies etc. The health records of employees are stored safely for periodic retrieval and analysis. A specific coding system is developed and followed for efficient and systematic placement. Efforts are in progress to store the historical employee health data in soft form and for online working. Two, Fully–equipped, round the clock functioning Emergency Medical care units provide services inside the Plant. It coordinates emergency medical care services, provides first aid facilities and training in Health Education Programme (class-room & shop-floor based) &first aid & emergency care with the help of the training department. Two first-aid stations are located in the plant, functioning round the clock with qualified doctors, paramedical staff and ambulances. Supporting facilities for providing specialist care are available at the Visakha General Hospital. Air conditioning systems (ACS), covered under QMS, EMS, EnMS and OHSAS, department maintains water coolers and the air conditioning units required for operation of various equipments in the plant. These units consume electricity for running of this ventilation systems equipment. The latest technology such as backward curved fans, double skinned insulation, variable frequency drives for high capacity motors with motor protection relay and three way mixing valve is installed

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in air handling units to improve the quality of performance, reduce energy consumption, heat loss, noise level etc;. The refrigerant recovery unit is used to evacuate refrigerant from unit to avoid loss of refrigerant. The replacement of reciprocating compressors with energy efficient scroll compressors and rotary compressors (in case of window/split A/c) along with phase reversal protection for scroll (unidirection) compressor is value addition towards better quality of service. It controls the consumption / leakages / phasing out of ODS while carrying out the operation and maintenance of their equipment and takes actions to comply with the provisions of ‘Ozone depleting substances (regulation and control) rules, 2000’. Central Mechanical Maintenance department (CMM), covered under QMS, EMS, EnMS and OHSAS, is one of the major service departments in VSP which renders major mechanical maintenance and conveyor belt replacement activities throughout the plant. CMM services are provided through five zonal offices termed as Coke, Iron, Steel, Mills zones for the planned maintenance, unplanned maintenance and capital repairs schedules of respective zones and other equipment maintenance services through workshop. It is the first maintenance section in VSP to implement one of the best ten practices i.e; “Work Flow and control management” as part of QMS. While executing maintenance activities, as a part of concern towards environment, solid waste in the form of scrap conveyor belt is collected and sent to central stores for further disposal. This helps in earning revenue through auction of scrap belt. Engineering shops and foundry Engineering Shops & Foundry is covered under QMS, EMS, EnMS, OHSMS and all the systems are at sustenance stage. In addition to these systems, ES&F is a 5S implemented department having 640 employees and 200contract workmen. ES&F is a set up to meet the requirements of Ferrous & non-ferrous spares of different departments and for repair major equipments. ES&F is divided into 5 shops and they are Central Machine Shop (CMS), Steel Structural Shop (SSS), Forge shop (FS), Foundry (FDY), and Utility equipment repair shop (UERS). All the shops except Foundry operate on two-shift basis for 300 days in a year and Foundry operates in three Shifts. CENTRAL MACHINE SHOP: At CMS, for preparing the raw material for machining, material saws, facing and centering machines, hacksaws, and gas cutting facilities are provided. The machining section has over 100 major machines including lathes, milling, boring, and planning, slotting, shaping, grinding and other machines. The assembly section undertakes medium repair and general overhauling of mechanical equipment. Horizontal and vertical presses, washing tanks, oil berths etc. are provided. The tool room has facilities for manufacturing of special tools, jigs and fixtures, re-grinding of tools and cutter and brazing of tipped tools. The heat treatment section is provided with annealing, normalizing, tempering furnaces, carbonizing furnaces, high frequency hardening machine, quenching tanks will oil cooling arrangements, welding generator and transformers for normal welding, sub-merged arc welding machines etc. Facilities for surface grinding, pipe bending and threading are also provided. The inputs to CMS are Iron & Steel castings, forgings, rolled sections, repair and rectification parts, non ferrous castings and the products & Services of CMS, are Shafts, Pinions, Gears, Crane Wheels, Rollers, Machining

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of various fabrication jobs, Repair & reconditioning of various assembly jobs like L&T Column, TK stands, pulleys, revisioning of gear boxes. FORGE SHOP In heavy forging section of FS, open die forgings of long shafts, gear blanks, couplings etc. are being made with the help of 3 ton & 2-ton bridge type pneumatic hammers. Each hammer will be provided with twin chamber heating furnaces. Floor type manipulator and Jib Crane are provided for handling heavy jobs. In general forging section, 1 ton, 500 Kg, and 200 Kg hammers with separate heating furnaces are provided. A 2-ton drop stamp hammer with a heating furnace trimming press etc. is provided for stamping. For cutting them to size, a band saw, a cold saw, a billet shear and gas cutting facilities are provided. For stress relieving, a bogie type-annealing furnace is provided. The Inputs are Ingots from Foundry, blooms from SMS, billets, rods from Mills and higher size rounds with different material specification from outside market. The products & services are raw material for shafts, couplings, gears, pinions, flanges bull head hammers, straightening of pallet middle frames of SP, shafts, gears, drill rods for BF, v-hooks for SMS. STRUCTURAL SHOP For marking, cutting to size, forming and bending, guillotine shear, circular saw plate bender, gas cutting unit etc. are provided. For welding, transformer, automatic and semi-automatic machines and submerged arc welding machines are provided. Thermit welding process is established for repairing Slag pots of SMS using thermit mix powder. In Tool room, lathe, shaper, drilling machines etc. are provided for running repair of shop equipment. The inputs are various sizes of plates, angles, channels, beams, flats, rounds for fabrication of jobs and the products & Services are all types of fabrication jobs, repair of slag pots, tundishes, Scrap boxes, ladles, crane beams of SMS, BDH-24 fan shaft of sinter plant, KAMAG body of FMD, scrap buckets of rolling mills. FOUNDRY Foundry operates in three Shifts out of which 2 shifts are for production and third shift i.e C shift, is meant for maintaining the temperature of induction furnace. A medium frequency furnace of 2-ton capacity and a 5T capacity main frequency induction furnace are provided for cast iron jobs. There is a centralized sand preparation unit. A drier and bins are provided for green sand. Belt conveyors transport green sand, prepared mix and burnt sand. Moulds and cores are dried in 3 ovens. Lip & bottom pouring ladles with capacity up to 15 tons are provided for handling hot metal. Two swing frame grinders and two pedestal grinders are provided for finishing of iron castings. The inputs are Pig Iron, MS scrap, Ferro alloys, graphite electrodes, sodium silicate, silica sand CO2 gas, moulding additives etc. and the products & services are Steel, cast iron &non ferrous castings, Emergency containers, tundish covers, bull gear for SMS, hot metal runners, ladle paw for blast furnace, coke roll liners, sprockets, pallets for sinter plant, manganese cast steel casings like bowl liner, lower mantle for RMHP, guide troughs for WRM, slag pot segments for SSS repair, ingots for forge shop, non ferrous castings like Mud-gun nuts for BF etc. Steel castings up to maximum piece weight of 10 T and

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Steel Ingots up to 2 tons for forging are produced. An 8 Ton arc furnace and a two-ton medium frequency electric induction furnace is installed for melting of steel scrap and pig iron. A bogie hearth furnace for annealing/ normalizing of plain carbon steel castings and fixed hearth furnace for heat treatment of manganese steel castings with quenching facility is provided. The pattern shop manufactures wooden, thermo coal patterns for making moulds. The principal equipment for pattern making are saws, disc grinding, wood working lather, adequate facilities are provided for saw grinding, painting, timber and pattern storage etc. UTILITY EQUIPMENT REPAIR SHOP The inputs are sheets, plates, channels, angles, beams, billets, rounds for forge shop for manufacturing Shafts, steel & iron castings and the products& Services are manufacturing and repair of impellers, repair of GCP Id fan, repair of steam exhausters for SMS, supply of cones & ducts of various sizes, in house manufacturing of MBC impeller for CCCD, buildup& machining of various components, reclamation jobs like valve repairs, conveyor idlers, PCM rollers etc. Repair of ventilation, air conditioning and water supply equipment is carried out. There is a machining section having 15 major machines like lathes, milling, slotting, shaping and grinding machines, Sheet bending machines, Guillotine shear & semi-folding machine are provided in fabrication section. 250 kg pneumatic hammer with necessary facilities and a welding section for semi automatic, automatic and shielded arc welding machines are provided in plumbing section. There is a separate equipment repair section All shops are provided with separate Stores facility for keeping operational, electrical and mechanical spares and consumables related to their processes to meet the day to day requirements. In addition to these shops, mechanical and electrical sections are provided for mechanical and electrical maintenance requirements of equipments of all shops, for ensuring equipment availability paying timely attention to running complaints and break down and to take up-gradation and technological improvements activities to overcome the problems of obsolete equipments. Central planning section(CPS) is another section of ES&F which plays an important role in coordinating with customer departments and the shops of ES&F for scrutiny of job requirements from customer departments, preparation of monthly plan & progress, material procurement plan, issue of work orders to sections based on the requirements from Customers. Inspection of semi/ finished jobs of 5 sections, daily monitoring of jobs progress and preparation of daily production report, inter-shop and dispatch to sections, drawings control and attending to MOU meetings with customer departments are also the functions of CPS. All the jobs of customers are identified by unique work order number. Manufacturing/ repair activities are carried out as per the drawing of the job. In process inspection of the jobs is carried out by respective shop employees where as the final inspection by central planning section. Calibrated measuring instruments are used at CMS, UERS and by CPS for inspection purpose. Under EMS, at all shops ES&F waste generated is segregated type-wise and disposed at regular intervals. Waste oils are collected and returned to lubrication& hydraulic department for further process. Under OHSMS, the special features provided are fume extraction systems, safety interlocks, pressure relief and safety valves at Arc furnace, sand plant, heat treatment furnace , safety limit switches to cranes etc,. Inflammable materials are stored outside the shops necessary safety interlocks are provided to all the equipments.

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Field Machinery Department, covered under QMS, EMS, EnMS and OHSAS, renders quality services to various departments of the plant on need and schedule basis by timely deploying right vehicles/ heavy equipments/ material transportation/handling equipments. It also repairs/maintains heavy equipments, vehicles; material handling equipments like dumpers, loaders, dozers, mobile cranes etc., CISF vehicles, fire tenders, forklifts, skid steer loaders ensures availability and reliability of the above equipment to the satisfaction of the users. FMD ensures that all wheel-mounted vehicles / equipment are PUC certified. Diesel is used as fuel in various mobile equipments. Electricity is used in lighting system. Plant Design department, covered under QMS, EMS, EnMS and OHSAS, renders services to various production departments for developing drawings of equipment spare parts/assembles/sub-assemblies through Reverse Engineering for the purpose of import substitutes & proprietary substitutes and in-house manufacturing. It develops drawings for modification of spare parts/assemblies for better operational efficiency and enhanced machine availability by re-engineering, thus improving the quality of product. It also archives the developed drawings for reprographic use. The development of drawing is done by using Autocad package and white prints are produced by using wide format scanner cum printer. The developed drawings are issued to the respective departments for producing spares. In addition, it digitizes the available drawings using the wide format scanner cum printer and making it available on-line at the intranet site. All the above activities are controlled through an IT application namely “DRAWMAN” which is an Enterprise Drawing Management System. It enables for customer to place their requirement on line and get updates feedback through mail and mobile. This not only eliminates the usage of paper but also makes the drawing accessible to the user department by the click of the mouse. Technical Improvement Cell (TIC), covered under QMS, is a nodal agency for coordinating and monitoring all functions and activities related to AMR (Additions, Modifications and Replacement) Schemes for Works and Mines in Planning, Scrutinizing the schemes, budgeting , obtaining approval and monitoring the implementation of schemes in a time bound manner till completion. The cell also acts as an interface between the Owner Department and Related Departments like Contract Awarding Departments and Work Execution departments etc. Technical services (TS) department, covered under QMS, EMS, EnMS and OHSAS, monitors the health of critical equipment of various departments through condition monitoring in which vibration analysis (ad per IS 10816), wear debris analysis, current data analysis and thermal images analysis etc. is done using the Vibration analyzer, Motor current analyzer, acoustic emission meter, vibration meters and thermography equipment for obtaining best quality results. Power Engineering Maintenance department, covered under QMS, EMS, EnMS and OHSAS, carries out the mechanical maintenance (Capital repairs, preventive maintenance, break down maintenance) of rotating equipments like Turbo-blowers, Turbo compressors, Turbines, High capacity exhausters, Boiler fans, Feed pumps, located in various departments throughout the plant. In addition to the above it carries out IN-SITU dynamic balancing, precision alignment, critical assembly works of high speed critical rotary equipments. During the mechanical maintenance

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of the above rotary equipments, the damaged parts (ferrous and non ferrous scrap) and consumables (soaked cotton waste with oil & grease) are dumped into the respective dust bins provided by respective shops. Central Maintenance Electrical (CME), covered under QMS, EMS, EnMS and OHSAS, carries out electrical maintenance activities such as routine maintenance & inspection to improve the performance of motors, periodic overhaul of motors above 200KW at the work shop and large motors at user site, alignment of motors with mechanism, electrical maintenance of ED (W), stores complex and other buildings, street & tower lighting inside the plant, cranes & weigh bridges under its scope. The overhauled / repaired motors are again reinstalled at site. The handling & storage of motors are carried out under controlled conditions. Electrical Repair Shop (ERS), covered under QMS, EMS, EnMS and OHSAS, carries out repairs, rewinding of the electrical equipment which includes AC / DC, LT/ HT motors and other electrical equipment with quality of raw materials confirmed to applicable BIS, and IPSS standards. It plans for procurement of related spares for carrying out the said services. It renders services on routine as well as during capital repairs of various production departments. Electro technical laboratory (ETL), covered under QMS, EMS and OHSAS, helps the shop electrical of all the production shops in maintaining the thyristorised AC and DC drives, uninterrupted power supply systems, programmable logic controllers, crane controls etc. It also repairs all the electronic cards used in the above drives and systems in its Electronic laboratory. Spares Management Department (SMD), covered under QMS, EMS and EnMS, is a nodal department between Works and MM department. Major activities are procurement of rationalized spares, processing of material indents including MBC /SMC and technical recommendation files of all Works departments. Maintains budgetary control and Inventory control. Maintenance and Management Systems (MMS) department, covered under QMS, is central group for managing Maintenance and Management Systems (MAMS) covering the maintenance activities of the works departments. It monitors & controls the expenditure incurred / to be incurred within the budget It also allots and maintains a unique number called Catalogue Number for equipments/ spares etc. Cost Monitoring Group, covered under QMS, monitors the production cost and provides MIS reports on costs. Works contracts department, covered under QMS, mainly deals with the award of contracts required for sustaining the production and maintenance of various departments/units in the plant. In order to provide quality service Works Contracts adheres to 3-tier scrutiny system supported by the contract procedures, legal and commercial aspects of contract management, amendments, delegation of powers, circulars, issued by management from time to time to select the suitable contractor to perform the required task.

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Civil engineering department, covered under QMS, EMS, EnMS and OHSAS, carries out all the civil maintenance works, garbage handling, afforestation and horticulture inside the plant. Structural Engineering Department, covered under QMS, EMS, EnMS and OHSAS, carries out inspection maintenance and painting activities of various steel structures in the plant. St. ED undertakes replacement of translucent sheets of various yards and bay.

Brief Description of Electrical System

The Main Receiving Station (MRS) is an Air Insulated Substation, which receives Incoming power from APTRANSCO through 2x220 KV OH lines. It is connected with LBSS-5, through three no 220 KV OH line called Main Lines 1,2,3 & one spare 220 KV OH line. LBSS-5 (Load Block Substation-5) is the main load distribution center. 3x60 MW Turbo-Generators (called TG1,2,3) are connected to 11KV GSB (Generator Switch Board #1), which in turn feed power to LBSS-5 (AIS) through 3 nos, 11/220 KV , 63.5 MVA Transformers (called T1,T2,T3). These TGs are run by steam from 6 Boilers by burning Blast furnace or Coke oven gas or Coal or Oil. 2x67.5 mW Turbo-Generator (called TG 4,5) are connected to 33 KV (Generator Switch Board#4) through 2x 90 MVA, 11/33KV Transformer, which in turn feed power to Extended-LBSS-5(GIS) through 3x 63.5 MVA , 33/220 KV Transformers (called T6,7,8). These TGs are run by steam from 6 Boilers as mentioned above, by burning Blast furnace or Coke oven gas or Coal or oil. 1x14 MW TRT (Top Recovery Turbine run by Hot Gas from Blast Furnace -3) and 1x14 MW COB(Hot Gas from Coke Oven Battery -4) are connected to 11 KV, GSB#2 & 3 respectively, which in turn feed power to Extended-LBSS-5(GIS) through 1x 50 MVA , 11/11/220 KV Transformers (called T9). LBSS-5(AIS) & Extended LBSS-5(GIS) are interconnected through 220 KV cable. 2x12 MW Gas Expansion Turbo Generator(GETG) & 2x 7.5 MW Back Pressure Turbo Generator(BPTG) are connected to 11 KV (Generator Switch Board#2&3), which in turn feed power to LBSS-5(AIS) through one 11/11/220 KV , 50 MVA Transformer (called T4). These GETG & BPTG are run by Blast furnace Top Hot Gas & Coke oven Battery Hot gas respectively. 1x20.6 MW Generator (called NEDO-New Energy Development Organization) run by Heat recovery boiler from Sinter Plant, which is connected to LBSS-5 (AIS) through 11/220 KV, 90 MVA Transformer (called T5). LBSS-1 Load is fed from 220 KV double circuit OH line from LBSS-5 (AIS). Township Load is fed from MRS through 220 KV/33KV Transformer LBSS-2, 3, 4, 6 are fed through 220 KV double circuit OH line. Total Vizag Steel Generating capacity (TPP & CPP) is added = 522.6 MW

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Category-I (Imported load) of 80 MW, fed from 11KV GSB#1. Category-I (Imported load) of 30 MW, fed from 33KV GSB#4. In average 40 to 50 MW/day, is imported from APTRANSCO (235 MVA is connected Load). Balance load demand is supplied from TPP/CPP

1.3 SCOPE

The safety audit was carried out on the guidelines as mentioned in Indian Standard IS: 14489 - 1998 on “Code of Practice on Occupational Safety and Health Audit”. The broad elements covered in the Safety Audit are as under:

1) Safety Management Systems 2) Safety Training Plans. 3) PPE Norms and Practices. 4) Compliance with Statutory Requirements pertaining to Safety. 5) Fire Hazards and their Control Measures. 6) Mechanical/Physical Hazards. 7) Electrical System and Personal Safeguarding. 8) Safe Operating and Maintenance Procedures. 9) Safety Procedures for Contract Work. 10) Review of Emergency Planning, Preparedness and Response Systems. 11) Safe Handling and Storage of Hazardous Chemicals.

1.4 OBJECTIVE OF AUDIT

The main objectives of the audit were to particularly examine Health & Safety (H & S) systems prevalent in the Factory, identify potential H & S hazards and suggest corrective actions wherever necessary. The success of the audit exercise lies in implementation of the recommendations made in the report. Due care has been exercised while framing the recommendations to make them simple, practicable, feasible and thereby workable. It is the responsibility of the top management to make available the necessary resources to implement the recommendations of this report.

1.5 METHODOLOGY

The information presented in the report is based on perusal of various documents and internal records, sample inspection of the Factory and discussions held with employees and management representatives. The recommendations made herein in the report, are based on the conditions and systems prevalent at the Vishakhapatnam Steel plant, Vishakhapatnam and hence applicable only to the said Factory or mentioned otherwise. Vishakhapatnam Steel plant, Vishakhapatnam may however, replicate the recommendations in its other such Plants after studying their implications depending on the conditions and systems prevalent therein.

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1.6 OPENING MEETING

As intimated in advance by NSC, there was a meeting with senior officers and audit team on 20th February, 2019 at 10:00 hr. The Team made the following points:

i) The assignment being carried out at the request of the Management of Vishakhapatnam Steel plant, Vishakhapatnam shows its keenness to make the Plant safer. As the Management is represented by the Executives present at the meeting, their involvement and co-operation are essential and important in carrying out the assignment successfully.

ii) The Safety audit is not an inspection of each and every activity/ item, but it is a sample inspection of the Workplace and study of key documents. The coverage of the Safety Audit will be limited to the field visit of areas planned to be inspected by the Management, information provided to the Safety Audit Team and documents and records produced for verification.

iii) The Safety Audit is not a fault finding exercise but identification of areas for improvement in safety based on observations, discussions at various levels and reference to the records & documents made available for verification.

iv) The recommendations that would be made in the audit report would be practical and information provided would be authentic.

v) The safety audit report will be a confidential document between NSC and Vishakhapatnam Steel plant, Vishakhapatnam.

1.7 STUDY OF DOCUMENTS

In order to check and assess the status of the H & S Management System prevalent in the plant and facilities, many documents such as safety policy, work permit system, pre & periodic medical examination records of all employees, operating & maintenance procedures, inspection schedules & reports and records of testing of critical plant equipment, earthing systems, fire extinguishers, etc. were perused.

1.8 CLOSING MEETING On 26th February, 2019 at 15:45 hrs a Closing Meeting was organized. Company

executives attended the meeting. The Audit Team presented some important observations and recommendations in this Meeting. There was a discussion on the recommendations, which was useful in clarifying the doubts.

1.9 AUDIT REPORT

Based on the information provided in the pre-visit questionnaire, discussions with the key persons, sample inspections carried out during the visit and perusal of the documents / records maintained in various Departments, observations and comments with our recommendations are given in the following parts of this report.

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1.10 Disclaimer:

“The findings and the recommendations mentioned in this audit report are based on the actual condition prevalent in the site during the time of our audit. This report should not be deemed as any warranty or certification of Safety Management System and other technical aspects related to preventing accident in future”.

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PART – 2

EXECUTIVE SUMMARY

A four member audit team from National Safety Council carried out the Safety audit of Vishakhapatnam Steel Plant, Vishakhapatnam from 20-26th February, 2019. The objective is to carry out a critical appraisal of potential hazards at workplace and ensure that OSH system fully satisfies the legal and other requirements. Indian Standard, IS 14489:1998 was used as a guide. SAFETY MANAGEMENT

• Most of the statutory requirements are found to be complied with. Factory License, Boiler License, Petroleum license; chlorine license and Consent to operate the plant from Andhra Pradesh Pollution Control Board are available in the plant.

• RINL Vishakhapatnam Steel Plant was IMS certified company and all the procedures were documented in the OHSAS safety manual which was available in the portal of RINL Company for ready reference of company employees.

• Company was having safety organization for looking after safety aspects of company, the roles and responsibilities were defined in the safety manual. The qualified safety officer was available in the company as required under Section 40 B of the Factories Act, 1948.

• The company has prepared Quality, Health Safety and Environment policy in English & Hindi version and Signed by occupier in October 2017 however the occupier was changed in recent past, the policy should be signed by the current Occupier and copies should be displayed in company premises.

• As Steel industry was listed in Schedule I of The Factories Act, 1948 and having more than eighteen thousand workers working in the plant. Central Safety Committee was formed for better co operation between management and workers related to Safety, health and environment aspects of workers which was required under Section 41 G of the Factories Act, 1948. The frequency was once in every quarter and tenure was as per the trade union member’s elections. Departmental safety Committees were formed under the Head of Departments chairmen’s ship for looking after the shop floor safety , health and environment aspects and meetings were conducted every monthly, format for same was prepared and records were available with most of the departments.

• Accident reporting, Recording, Investigation and Analysis procedure was documented in Safety manual, the formats of accident reporting was available in the manual and being followed by the company which was required under Section 88 Of the Factories Act, 1948. In 2017-2018 there was no Fatal Accident reported however reportable accidents were happened inside the company premises. The Severity rate and Frequency rate was calculated by Safety Engineering department. The accidents were analyzed cause wise. There was format for nearmiss and dangerous occurrence however less numbers of nearmiss accidents were reported in most of the departments which needs to be enhanced for that shop floor worker should be trained and educated and good nearmiss accident may be rewarded to motivate the workers. Neramiss

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accident was a vital tool to find out the unsafe conditions and unsafe acts present in the shop floor which may lead to serious accident.

• Safety trainings were imparted to the workers; training calendar for the entire year was prepared and circulated to all the departments for allocating the participants. After training imparted feedback was obtained from participants on the subject. This year external faculty from NSC, Navi Mumbai was called for imparting trainings to the employees.

• In company First Aid training was imparted to more than one thousand workers and these were working in shift schedule for attending first aid injury cases inside the company however out of that some certified first aider were undergone training on year 2015/ 2016 whose refresher training should be planned for being first aider as required under the statues.

• Hazard Identification and Risk Assessment (HIRA) study has been carried out in the company for more than five thousand operations to know the hazards and the risk in the operations. During visit some of the HIRA study was perused it was found that general safety and use of PPEs were mentioned in the control measures. HIRA study should be reviewed by incorporating the existing control measures available to eliminate or reduce the risk within acceptable level such as training, SOP, Interlocks available, engineering control, administrative control, work permit system etc so that detailed control measures will be mentioned in the study and study will productive.

• Company was handling hazardous chemicals like Chlorine, Hydrogen, benzene, BF gas, LD gas etc for these chemicals Quantitative Risk Assessment (QRA) has been carried out to know the effects of hazardous chemicals in case of eventuality but the results were not known to the concern workers. Training should be arranged for the respective departments for knowing the effects and making aware about the study. The observations made in the study should be completed and the compliance report should be documented for verification.

• HAZOP study was carried out in year 2015 for most of the departments like BF, COCCP, EMD, TPP, MMSM etc. The HAZOP study observations compliance report was not available for all points raised during study.

• More than one thousand numbers of First Aid boxes were provided in the company for treatment of first aid cases as required under Section 45 of the Factories Act, 1948 however, qualified first aider was available in the company for treating first aid cases. The content of first aid box was suggested by OHC of six contents. The replenishment was carried out by certified first aiders.

• OHC was available in the company handled by qualified doctor as required under Rule 61 (SC) B (2) (1) of the AP Factories Rules, 1950. The OHC was available for conducting periodic medical examinations of workers and in case of emergency the injured person was treated in the colony hospital. The numbers of doctors required in the OHC should be as per Rule 61 (SC) (B) (C) (i) of the AP Factories Rules, 1950.

• Three first aid centers and Ambulance vans were available in the company for treatment and transportation of injured cases at OHC, CO CCP, BF areas respectively.

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• Periodic medical examinations of workers were conducted in OHC around thirty to forty workers medical examinations can be conducted daily in the OHC. The frequency of Periodical medical examinations was defined in the OHC safety manual and accordingly medical examinations were carried out. The medical test records were maintained separately in the portal. Each worker was having separate file and access was given to worker for knowing the medical tests details through person login and pass word on the portal. In this year out of 8500 workers 8300 workers undergone medical examinations. As per the diagnosis by OHC for last year periodic medical examinations there were cases of hypertension, diabetics, anemia, vertigo, ringing in the years, hearing impairment, refractory errors, Asthma cases etc. Special care or attention should be given to these cases for maintaining their health.

MECHANICAL SAFETY

• Heat sensing arrangement may be installed along with sprinkler system in coal yard to take early action to avoid frequent fire which results with lot of air pollution and loss of coal.

• Safety valves on pressure vessels should be tested regularly and records maintained.

• All the pressure gauges should be marked at SWP with a red mark.

• The guarding of rotating parts of machines was missing in most of the places which may lead to accidents and positive guarding was required for that survey should be conducted.

• Standard Operating Procedures were prepared for most of the operations and available in the departments for ready reference. Some of the SOPs of Emergency shut down operations were reviewed it was found that general instructions like isolation valves should be closed however isolation valves numbers were not mentioned, for making full proof SOP for particular operation specific numbers of isolation valves, location and blinds etc should be mentioned in the SOP.

• The gas cylinders used stored and handled in the company at most of the departments. During visit it was found that the cylinders were not properly secured to avoid fall, end caps were missing and moreover 2007, 2011, 2013 hydro testing due dated gas cylinders were used inside the company. It was suggested that survey should be conducted for all the gas cylinders for due date of Hydro testing and make sure that only valid i.e. hydro tested gas cylinders were used, stored, handled inside the company premises.

• PPEs compliance in general needs improvement.

• Two wheelers are parked inside the plants which is unsafe.

• Vehicles are plying at much higher speed then prescribed speed limit of 30 KM/hr.

• Housekeeping should be improved in general.

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• Pedestal grinder should be maintained well with respect to gap between wheel & tool rest and wheel guard. A notice should be displayed near grinder as per statutory provision under sec 30 of The Factories Act 1948.

ELECTRICAL

• Each Electrical Department has maintained a Register with name of Officer/Supervisor/Technician with designation, no of years of experience on relevant field & duly approved by a Senior Person of department. This is required as per CEA Sub Reg (2) of Reg 3.

• It is suggested to carry out Infrared Thermograph once in 6 month after mapping all probable hot points. DGA of all HT Transformer is to be done once /year. The DGA report & all other Electrical test results are to be shared by DNW with all concerned area HODs for making action plan & trend analysis by individual section.

• Periodical Inspection of Electrical System by State Electrical Inspector is not found during audit which was required under CEA Regulation number 30 (2).

• Designated Electrical Safety Officer from within the organization is not recorded by individual department which is required under CEA regulation 2010 number 5.

• Latest CPR charts should be displayed in a language understood by majority of workers in all Switch gear room as required under CEA regulation number 28.

• Use Epoxy insulating paint in front of HT switchgears should be used to facilitate smooth breaker rack in/out operation as require under CEA regulation 2010 number 19 (5).

• An artificial respirator shall be provided in every manned generating station, substation or switching station of voltage exceeding 650 V. Regn 28 (3) which is shifted to 27(5)

• Two or more Gas masks shall be provided & installed & maintained at accessible places in every Generating station with capacity of 5 MW & above and enclosed substation with transformation capacity of 5 MVA & above for use in the event of Fire & smoke. Ref CEA Reg 2010, Reg no 27 (4)

• It may be noted that all Transformers of rating 10 MVA & above are to be provided with HVW spray system (design, installation as per IS 15325) or Nitrogen Injection Fire Protection System. Ref CEA Regn no 44 (2)(ix). Urgent attention is required for protection of these Transformers.

• Fire water systems, which are available at cable gallery, may be kept in service.

• Standard Maintenance schedule & Practices (SMP) of all electrical equipments are to be prepared as per O&M manual & experience of repeated failure if any. This is to be followed & record is to be kept for reference.

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• Lockout & Tag out (LOTO) system for Permit work system is not followed. Manual Permit format is used & a PTW register with all details is maintained. Start LOTO system

• Electrical Hand tools are to be tested at least once a year either by centralized Electrical Lab at DNW or by an NABL accredited testing lab & record of the same is to be kept. Defective tools shall be replaced with new ones immediately

• It was observed that temporary wiring with joints & without plug/sockets is used which may lead to accidents, follow CEA regulation 2010 for temporary wiring.

• Flame proof light fittings and flame proof enclosure for motor terminal box of exhaust fan were not used in Battery Room which may lead to explosion due to spark generation during operation.

• Earth resistance measurement record was maintained in register. But during site visit, it was found that, many Earth Pits were found not exposed, (buried in earth/debris), not cleaned, not accessible & not identified & earth resistance measured with date/due date were not displayed near the pit. It appears that at these locations, the earth pit resistance was not taken regularly.

• Electrical Zone classification should be carried out for installations of electrical fittings. FIRE AND CHEMICAL SAFETY

• The factory being a steel plant is of High Hazard Fire Occupancy, Sub Category A, both as per National Building Code and TAC. Compatible with the fire risk, the factory has adequate fire fighting capability in terms of manpower and other resources.

• The factory is a Major Accident Hazard (MAH) factory due to storage of ‘flammable gas’ (LD gas) above the threshold limit (>200 MT) as per schedule 2 part 2 of MSIHC Rules. The factory is in compliance with the requirement as per MSIHC Rules.

• Adequate fire water availability is ensured for more than 4 hours of fire fighting as the fire water tanks are inter-connected. Automatic starting and stopping systems for jokey pump and main pump may be implemented for the phase 1 fire water pumps.

• Inspection procedure and up keeping of PFE and fixed firefighting equipment are good and records are well maintained.

• Fire training attendance for employees is not satisfactory. Fire training plays key role in prevention of fire at first place, prevention of a large fire by controlling at initial stage and in rescue & evacuation. A mandatory fire training schedule may be prepared for all employees and contractor workers. All employees should receive fire training at least once in a year.

• The Factory may ensure that valid Fire NOC is in place as it was not available for review.

• It is suggested that operation personnel in CO, BF and SMS may be as much proficient in rescue and emergency operation using SCBA as the EMD personnel. In

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case emergency due to CO poisoning operation personnel should also be available for rescue.

• Use of portable CO meters may be strictly enforced or made mandatory in CO prone areas.

• As per SMPV Rules every pressure vessel (gas bullets containing O2, N2, Argon. LPG etc.) Should have label or name plate containing tank number, chemical name, design pressure, test pressure, etc.

• A tank farm containing 4 gas storage tanks in PRMS 1 may be maintained as per SMPV Rules if it is in operation. Otherwise, the tanks may be removed or the tanks may be isolated and a board saying ‘Not in Use’ may be displayed.

• Earthing confirmation system may be installed for class A chemicals loading or LPG unloading, which will confirm if proper earthing is established. This can be interlocked with starting of filling pump or unloading compressor.

• The high CO alarm may be made audible in control room also in SMS 1.

• Pipelines may be painted using colour code as per IS 2379 (1990).

• For LPG tankers, safety certificates of tankers, test certificate of safety valves and excess flow check valves may be checked before unloading. Drivers need to be trained in transportation of hazardous chemicals as per CMV Rules.

• LPG cylinders discharge manifold area may be provided with leak detectors.

• Dry vegetation in and the gas holder premises may be promptly removed.

• The booster compressor by pass line in GH 2 may be provided with jumpers across the flanges. The earthing for the line may also be ensured. This is important as the line may pick up static charges from the ESP.

• Welding job earthing may be provided closest to the job to avoid hazard.

• Dust extractors, wherever not working, may be repaired and more may be installed to reduce dust pollution in CRMP.

• In Crude and Finished Product Storage area of CCP it is observed that tank roof of benzene storage tank has holes, some other class A chemical tank roofs are corroded and vents are open and continuity clamps across flanges are missing in many places. These may be looked into.

• The factory is in compliance with Consent for Operation by State PCB and Hazardous Waste Management Rules. The factory may try to achieve zero liquid discharge. Online real time monitoring system of effluent may be commissioned as it is a requirement of CPCB.

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OBSERVATION RECOMMENDATION

PART – 3

SAFETY MANAGEMENT SYSTEM

3.1 HEALTH & SAFETY POLICY

Company has prepared Quality,

Health, safety and Environment policy as requirement of IMS certification in English and Hindi version. The policy was signed by occupier in October, 2017 however latest occupier signature was not available on the QHSE policy. During visit it was found that old version of QHSE policy displayed on some of the departments which was after some time corrected by concern person, the policy was displayed in English version in most of the departments at few places it was displayed in local language. New departments like special bar mill etc were formed for different types of products manufacturing.

As per Rule 61 (SB) A of the AP Factories Rules, 1950, formed under Section 41-B (2) of the Factories Act, 1948. The occupier shall prepare a written Statement of his policy in respect of health and safety of workers at work. QSHE policy should be signed by current occupier and copies should be displayed. The policy should be displayed in a language understood by majority of workers at plant premises. The policy should be reviewed as often as may be appropriate, but it shall necessarily be revised under the following circumstances, namely a) whenever any expansion or

modification having implications on safety and health of persons at work is made; or

b) Whenever new substance(s) or

articles are introduced in the manufacturing process having implications on health and safety of persons exposed to such substances.

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3.2 SAFETY ORGANIZATION

Company was having safety Engineering department (SED) for looking after safety aspects. The organization chart of safety department was prepared and available with safety department. SED in charge is Mr Krishnaiah (DGM safety) whose basic qualification was B. E. Mechanical and having production experience. Mr J. Rajendran who was DGM safety and having qualification of M. Tech Industrial safety with industrial experience. Mr. M. Vara Prasada Rao who was AGM Safety with basic qualification of B. E. Mechanical and having production experience. Mr Mohan Rao who was manager safety and ADIS with industrial experience. Mr. B. V. Prasad working as Deputy manager safety and having industrial experience Mr. R. Madhav Kumar working as Manager safety with industrial experience. Mr R. Raju Rao working as manager safety. SED in charge reports to General Manager (Safety & Environment In charge) SED was looking after safety aspects only and total strength of safety engineering department is around fifty persons. Roles and Responsibilities of

This is in order as per Section 40 B (2) of the Factories Act, 1948 and Rule number 61 A of the AP Factories Rules, 1950. It should be followed.

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safety officer were defined in the safety manual. Company has nominated persons from each department as Departmental Safety Co coordinator who was looking after production activities as well as coordinator for safety committee meeting, conducted safety inspections etc. to make workplace safer.

This is a good system to involve person from each department for looking after safety aspects at shop floor but ensure that the DSC was having sufficient time and facilities for doing his duties satisfactorily as a safety coordinator.

3.3 SAFETY COMMITTEES

The steel manufacturing industry was

listed in the Schedule- I of the Factories Act, 1948 hence Section 41 A- to Section 41 – H (provisions relating to hazardous processes) was applicable to this industry. Company was having central safety committee for better cooperation between workers and management regarding safety, health & environment aspects of the workers.

This is in order as per Section 41 G of the Factories Act, 1948 Workers' participation in safety management. 1) The occupier shall, in every factory

where a hazardous process takes place, or where hazardous substances are used or handled, set up a Safety Committee consisting of equal number of representatives of workers and management to promote cooperation between the workers and the management in maintaining proper safety and health at work and to review periodically the measures taken in that behalf.

The Central Safety Committee was

reconstituted on 27/08/2018 through office order.

This is in order.

The central safety committee consists

of thirty members from workers side and thirty members from management sides thus having the equal numbers of participation.

This is in order as per Rule 61 SG of the AP Factories Rules, 1950.

The tenure of safety committee was

as per the trade union tenure. Noted.

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The frequency of central safety

committee meeting was once in every quarter. The last two safety committee meeting was held as per following dates. 06/12/2018 in which total fourteen points were raised and around nine points were complied. 04/09/2018 in which total fifteen points were raised out of that five were old and ten new points were raised. The follow up of the points raised was done in next meeting beginning.

This is in order. All the observations raised during safety committee meeting should be completed as per the target dates and records should be documented for verification.

In Central Safety Committee accident

statistics, last meeting points, new points were discussed. Concern Person name with responsibility and target dates were defined in the safety committee meeting to complete the observation made. The MOM of Central Safety Committee meeting was distributed through Email, hard copy to members, ED/worker I/C / Chairman CSC/ALL EDs/GMs/All HODs/and Copy to ED (P &I/C), GM (Project)I/C/ TA to CMD/ TA to D (P).

This is in order, it should be continued.

Considering the number of workers

employed and departments in the company, company has formed departmental safety committees, head of department will be the chairmen for these departmental safety committees. The frequency of meeting was defined every monthly. The departmental safety officer was the Coordinator for safety committee meeting at departmental level.

Good, it should be continued.

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3.4 SAFETY INSPECTION Safety inspections were carried out by

Zonal safety officer and Departmental Safety Coordinator mostly at shop floor unsafe acts and unsafe conditions were found out. The procedure for safety inspections was documented. The shop floor safety inspections were carried out as per the schedule. The safety inspections records were maintained by DSC. During visit, at most of the department’s site we found lot of unsafe acts and unsafe conditions which may lead to accidents. For example at RMHS coal was auto ignited and persons were working nearby, Dozer was working nearby few workers sprayed water but the smoke and fire was their etc.

It was suggested that the safety inspections should be carried out by head of departments regularly so that the actual conditions at shop floor was known to them and corrective actions can be taken on priority.

3.5 ACCIDENT REPORTING, RECORDING, INVESTIGATION & ANALYSIS

(INCLUDING FIRE ACCIDENT) Company has documented the

Accident reporting, recording, investigation and analysis procedures in OHSAS safety manual. OHSMS/R/08 for incident reporting. Different formats have been prepared for incident reporting, investigation purpose. The accident data was available with the SED. All departments submit their accident statistics to the SED and then SED will prepare the Frequency rate and Severity rates. The graphical accident FR was prepared by safety department which

This is in order. Noted.

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shows that the fatal accidents FR were reduced from last three years. In 2017- 18 zero fatal accident happened. The total accidents happened in VSP including contract workers are as per following: year NR RE Fatal

17/18 12 11 0 16/17 23 07 06 15/16 10 11 03 14/15 03 13 05

During visit we found that less number of nearmiss accidents was reported. The cause wise accident analysis was prepared by SED which shows that 37 % of accidents happened due to hit by falling objects. 18% of accidents happened due to pressed between objects, 18% of accidents by other hot objects, and 9% of accidents by electrical, 9% of accidents by hot metal burns, 9% by slip and fall.

The statistics shows that the reportable incidents were happened every year, company should focus about reducing the reportable accidents for that nearmiss accident reporting at shop floor should be enhanced. Nearmiss accident reporting is an vital tool to find out the unsafe act and unsafe condition which may lead to fatal accident hence educate and trained the shop floor workers for reporting of nearmiss accidents and good nearmiss accident reporting may be rewarded to motivate the workers. Corrective actions should be effectively implemented to avoid reoccurrence of same type of accident in future.

The fatal accidents were investigated

by accident committee which was constituted by ED works. This committee includes DGM P/S, HR, DGM safety, GM, SGST/I/C and ED.

This is in order.

3.6 SAFETY EDUCATION & TRAINING (INCLUDING FIRST AID AND FIRE

TRAINING ) Company was having training hall in

which necessary training facilities like mike, computer, chairs, audiovisuals, screen, projectors, etc were provided for imparting training to workers. At a time forty participants can attend the

It should be maintained in future also.

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training program. The faculty for imparting training was internal as well as external faculty was also called from organization like National Safety Council, Mumbai.

This is a good practice to involve the external faculty for imparting the training to company workers so that the good practices and advance techniques which was being at other company will be shared to the workers and these good practices can be implemented at site.

Induction training to new comers will

be arranged by TTA, the duration of induction training will be of one month to three month. Induction training module was prepared and same being followed for induction training of newly employed workers. The trainings at TTA were given by qualified and experienced Safety officers. SED will provide training to new workers related to basic safety, general safety at site, brief about company, details of departments, maintenance practices and behavior base safety. The records of training imparted was reflected in the monthly review meeting and discussed in departmental meeting also.

This is a good system should be continued.

Structured training programmers were required to develop skill as well as safe working methods in plant level particularly in Hazardous operations as a part accident reduction policy.

Training calendar for every year was

prepared for all types of employees and circulated to all the departments for allocating the employees as per the training planned. The feedback on training imparted was obtained from participants. Refresher training will be arranged after three years. During visit we found that some of the workers were not aware about hazards associated with the fire extinguishers, Earth pits were observed buried in most of the

It is suggested that effectiveness of the training imparted may be checked by taking written test after training session over so that the persons who undergo the training can be assessed.

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departments, cable trays at RMHP with lot of coal dust and combustible materials, No proper access, working at coal reclaimer area where coal was auto ignited etc.

Training of top management was

carried out by TTA & MDC (HRD). Noted.

The first aid training was imparted to

around 1153 numbers of employees from different departments through Saint John Ambulance agency however during visit we found that the refresher first aid training was required to be arranged as the validity of first aid training was expired for example the first aid training was imparted in year 2015/2016 for workers which was not rearranged.

Survey should be carried out for refresher first aid certified training of these workers and fresh training should be arranged for them.

Few persons were sent outside the

company for attending the external training programs, conferences etc for enhancing the knowledge.

It should be continued.

3.7 PROMOTIONAL ACTIVITIES ON SAFETY & HEALTH (SAFETY

COMPETITION, SAFETY SUGGESTION SCHEME, SAFETY INCENTIVE SCHEME)

To promote safety and health in the

plant, the National Safety Day was celebrated in the plant on 4th March. Last Safety Day/week was celebrated from 4 to 10th March 2018. During this celebration various competitions are organized like safety slogan competition, drawing competitions etc and winners were rewarded. Fire Services week was observed from 14 to 20th April, 2018 in which different competitions were organized at company premises, fire demos

In order to improve the Safety & Health awareness among employees these campaign, observance & motivation programmes should be conducted in future also.

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were carried out and winners were rewarded. World Environment Day was celebrated on 5th June, 2018 on that day tree plantations was done in company premises. Road Safety week was celebrated at company. Foundation day of RINL, Vishakhapatnam was celebrated in year 2019 in which different competitions were organized at company and winners were rewarded.

Other than above company has

carried out Crush Helmet campaign, Rail safety at site. Company was having online suggestion scheme in which employees can share the suggestions to company on the company portal through own ID and password, which was reviewed by top management and good suggestions was rewarded.

This is a good system it should be continued. Suggestion boxes may be provided at site also and suggestions from contract workers/ shop floor workers may be obtained as these workers were exposed to hazards while working.

In company Safety posters of different

subjects were displayed for enhancing the safety culture inside the company. warning signs also displayed from entry gate till the departments office, site, shop floors like use helmet while driving bike, speed limit etc but during visit it was found that workers were not following speed limit, few workers were riding on bike with three seats etc.

The warning signs should be followed inside the company to maintain the discipline which will helpful to avoid injury/ accidents inside the company.

3.8 IDENTIFICATION & ASSESSMENT OF HAZARDS

Hazard Identification and Risk

Assessment (HIRA) study has been carried out in the company for all

HIRA study should be reviewed by incorporating the existing control measures available to eliminate or

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operations (around five thousand operations activities HIRA study conducted) to know the hazards and the risk in the operations however few Operations HIRA study was checked at BF plant it was found that HIRA study was having three by three matrix, In study general safety practices such as use of PPEs were considered as a control measures.

reduce the risk within acceptable level such as training, SOP, Interlocks available, engineering control, administrative control, work permit system etc so that detailed control measures will be mentioned in the study and study will productive. The HIRA study should be known to the concern workers who were working on the operation. This HIRA study will provide the information about Hazards’ available during the operations, what will be the risk and what are the control measures available to reduce the risk.

BUREAU VERITAS has conducted

HAZOP study of, BF, EMD, TPP, COCCP, MMSM etc departments in year 2015 and report was submitted on 4/03/2016. The HAZOP report was available on portal of RINL Vishakhapatnam and hard copy was available with concern department however during visit we asked the department persons about HAZOP study they were not aware about the HAZOP study. During visit we perused the HAZOP report of BF plant which has suggested around fifteen recommendations and total twelve nodes were considered for HAZOP study however the compliance report of HAZOP study was not available with the concern department.

The HAZOP study should be known to the operating staff and the recommendations compliance report should be documented for all the points suggested during the study. Other departments HAZOP study compliance report should also be documented if not available.

Company was handling hazardous

chemicals like Chlorine, Hydrogen, benzene, BF gas, LD gas etc for these chemicals Quantitative Risk Assessment (QRA) has been carried out to know the effects of hazardous chemicals in case of eventuality.

Training may be arranged for the respective department’s workers on QRA study so that they will be aware about the dispersion modeling effects of hazardous chemicals in case of eventuality.

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BUREAU VERITAS has conducted QRA study of hazardous chemicals at RINL Vishakhapatnam, they considered eleven scenarios for QRA study and individual & societal Risk level was calculated. The QRA study was not known to the concern departments persons w. The QRA report was available on the RINL portal.

The recommendations suggested should be followed and compliance of those points should be documented. The assembly points, fire fighting arrangements should be reviewed accordingly at site.

3.9 SAFETY DOCUMENTS

Company has prepared a “Safety

Manual” and approved by the top management to guide the employees for adopting safe practices and maintaining good health in performing various activities / operations / processes in the plant. Every department was having their departmental safety manual in portal of RINL Vishakhapatnam.

Health and Safety Manual is an important and useful document of safety and health for achieving company’s goal. Safety Manual should be reviewed after any changes made in process, operation, etc. The copy of safety manual should be easily accessible to workers.

3.10 SAFETY BUDGET

Company was having safety budget

which was being utilized for various safety activities, procurements of PPEs, trainings etc. The safety budget was basically for AR and non AR items. The Safety Budget for year 2019-20 was estimated 8.6 corers the details were as per followings: AR items 4.3 cr Non AR items 2.0 cr Revenue and admin capital items 77lakhs+ 76 lakhs + 25 Lakhs

The safety budget should be increased every yearly so that safety department can plan for advance techniques and equipments, which can be used at company for betterment of safety.

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respectively. 3.11 SAFETY AUDIT

Company was having system of

internal safety audit; the frequency of internal safety audit was once in a six month for all zones through the internal auditors of OHSAS. The list of authorized internal auditor was available to conduct internal safety audit. The checklist has been prepared for conducting internal safety audits, there were six points considered in OHSAS internal safety audit.

This is a good system to be continued. The observations made during internal safety audit should be complied within stipulated time and it should be documented for verification.

As the RINL, Vishakhapatnam comes

under the Major accident Hazard unit as per MSIHC Rules, 1989 every year external safety audit was conducted through third party. Last safety audit was carried out by Naga consultancy in year 2017. This was the first time National Safety Council; Navi Mumbai has conducted the external safety audit for year 2018/2019.

The frequency of external safety audit should be maintained as per MSIHC Rules, 1989 Rule 10 (4) 10. Safety Reports 1[And Safety Audit Reports] 4) The Manufacture, Storage and

Import of Hazardous Chemicals (Amendment) Rules, 1994, the occupier of both the new and the existing industrial activities shall carry out an independent safety audit of the respective industrial activities with the help of an expert, not associated with such industrial activities.

6) The occupier shall update the safety audit report once a year by conducting a fresh safety audit.

There was necessity to conduct structured safety audit to assess the safety standard of the Company Unless audit was done an organization cannot prepare effective plant safety management programme of their organization. As such internal

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& external safety audit necessary for proper planning of safety engineering and management system. The observations made in the external safety audit should be complied by preparing action plan and compliance report should be documented for verification.

3.12 FIRST AID FACILITIES AND OCCUPATIONAL HEALTH CENTRE (OHC)

Company has provided more than

eleven hundred first aid boxes at different departments for attending first aid cases at site level. The OHC doctor has suggested six contents for first aid boxes as three numbers of First aid centers were provided at the company premises. The first aid boxes were replenished by the certified first aiders and frequency of replenishment was defined in the OHC safety manual. The names of the first aiders were displayed near the wall of the most departments with contact numbers, they were available in each shift however during visit some first aiders was undergone first aid training in year 2015 but refresher first aid training was not arranged for them. There were three first aid centers also provided for attending first aid cases, The first aid center was attended by an MBBS doctor, male nurse 24X7. One doctor was available to attend the cases.

As per Section 45 of the Factories Act, 1948. First-aid appliances. 1) There shall in every factory be

provided and maintained so as to be readily accessible during all working hours first-aid boxes or cupboards equipped with the prescribed contents, and the number of such boxes or cupboards to be provided and maintained shall not be less than one for every one hundred and fifty workers ordinarily employed 1*[at any one time] in the factory.

2) Nothing except the prescribed contents shall be kept in a first-aid box or cupboard.

3) Each first-aid box or cupboard shall be kept in the charge of a separate responsible person 3*[who holds a certificate in first-aid treatment recognized by the State Government] and who shall always be readily available during the working hours of the factory].

Occupational Health Centre (OHC) Company was having OHC inside the

company premises nearer to the main Noted.

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gate. The OHC was having following facilities: Doctors consulting cabins Registration room Acoustic room for audiometry staff room pathology Laboratory Patient wards eye vision testing room First aid centre of two rooms, dressing material, dust bins, oxygen cylinder, register of first aid cases etc

The OHC was handled by Doctor

Madhavi (MD and AFIH) thus having the required qualification as per the AP Factories Rules, 1950. There were four doctors available in the OHC and first aid centre for treatment of workers in case of injury.

This is in order as per Rule 61 (SC) B (2) (1) of the AP Factories Rules, 1950. The number of doctors at OHC shall be, as per Rule 61 (SC) (B) (C) ( i ) of the AP Factories Rules, 1950 i) one full time Factory Medical Officer

for factories employing up to 500 workers and one more medical Officer for every additional 1000 workers on part therof

OHSAS OHC safety manual was

available on portal in which sixteen work procedures for OHC (QSHE-P-OHS revision dated 11/2/2018) was defined out of sixteen procedures on procedure was universal procedure for needle stick injury/ accident for exposures also available for ready reference.

Ensure that these procedures should be known to the operating staff for that Periodic trainings may be arranged on these procedures for refreshing the knowledge of operating staff.

Hospital at colony was having facilities

to treat the injured cases which were ten to fifteen minutes away from the company gate. OHC at the company premises were performing the periodic medical

Noted.

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examinations and injured cases were treated in colony hospital. The colony hospital was having the Consent and authorization number 18145/APPCB/ZO-VSP/CPO/W & A/2018-318 dated 02/06/2018 Bio medical authorization under Rule 10 of Bio Medical Waste Management Rules, 2016. In Part IV of the consent and Authorization the Bio Medical Waste Authorization (Form - III) (see rule 10) (Authorization for operating a facility for generation, collection, reception, treatment, storage, transport and disposal of Bio Medical wastes) M/s Vishakha Steel General Hospital was granted an authorization to generate, segregate and handle MW as per capacity given below: Number of Beds of HCF: 160 numbers Quantity of BMW handled, treated or disposed: type of waste category

Quantity permitted for handling

YELLOW 563Kgs/month

RED 160 Kgs/month

WHITE 10Kgs/month BLUE 2Kgs/month

This is in order as per BMW Rules, 2016.

The OHC BMW was collected in four

different bins of yellow, red, white and Blue color as per the nature of bio medical waste after three days these waste was handed over to Hospital for disposal purpose around 1KGs waste was collected in three days as per the records available.

Noted.

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The total staff of the OHC was

sixteen. Fourteen numbers were staff and two numbers were male nurse attendants. Details of staff is as per following: Manager, Deputy manager, Junior manager, AE Nurse, Audiology & Speech Therapist, Assistant, Senior technicians four numbers, health Assistant and three numbers trainees for paramedical staff. These staffs were working in General shift and A shift in OHC.

Maintain staff as per the Rule 61 (SC) (B) (C) of the AP Factories Rules, 1950.

During visit at laboratory jointed

cables observed. Two LPG cylinders were used which last hydro tested in year 2007 and till date it was being used in the laboratory. These cylinders were not placed on the trolley for transportation. Two refrigerator was available in the lab out of that one refrigerator was not working. TT vaccines were stored in the refrigerator.

It should be attended. These LPG cylinders should be immediately replaced with new hydro tested cylinders. Trolley should be provided so that transportation will be easy. If vaccines were stored in the refrigerator then cold chain should be monitored and records should be documented. The cold chain monitoring is required to maintain the potency of the medicines/ vaccines.

Pharmacy at OHC was handled by D.

Pharm qualified persons. The medicines stock was maintained as per mini max schedule. The medicines stocks expiry date was also available on the portal. In store room lot of combustible material was stored there may be chance of fire due to electric source

It should be continued. Housekeeping in store room should be done so that chance of fire due to combustible material storage will be

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available like A/C, switch boards etc. eliminated. Ward room was having three beds for

injury cases, there were three oxygen cylinders were available for emergency supply. Total nine filled and one empty cylinder were stored in the ward room near the door however it was found that the one oxygen cylinder last hydro tested in 2010 but still it was being used in the OHC ward room.

Noted. Survey should be conducted in the OHC and in company for hydro test date of gas cylinders. Ensure that the tested gas cylinders were used in the company premise which was required as per Gas cylinders Rule, 2016.

X ray room was available but it was

not used. Noted.

Hard copies of MSDS of chemicals

used in the company were not available in the OHC however soft copies were available in the portal.

It was suggested that the list of Antidotes may be prepared as so many hazardous chemicals were handled in the steel plant and make sure it can be available at OHC in case of any emergency it can be useful.

The cases like snake bite where anti

venom required for treatments were referred to Colony hospitals.

Noted.

There were three ambulances

available at OHC, CO CCP, BF areas respectively for transportation of injured cases to hospitals.

These ambulances vans should be maintained as per Rule 61 (Sc) (C) of the AP Factories Rules, 1950.

3.13 MEDICAL CHECK UPS OF EMPLOYEES RELATED TO HAZARDOUS

PROCESSES The premedical examination of newly

employed company worker was carried out at Colony hospital and record of same was available in the Hospitals. The medical examinations carried out were X ray, eye vision test, blood test, urine test, ultra sound and general checkups.

Noted.

Company has defined the frequency It should be followed.

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of periodical medical examinations of company workers in three groups. Periodic medical examinations yearly for shop floor workers working at Blast Furnace, CO CCP, SP, RMHP, SMS, RED, TPP, WRM, three yearly for office services like instrumentation, EMD/WMD etc workers and five yearly for administration, HR etc. The periodic medical examinations were carried out at OHC, in a day thirty to forty workers can undergo medical examinations. The samples collected were sending to the colony hospital after receiving results from colony hospital the data was entered in the portal where medical record of every company employee was available the respective employee can access the medical record through personal Login ID and password the concern worker can saw his own medical history.

The access given to employee for checking the medical history in the portal is a good system it should be continued ensure that all the workers having the portal or computer facility to check his medical history.

The medical tests carried out in

periodical medical examinations of employees were as per following: Lung Function Test, Blood test, Urine test, eye vision, audiometry and general checkups. The medical records were maintained in the physical records storage room and stand alone system and in this access was given to Doctor only. The medical record of employee can be seen by the employee in his personal three tire system. The medical records of all employees were maintained in Health Record Book as per the OHSAS manual.

Noted.

In last year out of 8500 workers 8300 Remaining workers medical

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workers were undergone the periodic medical examinations as per the statistics provided by The OHC doctor. As per the diagnosis by OHC for last year periodic medical examinations there were cases of hypertension, diabetics, anemia, vertigo, ringing in the ears, hearing impairment, refractory errors, Asthma cases etc.

examinations should be planned. Special care has to be taken for these cases to avoid further detoriation of health.

Canteen workers medical

examinations were conducted yearly in which physical medical tests has been carried out and records were maintained for verification. It was informed that the Industrial hygiene checkups of canteen workers were not carried out intermittently only lectures were arranged for awaring them about industrial hygiene.

The necessary medical tests required for canteen workers as mentioned in the AP factories Rules should be carried out. Frequency of industrial hygiene checkups for canteen workers should be prepared and followed to maintained good hygiene of canteen workers to avoid any disease spread due to unhygienic condition.

Loco motive drivers, Crane operators

etc eye vision testing frequency was also defined as per following; For less than or equal to 45 yrs the eye vision will be tested once in a year. For more than 45 yrs the eye vision will be tested once in a six month. From April to December 2018 around 806 workers were under gone eye vision testing.

This is in order it should be followed.

It was informed by the doctor that the

eye vision was checked by the optometrist at the OHC.

Ensure that the eye vision testing was carried out the qualified person as required under the AP Factories Rules, 1950.

Contract workers medical

examinations were in the scope of contractor after obtaining the fitness

It should be followed.

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certificate from doctor and induction from safety department the gate pass of the contract workers were prepared and then only he will be allowed to work at site.

3.14 COMPLIANCES WITH STATUTORY REQUIREMENTS (LICENSE,

CERTIFICATES, AUTHORIZATION ETC) RINL Vishakhapatnam Steel Plant has

paid factory license fees for renewal of factory license through on line portal of Government of Andhra Pradesh as per APTC form 10 and challan number 21086067562018.

This is in order as per AP Factories Rules, 1950.

The three boilers Licenses were

renewed every yearly through competent person for use of boilers.

This is in order.

RINL Vishakhapatnam Steel Plant

colony hospital has obtained orange category Consent, Authorization & BMWA from Andhra Pradesh Pollution Control Board, Zonal Office at Vishakhapatnam The consent and authorization number 18145/APPCB/ZO-VSP/CFO/W & A/2018-318 dated 02/ 06/ 2018 and valid up to 30/04/2019.

This is in order under Section 25/26 of the Water (Prevention & Control of Pollution) Act, 1974 and under Section 21/22 of Air (Prevention & Control of Pollution) Act, 1981 and amendments therof, Authorization under Rule 6 of the hazardous and other Wastes (Management & Transboundary Movement) Rules, 2016 & Authorization under Rule 10 of Bio Medical Waste Management Rules, 2016.

Companies Structural Engineering

department has (defined a fifteen structures block for checking structural stability) allotted contract for competent person to check the stability. Out of that four blocks certificate of stability was received and others stability testing was pending. As the company was more than twenty five year old it was having huge area with the buildings, structures and offices whose structural stability was not checked after starting

Considering the nature of work and more than twenty years of operation of plant, the structural stability of all the old structures should be planned and obtained the structural stability as require under Rule 12 of the AP Factories Rules, 1950.

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the plant. 3.15 EMERGENCY PREPAREDNESS PLAN & MOCK DRILL (INCLUDING FIRE

EMERGENCIES) Vizag Steel Plant is a Major Accident

Hazard factory as per MSIHC Rules, due to storage of more than 200 MT of flammable gas (LD gas). The factory has prepared the Safety Report, Emergency Preparedness plan, conducts mock drills and carries out safety audit in compliance with the MSIHC Rules. Emergency Preparedness Plan The factory has prepared an On-site Emergency Preparedness Plan, which was reviewed. The Plan has the requisite details, including the following:

• Hazardous critical installations.

• Hazardous materials handled.

• Major hazard scenario.

• Risk control facilities.

• Emergency response leadership.

• Maximum credible loss scenario

• Emergency siren and control room. Mock Drill 3 Mock Drills were conducted during 2018. Reports of the drills are available and reviewed. The report, however, does not contain:

• Reports of observers

• Compliance report of suggestions

This is in order. The On-site Emergency Preparedness Plan has almost all details. It is suggested to also include the following:

• Assembly points and escape route marked on layout.

• Although some of the properties of hazardous chemicals are mentioned, a chapter containing MSDS of all hazardous chemicals may be included,

Conducting 2 or more mock drills in a year meets the statutory requirement as per MSIHC Rules. The purpose of Mock Drill is to evaluate the EPP and also to check the preparedness of the factory. It is therefore suggested that observations and suggestions made by the observers and key persons are discussed, recorded and complied with. This will improve the plan and eliminate any weakness in

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For 2017 and 2016 only one Mock drill report for each year are available. Fire Mock Drill and plant wise mock drill Besides this, fire mock drills are carried out separately at least 24 times a year. Mock drills are also conducted in the major plants. Mutual Aid The factory has mutual aid tie-up with neighboring industry.

preparedness. Being a statutory requirement all Mock Drill records should be preserved and available for review. This is a good practice and may be continued. Noted.

***

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PART – 4

MECHANICAL & PHYSICAL HAZARDS

4.1 TESTING & EXAMINATION OF PRESSURE VESSELS/PLANTS

Most of the pressure vessels are

tested by competent person as per Section 31 of the Factories Act, 1948 and AP factories Rules and records are maintained. During visit it was found that in most of the departments the No identification nos. is given to pressure vessels. The test details like SWL, Test Date, Due date etc were not displayed on some of the pressure vessels.

Noted. The identification nos. should be given and test certificates should be issued as per identification number. The test details should be displayed on the pressure vessels like Id No., Capacity, SWP, Test date, Hyd. Test Pressure and Next due date.

Coal & Ore handling tipplers are

installed in two sheds and are in operation. List of pressure vessels is available (6 Numbers). Pressure test certificate/ultrasonic test certificates for pressure vessels available. List of pressure vessels is available (6 Nos.). Pressure test certificate/ultrasonic test certificates for pressure vessels available in WRM-2. Pressure vessels-24 Nos. are pressure tested and certification from competent Person is available in SBM. Pressure vessels-29 Nos. are

Warning lights at each tippler may be considered at the time of tippler operation for additional safe operating. Barricading at common shaft to be installed. Barricading at both ends required being potential tripping hazards It is in order. Compliance as per Sec. 31 of FA 1948. It is in order. Compliance as per Sec. 31 of FA 1948. It is in order. Compliance as per Sec. 31 of FA 1948. It is in order. Compliance as per Sec.

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OBSERVATION RECOMMENDATION

pressure tested and certification from competent Person is available in Structural Mill. List of pressure vessels (29 Nos.) available in LMMM. Pressure test certificates issued by competent person on form no. 8 are available. List of pressure vessel and hydro test report by competent person is available in MMSM. Safety valves installed on pressure vessels (Lube Oil Accumulators) are not tested since its commissioning in WRM-1, WRM-2, SBM, Structural Mill, and LMMM & MMSM. Pressure gauges are not marked for Max. Safe working pressure in WRM-1, WRM-2, SBM, Structural Mill, LMMM & MMSM. Hydro test of pressure vessels carried out and Form No. 8 available issued by competent person at SP-1. Certificate for use of boiler issued by Dy. Chief Inspector Boilers is available at MMSM. There are 39 loco (WDS6-31 Nos. & WDS6AD-8 Nos.) in Traffic. The Solid State Interlocking (SSI) is very good system for enhance safety in Traffic.

31 of FA 1948. It is in order. Compliance as per Sec. 31 of FA 1948. It is in order. Compliance as per Sec. 31 of FA 1948. Safety valves should be tested periodically and record maintained. Pressure gauge installed on vessels should be marked with Red mark for Max. safe working pressure. Compliance as per sec. 31 of FA 1948 It is in order. Good safety system.

In TPP the air receivers which were

not tested as per the section 31 of the Factories Act, 1948.

It should be tested and results should be displayed on the air receivers.

4.2 TESTING & EXAMINATION OF LIFTING MACHINES & TACKLES

List of EOTs, wire rope slings, D-

shackle, Chain pulley block, Hydraulic Compliance as per Sec. 29 of FA

1948. Display board on EOTs required

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OBSERVATION RECOMMENDATION

Jack is available. Load test certificate from competent authority is available in WRM-1. List of EOTs, wire rope slings, D-shackle, Chain pulley block, Hydraulic Jack is available. Load test certificate from competent authority is available WRM-2 EOT Cranes-17 Nos. and Jib Cranes-14 Nos. are in operation in SBM. However the load test of the cranes by the competent person is overdue. Similarly other lifting tools such as Chain pulley block, wire rope slings, D-shackles etc, required to be load tested and record maintained. EOT Cranes and Jib Cranes-30 apart from manual chain hoist are in use at Structural Mill. All are load tested by the competent person and records are available. List of EOTs and lifting equipment and load test certificate in Form No. 38 issued by competent person is available in LMMM. List of EOTs and lifting tools & tackles are available in MMSM. The load test certificate issued by competent person is available. Two circular EOT cranes of 20 Ton/5 Ton are available and their load test certificates are in place at BF-2. EOT-2 Nos (35Ton/10 Ton) are for second floor operation. Load test certificate from competent person is available at BF-3. List of EOT cranes & other lifting

indicating test date & next due date. Compliance as per Sec. 29 of FA 1948. Display board on EOTs required indicating test date & next due date. All the EOTs, Jib Cranes and other lifting tools should be load tested by competent person and maintain the record. Compliance is not there as per Sec. 29 of FA 1948. Compliance as per Sec. 29 of FA 1948. Install display board on EOTs indicating test date & next due date. Compliance as per Sec. 29 of FA 1948. Display board required for Test date and next due date on all EOTs. Eye test records for crane operators are available. Compliance as per Sec. 29 of FA 1948. Display board required for Test date and next due date on all EOTs. Eye test records for crane operators are available. Compliance as per Sec. 29 of FA 1948. Compliance as per Sec.29 of FA 1948. Compliance as per Sec. 29 of FA

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OBSERVATION RECOMMENDATION

equipment is available and certificate in Form No.-38 available issued by competent personSP-1. List of lifting equipment is available and load test certificate from competent person is in place at Traffic.

1948. Compliance as per Sec. 29 of FA 1948.

The identification no. is not given to

lifting machine, chain pulley blocks, wire rope slings etc. The test details are not displayed on lifting machines. during visit it was found that hook latch on some of the hooks of EOT Cranes, chain pulley blocks, Hydra etc. were missing

The identification numbers should be given to all the lifting machines, chain pulley block, wire rope slings and the test certificate should be issued as per these id nos. The test details should be displayed on all lifting machines. ID No., SWL, Test date, Test load, Next due date should be written. All the hooks should have safety latch for locking the sling.

4.3 MANUAL AND MECHANICAL MATERIAL HANDLING

Manual material handling is done in

the power house for dosing of the chemicals in DM plant, Stores, QATD.

Noted.

Manual material handling is mainly

limited to small items. Proper PPEs are worn by the workers during manual lifting operations. They are trained and periodic pep talks are given to them.

Sec 34 of the Factories Act 1948 is complied.

Mechanical handling – consists of

forklifts, Hydra cranes, cranes, conveyor belts, truck, JCB, etc. All the equipment is load tested and certificate issued by competent authority is available. It has been noticed that eye test for crane and hydra operators are done

Complied as per Sec 29 of the Factories Act 1948. It should be continued.

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OBSERVATION RECOMMENDATION

as per statutory requirement.

4.4 HANDLING & STORAGE OF GAS CYLINDERS Oxygen cylinders, LPG cylinders were

used in the company as well as contractors for welding and cutting works. During visit it was found that most of the gas cylinders were not having end caps. The gas cylinders were not properly secure to avoid fall of gas cylinders. Gas cylinders were lying on the floors and at few places filled and empty cylinders were stored together. At cutting and welding sets flash back arrestors were not provided at both the sides (torch end and gas cylinders end) to avoid back fire till the source. The properties and hazards associated with the gas cylinders were not known to the workers handling the same. In many places the gas cylinders hydro tested date was over even though they were being used in the company.

Noted. All the gas cylinders should be kept vertically in a shed with proper chaining arrangement to avoid fall. Flash back arrestors should be provided on both the ends of gas cutting and welding sets to avoid back fire. Training should be arranged for the workers regarding same so that these workers can be aware while working and take necessary safety precautions during handling. Survey should be carried out in the company for all gas cylinders and due dates gas cylinders hydro testing should be carried out & then only these cylinders should be used which was required as per Gas cylinders Rules, 2016.

4.5 GUARDING OF MACHINES & DANGEROUS AREAS

RMHP Coal & Ore handling tipplers are

installed in two sheds and are in operation.

Warning lights at each tippler may be considered at the time of tippler operation for additional safe operating. Barricading at common shaft to be

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OBSERVATION RECOMMENDATION

Cable cellar man entry is partially open at coal tippler shed. JUNCTION HOUSE-5 (COAL SIDE) Top cover & Inspection windows were open during operation. Hand railing to staircase (5 Nos.) to foot over bridge is missing. A potential safety hazard. Chute opening (20 Nos.) at middle shuttle floor is potential safety hazard. Guard of motor coupling missing. Coal conveyor 28 & 29; tail pulley side area is open. Fire seen at many locations in the non-coking coal yard.(Photo below)

installed. Barricading at both ends required being potential tripping hazards. Cable cellar man entry area to be barricaded to avoid accidental slippage. Required to be closed during operation to avoid any accident. Hand railing should be provided. Immediate action required to provide grill to avoid any accident. Coupling guard should be provided. Side area of conveyor should be covered to avoid accident. Heat sensing arrangement and sprinkler system may be installed in the yard for taking early action to avoid frequent fire which results with lot of air pollution and loss of coal.

Laddle preparation area in SMS-1:

Platform for repairs of ladle is unsafe as railing all around is missing. (Photo below) Approach to ladle repair is unsafe. LPG hose and welding machines is in close proximity leading unsafe situation in CCS. Valve stem is partially blocking the way and potential safety hazard at CCS.

Provide proper railing. Approach to ladle should be proper. Welding machine should be kept away from LPG supply points. Corrective measure should be taken to ensure safety of workers.

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OBSERVATION RECOMMENDATION

Due to positioning of scrape bin, path is obstructed and someone head may hit canopy.(Photo below) Uptakes gas pipe lines at 45 mts. elevation is potential hazard for burn at BF-3. Monkey ladder (for hot blast valve telfer) cage is not as per standard & potential safety hazard at BF-3. Tap gas ignitor: Railing for some portion missing and chain for ladder is also missing BF-3. Sinter machine No1: Area is not barricaded around replaced hot ballet. Area is exposed at both sides along the moving bed. Door cover is not available at discharge head. A potential safety hazards (Photo below). Un-loader area is open at both sides. Removable barrier at vacuum chamber platform entrance missing is potential safety hazard. Water pipes at low elevation on platform above A6 conveyor are potential safety hazard for head injury. A cross beam in the way to staircase from platform above A6 to ground level is potential safety hazard for head injury. Straight Line Cooler pump pit is not properly barricaded.

Scrap bin should be shifted to other location to avoid possible head injury. Uptakes gas pipe lines should be provided protection from burn. Monkey ladder (for hot blast valve telfer) cage should be extended down to avoid accidental fall. Railing/chain should be provided to avoid accidental fall. Area should be barricaded around replaced hot ballet. Also display board for safety instruction to be provided. Barricading at both sides along the exposed area to be provided. Door cover should be provided on priority. Provide barricading to avoid accidental fall. Provide barrier. Display board for taking care of Head should be available. Caution board should be available as a temporary measure. Further alternate staircase may be considered as a permanent solution. Barricading should be installed to avoid accidental fall.

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OBSERVATION RECOMMENDATION

Stair case entrance leading to burner area in Zone 4 is unsafe in WRM-1. Portable grinder found without shield, with cable joint and without electrical plug. Should be corrected for safe operation WRM-1. Fence cover for rotating parts at Roll Chock not there WRM-2. Area at reducing & sizing mill (RSM) motor is unsafe for tripping at WRM-2. Pedestal Grinding Machine is unsafe to operate as safety shield is missing. (Photo below) End stoppers for transfer cars are potential tripping hazard at Special Bar Mill. Rotating parts at furnace entry is without protection at Special Bar Mill. Open area at roller table after shear No.3 at Structural Mill. Partial ramp near stand 17 to avoid tripping hazards at Structural Mill. Tilter in front of stand No.7 is exposed to movement of workers at Structural Mill. Hot bloom rejection area is open at Structural Mill. Barricading at entire length of cooling bed missing. Potential safety hazard.

Temporary barricading required to be provided at staircase entrance. Grinder should be maintained in proper condition as it is potential safety hazard. Compliance as per sec 21(i) of FA 1948 is not there. Fence cover should be installed at Roll Chock as safety measure. Barricading should be provided at reducing & sizing mill (RSM) motor to avoid tripping hazard. Pedestal Grinding machine to be provided transparent safety shields and safety instruction board. Compliance is not there as per Sec. 30 of FA 1948. End stoppers for transfer cars should be properly covered to avoid tripping hazards. Provide barricading at furnace entry point to avoid contact with rotating parts. Provide barricading for safety. Provide ramp in the entire width. Tilter in front of stand No. 7 should be provided with hooter and beacon light for safety during its operation. Provide barricading and display board that rejected material is hot and do not touch. Provide barricading at entire length of cooling bed

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OBSERVATION RECOMMENDATION

Scale chute of pump house 17 is potential safety hazard in LMMM. Pusher end of furnace 1 & 2 is open & unsafe at MMSM. End stoppers are potential tripping hazard at MMSM. Stair case leading to scale tunnel is unsafe at MMSM. Portable grinding machine found without safety shield in MMSM.

Provide proper barricading to avoid accidental slippage. Provide barricading to avoid accident. End stoppers for transfer cars to be covered to avoid tripping when not in use. Stair case leading to scale tunnel to be blocked (Near column no. 45) if not in use to avoid incidental fall. Safety shield should be installed.

4.6 MEANS OF ACCESS, PLATFORMS & RAILINGS

Good staircases with hand railings are

provided in most of the department. To be maintained.

Drains at all exit points (3 Nos.) are

not covered at SMS-2.(Photo below)

Provide cover on drains at all exit points for safety.

Railing for temporary platform missing

which is more than 6 feet high at 2nd floor in BF-3. Handrails to cross over platforms missing WRM-2. Cross over platform are not provided with railings after plant 21 at Special Bar Mill.

Provide proper railing to avoid accidental fall. Handrails should be provided on cross over platforms to avoid accidental fall. Provide railing at cross over platform.

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OBSERVATION RECOMMENDATION

4.7 PREVENTIVE MAINTENANCE SYSTEM AND RECORDS Preventive maintenance schedule and

checklist is in place for effective maintenance of equipment in RMHP. Preventive maintenance schedule for drill machine & mud gun is available in BF-2. Preventive maintenance system is in place and jobs are being carried out as planned in SP-1. Preventive maintenance schedule is monitored through Maintenance And Management System (MAMS).Detailed checklists are available for various preventive maintenance jobs in all the plants. Preventive maintenance schedule are being followed at MMSM. Preventive Maintenance schedule for Loco is in place and being followed religiously. Exhaustive check list for PM jobs is in place in Traffic.

Good system of monitoring and checklist for effective preventive maintenance is in place. It is in order. However checklist may be revisited to update as per guide line of equipment manufacturer. It is in order.

4.8 VENTILLATION, ILLUMINATION, NOISE

High level of noise observed near ID

Fans in ID Fan House at SMS-1. Lighting at 2nd floor seems to be inadequate at BF-3. Illumination is not upto the mark in the area in SP-1. Noise survey report is available in SP-1. Noise study has been carried out &

Noise survey required for the area near ID Fans. Display board for “high noise -use of ear plugs near ID Fan” should be installed in ID Fan House. Illumination survey at 2nd floor to be done to improve the lighting system More lights may be provided after proper illumination survey which is pending. It is in order. It is in order.

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OBSERVATION RECOMMENDATION

areas with higher noise level have been identified. Necessary display board indication high noise level-use ear plugs are available at WRM-2. Illumination study has been carried out during the day & after 6 PM at WRM-2. Illumination survey record for day time survey is available in LMMM. Noise survey record is available in LMMM. Lighting inside the mill seems to be inadequate in MMSM. Noise survey report is available and is within limit in MMSM. Lighting is very poor on all the floors in Junction House 5 in RMHP.

It is in order. Illumination survey should also be done at late evening. It is in order. Action should be taken to improve the lighting based on the illumination survey. It is in order. Additional lights based on Illumination survey.

4.9 SAFE OPERATING PROCEDURE

SOP (10 Nos.) for various operational

activities are available RMHP. Standard Maintenance Procedure (38 Nos.) are available RMHP. SOPs list is available in SMS-2. Standard Maintenance Practices (SMPs) - 6 nos. available in BF-2. List of Safe operating Procedures (SOPs-13 nos.) available in BF-2. SOP – 20 Nos. is available for various operations and being discussed SP-1. List of SOPs is available and being shared among staff at WRM-2.

It is in order. It is in order. This is in order. However SOPs should be discussed among operation staff on regular basis.

It is in order.

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OBSERVATION RECOMMENDATION

List of SOPs-19 Nos. are developed for various operation activities. SOP for various operational activities are available at MMSM. SMP for maintenance activities are available at MMSM. Safe Operating Procedure (18 Nos.) is available in Traffic. Safe Maintenance Procedure (58 Nos.) available and being followed at Traffic.

Emergency shutdown SOP was

checked in the WRM 2 in that general statements were mentioned like close isolation valves etc and the SOP was available in soft copy at the portal.

It was suggested that specific isolation valves numbers and locations should be mentioned in the SOP to make hundred percent operations specific SOP, Hard copy of critical parameters and emergency shutdown Sop should be displayed near the display board for ready reference of operator as emergency can took place once.

4.10 MANAGEMENT OF CHANGE

Management of change (MOC) is

considered as proposal under Addition/Modification / Replacement (AMR) schemes and is well documented procedure including impact assessment report.

It should be followed.

4.11 MONITORING OF WORKPLACE & STACK EMISSION ( TREATMENT AND

DISPOSAL OF WASTE AND EFFLUENTS) All the 36 stacks (after 6.3 MTPA) are

provided with on-line stack monitors &

minutes to minute’s data being posted

to CPCB site.

3 Nos. continuous ambient air quality monitoring stations within the plant

This is in order. This is in order.

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OBSERVATION RECOMMENDATION

Bio Medical waste generated in OHC was collected in four different colors dust bins and after sufficient stock collected it was given to the colony hospital for disposal the frequency of BMW collection by hospital twice in a week. The Colony hospital was having the authorization for disposal of BMW.

It should be followed.

WMD: This department handles all

types of water required for the factory, like, receiving raw water from river, drinking water, fire water, process water, treatment of effluent and discharging the treated water to sea. Organic effluent from CCP is given micro biological and chemical treatment and then sent to ETP plant along with sewage. The effluent after surface aeration and clarification is sent to sea.

Noted.

4.12 HOUSEKEEPING

Housekeeping and proper

arrangement of material is required In RMHP. Housekeeping to be improved. Workers sweeping the floor are without dust mask-potential health hazard in SMS-1. Materials are lying haphazardly and housekeeping is not there in SMS-2. (Photo below)

Proper stacking of material & regular housekeeping required in all the area. Workers should be provided dust mask for sweeping. Major housekeeping and proper stacking of material required for safe environment.

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OBSERVATION RECOMMENDATION

Housekeeping is reasonably good in the plant in Blast Furnace-2. Housekeeping is good and material is properly stacked in WRM-1.

It should be maintained.

4.13 PERSONNEL PROTECTIVE EQUIPMENTS (PPE)

Workers found on job without safety

shoe & helmet at continuous Casting Department of SMS-1. Loco operators are using proper PPEs in Traffic. Shunting Porters are wearing not Retro-reflective jacket in Traffic.

Proper PPEs should be ensured. It is in order. May visit “Safety Standard on Loco Operation in Steel Industry- IPSS:1-11-033-17” adopted in January 2017 for required improvement. Retro-reflective jacket for Shunting Porter may be considered for easy identification. Many safety precautions listed may be reviewed for adoption as required.

Stock of PPEs is maintained by the

contractors. Satisfactory compliance.

PPEs are procured conforming to

national standard. Proper system of issue/replacement of PPEs is in place.

Satisfactory compliance.

4.14 WORK PERMT SYSTEM (WPS)

Company was having work permit

system to work on any job. The validity of the permit system was mention on the permit was one day, if any work was required extension then the permit was extended by the authorized person.

The work permit was a written statement given by the concern person that the work can be executed as the necessary isolations were done and safe to work. It should be followed.

During visit we checked the filled work

permit copies, it was found that all permit columns were not filled, concerned person signature was not

All the details asked in the Work permit format should be filled fully as it was for the safety of the people working on the job.

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OBSERVATION RECOMMENDATION

available on the permit. Permit system- Permits are cleared by

Operation department; however no records are available with them in SMS-2 however in STED the register was maintained for tracking and noting the numbers of work permit issued on the particular date. Permit system is in place at WRM-2

It should be reviewed and Permits records should be available in Control Room for tracking and closure of permit should be ensured. It is in order.

4.15 STATUTORY WARNING

There is no additional hazard specific

safety board at unloading area of Torpedo at SMS-2. Material is lying just below safety shower making it unusable in case of emergency at SMS-2.(Photo below)

Hooter/warning light during movement of EOT Crane with ladle in SMS-2. No display board for safety precautions found at prominent places in charging area of SMS-2. Ambulance is available on 24 hrs. basis to take care of emergency in

Display boards for safety- Do not come close during unloading of Torpedo ladle car process. Nothing should be dumped at safety shower area. May consider. Display board for safety precautions required at prominent places in charging area. This is in order. However it should be cleaned regularly from inside.

4.16 ROAD SAFETY

Speed limit boards are not available

on road side. Speed limit boards should be visible

along the road.

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OBSERVATION RECOMMENDATION

Four wheeler/truck drivers are playing with high speed. Two wheeler persons are not using helmet and sometimes three persons are riding.

Training on road safety should be given to all drivers to observe speed limit inside the plant area. Helmet should be made compulsory & not more than two persons should be allowed to move on two wheelers.

***

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OBSERVATION RECOMMENDATION

PART – 5

CHEMICAL & PROCESS SAFETY

5.1 STORAGE & HANDLING OF HAZARDOUS CHEMICAL INCLUDING TANK

FARM The hazardous chemicals like

Benzene, tar, Sulphuric acid 98%, BF gas, Chlorine, CO gas, LD gas etc were stored in the storage tanks. The details were discussed in the area wise observation.

Noted.

5.2 CHEMICAL TRANSPORTATION SAFETY

The loading & unloading SOPs

displayed at the plant site do not mention about checking the safety training of drivers transporting hazardous chemicals required as per CMV Rules and checking of LPG tankers before unloading. There is no training given to the drivers in the factory.

The drivers transporting hazardous chemicals need to be trained as per CMV Rules. For LPG takers, safety certificates of tankers, test certificate of safety valves and excess flow check valves may be checked before unloading. The drivers may be given on the spot training/ advice regarding handling of hazardous chemicals.

5.3 MATERIAL SAFETY DATA SHEET (MSDS)

MSDS of the hazardous chemicals are

available. Brief MSDS and DOs & Don’ts board are placed in storage and handling area of hazardous chemicals

Compliance related to MSDS has been achieved. All plant personnel may be given periodic training in hazardous properties of chemicals.

5.4 LABORATORY SAFETY (QATD)

RINL Vishakhapatnam steel plant was

having Quality Assurance Technical Division (QATD) section in which quality of products was checked. Total staff of QATD was 330 workers.

Noted.

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OBSERVATION RECOMMENDATION

The analytical instruments were used in the QATD for weight, strength checking etc. These instruments were calibrated as per the frequency mentioned in the safety manual and records were available for verification. Weight balances were calibrated by Sri Calibrations Services from Secundarabad. Vernier and screw cage, micrometers were calibrated from calibrating agencies. For in house calibration of instruments authorization has been given by company for few persons.

It should be continued. Noted.

HIRA study has been carried out for

twenty five activities of the QATD but in this study the legal requirement of IE rules were considered.

Now a day’s Central Electricity Authority Regulation 2010 was used in INDIA instead of IE Rules, 1956 hence the legal requirement as per CEA 2010 should be considered in HIRA study.

There was chemical laboratory in

which chemical analysis was carried out for effluent water. During visit to the laboratory area it was found that ceiling of most of the rooms were in damaged condition and repairing work inside few rooms were in progress.

Ceiling should be attended.

The mandatory PPEs were Safety

Shoe, helmet, Hand gloves, and eye goggles during operation at laboratory. Chemical compatibility chart was not prepared for storage of chemicals in the laboratory. If any chemical spilled on the floor then it was cleaned with the help of cotton and then placed in the dust bin.

It should be warned during operation. The chemical compatibility chart should be prepared and accordingly chemicals should be stored. Emergency spill kit should be provided at laboratory for handling the spillage of hazardous chemicals in the laboratory.

Dust extraction system was installed It should be maintained in good

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OBSERVATION RECOMMENDATION

in the laboratory for dust removal. AT laboratory AC were provided but no fire detection system was installed only first aid fire fighting extinguishers were placed on the floor moreover the workers were not aware about the hazards associated with the Portable fire extinguishers. Laboratory worker was not aware about the hazardous properties of the chemicals handled during the titration work. The solution of .1 N Sulphuric acid was prepared on 09/04/2018 was available in the rack which was supposed to expired on 26/12/ 2018.

working condition to avoid dust accumulation. For early detection of smoke or fire detection system may be provided and the fire fighting training should be arranged for lab workers to know about the hazards associated with handling of PFEs Ensure that the working staff should be having knowledge of hazardous chemicals properties and first aid measures in case of spilled on body part. It should be discard from the laboratory and ensure that no such solution was available on the rack.

Eye washer and safety shower was

provided in the corridor of the laboratory premises but there was no water flow coming from same.

Eye washer and safety shower was necessary in case of any chemicals were spilled on the body part hence it should be always in working condition as it was considered as emergency handling equipment.

During visit it was found that the PFEs

were placed on the floor and the combustible materials were stored inside the panel box number 34 of electrical supply which may lead to fire.

All PFEs should be installed on the wall as required under AP Factories Rules and fire potential materials should not be placed in the electrical panel boards.

5.5 COLOR CODING OF PIPELINES

A color code is used for the chemical

lines in the factory. The code followed is not strictly as per IS 2379 (1990) in all places. In one area in LPG tank farm LPG pipeline is seen painted in violet color. Flow direction is marked in many places.

Pipelines may be painted using color code as per IS 2379 (1990).

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OBSERVATION RECOMMENDATION

5.6 STATUTORY WARNING AND LABELING

Statutory warning is displayed in the

company premises such as Speed limits, Use of Helmet, Danger boards etc. Safety slogans were displayed in most of the premises for creating awareness amongst the workers.

Standard statutory warnings should be displayed in the company premises for enhancing the safety culture and awareness amongst the workers.

***

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OBSERVATION RECOMMENDATION

PART – 6

FIRE PREVENTION, PROTECTION AND MITIGATION

6.1 FIRE HAZARD OCCUPANCY

A. The factory being a steel plant is of

High Hazard Fire Occupancy, Sub Category A, as per para 7.2.3 of TAC Fire Protection Manual.

B. The Factory is of High Hazard Fire Occupancy, Category A, as per NBC Annex B, because it is: i) A steel plant ii) Has bulk storage of flammable

liquids iii) Engaged in manufacturing

chemicals with F.P. <230 C. C. The factory is a Major Accident

Hazard (MAH) factory due to storage of flammable gas (LD gas) above the threshold limit (>200 MT) as per schedule 2 part 2 of MSIHC Rules.

D. The Factory uses hazardous processes:

• Integrated steel plant

• Coke oven gas byproduct recovery as per the First Schedule of the Factories Act, 1948.

The factory has adequate fire fighting capability in terms of manpower and other resources compatible with the fire risk. The factory is in compliance with requirement as per MSIHC Rules.

6.2 ORGANIZATIONAL SET UP FOR FIRE FIGHTING

The Fire department in the Factory is

managed and manned by CISF. There are totally 246 CISF personnel engaged in the Fire Department. The organizational set up for Fire Department is:

Fire department is well organized and all team members are adequately qualified.

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OBSERVATION RECOMMENDATION

GM (SHE)

Dy. Commandant (Fire)

Asst. Commandant (Fire) The deployment of fire staff per shift in Main Fire Station is as below:

Sub-Inspector (2)

ASI (2) Head Constable Fire (7) + Head Constable Driver cum pump operator (1) Constable Fire (9) + Constable Driver (3) Deputy Commandant is BE (Fire). All Inspectors and sub-Inspectors have undergone Station Officer course in CISF Fire Service Training Institute, Hyderabad while SI and ASI have done Sub-Officer courses. Constables have undergone 1 year basic course in fire and security.

6 Inspectors 1) Fire coy commander & In-

charge of Main Fire Station

2) Fire Store

3) Fire Operation

4) In-charge CO-CCP Fire Station

5) Fire MT section

6) Fire Prevention & In-charge of

New Fire Station

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OBSERVATION RECOMMENDATION

6.3 FIRE STATION, FIRE TENDER, FIRE HYDRANT SYSTEM & MONITORS, There are 3 fire stations in the factory,

viz, the Main Fire Station, CO-CCP Fire Station and New Fire Station. All are manned in 24X7. The Factory has 12 tenders. These are: Water 2, Foam 5, DCP 1, Rescue 1, Mini tender 1, Multipurpose 1 and Hydraulic 1. The factory has a pressurized network of fire hydrant system maintained at 7 kg/cm2 g pressure. The system consists of about 3500 hydrants and monitors. The external hydrant system pipelines are placed underground while the internal (within plant area) lines are aboveground. The layout drawing of fire hydrants is available and reviewed. Hose boxes are located near the hydrant posts and in many cases fire hoses are removed from the hose boxes and kept in nearby secured places.

The fire hydrant system is adequate and well maintained.

6.4 FIRE PUMP HOUSE

There are 28 fire water pump houses

in different locations in the factory. All pump hoses have electrical main pump, diesel pump and jockey pumps. Visited pump house WRM 2. It has 2X 273 m3 overhead concrete tanks. Water tanks are inter-connected. The pump house has positive flooded suction. Automatic systems are in place for starting of jockey pump and electrical pump in all phase 2 pump houses while the operations are manual in phase 1 area. Also in phase 1, the

Adequate fire water availability is ensured for more than 4 hours as the fire water tanks are inter-connected. Automatic starting and stopping systems for jokey pump and main pump may be implemented for the phase 1 fire water pumps.

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OBSERVATION RECOMMENDATION

drinking water is used as fire water.

6.5 FIRE DETECTION AND ALARM SYSTEM Following FDA are used.

• Smoke detectors 13357 Nos

• Heat detectors 3106 Nos and

• 1495 Nos of MCP. The monitors of the MCP are placed in the respective control rooms and also in Main Fire Station.

Following types of fixed fire fighting installations are in place:

• CO2 flooding system 35 Nos

• Clean agent flooding system 28 Nos

• Foam flooding system 15 Nos

• Foam pourer system 4 Nos

• Water spray/ drenching system 41 Nos

• Water & foam monitors 41 Nos Checked the healthiness of one of each type of system for following

• Activation of detectors Inergen gas system in WRM 2 ECR 1 control room.

• Activation of smoke detectors in +5 m cable gallery

• Heat detectors in Lube B oil cellar heat detector for CO2 flooding system. Empty drums and parked two wheelers are noticed near the entry.

• LMMM oil cellar 7 foam flooding system. It is observed that foam is unable to flood the oil tanks as the area is not closed. The plant area is poorly illuminated.

The system is good and should be maintained in same way in future. Housekeeping may be improved. In LMMM oil cellar 7 foam flooding system may be reviewed as the foam is unable to flood the tank and spreading on floor only.

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• Load block distribution station 2 RP cable gallery water spray system.

Illumination may be improved.

6.6 PORTABLE FIRE EXTINGUISHERS

About 11000 PFEs are deployed in all

areas. PFE used are of foam, water, DCP, ABC and CO2 type. About 10% spare is also available in store. Big portable extinguishers are seen not secured to wall in some cases.

Fire extinguisher deployment is adequate. Big extinguishers may be secured by chain or bracket to prevent fall. It should be maintained.

6.7 UP KEEPING/ MAINTENANCE OF FIRE FIGHTING EQUIPMENT

The Fire Department has a Prevention

Unit headed by an Inspector who carries out inspections of all fixed fire fighting systems and PFEs. Pump houses are maintained by WMD and hydrant system is regularly checked by Fire team. Records have been reviewed. Up-keeping of portable extinguishers are done by Fire Department. Hydrostatic pressure test (HPT) of CO2 extinguishers, CO2 cartridges and BA set cylinders are done as per rules and test certificates are available. Certificates were reviewed. PFEs are checked quarterly and the last date of inspection is written on each extinguisher. FDA and other fixed fire fighting systems are inspected jointly by Fire and Operation team (monthly and quarterly) and records have been reviewed.

Procedure for up keeping of firefighting equipment is satisfactory and should be continued. All inspection records are well maintained.

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6.8 FIRE INCIDENCE REPORTING & RECORDING SYSTEM The system of reporting, recording

and investigation of fire incidents is in place. All fire calls are recorded in the Fire Call register in fire station. The register was reviewed; there were 395 fire calls in 2018. Fire incidents investigation is done by a committee set up in accordance with the seriousness of the incident. Reports have been reviewed; but the file does not contain records regarding the implementation of the recommendations made by the investigation committee.

The purpose of investigating a fire incident is to find and eliminate the root cause so that such incidents do not recur. So it is important to implement the recommendations.

6.9 FIRE PREVENTIVE MEASURES

Following fire preventive measures

are in place: 1. Hot work permit system 2. Monitoring and routine inspection

by fire prevention team 3. Training

Fire preventive measures are satisfactory and may be continued.

6.10 COMMUNICATION SYSTEM FIRE STATION

Following are used for communication

with Fire office: 1. Intercom and hot line 2. Mobile 3. Walky-talky - VHF sets 4. Manual call Points (MCP) alarm

This is OK and may be continued.

6.11 FIRE FIGHTING TRAINING

Fire training to employees and

contractors is given by the Prevention Unit of Fire department. In 2018.

A mandatory fire training schedule may be prepared for all employees and contractor workers. All should receive fire training at least once in a year. During training hazards associated

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with handling of PFEs should be taught for enhancing the awareness of workers.

6.12 DOCUMENTS RELATED TO FIRE SAFETY

The following fire related documents

have been reviewed:

• Fire Order

• Fire manual

• Fire call register

• Hydrant layout

• Maintenance record for PFE and fixed firefighting equipment

• HPT certificates for extinguishers, etc.

Fire NOC for the factory was not available for review.

This OK. Records and documents are well maintained in Fire Station. The Factory should ensure that valid Fire NOC is in place.

***

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OBSERVATION RECOMMENDATION

PART – 7

ELECTRICAL SAFETY

7.1 COMPLIANCE WITH CEA REGULATION, 2010 AND RULES Permission of Chief Electrical

Inspector (T&D) Andhra Pradesh, for initial charging & commissioning of electrical System:- a) Initial charging clearance

permission from Electrical Inspector is seen for newly commissioned 14 MW TRT & 20.6 MW NEDO Generator.

b) Periodical Inspection of Electrical

System by State Electrical Inspector is not found during audit.

It is suggested to intimate in writing to Electrical Inspector, after the system is commissioned & charged. These documents may be made available for other sub-station also. a) As per section 43 of CEA

Regulations 2010 the subject approval, drawings, Testing record are required in compliance for all the installations above 650v.

Any new addition is made to the

existing Electrical system is to be done with permission from State Elect Inspector

b) As per CEA Reg. 2010 no 30(2):-

The periodical Testing & Inspection of installations of voltage above 650 V belonging to the supplier, shall be carried out at intervals not exceeding Five years by Electrical Inspector,

Designated Person(s) to operate & carry out work on Electrical lines & apparatus. Competency certificates of Contractor from State Electrical Inspectorate : An individual department has not entered in a register, the name of Contractors working under them & having Electrical work permit from State Govt.

During audit at DNW sub-station, competency certificate - Electrical Contractor’s License “A” grade of M/s Vijaya Enterprises from Telengana Electrical Licensing Board & M/s Madhu Construction Company from Andhra Pradesh Electrical Licensing Board , has been checked :- This is required as per CEA Reg 2010 number 3(3)(i) These entire Contractor’s name is to be entered in a Register as per CEA

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Sub Reg (3) (ii) of Reg 3. All Contractors working on Electrical Lines & apparatus must have Electrical work permit from State Government.

Name of Designated Person(s) of

Department It is found that each Electrical Department has maintained a Register with name of Officer/Supervisor/Technician with designation, no of years of experience on relevant field & duly approved by a Senior Person of department. This is required as per CEA Sub Reg (2) of Reg 3. However training taken by the Designated persons on relevant field & from recognized training institute is not mentioned

These registers shall be produced before Electrical Inspector when required by him, as per CEA Regn 4. Training of above person(s) may be given as per CEA Reg 2010 number 6. The certificate of recognition of Training Institute, issued by CEA may be displayed by the Institute at its website.

Designated Electrical Safety

Officer/Officer(s):- Designated Electrical Safety Officer from within the organization is not recorded by individual department.

As per CEA Reg 2010 number 5 i. Sub Reg (1)-All suppliers of

electricity including generating companies, transmission companies and distribution companies shall designate Electrical Safety Officer Officer(s) from within the organization, for ensuring observance of safety measures specified under these regulations, for construction, operation and maintenance of power stations, sub-stations, transmission and distribution lines.

ii. Sub Reg (2)- The Electrical Safety

Officer shall be an Electrical Engineering degree holder with at least five years of experience in operation and maintenance of electrical installations or an

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OBSERVATION RECOMMENDATION

Electrical Engineering diploma holder with at least 10 years of experience in operation and maintenance of electrical installations.

iii. The Electrical Safety Officer under

Sub Reg number (1) shall carryout periodic tests and inspection of electrical installations for ensuring observance of safety measures at least once/year & keep a record of test reports. ( in Form I or Form II or Form III or Form IV as the case may be, of Schedule IV). He will also keep a register of recommended safety requirements duly acknowledged by the owner of installations with date and compliances thereafter. Such records shall be made available to the Electrical Inspector, as and when required.

CPR (Cardio Pulmonary

Resuscitation) Technique & First Aid :- The CPR chart is NOT displayed prominently & in proper condition at all Switchgear rooms. Record is not available that, all Operating Personnel in the electrical system are trained with CPR technique. During audit it is found that CPR technique charts are old/damaged & improperly supported/hanged on few switchgear room walls. Sufficient number of First Aid Boxes are not provided & maintained at appropriate locations. Ref CEA Reg 2010 no 27(3) & IS: 13115.

To print new CPR charts & display them with frame on walls of ALL switchgear room. CEA Regulation 2010 regulation number 28(2) should be complied with to ensure that all the persons, (including outsourced manpower), designated for the electrical work are acquainted with the CPR technique. It is recommended that such charts in English, Hindi and local language should be conspicuously displayed in compliance with CEA Regulations 2010 regulation number 28(1). Address & Tel no of nearest doctor, ambulance service & fire service is to be displayed near chart & near First aid box.

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All Designated Person (s) are not trained in CPR & First Aid & the list of such persons are not entered in a register.

At least one designated person must be available in a shift who is trained in CPR & First aid

Display of Danger Notice/Plate with

Skull & Voltage Level are not displayed and “Unauthorized Entry prohibited” board:- These boards are NOT displayed at the entrance door/gate of all charged Sub-station/Switchgear room/panels. During audit, the display is visible at the entrance gate of only at 220 KV switchyard & few other outdoor yards.

As per CEA Regulation 2010, regulation number 18, every Electrical installation shall affix permanently in a conspicuous position a danger notice in Hindi , English and the local language, with a sign of skull and bones of a design as per IS -2551. Also “Unauthorized Entry prohibited” notice is to be displayed at every entrance door/gate of outdoor yard & switchgear room.

Insulating Rubber mats in front of All

Switchgears Insulating mats are found, provided at front panels & also rear side of switchgears. But in some location these mats are old & torn/damaged condition. One has to remove insulating mats to carryout HT breaker rack in/out operation as the gap between floor & breaker trolley is less in comparison to thickness of mat.

It is suggested to use Epoxy insulating paint in front of HT switchgears to facilitate smooth breaker rack in/out operation. Technical detail of paint is shared with TPP Engineer. As per CEA Regulation 2010 regulation 19 (5), for safety of operating personnel, all non current carrying metal parts shall be earthed & insulating floors or mat of appropriate voltage level conforming to IS-15652:2006 shall be provided in front & rear panels, where such personnel are required to stand to carry out operation & maintenance or testing work.

Fire prevention, protection &

mitigation (Organizational set up for Fire fighting / portable fire extinguishers / fire detection & alarm

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system)

• Fire Extinguishers are found kept on the floor of switchgear & cable gallery

• Many Fire buckets are found empty.

• An artificial respirator is not available & Gas masks are not available

• The locations of fire extinguishers & first aid boxes, Gas masks & artificial Respirator are not displayed & Artificial respirator is not provided

• FDA- Fire Detection alarm system at Cable gallery & at Switchgear room are available & checking is done monthly once with protocol & defects are signed by representative from operation, CISF fire wing, maintenance & safety. HOD review the defects raised & get them

• Fire Extinguishers are to be mounted on the wall. Refer CEA Regulation: 2010 for measures relating to Safety & Electric supply, Regulation no 27(2) & IS 2190.

• Fire Buckets, filled with clean dry sand, in addition to fire extinguishers, are to be marked & kept in every enclosed substations & switching stations in convenient location. Ref CEA Reg 2010, Reg no: 27(1)

• An artificial respirator shall be provided in every manned generating station, substation or switching station of voltage exceeding 650 V. Regn 28 (3) which is shifted to 27(5)

• Two or more Gas masks shall be provided & installed & maintained at accessible places in every Generating station with capacity of 5 MW & above and enclosed substation with transformation capacity of 5 MVA & above for use in the event of Fire & smoke. Ref CEA Reg 2010, Reg no 27 (4)

• The locations of fire extinguishers & first aid boxes, Gas masks & artificial Respirator shall be displayed in the control room & operator cabin.

• Testing of FDA- Fire Detection alarm system is a scheduled programme, it is recommended that all members or their representative needs to be present during testing for quick response of the problem.

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attended.

• Cable entry/exit holes are not sealed with fire resistance paste

• It was observed that some Transformers of 10 MVA & above rating are not provided with Automatic High Velocity Water Spray system or N2 Fire protection system

• It was observed that Fire water system is available at 11 KV cable gallery of TPP, but it is NOT kept in service

• Power & control cable entry/exit holes at floor or wall, are to be sealed with fire resistant paste to prevent propagation of fire from one location to another location

• It may be noted that all Transformers of rating 10 MVA & above are to be provided with HVW spray system (design, installation as per IS 15325) or Nitrogen Injection Fire Protection System. Ref CEA Reg no 44 (2)(ix). Urgent attention is required for protection of these Transformers.

• Fire water systems, which are available at cable gallery, may be kept in service.

7.2 TESTING & EXAMINATION OF ELECTRICAL MACHINES & EQUIPMENTS

It was observed that, Electrical

Testing Lab is centralized & under the control of DNW section. Numerical relay Test kit (Freza- Pronovo make), BDV oil test kit from Meggar (automatic), Dobble Tan delta test kit, Hi pot test kit, TRM25 Winding Resistance test kit, Breaker timing kit (Scope), DCRM kit (Scope), SFR kit (Scope) & LA test kit (SA30 I) are available. Relay setting gradients is checked by PRDC Bangalore 2 years back. Infrared Thermograph is not done in a scheduled manner One 90 MVA Transformer DGA was not done during sample audit check. At DNW, battery bank 400 AH x 2 Capacity test is not done as per OEM

It was suggested to carry out Infrared Thermograph once in 6 month after mapping all probable hot points. DGA of all HT Transformer is to be done once /year. The DGA report & all other Electrical test results are to be shared by DNW with all concerned area HODs for making action plan & trend analysis by individual section. All battery system Capacity test is to be done as per schedule,

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recommendation. Now single bank is in service. 2nd bank procurement in progress.

recommended by OEM.

7.3 PREVENTIVE MAINTENANCE PRACTICES

It is observed that, very often

breakdown maintenance is done. There are oil leakages, silica gel become pink, WTI indicator are not working in transformers as preventive maintenance is not done for outdoor Transformers of different areas. No scheduled preventive record could be seen during audit. At RS & RS list of work for preventive maintenance (for CNC Lathe (05/01/2019) is maintained.

Standard Maintenance schedule & Practices (SMP) of all electrical equipments are to be prepared as per O&M manual & experience of repeated failure if any. This is to be followed & record is to be kept for reference.

7.4 ELECTRICAL WORK PERMIT SYSTEM & LOTO PROCEDURES

Lockout & Tag out (LOTO) system for

Permit work system is not followed. Manual Permit format is used & a PTW register with all details is maintained. Caution tag is used at electrical supply source, but in some cases without PTW number or name of person who Issued or received the PTW. PTW is issued after getting written clearance from Operator of equipment on the PTW format. In some cases, white copy of PTW is not signed after cancellation & normalization

Start LOTO system. Requisition Copy (either red or blue) of PTW form may be kept on a separate file, after completion of job & signature by concerned designated person(s). It is suggested to review PTW format for introducing column for mechanical isolation or Gas isolation, if any.

7.5 ELECTRICAL HAND TOOLS: INSPECTION & RECORD KEEPING

Electrical Hand tools like Insulation

Tester- 500V & 5 KV, Hand gloves, pliers, spanners, Multimeters are used by Electrical operator for testing/isolation/normalization. No record regarding testing of all these instruments are found during

Electrical Hand tools are to be tested at least once a year either by centralized Electrical Lab at DNW or by an NABL accredited testing lab & record of the same is to be kept. Defective tools shall be replaced with new ones immediately

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audit. At one location, the metallic tips of leads of Multimeter & Meggar are found dislocated from insulating grip portion, which is highly dangerous as finger may come in contact with live part, during testing. Electrical Arc Flash suit are not used during Isolation/Normalization of Electrical supply

Electrical Arc Flash suit should be used during Isolation/Normalization of Electrical supply

7.6 SAFETY IN TEMPORARY WIRING

It is observed that temporary wiring

with joints & without plug/sockets is used. At TPP, one HPSV lamp, temporary wiring is found fixed on the lattice structure of a tower in outdoor yard. At DNW area, temporary light supply is given from switchgear & its supply panel door is kept open, as its door cannot be closed due to fouling of temporary cable. Lizard/rat may enter to cause flashover.

Temporary wiring should never be a long term solution.

• Safety for Electrical Installation other than voltage not exceeding 250 V needs to be followed:- Use Of Residual Current Device : whose residual operating current shall not exceed 30 mA for protection against electric shock & 300 mA for protection against fire due to leakage current, so as to disconnect the supply on the occurrence of earth fault or leakage current. Ref CEA 2010 Reg 42 & IS/IEC 61008-1 & IEC 60364-4

• RCCB/ ELCBs are to be tested before use along with cord & its current carrying capacity. Industrial plug with heavy duty cables (indoor/outdoor type) must be used. Temporary bulb must be enclosed in a cage. 24v lighting supply must be used for working in confined space. Experienced & qualified person shall maintain the temporary supply system with a record of supply source from where it is given & it must be removed immediately after its use.

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7.7 FLAME PROOF ELECT EQUIPMENTS & FITTINGS It is observed that, flame proof light

fittings and flame proof enclosure for motor terminal box of exhaust fan are not used in Battery Room

These fittings are to be used in areas where flammable /petrochemical/oil vapors and/or pulverized coal dust exist or potential to exist, so that explosion or flames may be produced within them due to arcs, sparks while switching the lights) Flame proof Equipments/motors are designed to withstand any damage due to the pressure caused by an internal explosion & also to prevent flame propagation outside.

7.8 LIGHTENING & SURGE PROTECTION SYSTEM / STATIC ELECTRICITY PREVENTION & DISCHARGE SYSTEM

It is observed that, in 220 KV outdoor SWYD at TPP, leakage current indicator is not working in one of the Lightning Arrestor (LA). Testing of LA is not done at regular interval. Presently used Discharge rod for earthing, are found not in good condition- hand made (jugad) with copper cable with insulated tape wherever it is brittle

• It is suggested to prepare a walk down checklist for various equipment of outdoor switch yard like SF6 breaker, LA, PT etc & shift operator may fill it during yard visit on daily basis.

• Lightning Arrester (Zinc Oxide Gapless type) testing is to be done once/year to ensure healthiness.

• 220 KV outdoor Switch yard fence is to be earthed. It is to be permanently connected to earthing grid to prevent shock from static charge

• It is suggested to procure High Voltage detectors( 230V to 33kV & 11kV to 220 kV) from reputed company & are to be used as a safety device to verify that overhead line/HV switchyard/distribution lines/ switchgears is not live prior to earthing. It indicates the presence of High voltage by audio & visual annunciation with flashing red LEDs. It is a non contact type powered by a 9v battery. It is supplied with a HV detector probe & Telescopic

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Insulation stick.

• It is also suggested to procure Discharge rod which are used to discharge static charges to earth pit after power isolation of 220 KV outdoor Switchyard/33kv/11KV/6.6 kV/415v system, High voltage devices such as Cables, Capacitors, Insulators, Bus bars retain their charged energy even after switching off supply.

Earthing Discharge rod discharges the static charge to the earthing pit & protects the operating personnel from electrocution. FRP Discharge rod (length varies as per voltage level) with heavy duty copper tip, robust fiber glass make, maximum discharge capacity & flexible copper cable may be used.

7.9 EARTHING SYSTEM

• It is found that, Earth resistance

measurement record is maintained in register. But during site visit, it is found that, many Earth Pits are found not exposed, (buried in earth/debris), not cleaned, not accessible & not identified & earth resistance measured with date/due date are not displayed near the pit. It appears that at these locations, the earth pit resistance is not taken regularly.

• Earth pits location along with earth mesh drawing is not available

As per CEA Reg 48 (8), Resistance to earth shall be tested on a dry day during dry season not less than once a year & record to be maintained. Also, Ref CEA Reg 2010 no 41 & 48:- a) All non current carrying metal parts

associated with electrical installation shall be effectively earthed to a grounding system or mat to limit touch & step potential to tolerable values. To limit the ground potential rise to prevent danger due to transfer of potential through ground, cable sheath, fences & pipe lines

b) Neutral point of every Gen & Traf to be connected to earthing system not less than two separate & distinct connections without touching the

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frame , Ref IS 3043

c) The grounding resistance value should be < 1 Ohm. Low resistance will easily ground the lightning surges to prevent insulation failure of transformer and also maintain low touch & step potential inside substation. (BF1- Earth pit resistance is high 13.33 ohm at 5LBDS & 11.54 ohm at DG room – To be improved urgently)

d) It is to be ensured that, Earthing

strips from Switchyard Tower Earth Shield wire, High Mast tower (spikes from topmost tower), all equipments body, Transformer neutral are to be connected to substation earth mesh either directly or through earth pit.

7.10 EMERGENCY LIGHTING SYSTEM

It is found that emergency lights are

fixed at control room & same was checked ok by auditor at few locations, by switching off the normal supply. But schedule of checking is not found

It is suggested to give an identification number to every emergency lights & a record is to be maintained which are defective during schedule check, so that defect can be attended immediately. In addition, torch light may be provided to all shift personnel.

7.11 ELECTRICAL SAFETY & PERSONAL SAFEGUARDING

It was observed that at TPP

switchyard, Safety helmet & safety shoes are not used by contractor Employees during shutdown bay maintenance work on 21 Feb 2019.

Ref: CEA Reg 2010, Sec 19(2), Every person who is working on an electrical supply line or apparatus or both shall be provided with PPE, tools & devices such as rubber gloves (IS 4770) suitable for working voltage, Safety footwear (IS 15298), safety belts for working at height (IS 3521), non conductive ladder, earthing devices of appropriate class, helmet

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OBSERVATION RECOMMENDATION

(IS2925), voltage detector(IS 6863, 6864, 6865 & 6866 as applicable) hand tools (IS 13772) , Arc flash suit for LT & HT isolation/normalization use. These PPEs shall be maintained in sound & efficient condition.

7.12 ELECTRICAL ZONE CLASSIFICATION

No Electrical Zone Classification was

found during audit for switchgear/outdoor yard battery rooms. It is observed that Apron is not used by personnel while working at battery room (ex- Dupont Tychem. C Apron). SOP for battery bank to be displayed inside Battery room. Exhaust Fan are provided inside some battery room, but they are found not working.

It is suggested that, all Battery banks may be classified as Zone1; Group IIC &Temperature class T1. A lead acid battery emits Hydrogen during normal operation and during charging (at varied rate) & creates hazardous area inside sealed Battery Rooms. Hydrogen gas becomes explosive at a concentration between 4 percent & 75.6%. Over-charging a lead acid battery can produce hydrogen sulfide. The gas is colorless, very poisonous, and flammable (and has the odor of rotten eggs). It is recommended that, a) It is recommended to fix flame

proof enclosure motor for Exhaust fan. Flame proof enclosure Lighting & JB’s are to be provided.

b) H2 Gas detector may be inside battery room, which may control exhaust fan Operation whenever H2 concentration is >1%

c) Portable wall mounted Eye-wash shower may be provided.

d) PPE”s like Acid protective apron, Chemical splash face-shield & goggles, 12”Neoprene Hand gloves & Mat boots must be used during battery charging/discharging operation (to handle Sulfuric Acid which is potentially highly corrosive chemical & is explosive in

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concentrated form . It can cause severe skin burns, can irritate the nose and throat and cause difficulties in breathing if inhaled, it can burn the eyes and possibly cause blindness, and can burn holes in the stomach if swallowed. Lead can be a health hazard if not properly handled.

e) Fire extinguishers (class A, B, C) are to be kept inside battery room.

7.13 SAFETY W.R.TO UNDERGROUND CABLE WORK /LT PILLARS ETC.

INSTALLATIONS & WORK PRACTICES It is found at DNW that clearances are

taken from various departments during cable excavation work. Caution is mentioned before making trial hole.

It is recommended that, GIS- Geographical Information System may be prepared /mapped on Google for underground Cable route, underground Water lines & Road sections location for all over the steel plant & Township. GIS will plot Water line, Cable route Road section & Telephone cable route, which come across/adjacent to the proposed site of underground cable excavation. All concerned agencies are to be informed. Competent Persons finalizes the Trial Hole location manually before actual excavator digging as per cable plan. Cable fault locator may also be used to determine fault location. Great caution has to be exercised during Trial Hole excavation. The working party must ensure that the markings (both alignment & depth) identified by the competent person are available at site before excavation. Necessary safety precaution like barricading the area is to be taken

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7.14 ROLE OF CONTRACTORS IN SAFETY

During audit, one contractor’s

supervisor was called for a discussion regarding safety precautions he is taking for employees working under him. He had intimated that he had provided all PPEs like safety shoe, helmet. hand gloves etc & give pep talk during work.

• After medical checkup, Contractor’ supervisor may be advised to takes all his employees for one day general Safety training at Training center (of Vizag Steel). Then one day on-job specific safety Training may be given at location by Department safety co-coordinator & Engineer in charge.

• It is to be ensured that, Contractor/ supervisor provides all PPEs to his employees, related to job

• Contractor/supervisor may do tool box talk daily before starting the job.

• Reward system & penalty to workmen for good safety practices or violation may be thought of.

• Periodic vertigo check may be done for contractor employees

7.15 NEW EQUIPMENTS REVIEW /INSPECTION

During audit, it is found that, Electrical

Inspector clearance is available for new equipment charging. No such clearances are available for old equipments/system.

As per CEA Reg 43, It is suggested to get Clearance for charging new system/equipment is available from Electrical Inspector. It is also suggested to send intimation to Electrical inspector that the new equipment is erected & charged. All concerned Operation & Maintenance staff must inspect & follow commissioning checklist in line with O&M manual, drawing/documents, during commissioning of new equipments. One copy of all documents/factory & site test reports may be availed from Project group

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7.16 ELECTRICAL SAFETY AT RECEIVING STATION/HT SUBSTATION/LT

SUBSTATION During audit, at DNW switchyard, it

was informed that:-

• Isolators & Controlling Circuit breakers are interlocked, so that isolators cannot be operated unless corresponding breaker is open position

• Isolators & corresponding earth switches shall be interlocked so that no earthing switch can be closed unless the corresponding isolator is in open condition

• When two Transformers are operated in parallel, interlock is to be provided to trip the secondary breaker of a Transformer in case primary breaker of that Transformer trips.

In addition to the observation made, It is suggested that CEA Reg 45, the following electrical safety at 220 KV substation need to be complied:-

• Inadvertent paralleling is to be prevented with interlock where two or more supplies are not intended to be operated in parallel.

• Necessary Electrical protections like Over current, Earth fault, WTI/OTI trip, Buchlotz trip & Bus bar protection as per CEA 2010, Regn 45(1) (2)

• As per 45 (2)(viii) (a) - Every generating station & substation connected to grid at 66 KV & up to 400 KV shall be provided with disturbance recording & event logging facilities as inbuilt feature of & all such equipments shall be provided with time synchronization facility for global common time reference.

HOUSEKEEPING INSIDE SUB-STATION & SWITCHGEAR ROOMS Overall Housekeeping of switchgear

rooms, substation needs immense improvement. Debris like unused cables, parts of beyond repair switchgears , oil drums with remaining oil, paint drums , plastics , jute bags , dust deposits etc which are potential fire hazards, are seen at cable gallery, rear side of switchgear rooms. AHU system & AHU blowers in the switchgear room are available but remain defunct.

• It is suggested to seal the dust entry points of switchgear shutter-gap (found at RS & RS), water seepage/ leakage if any, are to be attended & painting to be done inside switchgear room/cable gallery. Cob-webs are to be cleaned.

• AHU system may be made functional to prevent dust entry ( due to effect of little positive pressure of AHU blower) & cooling effect

• it is suggested to prepare Walk

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down check list with points like :- Check for housekeeping, unused opening sealing, floor condition, painting, adequate ventilation, arc flash protection warning sign, danger board fixing, nomenclature writing, rain water seepage, breaker/switches covers closed/or open, any exposed energized conductor, adequate illumination, adequate working space for mtc, condition of cable support, insulating mat/paint etc may be recorded. For this a visit rotation of 3 to 4 senior maintenance person may be made to visit all location (location divided among them) once in 15 days. A daily walk down checklist for critical areas like GTs, DG sets, Cable gallery, Battery room needs to be prepared & defects are to be recorded for quick addressed.

ANY OTHER OBSERVATIONS SPECIFIC TO AREAS AUDITED &

IMPROVEMENTS SUGGESTED • SLD at all electrical locations are not

available

• Replacement of old switchgears with new ones & electro mechanical relays with numerical relays in a phased manner

• Few observations for improvement are suggested specific to locations visited & based on experience

• It is suggested to fix Single Line Diagram (SLD) of Electrical system at all switchgear room & substation & operator’s control room.

• Efforts may be made so that old switchgears are being replaced with new ones in a phased manner.

• It is observed that, Location of separate oil Soak pits could not be identified for some transformers. Soak pit below few transformer, is full of sludge (no gravel/pebble are visible) soaked with leaking oil which is floating, without any outlet to soak pit. It is a potential fire hazard.

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OBSERVATION RECOMMENDATION

(Ref Reg 44 (2) (vii) (b):- Provisions shall be made for suitable oil soak pit and where use of more than 9000 liters of oil in any one oil tank, receptacle or chamber is involved.) Ref: Under Reg 43(2)(a)(iii) of CEA- Technical Std for constn of Elect plant & Elect Lines Reg 105), For 66KV & above voltage class Transformer (Trf), a soak pit of 1/3 rd of total qty of oil of Transformer/reactor & minimum 300mm thickness of gravel or pebbles of approx 25 mm size, shall be provided below every Trf/reactor provided a common remote burnt oil pit of capacity of at least largest Trf/reactor is provided for a group of Trf/reactors. Soak pit below Trf/reactor shall be connected to burnt oil pit through a drain pipe of minimum 150mm dia for fast draining of oil/water from soak pit to burnt oil pit. The burnt oil pit shall be provided with automatic pumping facility to keep the pit empty & available for an emergency.

• Ref CEA Reg no 19 (6):-

All 220 KV outdoor yard equipments name-identification & R-Y-B ph identification are to be painted with yellow background & black letter. Similar identification is to be written at front & rear side of all HT/LT switchgear panels for individual feeders.

• It is suggested that, all HT/LT Incomer breaker panel & Bus coupler breaker panel may be painted with red color or red-striped for easy identification during power failure of that switchgear.

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OBSERVATION RECOMMENDATION

• It is also suggested to paint a red stripe (Z shape) at end to end of rear side panels of all HT & LT switch gear to avoid panels mismatch during re-fixing of panels after Bus/section overhauling. This will avoid accidental opening of back cover which may not match with front cover.

• All unused holes/openings of cable entry points are to be sealed to avoid entry of rats/lizards to cause flashover

• Accident Record & Investigation report/Register is seen at DNW section. It is informed & noted that no accident/incident occurred after 2012, at DNW section. It is suggested to keep a record of all near miss incidents by all sections & remedial action may be implemented. The same record is maintained at CO & CCP.

• Job safety analysis format may be prepared & may be kept as a safety diary

***

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OBSERVATION RECOMMENDATION

PART-8

AREAWISE OBSERVATION

RAW MATERIAL HANDLING PLANT (RMHP) List of equipment is available. It is in order. Coal & Ore handling tipplers are

installed in two sheds and are in operation.

Warning lights at each tippler may be considered at the time of tippler operation for additional safe operating Barricading at common shaft to be installed Barricading at both ends required being potential tripping hazard

List of EOTs, Electrical wire rope

hoist, Chain pulley blocks and wire rope slings are available. A further load test certificate by the competent person is available.

It is in order.

Safety shower & eye wash fountain

are not available at both tipplers shed. Workers found not using Hand gloves & dust mask while there are lot of dust. Fire extinguisher not available in Tippler Control room. Emergency number information displayed in Tippler Control room. Cable cellar man entry is partially open at coal tippler shed. JUNCTION HOUSE-5 (COAL SIDE) Top cover & Inspection windows were open during operation. Lighting is very poor on all the floors.

Should be installed as safety measure. Hand gloves & dust mask should be used by the workers engaged in manual handling & cleaning. Fire extinguisher should be available in control room. It is in order. Cable cellar man entry area to be barricaded to avoid accidental slippage. Required to be closed during operation to avoid any accident. Additional lights based on Illumination survey.

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OBSERVATION RECOMMENDATION

Hand railing to staircase (5 Nos.) to foot over bridge is missing. A potential safety hazard. Chute opening (20 Nos.) at middle shuttle floor is potential safety hazard. Guard of motor coupling missing. Dust extraction system is not functioning while lot of dust is seen around. Coal conveyor 28 & 29; tail pulley side area is open. Fire seen at many locations in the non-coking coal yard.(Photo below)

SOP (10 Nos.) for various operational activities are available. Standard Maintenance Procedure (38 Nos.) are available. Preventive maintenance schedule and checklist is in place for effective maintenance of equipment. Housekeeping and proper arrangement of material is required.

Hand railing should be provided. Immediate action required to provide grill to avoid any accident. Coupling guard should be provided. Dust extraction system should be made operational. Side area of conveyor should be covered to avoid accident. Heat sensing arrangement and sprinkler system may be installed in the yard for taking early action to avoid frequent fire which results with lot of air pollution and loss of coal. It is in order. It is in order. Good system of monitoring and checklist for effective preventive maintenance is in place. Proper stacking of material & regular housekeeping required in all the area.

The pull cord was not available on the

conveyor belt number 48, 45 of coal yard and only hydrant points were provided nearby conveyors as fire fighting media.

Pull cord was a safety device provided on the conveyor belt for emergency stop it should be provided on all conveyors wherever missing for that survey should be carried out.

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OBSERVATION RECOMMENDATION

Lot of coal dust and combustible materials were observed on the electrical cable tray. Welding work was going on however lugs were not used for earthing connection to welding machines.

Housekeeping should be done as combustible material on cable tray may lead to fire emergency in case of short circuit or by other reason. Lugs should be provided while earthing connection to welding machine.

• PTW format receipt & cancellation

column are not signed.

• Hand gloves are old-2011 make

• One Safety Training room is identified for CO & COP, RMHP & CRG. But Projector is not available

• Cable entry sealing required. One WTI is not working. Battery room glass window broken, dust entry observed.

• Temporary supply is taken from a wall mounted panel & it’s door is kept open

• Multimeter & Insulation Tester leads Tips are broken condition. Potential risk for flashover & injury during testing. It was replaced immediately after pointed out by auditor.

Permit should be signed by concerned officers. Electrical hand gloves should be of latest made to avoid any incident due to old hand gloves. Projector should be provided for better understanding while training program going on. It should be attended. Unsafe working condition needs immediate attention. It should be attended.

STEEL MELTING SHOP-1 (SMS-1) There are total 3 Nos of BOF

converters, operations of which are controlled in 2 control rooms with DCS. 4 CCTV are provided to each converter. Converters are visible from control room through IR proof glass windows. The cycle time of the converters is 40 minutes of which oxygen blowing is for

BOF has adequate in built process safety.

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OBSERVATION RECOMMENDATION

15 minutes. LD gas with over 30% CO during the blowing time is recovered; rest of the gas is vented through flare. There are three flare systems, one for each converter. There is water seal in the 3 way valve which should prevent any flash back. The recovered gas is temporarily stored in a LD gas holder. 3 Nos of gas analyzers are installed in the LD gas line between ID fan and gas holder. ID fan has interlock for O2 >2% and H2 > 5%. Old drums, replaced equipment and pipes are seen lying in ID fan area. Fixed CO meters are provided in each floor. The hooter for high CO alarm is audible only in field and not in control room. Plant personnel were seen in the in the gas prone area without portable CO meters.

Housekeeping in the ID fan area may be improved. The high CO alarm may be made audible in control room also. Use of portable CO meters may be strictly enforced in gas prone areas.

There is no safety board around jam

cutting stand for Oxygen Lancing and lot of splinters seen at site. Housekeeping to be improved. Workers sweeping the floor are without dust mask-potential health hazard Ladle preparation area: Material is lying all around and area requires housekeeping. Platform for repairs of ladle is unsafe as railing all around is missing. (Photo below)

Precaution board should be placed around jam cutting stand for Oxygen Lancing. Workers should be provided dust mask for sweeping. Area requires proper stacking of material and housekeeping to provide safe environment.

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OBSERVATION RECOMMENDATION

Approach to ladle repair is unsafe. ( Photo below)

Workers found on job without safety shoe & helmet at continuous Casting Department. Cutting operation was in progress without cutting goggles and helmet. High level of noise observed near ID Fans in ID Fan House.

Approach to ladle should be proper.

Proper PPEs should be ensured. Proper safety gear should be used during cutting operation to avoid eye injury/ head injury. Noise survey required for the area near ID Fans. Display board for “high noise -use of ear plugs near ID Fan” should be installed in ID Fan House.

One angle/channel protruding out at

cable gallery at walkway needs to be cut immediately. Indoor Transformers Rooms- Brick pavement may be done & louver door may be done to arrest dust entry.

It should be removed immediately. It should be done.

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OBSERVATION RECOMMENDATION

PRMS 1 8 Nos of 100 m3 O2 tanks operating at 40 kg/cm2 are installed in a licensed premise. The tanks are in floating condition with O2 network. The safety valves are tested every year and tanks are tested once in 5 years as per SMPV Rules. The tanks do not have any label except tank number. A tank farm containing 4 pressure vessels, 3 N2 (2X 125m3 + 1X 100 m3 and 1 Argon (100 m3) is seen in the area. No license number is displayed. Could not make out if this is operational. Gas cylinder filling, storage discharge etc. Different types of gas cylinders are handled in different compartments or sheds. The sheds are spacious and open for good ventilation and license numbers are painted in all sheds. There is a gas cylinder management system to track each cylinder in the factory and its status. There is a licensed DA cylinder storage area. It is seen that full and empty DA cylinders are not properly segregated. 1000 LPG cylinders are connected to discharge manifolds. The area has water spray system but no leak detectors are installed. The cylinders are mostly not secured

This is good and appreciated. Noted. It should be followed. As a good housekeeping practice full and empty DA cylinders may be properly segregated. LPG cylinders discharge manifold area may be provided with leak detectors. Gas cylinders stored vertically may be

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OBSERVATION RECOMMENDATION

to prevent fall. secured to prevent fall. STEEL MELTING SHOP-2 (SMS-2) There is no safety board at unloading

area of Torpedo. Hooter/warning light during movement of EOT Crane with ladle not being used. Drains at all exit points (3 Nos.) are not covered.(Photo below)

Material is lying just below safety shower making it unusable in case of emergency.

No display board for safety precautions found at prominent places in charging area. Ambulance is available on 24 hrs. basis to take care of emergency. Permit system- Permits are cleared by

Display boards for safety- Do not come close during unloading of Torpedo ladle car process. Hooter /warning light during movement of EOT Crane should be “On” as people crossing the way. Provide drains to cover at all exit points for safety. Door opening should be closed to avoid accidental fall. Nothing should be dumped at safety shower area. Display board for safety precautions required at prominent places in charging area. This is in order. However it should be cleaned regularly from inside. May be reviewed and Permits records

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OBSERVATION RECOMMENDATION

Operation department; however no records are available with them. SOPs list is available. Continuous Casting Shop (CCS) Materials are lying haphazardly and housekeeping is not there.

LPG hose and welding machines is in close proximity leading unsafe situation.

In the “Radiation Controlled Area”, workers found working without safety shoes and Fire resistant coat. On EOTs, test date and next due date are not displayed. Valve stem is partially blocking the way and potential safety hazard.

Due to positioning of scrap bin, path is

should be available in Control Room. This is in order. However SOPs should be discussed among operation staff on regular basis. Major housekeeping and proper stacking of material required for safe environment. Welding machine should be kept away from LPG supply points. Workers should be cautioned to use proper PPEs required for the job. On all EOTs, test date and next due date should be displayed. Corrective measure should be taken to ensure safety of workers. Scrap bin should be shifted to other

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OBSERVATION RECOMMENDATION

obstructed and someone head may hit canopy.

Two wheelers are parked inside the plant. Even one four wheeler also seen parked inside the plant.

location to avoid possible head injury. Vehicles should not be allowed to park inside plant area.

BLAST FURNACE-2 ( Krishna) Housekeeping is reasonably good in

the plant. Tapping opening job was in progress and the operator was without safety shoes, helmet, face shield & fire resistant coat.

Standard Maintenance Practices (SMPs)- 6 nos. available.

It is in order. Proper PPEs should be ensured during work. This is in order.

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OBSERVATION RECOMMENDATION

List of Safe operating Procedures (SOPs-13 nos.) available. Preventive maintenance schedule for drill machine & mud gun is available. Two circular EOT cranes of 20 Ton/5 Ton are available and their load test certificates are in place.

It is in order. These should be discussed regularly among operating staff. It is in order. However checklist may be revisited to update as per guide line of equipment manufacturer. It is in order.

• At BF1-- Earth pit resistance is high

13.33 ohm at 5LBDS & 11.54 ohm at DG room

• Charged Panel doors are found open. Lizard/rat may enter to cause flashover

• BF model & modification done is appreciable.

It should be attended as the value of EP resistant is high. It should be closed to avoid any short circuit or person can come in contact with live supply. Noted.

BF-3 The plant has pulverized coal injection

system which is energy efficient. The energy from top gas recovered in top gas turbine. The BF gas is sent to gas network at 1200 mm H2O. Process control is done by DCS/PLC. Four cooling circuits are provided for furnace wall cooling. In each circuit there are 2 running pumps and one standby on auto. There is a gas analyzer at the top of BF. Water leakage from cooling tubes can be detected by increase in hydrogen content in top gas. CCTC is deployed in the plant. Fixed CO meter is available in plant with alarm in control room. Control

The plant has adequate in built process safety. The safety systems may be maintained in future also. It should be maintained. Good system to be maintained. Good. Person working in control room should be aware about the operation of same

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OBSERVATION RECOMMENDATION

room has Inergen fire suppressant system. Plant mock drill file is reviewed. The compliance reports of observations / suggestions are not on record. Joint safety inspections are carried out and file is reviewed. FDA system checking register is reviewed; checking is done once in 3 months.

system. Compliance report of observations made during drill should be prepared and documented for closing the observations. It should be continued. It should be followed.

Uptakes gas pipe lines at 45 mts.

elevation is potential hazard for burn. Monkey ladder (for hot blast valve telfer) cage is not as per standard & potential safety hazard. Tap gas ignitor: Railing for some portion missing and chain for ladder is also missing.

Lighting at 2nd

floor seems to be inadequate. EOT-2 Nos.( 35Ton/10 Ton) are for second floor operation. Railing for temporary platform missing which is more than 6 feet high.

Uptakes gas pipe lines should be provided protection from burn. Monkey ladder (for hot blast valve telfer) cage should be extended down to avoid accidental fall. Railing/chain should be provided to avoid accidental fall.

Illumination survey at 2nd

floor to be done to improve the lighting system It is in order. Load test certificate from competent person is available. Provide proper railing to avoid accidental fall.

EMD EMD handles Coke oven, LD and BF

gas from generation point to the consumers. COG, after cleaning and chemical recovery, is distributed to consumers at 1400 to 1500 mm H2O network pressure. LD gas after cleaning is stored in gas holders at 180 mm H2O. From the gas holder the LD gas pressure is boosted and mixed with clean BF gas and sent

Noted.

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OBSERVATION RECOMMENDATION

to mixed gas network, maintained at about 1200 mm H2O. EMD maintains a fuel gas network of about 38 km. Entire operation is monitored and operated by SCADA system. There are 2 gas holders, one each for SMS 1 and SMS 2, of 80,000 m3 capacity each.

Gas Holders

Technology is supplied by a reputed UK company for GH 1 and by a German company for GH 2. Each holder has a control room. The holders have dry type double seal for GH 1 and single seal for GH 2. The holder pistons have 2 limit switches at top and 2 limit switches at bottom and pneumatic operated isolation valves. Volume Relief Valves which are impact operated if piston reaches top are provided; 10 Nos for GH 1 and 12 Nos for GH 2. Fixed CO meters are in place. Portable CO meters are used. These are calibrated once in six months. The gas holders have 3 Nos of online oxygen analyzers between the ID Fan and Gas Holder to eliminate possibility of oxygen ingress. The holder premises have fire hydrant system, PFE, wind socks, brief MSDS, Do’s and Don’ts, etc. Dry vegetation is observed in and around the premises.

The gas holders have adequate inbuilt engineering safety. Protection of gas holders against overfilling, negative pressure and explosion due to oxygen ingress, etc, is in place. Periodic maintenance of relief valves should be done as per the schedule. Good arrangement to be maintained in working condition. Good system to be maintained and calibrated as per the schedule. Dry vegetation in and the gas holder premises may be promptly removed.

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OBSERVATION RECOMMENDATION

For GH 2, the booster compressors by pass line (entering the gas holder is seen without jumpers across the flanges.

The booster compressor by pass line in GH 2 may be provided with jumpers across the flanges. The earthing for the line may also be ensured. This is important as the line may pick up static charges from the ESP.

Gas system

The gas system is maintained at 1200 mm H2O line pressure using booster compressor and pressure control valves. The line pressure is controlled by pressure control valves set at 1200 mm H2O. The discharge of control valve is released through flare stacks. There are 3 such flare stacks in the system. The gas pipelines are fabricated with 30% radiography and thickness testing is done every year. HAZOP study of the gas system was carried out in 2016 by a consultant. Observed the design and operation of water seals and condensate drain seal pots for vacuum condition (ID Fan suction side), low pressure and medium pressure lines. Water seals are provided with water level switches and condensate seals have proper seal height and siphon breakers. The water overflow is allowed to fall into an open funnel and properly visible. Maintenance on gas pipe line is done with water seal and isolation

The gas system has adequate safety considered in detail engineering. The SOPs may be followed and system be maintained in future also.

Coke Oven The plant was commissioned 1989 This is good and may be maintained in

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OBSERVATION RECOMMENDATION

with Russian technology. There are 4 batteries using dry cooling system for coke and thus generating power also. Batteries are in good shape and negligible emission is observed in the ovens. CO plant is PLC controlled. SOP is strictly followed for operation by qualified and trained staff. Changes are rarely carried out, but if any change is required protocol is followed. HIRA has been carried out as per OHSAS and HAZOP study has been done. Interlock bypass register is in place. ID fan is provided with high oxygen tripping. The area has fixed CO meters and smoke detectors. Cellar has fixed CO monitors. Control rooms are provided with smoke detectors. SCBA is available in control room. However, it is observed that operational personnel are not at ease in use of SCBA sets. They rely on EMD staff for rescue and emergency operation. This observation is also applicable to BF and SMS 1.

future. Records of change should be maintained for verification. The recommendations suggested in the report should be complied and records should be maintained for verification. Good. It should be maintained. It is suggested that operation personnel in CO, BF and SMS may be as much proficient in rescue and emergency operation using SCBA as the EMD personnel.

CCP

Visited the crude and finished product storage area which is a PESO licensed area for storage of 7215 KL of petroleum Class A, B and C type chemicals.

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OBSERVATION RECOMMENDATION

Following points are observed in the tank farm:

• No wind sock is seen in the location.

• Tank farm fencing is open in some sections and second gate is not provided.

• Tanks are provided with MVWS and class A tanks are equipped with foam injection system.

• Benzene tank No BT 401-1 roof is seen to have many holes; some other tank roofs are also corroded.

• Vent nozzles in some tanks are open.

• Jumpers (bonding for static electricity dissipation) across the flanges are missing in many places in benzene/ benzol lines.

• The tanks are provided with individual monkey ladders for going to roof.

As per Petroleum Rules, for Class A petroleum storage, following may be looked into:

• A wind sock may be provided near the tank farm.

• The licensed premise should have continuous fencing with two gates.

• Corroded and leaky roofs of tanks may be attended.

• Tank vents may be kept closed.

• All flanges may be provided with continuity clamps or jumpers.

It is suggested that an elevated gangway may be provided in the tank farm and each tank may be connected to the gangway. This will eliminate the need to climb each tank by using monkey ladder.

Benzene tanker loading bay

• There is no structure available for connecting the safety belts of the tanker personnel working on the top of road tankers for filling.

• Crocodile clips are connected to the tankers for earthing before loading is started.

• A fall arrester structure can be constructed above the tanker loading bay, to which the tanker personnel can connect their safety belts (harness).

• An earthing confirmation system may be installed which can be interlocked to the pump. This will eliminate risk of static discharge in case of faulty earthing.

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OBSERVATION RECOMMENDATION

Hydrogen plant: Jumpers (bonding for

static electricity) across the flanges are missing in many places in hydrogen gas lines.

All hydrogen line flanges may be provided with continuity clamps or jumpers as the flammability range of Hydrogen was 4 to 74 % if any spark generated then it can be explosion/ fire.

Sulphuric acid tank farm:

• Lot of hanging cables seen in the tank farm

• The tanks are vented to atmosphere. This may lead to corrosion at the stagnant liquid surface due to film dilution by moist air.

• The loose cables may be properly clamped in cable trays.

• To prevent corrosion and increase tank life it is suggested to connect the tanks vent to a breather vat containing 98% sulphuric acid. Air going into the tank during pumping out will flow through acid and remain dry.

SINTER PLANT-1 Sinter machine No.1: Area is not

barricaded around replaced hot ballet. Safety shower & eye wash fountain nearby is in bad shape. Even water was not coming at the time of checking. Floor is slippery under the safety shower. (Photo below).

Fire extinguishers are available. Area is exposed at both sides along the moving bed. Illumination is not upto the mark in the area.

Area should be barricaded around replaced hot ballet. Also display board for safety instruction to be provided. Safety shower should be made operational. Further there should be periodic checking to ensure that it is functional. It is in order. Barricading at both sides along the exposed area to be provided. More lights may be provided after proper illumination survey.

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OBSERVATION RECOMMENDATION

Door cover is not available at discharge head. A potential safety hazards.( Photo below).

Un-loader area is open at both sides. Removable barrier at vacuum chamber platform entrance missing is potential safety hazard. Hot material coming out from spillage hopper of Cinter Single Roller Crusher. Workers were at job for removal of hot material without proper safety precautions. Water pipes at low elevation on platform above A6 conveyor are potential safety hazard for head injury. A cross beam in the way to staircase from platform above A6 to ground level is potential safety hazard for head injury. Straight Line Cooler pump pit is not properly barricaded. Hydro test of pressure vessels carried out and Form No. 8 available issued by competent person. List of EOT cranes & other lifting equipment is available and certificate in Form No.-38 available issued by competent person.

Door cover should be provided on priority. Provide barricading to avoid accidental fall. Provide barrier. Ensure workers use proper PPEs before starting the job. Display board for taking care of Head should be available. Caution board should be available as a temporary measure. Further alternate staircase may be considered as a permanent solution. Barricading should be installed to avoid accidental fall. It is in order. It is in order.

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OBSERVATION RECOMMENDATION

SOP – 20 Nos. is available for various operations and being discussed. Preventive maintenance system is in place and jobs are being carried out as planned. Noise survey report is available. Lot of dust seen around in plant.

It is in order. It is in order. It is in order. As there were lot of dust around, necessary precautions such as using dust mask by working person should be mandatory to use.

WIRE ROD MILL-1 List of EOTs, wire rope slings, D-

shackle, Chain pulley block, Hydraulic Jack is available. Load test certificate from competent authority is available. List of pressure vessels is available (6 Nos.).Pressure test certificate/ultrasonic test certificates for pressure vessels available. Safety valves installed on pressure vessels (Lube Oil Accumulators) are not tested since its commissioning. Pressure gauges are not marked for Max. safe working pressure. Stair case entrance leading to burner area in Zone 4 is unsafe. Flash back arrestors should also be installed on cylinder side in cutting sets. Management of change (MOC) is considered as proposal under Addition/Modification/Replacement (AMR) schemes and is well documented procedure including impact assessment report.

This is in order. Display board on EOTs required indicating test date & next due date. This is in order. Safety valves should be tested periodically and record maintained. All the pressure gauges should be marked with RED mark for Max. SWP. Temporary barricading required to be provided at staircase entrance. Flash back arrestors should be provided at both ends (Cylinder side as well as torch side) in cutting set. This is in order.

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OBSERVATION RECOMMENDATION

Portable grinder found without shield, with cable joint and without electrical plug. Should be corrected for safe operation. Housekeeping is good and material is properly stacked.

Grinder should be maintained in proper condition as it is potential safety hazard. This is in order.

WIRE ROD MILL-2 List of EOTs, wire rope slings, D-

shackle, Chain pulley block, Hydraulic Jack is available. Load test certificate from competent authority is available. List of pressure vessels is available (6 Nos.). Pressure test certificate/ultrasonic test certificates for pressure vessels available. Safety valves installed on pressure vessels (Lube Oil Accumulators) are not tested since its commissioning. Pressure gauges are not marked for Max. Safe working pressure. Safety board in front of FRM not available. Fence cover for rotating parts at Roll Chock not there. Safety board is not available near TSIRT. Handrails to cross over platforms missing. Area at reducing & sizing mill (RSM) motor is unsafe for tripping. List of SOPs is available and being shared among staff.

This is in order. Install display board on EOTs indicating test date & next due date. It is in order. Safety valves should be tested periodically and record maintained. Pressure gauge installed on vessels should be marked with Red mark for Max. Safe working pressure. Display board for safety instruction in front of Fast Roughing Mill (FRM). Fence cover should be installed at Roll Chock as safety measure. Provide display board near TSIRT as reject material is hot. Handrails should be provided on cross over platforms to avoid accidental fall. Barricading should be provided at reducing & sizing mill (RSM) motor to avoid tripping hazard. It is in order.

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OBSERVATION RECOMMENDATION

Noise study has been carried out & areas with higher noise level have been identified. Necessary display board indication high noise level-use ear plugs are available. Illumination study has been carried out during the day & after 6 PM. Preventive maintenance schedule is monitored through Maintenance And Management System (MAMS).Detailed checklists are available for various preventive maintenance jobs. Flash back arrestors should also be installed on cylinder side in cutting sets. Pedestal Grinding Machine is unsafe to operate as safety shield is missing. (Photo below)

Permit system is in place.

It is in order. It is in order. It is in order. Flash back arrestors should be provided at both ends (Cylinder side as well as torch side) in cutting set. Pedestal Grinding machine to be provided transparent safety shields and safety instruction board. It is in order.The information regarding issue of permits should also be available with the control room.

SPECIAL BAR MILL Pressure vessels-24 Nos. are

pressure tested and certification from competent Person is available. Safety relief valves installed on

It is in order. Safety valves should be tested

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OBSERVATION RECOMMENDATION

pressure vessels are not tested. Pressure gauge installed on vessels should be marked with Red mark for Max. safe working pressure. EOT Cranes-17 Nos. and Jib Cranes-14 Nos. are in operation. However the load test of the cranes by the competent person is overdue. Similarly other lifting tools such as Chain pulley block, wire rope slings, D-shackles etc, required to be load tested and record maintained. End stoppers for transfer cars are potential tripping hazard. Rotating parts at furnace entry is without protection. Cross over platform are not provided with railings after plant 21. Flash back arrestors are not provided at cylinder ends- is potential safety hazards.

periodically and record maintained. Pressure gauge installed on vessels should be marked with Red mark for Max. safe working pressure. All the EOTs, Jib Cranes and other lifting tools should be load tested by competent person and maintain the record. End stoppers for transfer cars should be properly covered to avoid tripping hazards. Provide barricading at furnace entry point to avoid contact with rotating parts. Provide railing at cross over platform. Flash back arrestors should be provided at both ends (Cylinder side as well as torch side) in cutting set.

Two oxygen cylinders were used

which hydro test was valid up to 2016. Lot of material was stacked in front of the crane operator exit walk way.

Valid Hydro tested gas cylinders should be used in the company. It should be made free.

Rubber mat was not provided near

440 V electrical panels and Bus bar chamber of power distribution boards more over the door of Bus bar was in open condition. Grinders without guards were used in the service floor. Two pin was not used for industrial fan and moreover two supplies was given

It should be provided as required under CEA 2010 for safety of workers. Guards should be provided on the grinders. Two pin should be used for industrial fan. Standard practice for supply

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OBSERVATION RECOMMENDATION

from one button making the system overloaded. In furnace gas was used but color code of pipelines was not displayed in the respective areas for ready reference.

should be followed in the company to avoid any incident due to wrong practice followed. Color code of pipe lines should be displayed for awaring the workers in a language understood by majority of workers.

STRUCTURAL MILL Plant is under stabilisation.

Pressure vessels-29 Nos. are pressure tested and certification from competent Person is available. Safety relief valves installed on pressure vessels are not tested. Pressure gauge installed on vessels should be marked with Red mark for Max. safe working pressure. EOT Cranes and Jib Cranes-30 apart from manual chain hoist are in use. All are load tested by the competent person and records are available. List of SOPs-19 Nos. are developed for various operation activities. Open area at roller table after shear No.3. Partial ramp near stand 17 to avoid tripping hazards. Tilter in front of stand No.7 is exposed to movement of workers. Hot bloom rejection grid may be approached as area is open. Barricading at entire length of cooling

It is in order. Safety valves should be tested periodically and record maintained. Pressure gauge installed on vessels should be marked with Red mark for Max. safe working pressure. It is in order. Install display board on EOTs indicating test date & next due date. It is in order. Provide barricading for safety. Provide ramp in the entire width. Tilter in front of stand No. 7 should be provided with hooter and beacon light for safety during its operation. Provide barricading and display board that rejected material is hot and do not touch. Provide barricading at entire length of

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OBSERVATION RECOMMENDATION

bed missing. Potential safety hazard. Flash back arrestors are not provided at cylinder ends- is potential safety hazards. Structure/piping is painted (finish Coat) as per Colour Code VSP-6.3/GS-P-01.

cooling bed. Flash back arrestors should be provided at both ends (Cylinder side as well as torch side) in cutting set. It is in order.

Lot of scrap material was stacked

back side of JY11EDLYDO1B. Gas cylinders were not secured properly to avoid fall. PFEs were place on the floors. Below stacker lot of water was logged on the floor.

It should be removed. Cylinders should be chained to avoid fall. It should be installed on the wall. Drainage system should be checked.

LIGHT AND MEDIUM MERCHANT MILL (LMMM) List of pressure vessels (29 Nos.)

available. Pressure test certificates issued by competent person on form no. 8 are available. As per information safety valves are tested, however records are not maintained. Pressure gauge installed on vessels should be marked with Red mark for Max. safe working pressure. List of EOTs and lifting equipment and load test certificate in Form No. 38 issued by competent person is available. Scale chute of pump house 17 is potential safety hazard. Illumination survey record for day time survey is available. Noise survey record is available.

It is in order. Safety valves testing records should be maintained. Pressure gauge installed on vessels should be marked with Red mark for Max. safe working pressure. It is in order. Display board required for Test date and next due date on all EOTs. Eye test records for crane operators are available. Provide proper barricading to avoid accidental slippage. Illumination survey should also be done at late evening. It is in order.

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OBSERVATION RECOMMENDATION

Training is done for the employees on safety topics. Flash back arrestor should be also installed on cylinder side in cutting set.

Good. Flash back arrestors should be provided at both ends (Cylinder side as well as torch side) in cutting set.

MMSM List of pressure vessel and hydro test

report by competent person is available. List of EOTs and lifting tools & tackles are available. The load test certificate issued by competent person is available. Certificate for use of boiler issued by Dy. Chief Inspector Boilers is available. Pusher end of furnace 1 & 2 is open & unsafe. End stoppers are potential tripping hazard. Lighting inside the mill seems to be inadequate. Stair case leading to scale tunnel is unsafe. Sampling saw area is unsafe as lot of spark during cutting operation. Flash arrestors are not installed at cylinders & cutting torch. Portable grinding machine found without safety shield.

It is in order. It is in order. It is in order. Provide barricading to avoid accident. End stoppers for transfer cars to be covered to avoid tripping when not in use. Action should be taken to improve the lighting based on the illumination survey. Stair case leading to scale tunnel to be blocked (Near column no. 45) if not in use to avoid incidental fall. Caution board required near Sampling Saw Area & Cooling Bed Area to avoid any accident. Flash back arrestors should be provided at both ends (Cylinder side as well as torch side) in cutting set. Safety shield should be installed.

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OBSERVATION RECOMMENDATION

SOP for various operational activities are available. SMP for maintenance activities are available. Preventive maintenance schedule are being followed Noise survey report is available and is within limit.

It is in order.

TRAFFIC There are 39 loco (WDS6-31 Nos. &

WDS6AD-8 Nos.) The Solid State Interlocking (SSI) is very good system for enhance safety. Oxygen cylinders are not secured. Oil drums & empty drums are lying and there is no proper area marked. Fire extinguisher and first aid box are available in loco. Loco operators are using proper PPEs. Shunting Porters are wearing not Retro-reflective jacket. List of lifting equipment is available and load test certificate from competent person is in place.

For information. Good safety system. Oxygen Cylinders should be properly secured to avoid accidental fall. Proper area should be developed for used oil drums and for empty drums. It is in order. It is in order. May visit “Safety Standard on Loco Operation in Steel Industry- IPSS:1-11-033-17” adopted in January 2017 for required improvement. Retro-reflective jacket for Shunting Porter may be considered for easy identification. Many safety precautions listed may be reviewed for adoption as required. It is in order.

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OBSERVATION RECOMMENDATION

Preventive Maintenance schedule for Loco is in place and being followed religiously. Exhaustive check list for PM jobs is in place. Safe Operating Procedure (18 Nos.) is available. Safe Maintenance Procedure (58 Nos.) available and being followed.

It is in order. It is in order.

SCRAP SALVAGE DEPARTMENT Visited Central dump and processing

Yard (CDPY). Inspected the tripper AP31TF5045 and interviewed driver Mr Sonu Naidu G. and findings are as under. Having valid driving licence. He is not aware of speed limit inside plants. Eye test report is available. Vehicle fitness certificate is available. However the condition of vehicle found to be not up to mark.

• Indication lights are not working.

• No horn and light during reversing of vehicle.

• Alarm during dumping not working.

• Wind screen is crack.

• Tyre condition is poor.

• Wipers not working.

No first aid box and fire extinguisher Emergency numbers are not available in the vehicle Inspected 75 Ton capacity Crawler Crane which was in operation. Load Chart is not available.

For information. It is in order. Regular training on safe driving required. It is in order All vehicles should be checked for its condition for enhance safety. First aid box should be available in all vehicles. Display emergency numbers in all vehicles. Load chart should be in crane.

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OBSERVATION RECOMMENDATION

Load test certificate is available. Eye test of operator is done. Hoist limit switch is not working which is safety hazard Fire extinguisher and first aid box not available. Work procedures (11 Nos.) and Work Instructions (9 Nos.) are available. Training on “Safe driving” conducted on 30/05/2018 which was attended by 17 drivers only.

This is in order. This is in order. Hoist limit switch should work as it is safety device. Fire extinguisher should be kpt in crane. It is in order. More number of training sessions on safe driving should be conducted to cover all the drivers.Proper training material should be developed for effectiveness.

ENVIRONMENT All the 36 stacks (after 6.3 MTPA) are

provided with on-line stack monitors & minutes to minute’s data being posted to CPCB site. 3 Nos. continuous ambient air quality monitoring stations within the plant.

It is order It is in order.

L&H Total number of lifts in plant is 58.

Report of examination for lifts by competent person. The lift in the Sinter Plant -1 does not have the following.

• The copy of examination report is not available in lift.

• Display of emergency numbers is not there.

• Capacity of carrying person is not displayed.

It is in order. Ensure that the information is available in all the lifts.

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OBSERVATION RECOMMENDATION

GENERAL OBSERVATIONS • PPEs compliance in general needs

improvement.

• Two wheelers are parked inside the plants which is unsafe.

• Vehicles are plying at much higher speed then prescribed speed limit.

• Housekeeping should be improved in general.

Workers should be encouraged to wear PPEs. Vehicles should be made to park in parking area only. More speed limit boards should be installed & department should take initiative to educate workers. Interplant competition on housekeeping may motivate employees.

RS &RS • Temporary wiring found. Charged

Panel doors are found open. Sand buckets are empty

• HT Switch gear room insulating mat is torn up condition

• Cable gallery room is used as rest room by contract workmen

• Cable gallery fire water system is not commissioned

• Regarding temporary wiring follow CEA regulation 2010.

• It should be attended.

• Housekeeping inside the cable gallery should be maintained and entry to contract workers should be restricted to avoid any incident.

• It should be commissioned.

DNW • FDA was not checked at various

zone due to water logging

• Soak pit approach is to be made, bush are to be cut & identification/ internal inspection of soak pit to be done

• Cable gallery cable tray/support is corroded.

• Water logging problem should be

attended so that FDA system can

be checked.

• Approach to soak pit should be

made

• To be replaced with new one

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OBSERVATION RECOMMENDATION

• All Earth pits are to be elevated by at least one brick height & to be painted with identification & to be covered.

• It should be made elevated and earth pit as per require under CEA 2010 should be made.

TPP Pressure vessels like air receivers 17

numbers were not tested in the TPP. It should be tested as required under

Section 31 of the Factories Act, 1948. • Temporary yard light fixed on lattice

structure may cause electrocution.

• Transformer soak pit is choked & leaking oil is floating, a fire hazard. Soak pit to be cleaned

• Dry Grass inside outdoor yard is to be removed immediately

• No gravels at many locations at outdoor yard.

• Soak pit at bottom of Transformer is full of mud & leaking oil is floating. To be cleaned immediately

• Bus duct silica gel to be changed.

• To be removed.

• Transformer soak pit should be always cleared so that in case of oil leakage the oil will be collected in soak pit chamber.

• Dry grass should be cut which was potential for fire.

• Gravels should be provided on outdoor yard

• Soak Pit path should be cleaned and make sure that it will be clear all the time.

• Bus silica color was changed hence it should be replaced.

Mandatory PPEs in the TPP were

Safety Shoes, Helmet, and dust mask. Wearing of same should be monitored

as during visit few workers were not having all required mandatory PPEs.

Assembly point was defined on the

wall at the office entrance however there was no access for assembling.

Location of assembly point may be reviewed.

In main control room lighting is not

proper. Lighting should be improved inside the

control room. No trip bypass register was available

however abnormal cases of bypass were noted in the logbook but no easy record perusal.

Separate register may be prepared for same.

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OBSERVATION RECOMMENDATION

In Server room halogen flooding

system was replaced to inergen flooding system but the operation of same was not displayed in the control room for ready reference moreover control room workers were not aware about inergen system. Emergency exit was not available in server room.

Sop of Inergen system should be displayed and workers should be made aware about the system. Emergency exit should be provided at server room.

AHU system was not working it was

under break down. To maintain fresh air/ air changes at

working area AHU should be made operational at the earliest.

In control room no FDA system

provided however at server room it was provided.

Noted.

PFEs were provided at the control

room some people of control room was interviewed regarding hazards associated with the handling of CO2 type of PFE they were not aware about the hazards. No smoking boards were displayed however it was not followed.

Training should be imparted to the workers for making aware about the hazards while handling the PFEs. No smoking policy should be effectively implemented in the premises to avoid any incident.

Cable dressing on cable tray at some

location was not proper and old scaffolding structure was not removed from boiler number 6 even though the work was completed.

Cable dressing should be properly done so that no cable will come out of the cable tray. Old scaffolding should be removed from Boiler number 6.

Pull cord was not available on total

conveyor belt number 133 cc. Pull cord should be provided on the

conveyor belt and lot of coal dust was lying on the conveyor belt surrounding area it should be cleaned.

Manual call point was not working in

the boiler area. Non working MCPs survey may be

carried out in the plant and same should be attended as it will be useful for declaring fire emergency.

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OBSERVATION RECOMMENDATION

Fly ash was supplied to brick manufacturing industries and cement industries and remaining fly ash was dumped in the dump yard. There were two fly ash silos from which fly ash was collected in the collecting heavy vehicles. During visit it was found that the water was logging in the loading area.

Noted. The area should be cleaned and water logging should be attended. As the person has to go on the vehicle for operation of the manhole life line may be fixed and safety belt should be provided to avoid fall of person as the height was more.

Oxygen cylinder which hydro testing

was last carried out in 2015 was in use and it was lying on the floor.

Gas cylinder Rules, 2016 regarding hydro testing of gas cylinders should be strictly followed to avoid any emergency.

Chlorination area of TPP

There were two Chlorine tonners were used for dosing purposes in chlorination plant. One chlorine detector was provided near chlorine tonner for leak detection however it was set on 1.2 PPM. Water logging was observed on the flooring of the chlorine pumps. The chlorine absorption system was provided in case of chlorine leakage. The water supply line was taken from fire water network. Wind sock was not available on the chlorination building to know the wind direction. The Chlorine tonner dispersion

Noted. The setting level should be lowered to 0.5 ppm from 1.2 ppm as the revised TLV laid down is 0.5 ppm in the Second Schedule to the Factories Act, 1948 as well as ACGIH-2013. Water logging should be cleared. The fire water should be used for emergency handling only its use for other purpose should be stopped. Wind socks should be provided for knowing the wind direction. Training should be arranged on

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OBSERVATION RECOMMENDATION

modeling was carried out but the working staff was not aware of same. Emergency kit was provided in the control room which was five minutes from the plant, SCBA set was also provided in control room. The person was working was knowing the leakage handling procedures.

dispersion modeling effects for enhancing the awareness of workers. It should be maintained and ensure that in case of emergency at chlorine tonner can be attended without any time delay. Emergency kit should be easily available and working person should know the location. The SCBA set should have the maximum pressure inside so that it can be utilized for maximum time in case of emergency. Checklist of SCBA set should be prepared and frequency may be defined.

Utilities The Utilities department manages 5

Nos of Air Separation Units, Air compressors, 5 nos of chilled water plants, LPG tank farm and gas cylinder filling and storage. ASU 5: Visited ASU 5. The gas bullets containing oxygen, nitrogen and argon are installed in licensed premise as per SMPV rules. License numbers are displayed at the fence or gate. For the argon storage tank (200 KL), it is observed that the tank does not have any label containing license No., tank No., test pressure, chemical name etc. Some unused cable bundle is seen lying in the area. The control room has smoke detectors

As per SMPV Rules every pressure vessel should have label or name plate containing tank number, chemical name, design pressure, test pressure, etc. It should be removed. This is OK.

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OBSERVATION RECOMMENDATION

with inergen system. Transformers are provided with heat sensors and MVWS. LPG storage 2 Nos of 50 MT LPG storage tanks are located in a licensed premise. The premise has fencing, wind sock, MSDS display, boards for standard practice, LPG tanker unloading procedure and proper earthing for tanks. The tanks have automatic HVWS connected to deluge system and heat sensors (quartzoid bulbs). LPG tankers are earthed by crocodile clip during unloading. The earthing is checked once a year. The LPG tankers unloading instruction (in display) does not mention to check safety certificate of the tanker (like, test certificate of tanker, safety valves and excess flow check valve etc.)

This meets legal requirement. It should be maintained and periodically inspected. An earthing confirmation system may be installed which will confirm if proper earthing is established. This can be interlocked with starting of unloading compressor. LPG tanker before unloading may be checked to confirm if proper test certificates for tanker, safety valves and excess flow check valves are available. The driver should also be qualified to transport hazardous chemicals.

WMD This department handles all types of

water required for the factory, like, receiving raw water from river, drinking water, fire water, process water, treatment of effluent and discharging the treated water to sea. Organic effluent from CCP is given micro biological and chemical treatment and then sent to ETP plant along with sewage. The effluent after

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OBSERVATION RECOMMENDATION

surface aeration and clarification is sent to sea. Observations:

• Online monitoring system for effluent is not commissioned.

• Lot of sludge in noticed in the SMS 2 waste water treatment plant.

• The Factory has valid Consent for Operation for water pollution and authorization for hazardous waste management from state PCB.

• The Factory has submitted the annual returns, Form 5, for water pollution as per Consent for Operation for the year 2017-18. The concentration of pollutants in trade effluent is within the prescribed standard.

• Similarly, annual return in Form 4, for hazardous waste has also been filed for the year 2017–18.

• Near SMS 2 waste water treatment plant; welding job was being carried out on pipe rack top. It is seen that the earthing for the job was given at ground level about 50 m away.

• Online real time monitoring system of effluent may be commissioned as it is a requirement of CPCB.

• VSP may try to achieve zero liquid discharge.

• Waste water sludge may be collected in a truck trailer without allowing it fall and spread in the plant area.

• Annual returns as per Consent for Operation meet the legal requirement.

• Welding job earthing may be provided closest to the job to avoid hazard. Safety inspection may be strengthened.

CRMP • Dust pollution is observed in the

plant. Some dust extractors are not working.

• Eye washers are hardly seen in the plant.

• Dust extractors, wherever not working, may be repaired and more may be installed to reduce dust in the plant.

• In view of high dust, eye washers may be placed in suitable locations (avoiding lime area).

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OBSERVATION RECOMMENDATION

CMS, Structural, Foundry In foundry 10 MT cranes of 1984

made was in service, it was tested as per the statutes.

This is in order.

There were five empty carbon di oxide

cylinders stored but not chained. It should be stored in designated area

and should be properly secured to avoid fall.

Lot of empty drums were stored near

AB bay. These drums should be discarding

through proper channel and area should be made free.

Air receiver AR/ISF/03 on which hydro

test date and due date was displayed. Noted.

No smoking policy boards were

displayed however it was not followed at site.

No smoking inside the foundry area should be strictly followed as CO gas pipelines were there.

On MCC number 2 housekeeping

should be improved as cob bays were observed on panel room walls.

Housekeeping should be improved in this area to avoid malfunction of relays due to dust formation inside the panels.

Cloths were placed on the CO gas

pipelines which was adding fire hazard. It was observed that the gas pipelines were having corrosion.

Clothes should be removed from pipelines to avoid fire. Pipeline should be painted periodically to avoid rusting and periodic testing of pipelines should be carried out.

Resin sand drums were stored without

trays to restrict the spillage and avoiding the soil pollution.

Trays should be provided below such drums.

Induction furnace three pumps were

not having coupling guards. Bench grinder was not having guards and moreover earthing was not available to motor. Two electrical connections were taken from one single wire.

Positive guarding should be provided on all rotating devices to avoid any incident. Every motor should be earthed properly. Overloading of electrical system should be avoided which may lead to

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OBSERVATION RECOMMENDATION

emergency. In electric MCC room FDA system

was not provided for early detection of fire / smoke.

FDA system may be provided in such MCC rooms.

CMS Three cranes of 50 MT were used in

the CMS as per the requirement. Noted.

Welding and gas cutting set doesn’t

have two flash back arrestors. At Both end flash back arrestors

should be provided to avoid back fire up to source.

Person was working with grinder in

the area without proper PPEs like hand gloves, eye goggles. The connection of grinder was taken from board by placing wires inside the socket.

Grinding was an dangerous operation as per the Factories Act, 1948 hence proper care has to be taken while doing the operation.

Earth pit lay out diagram was

available and there were ninety five earth pits.

It should be maintained and resistance of all earth pits should be checked and records should be maintained.

CSD (Central Stores Department) Hydra was not having safety latch. Every hydra should be checked before

driver or operator starts the machine any non conformity should be attended at the earliest.

Asle marking was done on the flooring

for walk way of man and machine however due to space constrain the materials were not stored within the aisle marking.

It should be reviewed and ensure that the walk way should be free from obstruction.

PFEs were installed more than 1

meter from the ground which will create stress to person while lifting the PFE. The hazards associated with PFEs like CO2 was not known to concern workers while handling same.

PFEs should be installed as per the AP factories Rules, 1950. During fire fighting trainings hazards should be made known to workers.

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OBSERVATION RECOMMENDATION

B7 hydrant point was provided in the store but access was not available due to material storage. Electric switches near E 19 were not tagged for isolated supply. There were emergency exit doors provided in the store for emergency however these doors were not having proper access and found locked due to security reason.

Access should be available to reach the hose boxes so that in case of emergency hydrant can be used. Tagging should be done to such isolated switches for ready reference. It should be reviewed.

Two numbers of EOTs were available

in store which was tested as per the statues, certificates was available in form 38 and issue dated 13/12/2018 and valid up to 12/12/2019. E 17 EOT crane JB interlock system Switch found broken.

This is in order. It should be attended.

Old QSHE policy was displayed at

CED store which was replaced with 2017 QSHS policy.

Noted.

Company was having open storage of

chemicals drums storage. The drums of oil lubricating, servo oil stored in open yard where no electric lighting provided except high mast tower at the entrance but it was found that lot of grass was grown near the electric panel JB which may lead to fire.

The grass should be cut regularly to avoid the fire which is one of the sources for fire.

Conveyor Store in that lot of

combustible material like rubber hose, conveyor belts were stacked near live electrical switches which may lead to fire. There was EOT crane which having two staircases one for going up to the cabin and other was for exit however material was stacked at the exit

The stacking of combustible material should be away from the electric source to avoid fire. Ensure that emergency exit should be free from any obstruction.

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OBSERVATION RECOMMENDATION

staircase which blocks the exit root. STED The role of STED was cleaning of

roofs, structures regular inspections and painting of structures etc. STED has prepared regular inspections schedule for roof sheeting, structures, painting. The permits required for the height work job was taken in shift starting and the permits entry was made in the register for knowing the number of permits issued during the date and records were available for verification. STED has planned the structural stability for sixteen structures of the company for that contract was allotted to competent agency M/s Nova Nirmaan Engineering and Architect WO number 4410002218 and scope of work was Inspection of Steel Structures by competent authority for stability certificate. Out of sixteen structures four structures stability certificate was received after testing however other structures stability was not checked due to operation of the units.

Noted. This is a good system it should be continued. These structures should be checked for stability as more than thirty years of plant was in operation and it was suggested that other old structures stability checking should be planned.

Monthly schedule for painting of all

types of things were prepared and accordingly inspections were carried out and remarks were mentioned on the inspection records, these records were maintained in a file for verification.

This was a good practice same should be continued.

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