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7.7.0 Introduction

Steel making process poses difficult challenges in the area of Safety, Health and Environment when compared to many other industries due to complex nature of its operation and maintenance activities and wide range of associated hazards. Despite considerable technological progress, focused attention is needed for reinforcing safe behaviour and improving safety culture at job site. In the present scenario maintaining high standards in the arena of Occupational Safety, Health and Environment in steel industry is of paramount importance.

7.7.1 Identification of Hazards & Control Strategies

7.7.1.1 The whole process of production of iron and steel right from the raw material to the finished products ridden with many inherent hazards and risks. Hazards are also associated with the very nature of the shape and size of operation, and machines. There are physical hazards (noise, vibration, heat and cold stress, slip & fall etc.), chemical hazards (inhalable gases/ vapour/dust/fumes, asbestos, insulation wools etc.), Biological hazards, radioactive hazards etc.

7.7.2 Present Safety Status

7.7.2.1 Year wise fatality figures for major steel producers of the country are given below- Company 2006 2007 2008 2009 2010 SAIL (Incl. Mines) 23 22 25 28 33 TISCO (Incl. Mines) 11 8 6 4 6 RINL 5 2 4 4 3 NINL 0 1 0 2 4 Essar Steel 4 0 0 2 7 Ispat NA 3 4 2 Nil JSW - - - 2 Nil Bhusan Steel Ltd. - - - - 3

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7.7.3 Present Safety Efforts/Activities

 Major Steel Plants have comprehensive Safety policy.

 Safety aspects are incorporated in Standard Operating Practices (SOP) and Standard Maintenance Practices (SMP) adherence to which are monitored at Shop Floor Level of organized sectors.

 Consistent efforts are made for compliance of applicable statutory rules, regulations, norms, procedures, work instructions etc. at organized sectos.

 Annual Performance Plans (APP) in the areas of Safety and Fire services are formulated and review of implementation of APP is done by plants & SSO.

 Internal and external safety audits are conducted as per schedule at plant level / hazardous areas. The recommended points are implemented/ monitored. Compliance status of previous audits is reviewed before re- audit.

 Personal Protective Equipments (PPEs) like safety shoes, safety helmets, hand gloves etc. are provided to the workers including contractor workers.

 All major capital repairs/shut downs are closely monitored round the clock to prevent accidents.

 Regular preventive inspections of unsafe acts & conditions are being done on the basis of checklist and corrective actions are taken.

 Joint Inspection of cable galleries and underground cellars are done as per schedule and their upkeep is ensured to negate the chances of fire.

 Work-permit/Protocol system are in vogue for hazardous jobs where multiple agencies are involved like jobs on Gas lines, Steam lines, Pressure vessels, Lifting equipments, Electrical installations, Electrically Powered Machines, Hydraulic lines, while working in confined space, working at height etc.

 Job/area specific safety instructions are displayed at strategic locations to caution employees about associated hazards and take precautionary measures.

 Periodic campaigns are conducted to inculcate safety awareness up to grass root level. Regular publications of educative materials are being made by organized sectors in the form of Journals, Manuals, Reports, Bulletins, Booklets etc containing wide range of information pertaining to Safety, Health & Environment.

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 On-site disaster management plans are updated and mock drills are conducted at regular intervals as an emergency preparedness.

 All accidents are investigated and remedial actions are taken to prevent their recurrence.

 Safety training is imparted for contractor workers before issue of gate pass. In addition, job specific safety training is also imparted at site by the executing agency before starting the job.

 HRD intervention in the area of safety covers Senior executives, Line Managers & Departmental Safety Officers / Safety inspectors etc. Besides, area specific workshops are organised on identified themes like gas safety, rail/road safety, safety in iron, steel & coke making etc for sharing of best practices in safety management in organized sectors.

 Skill oriented job specific safety training is being imparted to various target groups like Crane Operators, Loco Operators, Porters, Riggers, Welders, Gas Cutters, Electricians, Heavy Earth Moving Equipment Operators etc.

 Safety awareness among housewives, school children etc. is generated through various workshops, campaigns, competitions etc in organized sectors.

 Movement of heavy vehicles is restricted during shift change hours to avoid any road accident. Entry of persons riding two wheelers without crash helmet is not allowed inside the plant premises. Surprise checks are also conducted for ensuring the usage of the same.

 Plants of organized sectors have well equipped Fire Services deptt. manned by qualified and trained fire professionals. The adequacy of existing fire protection system in the shop is periodically reassessed through structured system of inspections and augmented on continual basis. Employees are extensively trained in the use of suitable fire extinguishers and other fire suppression systems.

 Major plants of organized sectors have well established OHS centre primarily entrusted with preventive functions and responsible establishing and maintaining a safe and healthy work environment. It undertakes occupational health surveys / studies w.r.t Dust, Noise, Heat illumination etc. in identified hazardous locations and control measures are adopted accordingly. Various education and training programs are organized on Health related topics to apprise the employees about all possible adverse impacts of work environment on their health

 A bipartite forum named Joint Committee on Safety, Health and Environment for Steel Industry (JCSSI) headed by Director(Technical), SAIL as its Chairman & Executive Director(Safety), SAIL as Vice Chairman and having representatives from Management of all Steel Plants & Units of SAIL, RINL, TISCO, Ispat Group, ESSAR, NINL, Bhusan Steel Ltd., Ispat Steel Ltd as well as Central & Plant level Trade Unions is

157 functioning at National level for enhancing the overall standard of Safety, Health & Environment in respective member steel plants.

7.7.4 Thrust in next Five Years

a) Sustaining / Accreditation of OSHAS: 18001:2007 certification.

b) Universal usage of user friendly Personnel Protective Equipments (PPEs) and modern safety appliances by regular as well as contractor workmen. c) Safety aspects are to be integrated at design stage as well as during

operation and maintenance at steel plants entailing minimum exposure to safety hazards.

d) Upgradation of Occupational Health Centres with modern facilities for maintaining Occupational Health Standards of employees and computerisation of health records.

e) A culture of safety to be propagated with the involvement of workemen and assistance of bi-partite forums like JCSSI etc.across Steel Industry. f) Usage of Audio Visual Aids, Safety films etc.for imparting effective training

particularly to contractor workers.

g) Safety standards to be monitored by agencies like JPC, NSC, FICCI, CII etc. in order to bring about improvement in the secondary steel making sector consisting of Sponge Iron Plants, Mini Steel Plants, Re Rolling Mills etc.

h) Treating the Contractor Workers at par with Regular employees in matters related to safety and Occupational health aspects.

i) Pre-commissioning and regular Safety Audits to be conducted at regular intervals in both organized and unorganized sector.

j) Concept of Behaviour Based Safety management to be propagated & implemented across the industry in order to bring about basic change in perception towards performance of ones duty to achieve ultimate goal of producing accident free steel.

k) Modern water tight fire detection, protection, control and response system to be installed / maintained.

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CHAPTER - VIII