SAFETY MANAGEMENT SYSTEM

At
T S ALLOYS LIMITED

ABOUT THE PLANT

TATA STEEL LTD acquired 100% equity stake of raw
met ferrous industry in the year 2007 thus giving rise
to T S ALLOYS LTD.
It is an integrated Ferro alloy plant located at
Anatapur village of Athagarh sub-division in the
district of Cuttack, Odisha.
The existing production capacity of High carbon FerroChrome is 53481MT/Annum and the Briquetting plant
capacity is 100,000MT/Annum.
The current turnover of T S Alloys is 164.7 Crore.
The total manpower of T S Alloys is 800 and more than
95% of the work force comes from the local populace.

SAFETY ACHIEVEMENTS
Du-Pont Structure was incorporated under the leadership of Chief of
Corporate Safety on 4 th of May 2011.
Certification of ISO 9001: 2008, ISO 14001: 2004, OHSAS 18001: 2007
by Indian Register Quality Systems was attained on 10 th November
2011.
Implementation of 5S and Kaizen from 5th September 2012
T S Alloys received Kalinga Safety Award for best practices in Safety,
Health and Environment on 14 th September 2012.
TSAL received best safety performance in TIS Group award for its best
practices in safety from M.D Tata Steel Ltd on 30 November 2012.
implementation of LOTO {lock out tag out} process was initiated from
18th March 2013.

PLANT PROCESS LAYOUT

ORGANIZATIONAL STRUCTURE OF SAFETY

MD

GM

Asst.
Manager

(Admin &
Services)

(Safety &
Environment)

The Flowchart of safety organizational structure

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

SAFETY MANAGEMENT SYSTEM

A Safety Management System (SMS) is a systematic approach to
managing safety, including the necessary organizational structures,
accountabilities, policies and procedures.
Need of Safety Management System
To protect human life and environment from industrial Hazards.

to eliminate heavy losses from the direct and indirect cost of

accidents.

For the smooth operation of the Plant thereby benefiting the

society and country as a whole.
To satisfy and attain the legal compliance.

SAFETY MANAGEMENT AT T S ALLOYS LTD

T S Alloys management seeks to create and sustain a Company
culture in which employees share a commitment to HSE. T S Alloys
believes safety is as important as cost, productivity, or employee
relations.
T S Alloys follows Du-Pont Structure for safety which says Safety is
a line managers function.

FLOWCHART OF SAFETY MANAGEMENT SYSTEM

Safety Observation System

Incident Investigation
HIRAC Study
Safety Audit
Compliance to legal requirements
On-site Emergency Plan
Work Permit System

Safety Training System Induction, Work

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

ANALYSIS OF ON-SITE EMERGENCY PLAN

On-site Emergency Plan legal Compliance
Section 41-B(4) of Factories Act 1948 requires that every occupier of a
hazardous factory shall draw up an On-site emergency plan and detailed
disaster control measures for his factory and make it known to the workers
and the general public in the vicinity, the safety measures required to be
taken in the event of an accident taking place.

On-site Emergency
An on-site emergency is caused by an accident that takes place in an
industrial industry and the effects are confined to the factory premises
involving only the people working in the factory.

IDENTIFICATION OF HAZARD
Hazard is in fact the characteristics of a system/plant/storage that
has the potential for an accident and risk is the probability of
occurrence of hazard.
Hazard identification is of prime significance for the quantification
of risk and for cost-effective control of accidents in any industrial
installation.
Hazards are mostly manifested in the form of fire / explosion / toxic
release.

HAZARD AND ITS IMPACT

Sl
No

Area/Activity

Hazard

Impact

Furnace Oil

Pool fire/fire ball may

occur in case of direct
contact with flame.

Fire may propagate to the

near-by areas containing
furnace oil like Briquette
plant.

Liquid Oxygen

Leakage to atmosphere

May cause damage to

equipment if the combustion
mixture is formed.

Coal

Fire may occur due to

spontaneous ignition of
coal

Fire will propagate within the

coal storage yard.

HAZARD AND MITIGATION MEASURES

FURNACE OIL Furnace oil is a flammable liquid, having flash point of
66c and auto ignition temperature of 407 c and explosive limit of 5%
volume in air. So it is susceptible to fire hazard.
The pool fire modeling of furnace oil is done for three different situations
using fire equation.

LIQUID OXYGEN
LIQUID OXYGEN There is a liquid oxygen storage tank. Release of
oxygen from pipeline or oxygen storage tank accidentally may pose serious
fire hazards (leakage through 25mm diameter hole).
Leakage of liquid oxygen from oxygen storage plant will vigorously
accelerate the combustion or explosion of organic or other oxidizable
material.
Control measures
The liquid oxygen dispersion model has been prepared on the basis of
guassion model.
Emergency procedures are to be prepared including the event of
spillage of the cryogenic fluid.
emergency procedures are prepared in conjunction with the emergency
services or fire brigade and the local conditions are considered.
The procedures shall be readily available to all personnel involved,
regularly practiced and checked periodically.

COAL FIRE
COAL FIRE - Self-heating is the process whereby a coal particle
undergoes chemical and physical reactions that generate heat within the
coal particle.
Control Measure
Coal should not be stacked in the yard more than the process
requirement for a stipulated number of days.
As far as possible, coal must not be stored for more than 3 months.
Where it is unavoidable to store it for a longer period, the top and
sides of each heap/ stack must be well sealed with oil or other suitable
medium.
Coal handling unit/Agency shall provide adequate fire-fighting measure
to avoid any fire or related hazards.

T S ALLOYS ON-SITE EMERGENCY FACILITIES

Ambulance
One doctor with paramedical staff.
First aid boxes.
Portable fire Extinguishers total of 75 extinguishers including (ABC,
CO, DCP & FOAM type)
Fire hydrant points all over the plant total of 25 hydrant points.
Sand buckets total of 19 buckets.
Mobile equipment- Front wheel loader.
Transport vehicle Bus and light vehicles.
Assembly Points.
Security personnel.
Fire ladder (1nos).
Mutual Aid Arati steel Ltd (located 6kms away from the plant).

RAISING OF ALARM DURING

EMERGENCY & CLOSING PROCEDURE
Raising of Alarm During Emergency
The person noticing the emergency should immediately inform the shift incharge or the unit head who in turn will inform the combat team leader
immediately regarding the hazard.
Raise the alarm.
Summon help and emergency services.
Notify fire brigade immediately (if necessary).
Evacuate all persons from the immediate danger area and seal it off.
Closing procedure

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

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

COMMAND STRUCTURE DURING ON-SITE EMERGENCY

THANK
YOU