In a major stride towards ensuring workplace safety, the Safety Circle Team ‘Suraksha Prahari’ of Silicon Steel Mill (SSM), SAIL, Rourkela Steel Plant (RSP) has implemented an innovative solution by installing an Online Ammonia Detection System at strategic locations in the Ammonia Cracking Unit (ACU). The initiative has significantly bolstered safety standards and reduced the risk of casualties in the event of an ammonia leak.
The team realized the need for a more robust and proactive safety system. Going beyond mere compliance, the team took a holistic approach to improve overall safety by ensuring early detection, swift alerts, and preventive maintenance.
A comprehensive system analysis was carried out by the ‘Suraksha Prahari’ team, leading to several key upgrades. These included condition-based replacement of unloading hoses, improved access to isolation valves for emergency handling, and replacement of flange packing. The highlight of the initiative was the installation of four sensor-based online ammonia detectors near the ammonia storage tank and cracking furnaces. These detectors provide real-time alerts in the control room through an HMI with three-tier alarm levels including a visual lamp flashes when ammonia concentration exceeds 25 PPM, a buzzer sounds at 25 PPM and a continuous loud alarm is triggered at 50 PPM and above.
The system is also backed by CCTV surveillance with live monitoring in the control room, ensuring rapid response to any untoward situation. Enhanced housekeeping practices were also introduced to maintain a clean and hazard-free environment.
The team behind this safety enhancement comprises Mr. Kedar Nath Hui, Junior Engineer & Team Leader; Mr. Prasanna Kumar Swain, Junior Engineer & Deputy Leader; Mr. Syed Abdul Rajik, Junior Engineer; and Ms. Payel Sarkar, Junior Engineering Associate. The group was guided by Mrs. D. Shakuntala Reddy, AGM, SSM, who served as the facilitator.
The ‘Suraksha Prahari’ team also bagged the gold award at the 16th Chapter Convention on Quality Concepts (CCQC-2025), Bhilai Chapter, held at SAIL, Bhilai Steel Plant.
