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Transformative solution by Safety Circle team of New Plate Mill enhances safety and accrues huge savings for Rourkela Steel Plant

Newsmantra — Tue, 05 Aug 2025 08:48:41 +0000

In a significant step toward enhancing workplace safety, the TEJAS Safety Circle of SAIL, Rourkela Steel Plant (RSP) has successfully executed a critical project to mitigate hazards caused by hot flying scales from the primary descaler of the New Plate Mill (NPM). The initiative, underscores the commitment of the plant to promote a culture of proactive safety, innovation, and operational excellence.

The five-member TEJAS team comprising Mr. Deepak Sahu, Engineering Associate, Mr. Gopabandhu Behera, Mr. Shirshananda Das and Ms. Supriya Bhoi, all Junior Engineering Associates along with facilitator Mr. Abhijit Patnayak, Senior Manager (NPM) carried out a detailed safety audit in the descaling zone. During their inspection, the team identified over 100 unsafe conditions and acts, related to the hazard of hot flying scales. This particular hazard had the potential to cause serious injuries, fire incidents, and significant equipment damage.

Using the DIMAC (Define, Measure, Analyze, Improve, Control) methodology, the team conducted an in-depth root cause analysis. The investigation revealed key vulnerabilities. To address these challenges, the team implemented a robust and multi-faceted action plan that included installation of multi-layer chain curtains to contain flying scales, Fire insulation of exposed cables and motor areas, Protective shields for essential equipment, and Deployment of visual caution signage to enhance hazard awareness.

Following the implementation, there has been a substantial improvement in workplace safety. The initiative not only prevented potential production losses valued at over Rs. 1.56 crores but also led to a monthly saving of 24 man-hours. More importantly, it contributed to a stronger culture of safety, morale, and teamwork among employees.

The team Tejas presented the innovative project at the 16th Integrated Safety Circle Convention at SAIL, Bhilai Steel Plant and bagged the Gold medal for the project.

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Safety Circle Team Implements Innovative Safety Measures at Silicon Steel Mill of SAIL, Rourkela Steel Plant

Newsmantra — Thu, 31 Jul 2025 07:03:20 +0000

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.

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