Steel Plant Safety Practices and Risk Assessment Journey
Explore the safety practices, hazard scenarios, process studies, ladle lifting practices, risk assessments, and proactive engagement at a British Steel BOS plant. Learn about key safety steps, audit schedules, and comprehensive risk assessments for maintaining a safe working environment.
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Presentation Transcript
British Steel BOS Plant Safety Practices James Worsley BOS Plant Manager Hamid Rasool Steelmaking Works Manager
Process Safety Steelmaking Top Major Accident Hazard Scenarios 1. Explosive Mixture of BOS Gas and Air 2. Water and Molten Metal Reaction 3. Molten Metal Loss of Containment 4. BOS Gas Loss of Containment 5. Pilot Loss of Ignition The BOS Plant uses Bow Ties to visually represent the output from hazard studies such as Process Hazard Reviews (PHRs) and Hazard Operability Studies (HAZOP). Visual representation allows the illustration of the prevention and mitigation barriers in place to stop the event from occurring and reduce the severity if the incident should occur. Key Question Set 1. Do we understand what can go wrong? 2. Do we know what our systems are to prevent this happening? 3. Do we have information to assure us they are working effectively? 2
Ladle Lifting Practices Process Hazard Study and Bowtie Image result for green tick Human Factors - Human factors analysis study conducted - Trained and competent Crane Hook Spotters - Mandatory communication requirements - Multi-channel 2-way radio communication - Dedicated Crane Hook Spotter Zones - Cameras on blind side hooks - Training manual and competence questionnaires Engineering Control - Installation of point hold detection on a hot metal crane. 3
Comprehensive Risk Assessment BOS Plant Journey September 2018 2841 Risk Assessments 1st April 2019 October 2019 CRA Expectations CRA Only 574 Comprehensive Risk Assessments CRA Only Bi-Weekly Progress Meetings Ongoing audit and review process - Benefits Realised: - Number of Risk Assessments dramatically reduced - Clear and concise task specific Risk Assessments - Effective hazard identification and description - Mandatory Key Safety Steps detailing the critical control measures to prevent significant injury or loss to persons conducting the task or others - Clear links to the Business Standards 4
Proactive Engagement Audit Schedule - The BOS Plant has an audit schedule. The schedule covers all areas of the plant and all activities undertaken on the plant. - Specific audit templates - Mandatory requirement to conduct 1 audit per month - Average of 60 audits per month Positive Safety Conversations - Mandatory business requirement to conduct a minimum of 1 Positive Safety Conversation (PSC) per month - Year to date 100% engagement Briefs, BOS TV and Learning From Events (LFE) - Regular briefs delivered to all personnel - Following any high potential incident, near miss or accident a LFE slide is created and circulated around the BOS Plant as well as being displayed on the BOS TV - Monthly topics presented on the BOS TV. TV s are located around the plant in control rooms and team leaders offices. 5
