In Plant Industrial Safety Training in KFIL 2017-2018

PART-A
1. ORGANIZATION

Fig 1.1 KFIL company view

Kirloskar Ferrous Industries Limited (KFIL)
Incorporated in 1991, KFIL is the flagship company of the Kirloskar Group. KFIL
was promoted by Kirloskar Oil Engines Limited (KOEL) and Shivaji Works Limited (SWL)
and later in the year 2007, SWL was acquired by KFIL. KFIL was incorporated with the
objective of catering to the requirement of high quality Pig Iron and intricate, thin walled
grey iron castings to the emerging in Tractor, Auto, Engine and other related segments.
KFIL set up the manufacturing facility at Bevinahalli village considering the
proximity to major raw material i.e., Iron Ore which is available within the radius of around
40 KMs in Hospet-Sandur-Bellary area. Location is also well connected by road, rail and
port.
KFIL is having Pig Iron and Casting manufacturing facilities at Bevinahalli, Koppal
District, Karnataka and our foundry is the first of its kind having integrated set up to serve the
customer with quality castings. KFIL has captive power generation facility. KFIL is having
casting manufacturing set up at Shivasahi, Solapur with semi-finish machining facility.
KFIL has collectively two Mini Blast Furnaces (MBF) with an aggregate capacity of
3,60,000Tons per annum for manufacturing Pig Iron with Hot Blast Stoves to pre heat the
gases. KFIL has set up Sintering facility to use iron ore fines. KFIL has set up 11.5 MW
captive power plants which use the waste gases generated in the mini blast furnace. The
manufacturing facilities are equipped with latest technology to cater to the quality needs of
the customers.

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1.1Organization Structure
TheOrganization Structure is shown in Fig 1.2

Chairman

Managing Director

Factory Manager

Sr VP PIP&Foundry Sr VP HR & GA Sr VP Finance

Sr GM GM Finance
PIP Foundry

DGM
Manager
SBU Head
SBU Head

Sr Manager
Dept Head Deputy Manager
Dept Head

Manager
Section Head
Section Head Sr Officer

Deputy Manager
Shift Incharge
Shift Incharge Officer
Officer
Engineer Engineer
Assistant Officer
Assistant
Operator Operator
Assistant
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Trainee Trainee
1.3Safety Department
Safety Department hierarchy is as shown in Fig 1.3

Managing Director
(R.V Gumaste)

Factory Manager
(B. Sathish Shetty)

Safety Officer
(Muralidhar Nadiger)

1.4 Occupier and Factory Manager

Occupier: Mr R.V.Gumaste
Factory Manager: Mr B. Sathish Shetty
1.5 Chief Safety Officer
Chief Safety Officer: Mr Muralidhar Nadiger
1.6Chief Medical Officer
Chief Medical Officer: Dr Praveen Kumar
1.7 Plant Topography
The Following are the details of process flow from raw material to finished
Product in Kirloskar Ferrous Industries Limited (KFIL)
For Pig iron manufacture:
 Raw Material Handling Section (RMHS)
 Sinter Plant
 Mini Blast Furnace (MBF-1 & 2)
 PCM(Pig iron Cast Machine)

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For Cast iron moulding manufacture:

 Material (Pig iron ,Bronze, Bross)
 Induction Furnace
 Sand Core
 Mould Line
 Cooling
 Fettling
 Dispatch
1.8 Activities of Safety Department
 Accident / Incident review
 Work permit review
 Safety Audit / review
 Safety Training
 Conducting mock drill
 Statutory requirements
 Road safety inspection
 Accident investigation
 Maintain accident / injury records
 Penalty for violation of safety rules
1.9 Activities of Fire Safety Department

 Inspection of fire extinguishers

 Maintenance of fire fighting equipments
 Conduct fire mock drill
 Training
 Maintenance of records
1.10 Activities of OHC(Occupational Health Centre)
 Occupational health monitoring
 Pre-employment medical examination
 Periodical medical examination
 First aid treatment

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 Maintenance of first aid kits

 Maintenance of ambulance
Training on health, hygiene& first aid
2. SAFETY MANAGEMENT
2.1 Environment, Occupational Health and Safety Policy
 In accordance with our union “Tobe Product leader in pig iron and casting
business” we at Kirloskar ferrous industries limited manufactures of pig iron and
grey iron casting are committed to protect and upgrade our Environment,
Occupational health and safety of Human lives through:-
 Providing safe and healthy work Environment to prevent accident and Occupational
health hazard by involving all the concerned.
 Complying with all applicable legal and other requirements of Environment,
Occupational health and safety management system.
 Improving Environmental, Occupational health and Safety awareness to all employees
including contractor’s employees through training.
 Systematic and cost effective methods for waste management.
 Controlling all pollutants and hazard with in prevailing acceptable limits through belt
available technology, resources and periodic reviews enabling continual
improvement.
 Optimal utilization and conservation of resources through effective recycling and re-
use practices.
2.2 Safety Promotional strategies
The KFIL management has made as many activities in which the workman can part as
possible and future it should give them the major roles whenever and wherever possible.
Such activities include,.
 Safety Awards and Rewards.
 Employee’s participation.
a.Safety Awards and Rewards: Safety Awards and Rewards are given to the participants,
participated in the various safety competitions held prior to the National Safety Day and Fire
Service Day. The Safety competitions include via: safety quiz, safety essay, safety slogans
etc. To promote themselves in safety standards and the winners will be awarded with the
prizes. The safety person award will be given by department wise, and rewarded to the
department which has best safety performance in a year.

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b. Employee Participation in Safety: The KFIL management has encouraged employees

themselves in safety by means of participation of the workers in safety committees,
implementation of safety suggestion received from the workers, involving workers in safety
inspection etc.
2.3 Safety Committee
The safety department acts as the nodal agency with overall responsibility, employee
participation is also encouraged to formation of safety committee. Safety committee consists
of members drawn within the organization at all levels.
Objectives of the Safety committee:
 Provide a platform for discussion of the safety issues including the plans and
programs of the organization.
 To act as means of communication with employees and the views of employees.
 Functions of the safety committee,
 To monitor safety performance.
 To look into effectiveness of the organization health and safety policy.
 To study accidents statistics.
 To undertake safety audits.
 To review safety inspection and audit report.
 To consider proposals for the future developments.
 Creating Safety awareness among all workers
 General agenda points of the safety committee include:
 Review of safe work practice.
 Employee health and safety concerns.
 Occurrence of hazardous conditions or practices and recommended corrective action.
 Safety and health inspection.
 Accident investigation review.
 Accident prevention program review.
 Safety training.
2.4 Accident investigation procedure
 An incident investigation report should answer the WHO, WHERE, WHEN, WHAT,
WHY questions with regard to the incident.
 WHO

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Employer, injured person(s) involved in the incident, witnesses, and persons carrying
out the investigation.

 WHERE
Place, location where incident occurred
 WHEN
Date and the time of the incident.
 WHAT
A brief description of the incident, including the sequence of the events that preceded
the incident.
 After the incident occurred:
What were the events that led up to the incident?
 What process /es was/were occurring immediately prior to the incident?
 What was/were the worker(s) doing immediately prior to the incident?
 What was the last event the incident occurred?
 At the time of the incident:
 What happened at the time of the incident?
 What process (es) was/were occurring at the time of the incident?
 What was/were the worker(s) doing at the time of the incident?
 What hazard(s) was/were the worker(s) exposed to?
 What hazards may have contributed to the incident occurring?
 What hazards did the worker(s) encounter?
 What personal factors may be contributed to the incident occurring
WHY?
From the answers to “what”, identify any unsafe conditions, acts, or procedures the in any
manner contributed to the incident. Why did the unsafe conditions, acts, or procedures occur?
Why were the personal factors not identified and/ or addressed before the incident occurred.

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3. SAFETY EDUCATION & TRAINING

3.1 Unsafe conditions & Unsafe Act’s:
Unsafe Act:
The violation of the commonly accepted safety procedures which may result to an accident.
Therefore, the industrial management has provided unsafe acts by means of which the
accidents can be controlled.

Fig: 3.1(a)
Fig: 3.1(b)
Fig: 3.1 (a) worker not using PPE’s while gas cutting
Fig: 3.2 (b) Unsafe cylinder lifting and without PPE’s
Training is defined as any attempt to improve employee performance on currently held job.
This usually means of specific knowledge, skill, attitude etc.

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KFIL has training program to educate and impart practical training on all aspects to its
employees and outsourcing employees. The training program covers safety aspects with
respect to the various hazards involving in the plant premises.
Unsafe acts are like:
 Using the wrong tools
 Using the wrong material
 Using wrong method
 Failure to use PPE’s
 Unauthorized work
 Taking shortcuts
Unsafe Condition:
The conditions of the selected agency which could & should have been guarded or corrected
which is left as it is would lead to an accident is known as unsafe condition.
Unsafe conditions are like:
 Improper guarding of machine
 Improper ventilation
 Poor house keeping
 Damaged insulation on electrical lines

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Fig: 3.2 (a) Fig 3.2 (b)

Fig: 3.2 (a) Cylinder position is incorrect and gauges are damage
Fig: 3.3(b) No machine guarding
KFIL has provided training to reduce unsafe conditions like 5’s training. The unsafe act and
unsafe conditions are will reduce the productivity and increase the accidents. The
productivity will be increased and accidents will be decreased by good procedure of work and
condition of work area.
3.2 Interaction with work force
Interaction with the work force on regular basic has been made in all departments
throughexplanation like
 Working procedure
 New machines operation training
 Usage of PPE’s

Fig: 3.3providinginstructions to trainees

3.3 Conducting shop floor training program
Training is defined as any attempt to improve employee performance on a currently held job.
This usually means change in specific knowledge, skill, attitude etc. KFIL has a training
program to educate and training on all aspects to its employees and other out sourcing

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employees. The training program covers safety aspects with respect to various hazards in the
plant premises.
3.4 Conducting Tool Box Talk
The tool box talk programme, if implemented correctly can play a major part in our
continuing effort to create an increase in awareness of
 Hazards present in industry
 Precautions which must be taken to eliminate or control them and in doing so will
help to reduce unwanted incidents
The tool box talk programme has been written as a series of numbered discussion topics on
Safety, Health and Environmental issues.
3.5 Safety Patrolling at WorkSite Covers Road Safety
Traffic Mirrors
 Traffic Mirrors are provided at all blind corners and road diversions to have clear
vision about movement of vehicles. This helps control of accidents.
Vehicles Speed Limit:
 The Vehicles speed inside Factory premises is 16 KMPH
Driving License:
 The Driving License should be mandatory inside Factory premises for all persons who
is drive the vehicles.
3.6 Safety instructions at work site
Before starting any maintenance job the worker should be briefed about the hazards involved
in the process by the incharge and also safety boards are fixed near the hazardous areas.

Fig 3.4 Safety instructions at work site

3.7 Do’s and don’ts at work place

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Do’s:
 All the maintenance activities should be performed only after taking the permit and it
is to be approved by the authorizer.
 In case of any gas leakage assemble at assembly area & inform the concern
supervisor.
 Enter the plant area with adequate PPE’s like Safety helmet, Safety goggles, Ear
Plugs, Safety shoes etc.
 If any unsafe conditions inform to area incharge.
 In case of Emergency call
 2000 for Medical
 3000 for Security
 4000 for Safety
 As per job requirements PPE’s should be used.
 Use right tools for right job.
 Before handling any chemical material or toxic gases MSDS should be studied.
 After complete your wok keep all the tools in the toolkit.
Don’ts:
 Do not operate the machine without authority.
 Do not work at work area without proper PPE’s
 Do not enter in the gas areas without CO monitors.
 Do not enter unauthorized areas.
 Do not use worn-out PPE’s and Tools.
 Do not carry the tools in the pocket.
 Do not drink water which is in the bottle, until it is confirmed as drinking water.

3.5 Do’s and Don’ts at work place

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4. PROCESS SAFETY
4.1 Process flow chart raw material to finished goods

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Fig 4.1 Process flow-chart for Pig iron

Fig 4.2 Process flow-chart for Foundry Process

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4.2 Process Hazards

The hazards which are likely to occur during the series of operation of the process from
the raw material to finish products are given below
 Dust , Heat radiation , Running machineries due to raw material and conveyor belts
 CO inhalation, Dust , Heat radiation, Burn Injuries in the Mini Blast Furness(MBF
1&2)
 Noise due to Blowers
 Amine leakages, Dust while manufacture of sand core
4.3 Process Safety Measures
 Guards provided for conveyors & Tail end pulleys and Dust extractions system are
provided at Sinter Plant
 CO Monitor with alarm system provided to detect the CO levels
 Water coolers& cooling system installed to reduce heat and Medical Oxygen
cylinders provided at MBF (1&2)
 For decrease the noise provide PPE’s to employees and isolate the area
 Dust mask provided to workers and regular maintaince for checking Amine leakage in
core shop
4.4Physical Hazards
 Heat Radiation
 Noise
 Flying objects
 Falling objects
 Manual lifting
4.5Chemical Hazards
 Dust
 Fumes
 Inhalation
 Ingestion
4.6 Mechanical Hazards

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 Contact with protection on work or stock or projecting screws

 Flying metal chips
 Use of hand for holding emery against the work
 Attempting to remove chips or turning by bare hands
 Contact with rotating parts or job
 Insecurely clamped jobs
 Slipping or loose clothing in moving parts
 Unwiped, oily & uneven floor
 Bad housekeeping
4.7 Electrical Hazards
 Leakage from metallic enclosure
 Loose connection & improper joints
 Bad Contacts
 Overheating of contacts & moving parts causing spark
 Inadequate fuse rating
 Wrong cable size
 Rodent earing away installations
 Overheated transformers
 Spark due to build up static electrical charges
 Damaged insulation
4.8 Plant/Machinery Earthling Bonding
All motors, pipe lines, pumps, tanks have been given adequate earthing. Some equipment
especially in motors & pumps double has been provided for foundation & equipment
separately.
4.9 Static Electricity
All electro static precipitators DM water storage area where changes of generation of static
electricity is there adequate care has been taken.
4.10 Fire Hazards

 Solvent fires-solvent fires can usually be extinguished by the proper use of dry
chemicals or carbon dioxide extinguishers. Fires in small contains of solvents can
often be snuffed out by placing the lid on the container tightly enough to exclude air.

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 Chemical fires-Chemical fires can be of many different sorts & often special methods
of fire fighting must be used. For ex, a metal fire (sodium, titanium, magnesium, salt,
or inert gas in confined areas, never use water.
 Electrical fires- if possible, first turn off the power to the motor or other electrical
equipment. Use carbon dioxide or dry chemical on electrical equipment, never water.

5. MACHINE GUARDING & PPE

5.1 Types of Guards
Guards are used for avoid interact to the machine moving parts.
Different types of guards are:
 Fixed Guard
 Interlocking Guard
 Adjustable Guard
 Distance Guard
 Automatic Guard
5.2 Guarding of Different Types of Machinery
All the rotating equipment’s of the machinery should be guarded.
Different types of Guards are used for different machineries as per the applications.
 Coupling guards
 Pulley guards
 Nip guards
 Rotating shaft guards
 Chain guards
5.3Types of Personal Protective Equipment (PPE):
According can be avoided in two ways i.e., by eliminating & reducing the hazardous & by
providing PPE. Most of the injuries can be eliminated or minimized by using right type of
PPE required for the job.
Personal Protective Equipment categories
Non- Respiratory PPE
 All contractor work force is provide with yellow colour Safety Helmet of FRP make
& good quality safety shoes of Bata make as per ISI.

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 The persons engaged in hot area & dust area is provided with Safety helmet with
neck protection, face shield, cull neck cap, safety goggles, hand gloves, leg guards &
dust masks.
 The person engaged in the notice area provided with ear plugs/ear muffs.
 Heat resistance suit- approved jean jackets, aluminium suit, cotton shirt, pant, socks
is for provided employees working in the hot zone area.
 Adequate number of CO detectors are produced & distributed to different sections is
ensured.
Respiratory PPE
To prevent injury by dust, toxic gas & vapours respiratory protective devices are provided. In
Kirloskar Plant based on the hazards prevent following type of respiratory protective gadgets
are made available.
Dust Masks: Cloth, paper type & filter type dust masks are provided for the employees to
take care of silica dust & coal dust.
Breathing Air Sets:
Self-Contained Breathing Apparatus (SCBA): The SCBA consists of full face mask to
which air is supplied through a small diameter flexible hose pipe. Its period of working is of
about 40 minutes. It is a demand type airline respirator. Here the air is supplied to face piece
when the wearer inhales & then rate is governed by his volume rate of breathing. Air from an
air compressor/ cylinder of compressed air is supplied to face piece through a demand valve
& the exhaled air or the excess air entering the face piece escapes to surrounding atmosphere.
Emergency Life Breathing Apparatus (ELBA): The ELBA is designed to provide the
greatest possible respiratory protection: it is mainly used during escape. It consists of a small
filter element, a mouth piece & a means of carrying conveniently a body.
Blower/Pressure Hose Mask: It consists of full face peace connected to large diameter
flexible hose. Here the air is forced through a large diameter hose by a hand or motor
operated blower. The blower is to be operated continuously while the mask is in use. The
blower is to be placed in a free atmosphere where there is no oxygen deficiency.
Self-Contained Oxygen Breathing Apparatus: This is a device means of which the user
obtains resalable oxygen from the compressed oxygen cylinder which is an integral part of
the apparatus. Its working period is about 2 hours. It is a re-circulating type breathing
apparatus, high pressure oxygen from the cylinder passes through a pressure reducing &
regulating valve into a breathing bag. The wearer inhales this oxygen through a one way

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breathing valve & is exhaled breathe passes into a consisted containing chemical to absorb
exhaled Carbon-di-oxide & moisture & then through a coupler into the same breathing bag.
Selection of respirator:
The following factors should be considered,
 Nature of the hazard
 Severity of the hazard
 Type of the contaminant
 Concentration of the contaminant
6. STATUTORY INSPECTOINS
6.1 Inspection of Lifting Machines & Tackles
Lifting Machines & Tackles:
There are different types of lifting machines such as EOT cranes, HOT cranes, Hoists etc&
lifting tackles such as slings, chains, wire ropes etc used in the KFIL. These are required to be
used carefully to ensure safety of men & material. To ensure this the equipment are inspected
& certified by Competent Person once in a year. The following are the some of the
Inspections carried out on the lifting machines & tackles.
 Ensure long travel & cross travel brakes are working.
 Ensure all limit switches are working.
 Ensure power indication lamps are working.
 Ensure that all switches in the pendent box of the pendent operated crane are in good
condition.
 Ensure the festoon cable insulation.
 Ensure that there is no oil leakage from the gear box.
 Ensure the wheels are in good condition.
 Ensure that the main hoist & auxiliary hoist are in good condition.
 Ensure that rotary limit switch & gravity limit switch are working.
 Ensure that all the areas for the operator are clearly visible.
 Ensure that slings, wire ropes are in good condition.
 Ensure that slings are not shortened with knots or bolts.
 Ensure that lifting tackles should be protected from cuts.
 Ensure to get the lifting machine, lifting tackle to be inspected & certified by a
competent person once in a year.
6.2 Hoist & Lifts

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In every factory: Every hoist & lift shall be:

 Of good Mechanical construction, sound material & adequate strength.
 Properly maintained, shall be thoroughly examined by a Competent person at least
once in every period of six months, & a register shall be kept containing the
prescribed particulars of every such examination.
 The maximum safe working load shall be plainly marked on every hoist or lift, & no
load greater than such load shall be carried thereon.
 The cage of very hoist or lift used for carrying persons shall be fitted with a gate on
each side from which access is afforded to a landing.
Daily Operators Checks:
The following items shall be checked by the crane, hoist & lift operator,
 Battery plug connection.
 Battery Charge
 Brakes
 Lights
 Horn
 Tyres
 Hydraulic Control
 Other Condition
6.3 Shutdown Procedures
In case of any shut down permit to work is compulsory & the concerned operation incharge
should give the permission & clearance for the shutdown & he is the authorizer. Before
taking the shutdown, all the shutdown activities should be planned & to be discussed with the
persons who are going to carry out the task then after taking the shutdown permit is to be
written & the clearance should be given by all the Mechanical, Electrical & Operation
incharges. Mechanical should ensure that all the incoming valves are also isolated with blank.
Electrical should ensure that all the electrical controls are also isolated & isolation tags
should be placed near the controls. An operation incharge is an authorizer will give clearance
that the equipment is free to undergo maintenance. Then after shut down is cleared then the
permit should be closed by all three departments then after it can be started.
To initiate& act fallowing safe working practice
 Taking “Permit to Work” for all jobs.
 To identify Gas prone areas & monitor every half an hour and record of Gas PPM

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 Barricading the area

 Ensuring availability of CO monitor in good working condition
 Ensure & check availability of medical cylinder
 Information to plant medical centre regarding shut down
 Ambulance to be made available with driver nearby furnace
 First aid box with all its contents
 Ensure self-contained breathing apparatus is in good working condition
 Ensure fire extinguishers are made available
 Gas cylinders are handle in safe manner
6.4 Permit to work
Definition: A Permit to work is not simply permission to carry out a hazardous job, it is an
essential part of a system which determines how the job can be carried out safety. We know
that there are various serious serious& minor incidents in Iron & Steel Industries to be
designed as such a “safe working system”.
The Individuals are responsible to operate set of roles within the PTW system. The
individuals are:
 Permit Authorizer: Is an operational shift manager in charge of entire shop. He is
responsible for the control of work that may be carried out in that area & for the
validation & revalidation of permit, finally cancelling the permits.
 Permit Applicant: The person who applies for a permit & completes the description
sections in the work permit. He isResponsible for ensuring that a permit holder is
appointed at all times when the work is under way.
 Permit Holder: The person appointed by the applicant to be in charge of a work site.
In some cases, the permit applicant can also become permit holder. He is responsible
for ensuring that the work group at work site obeys the requirements of the
PTWsystem.
Scope & Objectives:
Scope: The permit to work system manual applies to KFIL Company & Contractors.
Permit to work is legal document authorizing persons to carry out the work safety after taking
necessary Safety measures.
Objective: To provide a formal system to allow specified work to start, continue & be
completed in a safe measures.

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The PTW system ensures persons engaged in a specific activity are formally made aware of
the hazardous involved in carrying out their work.
It highlights the precautions that have to be taken to ensure that activity is carried out in a
controlled & safe manner.
How the permit to work system operates:
The Permit forms: The Permit forms have a red edge colour. The areas within the edging
are also coloured as follows:
First copy White ------------ Area Authority Copy Second
copy Pink ------------ Safety Office Copy
Third copy Yellow
------------Permit Holder Copy
Applying for a permit: Permit forms are normally available from respective department
control rooms/ shift in charges & Safety Dept. during exigency. The applicant has to fill up
the permit neatly & clearly written in the remarks column, e.g.: The applicant is also
necessary to enter dates/ times between which it is planned to carry out the work.
Isolation & Locking System (ILS)
Mechanical Isolations: The Isolations Details are to be identified by the permit authorizer &
permit applicant at the time of site visit. The permit authorizer will authorize the isolation.
The person who carried out isolation insets the tag labels & lock it. Further, the isolation tag
numbers are to be entered in the permit & the permit number is also to be entered in the tag.
Electrical Isolation: The Electrical isolations is to be done only after getting necessary
written clearance from permit authorizer. Afterwards, the electrical shift in charge can isolate
the system & tag it. Necessary locking is to be done & fuses/ pad lock/ handle/ lever are to be
kept in his custody to avoid the misuse by any one.
The de isolation of both electrical & mechanical are to be carried out after getting the tags
stub, which is signed by permit holder, permit applicant & permit authorizer.
Permit Return:
A permit is to be returned when any one of the following occurs,
When work is complete
When work is not complete due to following reasons.
 A reportable incident occurs during the work.
 Any abnormal situation develops in the vicinity of the work (Gas/ Oil leaks).
 On hearing plant emergency siren (coded siren).

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In all the above cases the permit is to be returned to authorizer by the permit holder.
Activities that requires a permit to work:
 Hot work such as welding/ gas cutting etc involved near electrical cables, conveyor
belts, coal stock, gas lines and loco diesel tanks involving high risk.
 Excavation work using mechanized tools, foundation & structural work activates,
road cutting & repair work.
 Entry into vessels/ confined spaces, where is a possibility of concentration of dust,
fumes, or vapours where the oxygen content of the atmosphere could be reduced
below 20% by volume ( storage bins, sewage tanks).
 Housekeeping work at deck sheets & roofs such as roof cleaning/roof maintenance
activities.
 Installing & dismissing of nucleonic gauges.
 General/ visual inspection including preventive maintenance of pressure vessels,
cranes, hoists, lifts & safety valves.

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7. BULK STORAGE OF HAZARDOUS MATERIAL

7.1 Cylinder Manifold System

Fig 7.1Cylinder Manifold System

Cylinder Manifold system is a high pressure structure which is specially fabricated for
interconnecting two or more numbers of cylinders to a common gas supply line when
consumption requirement is high. Manifold interconnects two or more number of cylinders
for the purpose of availability of more gas at source which can be transmitted continuously.
The Gas Manifold pressure can be reduced to the required pressure by a regulator. The
pressure regulators can be conned to two manifolds for resulting in the changeover of
manifolds. The changeover can be done manually or automatically by changing the gas
supply from one set of cylinders to the other set without interrupting the continuity of the
supply. Manifolds comprise a control panel, manifold racks, tailpipes and an isolation valve

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and a pressure relief valve. Design of LPG Gas Manifold System is custom made gas specific
manifolds designed considering the types of applications.
LPG Manifold System used is stringently quality tested and used in line with the industry
standards. The Centralized LPG Manifold system is renowned for its salient attributes.

Highlights:
>Good control with automatic changeover device
 Reduced LPG consumption
 Provides quality assurance
 Reduced civil, structural & other related costs
 Easy operation
 Durable design
 Low maintenance
 Requires less area
Safety Precautions for LPG Manifold System
LPG cylinders shall be located at least 5m horizontally from any mechanical air intake which
is below any part of the manifold system and 1.5m from any mechanical intake which is
above any part of the manifold system.
LPG cylinders may be installed below windows or openings provided that there is a
minimum distance of 150mm between the top of any cylinder or the manifold system and the
bottom of the windows or openings.
LPG cylinders of total capacity up to 600kg shall be located at least 1.5m from any
uncovered opening that is below the level of the cylinders, such as drains, pits, openings to
basements, etc. For LPG cylinders having total capacity above 600kg, the distance from any
uncovered opening shall be at least 3m.
LPG cylinders shall be located at least 3m away from any boundary and any fire engine
access way.
There shall be no ignition source within 3m from the cylinder installation.
Vaporizers shall not be installed inside the steel cabinet or within the same housing of the
LPG cylinders. Wall-mounted vaporizers shall be located at least 1.8m above the ground and
600mm away from any LPG cylinder.
The distance between two separate manifold systems shall be at least 3m. If a 2-hour fire
rated wall is constructed, the distance between the two nearest cylinders may be halved.

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The location of the gas leak detector should preferably be not more than 30cm above the
ground level and not more than 4m away from the edge of the installation and the point of
consumption.
Fixed fire suppression system, if installed, shall be linked to the LPG cylinder installation in
such a way that activation of the system shall automatically shut off the supply.
7.2 Gas Holder

Fig 7.2 CO Gas Holder

A gas holder, sometimes called a gasometer, is a large container in which natural
gas or town gas is stored near atmospheric pressure at ambient temperatures. The volume of
the container follows the quantity of stored gas, with pressure coming from the weight of a
movable cap.
During the process of steel making in the basic oxygen furnace (BOF), significant amount of
gases, rich in carbon monoxide content, are generated during the blow time at a temperature
of 950 C. This gas is termed as converter gas or BOF gas. Converter gas is also known as LD
gas. It is a byproduct gas produced during the production of liquid steel in a basic oxygen
furnace (converter), where impurities of hot metal are oxidized with oxygen gas. The main

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constituents of converter gas are carbon mono oxide (CO), carbon di oxide (CO 2), oxygen
(O2) and nitrogen (N2).  Composition wise it is similar to blast furnace gas but with lesser
percentage of nitrogen in it.
Converter gas is highly poisonous and explosive and requires high degree of
disciplined operation at the time of recovery .The gas is invisible and colorless. It cannot be
detected by odor. It can readily form explosive mixtures with air, which are easily ignited by
a static charge. Therefore, any leakage from flanges, valves and joints, may lead to severe
explosion in the area resulting in fatal accident. Any ingress of external air or oxygen can
also cause explosion in the system. So, supreme care is needed to avoid any kinds of leakage
in the recovery, transportation as well as the utilization of the converter gas.
In case of leakage, all personnel from danger area are to be immediately evacuated.
Self-contained breathing apparatus (SCBA) are to be used where needed. All sources of
ignition are to remove if it is safe to do so. Gas concentration is to be reduced with fog or fine
water spray. Flow is to be shut off if it is safe to do so. Ventilation of the area is to be
improved.
Converter gas is a toxic and hazardous gas. Before entering the area it is necessary to
measure the level of carbon monoxide level with the help of a portable CO monitoring
device.
Occupational permissible exposure limit for CO gas is 50 ppm and for CO 2 gas is
5000 ppm. Converter gas is normally mixed with the blast furnace gas in various proportion
and the mixed gas is used for heating purposes in various furnaces of the steel plant.
Converter gas is a chemical asphyxiant. It displaces oxygen and cause rapid suffocation by
showing symptoms of oxygen deprivation. It may cause heart problems with prolonged or
repeated exposures.
Exposure to low concentrations for extended periods may result in dizziness or
unconsciousness, and may lead to death. If a person inhales converter gas of higher
concentration, he should immediately move to fresh air area and if he faces breathing
difficulties he should be given oxygen gas. Also he should be given medical attention if
needed.
In case of a leaking gas fire it should not be extinguished unless leak is stopped safely
or the fire is immediately impacting the human life. All ignition sources are to be eliminated
if safe to do so. The fire is to be extinguished with foam, carbon dioxide, dry powder or water

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fog, once leak is stopped. A solid stream of water is not to be used since it may scatter and
spread the fire.
There are special protective equipment and precautions for fighting the converter gas
fires. Self-contained respiratory protection and full protective clothing should be worn when
fumes and/or smoke from fire are present. Firefighters should wear full face piece self-
contained breathing apparatus and chemical protective clothing with thermal protection.
Direct water stream scatters and spreads flames and, therefore, should not be used. The area
is to be evacuated. The pressurized gas cylinders are to be removed from the immediate
vicinity. The containers exposed to flames are to be cooled with water until well after the fire
is out. The valve is to be closed if no risk is involved. It is necessary not to extinguish a
leaking gas fire unless leak can be stopped. If leak cannot be stopped and no danger to
surrounding area, then the fire is allowed to burn out. Fighting of the fire is to be carried out
from a protected location. The buildup of vapours or gases to explosive concentrations is to
be prevented.

Safety requirement for the converter gas

 The following are the safety requirements for the converter gas.
 No person is allowed to work in or go to the area where converter gas is present, if the
carbon monoxide content in that area is more than 50 ppm then gas mask is to be
used.
 On line monitoring system with alarm for carbon monoxide concentration is to be
provided in the areas around equipment/process handling converter gas. Performance
of on-line monitoring system is to checked once in a month for its proper operation
and records are to be maintained.
 Either non sparking tools or grease coated tools are to be used while working on
charged converter gas pipelines and gas handling system.
 No person is allowed to work on charged system (where there is possibility of
presence of converter gas) without gas masks.
 Proper escape route and scaffolding is to be provided while working on charged
converter gas system at height.
 The welding current is not to exceed 100 Amp while welding on charged converter
gas system.

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 Cutting or welding jobs are not to be allowed on isolated system without analysis and
written clearance of the competent authority. It is to be done only by trained welders
in the presence of a competent gas safety man. A minimum level of 20 % oxygen
shall be ensured.
 Proper electrical jumpers are to be provided between flanges and equipments before a
gap is created between them.
 Platform and adjoining structures are to be covered with asbestos/fire resistant clothes
while blanking and de-blanking and the person working is not to be allowed to wear
nylon or other synthetic fabric/garments.
 Fire fighting machinery is to be kept in attendance at the place of work in charged
converter gas system.
 All jobs within a radius of 40 m which could be a source of fire/ignition are to be
stopped and unauthorized persons are not to be allowed to remain in the area during
the shutting down of the gas system.
 Wherever necessary, lighting in enclosed area shall be done with portable spark proof
electric lamp of 24 Volts or explosion proof fittings.
 All pipelines/systems shall be checked for leakage after completion of repair job. The
leakages are to be detected by soap solution and all leakages shall be rectified before
charging the system.
 Blanking/de-blanking jobs on gas lines are not to be taken up at the time of extreme
bad weather conditions when the possibility of thundering/lightening exists.
 Drain pots and other auxiliaries of gas lines shall be inspected for proper operation at
least once a month and records are to be maintained.
 Purging steam/gas is to be used through a detachable hose. Permanent connections
shall be blanked after purging requirements are over.
 There must not be any discontinuity in blanking/ de-blanking. Once started it shall be
completed at a stretch.
 Testing of leaks of running mains of converter gas is to be done only by soap water.
 Persons required to work in gaseous atmosphere shall be trained in first aid and
methods of giving artificial respiration.
 Water seal/ valves are to be installed above ground level.

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8 CONCLUSION & SUGGESTIONS

Conclusion:
Based on the study of the major findings from the overall study regarding safety it has been
observed that safety culture and standards are established well; however there is a scope for
further improvement. In order to improve the overall performance the management must take
all possible steps as necessary by using analytical Information Management System by
coordinating various departments to have a close control over accident, incident and injuries.
This mechanism can happen by means of step by step strategic movements by safety
department and management towards imparting safety.
Through this study may be of academic in nature it will serve as a starting point for the
managerial plan towards enhancing safety and operational efficiency in KFIL.
Suggestions:
 Safety officers employed and according to the Factory act 1948 in the ratio 1:1000
shall be increased as this industry process manpower intensive process.
 Effective Safety on spot training, implementation and review steps to be taken place.
 Safety Culture to be imparted in the workers although it consumes time it can be done
after effective approach only.
 5 S safety instructions to be present and it needs to be reviewed in appropriate time
duration.
 Managerial level people need to involve in this safety implementation by Safety
Committee meeting for implementation of safety standards and its review.

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