Risk Assesment of An

Introduction

This report is an assesment of current HSE condition and risk involving annealing of coils from IIL. Several accide
Although only material damage/loss has occured in the past but it is likely that it can cause serious injuries and/
facts and suggestions based on our observations of the Annealing plant. We have tried to cover all possible aspe
We would like to thank Shift Incharge Mr. Shoaib,Engr S.M Rameez and D.M Pickling Mr. Shamsher Ali for their he

Background

IIL CRM Coils are sent to CRM-2 Annealing Plant of ISL for annealing. Coils sent from IIL are 350mm - 510mm in w
specific tong to lift IIL coils. The tong has some manufacturing flaws due to which griping of coils is not perfect a
which inturn increase the risk of falling of coils. Several messages regarding complains and possible hazards hav
towards possible Risk associated with the process.

Potential Hazard

Who is at Risk?

ISL En
Truck Accident
1- Collision

1234-

Workers
Staff
Enigneers
Equipments/Material

Loading/Unloading of
Coils from the truck
1- Falling of coil due to
improper handling by
operator

1234-

Workers
Staff
Enigneers
Equipments/Material

IIL En

Improper Tension and

sealer
1- Falling of Coil when wraps
get loose

1234-

Workers
Staff
Enigneers
Equipments/Material

Improper bailing hoops

1- Rusted material
2- Uneven distribution of
hoops for proper griping of
wraps.

1234-

Workers
Staff
Enigneers
Equipments/Material

Improper winding and

jointing of the coils
1- Coils shakes after staking
and may fall down

1234-

Workers
Staff
Enigneers
Equipments/Material

Manufact
Incompetant IIL coil Tong
design
1- Single Jaw
2- Inaqequate gripping
material
3- No accordance in design
with DIN 15018

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Workers
Staff
Enigneers
Equipments/Material

Incompetant IIL convector

plate Tong design
1- Narrow gripping space
2- No support

1234-

Workers
Staff
Enigneers
Equipments/Material

Conclusion

Based on the report, we can conlude that Annealing process of IIL coils require serious attention or it can lead to

Abbreviations
CRM- Cold Rolling Mills
IIL - International Industries Limited
ISL - International Steels Limited
D.M - Deputy Manager
HSE - Health, Safety and Environment

Risk Assesment of Anneling of IIL Coils

n and risk involving annealing of coils from IIL. Several accidents of low to high magnitude have been reported in the past a
the past but it is likely that it can cause serious injuries and/or loss of human lives. It remains one of the most "Vulnerable
the Annealing plant. We have tried to cover all possible aspects during completion of our report.
gr S.M Rameez and D.M Pickling Mr. Shamsher Ali for their help and support throughout the whole process.

SL for annealing. Coils sent from IIL are 350mm - 510mm in width which is less than a typical ISL coil's width. Because of d
ufacturing flaws due to which griping of coils is not perfect and several coils have fallen from it in the past. Moreover coils
eral messages regarding complains and possible hazards have been communicated to IIL from Annealing Plant in the past .

Existing Control
Measures

Severity

Likelihood

ISL End
1- Low speed entry of truck

Medium

1- Coils shouldn't hit the surrounding

HIgh
equipments
2-Start removing the coils from end
portion of truck
3- Moving the coil through a wide space
so that it doesn't hit the surrounding

IIL End

Low

High

No existing control at the moment

High

High

No existing control at the moment

High

High

1- Coil is placed slowly and allowed to

High
settle beforing loading the next coil
2- Workers are requested to stand
atleast 10 ft away from the loaded coils

Low

Manufacturing
1- Checker plate was fabricated for
better grip but its not very effective
2- No further existing control measures

High

1- 20 convector plates are modified by Medium

welding to 1900mm dia to lift them from
ISL convector plate tong

High

High

process of IIL coils require serious attention or it can lead to accidents in the future.

of IIL Coils

h magnitude have been reported in the past associated with the processing of IIL coils.
lives. It remains one of the most "Vulnerable to accident" process. This report contains
etion of our report.
roughout the whole process.

s than a typical ISL coil's width. Because of difference in width , IIL has provided a
ave fallen from it in the past. Moreover coils sent from IIL are not wrapped correctly
cated to IIL from Annealing Plant in the past . This report is prepared to derive attention

Preventive Measures

Responsibilities

1- Truck speed should be < 10 Km/hr

when entring the plant.

1- Truck Driver
2- Shift Incharge

1- Crane operator should stand

atleast 10 feet away
2- Rest of the staff should stay away
from the truck and workbase
3- Shift incharge should be present at
the spot where loading and unloading
is performed

1- Crane Operator
2- Shift Incharge

future.

1- Proper Re-winding
2- Usages of tensioner and sealers
instead of manual tightening of
bailing hoop.

IIL Team

1- Apply proper anti-rust oil on bailing

hoop
2- Distribute the bailing hoop evenly
through out the coil

IIL Team

1- Proper winding and jointing of IIL

coils

IIL Team

1- Gripping Material should be

installed as soon as possible
2- A double-rim-gripping-type vertical
coil tong should be purchased

IIL management

1- All convector plates should be

modified so that they could be lifted
from ISL covector plate tong

IIL management