Age of the plant (system considered) :

Total area covered :

Number of people working :

Location with respect to main plant : E+7600 (NS-50) TO E+8300 (NS-70)

N+3100 (EW-20) TO N+3600 (EW-10)
Nature of operation/work : Continuous

System Design and manufactured by :

Date of commissioning :

Commissioned by In-house/Outsourced : In-house

 WT Complex JH-1
WT CO-1/2/3 CO-7/8/9

JH-6/7/8/9 JH-3
CO-19/20/21/22
CO-30/OF-1/FX-1/CO-27 CO-15/16/17
With S/R

Legend
JH-2B/2C/2D/2E
Red Font Out of scope

In scope JH-2A
CO-17A
 CO-7/8/9

JH-2

CO-15/16/17

TCC-7
 System Breakdown structure

Stockyard

Material Stockpiles Conveyor Stacker-reclaimer

a. Iron ore fines a. Drive system a. Bucket-wheel
b. Limestone SMS Grade i. Motor b. Bucket-wheel drive
c. Limestone BF Grade ii. HS Coupling c. Boom conveyor
d. Pyroxenite iii. Gearbox d. Luffing system
e. Fluxes for BF iv. LS Coupling e. Slewing system
f. Anthracite v. Bearings f. Machine travel system
g. Lump ore vi. Brake g. Electrical
h. DRI for SMS b. Belt h. Structural
i. Iron ore fines (PP) i. Top cover i. Civil
j. Dolomite ii. Carcass
k. Bentonite iii. Bottom cover
c. Idlers
i. Transition idlers
ii. Troughing idlers
iii. Self-aligning idlers
iv. V-return idlers
v. Flat return idlers
d. Pulleys
i. Drive pulley
ii. Tail pulley
iii. Snub pulley
iv. Bend pulley
v. Take-up pulley
vi. Deflector roller
e. Take-up system
f. Accessories
g. Structure
h. Maintainability
 Junction Houses Other facilities
a. Civil a. Magnetic separator
b. Steel structure b. RM Building
c. Electrical c. Chutes
d. Mechanical d. Flap gates

avel system
 Flow process chart for Flow process chart for
Flow process chart for
reclaiming of material reclaiming of material
stacking of material
using yard equipment using hyva
Method Activity Facts Method Activity Facts Method Activity Facts
ABCDWXYZ ABCDWXYZ ABCDWXYZ
S.No. Type of Incident No. of Incidents No. of people exposed
1 Fatal 0 0
2 Serious 0 0
3 Reportable 1 1
4 Minor 21 21
5 Near miss / Near Hit 42 21
5 Fire 7 0

[* Fatal – death; Serious – permanent loss of any body parts;

Reportable – no disability of body parts but related to lost time
injuries (LTI) more than 1 day; Minor – LTI less than 1 day; Near
miss / near hit – LTI is equal to zero]

Source : Ensafe
 Hazard Triangle
S.No. Hazardous Element Initiating Mechanism
A. Material Hazards
For Iron ore & DRI
1 High density Low shear resistance
2 Fine and dry powder Air current
3 Moisture content Monsoon season
4 Toxic fumes Moisture + Oxidation + Iron
Large quantity of
5 Rock-fall
material stored
For Limestone
1 Reactivity of material Direct contact
2 Fine and dry powder Air current
Large quantity of
3 Rock-fall
material stored
For Pyroxenite
1 High density Low shear resistance
Large quantity of
2 Rock-fall
material stored
For Quartzite
1 High density Low shear resistance
2 Fine and dry powder Air current
Large quantity of
3 Rock-fall
material stored
For Anthracite
1 Flammable material Fire
2 Fine and dry powder Air current
Large quantity of
3 Rock-fall
material stored
For Dolomite
1 Reactivity of material Direct contact
2 Fine and dry powder Air current
Large quantity of
3 Rock-fall
material stored
For Bentonite
Improper position or
1 Wet material
attention
Large quantity of
2 Rock-fall
material stored
B. Belt Conveyor
During Material Handling
1 Dust Improper handling
2 Sticky material Improper handling
3 Abrasive material Improper handling
4 Corrosive material Improper handling
5 Sudden starting Unaware worker
6 Material Stream Engulfment in material
Insufficient friction between
7 Stored energy
pulley and belt
8 Static electricity Direct contact
Material or tool falling from
9 Open conveyor
height
10 Carryback accumulation Slip, Trip or fall
Improper handling and high
11 Reverse run of belt
inertia
Drive System
12 Shear point 1 Direct contact
13 Shear point 2 Direct contact
14 Shear point 3 Direct contact
15 Shear point 4 Direct contact
16 Shear point 5 Direct contact
Frictional heat (HS
17 Direct contact
Coupling)
Frictional heat (LS
18 Direct contact
Coupling)
19 Frictional heat (Shaft) Direct contact
20 Running conveyor Failure of brake
Bearing over-temperature
21 High temperature
(Insufficient lubrication)
Belt
22 Ripped belt Exposed carcass
23 Belt mistracking Excess sway
24 Sharp edge Exposed carcass
Frictional heat between
25 belt and other Excess heat
components
Absence of zero speed
26 Belt rupture
detector
Idlers
27 Nip point 2 Direct contact
28 Nip point 3 Direct contact
29 Nip point 4 Direct contact
30 Nip point 5 Direct contact
31 Nip point 8 Direct contact
32 Nip point 11 Direct contact
Pulleys
33 Nip point 1 Direct contact
34 Nip point 6 Direct contact
35 Nip point 7 Direct contact
36 Nip point 9 Direct contact
37 Nip point 10 Direct contact
38 Nip point 12 Direct contact
Take-up System
39 Suspended weight Belt rupture
Nip point in screw take-
40 Direct contact
up
Overtensioning in screw
41 Belt rupture
take-up
Accessories
Nip point between belt
42 Direct contact
cleaners and belt
Structure
43 Load on structure Unsafe design
Falling component or
44 Spillage
material from height
Maintainability
45 Confined space Lack of oxygen
46 Working at height Slip, Trip or fall
47 Lifting tools Heavy weight & tool failure
48 High voltage Direct contact
49 Rolling components High speed and inertia
50 Inadequate illumination Night operation
51 Slippery surface Slip, trip or fall
Monkey-ladders on
52 Slip, trip or fall
cross-overs
53 Loose hair and attire Entrapment
Low accessibility around
54 Slip, trip or fall
conveyor
55 Substance abuse Direct contact
56 Untrained personnel Direct or indirect contact
57 M2M miscommunication Failed control system
58 Welding and gas cutting Maintenance requirement
C. Stacker-Reclaimer (Additional to conveyors)
Hydraulic System
Poor oil quality Inspection failure
Suspended weight Unbalanced mass
d Triangle
Target / Threat
rial Hazards

Shear failure of bearing strata
Degraded health & dusty environment
Increased decay rate of reclaiming machine
Spontaneous combustion / Health
Injury & Fatal
Eyes & skin irritation
Degraded health & dusty environment
Injury & Fatal
All HEs has been identified considering proper PPEs availability and
usability.
Proximity switch failure
Cave-in/Voids - Sudden Collapse
Hywa & Excavators - Emergency Provision
U/g facilities - Hazards (brown field)
SRC Maintenance

Shear failure of bearing strata Sprinkler System

Injury & Fatal Proper Road Connectivities
Fire Fighting Sytem
Shear failure of bearing strata Drain
Degraded health & dusty environment
Injury & Fatal

Property & people Emergency shower

Degraded health & dusty environment
Injury & Fatal
Store in cool, dry and well ventilated place
Irritation to eyes, skin and respiratory
system
Degraded health & dusty environment
Injury & Fatal

Person / Slip

Injury & Fatal

Conveyor
Degraded health & dusty environment
Chute jamming / Hinderance to operation
Rapid wear & early failures of components
Corrosion & early failures of components
Fatality
Fatality 5%
Fatality 2%
Injury Very rare
Fatality Very rare
Injury
Property damage & Injury to personnel

Fatality
Fatality Pinch Point - A pinch point is any location where a person or p
Fatality body can be caught between two or more moving mechanical p
Fatality material and a moving part.
Fatality
Burn

Burn
Burn
Fatality
Bearing failure

Belt rupture / Fatality

Fatality 4% Shear Point - A shear point occurs where the edges of two mac
across or close enough to each other to cut a relatively soft ma
LTI / Fatality
shear point hazard, one part moves while the other part can be
moving.
Fire

Free movement of drive side / Injury

LTI / Fatality
LTI / Fatality
LTI / Fatality Nip Point - A nip point is a hazardous area at which an elemen
LTI / Fatality machinery moving in a line or rotating meets another element
LTI / Fatality rotating or moving in a line in such a manner that it is possible
squeeze, or entrap objects comming in contact with one of the
 Nip Point - A nip point is a hazardous area at which an elemen
machinery moving in a line or rotating meets another element
rotating or moving in a line in such a manner that it is possible
LTI / Fatality squeeze, or entrap objects comming in contact with one of the

LTI / Fatality
LTI / Fatality
LTI / Fatality
LTI / Fatality
LTI / Fatality
LTI / Fatality

Fatality 4%
LTI / Fatality

Catastrophic failure / Fatality

LTI / Fatality

Fatality 5%
Fatality 2%

Fatality
Fatality
Fatality
Electrocution
Noise
Fatality
LTI / Fatality
Injury
Fatality
Injury
Injury
Injury & Fatal
Property loss & Injury
Property loss & Injury
(Additional to conveyors)

Property loss
Fatality
oper PPEs availability and

y Provision
y location where a person or part of a person's
or more moving mechanical parts, or the bulk

s where the edges of two machine parts move

her to cut a relatively soft material. In a typical
es while the other part can be stationary or

dous area at which an element of the conveyor

tating meets another element which is either
ch a manner that it is possible to nip, pinch,
ng in contact with one of the two elements.
 Shear point 4

Shear point 5
Shear point 2

Fig. F 1.1 : Potential Shear points of drive system

Shear point 4

Shear point 3

Shear point 1
 Nip 2
Nip 4 Nip 3
Nip 6 Nip 5

Tail Nip 7
Bend

Nip 8

Legends
Troughing idler
Transition idler
Impact idler
SAC idler
Flat return idler
V-return idler
Deflector roller Fig. F 1.2 : Potential nip points in a belt conveyor syste
 Nip 1

Drive
Nip 11

Nip 9 Snub

Bend
Bend Nip 12

Take-up Nip 10

oints in a belt conveyor system

Safety Ontology