Sheet1Risk Assesment of Anneling of IIL CoilsIntroductionThis report is an assesment of current HSE condition and risk involving annealing of coils from IIL. Several accidents of low to high magnitude have been reported in the past associated with the processing of IIL coils. Although only material damage/loss has occured in 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 to accident" process. This report contains facts and suggestions based on our observations of the Annealing plant. We have tried to cover all possible aspects during completion of our report.We would like to thank Shift Incharge Mr. Shoaib,Engr S.M Rameez and D.M Pickling Mr. Shamsher Ali for their help and support throughout the whole process.

BackgroundIIL CRM Coils are sent to CRM-2 Annealing Plant of ISL for annealing. Coils sent from IIL are 350mm - 510mm in width which is less than a typical ISL coil's width. Because of difference in width , IIL has provided a specific tong to lift IIL coils. The tong has some manufacturing flaws due to which griping of coils is not perfect and several coils have fallen from it in the past. Moreover coils sent from IIL are not wrapped correctly which inturn increase the risk of falling of coils. Several messages regarding complains and possible hazards have been communicated to IIL from Annealing Plant in the past . This report is prepared to derive attention towards possible Risk associated with the process.

Potential HazardWho is at Risk?Existing Control MeasuresSeverityLikelihoodPreventive MeasuresResponsibilitiesISL EndTruck Accident 1- Collision1- Workers2- Staff3- Enigneers4- Equipments/Material1- Low speed entry of truckMediumLow1- Truck speed should be < 10 Km/hr when entring the plant.1- Truck Driver2- Shift InchargeLoading/Unloading of Coils from the truck1- Falling of coil due to improper handling by operator1- Workers2- Staff3- Enigneers4- Equipments/Material1- Coils shouldn't hit the surrounding equipments2-Start removing the coils from end portion of truck 3- Moving the coil through a wide space so that it doesn't hit the surroundingHIghHigh1- Crane operator should stand atleast 10 feet away 2- Rest of the staff should stay away from the truck and workbase3- Shift incharge should be present at the spot where loading and unloading is performed1- Crane Operator2- Shift InchargeIIL EndImproper Tension and sealer1- Falling of Coil when wraps get loose1- Workers2- Staff3- Enigneers4- Equipments/MaterialNo existing control at the momentHighHigh1- Proper Re-winding2- Usages of tensioner and sealers instead of manual tightening of bailing hoop.IIL TeamImproper bailing hoops1- Rusted material2- Uneven distribution of hoops for proper griping of wraps.1- Workers2- Staff3- Enigneers4- Equipments/MaterialNo existing control at the momentHighHigh1- Apply proper anti-rust oil on bailing hoop2- Distribute the bailing hoop evenly through out the coilIIL TeamImproper winding and jointing of the coils1- Coils shakes after staking and may fall down 1- Workers2- Staff3- Enigneers4- Equipments/Material1- Coil is placed slowly and allowed to settle beforing loading the next coil2- Workers are requested to stand atleast 10 ft away from the loaded coilsHighLow1- Proper winding and jointing of IIL coils IIL TeamManufacturingIncompetant IIL coil Tong design1- Single Jaw2- Inaqequate gripping material3- No accordance in design with DIN 15018 1- Workers2- Staff3- Enigneers4- Equipments/Material1- Checker plate was fabricated for better grip but its not very effective2- No further existing control measuresHighHigh1- Gripping Material should be installed as soon as possible2- A double-rim-gripping-type vertical coil tong should be purchasedIIL managementIncompetant IIL convector plate Tong design1- Narrow gripping space2- No support1- Workers2- Staff3- Enigneers4- Equipments/Material1- 20 convector plates are modified by welding to 1900mm dia to lift them from ISL convector plate tongMediumHigh1- All convector plates should be modified so that they could be lifted from ISL covector plate tongIIL managementConclusionBased on the report, we can conlude that Annealing process of IIL coils require serious attention or it can lead to accidents in the future.AbbreviationsCRM- Cold Rolling MillsIIL - International Industries LimitedISL - International Steels LimitedD.M - Deputy ManagerHSE - Health, Safety and Environment

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