Restart Project Summary Safety Report 2
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The document summarizes a comprehensive overhaul of a steel plant involving over 1.1 million man hours across four main areas: the blast furnace, steelmaking plant, power station, and sinter plant. It details the extensive scope of works in each area including replacement of refractory materials, vessels, cranes, pumps, and other equipment. Safety performance metrics are provided on a weekly basis showing leading and lagging indicators such as lost time incident rate, medical treatments and near miss reporting rates.
Restart Project Summary Safety Report 2
- 2. Comprehensive Overhaul Covering 4 areas Involving 1,230 Contractors at Peak Over 1 ½ million man hours Blast Furnace Sinter Plant Steelmaking Power & Energy
- 3. Heavy Vehicles Contractor / commissioning interface Asbestos Joint removal Confined Space Multi Level Working Manual Handling Work Heavy Lifting At Height Activities Traffic / Pedestrian Segregation Scaffolding
- 4. The blast furnace is the 2nd largest in Europe and has a 14 metre hearth. It is capable of producing in excess of 10,000 tonnes a day of iron. The blast furnace has 36 tuyeres which allows air to be blown into the furnace, and 4 tap holes for removing the iron out of the furnace. Works included but not limited to; -Partial carbon hearth replacement -Copper stave replacement -Cast iron stave replacement -Stove burners & refractory's repair -Replacement top hoppers & valve chest -Clean slag pits & repair -Replacement gas cleaning plant cones -Upgrade of PLCs / automation Outrigger crane repairs & recommissioning -Various casthouse works Preparation of plant for future coal injection Mechanical, hydraulic, electrical & instrumentation re-commissioning 1,000,000 Man Hours 850 Men at Peak Lost time Frequency Rate – 0.4 All Injury Frequency Rate – 5.4 121 Near Miss / hazard observations Over 1,400 Audits 541 Signed Toolbox Talk sheets returned
- 5. ! " The steelmaking facility is made up of the Basic Oxygen Steelmaking plant (BOS) where the steel is made by three basic oxygen convertors, and the Continuous Casting plant (Concast) where the liquid steel takes shape and is made into slabs. Works included but not limited to; -Vessel relines - LMF Cooling tower remedial works -Vessel distortion works -Vessel bearing replacement -Slag splashing reinstatement -Refurbishment of moveable assets -Strand guide segment refurbishment -Straightener segment refurbishment -Exhaust fan ducting -All cranes to be recertified and made available -Mechanical, hydraulic, electrical & instrumentation re-commissioning 280,000 Man Hours 300 men at Peak Lost time Frequency Rate – 0.35 All Injury Frequency Rate – 4.6 44 Near Miss / hazard observations Over 1,500 Audits 254 Signed Toolbox Talk sheets returned
- 6. # $ " The Power Station has three package boilers and two turbine blowers that provides the wind to the furnace. Works included but not limited to; - RPS Blower Overhaul - Heavy Fuel Oil Supply routes (Pipelines & Tanks) - Turbine Alternator 3 Overhaul - Estuary Cooling Water works - Oxygen Storage System requires inspection and verification - Nitrogen Storage System requires inspection and verification - HV Electrical supplies require fault calculation analysis and reinstatement 130,000 Man Hours 180 men at Peak Lost time Frequency Rate – 0.76 All Injury Frequency Rate – 4.6 25 Near Miss / hazard observations Over 400 Audits 220 Signed Toolbox Talk sheets returned
- 7. The Sinter plant has a 4 million tonne output and converts a mixture of iron ore fines, fluxes, waste materials and fine coke into an agglomerate, which makes up the majority of the blast furnace burden. Works included but not limited to; -Crane re-commissioning -New R6 pan conveyor -De-dust system overhaul -Sinter Plant process fans -Replacement of ROSOV valve PST14 -Serck Visco cooling tower replacement -Sinter machine lowering wheel replacement -Mechanical, hydraulic, electrical & instrumentation recommissioning 110,000 Man Hours 135 men at Peak Lost time Frequency Rate – 0 All Injury Frequency Rate – 4.5 27 Near Miss / hazard observations Over 185 Audits
- 8. % Site Induction CDM Project Steel House Plant induction Auditing Schedule Toolbox talks Minimum 1 per week SSI UK Senior Management Monthly audits Take Two Risk assessment Daily before each task SSI UK Mgrs/Eng/super Weekly Advansa audits Near Miss Incident / Investigation Reports SSI UK Mgrs/Eng/super Weekly Hazard specific audits / BOPs Safety concerns sheets For workforce Contractor Mgrs/Eng/super Weekly audits Accident Investigation Reports
- 9. 0 1 2 3 4 5 6 7 W/E 06/08 W/E -0n S ite 38 13/08 -On S 0 W/E ite 44 20/08 -On S 0 W/E ite 52 27/08 -On S 8 W/E ite 60 03/09 -On S 1 W/E ite 69 10/09 -On S 6 W/E ite 78 17/09 -On S 9 W/E ite 83 24/09 -On S 8 W/E ite 86 01/10 -On S 7 W/E ite 97 3 All Injuries 08/10 W/E -On S ite 94 15/10 -On S 2 W/E ite 98 22/10 -On S 9 W/E ite 10 29/10 -On S 76 W/E ite 11 05/11 -On S 60 W/E ite 12 12/11 -On S 23 W/E ite 11 19/11 -On S 43 W/E ite 11 26/11 -On S 34 W/E ite 12 03/12 -On S 01 W/E ite 12 10/12 -On S 14 W/E ite 11 17/12 -On S 15 W/E ite 12 24/12 -On S 29 W/E ite 11 31/12 -On S 34 Lost Time Injuries W/E ite 17 07/01 -On S 5 W/E ite 10 14/01 -On S 32 W/E ite 10 21/01 -On S 96 & W/E ite 11 28/01 -On S 67 W/E ite 12 04/02 -On S 11 W/E ite 12 11/02 -On S 02 W/E ite 10 18/02 31 W/E -On S ite 85 25/02 -On S 4 W/E ite 85 03/03 -On S 4 W/E ite 86 10/03 -On S 7 W/E ite 66 17/03 -On S 8 W/E ite 53 24/03 -On S 3 W/E ite 44 31/03 -On S 3 Medical Treatments ite 36 0 Project Lost time Frequency Rate – 0.38 All Injury Frequency Rate – 5.6
- 10. ' Restart Injury Cause Injuries by day Stationery Object Hot Work 7% 8% Airborne Particles 20 25% 15 Manual Handling 10 7% 5 0 Hit by Object sd ay da y y d ay ay rd ay ay F rid a 8% Slip/Trip/Fall S und n e sd Hand Tools Trap Injury T u es M on 17% Thur S a tu 15% 13% We d Restart Injuries Injuries By Time of Day Back Body Arm Foot 4% Eye 25 1% 5% 5% 27% 20 Head 15 11% 10 5 0 :0 0 :0 0 :0 0 :0 0 :0 0 :0 0 :0 0 :0 0 :0 0 :3 0 0- 10 0- 12 0- 13 0: 16 0- 18 0- 20 0- 22 0- 24 0- 02 0- 07 Leg Hand 17% 07 :3 10 :0 12 :0 13 :0 16 :0 18 :0 20 :0 20 :0 24 :0 02 :0 30%
- 11. %& ( ) * ++*,-*+,.. The Risk assessment and safe method of work to remove salamander from Furnace submitted By DGC Which was very different from the way they tried to move one lump of salamander
- 12. %& ( ) * ++*,-*+,.. DGC French demolition operative crushed two fingers, losing tip of middle finger while replacing wire strop in position. This operation was outside of the safe working procedure. 2. Salamander Segment 3. Front Loader Dragging Chained Up Segment via Chain 1. Digger Pushing Salamander Segment 4. Pecker Pulling Front loader via Wire Strop Attached to Tow Bar
- 13. %& ( +/*.,*+,.. A redundant platform had been placed on the cast house floor awaiting removal to scrap area. This had been laid for several hours, when the IP came and stood close to the platform talking to another operative. The second operative then stood on the platform causing it to move and land on the IP’s foot. The IP was taken to hospital where it was found that 2 metatarsals were broken. A support under the platform which had been Cut off, was attached to a cleat by Redundant Platform (wood should have been placed a bolt. Under platform to prevent movement) As weight was applied to the platform this acted as a pivot and made the structure move landing on the IP’s foot.
- 14. & " %& 0 Contractor tripped over step at the SSI Operative slipped while descending down stairs steelmaking clarifier. Dislocated knee and in the RBF work shop office area, as he slipped he received damage to ligaments. Hospital held on to the hand rail resulting in a dislocated treatment and operation on ligaments. shoulder. Redcar Power Station office worker fell exiting Power & Energy restart project cabin. Fractured ankle in fall.
- 15. 1 ) # % 23 ! 2& 4 5& ! 6 7 6 " Distributed to all project contractors & SSI personnel
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- 17. ' 84 "
- 18. 0 1 2 3 4 5 6 W/ E 20 W/ E /0 8 27 W/ E /0 8 03 W/ E /0 9 10 W/ E /0 9 17 W/ E /0 9 24 W/ E /0 9 01 W/ E /1 0 08 9 W/ E /1 0 15 W/ E /1 0 22 W/ E /1 0 29 & W/ E /1 0 05 W/ E /1 1 12 W/ E /1 1 19 W/ E /1 1 26 W/ E /1 1 03 " W/ E /1 2 10 W/ E /1 2 Trend 17 W/ E /1 2 24 W/ E /1 2 31 W/ E /1 2 07 W/ E /0 1 14 "84 W/ E /0 1 21 6 W/ E /0 1 Dropped / Falling Objects 28 W/ E /0 1 04 W/ E /0 2 ' 11 W/ E /0 2 18 W/ E /0 2 25 W/ E /0 2 03 W/ E /0 3 10 W/ E /0 3 17 W/ E /0 3 24 W/ E /0 3 31 /0 3
- 19. ) 6 Near Miss Incidents Fire Leak Access Hot work Isolation Lifting PTW Issue House Falling object Hand tools Scaffold Manual At Height Hot work Hazard Asbestos Vehicle 0 5 10 15 20 25 30 35 40 45 50
- 20. 9