A PROJECT REPORT ON

OCCUPATIONAL HEALTH
AT

DURGAPUR STEEL PLANT

Prepared by

Abhishek Vishwakarma

PROJECT PREPARED FOR

Partial fulfillment of the degree of MBA

 ACKNOWLEDGEMENT
I am extremely grateful to Mr. Subrata Mondal, Sr. Manager (CHRD), for giving me permission to
do the project work entitle “OCCUPATIONAL HEALTH IN DURGAPUR STEEL PLANT” in esteem
organization under his guidance.

I thank all the following managers of CHRD & SAFETY and also thankful to OHS, who interacted
with me in helping manner and provide me relevant advice, details and relevant information.

Mr.D.Daftuar DGM (CHRD)

Mr.S.K. Saha AGM (CHRD)

Mr. P. Shaw AGM (CHRD)

Mrs. R. Kumar AGM (CHRD)

Mr. C. Vankatesh Dy. Manager (SAFETY)

Dr. K. Chaterjee Sr. Doctor (OHS)

Dr. T. Mondal Doctor (OHS)

Mr. T.B. Konar Sr. Manager (CHRD)

Mr. P. Sett Sr. Manager (CHRD)

Mr. B. Barman Sr. Manager (CHRD)

Mr. S. Das Jr. Officer (CHRD)

I also thankful to several other employees of DSP who have help me in some or other ways.

Abhishek Vishwakarma

(Asian Business School)

Student, M.B.A. (H.R)

 Preface
Today more and more companies are spending substantial amount
of money on Occupational health of there employees to achieve long
term organization goal by promotion and maintenance of highest
degree of physical, mental and social well being of workers and
controlling risk with adaptation of work to people and people to there
job. Because any company do not want to loss skilled employee.
Occupational health services are designed and deliver after
extensive research and preparation so as to deliver acceptable returns
on investment and to secure sustainable competitive advantage.

“A healthy worker is productive worker”

 VISION
To be a respected world class corporation and the leader in Indian steel business in quality,
productivity, profitability and customer satisfaction.

Statement of belief
 SAIL build lasting relationships with customers based on trust and mutual benefit.
 SAIL uphold highest ethical standards in conduct of our business.
 SAIL create and nurture a culture that supports flexibility, learning and is proactive
to change.
 SAIL chart a challenging career for employees with opportunities for advancement
and rewards.
 SAIL value the opportunity and responsibility to make a meaningful difference in
people's lives.

Objective of Expansion Plan of SAIL

 100% production of steel through Basic Oxygen Furnace (BOF) route
 100% processing of steel through continuous casting
 Value addition by reduction of semi-finished steel
 Auxiliary fuel injection system in all the Blast Furnaces
 State-of-art process control computerization / automation
 State-of-art online testing and quality control
 Energy saving schemes
 Secondary refining
 Adherence to environment norms
 Steel Authority of India Limited (SAIL)

Steel Authority of India Limited (SAIL) is the leading steel-making company in India. It is a
fully integrated iron and steel maker, producing both basic and special steels for domestic construction,
engineering, power, railway, automotive and defense industries and for sale in export markets.
 
Ranked amongst the top ten public sector companies in India in terms of turnover, SAIL
manufactures and sells a broad range of steel products, including hot and cold rolled sheets and coils,
galvanized sheets, electrical sheets, structural’s, railway products, plates, bars and rods, stainless steel and
other alloy steels. SAIL produces iron and steel at five integrated plants and three special steel plants,
located principally in the eastern and central regions of India and situated close to domestic sources of
raw materials, including the Company's iron ore, limestone and dolomite mines. The company has the
distinction of being India’s largest producer of iron ore and of having the country’s second largest mines
network. This gives SAIL a competitive edge in terms of captive availability of iron ore, limestone, and
dolomite which are inputs for steel making.

SAIL's wide range of long and flat steel products is much in demand in the domestic as well as the
international market. This vital responsibility is carried out by SAIL's own Central Marketing
Organization (CMO) and the International Trade Division. CMO encompasses a wide network of 37
branch offices and 25 departmental Warehouses located in major cities and towns throughout India.

With technical and managerial expertise and know-how in steel making gained over four decades, SAIL's
Consultancy Division (SAILCON) at New Delhi offers services and consultancy to clients world-wide.

SAIL has a well-equipped Research and Development Centre for Iron and Steel (RDCIS) at Ranchi
which helps to produce quality steel and develop new technologies for the steel industry. Besides, SAIL
has its own in-house Centre for Engineering and Technology (CET), Management Training Institute
(MTI) and Safety Organization at Ranchi. Our captive mines are under the control of the Raw Materials
Division in Kolkata. The Environment Management Division and Growth Division of SAIL operate from
their headquarters in Kolkata. Almost all our plants and major units are ISO Certified.
 History
1959-1973

SAIL traces its origin to the Hindustan Steel Limited (HSL) which was set up on January 19,
1954. HSL was initially designed to manage only one plant that was coming up at Rourkela. For Bhilai
and Durgapur Steel Plants, the preliminary work was done by the Iron and Steel Ministry. From April
1957, the supervision and control of these two steel plants were also transferred to Hindustan Steel. The
registered office was originally in New Delhi. It moved to Calcutta in July 1956 and ultimately to Ranchi
in December 1959.

A new steel company, Bokaro Steel Limited, was incorporated in January 1964 to construct and
operate the steel plant at Bokaro. The 1 MT phases of Bhilai and Rourkela Steel Plants were completed
by the end of December 1961. The 1 MT phase of Durgapur Steel Plant was completed in January 1962
after commissioning of the Wheel and Axle plant. The crude steel production of HSL went up from 1.58
MT (1959-60) to 1.6 MT. The second phase of Bhilai Steel Plant was completed in September 1967 after
commissioning of the Wire Rod Mill. The last unit of the 1.8 MT phase of Rourkela - the Tandem Mill -
was commissioned in February 1968, and the 1.6 MT stage of Durgapur Steel Plant was completed in
August 1969 after commissioning of the Furnace in SMS. Thus, with the completion of the 2.5 MT stage
at Bhilai, 1.8 MT at Rourkela and 1.6 MT at Durgapur, the total crude steel production capacity of HSL
was raised to 3.7 MT in 1968-69 and subsequently to 4MT in 1972-73.

1973-present

The Ministry of Steel and Mines drafted a policy statement to evolve a new model for managing
industry. The policy statement was presented to the Parliament on December 2, 1972. On this basis the
concept of creating a holding company to manage inputs and outputs under one umbrella was mooted.
This led to the formation of Steel Authority of India Ltd. The company, incorporated on January 24, 1973
with an authorized capital of Rs. 2000 crore, was made responsible for managing five integrated steel
plants at Bhilai, Bokaro, Durgapur, Rourkela and Burnpur, the Alloy Steel Plant and the Salem Steel
Plant. In 1978 SAIL was restructured as an operating company.

Since its inception, SAIL has been instrumental in laying a sound infrastructure for the industrial
development of the country. Besides, it has immensely contributed to the development of technical and
managerial expertise. It has triggered the secondary and tertiary waves of economic growth by
continuously providing the inputs for the consuming industry.

SAIL today is one of the largest industrial entities in India. Its strength has been the diversified
range of quality steel products catering to the domestic, as well as the export markets and a large pool of
technical and professional expertise.
 Ownership and Management
The Government of India owns about 86% of SAIL's equity and retains voting control of the Company.
However, SAIL, by virtue of its ‘Navratna’ status, enjoys significant operational and financial autonomy.

Major Units of SAIL

Integrated Steel Plants

• Bhilai Steel Plant (BSP) in Chhattisgarh
• Durgapur Steel Plant (DSP) in West Bengal
• Rourkela Steel Plant (RSP) in Orissa
• Bokaro Steel Plant (BSL) in Jharkhand
• IISCO Steel Plant (ISP) in West Bengal
 

Special Steel Plants

• Alloy Steels Plants (ASP) in West Bengal
• Salem Steel Plant (SSP) in Tamil Nadu
• Visvesvaraya Iron and Steel Plant (VISL) in Karnataka
 

Subsidiary
• Maharashtra Elektrosmelt Limited (MEL) in Maharashtra
  

Joint  Ventures
NTPC SAIL Power Company Pvt. Ltd (NSPCL)
• A 50:50 joint venture between Steel Authority of India Ltd. (SAIL) and National Thermal
Power Corporation Ltd. (NTPC Ltd.); manages the captive power plants at Rourkela,
Durgapur and Bhilai with a combined capacity of 314 megawatts (MW). It has installed
additional capacity by implementation of 500 MW (2 x 250 MW Units) power plant at Bhilai.
The commercial generation of 1st Unit has commenced in April’2009 and 2nd Unit is likely to
start commercial generation by July 2009.

• Bokaro Power Supply Company Pvt. Limited (BPSCL)

This 50:50 joint venture between SAIL and the Damodar Valley Corporation formed
in January 2002 is managing the 302-MW power generating station and 660 tones per hour
steam generation facilities at Bokaro Steel Plant. BPSCL has proposed to expand its capacity
by installing 2x250 MW coal based thermal unit at Bokaro. In addition, construction activities
are underway for installation of 9th Boiler (300T/Hr) & 36 MW Back Pressure Turbo
Generator (BPTG) project at Bokaro.

• Mjunction Services Limited

A joint venture between SAIL and Tata Steel on 50:50 bases. This company promotes e-
commerce activities in steel and related areas. New added services includes E-Assets sales,
Events & Conferences, Coal Sales & Logistics, Publications etc.

• SAIL-Bansal Service Center Ltd.

SAIL has formed a joint venture with BMW industries Ltd. on 40:60 basis to promote a
service centre at Bokaro with the objective of adding value to steel.

• Bhilai JP Cement Ltd

SAIL has incorporated a joint venture company with M/s Jaiprakash Associates Ltd to set up
a 2.2 MT slag based cement plant at Bhilai. The company shall commence cement production
at Bhilai by March'2010, whereas clinker production at Satna shall start within 2009.
 
• Bokaro JP Cement Ltd
SAIL has incorporated another joint venture company with M/s Jaiprakash Associates Ltd to
set up a 2.1 MT cement plant at Bokaro utilizing slag from BSL. Construction work expected
to start by Oct’09 and cement production likely by July’2011.

• SAIL&MOIL Ferro Alloys (Pvt.) Limited

SAIL has incorporated a joint venture company with M/s Manganese Ore (India) Ltd to set up
Ferro-manganese and silico-manganese plants at Nandini / Bhilai, of 1.0 lakh tone capacity.

• S&T Mining Company Pvt. Ltd

SAIL has incorporated a joint venture company with TATA Steel for acquisition &
development of coal blocks/mines. New indigenous opportunities for coking coal
development are being explored by the Joint Venture company for securing coking coal
supplies.

• International Coal Ventures Private Limited:

Towards achieving the target of making steel PSUs self reliant in the area of coking coal, a
joint venture company has been incorporated comprising of five central PSU companies i.e.
SAIL, Rashtriya Ispat Nigam Limited (RINL), Coal India Limited (CIL), NTPC Limited and
NMDC Limited. The company is scouting for coal properties in Australia, Mozambique and
other target countries.

 
Durgapur steel plant
Durgapur steel plant set up in the late 50's with an initial annual capacity of one million
tones of crude steel per year, the capacity of Durgapur Steel Plant (DSP) was later expanded to 1.6
million tones in the 70's. A massive modernization programmed was undertaken in the plant in
early 90's, which, while bringing numerous technological developments in the plant, enhanced the
capacity of the plant to 2.088 million tones of hot metal, 1.8 million tones crude steel and 1.586
million tones saleable steel. The entire plant is covered under ISO 9001: 2000 quality management
system.

The modernized DSP now has state-of –the-art technology for quality steel making. The
modernized units have brought about improved productivity, substantial improvement in energy
conservation and better quality products. DSP’s Steel Making complex and the entire mills zone,
comprising its Blooming & Billet Mill, Merchant Mill, Scalp Mill, Section Mill and Wheel & Axle
Plant, are covered under ISO: 9002 quality assurance certification.

With the successful commissioning of the modernized units, DSP is all set to produce 2.088 million
tones of hot metal, 1.8 million tones of crude steel and 1.586 million tones of saleable steel
annually.

Product mix of Durgapur Steel Plant

TONNES/
PRODUCT-MIX
ANNUM
Merchant Products 2,80,000
Structural 2,07,000
Skelp 1,80,000
Wheels & Axles 58,000
Semis 8,61,000
Total Saleable steel 15,86,000

Historical background of Durgapur Steel Plant

 Set up in the late 1950s with an initial annual capacity of one million tones of crude steel per year,
the capacity of Durgapur Steel Plant (DSP) was later expanded to 1.6 million tones in the 1970s. A massive
modernization programmed was undertaken in the plant in early '90s, which, while bringing numerous
technological developments in the plant, enhanced the capacity of the plant to 2.088 million tones of [hot
metal], 1.8 million tones crude steel and 1.586 million tones saleable steel. The entire plant is covered
under ISO 9001: 2000 quality management system.

The modernized Durgapur Steel Plant now has state-of–the-art technology for quality steel making.
The modernized units have brought about improved productivity, substantial improvement in energy
conservation and better quality products. DSP’s Steel Making complex and the entire mills zone,
comprising its Blooming & Billet Mill, Merchant Mill, Skelp Mill, Section Mill and Wheel & Axle Plant,
are covered under ISO: 9002 quality assurance certification.

After the commissioning of the modernized units, DSP is all set to produce 2.088 million tones of
hot metal, 1.8 million tones of crude steel and 1.586 million tones of saleable steel annually.

GENERAL PLANT OPERATIONS

1. RAW MATERIAL HANDLING PLANT
2. COKE OVENS AND COAL CHEMICALS
3. SINTER PLANT
4. BLAST FURNACE
5. STEEL MAKING
6. ROLLING MILLS
7. GENERAL MECHANICAL MAINTENANCE
8. HYDRAULICS
9. ELECTRICAL AND ELECTRONICS
10. CONTINUOUS CASTING PLANT
11. BLOOMING MILL
12. BILLENT MILL
13. SECTION MILL
14. MERCHANT MILL
15. SKELP MILL
16. WHEEL AND AXEL PLANT

Railway products
Durgapur Steel Plant is the only major indigenous supplier of wheel sets, loco wheels, carriage and
wagon wheels, and axles to the Indian Railways. As per demand of the Railways, the plant has developed
loco wheels, which were imported earlier. The wheel and axle plant is producing wheels manufactured as
per the latest Indian Railways specifications, i.e. R-19/93 for carriage and wagon wheels, R-34/99 for loco
wheels and R-16/95 for axles.
 The wheel plant of the wheel and axle plant is provided with six PLC controlled band saws for
accurate slicing of the 14” and 16” fluted ingots. A fully computerized 63/12 MN oil hydraulic press is
there for forging and punching of the wheel blanks along with a fully computerized vertical wheel mill and
other down stream facilities. All the wheels are 100 per cent rim-quenched, tempered and tested as per IRS
specifications.

Machining of these forged rolled and heat-treated wheel blanks are carried out in the 15 CNC
machines. All the wheels are ultrasonically tested and inspected by RITES on behalf of the Indian
Railways. A number of sophisticated and modern online testing facilities are there to conform to the
stringent testing requirements of the Indian Railways.

Awards & Accolades:

 SHRAM VIR AWARDS by Govt. of India to 13 Employees of SMS & ETL.
 Vishwakarma Rashtriya Puraskars to 14 Employees of SMS, Merchant Mill and Oxygen
Plant.
 6 QC teams which participated at ICQCC in Dhaka, Bangladesh won 5 Gold & 1 Silver.
 QC team “SAVE” bagged the “Convention Best” crown – First time in India.
 GREENTECH Environment Excellence Award – Gold to DSP.
 Excellence Award to DSP – by IES.
 Ispat Suraksha Purashkar to DSP for NO FATAL ACCIDENT IN 2007 – By Joint
Committee on Safety, Health & Environment in Steel Industry.

 Awards to MD DSP
 KOHINOOR OF INDIA–by IEDRA.
 UDYOG RATNA Award – by IES.
 Best CEO in India – by QCFI.

HR policy of Durgapur Steel Plant

DSP a unit of SAIL, manufacturing various products of iron & steel, reaffirms its commitment to
create a value based organization and achieve excellence in performance & employ satisfaction
through an innovative, harmonic & productive work environment.

To accomplish this DSP shall:

 Ensure a pro active approach to maintain productive industrial relation.

 Build a culture of learning continually address, evaluate and improve technical and ensure
optimum utilization of man power.
 Encourage creativity, recognize and reward exemplary efforts, achievements and results.
 Adopt methods to empower employees and harness there potential by reinforcing a sense of
ownership & commitment.
  Strive for continuous improvement immoral, motivation and employee satisfaction through
innovative approach.
 Strengthen communication through participation approach.

Occupational health
Health is generally defined as being "a state of complete physical, mental, and social well-being
and not merely the absence of disease or infirmity" according to the World Health Organization (WHO).

The modern definition of Occupational Health (ILO and WHO) is:

“The promotion and maintenance of the highest degree of physical, mental and social well-
being of workers in all occupations – total health of all at work”

GOALS OF OCCUPATIONAL HEALTH:

• To reduce industrial accidents.

• To prevent occupational hazards/ diseases.

• To achieve maximum human efficiency and machine efficiency.

• To reduce sick absenteeism.

OBJECTIVES OF OCCUPATIONAL HEALTH:

• To maintain and promote the physical, mental and social well being of the workers.

•   To prevent occupational diseases and injuries.

•   To adapt the work place and work environment to the needs of the workers i.e. application of
ergonomics principle.

• It should be preventive rather than curative.

 Occupational health represents a dynamic equilibrium between the worker and his occupational
environment.

Occupational health care is preventive health care, which is provided on the basis of the
Occupational Health Care Act. The objective of occupational health care is a healthy and safe working
environment, a well-functioning working community, prevention of work-related diseases as well as the
maintenance of employees’ working ability and functional capacity, and promotion of their health.

Advantages of Occupational health care:

• Investigates and assesses load factors and hazards and gives expert assistance for eliminating them

• Gives information and advice

• Estimates employees’ working ability and monitors their health condition

• By its knowledge and skills supports action for maintaining working ability in the development of
individuals, working environment and working community, in this way also affecting productivity
continued

• Prevents occupational diseases and other work-related illnesses

• Prevents premature incapacity for work, reduces pension costs

• Reduces absenteeism due to sickness

• Can make calculations of the profitability of occupational safety and health and occupational health
care in cooperation with workplaces or encourage workplaces to make these themselves.

FUNCTIONS OF OCCUPATIONAL HEALTH SERVICE:

1. Pre-employment medical examination.
2. First Aid and emergency service.
3. Supervision of the work environment for the control of dangerous substances in the work
environment.
4. Special periodic medical examination particularly for the workers in dangerous operations.
5. Health education for disseminating information on specific hazards and risks in the work
environment.
6. . Special examination and surveillance of health of women and children
7. Advising the employer or management for improving working conditions, and placement
of hazards.
8. Monitoring of working environment for assessment and control of hazards.
 9. Supervision over sanitation, hygiene and canteen facilities.
10. Liaison and cooperation with the safety committees
11. Liaison and cooperation with the safety committees
12. Maintenance of medical records for medical check-up and follow-up for maintaining health
standards and also for evaluation.
13. To carry out other parallel activities such as nutrition program me, family planning, social
services recreation etc., Concerning the health and welfare of the workers.

Components occupational health services

 Medical treatment, First aid treatment in emergency.

 Health education, First aid education.
 Medical examination
 Pre employment examination
 Medical treatment, First aid treatment in emergency.
 Health education, First aid education.
 Medical examination
o Pre employment examination
o Periodic medical examination
o Special medical examination

 Health counseling
 Stress management
 Mental health
 And Physical health
 Rehabilitation program
 Medical rehabilitation
 Social rehabilitation
 Educational rehabilitation
 Vocational rehabilitation
 Supervision of the working environment
 Hazard identification
 Monitoring
 Evaluation
 Engineering project review
 Control measures
 Development of personal protective devices
  Family welfare program
 To take care of employee and dependents
 Disaster management
 Health records maintenance

OCCUPATIONAL HEALTH HAZARD:

``Source or situation with a potential for harm in terms of injury or ill health, damage to property,
damage to the workplace environment, or a combination of these``

A working condition that can lead to illness or death. Often, people in jobs which pose a high level of risk
are paid more than similar but less risky jobs to compensate for the danger involved.

TYPES OF OCCUPATIONAL HEALTH HAZARDS

A.      Physical
B.      Chemical
C.      Biological
D.      Mechanical
E. Psychosocial

PHYSICAL HAZARDS
 Temperature - Heat / Cold

 Illumination

 Noise

 Vibration

 Radiation

 Atmospheric pressure

DISEASES DUE TO PHYSICAL AGENTS

  Heat - Heat hyperpyrexia, Heat Exhaustion, Heat Syncope, Heat Cramps, burns,
Prickly heat

 Cold - Frost bite,

 Light - Occupational Cataract,

 Atmospheric-pressure - Caisson disease, air embolism, explosion.

 Noise - Occupational deafness,

 Radiation - Cancer,Leukemia,aplastic anemia, Pancytopenia

 Electricity - Burns, Shocks,

Human Heat Balance Equation

S = M + R + C + L + E + Res, (in W m-2)
Where: S - net heat storage (i.e. changes of body heat content - heat expenditure or
Accumulation), M - metabolic heat production, R - absorbed solar radiation, C - heat exchange
By convection, L - heat exchange by long-wave radiation, E - heat loss by evaporation, Res -
Heat loss by respiration.

Basic equation can be used for any adjustment in relation to existing Environmental condition to keep body
in thermo neutral in that particular environment

HEAT= Evaporative cooling will be more

COLD= Process of conserving heat from conductive, radioactive & convective heat will be more
so that the body will remain in thermo-neutral e.g. it will neither gain or loss heat irrespective of
environment heat or cold change.

Heat Illness
• Predisposing Factors

 Physical activity

 Extremes of age, poor physical condition, fatigue

 Excessive clothing

 Dehydration

 Cardiovascular disease

 Skin disorders

 Obesity

 Drugs

• Phenothiazines, anticholinergics, B and Ca channel blockers, diuretics,

amphetamines, LSD, cocaine, MAOIs

CHEMICAL HAZARDS
Routes of entry - Inhalation, Ingestion, skin absorption. (Inhalation is the main route of entry)

Chemical agents can be classified into-

1) Metals - Lead, TEL, As, Hg, Cd, Ni , Co etc.

2) Aromatic Hydrocarbons - Benzene, Toluene, phenol etc.

3) Aliphatic Hydrocarbons - Methyl alcohol

4) Gases –

*Simple asphyxiants : N2, CH4, CO2

* Chemical asphyxiants: CO, H2S, HCN

* Irritant gases: Ammonia, SO2, Cl2,

* Systemic poison: CS2

Gaseous hazards as gas position mostly happen at Blast furnish and POF in DSP.
 TLV CONCEPT
The Threshold Limit Value - Time Weighted Average(TLV-TWA) : ``Time-weighted average
concentration for a normal 8-hour working day and a 40-hour working week, to which nearly all workers
may be repeatedly exposed day after day, without adverse effect``

The Threshold Limit Value - Short Term Exposure Limit (TLV-STEL) is defined as a 15-minute,
time-weighted average which should not be exceeded at any time during a working day, even if the 8-hour
time-weighted average is within the TLV``

DUSTS

There is two type of Dust and due to this (Pneumoconiosis) disease occurs. Classification of dusts
and disease occurs by it is-

  Inorganic Dust
TYPE OF DUST DISEASE

-      Coal Dust -Anthracosis

¨       Silica -Silicosis

¨       Asbestos -Asbestosis

  Organic Dusts
¨       Cane Fiber -Bagassosis (Bronchi gets affected)

- Cotton dust -Byssinosis (In Textile industries)

¨       Tobacco -Tobaccosis, Lung Cancer

¨       Grain Dust -Farmer’s Lungs

In Durgapur steel plant more than 3000 employees are affected by DUST and from diseases like
Asthma, Pneumoconiosis, and Allergy.
 Biological Hazards
Bacteria -Tetanus, Tuberculosis, Anthrax, Brucellosis (Milkmen), Gonorrhea
(Sex-workers-Genital organs get affected).

Virus - Hepatitis, AIDS

Protozoal&Parasitic -Malaria, Hydatid (Dog handlers), Hookworms, tapeworms (Agri-

workers), etc.

Fungi-(Agri-workers) -Tinea-infections, Coccidiomycosis, Psittacoses, ornithosis, etc.

MECHANICAL HAZARDS
Injuries-Falls, cuts, abrasions, concussions, contusions, etc.

These mechanical hazards or injuries has happened because man or worker unable to adjust or fit
with machine. That is why injuries and ergonomic disorder has occur.

Ergonomic Disorders-

Musculo-skeletal disorders (MSDs),Cumulative-trauma-Disorders (CTDs) etc. 

Work physiology & Ergonomics Unit –

Objective of this unit are-

 Development of exercise program

 Study of vibration exposure
 Categorization of work load
 Determination of energy expenditure
 And design ergonomics (machinery, equipment)
 Evaluation of occupational work capacity
  Ergonomics analysis of work systems
 Work station design
 Development of pre employment job fitness tests
 Job analysis

Ergonomics:
``Adjustment of Man & Machine``

Ergonomics is defined as the science related to man and his work, embodying the anatomic,
physiologic, and mechanical principles affecting the efficient use of human energy.

It is Application of human biological sciences with engineering science to achieve optimum

mutual adjustment of man & his work, the benefit being measured in terms of human efficiency and well
being.

Manual Handling (According to Ergonomics) –

Back Injuries:
All forces which come down the spine compresses discs and as a result of
Continuous squeezing they can rupture and bulge causing severe pain. Most back
injuries are built over along period of time by repetitive pounding on discs caused by
improper methods. After sometime some minor lift can produce such rupture

``Straight back rule``

‘Thinking before lifting’

Control any risk by reducing necessity for manual handling by using

Alternative means of handling

*consider the load; size, awkward shape, etc
*consider need for mechanical or manual assistance
*position legs apart - one foot level with the load
*keep back straight, look up

*bend from the hips, avoid ‘twisting’ the body

*tighten the stomach muscles, but don’t hold breath
*BEND THE KNEES

*keep the load close to the body

*lift with the legs, not the back
*keep carrying distance short
*avoid changing grip or ‘jerking’ the load
*deposit the load by bending the knees and keeping the back straight

USER`S-ERGONOMIC GUIDELINES
SEATING POSITION

*Seat height to be adjusted so that thighs are horizontal & feet are resting flat on the floor
*Thigh-torso angle is not less than 90 degrees, with 100 degrees as preferable
*Chair should have ``Backrest’ with support for curvature in lumbar area

WORKING POSTURE

*Wrist and forearm-held in straight line to reduce tendon & nerve stress

*Upper & lower arm-at 90 degree angle

*Elbows to be kept close to the sides

*Head-Screen distance=25-48 inches (min 12 ``) from the VDT users eye

*Optimal viewing angle is 20 degrees below the horizontal line from the eyes
 VISION & LIGHTING

*NO GLAIR

*VDT to be placed 90 degrees to the light source, adjust screen angle

*Use screen filters to reduce glare

*Screen intensity needs to be adjusted

*Frequent breaks from the screen to reduce stress on eyes

*Optical illusion

GENERAL GUIDELINES

*Change positions, Stretch or walk around if feeling tiredness

*``LIGHT TOUCH`` on Keyboard to reduce hand stress or developing CTD`s

*Look at ``Optical Illusion`` for 1-2 minutes after every 20 minutes of work with VDT to reduce eye stress

*Rotate eye ball and also concentrate on a distant object & near object alternatively to reduce eye stress

*Keep the VDT screen and eyeglasses clean

PSYCHOSOCIAL HAZARDS:
Psychological hazards occur because of Lack of job satisfaction, insecurity, poor interpersonal
relations, work pressure, ambiguity, etc. and effect of psychological hazards is-

•   Psychological & behavioral changes – hostility, aggressiveness, anxiety, depression, alcoholism,

drug addiction, sickness absenteeism.

•   Psychosomatic disorders- Hypertension, headache, body-ache, peptic ulcers, asthma, diabetes,

heart disorders, etc.

Some more common occupational health disease found in DSP employee (executives), which is-

 Anxiety disorder
 Hyper tension
 Diabetic
 Problem in urinary track
 Excessive food habits
 Sleep disorder
 Blood pressure etc.
   Workshops & Seminars:
Durgapur Steel Plant regularly organizes workshops & seminars for his employees occupational
health by CHRD and Depart of OHS. Some progromme which regularly organizes by DSP are-

 Safety progromme on environmental & health education

 Training on environment, safety and occupational health
 Healthy DSP- life style management
 Common industrial health hazards
 Health education
 53RD National conference of Indian association on occupational health
 55th National conference on occupational health, safety & environment
 MTI – improving safety & health leadership
 National Seminar on safety, Health & environment
 Nutrition in health and diseases
 Occupational & environmental health
 Occupational health nursing, Bokaro General Hospital
 Program on safety, health & environment
 Recent advances in occupational & environmental health
 Workshop on ensuring safe & healthy environment

Industrial Hygiene Survey

OHS and Safety department always monitor work environment of industrial hygiene for increase
workers efficiency and maintain there health.

NOISE LEVEL MEASUREMENT

 Sound level meter

 Personnel Noise Dose meter

ILLUMINATION & RADIATION MEASUREMENT

• Lux meter
• UV digital meter
• Gamma Radiation Survey Meter

EVALUATION OF VIBRATION
• Human Response Vibration Meter
 EVALUATION OF ATMOSPHERIC CONTAMINANTS
• Personal air samplers
• Drager Multigas Detector
• Drager Polymeter
• Drager CMS analyser
• Real Time Aerosol Monitor
• Gravimetric Dust Sampler
• Hexhlet air sampler

HEAT STRESS EVALUATION

• Sling Psychrometer
• Kata Thermometer
• Hot Wire Anemometer
• WBGT index meter
• Dry Bulb thermometer
• Wet Bulb thermometer
• Globe thermometer
• Air velocity
• Physiological response to heat
• Humidity

MAN MAINTENANCE PROGRAMME

OHS department do regular health checkup of every employee of DSP and maintain record through man
maintenance progromme. This man maintenance progromme also helpful to study for employee’s health
history.

OHS Statistics

Activities 2005-06 2006-07 2007-08 2008-09

In numbers In numbers In numbers In numbers

Medicare 21307 25609 24653 23024

 Health Checkup 2345 3279 3364 3384
Rehabilitation 11 11 14 12
Audiometry 723 1239 1523 1570
Lung Function 516 1524 1668 1595
test
Counseling 137 136 125 110
( habits &
absenteeism)

Health and safety

Health and safety are important aspects of an organization’s smooth and effective
functioning.  Good health and safety performance ensures an accident-free industrial environment. 
 

The future of occupational health and safety

Occupational health and safety has come a long way from its beginnings in the heavy industry
sector. It now has an impact on every worker, in every work place, and those charged with managing health
and safety are having more and more tasks added to their portfolio. The most significant responsibility is
Environmental Protection. The skills required to manage occupational health and safety are compatible
with environmental protection, which is why these responsibilities are so often bolted onto the workplace
health and safety professional.
Bibliography
 DSP handbook manual
 OSHA Comes Up Short on Workplace, Safety Program Evaluations, Report shows, Stephen
Barr, The Washington Post, 04/26/06
 http://www.tech.plym.ac.uk/sme/MATS324/risk.htm
 Bernardino Ramazzini (1633-1714), ``De Morbis Artificum Diatriba``, The university of chocago
press, 1940- New York.
 www.google.com
 www.sail.co.in

Contents

 Acknowledgement 1
 Preface 2
 Sail (Vision, Credo) 3
 SAIL 4
 History (SAIL) 5
 Major units of SAIL 6
 Joint Venture 7
 Durgapur Steel Plant 9
 History (DSP) 9
 General plant operations 10
 Awards & Accolades 11
 HR policy of DSP 11
 Occupational health 12
 Advantages of OH 13
 Functions of OHS 13
 Components of OHS 14
 Occupational Health Hazards 15
 Human Heat balance Equation 16
 Heat Illness 16
 Chemical hazards 17
 Dust 17
 Biological hazards 18
 Mechanical hazards 19
 Ergonomics 19
 Manual handling(according to ergonomics) 20
 Ergonomics Guidelines 21
 Psychological hazards 22
 Industrial hygiene survey 23
 Man maintenance progromme 24
 OHS statistics 24
 Man maintenance progromme (format) 25
 The future of occupational health & safety
 Bibliography