STANDARD OPERATING PROCEDURE

SOP NO SFAL/WBN/SOP/EOT/01 EFFECTIVE 31.03.2020 REVISION NO 00.00

DATE

DEPT FERRO

STEP ACTIVITY ASSOCITED RESPONSIBILITY PROCESS/PPE’S REMARKS

NO REQUIRMENT
1 OVERHEAD DAMAGE ROPES, OPERATOR HELMET safety
CRANE DAMAGE HOOKS shoes
2 ARC WELDER FALLING OBJECTS WELDER SAFETY GLASSES,
TRAPPING HAZARDS safety shoes
3 GAS WELDING FLING SPARKS,FUMES WELDER WELDING
GOGGLES, LETHER
GLOVES
4 LOADING DRIVER HELMETsafety
&UNLOADING shoes
5 TRANSFORMER
6 RAW
MATERIALS
STORAGE
7 CHARGING OF
RAW
MATERIALS
8 FIRE
EXTINGUISHER
9 HEIGHT WORK fall from height SUPERVISOR SAFETY BELT,
HELMET
 Standard Operating Procedure:

STANDARD OPERATION OF F.G HANDLING

DOCOMENTS NO HAZARDS PPE TOOLS & EQUIPMENTS
SFAL/BWN/SOP/FGH/01 Helmet, safety shoe Reversible horn

1. Mn Ore, Nut Coke, Pearl Coke, Middling Coal etc. Size and Chemical Specification as per
Technical Norms.
In case of Middling Coal process to be followed as per MN Ore handling by Rake.

2. Check Invoice details before receiving trucks at Plant Gate. Pls also Check e-
Way bill if applicable
3. In case of any dispute, do not allow truck to enter and inform higher authority and
following instructions. Pls check safety aspect of the truck like reversible horn etc.
4. After receiving trucks, if found normal then send for gross weighment otherwise hold
truck in case of high moisture or water dripping and inform higher authority and
follow instruction.
5. After Gross weighment trucks to be sent to unloading plot and to be unloaded in
presence of TPA (if required). Trained Supervisor will be deployed for the supervision
while unloading.
6. While Unloading of trucks, utmost care to be taken to avoid any fines generation.
7. LAB will collect sample after unloading of each truck for Moisture, Size and Chemical
analysis.
8. Daily Truck wise moisture to be reported to higher authority and respective Supplier of
Transporter within 48 Hrs.
9. Chemical and Size analysis to be reported for the lot. Lot size will vary which is
based on day wise material supply. Normally it is 200 to 400 MT9.
10. In case of abnormality found during unloading of trucks like higher % of fines
contaminations or any abnormal moisture content, then truck to be held up and
respective supplier/transporter to be informed by SFL then joint inspection will be one
before unloading and accepting the material.
11. In case of any dispute in sampling or analysis, person from Supplier or Transporter to
be deployed for joint sampling. Plant can also go for Joint sampling(if required).
 Standard Operating Procedure:

STANDARD OPERATION OF F.G HANDLING

DOCOMENTS NO HAZARDS PPE TOOLS & EQUIPMENTS
SFAL/BWN/SOP/FGH/02 Helmet, safety shoe Reversible horn

1. LOT/Stack of Finished Goods (FG) to be prepared as per guideline of SHYAM FERRO ALLOYS
LIMITED & TPA (if required) after Sizing (10 to 60 mm) and confirmation of grade of the FG
tested in Lab as per contract norms.
2. Uniformity of stack to be maintained. “-10 mm” and “+60 mm” shall not exceed 3% Max in each
case.
3. Height of the Stack to be maintained up to 2 to 3 feet Max uniformly based on the space
availability at yard. Stack to be prepared in geometrical shape and Size should be 100 to 150
MT.
4. Large hole to be prepared in the middle of the Stack in such a way that ground can be touched
and sample to be collected from 4 sides (X manner) inside that hole.
st nd
5. Lot to be prepared after 1 time screening and 2 time screening to be done during
loading/packing in case of any fines observed.
6. Sample to be collected by LAB and TPA (if required) as per IS/BIS standard and procedure
7. Screen test will be done during offering of stack, if it is not within the limit, the stack to be
screened again before offering.
8. Sample Packet to prepared and Analysis to be done as per IS/BIS procedure
9. Analysis report to be published to all concerns with 48 Hrs of sample collection.
10. FGH will upgrade the Lot/stack and re-offer for sampling. Same procedure will be followed for
sampling and Analysis.
11. In case of dispute/conflict in Analysis or Grade of material. Joint Analysis can be done with the
Pilot Sample Packet. The Joint Analysis report will be taken as Final for Quality Report (if
required).
12. In case of Crisis of Mn Alloy Supply, GRN to be done with Plant analysis only for Invoicing and
TPA (if required) Analysis will be the final for Reconciliation.
13. Material to be kept under Shed only and measure to be taken to prevent ingress of water.
14. Only Dry Material to be packed into the Bag. In no case wet material to be loaded.
15. Bagging and Sealing to be done as per the dispatch program.
16. Bagging to be done in 1 MT or 50 KG bags as per requirement. Weight of the material to be
ensured during bagging in 1 MT or 50 KG. FGH to put weigh-scale or mechanism to ensure the
exact weighment with minimal tolerance (25 to 50 Kg Max in case of 1 Mt Bag) either before
loading or during loading.
17. Stitching (with Labeling if provided) to be done in each bags as per the requirement.
18. Seal numbers used for sealing to be mentioned on the back side of Invoice certificate.
19. Usage of Bags and Seals to be reconciled on Monthly basis, details to be submitted in Monthly
Report.
20. Loading to be done onto truck either manually or by Machine.
21. Despatch program to be circulated previous day, accordingly trucks to be loaded based on truck
placement and program.
22. Tare weight to be done before loading of trucks. After loading Gross weight will be done and Net
weight to be calculated for Invoicing. Tare and Gross to be done in the same Weigh Bridge
(WB). WB slips to be issued to each and every truck immediately after Gross Weighment.
23. Rounded figure to be maintained for Net Weight. Weight adjustment to be done in last two or
three bags to make it rounded like 20 MT, 25 MT, 30 Mt, so on.
 24. In case of weight variation reported by Logistics Partners/Transporters, cross check of truck
weighment to be done with 2nd WB.
25. Calibration of WB is very much important for correctness of Weight. Calibration Once in a
month is recommended.

SAFE OPERATION LODING & UNLODING

DOCOMENTS NO HAZARDS PPE TOOLS & EQUIPMENTS
SFAL/BWN/SOP/FGH/03 Helmet, safety shoe Reversible horn

Loading and unloading areas should be:

 Clear of other traffic, pedestrians and people not involved in loading or unloading.
 Clear of overhead electric cables so there is no chance touching them, or of
electricity jumping to 'earth' through machinery, loads or people.
 Level. To maintain stability, trailers should be parked on firm level ground,
 Loads should be spread as evenly as possible, during both loading and unloading.
Uneven loads can make the vehicle or trailer unstable.
 Loads should be secured, or arranged so that they do not slide around. Racking
may help stability.
 Safety equipment must be considered. Mechanical equipment and heavy moving
loads are dangerous.

 Ensure the vehicle or trailer has its brakes applied and all stabilisers are used. The
vehicle should be as stable as possible.

 Provide a safe place where drivers can wait if they are not involved. Drivers
should not remain in their cabs if this can be avoided. No-one should be in the
loading/unloading area if they are not needed.

 Vehicles must never be overloaded. Overloaded vehicles can become unstable,

difficult to steer or be less able to brake.

 Always check the floor or deck of the loading area before loading to make sure it is
safe. Look out for debris, broken boarding, etc.

 Loading should allow for safe unloading.

 Loads must be suitably packaged. When pallets are used, the driver needs to
check that:
o They are in good condition
o Loads are properly secured to them.
o Loads are safe on the vehicle. They may need to be securely attached to make sure they
cannot fall off.

 If more than one company is involved, they should agree in advance how loading
and unloading will happen.
o For example, if visiting drivers unload their vehicles themselves, they must receive the
necessary instructions, equipment and co-operation for safe unloading. Arrangements
will need to be agreed in advance between the haulier and the recipient.
  Standard Operating Procedure:
 SOP of Furnace checking & dust cleaning

DOCOMENTS NO HAZARDS PPE TOOLS & EQUIPMENTS

SFAL/BWN/SOP/ /04 Helmet, safety shoe

1. Inform to Mechanical & Electrical about Furnace switching OFF for GCP changeover &
dust cleaning
2. Call shift electrical to control room for electrical isolation of furnace as per procedure of
positive isolation.
3. Switch OFF the furnace in which dust cleaning is to be done.
4 Inform to mechanical for GCP OFF and furnace condition monitoring.
5. Open all inspection doors with the help of long handled hook and wait for at least 5
minute for allowing furnace inside gas to release.
6. Remove all accumulated dust from the furnace with the help of long handled raker &
trolley.
7. After completion of dust removal from all sides, rack the charge material to electrode
area & centre of furnace.
8. Check any castable repairing is needed to seal the gaps.
9. Close all inspection doors.
10. Ensure from Mechanical if any job is going on in GCP If yes ,then wait for Mechanical
clearance.
11. Physically go around the furnace & ensure no one is working on/near the furnace.
12. Request for power getting of furnace as per positive isolation system(Power getting
request form is filled with reference to power cutting form).
  Standard Operating Procedure:
 SOP of PAY LODER & JCB OPERATION

DOCOMENTS NO HAZARDS PPE TOOLS & EQUIPMENTS

SFAL/BWN/SOP/ /05 Helmet, safety shoe

1. Log sheet checking and assignment.

A. Read log sheet.
B. Talk to previous shit operation if required.
C. Talk to maintenance person to clarify any doubts.
D. Talk to shift in charge for site of deployment and description of job.

2. Visual inspection of equipment

A. Shall visually check for any leakage, loose parts, damage to any external parts,
arm, boom cylinders, bucket and teeth condition, tyre condition /pressure, back
horn automatic fire extinguisher system etc. by moving around the machine.

3. Inspection inside cabin.

A. Shall use three point contacts during climbing on ladder.
B. Shall visually check condition of electrical wiring fire extinguisher seat belt etc.
inside cabin for safe operating condition.

4. Functioning of indicators on panel board.

A. Shall put on the seat belt before starting the machine.
B. Before starting the loader blow a long horn to warn the nearby people. After
switching on initiation key shall see all meters & gauges. All lights should glow
and auto off except oil pressure & ampere meter.

5. Noting down log book reading.

A. Shall not the initial hour meter reading to access the run hour during the shift.

6. Loading of transport vehicle.

A. The loading operator shall ensure sufficient area for loading operation near the
stack.
B. Overloading should be avoided.

7. Stopping the engine and parking.

A. When not in use or end of the shift machine shall be brought to the designated
parking place and kept on a level ground keeping bucket on ground to prevent
roll down.
B. Shall not down closing hour meter on end of days work.
C. Close and remove the ignition key to off position.
8. Visual inspection.
A. Switch off the battery cut off switch.
B. Shall visually check for any leakage, loose parts, damage to any external parts,
arm, boom cylinders etc. by moving around the machine.
  Standard Operating Procedure:
 SOP of METAL BREAKING
DOCOMENTS NO HAZARDS PPE TOOLS & EQUIPMENTS
SFAL/BWN/SOP/ /06 Eye injuries Helmet, safety shoe

1. USE OF personal protective equipment.

A. Safety glasses must be worn at all times.

B. HAND GLOVES.
C. SAFETY HELMET.
D. SAFETY SHOE.

2. HAND TOOLS (HAMMER)

A. Always inspect any hammer before use to make sure its head is firmly fixed to
the handle.
B. The head should have no unevenness, burring, chipped or worn edges
or excessive wear.
C. Always grip the handle tightly near the end of its length to provide
maximum sticking force.
D. Strike the hammer or mallet squarely, deliberately and accurately to
avoid any mishits.
E. Never deliberately strike the faces of two steel hammers together as
this may cause small shards or chips to break away, potentially
causing eye injury.
F. Never deliberately strike a soft face hammer or mallet on metal edges
or sharp objects.

3. HOUSEKEEPING.

A. Return all hammers to their appropriate storage cupboard.

B. Leave the work area in a safe, clean and tidy condition.
C. If the handle of a hammer or mallet is broken, loose, splintered or
cracked, report it. Damaged handles will need to be replaced before
being used again.
D. The face of all soft faced hammers and mallets should be inspected
regularly and maintained if worn or damaged.
  Standard Operating Procedure:

SOP for OPERATION AND CLEANING OF CONVEYER BELT

DOCOMENTS NO HAZARDS PPE TOOLS & EQUIPMENTS

SFAL/BWN/SOP/ /07 Helmet, safety shoe