Bhilai Steel Plant (BSP) has further strengthened workplace safety by implementing a series of innovative engineering, digital and preventive safety measures across its major production units during June 2026. The technology-driven initiatives are aimed at eliminating operational hazards, preventing personnel from entering the "Line of Fire" (LOF), improving equipment protection and reinforcing a robust safety culture across the integrated steel plant.

At the Central Ore Handling and Coal Chemical Department (CO&CCD), an advanced Interlocking Fault Relay (IFR) protection switch has been commissioned at Wagon Tippler-07 to ensure that loaded wagons remain within the prescribed safe operating limit during tippling operations. Installed at the entry position limit of the loaded wagon, the system continuously monitors wagon movement and functions as an interlock protection mechanism. If a wagon crosses the predefined safety limit, the switch immediately generates a trip signal and halts the tippling operation before the wagon enters the tippling bed, thereby significantly reducing the risk of accidents, equipment damage and operational disruptions while minimising the possibility of human error.

At the Steel Melting Shop-2 (SMS-2), a major safety upgrade has been introduced in the Ruhrstahl-Heraeus (RH) Degasser pre-heating system, incorporating industry learnings from the accident at Visakhapatnam Steel Plant. Earlier, burner ignition was carried out through a spark plug. The system has now been upgraded to a pilot burner-based ignition system, in which the pilot burner is first ignited using a controlled quantity of gas. Once the flame sensor confirms successful ignition, the main Coke Oven Gas (COG) burner is automatically activated through the opening of the main gas valve, with subsequent gas flow regulated according to operational requirements. The modification substantially reduces the possibility of explosive ignition while enhancing operational safety and system reliability.

Further strengthening personnel safety, Steel Melting Shop-2 has also launched a dedicated 'Line of Fire' Identification Initiative. A prominently marked demarcation line has been created near the Semi Portal Crane in the Converter 8-metre operating area to clearly identify the crane movement zone and the associated Line of Fire. The visual safety intervention discourages inadvertent entry into hazardous operating areas, reduces man-machine interface risks and enhances employee awareness of potential danger zones.

At the Steel Melting Shop-3 (SMS-3), chute jam limit switches have been installed at the 36-metre and 40-metre conveyor chutes of the ferro-alloy addition system. In the event of chute blockage, the limit switches automatically stop conveyor belt movement, preventing belt damage, reducing equipment downtime and ensuring safer material handling operations.

To minimise exposure to moving machinery and further strengthen protection against Line of Fire hazards, the Sinter Plant-3 (SP-3) has installed continuous side guarding along the entire length of the Z16 Belt Conveyor (BC)-1 and Belt Conveyor (BC)-2 systems. The protective barriers effectively prevent accidental contact with moving conveyor components and provide enhanced safety for personnel working in the vicinity.

Meanwhile, the Ore Handling Plant (OHP) has introduced a weather-resilience initiative through the installation of portable wheel-locking skids on all stacker-reclaimers. During high-velocity winds and adverse weather conditions, the skids function as a secondary anchoring mechanism to prevent unintended movement of stacker-reclaimers, thereby improving equipment stability and safeguarding both personnel and critical infrastructure.

Through these proactive engineering interventions, digital safety solutions and preventive control measures, Steel Authority of India Limited-Bhilai Steel Plant continues to strengthen workplace safety, enhance equipment reliability and prevent Line of Fire incidents, reaffirming its commitment to creating a safer, smarter and more productive work environment across all operational areas.

 

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