Ingot Metallurgy Forum March 28 & 29, 2017 Coatesville Melt Shop Safety

1. Ingot Metallurgy ForumMarch 28 & 29, 2017Coatesville Melt Shop Safety

2. STEELMAKING OSHA RECORDABLE INJURY RATES FROM 1999 to 2016 • 2002 – 11.36 • 2003 – 19.36 • 2004 – 9.12 • 2005 – 11.82 • 2006 – 11.43 • 2007 – 8.81 • 2008 – 7.76 • 2009 – 2.28 • 2010 – 5.88 • 2011 – 3.56 • 2012 – 2.83 • 2013 – 4.07 • 2014 – 2.28 • 2015 – 5.14 • 2016 – 5.52

3. THERE IS NO SILVER BULLET!!

4. SWISS CHEESE MODEL • The slices of cheese represent layers of protection against errors or hazards • The holes in the cheese represent gaps in our layers of protection Individual Administrative • Incident • Engineered/ Physical FINAL BARRIER Danger / Root Cause

5. FOCUS ON LIFE-THREATENING HAZARDS • Hot/molten metal • Rail safety • Energy isolation / LOTOTO • Working at heights • Confined space entry • Cranes & lifting

6. ARCELORMITTAL USA ELECTRIC ARC FURNACE BEST SAFETY STANDARD Engineered / Physical • Protective glass and shielding in pulpits, tapping station and charge & ladle cranes • Electrode string swap rather than electrode add to alleviate fall hazard from top of furnace • Water leakage detection inside the furnace by measuring: • Intake and discharge flow differential of shell, roof, and delta • Hydrogen in off-gas at ductwork intake • Comprehensive video camera monitoring and DVR system • Work platforms for safe access and D-ring attachments for fall protection anchor points for unguarded work areas • Continued efforts to keep employees away from hot metal

7. PAST METHOD OF TAKING A MANUAL TEST & TEMPERATURE AT D FURNACE

8. MORE AUTO TEST AND TEMPERATURE SAMPLER The sampler is designed to automatically measure temperature, carbon/oxygen contents and take samples for steel chemical analysis without having to power-off the furnace. By removing the operator from the furnace door, it provides maximum safety during melting process. The equipment is installed on a fixed platform the side of the furnace slag door.

9. CHANGE NEEDED TO KEEP PEOPLE AWAY FROM FURNACE AS MUCH AS POSSIBLE • The safety advantages are significant. • Not only are the risks of burns significantly reduced, but also the hazards associated with strains and sprains from handling the manual sampling pole, pinch points with opening/closing the test port door and cleaning out the test port, and slips/trips/falls going up and down the test platform stairs were quantifiably reduced.

10. ANOTHER EXAMPLE IS THE INSTALLATION OF THE SLAG DOOR PUSHER

11. PREVIOUSLY DONE BY A CHARGER, THIS DEVISE PUSHES BUILT-UP SCRAP AND SLAG FROM THE SLAG DOOR OPENING AND INTO THE FURNACE… …FROM A REMOTE STATION AWAY FROM THE FURNACE

12. WHAT’S NEXT? AUTOMATIC ARGON COUPLING SYSTEMS TO LADLES

13. ARCELORMITTAL USA ELECTRIC ARC FURNACE BEST SAFETY STANDARD Administrative • Training employees on established written procedures for high-risk tasks such as: • Charging scrap, coal & lime • Taking test and temperature • Tapping the furnace • Clearing the slag door • Slag pit operations • Opening a plugged tap hole • Furnace water leak procedures for all scenarios • Retrieving a broken electrode • Welding or changing a furnace panel • Cleaning the furnace roof

14. ARCELORMITTAL USA ELECTRIC ARC FURNACE BEST SAFETY STANDARD Personal Protective Equipment • Demarcation of 25-foot “red zone” from hot metal • Triggers certain PPE requirements • Currently use signs to demarcate “red zone” however signs get dir • Experimenting with red LED

15. ARCELORMITTAL USA ELECTRIC ARC FURNACE BEST SAFETY STANDARD Personal Protective Equipment • Hard hat, safety glasses, high heat metatarsal shoes, high heat face shield & welding gloves • 3 layered protective clothing requirement • CarbonX underwear – top and bottom • 12 oz. FR Indura whipcord pants & 9 oz. FR Indura whipcord shirt • Aluminized Kevlar leggings and aluminized CarbonX or Kevlar hot coat • CarbonX balaclava or aluminized snood for neck protection

16. ARCELORMITTAL USA RAILROAD SAFETY STANDARD • No OSHA standard for non-FRA regulated rail operations • Standard provides rule-based guidance on • Training • Locomotive operations • Working between cars • Coupling & uncoupling • Track isolation when working on or within 10 feet a track • Pedestrian and vehicle crossings

17. ENERGY ISOLATION

18. ENERGY ISOLATION

19. WORKING AT HEIGHTS • Engineered fall protection systems installed at: • Hot top platform • Pouring car pit set-up area • EAF dust load-out area • Building roofs

20. CRANES & LIFTING • Also currently investigating crane proximity detection system on one of our remote-controlled cranes

21. NON-LIFE THREATENING TASKS • Attributed to many of our LTI injuries last year • Many involve life-long skills • Lifting, pushing, pulling > 50 pounds • Identify these activities and implement solutions • Ascending / descending stairs • Use handrail signage • Paint top and bottom step to signify termination of stairs

22. FOCUS ON THE LAST LINE OF DEFENSE....THE INDIVIDUAL • “Once on the pyramid you don’t know where you will find yourself” • Stay off the Pyramid! • Human Performance!

23. HUMAN PERFORMANCE IMPROVEMENT When you reduce error-likely situations, you improve your success rates and keep people off the pyramid that results in improved safety • People are fallible and even the best will make mistakes • People do what they do at the time because it makes sense to them at the time they do it • The things that cause the little things are the same things that cause the big things • Error-likely situations are predictable and preventable - only if you recognize them • We utilize a Pre Job Briefing form for all high risks jobs of the day to identify and manage risks and error potential

24. HUMAN PERFORMANCE IMPROVEMENT

25. HUMAN PERFORMANCE IMPROVEMENT

26. HUMAN PERFORMANCE IMPROVEMENT STOP when Unsure, Seek Out Help STOP Signs: • By area, criteria established of known STOP events • STOP signs made and displayed

27. HUMAN PERFORMANCE IMPROVEMENT STOP when Unsure, Seek Out Help