Introduction: The steel industry is known as the most important consumer of energy and fuel. In doing so, ensuring safety of energy sources of a country needs to expect the risks analysis in order to select a comprehensive approach. This study aimed to identify the energy consumption and control measures available in the Hot Rolling Kavir Steel Complex and to conduct risk assessment by Energy Tracking and Barrier Analysis method (ETBA).

Materials and methods: In this study, initially a team of experts identified mobilized energies and risks of the system and control measures using ETBA sheet that result of a standard MILSTD-882B. Then, the initial risk assessment was carried out using ETBA method. Finally, the control strategies were proposed and the secondary risk level was calculated.

Results: Using ETBA, in total 19 energy types and 74 risk types were successfully identified so that in the first stage, 19 risks were unacceptable, 50 risks were unfavorable and 5 risks were acceptable for which the corrective strategies were required Then, the corrective revisions were proposed to reduce the risk level and calculate RAC2.

Conclusion: Corrective controlling measures including safety, health and environmental training, continual monitoring and ongoing visit are effective using the safety equipment and personal protective equipment for reducing the unacceptable risks.