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Industrial Safety And Emergency Preparedness: NTPC Perspective

Shivam SrivastavaGM-Safety

NTPC Limited

Pathway

• About NTPC• Why Industrial Safety is Important• NTPC Safety Policy Framework• Major hazards in Power Station• Emergency preparedness at Engineering stage• Emergency preparedness at O&M stage

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About NTPC

Sl.No. NO. OF PLANTS CAPACITY (MW)

NTPC Owned

Coal 21 40,355

Gas/Liquid Fuel 7 4,017

Hydro 1 800

Renewable energy projects (Solar PV) 12 878

Wind 1 50

Total 42 46,100

Owned By JVs/Subsidiaries

Coal & Gas 9 7,551

Total 51 53,651

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About NTPCOPERATIONAL PERFORMANCE OF COAL & GAS BASED NTPC STATIONS

Gross Generation (BU)(COAL & GAS)

PLF (%)(Coal Stations)

2016-17 250.31 78.59

2015-16 241.98 78.61

2014-15 241.139 80.23

2013-14 233.269 81.50

2012-13 232.00 83.08

2011-12 222.07 85.00

2010-11 220.54 88.29

2009-10 218.84 90.81

2008-09 206.94 91.14

2007-08 200.86 92.24

2006-07 188.67 89.43

2005-06 170.88 87.52

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What is Safety ??

• Safety is not absence of accidents

• Safety is presence of defenses in the processes, procedures, facilities, methods and practices.

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What is Industrial Safety ??

• Industrial safety is defined as policies and protections put in place to ensure plant and factory worker is protected from hazards that could cause injury.

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Why Industrial Safety is important

• Occupational/ industrial accidents result in loss of production timeequivalent to millions of man hours, machine hours etc.

• 20% production time is lost by those actually injured due to temporaryand permanent disablement

• Balance 80% production time is lost by fellow operators/ people inhelping the injured, in taking care of the damage caused by accidentetc.

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Copyright © 2016 Your Company All Rights Reserved. 8

Intent of NTPC Safety Policy Framework

“All Accidents Are Preventable”Therefore, safety must be at the forefront of

all activities

Six Principles of NTPC safety Policy

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1. Our activities carry various hazards; however all hazards can be identified.

2. Every job shall be done safely, no matter how important or urgent it is.

3. Putting people to work carries a specific responsibility and accountability

for safety which shall be visibly demonstrated.

4. Right procedures and actions can bring the risks under control.

5. Trained and committed team can ensure incident free operations.

6. Compliance to all applicable safety regulations and other legal

requirements at the minimum.

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Major Hazard Potentials in Power Stations

Fire and Explosion Hazards:

• Hydrogen Plant and Storage area• Boiler / TG• Fuel oil Storage• Transformers and Switch Gears • Coal handling

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Major Hazard Potentials in Power Stations

Chemical Hazards:

• Chlorine storage and handling

• Sulfuric Acid storage and Handling

• Hydrochloric Acid storage and Handling

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Emergency Preparedness at NTPC

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Emergency Preparedness at NTPC

(A) At Engineering Stage

(B) At Execution stage

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Segregation of Layers of Safety

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Emergency Preparedness

At Engineering Stage

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Process Safety Design system

• HEZOP (Hazard and Operability Study)

• LOPA (Layer Of Protection Analysis)

• SIL (Safety Integrity Level)

• SIS / SIF (Safety Instrumented System / Function)

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SIF-1

Logic Solver(PLC)

Leveltransmitter

Leveltransmitter

Level switch

Temperaturetransmitter

Shut-offvalveSolenoid

GlobevalveSolenoid

MCC

Safety Instrumented System

SIL 2

SIL 3SIF-2

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Generic and application sector standards

IEC61508

Machinery sectorMedical sector

Process sector. . . . . . sector

Nuclear sector

IEC61511

IEC61513

IEC62061

IEC 61508 is an international standard published by theInternational Electrotechnical Commission of rules appliedin industry.

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IEC- 61508

• IEC 61508 is an international standard published by the “InternationalElectrotechnical Commission” of rules applied in industry. It is titledas Functional Safety of Electrical/Electronic/Programmable ElectronicSafety-related Systems (E/E/PE, or E/E/PES).

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Safety Specifications

EN 50156-1:2015 :Electrical equipment for furnaces and ancillary equipment. Requirements for application design and installation

EN 50178 :Electronic equipment for use in power installations.

NFPA-85Contributes to operating safety and prevents explosions and implosions in boilers

IS-3034Fire safety of Industrial Buildings

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Emergency Preparedness

At O&M stage

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Process Safety : Implementation

• Capacity building on DMP / OD/ OGN/ OIN and LMI.

• Awareness of Process Hazards and mitigation actions.

• Implementation of LMIs with “Zero Tolerance”.

• “No deviations” from NTPC safety systems (PTW / TC/ Process protections, General safety Rules etc)

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Disaster Management Plan

United Nations International Strategy for Disaster Reduction (UNISDR)

• International decade for Disaster reduction

• Hyogo Framework (2005-2015)

• Sendai framework (2015-2030)

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Sendai Framework

• Priority 1. Understanding disaster risk

• Priority 2. Strengthening disaster risk governance to manage disaster risk

• Priority 3. Investing in disaster risk reduction for resilience

• Priority 4. Enhancing disaster preparedness for effective response and to “Build Back Better” in recovery, rehabilitation and reconstruction

Source:http://www.unisdr.org/we/coordinate/sendai-framework

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Emergency Preparedness

• Well defined Disaster Management Plan

• Pre disaster elements: Prevention and Risk ReductionPreparedness

• Post disaster elements:Response Recovery

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Disaster Management Plan

1. Table top Exercise : “What if” for different scenarios

2. Functional Exercise

3. Full Scale drill

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Emergency Preparedness: Structure

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Emergency Preparedness

Mock Drills:

• As per Factory Act (Once in six months)

• Fire mock drill (CISF) (Once in 15 days)

• Mock Drills in association with NDRF, State Administration

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Emergency Preparedness

Other Activities:

• Weekly Fire fighting training of NTPC and associates by CISF /Safety

• Monthly Fire fighting system healthiness checking (CISF/NTPC)

• Mutual aid scheme (Anta/ Chambal Fartilizer, Auriya/ GAIL)

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Emergency Preparedness

Other Activities:

• Community awareness

• Involvement of CISF in inspection of Fire Fighting Equipment

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Top Line

Bottom Line

Safety

Production Targets

Personal targets

Ball of safety is made up of Glass andRest all balls are made up of rubber.

If left, all can bounce back But…..Ball of Safety Can’t

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Thank YouThank You

Someone is waiting for you at Home

Your safety is more important

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Mock Drill with NDRF

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Mock Drill with NDRF

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A View of Fire Station and Available fire tenders. Shivam NTPC 36

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Community Awareness

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