SAFETY & SECURITY NEWSLETTER

January 2014 Issue

MESSAGE DESK

.

CONTENTS

1 Metal Cutting Safety

2 Lessons Learned

3 Corporate Safety Highlights - Dec’13

4 Safety training & drills– Dec’13

5 Root cause analysis (RCA) of incidents – Dec’13

6 Security Highlights

Thought for the month

Have another day - by being safe today!

1. Metal Cutting Safety by L S V K S Murthy

Hazards

Metal that is not secured properly during cutting operations can fly off the machine or work surface.

Fingers or other body parts may be cut off if they come into contact with cutting blades.

Tool breakages can result in flying debris, and unexpected movement of equipment and material.

Fingers or other body parts can be injured when

material moves during cutting.

Eyes can be injured by dust or particles that are flung

out by the cutting action.

Feet and legs can be injured when the cut piece of product falls.

Hands can be cut on material edges.

Injuries can be caused by a machine being started by someone while another person is maintaining it.

Falls can be caused by debris left lying on floor.

Hazard Control Measures Only use a tool or machine if you have been trained to use it safely.

Only use a tool or machine if you are authorized to.

Only use a tool or machine if you feel confident about

using it.

Keep the blade covers and other guards in place at all times.

Check the equipment and tool for faults regularly; ensure the tool is fitted correctly, and that the tool and equipment are operating within their limits.

Never adjust any metal cutting tool while it is in operation.

Do not overload machines.

Remove off-cuts from the floor.

Disconnect the power and lock out the machinery when servicing or replacing blades.

If maintaining guillotines, either close the blades first or insert a block to prevent them closing accidentally.

Never override limit switches!

Minimize combustible materials for furnishing. Use fire retardant material for false ceiling, partitions and upholstery.

Always wear safety glasses and ear protection when

operating any metal tool.

Wear Personal Protective Equipment such as safety boots.

Gloves must be worn when handling metal but should be removed when operating tools or machinery where your hands are relatively close to the rotating parts (e.g. lathes or drills).

Never wear jewelery or loose clothing when operating metal cutting tools

and machinery.

Always refer to the machine‟s handbook on safe operation.

2. Lessons Learned

2.1 Saki-Vihar Road (Near K.T. Sons)

Date & Time : 30th November 2013 at 17:57 Hrs. Location : Saki Vihar Road Details : Multiple Fatal - Reportable due to blast in cable jointing pit

Description:

There was an incident on 30th November 2013 at Saki Vihar road where Distribution team was

working on repairs to a 22 KV cable. The incident resulted in severe burn injuries to 5 persons

including a passerby and another person manning a stall nearby. All these persons were taken

to Hiranandani hospital immediately and later shifted to National Burns Centre at Airoli. Three of

the affected persons succumbed to their injuries later.

Details:

22 KV cable between K T Sons Consumer Sub Station and River Rose Consumer Sub Station

(CSS) was kept out of service from 3rd September 2013 due to cable fault and this cable section

was isolated and kept grounded. Later the fault was identified at Chandivli Junction by a Cable

fault testing machine. Permission from MCGM for attending to the cable fault was put up

immediately but it was finally received only on 28th November 2013 and the Cable fault repair

work was scheduled on 30th November 2013.

Staff Injured in the accident:

Tata Power engineer, Cable Jointing Contractor‟s employee, (who were present in the cable

joint pit), Tata Power Driver, a worker at a nearby stall on the road, who were near the cable

joint pit and a person who was riding on a bike just passing by the cable joint pit received burn

injuries of varying degree.

These persons were taken to Hiranandani Hospital and thereafter all of them except rider were

shifted to National Burn Hospital at Airoli. Rider also came back on 3rd December to be admitted

in the hospital for treating blisters on his hand. He is cured and was discharged on 11th

December 2013. Stall worker has been discharged from hospital on 29th January 2014 after

treatment. He is recovering well. Cable jointer expired on 2nd December 2013 during the

medical treatment, driver expired on 7th December 2013 during the medical treatment and

engineer expired on 10th December 2013.

Tata Power has taken full care of employees as well as others who were affected in the incident

during their treatment and will continue to provide necessary support to the family.

Standard Operating Procedure elements & Execution Focus:

1. Safety Interlocking System: as a further reinforcement safety measure, LOTO system has

been introduced in all operating units and it needs to be followed fully without any exception.

It is required that the system is followed in all the divisions meticulously and exceptions if

any be brought to the notice of Division head and Corporate Safety.

2. Daily activities and Monitoring: Daily activities of Job Safety Analysis, tool box talk and

ensuring work permit is taken, need to be carried out diligently by the Engineers and

supervisors. Monitoring of activities by HODs like auditing of LOTO, JSA (job Safety

Analysis), implementation of critical safety procedures need to be more rigorous and

regular.

3. Safety assessment of all O&M and project sites to be done periodically by the corporate

safety teams with the help of divisional teams.

4. Earthing – „Make before break‟ principles should be strictly adhered. Also, at all potential

bearing conductors, earthing should be solidly done and before touching, it should be

established there is NO potential. For meggering circuits, such effective should be earthed

only when measuring end megger shows zero readings.

Measures Implemented:

A Safety Tracker consisting immediate, short term and long term recommendations has been

put in place to execute action items based on the lessons learnt from this incident across the

company.

The following recommendations of immediate nature have already been implemented in terms

of new measures and reinforcement of existing systems.

1. Correcting anomalies in implementation of LOTO –

a. Providing Minimum two locks for isolating points as per LOTO concept.

b. Placement of the key by Operation Engineers in KEY BOX & to take the key of KEY

BOX to nodal station for any shift change.

c. Cable Engineer to retain his key with himself till the job is over

d. KEY BOXES installed in every CSS and DSS.

e. Operation Engineer only entitled to carry out the operations.

2. Procedures for the cable fault release, testing & repair redefined.

3. Ground GODs on RMU Panels painted with different color for distinct identification.

4. Use of magnetic sticker for “DONOT OPERATE” of GOD under release.

5. Use of effective fail –safe earthing mechanism & use of test – rods (potential check).

Safety is one of the CORE VALUES of Tata Power. All employees to continue to imbibe it &

demonstrate in their daily working to enhance the safety standards continuously.

2.2 MEPL: Exposed to hot bed ash

Date & Time : 29th Aug 2013 & 08.30 Hrs

Location : Boiler House

Details : Loss Time Injury

Description: The Boiler Operator was observing the draining of bed material to atmosphere

through bed drain No.1; As there was a choke in the drain line, he was trying to clear it by

hammering. While doing so, the choke got cleared and the hot bed ash came out with force and

the boiler operator was exposed to hot bed ash over his body & head.

He has been provided first aid at our Occupational Health Center and sent to Narayana Hospital

at Nellore for further treatment.

Root Causes:

Human Factors

1-10 Shortcut: To save time, operation person has

4-1 Improper decision making or lack of judgment: Inadequate risk perception

Physical Factors

6-3 Improperly Prepared Equipment: The hose was not secured properly

7-4 Energized Equipment, other than electrical: The person was observing the operation standing near the energy source

System factors

8-1 Conflicting roles & responsibilities: Work carried out by operation instead of maintenance personnel

14-1 Lack of PSP for the tasks: Written procedure to be developed and followed for choke removal

13-4 Inadequate availability: Unavailability of standard fittings Recommendations: 1. Written procedure to be developed and followed

2. Permit to Work (PTW) system shall be followed as per the procedure

3. HIRA/ JSA shall be used for all jobs

4. All spares shall be made available in order to avoid makeshift arrangements

5. Only maintenance personnel shall carry out such jobs

6. Provide awareness session

Click here for detailed report

2.3 Carnac: Lift Stranded Incident

Date & Time : 05th Dec 2013 & 14.20 Hrs

Location : West-side lift of B block Bldg, Carnac

Details : High Potential-Near miss

Description :

10 employees of Carnac B-Block boarded the West side Lift at Ground floor. The Lift capacity is

for 10 persons. All the 10 employees were from same department & were to land on 6th floor.

Between 4th & 5th Floor, before reaching landing position at 5th floor the lift jolt violently, stopped

& overload alarm flashed. The trapped persons contacted Control room, Security personnel &

their colleagues for rescue from Lift Intercom. The Security, Control room personnel familiar with

emergency brake release for rescue attempted & were not successful due to machine jam.

OTIS Helpline was informed but they took more time to reach the site due to large scale

absenteeism (as informed by OTIS Sr. manager). Finally after about one & half hours OTIS

technicians were able to clear machine housing jam & lift was brought to landing position to

rescue the stranded persons.

SYSTEM FACTORS

11-2 Inadequate preventive maintenance:

Malfunctioning of overload sensor between 4th & 5th floor resulted in stoppage of the lift.

11-3 Inadequate repair (Lubrication / servicing):

The lift got jammed due to bur in the thrust housing, which is due to improper oil circulation.

This prevented emergency brake release key operation causing delay in rescue of stranded

persons.

OEM Service persons failed to check the improper oil movement in machine housing during

service visit. In the schedule of Preventive checks of OEM, the Point no. 4, mentions: check

proper oil level in motor, sleeve bearing and machine gear box. This point needs to be

complied by OEM during visits as per schedule

Recommendations:

• OEM maintenance team to check thoroughly the oil movement/ top up during every service

visit. (This is to ensure proper functioning of emergency brake release).

• OEM to perform Load test of the Lifts for satisfactory operation & submit the report.

(Simulation of lift overload)

• Emergency brake of lifts shall be checked during PM on quarterly basis.

• OEM to calibrate and reset the overload safety alarm

• Floor wardens, security and control room personnel to be trained for emergency rescue in

coordination OEM

• Emergency brake shall be operated by M/s. OTIS personnel only as it is critical activity.

(Suggested by M/s. OTIS).

• Control room is unmanned many times hence Security numbers to be added as emergency

numbers inside Lift car

• Alternate vendor for maintenance to be explored in view of poor maintenance from OEM.

• AMC to be renewed in time to ensure the regular PM of lifts.

• All in Tata Power (wherever lifts are available), incidents to be shared to prevent recurrence.

Click here for detailed report

3. Corporate Safety Highlights Dec’13

Conducted comprehensive safety assessment audit at Distribution Customer Services

(DCS) & Distribution Support Services (DSS).

Participated in incident investigation of Saki-Vihar road (near KTsons) electrical flashover

incident.

Reviewed CSM Step 1 check list (used for obtaining information from contractors) and

shared with CCO for implementation.

Reviewed safety helmet samples along with PPE review committee and prepared Safety

Helmet evaluation Report. Final Safety helmet evaluation report sent to CCO for their further

action.

Attended meeting with SAARTHI Team to finalize RICEFW (R-Reports, I-Interface, C-

Conversions, E-Enhancement, F-Forms, and W-Workflow).

4. Safety training, drills – Dec’13

Session on “Electrical safety” at Poolavadi, “PPE & inspection” at Gadag, “JSA” at Samana,

“Safety during maintenance” at Agaswadi, “Fire fighting & LOTO” at Dalot, “Fire fighting” at

Sadawagpur & Nivade wind farm

SPANDAN training was conducted in Trombay through “Aakar Charitable Trust”. Various

trainings such as Safety standards and procedures, first aid and fire fighting, Chlorination,

Health related, DMP, LOTO, working at heights, Basic safety & IMS awareness were also

conducted.

Mock drills of „Electric Shock‟, „Food Poisoning‟ were conducted at Sadawagapur, Supa

respectively and „Snake bite‟ in Bramanwel, Nivade wind farms

5. Root Cause Analysis (RCA) of incidents – Dec’13

Human Factors Physical Factors

System Factors

0.0%

5.0%

10.0%

15.0%

20.0%

25.0%

30.0%

35.0%

40.0%

45.0%

50.0%

Jan'13

361

Feb'13

416

Mar'13

639

Apr'13

332

May'13

251

Jun'13

203

Jul'13

336

Aug'13

324

Sep'13

310

Oct'13

275

Nov'13

320

Dec'13

359

Ca

us

es

Human Factors TrendProcedural non compliance No/ improper use of tools or equipment

Not using protective methods Inattention/ Lack of awareness

Total no.of causes

0.0%

10.0%

20.0%

30.0%

40.0%

50.0%

60.0%

70.0%

Jan'13

193

Feb'13

234

Mar'13

285

Apr'13

147

May'13

139

Jun'13

129

Jul'13

186

Aug'13

184

Sep'13

176

Oct'13

136

Nov'13

156

Dec'13

181

Ca

us

es

Physical Factors Trend

Inadequate/ defective tools, equipment & vehicle Work exposure to

Workplace environment layout Inadequate/ defective protective system

Total no. of causes

0.0

5.0

10.0

15.0

20.0

25.0

30.0

35.0

40.0

45.0

50.0

Jan'13

316

Feb'13

369

Mar'13

422

Apr'13

201

May'13

170

Jun'13

97

Jul'13

165

Aug'13

202

Sep'13

199

Oct'13

115

Nov'13

145

Dec'13

165

Cau

ses

System Factors Trend

Physical Capability

Physical Condition

Behavior

Skill Level

Training or Knowledge Transfer

Contractor Selection & Oversight

Management / Supervision / Employee LeadershipEngineering / Design

Work Planning

Purchasing, Material Handling & Material ControlTools & Equipment

Work Rules / Policies / Standards / Procedures (PSP)Communication

Mental Stress

Mental State

Note: Insignificantcauses (consistentlyless than 5%) arenot shown

Total no. of causes

6. Security Highlights

I. MPL-Maithon

Training:

A training session was taken by Mr. Dilip Singh , Head Security & Fire for all S/Supervisor, ASO and AM of all 03 agencies i.e G4S, BSS & IFSS. On Importance of Vigilance & Collection of Intelligence for Maithon Power Limited & Crisis Management System- Role of QRT, Fire crew, control room, SS/ASO/AM of agencies and MPL security Officers during crisis. Total 22 SNF personnel participate in this training.

Visit of Head Security and vigilance at MPL- Head Security and vigilance at MPL Mr. SN

Rudrappa visited MPL to review the security scenario. He addressed all officers of Security

& Fire department and distributed dress to MPL Warriors (Cricket Team of Security

department).

On 24th Dec 2013, Mr. SN Rudrappa met with SP Dhanbad, District Head IB and DIG (CISF)

BCCL and appraised them about the security scenario at MPL.

HYWA CHECKING BY MPL SECURITY TEAM – During the month of December 13, 347

hywas were checked by Security officers of MPL, randomly for driving license of hywa driver

as an initiative to stop any hywa accident caused by unauthorized driver. An amount of Rs

19,000 was imposed against the default.

IMS Audit -IMS Audit stage II was carried out at Maithon Power Limited by Indian Register

Quality System successfully. MPL was recommended for QMS, EMS & OHSAS all together.

II. Jojobera

Operational achievements - Successfully Conducted a number of training programmes to

enhance the operational skills of the guards. The sense of security awareness has also

been created among contract workers. All are adhering to the security instructions.

Training activities –

Social activities – Mr. Sunil Kumar, Head – Security and Mr. A K Srivastav actively

participated in organizing Homeopathic camp for villagers of the nearby villages on

20/12/13.

Reward-Recognition- A) The Team of Sunil Kumar, Head – Security, A K Srivastava and

Kaushik Dutta was awarded/rewarded for "Developing Various mechanism to gather

information which after analysis is converted in to intelligence.” B) Mr. A K Srivastava was

recognized for his activism in “Health Volunteer Programme”. C) One Inspector and three

supervisors of SIS were rewarded for their outstanding performances.

Mr Sunil Kumar receiving award Mr A K Srivastav awarded

Visit of Chief Security & Vigilance - Mr. S N Rudrappa, Chief Security and Vigilance, Tata

Power visited Jojobera and PH#6 and interacted with Heads of other departments. He

discussed security issues with other HODs and briefed the security personnel. He inspected

the whole plant area.

Inspection of reception by Chief Sec & Vig. Inspection of CHP area OPS Head

Briefing Mr Rudrappa in C/Room I/C Stores briefing Mr Rudrappa

Achievements - A) The well planned security sessions and it‟s execution will certainly go a

long way in achieving the aim of creating security awareness amongst the employees and

contract workers. B) Security Department won 8 awards/rewards during the month

December 2013

III. CGPL - MUNDRA VIP VISIT: On 05.12.2013, A delegation from Kenya visited CGPL, The VIP were

escorted to projects office reception. The visit was coordinated by security team .VIP left for Bhuj at1430 Hrs.

Training:

Alcohol Breath Analyzer Training: Security procured two Alcohol Breath Analyzers for

checking alcohol content blood sample. On the Job Training session on the usage of the

device was conducted for the security personnel

Central Briefing:

Central briefing of security guards was carried out by CMS V K Dogra, Executive security Mr. Nand Kishor Bhatt and Lead Associate Security- Mr. Poonam Singh Chauhan at L/Colony as on 17 Dec‟13. Team was briefed about their duties and responsibilities. Security related issues were discussed.

SPECIAL DRIVE:

Special traffic drive, daily speed monitoring initiative during rush hours is in continuation at Hostel gate & old main gate U-turn area during morning shift hours. Vehicles without proper entry passes were restricted. A total of 86 Debit Notes were raised in the month of Dec‟13. Out of which 30 Debit Notes were raised against Breach of Traffic safety and 56 for Breach of Security. Consolidated summary of the debit notes raised in the past month is available on demand.

IV. Transmission & Distribution

Training workshop was organized for security supervisors and guards of Transmission/

Distribution at Techno polis on 14 Dec 13. Total 30 security personnel attended the

workshop. The following topics were covered during the training:-

(a) Personnel conduct and behavior.

(b) Duties of security Supervisor/guard.

(c) People/ Vehicle/ Material management process.

(d) Use of communication set and fire extinguishers.

(e) Security gadgets and Documentation.

(f) Safety precautions.

(g) Disaster management- Action by security guard.

(h) Knowledge sharing.

The training capsule for PMT Security guards was conducted at Kalyan Receiving

Station on 15 Dec 13 in two shifts. Total 04 PMT Security personnel attended the

training

We invite your feedback on this newsletter. Write to us at safety@tatapower.com