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TRANSCRIPT
SAFETY & SECURITY NEWSLETTER
January 2014 Issue
MESSAGE DESK
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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
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