SAFETY & SECURITY NEWSLETTER

August 2013 Issue

MESSAGE DESK

.

CONTENTS

1 Conveyor Safety

2 Lessons Learned

3 Mock drills – Jul’13

4 Corporate Safety Highlights - Jul’13

5 Safety training – Jul’13

6 Root cause analysis (RCA) of incidents – Jul’13

7 Security Highlights

Thought for the month

Never think working safe is in vain when it could save

a life time of pain

1. Conveyor Safety Contributed by Murthy LSVKS, Executive, Corp. Safety

Do Not Climb, Sit, Stand, Walk, Ride, or Touch

the Conveyor at Any Time

Do Not Perform Maintenance on Conveyor Until Electrical, Air, Hydraulic and Gravity

Energy Sources Have Been Locked Out and Blocked

Operate Equipment Only With All Approved

Covers and Guards in Place

Lock Out All Power and Block Gravity Loads

Before Servicing

Ensure That All Personnel Are Clear of

Equipment Before Starting

Allow Only Authorized Personnel and Trained Personnel To Operate or Maintain Conveyors

and Accessories

Keep Clothing, Body Parts, and Hair Away

from Conveyors

Clean Up Spillage Around Tail Pulleys, Idlers,

and Load Points Only When the Power Is Locked Out and Guards Are In Place

Do Not Modify or Misuse Conveyor Controls

Ensure That All Controls and Pull Cords are

Visible and Accessible

Do Not Modify or Remove Controls, Guards, Interlocks, Warnings or other Safety items

without Manufacturer‟s Approval

Report All Unsafe Conditions

2. Lessons learned

Live grounding of 22KV Lube India 1 feeder while on Transfer Bus Date & Time : 14th Aug 2013 & 16:58Hrs Location : Station- A 22KV Switch Yard Details : High potential incident Description : 22KV Lube India Feeder 1 was transferred on Transfer Breaker. While isolating the own

breaker, the feeder tripped on 3 Phase to ground fault with a very loud noise causing heavy

voltage dip. On preliminary investigation, it has been established that the operation engineer

had inadvertently closed ground GOD of the live feeder.

22KV Lube India 1 Line side GOD with burnt out grounding contacts

22KV Lube India 1 Line side GOD & Ground GOD placed together with name plates facing in other direction

Pad lock keys placed inside breaker cubicle (22KV Lube India 1 Breaker)

Root Cause Analysis:

Human Factors:- 4-1 Improper decision making or lack of judgment: Mal operation due to inattention by the

operation engineer.

Physical Factors:- 5-1 Inadequate guards or protective devices: Absence of inter-locking system. 5-5 Inadequate warning systems: GOD name plates not in right position. 8-5 Inadequate work place layout: Operating handles of both line side GOD and ground

GOD are mounted close to each other.

System Factors:- 8-5 Inadequate implementation of MOC (Management of Change): No written authorization

/ documentation maintained for removing / by-passing interlocking system. 14-3 Inadequate implementation of PSP (Policies / Standards / Procedures):

a. Improper management / identification of pad lock keys. b. SOP check list not used for the operation.

11-6 Inadequate / inconsistent audit / inspection system which has failed to point: a. Absence of castle key interlock system b. Improper position of sign boards c. Inadequate key management process

10-2 Inadequate standards, specifications, and / or design criteria: a. Both operating handles of Line Side GOD & Bus GOD are placed very close to each

other which can sometimes lead to wrong operation. b. Name plates of the GOD‟s not in right position.

Recommendations: 1. EMD to restore all the bypassed castle key interlocks of the GODs. 2. As an interim arrangement Proper alignment of GOD handles is to be done for securely

fixing padlocks. 3. As 22 KV switchyard equipments are very old, GIS project to be implemented on fast track. 4. Procurement of PPEs with suitable rating for electrical insulations such as electrically

insulated shoes and hand gloves. 5. Unified SCADA, FDR system to be commissioned. Back up annunciations for “”SF6

pressure Lo‟‟ for 22 KV breakers to be provided on annunciation panel for facilitating quick response and avoiding unnecessary tripping to consumer.

6. All 110 KV and 22 KV Ground GOD operating handle to be painted with RED color for ease in identification.

7. Non opening of N-S tie breaker during such heavy fault to be investigated for its appropriate relay settings (fault level control scheme).

8. All GODs should be locked with padlock & keys with proper tags to be kept on control room LOTO board.

9. Work Instruction checklist to be followed. It should be filled & signed by Senior and Junior Operation Engineers. Periodic audits of filled checklists to be done by MO.

10. Every six months, Refresher training (covering important operations and safety hazards involved) to be given to all personnel involved in switchyard operation.

11. Prior discussion about the operations to be carried out should be held amongst operation engineers and shift attendant, before going to switchyard.

12. Nameplates to be placed at front side of GOD operating handle. 13. Numerical relays for Transfer breaker recommended.

14. Grounding system of Ground GODs to be checked once in six months. 15. BPCL & HPCL end protection details to be studied for protection coordination. 16. Management of change documents to be maintained for all changes in the equipment. 17. Strengthen the audit system covering management of keys, use of check lists, safety

tagging etc. Click here for complete report

3. Mock drills-Jul’13

Mock drills were conducted in wind sites following scenarious were considered ‘Panel fire with

Injury’, ‘Road Accident’,& ‘Heavy Rain-Natural Calamities’. Regular conduct of mock drills

improves our preparedness to emergency situations

4. Corporate Safety Highlights Jul’13

Comprehensive BSC 5 Star Safety Management System Audit in the following divisions,

a. Power House # 6 b. Jojobera

Carried out comprehensive Fire Audits at Maithon, Haldia & Jojobera

Conducted training on SURAKSHA & Annual Safety Plan at Services Division (MEPL,

Nellore), Behavior Based Safety (BBS) to SED & Tata Power Solar Team at Bangalore and

imparted training on Disaster Management Plan for Operation Dept at Trombay

Prepared Safe procedure to be followed during loading and unloading of heavy equipment

and materials and forwarded to CSM sub-committee Chairman for incorporating in CSM

procedure.

Participated in Tata Project‟s Annual Safety Meet.

5. Safety training – Jul’13

Specialized Training on CPR and Life Saving

Procedure was conducted for 45 own and

contractor employees at Haldia

Training and awareness session on Industrial

Hygiene and Occupational Health was

conducted for 24 employees at Haldia

Apart from “Basic safety & IMS awareness training”, Confined space training, working at height

trainings for contractors. Health related training, defensive driving, first aid fire fighting, LOTO,

working at heights trainings were conducted to own employees

At Wind sites, sessions were conducted on „First Aid & Basic Life Support’, ‘Working at

Height’, ‘Working at HT yard’, ‘Safe operation of Power tools and hand tools’ for increasing

the competency and capability of employees & contractors

Training on Behavior Based Safety (BBS) was conducted to SED & Tata Power Solar Team,

SURAKSHA & Annual Safety Plan at Services Division for MEPL, Nellore, and Disaster

Management Plan for Operation Dept at Trombay

6. Root Cause Analysis (RCA) of incidents – Jul’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%

Aug'12

383

Sep'12

393

Oct'12

344

Nov'12

294

Dec'12

323

Jan'13

361

Feb'13

416

Mar'13

639

Apr'13

332

May'13

251

Jun'13

203

Jul'13

336

Cau

ses

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%

Aug'12

205

Sep'12

236

Oct'12

186

Nov'12

148

Dec'12

178

Jan'13

193

Feb'13

234

Mar'13

285

Apr'13

147

May'13

139

Jun'13

129

Jul'13

186

Cau

ses

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

Aug'12

261

Sep'12

260

Oct'12

287

Nov'12

192

Dec'12

234

Jan'13

316

Feb'13

369

Mar'13

422

Apr'13

201

May'13

170

Jun'13

97

Jul'13

165

Ca

us

es

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(consistently less

Total no. of causes

7. Security Highlights

I. Trombay

02 Jul 13 - Security Officers monthly meeting for security review held at security conference room. Col. PBD, GMG, CGK, PSB, VRK & VYR were present in the meeting.

06 Jul13 - A mock drill on bomb hoax Tele call was conducted at 1630 hrs at coal jetty by PFSO & Security Staff.

07 Jul13 – A parade drill for security guards of Maharashtra Guard Board was carried out at Fuel Area Station – A.

17 Jul13 – IMS Audit of security by Capt. P K Jindal & Mr. Sengupta from IRQS was conducted at security complex.

18 Jul 13 – R & R Certificate was issued to Head Guard Y B Adhikari for his keen alertness on duty by detecting knife in the bag of contract staff while on duty at Material gate.

27 Jul 13 – Security training was conducted for security personnel at coal jetty from 1430hrs to 1530hrs for awareness & knowledge sharing.

24 Jul 13 – Monsoon Raincoats were donated as a CR activity under Headship of Head – Trombay to the police staff DCP Zone VI Office and R C F Police Station, Chembur, Mumbai.

30 Jul. 13 – A training session on SAP PM Module was conducted by Mr. Mahesh Gharat of CHP Dept. for all security officers at security complex conference room.

31 Jul 13 – Video Conferencing by ED (O) & CHRO across Tata power for security officers on Security held at conference room no.02 at STN-B from 1200 hrs to 1300 hrs. All security officers were present during video conferencing.

31 Jul 13 - Fortnightly security review meeting by Head – Trombay was held at security conference room and duly attended by Mr. PLM, Col. Dalvi, GMG, VSD, VYR &CGK were present.

II. CGPL

09/10.07.2013: Tata Power MD Sh. Anil Sardana along with Board of Directors Sh. Nawshir Mirza, Sh. S. Ramakrishnan, & Mr.Chandan Roy reached at CGPL site. Team Security & Admin escort him from Bhuj airport to CGPL site. Later they took part in a Meeting with CEO & ED K.K. Sharma and Head O&M Mr. Sharad Baijal & all HOD‟s. On 2nd day the VIP‟s visited CGPL Main gate (as inaugurated on 21st Jun‟13 & a customized Visitors Management System (VMS) software was also installed at the gate), warehouse, ICHS Coal stock pile, Project Office and township. Complete visit was coordinated by the security team from receiving the VIP‟s at the Bhuj airport to escorting their motorcade to site and Ashiyana Township and then returned back to Bhuj. Team Security adequately deployed sec. manpower and also coordinated the traffic in & outside the company during the visit.

12.07.2013: A delegation of Pakistani Visitor‟s Mr. Usman Ahmad, Mr. S Farreesrh, Mr., Awais Ul Rehman, Mr. R B Myus and Mr. Syed Nisar Ul Haq arrived at CGPL site and met site leadership team. The movement was thoroughly coordinated by Security and intelligence agencies.

25.07.2013: 05 Media persons including Mr. PB Jaykumar journalist business world, Mr. Subash Narayan journalist financial Express ,Ms. Anjali Berry , Account manager Edelman & Ms. Sahana Choudhary, Account manager Edelman Visited CGPL Site as a purpose of visit related show case Mundra UMPP. They Visited project office, Main Plant, west port, Main control room and Gaushala. Necessary security arrangements were made.

29.07.2013: At 1148 hrs, CISF Commandant arrived at CGPL project office. Later they took part in a meeting held at project office with CMS Capt. VK Dogra (Retd) & also visited main plant area.

26.07.2013: At 1634 hrs a mock drill being a scenario of fire broke out at CGPL Store at yard no.04 was conducted to check out the emergency preparation of fire, Medical and Security team. Mock drill was initialed at 1634 hrs and all clear action was given by incident controller at 1643 hrs. SCR Informed to all concerned.

A training related to “Visitors/Contractor Labour Management” was conducted at CGPL Main gate. The program was conducted by the technicians Mr. Sunny in which training regarding Visitor‟s & Contractors Gate Pass was given to security staff members. 05 security personnel including and 01 SO took part in it.

In-between 1730 hrs to 1830 hrs, a training related to “Security Guards Duties” was conducted at Labor Colony Recreation room. The program was conducted by the Mr. Prabhu Nath from Headquarter Surat (Gujarat) in which training regarding Security duties was given to security staff members. A total no‟s of 18 security personnel including and 02 SO took part in it. In-between 1730 hrs to 1830 hrs, a training related to “Security Guards Duties” was conducted at Labor Colony Recreation room. The program was conducted by the Mr. Prabhu Nath from Headquarter Surat (Gujarat) in which training regarding Security duties was given to security staff members. A total no‟s of 18 security personnel including and 02 SO took part in it.

10.07.2013: Open house/DARBAAR was carried out at Labour Colony. The DARBAR was chaired by CMS Capt. VK Dogra (Retd.) from CGPL security. The program was attended by 56 security personnel.

19/21.07.2013: A Labour Head Count Exercise (LHC) was scheduled wherein all the access locations like Main gate, Hostel gate, Tunda end wicket gate, Labor colony were covered for the exact manpower strength. A total strength of 1693 labors (Main gate-910, Hostel gate-120 and Tunda Wicket Gate-60 & LT gate-603) was physically checked by Security Team. Entry of the contract manpower without proper entry permit was restricted and the concern contractors were directed for the compliance.

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 77 Debit Notes were raised in the month of Jul‟13. Out of which 51 Debit Notes were raised against Breach of Traffic safety and 25 for Breach of Security. Consolidated summary of the debit notes raised in the past month is available on demand.

Weekly Security co-ordination meeting was held 03 times during this month at CGPL SCR conference room. Meeting was chaired by CMS Capt. VK Dogra (Retd) and joined by all security officers. Security related matters were discussed and the weekly plan was formulated among all members during the visit.

III. Jojobera

Training activities - Security awareness sessions were given to 143 contract workmen during the safety training by the security department officers to make the contractors workmen aware of the Do's and Don‟ts in respect to security, while working inside the Plant area. Training to 22 security personnel of GURU Security Force was given on Access control.

Blood donation camp inside the plant on 10th July 2013.

Security Meetings- Group Head Security (Mr Sunil Kumar) attended meeting with DC, City SP, and other Police Officers on 26/07/2013. He also met DCIO IB Mr M Mallik on 09/07/13.

IV. MPL

Appreciation from MD & CEO – MPL to Mr. Abhisek Singh & Mr. Hari Singh for ensuring the timely & safe transportation of GT equipment.

CEO – MPL

“Dear Abhishek, Harishankar,

Please accept my heartfelt thanks for the commendable job done by both of you in ensuring the timely and safe transportation of the GT overcoming & efficiently resolving all the hurdles and issues on the way. Keep up the good work... we are proud of you!!

Please also find attached below the recognition from Chairman MPL in this regard which, I believe is one of the most valuable achievements for you!!”

MD – The Tata Power Company Limited

“Good Bhaskar.....lets now do a clock work for its erection and commissioning.

It is with blessings of GOD and hard work of all of you, duly supported by two of our young colleagues & scores of associates that the GT has reached site.

Please convey my personal gratitude to both Abhishek and Harishankar for their contribution.”

First Aid Fire Fighting Training & Mock Drill

A Fire Mock drill was conducted in CHP at Stacker Re-claimer area to check the emergency drill, efficiency and preparedness of Fire crew of IFSS deployed at site. The aim of the mock drill was also to check preparedness of the Fixed Fire installations such as Monitor, spray System, Hydrant system etc. A control fire was created in waste material in a drum in CHP area. On duty SO Sunil Kumar Singh during the round at CHP area noticed the smoke & flame and alarmed security control room by Motorola walkie-talkie. Security control room passed over the information to Fire station, Ops Control room, Ambulance, QRT, CPS, HOD/Fire and all concerned as per SOP. The Fire crew reached in CHP area with Fire tender along with all equipments extinguished the fire. Security staff cordoned off the affected area, stopped the coal Hywa movement and assisted the fire team.

SURPRISE CHECKING OF PASS/ VEHICLE Special drive for checking of Hyvas was carried out randomly under the supervision of SO Sunil Singh along with security personnel at Approach road gate from 1430 hrs to 1600 hrs on July 26, 2013. Hyvas were examined for alcohol detection, inspection of driving license, checking of tarpaulin cover & wrong side parking, over speeding, not using of sit belt, discrepancies in challan etc. Vehicles found unsatisfactory & defaulter for uncovered coal load / environmental concern & other offences were panelized. The Security personnel of G4S and BSS actively participated in the said drive.

REWARD & RECOGNITION A special R & R session was organized by MPL / HR on 13-07-13 in which Station Head Mr

Sabyasachi Mukherjee appreciated Fire team for controlling and extinguishing the fire of GT

1 / R very effectively in a very short period of 71 mnts on 06-07-13. He also appreciated

security team, Civil team and Environment team for their active support, in his speech.

Station Head / Maithon Station awarded all 12 personnel of Fire, 16 security personnel of

BSS & G4S Security and officers of MPL Security & Fire Mr Dilip Singh, R.K.Rai, Sunil

Singh, P.S.Chauhan including the officers of Civil and Environment for their excellent

contribution during the fire fighting operation. Assemble crowd was also addressed by Head

/SHE, Head /HR and Head / Security & Fire. R&R by Station Head, Head SHE & Head HR

to Mr P.S.Chauhan, Sunil Singh, R.K. Rai & Dilip Singh

e

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