Industrial Safety Practices at NTPC

9th Odisha State Safety Conclave-2018

Shivam NTPC 1

P K Sinha

ED-SAE

Shivam Srivastava

GM-Safety & Envt

NTPC Limited

Pathway

• About NTPC

• CMD’s view

• Why Industrial Safety is Important

• NTPC Safety Policy

• Major hazards in Power Station

• Safety at NTPC Projects

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About NTPC

• 52.9 GW company with 21 coal based, 7 gas based stations, 1 Hydro based station and 1 Wind based station 9 Joint Venture stations arebased station and 1 Wind based station. 9 Joint Venture stations are coal based and 11 Solar PV projects.

• capacity will have a diversified fuel mix and by 2032, non fossil fuel based generation capacity shall make up nearly 30% of NTPC’s portfolio.portfolio.

• Capacity in pipe line : 18 GW

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About NTPC

• Ranked 1st among “Independent Power Producer and EnergyTraders” category by S&P Global Platt “Top 250 Global EnergyCompany Ranking-2018.

• Ranked 512th in the “2018, Forbes Global 2000” ranking of the World’s biggest companies.

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• British safety sword, Greentech Safety Awards, Kalinga Safety Awards etc. etc.

• Safety is our 1st priority. This is to be internalized and demonstrated through our systems and actions…. Safe behaviour should be a part of our culture Be it at home work place or while on the goour culture- Be it at home, work place or while on the go.

• Responsibility of creating safe workplace for ourselves and for all our stakeholders is on us.

CMD NTPC

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NTPC Core values

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Industrial Safety - A Pillar of Sustainability

• Safety is at the core of “Sustainability” with a mission to protect People, Planet and Profit.

• Sustainability really comes down to three principles:

• “Doing no harm” starts with the people closest to the business; no organization can credibly

claim sustainability while continuing to have life-altering injuries and fatalities or

environmental incidents

• “Leaving no footprint” helps leaders address product life cycle issues and the means by whichg p p p y y

products are made and delivered

• “Doing some good” represents the fundamental value an organization adds, which may go

beyond basic products and services.

Why Industrial Safety is important

• Loss of life

• Loss of production time

• 20-80 theory

• Legal Costs

• Low morale and erosion of Brand Image

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From Should to Ground Action

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Intent of NTPC Safety Policy

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“All Accidents Are Preventable”

Therefore, safety must be at the forefront of

all activities

Six Principles of NTPC safety Policy

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.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.

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

6. Compliance to all applicable safety regulations and other legal

requirements at the minimum.

Shivam NTPC

Major Hazard Potentials in Power Stations / Projects

Fire and Explosion Hazards:

• Hydrogen Plant and Storage areay g g

• Boiler / TG

• Fuel oil Storage

• Transformers and Switch Gears

• Coal handling

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Major Hazard Potentials in Power Stations / Projects

Chemical Hazards:

• Chlorine storage and handling

• Sulfuric Acid storage and Handling

• Hydrochloric Acid storage and Handling

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Segregation of Layers of Safety

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Question Yourself before start of job

Copyright © 2016 Your Company All Rights Reserved. 15

Safety at NTPC

(A) At Engineering Stage

(B) At Execution stage

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At Engineering Stage

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Process Safety at Engineering stage

• HEZOP (Hazard and Operability Study)( pe ty tudy)

• LOPA (Layer Of Protection Analysis)

• SIL (Safety Integrity Level)

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• SIS / SIF

Safety standards

Machinery sectorMedical sector

IEC

IEC61508 Nuclear sector

IEC61513

IEC62061

Process sector. . . . . . sector

IEC61511

IEC 61508 is an international standard published by the

International Electrotechnical Commission of rules applied

in industry.Shivam NTPC 19

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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Engineering Specification for Safety

EN 50156-1:2015 :

Electrical equipment for furnaces and ancillary equipment. Requirements for li ti d i d i t ll tiapplication design and installation

EN 50178 :

Electronic equipment for use in power installations.

NFPA-85

Contributes to operating safety and prevents explosions and implosions in boilers

IS-3034

Fire safety of Industrial BuildingsShivam NTPC 21

At Execution Stage

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Safety at Execution Stage

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

• JSA

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Nurturing Safety Culture and inculcating safety behavior

A Measurement Monitoring and Analysis of Safety IndicatorsA. Measurement, Monitoring and Analysis of Safety Indicators

B. Creating Safety ambiance

C. Emergency preparedness

D. Blending latest Technology with ground action

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Measurement, Monitoring Analysis of Safety Indicators

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Measurement, Monitoring and Analysis of Safety Indicators

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Click to edit Master title styleMeasurement, Monitoring and Analysis of Safety Indicators

Date- Daily Monthly

Reported Target Cumulative

Safety Deviations 10 50 200

Proactive Indicators (Lead Indicators)

Severe Event

Safety Deviations 10 50 200

Near Miss

SZLO

SOV

Pep Talk / TBT

Date- Daily Monthly

Reported Target ( < --) Cumulative (< --)

Reactive Indicators (Lag Indicators)

Reactive

Approach

Costly Events

Lost time Injury

(Reportable)

Lost time Injury

(Non Reportable)

First AidSome Cost

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p g ( ) ( )

First Aid

Non-Reportable

Reportable

Serious injury / Fatality

Fire Incident

Some Cost

Pro Active approach

Near Miss

Free eventsSafety Deviations

Analysis and Sharing of safety indicators

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Analysis and Sharing safety indicators

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Three tier Capacity Building Programme

Tier-1 CMD, Directors, REDs One hour appreciation Programme with a refresher at

every three monthsevery three months

Tire-2 REDs, EDs, HOPs, GMs Safety session in MCM

Tire-3 AGMs and below • Classroom training once in three months

• On line training programme with assessment.

Frequency-Once in three months.

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Capacity Building of Associate Worker :

Safety induction programme, High Risks activities training, Job Specific Training.

Done through External Experts, Line managers, OEMs etc.

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Creating Safety Ambience

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Safety Ambience

• Safety Parksy

• Safety Kiosks

• Safety Zones

• Safety Boards for “Good Safety Citizens”

• Awards and Rewards

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Emergency Preparedness

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Emergency Preparedness

• Fire fighting training of Employees, Associates, House makers

M thl Fi fi hti t h lthi h ki (CISF/NTPC)• Monthly Fire fighting system healthiness checking (CISF/NTPC)

• Mutual aid scheme (Anta-Chambal Fartilizer, Auriya-GAIL / T Kaniha - NALCO)

• Approved Disaster Management Plan

• Mock Drills

• Fire fighting training to Employees, Associates, House makers, School childrenShivam NTPC 37

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Fire Fighting training at Schools

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Emergency Preparedness

Mock Drills:

• As per Factory Act (Once in six months)

• Fire mock drill (CISF) (Once in 15 days) and online system checking

• Mock Drills in association with NDRF and Factory Authorities

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Mock Drill with NDRF

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Mock Drill in presence of Director of Factories

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Further Smart Initiatives • Programmes like “Voice of Victim” and “Catch them Young”

• Intense monthly Safety programmes at sites

• Monitoring of Safety deviation through High resolution Cameras at “Safety Centers”

U f l t t S ftw f I ide nd f ty de i ti l i nd nit i• Use of latest Software for Incidence and safety deviation analysis and monitoring

• Pilot project on safety using IOT

• Project with “Virtual Reality” at PMI Shivam NTPC 43

T LiTop Line

Bottom Line

Safety

Production Targets

Personal targets

Ball of safety is made up of Glass and

Rest all balls are made up of rubber.

If l ft ll b b k B tIf left, all can bounce back But…..

Ball of Safety Can’t

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Someone is waiting for you at Home

fYour safety is more important

Thank YouThank YouShivam NTPC 45

What is Safety ??

• Safety is not absence of accidents

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

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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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