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APROJECT REPORTONEVOLUTION OF SAFETY AND HEALTH STATUS IN NUCLEAR POWER PLANT Carried out for Partial fulfillmentOFADVANCE DIPLOMA IN INDUSTRIAL SAFETYCarried out atRAJASTHAN ATOMIC POWER PLANT2006 - 2007UNDER ELECTIVE PAPER VIII(SAFETY IN CONSTRUCTION INDUSTRY)SUBMITTED BYSANDEEP SURANACONDUCTED BYCENTRAL LABOUR INSTITUTE,GOVERNMENT OF INDIA,MINISTRY OF LABOURSION, MUMBAI 400022.CERTIFICATE

This is to certify that MR.SANDEEP SURANA , a student of Advance Diploma in Industrial Safety (2006-2007) being conducted by Central Labour Institute ,Govt. of India, Ministry of labour, Sion, Mumbai, has prepared his project report on EVOLUTION OF SAFETY AND HEALTH STATUS IN NUCLEAR POWER PLANT , at Rawatbhata , (via) Kota, Rajasthan, under my guidance. The work is under the elective Subject Safety in Construction Industry.(A.K. BHATTACHARYA)

Dy.DIRECTOR I/C (SAFETY DIVN.) ANDPRINCIPAL, CLI, SION MUMBAI

MUMBAI:

DATE

:

I acknowledge my whole hearted thanks to Shri C.P.Jhamb, Site Director RAPP for providing me an opportunity to improve my knowledge in the field of safety mainly in Nuclear Power plant Construction through project work at RAPP site.I am highly grateful to Shri P.K Sharda, (C.S) & Shri V.K Jain, (O.S), and Industrial safety section of RAPP site for their valuable support and co-operation.

I am extremely thankful to Shri A.K. BHATTACHARYA, Dy.Director In - charge, Central Labour Institute, Mumbai for their most valuable guidance & co-operation extended to me in carrying out this project work & grateful to them for giving me his valuable time & knowledge from their expertise.

Finally I extend my thanks for the co-operation given to me by all section heads, dept. heads, engineers, supervisors, workers and other employees for RAPP while carrying out field work, observation & other information provided and are related to this project work.

I would be failing in my duties if I would not be grateful to all the officers and staff of the Central Labour Institute, who proved as a source of information and inspiration to me while carrying out my project work.

Mumbai :

Date :

SANDEEP SURANASUBMISSION

I SANDEEP SURANA , a student of Central Labour Institute , for the course Advance Diploma In Industrial Safety during the year 2006 2007 , humbly submit that , I have completed , from time to time , project work as described in this report and study from 23rd October, 2006 to 22nd December, 2006.This report, I have prepared by my own skill and have not copied anywhere as per instructions and guidance of Shri. A.K. Bhattachaya, Dy. Director I/C .Principal, Central Labour Institute, Sion, Mumbai.

I have not copied the report or its appreciable part from any other literature in contravention with academic ethics.

Mumbai :

Date :

SANDEEP SURANAINTERNAL EXAMINER EXTERNAL EXAMINERPREFACEThis project report has been prepared in partial fulfillment of the requirement of the Advance Diploma in Industrial Safety conducted by CLI ,Sion , Mumbai 400 022.The topic of the project report Evolution of Safety and Health Status in Nuclear Power Plant at Rajasthan Site.Accident Data has been collected from the RAPP-5&6 site for past 3 years and study work carried out as per guidelines proved by Central Labour Institute, Sion, Mumbai 400 022.After all the detailed analysis an attempt is made to suggest ways and means for improvement in safety status of nuclear construction site.Observations noted down accordingly recommendations are given/suggested to follow safe system of work to reduce accidents in future with a thought.

ZERO ACCIDENTS, BELIEVE IT, ACHIEVE ITINDEXCHAPTERCONTENTSPAGE NOS.

1INTRODUCTION1-4

2OBJECTIVES & METHODOLOGY5-7

3ABOUT THE RAPP-5&6 SITE 8-11

4ACCIDENT DATA COLLECTION, ANALYSIS AND CASE STUDIES12-48

5SAFETY MANAGEMENT SYSTEMS49-133

5.1HAZARD IDENTIFICATION49-54

5.2DISCUSSION ON GENERAL ASPECTS RELATED TO NUCLEAR SAFETY .55-67

5.3SECTIONAL PROCEDURES68-77

5.4DUTIES AND RESPONSIBILITES OF VARIOUS FUNCTIONARIES.78-89

5.5APPLICATION OF ACTS/RULES FOR SAFETY .90-114

5.6EMERGENCY PREPAREDNESS AND PROCEDURES115-133

6FINDINGS AND RECOMMENDATIONS134-151

7REFERENCES152

8ANNEXURES153-157

CHAPTER - 1

INTRODUCTION

Industrial development is the indicator of growth and prosperity on any country with the rapid technological development, potential hazard arising from various dangerous operations carried out in these industries is also increased hence the number of major accident have also occurred and have had a major impact on surrounding communities.

Safety guidelines are basically a management tool to have an effectiveness of the safety program on a periodical basis, this is an useful technique for industrial management where by they can obtain a systematic appraisal of the effectiveness of safety management system.

Study of Evolution of Safety and Health Status in Nuclear Power Plant is carried out at Rajasthan Site , as Project work for partial fulfillment of Advance Diploma in Industrial Safety for the year 2006- 2007 being done at Central Labour Institute, Sion (Mumbai).

I hope that it will be found useful by the management, employees & contractors to establish and develop a good Safety, Health & Environment programme to achieve ultimate goal of production with 100 % Safety and clean Environment.

I am thankful to Shri A.K. Bhattacharya (Dy.Director/Principal) Central Labour Institute Mumbai, under whose guidance it is possible to bring out the project report and also I, wish to thank industrial safety section and management of RAPP Site, for their valuable support and cooperation.

I want to dedicate this project work to poor worker who is directly exposed to hazards and in the absence of work force especially in India, it would not be possible to achieve remarkable industrial development of the country.

SCOPE

Although the scope of Safety Management in Nuclear Power Plant Construction is very wide. To concentrate on specific topics with in this project, following topics were selected.

(A)Management Aspects.

Following elements were selected under this headings.

1Health & Safety Policy.

2Safety & Health Organization.

3Accident Reporting, Investigation And Analysis.

4Safety Inspection.

5Safety Education and Training.

6First Aid.

7Occupational Health Centre.

8General working condition.

9Hazard Identification and Control.

(B)

Technical aspects

Under this heading following elements were selected.

1Safe operating Procedures.

2Work permit system.

3Personal protective equipment.

4Fire protection.

5Emergency Preparedness.

6Lifting Machines & Tackle.

7Mobile Equipment and Vehicular traffic.

8Access.

9On site Gas Cylinder Storage area.

SAFETY POLICY OF RAPP 5&6

a)The safety policy of Rajasthan Atomic Power Project- 5&6 is an expression of the firm commitment of the management and the employees of RAPP 5-6 towards safety in all respects.

b)The management of RAPP 5-6 has moral, social and legal obligation to proven hazards which may lead to injuries or Occupational diseases to the personal working at this site and impart training and knowledge about safe working practices.

c)The management of RAPP -5-6 firmly believes in the motto Production must but safety first. The management considers it as its responsibility to ensure that high standards for safety are maintained within the plant as well as in the surrounding areas.

d)There shall be a well-defined safety organization with well-defined powers. Safety section shall advise and assist the management in prevention of personal injuries and maintaining a safe working environment.

e)Section heads and section in charge shall be responsible for maintaining safe working conditions and practices in their areas of jurisdiction.

f)Engineers and supervisors shall ensure that all workers, including the workers of the contractors, working under them are provide safe working environment, shall adhere to safe working practices and use necessary personal protective equipment while working.

g)All the employees of RAPP 5-6 shall make their sincere contribution for the cause of their safety of their fellow employees. It is their responsibility to work safely and set examples for others to follow.

h)The contractor / sub contractors shall be responsible for the safety of their employees.

SAFETY GOAL

Zero accident and zero injury through safe habits and safe environment.

The management and employees of RAPP 5-6 are firmly committed towards achieving this goal.

Project Management of Rajasthan Atomic Power Project- 5&6, has moral, social and legal obligation to prevent hazards to create safe working environment and guard against all possible hazards and risks. Management of RAPP 5&6 is committed to achieve its ultimate goal PROGRESS WITH SAFETY by adopting and promulgating the safety policy as described below.

ABOUT NPCIL

Nuclear Power Corporation of India Limited (NPCIL) is a public sector enterprise, wholly owned by the Government of India, under the administrative control of the Department of Atomic Energy (DAE). It has been registered in September 1987 as a Public Limited Company under the Companies Act 1956, with the objective of undertaking the design, construction, operation and maintenance of the nuclear power stations for the generation of the electricity in the pursuance of the schemes and programmers of the government of India under the provisions of the Atomic energy act.NPCILS MISSION

The mission of NPCIL is to develop nuclear power technology and to produce, to develop nuclear power technology and to produce nuclear power as a safe environmentally Benin and economically viable source of electrical energy to meet the increasing electricity needs of the country. Present nuclear power capacity of NPCIL is 3690 Mwe. With the projects under construction at Kaiga 3-4 (2x220Mwe), Kudankulam 1-2(2x1000Mwe) and RAPP5-6 (2x220Mwe), a total nuclear power capacity of 6570 Mwe is planned to be achieved by December 2008 progressively.

CHAPTER - 2

OBJECTIVES & METHODOLOGY

Details of methodology adopted for carrying out the project study in principles of safety in nuclear construction at Rajasthan Atomic Power Project-5&6 are given below.

1. Applicable codes of standards, regulatory requirements and all safe operating procedures were studied.

2. Collected the following information and evaluated with the applicable codes of standards and regulatory requirements.

(A)Safety policy and Safety manual.(B)Safe operating Procedures. (C) Emergency Preparedness Plan.

(D) Fire emergency plan.

3.Collected the following data.(A)Brief description of the accidents in the past three years.

(B) Accident statistics analysis of last three years.

(C) Details of medical examination of all employees.

(D)Record of testing and examination of all lifting machines and lifting tackles.

(E) Details of various training programmes being conducted.

(F) Details of various safety promotional activities like National safety day celebration, safety competition etc.

4. Studied all the minutes of meeting of Apex safety committee, safety fire protection committee meeting, and sectional safety committee meeting.

5. Through inspection of the project was conducted to verify and supplement the details on physical project conditions, work procedure followed by the workers and identification of hazards.

OBJECTIVES:

To assess compliance of regulatory requirement and to identify deviations from laid down procedures and standards.

To critically evaluate the effectiveness of the safety managements programmes.

To identify the fire, safety and health hazard and evaluate the effectiveness of the procedures for controlling them.

To find out the deficiencies and efficiencies of the present work cultures, procedures, practices and management system towards safety.

To recommend the various safety measures to be taken to improve the overall safety performance of the project.

BASIC SAFETY PRINCIPLES AND OBJECTIVES:DAE SAFETY PRINCIPLES/GUIDELINES:

Safety principles of DAE has been guided by the following statement by Dr. Bhabha, which was in relation to radiation safety: Radioactive materials and sources of radiations should be handled in the Atomic Energy Establishments, in a manner which not only ensures that no harm can come to workers in the establishment or any one else; but also in an exemplary manner, so as to set a standard which other organizations in the country may be asked to emulate.

Similarly DAE industrial safety principles, policies, programmes and practices shall be such as to be worth emulating by others.

The management of Rajasthan Atomic Power Project 5& 6 by adhering to the DAE guidelines and other statutory requirements shall provide a safe working environment for all those who enter or work in RAPP 5&6 and will contribute to the health and welfare of its employees, through the programmes of industrial safety.

RAPP 5& 6 SAFETY PRINCIPLES:

It is recognized that any industrial activity involves potential hazard, but has firm belief that with appropriate action all personal injuries can be avoided.

It is essential to train every employee so that;

i)He works safely

ii)He understands that it is to his advantage to work safely.

He must co-operate in working safely and behave in disciplined manner.

It is feasible to limit the property losses due to fire through its preventive measures.

Safety audits and inspections shall form an important part in RAPP 5&6 safety programmes.

Comply with the provisions of central and state legislations, regulations, and rules laid down by AERB and other statutory bodies.

SAFETY OBJECTIVES:

From the ideals set for the safety standards by Dr. Homi Bhabha guidelines provided by the industrial health and safety policy of NPC. The RAPP 5& 6 management sets the following

Objectives for its safety policy.

Identification and elimination of risks before personal injury incidents and losses occur.

Application of systematic safety training programmes to improve both managerial and employees competence and safety consciousness.

Reduction of incidents which may result in injury, damage to machines, plant and materials etc.

Consideration of safety matters in all activities so as to ensure safe working conditions.

Comply with legal requirements of Central and State Governments, AERB, Directorate of Health & Safety Group and other statutory bodies.

SAFETY AUDIT:

RAPP 5&6 management has firm belief that safety audit is essential and important tool to ensure that entire RAPP 5-6 organization is in good shape.

Internal audits are carried out by internal audit team headed by CE (Mech) of RAPP 5&6. External audits are carried out by NPC Head quarter- Industrial Safety Group and by AERB Inspectors.

CHAPTER 3

ABOUT THE RAJASTHAN ATOMIC POWER PROJECT -5&6 SITE.Rajasthan Atomic Power Project unit 5&6 is situated at Rawatbhata, which is 70 km from Kota (Distt. Chittoregarh). It is situated on the bank of river Chambal near Rana Pratap Sagar Dam. It is third Nuclear Power Project of Twin Units of 220 Mwe capacity at rawatbhata.It is eighth nuclear project in India.Rawatbhata is a nuclear city of 6 units of nuclear power and a Heavy Water plant. Electricity from the project will be distributed to rajasthan, U.P., Delhi, Haryana, Madhya Pradesh, Chandigarh, J&K, (Northern Grid).

Natural Uranium (U238) is being used as fuel. Heavy water is being used as a moderator and coolant. It is ideal site for the construction and operation of nuclear projects because of its rocky soil, low density of population and availability of resources. It is situated on the valley of Aravali hills.

Plant Layout :-

The main plant buildings are accommodated in approx 6000 m2 area (300 m x 200 m). Main plant building consists of two reactor buildings of 49 M out side diameter situated at 83 M center to center distance. for each Reactor unit, Reactor Auxiliary Building (including Emergency Control Room), Turbine Building, Diesel Generator Building, Induced Draft Cooling Tower and Natural Draft Cooling tower have been provided on a unitized basis where as the other building / structures such as Spent Fuel Building, Service Building Annex, Control Building, Stack, Stack Monitoring Room, Fire Water Pump Hose, Condenser Cooling Water Pump House, D2O Evaporation & Clean up Buildings, D2O Upgrading Plant and Switch Yard are common to the two units.

Power Generation Process :-

The Reactor is of pressurized heavy water type using heavy water moderator, heavy water coolant and natural uranium dioxide as fuel. The heat generated in the reactor core is removed by heavy water coolant, recirculated through the core. The coolant passes around the fuel elements and temperature is raised from 240 0 C at a pressure of 87 Kg / cm2 to 293 0 C.

The coolant from the reactor channels flows to a common header known as reactor outlet header the hot coolant is then carried from the out let header to steam generators. The heat energy from hot coolant (pressurized heavy water) is transferred to light water in four steam generators to produce steam and the steam is than directed to turbine via combined isolating and emergency stop (CIES) and governor valves.

A maximum flow of 1330 Te/ hr of saturated steam with 0.26 % moisture content from the steam generator to the HP Turbine is delivered at a pressure of 39.297 Kg / cm2 (g) and a temperature of 249.66 0 C .

The HP Turbine consisting of 5 impulse stages. Steam after expanding through HP Turbine is taken to Moisture Separator Reheater (MSR) at a pressure of 4.933 kg/cm2 (g) and a wetness of 11.0 %, where the steam is dried and reheated in two stages i.e. in bled steam reheater and live steam reheater. From MSR the steam is directed to a double flow LP Turbine through hot reheated pipes and LP Interceptor Emergency and Governor valve at a pressure of 4.631 kg/cm2 and a temperature of 232.9 0 C for further expansion, after which the steam condenses in a surface type condenser.

The generator is directly coupled to the turbine, the excitation is provided by the static Excitation System. The Hydrogen gas filled in the generator casing for cooling the rotor of the generator. The maximum out put at the turbo generator terminals is fixed at 235 Mw

Nuclear Power Corporation at present is having 3690 Mwe generating capacity, (3%) of the total power generation in India.

The above generation is from the following stations:

1. RAPS 1-2 Decommissioning under progress (Unit - 1) &

1X150 Mwe (Unit - 2).

2. RAPS 3-4 2X220Mwe.

3. NAPS 1-2 2X220Mwe.

4. MAPS 1-2 2X170Mwe.

5. KAPS 1-2 2X220Mwe.

6. KAIGA1-2 2X220Mwe.

7. TAPS 1-2 2X180Mwe.

8. TAPS 3-4 -2X540Mwe.

The following projects are under construction:

1.RAPP 5&6-2x220Mwe,at Rawatbhata (Rajasthan).

2.Kaiga3&4-2x220Mwe at Kaiga near Karwar (Karnataka state).

3.KKNPP-2x1000Mwe at Kudankulam near kanyakumari (Tamilnadu state).

The industrial safety aspect of the operating plants and construction projects are under department of Atomic Energy, which is regulated & inspected under the preview of Atomic Energy Regulatory Board.

Independent Directorate of Health and Safety Environment and public awareness exists in the headquarter of NPCIL, Whose director reports to CMD NPCIL. All project sites stations, have industrial safety organization set up. The head of IS&F directly reports to the head of the unit.

Overall Industrial safety and fire performance of NPCIL is very good and comparable to international standards.

ORGANISATION CHART OF SAFETY SECTION, RAPP-5&6 Project Director Head (IS&F) Safety Officer Safety Officer

Safety Inspector Safety Supervisor CHAPTER 4

ACCIDENT DATA COLLECTION . ANALYSIS&

CASE STUDIESAs per IS 3786 1983 lays guidelines for accident statistics and analysis, Accident Rate ,Severity Rate, Incidence Rate , are major factors , which are to be considered during accident statistics and analysis.IMPORTANT DEFINATINOS AS PER IS 3786 OF 1983

ACCIDENT: An unintended occurrence arising out of and in the course of employment of a person resulting in injury.DAYS OF DISABLEMENT (MAN-DAYS LOST): In the case of disablement of a temporary nature, the number of days on which the injured person was partially disables, In the case of death or disablement of a permanent nature whether it be partial or total disablement, man day lost means the charges in days of earning capacity lost due to such permanent disability of death. In other cases, the day on which the injury occurred or the day the injured person returned to work are not to be included or man days lost; but all intervening calendar days (including Sunday or ;days off ,or days of Plant shut down) are to be included. If after resumption of work, the person injured is again disabled for any reason arising out of the injury which caused his earlier disablement, the period of such subsequent disablement also to be included in the man days lost.MAN HOURS WORKED: The total number of employees hours worked by all employees working in the industrial premise. It includes managerial, supervisory, and professional, technical, clerical and other workers including contractors labour.

LOSS TIME ACCIDENT (LTA): is an accident, which extends beyond the day of the shift.FORMULAE USED

Frequency Rate (as per IS 3786-1983)Frequency Rate is one of the most important measures to know and judge the safety performance of the industry. Frequency Rate (F.R.) is calculated as given below.

Frequency Rate (F.R.) = Severity Rate (as per IS 3786-1983)Severity Rate is a measure to know the seriousness of the injuries. Severity Rate (S.R) is calculated as given below:

Severity Rate (S.R.) =Incidence Rate (as per IS 3786 1983)Incidence Rate is the ratio of number of injuries to the number of persons during the period under review. It is expressed as the number of injuries per 1000 persons employed. Incidence Rate (I.R.) is calculated as given below:

TABLE -1 ANALYSIS OF ACCIDENTS FOR THE YEAR - 2003S.NO.Category Avg. No. of EmployeesMan Hours Worked (in 1000)Reportable Injury Man days Lost

2003200320032003

1.Departmental Employees 1503594000114

2.Contractor Employees20997437712046108

3.Combined 22497797112056122

(Including 01 Fatal)TABLE -2 INJURY RATESS.NO.Category Frequency RateSeverity RateInjury Rate Incidence RateAvg. Days Charged

20032003200320032003

1.Departmental Employees 2.7838.950.1086.6614.00

2.Contractor Employees0.53821.220.4351.901527

3.Combined 0.64785.160.5022.221225.00

Longest Accident Free Period: 324 days (11.08.2002 to 02.07.03)

TABLE - 3 ANALYSIS OF ACCIDENT AGENCYWISE 2003S.NO.IS Code (B-1)Agency

Minor InjurySerious

InjuryTotalMan

Day Lost

2003200320032003

1.2062Machine 010145

2.2111Cranes010121

3.2421Floors01000114

4.224Electrical Installation 010142

5.213Means of Transportation 01016000

Total0104056122

TABLE - 4 ANALYSIS OF ACCIDENT TYPEWISE 2003S.NO.IS Code (B-5)Type of Accident

Minor InjurySerious

InjuryTotalMan

Day Lost

2003200320032003

1.102Fall of persons on the same level 01000114

2.124Struck by moving objects0001016000

3.13Caught in / between 010145

4.16Contact with electrical current010142

5.115Follow of objects during handing 010121

Total0104056122

TABLE - 5 ANALYSIS OF ACCIDENT LOCATION OF INJURY WISE 2003S.NO.IS Code (B-5)Location of Injury

Minor InjurySerious

InjuryTotalMan

Day Lost

2003200320032003

1.455Ankle010114

2.432Chest01016000

3.445Wrist010121

4.447Fingers010145

5.431Back00010142

Total0104056122

1.Environmental release:

Chlorine discharge to water body/day (kg)

: NA

Concentration of out fall (PPM)

: NA2.Safety Surveillance:(a)Number of work permits cleared.

: 570(b)Number of safety related deficiencies raised.

: 88(c)Number of material handing equipment Inspected and tested: 12

(d)Number of housekeeping Inspections carried out.: 06(e)Illumination survey.

: 023.Enforcement Measures.

(a)Number of persons detected, who were not using required PPEs : 91

(b)Number of defective equipment detected without safety provision: 42

(c)Number of Electrical equipment without safety provision. : 304.Fire safety and First Aid.

(a)Number of fire incidents reported.

: 00

(b)Number of fire drills conducted.

: 02(c)Number of persons trained in fire safety.

: 312(d)Number of persons trained in First-aid.

: 54(e)Number of fire safety inspections carried out.

: 065.Safety Promotion Activities.

(a)Number of new posters displayed / replaced.

: 271

(b)Number of safety competitions conducted.

: 08

(c)Number of housekeeping competitions conducted.: 01

(d)Number of safety seminars conducted.

: 02

(e)Number of video films on safety shown.

: 446.Safety Training.

(a)Number of training programme conducted.

: 1,191

(Including tool box and safety induction training)

(b)Number of persons covered.

Engineer

: 50

Supervisors

: 47

Technicians and helpers

: 17

Contractors.

: 78727.Any other information.

(a)Medical Examination.

(i)For height passes.

: 581

(ii)For occupational health.

: 201

(b)Details of Safety Audit/Internal Safety Audit.

: 038.Safety Committee Meetings.

(a)Sectional Safety Committee Meeting.

: 24

(b)Apex Safety Committee Meeting.

: 04

(c)Fire Protection Committee Meeting.

: 029.Details of Green Site Development.

: 171Nos trees

Planted10.Safety Award and Achievements.

: Nil11.Emergency Drills.

(i)Fire Emergency Drill

: 03(ii)H2S Emergency Drill.

: 02(iii)Radiation Emergency Drill

: 02TABLE - 6 ANALYSIS OF ACCIDENT FOR THE YEAR - 2004S.NO.Category Avg. No. of EmployeesMan Hours worked (in 1000)Reportable Injury Man days Lost

2004200420042004



3.Combined 379212695712056044

(Including 01 Fatal)

TABLE - 7 INJURY RATESS.NO.CategoryFrequency RateSeverity RateInjury RateIncidence Rate Avg. Days Charged

20042004200420042004


2.Contractor Employees 0.41496.80.2031.401209

3.Combined 0.39476.00.1851.321209

Longest Accident Free Period: 155 days. (04.01.2004 to 05.06.2004)TABLE - 8 ANALYSIS OF ACCIDENT AGENCYWISE 2004S.NO.IS Code (B-1)Agency

Minor InjurySerious

InjuryTotalMan

Day Lost

2004200420042004

1.2511Roof0001016000

2.2134Concrete miller 00010120

3.239Shuttering panel 00010107

4.231Explosives01000110

5.239Unloading of MS rods01000107

Total0203056044

TABLE - 9 ANALYSIS OF ACCIDENT TYPEWISE 2004S.NO.IS Code (B-5)Agency

Minor InjurySerious

InjuryTotalMan

Day Lost

2004200420042004

1.101Fall of persons from height0001016000

2.131Caught in an object00010120

3.115Fall of object during handling01000107

4.181Explosion01000110

5.133Caught between moving objects01000107

Total0302056044

TABLE - 10 ANALYSIS OF ACCIDENT LOCATIN OF INJURY WISE 2004S.NO.IS Code (B-7)Location of Injury

Minor InjurySerious

InjuryTotalMan

Day Lost

2004200420042004

1.417Head0001016000

2.449Upper limb unspecified locations00010120

3. 447Finger01000107

4.447Finger01000110

5.454Leg(lower leg)01000107

Total0302056044


Chlorine discharge to water body/day (kg.)

: NA

Concentration of out fall (PPM.)

: NASafety Promotional activity among general public: Environment day celebrated on 5th June 2004. Competition were also organized for employees.

2.Safety Surveillance:

(a)Number of work permits cleared.

: 1106

(b)Number of safety related deficiencies raised.

: 659

(c)Number of material handling equipment inspected and tested. : 119

(d)Number of housekeeping Inspections carried out. : 13

(e)Illumination survey.



(b)Number of defective equipment detected without safety provision. : 66

(c)Number of pending SRDs .

: 05

(d)Number of SRDs implemented

: 654

4.Fire safety and First Aid.


: 00

(b)Number of fire drills conducted.



: 30(e)Number of fire safety inspections carried out.

: 205.Safety Promotion Activities.

(a)Number of new posters displayed / replaced.

: 555

(b)Number of safety competitions conducted.

: 12

(c)Number of housekeeping competitions conducted.: 01


: 01



(a)Number of training programme conducted.

: 1459


Engineer

: 23

Supervisors

: 73


: 107

Contractors.






: 70


: 04


: 02TABLE - 11 ANALYSIS OF ACCIDENT FOR THE YEAR 2005

S.NO.Category Avg. No. of EmployeesMan Hours worked (in 1000)Reportable Injury Man days Lost

2005200520052005



3.Combined 4449141052570718133

*(Including 03 Fatal)

TABLE - 12 INJURY RATESS.NO.CategoryFrequency RateSeverity RateInjury RateIncidence Rate Avg. Days Charged

20052005200520052005

1.Departmental Employees0000000000

2.Contractor Employees0.531363.50.721.702590.5

3.Combined0.501285.50.641.572590.5

TABLE 13 ANALYSIS OF ACCIDENT AGENCYWISE 2005S.NO.IS Code (B-1)Agency

Minor InjurySerious

InjuryTotalMan

Day Lost

2005200520052005

1.229Others equipment not else where classified 010115

2.252Open cast mixing010122

3.2134Hydra01016000

4.229Doka shuttering 02026080

5.2214Gas cylinder 010116

6.2192Mech conveyor 01016000

Total02050718133

TABLE - 14 ANALYSIS OF ACCIDENT TYPEWISE 2005S.NO.IS Code (B-5)Type of Accident

Minor InjurySerious

InjuryTotalMan

Day Lost

2005200520052005

1.114Collapse of building walls ,scaffolds ladders , piles of goods etc. 010115

2.133Caught between moving objects (except flying or falling objects.)010122

3.123Striking against moving objects.01016000

4.114Collapse one of the solider of doka shuttering.02026080

5.115Fall of object during handling. 010116

6.101Fall of persons from height 01016000

Total02050718133

TABLE - 15 ANALYSIS OF ACCIDENT LOCATIN OF INJURY WISE 2005S.NO.IS Code (B-7)Location of Injury

Minor InjurySerious

InjuryTotalMan

Day Lost

2005200520052005

1.432Chest010115

2.446Hand 010122

3. 417Head01016000

4.432Chest

5.433Abdomen01016000

6.434Pelvis

7.42Neck

8.444Fore arm

9.432Chest010180

10.454Lower leg010116

11.411Skull brain01016000

Total02050718133


Chlorine discharge to water body/day (kg.)

: NA

Concentration of out fall (PPM.)

: NA

Safety Promotional activity among general public: Environment day celebrated

on 5th June 2005. Competition were also organized for employees2.Safety Surveillance:

(a)Number of work permits cleared.

: 703

(b)Number of safety related deficiencies raised.: 452

(c)Number of material handling equipment inspected and tested. : 348

(d)Number of housekeeping Inspections carried out.: 20

(e)Illumination survey.



(b)Number of defective equipment detected without safety provision. : 28

(c)Number of Electrical equipment without safety provision. : 28

(d)Number of pending SRDs .

: 25

(e)Number of SRDs implemented

: 3374.Fire safety and First Aid.


: 00(b)Number of fire drills conducted.



: 230(e)Number of fire safety inspections carried out.: 495.Safety Promotion Activities.

(a)Number of new posters displayed / replaced.: 190

(b)Number of safety competitions conducted.: 12

(c)Number of housekeeping competitions conducted. : 03


: 02



(a)Number of training programme conducted.: 1806


Engineer

: 125

Supervisors

: 101


: 20

Contractors.






: 79


: 04


: 02FATAL ACCIDENT INVESTIGATION DATA

Fatal Accident Report RAPP-5&6, July-2003 1. Date & time of accident : 3rd July, 2003, 0815 hrs. Place of incidence

: Turbine Building Unit-6 area Details of deceased : Shri Laxman Ray, Aged 27 years, Fitter of sub

contractor of M/s HCC 2. Details of the incident On 02/07/2003 at about 1930 hrs. a trolley loaded with reinforcement bars meant for Control Building-6 was dispatched by rebar yard. As it was observed that another trailer was being unloaded in that area, this trolley was parked with blockade of stones near Turbine Building-6 area. It was planned to shift the material to the required area i.e. control Building (CB) area adjacent to RAB- 6 on 03/07/2003.

On 03/07/2003, at about 0805 hrs. four workers of M/s S.C.Biswas, sub contractor of M/s HCC namely Shri Dular Dastidar, Fitter, Shri Amarlal, Khalasi, Shri Mukesh Yadav, Fitter and Shri Laxman Ray, Fitter were instructed by their supervisor Shri Ganen Sarkar to take the steel material from the trolley with help of CB Tower Crane. Workers reached and saw that trolley was at TB-6 area which was away from the approach of CB tower crane. They discussed among themselves and decided to take the trolley to the required place by manual pulling. They thought that it would be easy for them to manually pull the trolley with material instead of unloading and carrying the steel material for this distance (Approx. 45m).

At about 0810 hrs. all the four workers started the work. Out of these four workers, Shri Mukesh removed blockade of stones from rear wheels, Shri Amarlal removed blockade of stone from left front wheel and blockade of stone from front right wheel was removed by Shri Laxman / Shri Dulal. After removing the blockade, Shri Laxman Ray (the deceased) held the hooking arrangement of the trolley and Shri Mukesh, Shri Amarlal (at the left front side) and Shri Dulal (at the right front side)

Pulled the trolley to take it forward. Trolley started moving and subsequently got accelerated due to downward slope. All of them tried to stop the movement of the

Trolley but could not control. The weight of the trolley was 3500 Kg and weight of material on it was 1250 Kg. The trolley had no brakes. Seeing this they shouted for help and simultaneously all of them tried to run away from trolley. During running Shri Mukesh and Shri Amarlal fell at the left side and Shri Dulal fell at the right side of the trolley. Shri Laxman could not escape and got trapped under the left front wheel of the trolley and was run over by it. He was seriously injured and was immediately taken to HCC First Aid Centre in a Tata Sumo and from there to RAPS Hospital in HCC Ambulance. At RAPS Hospital medical treatment was given but Shri Laxman Ray did not respond to the treatment and he was declared dead at 0905 hrs. by the Doctor attending him.

3. Root cause of the accident: 1. Inadequate supervision and instructions. 2. The four workers should not have attempted to shift the trolley by physically pulling it. It should have been shifted using a tractor / truck. 4. Recommendations to prevent such incidents: 1. On the job training should be given to workers about potential hazards involved in material handling. 2. Adequate supervision is required when a job is done. 3. Before any job is taken up, the procedure to be adopted and hazards involved should be discussed by the supervisor and the workers concerned (pep talk). Fatal Accident Report RAPP- 5&6, June-20041. Name of the person : Shri Nagendra Paswan S/o Shri Brahmadev Paswan Age

: 32 years Designation

: Khalasi (Helper) Date and time

: June 12, 2004 at about 2055 hrs. Place : Service building Annexe of RAPP-5&6 under

construction Cause of death : Fall from 100 MEL to 95 MEL while moving out of work

place 2. Description of accident On June 12, 2004 at about 0830 hrs. Shri D.K.Gupta, Foreman of M/s Uttam Chand, sub contractor instructed four workers viz.Shri Chandrajit, Carpenter, Prakash, Carpenter, Harish, Helper and Nagendra Paswan, Helper to carry out shuttering work of staging in SBA. Foreman informed that the work near grid 4 (N to S) at 100 MEL was taken up after 1400 hrs. the two carpenters (S/Shri Chandrajit and Prakash), were involved in fixing of wooden planks during the shuttering work of staging and the two helpers (S/Shri Harish and Nagendra Paswan) were assisting the carpenters by shifting / handling and placing the planks in position. All the four persons while working at 100MEL used the required personal protective equipment like safety helmets and belts. The Foreman was present outside the building during the job. At about 2055 hrs. all the four persons have finished their work unhooked their safety belts and were moving out of the working area for leaving the site. The four persons were walking on a soffit beam (wooden) of 400 mm width having projections of embedded parts at three locations in a span of first 6000 mm at 100 MEL. They should travel a distance of about 19000 mm ( 6000 mm straight 7000 mm after right turn and another 6000 mm after right turn) to come out of the SBA building Shri Prakash was the first man moving out followed by Chandrajit, Harish and Nagendra Paswan walking one after another. Shri Prakash, Chandrajit and Harish could cross the three locations of embedded parts and turned to the right path for going out Shri Nagendra Paswan, who was the last person, in the process of crossing the third embedded part projection lost his balance resulting into a fall from 100 MEL to 95 MEL (basement) floor. Shri Gutpa, Foreman who was present outside the building saw him falling down. He immediately mobilized a crane with a cage arrangement to lift the victim. The victim was rescued and moved to the HCC First Aid Centre in a Ambulance located nearby. Shri Mukesh, Duty Compounder saw the condition of the victim and directed the ambulance to RAPS Hospital. At 2100 hrs. Dr. Shailesh Kumar Duty Medical Officer at RAPS hospital recorded that Shri Nagendra Paswan was brought dead. He reported that the victim sustained lacerated head injury of 2 x 1 over occipital area, multiple abrasions on face and limbs. 3. Observations : 3.1 Shri Nagendra Paswan was imparted with induction training on June 1, 2004 and with toolbox training on June2, 2004. The medical examination and physical ability test to work at heights was conducted on June 5, 2004. Shri Paswan was qualified to work at height after that. 3.2 The soffit beam, which was used as a working platform is not safe. The width of the beam was only 400 mm and has no guardrails. This doesnt qualify as a platform under rule 46 ( 9) (b) of Atomic Energy (Factories) Rules, 1996. 3.3 There is no practice of certifying the working conditions at a particular location before starting a new job. 3.4 There was no pr oper provision for anchoring of safety belts while working / walking on soffit beam. 3.5 Safety nets were tied at few work spots. The place where work was under progress at the time of accident doesnt contain any safety net. Wide gaps wer e observed within the net at few places and was sagging and sloping, which is not safe. 3.6 Both the helmet and safety belt were intact. This indicates that safety belts was unhooked and helmet might not have been on the head of victim or loosely worn when his head struck the ground. 3.7 The contractor supervisor who was present at the time of accident at site was supervising concreting job at SFSB (Spent Fuel Storage Bay), an adjacent building.

The supervisor designated is a safety steward and possesses only M.A(History) degree and has 6 months experience. He was not fully aware of the jobs being done in SBA area. The committee was informed that departmental supervision would be provided only when concreting job is done. Effectively no departmental supervision is available after 2000 hrs. 3.8 On review of Job Hazard Analysis report of m/s HCC noted that hazards involved while working at heights was identified but no preventive / control measures were implemented. 3.9 The shuttering work started at 0830 hrs. and was allowed to continue beyond 2030 hrs.(i.e the scheduled time) upto 2055 hrs. This might have led the deceased to hurry in leaving the work site for catching the bus to home. The job should not have been allowed to extend beyond 2030 hrs. by the sub contractor foreman. 4. Causes : Unsafe acts and Unsafe conditions : 4.1.Acts which could have averted the accident : 4.1.1 Had the walking over the soffit beam been prevented. 4.1.2Had there been proper supervision & instruction to stop the work at the schedule time. 4.2 Conditions which could have averted the accident : 4.2.1 Had there been a proper walkway of adequate width free from obstacles, guardrails and provision for lifeline attachment of safety belt as per provisions of Atomic Energy (Factories) Rules, 1996 and AERB Safety Guide on Works Contract. 4.2.2 Had there been a safety net along the soffit beam towards the working / walking area. 4.2.3 Had the working conditions been examined by the Engineer-In-Charge and declar ed fit for use. 4.2.4 Had there been proper hazard preventive / control measure implemented as identified by Job Hazard Analysis earlier. 4.2.5 Had there been proper supervision & instruction to stop the work at scheduled time5. Underlying factors acts and conditions : 5.1 Acts 5.1.1 Knowledge

5.1.1.1 The victim was trained in safety and possesses working knowledge. 5.1.2 Ability 5.1.2.1 The victim was medically and physically examined and certified as suitable to work at height. 5.1.3 Motivation5.1.3.1 The job continued upto 2055 hrs and the victim might have been in a hurry to catch 2100 hrs bus back to home. 5.2 Conditions 5.2.1.1 Proper walkway of adequate width free from obstacles and guard rails as per provisions of Atomic energy (Factories) Rules, 1996 and AERB Safety Guide on Works Contract. 5.2.1.2 A suitable pr ovision like running lifeline with anchor ing facility for safety belt which would also serve as barrier / guard rail along the walkway. 5.2.2 Maintenance 5.2.2.1Maintenance of Safe Working conditions and fall preventive measures through controlled procedures and instructions. 5.2.3 Actions of others 5.2.3.1 Enforcement of proper hazard preventive / control measures identified in Job Hazard Analysis 5.2.3.2 Examination of conditions of walkways/ platforms and safety measures by the Engineer In-Charge and declaring fit for use. 5.2.3.3 Availability of required number of departmental as well as contractors safety personnel as per Chairman, AERB notification dated July 8,2002. 6. Recommendations to prevent recurrence : 6.1 Proper walkway of adequate width free from obstacles and guardrails as per provision of Atomic Energy (Factories) Rules, 1996 and AERB Safety Guide on Works Contract should always be ensured. 6.2 Conditions of walkways/ platforms and safety measures should be examined by the Engineer-In-Charge for declaring fit prior to use. 6.3 Suitable pr ovision like running lifeline with anchoring facility for safety belt should be made available. 6.4 Safe Working conditions (like walkways / platforms etc) and fall preventive measures (like safety belts, guardrails etc) should be ensured through controlled procedures and pr oper instructions. 6.5 Proper hazard pr eventive / control measures identified in Job Hazard Analysis should be enforced. 6.6 Project management should ensure the availability of required number of departmental as well as contractors safety supervisors as per Chairman, AERB notification dated July 8, 2002 all the time. At present there is a short fall of one departmental supervisor and 2 contractor (M/s HCC) super visors which should be made up immediately. 6.7 No worker should work more than 12 hours on a particular day. Fatal Accident Report RAPP-5&6, July-2005 1. Fact about the accidentName of the deceased

: Shri Mangal Sharma Age


: Helper Date and time of accident : 26th July 2005 at 0940 hrs. Place of accident

: South Station Road near RAB-5 2. Description of accident : On 26th July 2005, a worker of M/s HCC connecting water hosepipe on South Station Road near RAB-5 building. One hydra of M/s IOTL (a piping contractor) as returning back from control building on the Station road and moving towards RAB-5. The said hydra hit the head of the person who was sitting in the middle of the road for connecting the water hosepipe. The helmet worn by the deceased caved in due to impact of the hit. The impact of the hit was so intense that the deceased was moved two feet away form the location of the work. The deceased was taken immediately to First Aid Centre and subsequently sent to RAPS Hospital. He was further referred to Kota Hospital and was declared dead on reaching Sudha Hospital, Kota. 3. Root cause : 1. Absence of an escort for the hydra movement, who ensures safe movement. 2. Hydra driver was not attentive towards road and did not realize that there could be somebody in the middle of the road. 4. Recommendations : 1. As per standard road safety requirements, a barricade of nylon or cotton ribbon in red colour should be installed around the work spot on the road or similar access where movement is expected. 2. Escort should be provided for each hydra movement for safe movement. 3. Adequate nos. of road safety signs / boards etc. should be displayed along roadsides. Fatal Accident Report RAPP-5&6, August-20051. Fact about the Accident Name of the deceased : Shri Raman Prasad Shahu Age


: Helper Date & time of accident: 12/08/2005 at 2150 hrs. Place of accident : Reactor Building#6, Inner Containment Wall 2. Description of the Accident On 12th August 2005, three workers of M/s S.S.Roy, a sub-contractor of M/s HCC were engaged in deshuttering job on outer face of Inner Containment wall of RB#6. at 2100 hrs. of the day deshuttering of one of the panels on the outer face of IC wall was taken over at a height of 121m elv. and three workers were on the landing mat for this job. The DOKA structure is attached to its shuttering by plates at six points. Each of the two solider of one unit is fixed with one conical nut to an embedded bolt of 16mm dia in the containment wall having square thread. It was reported that when the 6th plate was being removed, one of the soldiers came out from the bolt along with the cone nut. Two persons including the deceased, Shri Raman Prasad Shahu who had tied their safety belt to that solider and standing on the landing mat (placed on the same DOKA structure attached to this solider) fell down from a height of 121 m elev. to 99 m elev. in the annular space at about 2150 hrs. The third person who tied his safety belt on the soldier of adjacent shuttering panel was found hanging after the accident. All the three person were rescued immediately with the help of tower crane and passenger cage and were taken to RAPS Hospital by the ambulance.

The doctor at RAPS Hospital declared Shri Raman Prasad as brought dead. The other two persons having abrasion / fracture were referred to a Hospital at Kota for further treatment. 3. Root cause of accident : i) Existing design depends on one single nut which is engaged with the embedded bolt (of 16mm dia) in the containment wall for holding the soldier. There is no second protection in this case, though working person are standing on the landing mat supported on these soldiers. ii) Inspection of threads of cone and certification for full engagement of the cone with the embedded bolt was not done. iii) Safety belts were anchored on the affected soldier. Procedure for deshuttering as practiced at other sites were not followed here. Anchoring of safety belt to a stable structure (as done by third worker) was ignored. iv) Safety net was not provided. 4. Recommendations : i) QA inspection of the thread of cones and bolts should be carried out regularly and full engagement of the cone nut with the embedded bolt must be ensured. ii) Connect both inner & other shuttering panels by a sling or a chin during all stages of handling and placement to prevent any inadvertent fall. iii) Standard procedure for installation and removal of DOKA structure should be followed at all NPCIL sites. iv) Anchoring of safety belt to a stable, strong and independent structure must be ensured and full harness safety belt should be used while working at height. v) Qualified safety supervisors should be available with all major contractors. vi) Job Hazard Analysis carried out by the contr actors should be reviewed by departmental personnel and implementation of JHA recommendations must be ensured. vii) Working platform of at least 1 m width along with railings and safety net should be provided at all works at height. Fatal Accident Report RAPP-5&6, November-2005

1. Fact about the accident Name of the deceased : Shri Ajay Kumar Age


: Welder Date and time of accident : 27th November 2005 at about 0905 hrs. Place of accident : EOT Crane Girder at 122.8 m elev. in TB#5 2. Description of accident On 27th November 2005, a crew of four workers of M/s S.S.Roy, a sub contractor of M/s HCC was asked by their supervisor to remove the bottom support of channel welded over the EOT Crane Girder at 122.8 m elev. in TB#5. All the four workers including the deceased Shri Ajay Kumar accessed the said girder top using a temporary iron staircase from 116m elev. All the four workers after reaching the top the girder approached the channel pieces placed near Grid column B-3. The deceased was last in the line when they were walking over the girder of the width 0.5 m only. The deceased might have lost his balance and as he had not anchored his safety belt with available lifeline, he fell down from the girder top at 122.8m elev. into unloading bay at 100 m elev. While falling his head struck with a gas cylinder lying on the ground. he was immediately taken to HCC First Aid Centre at RAPP-5&6 site and from there to RAPP Hospital where he was declared brought dead. 3. Root cause of the accident: i) Non- anchoring of safety belt with lifeline available at worksopt. ii) Removal of the railings before removal of channels and non availability of safety net below the girder. iii) Ignorance of safety rules on part of the deceased was observed as he has been warned and penalized for violating the use of safety belt. iv) The working area was not engineered for safe operation as the standard platform of width >1 m was not provided for the job. 4. Recommendations :i) Railings on the working platform at higher elevation must be provided. ii) In case it is not feasible to provide railings on the platform, safety net must be put below the platform. iii) Contractor worker must be briefed properly about work hazards and requisite safety precautions. Workers who do not follow safety measure and avoid use of PPEs should not be allowed to work. Fatal Accident Report RAPP-5&6, May -2006

1. Fact about the accident Date & Time of accident : 27/05/2006 at 1645 hrs. Location

: South Station Road, RAPP-5&6 Fatality

: One Name of the victim : Mr. Raju, Beldar S/o Shri Kodar a worker of M/s New India Builders sub contractor of M/s HCC Limited Age / Sex

: 22 years / Male Address : Village:- Karanapada P.O:- Kawasha Distt. :- Jhabua, (M.P) 2.0 DESCRIPTION OF THE ACCIDENT On 27/05/2006 at about 1500 Hrs, Shri Bhanwar, Supervisor of M/s New India Builders a sub contractor of M/s HCC has given instruction to Shri Raju to fill the trolley, Shri Saitan to clean curb stones and Miss Leela to pour water on curb stones. Shri Raju started filling the trolley. At about 1630 Hrs. Shri Raju went for bringing water in a Chhagal. He brought the water & asked Shri Saitan & Miss Leela to drink water. After drinking water, Shri Saitan & Miss Leela r esumed their work Shri Raju went under the trolley to hang Chhagal in the lower rear portion of the trolley. At about 1645 Hrs, while coming out he used lower portion of trolley as support, causing backward tilting of the trolley. Shri Raju got trapped under the rear portion of the trolley with his head inside & lower portion of the body out side. The muck came out of the trolley and fell over the lower portion of the body of Shr i Raju. He cried for help Shri Saitan, Miss Leela & other workers working in the vicinity rushed to the accident spot and rescued him. He was rushed to First Aid Centre RAPP-5&6 in a jeep of M/s EEPL. From First Aid Centre, RAPP-5&6, he was shifted to RAPS Hospital in Ambulance. After giving necessary treatment at RAPS Hospital, he was referred to Sudha Hospital Kota. At Sudha Hospital Kota, he was declared dead. 3.0 ROOT CAUSE OF THE ACCIDENT 1. The trolley was parked without tractor for filling the material. 4.0 OBSERVATIONS 1. Tractor trolley was parked without tractor by the side of cur b stone on South Station Road. 2. Activity of disposal of muck generated out of fixing of curb stone was in progress. 3. The muck accumulated over a length of 2-3 meters was only dump inside the trolley. 4. The victim was found lying with legs out side the trolley with muck over lower portion of the body. Small quantity of muck is still available in the trolley. 5. Provision for filling the muck from both sides was available in the trolley. 5.0 RECOMMENDATIONS 1. While loading & unloading, tractor should be kept coupled with the tractor trolley. 2. Loading of tractor trolley from the rear side should be avoided. ACCIDENT ANALYSIS

Accident Investigation and analysis is one of the means used to prevent accidents. Accident Investigation and analysis is a defence in depth study against hazards. Thorough investigation of all accidents which result in lost time injury to determine contributing circumstances is a must. Accident that do not result in personal injury (so- called Near Miss Accident) are warning, they should not be ignored.

For purpose of accident prevention, investigation must be done for fact finding, not fault-finding, otherwise it may do more harm than good.

Observations :-

1All accidents data for the reportable accidents are available & properly maintained by Industrial Safety section.

2..All Near-Miss Accidents and accidents which are reported to industrial safety section are investigated by safety section.

3.The monthly, quarterly and yearly safety performance report are prepared by industrial safety group. These reports is a part of monthly progress report of RAPP-5&6, & distributed to all Section Heads & sent to Head Office also.

4. All accident & near miss accidents are classified as per IS-3786-1983.

5.Directorate of Health, Safety, Environment and Public Awareness, NPCIL is preparing monthly. Monthly, Quarterly & Yearly safety performance reports of all units of NPCIL & submit these reports to Chairman Cum Managing Director, NPCIL for appraisal of safety performance of over all NPCIL as well as individual units of NPCIL. This help in comparing safety performance of NPCIL units.

6. The accident data & analysis of accidents of last three years is given below:-

Analysis of Accidents for the period from 01.01.2003 to 30.09.2006Sl. No.Period 2003200420051st Jan. 2006 to 30th Sept.2006

1.Average no. of employees.2249379244494742

2.Man hours worked.7797112126957121410525711038290

3.Reportable injuries. 05050702

4.Fatal accident.01010301

5.Man days lost.61226044181336018

6.Frequency rate. 0.640.390.500.54

7.Severity rate.785.164761285.051616.05

8.Injury index.0.5020.1850.640.87

9.Average days charged / injury. 1225.001209.002590.051250.00

TABEL - NO - 17

ANALYSIS OF ACCIDENTS FREQUENCY RATE - 2003 TO 2005

FREQUENCY RATE (F.R.)

200320042005

Departmental Employees2.7800

Contractor Employees0.530.410.53

Combined0.640.390.5

TABEL - NO - 18

ANALYSIS OF ACCIDENTS SEVERITY RATE - 2003 TO 2005

SEVERITY RATE (S.R.)

200320042005



Combined785.164761285.5

TABEL - NO - 19

ANALYSIS OF ACCIDENTS- INJURY RATE - 2003 TO 2005

INJURY RATE

200320042005



Combined0.5020.1850.64

TABEL - NO - 20

ANALYSIS OF ACCIDENTS-INCIDENCE RATE - 2003 TO 2005

INCIDENCE RATE (I.R.)

200320042005



Combined2.221.321.57

TABEL - NO - 21

ANALYSIS OF ACCIDENTS- AGENCY - 2003 TO 2005

IS CODE AGENCYNO. OF ACCIDENTS

2062Machine 1

2111Crane 1

2421Floor1

224Electrical installation 1

213Means of Transportation 1

231Explosives1

2511Roof1

2134Concrete Miller1

239Shuttering Panel1

239Unloading of MS rods1

229Other Equipments1

252Open Cast mixing 1

2134Hydra1

229Doka shuttering 2

2214Gas cylinder1

2192Mech . Conveyor 1

TOTAL17

TABEL - NO - 22

ANALYSIS OF ACCIDENTS- TYPE - 2003 TO 2005

IS CODE TYPENO. OF ACCIDENTS

101Fall of persons from height2

114Collapse of building walls ,scaffolds ladders , piles of goods etc. 2

102Fall of persons on the same level 1

124Struck by moving objects1

13Caught in / between 1

16Contact with electrical current1

115Fall of object during handling3

133Caught between moving objects2

123Striking against moving objects.1

131Caught in an object1

181Explosion1

TOTAL16

TABEL - NO - 23

ANALYSIS OF ACCIDENTS- - LOCATION OF INJURY - 2003 TO 2005

IS CODE LOCATION OF INJURYNO. OF ACCIDENTS

431Back 1

432Chest1

455Ankle1

445Wrist1

447Fingers3

446Hand1

417Head3

433Abdomen1

454Lower leg2

411Skull brain1

449Upper limb unspecified locations1

42Neck16

Recommendations :-

1. A procedure / system should be introduced for reporting of all near miss and first aid accidents.

2.It is to be made mandatory that all accidents / near miss incidents including first aid injuries be investigated by line management supervisors / engineers. The recommendations based on the investigation should be implemented at the earliest.

3.A training programme may be organized for all line supervisors/ engineers on accident investigation.

CHAPTER 5 SAFETY MANAGEMENT SYSTEMS5.1 HAZARD IDENTIFICATIONCOMMON HAZARDS AND THEIR CONTROL MEASURES AT CONSTRUCTION SITES:

HAZARDS/ACCIDENTS

1.Trips, Slip

2.Fall from height

3.Fall of materials from height.

4.Fall from same level

4.Electric shock

5 Hit by speeding vehicle.

6 Hit by earth moving equipments

7 Fire.

8 Accidental actuation of tools.

9.Disconnection of pneumatic tools.

10 Dust/ fumes.

11.Handling solvents paints thinner etc.

12 Explosives/ Blasting

13 Heat / Radiation

14 Wrong postures of work etc.

15 Excavation work hazards.

16 Caught in between

CONTROL MEASURES:

TRIPS / SLIPS:

Good house keeping

Removing of unwanted material regularly

All temporary electrical connection should be routed above ground (2meter) or underground.

FALL FROM HEIGHT:

Use of scaffold Safety belt.

Safety net Fall arrestorFALL OF MATERIAL FROM HEIGHT:

Use of safety net.

Safety sheet

Proper slinging

Proper stacking

ELECTRICAL SHOCK:

Use of two-core wire.

Use of three-pin plug.

Use of defect free cables portable tools and ELCB

Demarking, warning sign, working procedures.

Permanent panels.

HIT BY SPEEDING VEHICLE:

Observe speed limit. Authorized entry of vehicle. Observing traffic rules and signs.HIT BY EARTH MOVING EQUIPMENTS:

Vehicle with proper condition of parking brake, service brake, warning light and horn while reversing. Trained and licensed driver. Barricading / flagging the area where such operations is going on. Observe speed limit to 20Km/hr.ACCIDENTAL ACTUATION OF TOOLS:

Tools with proper working switch Trained Operator. Prevent accidental disconnection of pneumatic tools.DUST AND FUMES:

Ventilation.

Use of dust masks.

HANDLING OF PAINTS, SOLVENTS THINNERS ETC.

Proper storage Use of gloves/ barrier cream/ masks No smoking Observe hygiene.

EXPLOSIVES:

Authorized storage

Authorized blaster

Keeping record Lock / key.

HEAT RADIATION:

Face shield, Welding goggles, Gloves

Aprons.

WRONG POSTURE OF WORK:

Right method of material handling

EXCAVATION HAZARDS:

Means for rapid access and egress should be provided. All trenches 120 meter or more in depth at site shall at all times be supplied with at least one ladder for every 30 meter along the trench. The ladders shall extend from the bottom of the trench to at least 1 meter above the surfaces of the ground. Workers should not be exposed to danger of being buried by excavated material or collapse of shoring. Measures to prevent dislodgement of loose or unstable earth, rock or other material from falling into the excavation by proper shoring shall be ensured. Persons who are not engaged in excavation work shall be prevented from approaching excavation work shall be prevented from prevented from approaching excavation areas by placing warning signs and signals barricades, etc. near the site of excavation. Excavation material shall not be dumped with in 1.5 meter of the edges. An excavated area shall have illumination level of at least 20 lux for night work.Safety management at construction sites is a challenging job because of its high accident-prone activities. Going by the statistics, the accident rates at construction sites are almost 3 4 times more than that in the manufacturing industry. The main factors responsible for higher risk at construction sites are:

Untrained, Unskilled, Uneducated, mostly speaking non-local language, temporary manpower.

Long working hours of manpower, working in harsh weather conditions.

Difficulty in wearing Personal Protective Equipments (PPES) due to warm and humid climatic conditions.

Continuously changing working situations requiring constant alertness of workers and supervisors.

Keeping in view all the above things in mind and as a proactive approach towards accident prevention this project on industrial safety is prepared with a view towards safe work at RAPP 5&6 site, unit 5&6.

Observations :-

1.All the hazardous area & hazards may arise during construction phase of RAPP-5&6 are identified.

2. The type of accident & types of hazards may arise during the construction phase of RAPP-5&6 are given below.

IDENTIFICATION OF HAZARDS AT RAPP 5&6 CONSTRUCTION SITE

1.Hazards in excavation.

2.Hazards in blasting.

3.Dust hazard.

4.Noise hazard.

5.Hazards in welding & gas cutting.

6.Hazards in use of portable power tools.

7.Electrical hazard.

8.Fire hazard.

9.Hazard due to failure of centering, shuttering & shoring.

10.Hazard associated with vehicular movement.

11.Hazard in manual & mechanical material handling.

12.Hazard in valve in work at height.

13.Hazard in work in confined space.

14.Hazard in pickling work.

15.Hazard in shot blasting.16.Other mechanical hazards.3.Following steps have been taken to prevent these hazards at RAPP-5&6 site.

(a)Before starting any new activities job safety analysis / safety procedures prepared by concerned supervisors / engineers & concurred by safety officer, after that work has been started with necessary precaution as mentioned in job safety analysis / safety procedures.

(b)In addition to point (a) the following works are being controlled by work permit system.

(1)Excavation

(2) Blasting operation.

(3) Work at height.

(4) Work in confined space.

(5) Hot work in fire prone area.

(6) Removal of guardrails / covering of the floor openings.

(c)A daily checklist system is used at RAPP-5&6 site. In this system each & every morning before start of work concerned supervisor / engineer visit work site & fill the checklist before start of job if any deficiency observed by them they write in the checklist & these deficiency are corrected before starting of job.

Safety officer & staff during daily site visit go through filled checklist & suggest additional precaution if required.

(d)Although engineering method are used to control of hazards. In addition to this use of personnel protective equipment is mandatory at RAPP-5&6 site.

(e)Safety Officer & staff are empowered to stop any job with the consent of Engineer In - charge if not carried out safely.

4.Internal safety audit once in six months & external safety audit by AERB Inspectors (once in year) have been carried out at RAPP-5&6 site and recommendations of these Safety Audits in being implemented on top priority.

5.All modification even minor modification are being done at RAPP-5&6 site after taking approval from the design groups of NPCIL Head Quarter.

6.The following environmental monitoring equipments available at RAPP-5&6 site for monitoring the environmental conditions.

a. Direct reading oxygen level monitor.

b. Direct reading explosives gas monitor.

c. Direct reading carbon mono oxide monitor.

d. Digital lux meter.

e. Digital sound level meter.

f. Direct reading H2S monitors.

Recommendations :-

1.All steps taken to prevent hazards, which are given in observation No. 3, should be followed strictly.

2.Calibration of all monitoring equipment to be carried out time to time & maintain all monitors in working order all the time.

5.2 -DISCUSSIONS ON GENERAL ASPECTS RELATED TO NUCLEAR SAFETY .COMMON CONSTRUCTION ACTIVITIES AT RAPP 5& 6Work at Heights:

Working at Height Including Roof work:

GENERAL PROVISIONS:

1. It is necessary to guard against danger, where the height of the structure or its slope exceeds that prescribed by national laws or regulations; preventive measures should be taken against the fall of workers and tools or other object or materials.

2. Elevated work places, including roofs more than 2 meter or as prescribed, above the floor or the ground should be protected on all open sides by guardrails and toe boards complying with the relevant national laws and regulations. Wherever guardrails and toe board cannot be provided; adequate safety harness should be provided and used.

3. Elevated workplace including roofs should be provided with safe means of access and egress such as stairs, ramps or ladders complying with the relevant national laws and regulations.

4. If guard rails are not practicable, persons employed at elevated workplaces including roofs from which they are liable to fall more than 2 meters or as prescribed should be protected by means of adequate safety nets or safety sheets or platforms, or be secured by safety harness with lifelines securely attached.

ROOF WORK:

1. All roof work operations should be preplanned and properly supervised.

2. Workers who are physically and psychologically fit and have the necessary knowledge and experience of such work should only undertake roof work.

3. Works on roofs should not be carried out in weather conditions that threaten the safety of the workers.

4. Crawling boards, walkways and roof ladders should be securely fastened to a firm structure.

5. Roofing brackets should fit the slope of the roof and be securely supported.

6. Where it is necessary for a person to kneel or crouch near the edge of the roof an intermediate rail should be provided unless other precautions such as the use of safety harness are taken.

7. On a large roof where work does not have to be carried out at or near the edge, a simple barrier consisting of crossed scaffold tubes supporting a tubing guardrail may be provided. Such barriers should be positioned at least 2 meter from the edge.

8. All covers for the openings in the roof should be of substantial construction and be secured in the position.

9. Roofs with a pitch of more than 10 should be treated as sloping.

10. For carrying out job on sloping roofs, suitable crawling boards or roof ladders should be provided and it should be firmly secured in position.

11. During extensive work on the roof, strong barriers or guard rails and toe boards should be provided to stop a person from falling off from the roof.

12. Where workers are required to work on or near roofs or other places covered with fragile Material, through which they are liable to fall, they should be Provided with sufficient suitable roof ladders or crawling boards strong enough, when spanning across the supports for the roof covering, to support those workers.

13. A minimum of two boards should be provided so that it is not necessary for a person to stand on a fragile roof to move a board or a ladder, or for any other reason.

14. To prevent danger, suitable material such as steel wire mesh should be placed in position before any roof sheeting of asbestos cement or other fragile material is placed upon it.

15. Purling or other intermediate supports for fragile roofing material should be sufficiently close together to prevent danger.

16. Where a valley or parapet gutter of a fragile roof is used for access, protection against falling through the fragile material should be provided by covering the adjacent fragile material to a minimum distance of 1 meter up the roof.

17. Building with fragile roofs should have a warning notice prominently displayed at the approaches to the roof.

WORK ON TALL CHIMNEYS:

1. For the erection and repair of tall chimneys approximate scaffolding should be provided. An adequate catch net should be maintained at a suitable distance below the scaffold.2. The scaffold floor should always be at least 65cm below the top of the chimney.

3. Under the working floor of the scaffolding the next lower floor should be left in position as a catch platform.

4. The distance between the inside edge of the scaffold and the wall of the chimney should not exceed 20 cm at any point.

5. Catch platforms should be erected over:

(a) The entrances to the chimney;

(b) Passageways and working places where workers could endanger by falling objects.

6. For climbing tall chimneys, access should be provided by:

a) Stairs or ladders;

b) A columns of iron rungs securely embedded in the chimney wall;

c) Other appropriate means.

7. When workers use the outside rungs to climb the chimney, a securely fastened steel core rope looped at the free end and hanging down at least 3 meter should be provided at the top to help the workers to climb on to the chimney.

8. While work is done on the independent chimneys the area surrounding fencing at a safe distance should enclose the chimney.

9. Workers employed on the construction, alteration and maintenance, or repair of tall chimneys should not:

a) Work on the outside with out a safety harness attached by lifeline to a rung, ring or other secure anchorage;

b) Put tools between the safety harness and the body or the pockets not intended for the purpose;

c) Haul heavy materials or equipment up and down by hand to or from the work place of the chimney;

d)Fasten pulleys or scaffolding to reinforcing rings without first verifying their stability;

e)Work alone;

f)Climb a chimney that is not provided with securely anchored ladders or rungs.

g)Work on chimneys in use unless the necessary precautions to avoid danger from smoke and gases have been taken. Work on any chimneys should not be carried on in high winds, icy conditions, and fog or during electrical storms.

Minimum safety Precautions to be taken during Working at Height

All open sites of a structure above a height of 3.5 meters from which a worker might fall and openings into which a worker might fall are adequately covered and barricaded. Providing suitable fencing or railing of one meter provides every opening in the floor of the building or in a working platform with suitable means to prevent fall of persons or material.

Where barricades cannot be installed a safety net is being installed closed to the level at which there is danger of fall. During erection of tall buildings and structures above 3.5 meters heights, nylon nets are being provided to ensure safety of man if there is a fall from height in case it is not possible to provide barricades.

Where a secured foot in impracticable safety belts / harness with secured anchorage points are being provided at the working place as well access to the access path to the working spot. All persons working at heights above ground or floor and exposed to the hazard of falling down are using safety belts.

At elevated places, secure access and foothold are provided. Adequate and safe means of access and egress are provided at all work places for all elevations. Means of access, potable or fixed ladders ramp or stairway. The use of crosses braces or framework, as a means of access to a working surface is not permitted.

Scaffolding or staging 3.5 meter above the ground floor are provided with guard rail properly attached, bolted, braced and secured at least one meter height above the floor and the platform.

Where the platform is more than 3.5 meter above the ground floor for working standing on the platform, the width is maintained minimum as 1meter.

SAFETY IN SCAFFOLDINGS:

Every year nearly 100 fatalities and 10,000 injuries occur world over on scaffolds despite numerous safety regulations aimed to prevent such incidents. If we work on scaffoldings, we must be able to recognize the hazards associated with the type of scaffolds we are using, and know what to do when we recognize something that just isnt safe. There are a number of different scaffolds type, having different rules and regulations surrounding their assembly, fall protection requirements, and inspections procedures.

An estimated 2.3 million construction workers, or 65% of the construction industry, work on the scaffolds frequently. Protecting these workers from scaffolds related accidents would prevent 4,500 injuries and 75 deaths every year, at a saving for employers of $90 million in work days not lost. In a recent BLS study, seventy two percent of workers injured in scaffold accidents attributed to accidents either to the planking or support giving way, or to the employees slipping or compliance with Building and Other Construction Workers (Regulation of Employment and Conditions of Service) act, 1996 and Central Rules, 1998.

TYPES OF SCAFFIOLDS:

There are 30 different types of scaffolds being used in construction industries all over the world. But the most commonly use scaffolds all over the world are given in the diagram attached with this portion of course material. In India the use is limited to few numbers, like welded frame scaffold, bamboo/wooden scaffold, pole scaffold and mobile scaffold.

SAFE WORKING--WITH SCAFFIOLDS:

Working with scaffolding requires your employees to be attentive to their actions and the tasks at hand to work safely. There are numerous safety rules and regulations they should follow. The following rules are generally accepted practices. When viewing with employees, add any rules that are specific to your operations as well as common sense rules we have learned through our experiences.

1.DESIGN

Footings

Scaffolding footings or anchorages must be sound and capable of carrying the maximum load with out setting. Do not use unstable objects such as barrels, boxes, loose brick or concrete blocks to support scaffolds or planks. Do not erect, move alter or dismantle.

GUARDRAILS

Guard rails made of lumber must not be less than 50x100mm(or other material providing equivalent protection). They must also be between 950mm and 1125mm high, with a midriff of 25x150mm lumber (or other material providing equivalent protection), and have a minimum 100mm high toe boards on all open sides and ends on scaffolds more than 3000mm above the ground or floor. Supports must be at intervals that do not exceed 2000mm. Ramps and walkways 1500mm above lower levels must have guardrail systems. Where persons are exposed to falling objects and are required to work or pass under the scaffold, there must be a screen between the platform and the guardrail. It must extend

along the entire opening and support a down ward or horizontal force of a minimum70Kgf (35Kgf on single point and two point adjustable suspension scaffolds). The screens openings should be small enough to prevent Passage of potential falling objects.

PLANKING

All planking of platforms must be over lapped (minimum of 300mm);or be secured from movement. Scaffold planks must extend over their end support not less than 150 mm or more than 300mm unless secured or blocked by a guardrail. Planks must be laid with their edges close together so that platform will be tight with no spaces greater than 25mm though which tools or fragments of material can fall. Platforms more than 350mm from the work surfaces must have the guardrail system and/or employees must use personal fall arrestor system (for plastering and lathing+450mm). Work areas must be fully planked from the front uprights to the guardrail supports. All planking must conform to the minimum requirements of IS: 3696(part-II).ACCESS

An access ladder or equivalent safe access must be provided. Rungs must be a minimum 200mm wide (internal prefabricated frames) and uniform distance between rungs not greater than 300mm. Cross braces are not acceptable for scaffold access.

SUPPORT AND STABILITY

Scaffolds and their components must be capable of supporting without failure at least four times the maximum intended load. Wire, synthetic or fiber rope used for scaffold suspension must be capable of supporting at least six times the rated load. The poles, legs or upright of the scaffolds must be plumb and securely braced to prevent swaying and displacement. Scaffo9lds must be tied back vertically at a height beginning at four times the scaffold width A then at a maximum every 8-meter. (Scaffolds 1meter and wider). The horizontal distance of the ties is not to be exceeded 9 meter.

PLUMB

When the first tier of scaffold has been erected it should be checked for plumb, alignment and level. Where necessary, adjustments can be made using the screw jacks. Settlements or slight variations in the fit of the components may require additional adjustments as tiers are added to the scaffolds tower. Braces should fit easily if the scaffold tier is level. If braces do not fit easily it is an indication that the scaffold is out of plumb or out of alignment.

GENERAL

Employees must not work on scaffolds during storms or huge winds. Slippery conditions on scaffolds must be eliminated before use. Any scaffold, including accessories such as braces, brackets, trusses, screw legs, ladders, etc. Damaged or weakened component must be repaired or replaced. Overhead protection must be provided for employees on a scaffold planking must conform to the minimum requirements of IS: 3696(part-II). Exposed to overhead hazards. The use of shore or lean-to- scaffolds is prohibited. Materials being hoisted onto a scaffold must have a tag line. Tools, scrap materials and debris must not be allowed to accumulate which may cause a hazard.

2. INSPECTION

Scaffolds materials should be inspected before use for the following:

Damage to structural components

Damage to hooks on manufactured platforms

Split, knots and dry rot in planks

Delaminating in laminated venner lumber planks

Presence of all necessary of all necessary components for the job.

Compatibility of the components.

Structural components, which are bent damaged, or severely rusted, should not be used. Similarly, platforms with damaged hooks should not be used. Similarly, platforms with damaged hooks should not be used until properly repaired. Planks showing damage should be discarded and removed from the site so that they cannot be used as platform material factors. Generally, running sills longitudinally because the sill has more contact with the ground will increase the bearing capacity.

3. USE

Base plates:

Base plates and adjustable screw jacks should be used whether the scaffold is outside on rough ground or indoors on a smooth level surface. Base plates should be centered on width of sill and nailed securely after the first tier has been erected. Sills may run either across the width or along the length of the scaffold depending on great condition & other.Ties

Scaffolds must be tied in to a structure or otherwise stabilized- in accordance with manufacturers instructions and the construction regulation- as Erection progresses. Leaving such items as tie-ins or positive connections until the scaffold is completely erected will not save time if it results in an accident or an injury. Moreover in most jurisdictions it is prohibited.

FALL PROTECTION IN SCAFFOLD ERECTION:

Providing practical fall protection for workers erecting and dismantling scaffold and shoring has been challenging for the construction industry. Workers erecting, using or dismantling scaffolds must be protected from falling by using guardrails, travel restraints, fall restricting systems, or fall arrest systems. For fall protection while workers a scaffold as a work platform, the safest solution is guardrails, provided they can be erected safely. Workers involved in erecting or dismantling scaffolds face a different challenge. Erecting guardrails and using fall arrest equipments requires specialized procedures since normally there is nothing above the erector on which to anchor the fall protection system. Recognizing that development and innovation continues in this field we are offering a sampling of fall protection techniques (fall prevention and fall arrest) in the fig below. These generic examples allow individual employers, trade groups, unions, and others to adapt the guidelines to their site-specific needs and to trigger further development.

TRAINING

Training must be provided by a person qualified in the subject matter and hazards associated with the scaffoldings being used. Training must be given to employees performing the work informing them of: E

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