SAFETY & SECURITY NEWSLETTER

September 2014 Issue

MESSAGE DESK

.

CONTENTS

1 Safety Valve

2 Lessons Learned

3 Safety training

4 Emergency Exercise

5 Corporate Safety highlights

6 R&R for Safety – Aug’14

7 Seat belt- Life saver (story of colleague)

8 Safety- a matter of life-third series

9 Root cause analysis (RCA) of incidents – Aug’14

10 Security Highlights

Thought for the month

Be a leader, follow safe procedures!

1. Safety Valve by Singh Pramod, CGPL

Safety Valve is one type of valve that automatically actuates when the pressure of inlet side of

the valve increases to a predetermined pressure, to open the valve disc and discharge the fluid

(steam or gas) ; and when the pressure decreases to the prescribed value, to close the valve

disc again. Safety valve is so-called a final safety device which controls the pressure and

discharges certain amount of fluid by itself without any electric power support.

Safety Valve is mainly installed in a chemical plant, electric power boiler, gas storage tank,

preventing the pressure vessels from exploding or damaging.

Nozzle" inside the Safety Valve starts to receive a

higher pressure from the inlet side of the valve.

When the pressure becomes higher than the set

pressure, "Disc" starts to lift and discharge the fluid.

When the pressure decreases until the

predetermined pressure, the force of the spring

closes "Disc".

(Role of the spare parts)

Nozzle--- Pressure Entrance

Disc --- Lid

Spring --- Pressure Controller

Components of the Safety Valve

Spring loaded Pressure-relief Valves

Generally, the safety valveｓ are referred to the Spring-loaded

Pressure-relief valves, the most common type ( See the left

figure). The load of the spring is designed to press the "Disc"

against the inlet pressure. Depending on the fluid type, such as

steam, gas or liquid, bellows are offered to clear the back

pressure effect.

Pilot-operated Pressure-relief Valves

Pilot-operated Pressure-relief Valves are composed of Pilot

Assy and Main Valve. Although Spring-loaded Pressure-relief

valves adopts the force of the spring against the inlet

pressure, the reliving pressure and reseating pressure of the

Pilot-operated Pressure-relief Valves is controlled by Pilot

Assy, which acts nearly as same as Spring-loaded Pressure-

relief valves. There is no adjusting function in the Main Valve.

Pilot-operated Pressure-relief Valves have larger size

variations compared to Spring-loaded type, which is applied in

a severe condition such as high pressure.

Dead-Weight Pressure-relief Valves

In case the design pressure of the pressure vessel is set

at very low pressure, Dead-weight Pressure-relief valve

adjusts relieving pressure only by the disc weight. The

Vacuum relief valve has been adopting this functional

characteristic which absorbs the pressure when the inside

of the pressure vessel falls into a negative pressure.

2. Lessons Learned

Division : Trombay

Date of Incident : 19th July 2014

Type of incident : Medical Treatment Injury

Incident Time : 12:10 Hours

Description of Incident:

During installation of additional lights at Unit 5 ESP stream 4 pent house a contract person fell

down in the opening caused due to removal of grating near portable Transformer set. The

person got blunt injury on his chest. He was given first aid at OHC and sent immediately for X-

ray to Joy hospital. The reports were found normal and after treatment he resumed back to

work.

Key Findings

PTW was issued for one month for the fabrication of unit #5 ESP

PTW was issued for Installation of lights under preventive maintenance

JSA was prepared for removal of insulation gladding and roof plate cutting for ESP work

A section of grating was removed by contractor for removal of insulation material from

ESP cold roof without approval

No hard barricading was provided

Person was given first aid at OHC and referred to Joy Hospital as a precautionary

measure for further investigation

Reports were normal and person resumed duty immediately

Root Cause Analysis

Human Factors

1.2 Violation by group –

1. Installation of lighting was done on PM PTW

2. Grating was removed but hard barricading was not provided

Physical Factors

5.1 Inadequate warning systems – No physical barrier / signs were provided

System Factors

8.4 Inadequate identification of worksite / job hazards – Inadequate PTW / JSA

Recommendations:

1. Apply Consequence management policy against group who has violated the safety Work

Rules / Policies / Standards / Procedures

2. Grating removal policy / procedure shall be in place which will posses risk of falling from

height

3. PTW shall be issued for specific job, location and period (max 1 week and daily

approval)

3. Safety training

Train the Trainers program on Critical Safety Procedures for all divisions

Train the Trainers program on “Critical Safety Procedures” was conducted at Trombay by

Corporate OH&S department with help of Trombay & DSS trainers. This program aims at

developing pool of in-house trainers

Our sincere thanks to trainers A K Shinde, Basavraj Sambal, M B Kale, Mahesh Gharat, R U

Qureshi, S A Surve, Sachin S Desai, Santosh Dange, Zakir H Mulani

Trombay

Defensive driving training conducted at TATA

Colony, Trombay

Tejaswini training conducted at TATA Colony

for women

Training on Spandan, PTW, First aid & health care, LOTO, PTW, DMP & Fire fighting trainings

were conducted for own employees. “Safety training & IMS awareness training”, Confined space

entry & WAH, First aid & Fire fighting, DMP, were also conducted during the month for

Contractor employees. Photo showing safety induction for contractor employees

Wind Operations

Session on ‘PPE’ at Dalot wind farm Session on ‘General Safety’ at NSW wind

farm

Session on ‘PPE inspection Theory &

Practical’ at Poolavadi wind farm

Session on ‘Working at Height’ at Agaswadi

wind farm

Session on ‘Using Safety Harness’ at Gadag

wind farm

Session on ‘Safe Winch Operations’ at

Samana wind farm

4. Emergency Exercises

5. Corporate Safety Highlights – August’14

Conducted weekly field safety audit at following sites:

i. DCS (Parel, Sion, Powai)

ii. Transmission (Parel, Mahalakshmi, Carnac, Backbay)

iii. Transmission Projects (BKC, Saki – Salsette Line)

Reports have been sent to respective personnel for their CAPA

Corporate OHSF member participated in Office Safety High Visibility Safety Tour of Technopolis

Participated in interview panel to certify O&M Engineers from T&D prior for assigning independent charge

Assisted “Corporate Administration” in preparation of DMP and BCP of Corporate Functions.

Prepared Safety requirement for Rehabilitation work of Old Tunnel at Bhira as requested by Central Civil.

Corporate OHS members participated in Safety Bipartite Committee Meeting of CGPL Mundra, Jojobera, Transmission, Hydros, DCS, DSS, Kalinganagar, Wind O&M, Transmission Line and Trombay.

Scenario of ‘Food Poison’ in Sadawagapur

Wind farm

Scenario of ‘Food Poison’ in

Nivade Wind farm

Held Meeting with CTTL at Parel for JV and Subsidiary alignment.

EPM Audit for Fire Management System was conducted.

Arranged & conducted Train the Trainer Courses for Tata Power employees on Critical Safety Procedures with help of in-house trainers. The training feedback is given below for reference.

6. R&R for Safety – Aug’14

Divisional Safety Champion

CG

PL

Mr. Tushar N. Tripathi, Group Head – CHP, of CGPL is Division Safety Champion for August 2014. He has reported 28 unsafe conditions each during the month.

Hyd

ros-B

hira

Mr. Akshay Ramdas Gawade, Lead Engineer - Operations, Bhira is Division Safety Champion for August 2014. He has reported 01 Near miss and 01 unsafe condition during the month.

Hyd

ros-B

hiv

puri

Mr. Ganesh Bhosale, Lead Engineer - Operations, Bhivpuri is Division Safety Champion for August 2014. He has reported 02 unsafe condition during the month.

Hyd

ros-

Kh

op

oli

Mr. Sunil Y Pansare Group Head – Stores, Khopoli is Division Safety Champion for August 2014. He has reported 01 Near miss and 01 unsafe condition during the month.

Ma

ith

on

Mr. Nilesh Amber, Lead Engineer - Maintenance Planning, MPL is Division Safety Champion for August 2014. He has reported 02 unsafe conditions during the month.

Win

d

Op

era

tio

ns

Mr. Ramesh C, Asset Manager-Poolavadi, Wind Power is Division Safety Champion for August 2014. He has reported 08 unsafe conditions during the month.

7. Seat belt- Life saver (story of colleague) by Mirza D. Adhikari

Translated by Corporate Communication Hello,

I am Mirza D. Adhikari. I would like to share an incident. I am working in the Electrical

Maintenance Department at Bhira Generating Station. I have shifted my family to Karjat to

facilitate my son’s higher education. And I myself shuttle between Bhira and Karjat one or two

times in a week in my four wheeler. I usually follow the safety rules and use the safety belt while

driving. In earlier days I used to wear the safety belt in the span between Karjat to Pali and

since the traffic is not much thereafter, I used to do away with wearing safety belt, and used to

feel relaxed while driving my vehicle.

But sometime after that we had a road safety training session where we were shown the road

safety rules and a few video clips of road accidents. After viewing those video clips, I took a firm

decision to obey the safety rules for myself, for my family, and for all the people. Our Company

places prime importance on safety. As such, a number of safety related initiatives are

undertaken in our company from time to time, which has helped me a lot. And the most

benefiting were the video clips I had seen. After that, I started wearing the safety belt not only

between Karjat to Pali, but thereafter also right till my destination i.e. Bhira, and it has saved me

from a serious injury.

It so happened that some of the road traffic on the Mumbai – Goa highway was diverted via

Pali, and I was driving my vehicle towards Bhira for attending my duty. Somewhere near the

turn at Nandgaon after Pali, I saw a big bus coming towards me. We both were on our sides of

the road keeping safe distance between us so as to not to have collision, however, while we

were approaching the corner, one Qualis suddenly came up from behind the bus, trying to

overtake it at the corner, and it was heading on straight towards me. Apprehending that we

would surely collide, I took my vehicle away from the road on the side, but as the ground on that

side was uneven, my vehicle went out of balance careening into a pit along the side. And I must

say that just because I was wearing the safety belt, I was saved from a serious head injury.

Looking back on the incident, I have realized that wearing a safety belt is far much beneficial

than ever. Therefore, I would like to share this incident and would like to suggest to all that each

one of us should obey the safety rules, thereby ensuring our own as well as other’s safety. If I

had not taken the safety training, I would have continued to not wear the safety belt, and would

have suffered major injuries. I request the Company to have the road safety awareness

programs every now and then, to keep each one of us alert about safety for one and all.

8. Safety- a matter of life-third series by Sirdesai Narayan R

Safety awareness- A mother’s advice to her son A boy asks his mother Why is father these days talking so much about safety? Forgetting football and cricket this subject seems have caught his interest lately ! The mother replies that his father has learnt an unforgettable lesson of his life as his casual and careless colleague is in the hospital battling for his life He did not wear the uncomfortable arc suit while racking the old breaker inside and fell victim to a flashover that has left him severely burnt on his right side that ‘Prevention is better than Cure’ he has now sadly off late realized Please take utmost care of safety as it is a matter of your life. Beware accidents can happen anytime in the day or at night anywhere in the house, your backyard on the road or at site to anyone working underground, at road level or at heights to persons whatever be their gender, age, experience or might Please take utmost care of safety as it is a matter of your life. Accidents can happen to anyone whatever be his nationality, caste, color or creed do not blame it on destiny or fate and find an easy way out indeed ! That accidents are preventable should be our firm belief thoroughly analyse the root cause and implement remedies so that incidents do not repeat Always uphold safety principles and go unscratched throughout your life Please take utmost care of safety as it is a matter of your life. The mother then jokingly tells her son It is good your father is lecturing us on safety and not on football and cricket otherwise by neglecting safety he is likely to score a self goal or be out hit wicket ! Let the lamp of safety awareness glow very brightly all your life Please take utmost care of safety as it is a matter of your life

9. Root Cause Analysis (RCA) of incidents – Aug’14

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%

Sep'13

310

Oct'13

275

Nov'13

320

Dec'13

359

Jan'14

293

Feb'14

309

Mar'14

472

Apr'14

369

May'14

283

Jun'14

207

July'14

319

Aug'14

284

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%

Sep'13

176

Oct'13

136

Nov'13

156

Dec'13

181

Jan'14

141

Feb'14

168

Mar'14

195

Apr'14

179

May'14

140

Jun'14

127

Jul'14

228

Aug'14

167

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

50.0

Sep'13

199

Oct'13

115

Nov'13

145

Dec'13

165

Jan'14

138

Feb'14

120

Mar'14

213

Apr'14

202

May'14

183

Jun'14

111

Jul'14

261

Aug'14

131

System Factors Trend

Skill Level

Management / Supervision / Employee Leadership

Engineering / Design

Work Planning

Purchasing, Material Handling & Material Control

Tools & Equipment

Communication

Mental State

Note: Insignificant causes(consistently less than 5%)are not shown

Total no. of causes

10. Security Highlights

I. Trombay 01 Aug 2014 – Internal Mock drill (Level –III) for security personnel was carried out to

refresh the Proficiency of Coal Jetty Control Room operator and follow up actions in case of

any suspicious ship found drifting in our sea channel. Asst Security Officer and Security

Supervisor, Operators of Coal Jetty Control Room & RADAR/AIS System found efficient in

identifying the targets and establishing communication. Both operators were found

satisfactory in operating the Security Control Room of Coal Jetty.

02 Aug 2014 – On Job Training was imparted to security personnel at Main Gate for

checking of Visitor Management System, Material Movement Management System and

Contractor Staff Management System processes. Total 20 sec personnel participated in the

sessions.

11 Aug 2014 – The classroom training for security staffs were conducted for following topics:

Training on Handling of Emergency Situation

Mock drill - Suspected explosive device found during checking of vehicle

MOCK DRILL:

11 Aug 2014 – Mock drill was carried out (Level III) at Trombay by Force One Commando, QRT Eastern Region, Mumbai and RCF Police Station on terror attack situations – ‘Forced entry by terrorist and taking hostages’ at Unit # 7 CR Building from 2000 hrs to 0220 hrs. Col. P B Dalvi Head – Security and Dy SP AU Pathan of Force One guided team security and Force 1 during the mock drill.

Independence Day Celebration:

15 Aug 2014 - The Independence day celebration was observed at station - B. National Flag was hoisted by Mr. MP Mhatre, MO unit#5 at 0830 hrs. Employees and Security personnel were present during the celebration. The National Anthem was played on the central PA system during the flag-hoisting.

VIP Events:

28 Aug 2014 – Mr. Arunova Mukerjee (Vice President –Tata Cleantech Capital Ltd) along with high dignitaries from Netherlands visited in the Plant. The foreign delegations were received at Main Gate. Visitor passes were issued, safety instruction conveyed and the delegation were escorted as per the security process. Necessary traffic and security arrangements were made for smooth passage of the delegation.

II. T & D:

Security training workshop

A training programme for Security Guards working at various locations of T & D was organized at Mahalaxmi on 30 Aug 14. Total 30 Security Guards from different Security agencies participated in this training workshop. This training was structured in two parts:-

Conduct. The class room and Practical training covered the following topics:- (a) Introduction. (b) Safety instruction. (c) Duties and Responsibilities of Guards. (d) Documentations at the gate. (e) Movement of personnel and material. (f) Gate Passes & its procedures. (g) Type of Fires and its causes. (h) Vehicle entry procedures. (i) Knowledge sharing

The following practical training was also conducted;-

(a) Hand Held Metal Detector. (b) Walky-Talkies/Radio set Communication. (c) Use of Portable fire extinguisher.

III. CGPL(Mundra):

INDEPENDENCE DAY CELEBRATION: CGPL Mundra celebrated 68th Independence Day at site and Aashyana Township with full of enthusiasm, zeal & Zest. Chief Guest of the ceremony Sh. Krishna Kumar Sharma, Executive Director & CEO – CGPL, hoisted the National flag and paid homage to the freedom fighters; A BADA KHANA was organized at CGPL Canteen where in Mrs. & Mr. K.K. Sharma; Mr. Dinesh Kudalkar and Dr. NN Jha along with Security Members served the food to Security Guards.

Training On 03 Aug’14 Fire fighting Training for Security Staff was conducted. 01 Security Officer and

13 Security Guards participated in the training. Theoretical and Practical Training classes

were conducted and knowledge was imparted by the Fire Department Supervisor.

First-Aid Training:-

On 29th & 30th Aug’14 In-between 0930 to 1230 hrs & 1400-1700 hrs, a First Aid Training

camp was organized by CGPL OHC medical team headed by Dr. NN Jha & Dr. Jagdish

from JK occupational health center at Safety hall and CGPL canteen. Total 60 No’s of

Security personnel and many contractor associates were attended the training.

BLOOD DONATION CAMP AT CGPL SITE

A Blood Donation Camp was organized at CGPL safety induction hall. Total 64 people

participated in this camp.

Mock Drill:-

A mock drill was conducted at MCB # 3.5 Mtr. to gage the emergency preparedness of level

-2 emergency. Mock drill was initialed at 1655 hrs and after all clear order by incident

controller the exercise was called off at 1710 hrs.

IV. Jojobera:

Operational achievements – The security department by regular patrolling and active

intelligence inputs kept the thieves away. Head – Security motivated the security personnel

to attend various programmes to enhance their skills. We successfully conducted a number

of training programmes for the security personnel and other contract workers.

Skill Development

Training activities - A) Mr. Sunil Kumar, Head – Security and Mr. Kaushik Dutta, Lead Associate – Security attended training programme on capability building. B) Security awareness lecture/training were given to 146 contract workmen by us to make the contractors workmen aware of the Do's and Don’t‘s in respect to security, while working

inside the plant area. C) 74 security personnel of M/s SIS Security were imparted training on Fire Fighting, Ceremonial Parade, Procedures for checking/frisking contract workers body/bag and procedure of Night Patrolling.

Capability

Social activities – On 8th Aug 14 Mr. Sunil Kumar, Head –Security along with Mr. Barun

Kumar(CSR) attended a programme, “Paigam-E-Aman” organized by citizens of Jamshedpur to honour police officials. Mr. Sunil Kumar, Head –Security and Mr. A K Srivastav, Lead security attended independence day function in the nearby village (Vivek Nagar) where Mr. Sunil Kumar was invited as chief guest. Mr. Sunil Kumar, Head –Security along with other two security officers actively participated in organizing Homeopathic camp for villagers of the nearby villages on 29/08/14.

Head-Security unfurling the nation flag in community

Security Meeting- Mr. Sunil Kumar, Head Security attended meeting on 4th Aug 14 in DC

Office in which DC, ADC,SSP , SP (City) and other police officers were present. On 13/08/14, Head – Security met with ADM (Law & Order), DDC and DPRO at Gopal Maiden, Jamshedpur. Head - Security met with ADM (Law & Order) and ACIO, IB in the chamber of ADM on 21/08/14.

Meeting with OC PS Govindpur (Mr. Ashok Tiwari) in the chamber of Head- Security

Independence Day: celebrated in the plant premises. National flag was hoisted.

V. MPL(Maithon):

From 1st August 2014 Orion security agency has been inducted in MPL and taken over Security of coal handiling plant. Agency has replaced G4s security.

Football tournament was organized at MPL in August,2014 . Total 8 team took part Final match was played between Power staker (Security/Safety and Fire/Store) Vs Athletico (Operation dept). Power Striker won the Championship.CEO was Chief guest DSP Dhanbad Mr Raja Ram Prasad was guest of honor.

On 07.08.2014 Ash loading work was stopped by the local villagers. They all assembled

near Main Silo near ATM gateSituation handled effectively by security.

On 05.08.2014 iron scrap approx 200 kg at BHEL yard when the culprits were trying to

take this scrap out. Total recovery for the month is Rs- 27,200/- from verious locations.

Dharna organised On 11th August by Visthapit Samitti

Organised for their demands. It was over after 2 hours the

situation brought under control by security.

Independence Day was celebrated in the MPL Township, Maithon (AANANDAM).

In Month August 2014 deployed 07 Dogs in which (4 Rot wheeler and 3 Great Den).

Fencing of Open Plot By security staff:Ground in fornt of Security control room was open,

leading to unwanted gathering and Security issues . Security at its own decided to

barrricade the place with the use of old and scrap material-Photos before & after.

VI. Tiruldih Projects (Land Acquisition):

Awareness drive: On cleanliness in some of the trains passing through Muri railway station and up to Jhalida Railway station under Tata Voluntary Week- II.

WELCOME ABOARD We are pleased to welcome Mr. Kailash Hadawale, 204202, (Ex – NELCO) who joined Tata

Power w.e.f. from 06th Aug 2014, as Lead Associate–Security, Trombay.

11.

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