SAFETY & SECURITY NEWSLETTER

June 2012 Issue

MESSAGE DESK

.

CONTENTS

1 Texting behind wheels kills

2 Monsoon precautions for Motorists

3 Lessons Learned

4

5

6

7

Office safety meeting @ Technopolis

Safety theme Jun’12 – Gas Cylinder safety

Root Cause Analysis (RCA) of Incidents in Tata Power - May’12

Security Highlights

Thought for the month

Tomorrow - your reward for working safely today

1. Texting behind wheels kills

WASHINGTON: Texting and talking on cell phones behind the wheel kills more than 5,000 people every year on US highways. Teen drivers seem to be especially susceptible to distraction, a study says.

A 2009 study focusing on drivers of larger vehicles and trucks has concluded that texting raised the risk of a crash by 23 times compared with non-distracted driving, says an environmental report.

Environmental researcher Uvid Hosansky, who authored the report for the journal CQ Researcher, wrote, "Texting drivers took their eyes off the road for each text an average of 4.6 seconds, which at 90kmph means they were driving the length of a football field without looking."

Talking on a cell phone is also dangerous. "Experts say that talking on a cell phone while driving is far more distracting than talking with an adult passenger because it consumes additional cognitive resources, including creating a mental picture of the person on the other end of the conversation," added Hosansky, who was twice nominated for Pulitzer Prize.

The National Highway Traffic Safety -Administration, US, estimated that 16 per cent of all drivers younger than 20 years involved in fatal crashes were believed to be distracted, "the highest proportion of any age group," by texting and mobile phone use, reports the journal CQ Researcher.

"Although some people may think they can safely talk and drive, researchers who observe people in driving simulators as well as in actual cars on the road find that a cell phone conversation will invariably intrude on a driver's attentiveness," said Hosansky.

"The distractions don't stop with cell phones. Car makers are adding new technologies to the dashboard, such as web browsers and GPS units. Car makers say that such technologies are designed very carefully for safety, but safety advocates worry that they are creating even more hazardous driving conditions," Hosansky concluded.

2. Monsoon precautions for Motorists

In monsoons motorists are the affected road users due to adverse weather and road conditions. Here are some tips that help-

1. Roads become slippery after first showers due to accumulated dust and lubricants. Hence drive carefully and avoid sudden braking.

2. Check wipers, car battery, tyres & your spare tyres. Replace worn out tyres.

3. Check breaks, break oil and condition of the brake axel and brake liners.

4. Keep a spare muslin cloth near the steering wheel for cleaning the dampness on the windscreen as well as the rear view

mirror.

5. Keep a small hammer in the vehicle for breaking the wind screen of your vehicles, if the central locking system fails. Also keep a small torch handy in your car’s cabin.

6. Keep a fire extinguisher in your car and a First Aid Box.

7. Keep sufficient quantity of fuel in the fuel tank.

8. Check the central locking system of the vehicle and tool kit of your car.

9. Get your air conditioner serviced before monsoon.

10. Pickup traffic updates on the F.M Channels before starting your journey. The updates are

provided to all F.M Channels by the Traffic Control Room.

11. Please go through the list of low-lying areas in your city that generally gets flooded during monsoon for choosing the alternate route for your journey.

12. In case of heavy water logging, leave the car at assigned parking places. Avoid Frantic/repeated calls as such calls jam the cellular networks.

13. Whenever high tide is coinciding with heavy rains, the rain water clogs the drainage system. This results in flooding of low lying areas.

14. Pool your cars, save fuel and the hassle of driving yourself every day.

15. Keep 2 litres of water and dry snacks in your vehicle. It will come handy if you are trapped in jams.

16. Try staggering office hours to reduce congestion in the Public Transport System.

17. Do not panic. Traffic Police is always there to help you. Call Local Traffic Police Control Room.

18. Help others in distress - whenever & where ever possible.

3. Learning from incidents

3.1 Steam Burn - Maithon

Date : 07th May 2012. Time : 15.00 Hrs Location : Boiler #1, 72 meter Drum and

super heater vent floor Company : Tata Power Injury Type : Burn Injury on Left leg

Description : Unit #1 start up activity was in progress. The affected person was taking his round in the boiler at 72 meter where he received steam impact on his left leg. This opening (T-joint) is used for nitrogen filling valve of which was not completely closed. Due to number of vents/drains remaining open during cold start up, the leakage could not heard and being in superheated stage, the steam blow was not visible. Immediately water shower was given in technical building and sent to first aid center. As per advice of company medical officer in first aid center he was shifted to hospital at Dhanbad.

PHYSICAL FACTORS: 5.7 Inadequate isolation of equipment – the nitrogen "T" Joint valve was not completely closed.

HUMAN FACTORS: 3-1 Lack of knowledge of hazards present – the person was not aware of such hazards present 4-2 Distracted by other concerns – No. of vents/ drains were open which camouflaged the

sound and steam being superheated could not be visible 4-6 Failure to warn – steam was not seen due to superheated

SYSTEM FACTORS: 10.6 Inadequate assessment of operation readiness – all unnecessary valves to be kept in

closed condition. PSSR shall be conducted. 11.6 Inadequate monitoring - Inadequate erection of valve at T-joint by BHEL (The BTG

Vendor). Lessons Learned : 1. Inspection/ auditing/ monitoring shall be improved to identify incomplete jobs and complete

them in right sequence.

2. Before start-up/ light-up all the valve shall be ensured to be kept in required position i.e., systematic work planning shall be done. Pre-Start up Safety Review (PSSR) shall be conducted.

3. Avoid such openings directed towards the personal movement areas to the extent possible.

3.2 Electrical Flashover– CGPL Mundra

Date : 14th May 2012 Time : 11:30 Hrs Location : UCB#40, 12.5 meter Contractor : M/s Excel Injury Details : Superficial Burn Injury on Face,

Eye, Neck, Chest and Arm.

Description: Injured was assisting CGPL engineer on panel (415V)-7R3 hoist for ACW booster pump. He racked out module and kept on the floor. He attempted to pull down stuck safety shutter with an un-insulated screwdriver which accidently touched the live bus drop. Suddenly a minor flash-over occurred and he sustained superficial burns on Face, Eye, Neck, Chest and Arms. Injured person was immediately taken to CGPL OHC. After First Aid, he was referred to Bhuj hospital for further check up & treatment. Injured is relieved from hospital on 22.05.2012.

PHYSICAL FACTORS :

6-4 Defective tools - Screw driver was not insulated. 6-5 Inadequate tools - Screw driver was used to lift safety shutter which accidently touched

the live bus drop and caused minor flash over. 7-3 Energized electrical systems - Minor Flash over in panel (415 V) 7R3 hoist for ACW

booster pump.

HUMAN FACTORS: 3.2 PPE not used - Injured was not wearing safety goggle. 4-1 Improper decision making - Using screwdriver for releasing stuck safety shutter.

SYSTEM FACTORS : 14-3 Inadequate implementation of Policies/ Standards/ Procedures - PTW system was not

complied. 15-2 Inadequate vertical communication - Inadequate Instruction (Tool Box Meeting) given

to injured person.

Lessons Learned 1. Only trained and experienced person shall be allowed to perform such critical jobs.

2. Right tool for the job shall be exercised.

3. Systematic work planning shall be done.

4. Method statement and HIRA shall be prepared and implemented while working on live

electrical system.

5. PTW requirements shall be addressed to workers before start of work.

3.3 Fall from Height- CGPL Mundra

Date : 22nd May 2012. Time : 17.30 Hrs Location : Boiler # 30, 63 meter. Contractor : Seonghwa/ Indwell Injury Type : Fracture on Left hand, leg, left

Ribs and clavicle bone.

Description: Shifting of CRH temporary steam blowing pipe from Unit #30 to Unit #40 was being done. Before cutting the chequered plate, area was hard barricaded and lifting cleat was welded on the chequered plate. After gas cutting more than three sides, a small portion was left uncut. Injured person tried to anchor the chain block lifting hook to the cleat by stepping on the chequered plate which was hinging only on a small uncut portion and fell down from 63 meter to 52 meter elevation through floor opening. He was taken to OHC and for further treatment he was sent to Sterling Hospital.

PHYSICAL FACTORS :

6-6 Improperly prepared tools - Lifting hook of Chain pulley block was not anchored to the cleat of chequered plate prior to cutting

HUMAN FACTORS:

3-2 Personal protective equipment not used - Failure to anchor the lanyard 4-1 Improper decision making - Lack of risk perception

SYSTEM FACTORS :

5-2 Improper supervisory example - Inadequate supervision 11-1 Inadequate work planning - Material to be anchored prior to cutting

Lessons Learned

1. Prior to cutting, cleat must be welded and hooked up

2. Improve site-supervision. Pay special attention to young workers

3. Work shall be meticulously planned and executed

3.4 Fall from Height- CGPL Mundra

Date : 2nd June 2012. Time : 16.00 Hrs Location : TG 40, 10.5 meter, AB Row Contractor : BHEL Injury Type : Fracture on elbow, thigh and

pelvic bone.

Description : Alignment of IPBD duct of Unit #40 at 10.5 meter level was being done. After tightening the web sling for alignment, the injured climbed the near-by hand railing to avoid passing through a congested area by bending (narrow space between bus duct and hand railing). While moving on the railing he lost balance and fell from 10.5 m level to ground. He was given first aid at OHC and later taken to Accord Hospital- Bhuj. He is in stable and conscious condition. PHYSICAL FACTORS : 8-1 Congestion - Narrow access and egress 8-2 Inadequate illumination

HUMAN FACTORS: 1-1 Violation by individual - Adopting unauthorized method 1-5 Improper position for the task– climbing over hand railing instead of leaning down and

passing through the narrow passage

SYSTEM FACTORS : 5-5 Inadequate reinforcement of critical safe behavior - Inadequate supervision 15-2 Inadequate vertical communication between supervisor and person - Inadequate work

instructions

Lessons Learned

1. Avoid short-cuts

2. Improve site-supervision. Pay special attention to young workers

3. Improve Safety awareness through Aakar.

4. JSA should consider all risks based on the prevailing ground conditions

4. Office Safety Meeting @ Technopolis

5.

1st Office safety meeting (floor safety wardens) was held on 31.05.2012 at Technopolis office (centec) and chaired by Mr. Guha Debabrata.

5. Safety theme Jun’12 – Gas Cylinder Safety

6. Root Cause Analysis (RCA) of incidents in Tata Power – May’12

Human Factors Physical Factors

System Factors

7. Security Highlights

TROMBAY

Elaborate security arrangements were made for MOEF Team visit on 05th May 12, MERC officials visit on 30 May 12, delegation from Exxaro Resources Ltd., South Africa on 23 May 12.

On 09th May 12, Red Alert was declared by Chief Security & Vigilance based on intelligence information received from police. All security personnel were kept on high alert.

Data bank of contractor’s staff is being generated for Access control System.

T & D

On 31 May 2012 Training was provided for Security Guards deployed at Ambernath Receiving station. As a part of training, fire fighting demonstration was also carried out by Exxon fire services.

Hydros

New Watch Towers with search light were installed at Bhivpuri junction & Patra Gate.

CGPL

On 4th May’12: Boiler Inspector visited CGPL. Mr. Guha, Chief- Corporate Engineering, visited CGPL site on 14th & 15th May. He visited

the Boundary wall & security surveillance areas and took part in a meeting with security and civil Departments.

On 24th May’12 Exxaro Delegates along with Mr. S.Padmanabhan, Executive Director (Operations) and Mr. Shubh Shrivastava, Chief – Global Power Business visited CGPL.

Labour Head Count Exercise (LHC) was conducted twice in May’12 (on 1st & 3rd week) in all the access locations like Main gate, Hostel gate & Tunda end wicket gate, L/colony & CGPL Township.

On 12th May’12 the first “ENTRY PERMIT” campaign was organized at CGPL Township. On first Saturday a total 365 labors with their concerned contractors were reported for TEP out of which 158 were issued their entry permits.

Daily vehicle speed monitoring during rush hours with speed gun is in progress.

Mock Drill depicting a fire scenario in one of the CGPL warehouse was conducted to check the emergency preparedness.

JOJOBERA

The construction of security barrack is in progress. Security induction was given to 169 contract workmen to make them aware of the Do's

and Don’ts while working inside the Plant area. Security training was imparted to 29 security personnel of SIS. The security officers actively participated in Blood donation camp organized by Tata

Power. MPL

On 19 May 2012 , in continuation of the training capsule “Fire awareness training at your door step “ training was imparted to Care services on First-aid and basic fire

fighting covering 24 participants.

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