SAFETY & SECURITY NEWSLETTER

November 2014 Issue

MESSAGE DESK

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CONTENTS

1 Safety on the stairs

2 Lessons Learned

3 Safety training

4 Emergency Exercise

5 Corporate Safety highlights

6 R&R for Safety – Oct’14

7 Root cause analysis (RCA) of incidents – Oct’14

8 Security Highlights

Thought for the month

Hold rails while moving on stairs!

1. Safety on the stairs

2. Lessons Learned

2.1 Electrical Shock & Fall from height

Division : CGPL

Date of Incident : 26th October 2014

Type of incident : LWDC

Incident Time : 20:32 Hours

Description of Incident:

A Flashover in outgoing male-female finger contacts of MCCB module resulting in arcing and

ionization which travelled to incomer side of MCCB creating 3 phase bus fault to 415 V Bus 2.

The four persons, who were present in the vicinity, received burn injuries due to the flash over

and were immediately shifted to Occupational Health Centre for First Aid treatment and

subsequently shifted to Adani Hospital, Mundra

Congested Work Area Deceased standing on wall

Root Cause Analysis

Human Factors

NIL

Physical Factors

5.1 Inadequate Guards & Protective devices - Only one out of three panel door locks was

locked.

System Factors

10.1 Inadequate Technical Design –

a)Absence of Shrouding / insulation of bare copper bus, incoming side of MCCB.

Absence of insulation barrier between phases.

b) Poor contact of sliding jaw mechanism of draw out type module

c) Flimsy Panel door locks.

11.2 Inadequate Preventive Maintenance - Delay in Fault clearance

11.6 Inadequate monitoring/inspection – frequent start of motor.

Recommendations:

1. Shrouding of bare copper bus in MCCB modules to be carried out.

2. Module power contact alignment and spring tension to be checked and defects to be rectified.

3. Panel door lock to be replaced by metallic bolts.

4. Ensure all panel door locks are in closed condition. To be added in checklist for

equipment start procedure.

5. Setting of instantaneous relay for 415V incomer breaker was determined at site. Balance

relay settings were provided by TCE. These need to be reviewed / validated by TCE/

QAIT.

6. CT secondary sliding contacts to be replaced by fixed or plug type connection.

7. Joints between aluminium and copper bus bars shall be with bimetallic washers.

8. 415V incomer and bus coupler relays to be replaced by Numerical relays with FDR

feature.

9. Clearances of 415V bus are less near racking mechanism and support insulator live bolt

and feeder separation plate. Phase isolation busbars / insulating tapes to be provided.

10. Survey to be conducted for missing shutters. Same to be installed.

11. The bolted joints of the busbars are to be properly tightened to avoid formation of

hotspots and heating of the busbars in general.

12. Panel no. and Feeder Description are to be clearly mentioned on the panel door.

13. BASP#3A and #3B are not included E-PTW. To be developed.

14. All unwanted openings in the panel to be sealed permanently.

15. Vendor recommendation regarding hourly number of starts and minimum rest time between starts (For both hot and cold starts) are to be adhered to.

3. Safety training

Train The Trainers on Critical Safety Procedures for Q2 conducted during 19th August To

22nd August 2014 at Trombay First Trained the Trainer programme on Critical Safety Procedures was conducted in Q2 at Trombay from 19th to 22nd August 2014. 125 O&M engineers undergone this trained the trainers programme. Similar programme are also planned for Q3 & Q4 to cover more O&M engineers in order to develop their safety competency. We appreciate the trainers to extend their help in developing internal trainers for Critical Safety Procedures. Details of nine Instructors conducted Q2 programmes are given below.

Mr. Zakir Mulani conducted Working At Height training on 19-08-

2014

Mr. R U Qureshi conducted Sloping & Shoring training on 19-08-

2014

Mr. M B Kale Confined Space training on 20-08-2014

Mr. Mahesh Gharat conducted Permit To Work training on 20-

08-2014

Mr. Sachin S Desai conducted Incident Investigation training on

21-08-2014

Satish A Surve A K Shinde

Mr. Satish A Surve & A K Shinde jointly

conducted Lockout Tag out training on 21-

08-2014

Mr. Santosh Dange conducted Heavy Equipment Safety training

on 22-08-2014

Mr. Basavraj Sambal conducted Mobile Crane Safety training

on 22-08-2014

Training programs at various divisions

Trombay

Training on LOTO, PTW, DMP & Fire fighting trainings, working at height & scaffolding safety

procedures were conducted for own. Apart from Safety Induction, “Safety training & IMS

awareness training”, Working At Height trainings conducted during the month for Contractor

employees.

Wind Operations

Session on “Supervision for Safety” at Samana, “General Safety” at Sadawagapur, “First

Aid” at Dalot, “Emergency Response & HIRA” at Gadag, “JSA” at Nivade, “Safety in

Hydraulic Systems” at Poolavadi, “Hazard” at NSW, “MSDS” at Agaswadi, “Supervision

for Safety” at Visapur wind farms were conducted

4. Emergency Exercises

Scenario of ‘Unconscious Person’ in

Sadawagapur Wind farm

Scenario of ‘Fire ’ in Nivade Wind farm

5. Corporate Safety Highlights – October’14

Conducted weekly & quarterly field safety audit at following sites:

1. DCS (CSS at Goregoan Sports Club, Boriwali -Green ridge substation, Sai Das CHS

CSS - Versova)

2. Transmission (Vikhroli, Mankhurd, Dharavi, Parel, Mahalaxmi)

3. Transmission Projects (Mahalaxmi, Boriwali, 110kV cable project at BKC, 220kV

Trombay-Dharavi – Salsette line).

4. DSS (Godrej tower-Vikhroli, 33 kV Vijay Nagar CSS, Boriwali, Powai & Cable Laying

Project, LBS road)

5. Trombay (U#8, U#5 ESP & switch yard)

Corporate OHSF member participated in Office Safety High Visibility Safety Tour of Mahalaxmi.

Corporate OHSF member conducted “Tarang” session on “Risk assessment”. Organized Basic Fire Safety & Life Safety training program at Parel for office based

employees. Prepared & finalized booklet on “Learning’s from incidents FY-14”. Forwarded to Corp.

Communication team to review & share across Tata Power.

Prepared analysis of road accidents for formulating guidelines on travel related risk.

6. R&R for Safety – Oct’14

Divisional Safety Champions

CG

PL

Mr. Tushar N. Tripathi, Group Head – CHP, of CGPL is Division Safety Champion for October 2014. He has reported 18 unsafe conditions each during the month.

Tra

nsm

is

sio

n

Pro

jects

Mr. Mayuresh Deodhar, Specialist-Transmission Projects is Divisional Safety Champion for October 2014. He has reported 18 unsafe conditions each during the month.

Tro

mb

ay

Mr. Magar R B, Control Room Engineer-Trombay is Divisional Safety Champion for October 2014. He has reported 04 unsafe conditions each during the month.

Win

d

Op

era

tio

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s

Mr. Subhakanta Nayak, Asset Manager-Samana is Divisional Safety Champion for October 2014. He has reported 11 unsafe conditions each during the month.

7. Root Cause Analysis (RCA) of incidents – Oct’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%

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

Sep'14

283

Oct'14

205

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%

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

Sep'14

187

Oct'14

125

Cau

ses

Physical Factors Trend

Inadequate/ defective tools, equipment & vehicle Work exposure to

Workplace environment layout Inadequate/ defective protective system

Total no. of causes 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

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

Sep'14

263

Oct'14

121

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%) arenot shown

Total no. of causes

8. Security Highlights

I. Trombay Training Events:

05 Oct 2014 – On-job-training of MGB Security personnel and permanent sec staff was

conducted at FOT Area & Material gate. Total 47 security personnel participated in the

training. Following topics were covered during the training session:

12 Oct 2014 –16 Oct 2014 – On job training for ESM security personnel was conducted on Port Security Procedure and Physical Checking under ISPS Guidelines at Coal Jetty by PFSO. Total 13 sec personnel attended the session.

22 Oct 2014 - “Samvaad”-An Employee Interaction Session Chief – Trombay was conducted for security personnel by HR Trombay.

MOCK DRILL: 16 Oct 2014 – Business Continuity Planning (BCP) Exercise cum Mock Drill of Level II under DMP Guidelines was carried out in the plant area.

Events:

Dussera Pooja: 03 Oct 2014 – Dussera Pooja was organized by the security staff on the auspicious occasion. Security staff and their family members attended the Pooja function.

28 Oct 2014 – 29th Oct 2014 – Security Audit was carried at Trombay Plant by Mr. G R Bhatti Asst Director, Mr. P K Bahree Dy. Central Intelligence Officer (DCIO) from Intelligence Bureau (I B), MHA, New Delhi. They were also assisted by Mr. S K Choube Dy. Central Intelligence Officer (DCIO) IB, BKC, Mumbai, Mr. R S Kokate Asst Commissioner State

Intelligence Department (SID, Maharashtra) and Asst Inspector K B Kharat from Security Branch, Mumbai. Audit Officials visited at CWPH, Coal Jetty, Plant Perimeter Area, Main Gate, Gate No. 2, Security Command & Control Room, PSCC, Fire Dept, Unit # 5 & 7 CR, Server Room at Prabhadevi.

GREENOLUTION

II. Jojobera

Operational achievements – The security department developed a good and effective relationship with community. It has also developed a good network in the community. Head – Security motivated the security personnel to attend various training programme to enhance their skills and successfully conducted a number of training sessions. No untoward incident occurred during the month.

Training activities - A) Security awareness lecture/training were given to 290 contract workmen by us to make the contractors workmen aware of the Do's and Don’ts in respect to security, while working inside the plant area. B) 79 security personnel of M/s SIS Security were imparted training on how to perform static guard duty, Procedures for patrolling in Wagon Tippler area, Vigilance duty and technique of searching vehicles.

Training on Vigilance Duty Training for duty at wagon tippler, Training to contract workforce

Social activities – On 2nd Oct 2014 Mr. Sunil Kumar, Head –Security along with Mr. Kaushik Dutta, Lead security attended a social function in the nearby village (Rahargora) where Mr. Sunil Kumar was invited as chief guest. Head –Security along with other two security officers actively participated in organizing Homeopathic camp for villagers of the nearby villages on 17/10/14.

IN VILLAGE RAHARGORA (2nd Oct 2014)

III. T&D

A training workshop for private security guards of Transmission and Distribution was

conducted at Boriwali receiving station on 12 Oct 14. Total 29 security personnel’s are

trained in this workshop programme.

The following topics were covered during the training:-

Security Process.

Job Description of Security Guards.

How to use communication Radio Sets

(Practical) Training.

Practical Training on frisking/checking

by HHMD.

Security Documentation.

Knowledge sharing session and etc.

IV. CGPL(Mundra):

TBEM Team VISIT: On 05th Oct’14, TBEM Audit team Mr. Jon Ferryman

and Mr. P. Anand arrived at CGPL Site (Project Office)

meeting with CEO & ED Mr. KK Sharma, Mr. Dinesh

Kudalkar (Head O&M) and all HOD’s after meeting

visited various locations of CGPL Plant and nearby

villages, HOD Security Capt. VK Dogra and LA-

Security Mr. Sheril T accompanied them.

Nilofar Cyclone Alert Boom: Temporary shops inside plant premises were dismantled with

the help of security staff.

Central briefing session has been carried out for

Security staff by LA-S Mr. Sheril T. and LA-S Mr.

PS Chouhan, Rescue methods and duties during

cyclone disaster were explained during the

briefing. Day/Night rescue teams were constituted.

An emergency meeting held in CGPL Conference

room for preparedness of Nilofer Cyclone, Sh. KK Sharma CEO & ED chaired the meeting

and Sh. D Kudalkar Chief –O&M and all other HODs attended the meeting, an Emergency

Control Room is set up inside Security Control Room-CGPL, Sheril T. LA-S attended the

meeting for Head Security.

EMERGENCY CONTROL ROOM FOR NILOFAR CYCLONE- INSIDE SECURITY

CONTROL ROOM

V. MPL (Maithon):

On 25th Oct’14 Dharna held by Madam Aparna Sen Gupta was called off at 0415 hrs after meeting with MPL Team at main Gate. Following remained highlight of this Dharna:

Main Gate was closed after our employee bus entered.

Dhambooi Gate was closed after vehicle entered plant premises.

Ample Security personnel from both BSS and Orion Security were deployed to counter any situation.

Suitable force under one ASI was given from Nirsa PS also.

Magistrate and Ample Police force was deputed by District Administration to maintain Law and Order.

We were able to provide Security cover to employee for smooth functioning of Plant without any disturbance there.

CORPORATE SECURITY-TATA POWER

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