SAFETY & SECURITY NEWSLETTER

July 2014 Issue

MESSAGE DESK

.

CONTENTS

1 Explanation of Safety Targets FY’15

2 Lessons Learned

3 Safety training

4 Emergency Exercise

5 Corporate Safety highlights

6 R&R for Safety – June’14

7 Safety – a matter of life – Sequel

8 Root cause analysis (RCA) of incidents – June’14

9 Security Highlights

Thought for the month

To avoid a scene, keep your workplace clean!

1. Explanation of Safety Targets FY’15

1. Pro-active Targets (Lead indicators):

a Annual Safety

Plan(ASP)

100% implementation of Annual Safety Plan for FY15.

Annual Safety Plan-FY'15 will be uploaded in Safety Inspection Module in SURAKSHA with target date for each item as last day of the month / quarter / year as per schedule. Sites will update the status against each action due for the month and Hyperion system shall compute compliance to ASP based on percentage completion of the activities due for a particular month.

b PTW Audits

Audit four (04) PTWs issued for medium & high risk jobs on a weekly basis.

PTW data is linked with SURAKSHA Safety Inspection module. This is existing feature and no change is proposed in the configuration. Each division to audit 4 PTWs issued for medium & high risk jobs on weekly basis which means that they have to complete annually (52*4 = 208) audits. Or in other words the monthly target is rounded off to 18 (208/12). This figure will be monitored by Hyperion every month. For all low risk / priority jobs not requiring PTW, the activity will be carried out under adequate supervision as well as after necessary Risk Assessment.

c Safety

Inspections

i) Achieve 90% adherence to critical safety equipment inspection schedule

The list of critical and regulatory inspections to be done by each site has been re-defined. Refer to sheet 2. From Critical safety equipment list Excavation, Confined space and Scaffold inspection have been removed since these are mandatory (100 % inspection) as per the procedure. Hence there is no monthly target for these inspections. From Regulatory list, PTW has been removed since it is already included as a separate target. Divisions are requested to confirm in writing if any other type of inspection is to be included either under critical or regulatory list. Compliance for each type of inspection shall be monitored every month

ii) 100% adherence for items listed in regulatory compliance.

iii) Publish comprehensive report highlighting all safety issues, post completion of major outage (>=7 days) by respective division (O&M) - 100%

a) For major outages which are ≥ 7 days a report needs to be generated by respective division highlighting safety issues observed & corrective actions taken. b) If there are no outages for the month or there are no safety issues observed during the outage in the month, respective Division Safety Head should fill the report indicating no outage or no safety issues. c) Format will be available in Safety inspection module.

d Repetitive Near miss

Achieve 25 % reduction in number of near misses for all repetitive immediate causes reported in FY’14.

25% reduction will be considered for Top immediate cause category reported in FY'14 for each division. Total number of near misses in Top category reported in FY'14 will be divided by Twelve (12) for monthly base data. 25% reduction on monthly base data will be target for repetitive near miss.

e STOP

Observations (SO)

80% of STOP trained employees doing a minimum of 1 STOP observation per week.

Safety Observation data is linked with SURAKSHA BBS module. SURAKSHA will be configured on weekly basis as per the following criteria i) Week1: 1st to 7th ii) Week2: 8th to 14th iii) Week3: 15th to 21st iv) Week4: 22nd to last day of month

f

Safety Intervention

Audit Training (SIAT)

Address all repetitive unsafe events (Unsafe Acts/Unsafe Conditions /Near Misses) proactively by conducting SIAT (safety Intervention Audit training) and ensure timely close-out of action items including training, supervision, engineering interventions.

Each division has to submit SIAT report in SURAKSHA Safety Audit module.

(i) Project sites - At least 2 SIAT audits per week.

(ii) Operating units - At least 1 SIAT audit per week.

g Safety

Training Index

Attain minimum of 0.4 training index per month (Excluding Tool box talk & Induction).

Safety Training Data is linked with SURAKSHA IRIS module. Formula will be = Total Capability Building training hours x 100/ Man hours worked

h

Implementation of

Recommendations

100% implementation of recommendations arising from Safety Audits and inspections, SIAT, Contractor Field Safety Audit (CFSA), High Visibility Tour, PTW audits, Field Safety visit, Town Hall meeting, as per timelines agreed.

Total recommendations completed from Safety audit + Safety inspection + BBS + CFSA / Total recommendations from Safety audit + Safety Inspection + BBS + CFSA

2 Reactive Targets (Lag indicators):

a Fatality: NIL.

(a) Numbers linked with SURAKSHA IRIS module. (b) Fatality is a death resulting from an injury or illness, regardless of the time intervening between injury and death

b

Loss Time Injury

Frequency Rate

(LTIFR):

ZERO.

(a) Numbers linked with SURAKSHA IRIS module. (b) The total number of Lost Time Injuries per million hours worked during the period. (c) Calculation: (No. of Lost Time Injuries (LTI) x 1,000,000) / Man-hours worked

c

Loss Time Injury

Severity Rate

(LTISR):

ZERO.

(a) Numbers linked with SURAKSHA IRIS module. (b) The total Mandays lost per million hours worked during the period. (c) Calculation: (Mandays lost x 1,000,000) / Man-hours worked. (d) Days lost due to injury in previous periods, that is, if any accident which occurred in previous period is still causing loss of time in the period under review, such loss of time is also included in the period under review. (e) Mandays lost will be counted till the date that the respective division submits fitness certificate of the injured person(s).

d Incident

Investigation

i.100% completion of Root Cause Analysis (RCA) for all incidents including investigation of all High Potential incidents by CFT as per incident investigation procedure. ii.100% implementation of Corrective and Preventive Actions (CAPA) within target date by action owner as identified in the investigation for all incidents including low and medium severity.

(a) Safety data linked with SURAKSHA IRIS module. (b) All incidents irrespective of their nature and magnitude need to be analyzed using RCA module in SURAKSHA portal. (c) In addition to RCA, all High Potential (HiPo) incidents need to be investigated by Cross Functional Team (CFT) as per incident investigation procedure. (d) All recommendations arising from incident investigations to be implemented within target date by action owners (e) Calculation of CAPA: (No. of action items completed which are due for the month + overdue action items from previous period + action items of future target date completed in the month under review) x 100 / (Total action items due for the month + total overdue action items before period under review + action items of future target date completed in the month under review)

e Sharing of

lessons learned

Issue Lessons Learned for all High Potential incidents (near-misses and occurrences) and LTI.

(a) Data is linked with SURAKSHA IRIS module. (b) Based on the outcome of investigation, issue “Lessons Learned” using standard format within 30 days of occurrence.

2. Lessons Learned

Division : TPDDL

Date of Incident : 1st June 2014

Type of incident : LWDC (Burn & Head Injury)

Incident Time : 13:30 Hours

Description of Incident :

While tightening HT fuse of 315 kVA D.T at Pole No. HT522-27/48/7-8, a flashover took place

and the Lineman (Sanjay) fell down striking his head against the pole and ground. He sustained

burn injuries on hands and legs as well as head injury.

Initially he was taken to Raja Harish Chandra Hospital from where he was referred to ESI

Hospital. Later he was referred to Safdarjang Hospital as Safdarjang Hospital is having better

neurological and burnt treatment facilities

SLD OF THE SECTION AND THE TRANSFORMER

SLD OF THE SECTION AND THE TRANSFORMER

TRANSFORMER - F - 1962 One G.O blade did not disengage properly

Root Cause Analysis:

Human Factors:

1.1 Violation by Individual - PTW process was not followed, Ladder not used, DD fuse

operating rod used for wrong purpose, safety chain not used for grounding

1.4 Operation of equipment without authority - The victim was not authorized for 11 kV

operations.

3.2 Personal protective equipment not used – Safety Belt not used

Physical Factors

5.7 Inadequate isolation of process or equipment - PTW process was not followed to ensure

safety zone / complete isolation

7.3 Energized electrical systems - The victim attempted to replace the fuse by opening G.O

switch without calling for ZSO or any other Zonal representative

System Factors

6.2 Inadequate practice of skill - There was a definite lack of domain knowledge and

knowledge for identifying risks of the victim. He could not acknowledge the risk posed by one

G.O Blade having insufficient gap with a charged contact.

11.6 Inadequate Monitoring - The work in question required supervision by an authorized

personnel which was not asked for by the lineman as per contract.

12.0 Material Control – Control of consumable / spares based on authorization for working on

LT/HT equipment

13.5 Inadequate repair / maintenance - The G.O blade of the B phase of the transformer in

question was found to be defective

14.3 Inadequate implementation of PSP (Policy, Standards and Procedures) - The scope of

work in LT and HT line is clearly identified in Contract terms and conditions including

requirement of PTW

Recommendations

1. Ensure usage of all PPEs, proper ladder and prescribed tools and tackles at all times

2. Ensure Adherence to PTW guidelines

3. Ensure supervision for all fuse blown cases in Industrial HVDS areas.

4. Focused training to L/M attached to Breakdown activities

5. Mapping of competency of lineman and issuing badges according suitability in functions

in which Lineman are fit to serve like Breakdown, NCC, Maintenance, Street Lighting

6. A systematic process shall be in place to ensure that consumable / spares based on

authorization for working on LT/HT equipment is issued to appropriate personnel

7. Implementation of Contractors Safety Management – Consequence Management Policy

Click here for detailed report

3. Safety training

Disaster Management Plan (DMP), LOTO, working at height, Training on rescue Operation

(Chimney), Office safety, External defibrillator, B.A Set trainings were conducted for own

employees. Basic safety & IMS awareness, Workings at height, first aid and fire fighting

trainings were conducted for Contractor employees. Picture showing Safety Induction at

Trombay

Session on ‘Supervision’ at Poolavadi wind

farm

Session on ‘Electrical Safety Identification’

at Gadag wind farm

Session on ‘Near miss awareness’ at Samana wind farm, Agaswadi wind farm & Dalot wind

farm

4. Emergency Exercises

Scenario of ‘Snake Bite’ in Bramanwel

Wind farm

Scenario of ‘Snake Bite’ in Nivade Wind

farm

5. Corporate Safety Highlights – June’14

Conducted weekly field safety audit at following sites:

i. Trombay

ii. Transmission Projects (Dharavi GIS, Powai, BKC, Bhivpuri & Khopoli)

iii. DSS (DZ-2)

iv. DCS North, Central & Metering

v. Transmission (Chembur, Mankhurd, Vikhroli, Borivali, Malad, Versova)

Reports have been sent to respective personnel for their CAPA.

Conducted quarterly safety audit at MEPL Nellore & BORL-Bina site

Conducted Apex Safety Bipartite Meeting

Corporate OHS members participated in Safety Bipartite Committee Meeting of Transmission, Transmission Line, DCS, and Trombay

Head Corp OHS attended Safety workshop organized by TESCO

6. R&R for Safety – June’14

Divisional Safety Champion

CG

PL

Mr. Suresh H. Khetwani, Head - Construction, CGPL is Division Safety Champion for June 2014. He has reported 12 unsafe conditions during the month.

DS

S

Mr. Onkar Pande, Lead Engineer-Dist. Capex is is Division Safety Champion for June 2014. He has reported 08 unsafe conditions during the month.

Hyd

ros –

Bh

ira

Mr. A L Mengade, Hydros – Bhira is Division Safety Champion for June 2014. He has reported 02 unsafe conditions during the month.

Hyd

ros –

Bh

ivp

uri

Mr. Mendgudle Dhanappa D, Head - Bhivpuri Hydro Power Station is Division Safety Champion for June 2014. He has reported 01 Near miss & 01 unsafe condition during the month.

Hyd

ros –

Kh

op

oli

Mr. A.R. Kedari, Operations, Hydros – Khopoli, is Division Safety Champion for June 2014. He has reported 01 Near miss & 01 unsafe condition during the month.

Mai

tho

n

Mr. Umesh Gautam, Shift Incharge – Operations, MPL is Division Safety Champion for June 2014. He has reported & 16 unsafe conditions during the month.

Tran

smis

sio

n

Mr. K. K. Datar, Borivali is Divisional Safety Champion for June 2014.

Tra

nsm

issio

n

Pro

jects

Mr. Thakore Viral, Specialist - Trans. Projects, is Division Safety Champion for June 2014. He has reported 01 Near miss & 16 unsafe conditions during the month.

Tro

mb

ay

Mr Mondkar Bhikaji S, Senior Fire Operator, Trombay is Division Safety Champion for June 2014. He has reported 08 unsafe conditions during the month.

Win

d O

pera

tion

s

Mr. Abhijeet Kore, Asset Manager-Dalot, Wind Power is Division Safety Champion for June 2014. He has reported 06 unsafe conditions during the month.

STAR Safety Champion for Q1 FY’15

CG

PL

Mr. Anand Kumar Tiwari, Lead Engineer - Mechanical Maint., CGPL is Divisional Star Safety Champion for 1st Quarter FY’15

DS

S

Mr. Sagar B Patne, Lead Engineer - Distribution CAPEX, DSS, is Divisional Star Safety Champion for 1st Quarter FY’15

Ha

ldia

Mr. Sukhendu Maity, Lead Engineer - Mechanical Maint., Haldia is Divisional Star Safety Champion for 1st Quarter FY’15

Hyd

ros -

Bh

ira

Mr. N T Kudpane, Bhira MMD is Divisional Star Safety Champion for 1st Quarter FY’15

Hyd

ros -

Bh

ivp

uri

Mr. B.Y.Jambulkar, Hydros Bhivpuri is Divisional Star Safety Champion for 1st Quarter FY’15

Hyd

ros -

Kh

op

oli

Mr. N.R.Deshmukh, Hydros Khopoli is Divisional Star Safety Champion for 1st Quarter FY’15

Mai

tho

n

Mr. Umesh Gautam, Shift Incharge – Operations, MPL is Division Safety Champion for June 2014.

Tran

smis

sio

n

Mr. P. P. Kamble, Transmission camp, Transmission is Divisional Star Safety Champion for 1st Quarter FY’15

Tra

nsm

issio

n

Pro

jects

Mr. Mayuresh Deodhar, Specialist-Transmission Projects is Divisional Star Safety Champion for 1st Quarter FY’15

Tro

mb

ay

Mr. G V Hariraman, Assistant Foreman, Trombay is Divisional Star Safety Champion for 1st Quarter FY’15

Win

d O

pera

tion

s

Mr. Namdev Shelake, Asset Manager - Visapur and Nivade, Wind Operations is Division Star Safety Champion for Q1 FY’15.

7. Safety - a matter of life-Sequel by Sirdesai Narayan R

Safety-Outage and Safety procedures After JSA, PTW, checking PPE and tool box talk Please confirm with the Receiving station and PSCC the outage that you are availing Check the isolations and do the site cordoning and barricading Confirm the grounding and implement LOTO on both sides Please take utmost care of safety as it is a matter of your life. Always be aware that you are working on life threatening voltages After testing the neon tester check the terminals for electrical charges Further, ground the equipment using a proper earthling rod then after putting portable grounds, set about safely carrying out your job This will fulfill the outage safety requirements at site Please take utmost care of safety as it is a matter of your life. For excavation work look for trench caving in and shoring and sloping For working at heights check the ladder and erect proper scaffolding For confined space work check oxygen level, flammability, toxicity and lighting Do not ignore early warning signs of hazardous or unsafe conditions at site Please take utmost care of safety as it is a matter of your life. For working on GOD’s use life line and platform with grating Whilst working on power cables do so only after proper identification and spiking when climbing towers use three point contact and while working check your anchoring With regards to safety do not in any way seek a compromise Please take utmost care of safety as it is a matter of your life. Safety is not a rocket science and can be easily followed by all alike Please note safely unawareness and violations have caused untoward incidents to rise Better give careful thought to safety at work ’NOW’ than embrace guilt feeling and suffering all your life Our nature of work is such that you won’t stand a second chance to set things right Please take utmost care of safety as it is a matter of your life. Diligently follow the safety rules and do not make any haste Free of fear, enjoy doing your work and return home safe Your life is too precious for your family so always take safety in your stride Your coming home cheerful, hale and hearty is what your family expects from your side Do not dash their hopes by ignoring safety and playing with your life Please take utmost care of safety as it is a matter of your life

8. Root Cause Analysis (RCA) of incidents – June’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%

50.0%

Jul'13

336

Aug'13

324

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

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%

Jul'13

186

Aug'13

184

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

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

10.0

20.0

30.0

40.0

50.0

60.0

Jul'13

165

Aug'13

202

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

Ca

us

es

System Factors Trend

Physical Capability

Physical Condition

Training or Knowledge Transfer

Contractor Selection & Oversight

Management / Supervision / Employee Leadership

Engineering / Design

Work Planning

Purchasing, Material Handling & Material Control

Tools & Equipment

Work Rules / Policies / Standards / Procedures (PSP)

Communication

Mental State

Note: Insignificantcauses (consistentlyless than 5%) are notshown

Total no. of causes

9. Security Highlights

I. Trombay 05 June 2014 – On eve of World Environment Day & Environment Week, Head – Security

and security staff participated in various awareness session, quiz competition, tree

plantation programs.

08 June 2014 – Training session was conducted for total 10 security personnel from M/s

Solaris security at Coal Jetty. It was conducted towards the ISPS compliance and the topic

was ‘Port organization and Handling of cargo’. In addition training was conducted for

handling of security gadgets.

10 and 14 June 2014 - A session for on-job-training of MGB Security personnel was conducted for the following topics:

1. Drill, Turn out, Knowledge of duties at designated Security posts and handing and taking over processes .

2. Core Processes of Security. 3. Handling of Security gadgets.

Total 40 and 42 security personnel participated in the training.

11 June 2014 – Courtesy visit was made at RCF Police Station to welcome newly

designated Sr. Police Inspector D V Raut by Chief – Trombay and Head – Security.

15 June 2014 - A monthly meeting cum- on-job training of security staff was conducted

at Main Gate for the following topics. Total 17 security personnel participated in the training.

1. IMS Policy 2. Awareness on HIRA 3. Physical security 4. Access control System 5. Value adding

15 June 2014 – ‘Ammonia Gas Leak’ Mock Drill was carried out by MMD Team at around 1015 hrs in Unit # 5 Ammonia Store. After receiving information, prompt action initiated by shift security officer, QRT and security staff at the scene of incident in evacuating personnel, cordoning off area and regulating traffic. The reaction of security staff was prompt and quick.

16 June 2014 - At 1400hrs seven men team of Force1, including their liaison Officer, API Palande were familiarized with the topography of the Company area. They were briefed about the entry exit points and vulnerable areas. Locations i.e. Bund Gate, Coal Jetty, CWPH & AFCON Jetty were shown to them explaining their significance and reason for the location being vulnerable. Further General Recce of unit # 8 and admin building was carried

out for better understanding of the floor plan and emergency exits and work areas. Finally they were debriefed at conference room at security complex.

17 June 2014 – Delegation Team from M/S Exxaro, South Africa visited Trombay plant. Necessary security and traffic arrangements were made during their visit.

20 June 2014 – Security Officers Monthly Meeting held from 0830 hrs to 1230 hrs at Security Conference Hall, Trombay with Head – Security.

21 June 2014 - Sr. Inspector of Police Dilip V Raut of RCF Police station made plant familiarization visit. After introductory meeting with Head – Trombay and Head – Security, visited the Plant Area, Coal Berth Jetty, Project Area, Unit # 5, 6, 7, & 8, Coal Yard, CWPH, AFCON Jetty and PSCC. Necessary briefings on Security infrastructure and plant area were provided during the visit.

22 June 2014 - A mock drill on baggage scanner proficiency by operator to identify the Copper wire/prohibited item was carried out. The security staff was able to detect Copper wire & knife kept in different bags at the baggage checking point using the baggage scanner. Total 11 security staff participated in the drill.

23 June – 25 June 2014 – Business Continuity Plan (BCP) workshop at Trombay was held at Chinar Hall, O&S Building Station B by Col Dalvi, Head Security. All HOD,s along with their team including Mr Manjrekar participated in the workshop. Guidance was provided by Mr S Joshi, BCP consultant. Mr S Joshi also presented the DMP certification of Trombay Station to Mr Manjrekar during the workshop.

23 June 2014 – The following Vietnam dignitaries visited in the plant from 1400 hrs to 1630 hrs Trombay Plant , Coal Berth Jetty, and Unit # 5 Control Room. Necessary security and traffic arrangements were made during the VIP Visit.

1. Mr. Le Thanh Quan, Vice Secretary of the Provincial Communist Party - Vice

Governor

2. Mr. Nguyen Trung Hieu, Chairman of the Provincial People’s Committee - Chief

Minister

3. Mr. Tran Thanh Nghiep, Standing Vice Chairman of the Provincial People’s

Committee - Dy Chief Minister

4. Mr. Ngo Minh Trang, Director of the Industry and Trade Department - Secretary

in state

5. Mr Truong Nguyen Thuy Trang, Director of the External Affair Department - Dy

Secretary in state.

6. Mr. Indronil Sengupta, Tata International Ltd Vietnam –VP Level

7. Ms. Dao Ngoc Minh, Executive Assistant-Tata International Ltd Vietnam

28 June 2014 – Security Awareness Session was held at Tata Housing Colony, Aziz Baugh, Chembur, Mumbai for Contractor staff, House Maids, Gardeners etc. Total 138 personnel attended session about colony security process and procedures.

29 June 2014 – On Job training of permanent and MGB security supervisor and guards was conducted between 1900 and 2000 hrs at conference room. The topic of training was ‘Operation of CCR and QRT’.

30 June 2014 - A training session on ISPS code compliance conducted by Mumbai Port trust and was attended by Mr. Vijay Desai PFSO and Mr. Hemant Parab Dy PFSO of Trombay Tata Power Coal Jetty.

We are pleased to welcome Mr. Prem Prakash, 204103 (Ex Indian Navy), who joined Tata Power wef from 9th June 2014 , as Lead Associate–Security Dept, Trombay.

II. 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. Training activities – A) Security awareness lecture/training were given to 321 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.

B) 76 security personnel of SIS Security were imparted training on “Foot Drill”, “Procedure of

Entry /Exit of contract workmen” and “Procedure of night patrol”.

Security Awareness Training to Contract Workforce

Social activities – Mr Sunil Kumar, Head -Security and Mr A K Srivastav, Lead security actively participated in Homeopathic camp for villagers of the nearby villages on 27/06/14 . On 28th June Head Security actively participated in the inauguration ceremony of RO Water Plant which was inaugurated by Station Head Mr D S Kudalkar in the village Sopodera.

Homeopathic Camp Interacting with Villagers

Inauguration of RO Plant by Mr D S Kudalkar(Station Head) Addressing the villagers

Security Meeting- Mr Sunil Kumar, Head –Security along with Mr Barun Kumar (CSR) met

with several ward members and social workers of village Govindpur on 16/06/2014 . Head -

Security along with Mr A K Srivastava attended meeting with Circle Inspector, Telco, OC

PS Govindpur and ACIO, IB Mr Choudhary on 18/06/2014. Head - Security organized

a meeting in the chamber of Station Head on 23rd June which was chaired by Mr D S

Kudalkar and attended by Dy SP (Law & Order) and OC PS Govindpur.

11.

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