JOURNEY OF EXCELLENCE IN

OCCUPATIONAL SAFETY & HEALTH ……….

A CURTAIN RAISER

ALUMINA REFINERY,

NALCO,DAMANJODI

MINESMINES REFINERYREFINERY

SOLAR POWERSOLAR POWER

SMELTERSMELTER

CAPTIVE POWER

PLANT

CAPTIVE POWER

PLANT

PORTFACILITIESPORTFACILITIESWIND POWER

PLANT

WIND POWER

PLANT

SOLAR POWERSOLAR POWER

PRODUCTS

� ALUMINA:

� Alumina Hydrate

� Calcined Alumina

� Specialty Hydrates

� Specialty Aluminas� Specialty Aluminas

� ALUMINIUM:

� Ingot/ Sow/ T-ingot

� Wire Rod

� Billet

� Flat Rolled Products

BEST SAFETY PRACTICES

Alumina Refinery, Damanjodi

ISO 9001:2015, ISO 14001:2015, OHSAS 18001:2007, EnMS 50001:2011 & SA 8000 Certified company

21 Lakh TPA(Normative capacity)

REGULAR EMPLOYEES :1675

CONTRACTOR WORKERS: 2200

TOTAL : 3875

�“Safety is not a gadget but a state of mind”.

�“Safety is cheap and effective insurance policy.”

�“Safety does not come with luck. It has to be“Safety does not come with luck. It has to be

prepared.”

�“Every day is Safety day. Safety has no holiday.”

�“Safety is not a slogan. It’s a way of life.”

�It is the condition of being Safe or free from any

danger or being protected from any danger.

� In actual, nothing is free from danger as long as our � In actual, nothing is free from danger as long as our

life exists, but we can almost make something safer.

�This is not only important in our professional lives but

also it is equally important in our personal lives.

�In today’s global scenario, Health, Safety & Environment (HSE) is

considered to be an integral part of the productivity.

�For Sustenance of any organization, apart from theFor Sustenance of any organization, apart from the

productivity, organisation has to focus on HSE aspects and

continually improve upon these standards so as to compete

globally in the long run.

�Culture of Health, Safety & Environment in any organization

should start from the top leadership."It takes leadership to improve Safety." - Jackie Steward.

�Culture of HSE is to be driven from top, which peculates into middle

and bottom level & ultimately to workers level at workplaces.

�We must think “HSE” for our interested parties like all our

Stakeholders.Stakeholders.

�Our planning and thought process ought to be channelized in such a

way that our interested parties shall not be affected in any way due to

any activity, any operation or process carried out in our industry.

�Basically, the paradigm needs to be shifted in all the levels, as regards

to “HSE” standards with adopting bench marking strategies for

sustenance of organization.

�Alumina Refinery,NALCO is pursuing the journey for Business

Excellence.

�Alumina Refinery has been assessed by a group of certified�Alumina Refinery has been assessed by a group of certified

assessors from CII in the month of October 2018.

�Unit has been recommended by the jury for Gold Plus level

under the CII-EXIM BANK Award for Business Excellence- 2018.

European Foundation for Quality Management (EFQM) Excellence Model

PEOPLEPEOPLE PEOPLE RESULTSPEOPLE RESULTS

EnablersEnablers ResultsResults

LEADERSHIPLEADERSHIPPROCESS,

PRODUCTS &

SERVICES

PROCESS,

PRODUCTS &

SERVICES

STRATEGYSTRATEGY

PARTNERSHIP

& RESOURCES

PARTNERSHIP

& RESOURCES

CUSTOMER

RESULTS

CUSTOMER

RESULTS

SOCIETY RESULTSSOCIETY RESULTS

BUSINESS

RESULTS

BUSINESS

RESULTS

Learning, Creativity and Innovation

EFQM Excellence Model

PEOPLEPEOPLE

ENABLERSENABLERSLEADERSHIPLEADERSHIPPROCESSES,

PRODUCTS &

SERVICES

PROCESSES,

PRODUCTS &

SERVICES

STRATEGYSTRATEGY

PARTNERSHIP

& RESOURCES

PARTNERSHIP

& RESOURCES

ENABLERSENABLERS

EFQM Excellence Model

LEADERSHIPLEADERSHIP EnablerEnablerLEADERSHIPLEADERSHIP EnablerEnabler

�Crash helmet have become compulsory for all the two wheeler

riders before entry to Plant premises.

�A separate material gate was constructed for entry of heavy

vehicles like material handling trucks.

LEADERSHIP (Initiatives)

vehicles like material handling trucks.

�A separate parking area was built up inside the Plant premises

for parking of the material truck.

�A separate parking area was built up outside the Plant premises

for parking of material truck.

�Retro-reflective Signage with SS steel post were displayed

through out Alumina Refinery at the side of the roads for

visibility in night.

�Road Safety studs were installed on the side of the roads for

easy visibility during night and demarcation.easy visibility during night and demarcation.

�Restriction of vehicles of Apprentice trainees and vocational

trainees inside the Plant.

�Widening of roads at various locations.

�Road Safety monitoring and campaigning is carried out regularly

by our Safety team.

�Procurement of Radar Speed Guns.

�Restriction of vehicles of workers inside the Plant.

�Installation of CCTV at vulnerable locations of the roads and

monitoring.

�Hazard and Risk Analysis of the Roads inside Alumina Refinery.

�Modification activities on the roads at some vulnerable

locations.

�Awareness & Campaign on Road Safety.

�Mobile conveying systems for ensuring safety to the workmen

Implementation of On-line Contract Management

SystemOn-line contract labour management system was implemented in

Alumina Refinery. Safety check is one of the process for contractor

workers. This is an on line control mechanism where Gate Pass is issued

to the contractor workers only after Safety check and induction trainingto the contractor workers only after Safety check and induction training

to contractor workers.

Setting up Tool Box Talk cultureCreating and propagating a culture of Tool Box Talk.

TOOL BOX TALKTOOL BOX TALK

SAFETY COMMITTEE MEETING (EVERY MONTH) SAFETY COMMITTEE MEETING (EVERY MONTH)

AVERAGE 60 NOS.

SAFETY RELATED

PROBLEMS ARE

RESLOVED EVERY

MANAGEMENT REPRESENTATIVES : 10 NOS.

WORKERS REPRESENTATIVES : 10 NOS.

SAFETY COMMITTEE PLANT INSPECTION : 15TH OF EVERY MONTH

SAFETY COMMITTEE MEETING : 25TH OF EVERY MONTH

MANAGEMENT REPRESENTATIVES : 10 NOS.

WORKERS REPRESENTATIVES : 10 NOS.

SAFETY COMMITTEE PLANT INSPECTION : 15TH OF EVERY MONTH

SAFETY COMMITTEE MEETING : 25TH OF EVERY MONTH

RESLOVED EVERY

YEAR

CONTROL MEASURE BEFORE ISSUE OF GATEPASS TO CONTRACTOR WORKERSCONTROL MEASURE BEFORE ISSUE OF GATEPASS TO CONTRACTOR WORKERS

SAFETY

CLEARANCE

THROUGH ON-LINE

CLMS

(CONTRACT

LABOUR

SAFETY

CLEARANCE

THROUGH ON-LINE

CLMS

(CONTRACT

LABOUR LABOUR

MANAGEMENT

SYSTEM)

LABOUR

MANAGEMENT

SYSTEM)

SEPARATE TRUCK PARKING AREA

NEW MATERIAL GATE AND SEPARATE TRUCK PARKING AREA (FOR ROAD SAFETY)

ROAD SAFETY MEASURES INSIDE PLANTROAD SAFETY MEASURES INSIDE PLANT

NEW MATERIAL GATE

SEPARATE TRUCK PARKING AREAINSIDE THE PLANT

TRUCK PARKING AREA

OUTSIDE PLANT

NEW MATERIAL GATE

MATERIAL GATE

ROAD SAFETY MEAURESROAD SAFETY MEAURES

Widening of Roads Near Bio-metric punching stationstation

Tree Patches Sign Posts

INSTALLATION OF RETRO REFLECTIVE SIGNAGES WITH STAINLESS STEEL POST ( FOR ROAD SAFETY)INSTALLATION OF RETRO REFLECTIVE SIGNAGES WITH STAINLESS STEEL POST ( FOR ROAD SAFETY)

ROAD SAFETY MEASURES TAKENROAD SAFETY MEASURES TAKEN

CONVEX

MIRRORS

ROAD SAFETY STUDS

MARKING WITH PAINT FOR

PARKING OF BUSES

MIRRORS

ROAD SAFETY MONITORING BY SAFETY TEAMROAD SAFETY MONITORING BY SAFETY TEAM

Mobile Conveying System

EFQM Excellence Model

STRATEGYSTRATEGY EnablerEnablerSTRATEGYSTRATEGY EnablerEnabler

�Since “5S” is the key to the safety, a holistic

5”S” implementation carried out in Alumina

Implementation of 5 “S”

5”S” implementation carried out in Alumina

Refinery including township.

Implementation of “HIRA” in Alumina Refinery

Department wise “HIRA” team is formed in Alumina

Refinery. There is total 18 teams. Each team consists of 4

to 6 members. It is reviewed and updated every year. Alsoto 6 members. It is reviewed and updated every year. Also

depending upon the incidents, change in man/machines,

this is updated regularly.

Engineering Control Measure

�Chlorine was replaced by Sodium Hypo-chlorite in WT Plant, as Hypo-

chlorite is in powder form and it is not hazardous.

�Structural painting is being carried out in a phased manner.

�Monkey ladders were replaced by Staircases for safe movement of the�Monkey ladders were replaced by Staircases for safe movement of the

workmen to top of any hoist platform.

�Spiral staircases adjacent to some caustic tanks were replaced by making

staircases away from the tank wall for safe movement of workmen for

O&M activities.

�Replacement of Reciprocating Compressors by Screw

Compressors/Centrifugal compressors to reduce noise pollution

Magazines/Bulletins

“Suraksha kabach” is an Annual Magazine (related to

Safety, Health and Environment) which is published everySafety, Health and Environment) which is published every

year and widely circulated in Odisha.

5 “S” IMPLEMENTATION5 “S” IMPLEMENTATION

MECHANICAL REPAIR SHOP CENTRAL DISTRIBUTION SYSTEM BAUXITE HANDLING AREASPP

ALUMINA

REFINERY

WAS

DIVIDED IN

TO 72

ZONES.

ALUMINA

REFINERY

WAS

DIVIDED IN

TO 72

ZONES.

MECHANICAL REPAIR SHOP

MECHANICAL REPAIR SHOPCENTRAL STORE

OUTSIDE STAIRCASE WITH PLATFORM MADE FOR APPROACHING TO CAUSTIC LIQUOR TANK

OUTSIDE STAIRCASE WITH PLATFORM MADE FOR APPROACHING TO CAUSTIC LIQUOR TANK

MONKEY LADDER WAS REPLACED BY STAIR CASE FOR APPROACHING HOIST PLATFORM

MONKEY LADDER WAS REPLACED BY STAIR CASE FOR APPROACHING HOIST PLATFORM

NEW STAIRCASE WITH PLATFORMNEW STAIRCASE WITH PLATFORM OLD SPIRAL STAIRCASE

ADJACENT TO TANK

OLD SPIRAL STAIRCASE

ADJACENT TO TANK

NEW STAIRCASE REPLACING

THE MONKEY LADDER

NEW STAIRCASE REPLACING

THE MONKEY LADDER

FIRE FIGHTING SYSTEM ( Manned by CISF Fire Wing) Total nos. Hydrant points: 421 nos.

Total nos. Fire extinguishers deployed: 2283 nos.

FIRE FIGHTING SYSTEM ( Manned by CISF Fire Wing) Total nos. Hydrant points: 421 nos.

Total nos. Fire extinguishers deployed: 2283 nos.

Foam Tenders : 3 nos. Mini Fire Tender : 1 no. BA Set : 14 nos.Towing Tender : 1 no. Trailer Pump: 2 nos.

DCP Trailer Pump 200Kg: 2 nos.

High Expansion Foam

generators

Honda Generators

Fire Extinguishers

Quarterly Checking

of Transformer

Mulsifier System

Quarterly Checking

of Transformer

Mulsifier System

HVWS

MOCK DRILLMOCK DRILL

PUBLICATIONS

EFQM Excellence Model

PEOPLEPEOPLE EnablerEnablerPEOPLEPEOPLE EnablerEnabler

Training and Development

�Regular toolbox talk are being conducted at work places.

�Safety training to all workers including contractor workers with�Safety training to all workers including contractor workers with

demonstration of videos are being imparted.

�Behavioral Safety training to employees.

�Competitions among employees and contract workmen on

Safety aspect.

PME and Health Check-up

�A well-equipped Occupational health Centre with all

infrastructures for occupation health check-up of workmen is

available at Nalco, Damanjodi.available at Nalco, Damanjodi.

�100% PME checks are being done for the own employees as

well as for the contractor workmen.

Contract Workmen

being trained

Employees being

trained

Demonstration on use of portable Fire ExtinguishersDemonstration on use of portable Fire Extinguishers

All the Areas are

covered Every year

All the Areas are

covered Every year

COMPETITIONS DURING CELEBRATION IN 2017COMPETITIONS DURING CELEBRATION IN 2017

QUIZ COMPETITION SKIT PLAY COMPETITION

OCCUPATIONAL HEALTH CENTRE OF ALUMINA REFINERYOCCUPATIONAL HEALTH CENTRE OF ALUMINA REFINERY

All PME tests under one roof

Separate Biochemistry & pathology Lab in OHC, for all PME

tests every day.

PME Examination of Employees in OHC NALCOPME Examination of Employees in OHC NALCO

Biochemistry & Pathology

Test Audiometry Test

� Anthropometry

� Audiometry (Pure tone)

� Titmus Vision Screening Test

� PFT (Pulmonary Function Test)

� ECG (Electro-cardiogram)

� X-ray chest( PA View)

� Lab tests :–

Blood (Hematology, Biochemistry),

Titmus Vision Screening

Physical Examination

Pulmonary Function Test

Audiometry Test

� Blood (Hematology, Biochemistry),

� Stool and Urine,

� Sputum for AFB for Canteen workers.

ECG TEST

Anthropometry

PME Facilities in Alumina Refinery PME Facilities in Alumina Refinery �New Practice Adopted

• PME Individual call letter to the Employees

• PME SMS to the Employees mobile

• Department wise PME list upload on NALCO Intranet,

well in advance for the subsequent month.

• Monthly PME Defaulters list of Employees to all HODs

• Scanned documentation uploading

�HMS (Integrated Hospital Management

General Examination & PME Counselling

�HMS (Integrated Hospital Management System for Digital Documentation)

• Extended format of Form 31-A

• Blood & Other test reports

• Audiometry report

• ECG report

• PFT report

• Titmus Vision Screening reports

• X-Ray report

Digital Documentation

RECOGNITION FOR INNOVATIVE IDEAS LIKE KAIZENSRECOGNITION FOR INNOVATIVE IDEAS LIKE KAIZENS

EFQM Excellence Model

PATERNERSHIP PATERNERSHIP EnablerEnablerPATERNERSHIP

& RESOURCES

PATERNERSHIP

& RESOURCESEnablerEnabler

�Engaging, communicating and working with existing and

emerging key stakeholders, for the purpose of developing long-

lasting and consistent relationships.

�Involving stakeholders in risk-assessments.�Involving stakeholders in risk-assessments.

�Partnership with National Safety Council (NSC) to educate and

influence people to prevent accidental injury and death.

�Stakeholders participation in HSE-led seminars, meeting and

events.

�Working hand in hand with the CISF for the safety of the

employees.

�Conducting Mock drills time to time at various locations.

�Displayed Safety instructions at the entry of the Plant�Displayed Safety instructions at the entry of the Plant

premises.

�Suppliers are being informed about the Safety Policies,

Aspects & Procedures of the unit during placement of P.O. &

W.O.

�Safety awareness training are being imparted to the

transporters, contract workmen, local community.transporters, contract workmen, local community.

�Guidelines to the transporters are being issued before entry

of the heavy vehicle inside the plant premises.

�Distribution of proper PPEs to the contract workmen.

EFQM Excellence Model

PROCESS,

PRODUCTS

PROCESS,

PRODUCTS EnablerEnablerPRODUCTS

& SERVICES

PRODUCTS

& SERVICES

EnablerEnabler

MANAGEMENT SYSTEM CERTIFICATION

ISO 9001- Certified during the year 1994

ISO14001- Certified during the year 1996

OHSAS 18001- Certified during the year 2005

SA8000- Certified during the year 2010SA8000- Certified during the year 2010

ISO 50001- Certified during the year 2014

VARIOUS AUDITS/ STUDY

�Alumina Refinery has foolproof firefighting system and infrastructure

manned by CISF (Fire wing). As a proactive measure, Comprehensive Fire

Audit was carried out by M/s MECON. Action Plan has been drawn out as

per the audit report.

�PESO Audit was conducted for Oil handling SYSTEM..�PESO Audit was conducted for Oil handling SYSTEM..

�As a pro- active measure, M/s CPRI ( Central Power Research Institute,

Bangalore) was engaged for testing of structural stabilities of some

concrete and steel structures of Alumina Refinery like Cooling Towers,

concrete structure of various equipments. Action is being taken in this

regard.

�RLA studies of the Boilers are being carried out as per statutory

requirement.

�Work Permit System

�Competent Persons for testing Lifting tools and tackles,

Pressure vessels and Confined Space

�Internal Safety Audit (Once in a year)

�Reporting of Near-misses and Corrective & Preventive Actions

OHS SYSTEMS & PROCEDURES

�Reporting of Near-misses and Corrective & Preventive Actions

�Incident Investigation and Corrective & Preventive Action

�Work zone monitoring

�SOP & SMP

�Plant Safety Inspection

�Display of MSDS (Material safety data sheet)Boards

�Adoption of Safety Practices

ADOPTION OF SAFETY PRACTICES ADOPTION OF SAFETY PRACTICES

SAFETY TAG

SAFETY TAGAREA LAYOUT DISPLAYED AT EACH SITE

SAFETY TAG

MSDS BOARDS AT WORK PLACESMSDS BOARDS AT WORK PLACES

PLANT SAFETY INSPECTION PLANT SAFETY INSPECTION

WORK ZONE MONITORING INSTRUMENTSWORK ZONE MONITORING INSTRUMENTS

WORK ZONE MONITORINGWORK ZONE MONITORING

� “PESO” AUDIT WAS CARRIED OUT IN ALUMINA REFINERY IN 2017

� COMPREHENSIVE FIRE AUDIT WAS CARRIED OUT BY M/S MECON IN 2017

PESO AUDIT

1. Visual Examination of RCC Structure of D.M. Plant

2. RCC Structure of Cooling Tower No.4

3. RCC Structure of Wagon Tippler Pedestals with discharge

hopper

4. RCC Structure of Lime slaking Unit

5. RCC foundation of Grinding Ball Mill (No.4)

6. Visual Examination of Old Bauxite Crusher

7. Visual Examination of RCC Structure of Steam Turbine U#2

8. RCC Water Tank at Hill Top

STRUCTURAL STABILITY TESTED BY CPRI, BANGALORE STRUCTURAL STABILITY TESTED BY CPRI, BANGALORE

8. RCC Water Tank at Hill Top

9. Tunnel of Lime Conveyor at Lime slaking unit

10.Tunnels of Coal Conveyor at CHP.

11.Precipitation Tank Foundation (TK No. 149)

12.RCC Structure of Intake Well Pump House

CELEBRATIONS

Various celebrations are observed to promote awareness

amongst the employees and contract workmen. like:

�National Safety Week,�National Safety Week,

�Chemical Disaster Prevention Day,

�Road Safety Week,

�National Pollution Prevention Day,

�Earth Day,

�World Environment Day etc.

OBSERVANCE OF VARIOUS CELEBRATIONSOBSERVANCE OF VARIOUS CELEBRATIONS

NATIONAL SAFETY WEEKNATIONAL SAFETY WEEK ODISHA DISASTER PREPAREDNESS DAYODISHA DISASTER PREPAREDNESS DAY

ROAD SAFETY WEEKROAD SAFETY WEEK CHEMICAL DISASTER PREVENTION DAYCHEMICAL DISASTER PREVENTION DAY

FIRE SAFETY DAY/WEEK

Mock Drill during Fire Safety Day/Week

EFQM Excellence Model

PEOPLE RESULTSPEOPLE RESULTS

RESULTSRESULTS CUSTOMER

RESULTS

CUSTOMER

RESULTS

SOCIETY RESULTSSOCIETY RESULTS

BUSINESS

RESULTS

BUSINESS

RESULTS

RESULTSRESULTS

Year Reportable

Incident

Non-reportable

Incident

First-Aid

Injuries

2016 0 0 432016 0 0 43

2017 0 0 37

2018 (up to

Sept)

1 0 30

PRODUCTION ACHIVEMENTS

(FY 17-18)

REMARKS

Hydrate Production 21,05,500 MT Highest ever

Calcined Alumina

Production

21,11,000 MT Highest ever

75

SGA Production 8,800 MT Highest ever

Power 484.33 MU Highest ever

Steam Generation, 68 ata 52,57,293 Highest ever

Total Rail Despatch 20,99,461 Highest ever

�Fly Ash Expo Award for Efficient utilization of Fly Ash by Mission

Energy Foundation, Mumbai.

�Good Green Governance Award by Shristi Foundation, New

Delhi.

AWARD & ACCOLADES

Delhi.

�Kalinga Safety Award(Silver) by Odisha State Safety Conclave for

the performance year 2016.

�Greentech Environment Award for outstanding achievement in

Environment Management by Greentech Foundation, New Delhi.

�Pollution Control Excellence Award(PCEA-2018) under Industry

Category of Odisha State for Excellent Pollution Control Practices

by Director of Factories & Boilers, Bhubaneswar, Odisha for the

performance year 2016.

�Best State Safety Officer Award by Director of Factories &

Boilers, Bhubaneswar, Odisha for the performance year 2016.Boilers, Bhubaneswar, Odisha for the performance year 2016.

�Best State Safety Practices Award by Director of Factories &

Boilers, Bhubaneswar, Odisha for the performance year 2016.

�Kalinga Safety Award(Gold) by Odisha State Safety Conclave for

the performance year 2017.

State Safety Award for 2016State Safety Award for 2016

Good Green Governance Award-2016Good Green Governance Award-2016

FLY ASH UTILISATION AWARD - 2018FLY ASH UTILISATION AWARD - 2018

KALINGA SAFETY AWARD – 2018KALINGA SAFETY AWARD – 2018

State Pollution Control Excellence Award-2018State Pollution Control Excellence Award-2018

BEST SAFETY OFFICER AWARDBEST SAFETY OFFICER AWARD

STATE POLLUTION CONTROL EXCELLENCE AWARD - 2018

�Alumina Refinery was recently awarded

Certification of 5 “S” from M/s QCFI, Hyderabad on

successful audit by certified auditors from M/s

Certification of 5 “S”

successful audit by certified auditors from M/s

QCFI and M/s JUSE.

�Very shortly, Certificate from “JUSE” will be

received by Alumina Refinery.

5 “S” Certificate received from M/s QCFI5 “S” Certificate received from M/s QCFI

"Safety isn't expensive,

it's priceless." it's priceless."

Thank YouThank You