SAFETY & SECURITY NEWSLETTER

October 2013 Issue

MESSAGE DESK

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CONTENTS

1 Safe Lifting and Shifting

2 Lessons Learned

3 New updates in Safety portal-Sangam

4 Corporate Safety Highlights - Sep’13

5 Safety training & awards– Sep’13

6 Root cause analysis (RCA) of incidents – Sep’13

7 Security Highlights

Thought for the month

Learn from others mistakes; don't have others learn

from you

1. Safe Lifting and Shifting

Almost every employee is a material handler at some time on the job. Everyone lifts and shifts something, and that means everyone needs to be trained to handle materials safely. Almost every manual material handling activity carries some potential for injury, from minor to severe. That's why at every stage in the process it is essential for workers to understand and follow best practices for safe material handling. Step 1. Preparing • Know in advance where you are going to set the load down, and whether stairs or ramps are involved • Make sure the entire path is free of obstructions or slipping hazards. • Watch out for nails, splinters, or anything else that could cause injury. • Wear appropriate protective gear—gloves that will provide a safe grip, and safety shoes in case of a dropped load • Think your way through the entire procedure. Step 2. Lifting • Face the load with feet about shoulder-width apart, one slightly ahead of the other. • Bend at the knees and keep the back straight (not vertical, but in a forward lean), and keep head up. • Grasp the load and draw it close to the body, with arms and elbows tucked to the sides. • Lift gradually and smoothly, using the leg muscles, not the back muscles, to power the lift. Step 3. Moving • Move steadily and slowly, keeping the load close to the body and balanced. • Turn the entire body when changing direction, as turning only the upper body causes severe strain. • When walking through doorways or between machines, adjust the grip or turn the load slightly so that fingers won't be trapped between it and the other surface. Step 4. Placing • To lower the load, reverse the lifting steps: bending the knees, keeping the back line straight and the feet in the proper position. • If the load must be placed at shoulder height or above, plan to rest it at about waist height and change the grip before completing the lift. • To make sure that fingers are not pinched by the load when setting it down, let one edge or corner rest on floor or table and then slide hands up the side of the object before completing the placement. Other Considerations Besides knowing the proper techniques of lifting, moving, and placing a load, it is important to fairly assess both the scope of the job and one's own strength. Ask for help if the load is too heavy or awkward (too bulky or too long) to manage safely alone. When employees perform a team lift, one person gives the orders to lift, turn, and set down. All members of the team perform these tasks in unison. They should move slowly and steadily, keeping the load level and weight evenly distributed, without changing their grips while carrying.

2. Lessons learned

2.1 Electrical induction & Fall from Height, Wind

Date & Time : 17th September 2013 & 18:40 Hrs

Location : 33KV line, Feeder # 05, Pole No. 3, Gadag wind site Details : LWDC-Reportable

Description : The injured was working at 33KV line, Feeder#05, PoleNo.3 for pulling the ACSR conduct or to joint at ground. During conductor pulling he got sudden induction charge and fell down on ladder and further on ground. Even though there were no physical injuries, immediately he has been taken to nearby Hospital at Gadag. Where in he was kept under observation and discharged him on 19.09.13. The person resumed duty on 25.09.13.

Root Cause Analysis Human Factor

1-1 Violation by individual: Not using the safety harness while climbing the pole

1-3 Violation of Supervisor: Allowing other team to work without any authorization and tool

box talk

3-1 Lack of knowledge of hazards present: Over looked the Feeder # 1’s internal line

crossing which was going to one of WEC of M/s GEI near by Feeder # 5 & 6’s DP cut point

3-2 Personal protective equipment not used

2-2 Improper use of tools: Earthing rod used near DP cut point, wire found with joint during

site inspection

Physical Factors:

14-1 Inadequate isolation of process or equipment: Feeder # 6 at DP cut point not earthed,

as they thought the earthing at Substation end is sufficient.

System Factors

8-4 Inadequate identification of worksite / job hazards: Unaware about JSA / HIRA

8-5 Inadequate management of change system: Lines not provided with crossing line guards

8-6 Inadequate incident reporting / investigation system: Previous near miss which

happened on other customer feeder was not investigated

Recommendations:

1. In Single pole double circuit HT lines, earthing need to be done for all the phases on both

circuit before and after the break down spot location. Suitable work instructions to work on

HT line to be developed.

2. Line crossing guarding to be provided.

3. Work to be done only with required PPE’s.

4. Tools & tackles to be inspected before its use by ensuring proper administrative controls.

5. Unauthorized entry other than working team need to get permission from the supervisor.

6. All the teams members should be covered during tool box talk

7. JSA/HIRA & PTW: To be reviewed & approved by TATA Power representative. Discuss the

JSA/HIRA with the work group during toolbox talk.

8. Incident Management Reporting / Investigation system to be strengthened.

9. During rainy time all HT line related work to be continued only after its closure.

10. During low visibility (late evening hours & night), sufficient emergency light to be arranged.

11. Need to ensure all the involved personnel's are trained / competent.

Click here for complete report

2.2 Flash over while removing fuse, Distribution Customer Support (DCS)

Date & Time : 30th August 2013 & 21:30 Hrs

Location : Aapki Industrial Estate, Kurla Details : LWDC-Burn Injuries

Description : While trying to remove burnt fuses from 125Amp Switch Fuse from GalaNo.72 Meter No.SC001890 a flashover took place as a result technician (AlliedTechno) received burn injuries on both his dorsal and face

Burnt SFU Screwdriver used at the site

Root Cause Analysis: Human Factor 3-2 Personal protective equipment not used: PPEs not worn by the victim 4-2 Improper decision making or lack of judgment: Inappropriate assessment of fault

condition. Physical Factor 7-3 Energized electrical systems: Defective SFU in which fuse terminals were not getting

disconnected from load and source end terminals even in off condition. 6-1 Defective equipment: Fuses were in burnt condition. 5-5 Inadequate warning systems: There were no visual indication on the SFU after the

removal of the cover to indicate the switch in closed or opened position of the switch.

System Factor 14-1 Inadequate PSP for the task: In existing procedures for fuse failure calls must include

FMEA of different situations. Recommendations 1. Consequence management to be strictly implemented for not using PPEs 2. Sensitizing technicians, that equipment can operate in abnormal way during fault condition 3. Modifying existing work instruction to include steps for positive confirmation of no-voltage

before removal of the fuse 4. Checking feasibility of providing indication on SFU after removal of cover Click here for detailed report

2.3 Struck by vehicle LWDC, Jojobera

Date & Time : 12th June 2013 & 06:25 Hrs

Location : Ash Bag loading area near CHP Details : LWDC

Description :Light Commercial Vehicle (LCV) Tata-709, had come to unload the ash bags in the designated ash bag unloading area in between the last two yard railway lines at CHP. It reversed and came to position to unload the bags. The injured person and his coworkers were sitting on the brink of the pathway. Helper of the vehicle told them to clear the area. Two of the workmen left the place immediately. In the mean time the driver of the LCV realized that he had to reposition his vehicle because it had not been placed properly for the same he turned the steering wheel towards the other side. One of the workmen (Sandip) was still sitting on the ground. From his position the driver could not see the workmen. As the driver was not reversing the vehicle on straight path but rotating the steering slightly, the rear wheel passed from distance of Mr.Sandip but front wheel hit causing injury on left leg.

Root Cause Analysis Human Factor 1-1 Violation of Individual: Injured was sitting at ash unloading area 1-2 Violation of Group: Workmen was sitting at ash unloading area

Physical Factor 8-5 Conflicting information is Presented: Driver was maneuvering the vehicle during reveres

motion. Rear Wheel Passed, Front wheel, injured the employee Recommendations 1. Workers must be sensitized to sit at safe place while waiting for vehicles 2. Enhance supervision during reverse movement of vehicle Click here for detailed report

2.4 Slip & Fall on road, Jojobera

Date & Time : 3rd Aug 2013 & 22:16 Hrs

Location : CHP Road

Details : LWDC

Description :

The injured left the staff bus at Service building as its tyre got punctured. While walking to CHP,

near Unit5 chimney, he got unbalanced due to small stones pieces on the road. When he was

about to fall, he took support of his right hand which resulted in to twisting of the wrist.

Root Cause Analysis Human Factor 1-1 Violation of Individual

1-7 Work or motion at improper speed

3-1 Lack of knowledge of hazards present

4-2 Distracted by other concern

4-3 Inattention of footing and surrounding

Physical Factor 7-9 Clutter or debris

System Factor 5-8 Employee perceived haste Recommendations 1. Employees were suggested to use Four Wheelers while going for a long distance in plant

2. House Keeping to be improved

Click here for detailed report 2.5 Fall of Crane Girder while erecting it in GIS Building, Kalinganagar

Date & Time : 17th Sep 2013 & 18:15 Hrs

Location : GIS building, column No E4 and E5 Details : Hi-Pot Incident

Description : A Crew (M/s Jayshree Engineering) was engaged for the crane girder (Wt- 700 KG, Length- 6 m) erection in GIS building in between column No E4 and E5. At 8m elevation while lifting the girder with winch machine, one end of the Sling was tied with pulley on beam at 9m height for positioning the girder. Suddenly the sling sheared due to improper Lifting arrangement as proper packing was not provided at the edge of beam where main pulley was fixed, resulting in fall of girder from 4m height to the ground floor.

Root Cause Analysis Human Factor 1-2 Violation by group: Insufficient coordination between winch operator and supervisor.

Physical Factor 6-1 Defective equipment: Slings are not in good condition.

6-6 Improperly prepared tools: Proper packing was not provided at the edge of beam where

main pulley was fixed

System Factor 11-6 Inadequate audit / inspection / monitoring:

a. Inadequate periodic inspection of lifting scheme. b. Inadequate periodic inspection of lifting Tools & Tackles

Recommendations

1. Periodic Inspection of lifting scheme 2. Periodic inspection of lifting tools & tackles.

Click here for complete report

3. New updates in Safety portal-Sangam

Management of Change (MOC) Form Management of change form is now available in Sangam-Safety which is in line with Tata Power’s MOC procedure. The form consists of stepwise details necessary for carrying out plant / facility modification. MOC process starts with raising the request for modification detailing in which facility / plant it is proposed, what is the existing system, proposed system & its justification. It also consists of a checklist which prompts about the effects of modification on plant machinery, building structure, Occupational Health, Safety & Environment and other aspects. Relevant studies are to be carried out to determine feasibility (technical / safety / business etc) of MOC and required approval from departments and various levels shall be taken. ―Area Manager‖ approves MOC after ensuring preliminary studies are conducted and necessary authorizations being taken. Finally Engineering department will review MOC, give its approval and prepares a technical package which will be implemented by respective departments Click here for MOC Form Lessons Learned Lessons learned from High potential incidents across Tata Power are now available in Lessons Learned section in Sangam-Safety Portal. These lessons learned can be used for learning purpose and also as Safety Contact during department or any other meetings Click here for lessons learned section

4. Corporate Safety Highlights Sep’13

Corp. Safety conducted comprehensive SMS audit @ Kalinganagar and Office Fire & Safety

audit of Mahalaxmi Office.

Awareness session on Disaster Management Plan & Business Continuity Plan was conducted for select Executives / Departmental Heads of MO.

Level III mock drill was supervised at Trombay in Fuel Oil Area, Station A and necessary observations for improvements were made.

Reviewed testing & maintenance status of fire prevention & protection systems during U#7 outage-Trombay.

Incorporated and released 5 new fire safety checklists in SURAKSHA safety inspection module.

Participated in OSH India safety exhibition at Goregaon, to get updated on best safety practices followed worldwide.

5. Safety training & awards– Sep’13

Trombay won award for accident free period over one million man hours in “Maharashtra

Safety Awards Competition 2012” organized by “National Safety Council”

SPANDAN training was conducted in Trombay

through ―Aakar Empowerment Trust‖

―Basic safety & IMS awareness‖, ―Standards & Procedures‖, ―Worker Development Program

(WDP)‖ trainings were conducted for contractors at Trombay

6. Root Cause Analysis (RCA) of incidents – Sep’13

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%

Oct'12

344

Nov'12

294

Dec'12

323

Jan'13

361

Feb'13

416

Mar'13

639

Apr'13

332

May'13

251

Jun'13

203

Jul'13

336

Aug'13

324

Sep'13

310

Ca

use

s

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%

Oct'12

186

Nov'12

148

Dec'12

178

Jan'13

193

Feb'13

234

Mar'13

285

Apr'13

147

May'13

139

Jun'13

129

Jul'13

186

Aug'13

184

Sep'13

176

Ca

us

es

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

Oct'12

287

Nov'12

192

Dec'12

234

Jan'13

316

Feb'13

369

Mar'13

422

Apr'13

201

May'13

170

Jun'13

97

Jul'13

165

Aug'13

202

Sep'13

199

Cau

ses

System Factors Trend

Physical Capability

Physical Condition

Behavior

Skill Level

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 Stress

Mental State

Note: Insignificantcauses (consistentlyless than 5%) are notshown

Total no. of causes

7. Security Highlights

I. CGPL

CROSS FUNCTIONAL SECURITY AUDIT:-

Col. Dalvi & SO Desai visited CGPL site for 02 days as a official cross functional security audit for Mundra site. The Auditor visited CGPL Main gate, Material Gate, West port, Intake & Outfall Channel and CGPL Township. Security processes were audited.

TRAINING PROGRAM FOR SECURITY PERSONNEL:-

Training related to Confidence building/ self defence tricks & Techniques for security guard was conducted at field hostel Training Hall. The program was conducted by the Mr. Joe and Mr. Reedy from Mumbai in which training regarding Self Confidence was given to security staff members. A total no’s of 48 security personnel including 02 SO,02 SS & 03 Admin JCO’s took part in it.

SPECIAL DRIVE:- Special traffic drive, daily speed monitoring initiative during rush hours is in continuation at

Hostel gate & old main gate U-turn area during morning shift hours. Vehicles without proper entry passes were restricted. A total of 101 Debit Notes were raised in the month of

Sept’13. Out of which 49 Debit Notes were raised against Breach of Traffic safety and 52 for Breach of Security. Consolidated summary of the debit notes raised in the past month is available on demand.

OPERATION REHABLITATION FISHERMAN FROM OUTFALL CHANNEL AREA:-

On 27th Sept’13: Heavy monsoon rains continued to lash several regions in western India throwing normal life out of gear and disrupting operations at the Mundra site on Friday 27th Sept’13. The district received approximately 167 mm of rainfall in the vicinity of Mundra during the 24hrs from 1800 hrs on 26th Sept’13 until 1800 hrs on 27th Sept’13.This created a flood like situation that had a huge effect on the Fishermen Families stay near Outfall Channel DFC (Diaphragm wall) area. Later Security QRT team in coordination with CSR dept. Rescue and rehabilitate these families in their security vehicle from outfall to Mundra at their destination.

II. HYDRO BHIVPURI

VISIT RAF AT BHIRPURI(24/09/13):- Visit by Rapid Action Force along with local police:The team of about 60 personnel of rapid action force headed by Deputy commandant Mr. Shiv kumar Shah from 102 RAF Battalion, Taloja, New Mumbai has visited Bhivpuri Generating station on 24th Sep 2013. (Duration of time is about is 1 hrs from 1730 hrs). This visit was made to get RAF familiarized with the generating station to take action on call from industrial companies in

case of emergency. Mr. Suresh S Giri Security Officer of the division is giving geographical view of our Power station to RAF

III. MPL – MAITHON

SECURITY & FIRE NEWS EVENTS AT MPL DURING SEP-2013:- To check possession of valid and authorized photo pass of workmen, a surprise checking of

Gate Pass was conducted in BTG area from 1130 hrs to 1230 hrs on 07.9.2013. A team led

by SO Sunil Singh along with 6 BSS & G4S personnel conducted checking of pass at Boiler

area , TG & ESP area. Security team checked the pass of approx 120 workmen of M/s

Bhawani M/s SAMS & M/s BSBK. All the workmen displayed their computerized photo pass

to security team.

SPORTS ACTIVITY:-

MPL Security & Fire department in surrounding area, MPL Security & Fire team participated in a local football tournament in the Saturday night i.e. 14-09-13 at Dambhui village ground. 32 teams participated and Team MPL WARRIORS played well but lost in semi final. However team was awarded with a goat of app 08 kg for qualifying in the semi final.

TRAINING AND MOCK DRILL:-

Fire Mock drill of electrical fire was conducted on 29-09-13 at PWS switch Gear Room in

front of Tech Building to check the emergency evacuation, efficiency and preparedness of

Fire crew of IFSS deployed at site. A control fire was created in the PWS switch gear room

in front of technical building to activate the smoke / heat detector. This mock drill was

deliberately conducted on Sunday to check the emergency response of Fire team, Security

team and Operation control room.

On 27 09-13 127 workers of McNally, P Mech , BSBK etc were trained in First Aid FF at site office conference Hall. Total 631 workmen/officers were trained in the month of Sep 13.

On 30th Septenber 2013 IMS awerenwss session was conducted at Site office conference Hall for 24 Security Personnel(MPL Security officers & Reps of G4S /BSS) .Followed by Monthly departmental meeting for the month of Sep 13 in which all officers of security & Fire attended the meeting. Main issues pertaining to MPL were discussed.

IV. TROMBAY: 07 Sep 2013 – A parade drill cum revision of BSI Training for MGB was conducted between

1830h and 2030h on 07 Sep 2013 by Security Officer P S Bani. Total 43 Security guards including supervisors were present during the session. Following topics were covered:

o Intelligence gathering o Physical Security o Explosive device o Suspicious signs

o Procedure for checking-personnel & vehicles

o Fire fighting o Trauma o Handling of suspect

10.09.2013 – Security training based on post BSI Israel on procedure of Entry / Exit of People, Vehicle, Material, baggage scanning machine, explosive detector, door frame metal detector and hand held detector was conducted between 1845 hrs and 1945 hrs. Total 35 security personnel including 06 permanent security staff were present during the session.

19.09.2013 – On job Security training cum briefing imparted to Pmt. Staff & MGB Staff, the security related topics post BSI Israel were discussed and shared to improve the security system and process to implement in a smooth way, the topics shared were as follows :-

o About EPM Process management system at Trombay. o IMS – INTEGRATED MANAGEMENT SYSTEM (EMS, QMS &OHSAS).

o Loyalty towards our professionalism. o Regularity on duty. o Discipline on duty. o Wearing of uniform in appropriate manner. o Approach to the seniors. o Body language while performing on duty. o Absenteeism without intimation and proper reason. o Alertness & vigilance while on duty.

15.09.2013 – On job Security training cum briefing imparted to 12 Pmt. Staff & MGB Staff on Explosive Detection training cum checking of vehicle at gate.

20.09.2013 – On Job training (OJT) on following topics and Security Gadgets were imparted to 09 permanent security staff from 2245 hrs to 0001 hrs on 20th Sep 2013.

o EPM Process management system at Trombay. o Security check of lady employees at Gates o Discipline on duty. o Intelligence gathering from various resources o Random checks of Laptops and its valid passes o OJT on monitoring & handling of Door Frame Metal Detector o OJT on handling & operating of UHF Communication System o OJT on handling, operating & detecting Objects - Baggage X Ray Scanner o Alertness & vigilance while on Gate duty and Vigilance rounds of the plant

23.09.2013 – Security Officers Monthly Meeting with Head – Security held at Security

Conference Hall from 0730 hrs 1130 hrs. 25.09.2013 – Security Refresher Training on following topics based on post BSI Israel

training as per schedule was imparted to 24 MGB security staff from 1800 hrs to 2000 hrs on 25th Sep 2013.

o Identification on suspect/intruder/thieves o Use of technology to plug the Security voids o Techniques & networking of Intelligence gathering from various resources o Alertness & vigilance while on Gate duty and Vigilance rounds of the plant o Team Building & Discipline on Duty.

28.09.2013 – Security Refresher Training on following topics based on post BSI Israel training as per schedule was imparted to 12 MGB/QRT security staff from 1800 hrs to 2000 hrs.

30 Sep 2013 – Mock drill of hi-jacking of an unknown ship inside Navigational channel of

Mumbai Port was conducted at 1100 hrs.

V. T&D

APPRECIATION FOR OUTSTANDING SECURITY PERSONNEL :

A theft attempt was foiled by the alert & brave security personnel at SEWREE fort on the night of 15 Sep’13.

Mr. Vijay Chourey, GM (Transmission) appreciated the personnel of T & D security in a brief ceremony at DHARAVI.

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