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Industrial Safety And Emergency Preparedness: NTPC Perspective
Shivam SrivastavaGM-Safety
NTPC Limited
Pathway
• About NTPC• Why Industrial Safety is Important• NTPC Safety Policy Framework• Major hazards in Power Station• Emergency preparedness at Engineering stage• Emergency preparedness at O&M stage
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About NTPC
Sl.No. NO. OF PLANTS CAPACITY (MW)
NTPC Owned
Coal 21 40,355
Gas/Liquid Fuel 7 4,017
Hydro 1 800
Renewable energy projects (Solar PV) 12 878
Wind 1 50
Total 42 46,100
Owned By JVs/Subsidiaries
Coal & Gas 9 7,551
Total 51 53,651
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About NTPCOPERATIONAL PERFORMANCE OF COAL & GAS BASED NTPC STATIONS
Gross Generation (BU)(COAL & GAS)
PLF (%)(Coal Stations)
2016-17 250.31 78.59
2015-16 241.98 78.61
2014-15 241.139 80.23
2013-14 233.269 81.50
2012-13 232.00 83.08
2011-12 222.07 85.00
2010-11 220.54 88.29
2009-10 218.84 90.81
2008-09 206.94 91.14
2007-08 200.86 92.24
2006-07 188.67 89.43
2005-06 170.88 87.52
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What is Safety ??
• Safety is not absence of accidents
• Safety is presence of defenses in the processes, procedures, facilities, methods and practices.
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What is Industrial Safety ??
• Industrial safety is defined as policies and protections put in place to ensure plant and factory worker is protected from hazards that could cause injury.
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Why Industrial Safety is important
• Occupational/ industrial accidents result in loss of production timeequivalent to millions of man hours, machine hours etc.
• 20% production time is lost by those actually injured due to temporaryand permanent disablement
• Balance 80% production time is lost by fellow operators/ people inhelping the injured, in taking care of the damage caused by accidentetc.
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Copyright © 2016 Your Company All Rights Reserved. 8
Intent of NTPC Safety Policy Framework
“All Accidents Are Preventable”Therefore, safety must be at the forefront of
all activities
Six Principles of NTPC safety Policy
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1. Our activities carry various hazards; however all hazards can be identified.
2. Every job shall be done safely, no matter how important or urgent it is.
3. Putting people to work carries a specific responsibility and accountability
for safety which shall be visibly demonstrated.
4. Right procedures and actions can bring the risks under control.
5. Trained and committed team can ensure incident free operations.
6. Compliance to all applicable safety regulations and other legal
requirements at the minimum.
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Major Hazard Potentials in Power Stations
Fire and Explosion Hazards:
• Hydrogen Plant and Storage area• Boiler / TG• Fuel oil Storage• Transformers and Switch Gears • Coal handling
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Major Hazard Potentials in Power Stations
Chemical Hazards:
• Chlorine storage and handling
• Sulfuric Acid storage and Handling
• Hydrochloric Acid storage and Handling
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Process Safety Design system
• HEZOP (Hazard and Operability Study)
• LOPA (Layer Of Protection Analysis)
• SIL (Safety Integrity Level)
• SIS / SIF (Safety Instrumented System / Function)
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SIF-1
Logic Solver(PLC)
Leveltransmitter
Leveltransmitter
Level switch
Temperaturetransmitter
Shut-offvalveSolenoid
GlobevalveSolenoid
MCC
Safety Instrumented System
SIL 2
SIL 3SIF-2
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Generic and application sector standards
IEC61508
Machinery sectorMedical sector
Process sector. . . . . . sector
Nuclear sector
IEC61511
IEC61513
IEC62061
IEC 61508 is an international standard published by theInternational Electrotechnical Commission of rules appliedin industry.
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IEC- 61508
• IEC 61508 is an international standard published by the “InternationalElectrotechnical Commission” of rules applied in industry. It is titledas Functional Safety of Electrical/Electronic/Programmable ElectronicSafety-related Systems (E/E/PE, or E/E/PES).
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Safety Specifications
EN 50156-1:2015 :Electrical equipment for furnaces and ancillary equipment. Requirements for application design and installation
EN 50178 :Electronic equipment for use in power installations.
NFPA-85Contributes to operating safety and prevents explosions and implosions in boilers
IS-3034Fire safety of Industrial Buildings
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Process Safety : Implementation
• Capacity building on DMP / OD/ OGN/ OIN and LMI.
• Awareness of Process Hazards and mitigation actions.
• Implementation of LMIs with “Zero Tolerance”.
• “No deviations” from NTPC safety systems (PTW / TC/ Process protections, General safety Rules etc)
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Disaster Management Plan
United Nations International Strategy for Disaster Reduction (UNISDR)
• International decade for Disaster reduction
• Hyogo Framework (2005-2015)
• Sendai framework (2015-2030)
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Sendai Framework
• Priority 1. Understanding disaster risk
• Priority 2. Strengthening disaster risk governance to manage disaster risk
• Priority 3. Investing in disaster risk reduction for resilience
• Priority 4. Enhancing disaster preparedness for effective response and to “Build Back Better” in recovery, rehabilitation and reconstruction
Source:http://www.unisdr.org/we/coordinate/sendai-framework
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Emergency Preparedness
• Well defined Disaster Management Plan
• Pre disaster elements: Prevention and Risk ReductionPreparedness
• Post disaster elements:Response Recovery
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Disaster Management Plan
1. Table top Exercise : “What if” for different scenarios
2. Functional Exercise
3. Full Scale drill
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Emergency Preparedness
Mock Drills:
• As per Factory Act (Once in six months)
• Fire mock drill (CISF) (Once in 15 days)
• Mock Drills in association with NDRF, State Administration
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Emergency Preparedness
Other Activities:
• Weekly Fire fighting training of NTPC and associates by CISF /Safety
• Monthly Fire fighting system healthiness checking (CISF/NTPC)
• Mutual aid scheme (Anta/ Chambal Fartilizer, Auriya/ GAIL)
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Emergency Preparedness
Other Activities:
• Community awareness
• Involvement of CISF in inspection of Fire Fighting Equipment
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Top Line
Bottom Line
Safety
Production Targets
Personal targets
Ball of safety is made up of Glass andRest all balls are made up of rubber.
If left, all can bounce back But…..Ball of Safety Can’t
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