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Industrial Safety Practices at NTPC
9th Odisha State Safety Conclave-2018
Shivam NTPC 1
P K Sinha
ED-SAE
Shivam Srivastava
GM-Safety & Envt
NTPC Limited
Pathway
• About NTPC
• CMD’s view
• Why Industrial Safety is Important
• NTPC Safety Policy
• Major hazards in Power Station
• Safety at NTPC Projects
Shivam NTPC 2
About NTPC
• 52.9 GW company with 21 coal based, 7 gas based stations, 1 Hydro based station and 1 Wind based station 9 Joint Venture stations arebased station and 1 Wind based station. 9 Joint Venture stations are coal based and 11 Solar PV projects.
• capacity will have a diversified fuel mix and by 2032, non fossil fuel based generation capacity shall make up nearly 30% of NTPC’s portfolio.portfolio.
• Capacity in pipe line : 18 GW
Shivam NTPC 3
About NTPC
• Ranked 1st among “Independent Power Producer and EnergyTraders” category by S&P Global Platt “Top 250 Global EnergyCompany Ranking-2018.
• Ranked 512th in the “2018, Forbes Global 2000” ranking of the World’s biggest companies.
Shivam NTPC 4
• British safety sword, Greentech Safety Awards, Kalinga Safety Awards etc. etc.
• Safety is our 1st priority. This is to be internalized and demonstrated through our systems and actions…. Safe behaviour should be a part of our culture Be it at home work place or while on the goour culture- Be it at home, work place or while on the go.
• Responsibility of creating safe workplace for ourselves and for all our stakeholders is on us.
CMD NTPC
Shivam NTPC 5
NTPC Core values
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Industrial Safety - A Pillar of Sustainability
• Safety is at the core of “Sustainability” with a mission to protect People, Planet and Profit.
• Sustainability really comes down to three principles:
• “Doing no harm” starts with the people closest to the business; no organization can credibly
claim sustainability while continuing to have life-altering injuries and fatalities or
environmental incidents
• “Leaving no footprint” helps leaders address product life cycle issues and the means by whichg p p p y y
products are made and delivered
• “Doing some good” represents the fundamental value an organization adds, which may go
beyond basic products and services.
Why Industrial Safety is important
• Loss of life
• Loss of production time
• 20-80 theory
• Legal Costs
• Low morale and erosion of Brand Image
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From Should to Ground Action
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Intent of NTPC Safety Policy
Copyright © 2016 Your Company All Rights Reserved. 10
“All Accidents Are Preventable”
Therefore, safety must be at the forefront of
all activities
Six Principles of NTPC safety Policy
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.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.
ed d ed d f
11
5. Trained and committed team can ensure incident free operations.
6. Compliance to all applicable safety regulations and other legal
requirements at the minimum.
Shivam NTPC
Major Hazard Potentials in Power Stations / Projects
Fire and Explosion Hazards:
• Hydrogen Plant and Storage areay g g
• Boiler / TG
• Fuel oil Storage
• Transformers and Switch Gears
• Coal handling
Shivam NTPC 12
Major Hazard Potentials in Power Stations / Projects
Chemical Hazards:
• Chlorine storage and handling
• Sulfuric Acid storage and Handling
• Hydrochloric Acid storage and Handling
Shivam NTPC 13
Segregation of Layers of Safety
Shivam NTPC 14
Question Yourself before start of job
Copyright © 2016 Your Company All Rights Reserved. 15
Safety at NTPC
(A) At Engineering Stage
(B) At Execution stage
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At Engineering Stage
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Process Safety at Engineering stage
• HEZOP (Hazard and Operability Study)( pe ty tudy)
• LOPA (Layer Of Protection Analysis)
• SIL (Safety Integrity Level)
Shivam NTPC 18
• SIS / SIF
Safety standards
Machinery sectorMedical sector
IEC
IEC61508 Nuclear sector
IEC61513
IEC62061
Process sector. . . . . . sector
IEC61511
IEC 61508 is an international standard published by the
International Electrotechnical Commission of rules applied
in industry.Shivam NTPC 19
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).
Shivam NTPC 20
Engineering Specification for Safety
EN 50156-1:2015 :
Electrical equipment for furnaces and ancillary equipment. Requirements for li ti d i d i t ll tiapplication design and installation
EN 50178 :
Electronic equipment for use in power installations.
NFPA-85
Contributes to operating safety and prevents explosions and implosions in boilers
IS-3034
Fire safety of Industrial BuildingsShivam NTPC 21
At Execution Stage
Shivam NTPC 22
Safety at Execution Stage
• 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• “No deviations” from NTPC safety systems (PTW / TC/ Process protections, General safety Rules etc)
• JSA
Shivam NTPC 23
Nurturing Safety Culture and inculcating safety behavior
A Measurement Monitoring and Analysis of Safety IndicatorsA. Measurement, Monitoring and Analysis of Safety Indicators
B. Creating Safety ambiance
C. Emergency preparedness
D. Blending latest Technology with ground action
Shivam NTPC 24
Measurement, Monitoring Analysis of Safety Indicators
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Measurement, Monitoring and Analysis of Safety Indicators
Shivam NTPC 26
Click to edit Master title styleMeasurement, Monitoring and Analysis of Safety Indicators
Date- Daily Monthly
Reported Target Cumulative
Safety Deviations 10 50 200
Proactive Indicators (Lead Indicators)
Severe Event
Safety Deviations 10 50 200
Near Miss
SZLO
SOV
Pep Talk / TBT
Date- Daily Monthly
Reported Target ( < --) Cumulative (< --)
Reactive Indicators (Lag Indicators)
Reactive
Approach
Costly Events
Lost time Injury
(Reportable)
Lost time Injury
(Non Reportable)
First AidSome Cost
Copyright © 2016 Your Company All Rights Reserved.27
p g ( ) ( )
First Aid
Non-Reportable
Reportable
Serious injury / Fatality
Fire Incident
Some Cost
Pro Active approach
Near Miss
Free eventsSafety Deviations
Analysis and Sharing of safety indicators
Shivam NTPC 28
Analysis and Sharing safety indicators
Shivam NTPC 29
Three tier Capacity Building Programme
Tier-1 CMD, Directors, REDs One hour appreciation Programme with a refresher at
every three monthsevery three months
Tire-2 REDs, EDs, HOPs, GMs Safety session in MCM
Tire-3 AGMs and below • Classroom training once in three months
• On line training programme with assessment.
Frequency-Once in three months.
Shivam NTPC 30
Capacity Building of Associate Worker :
Safety induction programme, High Risks activities training, Job Specific Training.
Done through External Experts, Line managers, OEMs etc.
Shivam NTPC 31
Creating Safety Ambience
Shivam NTPC 32
Safety Ambience
• Safety Parksy
• Safety Kiosks
• Safety Zones
• Safety Boards for “Good Safety Citizens”
• Awards and Rewards
Shivam NTPC 33
Shivam NTPC 34
Shivam NTPC 35
Emergency Preparedness
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Emergency Preparedness
• Fire fighting training of Employees, Associates, House makers
M thl Fi fi hti t h lthi h ki (CISF/NTPC)• Monthly Fire fighting system healthiness checking (CISF/NTPC)
• Mutual aid scheme (Anta-Chambal Fartilizer, Auriya-GAIL / T Kaniha - NALCO)
• Approved Disaster Management Plan
• Mock Drills
• Fire fighting training to Employees, Associates, House makers, School childrenShivam NTPC 37
Shivam NTPC
Fire Fighting training at Schools
39Shivam NTPC
Emergency Preparedness
Mock Drills:
• As per Factory Act (Once in six months)
• Fire mock drill (CISF) (Once in 15 days) and online system checking
• Mock Drills in association with NDRF and Factory Authorities
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Mock Drill with NDRF
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Mock Drill in presence of Director of Factories
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Further Smart Initiatives • Programmes like “Voice of Victim” and “Catch them Young”
• Intense monthly Safety programmes at sites
• Monitoring of Safety deviation through High resolution Cameras at “Safety Centers”
U f l t t S ftw f I ide nd f ty de i ti l i nd nit i• Use of latest Software for Incidence and safety deviation analysis and monitoring
• Pilot project on safety using IOT
• Project with “Virtual Reality” at PMI Shivam NTPC 43
T LiTop Line
Bottom Line
Safety
Production Targets
Personal targets
Ball of safety is made up of Glass and
Rest all balls are made up of rubber.
If l ft ll b b k B tIf left, all can bounce back But…..
Ball of Safety Can’t
Shivam NTPC 44
Someone is waiting for you at Home
fYour safety is more important
Thank YouThank YouShivam NTPC 45
What is Safety ??
• Safety is not absence of accidents
• Safety is presence of defenses in the processes, procedures, facilities, methods and practices.p
Shivam NTPC 46
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.
Shivam NTPC 47