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Aluminium Business 1 Towards Zero harm to People & Environment
Power plant Safety and Safety best
practices at Vedanta Ltd
By
K N V Kiran Kumar Head -HSE & Sustainability
Vedanta Ltd,Jharsuguda
Aluminium Business 2 Towards Zero harm to People & Environment 2
Geographical footprint of Vedanta
82000
workforce
REVENUE $12.9bn
4m beneficiaries of our community investment
Aluminium Business Towards Zero harm to People & Environment 3
VEDANTA LIMITED, JHARSUGUDA @ GLIMPSE
0.5 mTPA Aluminium Smelter-I 1215 MW Captive Power Plant
1.1 mTPA Aluminium Smelter-II 2400 MW Independent Power Plant
Aluminium Business Towards Zero harm to People & Environment 4
OUR SUSTAINABILITY FRAMEWORK
Aluminium Business Towards Zero harm to People & Environment 5
VEDANTA SUSTAINABILITY FRAMEWORK
Adding and Sharing Values
Responsible Stewardship Building
Strong Relationship
Management Standards
Policies › HSE Policy › Biodiversity Policy › Water Management Policy › Energy and Carbon Management Policy Technical Standards › Health Management › Safety Management › Environmental Management › Conducting ESIA to International Standards includes EMPS › Waste Management › Biodiversity Management (EMPs) › Water Management › Energy and Carbon Management › Land and Resettlement Management › Security Management › Emergency and Crisis Management › Transport and Logistics Management
Policies › Supplier and Contractor Management Policy › Human Rights Policy Technical Standards › Cultural Heritage › Supplier and Contractor management › Employee Consultation & participation › Stakeholder Engagement › Social investment management › Grievance Mechanisms › Indigenous Peoples / Vulnerable Tribal Groups
Policies › HIV/Aids Policy Technical Standards › HIV/Aids Management › Site Closure
Global Management Processes › New Projects, Planning Processes & Site Closure › Stakeholder Materiality and Risk Management › Performance Monitoring, Data Management and reporting › Incident Reporting and Investigation › Management of Change › Documentation & Records Management › Corrective and Preventive Action Management › Auditing and Assurance › Acquisitions, Divestment and Joint Venture Due Diligence
Policy Management Standard › Compliance and Other Requirements › Leadership, Responsibility and Resources › Objectives, Targets and Performance Improvement › Competency, Training and Awareness › Management Review and Continual Improvement
Aluminium Business Towards Zero harm to People & Environment 6
The Safety Journey
Aluminium Business Towards Zero harm to People & Environment 7
Aluminium Business Towards Zero harm to People & Environment 8 Aluminium Business 8 Towards Zero harm to People & Environment
Transaction #2 Safety interactions
• Confirm task planning • Confirm controls implemented
(submit & monitor)
TYPE I Task Based
(Making Good Decisions)
Employee pre-task hazard assessment
• Identify hazards • Implement controls (formal but not submitted)
Transaction #1
TYPE II System Based
(Following Rules)
Six Safety Performance Standards • Work at Height • Confined Space • Isolation • Electrical • Vehicles & Driving • Ground Control
TYPE III Catastrophic
(Understanding Risks)
Formal risk assessment (SQRA)
Bow Tie analysis
Critical Control Management
Two transactions Led by Front Line Supervisor
Report
Investigate
1.Eliminate fatalities 2.Zero Harm culture 3.Understand risks 4.Control effectiveness 5.Develop capability 6.Develop metrics
“Three Types of Risk”
Aluminium Business Towards Zero harm to People & Environment 9 Aluminium Business 9 Towards Zero harm to People & Environment
Mandatory Pre-medical , Safety Induction Training & Competency
Assessment to be done for issue of Gate Pass
Aluminium Business Towards Zero harm to People & Environment 10
INDUCTION TRAINING – AUDIO VISUAL
Training on Isolation Training on Height Work
Aluminium Business Towards Zero harm to People & Environment 11 Aluminium Business 11 Towards Zero harm to People & Environment
➢ Daily Tool Box Talk before Start of Job.
➢ Job specific trainings
➢ SOP/SMP/SWP/HIRADec training and ensuring
through Pre-Test and Post-Test.
Site Trainings
Aluminium Business Towards Zero harm to People & Environment 12 Aluminium Business 12 Towards Zero harm to People & Environment
CARDINAL RULES
Aluminium Business Towards Zero harm to People & Environment 13 Aluminium Business 13 Towards Zero harm to People & Environment
SAP Online Permit System
➢ Authorised Receiver,Issuers,Isolation
Authority, Gas tester etc.
➢ One Day Advance Planning of Permits
with Proper Risk Assessment
➢ Trainer Contractor Supervisors
/Engineers on SAP EHS
Key Features :
Eg. Hot work permit
STRINGENT WORK PERMIT WITH AUTHORISATION
Aluminium Business Towards Zero harm to People & Environment 14 Aluminium Business 14 Towards Zero harm to People & Environment
CRITICAL TASK ANALYSIS & RISK ASSESSMENT.
➢ HIRA,SOP & SMP for All Routine Activities
Non routine Activities :
➢ Preparation of Risk Assessment (HIRA )
➢ Method Statement
➢ Job Safety Analysis or SWP.
Training on SOPs and SMPs
Safe Work Procedure
Aluminium Business Towards Zero harm to People & Environment 15
Drives
Injury analysis and Interventions
Process Safety Management
Fleet management
Felt leadership programme
Visual impact
Critical drives
Six Safety Performance Standards
Aluminium Business Towards Zero harm to People & Environment 16 Aluminium Business 16 Towards Zero harm to People & Environment
➢ Welding Machine .
➢ Grinding machine .
➢ Gas cutting Set.
➢ Hydra, Crane,
➢ Vehicles ( LMV,HMV )
➢ Lifting Tools ,Tackles
➢ Flammable & Hazardous Materials
➢ Certification of Items.
Welding Machine Checklist Hydra Machine Checklist
INSPECTION OF TOOLS & MACHINERIES BEFORE ENTRY
Aluminium Business Towards Zero harm to People & Environment 17
CRITICAL ITEMS REVIEW.
Machine Guarding
Conveyor Guarding
Ladders & working platforms
Welding Machines
Lifting tools & Tackles
Gas Cylinders & Pressure vessel
Mobile Machineries Hydra ,Forklift,JCB,etc.
Aluminium Business Towards Zero harm to People & Environment 18 Aluminium Business 18 Towards Zero harm to People & Environment
➢ SustainabilityGuidelines are being followed for all New Projectrs
➢ Management of change is being practiced for any modifications with respect to,
➢ Plant & equipment,
➢ Procedures and practices,
➢ Raw materials,
➢ Processing conditions,
➢ Staffing including contractor change
➢ Training related to changes given to target group
➢ MOC compliance is being tracked monthly by coordinators
New Projects
NEW PROJECTS & MANAGEMENT OF CHANGE (MOC)
Aluminium Business Towards Zero harm to People & Environment 19
PSSR
PSSR is applicable on following areas for Process Safety ➢ Annual Overhauling of boiler ➢ All new projects / new constructions / major
modification against MOC ➢ Hazardous chemical operations, ex: LDO, HCL &
H2SO4 unloading ➢ Operation of critical equipment with an idle
condition >90 days
Aluminium Business Towards Zero harm to People & Environment 20 Aluminium Business 20 Towards Zero harm to People & Environment
➢ Safety Committee Meetings in all SBU’s
➢ Online NM /UA/UC reporting
➢ BBS schedule follow up
➢ CASHe Projects
➢ Housekeeping drives
➢ Incident Investigation
Incident Investigation Format
➢ 100% Investigation for all types of Incidents
➢ FAI-First Aid Injury
➢ MTI- Medical Treatment Injury
➢ LTI-Lost Time Injury
➢ Near Miss Incident
➢ Fatality
➢ Why-Why analysis in accident investigation is being followed
to find out the root cause
➢ Cost of accident captured for all accidents
➢ CAPA prepared and follow up for 100% compliance
➢ Circulation of Safety Alert on every accident for horizontal
deployment
Incident Investigation Before After
CASH-e Project
EMPLOYEE PARTICIPATION
Spray system above conveyor to reduce dust
Aluminium Business Towards Zero harm to People & Environment 21 Aluminium Business 21 Towards Zero harm to People & Environment
➢ Formulation & Implementation of Road Safety
Policy. ➢ Monitoring through Speed guns.
➢ Daily monitoring of Alcohol consumption
➢ GPRS based Vehicle tracking system ➢ Meetings with transporters to partner in
implementation of safety initiatives.
➢ Engineering controls viz road barriers & dividers, speed breakers, road markers, convex mirrors, spring posts, speed guns & illumination etc..
➢ Introduction of Defensive Driving Training by
expert agency .
➢ Journey Risk Assessment conducted for
Bhubaneswar, Sambalpur , Rourkela & Jharsuguda
Town ( Railway station & Air port route ).
➢ Monitoring and consequence management of speed
violations, drunken driving, PPE violators, and
required documentation etc.
Live tracking screenshot of Bus
no. OR23E3101 Speed Gun Monitoring of
Vehicles
FLEET MANAGEMENT
Aluminium Business Towards Zero harm to People & Environment 22
CONTRACTOR SAFETY MANAGEMENT
➢ Induction and job Specific Trainings conducted for workforce & Supervisors
➢ Competency mapping of contract employees
➢ Compliance of Tool Box Talks
➢ PPE Quality, adequacy and usage
➢ Near miss / Potential incidents reporting
➢ Compliance to SOP/ SMP
➢ Adherence to Site regulations
➢ Implementation of HSE inspection audit observations
➢ House keeping quality
➢ Safety, welfare initiatives & implementation of best practices
➢ Consequence management against violation –Yellow, red safety notices & penalty system
➢ Score card based payment system
Tool Box Talk & safety Pledge
Aluminium Business Towards Zero harm to People & Environment 23 Aluminium Business 23 Towards Zero harm to People & Environment
Contractor Safety Audits Checklist of Contractor Safety Audit
CONTRACTOR SITE AUDIT.
Aluminium Business Towards Zero harm to People & Environment 24
Internal Audit : ❑ Daily Safety inspections ❑ Senior management walk down ❑ AIC audits ❑ Sustainability Audit. External Audits: ❑ External safety audit by Competent Agencies. ❑ Electrical Safety audits. ❑ Ergonomics Survey ❑ Industrial Hygiene survey ❑ External Fire safety audit . ❑ HAZOP study . Statutory Audit : ❑ Statutory audits by Govt. bodies (e.g. Authorities
from Directorate of Factories & Boilers, Electrical Regulatory Audit ).
Senior Management Walk down
SPECIALIZED AUDITS FOR HAZARD ELIMINATION
Aluminium Business Towards Zero harm to People & Environment 25
INCIDENT INVESTIGATION & CAPA IMPLEMENTATION
➢ 100% Investigation for all types of Incidents
➢ LTI/Fatality
➢ MTI- Medical Treatment Injury
➢ FAI-First Aid Injury
➢ Near Miss Incident
➢ Why-Why analysis in accident investigation is being followed to find out the root cause
➢ 4 Step methodology for all LTI/HIPOs/Fatal incidents
➢ Cost of accident captured for all accidents
➢ CAPA prepared and follow up for 100% compliance
➢ Circulation of Safety Alert on every accident for horizontal deployment
Aluminium Business Towards Zero harm to People & Environment 26 Aluminium Business 26 Towards Zero harm to People & Environment
Yellow Safety Notice- Permit Violation Red Safety Notice- Permit Violation
CONSEQUENCE MANAGEMENT SYSTEM
Aluminium Business Towards Zero harm to People & Environment 27 Aluminium Business 27 Towards Zero harm to People & Environment
OCCUPATIONAL HEALTH PRACTICES
Initiatives:
➢ 100% pre employment and periodic medical examination of employees and service providers.
➢ Hazard identification, Hazard Risk Assessment, Similar Exposure group identification
➢ Food Handlers, Security personnel ,locomotive operators, persons working at height and in confined space, Persons involved in Loading, unloading , etc.
➢ Special medical examination of people for working at height and Confined space before issue of pass.
➢ Linkage of Contractor Medical Examination with gate Pass
➢ Life Style Modification ,Counseling and treatment for prevention and control of chronic diseases
➢ Industrial Hygiene Survey by expert agency
➢ Ergonomic survey conducted for the location by expert agency (Occupational Ergonomics Laboratory, University of Calcutta)
➢ Biological Monitoring for Heat Stress.
➢ Snake Bite-Polyvalent anti snake venom ➢ Life Saving neutralizing Agent Diphoterine placed near all Chemical
Storage area, Laboratories.
SEG & Work area monitoring
Telemedicine Facility at Apollo Clinic, Township
Structure for Height Pass
Aluminium Business Towards Zero harm to People & Environment 28 Aluminium Business 28 Towards Zero harm to People & Environment
EMERGENCY PLANNING AND RESPONSE
On site Mock Drill Conducted involving Sr. Mngt, Govt Authorities and Mutual Aid partners
Aluminium Business Towards Zero harm to People & Environment 29 Aluminium Business 29 Towards Zero harm to People & Environment
MOTIVATION AND PROMOTION
1 House Keeping( 5S Related) 50
2 Safe Working 50
3 Use of PPE(personal protective eqp.)
50
4 Fire Safety 50
6 Leading Indicator in % 300
TOTAL 500
Criteria for Safety Rolling Trophy Leading Indicator in % 300
Safety Training Actual/Target 50
Work Permit Complied/Issued 50
Weekly audit observation Complied/Raised
50
Hazard Complied/Identified 50
Near miss/Other Investigation recommendation implemented / Reported
50
Safety related improvements 50
Aluminium Business Towards Zero harm to People & Environment 30 Aluminium Business 30 Towards Zero harm to People & Environment
Safety Performance Review By CEO for the
Site
Monthly Safety Performance Review
Plant Level:by Plant Heads
Monthly Review through Safety Committee
Plant level.
Monthly Performance through Score card by HOD
& Safety Head.
REVIEW OF PERFORMANCE
Aluminium Business Towards Zero harm to People & Environment 31 Aluminium Business 31 Towards Zero harm to People & Environment
MBRD & BBS for Inspection and Building Safety Culture
➢ Engaged Experts for developing internal team ➢ Use of SNAP Tool ➢ Safety Interaction to change behavior
Aluminium Business Towards Zero harm to People & Environment 32 Aluminium Business 32 Towards Zero harm to People & Environment
EBRA for Catastrophic Risks
Aluminium Business 33 Towards Zero harm to People & Environment
Booklet on Safety performance standard distributed to target
group after training
Safety Performance Standard for System based Risks
Six Safety Performance Standards
• Work at Height • Confined Space • Isolation • Electrical • Vehicles & Driving • Ground Control Classroom Trainings,Videos,Authorisation at Shop floor Levels
Aluminium Business 34 Towards Zero harm to People & Environment
Thank You