April 2012 Issue SAFETY & SECURITY NEWSLETTER

Transcription

1 April 2012 Issue SAFETY & SECURITY NEWSLETTER

2 MESSAGE DESK Thought for the month Supervision is the key for Safety CONTENTS 1 Safety Targets FY 13 2 Know about Electrical Flashover 3 An earthquake- Do s and Don ts Safety Highlights Super-Vision for Safety - Safety Theme for Apr 12 An eye-opener- PG student dies in freak accident Root Cause Analysis (RCA) Trend- Mar 12 Security Highlights

3 1. Safety Targets FY 13

4 2. Know about Electrical Flashover by Ms. Chamundeeswari T Believe it or not!!!!!!! Arc temperatures can reach up to 35,000⁰F, four times hotter than the sun s surface. When someone is killed or injured by electricity, means the first thing comes to our mind is electrocution but electric shock is not the only hazard. There are several hundred serious burn victims each year as a result of electrical flashover and is a source of longterm injuries and sometimes a slow and painful death. Nothing can replace a worker / loved one who died or suffered the irreparable consequence of an electrical accident. When electrical system breakdown, the primary hazards and the consequence to personnel are Electrical Shock Exposure to Arc Flash Exposure to Arc Blast Exposure to excessive light and sound. Secondary hazards may include burns, the release of toxic gases, molten metal, air borne debris and shrapnel. Unexpected event can cause startled worker to lose their balance and fall from ladder or jerk their muscles possibly causing whiplash or other injuries. This article mainly focuses on the Arc Flash and Arc Blast hazards which lead to severe second and third degree burns. What is Arc- Flash and Arc-Blast? An Arc Flash is an unexpected sudden release of heat and light energy produced by electricity traveling through air. Any energized electrical conductor that makes accidental contact with another conductor or with ground will produce an Arc-Flash. The arcing current will continue to flow until the over current protective device used upstream opens the circuit or until something else cause to stop flowing arcing current. The arc current can vary up to the maximum available bolted fault current. FACT: 60% of work place electrical accident deaths are caused by burn injuries. The temperature at the arc terminals can reach up to F, or four times the temperature of the sun s surface. The air and gases surrounding the arc are instantly heated and conductors are vaporized which causing a pressure wave called as Arc Blast. Even large objects such as switchboard doors, bus bars, or other components can be propelled several feet at extremely high velocities. These events occur very rapidly with speeds exceeding 700 miles per hour making it impossible for a worker to get out of the way. The Effects of Arc-Flash and Arc-Blast... Personnel directly exposed to an Arc- Flash and Arc-Blast events are subject to third degree burns, possible blindness, shock, blast effects and hearing loss. Even relatively small arcs can cause severe injury. The secondary effect of arcs includes toxic gases, airborne debris, and potential damage to electrical equipment, enclosures and raceways. The high temperatures of the arc and the molten and vaporized metals quickly

5 ignite any flammable materials. While these fires may cause extensive property damage and loss of production, the hazards to personnel are even greater. What is incident energy? In order to understand the potential effect of Arc- Flash, one must be familiar about the term called Incident Energy (IE). An Arc-Flash produces intense heat at the point of arc. Incident Energy (E) is defined as the instantaneous energy released by an Arc- Flash and is expressed in calories per square centimeter (cal/cm 2 ). Many studies show that the industrial Arc-Flash events produce 8cal/cm 2 of Incident energy and just 1.2cal/cm 2 of IE is enough for causing a second degree burn to unprotected skin. That is why the personnel exposed to Arc Flash is seriously affected by second and third degree burns. The amount of incident energy a worker may be exposed to during an Arc- Flash is directly proportional to the total clearing ampere-squared seconds (I 2 t) of the over current protective device during the fault. High current and longer exposure time produces greater incident energy. Hazard Risk Category: NFPA 70E, standard for electrical safety in work place categories Arc-Flash Hazards into five Hazard Risk Categories (HRC 0 through 4) based on the amount of energy that can be released at certain working distance during an Arc-Flash event. What is Flash Hazard Analysis? A Flash Hazard Analysis shall be done in order to protect personnel from the possibility of being injured by Arc-Flash. This analysis shall determine the Flash Protection Boundary and personal protective equipment that people with in Flash Protection Boundary shall use. The flash Protection Boundary is the distance from a given arc source that will produce a second degree burn on exposed bare skin. For Flash hazard Analysis, the following data are required, Up-to-date one line circuit diagram of electrical distribution system. Available Fault current from the utility Maximum available bolted fault current Minimum self sustaining arcing current at each location Clearing time of all over current protective devices. If the maximum available fault current at a particular location and clearing time of the upstream over-current protective device are known, the amount of incident energy and the flash protection boundary distance in feet (D c ) can be calculated. Limits of approach: Observing a safe approach distance from exposed energized electrical conductors or circuit parts is an effective means of

6 maintaining electrical safety. As the distance between a person and the exposed energized conductors or circuit parts decreases, the potential for electrical accident increases. 1. Unqualified Persons, Safe Approach Distance. Unqualified persons are safe when they maintain a distance from the exposed energized conductors or circuit parts, including the longest conductive object being handled, so that they cannot contact or enter a specified air insulation distance to the exposed energized electrical conductors or circuit parts. This safe approach distance is the Limited Approach Boundary. 2. Qualified Persons, Safe Approach Distance. 2.1 Determine the Flash Protection Boundary and, if the boundary is to be crossed, appropriate flash-flame protection equipment must be utilized. 2.2 For a person to cross the Limited Approach Boundary and enter the limited space, he or she must be qualified to perform the job/task. 2.3 To cross the Restricted Approach Boundary and enter the restricted space, qualified persons must do the following: Have a plan that is documented and approved by authorized management Use personal protective equipment that is appropriate for working near exposed energized conductors or circuit parts and is rated for the voltage and energy level involved Be certain that no part of the body enters the prohibited space. Minimize the risk from inadvertent movement by keeping as much of the body out of the restricted space as possible, using only protected body parts in the space as necessary to accomplish the work. 2.4 Crossing the Prohibited Approach Boundary and entering the prohibited space is considered the same as making contact with exposed energized conductors or circuit parts. Therefore, qualified persons must do the following: Have specified training to work on energized conductors or circuit parts. Have a documented plan justifying the need to work that close. Perform a risk analysis. Plan & risk analysis approved by authorized management. Use personal protective equipment that is appropriate for working on exposed energized conductors or circuit parts and is rated for the voltage and energy level involved. Conclusion: There is no substitution for training and following proper procedures in the electrical business. There is no system, which cannot be de-energized, worth more than a human life.

7 3. An earthquake- Do s & Don ts Recently we have been hearing earthquakes in and around our country. Here are some guidelines to protect yourself and your family from any untoward events during an earthquake. What to Do Before an Earthquake Repair deep plaster cracks in ceilings and foundations. Get expert advice if there are signs of structural defects. Anchor overhead lighting fixtures to the ceiling. Follow BIS codes relevant to your area for building standards. Fasten shelves securely to walls. Place large or heavy objects on lower shelves. Brace overhead light and fan fixtures. Store breakable items such as bottled foods, glass, and china in low, closed cabinets with latches. Hang heavy items such as pictures and mirrors away from beds, settees, and anywhere people sit. Repair defective electrical wiring and leaky gas connections. These are potential fire risks. Secure a water heater, LPG cylinder etc., by strapping it to the wall studs and bolting it to the floor. Store weed killers, pesticides, and flammable products securely in closed cabinets with latches and on bottom shelves. Identify safe places indoors and outdoors. 1. Under strong dining table, bed 2. Against an inside wall 3. Away from where glass could shatter around windows, mirrors, pictures, or where heavy bookcases or other heavy furniture could fall over 4. In the open, away from buildings, trees, telephone and electrical lines, flyovers, bridges Educate yourself and family members Know emergency telephone numbers (doctor, hospital, police, etc) Have a disaster emergency kit (Battery operated torch, Extra batteries, Battery operated radio, First aid kit and manual, Emergency food (dry items) and water (packed and sealed), Candles and matches in a waterproof container, Knife, Chlorine tablets or powdered water purifiers, Can opener, Essential medicines, Cash and credit cards, Thick ropes and cords, Sturdy shoes) ready Develop an emergency communication plan 1. Incase family members are separated from one another during an earthquake (a real possibility during the day when adults are at work and children are at school); develop a plan for reuniting after the disaster.

8 2. Ask an out-of-state relative or friend to serve as the 'family contact' after a disaster; it's often easier to call long distance. Make sure everyone in the family knows the name, address, and phone number of the contact person. Help your community get ready 1. Publish a special section in your local newspaper with emergency information on earthquakes. Localize the information by printing the phone numbers of local emergency services offices and hospitals. 2. Conduct a week-long series on locating hazards in the home. 3. Work with local emergency services and officials to prepare special reports for people with mobility impairments on what to do during an earthquake. 4. Provide tips on conducting earthquake drills in the home. 5. Interview representatives of the gas, electric, and water companies about shutting off utilities. Work together in your community to apply your knowledge to building codes, retrofitting programmes, hazard hunts, and neighborhood and family emergency plans. What to Do during an Earthquake Stay as safe as possible during an earthquake. Be aware that some earthquakes are actually foreshocks and a larger earthquake might occur. Minimize your movements to a few steps to a nearby safe place and stay indoors until the shaking has stopped and you are sure exiting is safe. If indoors DROP to the ground; take COVER by getting under a sturdy table or other piece of furniture; and HOLD ON until the shaking stops. If there isn t a table or desk near you, cover your face and head with your arms and crouch in an inside corner of the building. Protect yourself by staying under the lintel of an inner door, in the corner of a room, under a table or even under a bed. Stay away from glass, windows, outside doors and walls, and anything that could fall, such as lighting fixtures or furniture. Stay in bed if you are there when the earthquake strikes. Hold on and protect your head with a pillow, unless you are under a heavy light fixture that could fall. In that case, move to the nearest safe place. Use a doorway for shelter only if it is in close proximity to you and if you know it is a strongly supported, load bearing doorway. Stay inside until the shaking stops and it is safe to go outside. Research has shown that most injuries occur when people inside buildings attempt to move to a different location inside the building or try to leave.

9 Be aware that the electricity may go out or the sprinkler systems or fire alarms may turn on. DO NOT use the elevators. If outdoors Stay there. Move away from buildings, trees, streetlights, and utility wires. Once in the open, stay there until the shaking stops. The greatest danger exists directly outside buildings, at exits, and alongside exterior walls. Most earthquake-related casualties result from collapsing walls, flying glass, and falling objects. If in a moving vehicle Stop as quickly as safety permits and stay in the vehicle. Avoid stopping near or under buildings, trees, overpasses, and utility wires. Proceed cautiously once the earthquake has stopped. Avoid roads, bridges, or ramps that might have been damaged by the earthquake. If trapped under debris Do not light a match. Do not move about or kick up dust. Cover your mouth with a handkerchief or clothing. Tap on a pipe or wall so rescuers can locate you. Use a whistle if one is available. Shout only as a last resort. Shouting can cause you to inhale dangerous amounts of dust. After an earthquake Keep calm, switch on the radio/tv and obey any instructions you hear on it. Expect aftershocks. Be prepared. Turn off the water, gas and electricity. Do not smoke and do not light matches or use a cigarette lighter. Do not turn on switches. There may be gas leaks or short-circuits. Keep away from beaches and low banks of rivers. Huge waves may sweep in. Use a torch. If there is a fire, try to put it out. If you cannot, call the fire brigade. If people are seriously injured, do not move them unless they are in danger. Immediately clean up any inflammable products that may have spilled (alcohol, oil, etc). If you know that people have been buried, tell the rescue teams. Do not rush and do not worsen the situation of injured persons or your own situation.

10 Avoid places where there are loose electric wires and do not touch any metal object in contact with them. Do not drink water from open containers without having examined it and filtered it through a sieve, a filter or an ordinary clean cloth. If your home is badly damaged, you will have to leave it. Collect water containers, food, and ordinary and special medicines (for persons with heart complaints, diabetes, etc.). Do not re-enter badly damaged buildings and do not go near damaged structures.

11 4. Safety Highlights A special safety session was organised for Wind operations team by Corporate Safety on 09 th and 10 th April The following topics were covered: Safety Intervention Audit & Training a Behaviour Based Safety (BBS), SuperVision for Safety, Suraksha Bandhan movie, BSC 5 star SMS. Safety Induction training session was held on for Contractor Supervisor & Workers of M/s S. D. Construction at Station A, CCS s Office

12 Jojobera & Power House#6 observed Fire Service Day on 14th of April and Fire safety week during 9 th to 14 th April. The Tata Power employees and contractors actively participated in large numbers. Fire brigade staff practically demonstrated the use of portable firefighting equipment & operation of deluge system and also conducted rescue drill. 5. SuperVision for Safety - Safety Theme -Apr 12 Supervisors play an important role in reinforcing safety at work place. Each Supervisor or gang leader supervises the job of at least workers. Supervisor instructs, directs and controls workers in the performing their duties. If supervisor fail to take action or delay in taking action, they are not only condoning the unsafe activity, but they are also encouraging such unsafe activity. Supervisors are responsible for ensuring the health and safety of their workers. Supervisors shall be knowledgeable on the work processes, the hazards involved, and effective control measures. Supervisors shall ensure that their workers are made aware of all hazards known or reasonably foreseeable. Supervisors shall be knowledgeable about the applicable safety acts, rules and company procedures, ensure workers comply with them meticulously. Supervisors shall have clear understanding of his roles and responsibility on safety. CGPL Mundra has recognized the critical role of supervisors in ensuring safety and had adopted NO SUPERVISION, NO WORK from the inception. CGPL has designed couple of training

13 programs for the development of first line Supervisors and gang leaders with the help of NGO. In-line with safety theme of the month Supervision for Safety, various training programs were organized for contract supervisors, safety supervisors and gang leader. CGPL, Mundra By Pramod Kumar Singh, Chief Manager-Safety, CGPL MPL, Maithon 6. An eye-opener - PG student dies in freak accident A post-graduate student of Tamil Nadu Agricultural University died in a freak accident on the university premises. According to the information, the 27-year-old student died of accidental strangulation when her dupattah got caught in the machine where she was working on at the laboratory.

14 Her death came to light when a watchman went to the laboratory to close the doors. He immediately informed the officials, who rushed her to the hospital, which declared her dead on arrival. So as to prevent such incidents, loose clothing shall be avoided while working on or moving near the rotary equipment and while riding mobike. 7. Root Cause Analysis (RCA) Trend Mar 12 Human Factors Physical Factors

15 System Factors

16 8. Security Highlights TROMBAY Heightening of perimeter wall construction - CAPEX Project in progress is under surveillance & physical security. Total expenditure of ` 2.4 Crore till date with capitalized amount of ` 2.4 Crores. On 3 rd March 2012, Founders Day celebrated in plant. Necessary Security & Traffic arrangements were made for employees and contract staff. On 4 th & 5 th March 2012, National Safety Week celebrated for all the employees and contract staff respectively. Necessary Security & Traffic arrangements were made for employees and contract staff. Security & traffic arrangements carried out for Outage Award Function at Sports Complex, Tata Colony on 09th March Mr. PL Manjrekar Head Trombay visited in Security CCR & Complex. Software on Material Movement Management System installed & training sessions conducted. Participation & preparation of Dept SDM for FY13. Security & Fire staff participated in DMP Awareness Demo conducted at Gavan village Ground by Civil Defence & MARG Chembur on 20 th March On 29 th March 2012, 137 th MARG Meeting Trombay Chembur Industrial Belt conducted. 06 R & R received by security officers & staff. 41 Delegates from HAVARD BUSINESS SCHOOL visited plant.

17 MARG MEETING T & D Preparation of Command & Control Centre is under progress at Dharavi with in the guide lines of PSCC. An Awareness session on Security for all available Kalyan employees was conducted on 29 Feb 2012 from 2 to 4 Pm at Kalyan R/S. Basic fire fighting refresher course for Sec personnel was conducted at Chunabhatti on 07 Mar 12 from 1500h to 1700h in the presence of Site-In-charge. Hydro CGPL Surveillance CCTV system installed and commissioned at Mulshi & Doongar Wadi Area. Heightening of perimeter wall of Power House at Bhira & Bhivpuri under progress. Ongoing survey of Hydro land assets & erection of boundary pillars by M/S MONARCH. On 02 March 2012 the Security team conducted a surprise labour head count at the main gate and on 03 March 2012 at the labour terminal gate for checking unauthorised entry. Security Team coordinated three VIP visits- Boiler Inspector Mr. R N Randhawa visited the CGPL Site on 05 Mar 2012, Deputy Director for Industrial Safety and Health Mr. UR Soni for official purpose on 06 Mar 2012 & Mr. Djoko Soelistiono (Superintendent of marketing & shipping in charge) of M/s. Kaltion Prima Coal & Mr. Agus Vulianto (Govt. Official) from Indonesia visited CGPL site on 15 Mar 2012.

18 Safety week was celebrated w.e.f. 05 March 2012 at the CGPL site and a Safety March was conducted for which all traffic movement coordination was carried out by Team Security CGPL. Mock drill was conducted on 29 Mar 2012 at 1546 Hrs, with a scenario of a trolley carrying labours getting toppled near labour terminal gate to check out emergency preparations of security, safety & fire & medical teams. An eight days Security automation capsule was run by the Honeywell Technician at the Security control room. JOJOBERA Second phase of the Heightening of the Boundary wall is completed in the CHP side area. VIP visit of 4 senior officials of Tata Steel Corus (U.K) was covered successfully. The mock Drill on terrorist attack was conducted. The security awareness security posters were displayed at some locations for better understanding of security concern. Security classes was given to 217 contract workmen during the safety training by the security officers of Tata power to make the contractors workmen aware of the Do's and Don ts in respect to security, while working inside the Plant area. The training was imparted to 25 security personnel of SIS by the security agency along with Head security and other security officers of Tata Power. Mr. Rajesh Prasad, Mr. A.K. Srivastava and Mr. Dinesh Kumar Dubey were rewarded on the occasion of Safety Day for good performance in STOP observation, Making Near miss and taking the security classes during safety training.

19 Founder's day was celebrated at Plant premises and at Tata Steel. VOLUNTEERING IN CR MPL Training of 156 Man-days were carried out to train the deployed security personnel of various agencies on Intelligence & IED.