Industrial Safty

8/13/2019 Industrial Safty

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IG/02For restricted Circulation Only

INDUSTRIAL SAFETY

Power Management InstituteNoida


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CONTENTS

S. No. Subject Page Nos.

1. Accident Causes and Factors 1

2. Cost of Accident 8

3. Accident Prevention 11

4. Accident Investigation & Records 16

5. Techniques of Discovering Hazards 23

6. Investigation of Accidents 43

7. Procedure for Reporting of Accidents/ DangerousOccurrences

52

8. Guidelines on Constitution of Enquiry Committee 63

9. Safety Policy 69

10. Industrial Hazards 74

11. Protective Clothing & Equipment 82

12. Safety in Movement of Men & Material 88

13. Safety in Construction 100

14. Safe Working Practices in Thermal Power Station 108

15. Permit to Work System 115

16. An Executives Role in Safety 119


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17. Factories Act - 1948 124

18. Indian Electricity Act & Rules 132

19. Gas Cylinder Rules - 1981 138

20. Legal Aspects of Safety Under the Acts 152

21. Health Hazards of Hazardous Chemicals 161

22. Indian Boiler Act 1923 171

23. Inspection of Steam Boilers 185

24. House Keeping 192

25. Fire Safety 197

26. Portable Fire Extinguishers 204

27. Fire Prevention and Protection System for Thermal Power

Station

234

28. Introduction to First Aid 243

29. First Aid to the injured 250


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1.1. AccidentsAccidents-- Causes & FactorsCauses & Factors

INTRODUCTION

The ordinary meaning of the word Accident as derived from lexicons is an

unforeseen of an unexpected event. This definition covers a wide range of

phenomena including even natural catastrophes and cannot, therefore, subserve

the purpose of a scientific investigation. The term accident when used in

industry, while in essence retaining this popular connotation, refers to a district

class of the phenomena. The American National Safety Council has defined

accident as that occurrence in a sequence of events which usually produces

unintended injury, death or the property damage. Heinrich has, however, defined

accident as an unplanned and uncontrolled event in which the action or reaction

on an object, substance, person or radiation result in personal injury.

Basically accidents constitute a behavioral problem signifying a disintegration in

the equilibrium of the individual in relation to the work situation. The forces that

make for the disequilibrium are mainly drawn from the stress of the work situation

and the psycho- social character of the individual involved. As soon as this filed

is distributed due to the displacement of the relatively specific situation or the

appearance of new one the equilibrium is upset, causing an interruption or

disorganization in performance. By and large, therefore, accidents are defined as

unforeseen, sudden, unintended or unconscious deviations in work activity

tending to end to an injury.

CAUSES OF ACCIDENTS

The causes may be human or mechanical failures .The two broad sources of the

accidents may be classified into:


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i) Unsafe conditions, and

ii) Unsafe acts

An unsafe condition may refer to the condition of the floor, of the ladder, of a

machine, of a stairway, of a tool, of a conveyor belt of anything else of physical,

environmental or mechanical character which could lead to an accident.

An unsafe act is something somebody does which may culminate in an

accident. The word may is used because it is not necessary that it should

always lead to an accident, but we can be sure that if such acts are persisted

they will result in avoidable injuries.

It is a matter of considerable debate whether out of unsafe condition and

unsafe act which is more important. The question is a difficult one. Both are

important. The significance of separating causes into two kinds is that it draws

attention to fact that the attack strategy should be two- pronged. We must

prevent unsafe acts, not one or the other. What then is the relationship between

the two?

The cause of nearly all accidents has relations to an unsafe condition. This

unsafe condition contains the POTENTIAL to injure someone (e.g., an

unguarded press, an unfenced floor opening. a piece of wood with a nail on the

floor, and so on.)

It is the unsafe act that leads to an accident. We may call it the triggering cause

because it releases the danger potential of unsafe condition somewhat as the

pressing of trigger of gun release the unsafe potential of the loaded bullet.

How do we tackle the problem?

-- The first attack has to be on the unsafe condition. Because it alone is

completely controllable


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-- The next important attack has to be on unsafe acts of the people. To

place this line to attack second does not mean that it is relatively

unimportant but only that it is harder to control less immediate in effect.

Even through, in the short run. More certain and quicker results can be

obtained by rectifying unsafe conditions in the long run the only way to

make places accident free is to teach the people to work safely and to see

they practice it.

FACTORS CONTRIBUTING TO ACCIDENTS

These are classified into four on the basis of the area of their origin, the person

or the environment and according to the basis of proximity to accident event:

-- Mechanical

-- Environment

-- Human

-- Human mechanical causes.

Mechanical causes

These relates to the defects and inadequate safeguards of machinery to unsafe

conditions of equipment

-- Inadequately guarded,

-- Unguarded

-- Unsafe design or construction,

-- Hazardous arrangement (pilling, Overloading, etc.)


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Environm ental Causes

The environmental causes of accidents refer to inadequate physical and

atmospheric conditions of work. They are distinguished from mechanical causes

by the fact they do not cause the accident directly, but indirectly contribute to its

occurrence, by virtue of their adverse effects upon the individual. The

environmental causes are also, sometimes, designated as External to the

individual and general where all the workers are affected by them. Some of the

important environmental factor which contributes to accident causation are:

-- Elimination

-- Ventilation

-- Temperature

-- Speed of work

--- Hours of work

-- Spread over to work period

-- Workload

Human Causes

Human causes constitute by far the most important category to accident causes.

Accidents due to human failure a preponderate over other of accidents. The

various factors that constitute the human causes may be grouped as under:

Individual Factors Psychological Factors

a) Age a) Attitude towards job

b) Marriage b) Interest and Difficulties


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c) Education c) Machine habits

d) Health d) Attention

e) Length of service e) Fatigue

f) Work performance

Personality Factors Sociological Factors

a) Intellectual level a) Size of family

b) Emotional maturity b) Number of dependents

c) Adjustment c) Financial position

d) Anxiety level d) Social Status

e) Interpersonal relations

f) Home environment

Accidents have many ways of attending consummation. An accident may injure

the workman or damage the machine or tools or injure a person other then one

involved in the accident or may not attain consummation at all. Suppose a

weaver is performing the operation of shutting on his loom and the shuttle

frequency slips from his hand. Here, the fact of the shuttle slipping form the hand

constitutes the accident, and the events that occur after that represent the effects

of the accident.

Accidents and injuries, therefore, represent two distinct classes of phenomena of

different psychological importance. The antecedent circumstances in the

causation of an injury are easily observable, but the predisposing causes of an

accident often lie hidden in the inner strata of the organism of the individual, his

history and the social environment factors of the work situation.


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CLASSIFICATION OF ACCIDENTS

Influencing Elements

An accident situation comprises three elements:

-- Work Deviation

-- Its causes and,

-- Its effects.

Accidents may, therefore, be classified on the basis of these three elements.

According to the nature of the work deviation, accidents are classified as:

-- Striking against

-- Struck by

-- Caught in or between

-- Fall on same level

-- Overexertion

-- Inhalation or absorption

- Contract with electrically charged objects.

Striking Against

This class refers to such incidents as the workers dashing against machines orother objects or colliding with a fellow worker or some other or object, Such

accidents constitute an important class for psychological study due to the

predominantly human character of their causation.


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Struck By

These accidents are caused due to machine parts of broken belts or other falling,

flying, sliding or moving objects striking of rubbing the body of the worker. Such

accidents are generally due to defective equipment or unsafe working premises.

Caught in or between

These consist of accidents resulting in either fingers being caught in between the

gears or in between the pinion wheels or moving rollers or the hand getting

entangled in the meshes of belt & pulleys. Other parts of the body may as well

get similarly involved.

Falls, on same level

Accidents of this type are a common experience of everyday life. While falls refer

to a complete collapse of the individuals musculature on the ground, slips signify

only a temporary disturbance in muscular balance.

Exposure

These are categories of infrequent occurrences. They are exemplified by such

events as heat, exhaustion, Poisoning, Drowning and electrocution.

Another classification on the basis of the severity of injury and consequent

incapability for the work is commonly followed in accident analysis. Accordning to

this classification. accidents may be divided into five categories:

i) Fatal

ii) Serious

iii) Minor

iv) Trivial

v) No injury accidents.


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2.2. Cost Of AccidentsCost Of Accidents

INTRODUCTION

Often the extent of the cost of accident is not evident and hence not appreciated.

Usually, only direct costs which represent compensation and medical expenses

to be borne by the management are taken into consideration when computing

costs due to accidents. The hidden or indirect costs to the management, the

injured and society at large ignored every often.

COST OF THE INJURED

The injured workers themselves are the very heavy losers. Their actual losses in

money may not be so great as employers but he can ill afford to withstand his

share of financial burden. Where he is not covered by any benefit schemes of the

management or any insurance, he will have to bear himself the loss of wages,

the cost of medical expenses and the loss due to the any permanent

disablement. Even when there are insurance of benefit scheme, the

compensation and medical benefits are rarely adequate. Further no costing can

be done to compensate for the suffering, pain, worry and effects due to

incapacitation.

COST OF MANAGEMEN

According to detailed study carried out by Heinrich the indirect costs which

present all the incidental costs due to an accent except those relating to medical

expenses and compensation, work out on an average to about four time the

direct costs. Some studies report indirect costs to be even six times the direct

costs. While these ratios indicate the average pattern, individual accidents could


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be very costly particularly when the accidents are serious or result in heavy

damage to equipment.

Direct Costs

The direct costs of accidents comprise of (a) the compensation paid to the

injured person; and (b) medical expenses on his treatment since both these are

generally covered under insurance, the cost of accident on these accounts are

also commonly as Insured Cost.

Indirect Costs

The following items contribute towards the indirect of uninsured costs ofaccidents and can be calculated in terms of money unlike the other less tangible

losses such as the effect of accidents on morale etc:

--- Lost time of injured employees: These are the wages paid for the time lost

by the injured worker other than those paid under the workmans

compensation law.

--- Lost time of other employees: After an accident all employees of the

section stop to watch, assist or talk about it. Some time is also lost as

the equipment damages in accident is required or the output or aid of the

injured person is required.

--- Lost time of Foreman, Supervisors or other executives: Time spent on

activities such as investigating the accident, preparing reports, settling

claims arising from it, selecting training or booking in new worker etc.

--- Cost of time spent by the first aid attendant and hospital staff of factory.

--- Cost of damage to material or equipment. This should also include the

cost incurred in back in order the material or equipment which may be

thrown into a state of disorder.


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--- Incidental cost due to interference with production like loss of profit on

contracts cancelled or orders lost.

--- Costs under employee welfare and benefit systems: These will be other

than those paid as compensation.

--- Cost due to continuance of wages to injured persons in full: The output of

injured worker is below normal for some period after he rejoins work.

--- Cost due to loss of profit on the injured workers productivity and on idle

machines.

--- Over head cost over injured worker: These are expenses for the light,

heat, rent and other items with continue over while the injured worker is

away from work.

COST OF SOCIETY

Industrial accidents place a heavy burden on Society. It is ultimately the Society

suffers all losses. For example, taking economical considerations alone, the

financial losses of direct and indirect costs by the management will have to be

met consumers in terms of increased cost of products. Further, it is society,

which again, ultimately bears the financial burden of maintenance of all the

disabled employees and their dependents. Looking at it from this board

perspective, every citizen bears a proportion of the cost of accidents and

knowing heavy costs, every effort should be made prevent accidents.


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3.3. Accident PreventionAccident Prevention

INTRODUCTION

An injury prevented is a benefaction, an injury compensated, an apology

Industrial accident prevention has come of age. The long struggle for its

recognition, for supporting interest and effective action, waged over a period of

years by Government, Industry, Labour and other organizations has borne fruits.

The need and value of Accident Prevention has not been well established and it

is realised that emphasis should be placed on the practical methods of

accomplishment.

Accident Prevention

Accident prevention is both Science and Art. It represents, above all other things,

Control Control of man performance, Machine performance and physical

environment The word control is used advisely because it connotes prevention

as well as correction of unsafe conditions and circumstances. It is a vital factor in

every industrial enterprise, one which, if ignored or practiced unskillfully leads to

needless human suffering and business bankruptcy.

Implication

The effect of accidents, besides the loss of life, property and money, is to restrict

seriously both employment and production of goods and sevices on which the

welfare of a nation depends. This prevention brings about spectacular

achievements in the saving of life and limb, compensation, continuity of service,

increased production, decreased labor turn-over and improved labour

management relations.


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CONTROLING ACCOUNTS

Where as three Es of Safety representing engineering, education and

enforcement are applied in the field of Industrial Safety, it seems much easier to

comprehended the fundamentals of Accident Prevention if the preventive

procedures are grouped in four general classifications which are a little more

selfdescriptive and which fit into the problem a little more closely than do three

Es These four classification may be :

-- Discover causes

-- Control environment causes

-- Control behaviorist causes

-- Supplementary activities

Discovering Accident Causes

Before any steps can be taken, it essential to find out:

-- The causes of pervious accidents, and

--- The existing of hazards that will cause accidents unless corrected

These activities are necessary not only before starting the actual procedure for

accident prevention but also afterwards, for they must given continuous never

ending attention. Otherwise the real effort of accident prevention will get out of

hand.

Controlling Environmental Causes

In this connection, it should be remembered that:

--- All the environment causes have something to do with machinery and

equipment -with things that one can see or feel.


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--- The Control procedures have relationship with engineering or with

application of engineering principles.

In some respects the control of environment causes (or hazards) is the most

essential factor in any accident prevention programme, since it proves to the

workers that management is sincere in its desire to prevent accidents and is

willing to do its part. In addition if there are two or more different ways to prevent

certain types to accidents, this is preferable.

For example. if there is hole in the floor and if any danger of workers falling it and

bearing injured, it is much wiser and cheaper in long run to eliminate and fill that

hole than to place a guard rail around it or to try teach workers to stay away.

Trying to teach men to avoid a hazard is a never ending job requiring constant

supervision and in some cases discipline, but the elimination of a hazard is an

immediate and permanent cure.

Controlling Behavioristic Causes

These can be controlled through the application of:

-- Job analysis

-- Job training

-- Supervision

-- Discipline

--- Personal Work

-- Physical examination

-- Proper placement of workers


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In general, it is much more difficult to control behavioristic causes than it is to

control environmental causes. Unlike environment, human behavior is without

substance, It can neither be seen or felt. It is the result of such complicated

factors as heredity, emotion, diet and habits etc, therefore; it is not surprising that

the method of control are somewhat complicated. They are exact sciences as are

various fundamentals of engineering such as mathematics, physics and

chemistry.

For example, a wrong attitude is an important behavioristic cause that is more

closely induced by worry. Many workers worry about current financial problem or

about the possibility of poverty in old age or the expense on medical care. In

many organizations personal activities have been instituted, such as pension

plans, group health and accident insurance, and employees credit unions, which

have helped to relieve thousands of workers from some of their worries and

problems, and thus helped in improving the companys accident record.

Supplementary Activ i t ies

These may be classified as under:

-- Posters

-- Booklets and other literature

-- Movies

-- Films strips

-- Contests

-- Meetings

-- Committees

-- Suggestion System


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-- Employee Magazines / Bulletins

-- Safety Handbooks.

These activities are of secondary importance when compared to others as they

do not aim directly at the discovery and elimination of accident causes, but they

are valuable in arising and maintaining interest in safety. It should be pointed out,

however, that is not advisable to undertake all of these supplementary activities

simultaneously. No attempt can be made to suggest their relative importance, for

this varies in different establishments, depending upon such factors as existing

conditions, personalities of executives, and needs of the moment.


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4.4. Accident Investigation & RecordsAccident I nvestigation & Records

PURPOSE OF ACCIDENT INVESTIGATION

The purpose of Accident Investigation is to discover hazardous conditions and

practices so that accidents from similar causes may be prevented. This is

accomplished through:

FIRST : Detailed investigation of each individual accident to discover

the Causative factors involved

SECOND : An analysis of the factors found

THIRD : Recommendations for the corrective action, based on the

Investigation and finding.

The idea of seeking to fix blame should be definitely avoided, for where this is

allowed to enter, an attitude of covering up develops amongst the employees

which makes it difficult, and many times impossible, to get all the facts. Care

must be taken to make sure that every person involved the supervisor, the

foreman, the workman and the person conducting the investigation is aware that

the sole purpose is to be prevent future accidents and not to fix blame. If this is

done, there will be no incentive for anyone to withhold essential information and

the people conducting the investigation will also have full facts to aid them in

order to prevent further accidents. if a policy of thoroughly investigation each and

every accident is established, a wealth of information on preventive measures

will be gradually built up. It will also provide valuable finding from the

investigation on which inspection can carried out and the particular hazards

watched carefully. Proper investigations are part of the foundation on which

accident prevention is founded.


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PRINCIPLES OF ACCIDENT INVESTIGATION

Accident investigation is actually a simple procedure but certain principles must

be followed if maximum results are to be obtained.

FIRST : common sense and clear thinking are a must.

SECOND : The people conducting the investigation should be familiar

with the equipment, operation and the process so that they

have an understanding of possible hazards in any give

situation.

THIRD : The investigation should not be under the control of the

Foreman of the Supervisor of the department in which the

accident occurred, because if they are, it is difficult for them

to given unbiased

Opinion about the situation involved. There attitude should

be one of cooperation with foreman to discover and secure a

means of correcting or eliminating the hazards.

FOURTH : Each clue that is uncovered should be investigated

thoroughly because quite often a clue that may appear to

give a reasonable answer to a problem will give an entirely

different light if it is explored further.

FIFTH : Since physical hazards can be eliminated, appropriate

means of correction of the unsafe practices should be

sought.

SIXTH : No investigation should be considered completed until a

definite Recommendation for corrective action is made.


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SEVENTH : It is advisable to have more than one person to investigate

the accident due to the fact that the old saying that two

heads are better one still applies and better constructive

criticism can be obtained this way.

EIGHTH : Investigation should be carried out as soon as possible the

occurrence , so that the conditions do not change and

details get forgotten.

The above principles, if followed, will have a good effect on the other workman in

an area as they see the importance the management attaches to the matter of

safety if immediately investigated because we must remember that once an

accident occurs the seriousness of the accident is largely a matter of chance.

Usually, no one has any control on the severity of an injury once an accident has

occurred.

WHO SHOULD MAKE INVESTIGATION

Generally speaking, it makes little difference who investigates an accident if the

principals mentioned earlier are followed. Certainly the safety officer/supervisor

should be on the investigation along with the plant committee, but one of the

things that must be watched is that group investigating should not be too large

because of the time element involved. If the group feels that because of the large

number involved not too much time can be spent, then there is the possibility that

there will be a lack of lack of thoroughness in the investigation as there will be

tendency to hurry. A smaller group can often spend more time and come with

much better results. Actually every supervisor / foreman should be required to

personally investigate every accident of workman under his jurisdiction in order toimprove his own supervisory performance as well as to make sure that he is

thoroughly acquainted with accidents that occur in his department. Committees

of workers themselves can be especially valuable in bringing to light physical

hazards and hazardous practices, which are not readily discoverable by persons

who are not actually doing the various jobs.


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When an accident occurs, the first concern, naturally, is for the injured person,

but when his welfare has been provided for, investigation should be next thing.

Every person who might possibly has information bearing on accident being

investigated should be interviewed and a full record made. The use of signed

statements by the persons questioned is rarely advisable, since many workmen

are suspicious of any attempt to have them sign anything associated with an

accident with the idea of blame and punishment. Usually accurate reports and

statements can be obtained by careful investigation.

Thoroughness is something that is a must in an accident investigation as there is

a temptation to carry the investigation only so far as is necessary to discover the

means of prevention. But in the majority of accidents more than one hazardous

condition or practice is involved.

WHY RECORDS

Records are the foundations of a scientific approach to accident prevention. The

prime purpose of keeping records is to:

-- Furnish the information necessary for the compensation of injured persons

-- Serve as a guide to preventive effort.

Records provide the safety man with an objective evaluation of his safety

programme. They identify high accident rate department and provide the

information needed to remove accident causes and hazardous conditions.

More specifically, records may be used:

-- To create interest in among supervisors by furnishing them with

information about the accident experience in their own department.


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-- Determine the principle accident source so that efforts may be

concentrated where the greatest reduction in accidents can be brought

about.

-- Provide supervisors and the safety committee information about the most

frequent unsafe practices and unsafe conditions so that these persons can

utilize their time and efforts to the best advantage.

Judge the effectiveness of the safety programme by comparison with the past

experience and by making similar comparisons with companies in like

operations.

STEPS IN RECORD KEEPING

The following are the steps in record keeping

-- Obtain a report of every injury (This should include all first aids cases).

-- Classify and record each injury

-- Analysis the circumstance and causes of accidents.

-- Prepare a monthly summary report showing the number of accidents and

breakdown analysis showing the nature of injury along with preventive

steps taken or recommended.

-- Prepare a yearly report including all factors as to injury agency, medical

and compensation costs, time lost, etc, to provide an overall picture to

highlight accident trends.

BASIC RECORDS

The basic records, which should be kept, are:

-- First aid report to accident


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-- Supervisors report of accident

-- Monthly reports

-- Accident analysis forms accident analysis charts.

-- Departmental and safety committee report.

-- Details to provide information necessary for computing accident frequency

and accident severity rates

-- Yearly summary reports:

-- To show the trend of the safety performance during the year.

-- To show comparisons with experience of previous year.

ACCIDENTS REPORTS

Because Accident Report Forms are the basis for the all accident records,

essential to include the following information in the accident report. To be value,

they must be complete and factual.

WHO the injured person or persons were. Also note others involved.

WHEN the accident took place ; Date, Shift, Time.

WHAT Actually happened. Reconstruct as fully and accurately as possible

what happened just before, during and following the accident Be

careful to indicate the sources of information and any fact which

can only be assumed. If necessary, sketch a diagram to help to

explain all the events.

HOW The persons were injured. Describe the injury itself Indicate the part

of the member of the body injured (toe, finger, back, head, arm etc.)


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Also describe the nature of the injury (burn, sprain, fracture,

laceration, etc.)

Why the accident happened. Make a full analysis of the causes:

-- Study conditions at the scene of the accident. What hazards

were present? Did an unsafe condition cause the accident?

Did an unsafe act cause the accident?

-- Analysis contributing causes, (Slips, falls. drops, etc.)

-- Consider personal causes; Study the employees safety

record for indication of recurring accidents.

-- Include action necessary or already taken to prevent similar

accidents in future.

An accident report should not be considered another paper work practice it can

and should be of prime importance.

In may cases it has been found that the supervisor of foreman fill out an accident

report as briefly as possible. This should not permitted because no one is in a

better position to tell the story than the foreman and often one is in a better

position to advise a cure for a specific condition which exists, To be effective,

preventive measures based on complete unbiased knowledge of accident should

be made by the supervisor who is in charge of the department were the accident

occurred.

The monthly report should be complied from the first aid report and the

supervisor reports.

The Yearly report should be complied from the monthly reports and Medical Aid

and Compensation Cost statements sent by the firm to the statutory agencies.


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5.5. TechTechniques Of Discovering Hazardsniques Of Discovering Hazards

To have a safe work place it is essential that apart from efforts towards accident

prevention, a comprehensive hazard programme should exist in an organization.

Hazard Control is that function which is oriented towards recognizing, evaluating

and working towards eliminating hazards and their destructive effects find the

work place.

HAZARD-A DEFINITION

Hazards Contro l Programmer

Hazards are causes of accidents, Defining it strictly, a hazard is any existing or

potent ional condition in the work place which by itself, or by interaction with

other factors result unwanted affects of injuries properly damage or other losses.

Hazard Iden tif ication

The essential components of hazards control programme are:

Here information regarding hazards is collective from various sources. Specific

jobs are subjected to analysis regarding their potentiality for hazards.

Ranking hazards by r isk

Here the probability (Frequency) and consequences (severity) are analysed, and

prioritisation for control is done.

Establ ishing prevent ive and co ntrol measures

Here solutions to the control of hazards are identified, and these measures are

executed.


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Moni tor ing

Continuous follow- up on isolated procedures through various techniques like

periodic inspections, measurement and accident investigation.

Evaluat ing p rogr amme effect iveness and feedback

A periodic evaluation of the programme is essential and feedback for connective

actions should be given.

HAZRAD CONTROL RESPONSIBILITY

Hazard control is not just a distinct function carried out by specifically allocated

persons alone. Like all safely activities, it is a line responsibility; it is integral part

of each persons jobs.

It is a collaborative effort between departments, with each department sharing in

its responsibility. Planning departments prepares specification, which is free from

hazards, and comply statutory requirements. Design executes these

specifications keeping in mind operating conditions and job requirement; it

assists other departments in hazard analysis. Production ensures hazard control

by hazard analysis and continuous monitoring. Maintenance sticks to its

preventive maintenance schedules, ensure that its work maintains the designed

standards, and implements solutions to specific problems identified in hazard

analysis. Even Material purchase occupies a crucial position by providing

specification for bought out items, that conform to safety and health criteria, and

ensuring that no hazards arise during the transportation of such items,

especially chemicals. The specific team for hazard identification, evaluation, and

establishing controls, will normally consists of persons drawn from Safety,

Production , Maintenance, Casing and Planning.


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HAZARAD CONTROL WHEN

The activity of hazard control is a continue and ongoing one .it is performed

before the plant is constructed and before an operation is established: through

hazard analysis at the planning and design stage. It is performed in the

operational phase: by programmes of inspections and monitoring. It is also

performed when the system has broken down: after the event, so to speak

through accident investigation and analysis.

TECHNIQUES FOR HAZARD IDENTIFICATION

A number of techniques exist to discover hazards. Many of these are composite,

i.e. they individually cover hazards identification, evaluation and control. They are

-- Hazards Analysis

* Failure Mode and Effect Analysis

* Fault- Tree Analysis

- Job Safety Analysis

- Plant Safety Inspections

- Hazard Measurement and Testing

- Safety Surveys / Audits

- Actions Investigation and Analysis.

Each technique is subsequently discussed separately


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HAZARD ANALYSIS

These are formal analytical techniques, which are used to identify hazards and

acquire failure data regarding a system. These are of two types, the inductive,

and the deductive.

The inductive method uses observable data to predict what can happen, It

begins with the component parts of the systems, and evaluated what impact

these individual failures will have on operation of the system as a whole. An

example of this is Failure Mode and Effect Analysis.

The deductive method analysis how failures take place. It begins with the failure

of the system and then identifies how the components could contribute to the

failure Fault Tree Analysis is one of this type.

Fai lure Mode and Effect Analysis

In FMEA, the failure or malfunction of each component is considered, including

the mode of failure. The consequences of the failure are traced thought the

system, and the ultimate impact on system functioning is evaluated: A

disadvantage of this method is that since only one failure is considered at a time,

interaction of two or more simultaneous failures is not considered, and therefore

certain synergistic possibilities are over- looked, This technique is widely used in

the space and Nuclear industry, and can also have wide application in the

chemical process industry. A form in FMEA is reproduced below: -


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Format for FMEA

Fault tree Analysis (FTA)

In FTA, the analysis begins with an undesired event, all possible happenings that

can contribute to this event are listed, and are put into a diagram in the from of a

tree. These happening are each component faults: Which can constitute either

sequences of event leading up to, or alternative modes of the selected system

fault, An example of a fault tree used in the case of shaping the wire rope of a

hoist is as shown below:-


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Job Safety An alysis (JSA)

JSA is a procedure used to review job methods at the design stage itself to

ensure safe working. However, It may also be used successfully to uncover

hazards that may have developed after production started: or that resulted from

change in work procedures.

PRODCURE

The procedure of job safety analysis is simple and consists of 4 basic steps.

Selecting the job

Jobs with potential for more frequent accidents, severity of injury and new jobs in


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which the accident potential is unknown should be selected first.

Breaking the job down

The Job should be broken down to basic steps in the hazards in the jobs propersequence. Descriptions of each step should give the idea of what is being done.

A job safety breakdown sheet giving the following 4 heads is used for analyzing

the hazards in the jobs.

Step No. Operation Hazard Precautions

Ident i fy ing the Hazards

The person examines all possibilities of accidents in each step. He should note

down these hazards under the second column of break down sheet. For

identifying the hazards, he should watch the operations as many times as may

be required and also have discussions with the operators concerned and others

who have knowledge of the job.

Developing Solut ions

The solutions to hazards in the job may be worked out by:

-- Finding a new method or procedure of doing the job.

-- Reducing the necessity or frequency of doing a job that is hazardous, and

-- Changing the physical conditions that create the hazards.

After the precautions to be taken in each step are developed, these safety

precautions are to be incorporated in the job or process sheets. Job safety

instruction sheets containing safe- guard and safe procedures to be adopted in

different jobs, particularly the hazardous ones could also be made out and is

issued to the supervisors and operators and necessary training imparted to them,

so that they could follow correctly the procedures of safeguards laid down. If


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accidents are happening in spite of complying with procedures laid down based

on job safety analysis, the analysis, obviously would need further review.

EXAMPLES

The procedures of job safety analysis are illustrated by an example.

PROBLEM : In a foundry, ferrous casting weighing about 20 Ibs are

fettled by hand on pedestal grinder (12 wheel diameter).

The casting are stored on one side of the grinder from they

are picked up, fettled on the grinder and replace on the floor

on the other side of the machine. Analysis technique and

determine the hazards and the safety precautions to be

taken.


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PLANTS SAFTY INSPECTIONS

Inspections are that monitoring function conducted in the organization to locate

and report existing and potential hazards which have the capacity to cause

accidents in the work place. Inspections are not primarily aimed at unearthing

new types of hazards; though that may be achieved also; but rather at locating

and correcting known hazards.

TYPES OF INSPECTIONS

There are basically 2 types of inspections either continues or conducted at

intervals.

Cont inuous inspections are conduced by those employees like

maintenance technicians, production supervisors. Tools

inspectors, etc,; as part of their specific job responsibilities.

Any apparent or potential unsafe act or condition is corrected

immediately or reported for corrective action. The checkingof controls by a crane operator or the checking of machines

by the new operator in each shift, also fall into this category

of inspection.


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As against ongoing inspections, planned inspections are

conducted at intervals. These are of four types: periodic,

intermittent, general and special.

Periodic inspections are well planned and made at regular intervals,

the periodicity being decided according to the hazard

potential involved. Machinery, Material, Handling Equipment.

Fire Fighting Equipment,other equipment, tools, storage

methods should all be inspected regularly. In such cases, it

is useful to follow a checklist, A typical checklist which can

be used on construction sites is included at the end of this

handout, The checklist enables the inspector not to miss

points and readily detect deviations. Certain items like

pressure hoists, lifts etc are statutorily required to be

checked by competent Persons.

Intermi t tent inspections are unannounced inspections made at irregular

intervals. These may be made by safety personnel, safety

committee, supervisor and usually cover a particular

department of work area.

A general inspection is planned inspection of places, which do not

receive periodic inspections. It covers especially those areas

which as one ever visits since no one ever pets hurt This

may be outlying areas of the plant, storage areas, locations

at heights like roof, EOT Carnes & Walkways etc. It also

covers inspections or regular areas under abnormal

conditions like second shift, weekly off under artificial

lighting.

Special inspections are those made based on specific needs, i.e. of

those areas where particular type of hazards are suspected,

This include high accident frequency areas or construction


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sites of locations where new equipment is under installation,

Other examples are inspections during campaigns like fire

prevention week: or health surveys determine the existence

of an occupational illness.

Who conducts Inspections?

Inspections are the responsibility of various functions in the organization.

Continuous inspections are normally the responsibility of the line personnel,

including the first line supervisor and maintenance engineer. However, it is

important that these persons also conduct inspection according to a checklist at

some frequency.

Periodic inspections must be conducted by middle and senior management

from the line, The safety officer should be associated. Apart from the hazards

detected, the mere presence of a senior manager in the inspection team sends

the indirect message home of the top managements concern for safety.

As already pointed out, workers must be made to inspect the plant and

machinery under control in each shift, and given relevant feed back.

Inspection Procedures

The persons making inspections should be familiar with the equipment, tools, the

process and operations and should have adequate knowledge of hazards

associated with these They should also be a familiar with the company rules and

polices and also dealing with safety and health, The inspectors should be

equipped with data based on a detailed analysis of previous accidents in the

plant. An inspection Check List often proves to be very handy and will eliminate

the chances of overlooking some of the sources of accidents A specimen of

broad checklist is given in the annexure. Detailed checklist could be dawn up for

individual plants or sections.


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The inspection should be systematic, and thorough, The Inspector should not

depend on his memory and make complete notes of the unsafe conditions which

are discovered at the time of the inspection. This can be used at the time of

writing the inspection report.

The implementation of suggestions arising out of inspections is to be carried out

by the various departments concerned with production, engineering,

maintenance etc. and therefore it is important that the recommendations are

discussed, Wherever necessary, with the concerned persons.

Reporting and Follow- up

The inspection report should be clear and concise with enough explanation to

make it understandable. Copies of the recommendation should be sent to the

concerned persons for implementation. Progress should be reported to the

management at regular intervals. Periodic check should be made until they have

been completed.

HAZARAD MEASUREMENT AND TESTING

This technique is applied to the special case of hazards, which are present in the

work environment. These may be physical hazards like noise, heat stress,

inadequate illuminations. Radiation etc. or chemical hazards like airbome dusts,

gases or fumes. The degree to which the hazard is present is measured (e.g.)

noise level in decides or airbome concentration in pp, parts per million by

volume) The concentration of these hazards can be measured by personal

monitoring where the measurement device is placed as closed as possible to

the site at which the contaminant enters the human body or Environmental

monitoring where in the concentration if the work station is measured.

Two other techniques exist which use the change in the human body as a

measure of exposure to chemicals, biological monitoring measure changes in

composition of body fluid, tissues or expired air to detect the level of absorption,


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while Medal monitoring examines the workers to see their physiological and

psychological response to the contaminant.

SAFETY / AUDIT /SURVEY

A Safety Audit subjects each area of companys activities to the systematic,

critical examination with the object of minimizing loss. Every component of the

total system is included, e.g. management policy, attitudes, training, features of

the process and design, layout and construction of the plant; operating

procedures emergency plans: personal protection standards; accident records;

etc.

A safety survey on the other hand is a detailed examination of a narrower field of

activity, e.g. key areas revealed by the Safety Audit; individual plants:

Procedures or specific problems common to the works as a whole.

The audit is an evaluation of the companys organization and procedures, an

appraisal with a view to detection weak points and initiating corrective measure.

It should normally be conducted once a year; preferably by an outsider to the

organization or by another branch of the same organization.

The audit should be initiated by the top management, or with their full support.

The Audit team submits a written report. The report and its recommendations

should be discussed and a minute action plan for their implementation should be

drawn up. The top management should receive intimations of the

implementations of the Audit report periodically.

ACCIDENT INVESTIGATION AND ANALYSIS

Accident investigation and analysis are useful tools to reveal hazards.

Appropriate corrective action taken on this basis is a keystone to accident

prevention.


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A systematic and thorough investigation of each accident helps build up a fund of

information. The analysis of rates to indicate high frequency & severity locations,

as well as the identification of accident are useful pointers.

Accident invest igat ion

The basic principles of good investigation are :-

It should be done on the spot, immediately after the accident by an

independent authority. The scene of the accident must not be disturbed

until after investigation is over.

The investigation should be fact-finding, and not fault finding.

Both types of causes; i.e. unsafe acts and hazard conditions must be

identified.

All accidents whether they result in injury or not must be investigated.

The same accident without injury today could lead to a serious injury

tomorrow.

The concerned workers, supervisors and departmental incharges must be

associated with the investigation.

A written report must be prepared which identified the preventive and

corrective measures required. This must be sent to the senior man, who

should issue instructions to implement the measures.

Accident Analys is

There are standard statistical to identify high risk areas based on the accident

data Two standard formulae are frequency Rate and severity rate:


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CALCULATION OF ACCIDENT RATES

TO compare the number of accidents in one factory with that in another in the

same branch of industry, it is necessary to take into account the differences,

which may result from differences in the numbers of workers, employed in the

two factories. This can be done calculating the accident frequency rate i.e. the

number of injuries for health for each million work- hours of exposure. This is

expressed by the following formula, in which F represents the frequency rate.

Number of injuries X1,000,000

F = ------------------------------------------Total work- hours of exposure.

Example: An undertaking with 500 workers, working 500 weeks of 48 hours

each, had 60 accidents causing injury one year. Owing to illnesses,

accidents and other reasons, the workers were absent during 5 per

cent of aggregate working time. Thus the total number of work

hours (500X50X48= 1,200,000) has to be reduced by 5 percent

(60,000) giving the real number of work hours of exposure as

1,140,000, This being so-

60 X 1,000,000

F = ------------------------ = 52.631.140,00

This frequency rate indicates that, in one year about 53 accidents causing injury

occurred per million work hours.

So far, only the number of accidents has been considered, and this is not a very

exact measure of the effect of accidents. To obtain a better idea of the situation,

the severity rate must also be calculated. The international resolution of the

method of compilation of severity rates, adopted in 1907 by the sixth International

Conference of Labour Statisticians, was not retained by the Tenth Conference in

1962. This was mainly because some countries calculate the severity rate on the


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basis of the total number of days per thousand work- hours of exposure, other

countries use the time expressed in days per million work hour of exposure and

yet other countries use as a denominator the average number of employees of

insured persons, or 300day work- years.

Example: If in the example given for the calculation of the frequency rate, the

number of days lost as result of 60 accidents was 1,200, the

severity rate(s) would be as follows:

1,200X 106

S = ----------------- = 1.0531,140,000

This means that in a year about one day was lost per thousand work-hours of

exposure , or 1,053 days per million work hours of exposure, or on the basis of

2,400 hours per year, 24 days per worker.


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6.6. I nvestigation Of AccidentsI nvestigation Of Accidents

The purpose of an accident investigation is to find the causes of the accidents in

order that appropriate measure can be taken. The National Safety Council in

United States gives the reasons for accidents investigation as: -

-- To learn accident causes so that the similar accident can be prevented by

mechanical improvement, better supervision or employee training

-- To determine the change or deviation that produced an error that in

turn resulted in an accident (system safety analysis);

-- To publicize the particular hazard among employees and their

supervisors, and to direct attention to accident Prevention in general

-- To estimate extent of loss/ damage of manpower/man hours plant and

machinery, etc; and

-- To make suggestion for prevention of recurrences of similar of related

nature of accidents.

Basically whatever type of investigation is undertaken, it answer the following

questions: -

WHO was injured?

WHAT happened and WHAT were the contributing factors?

WHEN did the accident occur?

WHERE did the accident occur?

WHY did the accident occur?


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AND finally, and most importantly:

HOW can a similar accident be prevented from happening again?

There are several number of conducting an accident investigation which are

neither too complicated nor too time consuming. For minor accidents, good

results have been obtained by the following method, The victim goes to the first

aid room, after treatment, is given an accident investigation form to take to the

supervisor; the later fills it and sends it to the safety engineer who, according to

circumstance, may decide to make a more detailed investigation (or to take some

other action) or simply to file it for statistical purpose or for discussion in the

safety committee, This method has the advantage of stressing the responsibility

of the supervisor for safety in that particular department. However in many

cases, accident investigation forms may be filled in by the victim upon arrival at

the medical center for Treatment.

An accident investigation should always be made on the spot. It will be much

easier if the investigator finds the situation at the scence of the accident exactly

as it was when the accident took place. Consequently, after an accident, the site

should be left undistributed unless changes have to made to ensure the safety of

persons or to prevent further damage.

Whether the site has been distributed or not, it is desirable to try to reconstruct

the sequence of events before, and during, the accident, possibility with the

assistance of injured person and with the cooperation of witnesses, The

investigator should carefully inspect the site and then examine the witnesses. In

many cases the causes of the accident will be discovered in this way, but in

some cases e.g., where breakages of metal are involved it may be necessary

to seek technical assistance.

If a part of a piece of apparatus, such as a chain or a wire rope, breaks, it is

desirable to know the causes of the failure and for this reason, the material

should be examined and tested to discover whether it was unsuitable, had been


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maltreated or was just worn out. The necessary information may be provided by

a microscopic examination, by tests carried out on a sample of the material, or by

chemical analysis.

Example: A chain used in a hoisting apparatus with a maximum safe load of

500 kg. Broke when 700 kg. was lifted. The chain was overloaded,

but this circumstance in itself was not sufficient to explain why it

broke. Tensile tests on two links showed that they broke when the

load was about 2500- 2600 kg. Links tested by hammering their

narrow and unit the long side became the short side did not show

any defect. A microscopic examination, with magnification of 200

and 1,000 showed ageing phenomena i.e changes in the properties

of the material occurred with the passage of time. These aging

phenomena resulted in decreased resistance to shock, such as that

which occurs in working conditions, and this had caused the

accident.

Often accident investigation is concerned with both responsibility

and prevention, and this may seriously hamper discovery of the

cause. If the persons questioned feel that someone will be blamedas a result of the investigation, those who consciences are not quite

at ease may give incorrect or incomplete information. It may then

be impossible to find the cause and consequently to devise means

of prevention. In accident investigations, it should always be borne

in mind that prevention of accidents is much more important than

the more apportioning of b lame.


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INVESTIGATION PRODCURE

I. DUTIES

1. Was the person concerned carrying out a

Task that was part of his / her normal duties? Yes/No

2. What was abnormal or different?

3. Was the task within job specification /

description of the person concerned. Yes/No

4. If no,

(i) In what way was it outside job

Specification/ description?.. Yes/No

ii) Who should have carried the task?

(ii i) Why should that person perform the task?

5. Was the person involved in activity associated Yes/No

with work but not directly related to task?

If yes,

The activity in which the person was

engaged

II. SUPERVISION

Was the persons immediate supervisor present in Yes/No

the area at the time of accident

If yes,

a) Location of supervisor at the time of

accident .

b) Any information given by the supervisor

prior to leaving the area..

c) Was the accident reported immediatelyand to whom.


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If No,

a) Why was there a delay

b) How long was the delay..

III. INFORMATION

Was the person concerned specifically warned Yes/Noof the hazards of the task?

If NO,

a) Was the hazards known to all?..

b) Who know them?.

IV INSTRUCTION

1. Was the person concerned instructed to carry outThe particular task / job ? Yes / no

If No,

a) Why was the task undertaken?.

b) Was there a change in intention? If so, state reason ofchange

c) Was task/ activity part of the total job?

2. Had the person concerned been given written or verbal instruction in the

general hazards associated with the task/ job? Yes/No

If Yes,

a) Method of instruction and when given..

b) Outline the instruction given..


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3. Was the work carried out according to instruction or normal practice?If No,

a) In what way was the task carried out that was different to normal

practice?

V. TRAINING

1. Was task/ job within the capability Yes/Noof the person concerned

If No,

a) What additional training was required

2. Was the person concerned familiar with Yes /No

Type of plant/equipment,Tools etc?

If No,

What knowledge/skill was lacking?.

3. Had the person concerned been trained to Yes /No.

carry out the task/job safety?

If Yes,

a) What training had been given?..

4. Was the job / task carried out by the prescribed method and the methodused

VI. PROTECTION

Was the personal protective equipment Yes /Nobeen worn?

a) Was it is supplied to him? Yes /No

b) Was it in good condition? Yes/No


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c) Was it practicable to wear? Yes/No

d) Was it adequate to deal with hazards? Yes /NoIf No, Why?..

VII PLANT /EQUIPMENT/ PREMISES

1. Were Plant/ Equipment/ premises Yes/Noin normal condition?

If No, state

What modification or alternationhad been made?..

2. Were means for controlling emergency

or emergency stops. etc where locatednear to hand? Yes /No/NA

If No,

Would such control have reduced that

consequences or eliminated the accident..

3. Were guards. Protective devices effective Yes/No/NAAnd/ or secure?

a) In what cases why was the guarding of the machine/ Plant insecure or ineffective..

4. Were warning notices displayed, Yes/No/NAWarning persons of hazard or to

used protective equipment etc.

If Yes,

Type and content of notice.

If No,

Whether workers were warned of hazards and way of working

Yes/NO/ NA.


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What they were told about.

5. Were Operating controls, pipelines, Yes/NO/NA

tanks, etc. clearly marked?

If No,

a) Reasons why not clearly marked

b) What additional marketing, etc,

Could be made..

6. Was the approach to work place vice versa was safe

Yes/No/NA

If No,

What was unsafe?..

VIII. SYSTEMS

1. Are procedure / instructions laid Yes/NO/NAdown for the task/ job?

What procedure could be laid down?

2. Is there a system for a monitoring that procedure/ Yes/NO/NAinstruction are followed..?

What method of monitoring could be used to ensure that the procedures

are followed ?.

3. Are Permit to work normally issued Yes/No/NA

For the type work

If No,

Why are they to work issued?

Was a permit to work issued?


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If No

Why permit was not issued?..

IX. ENVIROMENT

Did any of the following natural conditions lead to accident?(Tick mark)

Rain -- Typhoon -- No

X. If accident was caused due to fol lowing: -

Confined space

Condition of floor

Condition of scaffold/ platform

Condition of ladder

Illumination

Poor House- Keeping

Other (specify)


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7.7. Procedure For Reporting Of Accidents/Procedure For Reporting Of Accidents/Drangerous OccurencesDrangerous Occurences

OBJECTIVE

In order to make prompt report of accidents and dangerous OCCURENCES to

comply with requirements/ Obligation under different status; and to inform the

concerned authorities within the organization for keeping complete information of

accidents for the record, for analysis, which will be of help in taking remedial

measures for the accident prevention in future; it has been decided to introduce a

procedure for reporting of accidents / dangerous OCCURRENCES in NTPC.

PROCEDURE IN CASE OF ACCIDENTS CAUSING INJURIES/

FATALITIES

An office of the Section will immediately refer the injured to the corporations

Hospital / Dispensary/ First-aid unit with a preliminary report on From-1

(Annexure-1). In addition he will inform about the accident to Departmental Head,

Personnel head and Safety Office on telephone with full description of accident.

In case of study to contractors employees, the contractor will immediately inform

accident /dangerous occurrence to NTPC office Incharge and Safety Office

himself on telephone or through special messenger. Office In charge of NTPC,

will submit information of accident as above.

In case the injured has come / is taken directly to hospital/dispensary/ firstaid

unit in charge of unit will uniform about the injury to Departmental Head in

from II( Annexure-II) with a copy to plant Personnel Head and plant Safety

Officer. He will immediately inform of serious cases by telephone also to

Departmental head, personnel Head and Safety Officer.


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Subsequently the concerned department / section in charge will prepare a

detailed report of accident within 4 Hours of the accident in from III(Annexure

III) and will submit one copy each to the General Manager and Personal Head.

Third and fourth copy of the report will be sent to Safety Officer and he will retain

fifth copy for the departmental record.

The safety officer will intimate the accident to concerned Statutory Authorities as

per the provisions of relevant Act/Rules. However the State Rules concerned

should be referred to for additional provisions. If any.

The Safety Officer will also submit a copy of Form III along with his comments

to Corporate center safety Section within one week of occurrence of accident.

Safety Officer will send accident report of each calendar month to Corporate

Center Safety Section in FromV (AnnexureV) before fifth day of every

succeeding month. In case of no accident, a Nil report should be sent.

In case of fatal accident, information of the accident will be immediately intimated

to Corporate Center Personal by telegram / telex/ wireless.

PRODUCURE IN CASE OF DANGEROUS OCCURENCES

As Prescribed under the relevant rules made by the State Government with

reference to the provision of Section 88- A of the Factories Act, a schedule of

some common dangerous OCCURREANCES is given in Annexure - VI.

In case of dangerous occurrences, the same will be informed by Section In

charge to Safety Officer, Departmental Head and Personnel Head in From VII

(Annexure VII) Within 4 hours 4 .

The Safety Officer will intimate such dangerous OCCURRANCES to statuary

Authorities as indicated in the schedule at Annexure VI prescribed by the

concerned State Government


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ROLE OF CORPORATE CENTRE

Corporate Centre Safety Section shall put up monthly accident/ dangerous

occurrence report to GM (P&A) Director (P) for information.

Corporate Centre Safety section will issue guidelines to various units on

accident prevention activities from time to time, as may be deemed necessary.


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ANNEXUR-1FROM -I

National Thermal Power Corporation Limited

----------------------- Super Thermal Power Project /Station

To

In charge

------------------- Hospital / Dispensary/ First aid Unit

-----------------------------------------------------------------

Subject: Accident of Shri / Smt----------------------------------------------------

Shri / Smt.-------------------------------- is referred to your hospital for Treatment. The

Details of the injured and incident are as below:

1. Designation of Injured : -------------------------------------------

2. Employee No. : ------------------------------------------

3. Department : ------------------------------------------

4. Date & Time of Accident : ------------------------------------------

5. Details of Accident : ------------------------------------------

6. Case of the Accident : -------------------------------------------

Date:------------------------------------------ Signature ----------------------

Name----------------------------

Designation--------------------

Department--------------------


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FORM-II


------------------Super Thermal Project / Station

Dated:------------------No.

To

The Head of Safety,--------------- Project.

Sub: Work Related injures.

Dear Sir,

Shri . S/0 Shri .. Age .. Years

employed by. Sub Contractor of. Dept. of NTPC has

reported for treatment of injury in his hospital. The details of injury are as below:

Nature of injury Part of the body injured1. Laceration/Contusions 1. Head.

2. Bums 2. Eyes3. Amputation 3. Face/neck

4. Fractures 4. Chest5. Puncture wound 5. Abdomen6. Multiple 6. Spinal column

7. Electric shock 7. Hands and shoulder99. Not Known 8. Legs and perils

9. Multiple10 Others99 Not known

Fatal permanent temporary Expected

Disablement% Disablement.Days

This is for your information and necessary action.Signature

Name of M.O..


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ANNEXURE VI.


---------------- Super Thermal Power Project/ Station

DRANGEROUS OCCURRENCES

i) Bursting of a boiler or vessel used for containing steam under pressure

greater than atmospheric pressure.

ii) Collapse of failure of a carne, derrick which hoist or other appliance used

in raising or lowering persons or goods, or any part thereof. Or the

overturning of a crane.

iii) Explosion of fire causing damage to any room or place in which persons

are employed.

iv) Explosion of a receiver or container used for the storage at pressure

greater than atmospheric pressure or any gas or gasses (including air) or

any liquid or solid resulting from the compression of gas.

v) Collapse or subsidence of any floor, gallery, roof, bridge, tunnel, chimney,

wall or building forming part of the factory with in the compound of factory.

vi) Leakage of any dangerous gas /chemical.

Note:

1. The above is only illustrative.

2. A list/ schedule of dangerous occurrences are prescribed in the

rules framed by the State Governments reference to Section 88-A

of the Factories Act, 1948, which should be referred to by the

project/ Establishment.


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ANNEXURE VII


--------- Super Thermal Power Project / Station

DEPARTMENTAL REPORT OF DANGEROUS OCCURRENCE

1 Time of occurrence (a) Date --------------------------------- (b) Hours--------------

2. Nature of the dangerous occurrence

3. Equipment involved (a) Name------------------------------------

b) Manufacture----------------------------

c) Use---------------------------------------

d) Location in

Building----------------------------------

4. Approximate length of service of equipment ----------------------------------------

5. a) Parts damaged---------------------------------------------------------------------

b) Date when last tested------------------------------------------------------------

c) Nature and extent of damage -------------------------------------------------

6. Apparent reasons of the occurrences-------------------------------------------------

7. Was is due to willful negligence of anyone-------------------------------------------8. Was there any infringements of rules or instructions? ----------------------------

9. Could this occurence be avoided ------------------------------------------------------

10. What action is being taken

to prevent reoccurrence -----------------------------------------------------------------

11. Additional remarks-------------------------------------------------------------------------

Date--------------------------- Signature----------------------

Name---------------------------

Designation--------------------

Department--------------------

To

1. Personal Head

2. Plant Safety Officers


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8.8. Guidelines On Contribution OfGuidelines On Contribution Of EnquiryEnquiryCommittee And Conduct OfCommittee And Conduct Of Enquiry InEnquiry I n

Case Of Accident /Case Of Accident/ DangerousDangerous OccurrencesOccurrences

OBJECTIVE

With a view to investigate all accidents in order to examine each to examine each

case in details and depth to find out the causes of accidents, the extent of

losses caused. The circumstance / individuals responsible and to obtain

considered recommendations for the prevention of recurrences in similar or

related nature of accidents, it is has been decided to prescribe a guidelines for

consulting committees for conducting enquires in case of various types of

accidents and dangerous occurrences.

APPLICABILITY

The procedure shall be applicable in case of all accidents, caused in respect of

its own employees or of contractors / associates of NTPC.

DEFINITIONS

Non repo rtable inju ry

Non reportable injury would mean an injury by reason of which injured is either

not prevented, or is prevented from working for a period less than 48 hours

immediately following the day of accident.

Disablement of Permanent Nature.

Provided under the workmens Compensation Act, 1923 and shall include partial

and total disablement of permanent nature.


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Dangerous Occurrence

As prescribed under the relevant rules made by State Govt, with reference to the

provisions of section 88-A of the Factories Act.

PROCUDRE

The Enquiry committee to the constituted for various types of the accident, the

authorities competent to appoint enquiry committee and the constitution of the

Enquiry Committees have been prescribed in Annexure-1,

As soon as the accident occurs. The Safety Officer Concerned in the project, will

immediately initiate in cases of A(i) and B(i) where he is to act an enquirycommittee.. Wherever the Enquiry Committee is to be appointed by the HOP

or GM, the Safety Officer will make a proposals as per guidelines , for approval

of the concerned competent authority and issue necessary office order for the

enquiry.

Wherever the authority competent to constitute an enquiry committee is ED and

above, the GM of project, shall immediately contact authority through quickest

means of communication and take approval for the constituting enquiry

committee, An office under for constituting enquiry committee in that case be

issued by GM of the project.

Wherever an Officer of an other Project/ Corporate Center has been prescribed

Annexure 1 to be a member of the committee , the GM of the project , shall

immediately contract the concerned controlling officer through the quickest

means of communication for obtaining a name including in the committee .

In case finalising the nomination of other project/ Corporate Center, may take

time the GM of the project Concerned can still issue the order constituting the

enquiry the committee indicating against the member: An Officer to be nominated

by Corporate Center / Project concerned, The enquiry committee shall start


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investigation immediately within the shortest possible time from the

communication of the order constituting enquiry.

Normally the enquiry report will be submitted within one month from the date of

notification of the committee. However, the competent authority feels it expedient

under certain circumstances he may require the report to be submitted even

earlier.

The terms of the reference from the Enquiry Committee should generally include.

a) Determination of circumstances and reasons of the accident.

b) Estimate of extent of loss/damage of manpower /man hours/ plant/

machinery etc.

c) To the extent possible fixation of responsibility.

d) Suggestion for the prevention of recurrence of similar or related mature of

accidents, and

e) Any other relevant aspect.

Occurrence of accidents involving loss/ damage of Rs.10 lacks or more and / or

death shall be intimated to Director (Personnel) and Executive Director

concerned by the quickest possible means to communication.

Report of an Enquiry Committee in cases at A(v) to (viii), B(iii) to (v) and C as in

Annexure- I will be sent to Director ( personnel ) Executive Director Incharge and

Corporate personal immediately for action. Corporate Personnel Division will,

on a regular basis analyse the reports, covering serious injuries and fatal

accidents for remedial action.

The authorities competent to constitute and order enquiry committee have been

indicated Annexure 1 However, if it is considered expedient the Chairman and

Managing Director, can appoint an Enquiry Committee constituted by the


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authority prescribed in the Annexure 1, shall become in operative, While

passing such order, the CMD can also include additional members in the

Committee or alter the level of committees as deemed necessary.


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ANNUXURE-I


GUIDLINE ON CONSTITUTION OF ENQUIRY COMMITTEE

SINo

Type of Accident Enquirycommittee to beappointed by

EnquiryCommittee tobe headed by

Othermembers

A In case of Personalinjury

i) In case of non reportable injury up to 2persons

Safety officer ofthe project

ii) Non reportable injury upto 5 persons

HOD in whoseDeptt. Accidenthas occurred

Not below therank of Mgr.(not connectedwith theaccident)

1. Safety officerof the project

iii) Non reportable injuryto more than 5 persons

-do- Not below therank of Sr.Mgr.( notconnected withthe accident)

1. d0-

iv) Reportable accidentcausing minor/temporary injuries

-do- Not below therank Mgr.(notconnected withaccident)

1. d0-

v) Reportable accidentcausing major/ seriousinjuries like amputationof limbs/ other parts ofbody and / or injuriesexpected to result intodisablements ofpermanent nature(partial or total )

GM Not below therank of DGM/Sr. Mgr/ Sr.Supdt ( notconnected withthe accident )

One officerat the Mgr./Sr. Mgr.From CCor otherproject.

vi)Fatal accident of oneperson

- do- -do- -do-

vii Accident causing fatal

injury to one person butinvolving a number ofpersons

ED Not below the

rank of DGM/Sr. Mgr ofother project /CC

1. An officer of

the rank ofMgr./ Dy. Mgr.Of the project (not connectedwith theaccident)2. SafetyOfficer of theproject.


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9.9. Safety PolicySafety Policy

INTRODUCTION

NTPC recognize and accept its responsibility of establishing and maintaining a

safe working environment for all its employees. This responsibility arises from.

-- Companys moral responsibilities to its employees. To provide the best

practicable conditions of work from the point of view of health and safety.

-- The obligation to consult with its staff and their representatives toimplement policies and procedures developed as a result of discussions.

-- Statutory responsibility in respect of health, safety and welfare of

employees emanating from relevant legislation such as the Factories Act.

The Indian Electricity. Act., The Explosive Act, the Boiler Act etc.

COMPANYS RESPONSIBILITY

The Company shall take all such steps , which are reasonably practicable to

ensure best possible conditions of work, and with this end in view the company

shall do the following:.

-- To allocate sufficient resources to provide and maintain safe and healthy

conditions of work.

-- To take steps to ensure that all known safety factors are taken into

account in the design. Construction, operation and maintenance of plants,

machinery and equipment.

_ To ensure that adequate safety instructions are given to all employees.


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-- To provide wherever necessary protective equipment, safety appliances

and clothing, and to ensure their proper use.

- To inform employees about materials, equipment or process used in their

work, which are known to be potentially hazardous to health or safety.

-- To keep all operations and method of work under regular review for

making necessary changes from the point of view of safety in the light of

experience and up to date knowledge.

-- To provide appropriate facilities for the first aid and prompt treatment of

injuries and illness at work.

-- To provide appropriate instruction, training, retraining and supervision in

health and safety and first aid and ensure that adequate publicity is given

to these matters.

-- To ensure proper implementation of fire prevention and the appropriate

fire fighting service, together with training facilities for personnel involved

in this service

-- To ensure that the professional advice is made available wherever

potentially hazardous situations exist or might arise.

-- To organize collection analysis and presentation of data on accident.

sickness and incident involving personal injury to health with a view to

taking corrective, remedial and preventive action.

-- To promote through the established machinery. Joint consultation in

health and safety matters to ensure effective participation by all

employees.

_ To publish /notify regulation. Instruction and notices in the common

language of employees


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-- To prepare separate safety rules for each type of occupation / process

involved in a project.

-- To ensure regular safety inspection by a component person at suitable

intervals of all buildings work places and operations.

-- To co ordinate the activities of the company and of it contractors working

in the companys premises for the implementation and maintenance of

safe system of work to comply with their legal obligations with regard to

health. safety and welfare of their employees.

THE RESPONSIBILITES OF THE EMPLOYEE

The establishment and maintenance of best possible conditions of work is no

doubt, the responsibility of Management. it is also necessary that each

employee follows prescribed methods of work . He should take reasonable care

for the health and safety of himself, of his fellow employees and of other

persons who may be affected by his actions at work. With this in mind.

employees should be health and safety conscious and:

Report Potential hazards.

Observe Safety rules, procedures and codes of practice.

Use With all reasonable care the tools, equipment, safety and

protective clothing provided by the company; these items

should be kept in good condition.

Participate In safety course when called upon to do so.

Make use Of safety suggestions scheme.

Take An Active and personal interest in promoting health andsafety at Work.


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RESPOSIBILITES FOR IMPLEMENTATION

-- The ultimate responsibilities for ensuring the i

Documents

Industrial Safty