SAFETY & SECURITY NEWSLETTER

July 2013 Issue

MESSAGE DESK

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CONTENTS

1 Hazards of CFL Bulbs

2 Lessons Learned

3 Mock drills-Jun’13

4 Corporate Safety Highlights Jun’13

5 Safety training

6 Root cause analysis (RCA) of incidents – Jun’13

7 Security Highlights

Thought for the month

Safety does not come instantly,

You should implement it consistently.

1. Hazards of CFL Bulb by Murthy LSVKS, Executive, Corp. Safety

The use of CFL in recent years has increased due to its energy saving capacity and long life. But fluorescent light bulbs contain a small amount of mercury sealed within the glass tubing. When a fluorescent bulb breaks, some of this mercury is released as mercury vapor. Here are some tips to avoid breakage of fluorescent bulbs and also cleanup procedures if they break

Actions You Can Take to Prevent Breakage of Compact Fluorescent Light Bulbs Fluorescent bulbs are made of glass and can break if dropped or roughly handled. To avoid breaking a bulb, follow these general practices:

Always switch off and allow a working CFL bulb to cool before handling.

Always handle CFL bulbs carefully to avoid breakage.

If possible, screw / unscrew the CFL by holding the plastic or ceramic base, not the glass tubing.

Gently screw in the CFL until snug. Do not over‐tighten.

Never forcefully twist the glass tubing.

Consider not using CFLs in lamps that can be easily knocked over, in unprotected light fixtures, or in lamps that are incompatible with the spiral or folded shape of many CFLs.

Do not use CFL bulbs in locations where they can easily be broken, such as play spaces.

Use CFL bulbs that have a glass or plastic cover over the spiral or folded glass tube, if available. These types of bulbs look more like incandescent bulbs and may be more durable if dropped.

Consider using a drop cloth when replacing a CFL to minimize the chance of breakage should the lamp fall or to protect the flooring and assist in clean-up should the bulb drop and break.

Cleanup and Disposal Procedure

The broken bulb can continue to release mercury vapor until it is cleaned up and removed from the residence. To minimize exposure to mercury vapor, it is recommended to follow the cleanup and disposal steps described below.

1. Before cleanup a. Have people and pets leave the room.

b. Air out the room for 5‐10 minutes by opening a window or door to the outdoor environment.

c. Shut off the central air‐conditioning system, if you have one.

d. Collect materials needed to clean up broken bulb:

stiff paper or cardboard;

sticky tape;

damp paper towels or disposable wet wipes (for hard surfaces); and

a glass jar with a metal lid or a sealable plastic bag.

2. During cleanup

a. DO NOT VACUUM. Vacuuming is not recommended unless broken glass remains after all other cleanup steps have been taken. Vacuuming could spread mercury‐containing powder or mercury vapor.

b. Wear disposable gloves, if available, to avoid direct contact with mercury and to prevent cuts.

c. Scoop or sweep up the broken pieces and debris with two pieces of stiff paper or cardboard. Do not use a broom.

d. Use sticky tape, such as duct tape or masking tape, to pick up any remaining fine glass or powder. Be thorough in collecting broken glass and visible powder.

e. Wipe the area with a damp paper towel, cloth or disposable wet wipe to remove any residual particles.

f. Place cleanup materials in a sealable container.

3. After cleanup

a. Promptly place all bulb debris and cleanup materials outdoors in a trash container or protected area until materials can be disposed of. Avoid leaving any bulb fragments or cleanup materials indoors.

b. Wash your hands with soap and water after disposing of the jars or plastic bags containing bulb debris and cleanup materials.

c. If practical, continue to air out the room where the bulb was broken and

leave the air conditioning system shut off for several hours.2.

2. Lessons learned

2. a. Caught in between marble slab while unloading Date & Time : 19th May 2013 & 15:30Hrs Location : Behind ED Bungalow (Under Construction), Township Details : Fatality Description : Italian Marble slabs were to be unloaded from a truck. Slabs were stacked in the inclined manner against the both sides of truck. A team of 6 workers were unloading slabs one by one from the truck manually. All of a sudden a bunch of approx 7 to 8 slabs got tilted uncontrollably and the deceased got stuck in between the fallen slabs and the slabs on the other side. Immediate attempts were made manually to remove slabs but failed. Hence slabs were removed with the help of a JCB. Injured was taken by Contractor through his private car to the AIMS Hospital, Mandvi; there it was advised to take him to Bhuj, Accord Hospital. After reaching to Accord Hospital, authorities declared him brought dead.

Root Cause Analysis:

Human Factors:- 1.9 Improper loading: Incorrect process followed resulting in uneven unload in the truck.

3.5 Equipment or materials not secured: Poor perception towards the risk - Slab was being removed without making any provision to hold the remaining slabs.

Physical Factors:- 5.1 Inadequate guards or protective devices : No support to hold slabs in the truck during

unloading. 6.9 Improperly prepared vehicle: Body of Truck leaned on right side due to uneven

Distribution of the load. 8.5 Inadequate work place layout: Uneven ground also slightly contributed towards change

of angle beyond vertical 6.7 Defective vehicles: Jerky release of Leaf spring caused major change of slab angle

beyond vertical.

System Factors:- 8.2 Inadequate leadership: Inadequate supervision. 14.2 Inadequate development of Policies, Standards & Procedures (PSP): Risk review not

carried out - No provision to hold the slabs.

Recommendations: 1. A practically feasible arrangement to retain resting slabs to be made. Web belt with

tensioner buckle fixed in the truck can be used to prevent inadvertent falling of slabs. 2. Improve supervision to ensure “uniform unloading“of slabs. Policy of "No Supervision, No

Job" should be followed strictly. 3. HIRA should be prepared for all non routine activities and to be discussed before doing the

job each time. 4. Sharing of Incident with all the contractors of CGPL. (Note: Shared with the plant side

contractors from 21.05.2013 to 23.05.2013). 5. Sharing incident with other sites of TATA POWER.

2. b. Flashover while taking trial pit Date & Time : 15th April 2013 & 14:40Hrs Location : Near proposed J.B.Nagar Metro Station, Andheri –Kurla Road, Andheri (E) Details : LWDC-Reportable (Burn injuries on face, forearms & legs) Description : Two workmen of S.D. Construction were digging the trial pit for cable trench. While excavating at a depth of around 1 foot, the insulated crow bar (insulated for 33 KV) hit the R Infra‟s 22 KV Underground live cable joint and flashover occurred. This resulted into burn injuries to both the workmen.

Root Cause Analysis:

Human Factors:- 3.1 Lack of knowledge of hazards present: Though the workmen were aware about the

possibility of live cables in the trial pit area, they did not know about the shallow depth of 1 foot at which the cables might be laid and that too without any protection tiles/ concrete.

Physical Factors:- 5.5 Inadequate warning systems: The Power Cable of R Infra was laid at a shallow depth of

1 foot and without any protection (cable tiles / tapes / concrete / brick wall. 5.3 Personal protective equipment: Though both the workmen used the PPE as specified,

they suffered burns on the exposed portion of their body, which was neither covered by PPE nor their personal clothing. If the workmen had used garments covering the legs and arms, the injury could have been minimized.

System Factors:- 15.3 Inadequate communication between different organizations: There is no information

available about the Cable routes for the cables laid by other power utilities.

Recommendations: 1. Establish the process of formally sharing the relevant information (about cables laid)

amongst utilities prior to making trial pits

2. Use suitable Cable Avoidance Tool for detecting live underground power cables before

digging for any trial pits

3. JSA and Checklist should be prepared in other languages also (Hindi, Marathi), so that

it can be clearly understood by Contractor‟s supervisor

4. Use of full cotton pant and shirt should be made mandatory while digging the trial pits

5. Make suitable video film in different languages for continuous emphasis regarding

precautions and use of PPE‟s while making trial pits and trench for Cable laying. This

video film shall be used for the training of Contractor workmen.

2. c. Fire at boundary wall

Date & Time : 23rd April 2013 & 14:30Hrs Location : Near MIAL taxi stand (East side fencing) Details : Fire Description : Smoke was observed by the workers near fencing of east side where wooden scrap was stored. Immediately water was poured on wooden scrap. This is second occurrence of fire at the same site; the last incident was reported in the month of Feb'13. In both incidents, wooden scrap caught fire.

Root Cause Analysis:

Human Factors:- 4.5 Acts of violence – Due to lack of any other evidence (for source of ignition), it is

suspected that some anti-social elements from outside our premises have set fire to the wooden scrap.

Physical Factors:- 7.1 Fire or explosion– Wooden civil construction material (shuttering) and packaging

material used for transportation of equipment which was left unattended near the fencing, served as the combustible medium.

System Factors:- 12.5 Improper storage of materials or spare parts-

1) Foreign packing material (GIS equipment wooden packaging) stored at site for long

period.

2) Shuttering material stored at site.

Recommendations: 1. Combustible material to be stored at such locations to which access will be controlled.

This needs to be done during site mobilization /preparation and be included in the site

plan.

2. Fire extinguishing equipments to be placed near combustible material.

3. Scrap disposal procedure to be revised / fast tracked to prevent stacking of material for

long period. (Shall have rate contract for fast clearance of wood scrap).

3. Mock drills-Jun’13

Scenario of ‘Causality inside WTG’ in Visapur Wind farm

Scenario of ‘Snake Bite’ in Sadawagapur Wind farm

4. Corporate Safety Highlights Jun’13

Corp. Safety continued comprehensive BSC 5 Star Safety Management System Audit in the following divisions,

a. Jojobera b. Power House #6

Conducted training on Safety Intervention Audit & Training (SIAT) to Transmission & Distribution Division.

Held meeting with all Safety Advisors of Mumbai Operation to explain Safety Targets for FY‟14 and significance of their contribution for achieving the targets.

Organized knowledge sharing session by M/s Raychem to all Safety Advisors in Mumbai Operations (MO) for understanding hazards of electrical arc flash and range of protections available including PPEs against the hazards.

Attended Annual Incident Investigation Sub-committee meet at MPL, Maithon and shared views / thought on how to carry forward good initiative for improving performance of Incident Investigation Sub-committee.

5. Safety training

Spandan training program being conducted own employees at Trombay

Worker Development Program being

conducted in Trombay

Safety induction training being administered at

Trombay

Session on “ DROPS” at Gadag Wind farm Session on “Flash Arc Protection” at

Agaswadi wind farm

Session on “Role of Supervisor & Safe

operation of winch m/c” at Samana wind farm

Session on „Fire Fighting” at Khandke wind

farm

Session on „Permit to Work – Refresher Training- ” at Poolawadi wind farm

6. Root Cause Analysis (RCA) of incidents – Jun’13

Human Factors Physical Factors

System Factors

0.0%

5.0%

10.0%

15.0%

20.0%

25.0%

30.0%

35.0%

40.0%

45.0%

Jul'12

373

Aug'12

383

Sep'12

393

Oct'12

344

Nov'12

294

Dec'12

323

Jan'13

361

Feb'13

416

Mar'13

639

Apr'13

332

May'13

251

Jun'13

203

Ca

us

es

Human Factors TrendProcedural non compliance No/ improper use of tools or equipment

Not using protective methods Inattention/ Lack of awareness

Total no.of causes

0.0%

10.0%

20.0%

30.0%

40.0%

50.0%

60.0%

70.0%

Jul'12

224

Aug'12

205

Sep'12

236

Oct'12

186

Nov'12

148

Dec'12

178

Jan'13

193

Feb'13

234

Mar'13

285

Apr'13

147

May'13

139

Jun'13

129

Ca

us

es

Physical Factors Trend

Inadequate/ defective tools, equipment & vehicle Work exposure to

Workplace environment layout Inadequate/ defective protective system

Total no. of causes

0.0

5.0

10.0

15.0

20.0

25.0

30.0

35.0

40.0

45.0

Jul'12

313

Aug'12

261

Sep'12

260

Oct'12

287

Nov'12

192

Dec'12

234

Jan'13

316

Feb'13

369

Mar'13

422

Apr'13

201

May'13

170

Jun'13

97

Ca

us

es

System Factors Trend

Physical Capability

Physical Condition

Behavior

Skill Level

Training or Knowledge Transfer

Contractor Selection & OversightManagement / Supervision / Employee LeadershipEngineering / Design

Work Planning

Purchasing, Material Handling & Material ControlTools & Equipment

Work Rules / Policies / Standards / Procedures (PSP)Communication

Mental State

Note: Insignificantcauses(consistently lessthan 5%) are notshown

Total no. of causes

7. Security Highlights

I. Trombay

04 Jun13 – Security officers meeting held for reviewing of IMS/Security/Audit. All S.O were present.

07 Jun 2013 – A police Bandobust of 12 policemen were deployed at Main Gate of the plant by RCF Police station in the wake of proposed Morcha by Shivsena activists in protest against Unit # 6 Coal Conversion project. Apart from police Bandobust, necessary plant security tightened up.

08 Jun 2013 - Mumbai Operation Security Officer‟s Meeting was held in the conference Hall at Station „B‟ duly attended by all security officers of Trombay, Hydro, T & D.

18 Jun 2013 – Security officers meeting held for reviewing of IMS/Security/Audit. All S.O were present.

26 Jun 2013 – Security officers meeting held for reviewing & preparation of IMS/Security /Audit. All S.O were present.

29 Jun 2013 – Security officers meeting held for reviewing of Security/Audit compliance status. All S.O were present.

10 Jun – 18 Jun 2013 – 2nd Security Prevention Advance course by M/S BSI Ltd, Israel conducted at Trombay. Total 29 security personnel from MO Area undergone the training.

20 Jun – 22 Jun 2013 – 2nd Control Room Operator Course by M/S BSI Ltd, Israel conducted at Trombay. Total 16 security personnel from MO Area undergone the training.

II. Transmission & Distribution - Mumbai 19 June 2013- Second Security Awareness program conducted for employees at

CENTEC by BSI instructor Mr Gal Or.

The broad outline of the talk was as follows:- (a) India, Mumbai Terror attacks and its implication . (b) Security awareness for all employees and action during emergency. (c) Crisis Management.

11 June, 2013- The training workshop for security supervisors and guards of T & D was conducted at Salsette on 11 Jun 13. Total 26 security personnel attended.

The following was covered during the training:-

(i)Security process, (ii)Duties and responsibility of security guards.(iii)Use of communication radio sets.(iv)Documentation at security gate.(v)Use of fire extinguishers.(v)Knowledge sharing.

HYDRO ANTI- ENCROACHMENT ACTIVITIES:

28 June 2013: team of hydro encroachment led by Mr Vidyadhar Narkar removed successfully the so called seasonal huts erected by the locals/tourists at Lonavala Dam area from company land.

III. CGPL 03.06.2013: Western Region Power Committee (WRPC) quarterly meeting was organized at

CGPL Mundra on 3rd and 4th June 13. Participants from different organizations attended the meeting.

04.06.2013: At 1226 hrs, Boiler Inspector Mr. R.N Rathwa arrived at CGPL site for official purpose.

27.06.2013: 02 CEA officers, Mr. Alok Saxena – Chief Engineer & Mr. S P Siwal – Director visited.

Tree Plantation Program in CGPL: On 04.06.2013 at 0900 hrs: 03 Security Officers and 68 Security Guards took part in plantation programme at CGPL Labour colony. Security and HR teams participated in the event. A message of clean & green environment was conveyed to all.

The “ENTRY PERMIT MAKING” camp was continued at CGPL Township during this month too. A total of 216 Entry Permits (183 New & 33 Renew EP) were issued to the labors working at CGPL Township during the month of Jun‟13.

LABOR HEAD COUNT: A Labour Head Count Exercise (LHC) was scheduled wherein all the access locations like Main gate, Hostel gate, Tunda end wicket gate, Labor colony & CGPL Township were covered for the exact manpower strength. A total of 1413 labors were physically checked by Security Team. Entry of the contract manpower without proper entry permit was restricted and the concern contractors were directed for the compliance.

SPECIAL DRIVE: Special traffic drive, daily speed monitoring initiative during rush hours is in continuation at Hostel gate & old main gate U-turn area during morning shift hours. Vehicles without proper entry passes were restricted. A total of 66 Debit Notes were raised in the month of Jun‟13. Out of which 45 Debit Notes were raised against Breach of Traffic safety and 21 for Breach of Security. Consolidated summary of the debit notes raised in the past month is available on demand.

MOCK DRILL BY SAFETY DEPT: On 06.06.2013 at 1528 hrs, to check the emergency preparedness of fire, safety, medical and security team a Mock drill was conducted; depicting a scenario of fire broke out in LDO

Tank at FOPH area. SCR timely conveyed emergency situation to all concerned dept. Mock drill was initiated al 1528 hrs and all clear was given by Incident controller at 1551 hrs.

CGPL SITE MAIN GATE INAUGURATION : Mundra UMPP main gate and security office was inaugurated today at 1000 hrs by Mr. Krishna Kumar Sharma, ED & CEO in the august presence of Mr. Sharad Baijal, Head - O&M and all other HOD‟s. Before inaugurating the gate customized Visitors Management System (VMS) software was installed at the gate. The system is capable of preparing a bar-coded gate pass with visitor photo in few seconds.

IV. MPL At about 100 local villagers including land looser of Railway line area sat on a day long

dharna for their various demand related to Rail Project led by MLA Arup Chetterjee. After long negotiation the Dharna was called off peacefully by evening.

Some unidentified local villagers had stopped coal and ash transportation in demand of erection of electrical pole which was met by the MPL authorities. The transportation resumed after the demands were met on 10/6/13.

19 Jun 2013, a mob of about 200 people forcefully entered the Prohibited area of MPL and ransacked Security Control Room, Site office & Material Gate Porta cabin and manhandled few Security personnel on duty. Necessary mob control action was initiated by the security in charge. FIR was lodged against the culprits in local Police station for forceful entry, damaging the property and criminal assault causing grievous injuries to the security personnel of MPL.

MPL Property vandalized by the local villagers

Awareness on Fire Fighting.

Familiarization with various types of extinguishers and Practical operation of extinguishers were covered in the awareness session. Total 16 officers attended the awareness session.

Surprise vehicle / individual pass checks carried out under security in-charge.

We invite your feedback on this newsletter. Write to us at safety@tatapower.com