Vedanta Limited, Jharsuguda

HSE Improvement Journey

Joe Chan

2nd November 2018

0.5 mTPA Aluminium Smelter-I 1215 MW Captive Power Plant

Vedanta Limited, Jharsuguda @ Glimpse

0.5 mTPA Aluminium Smelter-I 1215 MW Captive Power Plant

1.1 mTPA Aluminium Smelter-II 2400 MW Thermal Power Plant

Vedanta

Trust

Entrepreneurship

Care

Vedanta Purpose & Values

Core Purpose

“Vedanta is a globally diversified natural resources company with low cost operations. We empower our people to drive

excellence and innovation to create value for our stakeholders. We demonstrate world-class standards of governance, safety,

sustainability & social responsibility”

Vedanta Core

ValuesInnovati

on

Excellence

Integrity

Respect

Three Pillars for Zero Harm

SPAs – Example of Nomination

CEO

Operations HOD

Operations HOD

Operations HOD

Operations HOD

Function (HR) HOD

Obj, Goal & Performance

Isolation M/Guarding Resource Use & Waste

Mngt OfChange

Leadership

SPA assignment starts from top to levels down

Operations Unit Head

Operations Unit Head

Operations Unit Head

Operations Unit Head

Operations Unit Head

Operations Unit Head

Operations Unit Head

Operations Unit Head

Function Unit Head

Function Unit Head

Use & Waste Change

Fall Prevention

Crane & Lifting

Vehicle & Road

Technical Vehicles

Fleet Management

Confined Space

Electrical Safety

ContractorSafety

Molten Material

Training

29 SPAs – All are Executive and senior leaders

SPAs – Technical Vs Leadership

Technicalframework

and technical competency

Pull

System and

Single Point Accountability & Deputy SPA

From HSE Team

• HSE Technical SPA teamshave 25-35 members

• HSE Management SPA teams have 5-10 members

• This makes up additional 300 future part-time HSE SME in the organization

Each of the 23 HSE elements has a SPA from operation or function senior management

Competency

Pull/Push

Developing to become Subject Matter Experts

PullSystem and

technicalguidance

Execution

JSG HSE ”University” Led by ChiefHSE Officer• Assignment –Element F/Work• Guidance – Doc. & Network• JSG HSE E- Library• Coaching – Chief HSE officer• Skill Builder Training• Subject Matter Expert building• Performance Measure & Tracking• Cross SBU assessment

Future Stage• Cross site assessment & support

& Deputy SPA

Change Agents – Example of Nomination

Chief HSE Officer

Safety HODsOccupational Health HOD

Environment HOD

Fire HODHSE

Excellence Manager

1. Obj, Goal & Performance 2. Isolation

Contractor safety

Health Resource Use & Waste

Lost Prevention

Audit

Safety Officer Safety Officer OH Officer OH OfficerEnvironment

OfficerEnvironment

OfficerFire Officer Fire Officer

HSE MIS Officer

Subject Mater Experts

safetyFall

Prevention

Use & Waste Prevention

Electrical Safety

Machine Guarding

Respirator Technical Vehicles

Waste Management

Chemical Management

Emergency Response

Molten Material

CSR and Community

Training

23 Change Agents – Mostly from HSE + Subject Matter Experts

SPAs – Competency development

Received/involved in:

Received/involved in:• Research coaching (C/Agents only)• Skill Builder training >16 hours• Field coaching• PDCA skill through execution• Major incident investigation• Standardization• Continual improvement• Train the Trainer training• Audit coaching

Subject Matter Expert Level with 5 to 30 persons for each of the 23 HSE elements

Received/involved in:• Authorized Person training• SOP training• Related Risk assessment training• Deployment & Feedback• Risk identification training• Incident investigation

SupervisorShift-in-Charge

Authorised Persons Affected Persons

Received/involved in:• Awareness Training• Communication sharing

Other employees and contractors

Not developed from PowerPoint

They learn from training, practice, execute processes,

Subject Matter Experts (SME)

9

practice, execute processes, face problems, resolve, then

understood & became agent of continual improvement

Element A3 Example – Energy Isolation Element

Element Action Plan – Example Energy Isolation Element

VSAP Vs JSAG – Example from Energy Isolation Element

VSAP - Energy Isolation

1

Isolations are carried out by an Isolation Officer

who has been trained, assessed and authorized

as competent to isolate specific plant or

equipment.

2

The Isolation Officer’s lock must be a master

series lock and his/her lock and tag must be the

first to be applied and the last to be removed.

3

Every person working on isolated plant,

equipment or systems first applies an

identification tag and a personal lock that can

Requirement

Does the site have an appointed SPA to manage deployment of the LOTOV program?

The SPA and his/her support team are competence persons who received appropriate training and experience to properly deploy a safe LOTOV system and provide managerial oversight to the program.

Has the site developed a written, site-specific lock/tag/verify (LOTOV) program for managing energy control to ensure that all equipment, machinery, and production systems/processes are at a zero energy state before constructing, installing, setting up, adjusting,

inspecting, modifying, maintaining, servicing, lubrication, cleaning, un-jamming, making adjustments and tool changes where there is exposure to unexpected energizing. The written program includes:

a. Equipment specific energy control(LOTOV) instructions.

b. Requirements for employee training including proficiency testing and retraining requirements.

c. Procedures for periodic inspections to verify compliance.

d. A section for contractors.

e. Prohibits the use of control circuitry such as emergency stops, light curtains, interlocked guards, PLCs, pressure mats, etc. as isolation devices.

f. Defines the method for removal of personal danger tags and personal locks when the employee(s) who applied the personal tags(s) and personal lockout device(s) is not available.

g. Prohibitions against pulling fuses as a substitute for proper Lockout/Tagout/Verify.

h. Prohibitions against using control circuitry and devices such as push buttons, toggle switches, and PLCs for isolation.

i. Defines specific responsibilities.

j. Defines when a “Tagout” only procedure would be acceptable and additional precautions that must be taken.

k. Defines tags and hardware to be used for energy control. Prohibits locks used for lockout to be used for any other purpose.

l. Required precautions when working on electrical conductors or energized parts.

m. Defines procedures for testing or positioning of machines.

n. Defines procedures to be utilized during shift or personnel changes.

o. Defines Pressure path entry procedure

p. Training requirements including verfication of proficiency process.

q. Applicable regulatory requirements.

Has the site incorporated regulatory requirements in the site-specific energy control procedure if the requirements are different or more stringent than the requirements outlined in LOTOV Requirement 3?

Is the program written and readily available to all employees? When was it last reviewed and updated?

The location has an equipment inventory in place and equipment specific task LOTOV instruction for all known tasks that require energy isolation.

Are all isolation point of each equipment properly label with a unique identification number

Production systems, machinery, or processes with multiple energy sources (e.g., confined spaces, etc.) have pre-planned documented equipment specific LOTOV instructions. The developed equipment-specific energy control instructions that address the elements listed

below for each piece of equipment ?

• Identification of the equipment and/or task;

• Type and magnitude of all hazardous energy sources;

• Listing of all applicable energy isolation devices;

* PPE requird to perform the LOTOV

• Specific steps to obtain zero energy state; and

• Specific steps for verifying energy control including the release of stored energy.

Are personal red locks equipped with tags that are white and red colors and include in local language, “ Danger - Do Not Operate", or equivalent, and identify the person using the lock?

Are equipment yellow locks equipped with tags that are yellow and black colors and include in local language, “ Out of Service - Do Not Operate", or equivalent, and identify the person using the lock?

Are group blue locks equipped with tags that are white and red colors and include in local language, “ Danger - Do Not Operate", or equivalent, and identify the person using the lock?

Are hazardous energy sources locked in the “off” or safe position using an energy isolation device that provides physical separation between the energy source and equipment to be worked on?

Does equipment-specific lockout instruction developed, and made assessible to authorized persons before placing into service new equipment or processes?

All Lockout/Tagout/Verify instructions include methods of verifying that zero energy state is achieved. Typical methods of verification may include:

a. Use of voltage testing equipment.

b. Trying to start the equipment by following the start procedure.

c. Visual verification that disconnect knife blades are open.

d. Ensuring drain valves are opened, pipes are offset or blanked, or means of double block and bleed are in place.

e. Ensuring mechanical drives are disconnected.

f. Ensuring that gravity powered parts of machinery is secured against movement.

g. When there is potential for intentional or inadvertent contact with an exposed electrical conductor or part or when only electrical work is being performed, the following verification steps must be completed:

i. When possible, verify blade openings visually when working on electrical conductors or energized parts.

ii. Test for no voltage on phase-to-phase and phase-to-ground. Use a properly calibrated and tested meter.

VSAP – 6 broad expectations from current HSE

management system

JSAG – 58 detail expectations developed by Change Agent

3identification tag and a personal lock that can

only be locked/unlocked by the owner.

4

Implement a written procedure for removal of

personal locks in cases where a lock cannot be

removed by the owner under the direct

supervision of the department or area

manager.

5Implement the nine mandatory steps for

isolation.

6

Implement a project isolation procedure for

work that extends over multiple shifts or where

there are large numbers of people involved in

the work.

Where applicable, written instructions address:

a. Removal of free moving and fixed rail mobile equipment from service for repair/maintenance and for the prevention operation,

b. Railroad track isolation (e.g., blue flag/derailer),

c. Confined space issues such as blanking/blinding, double block and bleed, and removing sections of piping,

d. Fixed rail equipment such as overhead or gantry cranes.

Instructions and practices exist and are used by employees when making equipment adjustments or clearing jammed materials. Normal production operations that have the following exposure require LOTOV:

1. Removing or bypassing guards;

2. Placing any part of body into point of operation;

3. Required to place any part of body into a danger zone associated with a machine operating cycle.

LOTOV instructions are required unless the location can demonstrate that these are Minor tool changes and adjustments, or other minor servicing activities, which take place during normal production operations and if they are routine, repetitive and integral to the use

of equipment for production, provided that the work is performed using alternate measures which provide effective protection.

Site LOTOV procedure and equipment -specific LOTOV instructions are reviewed on an annual basis and maintain an inventory of all energy control instruction?

Instructions and practices exist and are used by employees when making equipment adjustments or clearing jammed materials. Normal production operations that have the following exposure require LOTOV:

1. Removing or bypassing guards;

2. Placing any part of body into point of operation;

3. Required to place any part of body into a danger zone associated with a machine operating cycle.

LOTOV instructions are required unless the location can demonstrate that these are Minor tool changes and adjustments, or other minor servicing activities, which take place during normal production operations and if they are routine, repetitive and integral to the use

of equipment for production, provided that the work is performed using alternate measures which provide effective protection.

Does the site meet the requirements listed in section 11.4.5 of the LOTOV Program when removing fuses from electrical panels?

Are the site's energy isolation devices labeled with a unique identification number to correspond with the written equipment-specific energy control procedure?

Is any equipment installed at the site after March 31st, 2018 installed with lockable energy isolation devices that are readily accessible to authorized persons?

Do all persons performing servicing or maintenance activities that require lockout place locks on the applicable energy isolating devices in accordance with the written equipment-specific energy control instruction?

Does the site follow the requirements, listed in section 11.7 of the LOTOV Program, for the use of red locks?

Does the site follow the requirements, listed in section 11.7 of the LOTOV Program, for the use of yellow locks?

Does the site follow the requirements, listed in section11.7 of the LOTOV Program, for the use of blue locks?

Do locks used for energy control have only one key? (Spare keys may not be maintained.)

Does the site follow the basic lockout sequence requirements , listed in section 11.8 of the LOTOV Program?

Does the site follow the lock transition requirements , listed in section 11.9 of the LOTOV Program?

Does the site follow the group lockout requirements , listed in section 11.10 of the LOTOV Programy?

Does the site follow the Tag Harware, Barricade and Flagging requirements, listed in section 11.11 of the LOTOV Program?

Does the site follow the lock removal requirements listed in section 11.14 of the LOTOV Program?

Does the site follow the equipment testing/positioning requirements , listed in section 11.16 of the LOTOV Program?

Is there an orderly transfer of locks during shift change so that a piece of equipment is never left in an unsecured state 11.9?

Is pressure path entry or line breaking permit only utilized before opening any hazardous substance process line 11.12.3?

Does the site maintain an inventory of hazardous substance process lines in their site-specific hazardous energy control training program?

Does the site follow the Pressure path entry preparation activities requirements listed in section 11.12.3.D of the LOTOV program?

Are pressure path entry or line breaking permits signed by the supervisor in charge of the area and each person involved in the pressure path entry activity?

Covered by LOTOV 27??

Does the site follow the break-in activities requirements listed in section 11.12.3 of the LOTOV program?

Does the site follow the return-to-service requirements, listed in the LOTOV program?

Are periodic, documented inspections conducted to verify that energy control is utilized properly?

Employee interviews confirm consistent knowledge of lock/tag/verify program and procedures. Field observations confirm compliance and enforcement of lock/tag/verify procedures.

Does the site maintain documentation in accordance with the correct retention periods listed in section 9 of the LOTOV program?

Do new sites, operations or acquisitions fully implement the LOTOV program requirementss within twelve (12) months of initial operations by Jharsuguda?

Has the site translated the LOTOV instructions into the local language used to conduct business at the site?

Does the site identify authorized persons and Group Taggers that are responsible for performing hazardous energy control?

Does the site's authorized person applying lockout verify that the isolation and de-energizing have been effective by attempting to start the equipment and release residual energy before starting servicing or maintenance work?

Does the site use an Electrical Safe Work Permit when qualified electrical personnel perform on live electrical work on exposed, energized parts?

Does the site utilize the Partial Energy Work Permit when complete de-energization of a piece of equipment is not feasible and team members are exposed to mechanical hazards?

Has the site completed a task analysis to identify all minor servicing tasks that are routine, repetitive and integral to the operation?

Does the site complete an annual program evaluation through the site's annual JSAG assessment and maintain an annual certification that the evaluation has been completed?

Does the site complete periodic inspections at least quarterly that is in accordance with the quantities and requirements specified in section 12.1 of the LOTOV program?

All employees and contractors have received the appropriate level of Lockout/Tagout/Verify training for their

exposure:

a. Shift In-charge, Maintenance, Production, Engineering and Technical employees (authorized employees) have documented training in the safe application, usage and removal of Lockout/Tagout/Verify controls. Authorized employee training includes: Recognition of

applicable hazardous energy sources; Type and magnitude of the energy sources available in their work place; The means, devices and methods of isolating and/or controlling energy; The means of verification of effective energy control, and the purpose of the

procedures to be used; Procedures for removing locks and tags and returning a machine or piece of equipment to operation; and Transfer of lockout/tagout responsibilities (if allowed by the facility).

b. Contractors have same training as employee otherwise must be briefed on the same requirments and FULL TIME supervised by Vedanta authorized person(s).

c. Affected personnel (office employee, etc.) have received awareness training in Lockout/Tagout/Verify

Employees maintaining/servicing equipment under Lockout/Tagout/Verify have received “authorized employee” training and the employee demonstrates proficiency. Initial and re-occurring training is documented.

a. Retraining occurs when changes are made to the Lockout/Tagout/Verify procedures.

b. Retraining occurs when an individual does not demonstrate competence.

c. Retraining occurs when a deficiency is noted after periodic inspections.

Do employees complete the required exam at the conclusion of the classroom training?

Does the site require authorized employees, who pass the written examination, complete a verification of proficiency as part of the initial training process?

Contractor personnel follow the location's established LOTOV instructions or have clearly communicated their own instructions. Contractor personal tags and locks are clearly identified.

Does the site verify, on an annual basis, each authorized employee's proficiency in the sure of energy control?

Do affected and authorized employees receive initial and refresher classroom-style and hands-on training prior to assignment and a requirement to perform lockout?

Machinery is equipped with striking gear and devices for cutting off power.

If the Company uses machine that inadvertently shift from off to on position, it has provided device to cut off power in emergencies and arrangements has made for locking the device in a safe position to prevent accidental starting of the transmission

machinery or other machines to which the device is fitted.

Self-Assessment Example – Energy Isolation

Safety Performance Standard Status Tracking

30

40

50

60

70

80

90

Work at Height

LOTOV

Electrical SafetyPit, slope, Waste dump

Stability

Supplier and Contractor Management

VSAP VSS

Target Base Jun Sept

0

10

20

Confined Space

General Vehicle & Road Safety

Technical Vehicle

Fleet Management

Crane And Lifting

Machine Guarding

Molten Material

30

40

50

60

70

80

90

Leadership

Objectives, Targets, Planning and Perform

Competency and TrainingProcess Safety and MOC

Resource use Management

VSAP Other (Except VSS)

Target Base Sept

HSE Management Standard Status Tracking

0

10

20

30

Incident Investigation

Audits - Management Review

Stakeholders Engagement & Strategic Communication

Occupational Health

Compliance

Supplier and Contractor Management

Enabler - JSG HSE E-Library – “Safety”

Enabler - JSG HSE E-Library – Energy Isolation Training

Enabler – Satellite Training

• Single Trainer

• Multiple Location training simultaneously

• Resource optimization - Time and Money

Driving a Zero Harm Culture

2-days F2F Leader Workshop for M1, M2, M3)

Group exercise & Presentation on “ZERO HARM CULTURE “

� Define Care of our Business � Leader interaction with workers� HSE Competency of employees and Business Partners� HSE Performance measures and tracking� Positive and Negative HSE enforcement

Driving a Zero Harm Culture

20

Group exercise & Presentation including Plant Head Mr. GG Pal

2-day Workshop on Zero Harm Culture including CEO, CFO, Plant Heads, Group HR

2-day Workshop on Zero Harm Culture including CEO, CFO, Plant Heads, Group HR

Senior Leaders Safety Walk Down

Enforcement - Life Saving Rules

Safety Devices and Guards:

Devices installed to assure

safe machine operation shall

not be removed, tampered with

or bypassed without isolation.

Electrical HV Work/Arc/Flash:

Appropriate PPE must be used

when electrical work is being

done or there is arc flash

potential.

Confined Space Entry:

No person shall enter confined

space without an approved

permit and a standby person.

LIFE SAVING RULES

Lockout/Tagout/Verification:

LOTOV instruction must be

strictly followed..

Fall Protection:

Fall arrest systems must be

used when working at height of

6 feet (1.8 meters) or greater

Illegal Drugs and Alcohol:

No one shall come to work with

influence of illegal drugs or

alcohol.

LIFE SAVING RULES

Rules to LIVE by

Thank you

Question?