Best Safety Practices

In O&M Activities
• Mechanical Engineer & PG in management

• 37 years experience (17 years in Health &

Safety consultancy)

• A regular faculty overseas – Middle East &

S.E.Asia
 Professional roles
During Employment (1984-2002)
– Headed– Engg.Projects, Manufacturing, Quality Systems, Training
& Corporate HSE in Shell in India
– Extensive project management experience with BPCL & Shell, and
sales experience with Batliboi & Co.

As Safety Consultant (Since 2002)

– Empanelled consultant for GRASIM Plants –India & Overseas
– An advisor & Trainer for National Safety Council of India
– Exam host in India for Robert Gordon University – Aberdeen, UK
– Advisor to Shell for Road Safety initiative–first time ever in India
– Coach for Lifestyle risk & obesity management
•NTPC •Adani(Multiple)
•L&T(Power, Hydrocarbon, ECC,HED) •Jindal Steel & Power
•Hindalco •Siemens
•BPCL •Wartsila
•British Gas •Petronet LNG
•Bharat Forge •Cummins India
•Welspun •Godrej Properties
•Thermax • OTPC
•Tata BlueScope Steel •Tata Technologies
•Tata Motors •Cognizant
•Lanco •FIAT
•Thyssen Krupp •IOC
•Afcons Infrastructure Ltd •Suzlon
Shell Malaysia Project Safety

PDO Oman Modern Safety

Siemens Qatar Defensive Driving

Sembawang Engg Singapore Audit & trg

Thai Rayon Thailand Multiple programs

Combined Engg Kuwait Const. Safety

Bader Al Mulla for

• KNPC Kuwait Modern Safety
• KOC Kuwait ------DO------
 Pradyut Mitra
IIT Kharagpur & IIM Kolkata
30 years of experience in India & abroad
Ex Prax Air & KPMG

EXPERTISE
1. Chemicals
2. Process Safety
3. HAZOP
4. Audits & Coaching
 Ashok Pandya
MSc Microbiology & PG Diploma Industrial Safety
Ex Head of Safety Glaxo with 38 years of
experience in India & abroad

EXPERTISE
1. Certified Lead Auditor: ISO 14001; OHSAS 18001
2. HAZOP
3. Process Safety Mmt (PSM)
4. ETP Mmt. systems
Certified Fire Officers from Nagpur with 25 years
of field experience
Expertise:
Designing and Commissioning, Auditing, Training
and Certification for necessary approvals
.Certifying the Adequacy of FF System.
 R T Mannur
Diploma Electrical & P G Diploma
in Industrial Safety with 50 years
of experience across industries
EXPERTISE
Electrical Safety
Fire Safety
Audits
Coaching & Consulting
S. P. CHATTOPADHYAY
B.E Mechanical - NIT & XLRI -
Finance,
A Chartered engineer
Trained in safety in the UK
EXPERTISE
Power Sector
Change Mmt. Specailist
Safety leadership
Safety Culture
What Is SAFETY ?
What Is an ACCIDENT ?

CONTD..
1. THEY FAILED TO IDENTIFY RISKS OR
Does that imply
UNDERESTIMATED ITS POTENTIAL
HUMAN BEHAVIOR
2. THEY FAILED TOIsTAKE
the Root Cause ?
PRECAUTION

3. THE PRECAUTION WAS INADEQUATE

What Is Risk?
High
“Trust me”

“Tell me”
Trust

“Show me”

“Involve me”
Low

Low Transparency High

As trust diminishes, the demand for transparency

in the form of assurance mechanisms increases
IOC Jaipur

20
Vedanta disaster - Chhatisgarh

21
Harduagunj Thermal Power Station at Kasimpur
near Aligarh

May
2015

MAy

3 killed and 16 seriously injured in an explosion due to

LPG cylinder leak during welding
 29th Mar 2015
Thermal power plant of IL&FS at
Karikuppam near Parangipettai in
Cuddalore district.
Cooling tower completely gutted.

Likely reason

Welding sparks
 PRIVI
ORGANICS
MAHAD
NTPC UNCHAHAR
Sun Pharma
 Old Approach To Safety
The Three Traditional Es
1. Engineering: Design the safest equipment,
environment setting or protective devices

2. Educate: Educate people regarding the use of

engg. Interventions

3. Enforce: Use discipline to enforce compliance

Best

New Approach To Safety

Practice

The Three Modern Es of BEST PRACTICE

1. Ergonomics: Focus on man-m/c interface

2. Empowerment: Reverse of Discipline

3. Evaluation: Feedback to people on their

behavior for proper evaluation
The Most Unique Safety Concept
 Your ability to influence safety….

High
Contractor Selection
Contractor Mobilises
Ability to Shutdown Work Begins
Influence More staff joins & work picks
Safety momentum
Construction

Shutdown Over
Low

Week1 Week 2 Week 3-6 Week 7-12 Last Week

Schedule
 Your ability to influence safety….

High
GETs join
Induction completed
Ability to Department allocated
Influence
Safety Confirmed after one year
Construction

Promoted
Low

Week1 Week 5 Week 3-6 Week 52 3rd or 4th Year

Schedule
What is First Major Weakness
Of PPEs?
Best

Practice
100% Compliance
Of PPE
What is Second Major Weakness
Of PPEs?
What Is Your
Safety Goal?

Can You Think

Of A Better
Safety Goal?
 What Is The
Best Way To
Achieve Safety
Goals?
 What
Prevents
Accidents
Then?

Risk Management
 What Gave Birth To These?

Safety/security of personnel
& property

Air bag for driver safety

Data safety
 Which Means
If you want workers to follow
If you want workers to follow
SAFETY
SAFETY
Stop talking
Whenever we about
think andSAFETY
talk Risk
Start talking about RISK
Safety becomes highly relevant
Best

Practice
List down a minimum of 5 hazards in
your work zone
Best

Practice

The Best Practice Of Managing Risks Is

To Apply The Principle Of...

As Low As Reasonably Practical

Best

Practice
1. Societal expectations from Industry have
become very demanding on Safety
2. Accidents cost are extremely high
3. Zero Accident is not the right goal – 100%
right activities is the correct goal. Zero PPE
could be a better goal.
4. PPEs cannot prevent an accident
5. Dependence on PPEs stop us from
thinking
7. Risk management = Safety Management
8. Do not focus on People safety alone.
PROCESS SAFETY is the key
9. The sooner the culture of Safety is created
the more impact it will have – The Day 1
Principle
Contractual Employees – The Weakest Link

1. Poor literacy & lack of safety

awareness
–Do they have adequate knowledge of
safeguards for a modern process
plant which has multiple levels of
protection interlocks?

2. Minimal risk consciousness

Contractors’ Performance
=
Client Performance
Best

Practice
 Periodic
Periodic 6
Evaluation
Evaluation

Work Co- 5
ordination
and Auditing

4
Orientation
and Training
The 6 Step
Contractor Safety
3
Contract
Award
Management
Process
Contract
2
Preparation

Contractor
1
Pre-qualification
 Step 1- Contractor Pre-qualification
Intent and desired outcome of Step-1

• Clear the scope

 Safety expectation
 Technical specification
 Safety requirement
 Special conditions of the site …etc.

• Identifying the qualified bidders list

 Compatible with NTPC’s Safety principles
 Technically Competent
 Good safety track record…etc.
Bidders Pre-Qualification Checklist
A “Sample” Rating System

Job Risk High Medium Low

Bench Mark 85% and 60 to 85% Less than 60%

Score Above

Actual Score
Job Risk High Medium Low

Bench Mark Score 85% and Above 60 to 85% Less than 60%

Actual Score

Create An Action Plan If score is <50%

If score Is successively 3 times:
less than Benchmark Barred for 1 year

Pre-Q Validity- 1 Top 5 scorers may

year be shortlisted
 Step 2- Contract Preparation
Salient Features
1.Preparation of final bid document with SOW
including safety expectations
2.Preparation of job plan and safety plan with time
schedule
Establish The “Rules: Of The Game”
Standards for execution of the work
Capabilities of Key Personnel
Expected behaviors
Ensure there is no ambiguity nor any surprises
 Step 3- Contract Award
Bid clarification meetings

Ensure safety cost has been built in Contract Award

by the contractor

Pre-Mobilisation Meet
+
Explaining Expectations on
PPE, procedures, Policies
 Step 4- Contractor Orientation and Training

1. SAFETY ORIENTATION
& REORIENTATION
2. PERIODIC SAFETY TRG
3. TRADE & SKILL TRG
4. ANY JOB SPECIFIC TRG

TRAINING DURATION: Around two hours. Must not always

be done by Safety Staff.
A Best Practice is that Line Managers – The Senior
The Better, should do it
Step 5- Contractor Work Co-ordination & Auditing

1. WORK COORDINATION
2. FIELD SAFETY AUDIT
3. MONITORING OF TRG
4. COMMUNICATION CHANNEL
5. FOLLOW UP PROCESS FOR
CONTINUOUS IMPROVEMENT
 Step 6- Contract Evaluation

Salient Features:
- Post contract evaluation to help
contractors improve performance.

Updated Data base of contractor can be used

for inputs in requalification
Height Pass Test Rig: Acrophobia Test
Expectations Of
The Quality Of
Temporary
Power Switches
At Site
Risk Based Maintenance Methodologies
Small Items
Non-critical
1
CORRECTIVE MAINTENANCE Inconsequential
Unlikely to fail

2 Subject to wear-out
PREVENTIVE MAINTENANCE Consumable Replacement
Failure Pattern

3 Failure Pattern
PREDICTIVE MAINTENANCE Unpredictable wear
PM induced Failure

4
PROACTIVE MAINTENANCE Age Exploration

Renovate
Modernize
5 Retire
MAINTENANCE PREVENTION Replace
Design out
 Leading and Lagging Indicators
Few examples of indicators but not limited to:

– Total No of contracts awarded as per risk involved i.e. Low,

Medium and High
– No of contracts awarded with >85% Prequalification score
– No of contracts awarded with <50% Prequalification score
– No of contractors prequalification performance improved
>50% after site intervention
– Total No of Post / Periodic contracts evaluated
– No of contracts evaluation score >=85%
– No of contracts evaluation score <=50%
– Number of CSM audits conducted Best
– Number of pending items from CSM audit
Practice
Best

Practice

Highly recommended
ITEM QTY RATE

Cost of Safety Lump Sum Rs.

Compliance
Best

Practice

A Practical & Efficient Way Of Good

SAFETY COMMUNICATION
1

Expected
PPE
Compliance

You may create a different

Set of pictures for this
2
3 MAKE 3 POINT CONTACT WHEN CLIMBING LADDERS & USING TOOL
BELTS

75
4
Expected
Only upto 10 Behavior
kg While
material
Working
On Step
Ladders

3 Point
contact
Work
15-30
minutes
max at a
time
5

1. Hard Floor
2. Cage
3. Chained Cylinders
4. Cap on Every Cylinder
5. Safety Signage and
6. Name of the Gas
6

This is How
The Gas
Cylinder
Trolley
Should
Look Like
7 A Model Portable Scaffold
8
Top Rail

Mid- Rail
42" high
with
middle rail Toe-board
halfway up

Specifications for Barricading

9 Working on Sloping Roofs

Crawling Boards with

provision for
Harness anchoring

82
10
Best

Practice

But Why Intervene ?

Any Time You See An Unsafe Act Happening
OR
An Unsafe Condition
OR
A System Defect
An Unsafe Job
Being Done At
The Admin Block
Itself.
Does it Need
Intervention or
not ?

86
Restrict The Use Of Mobiles
Safety Compliance Will Lead To Productivity
These workers are
planning
to use this fire water
hose in case of any
welding related fire
here
They have not
arranged fire
extinguisher

92
Ensure That Worker/Contractor Actually
Know The Expected Safety Behavior
Thru
Safety Communication
Correct Way:
The only thing in
front of the
electrical panel
should be-
1. A rubber mat of
rated voltage
2. Co2 type Fire-Ex.
3. A First Aid Chart
For Electric Shock in
Local Language.
 1. Remove
gas cylinders

2. Display
First aid
chart

Electrical installation with rubber mat and identification

What can be added and removed from this picture to show
Correct EXPECTED SAFE BEHAVIOR?
97
Integrate
1. Environment factors
2. Personal Factors &
3. Behavior Factors
 Employees’
Equipment, knowledge, skills,
Tools, abilities,
intelligence,
Machines, motives, personality
Housekeeping,
Heat/Cold,
Engineering

Complying, coaching,
recognising,
Behavior Factors communicating,
Actively caring
 Cycling For
Internal
Commute Not
Only Saves
Time But
Keeps People
Healthy
Footpath
design
that
attracts
employees
to walk on
footpath
&
prevents
walking on
road
If railing is fixed alongwith
the conveyor the
dependence & need
of PPE reduces

Result?
Faster and safer progress
What Is Integrated in A Simulator
Based Training?
What is not integrated here?
What is Not Integrated Here ?
Best

Practice
If SOPs are being bypassed,
Why not modify them to reflect actual work
practice?
Best

Practice

World Class Companies follow MOC as a default

practice
Best

Practice
Unsafe Conditions

Unsafe Acts

System Defects
Safety Data Collation In Large
Multi location Organisations

Software based reporting

“TRAFFIC LIGHTS”
Best

Practice
• WEARABLE SENSORS: Help locate workers
In Potentially Dangerous Environments

This can be clubbed with

• VOICE & VIDEO TECHNOLOGY to monitor
& Communicate with them in case of
accidents
119
 Deployment Of Drones For
• Site monitoring
• PPE Compliance Verification
• Any visible safety action
Drones Are Extremely Useful For:
1. Highrise constructions safety compliance
2. Monitoring quality at height
3. Complex areas where human inspectors may not
reach easily
122
 Interactive HSE Apps
1. Stay Safe Business App: Provides personal
protection for lone workers
Available From : Apple AppStore, Android
GooglePlay Store, Windows Store & Blackberry

2. dB Volume Meter: Measure audio volumes in

your work area to stay safe
Available From : Apple AppStore
 Interactive HSE Apps
3. First Aid App: Official app from American Red
cross allows immediate access to expert
information. Easy-to- digest, step-by-step
instructions let workers and managers quickly
and efficiently address an array of mishaps and
serious injuries

Available From : i Tunes & GooglePlay Store,

 Interactive HSE Apps
4. Heat Safety Tool App: Workers calculate weather
conditions and make educated decisions using this app.
The app will compute health risk levels; prompt users on
wearing and using protective gear; remind workers to
take breaks, drink water, etc. Key features include:
• calculating the heat index
• providing heat illness signs and symptoms
• displaying warnings of possible threats to workers.

Available From : i Tunes & GooglePlay Store,

 Interactive HSE Apps
5. Ergonomic App: For many staff, the day offers
limited or no field work, yet, ironically, sitting for long
periods poses health risks. The Ergonomics app is
replete with equipment advice, workplace specific
stretch exercises, and prompts that remind users to
take breaks. Supported with illustrations. It also
provides workplace-specific exercises, and a
countdown timer.

Available From : i Tunes & GooglePlay Store,

Best

Practice
 Best Parking slot reserved for..
The person who arrives first irrespective of
his/her position
This is a great motivation for arriving on time
All the titles should be removed from the
parking slots.
 To Prevent Fall Injuries…
• Dedicated Scaffolding Contractors

• No Straight Ladder Policy

Tank & Vessels History Sheets
Online
1. Year Of Manufacture
2. Built by
3. Type of Foundation
4. Products stored, capacity
5. Specs of steel plates used
6. Appurtenances
7. Any modifications
8. Last ultrasound done
9. Tank Cleaning data
10. Info of Any leaks etc.
• STANDING MEETINGS
Decisions are reached more quickly
Studies show that when standing people
react more enthusiastically whereas when
they are sitting they are more skeptical
• Meetings are highly efficient when done in 15
minutes
PPE
D
I
S
P
E
N
S
O
R
 EYE SHOWER

To Provide Warm
Water in Cold
Weather Locations
Convex Mirror For Crane Operators’
Ground Visibility
 Block off areas where certain tasks will take
place, install nets and catch platforms, and
apply any other safety measures.
Stage and stock each work area with the
necessary tools, PPE, and equipment before the
workday begins. This will make it easier and
safer for workers to access what they need.
Preventing Information Overload
On Workers

PICK 3
Example: Say, green color for the months of Jan to May,
brown color from June to Sep, Yellow color from Oct to Dec

And Red color for any defective tools found

 An Example

INSTRUCTIONS FOR DOING THE EXERCISE

Every body read the words loudly

and count the seconds it takes
 green brown black blue green pink blue
green black red blue red black brown green
red brown green pink blue red black pink
green brown red green
green black brown blue pink red blue
brown green black pink black blue brown
red red pink red pink black brown
brown green green red pink brown blue black
pink blue red pink black
black brown green blue red blue
 INSTRUCTIONS FOR DOING PART 2
OF THIS EXERCISE

Every body read the color of the

words loudly NOT THE WORDS
and count the seconds it takes
 green brown black blue green pink blue
green black red blue red black brown green
red brown green pink blue red black pink
green brown red green
green black brown blue pink red blue
brown green black pink black blue brown
red red pink red pink black brown
brown green green red pink brown blue black
pink blue red pink black
black brown green blue red blue
The Learning?
Best

Practice
 1

• Always encourage questions during your training &

• Never take silence as an indication of understanding,

• Do you really know what do they think about your safety ?

• Do you know their problems about safety?
How difficult is it for them to get their PPEs? To Store
them ?
• Do they feel threatened ? If so they will never speak up
 2
Teach Deliberately
What You Practice Instinctively
 3
• Some workers may never interact with senior
management. It’s found that these employees
are more likely to value and internalize safety
messages when they are occasionally
delivered by higher-level management rather
than passed down in the chain of command.
 4
Safety Training For Operators
1. Design & Deliver short modules not
exceeding 30 minutes to one hour
2. Design modules around case studies
3. Present as STORIES
 5
Develop A Safety Knowledge Pool Of
Experts – Invite Them From Time To Time
 A SIMPLE BUT SMART WAY TO
WEIGHT LOSS & EMPLOYEE GOOD
HEALTH
• Ask them to maintain a journal of food they
eat everyday ( start with say, three times a
week & then increase)
• The very fact of recording makes them see a
pattern of where they are eating wrong and
how.