Safety Review - ORT

CC-Safety
SAFETY PARAMETERS : Safety index (till date January ’21)
0.41

1617
FR SR

0.32

0.31
0.3

0.19

432
418

316
202
16-17 17-18 18-19 19-20 20-21
16-17 17-18 18-19 19-20 20-21

Safety Index 2019-20 20-21 (till January)

Man-hours : NTPC 42.5 Million 33.9 Million
Man-hours : Agency 249 Million 170.71 Million
Fatal & Reportable Injury 21 Fatal + 71 Reportable 11 Fatal + 28 Reportable
FR 0.31 0.19
SR 432 316
Man-days lost 127,647 66392

FR=(Total Reportable injuries x1,000,000) / (Total Man-hours worked) SR=(Total Man Days lost x 1,000,000) / (Total Man-hours worked)

2
Best Practices- Patratu
• SAFETY INFO – EARTHING CHECKING AT PATRATU

3
Best Practices- Patratu
• SAFETY INFO –ILLUMINATION LEVEL CHECKING AT PATRATU

4
Best Practices- Patratu
• Height Barrier provided below all over head electrical lines to avoid accident.

• New system for Stringing of Conductor got replaced with clamp.

5
 Lag indicators: Fatalities 20-21
4
Area-wise
2 Plant-wise -11

1 1 1 1 1 1 1 1 1
1 1 1 1 1 1 1

k ka r..
. CL ul
i
da u ... dgi a... da uni
a G a n u
ra K NP ng
r Ta ag Ku hy o ara
Fa t h i m nd M B
r S Ra Vi
No

2 Agency-wise Cause-wise
3
1 1 1 1 1 1 1 1 1 2 2 2
1 1
L .. ... ... l
ES UP
h L on V. ES ir ca
IT t ec HE t ne S h a
R
f ra B
Le
p
n do ngi G
ly
B
e ct Fall of Material Fall from Slip & Trip Road Accident Electrical Hit by moving
In ja
I
n
E al El N.Karanpura height Ramagundam Kudgi Singrauli object
C r a cN SR Tanda N.Karanpura Farakka Barauni NPGCL
RO iU m M Vindhyachal Mouda
Sa Su

6
Fatal Incidences 2020-21
Station Date Main Area Reason
NPGCL May 03 2020 CHP, Wagon Tippler Head Injury

Ramagundam Jul 02 2020 Bunker Floor, Conveyor – 15 A Injury due to moving of conveyor

North Karanpura July 04 2020 Deaerator Floor Head Injury due to fall from height

North Karanpura Jul 13 2020 Stock Yard , Unloading Area Injury due to fall of material
Farakka Aug 26 2020 Coal Yard TP -12, ) Mtr Head Injury from Hyva

Tanda Sep 22 2020 CHP, Stacker Reclaimer Toppling of Crane

CW Pump House,Switchgear
Singrauli Oct 10 2020 Burn Injury due to Flashover
Panel
Mouda Nov 02 2020 Ash Silo, Connecting Silo walkway platform Injury due to Fall from Height
Barauni Dec 16 2020 Main Plant, Excitation Transformer Electrocution
Kudgi Jan 08 2021 T junction Road Accident
Vindhyachal Jan 17 2021 Near old maintenance office area Fall of Material

7
 O&M and Project wise Fatal Accident trend:
14
13
O&M Project Singrauli &
12 Barauni:
Electrocutio
10 n
8
8 8 8 Ramagunda
m : Stone
6
6 picker
Farakka: JCB
4
hit 3
2 Tanda:
Crane
0 Toppling in
2018-19 2019-20 2020-21
stacker area
NPGCL: MGR
wagon roll
back
Kudgi: Road
Accident
Vindhyachal
: Fall of
Material
• Road Safety measures such as road barriers , marking, Speed limit signage's, LED Boards on road safety to be displayed.
• Electrical Incidences are completely avoidable and hence, systems must be followed. No bypassing is acceptable.

8
 Overall Safety Parameters
No. of attributes No. of Incidents
Sl No Lead Indicators Lag Indicators
2018-19 2019-20 2020-21 Sl No
2018-19 2019-20 2020-21
1 Deviations 53559 102835 44963
2 SOV+CFTV+ZLSV 4302 44151 20800 1 Fatal 16+3 21+13 11+15
3 Near Miss 468 731 628 2 Fire Incident 126 186 136
4 Training 4302 7903 3529 3 First-Aid 695 822 470
5 TBT / Pep Talk 6257 29989 7613 4 Non-Reportable 65 57 39
6
Reward & 1547 5261 2056
Recognition 5 Reportable 65 65 28

Red marked : Medical fatal

9
Lag indicators: Reportable & Non-reportable Accidents
Reportable 20-21 Non-Reportable 20-21
Road Accident Slip and FallAnimal BiteBurn
Slip and Fall 10% 5%
14% 3% Burn Injury
18%
5%
Road Accident
Burn Injury 10%
7%

Prick by Object Caught In

Caught In 5% 21%
7%
Flash Over Medical
21% 5%
Fall of Material
7%
Hit by Moving
Toppled Object
10% Flash Over Fall From Height
Hit by Moving
11% Fall From Height 13%
4% Object 3% Fall of Material
11% 10%

10
Lead indicators: Near Miss incidents reporting
Sl Top five Root Causes % %
(Near-Misses) 2019-20 2020-21
Near Miss Reported
731 1 Fall of Material 47% 41%
636 2 Slip and Fall 8% 38%
468 3 Hit by moving object 7% 32%
4 Electrical fire / Flash over 9% 25%
110 5 Road incident 17% 16%
77
16-17 17-18 18-19 19-20 20-21

Other common causes13 % (2019-20) and 21% (2020-21) are:

• Caught in
• Electrocution
• Fall from height

For 11 Fatal cases, 3300 near misses should be recorded. So, near
Heinrich Triangle miss capturing needs improvement.
11
Gist of Fatal Enquiry Committee Report with Recommendations

•Brief of Incidence:

An Accident took place in one of the station on 08.01.2020 in a T Junction near new canteen building. The backhoe loader

operator was trying to take right turn. During that time, the motorcycle coming in opposite direction hit the front bucket of

the backhoe loader and motorcyclist fell down. He suffered head injury during the incident. He was shifted to Hospital

where the victim was declared dead.

•Cause of Accident:
a. It appears that the motorcyclist was in a hurry and moving towards switchyard and suddenly the backhoe loader operator
has taken a right turn at T Junction near new canteen building and sudden turning of backhoe loader and hurriedness for
returning home of both the persons may be the reason.
b. During travel in idle condition, the front shovel teeth should be in upward direction, whereas it is observed that shovel
teeth were in horizontal position and motor bike (Head Light- Right side found first impact) directly hit one of the teeth.
c. It is observed that there was no speed breakers on all the roads near T Junction despite steep gradient in one of the road
near junction. It is observed there are speed breakers available at few road cross junctions.
d. It appears that victim was driving at high speed and not wearing the crash helmet even though it was available with him.
12
Recommendations for prevention of recurrence:
• Vehicle speed of 20 KMPH or respective state’s factory rules to be maintained and monitored. Handheld speed
monitoring devices to be procured and regular monitoring to be carried out. Speed capturing devices with hooters and
speed sensing cameras for capturing vehicle number plates to be installed and monitored.
• Speed breaker/ bolting type road rumblers should be provided at each side of T junctions/ X Junctions/ Soft turnings. For
restricting speed, water filled road barriers may be provided.
• Convex spherical mirrors to be installed in all sharp turnings and where visibility is obstructed.
• A committee may be constituted to find out the locations of requirement and installation in the plant and township
areas for the quantity requirement. Projects to ensure the procurement within one month.
• Speed capturing/ monitoring to be done on daily basis and the violators should be penalized by deduction of salary.
• Employees/ Contract workmen riding two wheelers must wear crash helmet on the roads. Violator’s gate pass may be
cancelled by HR department for a suitable period.
• Weekly PEP talks to be conducted for drivers and heavy vehicle operators by Safety department.
• Quarterly vehicle checks should be done to ensure healthiness of the vehicle.
• Each heavy vehicle/ Construction equipment shall maintain a vehicle movement register for locational changes and it is
to be countersigned by concerned engineer.
• Road safety signage and speed limit boards to be fixed at appropriate locations.

13
Gist of Fatal Enquiry Committee Report with Recommendations

•Brief of Incidence:
A fatal accident took place while dismantling a small steel fabricated container lying near Old EMD building on 16.01.2021 in which a
worker came under a steel plate during dismantling process due to fall of plate over him, he got injured and succumbed to his injury.

•Cause of Accident:
a. Unruly nature of supervisors and labour among the contractual organization structures.
b. Unsafe behavior and indiscipline across the contractual cadres
c. The work was executed without proper tools, supervisors, methodology, proper planning skill and training.
d. Improper existence of system in monitoring of contractual work.

•Key Recommendations:
a. “Ethical behaviour” training modules for contract labour for the culture build up.
b. A change in the system management towards contract works execution is required. “Work intimation notification” by EIC / Area
incharge to contractor.
c. CLIMS should be strengthened. CLIMS should be a single data base and control trigger access for EIC , HR , Medical, Safety, CISF etc

14
 Incidents-January
Station Incident Area Incident Details of Accident/Incident
Time Description Type

The motorcycle coming in opposite direction hit the front bucket of the backhoe loader and
Kudgi Jan 08 2021 Switchyard Road Fatal motorcyclist fell down. He suffered head injury during the incident. The victim was declared dead
at Hospital.

Near old
At the site of incident FGD enabling work of dismantling of existing structure was going on. Plate
Vindhyachal Jan 17 2021 maintenance Fatal
cutting was in progress and one of the plate fell on the victim.
office area
Outside R&R Fatal An Unskilled contract worker working in R&R department felt uneasy with chest pain during his
Barh Jan 14 2021
Department (Medical) duty and died due to cardiac arrest.
A piece of metal split from metal pin & struck to the left eye during hammering the metal clip/pin
Patratu Jan 05 2021 TG 1 Area Reportable
of the crawler chain for its tightening & locking.
After some time of installation of the fuses of discharge valve module, the Flash Over occurred in
D M Plant,
Mouda Jan 09 2021 Switchgear Reportable which operator sustained burn injury in right hand and heat mark at right side of face. The extent
of burn injury was 10-15%

Simhadri Jan12 2021 Central stores Reportable One worker got tripped by the wooden sleeper(used for stacking the material) which was
projected on to the road and his left leg got fractured above the ankle.
Near Cooling Non-
Dadri Jan 07 2021
Tower STAGE-I Reportable
Supervisor engaged in Civil (O&M) got disbalanced & slipped and fell from his bike near Cooling
Tower STAGE-I, he collided with bicycle going parallel to him.

15
 Critical Near Miss Cases-January
Incident Incident
Station Time Type Sub Type Details of Accident/Incident

Rihand Jan 02 2021 Near Miss Electrocution Monkey climb on 11 KV live conductors above transformer of substation-A for stage-1 Aux Pump
House, resulted in immediate tripping of MGR feeder-3 Earth fault. Monkey got electrocuted
Flashover in ESP Board-C/Module. Flashover occurred without any remote command or local
Darlipali Jan 05 2021 Near Miss Flash Over
activity.
UCR -6 locomotives lightly dashed the railway locomotive at 5:50 AM, resulting in partial damage of
Unchahar Jan 06 2021 Near Miss Railway Incident centre buffer coupler of railway locomotive.

Sipat Jan 06 2021 Near Miss Caught In A Dumper involved in low lying area filling at Ash Dyke 3 (ramp towards Gatora) while going up the
ramp did not lower the Dala (body of Dumper) & it touched a 11 KV line.

Darlipali Jan 07 2021 Near Miss Road Accident During unloading the eye bolt got broken & tractor trolley of M/s L&T was toppled in FGD area.

Hit by Moving Removal of unused pipeline (Partially buried under earth) was in progress with the help of mobile
Kudgi Jan 07 2021 Near Miss Object hydra crane. During pulling of pipe from earth, the web sling (5T Capacity) used got snapped.
The root removal of already uprooted trees work was taken up by township horticulture group.
Unchahar Jan 10 2021 Near Miss  Electrocution During the process the blade of JCB hit the underground three phase cable. Line tripped under
overload.
Kahalgaon Jan 11 2021 Near Miss Road Accident A tanker was standing on the Drain cover concrete slabs, suddenly the concrete slabs broken while
watering the nearest garden.

16
 Critical Near Miss Cases-January
Station Date Incident Sub Type Details of Accident/Incident
Type
Darlipali Jan 12 2021 Near Miss Fall of During 2nd stage steam blowing of Unit #2, an iron piece was blown out with steam and fell on
Material ground at a distance of half km from blowing point

Jhanor Gas cutting of drums filled with scrap metal chips kept in Central Stores was in progress. While
Jan 22 2021 Near Miss Burn cutting the drums smoke was observed from metal chips. It is observed that while gas cutting
Gandhar
the cotton waste along with scrap metal chips got heated and smoke was generated.

Children while playing hide and seek in township location in front of Avantika Guest House,
Khargone Jan 25, 2021 Near Miss Hit by Children suddenly appeared on their bicycles in front of the moving car which was driving at
limited speed. Vehicle driver got alerted and applied the sudden emergency brakes and the car
skidded on the road. No injury was happened to any one.

Jan 27 2021 While removing ash accumulated along PA fan 2A with the help of pay loader, while removing
Gadarwara Near Miss Electrocution of ash electrical cable to PA fan 2A got damage resulting into tripping of unit#2. There was no
7:55PM
injury reported.

During gas cutting of beam , a metallic piece of 40mm dia and 10mm thick fell from 18mtr to
Darlipali Jan 28 2021 Near Miss Fall of 11mtr. TG Area
3:30PM Material

17
 First Aid Incidents-January
Station Date Area Sub Details of Accident/Incident
Type
Wind box duct, Welder while moving down after completion of repair welding works fell from 2m height to duct
Unchahar Jan 18 2021 First-Aid
LHS,corner-1 inside floor.

Cutter while lighting the gas cutter with the help of lighter, gas blow back occurred on his lower
Farakka Jan 18 2021 Workshop First-Aid abdomen part.

Kahalgaon Jan 24 2021 Road Accident First-Aid The car hit a tree when the driver tried to turn the car away from divider. Two person received
minor abrasion injury and were given First Aid . In a hurry, the accelerator got pressed

On Road under the Operator was going on road under the cable trestle. A stud with nut (200 MM X 16 MM) had
Simhadri Jan 27 2021 cable trestle First-Aid fallen on peak portion of safety helmet from the trestle of approx. 8mtrs height while cable
passing from ESP-2 dressing work was going on. Person Got got an minor injury on his Fore Head, due to the impact
to Ash slurry PH -2. of inner edge portion of helmet peak.

Boiler-2 Mill C CAD First-Aid While adjusting the length of the CAD link at mill 2C, 28 meter RHS while carrying out the job link
Gadarwara Jan 28 2021 fell down from the hand causing minor cut injury to the person on left hand thumb executing the
28 mtr RHS job.
Anta Jan 29 2021 Township First-Aid A horticulture contract worker was stinged by honey bee on his neck.
• Workers to be advised not to run at duty end times,
• Honey Beehives to be removed regularly.
• There were many road accidents involving employees. If driving speed limit is 20 kmph, there should not be any hitting to divider or,
tree etc. So counselling and monitoring of all employees for careful driving to be ensured.
18
 Fire Incidents-January
Station Date Area Sub Details of Accident/Incident
Type

A tube light near CEP Motor #3 was burning with flame. Reason of Flame is suspected to be short
Anta Jan 04 2021 Fire Incident Flash Over
circuit.

A flash over occurred in panel of Ash Handling Transformer. Due to short circuit . Nobody was there at
that time . Water from Express lab entered into cable gallery at 5.5 m and subsequently into Unit 6.6
Singrauli Jan 09 2021 Fire Incident Flash Over kV bus 7A ash handling service transformer TON feeder due to top entry of power cable from cable
gallery. This resulted in flash over in breaker cubicle

Vindhyachal Jan 16 2021 Fire Incident Fire Others Fire Caught in thinner cane due to last burnt out pies of cigarette by unknown person.

North Fire
Jan 21 2021 Fire Incident Incident Fire occurred in BHEL material yard no injury reported. Property of Rs.4 Cr. Approx lost.
Karanpura

Vindhyachal Jan 25 2021 Fire Incident Fire

Incident
Fire caught in cable there was water leakage from Deaerator floor U#3, boiler side area
which might have entered into a cable joint causing flash over.

• In view of upcoming Summer, all dry grass must be cut and removed from Location. Regular visits to be conducted and such dry grasses
be identified for removal.
• Being a NO TOBACCO ZONE, No smoking in plant area must be ensured.
• Water leakage, water splashing, water seepage and dripping points to be checked particularly above switchgears, motor terminals to be
checked and arrested

19
Thank You

20