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International Journal of Emerging Technology and Advanced Engineering

Website: www.ijetae.com (ISSN 2250-2459, ISO 9001:2008 Certified Journal, Volume 5, Issue 1, January 2015)

Analysis of Safety Performance Rating in Thermal Power Plant


Abhaynath Kumar1, N. K. Jain2, Praveen Patel3
1
M.Tech Student, 2Professor, 3Professor, Department of Fire Technology and Safety Engineering, IES-IPS Academy, Indore
(M.P), India
Abstract Safe working and operation of any plant, It is widely accepted to pay attention by companies as
machinery is first priority and it is a cumulative effort of the well as by safety authorities that to work safely, reliably
manager, safety officer, head of department of concerned and effectively necessitates a management attention at all
department, supervisors and workers etc. This provides a organizational levels, and also effective and efficient tools
better end result in minimizing the accidents. Finding out
to be used by managers.
comparative result and performance of the team past few year
accidents. Hence we need some techniques for measuring
safety measures and to provide safety measuring rating. Such II. SAFETY TERMINOLOGY
type of rating and monitoring help to identify the weakness in Accident- Accident is dangerous occurrence resulting
implementation of safety program in plant and providing a into injury to the worker or damage to the property.
more strong safety program. The rating and measurement of
safety performance is useful to all people in management to
know the progress of safety culture in their power plant .It CAUSES OF ACCIDENTS
provides and promotes safety in all incident like road safety,
home safety, industrial safety and safety at the sea and the Accident
sky. The industries are paying huge amount every year in Ancestry Unsafe
Fault
terms of Workmen compensation, wage and incentives and or Act or
of
other benefits. Many insurance companies also pay the huge Environm Unsafe
amount for accident injuries, deaths, and property damage. In Person
ent Condition Injury
how if they know the real measurement of safety performance
they may try to suggest necessary safety measures to reduce
the premium amount. Quantitative monitoring is more
Incident -Incident is dangerous occurrence without injury
powerful tool to identify the severity of accident. This gives a
proper value and clear indication about the most and least or damage.
unsafe work in terms of safety. Along with it also gives Death - Fatality resulting from an accident.
information about the money and man -days lost due to Injury - An injury is an external damage to the human
accidents. This will help us to concentrate on that area that
body.
needs more attention and to provide remedial action to stop or
minimize the various losses due to accidents. Loss Time Accident- LTA is an accident which extends
In this work we are focusing on the quantitative measures beyond the day of the shift.
of various safety performance rating. Disabling injury - Any injury (single or multiple) to a
Keywords Accident analysis, Quantitative monitoring, person which is caused out of his employment (personal
Safety performance rating, Safety program, Safety measures, injury & occupational disease) and leads to disablement of
Workman compensation. the injured person temporarily or permanently which may
be partial or total disablement of the injured person for a
I. INTRODUCTION period extending beyond the day or shift of occurrence of
accident.
Safe operation and prevention of accident is the ultimate
aim of thermal power plant. The objective is fulfilled Near Miss - The management will ensure health & safety
through the quantitative measurement of safety policy of worker and will ensure the compliance strategy
performance and by use of reliable safety measures and requirement in order to protect man, machine, material and
structures, components, systems and procedures in Thermal environment from hazards.
power plant, which are operated by a group of people who Fatal - It is capable of causing death.
are committed for a strong safety culture. As a lesion from Non-fatal - It is not resulting in or capable of causing death.
accidents occurred in past like Bhopal gas tragedy,
management have to very attentive for the safety of the
plant.

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International Journal of Emerging Technology and Advanced Engineering
Website: www.ijetae.com (ISSN 2250-2459, ISO 9001:2008 Certified Journal, Volume 5, Issue 1, January 2015)
Reportable Accident - is one which injured person does not 3. Temporary Total Disabilities - This type of disablement
report back after injury within 48 hours. The accident is related to the minor injury which can be medically
which is required to be reported by the factory manager to treated and the workers becomes 100% fit after treatment
the inspector of factories in accordance with Sec 88 of the or after taking rest to certain no. of days. There after he
factory Act 1948 read with rule 108 of M P Factories Rules becomes 100% capable of doing the work as he was doing
1962 is called reportable accident. before the injury. In fact he has become temporary disable
Non-Reportable Accident - The accident which are not only for certain no. of days & in those days he has lost
reported to inspector of factories. This accident is called 100% of earning.
Non-reportable accident.
Safety Performance Rating
Unsafe Acts - Unsafe act is a human action resulting in an
accident or injury to him, others or environment or to all.
Frequency Rate Disabling Index
Unsafe Conditions - Unsafe condition is created by an
Rate Rate Rate
unsafe act of a person or act of God or by any agency or
due to failure or weakening of any material, structure, Severity Rate Safety Activity Rate
situation, condition or system. Rate
Incident Rate Safe T Score
Disabling Injury (Lost Time Injury) - An injury causing
disablement extending beyond the day of shift on which the Rate Rate
accident occurred.
III. PROPOSED METHODOLOGY
Accidents reportable under Factories Act & E.S.I. Act; The main objective this work is to do quantitative
Factories Act - Accident which causes injury to person to monitoring in thermal power plant for past few years
such an extent that the injured person becomes disabled to (2007-14). The data presented in this paper were compiled
work for a period of 48 hrs. or more. as a part of research project. Accidental data may serve as
E.S.I. Act - Accidents which causes disablement to the an important feedback instrument to monitor safety
injured person for not less than 3 days (excluding the day performance. Accidental data are commonly expressed as
of accident) and which arises in course of injured persons rates, per unit population or per unit time worked.
employment. Calculation of rates requires number of injuries and
Man Hours Worked - The total number of employee hours exposures. Frequency rates express injuries in terms of
hours of exposure taking into account actual exposure to
worked by all employees working in the industrial
the risk, e.g. including overtime hours. Severity rates
premises. It includes professional, supervisory, managerial,
express the number of days lost in terms of hours of
technical, clerical and other workers including contractors
labour. exposure, taking into account the gravity of the injury.
Incidence rates tell injuries in terms of number of persons
Disablement - The disablement means loss of capability of exposed to the risk per year. Rates can either be calculated
a person to do some work for which he has been employed for employees (insured) or for workers (insured and
in industry just before an occurrence of the accident which uninsured combined) in comparison do statistics of
has resulted into minor injury, serious injury. fatalities and serious injuries which provide more reliable
Such disabilities are three types as under; indices of safety performance.
1. Permanent Partial Disabilities -This is particularly in This paper focuses on safety performance monitoring or
nature which reduce earning capacity in every partial rating. This also examines some of the general limitations
disability in which he might he employed before the of statistics on occupational accidents for the thermal
accident. power plant. The main purpose is to provide a basis for
discussion on the safety performance rating of thermal
2. Permanent Total Disabilities -This type disablement is
power plant with a perspective on limitations of the data
of remaining period of life such accident may result into
available.
severely injury & makes a worker incapable of working
any type of work which he was able to work earlier as such
he has the loss of 100% earning capacity such disablement IV. ANALYSIS / CALCULATION
is called Permanent total disability. Now this data have taken from the Thermal Power Plant.

121
International Journal of Emerging Technology and Advanced Engineering
Website: www.ijetae.com (ISSN 2250-2459, ISO 9001:2008 Certified Journal, Volume 5, Issue 1, January 2015)
TABLE I
Collection Data:From Accident Register and Attendance Register

Severity of
Types of Accident
Year Accident Man Days Average No.
Total Man- Total No.
(1 April Lost Due to of Employee
Sr. Hours of Accident
To 31 Fatal Non- Reportable Non- Reportable Present in
No. Worked (Per Year)
March) Fatal Reportable Accident one Day
(F) (NF) (R) (NR)

1. 2007-08 - 5 1 4 2 1410560 580 5

2. 2008-09 1 2 1 2 5 1264640 520 3

3. 2009-10 - 5 1 4 21 1155200 475 5

4. 2010-11 - 5 1 4 21 1301120 535 5

5. 2011-12 4 23 5 22 28 1211136 498 27

6. 2012-13 2 7 3 6 23 1374080 565 9

7. 2013-14 - 5 2 4 8 1301120 535 5

Example (Calculation) Total man hours worked = Avg. no. of employees present
As chosen sr.no.7 from table no.1, year 2013-14. in one day No. of working day in a year 8
Details:- Total man hours worked = (535 304 8)
No. of Injuries (Accident) in a year = 5 Total man hours worked = 1301120 Man hours
(Taken from accident register,)
Avg. no. of employees present in one day = 535 (Now we calculate the accident Indices)
(Taken from Attendance register) Frequency Rate - It is define as number of disabling
No. of reportable Accident = 2 accidents per million man-hours worked by factory, in a
(Taken from Accident register) year.
Man days lost due to reportable Accident = 8 Purpose - To know how often disabling accidents occur.
(Taken from Accident register) Formula -
Man hours worked = 1301120
(Taken from Attendance register)
Total no. of working days in a year = 304
(Taken from Attendance register)
Total Safety Activity = 150+390+50+10 = 600
(Taken from Attendance register)
Safety recommendation = 150 Frequency Rate = 3.8428 Indices
Unsafe Practices = 390 (Per million man-hours worked)
Unsafe Condition = 50
Severity Rate - It is define as the number of man days
Safety Meeting = 10 lost per million man-hours worked.
We know that Purpose - To know how serious the injuries are.

122
International Journal of Emerging Technology and Advanced Engineering
Website: www.ijetae.com (ISSN 2250-2459, ISO 9001:2008 Certified Journal, Volume 5, Issue 1, January 2015)
Formula - in a calendar
year
in a calendar
year

Frequency Coefficient= 0.00384 Indices


(Per million man-hours worked)
Severity Coefficient =
Severity Rate = 6.1485 Man Days Purpose -To know the simple ratio of number of man days
(Per million man-hours worked) lost to number of injuries.
Incident Rates - It is the ratio of number of accidents to Formula
number of employees during the period under review.
Purpose -To know the simple ratio of number of accidents
to number of employees.
Formula - in a calendar
year

in a calendar
year
Severity Coefficient = 1.6 Man Days lost per Injury
Safety Activities Rate - This number is calculated to find
out the safety performance in a unit time period say one
year.
Incident Rate = 9.3457 Indices Purpose: - To compare safety performance of factory with
(Per million man-hours worked) respect to different time periods. Unit time period may be a
Disabling Index week, month, year etc. Thus the safety activity rate curve
Purpose -To know the simple product of frequency rate can be plotted as follow.
and severity rate which divide by 1000. Graph-
Formula -

in a calendar
year

Disabling Index = 0.00236 in a calendar year


Frequency Coefficient
Purpose -To know the simple ratio of number of injuries to
man hours worked.
Formula Definition - Safety activity is the sum of safety activity in a
year, with respect to man hours worked and average
number of employees.

123
International Journal of Emerging Technology and Advanced Engineering
Website: www.ijetae.com (ISSN 2250-2459, ISO 9001:2008 Certified Journal, Volume 5, Issue 1, January 2015)
Safety Activity Numbers = N = N1+N2+N3+ Formula-
N4+.
N1, N2 are the performance rating number (1-5) given to
each safety activity such as Safety audit, Safety policy,
Accident analysis etc.
in a calendar
Formula: -
year

in a calendar
year
in a calendar
year

in a calendar
in a
year
calendar year
FR1 = Past Year 2013 (No. of Accident =5)
FR2 = Current Year 2014 (No. of Accident =4)

Safety Activity Rate in a calendar year


The parameters for safety activity as follows.
FR1 = 3.8428
1. Number of safety recommendations mentioned in safety
audit report, are complied with (N1).
2. Number of unsafe practice detected (N2).
3. Number of unsafe condition detected (N3).
4. Number of statutory compliances carried out (N4). FR2 = 2.7321
5. Number of safety committee meeting held (N5).
6. Number of training session of health & safety arranged
internally (N6).
7. Number of training session of health & safety done Safe-T-Score = -0.6855
trainer being external agency (N7).
8. Number of mock-drill of on-site emergency planning Performance-
conducted (N8). 1. From this above result it will be concluded that the safety
9. Number of safety motivation programmers like safety performance is increased in 2014 compared to 2013.
arranged (N9). 2. Positive (+) STS indicates a worsening record while
10. Number of suggestions for safety received from negative (-) STS indicates an improving record over the
employees (N10). past.
Safe-T-Score - TABLE II
Safe-T-Score and their values
1. If safe T score is +2 or more, than safety performance
is worked. STS Description
2. If safe T score is -2 or more in negative side than safety Between +2 & -2 Change is not significant. There may be
random fluctuation only.
performance.
More than +2 Record is worsening than it was in the past.
Purpose - It may be concluded that safety performance has Something wrong has happened.
improved, The simple ratio of current and past accidents. Less than 2 Record is improving than it was in the past.
Something better has happened.

124
International Journal of Emerging Technology and Advanced Engineering
Website: www.ijetae.com (ISSN 2250-2459, ISO 9001:2008 Certified Journal, Volume 5, Issue 1, January 2015)
Accidental graph of thermal power plant (2007-2014)

A CCI DEN TA L GR A PH

27
No. of Accidents Per Year

9
5

5
5

5
3
2 0 0 7-082 0 0 8- 092 0 0 9- 102 0 1 0- 112 0 1 1- 122 0 1 2-132 0 1 3- 14
yea rs

CALCULATED DATA
Co-efficient Safety
Sr. Frequency Severity Incident Disabling Safety T Score
Year Activity
No. Rate Rate Rate Index Frequency Severity Rate
FR2 - FR1 (STS2)
1. 2007-08 3.544 1.417 8.620 0.000502 0.0035 0.4 3.666 2008-2007 -0.70010
2. 2008-09 2.3722 3.953 5.769 0.0093 0.002 1.66 4.5619 2009-2008 1.364
3. 2009-10 4.328 18.178 10.526 0.0078 0.004 4.2 5.4672 2010-2009 -0.2665
4. 2010-11 3.842 16.139 9.345 0.0062 0.003 4.2 4.3097 2011-2010 10.358
5. 2011-12 22.293 23.118 54.216 0.5153 0.0222 1.03 4.9739 2012-2011 -3.9086
6. 2012-13 6.5498 16.738 15.929 0.1096 0.0065 2.55 3.8642 2013-2012 -1.20609
7. 2013-14 3.8428 6.1485 9.3457 0.00236 0.00384 1.6 4.3097 2014-2013 -0.6855
Graphically representation of all safety performance Now graphically represented..
rating i.e. frequency rate, severity rate, incident rate etc.
Incident Rate
Frequency & Severity Chart
55
27 50
24 45
21 40
18 35
15 30
12 25
9 20
6 15
3 10
0 5
2007-08 2008-09 2009-10 2010-11 2011-12 2012-13 2013-14
0
2007-08 2008-09 2009-10 2010-11 2011-12 2012-13 2013-14
Frequency Rate Severity Rate
Incident Rate

125
International Journal of Emerging Technology and Advanced Engineering
Website: www.ijetae.com (ISSN 2250-2459, ISO 9001:2008 Certified Journal, Volume 5, Issue 1, January 2015)
VI. MOTIVATION
Safety Activity Rate (Zero Accident Zone)
Motivation is the tool for development of attitude of
Safety Activity Rate loyalty & capacity for marketing sacrifice to achieve some
goal. Motivation runs from top to bottom therefore top
management of supervisors should be motivated first,
5.4672 motivation include, inspiration communication auto
4.5619 4.9739 suggestion in the process of arousing active for the
4.3097 3.8642 4.3097
3.666 advancement of the safety. Motivating an employee is a
personal mix of seven key strategies. These include, setting
expectations, effective punishment, fair treatment, rewards,
2007-08 2008-09 2009-10 2010-11 2011-12 2012-13 2013-14 employee needs, work related goals and restructuring jobs.
The purpose of motivation is improve the work
performance of an individual or a group therefore
Safety T Score Performance =Ability x Motivation
Therefore motivation is needed to improve the work
performance.
To reduce the loss of life and property along with time,
money and industrial production.
To minimize human error, unsafe act and unsafe
condition to prevent accident.
There are three 3 major Steps of motivation.
Force or drive to lead some behavior.
2007-08 2008-09 2009-10 2010-11 By use of this function we can guide the behavior of a
2011-12 2012-13 2013-14 particular person in the desired direction.
By maintaining and sustaining the behavior once it
V. NEAR - MISS INCIDENTS occurred.
Near-miss incident is nothing but an unpredictable, VII. PUNISHMENT
unplanned event that may not cause loss of life and
property. We must learn from near-miss incidents and In order to prevent any kind of accident that takes place
accidents as to prevent recurrence. The investigation is the can be minimized by punishing the incorrigible workers, by
first step while determining the cause for near miss incident the management so that any disaster could not take place in
or accident occurrence. A strong investigation will identify future.
management system weaknesses of plant location. Safety
audit by management system is one of the highest value VIII. SAFETY RECOMMENDATIONS
activities in which a company can invest. So learning from Normal habit of a person or management is to follow
near misses is much cheaper than learning from accidents. this reactive or corrective approach only after an accident.
Much power generating plants should focus on getting They do not think to invest money or time for preventive
near-miss incidents report and must improve safety measures to avoid accidents by advance planning.
management system. One should implement it by making Drawback of this approach is to suffer some loss due to one
group of five employees from each department and make or more accidents. In this work approach, action is started
report about the near miss incident that takes place in after accident. Accident causes are investigated analysed
company premises every week to improve the safety and preventive action is determined. Then it is applied to
system in future. prevent recurrence of the similar accident. This works as a
lesson from the accident.

126
International Journal of Emerging Technology and Advanced Engineering
Website: www.ijetae.com (ISSN 2250-2459, ISO 9001:2008 Certified Journal, Volume 5, Issue 1, January 2015)
SAFETY So with the help of the quantitative safety performance
monitoring or measurement for implementation of safety
5 Application of remedy program in thermal power plant will definitely improve the
safety system in future.
4 Selection of remedy
Acknowledgement
3 Analysis
The authors thank to all the employee of thermal power
2 Fact finding plant, who participated in this study and shared their
experience and information, as well as those who guided
1 Organisation me to complete this work. I would specially like to thank
Prof. N.K Jain, Fire Technology & Safety Engg. Deptt.,
Fig. 1.1 Steps of Accident Prevention IES, IPS Academy Indore & Ex. Director of Industrial
Health & Safety, Government of M.P. for his valuable
IX. CONCLUSION inspiration, able guidance and untiring help, which enabled
This paper discusses safety performance rating by me to carry out and complete this work. I am sincerely and
quantitative monitoring in the thermal power plant during heartily grateful to Prof. Praveen Patel, Head of
previous seven years, from 1st April 2007 to 31st March Department, Department of Fire Technology & Safety
2014. Safety performance measurement is a crucial part of Engineering IES, IPS Academy Indore to support me
achieving efficiency in continuous improvement, with the throughout my project. I express our sincere gratitude to
help of this quantitative monitoring method we have Dr. Archana K. Chowdhary, Principal, Institute of
calculated frequency rate, severity rate, incident rate, Engineering & Science, IPS Academy for extending all the
disabling rate, safe activity rate and also calculated safe T facilities during the course of study. At this juncture I also
score for 2007-08 (-0.70010),2008-09(1.364),2009-10(- take this opportunity to express our deep gratitude to all the
0.2665),2010-11(10.358), 2011-12( 3.9086), 2012-13(- Faculty members and Staff of Fire Technology & Safety
1.20609) and 2013-14(-0.6855). After calculation of all this Engineering Department, for their appreciation and moral
safety performance status is cleared, because when we got support. I am also thankful to all the persons who helped us
the negative value of Safe-T-Score (Less than -2) that time directly or indirectly to bring the research paper work to the
the record is improved as compared to with the past. In the present shape.
year of 2007-08 and 2009-10 the safety performance record
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International Journal of Emerging Technology and Advanced Engineering
Website: www.ijetae.com (ISSN 2250-2459, ISO 9001:2008 Certified Journal, Volume 5, Issue 1, January 2015)
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