CONTENTS

S.NO. TITLE PAGE NO.

1 CHAPTER-I
INTRODUCTION 1-3
INDUSTRY PROFILE 4-17
COMPANY PROFILE 18-31

2 CHAPTER-II
REVIEW OF LITERATURE 32-38

3 CHAPTER-III
RESEARCH METHODOLOGY 39
STATEMENT OF THE PROBLEM 40
SCOPE OF THE STUDY 40
OBJECTIVES OF THE STUDY 40
METHODOLOGY 40

4 CHAPTER-IV
DATA ANALYSIS AND INTERPRETATION 41-80

5 CHAPTER-V
FINDINGS 81-82
SUGGESTIONS 83
CONCLUSION 84

6 BIBLIOGRAPHY 85-86

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 Chapter -I

INTRODUCTION
1.1 Topic Introduction
1.2 Industry profile
1. 3 Company Profile

2
1. Industrial safety:

Industrial safety refers to the management of all operations and events

within an industry in order to protect its employees and assets by minimizing hazards, risks,
accidents, and near misses. Industrial safety is overseen by federal, state, and local laws and
regulations to ensuring industrial safety. Covers a number of issues and topics affecting safety of
personnel and the integrity of equipment in a particular industry.

The following topics are generally discussed:

 General Safety – General aspects of safety which are common to all industries
 Occupational Safety and Health – Particularly associated with the occupation
 Process and Production Safety
 Material Safety
 Workplace Safety – Safety issues directly related to the workplace setting
 Fire Safety
 Electrical Safety – Arising from the equipment used
 Building and Structural Safety – Including installations as per existing building code
 Environmental Safety – Concerns the direct and indirect environmental impact of the
industry

Safety is very important aspect for any industry as an accident free work environment
boosts the morale of the team members working in any hazardous situations. Recognizing
these facts industries involving various hazards and risks industries prepare their own
safety policy, safety manual and have a separate department/section for safety so as to
create proper awareness and provide the know-how-about the safety. Adherence to the
useful information, rules, and mandatory requirements governing the safety and guidelines
will help prevent occupational injuries and accidents which constitute an unavoidable and
needless waste of human and material resources.

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 Safety means continuing and healthful living without injury. Safety is freedom from harm
or the danger of harm. The word safety also refers to the precautions people take to prevent
accidents, harm, danger, damage, loss and pollution. Safety also deals with improvement
in working conditions for better health. Management is responsible to provide safe working
condition and individual’s safety.

 All undesired events in a workplace which can give rise to death, ill health, injury, damage
or other loss need to be thoroughly investigated, people are trained to safeguard against
them, and need to be eliminated. Similarly, all hazards, i.e., source/situation capable of
injury or ill health, damage too properly or workplace environment etc., should be
identified and action plan drawn for safeguard against them.

 It is not only sufficient to care of safety but other two inter-related aspects, viz., health
(well-being of employees) and environment are also given equal importance and
considerations. All these three elements i.e., safety, health and environment (also known
as SHE) are inter-related and affect each other. For instance, if health of employee is not
given due regards, it may lead to accidents.

 If industry pollutes the environment around work place, it will affect health of employees
which may ultimately affect production. It is only if health and environment are in control
than safety can be ensured. Each industry, therefore, has certain obligations towards
keeping good environment and also towards health of people.

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1.2 Industry Profile
Industrial Core Sector

Energy & Power

Petroleum, Gas and Chemical

Metals, Minerals and Steel

5
Cement

Coal

Defense Production

6
Telecom & IT

Automobiles

Textile

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 And many more

1.2.2 Industrial domain

Storage (Raw Material - Solid, Liquid, Gases)

Process Plant & Machinery

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Utilities ( Power, Steam, Nitrogen etc.)

Finished Product

People (Operation, Maintenance and Supporting Staff)

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Power generation industries:

As described above industries I am going to study one Electrical

safety in power generation industries. There are various types of power generating industries or
there in India Power is one of the most critical components of infrastructure crucial for the
economic growth and welfare of nations. The existence and development of adequate
infrastructure is essential for sustained growth of the Indian economy.
India’s power sector is one of the most diversified
in the world. Sources of power generation range from conventional sources such as coal, lignite,
natural gas, oil, hydro and nuclear power to viable non-conventional sources such as wind, solar,
and agricultural and domestic waste. Electricity demand in the country has increased rapidly and
is expected to rise further in the years to come. In order to meet the increasing demand for
electricity in the country, massive addition to the installed generating capacity is required

Various power generating stations are there in India, from their main are as follows

1. Thermal power plants-75% (Coal, Bio mass, Nuclear & Gas etc)
2. Hydro power plants - 9%
3. Wind power plants -7 %
4. Solar power plants -8%

As described in above 75% of the power is generating from thermal power plants in India.
Renewable power plants are also very important in environmental safety side.

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Electricity generation (utility sector) by source in India

Thermal
hydro
wind power
solar power

As shown in the above chart 75% power generating from thermal power plants in India. Hence I
am going to discuss about the safety in thermal power plants

1.4THERMAL POWER PLANTS:

Thermal Power Generation This process involves the generation of

electricity from the burning of fossil fuel in a large industrial furnace. In very simple terms, in a
coal-fired station the coal is pulverized and blown into the furnace where it burns, much like
a gas flame, to heat water and generate steam, which moves at high speed to a turbine. The turbine
spins and drives a rotor attached to a magnet in a generator. The rotating magnetic fields moving
across coils in the generator produce electric currents. The thermal machines used to convert the
stored energy in the fuels to the kinetic energy of the rotor are complex units. Each consists of two
principal parts: boilers and turbines. They also include a variety of auxiliary equipment to provide
fuel and water to the unit and to eliminate waste gases and products of combustion. The basic

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operations are mechanical and highly automated. In a coal-fired power station, where boilers and
turbines are combined, there is automatic control of coal pulverization, of supplied.

There are several types of thermal power stations are there as described below

(a) Coal power plant

(b) Gas power plant

(c) Diesel power plant

(d) Bio mass power plant

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Figure 1GAS POWER PLANT

Figure 2BIOMASS POWER PLANT

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14
1.4. Company Profile:

Bharathi Cement Corporation Private Limited (BCCPL) is a producer of Superior Quality

Cement has set new standards in the cement business. It is a joint venture of Vicat Group, France
(pioneers in cement) in India having 51% majority stake.

Bharathi Cement has a 2 production lines with using state-of-the-art technology having a total
capacity of 5 MTPA and is located at Nallalingayapalli, in Kadapa district of Andhra Pradesh. The
cement is marketed as“Bharathi Cement” since 2009.

The Company was incorporated on May 12, 1999 as Raghuram Cement and Minerals Private
Limited. The ownership of the company was changed and the company was renamed later
as Bharathi Cement Corporation Limited on August 6, 2008. In April 2010, Vicat SA,
France acquired a majority stake in the company. Later, the name of the company was changed
to Bharathi Cement Corporation Private Limited from September 1, 2010.

The company commenced the commercial production of line 1 with a capacity of 2.25 MTPA on
September 28, 2009 at Nallalingaya Palli, Kamalapuram Mandal, YSR District, AP. It sells the
cement under the brand name, “Bharathi Cement”. Later the line 2 was commenced on February
4, 2011 and the total capacity was increased to 5 MTPA. In 2015, a 30 MW captive power plant
was set up to meet the power requirements of the company. The company has also 2 subsidiaries,
Bharathi Polymers India Private Limited (laminated PP bag manufacturing unit) and
Bharathi Rock Products India Private Limited (Aggregates division).

It also invested to build a robust back-end rail and road transport system ensuring the delivery of
cement within 24 hours of placing an order.

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BHARATHI CEMENT CORPORATION PVT LIMITED

BCCPL CAPTIVE POWER PLANT (1*30MW)

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1.4.1 First Aid team:

For first aid team members we are giving training from third party (St. Ambulance) after training
certificate in first aid also given to trained members.

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1.4.2 Environment:
All the environmental aspects have been considered while designing the plant as well as in
selecting the equipment. Fume Extraction Systems with wet scrubbers have been provided at all
locations where fumes are generated .ETPs have been provided to prevent Effluents being
discharged into storm water and sewage drains.
Wherever possible, ‘Water Recycling Plants’ have
been installed to reduce consumption of fresh water. Treated water from Effluent Treatment Plant
(ETPs) is used for watering the plantation within the estate thus, effectively saving the water. As
a good corporate citizen, BCCPL has satisfied all the legal requirements of State and Central
Pollution Control Boards. About 4% of the total project costs have been spent on the pollution
control equipment alone. This equipment will consume about 5% of the total electrical energy of
the plant. Separate storm water drains are constructed for effective drainage of rainwater without
mixing with the trade effluents or domestic effluents. A rainwater harvesting and storage tank has
been formed in a total area of about 20 acres to increase the ground water table.

GREEN BELT DEVELOPMENT:

BCCPL developed around 15 acres of land, as green belt around

the plant. The plant species are specially selected keeping in view the terrain conditions and the
environmental conservation as well as the possible pollutants from the plant. The plantation of
shelter belt around the boundary of the plant, general greening, landscaping hedges, lawns,
ornamental plantation etc., are taken up regularly. A Trust is formed and named as BCCPL
CORPORATION PVT LIMITED TRUST. The trust will work from the annual contributions from
M/s BARATHI CEMENT CORPORATION PVT LIMITED and its group companies. Each
company will contribute 0.2% of the profits towards annual contributions to take up different
activities pertaining to improvement of various infrastructural facilities.

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1.4.4 Safety Committee:
Main objective of safety committee is to promote safety by co-
operation between employer and employees. Management uses the safety committee to explain
the safety importance and its benefits to all workmen. The workmen in turn use the committee
to put their views and suggestions on safety matters to the management. The Unit has a safety
committee and was reconstituted on 2019. A safety committee has been constituted in 2018.
Chairman of the Committee is senior manager of Thermal power plant. They have four
representatives from management and two from employees.

Safety Committee meets every month once. Previous incidents are discussed in the committee.
Minutes are prepared and follow-up action taken on the issues brought up in the committee,
fixing responsibility and target dates for compliance and we are maintaining safety defect
register for workers and employees of company. Monthly once safety training program will be
conduct by safety officer with concerned department.

Date:
SAFETY COMMITTEE MEMBERS-CPP
09.07.2019

Position in
Sl.No Name Department
SafCom
1 Talib hussain Operations Chairman
2 Prasad reddy HSE Secretary
3 Sai kiran QHSE Member
4 Pavan kumar ELE Member
5 Gowri reddy ELE Member
6 Sagar reddy ELE Member
7 Siva kumar OPE Member
8 Siva reddy INS Member
9 Mahesh reddy INS Member

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 10 Ram sagar reddy HR Member
11 murali HR Member
12 sreekanth OPE Member
13 Subba reddy OPE Member
14 Anil OPE Member
15 Siva sankar OPE Member
16 Siva sankar reddy MECH Member
17 Siva kumar reddy MECH Member
18 Venu kumar MECH Member
19 mallikarjuna MECH Member
20 sudharshan MECH Member

1.4.5. Safety Audit:

Safety Audits are normally designed to achieve one or more of the goals.
The scope of the internal safety audit to identify the potential hazards, possible accidental causes
to prevent the accidents. Safety Audit conducted in every two months once.

1.4.6 Safety Education and Training:

Training, in a broader sense, is a continuous process in
life to equip oneself with knowledge; skills desired behavior so that an individual can be effective
in his own functions as well as a member of any group. Trained manpower will not only
contribute to better productivity but will also ensure better safety performance of the unit.
Training is an ongoing process. HR Manager - Safety officer and Manager - Training looks after
the training programs.

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1.4.7 Motivation and Promotion:
The Management has been developed schemes through which
employees to contribute/ highlight SAFETY, HEALTH and ENVIRONMENT related aspects.
Management encouraged suggestions from the employees for improvement of HSE systems.
Management exhibited Safety boards, Safety information at critical areas. National Safety day is
celebrated in the Unit by taking Safety pledge, arranging Safety awareness programs and
exhibiting Safety posters and banners during that week.

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1.4.7. Work Permit System:
Work permit system is essentially a document that, categorically spells out the
task, equipment involved, its location, personnel involved, time limitations, precautionary measures to be
taken together with likely hazards to be encountered if any. Work permits written information on the
prevalent hazards connected with the job performance. It serves as a predetermined check list for various
safety precautions to be taken. Close liaison between all concerned is provided so that personnel and
equipment are protected from accidents. We are issuing the below mentioned work permit system For
effective implementation we have appointed the floor level inspector for Work Permits to check the
sustainability of the permits usage in the plant premises.

1.4.8. Fire Extinguishing Appliances:

Fire Extinguishers and other firefighting accessories are maintained
there is a fire extinguisher lay out chart for individual units and they are available in the respective Plant
Office rooms and shop floors. There are total 62 Fire Extinguishers are available in the plant Extinguishers
are serviced by the Plant personnel once in 3 months. Plants where periodic inspections are carried out. The
weight of CO2 cartridge, the DC powder free flowing condition, condition of the hose.

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Chapter –II

23
 SAFETY IN THERMAL POWER PLANT:

INTRODUCTION:

Industrial Safety, area of safety engineering and public health that deals with the protection of
workers' health, through control of the work environment to reduce or eliminate hazards.
Industrial accidents and unsafe working conditions can result in temporary or permanent injury,
illness, or even death. They also take a toll in reduced efficiency and loss of productivity.

Various external sources, such as chemical, biological, or physical hazards, can cause work-
related injury. Hazards may also result from the interaction between worker and environment;
these so-called ergonomic hazards can cause physiological or psychological stress.

Chemical hazards can arise from the presence of poisonous or irritating gas, mist, or dust in the
workplace. Hazard elimination may require the use of alternative and less toxic materials,
improved ventilation, leakage control, or protective clothing.

Biological hazards arise from bacteria or viruses transmitted by animals or unclean equipment
and tend to occur primarily in the food-processing industry. The source of the contamination
must be eliminated or, when that is not possible, protective equipment must be worn.

Common physical hazards include ambient heat, burns, noise, vibration, sudden pressure
changes, radiation, and electric shock. Industrial safety engineers attempt to eliminate hazards
at their source or to reduce their intensity. If this is impossible, workers are required to wear
protective equipment. Depending on the hazard, this equipment may include safety glasses,
earplugs or earmuffs, face masks, heat or radiation protection suits, boots, gloves, and helmets.
To be effective, however, the protective equipment must be appropriate, properly maintained,
and worn by the worker.

If the physical, psychological, or environmental demands on workers exceed their capabilities,

ergonomic hazards arise. This type of hazard frequently occurs in the area of materials handling,
where workers must lift or carry heavy loads. Poor working posture or improper design of the

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workplace often results in muscle strains, sprains, fractures, bruises, and back pain. These injuries
account for 25 percent of all occupational injuries, and their control requires designing the job so
that workers can perform it without overexerting themselves.

2.1 ACCIDENT:

An accident is any unforeseen or unexpected event that may or may not result in an
injury or damage to property or equipment. The ultimate goal in accident prevention
is zero disabling injuries and no work time lost. However, there are many barriers to
achieving this goal, the most important of which is the human attitude. Most people
feel that it won't happen to me" or "it couldn't happen here". You can do more to
protect yourself and your fellow worker by constantly thinking and practicing
accident prevention than you can by memorizing all of the rules, regulations and
safeguards ever invented or written. You must think before you act.

Accidents take place only by either or both of two reasons:

2.1.1 Unsafe Conditions:

Unsafe conditions are defined as hazards built-in the environment or
equipment or machine which has potential to cause accident. These unsafe conditions in industry
or most commonly available and can be eliminated with a bit redesigning and putting up a small
additional amount of finance. These unsafe conditions are unguarded rotating machines or
machine parts, unsafe material handling equipment defective tools, unguarded opening etc.
Unguarded rotary machines, Unsafe material handling equipment, Defective tools, Unsafe
electrical equipment’s, High working platforms without protection rails, Broken ladders,
Slippery floors, Fire hazards, Toxic gases, Enclosed space, High temperature, Radio activity.

2.1.2. Unsafe Act:

Unsafe act is a built-in hazard which is developed by human error, lack of
knowledge, lake of training, carelessness etc. Unsafe act on apart of operators at plant is to use
a wrong tool or to use a tool at wrong place, may be the tool is ok but it will built-up a potential

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for an accident. Unsafe act can be minimized by education of people, proper training to do a
certain job and developing safety awareness and reducing carelessness while on job.

2.3 INDUSTRIAL HAZARDS

Industrial hazards consist of four principle hazards. This is because industries employ many
different processes involving a wide range of different raw materials, intermediates, waste products
and final products. The hazards encountered are fire, explosion, toxic release and environmental
damage.

Fire: This is the most frequent of the hazards however the consequences are generally less. The
effect of fire on people usually takes the form of skin burns and is usually dependant on the exposure
time and the intensity of the heat. Fire can also produce toxic fumes like Acrolein, Carbon monoxide
and Cyanides. Physical structures can be damaged either by the intensity of the heat or combustion.
It may also have an effect on essential services like power and instrumentation which can cause an
escalation of the incident

Explosion: Explosions are usually heard from far away as a ‘bang’. This is the result of a shock
wave. This overpressure can kill people but usually the indirect effects of collapsing buildings,
flying glass and debris causes far more loss of life and severe injuries. There are different types of
explosions which include gas explosions and dust explosions. Gas explosions occur when a
flammable gas mixes with air and is exposed to an ignition source. Dust explosions occur when
flammable solids, especially metals, in the form of fine powders are intensively mixed with air and
ignited.

Toxic/Chemical release: Sudden releases of toxic vapours have the potential to cause death and
severe injuries several miles from the release point. They are carried by water and air. Their release
into public sewage systems, rivers, canals and other water courses, either directly or through
contaminated water used in fire fighting can result in serious threat to public. The number of
casualties depends on the weather conditions, population density in the path of the cloud and the
effectiveness of the emergency arrangements.

Environmental Damage: As well as having the potential for causing injury, loss of life and
damage to property, the hazards of fire, explosion and toxic releases may pose a severe threat to the

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environment. Release of other substances, not directly toxic to humans can cause major pollution
problems. It is becoming increasingly recognized that damage to natural resources such as plant
and animal life can have serious long term consequences. E.g. destruction of trees is increasing the
effect of global warming and extinction of animals are severely disrupting food webs and causing
an increase in pests.

2.2.1 Process Environmental Hygiene:

Poor housekeeping is an industrial hazard and a frequent contributor cause of accidents, often by
masking other hazards. Most safety specialists have a keen eye for good and bad housekeeping,
typical features of the latter being poor lighting, dirt and untidiness, with materials, tools and scrap
dumped on floor and benches, and no clear gang-ways between machines.
Poor housekeeping may constitute a tripping or falling hazards, a fire hazard or dust explosion
hazard. In the general disorder the greasy or damaged floor is camouflaged and defective guards,
tools, machinery and electric cables appear normal.
Good housekeeping requires more than good
habits, regular cleaning, washing and maintaining walls, floors, doors, windows; in the first place
it requires positive planning. The flow of materials through a process i.e. Modification must be
studied and proper provision made for by-products (off-cuts, dust, turnings packing, scaffolding
and transient combustible materials) to be segregated, removed and disposed of.

1. The hazards of poor housekeeping are especially acute when the materials left lying about
Are toxic, flammable or react violently with water.

2. The subject of housekeeping is closely allied to cleaning. Many aspects of both of these are
Covered by the followings which sets out the basic rules of factory cleanliness.

3. Daily removal of refuse and dirt from floors and benches.

4. Weekly cleaning of workroom floors.

5. Inside ceiling, walls and partitions to be cleaned with hot water at least every fourteen months
And painted or varnished at least every seven years.

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6. Proper vacuum cleaning equipment with tools for reaching into nooks and corners and
Adequate and well maintained dust filters are a must for all operations where dust is present.

7. Brooms, brushes, waste for removing floor spillages, cleaning tools and detergents or other
cleaning solutions should be provided for use by employees as the job demands.

8. Slipshod and ill-conceived lubrication methods can contribute seriously to bad housekeeping
either through oil spillages or through the discharge of fine oil mist into atmosphere. Specialist
advice should be sought where this is a problem. Even the compressed air in many works
contains small amounts of finely suspended oil from the compressor.

2.2.2 Hazards Of Entry Into Confined Spaces:

 Vessels, tanks, pits etc. which contains inflammable liquid or chemical or there exist
oxygen deficiency are confined spaces.

 No body shall be allowed to enter a tank, a vessel, a tunnel etc. containing toxic vapors
or oxygen deficiency unless the atmosphere is tested and certified fit for working, after
the vessel or tank is cleaned, washed and purged.

 Adequate ventilation and protective measures should be adopted during work inside
such areas.

 No tank or vessel which contains or has ever contained any explosive or inflammable
shall be subject to:

 Any welding, brazing or soldering operations

 Any gas Cutting or grinder cutting

 Any operation involving heat unless and until

Precautions:

 Remove ignition smoke

 Blanking of inlet and out let lines by using bolted blanks

 Open man-holes

 Remove sludge

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  Monitor wind direction

 Perform gas flammability test

 Isolation of moving part like cutters and stirrers by locking isolation switches in the
off-position.

 Pasting of notice Danger, men working in tank outside the tank.

 Cleaning of tanks and vessels

 Before starting of hot work, vessel or tanks shall be completely cleaned by taking the
following steps.

 Washing with cold water with high pressure hose

 Air blowing for removal of volatile liquid steaming out

2.2.3 Electrical Hazards:

An electrical hazard can be defined as a dangerous condition where a worker could make
electrical contact with energized equipment or a conductor, and from which the person may
sustain an injury from shock; and/or there is potential for the worker to receive an arc flash
burn, thermal burn, or blast injury.

Precautions:

 There are ways to work with or near electrical equipment and wiring that will help
keep you safe. All workers should follow these rules, whether or not they are
electricians.

 Clothing: Do not wear rings, watches, or any metal jewelry or ornaments when you
are working near electrical circuits. Do not wear a metal hard-hat. Wear shoes with
non-conducting (rubber) soles.

 Equipment: Do not use metal ladders or un-insulated metal tools near electricity. Use
only intrinsically safe or explosion-proof tools and hand lamps. In dangerous location
like metal tanks, use 6 or 12 volts equipment.

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  Keep electrical machinery free of dust, dirt, and oil. Do not store lunch or anything
else in switch boxes. Keep all switch doors closed. Be sure all equipment meets the
requirement of a recognized testing laboratory. Never overload a circuit, event when
all equipment is certified.

 Examine all electrical tools and equipment for signs of damage. Never use faulty
power tools. When tools or their cords are damaged, replace them at once.

 Wiring: Wires with damaged or deteriorating insulation should be replaced. Only in

an emergency, and for temporary use only, should a wire be wrapped with electrical
tape.

 When joining wires, tape the connection, cap the wires with wire nuts, or coat them
with a special potting compound. These methods prevent accidental contact with a
bare wire.

 Water: Water and electricity do not mix. Check your work area for puddles and wet
surfaces. Never try to put out an electrical fire with water. Use the extinguisher
designed for electrical fires.

 Making Repairs: The most important rule to follow when making repairs on or near
an electrical circuit is to shut off and lock out the power. Then, to be sure, test the
circuit with a current tester or meter before you work on it. Obey the lockout rules in
your plant.

2.2.4 Fire Hazard:

Jobs that involve welding, flame cutting and grinding may cause fire.

Precautions:

 Before start of work, carry out inspection of area and remove any combustible materials
from the area.

 Nearby equipment and hole or opening in floor shall be covered by fire blankets.

 Appropriate fire extinguishers and water buckets shall be placed near the job site.

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  A fire fighter will supervise the activity. The area will be watched for one hour after
the activity is finished.

2.2.5 Hazards Of Falls:

 Falls to a lower level

 This type of fall can arise in several ways, the most common of which are:

 Falls through floor openings and into pits, vessels and trenches

 Falls from roofs

 Falls from ladders and stains

 Falls from high working places.

Precautions:

 All openings in floors including doors through which a person could fall onto a lower
floor or into pit or vessel shall be properly guarded with fix barrier rails of adequate
height, which shall be firmly supported and strong enough to with stand rough usage
and occasional impacts.

 Safety belts shall be used while working at heights.

2.2.6 Hazards Of Falling Objects:

Protection against injury from falling object shall be ensured by taking following measures.

Precautions:
 Never work under suspended loads of cranes.

 Never through any object from height

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  Tool box managing on hook shall be used instead of loose tools

 Care shall be taken in stacking materials.

 Safety net shall be fixed below the work area so that accidentally falling objects shall
be trapped in the net.

 Area on ground beneath the working area shall be cordoned and supervised by safety /
security personal

 Worker shall wear protective clothing, safety helmet, safety shoe, and safety gloves.

Hazards Of Compressed Air:

 Most workshops and factories are equipped with a comprehensive system of

compressed air connections for general use. It is not always appreciated that
compressed air, at the normal factory pressure of 5-6 bar, can cause grievous injury to
workers, whether they are actually operating the compressed air equipment, or merely
standing within a range of up to 12 m from it. General cleaning down of machines and
work surfaces, or cooling of parts, are among the common usages of compressed air in
factories.

 When blowing down the danger lies in particles of metal and sward which, propelled at
high velocity, can get into the operators eyes when cleaning out a blind hole, for
example. Or, and this is common, the particles can be blown into the eyes of a person
standing nearby, whose reflexes are not conditioned to the danger.

 There is danger in allowing compressed air to enter the blood stream through a cut or
abrasion on the skin. This has been known to happen, with fatal results, when a
workman was using compressed air equipment to clean his clothes after work: a highly
dangerous practice which must be strongly discouraged.

 Apprentices and young factory workers not made aware of the dangers, can injure
themselves severely, and injure other people, if they are allowed to indulge in horseplay
while using compressed air equipment. They must be well and fully trained in the
correct use of all such equipment.

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  There is a high and sometimes dangerous noise level from compressed air jets. This
noise may occur during a cooling or drying-off operation; generated over a long period
it can cause damage to hearing.

 Harm can also be done to machinery. When cuttings are being blown from a surface,
for example, they may become lodged in gearing or under slides and, if they remain
unnoticed, can cause damage.

 It should always be remembered that compressed air is dangerous, compressed air is

expensive, and compressed air is not a toy. Operators must be trained to recognize the
dangers en that they may work in personal safety and not endanger by standers or
machinery. Taking precautions to reduce the accident

 Safety net shall be fixed below the work area so that accidentally falling objects shall
be trapped in the net.

 Area on ground beneath the working area shall be cordoned and supervised by safety
or security personal

 Worker shall wear protective clothing, safety helmet, safety shoe, and safety gloves.

2.3 GENERAL SAFETY:

 Following Industrial safety rules should be observed at the work area

 Use of Helmet in Helmet area is necessary

 Use of Safety shoes is necessary.

 Use of loose cloths should be avoided in all working areas, uniform and dungarees should
be used.

 Use of gloves is necessary for work like grinding, scaffolding, welding, chemicals
handling etc.

 Use of safety glasses/face shield is necessary for welding, flame cutting, grinding etc.

 Use of dust filter with half mask is necessary in work area involving dust/radiation / mist.

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 Chemical filter cartridge with half mask should be used in work areas, involving
hazardous fumes, Toxic vapors like, painting, chemicals.

 CO2 filter cartridge shall be used in case smoke / fire

 Breathing apparatus must be used inside confined space.

 Use of safety belt is necessary while working at height,

 Ear muffs must be used in noising areas for ear protection, like turbine hall and Diesel
Generator Rooms.

 Welding, flame cutting, making of fire and grinding must not be allowed without
Industrial Hazard permit.

 Electrical Exit signs boards with the instruction ― Exit‖ must be available that should be
used in emergency.

 Walk-ways, stairs, openings and high rise must be protected by safety railings / lids etc.

 Many special works involving potential risk like suspended loads of crane throwing of
objects from heights etc. should be marked off to protect workers. Marked ropes /
masking tapes should be used for this purpose.

 Good housekeeping should be maintained through regular cleaning and removal of

refuse.

 Entrances / Exists, Passages and Corridors should be kept clean clear and unobstructed.

 Proper lighting should be provided in all the working areas

 Torches and emergency light should always remain available and within reach.

 Special care should be taken while passing through slippery areas caused either due to
oil spillage or water etc.

 When handling object manually, consideration should be given to the weight, nature and
shape of the object to avoid slipped disc syndrome, injury etc.

 Protective guards have been fixed around moving parts of machines, like grinding disk
and motor belts etc. to protect workers and avoid injury.

 Gas cylinders i.e. oxygen and acetylene and for welding and flame cutting should be
handled properly. Following precaution should be taken:-

34
  Should be kept in racks in upright position.

2.3.1 Safety in Working Areas:

 Good housekeeping is an essential part of every job. Work areas, walkways and
equipment shall be kept clear of loose materials, tools and scraps.

 Materials such as pipe and lumber shall be stored in an orderly and secure manner.

 Spills such as grease, water or oil shall be cleaned up as soon as possible; a delay could
result in an accident to you or a fellow worker.

 A safe access shall be maintained to work areas. Short cuts should be avoided.

 Never block fire exits with equipment or materials.

2.3.2 Safe Operation of Lifting Machinery and Tackles:

Thorough examination of Cranes and lifting
Tackle suspended from the Crane hook should be performed before operation. The parts to be
examined include Crane Wheels, Crawler tracks, load hook, chains, ropes, tackle etc. All these
parts should be in good working condition. Any defect found/observed should be immediately
reported to the in charge/Supervisor for corrective action.

2.3.3 Electric over Head Traveling Crane:

The crane should be operated only by qualified persons
authorized by the competent authority. The operator should be medically fit. He should follow
instruction for safe operation of the Crane contained in the manual provided to him. Electric
overhead Cranes should only be used for making direct lifts and should not be used for dragging
loads from bays on either side of the Crane tack, this can cause the load ropes to leave the hoist
barrel grooves. A subject matter expert should be arranged for delivering lecture on the safe
operation of Electric overhead Crane and tackles. The codes of hand signals recommended for
operation of Electric overhead areas should be used.

Crane Operator must take signals from the person responsible for the lift and must make no
movement until such a signal is given. Only signals in accordance with the relevant codes
should be used. Over loads are forbidden except for the purpose of test and the operator should
demand a weight check on any suspected load. The slinger is responsible for ensuring that the

35
load is properly sling before giving instructions to the driver. Under no circumstances must any
person be allowed to ride on the load or on the empty hook.

2.3.4 Identification of Gas cylinders:

The prerequisite of safely using cylinders is the knowledge of
distinguishing gas cylinder. There are different colours and different characters painted on the
surface of gas cylinders to identify the different kinds of medium filled in gas cylinders.

Medium Surface Character Colour Of Property

Colour Character

Hydrogen Dark Hydrogen Red Highly combustible

Green

Oxygen Azure Oxygen Black Highly combustible

Ammonia Yellow Liquid Black Poisonous,

Ammonia combustible

Chlorine Gas Liquid White Toxic

Green Chlorine

Nitrogen Black Nitrogen Yellow Inert

Acetylene White Acetylene Red Combustible

36
2.3.5 Compressed Gas cylinders Safety:

 Store, handle and transport with care

 Look for signs of danger; including leaks, corrosion, cracks or burn marks,
contaminated valves, worn hoses, broken gauges or regulators.

 Identify the gas in the cylinder before using it.

 Keep steel cap on while stored.

 Keep upright and secured with a safety chain.

 Make sure connections and regulators are in good condition.

 Point outlets away from people or sources of ignition when opening cylinder.

 Mark empty cylinders MT‖ or Empty.‖

 Store empty cylinders separate from full cylinders.

 Store oxygen and fuel gas cylinders separately.

 Rotate cylinder storage so that older stock is used first.

 Store oxygen at least 20 feet from flammables and combustibles, or separate them by a
five-foot fire-resistant barrier

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2.3.6 Electrical Safety:

One of the best ways to prevent electrical accidents at industrial sites is

to be aware of electrical dangers in the workplace. Once hazards have been identified, they
must be pointed out and proper steps taken by a qualified person.

The following, where used, will improve the safety of the workplace:

o Maintain good housekeeping and cleanliness

o Anticipate problems.

o Use properly rated test equipment and verify its condition and operation
before and after use.

o Know and practice applicable emergency procedures.

o Become qualified in cardiopulmonary resuscitation (CPR) and first aid and

maintain current certifications.

o Wear appropriate personal protective equipment (PPE).

o Refer to system drawings and perform system walk downs.

o Electrical equipment should be maintained in accordance with the

o Manufactures instructions.

o While working near electrical circuit do not wear, rings, watches, metal
jewelry, metallic hard hats etc. Wear rubber sole shoes or rubber insulated
gloves.

o Double insulated and explosion proof electrical tools should be used while
working on electric circuits and equipment.

o Do not hang clothes over electric panel and switchgear.

o Do not touch switches with wet hands, do not stand on wet floors.

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2.3.7 Fire Safety:
Fire Fighting, techniques and equipment used to extinguish fires and limit
the damage caused by them. Firefighting consists of removing one or more of the three elements
essential to combustion fuel, heat, and oxygen or of interrupting the combustion chain reaction.

Extinguishing the Fire:

Defense in Depth Concept:

There should be arrangement that

a. Fire may not occur (Fire prevention)

b. Fire may not spread, if occurred

c. To extinguish fire and minimize the damage.

Preventing Fires:
Fire prevention requires a continuous effort to keep the three conditions
of the fire triangle-fuel, oxygen, and temperature from existing in the same place at the same
time. We should also be careful about the usual initiating source of fire; some of which are
described below:
Causes of Fire:
Carelessness, ignorance and accident are main cause of fires. A good portion of fire
prevention can be achieved through detection and elimination of following ignition sources.

39
Steps to Avoid Fire:
 Good Housekeeping
 Prevent Dust Explosions
 Maintain Proper Electrical Connections
 Designated Smoking Areas
 Fire Safety Training

2.3.8 Chemical Safety:

Following safety rules are strictly enforced in chemistry laboratories or industries.

 Safety goggles or safety glasses which provide adequate protection

from chemical splashing are to be worn in laboratories Industrial
Safety (Chemicals Safety) whenever dangerous and irritating
materials such as acids are handled.

 Contact lenses provide no protection and are an additional hazard in

the laboratory. Contact lenses must not be worn in the laboratory. This
is standard practice in all chemical laboratories. If chemicals are
splashed directly into the eye, the presence of a contact lens greatly
exacerbates the problem. Even if you are not using chemicals directly
or are wearing safety goggles over the contacts, contact lenses are not
good in the laboratory. Solvent vapors can permeate the lenses and be
held in close contact to the cornea, causing long term scarring. You
should have a pair of normal prescription glasses for use in the
laboratory.

 Safety goggles or safety glasses which provide adequate protection

from chemical splashing are to be worn in addition to conventional
glasses. Conventional glasses do not provide adequate protection
against splashing.

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 Use a laboratory coat, made from cotton or cotton/polyester material.
Lab coat must be worn when handling corrosive, toxic, or flammable
materials

 Gloves should be worn when necessary especially when handling

radioactive, corrosive and highly toxic materials.

 Safety shoes must be used

 Long hair must be safely confined Hair is flammable and is to be tied

or pinned back or confined in a hair net.

 Solutions must not be pipetted by mouth rubber bulb pipette filler

should be used for all solutions.

 No food or drink is to be consumed in the laboratory.

 Smoking is not allowed in any part of chemistry laboratories area.

 Know where the following safety equipment is located and how to

use it:

o Fire extinguishers

o Fire blankets

o Safety showers

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Chapter- III

45
 RESEARCH METHODOLOGY

3.1 Scope of the Study

3.2 Statement of the problem

3.3 Objectives of the study
3.4 Method of study

46
 3.1. SCOPE OF THE STUDY

The study will be related to safety in BCCPL Captive power plant a group of Bharathi Cement
Corporation Pvt Limited, Kadapa. This study is also conducted to know what are the challenges
faced by BCCPL Captive power plant, Kadapa. Implementing security measures on electrical
safety.

3.2 STATEMENT OF PROBLEM

Safety workplace is one of the core affairs considered by Bharathi Cement Corporation Pvt
Limited that are responsible for protecting and optimizing the functionality of their Human
Resources. Safety issues have always a major problem and concern in any organizational or
industry. Organizational nature of industrial electrical accidents and empirical work has focus on
the identification of workers attitudes, work environment, management concern for Electrical
safety and conflict between productions with safety that influence accidents causation at
workplace.

3.3 OBJECTIVES OF THE STUDY

The study will be related to safety, various examples, and realistic work scenarios, the workers
Shall be able to identify and describe electrical hazards and precautions that should be taken to
Avoid injury in the workplace. The main objectives or explained below

 Prevent accidents and health problems of workers.

 Plan periodic inspection of standard physical and occupational safety facilities and plan on auditing
against the place, systems and procedures to secure employment.
 Reporting and investigating all incidents that cause injury and damage to property and plan
mitigation measures.

47
 Prepare and maintain a good working environment and to prepare equipment and secure facilities
to safety and health.
 To provide the latest information to employees and provide health and safety training adequate.
 Review and improve safety, health and the environment from time to time

3.4 METHOD OF STUDY:

o Hazard Identification and Risk

Assessment (HIRA) Incidents statistics
o Safety Audits

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 Chapter –Iv

Data analysis &

Interpretations

49
4.1 THERMAL POWER GENERATION PROCESS:
Thermal power plant is electricity
generation plant which converts the fossil fuel stored energy to electrical energy by means of
generating electricity. In other words, it is merely a chain of Energy conversion as follow:

 Chemical energy in the fuel is converted to Heat energy of steam.

 Heat energy of steam is converted to Mechanical or rotating energy of a rotating wheel
Called Turbine.
 The mechanical energy of Turbine is converted as Electrical Energy in a Generator

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The different types of systems and components used in steam power plant are as follows:
1. Coal handling plant
2. D.M. plant

3. Boiler and furnace

4. Turbine and Generator
5. Transformer and switch yard
6. Ash handling plant
7. Cable gallery
8. Fuel Storage Tank / Pump House

PROBLEM FORMULATION

The thermal power plant consist several risk and hazard in their various part of plant and its
operational processes. This may cause harm to people, property and environment. Those
hazards are for example “coal dust explosion” in the coal storage area and coal mill where fine
particles of the coal present may occur when concentration of coal dust particles are within the
explosive range. That can also occur in the plants where coal dust collectors are present due to
the failure or low efficiency of the collector system.

Another most hazardous area of the thermal power plant is boiler room which includes furnace,
boiler tank, and water & steam tubes and exists for byproduct of coal combustion operation
like fly ash, suspended ash and flue gases. The boiler room has risk of fire and explosion may
cause Due to improper ignition of fuel, lack of air supply in combustion chamber, improper
pulverized coal lack of water, over pressure & over temperature ,cracks & metal fatigue in
boiler body. The periodical inspection of the boiler is done as per “the Indian boiler act” but
due to some sudden occurrence of hazardous event it may occur.

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Flue gas the byproduct of combustion in furnace content high pollutant like SOx , NOx , CO2
and fumes of heavy metals like arsenic (Ar), Mercury (Hg), Boron (B). When they emits in
excess amount from the permissible limit can cause hazard to flora and fauna.

There are several other hazards which can be listed to analyze for reduction are electrocution,
Thermal Exposure, physical hazard, chemical exposure hazard, noise in turbine room, chronic
and acute health hazard.

Table .1 Hazards in Coal handling plant:

S. Hazard Description
No.
1. Fire in coal storage Fire can occur in the coal storage due to excess environmental temperature
in summer days. Or come in contact with external fire and explosion.
2. Coal dust explosion in Confinement of coal bunker can have coal dust level up to lower explosive
coal conveyer bunker limit of coal dust, when got ignition can cause explosion
3. Injury during coal Various obstructs in the handling pathway of workers
handling like slip and
trip
4. Respiratory problem due Very fine coal dust can cause respiratory problem
to coal dust
5. Catches on conveyer Loose clothing of worker can be catch by the moving parts
belt
6. Rail line and other Carelessness of driver or personnel can cause accidents
transport line accidents
7. Injury during Heavy rollers have to be changed time to time during which physical injury
maintenance on ball mill can occur
8. Fall from the height Fallen structure, slippery surface, avoidance of PPE, imbalance of object or
during work on foot of worker
conveyer belt, conveyer
control room etc.
9. Struck by falling object Tools, coal pieces can fall from high operational area

Table .2 Hazards in D.M. plant:

S.No. Hazard Description
1. Fire hazard Electric Motor Short Circuit / Fire in electrical panel
2. Chemical burn by Spillage of sulphuric acid and caustic soda lye during unloading,
overflow, Damage on storage tank or pipe line
3. High noise level By various pump and equipment’s vibration

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 Table 3: Hazards in Boiler and furnace:
S.No. Hazard Description
1. Explosion in boiler due to over pressure and temperature caused faulty gauge, inoperable trip
System, due to improper combustion of fuel.
3. Burn injury due to hot water and hot steam pipeline leakage, Exposure to the hot surface
of pipeline or machineries, by hot fly ash
4. Water tube burst due to Failure in boiler water level control
5. Fire in diesel supply line Due to leakage, overpressure rapture of pipe
6. Physical injury Catches on the moving part of the machinery like F.D. fans or motors
7. Equipment damage rupture of the equipment body due to over pressure and over temperature
8. Sleep , trip and from the during routine work, maintenance or inspection, Fallen structure, slippery
height surface, avoidance of PPE, imbalance of object or foot of worker

Table 4: Hazards in Turbine and Generator:

S.No. Hazard Description
1. Equipment damage Damage on generator due to lack of lubrication in coupling shaft, Damage
on generator due to lack of lubrication in coupling shaft
2. Fire / explosion on cooling oil, on hydrogen tank, Explosion in turbine due to cooling system
failure, Explosion in turbine due to cooling system failure, Fire on cooling
oil, Fire and explosion on hydrogen tank
3. High noise level Due to operation and vibration of equipment
S.No. Hazard Description
1. Equipment damage Damage on generator due to lack of lubrication in coupling shaft, Damage
on generator due to lack of lubrication in coupling shaft
2. Fire / explosion on cooling oil, on hydrogen tank, Explosion in turbine due to cooling system
failure, Explosion in turbine due to cooling system failure, Fire on cooling
oil, Fire and explosion on hydrogen tank
3. High noise level Due to operation and vibration of equipment

Table 5: Hazards in Transformer and switch yard:

S.No. Hazard Description
1. Fire on transformer Explosion of transformer / Pneumatic actuator cylinders installed
nearby, Transformer oil may splash up to long distance if transformer gets
Exploded due to fire.
2. Electric shock and routine work, maintenance or inspection of electrical panels in switch yard
electric burn
3. Slip , trip and from the during routine work, maintenance on switch yard
height

Table 6: Hazards in Ash handling

plant:
S.No. Hazard Description
1. Fire hazard fire risk due to electrical short circuit or failure, overheating, ignition in
accumulated coal dust

Table 7: Hazards in Cable gallery:

S.No. Hazard Description
1. Cable room fire hazard fire risk due to electrical short circuit or failure, over heating of cables,

Table 8: Hazards in Fuel Storage Tank / Pump

House/Battery:
S.No. Hazard Description
1. Fire hazard Spillage or drain is risky because it may result in to back fire and consequent
Damage to plant.

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 Table 9: Hazards in Hydrogen
plant:
S.No. Hazard Description
1. Fire or explosion hazard hydrogen is highly explosive any leakage of Hydrogen in turbo generator
area or Hydrogen plant area may lead to explosion /Fire
2. Electrocution Electrodes used in generation panel can cause electric shock

Frequency range of event can be established using a format that includes time between the
occurrences, a qualitative description of these frequency range and categories or level of
likelihood. A likelihood category chosen for the risk assessment to provide a frequency range
to work when for example a likelihood category in table relates a frequency range and
midpoint.

Establishing event consequences category Ranges

The consequences relate the potential expected damage to property, people’s life safety etc.
The following table’s gives the consequence rage related to the qualitative losses data first
on the base of life safety consequences and other property damage consequences.

Table 11: Life Safety Consequences Categories

Consequences General Description
Level
1-Low First aid
2-Moderate Single person injury required hospital treatment
3-Heavy Multiple person injury required hospital treatment
4-High Life threatening injury or death On site
5-Very High Life threatening injury or death Off site

The table give for selecting likelihood tolerance:

Table 12: Property damage categories

Consequence Level Damage Factor Range General Definition
(%)
1-Slight 0-1 Limited localized minor damage not requiring repair
2-Light 1-10 Significant localized damage of some components
Not requiring major repair
3-Moderate 1-25 Significant localized damage of some components
Warranting repairs
4-Heavy 25-60 Extensive Process equipment damage requiring major
repairs
5-Major 60-100 Major wide spread damage that may result in facility
major structural damage and the release of contaminated
combustion products OFF SITE

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Risk rating

Risk initiating event likelihood and consequences are assumed by taken reference of visited plant
real activities.
Risk Classification screening table is given below.

Table 14: Risk Classification Screening Table

Unmitigated
Consequences

S. N Hazard Initiating Risk

Event
Description Class
Likelihood Life Property
Safety Damage

1 Coal Handling Plant Hazard

Fall fromthe height during work on

i conveyer belt, conveyer control room 3 4 - C
etc
Fire in coal storage
ii 2 1 2 B
Coal dust explosion in coal conveyer
iii 1 3 4 B
bunker
Respiratory problem due to coal dust
iv 3 3 - B
Catches on conveyer belt
v 2 2 2 B
Injury during maintenance on ball mill
vi 3 3 1 B
Injury during coal handling like slip
vii 4 1 - A
and trip
Rail line and other transport line
viii 4 2 1 A
accidents
Struck by falling object
ix 4 2 1 A

2 D.M. Plant Hazard

Fire hazard
i 2 3 3 B
Chemical burn by Spillage of sulphuric
acid and caustic soda lye during
ii 4 3 2 A
unloading, overflow, Damage on
storage tank or pipe line
High noise level
iii 1 3 - A
Boiler
3. Hazard

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 Explosion in boiler due to over pressure
i 1 4 4 C
and temperature
Explosion in boiler due to improper
ii 1 4 4 C
Combustion of
fuel.
Water tube burst due to Failure in boiler
iii 2 - 4 C
water level control
Burn injury due to hot water and hot
iv 3 3 3 B
steam pipeline leakage
Fire in diesel supply line
v 3 3 3 B
Sleep , trip and from the height during
vi routine work, maintenance or 4 4 2 B
inspection
Burn injury by hot fly ash
vii 4 1 - A
Catches on the moving part of the
viii 3 2 1 A
machinery like F.D. fans or motors
Burst of the equipment body due to
ix 3 1 4 A
over pressure and over temperature
Exposure to the hot surface of pipeline
X 3 1 - A
or machineries.
4. Turbine hazard
Fire and explosion on hydrogen tank
I 2 5 4 D
Explosion in turbine due to cooling
ii 1 4 5 C
system failure
Explosion in turbine due to cooling
iii 1 4 5 C
system failure
Fire on cooling oil 3 3 3 B
iv
High noise level 1 3 - B
V
Switch Yard Hazard
5.
Fire on transformer 3 - 4 C
i
Electric shock and electric burn routine 5 4 1 B
ii work, maintenance or inspection of
electrical panels in switch yard
Slip , trip and from the height during 4 4 1 B
iii routine work, maintenance on switch
yard
Other Hazard
6.
Fire on ammonia storage tank 2 4 4 C
I

56
 Fire hazard on fuel storage tank 2 4 4 C
ii
Control room fire hazard 2 1 3 A
iii
Eye irritation and respiratory problem 4 1 - A
iv from the exposure of ammonia leakage
from storage tank or pipeline

Hazard identification and risk analysis was carried out for a thermal power plant and the
hazards were identified and risk analysis was carried out. The different activities were divided
in to high, medium and low depending upon their consequences and likelihood. The high risks
activities have been rated ‘C’ or ‘D’ are un-acceptance and must be reduced. The risks which
are rated ‘B’ are tolerable but efforts must be made to reduce risk without expenditure that is
grossly disproportionate to the benefit gained. The risks which are rated ‘A’ have the risk level
so low that it is not required for taking actions to reduce its magnitude any further. The risk
rating calculations were carried out by a qualitative method as mentioned in the table
respectively.

57
Chapter –v

5.1 Finding
5.2 Recommendation
5.3 Conclusion

58
5.1 FINDINGS:

In the BCCPL Captive power plant area, though the work place there is a safety system
is following but still there is unsafe conditions & unsafe actions are performed by the
workers in their preventive maintenance, corrective maintenance and modification
works.

o Lock out tag out system not effectively followed while doing maintenance

o In coal handling plant coal spillage on road leads to slips

o MSD’s procedures are not following In water treatment plant

o In condensate drain pump area there is no work place monitoring system

o First aid boxes maintenance is poor

o Workers and employees involvement is poor in identification of near

Misses, unsafe actions & conditions

o Illumination levels are poor at Air cooled Condenser area.

o There are no Caution boards in Boiler as per boiler act.

o PPE compliance is not effective

o Co2 gas cylinders unloading is unsafe

o First aid procedure charts are not prepared

o Firefighting methods knowledge is poor for workers and employees

o Tool box Talks not following properly before going work.

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5.2 Recommendations

The study highlights the effect of safety in thermal power plant. As a

recommendation, BCCPL Captive power plant can develop tools that department of
safety can use to motivate high performance and prevent workers from appealing in
other behavior ‟s that block from organizational effectiveness.

Issues Identified Recommendations

Low response on • Communications with Managers needs to be
communication improved
• Employees should be encouraged to get involved in
matters related to safety
• Safety Committees headed by Project Managers
should be formed and frequently meet to discuss
matters related to safety
• Awareness must be created among all employees
about the functioning of Safety Committee and
encourage them to report on any safety related issues
• Effective induction training programs should be
Conducted for the new recruits.
Working under unsafe • Hazard Identification and Risk Assessments (HIRA)
conditions Should be conducted for all work sites.
• Measures should be taken to eradicate hazards in
Work sites.
• Safe work procedures should be established for all
Workers.
• Work procedures should be reviewed periodically
• Regular toolbox meetings should be conducted and
relevant safety issues should be discussed and ensure
that workers are aware of the dangers and take
Precautionary measures to avoid them.
• Warning signs should be erected at appropriate
locations
Working without PPE • Awareness on the importance of PPE should be

60
 emphasized
• Site Supervisors should emphasize that all the
workers are equipped with PPE and wear them while
On duty.
Unsafe Heavy • Strict measures should be taken to deploy trained
Machinery Operation Flagmen to guide heavy machinery operators.

• Machinery should be equipped with audible reverse

Horns.
• Heavy machinery operating area should be properly
demarcated with warning sign boards and measures
should be taken to prevent workers and public
Entering in to the work zone.
Incapacity of Safety • Well qualified experienced Safety Officers should be
Officers employed
• Appropriate training on safety management should
be provided for the Safety Officers to strengthen their
capacities
• Safety Officers should develop their capacities to
identify hazards and conduct appropriate tool box
meetings and ensure that safe work zones are
Provided for workers before deploying them.
Management • Managers must pay more attention to health and
commitment Safety management issues within his command area.
• Safety must be given a high priority in worksites
• Managers must get involved in all matters relevant to
Safety.
Safety Violations • Random visits to work sites should be conducted to
identify the shortcomings and measures should be
Taken to rectify them.
• Officials from the Labor Department should visit
the construction sites randomly to check the
Compliance.

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5.3 Conclusion

By taking the study on “Safety in Thermal power plants” at Bharathi Cement Corporation Pvt
Limited”

as Project work we are able to achieve the following results.

Identified the high hazardous areas and formed a team /

External service for improvements.
Minimized risk levels by Engineering control measures
which is the best always.
Extended the usage of PPEs for all the employees exposed on hazardous areas.

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62
Ensured the employees to get continuous safety training after
analyzing the risks.
Ensured the human comfort / health safety by organizing
periodical medical examinations.

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