A Presentation on

NPGC
Safety initiatives
and Compliances in achieving
“Accident Free Environment”
Fatal Injuries, Reportable Accidents and Near Miss Accidents (during Award Year-2017),
Root Cause Analysis and steps taken to prevent recurrence.
 Fatal injuries : Nil
 Reportable accident : Nil
 Near Miss : 02
Nearmiss Incident #1 : Leakage of residual ammonia in Unit#1 Boiler Area

Root Cause: Cutting of dummy pipe without evaluation of risk.

Steps taken :
1. Immediate Evacuation of the workforce from the vicinity.
2. MSDS dispaly in local language & availability of Gas masks with acrtridges in the vicinity.

Nearmiss Incident #2 : Steam burn

Improper routing of steam discharge
• Steps taken:
1. Routing of steam dicharge to unmanned area
2. Proper cordoning of steam discharge area.
3. Additional siren been provided in boiler area which shall be blown before the start of steam
blowing.
 Potential Emergency Situations
The following potential major emergencies have been identified at site:

 Fire hazard at electrical substation & Control room, DG Set, Welding machines,Cable
joints, short circuit, etc.
 Collapse of structure, cranes (e.g. Tower crane)
 Fall from height with severe consequence while construction/erection works.
 Personnel Electrocution / electrical Hazards.
 Men being trapped under soil/in the confined Space.
 Explosion involving storage of material, flammable materials of gas cylinder or Oil/Diesel
storage etc
 Fire or Explosion
 Collision between moving vehicles / toppling
 Chemicals / gas leakage
Potential
Response Emergency Response Procedure Coordination
Procedure.
Onsite Emergency Co-ordinator

On site Emergency controller Onsite Emergency Advisor Team

Administration &
Tech Support Team
Legal support Team

Fire Figting team Rescue Team

Medical Team Site Engineer Site Engineer Recovery operation & Continuity
Safety Stewards Safety Stewards
 Specific initiatives & mesures in the area of safety
NPGC is giving thrust towards “Accident free environment” by driving the following measures to
improve safety system & culture in work area :
1. Class room Training: ( In induction Training center)
Training through Safety Training Kiosk thru different activity specific modules of Training with Audio Visual support
2. Onsite Training:
 Peptalks & Monthly mega peptalks
 Toolbox talk
 Counselling
3. Mock Drill: Periodic drills to gauge the response of emergency response teams and the corrective actions required to improve on.
4. Safety Park: Realistic models of all safety sytems in different types of activity in plant area displayed to make workers aware of the
different area specific risks involved and Safety measures required as:
 set up for vertigo test
 Mannequine with full PPE dressing
 Different types of Scaffolds
 Fire fighting System
 Gas cutting system
 Confined space
 Play of safety song through PA system
 Regular medical checkup camp
5.safety awareness drive
 National safety day,Fire service week,NPGC Safety Month,Road safety week,Safety literature distribution, circulars, Manuals,
publications if any during the year , whatsapp groups,
1. Recognition of best worker ,agency & Project manager in the aspects of safety complainces
2. Division of Plant into 20 safety zones and each zone safety activities are driven by specific EIC supported by a committe.
 Fire figting system implemented and proposed for future
 Safety team is handling the Fire system in addition to regular safety acitivity.
 Total 03 no of fire tenders are available & opearting round the clock.
 Fire Extinguishers deployment details as follows

Contingency fire extinguishers deployed at follows :

S.No 9LTR 9LTR 4.5Kg 6.0Kg 50LTR 22.5Kg 50.0Kg
water Foam CO2 DCP Foam CO2 DCP

1 200 90 175 150 10 50 30

Totol no of fire extinguisher:705 have been deployed as per the risk analysis schedule.

In addition to the above, an IGS & Foam deluge supported integrated fire fighting system is under the
process of commissiong and expected to be opearational by the end of Dec'2017.
 Status of Safety Audit: By corporate safety Team
S.No Observation Location Status
1. Painting of storage acid storage tanks and structures need to be DM Plant Complied
done to prevent corrosion of tank and structures.

2. Identification board to be displayed in the storage shed for various DM Plant Complied
cylinders.

Welding receptacle to be provided for all welding machine CHP Area

3. connection in track hopper. Complied

4. Water logging prevailing along track hopper needs to be Wagon Tripler Complied
removed.

5. Illumination level in wagon tippler area needs to be improved. Wagon Tripler Complied

6. Temporary lighting arrangement done in the area to be removed Wagon Tripler Complied

7. Installation of water system at Fuel oil area FOPH Complied

8. Test date marking of winch system Boiler#2 Complied

9. Effective earthing at welding booth Boiler#1 Complied
10. Removal of extended material Boiler#1 Complied
11. Toe guard Boiler#1 25 Complied
12. Placing of fire extinguisher Boiler#1 Firing floor Complied
13. Closing of opening TG#1 Complied
14. Joining of earthing of welding booth to earth grid TG#1 Complied

15. Marking of Fire point TG#1 17M Complied

16. Removal of extended material TG#1 17M Complied
17. Rubber mat at MCC room TG#1 6.5M Complied
18. Proper earthing of DB TG#1 unloading bay Complied
19. Eye shower near battery room Switchyard Complied
20. Rubber mate switchyard Complied
21. Cover of trench switchyard
22. Removal of scrapes switchyard Complied
23. Handrail Cooling tower Complied
24. Approach Boiler#2 Complied
25. Sandblasting Fabrication yard Complied
26. Loose connection TG1 unloading bay Complied
 Status of external safety audit

S.No Observation Location Status

1. One more no eye shower DM Plant Complied

2. Display of MSDC in local language DM Plant Complied

3. Approach DM Plant Complied

4. Removal of extended material TG#1 17M Complied

5. Lighting TG#1 8.5M Complied

6. Opening TG#1 8.5M Complied

7. House keeping Boiler#1 0M Complied

8. Lighting Boiler #1 20m Left side Complied

9. Barricading Wagon Tripler Complied

10. Improvement of slope Wagon Tripler Complied

Specific communication mesures in the area of safety
SAFETY MEETING

S.No. Forum Frequency of meeting Chaired by

1 Weekly Safety Communication Every Week AGM

Meeting (Safety)

2 Project Safety Review Meeting Monthly CEO

(NPGC)

3 Safety Cross Functional Audit Bi-Monthly CEO

(NPGC)
Beside these, safety issues are being discussed after daily site visits by safety supervisors on
the compliance of previous day observations.
Specific mesures in the area of safety

 SAFETY ALERT CARD(SAC): All the safety obsevation routed to corresponding EIC
through SAC. SAC card covers the various aspects as :

 PPE's
 Movement at height
 Climbing at height
 Barricading the unsafe area
 Working platform
 Vehicle movement
 Material transportation
 Other if any
STATUS OF “SAFETY ZONES” AND “SAFETY PARK”

 Safety zones have been declared and each areas are

are accountable to specific executivies.
 These areas have been declared as safe zone
 Total 18 no. of zonea are safe.
BEST SAFETY PRACTICES

 ROAD SAFETY MARSHAL

 Seven no. of traffic contoller deputed for road safety in the plant premises
 Two wheelers vehicular movement totally restricted

 MATERIAL MOVEMENT
 Zero material movement by hydra

 HANDLING OF FIRE SYSTEM