Suraksha Jagriti.pptx

Vision : To be a World Class Integrated Aluminium & Power Producer Generating Sustainable Value for All Stakeholders
Care
Respect
Innovation
Excellence
Integrity
Trust
Entreprene
urship
CORE
VALUES
Suraksha Jagriti
HSE Training Module

Vedanta Limited, Aluminium - BALCO | 1
Content
 Aim of BALCO
 Basic Safety and definition
 Safety Rules of BALCO
 Basic Fire Safety

Care
Respect
Innovation
Excellence
Integrity
Trust
Entreprene
urship
CORE
VALUES
AIM

HSE VISION and Strategy -
“Zero Harm to People and Planet”
Zero Harm -
ZERO Fatality
ZERO LTI
ZERO Occupational Diseases
Zero Waste / Zero Discharge
Reduce /optimize resource consumption
Recycle/ Re-use ; Wastes to the extent possible.
HSE MISSION
“To achieve zero harm to people and planet by leveraging our core competencies, technical strengths,
leadership, innovation, benchmarking best practices and involving stakeholders”.
HSE Vision & Mission

Care
Respect
Innovation
Excellence
Integrity
Trust
Entreprene
urship
CORE
VALUES
Basic Safety

Definition- Safety, Health and Environment
Safety can be defined to be the control of recognized hazards to
achieve an acceptable level of risk.
Health- As defined by World Health Organization (WHO), it is a "State
of complete physical, mental, and social well being, and not merely
the absence of disease.
Environment- the surroundings or conditions in which a person,
animal, or plant lives.

Risk: Combination of the likelihood of an occurrence of a hazardous
event and the severity of injury
The likelihood is the chance that the hazardous event will occur.
The Severity is extent of loss of property/health Or environment.
What is Risk?

Incident: According to OSHA Incident is an unplanned, undesired event
that adversely affects completion of a task.
Incident - A brick fall from the building
Situation 1 - After that brick hit over the worker head and got injured
(Accident)
Situation 2 - if that brick fell down on floor 1 feet away from the
worker ( Near Miss- Critical and Non critical)
What is Incident?

Accident & Near Miss
Accident: refer to an sudden unplanned, unwanted event which
leads to injury, damage or loss.
Near Miss: An incident, which did not result in bodily harm or
property damage, but had a high potential to become an accident
under slightly different circumstances.
Incident can be accident or near miss.

Accident & Near Miss

HIPO
High Potential Events are defined to be any incident or near miss that
could, in other circumstances, have realistically resulted in one or
more fatalities.

UNSAFE CONDITION-10%
UNSAFE ACT -88%
OTHERS(Unavoidable) -2%
Accident Data

Unsafe Act
Unsafe act is the violation commonly accepted safe work practices.
breaking of safety rules.
Example
1. Smoking in flammable area
2. over speed rash driving
3. Tampering with safety device
4. Not using PPE
5. Unauthorized working

The unsafe condition is one in which the tools, work environment and
machine is in full of hazards leading to accidents .
Example
1. Oily floor
2. unguarded floor opening
3. staircase, work platform without hand rail
4. Unguarded machinery
Unsafe Condition

Identified the Hazards

General Classification of Incidents

No. of Lost Time Injury X 1000000
Man hour worked ( Reporting date)
Man hour worked= Average entry of employees X 8 X ( Month days)
LTIFR =
No. of Injury (MTI, LTI & FATAL) X 1000000
Man hour worked ( Reporting date)
Man hour worked= Average entry of employees X 8 X ( Month days)
TRIFR =
Calculation of LTIFR & TRIFR

5 steps of Risk assessment
Step 1: Identify the hazards
Step 2: Decide who might be harmed and how
Step 3: Evaluate the risks using Severity and probability with the existing
control measures and decide on precautions for further control of risk
Step 4: Record your findings in Risk register and implement them in the
company
Step 5: Review your risk assessment and update if necessary

Most Effective
Least Effective
Hierarchy of Hazard Control
Elimination
Substitution
Engineering Control/
Isolation
Administrative
Control
PPEs
• Redesign the task to eliminate the hazard.
• Replace materials, equipment or processes with
less hazardous ones.
• Provide mechanical aids, barriers, guarding, LOTO
etc to isolate the hazard.
• Use caution, signage, training and procedures to
inform people how to avoid the hazard.
• Use Personal protective equipment to avoid
impact with hazard.

COST OF AN ACCIDENT
TO THE VICTIM
pain
Worry
no recreation
loss of wages
loss of life
medical expenses
inability to perform normal work
TO THE MANAGEMENT
Direct cost
medical expenses
compensation to the worker
time lost by employees
reduction in productivity
TO THE MANAGEMENT
Indirect cost
 production delay
 loss of morale
 cost of training another
employee
 repair cost
 loss of prestige

COST OF AN ACCIDENT

Care
Respect
Innovation
Excellence
Integrity
Trust
Entreprene
urship
CORE
VALUES
BALCO Safety Rules

Cardinal Rules

Zero Tolerance Rules

Road Safety Instructions

Vedanta Safety Standards (VSS)
Work At Height
Isolation
Vehicle & Driving
Electrical
Confined Space
Ground Control
Crane & Lifting
Machine Guarding
Molten Material
Pit, Stockpile & Waste Dump Stability
Rail Safety
Civil Excavation

Work At Height :-Determined as working at 1.8 meters height or
more; and applies to an area where it is possible for a person to fall
1.8 meters or more from one level to another.
Isolation:-
1. Prepare for isolation
2. De-energize the plant or machine;
3. Isolate all energy sources;
4. Drain or block and, where appropriate, bleed residual energy to
achieve a zero energy state;
5. Secure each isolation device, generally with locks & suitable tags;
6. Verify zero energy;
7. Perform the task or activity;
8. Inspect & restore normalcy -inspect the work area and remove
isolation after job completion;
9. Startup -ensure the safety of all.

Vehicle & Driving:-

Electrical:-
This standard applies to all electrical work above 110 volts DC or 50 volts AC.
Confined Space:-
Confined space is an enclosed or partially enclosed space that:
Is large enough for a person to enter; and may have limited or restricted means
of entry or exit; or Is not designated as a place of work; or Has been identified as
such in a risk assessment; and may:
•Have an atmosphere which contains potentially harmful levels of toxic or
explosive atmospheres
•Not have a safe level of oxygen e.g. following a nitrogen purge; (Must have to
be in between 19.5% - 23.5% .)
•Cause entrapment or engulfment.

Any person designing or approving a lifting plan must be trained and certified as
competent through a Vedanta- approved approach or a National certification system .
The selected crane must have valid visual inspection; NDT inspection for all load
bearing parts; a load test certificate signed by a competent authority of the respective
state government/regulator.
Cranes with a safe working load beyond 15T shall be fitted with rated load indicator.
No lifting is permitted above 90% of the maximum rated load in the specific lifting
configuration.
Each lift is to be categorized as a Routine or Critical Lift, Activities at night or during
inclement weather are Critical Lifts and require that emergency response personal are
available at all times during the lifts.
Crane & Lifting

A dry run should be conducted prior to the lift.
Hand signals or two-way radio (not mobile phone)shall be used for communication
during crane operations.
Overhead travelling cranes must be fitted with audible travel alarms or an equivalent
warning device.
Tag lines must be attached on both the side of loads which require steadying or
guidance while suspended.
A register of cranes and lifting equipment must be established that records all
maintenance history which will begin once the crane has mobilized on site. These
records are to be maintained by the business
All sensors/load cell of the crane should have valid calibration, certified by OEM or
authorized representative.
All documentation including recorded crane data is to be preserved
Crane & Lifting

Equipment guarding should be designed and installed by the equipment OEM, noting
that such guarding must be in accordance with GN18 – Machine Guarding. Where
guarding is designed by other agencies or by Vedanta personnel, those persons must be
certified as competent by respective business.
Ensure that all dangerous parts and nip points are guarded so that no one can be
injured by the machine during operation.
Implement a robust interlock protection system on all machine guarding wherever
practicable to ensure the machinery will stop if the guarding is removed or tampered
with.
Machine Guarding

Revoke the Isolation and Permit to work only after completion of the job.
Fixed guards must be installed such that guard removal/ opening is impossible without
using tools, either by permanent means (e.g. welding) or by means of fasteners (bolts
etc.).
Ensure systems and equipment are in place that provide positive feedback for the safe
start-up of conveyors, such as audio warning, radio communication, CCTV and visual
display for the operator.
Ensure adequate illumination during machinery inspection, maintenance, cleaning and
operation.
Before starting equipment, physically inspect to ensure:- Nobody is working on the
equipment; Access platforms are clear; Guards are fitted and tightly secured; and PTW
and isolation are surrendered.
Machine guarding inspection must be part of the Preventive Maintenance schedule of
equipment.
Machine Guarding

All personnel working in the railroad environment have general awareness training on
“Line of Fire” risks associated with moving trains or wagons; pinching between wagons;
or caught under wheels of locos or wagons.
All personnel working in a rail yard, on tracks and in rail activities wear appropriate PPE
and clothing with 360⁰ retro-reflective 50 mm strips on chest, back, arms and legs.
The authorized person to ensure that; each operation has completed a hazard
identification and risk assessment to ensure that all hazards associated with rail
operations are identified, risks are assessed, and appropriate controls are in place.
Rail Safety

Each rail crew has one person designated to give radio instructions to the loco driver.
No person shall mount or dismount a moving loco or wagon.
Adequate supervisors are visible in the field for monitoring work activities.
Use two-way radios to communicate with loco driver, avoid mobile phone during critical
loco movements.
A loco and track maintenance plan is in place and updated weekly to eliminate
derailments.
All locos and wagons parked on a slope have four skids available under the wheels of
the wagon next to the loco to prevent rolling.
Rail Safety

The term excavation can include trench, pothole, earthwork, trenching, wall shafts,
tunnelling, retaining walls, pit excavation that are used in the following applications:
exploration, environmental restoration, mining, formwork foundation and construction.
The SOP shall be revised every two years, or as required by an accident investigation
CAPA.
No excavation shall be allowed to be 1.5 meters or deeper unless the walls are sloped
back at a minimum of 450 in type one & two soil. In type three and four soil, slopping
shall be designed by a competent person.
All excavations must have a minimum two means of access. The project shall determine
the number of additional access as required by the risk assessment based on the
number of workers & size of excavation pit.
Excavation Safety

Excavation must be keep dry and free of water and debris at all times.
The workers in the area shall keep site tidy and free from trip hazards and loose
materials, which may lead to an accident.
Excavation permits are required for all excavation activities. If excavation meets the
definition of a confined space, them a confined space permit applies.
Hard barricading for excavation area to restrict access.
Daily inspections or after a heavy rain is done on the excavation
Excavation Safety

Care
Respect
Innovation
Excellence
Integrity
Trust
Entreprene
urship
CORE
VALUES
Basic Fire Safety

Three Elements of Combustion (Fire Triangle)
All required for a fire to occur.
Trend is to include “Chemical Reaction” as fourth element (Fire
Tetrahedron).
Causes Of Fire
• Electrical faults
• Overloaded electrical circuits
• Smoking
• Heating equipment
• Unsafe storage of materials
• Use of flammable materials hot work
• Friction / sparks
• Spontaneous Ignition
◦ Method of Extinguishment
• Reduction of heat (Cooling)
• Reduction of Air – Oxygen (Blanketing / Smothering)
• Removal of Fuel (Starvation)
• Inhibited of Flame (Breaking Chain Reaction)
Elements & Causes of Fire
TEMPERATURE
F
U
E
L

Classification of Fire
Class A - Wood, paper, cloth, carpets, trash, plastics
Solid combustible materials that are not metals. (Class A fires generally leave an Ash.)
Class B - Flammable liquids: gasoline, oil, petrol, diesel, grease, acetone
Any non-metal in a liquid state, on fire. This classification also includes flammable gases. (Class B
fires generally involve materials that Boil or Bubble.)
Class C – Flammable Gases: Methane, Propane
your Domestic LPG Gas cylinders, it would be considered a class C fire.
Class D - Metals: potassium, sodium, aluminum, magnesium
Unless you work in a laboratory or in an industry that uses these materials, it is unlikely you'll have to
deal with a Class D fire.
Class E – Electrical Started Fire.
Electrical—energized electrical equipment. As long as it’s “plugged in.”

Consequence Management Framework
 Commitment by governing bodies, management, resource allocation etc.
 Implementation of the program, including a clear outline of key
responsibilities and roles, training needs and behaviors/actions required.
 Monitoring and Measuring the performance of the program and
demonstrating this performance through documentation and practice.
 Continual Improvement of the program through regular assessments and
reviews.

Thank
You!
Bharat Aluminium Company Limited
Korba, Chhattisgarh
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