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Aluminium Business 1 Towards Zero harm to People & Environment

Power plant Safety and Safety best

practices at Vedanta Ltd

By

K N V Kiran Kumar Head -HSE & Sustainability

Vedanta Ltd,Jharsuguda

Aluminium Business 2 Towards Zero harm to People & Environment 2

Geographical footprint of Vedanta

82000

workforce

REVENUE $12.9bn

4m beneficiaries of our community investment

Aluminium Business Towards Zero harm to People & Environment 3

VEDANTA LIMITED, JHARSUGUDA @ GLIMPSE

0.5 mTPA Aluminium Smelter-I 1215 MW Captive Power Plant

1.1 mTPA Aluminium Smelter-II 2400 MW Independent Power Plant


OUR SUSTAINABILITY FRAMEWORK


VEDANTA SUSTAINABILITY FRAMEWORK

Adding and Sharing Values

Responsible Stewardship Building

Strong Relationship

Management Standards

Policies › HSE Policy › Biodiversity Policy › Water Management Policy › Energy and Carbon Management Policy Technical Standards › Health Management › Safety Management › Environmental Management › Conducting ESIA to International Standards includes EMPS › Waste Management › Biodiversity Management (EMPs) › Water Management › Energy and Carbon Management › Land and Resettlement Management › Security Management › Emergency and Crisis Management › Transport and Logistics Management

Policies › Supplier and Contractor Management Policy › Human Rights Policy Technical Standards › Cultural Heritage › Supplier and Contractor management › Employee Consultation & participation › Stakeholder Engagement › Social investment management › Grievance Mechanisms › Indigenous Peoples / Vulnerable Tribal Groups

Policies › HIV/Aids Policy Technical Standards › HIV/Aids Management › Site Closure

Global Management Processes › New Projects, Planning Processes & Site Closure › Stakeholder Materiality and Risk Management › Performance Monitoring, Data Management and reporting › Incident Reporting and Investigation › Management of Change › Documentation & Records Management › Corrective and Preventive Action Management › Auditing and Assurance › Acquisitions, Divestment and Joint Venture Due Diligence

Policy Management Standard › Compliance and Other Requirements › Leadership, Responsibility and Resources › Objectives, Targets and Performance Improvement › Competency, Training and Awareness › Management Review and Continual Improvement


The Safety Journey

Aluminium Business Towards Zero harm to People & Environment 8 Aluminium Business 8 Towards Zero harm to People & Environment

Transaction #2 Safety interactions

• Confirm task planning • Confirm controls implemented

(submit & monitor)

TYPE I Task Based

(Making Good Decisions)

Employee pre-task hazard assessment

• Identify hazards • Implement controls (formal but not submitted)

Transaction #1

TYPE II System Based

(Following Rules)

Six Safety Performance Standards • Work at Height • Confined Space • Isolation • Electrical • Vehicles & Driving • Ground Control

TYPE III Catastrophic

(Understanding Risks)

Formal risk assessment (SQRA)

Bow Tie analysis

Critical Control Management

Two transactions Led by Front Line Supervisor

Report

Investigate

1.Eliminate fatalities 2.Zero Harm culture 3.Understand risks 4.Control effectiveness 5.Develop capability 6.Develop metrics

“Three Types of Risk”


Mandatory Pre-medical , Safety Induction Training & Competency

Assessment to be done for issue of Gate Pass


INDUCTION TRAINING – AUDIO VISUAL

Training on Isolation Training on Height Work

Isolation - oriya.mp4

Isolation - oriya.mp4

working at heights - oriya v2 - vo fixed.mp4


➢ Daily Tool Box Talk before Start of Job.

➢ Job specific trainings

➢ SOP/SMP/SWP/HIRADec training and ensuring

through Pre-Test and Post-Test.

Site Trainings


CARDINAL RULES


SAP Online Permit System

➢ Authorised Receiver,Issuers,Isolation

Authority, Gas tester etc.

➢ One Day Advance Planning of Permits

with Proper Risk Assessment

➢ Trainer Contractor Supervisors

/Engineers on SAP EHS

Key Features :

Eg. Hot work permit

STRINGENT WORK PERMIT WITH AUTHORISATION


CRITICAL TASK ANALYSIS & RISK ASSESSMENT.

➢ HIRA,SOP & SMP for All Routine Activities

Non routine Activities :

➢ Preparation of Risk Assessment (HIRA )

➢ Method Statement

➢ Job Safety Analysis or SWP.

Training on SOPs and SMPs

Safe Work Procedure


Drives

Injury analysis and Interventions

Process Safety Management

Fleet management

Felt leadership programme

Visual impact

Critical drives

Six Safety Performance Standards


➢ Welding Machine .

➢ Grinding machine .

➢ Gas cutting Set.

➢ Hydra, Crane,

➢ Vehicles ( LMV,HMV )

➢ Lifting Tools ,Tackles

➢ Flammable & Hazardous Materials

➢ Certification of Items.

Welding Machine Checklist Hydra Machine Checklist

INSPECTION OF TOOLS & MACHINERIES BEFORE ENTRY


CRITICAL ITEMS REVIEW.

Machine Guarding

Conveyor Guarding

Ladders & working platforms

Welding Machines

Lifting tools & Tackles

Gas Cylinders & Pressure vessel

Mobile Machineries Hydra ,Forklift,JCB,etc.


➢ SustainabilityGuidelines are being followed for all New Projectrs

➢ Management of change is being practiced for any modifications with respect to,

➢ Plant & equipment,

➢ Procedures and practices,

➢ Raw materials,

➢ Processing conditions,

➢ Staffing including contractor change

➢ Training related to changes given to target group

➢ MOC compliance is being tracked monthly by coordinators

New Projects

NEW PROJECTS & MANAGEMENT OF CHANGE (MOC)


PSSR

PSSR is applicable on following areas for Process Safety ➢ Annual Overhauling of boiler ➢ All new projects / new constructions / major

modification against MOC ➢ Hazardous chemical operations, ex: LDO, HCL &

H2SO4 unloading ➢ Operation of critical equipment with an idle

condition >90 days


➢ Safety Committee Meetings in all SBU’s

➢ Online NM /UA/UC reporting

➢ BBS schedule follow up

➢ CASHe Projects

➢ Housekeeping drives

➢ Incident Investigation

Incident Investigation Format

➢ 100% Investigation for all types of Incidents

➢ FAI-First Aid Injury

➢ MTI- Medical Treatment Injury

➢ LTI-Lost Time Injury

➢ Near Miss Incident

➢ Fatality

➢ Why-Why analysis in accident investigation is being followed

to find out the root cause

➢ Cost of accident captured for all accidents

➢ CAPA prepared and follow up for 100% compliance

➢ Circulation of Safety Alert on every accident for horizontal

deployment

Incident Investigation Before After

CASH-e Project

EMPLOYEE PARTICIPATION

Spray system above conveyor to reduce dust


➢ Formulation & Implementation of Road Safety

Policy. ➢ Monitoring through Speed guns.

➢ Daily monitoring of Alcohol consumption

➢ GPRS based Vehicle tracking system ➢ Meetings with transporters to partner in

implementation of safety initiatives.

➢ Engineering controls viz road barriers & dividers, speed breakers, road markers, convex mirrors, spring posts, speed guns & illumination etc..

➢ Introduction of Defensive Driving Training by

expert agency .

➢ Journey Risk Assessment conducted for

Bhubaneswar, Sambalpur , Rourkela & Jharsuguda

Town ( Railway station & Air port route ).

➢ Monitoring and consequence management of speed

violations, drunken driving, PPE violators, and

required documentation etc.

Live tracking screenshot of Bus

no. OR23E3101 Speed Gun Monitoring of

Vehicles

FLEET MANAGEMENT


CONTRACTOR SAFETY MANAGEMENT

➢ Induction and job Specific Trainings conducted for workforce & Supervisors

➢ Competency mapping of contract employees

➢ Compliance of Tool Box Talks

➢ PPE Quality, adequacy and usage

➢ Near miss / Potential incidents reporting

➢ Compliance to SOP/ SMP

➢ Adherence to Site regulations

➢ Implementation of HSE inspection audit observations

➢ House keeping quality

➢ Safety, welfare initiatives & implementation of best practices

➢ Consequence management against violation –Yellow, red safety notices & penalty system

➢ Score card based payment system

Tool Box Talk & safety Pledge


Contractor Safety Audits Checklist of Contractor Safety Audit

CONTRACTOR SITE AUDIT.


Internal Audit : ❑ Daily Safety inspections ❑ Senior management walk down ❑ AIC audits ❑ Sustainability Audit. External Audits: ❑ External safety audit by Competent Agencies. ❑ Electrical Safety audits. ❑ Ergonomics Survey ❑ Industrial Hygiene survey ❑ External Fire safety audit . ❑ HAZOP study . Statutory Audit : ❑ Statutory audits by Govt. bodies (e.g. Authorities

from Directorate of Factories & Boilers, Electrical Regulatory Audit ).

Senior Management Walk down

SPECIALIZED AUDITS FOR HAZARD ELIMINATION


INCIDENT INVESTIGATION & CAPA IMPLEMENTATION

➢ 100% Investigation for all types of Incidents

➢ LTI/Fatality

➢ MTI- Medical Treatment Injury

➢ FAI-First Aid Injury

➢ Near Miss Incident

➢ Why-Why analysis in accident investigation is being followed to find out the root cause

➢ 4 Step methodology for all LTI/HIPOs/Fatal incidents

➢ Cost of accident captured for all accidents

➢ CAPA prepared and follow up for 100% compliance

➢ Circulation of Safety Alert on every accident for horizontal deployment


Yellow Safety Notice- Permit Violation Red Safety Notice- Permit Violation

CONSEQUENCE MANAGEMENT SYSTEM


OCCUPATIONAL HEALTH PRACTICES

Initiatives:

➢ 100% pre employment and periodic medical examination of employees and service providers.

➢ Hazard identification, Hazard Risk Assessment, Similar Exposure group identification

➢ Food Handlers, Security personnel ,locomotive operators, persons working at height and in confined space, Persons involved in Loading, unloading , etc.

➢ Special medical examination of people for working at height and Confined space before issue of pass.

➢ Linkage of Contractor Medical Examination with gate Pass

➢ Life Style Modification ,Counseling and treatment for prevention and control of chronic diseases

➢ Industrial Hygiene Survey by expert agency

➢ Ergonomic survey conducted for the location by expert agency (Occupational Ergonomics Laboratory, University of Calcutta)

➢ Biological Monitoring for Heat Stress.

➢ Snake Bite-Polyvalent anti snake venom ➢ Life Saving neutralizing Agent Diphoterine placed near all Chemical

Storage area, Laboratories.

SEG & Work area monitoring

Telemedicine Facility at Apollo Clinic, Township

Structure for Height Pass


EMERGENCY PLANNING AND RESPONSE

On site Mock Drill Conducted involving Sr. Mngt, Govt Authorities and Mutual Aid partners


MOTIVATION AND PROMOTION

1 House Keeping( 5S Related) 50

2 Safe Working 50

3 Use of PPE(personal protective eqp.)

50

4 Fire Safety 50

6 Leading Indicator in % 300

TOTAL 500

Criteria for Safety Rolling Trophy Leading Indicator in % 300

Safety Training Actual/Target 50

Work Permit Complied/Issued 50

Weekly audit observation Complied/Raised

50

Hazard Complied/Identified 50

Near miss/Other Investigation recommendation implemented / Reported

50

Safety related improvements 50


Safety Performance Review By CEO for the

Site

Monthly Safety Performance Review

Plant Level:by Plant Heads

Monthly Review through Safety Committee

Plant level.

Monthly Performance through Score card by HOD

& Safety Head.

REVIEW OF PERFORMANCE


MBRD & BBS for Inspection and Building Safety Culture

➢ Engaged Experts for developing internal team ➢ Use of SNAP Tool ➢ Safety Interaction to change behavior


EBRA for Catastrophic Risks


Booklet on Safety performance standard distributed to target

group after training

Safety Performance Standard for System based Risks

Six Safety Performance Standards

• Work at Height • Confined Space • Isolation • Electrical • Vehicles & Driving • Ground Control Classroom Trainings,Videos,Authorisation at Shop floor Levels


Thank You

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