KNOW YOUR HELMET SAFETY DURING EXCAVATION VISIBLE LEADERSHIP in EHS SAFETY at QUARRY OPERATIONS WORKING SAFELY at HEIGHTS Focus

HelmetEnvironment Health Safety July - Sep 2012 • Volume - 2 • Issue - 3

KNOW YOUR HELMET SAFETY DURING EXCAVATION VISIBLE LEADERSHIP IN EHS SAFETY AT QUARRY OPERATIONS WORKING SAFELY AT HEIGHTS Focus

This issue of Helmet comes to you with Contents its usual compilation of events and happenings from each IC. Apart from that, this issue also features insightful BUILDINGS AND information on “Working Safely at FACTORIES...... Heights, Know your Helmet, Safety in EHS updates from B&F IC 3 quarry operations, etc.

The issues also covers project preparedness and EHS management INFRASTRUCTURE ...... systems implemented at L&T’s Gulf Safety in Drilling & Blasting activities at Quarry operations 15 operations.

We hope that you will find this issue an interesting read and also wish that METALLURGICAL good practices are emulated to reach AND MATERIAL far and wide. HANDLING...... 22 Project Commissioning Preparedness Happy reading POWER TRANSMISSION & DISTRIBUTION...... Visible Leadership in EHS 28 Editor : V. S. Ramana

Editorial team : V. Ramesh Kumar | Gopi Kannan. S Ashwin Chand | Mayura. K Subha Anand | Shamala Nadendla

Content by : R.N.Tripathy | Mathivanan Palaniappan P. Nagarajan | M. Nachiappan Shailendra Kumar | Md Quaisar Imam Sathyanarayana Seelamanthula Murali Krishnan | P.V. Kaliappan

Photography : V. S. Natanavelu

Design & layout : Global Print Design, Chennai EHS updates from B&F IC

B&F IC’s 47 projects out of To fulfill the above requirements a web-based application 150 projects have achieved on “Confirmation on Action Taken (CAT)” in “EIP more than THREE million Vidhya” has been launched. safe man-hours which is a phenomenal achievement This system is designed to disseminate Corrective action in the construction sector. to be taken for EHS as well as to track implementation till compliance, in all projects. Also, many of our projects have been awarded by The main objectives are: clients with merit certificate yy Systematically share corrective action to be taken for best implementation of across all projects. EHS management system yy Proactively receive confirmation from projects on and achievement of mile stones in safe man-hours. status of implementation. Scaffolding training yy Escalation to next level, if not complied within the given deadline, until completion. To improvise the skill level of workmen who are engaged in scaffolding activities a massive drive was organized by Flow of this system, our formwork department. More than 4000 workmen have yy Corrective action to be taken at all projects issued been covered since July 2012. by HQ-EHS function based on an audit, inspection and incident investigation of any of the project It is also necessary to check and certify scaffolds erected online. at projects. In line with this 101 scaffold inspectors have been certified for inspecting & certifying the scaffolds yy Email Communication automatically reaches all through four days “Scaffold Competent Person” training project managers & EHSO with details like proposed programs. corrective action and deadline for compliance. yy After the implementation of corrective action Implementation of “On Spot Appreciation” system at project, the concerned Project Manager shall Motivation of workforce is one of the instrumental in confirm the corrective action online with evidence of implementing a sound EHS management system at implementation. projects. An “On Spot Appreciation” system has been yy Summary of sites & action taken automatically gets introduced recently apart from monthly motivational compiled at HQ. scheme to motivate the workmen for following best EHS yy Projects which have not complied within the deadline, practices and reinforcing the safe behavior. As a kick start, will be automatically escalated to next level such as minimum of Rs. 2000 has been fixed per month for a Cluster projects manager and subsequently to segment project. & BU head levels until compliance based on the deadline. Projects have started rewarding them during EHS committee walk-downs. Request all concerned to consistently follow 1st Confirmation on action taken (CAT) has been posted this system to improvise the safe behavior. based on an incident such as: yy Hard barricades shall be provided in the periphery Online Confirmation on Action Taken (CAT) module of all working floors as an integral part of slab launched formwork system before starting the reinforcement Identifying hazards and implementing the corrective work as per SOP. actions is the key in EHS management system. Corrective yy As a secondary protection, Safety catch net shall be actions are identified during Audits, Inspection & Incident provided within 6 meter below the working level. investigation. The key objective of all these exercises is to implement the corrective measures across all projects. Most of the projects have complied before the deadline across B&F IC.

Buildings & Factories HELMET July - Sep 2012 3 Every section/department head Confirmation on Action Taken – CAT – Flow Chart from HQ/Cluster visiting the

HQ – EHS will post the area of concern Level - IV site shall conduct executive safety audit & report the

Level – I IC Head feedback to HQ /cluster. This Level – II feedback will be valuable to EHSO Project Manager site for improvement and keep Level - III Cluster Projects Cluster EHS *Cluster Plant *Cluster Formwork Manager / PD Manager Manager Manager the cluster/HQ management updated about the latest EHS

* Head – P&M * Head - BSCC Segment Head BU Head *Head EHS – Res BU Head EHS – B&F IC implementation status.

Level – II Project Managersubmits the Confirmation on Action Taken (CAT) Potential Time Frame Apart from measuring High 7 Day Moderate 10 Days & improving the safety Acceptance / Rejection by Cluster EHS Manager after review Low 15 Days Level – III High 10 Days implementation, it shall Moderate 15 Days drive down the message of *Plant & Machinery related CAT shall be raised to Cluster Plant Managers and head – P&M Low 20 Days Level – IV *Formwork related CAT shall be raised to Cluster Formwork Manager and head –BSCC Manually by Head - importance of safety and need EHS for every one involvement for achieving higher safety standards. Executive Safety Audit It is very important to review the EHS implementation of projects by P. Nagarajan senior management and involving them shall result in improving the EHS DGM & Head - EHS, Buildings & performance. To improve the involvement of section / department head at Factories IC HQ /cluster an executive safety assessment system has been developed with a structured “executive safety audit” template.

NSC Award

B&F IC Bags Prashansa Patra Safety Award from National Safety Council, India

Buildings & Factories Independent Company’s South city project, Bangalore has bagged the Prashansa Patra Safety Award from the National Safety Council – India (NSCI*) under the Construction Awards Scheme 2011.

The awards are given in recognition of efforts to develop and implement highly effective Environment, Health & Safety (EHS) systems & procedures and achieve outstanding performance in construction projects.

The selection process involved verification of the data provided in the application through the Client Organisation and personal presentation before the Awards Committee by senior representatives of the top short-listed contenders.

*National Safety Council is a tripartite body set up by Ministry of labour, Govt of India in 1966 constituting members from employees, employers & government.

4 HELMET July - Sep 2012 Buildings & Factories Helmet Congratulates the following sites for achieving THREE Million and more LTI Free Safe Man-Hours

Safety l of Hono Rol ur

MUD Project, Chandigarh ESIC Hospital Project, Kovai 24 Million Safe Man Hours, November 2010 to 10 Million Safe Man Hours, March 2011 to September 2012 September 2012

Heidelberg Project, Damoh Godrej Housing Project, Kolkata 17 Million Safe Man Hours, July 2010 to 9 Million Safe Man Hours, July 2009 to September 2012 September 2012

The Address - Wadhwa Housing Project, Ghatkopar Bengal NRI Housing Project, Kolkata 17 Million Safe Man Hours, January 2010 to 9 Million Safe Man Hours, July 2011 to September 2012 September 2012

BARC Phase-I Project, Mysore ESIC Hospital Project, Kollam 16 Million Safe Man Hours, August 2009 to 8 Million Safe Man Hours, April 2010 to September 2012 September 2012

Kohinoor Square Project NISER Project, Bhubaneswar 14 Million Safe Man Hours, June 2009 to 8 Million Safe Man Hours, September 2011 to September 2012 September 2012

Vicat Sagar Project ITC Sonar Project, Kolkata 14 Million Safe Man Hours, July 2010 to 8 Million Safe Man Hours, August 2009 to September 2012 September 2012

Salalah Airport Project ESIC Hospital Project, Joka 13 Million Safe Man Hours, December 2010 to 8 Million Safe Man Hours, November 2009 to September 2012 September 2012

JIPMER Phase – II Project, Pondicherry Maruti C-line Project, Manesar 13 Million Safe Man Hours, August 2010 to 8 Million Safe Man Hours, October 2010 to September 2012 September 2012

Vedanta Housing Project, Jharsuguda Manikgarh cement Plant Project, Chandrapur 13 Million Safe Man Hours, June 2010 to 7 Million Safe Man Hours, March 2011 to September 2012 September 2012

RLICD - Khurja Project Godrej garden city ph I & II project, Ahmedabad 12 Million Safe Man Hours, February 2010 to 7 Million Safe Man Hours, September 2011 to September 2012 September 2012

Rajashree cement plant Project, Malkhed Orchid Crown Project, Prabhadevi 11 Million Safe Man Hours, March 2011 to 7 Million Safe Man Hours, February 2010 to September 2012 September 2012

Buildings & Factories HELMET July - Sep 2012 5 Delhi ONE Project HCL project, Sholinganallur 6 Million Safe Man Hours, December 2011 to 4 Million Safe Man Hours, October 2011 to September 2012 September 2012

Century Bhavan Project, Mumbai SNU Project, Dadri 6 Million Safe Man Hours, May 2009 to September 2012 4 Million Safe Man Hours, October 2011 to September 2012 GIFT CITY Project, Gandhinagar 6 Million Safe Man Hours, July 2011 to BMRCL R3a Project, Bangalore September 2012 4 Million Safe Man Hours, January 2010 to September 2012 BMRCL R3-P1 Project, Bangalore Million Safe Man Hours, July 2009 to 6 Seawoods Project, Mumbai September 2012 4 Million Safe Man Hours, July 2011 to September 2012 Mall of India Project, Noida 6 Million Safe Man Hours, September 2011 to RMZ Galleria Project, Bangalore September 2012 3 Million Safe Man Hours, February 2012 to River View Apartments Ph-II Project, Lucknow September 2012 6 Million Safe Man Hours, March 2012 to September 2012 Lodha Fiorenza Project, Goregaon 3 Million Safe Man Hours, August 2011 to TCS project, Kochi September 2012 5 Million Safe Man Hours, October 2011 to September 2012 M3M Golf Estate Project 3 Million Safe Man Hours, June 2011 to Grasim project, Bharuch September 2012 5 Million Safe Man Hours, October 2011 to September 2012 DIAL ATC Tower Project 3 Million Safe Man Hours, January 2012 to Godrej garden city Ph III project, Ahmedabad September 2012 5 Million Safe Man Hours, July 2011 to September 2012 Omkar Rehab building project, Bhoiwada 3 Million Safe Man Hours, June 2011 to Torrent Pharmaceuticals Project, Dahej September 2012 9 Million Safe Man Hours, September 2011 to September 2012 Omkar Rehab Project, Malad AIIMS Project, Bhubaneswar 3 Million Safe Man Hours, July 2011 to 5 Million Safe Man Hours, October 2011 to September 2012 September 2012 CMRL Depot project, Koyambedu Boeing MRO Project, Nagpur 3 Million Safe Man Hours, December 2010 to 5 Million Safe Man Hours, March 2011 to September 2012 September 2012 Agartala Medical College Project Formwork Factory, Pondicherry 3 Million Safe Man Hours, February 2010 to 5 Million Safe Man Hours, February 2011 to September 2012 September 2012

6 HELMET July - Sep 2012 Buildings & Factories APPRECIATION

The Address Project, Wadhwa Group – Mumbai Cluster

B&F’s The Address Project - Mumbai Cluster has received a certificate of appreciation from client M/s. The Wadhwa Group for achieving 17 million safe man-hours during the period January 2010 to October 2012.

JIPMER Phase-II Project – Chennai Cluster

B&F’s JIPMER Phase-II Project – Chennai Cluster has received a certificate of appreciation from client M/s. Jawaharlal Institute of Post - Graduate Medical Education & Research, Puducherry for achieving 12 million safe man-hours during the period July 2010 to July 2012.

Delhi ONE Project

B&F’s Delhi ONE project has received a certificate of appreciation from client M/s. The 3C company for achieving 5 million safe man-hours.

Buildings & Factories HELMET July - Sep 2012 7 MIOT International Hospital Project – Chennai Cluster

B&F’s MIOT International Hospital Project, Chennai has received a certificate of appreciation from client M/s MIOT Hospitals for achieving 7.5 million safe man-hours during the period March 2010 to July 2012.

Grasim Project – Ahmedabad Cluster

B&F’s Grasim Project – Ahmedabad Cluster has received a certificate of appreciation from client M/s Grasim for achieving 5 million safe man-hours during the period September 2011 to September 2012

UTCL Hotgi cement plant project – Hyderabad cluster

B&F’s UTCL Hotgi cement plant project – Hyderabad clusterhas received a certificate of appreciation from client M/s UltraTech for achieving 2.5 million safe man-hours during the period April 2011 to July 2012.

8 HELMET July - Sep 2012 Buildings & Factories Agartala Medical College Hospital project – Kolkata Cluster

B&F’s Agartala Medical college hospital project - Kolkata cluster has received a certificate of appreciation from client for achieving 3 million safe man-hours.

DIAL ATC Tower project

B&F’s DIAL ATC Tower project has received a certificate of appreciation from client M/s. GMR Group for achieving 3 million safe man-hours during the period December 2011 to August 2012.

NISER Project, Bhubaneswar – Kolkata Cluster

B&F’s NISER Project, Bhubaneswar – Kolkata Cluster has received a certificate of appreciation from client for achieving 7 million safe man-hours during the period July 2011 to August 2012.

Buildings & Factories HELMET July - Sep 2012 9 Construction Safety

TWO Days Construction Safety Program

A two day “construction safety program” was conducted at various Clusters of B&F IC. More than 600 staff benefitted in these programs during the last quarter (July to September 2012).

Mumbai

Delhi

Kolkata

Hyderabad

Ahmedabad

Chennai

10 HELMET July - Sep 2012 Buildings & Factories Working Safely at Height

awareness about the issue, working at height still remains the most common cause of fatalities in the construction industry. Preventing injuries from work at height requires a practical approach, based on sound knowledge of work method. Working at height is defined as work in any place from which, if measures were not taken, a person could fall a distance liable to cause personal injury. As the single biggest cause of workplace deaths and a major cause of accidents at work, working at Heights presents many and varied problems. These can be overcome by ensuring all workers are properly trained in method and usage of the correct equipment for the task. How dangerous is it anyway?

We all know that nothing in life can be 100% safe. We Method, Equipment, Training and strive to make things as safe as possible by doing a risk Enforcement are Top Priorities assessment, considering the dangers and applying suitable controls. Humans instinctively take more care when the In construction industry worldwide, falls are the leading danger is obvious. If the danger is less obvious, people cause of worker fatalities. In most countries, fall from become complacent and more willing to take chances and heights account for around about 50% of all fatal accidents. short cuts.Everyone must remember that taking care in Despite numerous trainings and campaigns to raise these situations includes those in charge correctly assessing

Buildings & Factories HELMET July - Sep 2012 11 the danger and putting suitable controls and training in Training: The above will only work if ALL workers are place. Safety is not an optional extra. trained and suitably supervised against the assessed risks and in the safe systems of work. Considerations Safety equipment versus safe systems of work? The first question to ask ourselves is, do we need to work at height? If the answer is yes, then consider the following: Of course there is an excellent argument for providing good quality Personal Protective Equipment (PPE), for working yy Follow the risk assessments you have carried out for at height in the form of fall prevention and arrest devices. work at height activities and make sure all work at However, it is far more effective and sensible to use our best height is planned, organised and carried out by trained endeavors to ensure that we design out hazards, making a and competent persons. safe place of work, rather than rely on workers to use PPE. yy If you can’t avoid working at heights, follow the hierarchy for managing risks, and take steps to avoid, Providing a safe worker in an unsafe prevent or reduce risks workplace - use of PPE 1. Provide a safe place of work If you do decide to use PPE - harnesses, fall arrest/restraint/ Scaffolding - a correctly designed and built scaffold should prevention and the like - please consider the competence of be as safe to work on as standing on the ground. the expected user in wearing/using such equipment. Also consider the provision of suitable quality and sufficient Mobile Elevating Work Platform (MEWP) - as with a numbers of anchor points for the area of work, which will scaffold, a correctly positioned and used MEWP should be allow the required range of movement. We frequently see as safe as working with our feet on the ground. workers clipping on to inappropriate anchor points, risking Suspended access platform - when correctly installed and failure of the anchor and in several cases, potential collapse operated, these too should be as safe as standing on the of the platform they are working on. ground. All good PPE providers will be able to suggest suitable 2. Provide collective protection anchor design and/or systems and also provide training for staff in competent use of any PPE that they provide. So, Safety nets - these protect all workers. overall, although we can’t completely do away with PPE 3. Provide individual protection as our solution, we must really think of it as a last resort. Safety lines and harnesses - fall prevention, using a suitable Goal setting anchor point and retention line/harness. Fall arrest - such as inertia reel equipment. Rope access systems - using The good practice requires that all work at height is risk abseil techniques. assessed. The assessment should really be based on a ‘goal setting’ approach, which means that there is no absolute 4. If all the above fails right or wrong way to do the activity. Instead we follow a Use a ladder or ‘hop-up’, but only if the work is low risk hierarchy of control. When planning an activity that may and of short duration, and does not require both hands at involve work at height we should consider the following: any time to complete the activity. yy Can work at height be avoided? Is it reasonably practicable to introduce a system where the work can be done from ground level, where there is no risk of a fall from height? yy Where you must work at height, what can be put in place that would prevent a person falling? Could guard rails or a movement restraint system be used? yy If it is not reasonably practicable to put measures in place that will prevent a fall occurring, think about what you can do to reduce the distance and consequences of a fall should one occur - mats, air bags and fall arrest harnesses, for example. yy If the risk of a fall remains, think about other measures that will stop a person being injured, such as extra training.

12 HELMET July - Sep 2012 Buildings & Factories yy If you review your procedures and risk assessment, ladder - do not work from a ladder for longer than 10 you should be able to decide what suitable, sensible minutes at a time. measures need to be put in place to make sure the yy If you use a ladder keep three points of contact people who are doing the job can do it safely. This may wherever possible. include further training. yy If you are hiring access equipment, make sure you yy If you conclude that guard rails, tower scaffolds or know how to install and dismantle it safely - ask the mobile elevating work platforms cannot be used, any hirer for instructions or assistance if you need them. work restraint system chosen should be set up so that Next time you are tasked to put people to work at height, the user is prevented from reaching a position from consider: where a fall can occur. Full body harness may be appropriate where a person cannot reach a position Do they need to do it? from which a fall can occur. If a fall can occur, the If the answer is yes, think ‘How can I plan it so that they are system is not working restraint but fall arrest. In this as safe as possible - and still achieve my production targets?’ case, the person will need a full body harness, energy absorbance and sufficient fall distance to safely arrest Remember the hierarchy above the fall. Don’t do it, or if you must: Tips for safe working 1. Provide a safe place of work, or if you can’t yy Plan what you will do in an emergency, or if someone falls. 2. Provide collective protection, or if you can’t yy Make sure the people who will be doing the job have 3. Provide individual protection the right skills, experience and training to use the 4. Always ensure that all workers are properly and equipment safely and have been consulted about the appropriately trained right equipment to use. 5. Enforce to work as per training and procedure. yy Inspect and enforce to work as per procedure and training. V.Janardhanam DGM - Head EHS Training, B&F IC yy Take frequent breaks, especially when working from a

Buildings & Factories HELMET July - Sep 2012 13 Do you know your Helmet?

How does safety helmet protect our head when we fall from height or objects fall on our head?

Safety helmet is intended to protect our head from injuries, caused by falling objects, fall from height or hitting our head against any hard surface.

We must know how helmet works to protect our head from above mentioned causes. Helmet works on simple principles of physics. When an object falls on our head or our head hits on a hard surface, a large force is applied on our head in a very short time. In physics, this phenomena is known as Impulse.

Hence Impulse = Force x Time

Force = Impulse / Time

As you know , from the above formula, if time increases force will reduce and impact of the hit or fall will be reduced. The anti-concussion tapes (helmet refill) inside the helmet increases the time over which the impulse acts. Hence the impact of the hit/fall on our head will be reduced. At the same time the outer rigid shell of the helmet, spreads the force to a larger area instead of allowing the object to hit at a point on our head. Hence the pressure exerted by force is reduced. Pressure = Force / Area

As area increases, effect of pressure reduces. Lastly the chin strap and nape strap plays a crucial role to keep the helmet in position, while we fall from height or during fall of object from height on our head.

Suresh Thomas EHS Manager, BARC Phase – I Project, Mysore

14 HELMET July - Sep 2012 Buildings & Factories Safety in Drilling & Blasting activities at Quarry operations

Considering the criticality yy Handling of explosives shall be avoided during of operations, the following thunderstorm or when thunderstorm is expected. safety precautions shall be followed at every stage, Loading Explosives into Drilled Holes

Drilling yy All the drill-holes should be sufficiently large to admit freely the insertion of the cartridges of explosives. yy Area to be cleared of all Tamping shall be done only with wood sticks or plastic loose materials. tamping poles.

yy Usage of respiratory yy No holes shall be loaded except those to be fired in the protection, eye protection, next round of blasting. After loading, all remaining ear protection to be ensured explosives and detonators shall be returned to the during drilling operation. explosives van for conveying it back to the magazine. yy Preventive measures to minimize respirable dust and yy Stemming shall be done only with sticks made of small particulate matters like covering the drill hole wood or fibrous material. In no case, drill holes shall with wet gunny bag or wet drilling to be ensured. be stemmed with metallic objects. Shock tubes to be used should show no sign of bend or compression. yy Fall protection to be ensured when the person is working at edges of the bench is more than 2 m height. yy All electric detonators to be used in blasting should be checked suitably for their continuity using an Ohm- yy Wagon drilling machine or tractor compressor, hose Meter. No explosives or blasting agents shall be left pipes to be subjected to pre-deployment inspection unattended at the blast site. and ensured fit and by EHS dept. before engaging on job. Firing yy If the drilling crew is permanent, pulmonary functions yy Area in radius of 500 meters (blasting danger zone) test to be conducted once in a year to the crews. of the blasting face must be cleared and ensured of all men, machineries and cattle herds and sentries Transportation / handling of explosives: with red flags should be sent to the boundaries of the yy Agency performing blasting activity should posses the blasting danger zone to avoid entry of any person in valid license in form 22 (LE-3). the danger zone. yy Explosive and detonators shall not be transported together in the same vehicle and only valid license (Form 25/LE-7) VAN to be used. Containers shall be made of finished wood / plastic / fiber. yy Blasting activity shall be carried out only after availing the blasting permit / NOC for Blasting by the concerned authority. Only shot firers with valid license in form LE-10 or Blaster possessing Blasters Certificate issued by DGMS to be engaged for receiving and handling explosives. yy No person shall be allowed to smoke, carry matches, mobile phone / walkie-talkies or any other flammable materials near to explosives being handled.

Infrastructure HELMET July - Sep 2012 15 yy The blasting circuit should be checked for its continuity yy An audible siren shall be blown to declare that blasting both before connecting the circuit to the main blasting area is now safe for entry of men and material. cable and after connecting blasting cable immediately Safe Handling of Misfires before the firing. yy If a misfire is detected, the area shall be barricaded so yy Key of the exploder should always be retained with the as to prevent entry of persons who are not required or /shot firer / blaster or competent person designated to not trained in handling a misfire. carry out the blast. yy No other work should be done except that necessary yy A loud siren to be blown to aware the surroundings to remove the hazard of the misfire and only those of the blasting. First siren shall be blown 10 minutes employees necessary to do the work should remain in before the blasting and second immediately before the the danger zone. blasting shall be blown. yy Unexploded explosives shall be removed from the Inspection after Blasting hole with the help of compressor or water jet. if the yy Immediately after the firing the holes, the firing line explosives could not taken out from the misfired should be disconnected from the exploder. hole, a hole(s) shall be drilled parallel to the misfired hole(s) keeping a distance of 300mm and fired, if yy Shot firer / blaster shall wait for sufficient time to go any explosives found in the blasting muck same to be the blasted spot for inspection till the smoke and fumes collected and handed over to shot firer / blaster. are cleared off from blasted area. S.Sathyanarayana yy An inspection of the area of blasted location shall be Head - EHS, Infrastructure IC carried out by shot firer / blaster to determine status of misfired holes before workers are allowed to return back to the location.

16 HELMET July - Sep 2012 Infrastructure Helmet Congratulates the following sites for achieving THREE Million and more LTI Free Safe Man-Hours

Safety l of Hono Rol ur

Kakrapar Atomic Power Project DMRC – CMC1 Project 19 Million Safe Man Hours, February 2010 to 5 Million Safe Man Hours, July 2010 to September 2012 September 2012

Nashik Elevated Corridor Project Beawar-Pali-Pindwara Road Project 14 Million Safe Man Hours, January 2010 to 4 Million Safe Man Hours, Dec 2011 to September 2012 September 2012

Tapovan Vishnugad Hydel Project Bharuch Dahej RC Project 7 Million Safe Man Hours, May 2010 to 4 Million Safe Man Hours, June 2009 to September 2012 September 2012

Samakhiali Gandhidham Road Project Krishnagiri Walaja Road Project 6 Million Safe Man Hours, Sep 2010 to 4 Million Safe Man Hours, Dec 2011 to September 2012 September 2012

Subansiri Hydel Project Vizag Vessels Project 6 Million Safe Man Hours, May 2011 to 4 Million Safe Man Hours, Nov 2011 to September 2012 September 2012

Singoli Bhatwari Hydel Project Panskura-Kharagpur RC Project 6 Million Safe Man Hours, June 2011 to 4 Million Safe Man Hours, Sep 2009 to September 2012 September 2012

Kattupalli Shipyard Project BMRC -R3A - Yeshwant to Peenya Elev. 6 Million Safe Man Hours, Oct 2011 to 4 Million Safe Man Hours, Apr 2011 to September 2012 September 2012

Punatsangchhu HEP Ganjbasoda Sanchi RC Project 6 Million Safe Man Hours, Feb 2012 to 4 Million Safe Man Hours, March 2010 to September 2012 September 2012

Chennai Metro Elevated Bina Ganjbasoda RC Project 5 Million Safe Man Hours, Mar 2012 to 4 Million Safe Man Hours, Oct 2009 to September 2012 September 2012

Shrinagar HEP Ahmedabad-Viramgam-Maliya Road Project 5 Million Safe Man Hours, Apr 2012 to 3 Million Safe Man Hours, Mar 2012 to September 2012 September 2012

Infrastructure HELMET July - Sep 2012 17 Safety TRAINING PROGRAMMES

Two day in-house training programme on Construction EHS Requirements

Five Widespread two-day training programmes on “Construction EHS Requirements” for Line management were organized at different locations - Kolkata cluster office, Jaipur cluster office, Bina - Ganjbasoda Railway project site, Krishnagiri Walaja Road project and Delhi Cluster office. Participants were exposed to topics like P&M safety, fire prevention, EHS management system, material handling, excavation, work at height, formwork, electrical, traffic management, environment requirements, welding and grinding, case studies.

18 HELMET July - Sep 2012 Infrastructure Construction Safety

Behaviour Based Safety Programme

Behaviour Based Safety (BBS) workshops were organized at Mumbai cluster office(24th Jul’12), Ahmedabad Cluster (23rd & 24th Aug’12), Krishnagiri Walaja Road project (11th& 12th Sep’12), Kolkata cluster (18th & 19th Sep’12), Delhi cluster (20th & 21st Sep’12) and Mumbai mono rail project (25th & 26th Sep’12) to develop Mentors of Behaviour Based Safety (MBBS) for working towards enhancing the safety culture. These programs were organized through expert faculty Dr. H.L. Kaila, Professor of Psychology, BBS Trainer & Implementer.

Infrastructure HELMET July - Sep 2012 19 APPRECIATION

GVK Srinagar Hydroelectric Power Project Site, Alaknanda BINA – GANJBASODA THIRD LINE RAILWAY Hydro Power Company Limited, Srinagar received an CONSTRUCTION PROJECT SITE, Rail Vikas Nigam appreciation certificate for achieving 5 Million Safe Man- Limited, Bhopal received an appreciation certificate for Hours during the period of March 31, 2012 to September achieving 3.5 Million Safe Man-Hours during the period 13, 2012. 07 July 2010 to 31 July 2012. Quarry Awards

distribution function was held on 18.08.12 at Vellore for Chennai region and state level function was held on 02.09.12 at ACC Cements, Madukarai, Coimbatore. The Chief Guest at State Level Function was Mr.Satish Puri, Director General of Mines Safety – Dhanbad. yy 1st Prize in Welfare Amenities and Safety Management – Karungali Quarry yy 1st Prize in Trade Test for Electrician – Karungali Quarry yy 1st Prize in Trade Test for Heavy Equipment Operators – Karungali Quarry yy 1st Prize in Injury Rate Performance – Bargur Quarry yy 2nd Prize in Welfare Amenities and Medical Facilities – Bargur Quarry Our quarry establishments at Arapakkam, Karungali and yy 3rd Prize in Blasting Storage and Use of Explosives – Bargur under operation in KWRP were awarded in seven Arapakkam Quarry different categories from Tamil Nadu - Kerala State Mines yy 3rd Prize in Standard Supervision – Arapakkam Safety Association for the year 2012 - 13. The awards Quarry.

20 HELMET July - Sep 2012 Infrastructure National Safety Council Award

Tapovan Vishnugad Hydel project bagged prestigious National Safety Council Award - Prashansa Patra in Construction sector for the year 2011. Familiarization Program for EHS

Familiarization program for EHS personnel (lateral recruits) was organized at Chennai HQ 17th & 18th Sep ’12 to induct them about the Company’s established EHS systems and practices so as to equip the participants for effective functioning at site.

Infrastructure HELMET July - Sep 2012 21 Project Commissioning Preparedness

Project Commissioning: yy Risk Management, Project commissioning is the yy Safety Compliance. process of assuring that all the systems and components of Elements of successful Commissioning: a building or industrial plant yy No Incident are designed, installed, tested, yy No equipment damage operated, and maintained yy Timely completion. according to the operational requirements. Minimum Facilities Before Start Up:

A commissioning process may yy Availability of adequate PPEs & Safety devices; be applied not only to new yy Availability of Gas detectors; projects but also to existing units and systems subject to yy Availability of First aiders & First Aid boxes; expansion, renovation or revamping. yy Availability of Ambulances; Plant Start-up and Commissioning: Commissioning is yy Implementation of work permit system; the first activity in starting the plant. Safe Commissioning yy Fire fighting facilities including positioning of plays a vital role for running the plant successfully in long extinguishers & Fire brigade etc.; run. Commissioning activity is crucial from safety point of yy Clearly defined emergency exits, with display boards; view since, it involves many unknown factors & potential yy Tested paging systems & availability of walkie-talkies hazards. / PA System; yy Plant Commissioning is the start of many start-ups, yy Housekeeping. yy Potential hazards: Ability to operate is not proven, yy Many other unknown factors. Maintenance Responsibilities: yy Develop SOPs; Incidents: They delay the commissioning work. Any yy Specify maintenance activities; incident just prior to or during the commissioning will delay the whole commissioning process. It is worth to yy Develop SMPs; emphasize that taking preventive measures and proactive yy Keep maintenance records; approach towards safety help reducing the incidents during yy Keep detailed designs of any changes and additions the commissioning process. made.

Effects of delayed Commissioning: On time commissioning Hazard identification to be done by the sub group of is essential for any plant for its production, business and various activities of the plant. In the sub group the following sustainability. Delayed commissioning will have a huge executives should do this exercise. impact on the organization. The following are three of the major effects due to the delayed commissioning. 1. Operation section head, yy Expensive, 2. Maintenance section head, yy Return On Investment is severely affected, 3. Representative of energy management department, yy Financial viability (Survival of the Organization) is 4. Representative of field machinery maintenance under question. department, 5. The concerned safety officer etc. Key to a Safe Start-up: The following are the key points for a safe start-up of any plant. The different sub groups will make their own SOPs & yy Planning, SMPs and will be finally approved by the unit head. yy Commissioning Management, R.N.Tripathy yy Prepare specific plant procedures, Head – EHS, MMH IC

22 HELMET July - Sep 2012 Metallurgical & Material Handling Helmet Congratulates the following sites for achieving THREE Million and more LTI Free Safe Man-Hours

Safety l of Hono Rol ur

Vizag Steel Plant Expansion Project - BF # 3 CHP-Mahan (HINDALCO), Singrauli 31 Million Safe Man Hours, April 2009 to 8 Million Safe Man Hours, January 2011 to September 2012 September 2012

Mahan Aluminum Plant (HINDALCO) - Singrauli Civil and Structural works for BALCO, Korba 27 Million Safe Man Hours, Dec 2010 to Sep 2012 7 Million Safe Man Hours, November 2011 to September 2012 Dhamra Port Project 18 Million Safe Man Hours, April 2007 to Bhushan Steel Limited Site - Angul (M&M) September 2012 6 Million Safe Man Hours, August 2012 to September 2012 UAIL – Rayagada 18 Million Safe Man Hours, July 2011 to Engineering Workshop Limited, Kanchipuram September 2012 6 Million Safe Man Hours, September 2011 to September 2012 Wheel Manufacturing plant at Chhapra 17 Million Safe Man Hours, February 2009 to Adani Power Maharashtra Limited (CHP-Tiroda) September 2012 6 Million Safe Man Hours, Dec 2009 to September 2012 Can Mill Project Hirakud Site 16 Million Safe Man Hours, July 2010 to NLC Thermal Plant Site, Tuticorin September 2012 6 Million Safe Man Hours, September 2009 to September 2012 Coal Handling plant for NTPC - Barh 15 Million Safe Man Hours, August 2006 to Bhilai Steel Plant Expansion Project - September 2012 6 BF # 8 & SP # 3 Million Safe Man Hours, August 2010 to Bhushan Steel Limited Site – Angul (BMH) September 2012 14 Million Safe Man Hours, July 2011 to September 2012 Aditya Alumina Lapanga 4 Million Safe Man Hours, April 2011 to SAIL-Burnpur Site September 2012 12 Million Safe Man Hours, February 2010 to September 2012 JSW - Bellary Site 4 Million Safe Man Hours, March 2012 to Coal Handling plant, DVC – Koderma September 2012 9 Million Safe Man Hours, March 2008 to September 2012 NTPC- Barh Phase-II 3 Million Safe Man Hours, August 2010 to NTPC – Simhadri (Vizag) Coal Handling Plant September 2012 9 Million Safe Man Hours, May 2009 to September 2012 Pot Super Structure (HINDALCO), Mahan, 3 Singrauli SSTPL (CHP)-Khandwa Site (MP) Million Safe Man Hours, March 2010 to 9 Million Safe Man Hours, December 2009 to September 2012 September 2012

Metallurgical & Material Handling HELMET July - Sep 2012 23 Project Suraksha Jeet

Bhushan Steel Project, Angul (MMH IC) in the programme and committed to work towards the transformation of safety culture by adopting proactive Project Suraksha Jeet, an initiative to transform the steps to ensure incident and injury free workplace. safety culture within L&T, was launched at Bhushan Mr.Indranil Chakraborty, Cluster EHS Manager, Steel Project, Angul. The programme commenced with Kolkata, Mr. N.K.Dhal EHS Manager, Rayagada and the administration of safety pledge. The site conducted a Mr. Anurag Singh EHS Engineer, Rayagada were the one day training programme titled “Safety Observation faculty member for these programs. & Safety Contact” on July 31, 2012. Mr.Tinanjan Mitra (Project Manager, BSL Angul) inaugurated the Kolkata Cluster office programme and Mr.R.N.Tripathy (Head – EHS, MMH One day workshop on Safety Observation & Safety IC) briefed the participants about the programme. A Contact training program was organised at Kolkata total of 26 senior staff participated in the programme Cluster office of MMH IC. The programme commenced and committed to work towards the transformation with the administration of safety pledge. Cluster Head- of the safety culture by adopting proactive steps to Mr. T.Azhaguvel and Mr. G.Dasgupta- Cluster HR ensure incident and injury free workplace. Mr.A.K.Das Manager, addressed all the participants. The one day (Cluster EHS Manager – Ahmedabad) & Mr.Indranil training programme was conducted on 14th Sep, 2012. Chakraborty (Cluster EHS Manager – Kolkata) were the A total of 19 senior staff participated in the programme faculty members for this program. and committed to work towards the transformation Utkal Alumina Project conducted 3 training programs of the safety culture by adopting proactive steps to on Project Suraksha Jeet ensure incident and injury free workplace. Mr. Indranil Chakraborty (Cluster EHS Manager – Kolkata) was the Project Suraksha Jeet, an initiative to transform the faculty member for this program. safety culture within L&T, was launched on 17th August at Utkal Alumina Project, Rayagada of MMH IC. Bhilai Steel Plant Project following that two more training programs titled “Safety One day training programme (4th Sept 2012) on Observation & Safety Contact” were conducted on 3rd “Safety Observation & Safety Contact” organised at Sept & 12th Sept 2012. Mr. A.K.Dalui, Project Manager, Bhilai Steel Plant Project Site of MMH IC – Hyderabad UAIL Rayagada Site, inaugurated all the programs Cluster, as an essential objective of Project Suraksha which commenced with the administration of safety Jeet. pledge. A total of 54 senior staff members participated

24 HELMET July - Sep 2012 Metallurgical & Material Handling JSW Project, Bellary by Mr. Gautam Jain (Cluster HR Manager) who had briefed the participants about the content of Project Suraksha Jeet initiative – One Day Workshop the program. Mr. R . K . Singhvi, GM (Projects) of on Safety Observation and Safety Contact program M/s Hindustan Zinc Limited had inaugurated the held at our JSW Project Site – Bellary on 07th and 08th workshop and Mr. P. Muthuraj (Project In-charge, September 2012. The program was held in two batches HZL-Dariba Site) briefed the participants on the for 36 participants. Staff members in all the cadres initiative and intention of the workshop. Mr. A . K participated in this one day program. The program . Das (CEHSM- Ahmedabad Cluster) & Mr. Suman was inaugurated and addressed by Mr R Umasathiyan Das (Asst. Cost. Manager – Civil, HZL-Dariba - Project Manager. Since this program was unique in Project) were faculties for the program. The workshop nature and different from the regular programs, the staff was conducted through discussion, interaction with members participated actively with enthusiasm. Mr P participants followed by a practical session on how to Mathivannan, Cluster EHS Manager, Chennai was the observe Unsafe Behavior of Workmen and Motivate faculty co-ordinator for this programme. them for following safe work practices at site. CHP-Khandwa Project

Workshop on “Safety Observation & Safety Contact” was conducted at CHP-Khandwa project site on 27th September 2012. 19 staff members were trained through the program. Mr. Ajaya Kumar Das (Cluster EHS Manager) was the faculty coordinator for the program.

HZL-Dariba Project

To transform the Safety Culture down the level, MMH IC – Ahmedabad Cluster had conducted the “Workshop on Safety Observation & Safety Contact” at HZL-Dariba Project Sites on 14th September 2012. This is an initiative of “PROJECT SURAKSHA JEET” aiming to ensure an Incident & Injury Free Workplace. The guest & participants were welcomed

Metallurgical & Material Handling HELMET July - Sep 2012 25 Construction Safety

Fall protection and Rescue Demo at JSW-Bellary Projects Site

As a part of EHS implementation at site a Demo on fall protection system and rescue at height work was organised at JSW-Bellary Projects Site on 13.09.12. The demo was conducted by M/s. KARAM to about 200 participation that included workmen and staff members who enthusiastically participated in the program. M/S Karam had given demo on proper usage of fall arrestor, safety harness, Rope descender and Rescue operations. Response from the workmen was appreciated and prize has been issued to the actively participated workmen for the above demo.

26 HELMET July - Sep 2012 Metallurgical & Material Handling APPRECIATION

Mr. Ajoy Bhattacharyya – Cluster Head - Hyderabad The prize for best safety conscious Staff and Workmen was Presenting the Safest Medium Jobsite EHS Rolling Trophy distributed by Mr. Kumar Vikram – VP & Head – BMH for the Year 2011-12 to Mr. R. Suresh Kumar – Project BU at GMR CHP Tilda Project Site – Hyderabad Cluster Manager – Bhilai Steel Plant Project Site. Mr. Ajendra on 4th Sept 2012. Agrawal – Cluster EHS Manager - Hyderabad joined during the Occasion.

Metallurgical & Material Handling HELMET July - Sep 2012 27 Visible Leadership in EHS

Leader is a pioneer and What makes a good leader? Leadership is the Ability yy A leader has a clear vision of what’s to achieve. to influence others, with or without authority. Ability yy Sets this out in policies and expected performance. to influence others is a yy Makes sure everyone knows what these are and derivative of Interpersonal what they must do to succeed. communications skills, Conflict management yy Has clear picture of consequences for both success and failure. technique and problem solving attitude. Leadership yy Is courageous and humble. is the most important factor in business in general and yy Dares to walk an untroden path with conviction and EHS in particular. It includes all level of management commitment. from chief executive to the front line supervisor. It requires proactive approach/ involvement to EHS and Leading Improvements reinforces management commitment to “Safe Progress To be effective as a leader, you will need to: Culture”. All successful endeavors are the result of yy Communicate the vision human effort. ¾¾ You need to create alignment with your

28 HELMET July - Sep 2012 Power Transmission & Distribution workers of what is expected and how it should be achieved. yy Leadership Behaviours

¾¾ Frequently explaining what you expect in terms of EHS through tangible examples

¾¾ Be visible in the workplace and act on what you see (Correct or commend but don’t walk past)

¾¾ Using each meeting as an opportunity to express your personal commitment for EHS

¾¾ Frequently ask what your direct reports are doing for safety

¾¾ Provide and offer assistance to those who need yy Clear request for actions supporting Value-Based help Safety efforts.

¾¾ Provide positive feedback and share success yy A contingency system that supports and reinforces stories action consistent with Values-Based Safety yy Motivate People 4. Monitor the Process

¾¾ You need to shape and reinforce the behavior yy Review implementation and training progress you expect from workers including your yy Review how results are achieved, not just the results contractors asked

Leadership Practice yy How the new process is going?

1. Create Alignment yy What safety committees are targeting for yy Alignment means that the behaviours and actions improvement? of all involved with Value-Based EHS are consistent yy What actions are being taken? with, and demonstrate the importance of EHS in the organization. yy Care about levels of participation? yy Model safe practices at every opportunity yy What kinds of behavior are being recognized? yy Ensure management systems support safety and do yy What celebrations are planned? not create barriers. 5. Shape and Reinforce Behaviour 2. Communicate Value for Safety Target behaviours that will have high impact on safety, yy Include safety in every presentation and discussion such as planning an effective process, identifying areas for improvement, promoting participation and developing yy Include safety as the first agenda in every meeting and implementing action plans to address periodic, say yy Learn about your Value-Based Safety process. “monthly safe behavior focus”. yy Look for opportunities to talk about safety in the company and community Kumar Shailendra 3. Build Support Chief EHS Manager, PT&D yy Take stock of compelling information about the need for change.

Power Transmission & Distribution HELMET July - Sep 2012 29 Helmet Congratulates the following sites for achieving ONE Million and more LTI Free Safe Man-Hours

Safety l of Hono Rol ur

IE - PPEL, Jindal Project, Angul, Odisha Lucknow Sub-station 1 Million Safe Man Hours, Nov 2009 to May 2012 3 Million Safe Man Hours, Sept 2009 to Sept 2012

Agra Jattikalan TL MVPDS & SCADA, RSP, SAIL, Odisha 1 Million Safe Man Hours, Feb 2012 to Aug 2012 3 Million Safe Man Hours, Apr 2010 to Apr 2012

COB, IE-project, TSL, JSR IE- Bhushan Steel Limited, Angul, Odisha 1 Million Safe Man Hours, Apr 2011 to Jun 2012 4 Million Safe Man Hours, Jun 2008 to Jul 2012

BTTL-Tezpur, Assam (PGCIL) Project KKNPP, Job Site Kudankulam 2 Million Safe Man Hours, Feb 2010 to Feb 2012 9 Million Safe Man Hours, Oct 2008 to Sept 2012

Balia Sub-station Anta – Phagi TL 2 Million Safe Man Hours, May 2009 to Sept 2012 10 Million Safe Man Hours, Jan 2011 to Sept 2012

765/400 kV Sub-station, Lucknow 3 Million Safe Man Hours, Sep-2009 to July-2012

Demonstration on rescue operation

BTTL-Assam site conducted demonstration on rescue operation by Gotcha Shark Rescue kit & Horizontal life line on 24th Sep 2012. The demonstration was imparted by Mr. Rajiv Sinha (from Udyogi). Following the training fitters also practiced the rescue operation by using the rescue kit.

30 HELMET July - Sep 2012 Power Transmission & Distribution Safety TRAINING PROGRAMMES

APDRP Safety Shailendra-Head EHS. The program was inaugurated in the presence of Mrs. Saswati Basu-Manager-P & OD. One day training programme on APDRP safety Faculties of this program were Mr. Kumar Shailendra & was organized at Bijapur on 3rd September-12. The Mr. Aloke Chatterjee programme faculty was Mr. Kumar Shailendra-Head- EHS & Mr. Jayakrishnan-EHSO. 45 Candidates Safety in Construction participated & got trained. The same programme was Two days In- House Training Program on Safety in conducted on 1st September at Tumkur where 36 Construction was conducted on 24th & 25th July ’12 for candidates were trained. IE & SS Staff at Delhi cluster Office. Industrial Electrification The program was inaugurated by Mr. Sachindra Parkash A two days EHS Training Program on Industrial Pandey (P&OD) and faculty was Mr. A K Rajput (COH Electrification was conducted at Rourkela for staff from -SS & IE), Mr. Aloke Chaterjee (CEHSM-KKCO) & Mr. 16th Jul to 17th Jul 2012. The program was coordinated Krishna Kumar (CEHSM-DLCO). by Mr. Aloke Chatterjee,CEHSM-KKCO. Mr. Debashish First Aid Training Roy, COH IE-BU inaugurated the program in presence of Mr. Kumar Shailendra-Head EHS, Mr. D.K.Singh- One day training program on First Aid was PM-IE-RSP & Mrs. Saswati Basu-Manager-P & OD. conducted on 17th July at Satna and on 23rd July Mr. Kumar Shailendra, Mr. Aloke Chatterjee& Mr. Raja at Lucknow SS. The program covered Dressing, Basu were the faculties of this program. Bandages, DRABC, CPR, Listening of heart beat, Casualty in lifting etc. Safety in Construction Training for Gang Leaders Role & Responsibility A two day EHS Training Program on Safety in Construction was organized at Kolkata for staff from A three day training program for Gang Leaders Role 21st to 22nd Aug 2012. The program was coordinated by & Responsibility for safe execution of Project was Mr. Aloke Chatterjee, CEHSM-KKCO and Mr. Kumar conducted at RE-West Midnapur Project from 6th to 8th

Power Transmission & Distribution HELMET July - Sep 2012 31 August 2012. The training program was organized by Training on Electrical Safety Cluster EHSD & Operation in-coordination with RE- A training program on Electrical Safety was organized West Midnapur Project team. A total of 16 numbers of by L&T Power along with PT&D IC at 2X600 MW DB Gang Leaders were trained through this program. At the Power Plant Project, Raigarh. end of the program an evaluation of the training was made in terms of interview & the best three performers Mr.Sanga Srinivas - AGM Safety was the faculty for the were awarded with a token gift. Attendance certificates program organised by Mr.Pradeep Kumar Gupta - EHS were awarded to all the participants. Mr. Aloke Chatterjee Engineer. - CEHSM-KKCO, Mr. Asif Inon-EHSO-KKCO, Mr. S. K. Biswas & Mr. Sumit Mazumder were the faculty for First Aid & Fall Protection this program. At 400 kV Quad Jindal Power TL Project, First aid & First Aid Training Fall Protection Training to workmen was provided by Mr. R. Saravana Kumar, EHSO. First Aid Training was conducted at Powai Site and Saki Site on 26th September 2012 by Dr.Abhinandan from external agency Covered the different type of first aid along with CPR Procedure

32 HELMET July - Sep 2012 Power Transmission & Distribution Construction Safety

Transmission Line

Two days In- House Training Program on Safety in Transmission Line was conducted on 26th & 27th July ’12 for TL Staff at Delhi Cluster Office. The faculty was Mr. N. Arora (COH-TL), Mr. Krishna Kumar (CEHSM-DLCO) & Mr. Aloke Chaterjee (CEHSM- KKCO) Transmission Line

A two days EHS training program on Safety in Transmission Line was conducted on 20th & 21st July 2012 at Bilaspur, Chhattisgarh. & Good practices. 20 staffs were trained during the program. The session was inaugurated by Mr. Rajan Bansal, Cluster Project Manager & Mr. Durgapada Kuity, Substation Cluster Accounts & Admn. Manager for TL BU, Raipur Cluster. Two days In- House Training Program on Safety in Substation was conducted on 19th & 20th July ’12 for SS Mr. G.R. Soundarraj – CEHSM – HYCO & RPCO was Staff at Mumbai Cluster Office. the faculty coordinator for the program & Mr.Ch. Naidu & Mr. U. Manikandan – EHS Engineers convened the The faculty was Mr.Saifee, Mr.Satish Naik & Mr.JJ program. David A session on Stress Management was conducted by Mr. Industrial Electrification P. Sathya Narayana, Cluster HR Manager for Raipur. Two days In- House Training Program on Safety in The program covered Safety in Survey, Excavation & Industrial Electrification was conducted on 23rd& 24th Blasting, Safety during Foundation, Erection, Stringing, August ’12 for IE Staff at Mumbai Cluster Office. PTP & LC shutdown LOTO procedures, Safety in Material handling & P&M operation, TL case studies The faculty was Mr.JJ David,Mr.Manoj Pawar

Power Transmission & Distribution HELMET July - Sep 2012 33 Transmission Line

A 2 day’s in house EHS training program on Safety in Transmission Line was conducted on 16th& 17th July 2012 at Sawai-Madhopur, Ranthambore. The faculty was Mr. Kunal Banerjee (CEHSM-JPCO). The training program covered the topics of Excavation, Foundation, Erection, Commissioning, Case studies etc. A total of 14 candidates participated in this program.

Sub-Station HWHTL Project Organizes Fire Drill A 2 day in house EHS training program on Safety in at Store yard Sub-Station was conducted on 13th &14th August 2012 at Lucknow. The faculty was Mr. Krishna Kumar HWHTL Project organized a session on Fire Prevention (CEHSM-DLCO) Mr. Kunal Banerjee (CEHSM-JPCO). method. During this session Mr. Sukhen Nandy The training program covered the topics of Survey, (Site EHSO-HWHTL) briefed about the fire triangle, Excavation, foundation, Panel Erection, Stringing, classification of fire, usage of fire extinguishers, Testing& Commissioning etc. 22 candidates participated handling procedure of fire extinguishers and a fire drill in program. was conducted among staff, store personnel and security personnel at Store-Uluberia. A 2 day in house EHS training program on Safety in Sub-Station was conducted on 6th &7th September 2012 Fire drill programme was organised by BTTL,TEZPUR at Jaipur. Mr. Y.S. Chauhan-PM-DMRC was present site on 8th August, 2012 in the training programme. The faculty was Mr. Kunal Banerjee (CEHSM-JPCO).

34 HELMET July - Sep 2012 Power Transmission & Distribution APPRECIATION

220/132 kV GIS Mansarovar Project received the Merit certificate as “Incident Free Safe Work” during 10-01-2011 to 31-07-2012 from Rajasthan Rajya Vidut Parasan Nigam Limited, Jaipur

RoSPA Award

3 X 800 MW CCPP, Reliance Samalkote Expansion Project has won the RoSPA Occupational Health and Safety Silver Award 2012 for best safety practices during the year 2011.

Monthly Reward Scheme

Appreciation of Best Safety conscious (Behavioral) workmen/supervisors was rewarded on a monthly basis by BTTL-Assam Project Management. The program was initiated by Mr. D.Mukhopadhyay- Project Manager for better implementation of Behaviour Based Safety.

Best safety conscious award

2 x 600 MW DB Power Plant Project, Raigarh organized the best safety conscious award to workmen & staffs during the quarter Apr – June 12.

Mr. Sunil Kumar Yadav, CM & Mr. Pradeep Kumar Gupta EHSO were rewarded as the eligible candidates.

Power Transmission & Distribution HELMET July - Sep 2012 35 EHSO Meet

Jaipur

EHSO Meet at Jaipur was organized on 10th & 11th September-12. Twelve EHSOs presented EHS overview of their respective projects. Bilaspur

EHSO’s meet was organized at Bilaspur on 19th July 2012. The program was inaugurated by Mr. S. Sivasamy – Construction Manager of 400 kV GCEL TL & G.R. Soundarraj, CEHSM - Raipur Cluster.

During this meet EHSO’s shared their views on good practices, near misses, accident case studies, constraints, solutions, need for improvement & self-development, specific IMS requirements & EHSO requirement. 11 staff participated in the program.

36 HELMET July - Sep 2012 Power Transmission & Distribution EHS Management system in Gulf Projects

L&T’s Gulf projects follow the below EHS management systems:

After awarding the project to our organization, Kick off meeting is the first step to explain the project location, scope of work, client and consultant to all key Stakeholders.

Our EHS Plan will be prepared after the site visit of the project of particular location. EHS Plan will be specific to the project having the details of project description, scope of work, specific hazards and risk to the project, client, consultant & country legal and other requirements. yy EHS training The following systems are implemented yy Tool Box talk meeting on regular basis yy EHS Induction to all staff and workmen yy Inspection of portable power tools and Hand tools yy Screening the workmen by construction team yy PPE inspection and PPE compliance yy Weekly EHS walk down yy Daily EHS inspection yy Inter project EHS audit once in two months yy Quarterly country office EHS audit yy Bi - annual regional EHS Audit yy Operator competence and vehicle fitness certificate yy Monthly site EHS meeting yy Workmen monthly motivation yy EHS Month and World Environment Day celebration yy EHS alert and communication to all staff yy Environment management

All the above measures will help minimize incidents and to promote a safe work place in the site.

P.V.Kaliappan Head EHS (Gulf) PT&D (International)

Power Transmission & Distribution (I) HELMET July - Sep 2012 37 Cable Pulling in Bend / Curved Area

Activity Cable pulling in bend /curved area using rollers control says “When determining controls, or considering and winch machine changes to existing controls, consideration shall be given to reducing the risks according to the following hierarchy: Potential Hazards Present Flight of Cable or wire rope from roller and possible due to different altitude of cable a. Elimination drum & puller machine location and cable route which b. Substitution may hit the near bystanders / public/employees c. Engineering control The following minimum control measures are followed d. Signage/warnings and or administrative controls in cable pulling by conventional bend rollers: Based on management advice, an action team comprising yy Bend roller are used in sharp bend Head - EHS, Project Manager, Construction Manager yy Sand Bags are used as back support for bend rollers and Site EHS Engineer were formed. In this activity yy Bend rollers are tied with concrete trough to restrict Elimination/ Substitution control measures are not the movement of rollers feasible. So, the team consulted with various agencies and yy Flagmen provided near cable pulling location to recommended the following engineering controls caution the public and others yy As suggested by senior management, Mechanical yy All machineries, tools and tackles, riggers, operators Modification of bend roller executed as an engineering involved in cable pulling were certified by third party control to arrest the flight of cable /wire rope from the and in line with legal requirements. roller by the project team in consultation with project managers yy All required permits and No objection certificates are obtained from the concerned authorities. yy Additional square bars (existing metal scrap) are welded with the bend roller by in-house team, which yy Safety in EHV cabling conducted for all involved will reduce the flight of cable and wire rope workmen and Staff yy Welded bar edge was protected with cab and cable side yy Onsite inspection done for all the above as per the with foam approved Project EHS plan checklists. yy In-house Modifications Work cost for each piece is yy Continuous supervision by qualified supervisors and AED 40 per roller against the AED 350 per roller by monitoring by Construction Engineer’s outside vendor for the same work and However a Lost time injury was reported during EHV yy This was implemented in 132 kV cabling job and Cable pulling activity due to the flight of wire rope in the found more advantageous than conventional bend beginning of the year. roller usage

After the detailed incident investigation and review, senior Direct Benefit : Reduction of risk potential management advised for implementation of alternate Indirect benefit : Less administrative control cost controls measures to eliminate the possible recurrence of Safety of employee and public similar incident as per as OHSAS 18001:2007 clause 4.3.1 Hazard Identification risk assessment and determining Reuse of scrap material

38 HELMET July - Sep 2012 Power Transmission & Distribution (I) Erection of Precast Boundary wall elements near Energized mobile substation

Activity Erection of Precast Boundary wall Elements using truck mounted crane near Energized Mobile SS under the live 132kV OHL. Potential Hazards 132kV Overhead live lines, Energized Mobile substation, Failure of lifting Equipment, Fall of material, Electrocution due to induction. Lifting Plan and risk assessment Lift Assessment 1. Load : Precast Boundary wall Column Weight: 1.5 t Dimensions: 3.78 m x 400 mm x 400mm Height of lift required : 07 m Max. radius (worst case only):06 m Competent: All are competent to carry out the activity. Precast Boundary wall panel Certified: All the competency certificates verified and Weight: 4.1 t Dimensions: 3.74 m x 2.9 m x 0.15 m Emergency Coordinator and First aider and all required Height of lift required: 9.5 m Max. radius (worst case Emergency arrangements are in place. only): 07 m Client (TRANSCO) System Safety Rule 2. Equipment The distance from the nearest exposed High Voltage Truck Mounted Crane (HIAB) Model:377-ep-3xs hiab14 Conductor Not earthed, or from an insulator supporting an Cap: 10.2 t at 3m rad. length 3t at 10.2m rad. Length, exposed High Voltage Conductor, which must be maintained Jib length: 14m Outrigger spread: 1.5m Web Slings: 2no’s at all times to avoid danger to persons 3m for 132kV, (Note: SWL- 4 t,D Shackles: 02 no 6.5 t SWL High Voltage Insulators minimum safety clearance distance =0.5m). 3. Task Preventive EHS Measures Precast elements shall be shifted to erection area in yy Detailed Activity specific Lifting Plan prepared. “A” frames which is arrest in truck mounted crane in yy TRANSCO/FEWA Work permits obtained by competent vertical position,02 no’s of wall panels shall be brought person for the works under the energized gantry area. in erection area at one time, panels will be tied with chain slings with the vehicle. Frame lifting clutch will yy Uninterrupted supervision by competent person. be connected to the anchor and clutch will connect to yy Entire crew oriented for the approved method statement the lifting web sling using ‘D’ shackles. Precast element &Risk Assessment and their competency double checked. will be lifted vertically using truck mounted crane and yy All equipment earthed at all times. guideline rope will be used to guide and control the load, yy All the lifting gears, tools and tackles, riggers, operators special care shall be taken while erecting that load will involved in lifting were certified by third party and in line be away from substation and chain link fence. Panels with legal requirements. will insert between the Columns. Lifting clutch will be yy Weather forecast verified. On site weather (Wind speed removed from element. and Temperature) checked and confirmed for the lifting 4. Environment activity. o Temperature: 38 C, Wind speed: 10 Kmph, Visibility- Clear yy Physical Goal Post fixed to restrict the Load and Overhead - Live 132 kV OHL Ground- Leveled and Equipment movements within the safe working area. Compacted yy Onsite inspection done for all the above as per the 5. Personnel approved Project EHS plan checklists. Trained: Specific job training given to all the crew prior yy Entire crew was attentive while working below the live to commencement of the activity and tool box talk OHL. Zero Tolerance on required Safe distance from live conducted. OHL was maintained at all times as per the lifting plan.

Power Transmission & Distribution (I) HELMET July - Sep 2012 39 Helmet Congratulates the following sites for achieving ONE Million and more LTI Free Safe Man-Hours

Safety l of Hono Rol ur

Awali Field Development Fit out of 3 X 220 kV 400 kV Overhead Transmission Lines Fujairah to .5 Electrical Substation and 220 kV Distribution 2 Ras Al Khaimah, Contract No. N 6318, UAE System, Bahrain 2 ADPC 1001 -272, UAE New 132/33 kV Substation at Kalba (N 8033), UAE 1 GTC/371A/2010 Qatar Power Transmission 2 expansion Phase 10 – Substations, Qatar N – 7133 : 132/11 kV Substation at Sir Baniyas 1 Island, UAE EPIC for Electrical & telecom Utilities for SSA 4 Phase 1& 2 and West End Extension, Ras laffan, 33 kV OHL for Bab Thamama G & Habshan 1.8 Qatar 1 MMBOPD Phase -1 Development Project, UAE 10 OETC Projects, Oman

PT&D (INTERNATIONAL) – BAHRAIN

Memento issued by Mr.Marcel to all L&T Project staff Participation from Tatweer Project Management team

On 31st July 2012, Awali Field Development Fitout of 3X220 kV Electrical Substation and 220 kV Distribution System - Tatweer project achieved Half Million Safe Manhours without any reportable Lost Time Injuries from the inception of project. This milestone is even more remarkable as it has been achieved in a difficult circumstances and a demanding schedule. As part of this milestone achievement, on 20th September 2012 a get together was organised with client representatives and mementos were distributed to all L&T project staff.

40 HELMET July - Sep 2012 Power Transmission & Distribution (I) APPRECIATION

BAHRAIN

On 30th August 2012, on site Mass Tool Box Talk meeting was conducted at Tatweer project 220 kV OHL Platform by Mr.P.V.Kaliappan EHS Head of PT&D (I). Prizes were distributed to best EHS conscious workmen.

UAE

N 6318 project team in UAE achieved two million safe man hours without any Reportable Lost Time Injuries from the inception of project. As this project is one of the high risk level project spread over three emirates namely Fujairah, Sharjah (Khorfakkan) and Ras Al Khaimah (Rough terrain including valleys and steep mountain), all project staff, workmen, subcontractors and all stakeholders were appreciated with special memento on this special achievement.

A memento was issued to Mr.J.S.Sudarsan EVP & Head PT&D IC by Mr.G.Kesavan JGM – Gulf I in the Presence of Mr.P.V.Kaliappan Head EHS PT&D (I) on 08.09.12

Power Transmission & Distribution (I) HELMET July - Sep 2012 41 Safety TRAINING PROGRAMMES

QATAR

On 22nd September 2012 “Construction Safety Training Program” was conducted in Doha. 18 staff from various Projects in Qatar participated in the training Program.

Mr.P.Asokan Phase X Project Manager Inagurated the Training program. In his speech he stressed the importance of good EHS culture in the construction industry.

The Program was coordinated by Mr.P.V.Kaliappan Head – EHS of PT&D (I) and organized by Mr. Satya Prakash & Mr.Ananth Sankararaj of HR Dept.

Topics Including EHS Management in PT&D Projects,Safety in Substation and EHV Cabling Work,Safety in Testing and Commissioning Work,Environmental Compliance requirements in Construction, EHS legal & other requirements of Qatar and HIRADC are covered in the Training program.

Mr.P.V.Kaliappan, Mr.B.Rajagopal and Mr. Narendra Mishra are Internal faculties for the Program.

Certificates were issued to all Participants by Mr. P.Asokan.

42 HELMET July - Sep 2012 Power Transmission & Distribution (I) Construction Safety

On 23rd September 2012, Emergency Evacuation awareness program was conducted in the newly established Sharjah office located in the 4th floor. All staff participated in the program. Topics including Emergency Evacuation plan, Emergency Contact numbers, Basics of Fire Extinguisher and communication to the Visitor’s were covered in the program.

Mr. Robert Coleman, CEO of C Y Holding company Ltd, USA explained the risk involved in high rise Building fire, fire prevention & protection methods and usage of Fire Escape Hood during fire incidents.

EHS Management System Kuwait

On 15th September 2012, EHS Management system orientation was conducted in Kuwait PT&D Country office and Project Office. EHS Head Mr. P.V.Kaliappan was the faculty for the program. Topics like Effective EHS Management in Oil & gas projects, Critical activities of Substation & OHL projects, Importance of team work to achieve Zero accident and Case studies were covered in the program. Kuwait EHS Manger Mr.Jayakarthick organized the program in coordination with EHS Head.

Orientation at Fintas Country Office Bahrain

On 7th September 2012, Bahrain PT&D projects EHS Management review meeting was conducted. Mr.P.V.Kaliappan EHS Head and Mr.K.Venkatesan Project Manager of Tatweer projects and Bahrain EHS staff participated in the meeting. Key Performance indicators (KPI) were reviewed and risk potential & relevant control measures for Substation& OHL projects were discussed.

Power Transmission & Distribution (I) HELMET July - Sep 2012 43 Crossword Puzzle Answers of Last Issue 6 5 F I R S T A I D

C 9

C 8 S

4 I M P A C T

2 H A Z A R D O O

7 E 1 L O T O

3 G R E E N I C

R T C H

P Y

QUESTION

Left - Right

1 Procedure to protect workers from unexpected energisation during maintenance work

2 Source, Situation or act with a potential to cause harm

3 Colour of scaffold tag indicating “safe for use”

4 Any adverse effect to the environment due to our operations

5 ______is the life saving, critical help given to an injured person before professional medical aid arrives.

Top - Down

6 A type of incident which has given rise to injury, ill health or fatality

7 Acronym of the procedure meant to handle emergency situations

8 EHS ______provides overall intentions and direction of an organization towards EHS management

9 ______block is used to prevent inadvertent movement of parked vehicles TOP 4 WINNERS

1 Madhamanchi P Saradhi, Infra IC 2 Amitava Chaudhuri, B&F IC 3 Raja Basu, PT&D IC 4 Prabhakar Srivastava, PT&D IC

Printed at RR Donnelley Publishing India Pvt. Ltd., Sriperumbudur. Edited by Mr. V.S. Ramana for L&T Construction from L&T Construction Headquarters, Manapakkam, Chennai - 600 089. The views expressed in this magazine are not necessarily those of the Management. The contents of this magazine may not be reproduced without the written permission of the Editor. Not for sale. Only for circulation among employees of L&T Construction.