Hazard management in Power Sector: Techniques for Hazard Identification & Risk Mitigation By

1. Hazard management in Power Sector: Techniques for Hazard Identification & Risk Mitigation By Dr. RohitVermaDy.Director NPTI Dr. Manisha Rani Fellow,NPTI

2. DEFINATIONS HAZARD Source or situation with a potential for harm in term of injury or ill health, damage to property, damage to workplace environment, or combination of these.

3. HAZARD IDENTIFICATION Process of recognizing that a hazard exists and defining its characteristic

4. RISK Combination of likelihood & consequences of a specified hazardous event

5. RISK ASSESSMENT Overall process of estimating the magnitude of risk and deciding weather or not the risk is tolerable

6. ACCIDENT Unplanned & unexpected event which results into injury or property damage is known as accident.

7. Causes of accidents • Unsafe conditions • unsuitable clothing for a particular job • untidy work area • tools in poor condition • poor lighting in work area • Unsafe act • using equipment without having received proper training in its use • failing to use the appropriate protective equipment  • distracting others from their work or allowing yourself to be distracted • using tools or equipment incorrectly.

8. Types Of Occupational Hazards • · Physical hazards • · Chemical hazards • · Biological hazards • · Mechanical / Electrical hazards • · Psychosocial hazards

9. Types Of Occupational Hazards • Physical hazards • Heat • Cold • Light • Vibration • Radiation • Noise • Chemical • Biological • Mechanical-electrical • Psychological

10. Physical Hazards HEAT The direct effects of heat exposure are Heat exhaustion heat stroke [civil works] Burns [boiler area, electrical flash over] Heat cramp [civil works, boiler area] COLD [[[[[[ Important hazards associated with cold work Frost bite Chilblains Immersion foot General hypothermia as a result of cutaneous vasoconstriction

11. Physical Hazards HEAT- As a hazard in power stations can cause • Heat stress-it is the aggregate of environmental & physical work factor i.e. Total heat imposed on the body. • Heat strain- it is the physiological responses to the heat stress. • Heat disorders-these result in heat cramps, heat exhaustion, heat stroke. • Heat cramps: painful intermittent spasms of voluntary muscles after hard physical work in hot environment. Cramps usually occur after heavy sweating. • Heat exhaustion: profuse sweating, weakness, rapid pulse, dizziness, nausea & headache. Skin is cool/pale. Body temperature is normal, nausea, vomiting and unconsciousness may occur.

12. Physical Hazards Light as a hazard in working condition can be due to: • Less lighted areas when the light is insufficient person strains his eyes to see the work object/area. Light requirements are increasing with age of a person to see and work on the object. • Excessive light- it is dangerous for eyes when light in work area is excessive since it causes glare.

13. Physical Hazards LIGHT Effect of poor illuminations are :- • Headache • Eye pain • Lachrymation • Congestion around the cornea • Eye strain • Eye fatigue Exposure to excessive brightness is associated with discomfort, visual fatigue, blurring of vision and may lead to accidents.

14. Physical Hazards VIBRATIONVibration especially in the frequency of 10 to 500 Hz, can affect hand and arm after month of years of exposure Ill effects: • The fine blood vessel of finger becomes increasingly sensitive to spasm (white fingers). • Injuries of the joints, of the hands elbow and shoulders may take place

15. Physical Hazards • NOISE • Industrial noise can give rise todeafness • Non auditory effects are irritation, nervousness, annoyance, fatigue, inefficiency etc. • Hearing impairment due to Noise is, as per the schedule of the Factories act, is reportable as well as compensable. • Hearing loss in most cases is not sudden but increases with the length of the work time in the noisy zone.

16. Physical Hazards NOISE Threshold Limit Valuefor noisy working conditions: (An 8 hour shift in all following cases) • 8 hours work – 90 dBA • 4 hours working – 95 dBA • 2 hours working – 100 dBA • 1 hour working – 105 dBA • half hour work – 110 dBA • Threshold of hearing – 125 dBA • Sudden deafness/rupture of ear drum can occur at 140 dBA

17. Physical Hazards RADIATIONA. Ultraviolet Radiation hazard-Seen in work with arc welding and mainly affects the eyes. Exposure to such radiation may lead toConjunctivitis and Keratitis (Welder’ s flash)B. Ionizing radiation hazards[X room USG CT]Anemia Leukemia Cancer SterilityFetal Malformation in case of pregnancy Ulceration In extreme cases death can take place

18. Mechanical / Electrical Hazards • Accident • Fall • Injury • Electricity burn • Electric shock.

19. Electrical Hazards Injury from direct contact • Injury by shock • Injury from internal burns Injury without current flow through body • Direct burns from electrical arcs • Radiation burns from very heavy arcs • Injury from fire & explosion from electrical arc • Physical injury from false starting of machinery, failure of controls • Eye injury from electrical arc welding

20. Chemical Hazards Chemical hazards – liquid and gaseous hazards • Dust • Smoke • Fumes • Poisonous gases • Acids • Alkalis

21. Chemical Hazards They enter our body through • Skin • Inhalation • Mouth They can cause internal as well external injuries • Skin diseases • Lung diseases • Internal blood and other diseases

22. Biological Hazards • Exposure to infective and parasitic agents • Inset bite • Dog bite • Snake bite

23. Psychosocial Hazards FACTORS - • Maladjustment with work environment. • Lack of job satisfaction • Insecurity • Emotional tension • Poor human relationships • Health problems • Fatigue • Headache • Hypertension • Heart disease • Peptic ulcer • Behaviors changes • Anxiety/Depression • Sickness absentees

24. Prevention

25. Mechanical Hazard PREVENTION • Preventive maintenance • Adequate job training • Ensuring safe working environments • Establishment of safety department with qualified safety engineer • Periodic survey for finding out hazards • Application of ergonomics

26. Physical Hazards NOISE Noise can be controlled by; • Reducing vibrations • Enclosing the noise producing equipment • Enclosing the operator • Moving away from the noisy area • Use of personal protective equipments

27. Physical Hazards Effective temperature and heat effect in an environment can be controlled by: • Increasing air changes • Reducing radiated heat by insulation • Reflection of heat • Drinking plenty of water and intake of salt • Use of personal protective equipments

28. Physical Hazards VIBRATION • Continuous working should be avoided and rest pauses after some time of work must be allowed to workers. • The driving force of vibrating surfaces may be reduced by; • 1. Reducing the forces • 2. Minimizing rotational speed • 3. Isolating • The response of vibrating surfaces may be reduced by • 1. Damping • 2. Additional • 3. Increasing mass of vibrating surfaces • 4. Changing size to change resonance frequency

29. Mechanical Hazards MACINERY HAZARDS: • These are due to revolving parts of the machines. • These can be controlled by providing machine guards which are a statutory requirements under Sections 21 to 26 of the Factories Act 1948. • As per section 21 of the Factories Act- provide guards at following; • Moving parts of the machinery including fly wheels • Transmission machinery • Point of operation • Any other dangerous part

30. SAFETY OF MAINTENANCE PERSONNEL Mechanical Hazards • Safety precautions are required to safe guard the maintenance personnel from getting involved in machinery accidents owing to inadvertent starting of machinery by; • Design of control switches • Safe guards for the operating levers • Interlocking of power system

31. PREVENTION Physical hazards • Application of ergonomics • Maintenance of temperature- 69 to 80 deg. F is the comfortable zone • Proper ventilation • Good housekeeping • Proper illumination • Personal protection • Personal hygiene • Health education • Job rotation • Periodic health Check up

32. Biological Hazards PREVENTION Personal Protection Post Control

33. Psychosocial Hazards • PREVENTION • Good induction program. • Management by participation. • Establishment of Proper communication channel. • Establishment of Healthy personnel policies • Establishment of healthy HR relationship. • Regular stress management program.

34. Chemical Hazards Chemical Safety • There are thousnands of chemical compounds, which presents some form of hazards either major or minor incidents usually termed as chemical accidents. • To avoid chemical accidents some points to be kept in mind. • knowledge of chemicals • knowledge of pocessing plant • knowledge of operator

35. Chemical Hazards in power plant • Coal/silica dust is major health hazard in power station • These dusts enter our body through inhalation • Respirable dust particles can enter our lung sacks and reduce our breathing capacity since this reparable dust settles there, • Normally coal dust particle less than 1 micron only can enter in our lung sacks. • Bigger dust particles either remain in our nose or get stuck in throat. Then they go into stomach and get removed from our body system in natural way. • Coal dust is non toxic and as such no effects are caused on body due to the particles of dust in stomach.

36. Chemical Hazards • Respirable dust particle which enter into our lungs can not be removed and they remain settled there. • Disease which can occur due to inhalation of coal dust is known as “pneumoconiosis” and is irreversible till person is shifted from job • Silica dust can cause “silicosis” • Both are reportable as well as compensable diseases under the schedule of the factories act

37. Chemical Hazards Control of coal dust by • Reduction of dust emission by suppression by wetting coal in wagons, at the time of tippling, water spray in coal conveyors. • Suction of coal dust from environment in above areas. • Use of personal protective equipments like filter respirators which can filter out reparable coal dust particles. • Continuous monitoring of environment by measuring and keeping it below.

38. Chemical Hazards 2. Gases Gases are the common hazards in many industries leads to suffocation and asphyxia. Asphyxiating gases are – CO, Cyanide, SO2, Chlorineetc. Smoke: inhalation of smoke which can contain poisonous gaseous fumes also and can have effects on our health; Fumes: fumes emanating from liquid chemicals can cause ill effects on our health when inhaled; Vapor: vapors of chemicals liquids are also dangerous to our health when inhaled. Vapours of hydrazine hydrate can cause unconsciousness when inhaled.

39. Chemical Hazards 3.Metals and compounds Toxic hazards are seen from Lead, Mercury, Chromium, Arsenic etc 4.Chemicals Acid (water treatment/ chemistry), Alkali and Pesticides. • Hazardous chemicals used in thermal power stations: • Chlorine • Hydrochloric acid • Euphoric acid • Hydrazine hydrate • Liquor ammonia • Sodium hydroxide

40. Chemical Hazards Chlorine • It is the most hazardous chemical used • It is used in water treatment plant • It is procured in toners for use in chlorinationation • When more than 10 tons of chlorine is stored/ handled/used in any industry, a Disaster Management Plan (DMP) is required to be prepared and submitted to statutory authorities. • This DMP is required to be practiced through mock drills periodically and review meeting are to be conducted for checking discrepancies.

41. Chemical Hazards Chlorine • Chlorine vapor is poisonous when inhaled • Will cause burn in eyes • Chlorine liquid can cause burn on skin and eyes • Threshold Limit Value (TLV) for chlorine is 1 ppm • At 100 ppm it can be fatal.

42. Plant / sections which are prone to emergencies • Coal handling plant • Main plant • Water treatment plant • Hydrogen generation plant • Mgr transpiration system

43. Prevention of Chemical Hazard (Pneumoconiosis) 1.Dust control- · Proper Ventilation · Exhaust · Enclosed apparatus · Good house keeping 2.Personnel protection · Mask, clothing, cloves, apron, boots barrier cream etc 3.Personal hygiene 4.Health education about respiratory evolvement and personal protection 5.Medical control Periodic medical check up for early detection 6. Bagasse control- · Spraying with 2% propionic acid- · Keep the moisture content around 20%

44. Fire hazard Fire is a chemical reaction or series of chemical reaction accomplished by heat, light, smoke or other gases.

45. Fire Hazards In Power Plants • Coal handling plant: coal dust accumulation on conveyor decks, cable trays, head & tail pulleys, jamming of idlers and pulleys, belt sway, belt tension, dust & coal deposited at tops, crusher house and vibrating scene floors, bunker house , failure of belt joints, snapping of belts, partially damaged belt in operation, smoldering fire in bunkers

46. Fire Hazards In Power Plants • Cables in cable galleries and on trays in all plant sections, coal dust deposited on cable trays in mill area • Fuel oil handling and oil tanks (hsd,hfo,lshs, naphtha, petrol, diesel oil ) • Transformer oil, turbine oil, control fluid, seal oil, • Natural gas • Electrical system • Heat path damaged insulation • Grass • Accumulation of waste material etc.

47. Explosion Hazard In Power Plant • Hydrogen plant • Turbo generators where hydrogen is used for cooling of Generator. • Boilers

48. How to Control Hazard ? 3 step process

49. Step 1: Hazard Identification Techniques

50. Hazard Identification Techniques • Safety audit • Safety survey • Safety inspection • Safety tour • Safety sampling • Job safety analysis • Hazard & operability studies • Fault & event tree analysis • Failure mode & effect analysis (FMEA)