Recommendations of the 7th Heads of Operation Meet November 2010

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Area of concern /Action plan Proper display of equipments and locations Proper identification for all equipments , pipe lines, valves, dampers etc Proper identification for electrical modules, breakers Emergency drives supply module are marked with red circles. Modules feeding to other units shall be marked suitable signs or shades(AC&DC ) Modules feeding to auxiliaries of major equipments like TBBFP LOP, APH drives etc to be segregated from that of non critical equipments Healthiness of all indications lamps to be ensured Marking of opening/closing directions of valves and dampers Position indications of all valve and dampers in UCB and local EPBs to be located at suitable locations with proper approach with cover and correct description Switching off the power supply for the identified valves which are operated only offline. Clear identification of aux steam header interconnecting valves, vacuum breaker , TDBFP exhaust valve etc and providing physical barrier Locking/removing valve handles to prevent unintentional operation Strictly follow the standard industry practice of naming the equipment and preferably provide indication in local.(Avoid names sounding similar-Control fluid pump, Control fluid R/C pump etc.) Use of distinctly different shades for switchgear rooms of various units Skill based errors Advance automation Ensure that personnel only perform tasks when they are properly trained, skilled and qualified. One activity at a time Equipment change over Judiciously plan change over schedule Proper procedure to be formulated Follow proper checklist

Responsibility HOD(O) HOD(O) HOD(O) HOD(O) HOD(O) HOD(O) HOD(O) HOD(C&I) HOD(EM) HOD(O) HOD(O) HOD(O) HOD(O)

Target

HOD(O) HOD(C&I) HOD(O) HOD(O) HOD(O) HOD(O) HOD(O)

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Confirm the status of equipment with local operator before proceeding to next step Confirm the ON/OFF status either from UCB or switchgear before stopping a running equipment Communication system availability PA System availability at all locations to be maintained in working condition Dedicated lines to SCE /Switchyard control room Knowledge-based errors No activity in case of confusion allow the machine to trip Prepare activity chart in detail Prepare comprehensive check list Evaluate risk perception Discuss with all the team members Carry out the actions under the guidance and approval of experienced personnel and level of authority All instructions are to be displayed at noise prone area Display of HOT PERMIT and NO SMOKING ZONE Rule based errors Assess the situation before applying the rule Clear cut Practices/instructions Time of the day effects Avoid planning major activity during odd hours Device means to improve the alertness during early hours Fatigue Management. Ensure that a well-designed shift roster ,breaks and adequate controls in place for managing overtime work Sufficient manpower resource to avoid extended working hours Violations Regular review of procedures and practices Strict adherence to established procedures Close monitoring of violations irrespective of the loss or damage Educating all concerned. Appreciation for voluntary compliance Administrative measures to deal with violations

HOD(O) HOD(O)

HOD(O)/IT/EM HOD(O)/IT/EM HOD(O) HOD(O) HOD(O) HOD(O) HOD(O) HOD(O) HOD(O) HOD(O) HOD(O) HOD(O) HOD(O) HOD(O) HOD(O) HOD(O) HOD(O) HOD(O) HOD(O) HOD(O) HOD(O) HOD(O) HOD(O)

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Regular review of procedures and practices Control Distractions. Good work environment, Ventilation, lighting etc No simultaneous activity Avoid involving in unrelated activity Information passing on to other agencies, arranging transport during odd hours, wake up calls etc. Miscellaneous jobs not connected with core responsibility during office hours Design- Layout deficiency Control stations may be physically separated if control stations of critical equipment placed very close to non critical equipments (PA fan and its LOP) Mimics may be modified in DDCMIS screens Common valves indicated in various mimics shall be marked clearly (TDBFP extraction block valve) Control stations shall follow the same pattern of layout as that of physical layout (FRS lines and its control , BFP A,B,C etc) Proper indication for lines and valves which are blocked by other equipments, walls etc Ensure healthiness of protections so that need to bypass the protections do not arise Protection bypassing to be done only as per LMI Extreme care to be taken while bypassing and normalising protections Ensure that no alarm conditions persist while restoring protections Fatigue Management Ensure that a well-designed shift roster ,breaks and adequate controls in place for managing overtime work Workload sharing Documentation E-logbook ,shift activities & any equipment defect to be made on line Any abnormal conditions , status of auto loops etc to be recorded and verbally communicated to next shift engineers. External reasons Restrict entry to control equipment room, DAS Room, UCB

HOD(O) HOD(O) HOD(O) HOD(O)

HOD(C&I)

HOD(C&I) HOD(C&I) HOD(C&I) HOD(C&I) HOD(C&I) HOD(C&I) HOD(C&I) HOD(C&I)

HOD(O HOD(O

HOD(C&I)/HOD(O)

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Restrict entry to the plant only to authorized personnel Rodent control Do not plant fruit bearing trees inside the plant compound to control animal menace Avoid storage of food and left over inside UCB/Control equipment room Provide closed bins for depositing food waste inside plant area Safety Establish as role models in safety. Safety is part of the activity Using lockout boxes for PTW Issuing PTW through SAP Displaying Danger Tags at isolated modules Critical isolations under supervision of experienced personnel. Always use proper tools (fuse pullers fuse pullers ,spark free Allen keys for H2 cylinders etc) Proper illumination in all areas Compulsory use of 24V supply for lighting in enclosed space-Boiler, ducts , vessels etc Standard isolation procedure for each equipment All isolations shall be completed by operation before issuing the Permit to work No isolation shall be entrusted to PTW holder or contracting agency. Regular review of procedures and practices Awareness program for outsourced manpower to be held regularly Compulsory use of PPE by all personnel working inside the plant area and offsite locations Scrap and scaffolding removal to be on top priority Insulation work to be completed before boiler light up All violations to be recorded and notice shall be served Relocate valves to suitable locations for ease of approach Ensure proper approach to all equipments Barricade area occupied by maintenance personnel Barricade area where work is carried out on upper elevations Do not move alone in isolated locations especially during odd hours Be in regular touch with control room while working in plant/offsite locations

HOD(O HOD(O HOD(O HOD(O HOD(O HOD(O HOD(O HOD(O HOD(O HOD(O HOD(O HOD(O HOD(EM) HOD(EM) HOD(O HOD(O HOD(O HOD(O HOD(Safety) AGM(O&M) AGM(O&M) HOD(BM) AGM(O&M) AGM(O&M) AGM(O&M) HOD(O HOD(O HOD(O HOD(O