Executive Summary of Safety

Audit for BPSCL, Bokaro

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Good safety practices prevailing:
 
• Positive & supportive attitude by all employees towards
safety.
• All Safety documents are maintained in Safety Deptt.
• Safety issues are discussed in the Daily Planning
Meeting.
• Daily safety inspections are carried out by the Safety
Officer.
• Use of Safety Helmets with Chin Straps on.
• Submission of Online Annual return on safety to Factory
Inspectorate.

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 Statutory Provisions required to be fulfilled
Sl. No Statutory points / issues Observations Recommendations
1 Safety Manual & Policy as per Factories Safety Manual is To be approved and
Act & CEA Regulation-2011 prepared and Policy to be displayed
submitted to CEO at site
2 On Site Emergency Plan and Mock Emergency Plan is To be approved by
Drill, prepared and CIF, Jharkhand
(MSIHC Rule) submitted to CEO.
3 Constitution of Plant Safety Committee Committee Equal representation
and meetings(Factories Act- Sec 41G) constituted and of management as
regular meetings well as workers
are organized. should be there.
4 Inspection and testing of Lifting tools Done by Display of SWL, Next
and tackles/Lifts & Hoists(Factories Act- Competent Person due date to be done.
Sec 28 & 29) in July-2018. Copy of all such test
reports should be
available in Safety
Department

5 Establishment of Occupational Health OHC is not No qualified Doctor.

Centre and posting of Qualified established.
Medical Officer(Factories Act- Sec 41C)
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 Statutory Provisions required to be fulfilled
Sl. No Statutory points / issues Observations Recommendations
6 Provision of First Aid Centre and First Aid center is not At least one First aid
First Aid Boxes at Plant established with center should be
area(Factories Act- Sec 45) trained Pharmacist and established.
First Aider. But first aid
boxes are deployed at
various locations of
plant.

7 Reporting of Head of Safety Manager (Safety) is Head of Safety should

(As per Factories Act- Sec 40B) reporting to DGM report directly to CEO
(Maint) (BPSCL)
8 Safety of Building & Structures Done as per Statutory This is to be done
(Factories Act-Sec 40) requirement in July every year.
2018
9 Deployment of Electrical Inspector No electrical inspector Electrical Inspector to
(CEA Regulation) is deployed. be deployed as per
CEA regulation 2011
10 Welfare Officer (Factories Act- Sec No welfare officer is Welfare officer to be
49) deployed. deployed as per
Factories Act- Sec 49
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System Improvement:
 
• Cross Functional Safety Team – Concept may be
implemented for further improvement in OSH system.
• Display of Safety instructions / messages throughout the
plant in local language.
• Safety Park / Safety Centre may be established.
• Capacity building of safety professionals.
• Specific budget allocation / Imprest money for Safety
Department

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General observations
• Growth of heavy grasses & bushes inside entire plant &
peripheral area.
• Accumulation of Scraps and unwanted material
scattered in entire plant,
• Conveyor belt scrap accumulated near Hammer crusher
behind SMS II bursting yard which is prone to Fire
hazard
• All the structure and metallic parts are either rusted /
corroded or discolored need urgent repainting.
• Growth of grasses and vegetation on roof tops of boiler
and turbine main building, conveyor gallery ,window
sheds & all temporary sheds.
• Temporary stores and sheds below gas pipeline behind
GMI/c PP’s office and ID & FD fan area
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• Almost All the doors ,windows , structures and Equipments are
found having thick coat of dust
• Lack of Safety display boards, signage and area identification
boards in entire plants
• Exclusive agency for Fire protection and prevention needs to be
engaged to take care of fire eventualities. Static water tank,
jockey pumps, fire tenders are not available in the plant.
• Trench covers found missing in many areas in entire Power Plant
• Two level crossings are found without manning.

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Site Observations

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A. Switch yard:
 
• Wild vegetation inside the switch yard.
• Entry gate should be in closed position.
• Proper Display of “un authorized entry restricted “to be made
 
 
B. TG Building: (I – VIII)
 
• Unguarded trench and openings at various locations at “0” mtr.
• Electrical panel boards without back covers
• Loose wires with temp. Joints lying on ground
• Connection taken from boards without plug top
• H2 cylinder Manifold rooms found in open condition.
• Motor Earthing found missing in some cases
• T.G Hall out side wall towards Boiler found totally damaged
because of seepage of Water. 9
C. PTW system: (UCR)
• LOTO system is not implemented.
• One single format for all types of permits.
• Format is not matching with the present situation, needs review
• Checklist for different types of jobs can be made to ensure better safety.
• Safety department should be involved in permit checking
• Fire protection system in UCR to be installed (Inert Gas system)
 
D. Boiler: (I – V)
• Extended / projected rods / channels at number of locations in Zero meter
• Temporary welding sheds (Unit # I – V) needs to be removed
• All platforms and walk ways should have toe guards
• Very bad house keeping in front of defunct lifts
• All opening should be adequately covered or guarded
• Obstruction in front of stair case going down to be removed
• Damaged and hanging insulation on coal pipe lines at various location
• Shabby cabling at different locations
• Damaged stair case and hand rails at various elevations/locations
• Coupling guards and motor terminal boards missing in AC plant room motor at
13 meter.
• Electrical panel boards without back covers
• All ID Fan coupling Guards are not there 10
E. FOS :
• No display Board near Unloading area for Furnace Oil Tank ,
• Foam Pouring System is not available for Fire Fighting.
• Sprinkler network for external cooling of tank is also not installed.
• Lot of wild vegetation found inside dyke area.
• Oil Tank earthing and lightning arrester found missing.

F. WCTP Plant :
• Repainting of display board near entry gate to be done
• No Eye shower installed in entire WCTP plant
• No insulating Rubber mats found in front of control panel
• Loose & Temp. wires found everywhere in very shabby condition.
• Proper Dos & Donts to be displayed in local language

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G. CHP Area :
• Housekeeping to be improved in crusher house & all conveyor
galleries.
• Lot of coal dust accumulated on various floors of crusher house
• DE system to be made functional
• Photo cell barrier on both side of wagon tippler may be installed for
restriction of trespassers
• Water sprinkling system is not available in conveyor galleries
• Water logging seepage, slippery floors of walkways in almost all
conveyor galleries
• Roof ceiling found damage at many places of gallery & below gallery
• Barricading near entrance of Track Hopper to be provided
• No Warning boards & public alarm system found in this area .
• Speed of the Coal Rake found higher and unsafe
• Workers are engaged for clearing of boulders from the grating area
which was found very unsafe.
• Wagon is in tilted position for almost half an hour instead of 3
minutes cycle which is another dangerous situation.
• Caution boards to be displayed on either sides of railway track 12
Thanks

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