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Greenfield Projects in India

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Submitted By erskd
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Improving Behavioural Safety Culture at M/s ITPC

Problem Statement:
Several Greenfield thermal projects have recently mushroomed under 11th five year plan in India. Being a green field project in the remote location, getting skilled man-power is one of the biggest challenges. As a part of inclusive growth approach, employing plant affected people (PAP) is an obligation. Irrespective of the qualification & educational background, industry needs to employ plant affected people which consists mainly raw hands. Being new to the industry and its requirement, they invariably lack industrial safety and behavioural safety as well. ITPC has experienced 3 fatal accidents and 32 Lost Time Incidents (LTI) which back laid the organization and the plant was required to shut for almost a period of 24 days in totality.
Operating a plant with Safety is of paramount priority and with this vision inculcation of safety culture among workmen coming from PAP (Project Affected People) in a Greenfield project is a big challenge. In Indian Thermal Power Company (ITPC), hundreds of unskilled, semi-skilled & unskilled people were engaged. 98% of them are from rural background. Some of them were first generation learner. They have never seen industrial work culture. Operating plant with such raw hands was challenge for ITPC. ITPC top management was in dilemma that to improve the safety work culture where majority of the work force is not even familiar with the ABC of safety.

Background: ITPC is renowned power generating public limited company and started a new power plant in Chhattisgarh state. Being a green field project in the remote location, getting skilled man-power is one of the biggest challenges. As a part of inclusive growth approach, employing plant affected people (PAP) is an obligation. Irrespective of the qualification & educational background, industry needs to employ plant affected people which consists mainly raw hands. Being new to the industry and its requirement, they invariably lack industrial safety and behavioural safety as well. ITPC has experienced 3 fatal accidents and 32 Lost Time Incidents (LTI) which back laid the organization and the plant was required to shut for almost a period of 24 days in totality. It is quite challenging for the entire operation team to run and maintain unit#1 while the other one is still in commissioning stage as several systems are common for both the units.

Narrative Incidence: ITPC moved from a green field project to stable operation phase. As per the strategic decisions by management; one unit is made ready for the commissioning and at the same time other was under progress for erection and commissioning. It was quite challenging for the entire operation team to run and maintain unit#1 while the other one is still in commissioning stage as several systems are common for both the units. Safety deficits in the units can threaten the environment & health of the employees working. Out of compulsion, the locally recruited operators, namely skilled, semi-skilled and unskilled were engaged for the operation of commssioned Unit#1. These people are the frist genearation industrial workforce and were totally unaware of minimum safety standards and practices. This was the the key hurdle faced during each phase of plant start up, commssioning and ramp up. It was very challenging task to get the workdone from this workforce by ensuring overall safety and safety of personnels engaged by aggencies for smooth execution of the job at site It was need of hour to drive, develop & sustain culture of safe work practices in the plant premises. Creating awareness for better implementaion and follow up PPE’s, SOPs SMPs, JSA‘s etc.

Blueprint:
The top management of ITPC is in dilemma that how to improve the safety work culture of its workmen who largely come from rural and farming sectors. Improving behavioural safety may lead to improve the safety standard but how to re-inforce this behaviour among the workmen. * How to implement prudent tools like Job Safety Analysis, Work Permit System, Standard Operating Procedure, Standard Maintenance Procedure, Internal Audit System, LOTO, Conducting daily, Weekly and Monthly Meetings, Safety Tool box Talk, PEP Talk before execution of all critical jobs, Height Pass System, Work explanation along with hazard, physical check along with work group. * Minimizing minor incidents like near-miss, Unsafe Acts, Unsafe Conditions along with joint investigations and circulate to all concern in plant to avoid repetition of such type incidents in other area of plant * How to initiate for organizing and providing, Safety Training, First Aid training and Fire mock drills to team for assisting in any emergency and unavoidable situations * How to establish Reward & Recognition policy to enhance level of motivation

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