SAFETY IN COAL

HANDLING PLANT
A K KESHRI
GM-FM/FT (Retd)
NTPC Ltd.
 INTRODUCTION

 CHP in any coal based power house has a

reputation of most hazardous workplace.
 Workers faces many safety risks due to nature of job.
 Our Aim is to reduce the work related accidents
at CHP
 INTRODUCTION

 The work environment of CHP is often Dusty,

Noisy, some places are hot, consists of several
major equipment and operations involved.
 There is an always present risk for falling,
crushing injuries, electrical shocks, fire, coming
in contact of CO, CO2 etc.
 INTRODUCTION

 Due to the risky workplaces that Coal Handling

Plants constitutes, the companies need to assure
safe working conditions through systematic and
regular Hazard Identification and Risk Assessment.
 Many business enterprises have proven that good
safety management leads to increased
productivity and the same hold good for Power
Plants.
 INTRODUCTION
 By having a good safety management program,
not only minor injuries can be avoided, but also
other incidents that are costly, time consuming,
stressful and inconvenient can be prevented.
 OHSAS 18001 (Occupational Health and Safety
Assessment Series) suggests that a safety
procedure is must to ensure the identification of
Hazard, Assessment of Risk, and its determination
to eliminate, reduce or control the possibility for
any accident to occur.
 INTRODUCTION

 The most effective tool to reduce such accidents

is - HIRARC (Hazard identification, Risk Assesement and
Risk Control.
 HIRARC

 Hazard Identification, Risk Assessment and Risk

Control have become fundamental to the practice
of planning, management and the operation of a
business as a risk management.
 HIRA – Processes used to identify and evaluate
both existing and potential hazards on a worksite
and the methods used to control or eliminate the
hazards identified.
 RISK ASSEMENT AND MITIGATION
 The organizations that have carried out Risk
Assessment at the work place have noted
numerous changes in their working practice.
 Those who have already carried out risk
assessment in their work have reported positive
changes in their working practice.
 They recognized substandard act and working
condition as they develop and take necessary
corrective action.
 The risk assessment process should be continuous
and should not be regarded as a one-off exercise.
 HAZARD IDENTIFICATION

 Hazard is defined as anything (e.g. condition,

situation, practice, behaviour, etc.) that has the
potential to cause harm, including injury, disease,
deaths, environmental, property & equipment
damage.
 This is the process of examining each work area
and work task for the purpose of identifying all
the hazards which are inherent in the job.
 RISK ASSESSMENT

 Hazard is closed relationship with the risk.

 Risk is a measurement to analyze and evaluate
the hazard.
 The measurement is made by identification on
how sever and when likely of the hazard will
happen.
 Risk can be calculated using the following formula
Risk (R) = Likelihood (L) x Severity (S)
 RISK ASSESMNT MATRIX
LIKELYHOOD SEVERITY OF HAZARDS
OF HAZARDS
INSIGNIFICANT MINOR MODERATE MAJOR FATAL
(1) (2) (3) (4) (5)
RARE (1) 1 2 3 4 5

UNLIKELY (2) 2 4 6 8 10

POSSIBLE (3) 3 6 9 12 15

LIKELY (4) 4 8 12 16 20

ALMOST 5 10 15 20 25
CERTAIN (5)
INDICATION OF RISK LEVEL

RISK LEVEL
1 to 2 LOW
3 to 6 MEDIUM
7 to 12 HIGH
More than 12 EXTREME
 PURPOSE OF HIRA

 The purpose of Hazard Identification and Risk

assessment is to highlight the critical operations
of tasks that poses significant risk to the health
and safety of employees as well as highlighting
those hazards pertaining to certain equipment
due to energy sources, working conditions or
activities performed
 Risk level is assigned to each hazard for
identifying required corrective action to minimize
the risk or eliminate the hazard.
 RISK CONTROL

 Risk control is the elimination or inactivation of

hazard in a manner such that the hazard does not
pose a risk to workers.
 Hazard should be controlled at their sources
where the problem is created.
ACTIONS TO PREVENT UNSAFE CONDITION
Hazard is defined as anything
condition, situation, practice, behaviour etc.
 House Keeping
 Use of PPEs
 Awareness (Proper Training)
 Proper protection (Coupling guard/ pulley guard/ Toe guard
etc).
 Fire Detection & Protection
 Good Operation Practices.
 Proper and timely maintenance.
 HOUSE KEEPING and 5S

 ..\..\Image CHP 5 S\industrial-manufacturing-

shop-floor-factory.jpg
 ..\..\Image CHP 5 S\Tools.jpg
 5S Rihand.mp4
 DIFFERENT SECTIONS OF CHP

 UNLOADING AREA
 CRUSHING AREA
 STACKING / RECLAIMING AREA
 CONVEYOR BELT
 BUNKER AREA
 PUMP HOUSE
 ELECTRICAL PANEL ROOMS
 CONTROL ROOM AND CABLE GALLERY
 UNLOADING AREA
 Wagon Tippler
 Fugitive dust
 Man stuck between two wagons
 Misalignment of cradle and derailment of
wagon
 Falling of bogie due to improper clamping.
 Overrun during pushing / pulling of coal rake.
 Roll back of coal rake.
 Fall due to slippery area
 UNLOADING AREA
 Apron Feeder
 Fugitive dust
 Man stuck in Dribble Conveyor
 Injury
due to rotary part ( Due to missing
coupling guard)
 Suffocation due to presence of gas.
 Presence of CO.
 Insufficient Lighting
 UNLOADING AREA
 Track Hopper
 Fugitive dust
 Man stuck in Bottom Door opening of BOBR wagon
 Misalignment of track and derailment of wagon
 Derailment due to coal heap in Track Hopper.
 Overrun during pushing / pulling of coal rake.
 Accident/derailment due to miscommunication between MGR control room and
loco driver / unloading supervisor.
 Injury due to fall in gratings.
 Fall due to slippery area.
 Falling in wagon from cross over.
 Sinking in BOXN wagon coal while pocking from top. (due to hidden fire inside
coal)
 Movement of rake while person still taking coal sample from wagon top.
 UNLOADING AREA
 Track Hopper
Track Hopper (-) level
 Fugitive dust.
 Injury due to falling coal
 Fall due to slippery area.
 Electrocution in Sump Pit
 Accident due to darkness.(Insufficient Lighting)
 Suffocation due to presence of gas.
 Presence of CO.
 CRUSHING AREA
 Crusher Area
 Very high noise
 Fugitive Dust.
 Injury due to rotary part ( Due to missing coupling
guard)
 High vibrating area.
 Fire due to coal dust / oil accumulation on floor.
 Sudden fall of huge quantity of coal from impact
area of chut.
 Accident due to material kept in pathway.
 CRUSHING AREA
 Vibro Feeder /Grizzly feeder
 Very high noise
 Fugitive Dust.
 Injury due to rotary part ( Due to missing coupling
guard)
 High vibrating area.
 Fire due to coal dust / oil accumulation on floor.
 Sudden fall of huge quantity of coal from impact
area of chut.
 Accident due to scrap kept in pathway.
 STACKER RECLAIMER AREA
 Fire in yard and fire in Electrical Panel Room (due to
ingress of coal dust)
 Sinking in coal while moving on coal heap. (due to
hidden fire inside coal)
 Fall of coal on track
 Self Movement of Stacker during heavy storm.
 Striking of Reclaiming Bucket with Dozer during
reclamation.
 Toppling of Dozer, due to improper movement on
coal.
 Fall due to slippery area near Hydraulic Motor.
 CONVEYOR BELT
 Fallon conveyor belt while crossing over running
belt.
 Loose cloth get entangled in conveyor belt.
 Accident due to belt snap / belt sway
 Injurydue to tail pulley (due to missing tail pulley
guard).
 Injurydue to fall of Take-up (Take-up area not
guarded properly)
 Firedue to coal dust accumulation on Deck Plate /
on plate below return conveyor.
 Accident due to material kept in pathway.
 CONVEYOR BELT AT (-) VE LEVEL
 InsufficientLighting
 Water accumulation at tail end.
 Coal accumulation in tail end and in pathway
 Fall on conveyor belt while crossing over running belt.
 Loose cloth get entangled in conveyor belt.
 Accident due to belt snap / belt sway
 Injury due to tail pulley (due to missing tail pulley
guard).
 Injury due to fall of Take-up (Take-up area not guarded
properly)
 Fire due to coal dust accumulation on Deck Plate / on
plate below return conveyor.
 Accident due to material kept in pathway.
 BUNKER AREA

 Suffocation due to presence of gas

 Presence of CO gas.
 Fugitive Dust.
 Injury due to rotary part ( Due to missing
coupling guard)
 Fire due to coal dust / oil accumulation on
floor.
 Sudden fall of huge quantity of coal from
discharge chute of impact area of chut.
 Accident due to material kept in pathway.
 PUMP HOUSE

 Water accumulation in pathway

 Injury
due to rotary part ( Due to missing
coupling guard)
 Accident due to material kept in pathway.
 Fall
due to improper layout of suction /
discharge pipes
 ELECTRICAL PANEL ROOM

 Injury due to loose chequered plate

 Fall in pit
 Flash over due to wrong isolation
 Wrong panel door opening from back side.
 Flash over due to coal dust accumulation
 Accident due to material kept in pathway.
 CONTROL ROOM AND CABLE GALLERY

 Coal Dust accumulation in Cable Gallery

 Wrong Isolation
 Miscommunication
 Improper Record Keeping
 Improper filling of safety formats
 ELECTRICAL SAFETY

 Wrong Isolation
 Wrong Identification
 Insufficient Isolation
 Miscommunication
 Over Confidence
 HIRARC
HAZARD LIKELYHOOD OF SEVERITY OF Risk (R) = RISK CONTROL
HAZARDS HAZARDS Likelihood (L) x
Severity (S)

Fire in coal yard 4 4 16 Regular inspection,

water spray, isolation
from ignition sources
Respiratory problem due 5 4 20 Use of Mask, Working
to coal dust. of Dust Suppression
system
Injury during coal handling 4 3 12 Use of PPEs, Proper
like slip and trip House Keeping, 5S

Catches on conveyer belt 3 5 10 Safety Guard on

moving parts
Injury during maintenance 2 4 8 Training, proper
on Crusher supervision, PPEs
Struck by falling object 2 5 10 Use of Helmet,
Safety Net etc
PROTECTIONS IN CHP
 PROTECTIONS IN CHP

 PULL CHORD
 ..\..\Video CHP\Pull Chord.mp4 (4.37)

 Belt Sway Switch (BSS)

 ..\..\Video CHP\BSS.mp4 (2.53)
 PROTECTIONS IN CHP

 Zero Speed Switch (ZSS)

..\..\Video CHP\ZSS.mp4 (3.00)

 Block Chute
 ..\..\Video CHP\Block Chute.mp4 (3.14)
FIRE
LINEAR HEAT DETECTION SYSTEM (LHDS)

 Linear Heat Detection System (LHDS)

..\..\Video CHP\LINEAR HEAT DETECTOR_SENSOR IN

FDA SYSTEM _LHS_LHD क्या होता है और कैसे काम
करता है ! _In Hindi_.mp4. (8.19)

 ..\..\Video CHP\Linear Heat Detector.mp4 (2.51)

FIRE DETECTION WORKING PRINCIPLE

➢ Fire Detection Working Principle

➢ ..\..\Video CHP\Fire Detection Working
Principle.mp4 (11:05)
 FIRE FIGHTING

 Deluge Valve Working

 ..\..\Video CHP\fire fighting Deluge system

Working.mp4 (10.49)

 Deluge Valve at site

 ..\..\Video CHP\Fire Fighting Deluge valve at site.mp4
(3.51)
 DUST SUPRESSION

 Dust Suppression after Apron Feeder

..\..\Video CHP\Dust Suppression after Apron

Feeder.mp4 (0:48)

 Dust Suppression at Wagon Tippler

 ..\..\Video CHP\Dust Suppression at Wagon
Tippler.mp4 (1.29)
 DUST SUPRESSION

 Dust Suppression – Dust Fighter

..\..\Video CHP\Dust Supression - Dust Fighter.mp4 (0.32)

 Dust Suppression – Dry Fog

 ..\..\Video CHP\Dust Supression Dry Fog.mp4 (1.04)

 CASE STUDY
 1) Death of two NTPC employees in Staff Room near
Track Hopper during winter season due to Carbon
Mono-oxide (Rihand -Yr 2005-06).
 2) Fall of a contractor labour while crossing conveyor
at tail end (Jhajjar Yr 2011-12) .
 3) Fall of NTPC Executive (AGM) due to leg got
entangled in scrap material in Crusher House (Korba
Yr 2015).
 4) Fall of an executive from height, while going
upstair, due to rusting of chequered plate of Landing,
(SSTPS Yr 2016).
 5)While cleaning chute in rainy season, huge lump fall
on the head of labour, while he was trying to inspect
the chute putting head inside the chute.
 CASE STUDY
 6) Fire on coal bunker area while welding small
openings in chequered plate of pathway.
 7) Head of labour got stuck in between Bottom
Opening Door of BOBR wagon (Rihand Yr 2002-03)
 8)NTPC Executive got pulled in Dribble Conveyor
below apron Feeder (Farakka Yr 2021).
 Labour Stuck in belt.mp4
 Conveyor Belt accident - man loses his hand.mp4
 THANKS

 ANY QUESTION

 ?