Integrated Environment, Safety, Health & Quality (ESHQ) Management System (ISO14001:2004, OHSAS 18001:1999, ISO9001:2000)

An Overview

Integrated Environment Safety Health and Quality Management System ISO 9001: 2000- Quality Management System ISO 14001: 2004- Environment Management System OHSAS 18001: 1999- Occupational Health and Safety Assessment Series

Document structure

Apex Manual System Procedures and departmental procedures application

WIs, OCPs, Guidelines, Specifications, ESHQ MPs, LR, Aspect /Risk Register Formats, Forms, records, register, file, correspondence& minutes

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III

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Document Control
Limited hard Copy Distribution All Documents available on Home Page

pyaa-varNa, saurxaa, svaasqya evaM gauNava<aa naIit

enaTIpIsaI ilaimaToD ivaQMyaacala

enaTIpIsaI ilaimaToD ivaQMyaacala p`itvaw hO saMvaOQaainak AavaSyaktaAaoM ko Antga-t pyaa-varNa evaM svaasqya ko saaqa-saaqa saurixat rKkr inarntr kayainaYpadna maoM sauQaar krto hue imatvyayaI evaM gauNava<aa sao yau@t ijammaodarI sao ivaVut ]%padna krnaa. nayaI tknaIikyaaoM kI phla krnaa evaM ga`ahk saMtuiYT sampUNa- gauNava<aa TIma kaya-Baavanaa evaM maanava saMsaaQana ko ivakasa pr Qyaana koind`t krnaa. nava p`va-tna evaM gait kao ivakisat krnaa tqaa dxata pwit ka p`caalana evaM jaaoiKma va p`dUYaNa sao bacanaa. saMgat kanaUnaaoM, ivanayamaaoM evaM laagaU Anya AavaSyaktaAaoM ka Anaupalana krnaa. nyaUnatma Apvyaya krnaa, AiQaktma raK ka sadupyaaoga krnaa, hiryaalaI kao ivakisat evaM Anaurixat krnaa tqaa p`akRitk saMsaaQanaaoM ka saMrxaNa krnaa. sauvyavaisqat maanyata p`aPt p`baMQana p`NaailayaaoM kao p`BaavaI ZMga sao kayaa-invat krnaa. idnaa^k : 15.12.2006 punarIixat jaarI :00 mahap`baMQak

Integrated Environment, Safety, Health & Quality (ESHQ) Management System (ISO14001:2004, OHSAS 18001:1999, ISO9001:2000)
Environment, Safety, Health & Quality Policy NTPC Ltd. Vindhyachal is committed to: Generate reliable, economical and quality electric power in eco-friendly, healthy & safe working environment in accordance with statutory requirements & norms with continual improvement in performance. Focus on Customer Satisfaction, Total Quality, Teamwork, Human Resource Development and initiative for New Technologies. Promoting innovation, speed & efficient operating practices and prevention of Pollution & Hazards. Compliance with relevant legislation, regulations and other requirements as applicable. Waste minimization, Ash Utilization maximization, developing & maintaining greenery and conservation of Natural Resources. Effective implementation of well recognized management systems 15th Dec.2006 Rev. No.: 00

Strategic Objectives

ESHQ 1 Minimise risks and Environmental Impacts due to all types of hazards and significant Aspects at work place ESHQ 2 Ensure greater involvement of employees in matters of ESHQ through suggestion schemes, reward schemes, training programmes, safety circle and safety awards ESHQ 3 Increase the use of personal protection equipments (PPEs) like safety shoes, helmets, hand gloves etc. through stricter enforcement, motivation, attitudinal and behavioural changes

ESHQ 4 Better management of First-Aid Boxes

ESHQ 5 Increase the number of Trained First-Aiders available in each shift

ESHQ 6 Enhance the medical surveillance of personnel working in areas having hazardous substances like acids, alkalis, coal-dust, ashdust and radio-active substances
ESHQ 7 Introduce and maintain a Management Information System (MIS) for reportable and non- reportable accidents and near-miss incidents and Efficiency

Strategic Objectives cont.

ESHQ 8 Generate awareness on possible occupational illnesses and

related improvements at workplace employees of contractors

ESHQ 9 Create greater awareness about ESHQ matters among ESHQ 10 Improve standards of maintenance in sewerage and
drainage systems

ESHQ 11 Converting Organisational MoU in to Functional Level

Department Targets System

ESHQ 12 Increasing the Scope of Integrated ESHQ management ESHQ 13 Establishing Efficient ERP system ESHQ 14 Improvement in Power Generation

SCOPE OF CERTIFICATION

Generation of Electrical Power from Vindhyachal Super Thermal Power Station ( 6x210 MW + 4x 500 MW) from combustion of fossil fuel and supply of power to Grid

Department Objectives & Targets

Based on Strategic Objectives/ MoU Measurable Time Targeted Based on Past Performance Trend

MR & Dy. MRs

AGM(O&M) as MR DGM(C&I) as Dy. MR(Quality) for ISO9001:2000, DGM(EMG) as Dy. MR (EMS) for ISO14001:2004 DGM (Operations) as Dy. MR(OH&S) for OHSAS 18001:1999

Internal & External Audit Plan

Internal Audit once in six months All three systems will be audited once Single Certification body Yearly External Audit

REFERENCES
Standards/ Guidelines:

ISO 9000: 2000 Quality Management Systems Fundamentals & Vocabulary ISO 9001: 2000Quality Management Systems requirements ISO 9004: 2000Quality Management Systems Guidelines for Performance Improvements ISO 14001: 2004Environmental Management System Specification with guidance for use ISO 14004: 2004Environmental Management System General guidelines on principles, systems and supporting techniques OHSAS 18001: 1999 with 2002 rev. Occupational Health and safety assessment series OHSAS 18002: 2000 Guidelines for the implementation of OHSAS 18001

EXCLUSIONS
ISO-9001: 2000

Clause 7.3 Design & Development: The Company is not involved in design activities mentioned in the scope. The power generated and supplied by the company is as per the relevant requirements. Hence, this clause is not applicable to the activities of the company. Clause 7.5.2 Validation of Special Processes: The Company does not have any such activities where the outputs cannot be tested / verified for its conformity. Hence, This clause is not applicable to the activities of the company Clause 7.5.4 Customer Property: The Company does not receive products, tools, or any other materials from customers for incorporation or use of it in the plant activities. Hence, this clause is not applicable to the activities of the company.

ISO 14001: 2004 No exclusion from any clause of ISO 14001: 2004. OHSAS 18001: 1999 No exclusion from any clause of OHSAS 18001: 1999

Common Procedure Manual

S. No 1 2 3 4 5 6 7 8 9 System Procedure for Control of Documents System Procedure for Control of Records System Procedure for Internal Audit System Procedure for Control of Accidents, Incidents, non-conformances System Procedure for Corrective and Preventive Actions System Procedure for Identification of Legal and other requirements System Procedure for Hazard identification, risk assessment, risk control, identification and analysis of critical tasks System Procedure for Environmental Aspect And Impact Analyses System Procedure for Consultation & Communication Title Doc. No Csp/01 Csp/02 Csp/03 Csp/04 Csp/05 Csp/06 Csp/07 Csp/08 Csp/09

10
11 12 13

System Procedure for Operational Control

System Procedure for Emergency Preparedness And Response System Procedure for Performance Measurement And Monitoring System Procedure for Management Review

Csp/10
Csp/11 Csp/12 Csp/03

Departments Covered under ESHQ Management system

Operation Department Turbine Maintenance Department C&I Department Chemistry Department EEMG Department Fuel Handling MTP Department FQA Department C&M Department Boiler Maintenance Department Electrical Maintenance Department Ash Handling Department Fuel Transportation TAD O&M Civil TS Safety EMG Health Centre CISF HRD IT Department

Competence Matrix
Sl. No. Designation Minimum Education/ Qualification Graduate Engineer, of the rank Manager or higher Minimum Experience 15 yrs in NTPC Skills required Knowledge over the business process of the organization, Communicati on Skills. Knowledge over the business process of the organization, Communicati on Skills. Good Communicati on Skills Training required

Management Representative (MR)

Internal Auditors Training on ISO9001: 2000, ISO14001:2004 OHSAS 18001:1999 Internal Auditors Training on ISO9001: 2000, ISO14001:2004 OHSAS 18001:1999 Internal Auditors Training on ISO9001: 2000, ISO14001:2004 OHSAS 18001:1999

Dy. Management Representative

Graduate Engineer, of the rank Manager or higher

10 yrs in NTPC

Internal Auditors

Executives of the rank E1 and above

2 yrs in NTPC

DOCUMENT MATRIX

Sl.No
1

Document
Apex Manual

Review
MR/ Dy. MR (Quality) Dy. MR (EMS) Dy. MR (OH&S) MR/ Dy. MR (Quality) Dy. MR (EMS) Dy. MR (OH&S) Concerned Sectional Head Concerned Sectional Head Concerned Sectional Head

Approval
G.M.

Modification
G.M.

Records
MR

Issue
MR

Integrated ESHQ Policy

G.M.

G.M.

MR

MR

3 4 5

Department Manuals Objectives & Targets Management Programs

Concerned HOD Concerned HOD Concerned HOD

Concerned HOD Concerned HOD Concerned HOD

Concerned HOD or his Nominee Concerned HOD or his Nominee Concerned HOD or his Nominee

MR MR MR

Emergency Response Plan Work Instructions & Operational Control Plans

Concerned Sectional Head Concerned Sectional Head

Concerned HOD Concerned HOD

Concerned HOD Concerned HOD

Concerned HOD or his Nominee Concerned HOD or his Nominee

MR

Concerned HOD

Legal Aspect Register (EMS)

Legal Aspect Register (OH&S) Environment Aspect Register Risk Assessment Work Sheet

HOD (EMG)

HOD (EMG)

HOD (EMG)

MR

Concerned HOD
Concerned HOD Concerned HOD Concerned HOD

HOD (Safety)

HOD (Safety)

HOD (Safety)

MR

10

Concerned Sectional Head/ Dy. MR(EMS) Concerned Sectional Head Dy. MR(OH&S) Concerned Sectional Head

MR

Concerned HOD Concerned HOD

MR

11

MR

MR

12

Forms/ Formats & Log Books

Concerned HOD

Concerned HOD

Concerned HOD or his Nominee

Concerned HOD

Example of Departmental Objectives and Targets

OBJECTIVES & TARGETS (FQA)

Improvement Project/ Key Performance Indicator Station Availability Factor Forced outage due to Boiler Tube Leakage Accidents Reported in Department Training to all employees

Unit of Measurement

Past performance data if applicable

Target(2006-07)

% %

92.52 0.89

89.59 0.5

Nos. Days per Employee per Year

0 7

Example of Management Programme

MANAGEMENT PROGRAMME(MP/FQA/02)

Objectives & Targets: Reduction in Forced outage due to

Boiler Tube Leakage

Action Plan:

Sl. No. 1 2

Activity To analyse the past cases of failures/outages To decide necessary corrective actions.

Responsibilit y Head(FQA) Head(FQA)

Target Date

Monitoring regularly the effectiveness of the corrective actions taken.

Head(FQA)

Example of work instruction

TITLE ROTATION OF ASH PIPE LINE (STG. 1 & 2) Work Instruction no. WI/AHM/007

Revision No.: 00 Page 11of --20 Date of issue : 15th Dec2006

ROTATION OF ASH PIPELINE:

Ensure proper isolation and PTW before start of work. Mark the pipe by point, which are to be rotated. Open sleeve couplings for draining the line. Rotate the complete length of pipe as given below by using tested pulling & lifting tools. If required cut the pipe at suitable length to facilitate the turning. First Rotation by 1800 Second Rotation by 900 Third Rotation by 1800 Weld the pipe after proper alignment & using proper electrodes. Re-fix the couplings & take the trial. Record the details in SR no.: 003/BM/ASH/007

Example of Operational Control Procedure

TO REDUCE THE RISK OF FAILURE OF CRANE, CHAIN PULLEY BLOCK.
TITLE: Work Instruction no. OCP/AHM/001 Revision No.: 00 Page 15of --20 Date of issue : 15th Dec2006

1.Purpose: To reduce the risk of failure of crane, chain pulley block 2.Scope: ASH HANDLING 3.Responsibilities: DGM (AHM) 4.Performance criteria: Reduction of instances of failure of above lifting tool. Cross reference :a)NTPC Safety rules handbook. b) Risk assessment worksheets (Ref OM-(AHM)/07) 5.Activities Sl No 01 02 03 04 05 06 Activity To ensure that load test of crane & chain pulley block has been done and the lifting load is withine the limit. To ensure that all protection e.g. Travel, Movement of hoist overload and Failsafe working. To ensure that load is properly tied with the sling and hook. To ensure that chain pulley block knot are properly tied with the load. Check for approach at working location Check illumination before start of work. Responsibility Area Engineer Area Engineer Technician Technician Technician Technician

07 To ensure use of safety helmets, shoes & other essential PPEs. Technician 6. Verification, Corrective & Preventive Actions: Engineer In-charge of the contract shall conduct site visits and check for deviations from laid down procedures. Safety officer shall conduct surprise inspections.

Example of Format

FORMAT No. SR-006/F8.5.2 NTPC VINDHYACHAL UNIT OUTAGE REPORT Sl. Unit Trip No. No. Code Date Page-1 of 1

Trip B.L.U. Syn. Outage First Time/ Time/ Time/ Hours Cause of Date Date Tripping

ANALYSIS: Root cause: Corrective/Preventive actions taken/being taken :

Format for Internal Audit

AUDIT NO.: 02 NCR NO. : DEPT/ LOCATION : AUDITOR (S) NAME (S) DATE (S) OF AUDIT :

DOCUMENT (S) USED FOR AUDITING : Apex Manual, Common Procedure Manual, WI/OCP,DM NON-COMPLIANCE ISO9001/ ISO 14001/OHSAS 18001 (DESCRIBE DEFICIENCY IN DETAIL : i.e. what ? where ? CLAUSE NO. : _______ impact on Quality/Environment/Health/Safety of activity? ) AUDITOR (s) AUDITEES SIGNATURE (s) SIGNATURE ROOT CAUSE: CORRECTIVE ACTION : PROPOSED COMPLETION DATE ____________ AUDITEES ______________DATE____________ SIGNATURE

CORRECTIVE AND PREVENTIVE ACTION VERIFIED : YES / NO (MENTION COMMENTS) SIGNATURE DATE __________ AUDITOR (S) NCR CLOSED : REVIEWED BY : ______________________ (SIGNATURE OF MR)
Date of Issue: 15 th Dec2006

DATE _____________

SR/CSP/003/F-03

Revision No. 00