Indira Gandhi National Open University PGDM Industrial Safety Health and Environment (2010) 1. INTRODUCTION SAFETY IN INDUSTRY The modern safety movement started around 1912 with the First Cooperative Safety Congress and the organisation of the national safety council in USA.From 1912 to the present time, remarkable advance have been made in reducing the rate and severity of accidents. The importance of industrial safety was realised because every year millions of industrial accidents occur which results in either death or in temporary and permanent disablement of the employees and involves a good amount of cost such as resulting from wasted man-hours machine hours etc which results in low productivity ,profitability etc. But the people do not give enough seriousness to it, again, In India, the world's worst industrialcatastrophe, Bhopal gas tragedy occurs. It occurred on the night of December 2-3, 1984 at the Union Carbide India Limited (UCIL) pesticide plant in Bhopal, Madhya Pradesh. A leak ofmethyl isocyanate (MIC) gas and other chemicals from the plant resulted in the exposure ofseveral thousands of people. The official immediate death toll was 2,259 and the government ofMadhya Pradesh has confirmed a total of 3,787 deaths related to the gas release. Othergovernment agencies estimate 15,000 deaths. The government's classification was criticized after the deaths of people who were classed as having minor injuries. Chemicals (~390 tons) abandoned at the plant continue to leak and pollute the groundwaterwhether the chemicals pose a health hazard is disputed. The costs of the above two disasters are unaccountable, the main cause of the above two are lack in safety. These points to the need of safety in the industry. Loss of lives and accidents cost gradually led to the formation of Factories Act,Office,Shops and Railway premises act etc.The requirement for consideration of safety by management as part of its responsibility arises primarily from these Acts. Safety begins on the drawing board when in the original designs of tools of work place layout; accident hazard may be built in or eliminated. In an industry, safety may be considered from the mechanical side (equipment tools etc) or from legal angles of workmen’s compensation or even as a matter of training in and motivation towards safe work practices for workers (especially newly recruited ones). Institute of Industrial Management for Safety Health and Environment. Page 1
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Indira Gandhi National Open University PGDM Industrial Safety Health and Environment (2010)
1. INTRODUCTION
SAFETY IN INDUSTRY
The modern safety movement started around 1912 with the First Cooperative Safety Congress
and the organisation of the national safety council in USA.From 1912 to the present time,
remarkable advance have been made in reducing the rate and severity of accidents.
The importance of industrial safety was realised because every year millions of industrial
accidents occur which results in either death or in temporary and permanent disablement of the
employees and involves a good amount of cost such as resulting from wasted man-hours
machine hours etc which results in low productivity ,profitability etc.
But the people do not give enough seriousness to it, again, In India, the world's worst industrial
catastrophe, Bhopal gas tragedy occurs. It occurred on the night of December 2-3, 1984 at the
Union Carbide India Limited (UCIL) pesticide plant in Bhopal , Madhya Pradesh. A leak of
methyl isocyanate (MIC) gas and other chemicals from the plant resulted in the exposure of
several thousands of people. The official immediate death toll was 2,259 and the government of
Madhya Pradesh has confirmed a total of 3,787 deaths related to the gas release. Other
government agencies estimate 15,000 deaths. The government's classification was criticizedafter the deaths of people who were classed as having minor injuries. Chemicals (~390 tons)
abandoned at the plant continue to leak and pollute the groundwater whether the chemicals pose
a health hazard is disputed.
The costs of the above two disasters are unaccountable, the main cause of the above two are
lack in safety. These points to the need of safety in the industry.
Loss of lives and accidents cost gradually led to the formation of Factories Act,Office,Shopsand Railway premises act etc.The requirement for consideration of safety by management as
part of its responsibility arises primarily from these Acts.
Safety begins on the drawing board when in the original designs of tools of work place layout;
accident hazard may be built in or eliminated.
In an industry, safety may be considered from the mechanical side (equipment tools etc) or from
legal angles of workmen’s compensation or even as a matter of training in and motivation
towards safe work practices for workers (especially newly recruited ones).
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Indira Gandhi National Open University PGDM Industrial Safety Health and Environment (2010)
Employees shall be the focus point in any industry and money, material machinery which are
the inputs of the industry can only reckoned in importance after human resource only.
Increased productivity is only possible through increased safety.
2. SAFETY MANAGEMENT
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Indira Gandhi National Open University PGDM Industrial Safety Health and Environment (2010)
Safety Management is the implementation of a " Safety Management System" into an
organization.
Safety management system’ means the organisation and arrangements established by aninfrastructure manager to ensure the safe management of its operations;"
An effective safety management system has proved that the quality, productivity and
profitability are co-partners in business enterprises. It is very important to note that an
effective safety management system has become paramount important in industrial
activities. The effective safety management system requires an infrastructure within the
organization. Present infrastructural facilities in Medium and Small scale units are not to be
desired level. Building such an infrastructure has associated costs
In order to implement a Management System into an organization, there have to be some
procedures, processes and key documents that must be used and updated by the organization.
Key elements of a Safety Management System should contain a company policy, a safety plan ,
a hazard log, internal audits and a failure reporting and corrective actions system , a risk
estimation process etc.
THE KEY DOCUMENTS
A number of documents can be considered as "key" documents in a Safety Management system
1. The System definition: Defines the system on block diagram level.
2. The Safety Plan: Describes "Who does what and when".
3. The Hazard log: Contains all known hazards and their history.
4. The Risk analysis : Contains the risk analysis performed for each hazard.
5. The Safety Requirements : The safety requirements to the system
The Safety Case : The document that proves the system is safe.
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It is then up to the organization to adjust size, amount and complexity of these key elements
into a suitable and operative Safety Management System for the product and organization in
question.
SAFETY RESULTS
• From safe plant, process and operations and
• By educating and training workers and supervisors regarding safe practices on shop
floor.
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Indira Gandhi National Open University PGDM Industrial Safety Health and Environment (2010)
3. VISION OF THE PROJECT
The vision of the project is to increase the productivity of the plant with reduced rate of accident
and to gain knowledge. In all workplaces the health and safety of employees is closely linked
with the company's profitability. Safety and productivity are the two sides of the same coin and
productivity without safety is not possible. Employees shall be the focus point in any industry
and money, material machinery which are the inputs of the industry can only reckoned in
importance after human resource only The onward march of industrialisation cannot stop
because we are in the need of greater employment opportunities and improved goods so that
there can be continuing rise in the standards of living. Thus the challenge before us today is to
operate our industrial activities in a safe manner and to achieve the desired economic growth.
Increased productivity is only possible through increased safety. Human resource strategies
for improving the health and safety of people in the workplace do not necessarily cost money -
in fact they usually save money.
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Indira Gandhi National Open University PGDM Industrial Safety Health and Environment (2010)
4. OBJECTIVE OF THE PROJECT
Occupational accidents severely deteriorate human capital, and hence negatively affect theproductivity and competitiveness of countries. But despite this, we still observe a scarcity of
preventive practices, an unsatisfactory management commitment and an absence of safety
culture among firms. The result is evident in firms’ high accident rates. This situation is a
consequence of the general belief among firms that investing in safety is a cost, and hence has
negative repercussions for their competitiveness. The current work shows how Productivity and
Profitability gains through Health and Safety management system. It also creates awareness
among employees about the hazard and how accident effects the production of industry so thatthey can go hand in hand with safety management system toward the growth of industry.
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Indira Gandhi National Open University PGDM Industrial Safety Health and Environment (2010)
5. COMPANY PROFILE
BHARAT H EAVY E LECTRICALS L IMITED
Bharat Heavy Electricals Limited (BHEL ) is one of the oldest and largest state-owned
engineering and manufacturing enterprise in India in the energy-related and infrastructure sector
which includes Power , Railways , Telecom , Transmission and Distribution , Oil and Gas sectors
and many more. It is the 12th largest power equipment manufacturer in the world. BHEL was
established more than 50 years ago, ushering in the indigenous Heavy Electrical Equipment
industry in India. The company has been earning profits continuously since 1971-72 and paying
dividends since 1976-77. 73% of the total power generated in India is produced by equipment
manufactured by BHEL . The power generating equipment including turbines, generators,
boilers and auxiliaries in the country. BHEL has already supplied thermal sets up to 500 MW
rating and has the technology to go up to 800 MW. BHEL manufactured 500/236 MW Nuclear
sets are also installed in the country.
The BHEL manufactured sets accounts for 65% of total installed capacity in India. There is
ample scope for improving the plant availability by cutting down the shut down period, by
Renovation & modernization, Rehabilitation and by timely arranging the spare parts and other services.
BHEL has more than 35 years experience in the field of Design, manufacturing, erection and
operating experience, services in steam turbine .So that BHEL is undertaking Renovation and
modernization of BHEL & NON-BHEL Thermal Power Plants. This includes, Life assessment
studies recommendation for up-rating / up gradation, also includes retrofitting, repairs,
overhauling, with improved efficiency and heat rate and performance guarantee for a reasonabletime period. BHEL has taken lead role by providing specialized services, retrofitting renovating
and supply of even such spare parts for which complete design information and manufacturing
drawings are not available from original suppliers.
It is one of India's nine largest Public Sector Undertakings or PSUs, known as the Navratnas or
'the nine jewels’. It is India’s Largest Engineering & Manufacturing Enterprise of its kind
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Committed to Enhance Stake-holder Value, one of the Major Power Plant Equipment
Manufacturers in the World and consistent dividend paying company over three decades .
M AIN M ANUFACTURING P LANTS
Bhopal (Madhya Pradesh )
Bharat Heavy Electrical Limited, Raipur , Haridwar (Uttarakhand )
Hyderabad (Andhra Pradesh )
Jhansi (Uttar Pradesh )
Tiruchirapalli (Tamil Nadu )
Ranipet (Tamil Nadu)
Bangalore (Karnataka )
Jagdishpur (Uttar Pradesh)
Rudrapur (Uttrakhand )
Goindwal (Punjab )
Bharat Heavy Plates and Vessels Limited (Vizag )
Besides these manufacturing units there are four power sectors which undertake EPC contract
from various customers. The Research and Development arm of BHEL is situated in Hyderabadand two repair shops are at HERP (Heavy Equipment Repair Plant), Varanasi and EMRP
(Electric machines repair plant) Mumbai.
P RODUCTS
• Steam Generator
• Gas Generator
• Hydro Generator • Steam turbine
• Gas turbine
• Hydro Turbines
• Transformer
• Switchgear
• Oil field equipments
• Boiler drum
• Wind mill
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BHEL B HOPAL P ROFILE
Heavy Electrical Plant, Bhopal is the mother plant of Bharat Heavy Electricals Limited, the
largest engineering and manufacturing enterprise in India in the energy-related andinfrastructure sector today. With technical assistance from Associated Electricals (India) Ltd., a
UK based company; it came into existence on 29 th of August, 1956. Pt. Jawaharlal Nehru, first
Prime minister of India dedicated this plant to the nation on 6 th of November, 1960.
BHEL , Bhopal with state-of-the-art facilities, manufactures wide range of electrical
equipments. Its product range includes Hydro, Steam, Marine & Nuclear Turbines, Heat
Exchangers, Hydro & Turbo Generators, Transformers, and Switchgears, Control gears,
Indira Gandhi National Open University PGDM Industrial Safety Health and Environment (2010)
In all workplaces the health and safety of employees is closely linked with the company's
profitability. Safety and productivity are the two sides of the same coin and productivity without
safety is not possible. Human resource strategies for improving the health and safety of people
in the workplace do not necessarily cost money - in fact they usually save money.
For greater productivity, a healthy manpower is essential requisite. In order to ensure the health
care of the employee, the pre employment examination and pre placement examination are of
importance. To provide a congenial atmosphere, the work environment is to be monitored to
detect the symptoms of occupational health problems.
ACCIDENTS
An industrial accident may be defined as an event, detrimental to the health of man, suddenly
occurring and originating from external sources and which is associated with the performance
of a paid job, accompanied by an injury, followed by disability or even death. In every sphere of
human activity there is the possibility of an accident and the work place is no exception.
Industrial accidents are the end products of unsafe acts and unsafe conditions at work .
Many of the accidents have been attributed to human errors. As bought out by Heinrich
Pyramid one fatal injury arises out of 30 which in turn is the result of about 600 near missinjuries. Ample scope is therefore available to mould the employees attitude by supervision,
inspection etc, to control the unsafe acts and unsafe condition .
C AUSES OF ACCIDENTS
Accidents may be caused due to
• Technical causes or unsafe conditions• Human causes or unsafe acts
Indira Gandhi National Open University PGDM Industrial Safety Health and Environment (2010)
While the cost of accident prevention is pre planned allowing greater flexibility and control to
the management, the cost of accident has to be borne in a totally unplanned manner. Intangible
benefits of better worker morale, higher productivity, reduced cost of production, better labor
relation also accrue to the Company. Above all it helps in safeguarding valuable human
resource hence; adoption of measures for safety of the workers is always the better option.
ACCIDENT PREVENTION
Prevention of accidents is a true humanitarian concern, it doesn’t occur by itself ;there should
be a consistent implementation of safety measures and safety programmes emphasizing the
need for 1. Safe work place lay out and working conditions.
2. Safe material handling.
3. Personal protective devices.
4. Safety activities in the organisation.
PRODUCTION MUST SAFETY FIRST
The studies on accidents during the last five years’ have well established that around 90% of
the accidents took place because of human reasons. It has also been accepted that the journey
towards excellence in safety could be made, in a nutshell, through
(a) Well laid policy, systems & procedures.
(b) Infrastructural support.
(c) Human Competency and
(d) Human attitude.
A deep insight into the failure to achieve excellence in safety from an otherwise efficientorganization revealed that the major factors responsible for the lack of success in safety are: -
(1) Lack of visible and felt leadership across all levels.
(2) Belief that safety is the function only of a particular division.
(3) Tolerance of non-conforming habits.
(4) Concern for corrective actions rather than for preventive actions.
(5) Expenditure on safety viewed as mere outflow of funds.
(6) Feeling that importance on safety affects productivity.
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The root cause behind this lack of genuine interest and commitment for Safety emanates from
the perception of dichotomy between productivity and
safety – a feeling that safety is extraneous to the core operation not having positive impact on
productivity, Balance Sheet and Profit & Loss accounts.
Therefore, there is a need to explore
(i) Whether synthesis between Safety & Productivity is possible and
(ii) Whether that is really rewarding for the organization.
DICHOTOMY – HISTORICAL PERSPECTIVE
Previously, since the days of industrial revolution, the main objectives of the
Organizations were productivity & profit making. The working conditions used to be
horrible with no concern for safety & health of the workers. However, with the
pressure from the middle class intelligentsia and enactment of laws, the concept of
safety was incorporated.
As the concept of safety did not grow naturally from within and was mostly
thrust upon from outside; it was perceived as an extraneous obligation eating
away productivity & profitability. This belief compelled the organizations to framepolicies, procedures and systems separately for safety and for productivity using
different sets of resources.
DISSOLVING THE DICHOTOMY
The dichotomy can be dissolved by proper “synthesis” of the factors
influencing both productivity & safety and through “harmony” in their
manifestation.
(A) POLICY, SYSTEMS & PROCEDURES
“Well Laid Policy” for better safety has always many common elements
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meant for higher productivity. “Well framed systems & procedures” for safety also
give impetus to productivity. For example, Safety requires compliance regarding
quality maintenance, testing and certification to avoid breakdown or unwarranted performances.
This also helps in higher productivity and longer life span, thereby leading to more earning &
more saving.
Excellent infrastructural support statutorily required for safe operation directly improves
productivity through uninterrupted and quicker operations. Giving human protection through
right personal protective equipments for safety also gives confidence and courage to work
efficiently on sustainable basis, thereby having direct positive impact on profit. The variables
influencing policy, systems &procedures for safety being also contributory to productivity.
(B) HUMAN ASPECTS
(I) H UMAN C OMPETENCE
Competence, an essential precondition for productivity, is based on
education, experience and training. Analysis of the above components would
reveal that competence for productivity is a pre-requisite for gaining competence
in safety. Whereas, separate programmes are generally framed for improvingcompetence in productivity and safety, it is feasible, effective and economical to
synthesize the productivity and safety related competence developmental
programmes.
(II ) A TTITUDE
The intangible yet most dominant factor for both productivity & safety is the ATTITUDE .
Attitude development has an all-encompassing effect on organization, nation and the human
civilization as a whole.An introspection into the above behavioural pattern would reveal that they are also essential for
excellence in safety. Therefore, behavioural development through ethico-moral transformation
and creation of the organizational culture for its sustainability need not be addressed separately
for improving productivity and safety. The core values influencing both productivity and safety
being similar, the organization would reap multiple benefits through value orientation if the
apparent dichotomy between safety & productivity is ignored and be rightly integrated and
synthesized.
SOLUTION
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Although all the aspects for ensuring safety are not identical to those for ensuring productivity,
they are so much similar that it is not practical and economical to treat them in disintegrated
fashion. The different components of productivity i.e. production process, maintenance, quality
control etc. having partially different domains; which were earlier treated as separate
disciplines, have long been adopted as an integrated one. The economy and the synergy thus has
been so successfully reaped, that now it is unbelievable that once some of them were
disintegrated.
Similarly, “Safety” having so many common variables with “Productivity” in the systems,
procedures, infrastructure and human components should be synthesized with “productivity” in
a holistic manner . Such integration would ensure
(i) higher productivity through safety,
(ii) eliminate separate monitoring process,
(iii) reduce overheads,
(iv) reduce expenditure and most importantly,
(v) the managers would be genuinely interested in safety while
focusing on productivity.
This will bring radical positive transformation from the “compulsive extraneous thrust” on
safety to the “inspiring empowerment coming from within” in the journey beyond excellence insafety.
9. AREA VISITED/INSPECTED/OBSERVATIONS
I am doing my project work in Heat exchanger and condenser manufacturing division
(HCM).It is situated in bay8 of block1. There are 125 employees working in the HCM
division. Out of the total employees 92 artisans are engaged in various activities like
machining, fitting, grinding, store keeping, and material handling.
Here heat exchangers of different types and sizes are manufactured and the installed capacityis 250MW high pressure heaters ,270-500MW low pressure heaters and 500MW surface
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HAZARD & RISK ANALYSIS
A hazard analysis is a process used to assess risk. The results of a hazard analysis are the
identification of unacceptable risks and the selection of means of controlling or eliminatingthem. The term is used in several engineering specialties, including avionics , chemical process
safety, safety engineering and food safety to identification, studies and monitoring of any
hazard to determine its potential, origin, characteristics and behaviour.
Risk analysis should be performed as part of the risk management process for each project . The
data of which would be based on risk discussion workshops to identify potential issues and risks
ahead of time before these were to pose cost and/ or schedule negative impacts.
The risk workshops should be chaired by a large group ideally between 6 to 10 individuals from
the various departmental functions (e.g. project manager, construction manager, site
superintendent, and representatives from operations, procurement, [project] controls, etc.) so as
to cover every risk element from different perspectives.
The outcome of the risk analysis would be the creation or review of the risk register to identify
and quantify risk elements to the project and their potential impact.
Given that risk management is a continuous and iterative process, the risk workshop members
would regroup on at regular intervals and project milestones to review the risk register
mitigation plans, make changes to it as appropriate and following those changes re-run the risk
model. By constantly monitoring risks these can be successfully mitigated resulting in a cost
and schedule savings with a positive impact on the project.
HAZARD IDENTIFICATION RISK ASSESSMENT AND DETERMINING CONTROL
(HIRA DC)
HAZARD
Source or situation with potential for harm in terms of injury or ill health, damage to property,
damage to workplace environment, or combination of these.
(i) Safety Hazards (Injury, fatal accidents)
(ii) Health Hazards (illness, chronic diseases )
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HAZARD IDENTIFICATION
Process of recognizing that a hazard exists and defining its characteristics.
RISK
Combination of the likelihood and the consequences of a specified hazardous event occurring.
RISK ASSESSMENT
Overall process of estimating the magnitude of the risk and deciding whether or not the risk is
tolerated.
DETERMINING CONTROL
Providing control measures to reduce the risk to acceptable level.
RANKING HAZARDS BY RISK.
Hazards may be categorized in several different ways. The actual method used will depend on
the safety management teams approach to the problem, what is important is that hazards are
properly and realistically assessed and priorities established. Techniques for producing a
ranking vary from very simple to complex. Here we have taken the severity of consequence,
extent of exposure to hazard and the probability of the event occurring as the measuring system.
The risk is assessed by introducing a new factor called Risk Assessing Factor
SEVERITY R ATING (SR): An assessment of the worst potential consequence, defined
by the degree potential injury, illness or property damage which ultimately occur.
F REQUENCY R ATING (FR): An assessment of the probability that any particular hazard will resultin an injury, an occupational illness or property damage.
The assessment is based on such factors as location and extent of exposure (ER) to the hazard in
terms of cycle or hours of operation. It also helps to calculate the immunity power of a worker
involved in a work, with particular occupational health hazard.
R ISK ASSESSING F ACTOR (RAF): Products of hazard rating. It helps to access the risk.
RAF=SR× FR
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11. SITUATION OF SAFETY MANAGEMENT
SAFETY MANAGEMENT IN BHEL, BHOPAL
Concern for and action to control a safety, health and environmental for the action to controlsafety, health and environmental risk to the world’s population are rapidly accelerating.
Industries have responded to the need for reliable control of these risks with a broad range of
system employing physical, operational and management control. Each system is designed to
reflect the inherent risk of operations, the structure and culture of the organisation.
Employees are assets of any industrial complex and it will remain healthy if its workmen are
healthy. The health of the workmen gets affected because of constant exposure to toxic
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by an audit to check that records are being kept and documented working practices are being
followed.
After a successful audit, a certificate of registration to OHSAS 18001 will be issued. There willthen be continual surveillance visits (usually once a year) to ensure that the system is
maintained and continues to be effective
IMPLEMENTATION OF ISO 14001
ISO (the International Organization for Standardization) is a worldwide federation of national
standards bodies (ISO) member bodies. The work of preparing International Standards is
normally carried out through ISO technical committees. Each member body interested in a
subject for whom a technical committee has been established has the right to be represented on
that committee. International organizations, governmental and non-governmental, in liaison
with ISO, also take part in the work. ISO collaborates closely with the International Electro
technical Commission (IEC) on all matters of electro technical standardization.
As a part of implementing the ISO standards a MR (Management Representative) (HSE) will be
appointed and he will be given full authority and organizational freedom to approve, revise,
manage and implement this manual consistent with Company’s policies and objectives relatedto HSE.
All the other concerned departments are responsible for complying with this manual. Each
section head identified in this manual is responsible for implementing the requirement and
resolves any non-conformity within his department/section.
The organisation shall ensure that interning audit of the ems are conducted period of intervals to
1. Comfier med to planned arrangements for environment management systemincluding the requirements this international standard
2. Hs been properly implemented and is maintained
a. Provide information on the results of audit to management
After a successful audit, a certificate of registration to ISO 14001 will be issued. There
will then be continual surveillance visits (usually once a year) to ensure that the system
is maintained and continues to be effective
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Displacement of social objectives by political objectives, which may lead to
redundant costs and also rising costs
Direct political intervention in managerial decision over an arm length relationship thatwould restrict government’s task of setting appropriate managerial incentive structure.
Internal inefficiencies in bureaucratic activity.
OPPORTUNITIES
Demand for power and hence plant equipment is expected to grow.
Private sector power plants to offer expanded market as utilities suffers resource crunch.
Ageing power plants would give rise to more spares and services
business.
Life expansion program for old power stations.
Easy processing of joint ventures/ collaboration/import/ acquisition of
new technology.
Financial and operational autonomy for profit making public sector enterprises. To make
the public sector more efficient government has decided to grant enhanced autonomy
and delegation of powers to the profit making public sector enterprises
THREATS
Increased competition both national and international
Multilateral agencies reluctant to lend to power sector because of poor financial
management of S.E.Bs
More concessions to private sector and not to government owned utilities like NTPC or
S.E.Bs, so future power projects would be opened up in private sector
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