PptxGenJS Presentation

[Audio] At Tata Power Renewable Energy, safety is driven by technical expertise, effective collaboration, and a commitment to operational excellence. Through our EHS Learning from Success Stories initiative, we highlight practical achievements that demonstrate how complex industrial activities can be executed safely and systematically. In this success story, we present the safe decommissioning and handover of the Nexa and Nova Cell Production Lines, showcasing effective risk management, multi-energy isolation, cross-functional coordination, and uninterrupted production. A success story that reflects our commitment to safety, teamwork, and operational excellence..

[Audio] The activity involved preparing the Nexa and Nova cell production line chemical bath tools for safe dismantling. The main challenges were controlling residual chemicals, isolating all relevant energy sources and managing the shared chemical supply system without affecting the operational Hexa Cell Production Line. The work included chemical draining and flushing, multi-energy isolation, LOTOTO, safety verification and formal handover. The activity was completed without reported safety incidents or interruption to Hexa Cell Production Line operations..

[Audio] Before starting the activity, the chemical inventory and associated safety data sheets must be reviewed to identify the chemicals present in the baths and connected pipelines. The chemicals included hydrochloric acid, nitric acid, hydrofluoric acid, hydrogen peroxide, potassium hydroxide and sulphuric acid, along with a sodium-based chemical whose exact identity must be confirmed. Actual concentrations should be taken from the approved inventory or SDS rather than assumed. The assessment also covered chemical and gas supplies, electrical connections, pneumatic lines, trapped pressure and other stored energy. Isolation boundaries, responsibilities and verification requirements were established to support safe execution and protect the operational Hexa Cell Production Line..

[Audio] Chemical decontamination was a critical stage in preparing the equipment for dismantling. The applicable chemical supplies were addressed through the approved procedure, followed by draining of the process baths and associated pipelines. Relevant connections were flushed using an approved, chemically compatible method, with care taken to prevent incompatible chemicals from mixing. The resulting effluent must be collected and managed through the designated system. Before proceeding, the decontamination status must be checked against the approved acceptance criteria to ensure that residual chemical hazards are adequately controlled..

[Audio] A major challenge was decommissioning the Nexa and Nova tools while maintaining the operation of the Hexa Cell Production Line, which shared the common chemical supply system. The supply routes and connections associated with the equipment were identified, and isolation boundaries were defined to separate the equipment being decommissioned without unintentionally affecting the operational line. The isolation and flushing sequence required coordination with the concerned operating teams and adherence to the approved system configuration. This was important because incorrect isolation could cause unintended chemical supply or release at the decommissioned equipment, or create unsafe conditions and production disruption in the adjacent line. The activity was completed without interruption to Hexa Cell Production Line operations..

[Audio] All relevant chemical, gas, electrical and pneumatic supply lines feeding the Nexa and Nova tools must be isolated and secured using the approved LOTOTO procedure, meaning Lock Out, Tag Out and Try Out. Chemical and gas lines require appropriate isolation and control of residual contents and pressure. Electrical supplies require isolation, LOTOTO and the prescribed verification of electrical safety. Pneumatic supplies must be isolated, with residual pressure released as required. Other stored energy and potential unexpected movement must also be controlled. Dummy caps and other physical safeguards are used where required to protect disconnected connections. The prescribed try-out and verification must be appropriate to each energy source. An applied lock alone does not establish that all hazardous energy has been eliminated or controlled..

[Audio] After decontamination and energy isolation, the overall equipment status was verified using the approved checklist. Verification was confirmed by the concerned representatives from Maintenance, Production, Process, Utilities and EHS, along with the Plant Head, as recorded in the applicable documentation. The verification covered chemical decontamination, relevant energy isolation, LOTOTO, required try-out, physical safeguards and control of stored energy. Outstanding hazards and restrictions also needed to be identified and communicated. Following the required checklist confirmations and approvals, the equipment was handed over to the Utilities and Scrap Teams for dismantling. This formal handover ensured that responsibility was transferred with the equipment status, isolation boundaries and applicable precautions clearly communicated..

[Audio] The Nexa and Nova Cell Production Line decommissioning was successfully completed through strong technical expertise, systematic planning, and effective cross-functional coordination. Subject matter experts from Maintenance, Production, Process, Utilities, and EHS played a crucial role in identifying potential hazards, defining safe isolation boundaries, and implementing appropriate safety controls. All identified chemical baths and pipelines were safely drained and flushed. Chemical, electrical, and pneumatic energy sources were isolated with LOTOTO controls implemented. Joint verification using approved checklists ensured that all safety requirements were fulfilled before controlled handover to the Utilities and Scrap Teams. A key achievement was maintaining uninterrupted operations of the Hexa Cell Production Line throughout the activity. The combination of technical expertise, layered safety controls, teamwork, and disciplined execution ensured successful decommissioning with zero safety incidents and zero production disruption..

[Audio] The key learning is that safe decommissioning requires a structured approach from planning through handover. Chemical inventories and energy sources must be identified, decontamination must be verified, and all relevant supplies must be isolated through the approved LOTOTO procedure. Try-out, verification and physical safeguards provide additional assurance that hazardous energy and residual risks are controlled. Where chemical supply systems are shared with operational equipment, isolation boundaries and coordination are essential to protect adjacent production. Cross-functional checklist verification and formal handover establish accountability before dismantling begins. To strengthen future activities, a standardized Equipment Decommissioning and Multi-Energy LOTOTO Checklist can bring these requirements together into a repeatable plant-wide process..