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 preparation and handover of the Nexa and Nova Cell Production Line equipment for dismantling, 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 handover for dismantling. The main challenges were controlling residual chemicals present within the tools, isolating all relevant energy sources, and managing the shared chemical supply system without affecting the operational Hexa Cell Production Line. The work included chemical decontamination through draining and flushing, multi-energy isolation, LOTOTO implementation, safety verification, and formal handover. Following successful verification and departmental confirmation, the equipment was safely handed over for dismantling. The activity was completed without safety incidents and without interruption to Hexa Cell Production Line operations.".

[Audio] Before starting the activity, the hazards associated with the residual chemicals present in the baths and connected pipelines were identified. The chemicals included Hydrochloric Acid at 32%, Nitric Acid at 69%, Hydrofluoric Acid at 50%, Hydrogen Peroxide at 30%, Potassium Hydroxide at 48%, Sulphuric Acid at 95%, and Sodium Hydroxide at 47%. 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] 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] Chemical decontamination was a critical stage in preparing the equipment for dismantling. The chemical supplies to the Nexa Nova line tools were isolated, followed by draining of all process baths and associated pipelines. The chemical supply pipelines from the valve manifold to the tool, as well as the pipelines, baths, and tanks inside the tool, were flushed with DI water, and care was taken to prevent incompatible chemicals from mixing. All personnel involved followed the approved JSA requirements, utilizing the prescribed PPE and implementing the necessary safety precautions to control exposure to chemical hazards throughout the activity. The resulting effluent was collected and managed through the appropriate disposal method. Before proceeding, the decontamination status was checked and verified to ensure that residual chemical hazards were adequately controlled..

[Audio] Following chemical decontamination, all chemical, gas, electrical, and pneumatic utilities supplying the Nexa and Nova tools were safely isolated using the approved LO-TO-TO, Lock Out, Tag Out, and Try Out procedure. Isolation effectiveness was verified through appropriate try-out and testing. Electrical systems were confirmed de-energized, pneumatic systems were depressurized, and residual chemicals, gases, and pressure were safely managed. After verification, all utility connections were disconnected and secured. Dummy caps and other physical safeguards were installed where required to prevent leakage and contamination. Stored energy sources and potential unexpected movement were also controlled, ensuring the equipment was safely prepared for dismantling and handover.".

[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 the control of stored energy. Any outstanding hazards and restrictions were also identified and communicated. Following the required checklist confirmations and approvals, the equipment was handed over for safe 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 from this activity is that safe decommissioning requires a structured approach from planning through handover. Chemical hazards must be identified and eliminated, energy sources must be isolated and verified, and responsibilities must be clearly transferred through formal verification and handover processes. The Nexa and Nova cell production line decommissioning activity demonstrated how technical expertise, effective risk management, multi-energy isolation, and strong cross-functional collaboration can ensure safe execution while maintaining operational continuity. These learnings provide a practical and repeatable framework for future decommissioning activities across the site, helping ensure safety, operational reliability, and environmental protection..