Industrial safety and in-process monitoring

Промышленная безопасность

Production facilities of PJSC RusHydro are subject to planned monitoring and control for compliance with the safety standards of operation. This is necessary to avoid disruptions in the equipment operation and the appearance of emergencies, including the likelihood of flooding residential areas.

Monitoring of the hydraulic structures’ condition is carried out using standard monitoring systems installed at the construction stage and modernized during operation.

2.2.1. In-Process monitoring

Safety supervision of the hydraulic structures of PJSC RusHydro

An effective safety control and reliability of assets in operation are achieved through double monitoring system: internal – at the account of in-process monitoring for the compliance with industrial and professional safety at hazardous production facilities, and external – by state supervisory bodies.

The Company’s internal HS safety monitoring system is supportive towards HS safety state supervision and shall interact with federal executive bodies that perform state monitoring (supervision). Monitoring system includes:

  • permanent control of hydraulic structures in construction and in operation to assess and reveal their technical condition;
  • compliance control related to standards and rules in terms of hydraulic structure operation, construction and decommissioning;
  • timely detection and elimination of damages and emergency situations;
    arrangement of scheduled preventive repair and overhaul;
  • timely submission of safety declarations for hydraulic structures to state monitoring (supervisory) bodies.

Mechanisms that ensure operation and safety reliability of the facilities are:

  • quality control at the engineering and construction stage,
  • external regulatory supervision,
  • internal production control,
  • standards and operating procedures (sectorial and corporate),
    technical policy and technical management system.

Industrial control of compliance with the rules of industrial safety is necessary for accident-free operation of the power facilities.

A significant impact on the quality of production and technological complexes, especially, the prolongation of the service life and accident-free exploitation of the operating assets, is provided by the organization of timely maintenance, scheduled repair work, modernization of equipment, buildings, facilities and power plants communications.

Since 2014, the Regulations for industrial control over compliance with industrial safety requirements at hazardous production facilities have been developed and are being applied at all branches of PJSC RusHydro.

There are no deviations in relation to industrial safety requirements for the reporting period. In 2016, the Privolzhsk Administration of Rostekhnadzor issued an order with five measures to Cheboksarskaya HPP. All measures are implemented.


As of the beginning of 2016, there were 98 RusHydro HPF-sites registered in the State Register of HPF, as of the end of 2016 – 127 HPF-sites. The change was due to the continuing procedure of HPF-sites disaggregation.

In addition to compulsory insurance of civil liability of the HPF owner, RusHydro carries out voluntary insurance of civil liability. The limit of insurance compensation under this agreement is set at 35.5 billion rubles. Payment is made if the insurance indemnity for compulsory insurance of civil liability of the HPF holder is not sufficient to compensate for harm that may be caused to third parties as a result of an accident.

License No. BX-00-015161 dd. 16.12.2014, issued by the Federal Service for Ecological, Technological and Atomic Supervision for the «Operation of explosive/flammable and chemically hazardous production facilities of I, II and III hazard classes». License type – permanent.

Typical structure of an in-process monitoring arrangement at RusHydro

Typical structure of an in-process monitoring arrangement at RusHydro

In accordance with the Certificate of Registration of hazardous production facilities in the State Register of HPF, PJSC RusHydro has no hazardous production facilities of I and II hazard classes, and pursuant to the Paragraph 2 Article 14 of the Federal Law of 21.07.1997 No. 116-FZ «On Industrial Safety of Hazardous Production Facilities», no industrial safety declaration is required.

2.2.2. Accident and emergency response


Due to the on-going equipment reconstruction and modernization, the number of accidents in the Company’s branches decreased by 31 units (to 97 accidents) in 2016, with the number of accidents through the plant personnel’s fault decreased by 5 units (to 9 accidents).

The greatest results in reducing the number of accidents were achieved in the branches of PJSC RusHydro – Cascade of Kuban HPPs (-10 accidents), Dagestan branch (- 8 accidents), Kabardino-Balkaria branch (-8 accidents).

In PJSC RusHydro the number of accidents on turbine equipment also decreased (by 30 %), on generators (by 30%) and on relay protection and emergency automatics (by 50 %).

The greatest number of accidents is associated with the failure or incorrect operation of the equipment management systems. The main causes of accidents in 2016 were:

  • defects in engineering, construction, manufacture, installation;
  • aging factors of equipment.

In 2016, the number of accidents was 5,433 in RAO ES of the East, it is 389 times less than in 2015.

The dynamics of accidents in the branches of PJSC RusHydro, pcs.

динамика аварий


Emergency response measures are developed and implemented by the technical specialists of the branches on the basis of the investigation results of the occurred accidents and are controlled by the Company’s Executive Office.

Based on the investigation of the causes of accidents in the Company’s branches in 2016, 402 emergency response measures were developed, most of which (329) were completed. The deadline for 73 actions was set for 2017-2024.

The main organizational emergency response measures based on the investigation of the accidents causes in 2016 include:

  • interaction with project organizations and manufacturing plants for amendments to engineering solutions, elimination of engineering flaws in equipment, quality of supplied equipment, spare parts and materials;
  • improvement of the quality of incoming control of equipment, materials and spare parts;
  • increase in the scope of routine maintenance of electrical equipment;
    operational documentation amendment;
  • strengthening control over the parameters of the equipment technical condition.

The main technical emergency response measures based on the investigation of the causes of accidents in 2016 include:

  • restoration of the operational condition of the failed equipment;
    carrying out post-accident checks;
  • implementation of activities recommended by engineering organizations, equipment manufacturers.

Among the emergency plans for 2017, along with the work on further modernization of equipment, there are:

  • development of an action plan to reduce the flow of failures of electrical equipment, secondary control equipment and communication devices;
  • update of programs to reduce accidents;
  • strengthening of the control over the operational personnel training;
    improvement of the input inspection system to assess the condition and to enable compliance with the requirements for equipment and materials (participation in the factory acceptance);
  • maintenance of the equipment in a good working order outside the factory service life by frequent monitoring of technical condition, technical inspection.

The holding of RAO ES of the East carries out measures to analyse the breakdown of energy equipment, develops recommendations and measures to reduce the accident rate, including those with involvement of specialized organizations and application of advanced and innovative instrumental control methods during technical audits. Special attention is paid to measures of control over the quality and completeness of repair and post-repair testing of the equipment, measures to conduct input control of materials and equipment and measures to increase the responsibility of repair personnel for the quality of the performed work.

Противоаварийные мероприятия


Dangerous production facilities of I and II hazard classes17 are not in operation in PJSC RusHydro branches, therefore development of action plans for localization and elimination of accidents is not required. In the branches of PJSC RusHydro – Cascade of Kuban HPPs, Votkinskaya HPP, Karachaevo-Cherkessky Branch, North Ossetian Branch such plans have been developed on a voluntary basis.

On 12.07.2016, there was one technological incident at the HPF «The site of the main building of the PSPP of the PJSC RusHydro branch – Zagorskaya PSPP». The beam of the main lift truck was damaged by a hook suspension due to the elevation of the suspension and the failure of the lift limiter of the overhead electric crane.

The economic damage amounted to 672 thousand rubles. Based on the investigation results, the incident causes were: violation of normative and technical documents and regulations in the field of industrial safety, unsatisfactory quality of the mechanism maintenance.
To prevent such incidents, a special instruction was issued with a list of preventive measures. The operational instruction OU-11-2016 (AOPO) has been implemented.

There were no other accidents and incidents at the HPFs.


At PJSC RusHydro, the management of the fire safety system is carried out by the Industrial Safety and Labor Protection Department of the Department of Occupational Safety and Labor Protection. Every year, organizational and administrative documents regulating the employees’ activities in the field of fire safety are developed and approved.

Each branch of PJSC RusHydro has developed measures aimed at improving the level of fire safety, including:

  • modernization of automatic fire alarm systems, warning systems and evacuation
  • control system in case of fire, automatic fire extinguishing systems;
  • modernization of supply and exhaust ventilation;
  • repair and installation of internal and external fire water supply;
  • acquisition (reloading) of primary fire extinguishing means (fire extinguishers).

The production and administrative premises, buildings, structures and territory of the branches of PJSC RusHydro meet the requirements of fire safety norms and rules, are provided with primary fire extinguishing means. In 2016, there were no fires in the branches of PJSC RusHydro.

There are schedules of fire-prevention trainings in each branch. The trainings are conducted with operational personnel and facility-based fire departments. Once a year, a joint general fire-prevention training is conducted at all branches together with fire departments of the fire-protection garrison.

Nine branches concluded contracts for work performance and services provision in the field of fire safety for protecting property of organizations from fires.

2.2.3. Monitoring and assessment of the hydraulic structures’ condition

The monitoring of the hydraulic structures’ condition is carried out using regular monitoring systems installed at the construction stage and modernized during operation.

Detailed information on the methods of monitoring of the hydraulic structures’ parameters, as well as information and diagnostic systems for the technical condition monitoring is presented in the Corporate Social Responsibility and Sustainability Report of RusHydro Group for 2015.

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