Holistic Approach

to Plant Safety Management

for Zero Accident and Beyond

Japan Coal Energy Center

Indian Power Stations 2018 February XX, 2018

@Power Management Institute,
NTPC
 Contents

1. Fundamentals of plant safety management

2. Standard practices to prevent all kinds of accidents

3. Standard procedures with focus on high-risk tasks

4. Knowledge sharing and management involving all levels

of plant people-from management to workers

5. Conclusion
2
0
Why plant safety
management is important

3
1
Fundamentals of plant
safety management

4
1
Safety policy is well shared

5
1

Manuals are in place

6
1

What helps us
to make a difference?

7
1

Make a big change

by having any and all near miss
incidents as well as undesired
circumstances reported and shared
in timely manner.

8
1

Share exactly the same safety

information with all colleagues,
seniors and relevant workers as
every one of them constitutes
the team working in the interest of
plant safety.

9
2
Standard practices to
prevent all kinds of
accidents and incidents

10
 2 Organization of piping systems, etc. by color (1)

Pipes are colored for

organization and
identification according
to JIS (Japan Industrial
Standards).

11
2 Organization of piping systems, etc. by color (2)

Inspected tools are marked

in specific colors for
identification of the month
of the latest inspection.

12
2 Organization of piping systems, etc. by color (2)

“Working tag (white)” for

the maintenance section
and “Danger tag (red)”
for the power generation
section

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 2 Passageway safety management (1)

 Plant engineers and

workers are urged to
use pre-established
safety passages.
 Detours are established
if these passages
should become
unavoidably obstructed.

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 2 Passageway safety management (2)

 Visitors are also requested to

use pre-established safety
passages.
 Hazardous areas are
highlighted so that plant
engineers and workers as
well as whoever visits the
plant may easily recognize
the possible hazard on site.

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2 Safety management at specific areas (1)

Attention-getting warning signs

16
Safety management at specific areas (2)

Things like these can be

improved at no or small cost…

17
 2 Safety management at specific areas (3)

Measures to firmly
prevent falling objects

18
2 Safety management at specific areas (4)

Proper lighting

19
2 Tools and disassembled parts management

20
3
Standard procedures
with focus on high-risk
tasks

21
 3

“Specified High-Risk Tasks”:

1. High place work

2. Heavy loads handling work
3. Handling of hazardous substance or material
4. Outage work and work at areas adjacent to electrical
system
5. Work at risk of anoxia by working at oxygen-depleted areas
6. Handling of electric devices in a confined space
7. Work at areas adjacent to high pressure/high
temperature/excessive low temperature part of the plant

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3

23
4
Knowledge sharing and
management involving all
levels of plant people-from
management to workers
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 4
Documentation & record-keeping (1)
Operation Instruction Worksheet

Basics of Safety & QC:

-Daily checks prior to operation
-Sharing of detailed instruction
-Using protective clothing and tools
-Assignment of qualified
supervisors
-Verification of the work area and
posting a sign
-Establishment of safety passages
-Implementation of 5S
-Taking advantage of lessons
learned from past accidents and
incidents

Supervisors in
charge respectively Who has checked
from the major Crucial and confirmed
Work items company and measures for
subcontractor safety and QC 25
 4 Documentation & record-keeping (2)
Non-compliance Reporting and Case Sharing &
Learning System 1)
Hydraulic hunting
caused by left-
behind waste cloth

Incorrect wiring
has incurred
improper operating
signals

Hazard, near-miss and

Incident Report Form

“Case Learning for All” Form

Plan for sharing 26

 4 Documentation & record-keeping (2)
Non-compliance Reporting and Case Sharing &
Electrical shocks and burns
Learning System 2)
during cleaning of insulator
and isolator
Hazardous Accident/Incident
Report Form

Falling with safety lanyard tangled

to an unshielded protruding object
in the way

Scaffolding fell off and struck an engineer working

downstairs

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 Documentation & record-keeping (2)
4 Non-compliance Reporting and Case Sharing &
Learning System 3)
Near-miss Incident Report Form

When Where Who During what kind of work

Work engaged How and Why Nearly got caught between the
Have the left hand nearly caught into a hoisted load (ash cooler) and the
grinder while tryingWelding sparks
to handle the deviceflying
with onto the nearby pillar.
Have got a light electric shock
the right hand.
flammable.
Nearly fall off from the ladder
due to the wet gloves.
while working alone.

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 Documentation & record-keeping (2)
4 Non-compliance Reporting and Case
Sharing & Learning System 3)

“Case Learning for All” Scheme

Reporting and Sharing System 29
4

Regular/daily on-site meetings

and training

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 Conclusion
 Plant safety enhancement saves the utility money by saving medical
expenditures, workers’ compensation insurance costs, and adds value to
its business by enhancing work efficiency and productivity.

 Protecting people on the job is in the best interest of the plant owner.
Enhancement of plant safety management will add value of the plant
through uprating the work efficiency and improving economy of the plant,
which will help utility build good reputation.

 The most crucial keys to a successful plant management are:

a. Identifying one who is the center of the entire plant safety
management.
b. Documentation should be done appropriately and in timely manner.
c. Knowledge sharing and management involving all levels of plant people-
from management to workers
d. Not only accidents and hazardous incidents but also near-miss incidents
are to be dealt with.

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 Thank you
http://www.jcoal.or.jp/eng/

Email: kzmurakami@jcoal.or.jp
ozawa@jcoal.or.jp
fyamada@jcoal.or.jp
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