POWER PLANT

OPERATION &
MAINTENANCE
Safety
Objectives
• To make participants aware of the hazards involved
during the various activities of the Power plant operation
& maintenance.
• To enable participants understand the hazards and
establish controls on the hazards.
 Key Performance
Indicator 2019-20

Disclaimer: This presentation is solely for the use

of THERMAX Limited. No part of it may be
circulated, quoted or reproduced for distribution
outside Thermax.
 Key performance Indicator 2019-20
Criterion Target Mark
Frequency Rate <0.18 1

Severity Rate 0 1

Total recordable incident rate < 0.7 1

Near-miss Closure = 100% 1

Three observation per Thermax person
>3 1
/ month
Average SSIR for the Month <2.5 1

Observation Closure >90% 1

Competency Evaluation (Average) >80% 1

Site Category OHSAS Status Status C 1

Basic Safety Measure (BSM / Legatrix) >90% 1

April 17, 2019 Power Division – Safety dept.

Introduction
• Power Plant operation involves following key processes.
• Light up of boiler.
• Ash, bed drain.
• Venting or draining of Steam.
• Measuring the temperatures, vibrations, current flow, fluid flow, &
others.
• Dosing of chemicals.
• Collection of samples. Eg, steam & water.
• Operation of equipment's periodically. Eg CHP Soot blower.
OHSAS 18001: 2007
OCCUPATIONAL HEALTH
AND SAFETY ASSESMENT
SERIES
 THE PDCA METHODOLOGY
 The PDCA methodology is used to
organize
OHSAS 18001 in the following way:

 PLAN- Clause 4.1, 4.2, and 4.3 expect

you
to plan the establishment of your
OHSMS.
 DO - Clause 4.4 expects you to
implement your OHSMS.
 CHECK - Clause 4.5 and 4.6 expect
you to monitor, measure, and report on
the performance of your OHSMS.
 ACT - Clause 4.5 and 4.6 expect you to
improve your OHSMS

Develop, Document, Implement , Maintain

4.1 - GENERAL 
& Improve OHSMS in accordance with
REQUIREMENTS OHSAS 18001.
Introduction
• Power Plant Maintenance involves following key
processes.
• Gas Cutting / welding.
• Finishing – Grinding.
• Fitting.
• Electrical jobs. .
• Heavy Lifts.
• Assembling & Dismantling.
Hazards involved - Operation
Boiler light up.
• Burn Injury due back fire from furnace Man hole.
• Fire Due to leakage of LDO or Gases.

Bed or ash Drain.

• Burn due contact with ash or bed material while draining at drain points.

Venting or Draining of Steam.

• Burn injury due to contact with spilled hot condensate from the drain points.
• Burn injury due to hot steam / condensate leaking from the valves during
operation of valves.

Measurement of flow, temperature, vibrations, etc.

Incorrect use of measuring tools.
Unavailability of access or approach to these locations.
Hazards involved - Operation
Dosing of Chemicals
• Leakage / spillage of chemicals while dosing
manually.
• Contact with chemicals

Sample Collection
• Burn Due to contact with steam or condensate.
• Improper approach to the sampling points.
• Unsafe methods of sample collection.

Operation of equipment's periodically

• Automatic operation of equipment.
• Condition of the equipment.
Hazards involved - Maintenance
Gas cutting welding
• Fire if done in combustible environment.
• Electrical shock during welding.
• Radiation from welding.

Grinding
• Injury from grinding wheel.
• Electric shock

Fitting
• Wrong use of tools.
• Use of worn out tools.
Hazards involved - Maintenance
Working on energized equipment's.
• Injury from the stored energy in any form.

Heavy Lifts
• Failure of lifting tools.
• Fall of load being lifted.

Assembling & Dismantling

• Trapping of fingers between components.
Controls
1. Risk assessment & Job safety Analysis.
2. Plan for safety measures with job execution.
3. Training to impart Job knowledge.
4. Identify and eliminate unsafe conditions during the initial
stages.
5. Compliance with SOP.
6. Compliance with work permit requirements.