Prevention Of Catastrophic Events at Process Plants and Fossil Fuel Steam Plants

Modern plant safety process – what does it do ? 2  Enhances the company safety culture by addressing individual attitudes and behaviours which lead to unnecessary risk.  Improves attitudes and behaviors of individuals towards safety programs.

Modern safety process addresses TWO key influence co-efficient of Safety Culture. 3 These are: THE INDIVIDUAL Modern Process focuses on individual motives, skills, personality and improves propensity for risk taking. SAFETY PROGRAMS Improves policies, procedures and specialty programs

Are there any other influence co-efficient for Plant Safety Culture? 4 YES There are three more equally important influence co-efficient (IC) for Safety Culture. It is imperative to consider these additional ICs in order to elevate level of safety culture in order to prevent occurrence of catastrophic events

AND …THEY ARE…. 5  Management Style  Work Management program and processes  Production Equipment

System thinking – holistic approach 6 Management Style Values, Beliefs, operating principles and sense of purpose. All employees are directly influenced by the management style and adopt similar values, beliefs, operating principles and sense of purpose.

System Thinking – holistic approach Other two influence co-efficients for Safety Culture - Production Equipment Properly designed defect free equipment which are operated and maintained as per precision standards, codes and regulations. -Work Management processes Pro active culture to prevent and eliminate defects from equipment by performing right amount of maintenance work at the right time. Planning, scheduling and MRP Engineering forming the foundation of Work Management. 7

All five “ influence co-efficient ” together upgrade a safety culture 8 1. The Individual 2. Safety Programs 3. Management style 4. Work Management processes 5. Production equipment

MANAGEMENT STYLE 9 Hands-on implementation by leaders. Playing on-going and personal roles - constant involvement throughout the tensions of implementation ! Having deep confidence in the capabilities of employees. Creating an atmosphere of superior performance throughout the plant. Recognizing that pursuit of excellence is the most powerful emotional motivator in any organization ! Most importantly, commitment of personal time to the implementation process !

WORK MANAGEMNT PROGRAM 10 Planning and Scheduling in Work Management Maintenance, Reliability and Process Engineering as foundation to Work Management Together we create a proactive culture and sustain the defect free equipment.

PRODUCTION EQUIPMENT 11 - Equipment Designed, fabricated, installed, maintained and operated properly meeting all standards, codes and regulations. -Equipment must be defect free at all times.

TO CHALLENGE OR NOT TO CHALLENGE? 12 If we wish to take a real step closer to a Proactive Zero Injury culture, we must address all five key influence co-efficient for the safety culture. Current processes must be supplemented by addressing * Management style * Work Management processes and guidelines * Defect free production equipment Otherwise prevention of catastrophic events would be very distant !

What is the roadmap ? 13 Motivation to elevate conventional safety culture of a process plant must come not only from the top management but also from the shareholders of a corporation and the society at large. This upgraded safety culture can truly work towards prevention of catastrophic events.

It is only a step from the sublime to the ridiculous - Napoleon Bonaparte