Power plants in industries are among the most complicated and expensive construction projects in the modern engineering practice. They are the work of complex systems, high-voltage electrical networks, heavy machinery, thermal systems, chemical processes, and civil structures, all of which work under challenging safety requirements.

Safety in both construction and commissioning is not only a regulation, but it is a moral, operational and economic need. One safety failure may result in major injuries, wasted time, harm to the environment, and loss of reputation.

This paper will discuss how industrial power plants can provide safe implementation, operation and management of their construction projects by providing the systematic planning, high technologies and a safety excellence culture.

The Primer on the Complexity of Building Power Stations.

Multi-Disciplinary Character of Projects.

    The construction of power stations is an intersection of the disciplines, i.e. civil engineering, electrical systems, mechanical installations, control systems and environmental engineering. It is necessary to coordinate all these fields by means of a powerful project management system which will make safety a primary concern throughout the process.

    High-Risk Environments

      Among workers during the construction process, there is the risk of electrical hazards, high pressure systems, elevated buildings, and chemical substances. Early identification of these risks helps project teams to design and provide a targeted safety measure at the project level.

      Developing a Global Safety Management System.

      1. Safety by Design

        Safety is not only started after the first brick is laid. At the engineering and design stage, the developers of a power station incorporate the concept of safety in the design, location, and equipment choice. For example:

        • Maintaining safe access of maintenance workers.
        • Designing disaster systems on hazard materials.
        • Incorporating fire detection systems and suppression systems.

        This active method which is commonly referred to as Safety in Design (SiD) avoids risks instead of regulating them once they have set up their construction.

        2. Safety Management Frameworks.

          Power stations in industries embrace globally accepted safety management systems including:

          • Standard 45001: Management systems occupational health and safety.
          • Construction safety standards of OSHA Standards (U.S.) or the HSE Guidelines (U.K.).
          • High-hazard operations Process Safety Management (PSM).
          • The frameworks assist in organizing safety policies, roles, responsibilities, and performance evaluation.

          Pre-Construction Planning and Risk Assessment.

          1. Hazard Identification and Risk Analysis.

            Hazard Identification (HAZID) and Risk Assessment (RA) studies are carried out before the commencement of the construction. These evaluations assess the safety risks, the probability of occurrence of such risks, and the potential outcomes.

            Special permits and supervision procedures apply to high-risk activities, including crane operations, welding within the vicinity of fuel or an entry into a constricted space.

            2. Safety Planning and Method Statements.

              Every construction phase is backed by a Construction Safety Plan and Safe Work Method Statements (SWMS) which explains how work will be carried out safely such as:

              Equipment to be used.

              • Step-by-step procedures.
              • Personal protective equipment (PPE) that is required.
              • Evacuation and emergency plans.
              • Such documents provide uniformity, responsibility and adherence in all the contractors.

              Training and Competency Development.

              1. Training Programs in Workforce.

                Safety depends on people. Power stations in the industry spend a lot of money in training engineers, contractors and the laborers so that they can be aware of the risks involved, and the correct procedures. Training topics include:

                • Safety, electrical and mechanical.
                • Handling of hazardous materials.
                • Lockout/Tagout (LOTO) systems.
                • Labor in restricted spaces and at elevation.
                • Emergency response drills.

                2. Certification and Competence Evaluation.

                  Special jobs can only be done by qualified employees whose certifications are valid (e.g. crane operators, welders, scaffolders, and electricians). Periodic competence appraisals help to keep employees fit to work and abreast with changing safety regulations.

                  Safety Controls at Construction Sites.

                  Personal Protective Equipment (PPE).

                    Insurance of PPE- helmets, flame resilient clothing, safety harnesses, gloves and protective eyewear- all of these are mandatory in the construction site. Power plants have rigorous measures of PPE inspection, replacement and compliance.

                    Safety Signage and Zoning

                      The construction sites are segregated into distinct areas, such as restricted areas, dangerous areas, and safe walkways. Signage conveys a possible danger, emergency outlets and meeting points.

                      Isolation Procedures and Work Permits.

                        In the case of high risk activities, permit-to-work (PTW) systems are implemented. These also make sure that every job such as hot work, electrical isolation or pressure testing is thoroughly authorized and safety checked prior to work.

                        Lockout/ Tagout locking procedures are to provide a safe isolation of energy sources during maintenance or installation to avoid accidental energization.

                        Supervision, Communication and Monitoring.

                        Dedicated Safety Officers

                          The industrial power station projects usually utilize the use of the safety officers and HSE managers who observe the daily activities on the site, inspect the site and instill compliance. They are also meant as contacts of safety and incident reporting.

                          Real-time Monitoring Systems.

                            The construction sites are picking up modern sensors that are IoT-enabled and will monitor environmental parameters and structural stability and also equipment performance. As an example, sensors can reveal leaks, temperature spikes or other anomalies in vibration, and the intervention can be provided in time.

                            Appropriate Communication Channels.

                            There is a clear line of communication between the teams because of daily briefings, toolbox talks, and computer-based reporting systems. Open communication can be used to avert unsafe behaviour or new hazardous situations before they develop.

                            EHR Preparedness and Response.

                            Casting Emergency Response Plans.

                              All construction sites of power stations have a detailed Emergency Response Plans (ERP) that details a plan of action in case of:

                              • Fire outbreaks.
                              • Chemical spills.
                              • Medical emergencies.
                              • Natural calamities (e.g., floods, earthquakes).

                              The emergency coordinators and the response teams are designed to practice common exercises to facilitate quick and efficient response.

                              On-Site First Aid and Fire fighting Facilities.

                                First-aid stations, trained medics and firefighting equipment are provided at industrial construction sites. The level of response is quick and reduces the extent of the occurrence and builds confidence among the workers.

                                Using Technology to Keep Construction safer.

                                Drones and Remote Sensing

                                  More in inspection of sites, tracking of progress, and monitoring of safety is being done using drones, eliminating the physical access to workers to hazardous locations.

                                  Building Information Modeling (BIM)

                                    BIM [ Business Information Modeling] enables the engineers and safety teams to model construction stages, identify possible clashes, and evaluate risks virtually in advance of construction in the field. This digital twin solution improves the accuracy of planning and reduction of risks.

                                    Wearable Safety Devices

                                    Smart helmets and other biometric sensors monitor vital signs of workers and detect fatigue and warn the supervisors when the person goes into a prohibited area or is in trouble.

                                    On-going Improvement and Auditing.

                                    1. Audits and Inspections of Safety.

                                      Internal and third-party safety audits are conducted on a regular basis and help to assess the effectiveness of safety practices and highlight areas of improvement. These audits will make sure that the company will adhere to the national and international standards.

                                      2. Learning from Incidents

                                        The incident reporting systems promote blame-free communication. Root cause analysis is carried out on each incident including minor ones to ensure that they do not happen again. Lessons learned are put in new safety measures and training modules.

                                        3. Safety Culture and Leadership.

                                          A well-established safety culture is the most significant aspect of systems and technology. Leadership should show its dedication to safety by being visible, accountable and rewarding safe practices.

                                          Constructing and Post Construction Safety.

                                          The commissioning stage can be difficult even after the construction is final since tests are first performed on systems where the systems are first energized. Stern control measures, testing in phases and shared safety audits are some of the measures used to make sure equipment moves smoothly between the construction and operation phase.

                                          Additionally, the safety programs in post-construction, i.e. the continuous maintenance training and re-assessment of risks will guarantee the safety and reliability of the operation in the long term.

                                          Conclusion

                                          To ensure the safe operation of the construction projects of the industrial power stations, a multidimensional approach should be taken, and this approach is characterized by the combination of engineering accuracy, compliance with regulations, human consciousness, and technological progress.

                                          The industrial power stations prove that technological safety facilities and strict training are not mutually exclusive, and even digital observation and constant progress, as well as safety and productivity are complementary strategies.

                                          This can be achieved by making safety an integral part of any process, whether it is planning or commissioning, of such massive engineering projects; they are not only keeping their people and assets safe, but also ensuring the credibility and dependability on which the contemporary energy systems rely.

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