our project – modification of wind sock structure our project – modification of wind sock...
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Our Project – Our Project – Modification of Wind Sock Modification of Wind Sock
StructureStructure3 Sep 2007
TeamTeam DetailsDetails
Team Name: Maintenance TeamTeam Name: Maintenance TeamTeam Members: Team Members:
Facilitator Mr Yeo Soo Hock HSE Manager
Leader Mr Rajandran Senior Machinery Technician
Members Mr Cheng Swee Guan Tong Hoi Site Manager
Mr Jagan Penta Tong Hoi Site Supervisor
Mr Kalaivanan K HSE Officer
Mr Foo Seck Ket Lead Technician
Team MeetingsTeam Meetings
100% 100% 100%
80%
100%
0%
10%
20%
30%
40%
50%
60%
70%
80%
90%
100%
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Oct-06 Nov-06 Dec-06 Jan-07 Feb-07
Team Participation
Project ScheduleProject Schedule
Project Selection –Project Selection –Brainstorming SessionBrainstorming Session
Total 13 suggestions were contributed; only three were qualified to be safety & health related project.
Three suggestions or safety concerns were as follows:
– Problems/ Risks Involved When Changing of Wind Sock.
– Problems/ Risks Involved Using Emergency Chlorine Shut-Off Valve.
– Risks Involved Without Proper Access platform for operating valves
Project Selection Matrix – Project Selection Matrix – Risk AssessmentRisk Assessment
Safety & Health Problems/ Risks
No of Potential Hazards
Risk Level
Problems/ Risks Involved When Changing of Wind Sock
10Medium
Risk
Problems/ Risks Involved Using Emergency Chlorine Shut-Off Valve.
6Medium
Risk
Risks Involved Without Proper Access Platform for Operating Valves
3 Low Risk
SELECTEDSELECTED
Rev 2 Jun 06 Infineum Singapore Risk Assessment
Job/Tasks:
Changing of Wind Socks on Top of Tank Tops
Conducted by: Rajandran, Cheng, Jagan, Foo SK, Kalai
Reviewed by: Facilitator
Yeo Soo Hock – HSE Manager
Date of Conduct:
25 Oct 06
S/N Hazard Identification Existing Control Measures Risk Level
1 Man fall from height Use safety harnessUse man-cage with proper locking deviceUse crane (after verifying its safe for use)Ensure crane operator, lifting supervisor, rigger and fitters are competent for the job.Adhere to lifting procedures in HSE manual.Adhere to Permit-To-Work System
Low Risk, A3
2 Manual handling (pull, push, stretching) Supervisor at site to advise labourers and reduce the number of re-occurrences. Medium Risk, C3
3 Excessive Exhaustion –Long hours (fatigue) Take breaks in-between.Take lots of water before and during workTry to reduce wasting time or delays.
Low Risk, A3
4. Crane failure – Crane topple Verify safe for use before commencement.Adhere to lifting procedures in HSE manual.Adhere to Permit-To-Work SystemEnsure ground is firm for lifting
Medium Risk, B2
5. Lifting gear failure- load fall from height Verify safe for use before use Low Risk, A2
6 Labourer not understanding hazard. Ensure workers are aware of hazards and competent for the work. Supervision at site is enforced
Medium Risk, C3
7 Trip and fall Ensure only essential materials are brought up tank top. Ensure housekeeping. Low Risk, A2
8 Oil leak from crane Ensure oil is contained if any spill Low Risk, A2
9 Inhalation of vapour from tank hatch Stop work and inform Shift Superintendent. Low Risk, A2
10 Inclement weather Stop work if there is risk of lightning and strong wind. Low Risk, A3
RemoteA
OccaB
FreqC
Major 1 Med risk Hi risk Hi risk
Mod’ 2 Low risk Med risk Hi risk
Minor 3 Low risk Low risk Med risk
Most of the Hazards were Due to Crane
Operation
(MOM Risk Matrix)
Risk Assessment – Before Implementation
ImplementationImplementationSteps of Operation Steps of Operation BEFOREBEFORE Implementing Selected Solution. Implementing Selected Solution.
Step 1: Preparation Prepare manpower,
accessories and crane service.
Step 2: AdministrationApply permits (cold work, lifting, road
closure permits). Conduct tool box briefing. Inform control/guard room.
Validate document
Step 3: Site Inspection & LMRA Cordon off to prevent unnecessary entry.
Conduct inspection with checklistConduct LMRA (Last Minute Risk
Assessment)
Step 5: Lifting and Change Wind SockCommence lift and change wind sock
Step 6. CompletionComplete work and
finish off all administrative work.
Step 4: Trial Lift (w/o load)
Ensure all measures taken prior to actual lift
Location of Windsocks – Location of Windsocks – Before ImplementationBefore Implementation
Above Pipe Rack Blending Process Unit
Illustration ofChanging Wind Sock-Before Implementation
Analytical Techniques –Analytical Techniques –Root Cause AnalysisRoot Cause Analysis
Method
EnvironmentMaterials
MachineMan
Potential risks/problems when changing
wind sock
Long hours
Wind sock comes in different sizes
Transport excessive tools and accessories to the tank top.
Apply PTW (crane, road clearance and lifting permit).
Barricading of road
Change of bearing
Fatigue
Too many procedures to be adhered to.
1 crane driver, 1 lifting sup, 1 rigger & 2 fitters Fall from
height
5 wind sock locations.
High cost for labour
Excessive coordination
Fear of working at edge of tank
Manual handling (pull push stretching)
Use of man-cage
Set-up of crane and prep for operation.
Potential crane topple
High cost for equipment
Windy
Vapour smell from the tank hatch
Oil leak from crane
Exhaust from craneFall from
height
Crane failure
Use of crane
Lifting gear failure
Trip and fall
Housekeeping
Lightning risk
To reduce all problems by 75%
00.5
11.5
22.5
33.5
44.5
5Safety
Human
CostTime
Method
To reduce all factors by 75%
Analytical TechniquesAnalytical Techniques
Proposed SolutionsProposed Solutions Proposal 1 - Telescopic Structure:
– Simple and effective idea – Not practical; Corrodes easily and flimsy. – Expose to inclement weather; possibility of the wind sock structure to
topple.– Expose to caught in between hazard while adjusting the telescopic pole
Proposal 2 - Pulley System:– Not effective. – Design not suitable for strong wind condition.– Rope can get entangled with wind sock and pulley. – Pulley requires maintenance
Proposal 3 - Two-Section Structure– Safe, effective and strong – Easy to implement. – Minimum maintenance was required.
Proposed Solution
Safety & Health Rating
Installation Cost Rating
Cost Saving Rating
Effectiveness & Efficiency
Rating
Within Team’s
Capability Rating
Total score
(Higher the
score the
better)
1. Telescopic Solution
6 8 7 7 9 37
2. Pulley System 6 8 6 6 9 353. Two-Section Structure
9 8 7 9 9 42
Proposed Solutions –Proposed Solutions –SelectionSelection
Selection Criteria RatingSelection Criteria Rating
Safety and Health - 1 is high (high risk) and 10 is low (0 hazard)
Installation Cost - 1 is high cost (>S$ 20, 000) and 10 is low
cost (<S$ 1000)
Cost savings - 1 is less savings (<S$ 1000) and 10 is high
savings (>S$ 20, 000)
Effectiveness and Efficiency - 1 is low (Less effective and
efficient) and 10 is high (Very Less effective and efficient)
Within Team Capability - 1 is low (take more than> 12 months
to implement proposal & and 10 is high (take less than 3
months to implement proposal )
Finalizing Selection Finalizing Selection Selection of Proposal. Based on the ranking
score and comparison made in the evaluation of proposed solutions, the team selected the “Two Section Structure” solution.
Management Presentation.
– Short presentation of the study was tabled for the management’s endorsement.
– Team was commended for its efforts and the proposed solution was endorsed for implementation.
Risk Assessment – After ImplementationRev 2 Jun 06 Infineum Singapore Risk Assessment
Job/Tasks:
Changing of Wind Socks on top of tank tops
Conducted by: Rajandran, Cheng, Jagan, Foo SK, Kalai
Reviewed by: Facilitator
Yeo Soo Hock – HSE Manager
Date of Conduct:
15 Jan 07
RemoteA
OccaB
FreqC
Major 1 Med risk Hi risk Hi risk
Mod’ 2 Low risk Med risk Hi risk
Minor 3 Low risk Low risk Med risk
(MOM Risk Matrix) S/No Hazard Identification Existing Control Measures Risk Level
1 Man fall from height -There is no longer a requirement to work using a man-cage.
No hazards. -
2 Manual handling (pull, push, stretching)
Minimal exposure to manual handling. Low Risk, B3
3 No exhaustion – Each wind sock take no longer than 30min to be fitted
No hazards. -
4. No usage of crane No hazards. -
5. No usage of lifting gear No hazards. -
6 Labourer not understanding hazard. Work is now simplified and straight forward. However, Last Minute Risk Assessment (LMRA) is still enforced.
Low Risk, A2
7 Trip and fall Labourer only needs to bring an extra wind sock up to the tank top. Less materials on tank top. However, proper housekeeping must be enforced at all times.
Low Risk, B3
8 Oil leak from crane- No usage of crane No hazards. -
9 Inhalation of vapour from tank hatch Stop work and inform Shift Superintendent. Low Risk, A2
10 Inclement weather Stop work if there is risk of lightning and strong wind. Low Risk, A3
From medium to low risk
From medium to low risk
(MOM Risk Matrix)
ImplementationImplementationSteps of Operation AFTER Implementing Selected Solution.
Step 1: Preparation Standby man and spare wind sock
Step 2: AdministrationApply cold work permit only
Conduct LMRA (Last Minute Risk Assessment)
Step 3: Change wind sockChange wind sock
=> Leads to reduction in time => Less exposure to HAZARDS
Reduce/less
•Steps
•Admin work
•Coordination
For better accessibility and
proper/stable platform
Relocate all to Tank/Roof-Top.
Re-Location of Windsocks –Re-Location of Windsocks –After ImplementationAfter Implementation
Illustration of ChangingWind Sock-After Implementation
Lowering Upper Section
Removing Securing Pin Replacing
Wind Sock
Fixing Back Wind Sock Structure
Illustration of ChangingIllustration of ChangingWind Sock- After ImplementationWind Sock- After Implementation
Total Cost forTotal Cost forImplementation & Implementation & Installation Installation
Each location: S$600/-Structure” solution.
Five Locations: One-time Cost of S$3,000/- only
Results Achieved –Results Achieved –Tangible Results Tangible Results
Cost Savings
ItemsBefore
ImplementationAfter
ImplementationCrane Service $300 $0
Labour Charge $1000 (5 Men) $200 (OMO)
Service bearing $100 $0
For 5 locations: $1400 x 5= $7000 $200 x 5 = $1000
P.E. Certification (one-time) $500 $0
Total $7500 $1000
Annual Cost reduction by: 86%
Results Achieved –Results Achieved –Tangible Results Tangible Results
Save Time
Time reduction by (every year): 83%
The above calculations are done according to yearly maintenance schedule. However, there are instances where ad-hoc maintenance
may be required. Therefore, further reductions can be expected.
Before implementation :
– Operation used to take two to three hours per location
– For five locations: Approx: 15hrs
After Implementation:
– Operation now takes 30min per location
– For five locations: Approx: 2.5Hrs
Time Reduction by: 83%
Results Achieved –Results Achieved –Intangible Results Intangible Results
Safe operation and very minimum hazard exposure.
Reduce work steps (no machinery used, less man/ materials utilized and minimum administration)
Increase productivity and morale of workers.
Enhance efficiency and maintenance effectiveness.
Less time waste (no need to wait for crane and applying permit)
No possibility of environmental issues.
Confidence in our team’s ability to address and overcome problems has been enhanced.
Teamwork, sense of team identity and team morale has improved.
Variation of ResultsVariation of ResultsBetween Results & Initial Target: Between Results & Initial Target:
0
0.5
1
1.5
2
2.5
3
3.5
4
4.5
5
Safety
Human
CostTime
Method
Risk Reduction Risk Reduction In Summary
Before Implementation After Implementation
Number of Hazards
10 5
Risk level Medium Risk Low Risk
Equipment Crane & man cage(inherent high risk)
Crane/ man cage not required.
Human Factor 5 men OMO
Exposure (Duration)
15Hrs 2.5 Hrs (Reduce by 83%)
System/ Procedure
Need to comply with many procedures/
requirements
Simplified/ reduction in procedures to enhance safety
StandardizationStandardization
Documentation
Management was kept abreast of the success.
Updated procedures.
Amended JSA was endorsed by the management
JSA maintained in accordance with WSH (Risk Assessment) Regulations.
Review & SustenanceReview & Sustenance
Review for Future Improvement
No negative feedback but only positive on the implementation
Receptive to new ideas and future improvements
Continuous improvements to the existing projects
Team’s Next Project.
Working on with the second project under the project prioritization; i.e “Problems/ Risks Involved Using Emergency Chlorine Shut-Off Valve”.
Review & SustenanceReview & Sustenance
Self Examination.
Team made up of committed colleagues and contractors.
Great success of this project reflects on the positive participation and co-operation of the team members.
Project has given the team greater confidence and morale.
It has also revealed that with good team work and overwhelming management support anything can be achieved.
ConclusionConclusion Infineum Maintenance Team has always believed in making our
plant a safe working environment for our colleagues, contractors and visitors.
The Maintenance Team looks forward for more challenges and opportunity to enhance the safety and health in Infineum
Lastly, we all know that lifting equipment is the second highest contributor of workplace deaths in 2006 and it has always been in the area of safety concern.
Safety as a Culture in Infineum, we have taken steps to prevent such occurrences in the plant and at the same time contributing to a healthier nationwide safety statistics
The Maintenance The Maintenance TeamTeam
Thanks youThanks you
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