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Page 1: Our Project – Modification of Wind Sock Structure Our Project – Modification of Wind Sock Structure 3 Sep 2007
Page 2: Our Project – Modification of Wind Sock Structure Our Project – Modification of Wind Sock Structure 3 Sep 2007

Our Project – Our Project – Modification of Wind Sock Modification of Wind Sock

StructureStructure3 Sep 2007

Page 3: Our Project – Modification of Wind Sock Structure Our Project – Modification of Wind Sock Structure 3 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

Page 4: Our Project – Modification of Wind Sock Structure Our Project – Modification of Wind Sock Structure 3 Sep 2007

Team MeetingsTeam Meetings

100% 100% 100%

80%

100%

0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

% o

f A

tten

dan

ce

Oct-06 Nov-06 Dec-06 Jan-07 Feb-07

Team Participation

Page 5: Our Project – Modification of Wind Sock Structure Our Project – Modification of Wind Sock Structure 3 Sep 2007

Project ScheduleProject Schedule

Page 6: Our Project – Modification of Wind Sock Structure Our Project – Modification of Wind Sock Structure 3 Sep 2007

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

Page 7: Our Project – Modification of Wind Sock Structure Our Project – Modification of Wind Sock Structure 3 Sep 2007

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

Page 8: Our Project – Modification of Wind Sock Structure Our Project – Modification of Wind Sock Structure 3 Sep 2007

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

Page 9: Our Project – Modification of Wind Sock Structure Our Project – Modification of Wind Sock Structure 3 Sep 2007

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

Page 10: Our Project – Modification of Wind Sock Structure Our Project – Modification of Wind Sock Structure 3 Sep 2007

Location of Windsocks – Location of Windsocks – Before ImplementationBefore Implementation

Above Pipe Rack Blending Process Unit

Page 11: Our Project – Modification of Wind Sock Structure Our Project – Modification of Wind Sock Structure 3 Sep 2007

Illustration ofChanging Wind Sock-Before Implementation

Page 12: Our Project – Modification of Wind Sock Structure Our Project – Modification of Wind Sock Structure 3 Sep 2007

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

Page 13: Our Project – Modification of Wind Sock Structure Our Project – Modification of Wind Sock Structure 3 Sep 2007

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

Page 14: Our Project – Modification of Wind Sock Structure Our Project – Modification of Wind Sock Structure 3 Sep 2007

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.

Page 15: Our Project – Modification of Wind Sock Structure Our Project – Modification of Wind Sock Structure 3 Sep 2007

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

Page 16: Our Project – Modification of Wind Sock Structure Our Project – Modification of Wind Sock Structure 3 Sep 2007

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 )

Page 17: Our Project – Modification of Wind Sock Structure Our Project – Modification of Wind Sock Structure 3 Sep 2007

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.

Page 18: Our Project – Modification of Wind Sock Structure Our Project – Modification of Wind Sock Structure 3 Sep 2007

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)

Page 19: Our Project – Modification of Wind Sock Structure Our Project – Modification of Wind Sock Structure 3 Sep 2007

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

Page 20: Our Project – Modification of Wind Sock Structure Our Project – Modification of Wind Sock Structure 3 Sep 2007

For better accessibility and

proper/stable platform

Relocate all to Tank/Roof-Top.

Re-Location of Windsocks –Re-Location of Windsocks –After ImplementationAfter Implementation

Page 21: Our Project – Modification of Wind Sock Structure Our Project – Modification of Wind Sock Structure 3 Sep 2007

Illustration of ChangingWind Sock-After Implementation

Page 22: Our Project – Modification of Wind Sock Structure Our Project – Modification of Wind Sock Structure 3 Sep 2007

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

Page 23: Our Project – Modification of Wind Sock Structure Our Project – Modification of Wind Sock Structure 3 Sep 2007

Total Cost forTotal Cost forImplementation & Implementation & Installation Installation

Each location: S$600/-Structure” solution.

Five Locations: One-time Cost of S$3,000/- only

Page 24: Our Project – Modification of Wind Sock Structure Our Project – Modification of Wind Sock Structure 3 Sep 2007

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%

Page 25: Our Project – Modification of Wind Sock Structure Our Project – Modification of Wind Sock Structure 3 Sep 2007

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%

Page 26: Our Project – Modification of Wind Sock Structure Our Project – Modification of Wind Sock Structure 3 Sep 2007

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.

Page 27: Our Project – Modification of Wind Sock Structure Our Project – Modification of Wind Sock Structure 3 Sep 2007

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

Page 28: Our Project – Modification of Wind Sock Structure Our Project – Modification of Wind Sock Structure 3 Sep 2007

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

Page 29: Our Project – Modification of Wind Sock Structure Our Project – Modification of Wind Sock Structure 3 Sep 2007

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.

Page 30: Our Project – Modification of Wind Sock Structure Our Project – Modification of Wind Sock Structure 3 Sep 2007

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”.

Page 31: Our Project – Modification of Wind Sock Structure Our Project – Modification of Wind Sock Structure 3 Sep 2007

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.

Page 32: Our Project – Modification of Wind Sock Structure Our Project – Modification of Wind Sock Structure 3 Sep 2007

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

Page 33: Our Project – Modification of Wind Sock Structure Our Project – Modification of Wind Sock Structure 3 Sep 2007
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Page 36: Our Project – Modification of Wind Sock Structure Our Project – Modification of Wind Sock Structure 3 Sep 2007

The Maintenance The Maintenance TeamTeam

Thanks youThanks you

Page 37: Our Project – Modification of Wind Sock Structure Our Project – Modification of Wind Sock Structure 3 Sep 2007

Question Question TimeTime