Established in 1982 to provide maintenance service to the Singapore Shell Refinery in Bukom

Transcription

1 The PEC Innovation

2 Introduction to PEC Innovation What is the concern? Initial Practice What Should We Do? Objectives Solution Wind Blocker In Action Evaluation Conclusion Contents

3 Introduction to PEC

4 Company Introduction Established in 1982 to provide maintenance service to the Singapore Shell Refinery in Bukom Main Business Segments Project Works (EPC, EPCm and Plant Construction) Plant Maintenance & Turnaround Customer base includes major MNC s in the oil & gas, petrochemical, pharmaceutical and oil & chemical terminal industries Operations in Singapore, Malaysia, Indonesia, Thailand, Vietnam, China and the Middle East.

5 Our Geographical Footprint Legend SAUDI ARABIA QATAR UAE - PEC Fabrication & Maintenance Facilities - PEC Projects THAILAND CHINA VIETNAM MALAYSIA SINGAPORE INDONESIA

6 Innovation What is an Invention? An invention is useful only to the inventor unless it is offered to the public, however niche that public may be. What is an Innovation? If the invention improves some product, process or service for the public, then that invention transforms into an innovation.

7 What is the concern? Tank shell plate welding done at a height of about 20 to 30 metres. Windy conditions that contributes to hot flying sparks. Safety of the welder is at risk as flying sparks may fall on him. Quality of the welding works is affected. Impact in the progress of the job.

8 The Initial Practice Fire Retardant Uniform Canvas or Fire Blankets with the aid of metal frames to protect or shield the welding area from the windy conditions Refrain from welding when its windy

9 The Initial Practice

10 What should we do? Issue was shared & discussed during the Site Progress Meeting. A team was identified to brainstorm for a solution. Team TPU was formed. The team members generated some ideas collectively.

11 Team TPU Members Facilitator : Ronnie Seah (Senior Manager, Project) Team Leader : James Foong (Manager, Construction) Members : 1. Nay Lin Aung (Manager, Construction) 2. Kyaw Thi Ha (Senior Engineer, Projects) 3. Cheng Haifeng (Engineer, Projects) 4. Chidambaran Solai, (Senior Exec, Procurement) 5. Kmiel Kannan (Asst. Manager, HSSE)

12 Objectives Ensure the safety of welders when welding on the tank. Windy conditions should not disrupt the welder from performing his task efficiently. Solution should be hassle free and simple to use.

13 Brainstorming & Considerations Check legal requirements with the relevant authorities Hierarchy of Control Feasible to the organizations' business needs. (Safety, Quality, Time & Cost)

14 Legal Requirements Any tools, equipment or fittings used must be secured. Should meet the Safe Work Load of the platform.

15 Hierarchy of Control 1. Elimination :- Welding works on tank cannot be eliminated. 2. Substitution :- (a) Using a machine will not be feasible or cost effective. Manpower still required to monitor, set up and make adjustments. (b) Other types of welding may not be suitable for tank erection.

16 Hierarchy of Control 3. Engineering :- Modify the existing fire box with an equipment that is easy to use. 4. Administrative :- Educate and brief the workforce on the easy usage of the Wind Blocker. 5. PPE :- Continue to use all PPE from pre-wind Blocker implementation.

17 Vital Statistics : - Technical Data An aluminium plate which measures about 1.2 x 0.4 m and 3mm thickness 8 Magnets that measure 28mm in diameter each. Each magnet can carry a load of 5kg. Fabricate the materials together according to design.

18 28mm diameter magnet 3mm thick aluminium plate Total Weight : 5kg

19 Front View Side View

20 Estimated Initial Cost 1. Assuming we use the fire blanket with metal frame welders at any one time performing welding works on a tank. 3. Fire blankets to be replaced weekly due to wear and tear. Cost of 3 metres of Fire Blanket : $21.60 Cost of metal frame including fabrication : $100 Cost per week : $ Cost per month [($21.60 x 4) + $100] : $ Cost per year ($ x 12) : $ Cost for 12 welders per year ($ x 12) : $

21 Cost of Innovation 1. No replacement due to wear and tear needed as it is fire spark resistant. 2. One time purchase of equipment and fabrication. Cost of one magnet : $6 per piece Total cost of magnet per Wind Blocker ($6 x 8) : $48 Cost aluminium material and fabrication : $91 Total cost of Wind Blocker ($48 + $91) : $139 Total cost for 12 welders ($139 x 12) : $1668 Total cost per year (No Replacement Needed) : $1668 Cost Savings Per Year ($ $1668) = $

22 Increased Productivity 1. Welders were able to perform task during windy conditions. 2. Passing rate of welding joints after Radiography Test improved significantly. 3. Setting up of the Wind Blocker within a minute contributes to more time dedicated to progress.

23 Implementation & Standardization 1. The Wind Blocker was introduced to the workforce and all affected employees were briefed on how to use it. 2. The implementation of the Wind Blocker was documented into the tank welding procedure. 3. Regular checks were done to ensure the Wind Blocker is adopted and used accordingly.

24 Wind Blocker In Action

25 Wind Blocker In Action

26 Wind Blocker In Action

27 Wind Blocker In Action

28 Risk Assessment (RA) Review Past Canvas/Fire Blankets used to shield from windy conditions. Use Fire Blankets to prevent flying hot sparks. Stuffy and smokey condition when enclosed with Canvas/Fire Blankets Present Use Wind Blocker Use Wind Blocker Use Wind Blocker.

29 Hazards Wind Blocker detaches from position due to strong wind Integrity of the magnet after prolonged usage. Any New Hazards? Mitigation Test has been done overnight during rainy and windy conditions to ensure the reliability of the Wind Blocker Visual check on the magnets when attach to the tank plates. Do not use if magnetic strength does not hold Wind Blocker in place. Additional Control Measures Front Line Supervisors & Safety Personnel to assess the wind conditions and stop work if perceived as unfavourable conditions. Calibrate the magnets annually.

30 Verdict The Wind Blocker had been used for about 9 months to complete erection of 4 water tanks measuring about 30 metres in height and 20 metres diameter. At present the Wind Blockers have been passed over to another project which is also in the midst of erecting a few water tanks. No added cost in fabrication of the Wind Blocker but probably to calibrate the magnets.

31 Evaluation Disadvantages Regular cleaning of the Wind Blocker from dust and debris Due to its straight edges it can t t be used around circular areas Only comes in one size and may be too small or too big for certain welding areas

32 Advantages The PEC Innovation Durable Cost Effective Set up in less than a minute Work progress is enhanced Windy conditions will not disrupt welders Improve welding results upon implementation of the Wind Blocker

33 Tangible Saves Time. Results Saves Money for the Company/Organization, Savings passed on to next project. Increased Productivity & Quality. Intangible Improve the process/method of performing welding on tanks during windy conditions. Welders are more confident when performing task. Welders need not be enclosed in a smoke filled environment which may pose as a chronic health effect.

34 Conclusion The Wind Blocker has proven to be safe to use and it does protect the welder from flying sparks during windy conditions. The Wind Blocker has achieved more than what the objectives were in terms of feasibility, easy to use and even cost savings. As we are committed to continual improvement in safety, our organization is constantly looking to improve our safety performance.

35 Review & Sustenance for New Project Based on the evaluation, the team is looking to improve further on the design of the Wind Blocker to be able to withstand stronger windy conditions. Modify or design different sizes for various types of location. Explore the idea of securing with other means rather than a magnet. Explore the possibility of making a wind blocker with other materials. Reason:- Possibility of sharing the idea with other industries Continuous Improvement is key to our Industry, best practices/methods today may not be the same tomorrow.

36 Presented by : Kmiel Kannan