Tools Box Meeting

Items discuss during Toolbox Meeting

1. Job Hazard Analysis



2. Tools for job



3. PPE



4. Fitness



5. Breakfast/Lunch/Rest



6. Communication



7. Emergencies



8. Others

Toolbox Meeting Tips

When? - Ideally, you want to have a short toolbox safety meeting the first thing in the morning on Mondays, assuming your company has Sundays off. I know of companies that get everybody together on Friday afternoons (because they're picking up pay checks). If I'm about to get money in my hand on a Friday afternoon after a long hard week of work, the last thing I'm thinking about is safety. And how much of what was said Friday do I remember on Monday. If your employees report to smaller job sites on Monday mornings, then have smaller safety meetings at the sites on Mondays.

Where? - You need room for every one to sit/stand comfortably and relax with as few distractions as possible, and where you can be easily seen and heard. If the topic is crane safety, try holding the meeting next to the sites crane if possible or work area.

How Long? - Try to limit the safety meeting to five or ten minutes. It may go longer if you are discussing other job site business. If the discussion goes on too long, it can be continued at the next meeting.

What to Say? - Say is the key word. Don't grab a printed topic and read it. They're meant to just be a guide not a cue card. Pick a topic relevant to what the employees are doing or will be doing. Do some preparation so you can give the talk in your own words. Don't try to B.S. your audience and don't preach to or teach to them. You might have the safety title but your audience has got the experience. Play Columbo by asking more questions than stating safety procedures. Getting a response from your audience means a successful meeting. Try throwing in a statement so wrong just to see if any one is awake and will challenge it.

Talk about accidents or near misses that might have happened or what's been on the news/grapevine that could happen on your job. Avoid the gory details. Discuss an accident to help prevent another similar one from happening rather than to identify the persons involved or to place blame.

Get input from the crew about any concerns they may have or about topics that could be discussed. Discuss any unsafe acts or conditions observed during the past week and how they were corrected. Discuss new equipment on the job or upcoming activities.

Handouts, photos, diagrams, etc - do you think that stack of paper, diagrams, etc you hand out to employees gets read during lunch or taken home to be studied. If you feel strongly about killing trees, put a few copies of handouts near the exit. Don't litter the job site. A better handout would be after discussing heat exposure in a safety meeting, give your audience a small bottle of water or Gatorade.

Remember to prepare, start on time, end on time, talk don't read, and thank your audience for their time, for doing a good job, and maintaining a good safety record.

Shaft Press Patah

1. Baru - baru ini saya diajurkan dengan soalan bagaimana hendak membersihkan press selepas beroperasi.
2. Perbincangan tersebut menjurus kepada masalah utama, kenapa shaft press selalu patah?
3. Berikut adalah pendapat saya berdasarkan pengalaman dan perbincangan dengan rakan - rakan :-

Faktor shaft press patah :-

1. Pengeluar utama press di Malaysia seperti CHD, CBP, EMI, Waun Yon, GS dan sebagainya. Setiap press mempunyai kelebihan dan keburukan. Berdasarkan pengalaman saya, rekabentuk shaft, key way memainkan peranan penting dalam menentukan jangka hayat shaft. Kebiasaannya, shaft tersebut gagal pada key dan menyebabkabnya patah.

2. Bahan yang digunakan untuk menghasilkan shaft. Ramai yang mendakwa shaft mereka dihasilkan menggunakan EN9, EN10, EN 16.. namun, tiada siapa dapat memberi jaminan adakah bahan yang digunakan sama seperti didakwa. Hardness test boleh dijalankan, namun adakah kita mempunyai cukup peralatan untuk menguji?

3. Operasi ; Salah satu prosedur utama press adalah mengosongkan press cage selepas tamat proses. Jika ini tidak dilakukan, fibre (mesocarp) yang tinggal di dalam press cage akan menyejuk. Fibre yang sejuk akan menjadi faktor shaft press patah apabila dihidupkan keesokkannya. Fibre semasa sejuk dan panas amat bebeza. Namun, perkara ini sepatutnya tidak menjadi masalah jika press itu direkabentuk dengan safety factor yang tinggi. Adalah kecuaian utama ini tidak diambil kira oleh jurutera semasa mereka bentuk press tersebut? Namun, tidak dapat dinafikan, praktis mengosongkan press cage sebelum press dimatikan amat penting. Tidak kurang juga praktis mengosongkan digester. Kesan yang sama akan berlaku jika tidak dikosongkan dan digester mesh dibiarkan sejuk. Satu kaedah biasa yang digunakan untuk mengosongkan press cage adalah dengan memasukkan shell ke dalam press feed conveyor. Ini dilakukan apabila proses pembaikan untuk menukar screw. Namun amat tidak praktikal jika dilakukan setiap hari. Tambahan kerja kepada operator. Cukup sekadar mengosongkan dengan mengoperasikan press.

4. Tandan kosong carry over ke station press.

Ini adalah mimpi paling ngeri. Jika jarak flatbar di Thresher drum lebih dari 1", kebarangkalian EFB carry over ke digester dan seterus ke press amat tinggi. pastikan thresher diperiksa setiap minggu. Jika EFB memasuki press, ini juga boleh menjadi punca shaft patah.

5. Memanaskan fibre sebelum press dioperasikan.

Terdapat air panas atau stim di bahagian press atau digester. Panaskan terlebih dahulu semua bahagian digester dan press sebelum press dihidupkan. Seperti saya katakan diawal bahagian, fibre yang sejuk amat kuat, apabila dipanaskan ia akan menjadi lembut, berminyak dan boleh mengelakkan kerosakkan pada press.

... sekian, byk lagi faktor yang boleh dibincangkan...

Pakage Boiler-Diesel meletup di refinery @ Sandakan

1. Awal Disember 2009, sekali lagi Industri Sawit dikejutkan dengan kemalangan melibatkan boiler di salah satu rifenery di Sandakan, Sabah.Tidak perlu saya menyebutkan nama kerana makluamat megenainya boleh diperolehi di semua akbar, Facebook etc.
2. Sejak saya menulis mengenai kejadian yang sama pertengahan tahun ini di Lawas, tidak ada kejadian serius yang saya dengar di Borneo. baca http://zul1979.blogspot.com/2009/05/boiler-failure-downcomer-tube-melting.html
3. Namun kejadian ini mengejutkan semua orang. 2 maut. Seorang mati di tempat kejadian.Seorang lagi parah dan meninggal semasa sedang dirawat.
4. Punca sebenar masih di dalam siasatan.
5. Namun berikut adalah beberapa spekulasi yang dibuat daripada maklumat tidak rasmi yang diperolehi :-

• Burner bermasalah - 'impigmentation' pada saluran burner menyebabkan pembakaran setempat berlaku-tidak sama rata.Permbakaran ini menyebabkan kesan 'overheat' pada sebahagian shell/tube boiler.Overheat akan menyebabkan shell buldging-lemah setempat.Dengan tekanan tinggi, bahagian ini akan gagal/bocor/meletup lebih cepat daripada sepatutnya. Ini bertepatan dengan maklumat yang diperolehi iaitu- ada boiler sempat keluar daripada bilik boiler apabila melihat kesan panas/overheat.
• Kegagalan untuk menukar burner yang bermasalah - Boiler tersebut hanya dijadikan 'standby' untuk operasi jika Biomass Plant tidak beroperasi. Kerosakkan burner tidak diganti atau dibaiki untuk menjimatkan kos. Apabila burner tidak berfungsi seperti sepatutnya, lain - lain safety device seperti Interlock System - ID Fan Cut Off dan sebagainya akan turut diganggu. Boiler yang sepatutnya dijalankan secara auto, dijalankan secara manual kerana burner tidak akan berfungsi jika dijalankan secara auto. Burner Rosak - Jalan Manual - Pelbagai risiko boleh berlaku.
• Fuel cut off gagal berfungsi. Disebabkan boiler dijalankan secara manual.
• Low water level - Boiler kedua sedang dalam proses menaikan tekanan. Supply air kepada kedua - dua bolier menjadi common, menyebabkan aliran air ke boiler yang sedang beroparasi kering. Sudah tentu akan berlaku low water level jika bahan bakar tidak dapat dikawal. Sepatutnya, jika 1st & second low water level berlaku, boiler secara automatik akan memulakan prosedur Auto Cut Off. Namun prosedur ini tidak berfungsi kerana boiler telah dijalankan secara manual - disebabkan masalah burner.
• Boiler lama. Boiler ini berusia sama dengan refinery tersebut. Sepatut telah lama ditukar.Namun, seperti sedia maklum, syaikat ini antara syarikat yang paling suka 'save cost', termasuk tidak mengeluarkan kos untuk menukar burner bermasalah. Tanpa mengira pandangan jurutera untuk menukar kepada boiler baru, saya rasa ini boleh menjadi alasan bahawa, duit bukan penentu segala-galanya. 'Safety First' bos!

Namun, kita tidak tidak dapat menjangkakan apa yang berlaku memberikan kesan besar seperti letupan tersebut. GM syarikat tersebut merupakan seorang yang komited kepada keselamatan dan operasi boiler yang baik. Seperti kata pepatah, malang tidak berbau. Kita setiap saat di tempat kerja perlu berdoa kepada Allah untuk keselamatan diri, pekerja dan harta benda, walaupun perbagai usaha atau langkah keselamatan telah dipatuhi. Usaha kita bukanlah penentu akhir kepada mutlaknya tiada apa yang bakal berlaku.

Allah menentu segalanya, mungkin ada tersirat dan tersurat untuk dijadikan pedoman buat kita semua supaya jangan leka atau sombong dengan kehebatan kita. Kalau kita terlupa, kita diingatkan. Ingatan itu lebih baik melalui pengalaman orang lain, bukan kita sendiri yang terpaksa menanggung beban akibat kealpaan kita.

Artikel ini bukanlah berniat untuk menunjukkan kelemahan syarikat terbabit. Namun, lebih daripada itu, untuk mengambil pengajaran daripada kejadian terbabit.

Seperti yang saya kata sebelum ini, seorang jurutera mempunyai tanggungjawab besar ke atas :-

• Keselamatan orang di bawah jagaannya.
• Keselamatan harta benda
• Memastikan semua prosedur keselamatan dipatuhi.

Nasihat daripada orang - orang tua masih perlu diulang-ulang lagi :-

• Don't take for granted
• Go and check on your own, don't let it to you staff or operators

wassalam.

Goals of Maintenance

ZERO BREAKDOWN

Five counter measures :-

1. Maintaining well regulated basic conditions (cleaning, lubricating & bolting).
2. Adhering to proper operating procedures.
3. Total condition monitoring (performance, mechanical & diagnostic based).
4. Improving weakness in design.
5. Improving operation & maintenance skills.

Philosophy of Maintenance

defined as the "upkeep of property". Involves restoration of tolerances trhough a series of intelligent compromises.

Total Productive Maintenace
Combining the practice of preventive maintenance & total quality control & total employee involvement results in an innovative system for equipment maintenance that optimizes effectiveness, eliminates breakdowns & promotes autonomous operator maintenance through day to day activity. The concept known as Total Productive Miantenance (TPM), Seiichi Nakajima.

Life Cycle Cost
Selection of all equipment.

Performance Based Total Productive Maintenance System
Combination of total condition monitoring & the maintenance principles of total productive maintenance.

5 P's for major maintenace for power plant

1. Panic maintenance based on breakdowns
2. Preventive maintenance
3. Performance based maintenance
4. Performance productive maintenance
5. Performance based total productive maintenance (PTPM)

PTPM consists of the following elements :-

1. To maximize equipment efficiency & time between overhaul.
2. To maximize equipment effectiveness.
3. Establishes a through system of PM for the equipment's entire life span.
4. Impremented by various departments (engineering, operations, maintenance).
5. Involves every single employee, from top management to workers on the floor.
6. Based on the promotions of PM through motivation management; autonomous small group activities.

'Total' means ;

1. Total overall performance effectiveness indicates PTPM's pursuit of maximum plant efficiency & minimum downtime.
2. Pursuit of economic efficiency @ profitability.
3. Total maintenance system; Maintenance prevention & maintenance improvement (MP/MI).
4. Total participation of all employees, autonomous, small group activities.

Down time :

1. Loss of time due to unnecessary overhauls based only on time intervals.
2. Equipment failure-from breakdowns.
3. Loss of time due to spare part unsuitability @ insufficient spares.
4. Idling & minor stoppages - due to the abnormal operation of sensors or other protective devices.
5. Reduced output - due to discrepancies between designed & actual operating conditions.

Defect :

1. Process defects - due to improper process conditions that do not meet machinery design requirements.
2. Reduced yiled - from machine start up to stable production due to the inability of the machine to operate at proper design conditions.

Ultrasonic evaluation

Ultrasonic testing is used to check for: arcing, tracking, corona discharge and vibration.
In certain instances it is easier to ‘listen’ for problems from a distance when it is difficult to get right next to the equipment in question.
Ultrasound is an effective, low cost means of evaluating the condition of insulation components on high-voltage transmission and distribution equipment.
Initial Equipment Cost: $4300
Training Costs:
Initial Training = 40 hours offsite, fee= $1,500
Recertification = 8 hours, twice per year, offsite

Ultrasound should be used in conjunction with Infrared Imaging when Infrared Imaging is not practical.
Ultrasound can often detect potential insulation faults that do not show up in an infrared survey.
A combination of infrared and ultrasound is often used on high-voltage electrical equipment, particularly enclosed switchgear.
Infrared locates resistive faults (e.g. dirty switch contacts or loose joints)
Ultrasound locates developing insulation faults
Ultrasound instrument can be used on enclosed switchgear that cannot be ‘viewed’ with an infrared instrument. Removing a few bolts allows ultrasound to penetrate into the inside of the gear.

Infrared imaging

A hand held camera is used in a way that enables you to ‘see’ temperature differences. The camera is a lot like a video camera in size and weight.
The hotter the temperature, the more yellow the equipment
Not all temperature differences are indicative of problems
You must be trained to recognize those temperature differences that are significant
Some Infrared Imaging Costs:
Thermal imaging system ~$30,000
Technician training & fluency education

Here is a transformer as seen through a short wave infrared camera.
The yellow coloring does not indicate a problem. It is the reflection of sunlight.
The maintenance technician must be trained to recognize this. Otherwise he will report ‘false’ hot spots that will lead to wasted corrective action.

Here, the same transformer is seen through a long wave infrared camera.
The ‘false’ hot spots seen through the short wave camera do not show up here but maintenance technician must be trained to recognize significant yellow areas.
Maintenance programs that require outdoor surveys are best served by long wave cameras.

Laser alignment

Provides quicker and more accurate means of shaft alignment than dial gauges.
There are many sources of error in dial gauge readings:

sagging indicator brackets
sticking/jumping dial hands
low resolution means rounding losses
play in mechanical linkages
tilted dial indicator leads to offset errors
axial shaft play leads to gap error

Laser alignment tool costs $13,000 - $15,000.
Technician requires one day training about how to use the tool

Vibration analysis

Vibration is measurement of the periodic motion of equipment (I.e. the ‘shaking’). Vibration is measured in units of inches/second (in/sec, IPS).

All equipment vibrates, but if this vibration becomes too severe, it indicates problems. Use vibration levels to prioritize repairs.

Some Rules of Thumb to judge the condition of your equipment:
less than 0.050 IPS Excellent
0.050 - 0.100 IPS Good
0.100 - 0.200 IPS Acceptable
0.200 - 0.400 IPS Unacceptable
greater than 0.400 IPS Failure Likely

The technician takes a simple hand held instrument out each piece of equipment to be tested.
He then attaches a magnetic accelerometer to several specific places and records readings electronically.
These readings are then downloaded to a computer and analyzed with a software program purchased with the hand held instrument.

Costs to set up your own on-site program
Approximately $40,000 for software and hardware
One week training for your technician
Your technician must work on vibration monitoring at least 3 days/month to stay fluent in the technology and analysis

Costs to contract out
Approximately $7,000 per year (depends on number of pieces of equipment and accessibility)

Oil analysis

• Take periodic samples of oil from equipment & sent out for laboratory analysis.
• Test condition & wear of components.
• Will wam of impending problems & reduce chance of premature failures.
• Will possible point out root causes of failure
• Costs.

A typical machine condition - vibration trend

Predictive Maintenance

Condition based management :-

1. Vibration analysis
2. Oil Analysis
3. Temperature analysis
4. Pressure Analysis
5. Ultrasonic
6. Wear analysis
7. Efficiency analysis
8. Visual analysis

Crank shaft

Kek Lapis Sarawak

Kek lapis Sarawak yang terdapat di Pasar Malam Seberkas, setiap hari Sabtu.

1. Kek Lapis Sarawak merupakan salah satu daya tarikan yang unik di Sarawak.

2. Tiba musim perayaan dan cuti sekolah, jualan akan meningkat secara mendadak. Tempahan banyak dilakukan untuk dijadikan buah tangan atau hindangan semasa hari raya.

3. Keunikan kek lapis ini pada kepelbagaian corak, jenis dan rasanya.

4. Walaupun harga bermula dari RM10 hingga mencecah RM100 ke atas untuk satu kek lapis, ia tetap laris di pasaran.

5. Kek Lapis merupakan salah satu simbul masyarakat Sarawak yang sukakan kesenian. Seni melambangkan masyarakat yang halus dan cintakan keindahan. Seni lahir daripada ketekunan untuk menghasilkan sesuatu yang indah pada pandangan mata.

Cake Breaker Conveyor

1. CBC selalunya direkabentuk dari jenis ribbon conveyor.
2. Namun, Boustead telah menggunakan scrapper conveyor. Hanya 5 kaki ribbon conveyor digunakan sebelum separating column.
3. Selain daripada aktiviti pembaikan yang kurang, tujuan utama conveyor ini untuk mengeringkan fibre untuk proses seterusnya tetap tidak terjejas.

ID Fan Motor, 125 HP / 100 kW

DIPOM ; Electrical Application > Motor

Cost Of Motor Failures

1. Electrical

1.1 Overload
1.2 Overheat
1.3 Short-circuit
1.4 Open - circuit
1.5 Poor insulation
1.6 Single phasing
1.7 Starter defects

2. Mechanical

2.1 Bearing defect
2.2 Shaft defect
2.3 Alignment
2.4 Driven machinery jam
2.5 Fan defect

3. External

3.1 Dust & dirt
3.2 Liquid ingression
3.3 Submersion
3.4 Rodent attack
3.5 Chemical erosion
3.6 Vibration

4. Operational - winding overheat

5. Undefined

Turbine

Nozzle

Steam chest

Reducing gear to 1500 rpm Turbine coupling bush - terdapat kesan misalignment

Kesan 'erosion' stim dan 'carry over' air pada turbine wheel

Bearing seat

Turbine wheel