Safe Maintenance Operations

8/6/2019 Safe Maintenance Operations

1/61

Principles of Safe

Maintenance operationsby

Dr. Mohamed Fathy Tash


2/61

In this subject wewill try to find an

answer for thefollowing question:


3/61

How could we perform themaintenance operations

safely ?


4/61

But first , we

have to look atthe followingdefinition:


5/61

Maintenance:An activity involved inmaintaining ( upkeep)something ( property orequipment) in goodworking order.


6/61

That was the generaldefinition , what about the

scientific definition ?


7/61

According to the European Standard 13306,1Maintenance concerns the combination of alltechnical, administrative and managerial actions

during the life cycle of an item workplace

(building), work equipment, or means of transport intended to retain it in, or restore it to, a state in

which it can perform the required function.


8/61

Any other definitions?


9/61

Hazard:A hazard is anything ( subject)that has the potential to cause

injury or disease to people,damage to the environment,

property, plant or equipment.


10/61

Risk :

The likelihood that a hazardwill result in injury, illness,loss or damage to people, to

the environment, property,plant or equipment and thepotential consequences ofthat injury, illness, loss ordamage.


11/61

Safe job procedures:

Safe job procedures are aseries of specific steps thatguide a worker through a task

from start to finish in achronological order. Safe jobprocedures are designed toreduce the risk by minimizingpotential exposure.


12/61

Any example for safe jobprocedure?


13/61


14/61

what would happen in caseof lack or inadequate

maintenance operations?


15/61

Serious

anddeadly

accidents


16/61


17/61

Health problemsaffecting not only

workers but also thegeneral public.

Products of poor

quality


18/61

What are the main types ofmaintenance operations?


19/61

1- Correctivemaintenance,

when actions are intended torestore a system from a failedstate to aworking state (e.g.repair or replacement of brokencomponents). This type ofmaintenance is also known as

reactive maintenancebecause the action is initiated

when the unscheduled eventof an equipment failure occurs.


20/61

2-preventivemaintenance:

when actions are carried outat predetermined intervalsor according to prescribedcriteria intended to reduce theprobabilityoffailure or thedegradation of the functioningof an item.In this case, actions arescheduled, proactive and

intended to control thedeterioration process leadingto failure of a system (e.g.replacement, lubrication,

cleaning or inspection).


21/61

from these types, there arefour subcategories derivedrelated to maintenance

operations:


22/61

1- setting up, preparation,

installation, mounting,disassembling, dismantling.

2- repair, tuning, adjustment.


23/61


24/61

The type of maintenance maybe different depending onthe sector in which themaintenance task is

conducted. As a result, thehazards to whichmaintenance workers areexposed can also be very

different depending on thetask and the sector beingworked in.


25/61

Chronic exposure to certainhazards may cause health

problems such as cancers,hearing problems, skindiseases, respiratorydiseases, musculoskeletal

disorders .


26/61

What are the principalhazards associated with

maintenance operations ?


27/61

Physical hazards

Chemical hazards

Psychological hazards

Mechanical hazards


28/61

Physical hazards Include :

NoiseVibrationSevere environmentalconditions like: high or lowtemperature, strong wind,

dust,etc


29/61

Noisecan be caused by machinery,

equipment or by vehicles.Repeated exposure to highsound levels may have severalundesirable effects on thehealth of operators. causing hearing impairment,hearing loss or tinnitus, andnon-auditory complaints

difficulties in concentrating,sleeping disorders, gastriculcers, and increased bloodpressure.


30/61

Vibration :Exposure to hand-arm

vibration occurs when hand-held power tools, such asgrinding, polishing, or rivetingtools, percussion hammers,

vibrating compactors, mowersor chain saws are used. These tools can transmit

vibrations to the workers hand

causing vascular, neurologicaland musculoskeletal disorderssuch as white finger syndrome,a decrease in the sense of touch.


31/61

Vibration :Exposure to whole-body

vibration occurs when a largepart of the body rests on a

vibrating surface. This is thecase for drivers of commercial

vehicles, such as tractors, fork-lift trucks, lorries or buses.Vibrations can be transmitted

through seats or through thefeet while workers are standing.


32/61

Chemical Hazards:In certain industries, such as thechemical industry andconstruction, maintenance workerscan be exposed to chemical

hazards.. Workers might be exposed tochemical hazards for example,during electric arc welding, while

working in car repair

shops or waste treatment plants,while performing maintenance ofswimming pools or industrialinstallations where hazardouschemicals are present.


33/61

Chemical Hazards:Exposure to chemical hazards

leads to diverse and sometimessevere health problems.skin diseases, and respiratorydiseases are just a few examples


34/61

Psychological Hazards:Stress is the major hazard thatmaintenance workers mayexperience during work, causedby:Time pressure : during

maintenance work, theproductivity of anorganization is frequentlyreduced and maintenance

workers have to cope not onlywith the demands of the taskin hand, but also with a senseof responsibility for thestartup of production.


35/61

Psychological Hazards:

Communication problems for example, working withcontractors, or several

contractors at the same site.Working alone and inisolation.Irregular working hours such

as shifts, weekend work, nightwork, or being on call.


36/61

Mechanical hazards


37/61

Entanglement risk

Entanglement involves hair. Clothing ,rings,etc becomingentangled in revolving shaft drills


38/61

Trapping risk

This means being drawn in between the machine and any rotatingparts such as two revolving rollers


39/61

Impact risk

Impact means being struck by the movement of a machine parte.g. robot arm, movement of machine bed ,etc


40/61

Ejection risk

This means being struck by particles ejected from the materialbeing worked on or a part of the machine itself e.g. abrasive wheel


41/61

Any other hazards?


42/61


43/61

What are the Key success factorsthat aid in the prevention of risksduring maintenance operations?


44/61


45/61

Management commitment and safety culture in theorganization

Management commitmentmay be the single most

important determinant ofthe safety culture of anorganization.(why?) Itdetermines the resources

(time, people, money)allocated to safety and healthand produces higher levels ofmotivation for health andsafety throughout the

organization.


46/61


47/61

A well-conducted risk assessment

Before starting any maintenancework, a risk assessment shouldbe carried out. Workers shouldbe involved in the initial riskassessment. They may need to

conduct further assessmentsduring the task.


48/61

Safe work procedures and clear guidelines for

maintenance work

A well-defined workflow for each

maintenance task needs to beprepared and safe work proceduresmust be clearly communicated andunderstood. Procedures need to bein place for unexpected events.

Part of the safe system of workshould be to stop work when facedwith an unforeseen problem or aproblem exceeding ones owncompetence.


49/61


50/61


51/61

Do you have any Good examples forthe successful maintenance

operations?


52/61

1-NedTrain


53/61

NedTrain, a company based in the Netherlands, has conducted a pilotproject to design a workshop for the maintenance of high-speed trains.

This inclusive approach has led to several innovations such as theintroduction of an automatic lifting robot to prevent mechanics having

to lift heavy loads, and several solutions to improve safety whenworking at height.


54/61

2- BASF The largest

chemical company in theworld and isheadquartered in Germany


55/61

At the BASF site in Ludwigshafen

there are more than 32,000 workersand about 6,000 contract workers.Maintenance is dealt with byapproximately 7,000 skilled workers,made up of 4,000 employees and 3,000contractors.The workers are well qualified intheir professions, e.g. mechanics,electricians or welding operators.The sites 225 production units aresupplied with liquid and gaseous

chemicals bymore than 2,000 km of pipes. Safemaintenance of the piping system andmachineryrequires continuous attention and

improvement.


56/61

When maintaining installations andpipes that contain dangeroussubstances, the risk of coming intocontact with them cannot be

completely prevented by technicalmeasures. Pockets of chemicalresidues can always be found in deadspaces.


57/61

In order to prevent workaccidents, BASF has introduceda number of safety measuresincluding a well-defined work

flow which covers every step ofmaintenance work from riskassessment (with aconsignment note system)


58/61

The consignment system covers allitems , not only before starting the

work, but till remounting(restarting) pipes at the end of theprocess.

In addition, the managementactively supports the training of itsown employees and contract

workers, and encourages a livelysafety culture.


59/61

Golden rulesPlz don not forget that :


60/61

People always make mistakes .

People always forget .

People never forgive.

Do the right whatever the right is.

Do not take shortcuts to save time andeffort.

Money is precious, your safety is more.


61/61

Wish u all best of luckhttp://facebook.com/mohamed.f.tash
http://facebook.com/mohamed.f.tashhttp://facebook.com/mohamed.f.tash

Safe Maintenance Operations

Documents

Transcript of Safe Maintenance Operations