Manager / Responsible Care Leader
Environment Health And Safety
Total years of experience :10 years, 2 Months
User of petrochemical products such as Butanol as raw material to
Manufacture and market of polymer emulsions to paints, adhesives, printing inks and textile
industries)
Main job function - Manage all implementations of company safety standards and monitor its effectiveness.
Achievements :
Successfully Implemented and Provide Training on all the following company standards.
•Safe Work Permitting Standards, Line And Equipment Opening Standards, Hot Work Permitting Standards, Master Red Tag Standards, Hydro blasting And Pressure Washing Standards, Confine Space Entry Standards, Motor Vehicle Safe Handling Standards, Emergency Services and Security Standards, Implement Compliance Task Tracking program and Maser Task List for the plant.
•Successfully Implemented and Provide Training on all the following company EH&S Work Processes.
•Behavior Based Performance (BBP) Work Process, Root Cause Investigation process (RCI), Pre Task Analysis (PTA) Work Processes, Antecedent, Behaviour And Consequence (ABC) Analysis, Balance Of Consequence (BOC) Analysis, Event And Action Tool (EAT), Management of Change process. (MOC), Fire Protection Systems, Emergency Drills.
•Conducted Pre Start-up Safety Review (PSSR) for the following projects
•Tank truck loading and unloading upgradement.
•New monomer mix (MMT) tank
•Throx blower modification project
•Waste water recycle project (Six Sigma project)
•New fire water storage tank and sprinkler upgradements
•Drum unloading facility
•Installation of Nitrogen Generon system and storage tank.
•Successfully Implemented and Provided Training on following company Industrial Hygiene Programs :
•Personal Protective Equipment Standards, Respiratory Protective Equipment Standards, Noise Conservation Standards, Ergonomics, Ventilation Standards, Qualitative exposure analysis (QEA), IH monitoring
•Coordinated the Emergency Rescue & Evacuation Team on the followings :
•Emergency drills, Fire extinguisher trainings with mock fire, Activate and conduct drills on fire monitoring systems
•Mentored Responsible Care program for the Company and Customer
•Achieved a silver award for the company in 2006 in Responsible Care program by Chemical Industries Council Of Malaysia.(CICM).
•Represented company to provide Responsible Care mentoring service to selected customer. This is an initiation by the (CICM)
•Conducted the following audits for the plant :
•Operating Discipline Management System (ODMS) annual self assessments (SA), Plant annual hazard recognition audit
•Facilitated the following audits for the plant :
•Reactive Chemical & Process Hazard Risk Analysis (RC PHA), Loss Prevention Principle (LPP), Layer Of Protection Analysis (LOPA), Periodic EH&S audit
•Incident Investigations:
•Facilitated Incident Investigations using the Apollo Root Cause Analysis methodology to identify the root cause and contributing causes and recommending corrective actions.
•Implemented the following tools and software for the plant:
•Management of change (MOC)
•Master task List (MTL)
•Qualitative Exposure Review (QEA)
•Event and Action tracker.
•Communications with Stakeholders
•Acquired extensive experience working with various stockholders including internal and external customer to develop network and timely document approvals and project implementations. This is including local authorities.
•Have developed ability to be a good team player who can work with various teams on different levels that would help organizations in networking process.
•Experience working with various teams to develop an empowered environment
Estimation of project cost including fabrication and machining using Microsoft software
•Manage maintenance and engineering project until commission
•Drive engineering teams to conduct plant improvement opportunities.
•Define, review and implement Engineering, Reliability & Maintenance projects
•Erection, alignment, fit out of site process buildings and ensuring schedule progress is met
•Interfacing with all disciplines to ensure planning of installation meet construction requirements
•Manage main contractor's performance and oversee Subcontractor's resources.
•Provide expertise and advice to other disciplines on safety and matters relating to company standards and requirements.
•Inspection of all materials and installation methodology to ensure compliance to specification requirements
•Foster a culture amongst with Subcontractor to ensure that safety and environmental considerations are rigorously and consistently applied during all delivery tasks
•Preparing reports and forecasts, including summary of construction progress of projects.
•Monitoring the activities of subcontractors to ensure compliance with specifications and schedules.
•Implementation of corporate/project policies, procedures and instructions within assigned operations.
•Coordinating activities with other disciplines and as instructed by project management.
Additional Responsibilities:
•Improvement Engineering - Leadership role in plant engineering improvement opportunities for the following areas:
•Equipment reliability and failure
•Asset Utilization
•Raw material efficiency
•Unplanned downtime
•Waste reductions
•Loop systems and System automations
•Energy conservations
•General plant design and layout
Leadership role for maintenance planning and execution for the whole site.
•‘Walk the Talk' on safety while executing maintenance jobs.
•Directed and supervised inspection team on routine inspection activities, surveillance programs and condition monitoring of equipment.
•Liaison with Department of Occupational Safety and Health (DOSH) on all matters related to registered equipment inspection.
•Developed and executed inspection contracts-painting, NDT, insulation and 3rd Party Inspections. Successfully completed 2 turnaround inspection and gained three years exemption from DOSH (Dept of Occupational Safety & Health).
•Initiated and developed the formation of the Corrosion working committee in PETRONAS Group-received congratulatory letter from CEO for initiating this
•Regular review of maintenance schedule and plans for the site through the CMMS.
•Schedule shutdown maintenance plan for the site to ensure efficient planning and execution.
•Review and approve Management Of Change for new projects and expansions
•Improvements on plant Preventive Maintenance schedules
•Developed response plans for plant Breakdown Maintenance.
•Manage external service providers and contractors during annual turn around.
•Conduct investigation for unplan breakdown and propose improvement opportunities for the site.
•Monitor and improve the plant equipment calibration schedules to meet plant internal and regulatory requirements.
•Upgraded engineering drawings from Auto CAD and MICRO STATION software to meet project requirements.
•Identified and developed Housekeeping schedules for the plant
•Approving authority for hazardous works such as confined space entry, Hot Work, Elevated works, Critical Lifting and Hydro blasting.
•Overhaul management for major equipment for utilities.
•Custodian for equipment asset numbers and ensure records are current and maintained in company database
•Developed maintenance work order request prioritization criteria.
•Conduct regular study for cost efficient and effective study for the whole site.
•Conduct energy conservation study for the site.
•Lead and conduct departmental safety programs for maintenance crew
•Conducted in house maintenance training for maintenance and production personnel's.
•Panel member for domestic inquiries in case of behavior based incidents in the plant.
•Conduct regular departmental meetings to improve internal communications
•Prepare monthly project and maintenance report and communicate to the Plant Manager.
•Propose annual maintenance budget for the site and ensure expenditures are within the bench mark.
•Propose annual budget improvement opportunities.
•Implement Maintenance Work Process and support maintenance team on the empowerment process.
•Support identifications of critical task for the behaviour base program to achieve habit strength.
•Facilitate and also maintenance team representative for Hazop studies.
Achievements:
Provided support to improvement projects in the following areas:
•Facilitated HAZOP evaluation for new Monomer Mix tank project. (This evaluation was guided by a Union Carbide person from USA)
•Facilitated FOCR (Facility and Operation Change Review) for new projects
•Reviewed and approved MOCs for plant expansion and new projects.
•Facilitated training for plant personnel's on new systems.
Facilitated Root cause Investigations for the followings:
•Frequent equipment breakdown cases
•Failure in preventive maintenance
•Drop in equipment efficiency
•Material failure during operations
•Accident and incidents
(Dynea is a chemical company which manufactures formaldehyde and a leader in providing high performance adhesion and surfacing solutions. Products are such as liquid formaldehyde, Urea formaldehyde adhesives, Phenol formaldehyde adhesives, Melamine Urea based adhesives and Urea formaldehyde concentrates)
Responsibilities:
Responsible for the overall operation of the production facilities. Manage the smooth operations through controlling production parameters, daily production schedules, manpower arrangements and staffs leave arrangements.
Conduct induction and on job training programs for new employees, refreshment training programs and monitor all employees on the abidance to company safety rules and regulations at all times during plant operations. Carry out safety awareness programs to enhance safety awareness of employees.
Responsible for plant production planning based on the following factors:-
a) Customer order
b) Raw material stock and its availability
c) Product stock levels
Manage production teams to meet company operational expectations to achieve production targets such as production goals, Process parameters, product quality consistency and production buffer storage targets.
•Responsible for the overall operation of the production facilities offshore-Wellhead and separation, gas compression, chemical injection, dehydration, power generation, pigging, safety, start-up and shutdown of facilities, etc.
•Coordinated with Drilling and Construction contractors to ensure Safety at all times during SIMOPS, hot work etc.
•Coordinated Permit To Work for all Platform activities.
•Inspection of Rig Floor prior to Hot Work permits issuance.
•As a Safety Chairman during simultaneous Drilling and Operations for 2 Platforms, organised weekly HSE meetings with all staff on board. Gave short talks on Safety every week during this period.
•Led the Safety Committee on emergency drills such as Man Overboard, Fire and Abandon Platform drills.
•Chaired Accident Investigation meetings and led team to find root causes of incidents
Other functions are to provide leadership support in the followings:
•Documentation of data's to meet ISO 9000 requirements.
•Prepare daily duty roasters for various departments.
•Monitor and control on number of medical and annual leaves taken weekly.
•Requisite raw materials on daily basis from warehouse.
•Control and coordinate raw materials purchase Vs stock.
•Conduct induction and on job training programs for new employees.
•Conduct refreshment training programs for employees from various departments.
•Monitor all employees on the abidance to company safety rules and regulations.
•Compile appraisal reports on employees individual quality performance
•Verify and Report all production down time and current status.
•Compile daily Production reports to Production Manager.
•Conduct production meetings.
•Carry out safety awareness programs.
•Monitor plant maintenance through Computerized Maintenance Management System.
( CMMS )
Improvement Projects:
•DI Water upgradement project: To improve DI water supply to the Formaldehyde plant.
•Waste water treatment - The purpose of this project is to improve the sedimentation rate and recycle waste water back to production to improve the plant efficiency.
Senior Engineering role for project and services. Servicing mainly the mining and Oil & Gas companies in Australia. Conduct project performance review to identify gaps for improvements. Perform safety reviews for jobs undertaken and support clients on conducting Pre Start-up Safety Review (PSSR) and ensure all aspects of Health, Safety and Environmental elements are adhered to and meeting company safety standards.
Responsibilities:
•Specialized Maintenance Services for Power equipment using diagnostic techniques for evaluation of rotating machinery and High Voltage Motors.
•Develop reliability programs for critical equipment and develop specific PPE user list.
•Switchgear and circuit breaker reliability assessment through diagnostic testing.
•Provide High Voltage Apparatus Maintenance Audits
•Transformer Matrix Test Suite - Conduct a complete evaluation of Power Transformers through diagnostic tests performed in the field which covers a range of all possible failure modes associated with Power Transformers using Sweep Frequency Response Analysis (SFRA).
•Provide expertise consultation on Power Transformer on the safe operation, based on Loss Prevention Principle.
•Process Safety Assurance Manager - PETRONAS - 2012
(PETRONAS is a leading Oil & Gas company)
Global role for system assurance for PETRONAS major hazard projects and operating sites. Perform
assurance audit on sites to ensure Process Safety Management (PSM) standards and systems
compliance.
Key Responsibilities:
•System assurance for company projects and operating sites (Upstream, Downstream and Gas & Power).
•Identify high risk area in operating sites and map out areas in company Technical Standards (PTS).
•Draft audit scopes based risk profile, input from corporate department heads and business EHS performance.
•Process safety technical expert for the Mechanical Integrity Standards with focus on safety critical equipment's.
•Ensure implementations of Technical Standards (PTS) for all sites (Local as well as International sites).
•Perform assurance audit on sites to ensure HSE Standards and Systems compliance.
•Leadership role on monthly tracking of audit gap closure status and provide technical support through respective subject matter experts.
•Develop and share the quarterly audit gap status reports to top management, business units and the country office.
•Mentorship role to business audit gap closure teams on effective closure of findings and provide know how inputs.
•Drive implementation of Process Safety Management plans and objectives in line with PSM standards and initiatives for normal operation and during shutdown/turn-around activities.
•Review and support on the development of site Emergency Response (ER) Preparedness Standards and procedures based on relevant hazards and risks in order to achieve optimum management and capability in handling emergency situations.
•Review on allocations of resources to monitor effectiveness of Emergency Response Plan and evacuation drills.
•Advise and communicate Process Safety matters to General Manager Cooperate Audits to enable him to prioritize decision making.
•Ensure HSE inspection and audit programs are implemented at all levels and tiers so as to ensure continual improvements for the enhancement and sustenance of safety performance and management of hazards and risks.
•Review and ensure the significant hazard risk registers are up-to-date and followed up.
•Review records of process safety related near miss and incident investigations, report and follow up of the recommended actions associated to the incidents.
•Review specific process safety proposals made by technology centers to refinery sites are install and monitored.
•Ensure and realizing the consulting activity in the field of process safety management for all refinery departments (for existing facilities and new projects).
•Review PHA studies and ensure HAZOP/LOPA gaps are implemented effectively.
•Review and recommend improvement opportunities in the coordination of all activities in the Management of Change process.
•Review Process Safety performance indicators standard to ensure it meets company goals and identify deviations.
Achievements:
Successfully conducted corporate audits for two major projects and site as follows:
•East Malaysia Gas Pipe line project
•PETRONAS Gas Terminal project.
•Malacca PETRONAS Refinery plant.
(OPTIMAL is DOW Chemical's and PETRONAS JV Company produce a wide range of petrochemical products from basic feedstock of Ethylene and Propylene to intermediate products)
Key Responsibilities:
•Process safety resource engineer for the Olefin plant, EOG plant, Butanol plant, Derivatives plant, Utilities, Maintenance Department, Central Laboratory and Plant Technical Service Department
•Develop and drive annual process safety KPI's for site.
•Develop and deliver annual process safety improvement plan for site.
•Identify and track deviations from plan and initiate appropriate corrective actions.
•Focal point for update and maintenance of the Process Safety Management system
• Facilitate QRA studies and submit CIMAH reports for the company
•Develop and maintain Safety Cases for the company
• Scheduling and coordination of PHA studies for operating sites and new leader appointments.
•Coordinating of all activities in the Management of Change (MOC) process.
•Coordination the incident investigation and Improvement of process safety culture
•Work with technical teams on safety risk assessment tools (such as HAZID, HAZOP, SIL, LOPA & Bow-tie).
•Focal person for engineering codes and standards such as ISO, API, NFPA and Energy Institute and their application in the oil & gas industry.
•Ability to lead and work in multi-disciplined teams and be able to manage multiple tasks with a high degree of initiative and independence.
Drugs and Alcohol test and monitor for contractors.
•Tool Box meeting facilitation and JSA implementations
•Provide updates as part of contractor selection process.
•Special Projects Accomplished (During career life)
•Harmonized OSHA PSM codes to PETRONAS PS standards
•Developed Train-The-Trainer training package for process safety, PTW system and Behavior Based program subsequently saving a significant amount of money for the company.
•Trained people as subject matter experts in a broad range of HSE subjects.
•Carried out three CICM Responsible Care audits for chemical and Oil & Gas plants. Audit covered Plant Process Systems, Transport and Distribution of Dangerous Goods, Emergency Response, Environment, Occupational Safety and OHS Management Systems.
•Had carried out Internal Audits covering permit to work, Forklift Safety, Hazardous chemicals, use of Ladders, Machinery Safety and Contractors Safe practices.
•Facilitated PETRONAS Corporate HSE MS Audits for PETRONAS Gas and Pipeline Projects.
•Had carried out turnaround supportive projects which successfully lead to zero LTI.
•Updated and submitted COMAH (CIMAH) reports for five major facilities at PETRONAS.
•Facilitate Annual HSE and Responsible Care week in promoting HSE/Responsible Care among Staff and Contractors with involvement of Authorities and the Community nearby the site. This contributed significantly in enhancing the Safety Culture in PETRONAS Sites locally and regionally.
Rolled out the DOW company Global Reliability engineering Work Process
•Rolled out plant reliability opportunities by working with the Pacific and global Facility Reliability Team and leverage improvement opportunities.
•Monitored on-site and off-site contractors to ensure full compliance to company safety rules and regulations.
Achievements:
•Project Implementation - Lead engineering and maintenance project teams to prepare project documents to meet company requirements in project approvals.
•Conducted project risk screening to determine the risk level of the implementations.
•Conducted project design safety review and have identified all the various typed of safety issues and provided recommendations.
•Prepared Business Opportunity Plan (BOP) to describe the project purpose, background and project justifications.
•Calculate cost estimations for projects with Net Present and Depreciation values.
•Identified project implementation constrains with regards to cost and safety and provided recommendations.
•Interfaces with various site teams to develop Return to Operations (RTO) for projects.
•Prepared Technological Implementation Plan (TIP) for capital projects and identified typed of technology and standards to be used.
•Prepared Project execution Plan (PEP) and finalised progressive dated for implementations.
•Reviewed Loss Prevention Principles (LPP), Layer of Protection Analysis (LOPA) & HAZOP for projects - Safety reviews
•Conduct Reactive Chemicals and Process Hazard Analysis (RC PHA) review for projects.
•Prepared project pre start-up (PSSR) safety review to ensure the system is ready to start up safely.
•Conducted pre start up training programs for projects teams.
•Responsible for project commissions and prepared reports on the outcomes
•Coordinated with Government Authorities (such as the Water works department, Public Works Department (PWD), Fire Brigade Department and the Department of Environment (DOE) for Certificate of Fitness (CF) approvals for projects.
•Monitored and tract project for performance.
Special Engineering Projects delivered
•Upgrade Soft water system - upgraded plant soft water system to improve consistent supply of soft water for production usage.
•Upgrade Potable water system - made improvements to the plant potable water pipes and tank installations to have clean and continues drinkable water supply for the site. Evaluated the pipeline backflow prevention as per the Loss prevention Principles.
•Upgrade Fire water storage tank - Through this project, have made improvements fire water storage to ensure there is sufficient fire water storage in the plant in the event of an incident. Worked with various subject matter experts on reinforced concrete (RC), M&E for pipe layouts, Tank output to fire pump and supply pipe lines to hose reels, hydrant, sprinklers and deluge.
•Upgrade waste water treatment plant - Calculated and successfully installed the right capacity of aeration basin (Biological treatment plant), Activated carbon filters and Filter press to control and meet the local regulatory requirements in COD and BOD.
Six Sigma Projects - Successfully initiated two Green Belt Six Sigma Green belt projects
•Reduce waste disposal cost
•Reduce chemical spills at plant (Loss Of Primary Containment)
•Waste Water sludge project - This project is to convert waste water sludge to sellable product.
•Member of Six Sigma Black Belt projects - successfully implemented the Waste water recycle project. The purpose of this project is to recycle waste water into process to reduce waste water discharge and also to improve plant efficiency.
TABLE 2: PROCESS SAFETY STUDIES FACILITATION EXPERIENCE (HAZOP / RE-HAZOP / HAZID / CE ANALYSIS / RC PHA / BOW-TIE / PSSR / HSE CASE