>
« back to results for ""
Below is a cache of http://www.fwc.com/publications/pdf/fw_Winter_2007.pdf. It's a snapshot of the page taken as our search engine crawled the Web.
The web site itself may have changed. You can check the current page or check for previous versions at the Internet Archive. Yahoo! is not affiliated with the authors of this page or responsible for its content.
Global teamwork, global success
NEWS
W I N T E R 2 0 0 7
Foster Wheelers E&C people, projects and successes around the world
Global teamwork,
global success Published by
Foster Wheeler
Shinfield Park
Reading
Berkshire RG2 9FW
UK
www.fwc.com
Managing Editors
Carolyn Greenhalgh
Director, Strategic Planning &
Marketing, Global E&C Group
T +44 (0)118 913 2494
E carolyn_greenhalgh@fwuk.fwc.com
Anne Chong
Public Relations Manager
T +44 (0)118 913 2106
E anne_chong@fwuk.fwc.com
Dominic Hale
Creative Manager
T +44 (0)118 913 2329
E dominic_hale@fwuk.fwc.com
© Foster Wheeler
Produced by MMCS
ERTC, Barcelona
Inspired by Miró
18
EPC win
Pluto LNG, Australia
16
HRH The Duke of York
in Singapore
22
24
Shell, Singapore
Our zero-incident goal
4
SHARQ - world-class HSE
Contents
2
FW NEWS QP Honam, Qatar
Petrochemicals success
38
Petronor, Spain
A long-lasting relationship
46
Khurais Gas Programme
Truly a mega-project
36
Spotlight on
Gasification
26
28
Singapore Parallel Train
ExxonMobil gives green light
10 IEA Greenhouse Gas R&D Programme
14 Browse, Australia
Novel offshore LNG solutions
17 Developing refinery investment plans
20 Chemicals & petrochemicals
Global insight
34 Fawley FCC turnaround
A record-breaker
39 Dow, Thailand
Another petrochemicals win
40 Fired Heaters
International success
44 Paradip Refinery Project, India
Developing a world-scale vision for IOCL
48 Innovation by design
Celgene, Switzerland
49 Birthday celebrations in Basel
50 GSK, Singapore
State-of-the-art facility
51 Novartis, Singapore
Another safety award
52 BAPCO refinery upgrade
54 World Energy Congress, Rome
55 Chile power plant win
3
FW NEWS
Front cover image: With the kind permission of George McCleskey (right) and Keith Batchelor.
Photographer: Stewart Turkington. A world-class
HSE performance
4
FW NEWS
SHARQ utilities & offsites,
Saudi Arabia Sharq
5
FW NEWS
e
As well as being overall programme manager for the world-scale expansion of
SHARQs existing petrochemicals complex at Al-Jubail, Saudi Arabia, we are also
the EPC contractor for the complete utilities and offsite (U&O) facilities to support
this major investment.
We are extremely proud of the world-class HSE performance we have delivered
so far on the U&O project, having achieved over 21 million manhours without a
lost-time incident (LTI) to date.
Right to left: Ian Guy, U&O resident construction manager, FW; Audah Al-Shammari, U&O project manager, SHARQ;
Roman Garzulli, area superintendent, FW; Guy Maloney, field manager, FW; and Alan Foster, U&O HSE manager, FW. 6
FW NEWS
FW: Alan, tell us a little about when you started
on this project and about the workforce.
AF: I was in the enviable position of being only
the third person to start work on site and was thus
able to start off with a completely clean sheet. The
worker induction system, the security and training
schemes were all up and running before the bulk
of the workforce arrived. Our clients team made it
very clear that its safety expectations were in full
alignment with Foster Wheelers policy and
commitment to safety. Our client has continuously
provided its full support and encouragement in
achieving that goal.
FW: How do you manage such a large and
diverse workforce?
AF: We have managed to establish a formidable
force of some 160 full-time HSE inspectors and
administration support staff, with the valued help
and support of the main sub-contractors
management teams. The desired ratio of HSE
inspectors to workforce is about 1:40. All of the
inspectors are easily identifiable by their distinctive
uniform of mauve shirts and black helmets.
There is also a fully functional medical centre
staffed by a full-time doctor and nurse who are
an integral part of the HSE team. Various health
and well-being campaigns have been run,
including heat stress advice, healthy eating,
and stress management.
FW: Do you need to undertake any training?
AF: Yes we do. All projects are only as good as
their poorest performing sub-contractors and so
training received special focus and significant
investment very early on. A training facility
complete with dedicated and highly skilled
HSE trainers was established to deliver
bespoke HSE training courses.
These included the high-risk activities which have
been identified by hazardous construction studies.
These courses include: Confined space Working at height Lifting operations Roles and responsibilities of supervisors Flagman/banksman Vehicle/plant movements on site Excavation awareness Lock out/tag out procedures
The courses also include the more general site
inductions (over 13,000 to date) and general
safety awareness sessions, plus the Institution of
Occupational Safety and Health three-day Managing
Safely courses for all supervisors and managers,
and accident/incident investigation sessions.
FW: Are you using the latest techniques?
AF: Yes, in addition to the above training, we
have implemented our behavioural-based safety
programme, CORE (Continuous Observation and
Risk Evaluation) to great effect.
Some 14,000 observation cards have been
completed, analysed and interrogated to identify
where negative and positive trends may be
developing. We have then been able to establish
suitable intervention plans to counter any poor
working practices at a very early stage.
Some notable examples include the identification of
operatives working at height using shock absorbing
lanyards incorrectly and vehicles and plant reversing
on site without appointed banksmen.
FW News
asked Alan Foster, our U&O project HSE manager, to
explain the secret of this projects outstanding safety performance.
SHARQ utilities & offsites, Saudi Arabia 7
FW NEWS
Sharq
The lions share of the U&O construction
workforce, which currently totals around 5,500
people, comes from India, Bangladesh, Pakistan,
Nepal and the Philippines. These workers have
all been inducted either in their native tongue or
in another language they understand.
A world-class
HSE performance 8
FW NEWS
FW: Have you been able to take on board
lessons learned from other projects?
AF: Twenty-one million manhours without an
LTI have been achieved by the hard work and
commitment of the team. There is a lot of
planning and organisation involved to get the
basics right. We have incorporated lessons
learned from previous experience around the
world, as well as from our own project and
have instilled a positive behavioural culture
across a workforce of over 10 different
nationalities and languages.
We have also learned from the experiences of our
client, SHARQ, who already has a world-class
safety programme in place in its operational
plants with over 21 million manhours worked
without an LTI. Our client also runs monthly
competitions among ourselves and the other
EPC contractors on this expansion project, with
ranking and recognition of the high performers.
We have also now introduced an occupational
health screening procedure for high-risk
occupations such as crane, plant and bus drivers
and we will be monitoring these closely to pass
the benefits on to other projects.
SHARQ utilities & offsites, Saudi Arabia 9
FW NEWS
FW: Aside from zero LTIs, how can you tell
how well your HSE management is doing?
AF: No project can accurately assess how well
or badly it is performing unless there is a system
in place to measure and provide timely reality
checks: this project is no exception.
In addition to a corporate audit carried out in
July 2007, we have a very robust site audit and
inspection regime in which all the project team
members are encouraged and expected to
participate. From the outset senior managers
have set time aside to carry out systematic daily
HSE walk-throughs which allow them to keep
their fingers on the pulse.
Area supervisors in turn carry out regular HSE
tours accompanied by the sub-contractors
managers and photographic evidence is used
to good effect. A monthly picture board is
produced which is affectionately known as the
good, the bad and the ugly! This, as the name
suggests, also homes in on good and bad HSE
practices which are captured and shared.
A just culture prevails on this project and
evidence of this is seen everywhere. Site rules
are very clear and unambiguous and every one
is empowered to stop any task if they believe
there is a risk to anyones safety or health.
FW: How do you motivate individuals to take
r