Risk Assessment for Rope change at MGD Sentosa Iland – Mt. Faber ( Singapore)

Step Description of the step Possible hazards Controls / precautions1 Set-up of the equipment as shown in

attachment General public accessing rigging areas

Oil leaking from the winches

Manual pushing of heavy equipment components

Cuts and grazes

Punches and blows to the head Falling, slipping, stumbling

Fence around the winch and the area to be equipped on the west side

Warning signs to prevent persons from trespassing the area

Entombment package nearby the winches

Observe entombment plan specific to the location

Employees qualified by training in handling of heavy components

Use shoes with steel toe cap Always wear shirts with short

sleeves and trousers Compulsory wearing of a helmet Working area must be kept clean Works on the ground acc. to

Doppelmayr instructions2 Installation of anchors, bottom roll, deflection

roll Failure of the anchor or rigging points

respectively Install double anchor or rigging

points for high forces. Anchor calculated with a safety factor of 3 to max. Acting load.

Helmet / stepping aside As few people as possible Keep working area clean / secure

with guy ropes Visual check the anchor

3 Working with ropes and slings Endangerment third parties During pulling work no persons are allowed to stay under the

Tear of ropes/ slings

Fall down from assembly material and slings/ropes

Incorrect serving of winches, and machines

Slip of clamping plate and ropes

Uncontrolled unreeling from ropes

ropes. Walk ways and traffic road have to be secured. The lateral safety margin between people and the rope is to be adapted to the local conditions and should at least 10 meter.

The maximum rope and anchorage forces must be admit . Slings and ropes must be selected with a security from at least 2,5 to the minimum breaking load. The condition of ropes and Slings are to be visually examined before use. Defective material has to to be removed.

Rope, assembly aids and tools for the work are to be secured against falling down.

Only trained personal to allowed to operate winches and machines.

For the rope attachments use only anchorage material which is appropriate for the selected kind of anchorage and the arising forces . Clamping plate diameter must correspond with the rope diameter. Screws (e.g. of clamping plates) are to be tightened with torque wrench.

Rope drums are to be secured against uncontrolled unreeling. Nobody is allowed to stay inside loosely rope rings. Likewise

Hang up at construction works and structures

critical rope angles from guide rollers are to be avoided.

During the pulling work the rope is to be controlled on the critical places and/or accompanied during pulling. It has to be considered that changing the rope tension means changing also the rope position.

4 Fixing 29 mm Hauling Rope at Sentosa Station by installation of Attachment slings.

Falling of parts from certain height Slipping of clamping plate Tear of attachment slings Tear of anchors

See point 3

5 Fixing 29 mm hauling rope at Mount Faber by installation of attachments slings on one side and 5 To Winch and 16 To tackle block on the other side.

Falling of parts from certain height Slipping of clamping plate Tear of attachment slings Tear of anchors

See point 3

6 Pull with 5 To Winch until 29 mm Rope at Mt. Faber is loose.Cut 29 mm rope at Mt. Faber.Release 29 mm Rope until the tension weight at Sentosa is placed on the ground.

Sparks and fire

Injuries caused by the falling or releasing rope and by falling parts

Loss of the rope Sparks and fire

Twisted ropes

Protect surrounding area against sparks. Place fire extinguisher.

Only trained operators on winches and machines

Clean area below counterweight at Sentosa

Ensure that the tension of the rope has been released before cutting it.

Use tension holder against twist of tackle block and rope

7 Fixing 29 mm Hauling Rope at Sentosa Station by installation of Attachment slings with 16 to tackle block an Tirfor. Same side as winch.Cut 29 mm rope at Sentosa

Falling of parts from certain height Slipping of clamping plate Tear of attachment slings Tear of anchors Sparks and fire

See point 3

Protect surrounding area against

sparks. Place fire extinguisher.

8 Pull 29 mm Hauling Rope trough 25 to winch at Sentosa and roll up on Hasp winch. At Mt. Faber, connect the 29 mm hauling rope to 14 mm winch rope by means of splice connection.

Twisted ropes Incorrect serving of winches, and

machines Falling of parts from certain height Slipping of clamping plate Tear of rope splice connection

See point 3

Splice connection to be done only by special trained Garaventa people.

9 Pulling out 29 mm Hauling Rope with 25 to winch over the spilling ring and roll on to hasp winch. Continue release with 5 to winch until 14 mm winch rope has reached Sentosa

Endangerment third parties Loss of the rope Loss of communication Loss of winch control

See point 3 Limit winches to breaking load of

rope Ensure adequate communication Check radio equipment before

using it Back-up radio for the operator of

the winches Headset for operator of winches One person to regulate the winch

speed Limiting to the tensioning values

indicated by the Engineering Dept.

10 Fix 14 mm winch rope at Sentosa and Mt. Faber. Cut 14 mm rope between winch an fixation at Mt. Faber

Falling of parts from certain height Slipping of clamping plate Tear of attachment slings Tear of anchors Sparks and fire

See point 3

Protect surrounding area against sparks. Place fire extinguisher.

11 Change Winches in both Stations to the opposite Side and pull out 29 mm hauling rope as described in point 8 and 9.The 14 mm winch rope remain placed.

Clamping fingers and feet Personal falling over slings and tools

Wear hand cloves and safety shoes

Clean up working tools and equipment

12 Install 40 to tackle block to Track rope at Mt. Falling of parts from certain height See point 3

Faber and release Track rope until counter weight is placed on the ground.

Slipping of clamping plate Tear of attachment slings Tear of anchors

13 Install chain hasp in the parking area at Faber.

Endangerment third parties Fall down from assembly material and

slings/ropes Loss control of mobile crane

See point 3

Use only trained machinist on mobile crane

14 Install Liner hoist at Mt. Faber and feed the 42mm track rope through the liner hoist to the chain hasp

Twisted ropes Incorrect serving of winches, and

machines Clamping fingers and feet Personal falling over slings and tools

Wear hand cloves and safety shoes

Clean up working tools and equipment

15 Fix the 29 mm rope at Sentosa coming through the spilling ring of the 25 to winch to the track rope by means of casting head

Twisted ropes Incorrect serving of winches, and

machines Clamping fingers and feet Personal falling over slings and tools Sparks and fire

Wear hand cloves and safety shoes

Clean up working tools and equipment

Casting head to be installed only by special traind Garaventa people

16 While pulling with the liner hoist, releasing with the 25 to winch the 29 mm rope. Pull 42mm track rope on to the chain hasp until 29 mm rope has reached Mt. Faber.

Endangerment third parties Loss of the rope Loss of communication Loss of winch control

See point 3 Limit winches to breaking load of

rope Ensure adequate communication Check radio equipment before

using it Back-up radio for the operator of

the winches Headset for operator of winches One person to regulate the winch

speed

Limiting to the tensioning values indicated by the Engineering Dept.

17 Fix 29 mm rope at Sentosa and Mt. Faber.Cut of casting head. The 29 mm rope remain in place.

Sparks and fire

Injuries caused by the falling or releasing rope and by falling parts

Loss of the rope Sparks and fire

Twisted ropes

Protect surrounding area against sparks. Place fire extinguisher.

Only trained operators on winches and machines

Clean area below counterweight at Sentosa

Ensure that the tension of the rope has been released before cutting it.

Use tension holder against twist of tackle block and rope

18 Move linear hoist an winches to the opposite side.

Clamping fingers and feet Personal falling over slings and tools

Wear hand cloves and safety shoes

Clean up working tools and equipment

19 Repeat point 12 to 16.