Job: Bulk Operator Kinder Morgan Description: Operates the controls for the scale, rotary dumper, agri dumper and ship loader.

Transcription

1 Job: Bulk Operator Kinder Morgan Description: Operates the controls for the scale, rotary dumper, agri Equipment Assessed: dumper and ship loader. Control rooms as above ESSETIAL DUTIES A. Operate Scale/ Rotary Dumper/ Agri Dumper A. Sitting B. Handling Controls C. Climbing Stairs Loadout Scale Workstation Rotary Dumper (Sulpher Station) and Workstation Agri Dumper/Agri Receiving Workstation ErgoRisk 2008 Page 1 of 11

2 B. Operate Ship Loader A. Sitting B. Handling Controls C. Climbing Stairs Shift Schedule: There are two 8 hr shifts from 8am-4:30pm and 4:30pm-1am with a 30 minute scheduled lunch break and two 10 minute coffee breaks. There is also a graveyard shift of 6.5 hrs from 1am- 8am with a 1/2hr lunch break. The receiving tasks (Scale, Rotary Dumper, and Agri Receiving) are normally performed on day shift but may occur on afternoon shift as well. The Ship Loader may work on all shifts when loading a vessel. Staffing: At Kinder Morgan, there are many pieces of equipment. One person may be dispatched to the Scale, Rotary Dumper and Agri Receiving. There are four Ship Loading stations and one Bulk Operator may be dispatched to each. The Bulk Operators work independently but also rely on Switchmen and Bulk Labourers that are dispatched onsite. ErgoRisk 2008 Page 2 of 11

3 DESCRIPTIO OF ESSETIAL DUTIES 1. OPERATIG BULK EQUIPMET COTROLS Frequency Operates the controls of the bulk equipment for up to 7.5 hours of an 8 hour shift. Equipment Multiple monitors and displays, keyboard, mouse, joysticks. Task Description Loadout Scale Workstation: This workstation is used when rail cars are being loaded in the bulk warehouses. Front end loaders fill the railcars while they are on the scale. The operator is responsible for directing rail car movements, keeping a record of the amount of concentrate going into each car, tracking the tare and gross weights (ensuring that the gross weight is kept below the assigned limit). Rotary (Sulpher) Dumper: The rotary dumper can be operated using controls at the rotary dumper or remotely in the control room using a computer based workstation (see picture). The first three cars are usually dumped using the controls at the rotary dumping workstation. Afterward, the operator uses the control room controls in the site services building to remotely operate the rotary dumper. The product is dumped into chutes to a conveyor system. The product may be directed to a ship or bulk storage. Agri Receiving: The Bulk Operator uses remote controls to operate the indexer and car door opener. The controls for this operation are in the site services building directly beside the Rotary Dumper controls. The joystick controls and video monitors are used to open the bottom dump cars. The operator also controls the indexer which moves the railcars forward after they have been emptied. Both the car door opener and indexer can be controlled manually at the Agri Receiving station if needed (rare). In addition to the joystick controls, there are two monitors for changing routes and setting up the dumper as well as a dead man s pedal which requires that the operator must rest his foot on at all times. The product is dumped into pits and directed onto conveyors. The product may be stored in onsite in silos. All three of these jobs are sedentary and require frequent monitoring of video displays and operation of the associated joysticks, foot pedal and hand controls. Additionally, all frequently use radios to communicate with labourers and switchmen. ErgoRisk 2008 Page 3 of 11

4 A SITTIG Equipment Office Chair Duration Up to 7.5 hours Frequency Constant when operator Force A Operator sits in office chair for the majority of the shift. atural seated posture is typically with a rounded upper back and slightly head forward posture. Frequent neck rotation and extension when viewing monitors or MMI interfaces (touch displays) to the side and above the operator. Frequent neck flexion when looking down at documents on the desk. The Agri Receiving and Sulpher workstations are located in an administration building (clean, air conditioned). The Loadout Scale workstation is in the Bulk Warehouse (not as clean and not air conditioned). B HADLIG COTROLS Equipment Joysticks, switches, button controls Duration Up to 7.5 hours Frequency Constant when operating Force Minimal The hand controls for the various bulk operations vary. Joysticks, switches, mice and touchscreens are all used to operate the equipment remotely or to determine and track the weight of the railcars (Loadout Scale). The amount of control manipulation varies by job (Agri Receiving> Rotary Dumper > Loadout). The Agri Receiving workstation operator opens 35 (average) to 52 (peak) rail car doors using the joystick controls per shift. It was estimated that the operator has their hands on the controls for approximately 1.5 hrs/shift. When handling bulk product, once the product is flowing, the operator is able to monitor the product flow (minimal operation of joysticks, switches). The joystick controls are height adjustable. The office chairs have some adjustability (height, back angle). C OPERATIG FOOT PEDAL (Agri-Receiving only) Equipment Dead man s Pedal Duration Up to 7.5 hours Frequency Constant when operating Force Minimal At the Agri Receiving workstation, there is a dead man s pedal. This is a pedal that must be depressed at all times or the operation comes to a halt. The weight of the foot easily depresses the switch. This is a failsafe mechanism for this operation. ErgoRisk 2008 Page 4 of 11

5 FUCTIOAL DEMADS with MSI POTETIAL Operating Bulk Equipment eck Back Frequent neck rotation when viewing the monitors and MMI displays. Frequent neck extension if viewing monitors above head level (Agri Receiving) Static sitting for the majority of the shift. Operators may sit in slouched or reclined posture, increasing the stress on the discs and soft tissues of the neck and low back. Shoulder Operators may not adjust the workstation (joystick controls, seat) to fit their body. This can result in forward reaching, reaching to the side and awkward, static postures of the shoulder. Elbow/Wrist Ankles Occasional, static gripping of the joystick or mouse controls. Static depression of the dead man s pedal when operating at the Agri Receiving workstation. When muscles remain in one position (static posture) for long periods of time, the muscles can become fatigued and sore. STRATEGIES TO MIIMIZE MSI Operating Bulk Equipment eck Back Stretch the neck muscles often to allow tissue recovery resulting from awkward postures. Try tucking the chin to place the neck in proper alignment with the spinal column and then rotate the head to one side or the other. Hold the stretch for 20 seconds. Shoulders As much as possible, avoid sitting for extended periods of time to minimize static use of back muscles. Stand and stretch whenever possible. Take the opportunity to stretch or walk during scheduled breaks to restore blood flow to the spinal tissues. Minimize awkward sitting posture by taking the time to adjust the chair for best fit. Reverse forward leaning postures by arching the back, squeezing the shoulder blades together and sticking the chest out (see picture at right). Perform back stretches or take a short walk during breaks to relieve stress File photos ErgoRisk 2008 Page 5 of 11

6 Take hands off the joystick whenever not operating the controls. Let shoulders relax and hands rest in lap until required to reach back for joystick again. Minimize awkward shoulder postures by taking the time to bring the input devices and joysticks to the right height and within reach when the elbows are positioned tight to the side of the body. Elbow/Wrist Maintain neutral wrist posture when operating joystick and controls. Where possible use a power grip on the joystick to reduce stresses to the small structures in the hand. Keep wrist straight when reaching behind for other controls Let go of the joystick whenever possible to reduce static grip stresses to the elbow, hand and forearm. Perform wrist and forearm stretches with elbow straight to stretch muscles and increase blood flow after periods of particularly repetitive or prolonged static wrist and hand postures. 2. OPERATIG THE SHIP LOADER Frequency Operates the ship loader for 7.5hrs per 8-hour shift (2 15m breaks). Equipment Ship loader operating stations Task Description At Kinder Morgan, there are a variety of different loader workstations. The operator is responsible for accessing the operating station by a combination of stairs and walkways. The control booth is positioned directly over the bulk vessel. Some of the loaders are stationary while others move on a track at a radius to the dock. The operator is responsible for ensuring that the equipment and radio are operating correctly. The operator then positions the discharge head over the hold and works with the foreman and labourer as needed to start the flow of product to the vessel (from rail cars or from bulk storage). The operator is responsible for the manual control of the loader. Depending on the design of the ship loader, the operator may control movement of the discharge head in the vertical (up/down), horizontal (left/right) direction as well as the horizontal throw of the product (typically used when trimming the load). The operator is required to maintain a constant awareness of the loading process including an awareness of the ships structure (e.g. hatch covers). At Berth 4, the ship loader is not self leveling. This means that as the discharge head is raised and lowered, the cab changes angle. The cab can reach an angle of 30 degrees. ErgoRisk 2008 Page 6 of 11

7 A SITTIG Equipment Ship loader Seat Duration up to 7.5 hours Frequency Constant Force n/a The Bulk Operator sits in the Ship loader seat for the duration of the operating task. ot all Bulk Operating Control Booths are self leveling. on-leveling loaders cause the cab to be on an angle (angle increases as the hold fills with product and the loader is raised). The angle of the cab increase the forward bending required to view the discharge chute through the front window of the control booth. Frequent and sustained neck and back flexion when hunching forwards to look down through the floor windows to see the work. Frequent rotation of the neck to the left or right when moving the ship loader to the right or left. Frequent rotation of the neck to view MMI controls. atural seated posture is typically a rounded upper back and forward head posture. The operator may choose to look out the front window or two smaller windows behind the operator (workstation is designed to rotate). If the operator decides to turn the console, it requires from 35 to 69 lbs of force depending on where it is grabbed (35 lbs grasping monitor bezel (point of maximum leverage)). Whole-body vibration when gantry is in operation. Significant jolts may occur when moving the ship loader from side to side. B HADLIG COTROLS Equipment Joysticks, switches, button controls, radio controls, touchscreens Duration up to 1 hour/shift Frequency Occasional Force minimal The Ship loader operator s seat has a right and left console for the ship loader controls. This includes joysticks, warning lights, and a trackball. A MMI display (touch screen interface) is positioned to the left of the operator. Air conditioning controls are positioned overhead. The operator at Berth 4 was noted to adjust the controls when looking through the front window. This resulted in reaching behind the line of the body (shoulder extension). The operator indicated that once the controls are set and the product is flowing, he operator normally looks down approximately 1/5 min for 30s. Various different grips including power grip, pinch grip and modified pinch grips are required to handle the controls When handling the joysticks and leaning forward to view the operation, the operator s shoulders are typically in an extended position. Additional shoulder extension is required when operators reach further back to access the roller ball by the right hand/elbow. Complex small wrist movements in all directions may be required to manipulate the different controls. There are significant dexterity requirements to make fine adjustments to the crane. The arms are typically unsupported during all these control movements. ErgoRisk 2008 Page 7 of 11

8 C ASCEDIG/DESCEDIG THE SHIP LOADER. Equipment A Duration 5 minutes Frequency Up to 4 times/shift Force Body weight The operator must access the ship loader cab using a series of stairs, walkways or ladders. Total travel time may exceed 5 minutes. The bulk operator carries a hand held radio and may carry a backpack. FUCTIOAL DEMADS with MSI POTETIAL Operating the Ship loader eck Static neck flexion, rounded upper back and forward head posture when looking down at the work can stress the structures in the neck and upper back. eck rotation in the horizontal plane to watch for hazards when moving to the left or the right or twisting to look at the control panel puts rotational stress on the structures in the neck. Back Lumbar spine rounds when sitting which places increased stress on the discs and other spinal tissues. Increased C-curve with unsupported forward leaning postures place increased mechanical stress on the back. Static use of back muscles from sitting for extended periods can increase fatigue. Twisting or side bending postures to access control panel or when viewing to the side can stress spinal tissues. The angle of the ship loader cab can increase the amount the operator bends forward, increasing the stress on the discs and soft tissues of the low back. Shoulder Static shoulder extension when operating joystick controls while leaning forward can stress the shoulder joint Sideways reaching with an unsupported right arm to access control panel. Awkward arm and shoulder movements are required to access controls that are behind the seated operator at the rear of the consoles. ErgoRisk 2008 Page 8 of 11

9 Elbow/Wrist/Hand Complex small wrist movements are required in all directions to operate the joystick controls. Repetitive pinch grip is required for some knobs and switches. Repetitive thumb and finger movements are required to push buttons and manipulate joystick for small movements. STRATEGIES TO MIIMIZE MSI Operating the Ship loader eck When not required to view the load return neck to a neutral position and look straight ahead until required to look down again. Back As much as possible, avoid sitting for extended periods of time to minimize static use of back muscles. Stand and stretch whenever waiting for bomb carts or during other breaks from activity. Take the opportunity to stretch or walk during scheduled breaks to restore blood flow to the spinal tissues. Minimize awkward sitting posture by taking the time to adjust seat for best fit. Reverse forward leaning postures by arching the back, squeezing the shoulder blades together and sticking the chest out (see picture at right). Shoulders Take hands off the joystick whenever not operating the controls. Let shoulders relax and hands rest in lap until required to reach back for joystick again. Sit as far back in the seat as possible to reduce the distance needed to reach behind to access the controls If rotating the operating console, use the handle on the rear of the monitor in order to reduce the required pull force. Elbow/Wrist Maintain neutral wrist posture when operating joystick and controls. Where possible use a power grip on the joystick to reduce stresses to the small structures in the hand. Keep wrist straight when reaching behind for other controls Let go of the joystick whenever possible to reduce static grip stresses to the elbow, hand and forearm. Perform wrist and forearm stretches with elbow straight to stretch muscles and increase blood flow after periods of particularly repetitive or prolonged static wrist and hand postures. ErgoRisk 2008 Page 9 of 11

10 3. EVIROMETAL COSIDERATIOS Exposure to Elements The Bulk Operator is performed indoors or in the cab of a ship loader for the majority of the shift. The Loadout Scale and Ship loader Operators may be exposed to bulk materials. PPE may be required depending on the bulk material (e.g. full face respirators, coveralls). Uneven Surfaces In order to access the Ship loader and Loadout Scale, the operator must travel through the yard, up stairs, ladders and walkways. Debris, precipitation, and other obstacles may obstruct movement. oise The Agri Receiving and Rotary Dumper workstation are performed indoors. oise is minimal. The Loadout Scale Operator may be exposed to the noise associated with the front end loaders and/or skidsteer. Proximity to Moving Objects When walking around the yard, lift trucks, trucks, and other equipment frequently travel through the area. ErgoRisk 2008 Page 10 of 11

11 PHYSICAL DEMADS SUMMARY TABLE Job Demands Max. Weight/ Avg. Weight (kg) Duration per exposure h=hrs s=secs, m=mins Frequency UABLE to perform Comments STREGTH POSTURE & MOBILITY EVIROM T Lifting/Carry <1kg 5min O Handheld Radio Push/Pull 10kg 5s O Opening doors to access control booths/rooms Supporting Body Weight 15s O Climbing ladders, stairs Gripping / Handling 30s F Handling controls to operate car door openers or to operate discharge head controls Fine Motor Skills 30s F When operating hand controls Sitting 2h C When operating equipment Driving Standing May occur when not operating. Walking 5m O When travelling to operating booth Bending/ Stooping 5m O When setting up discharge chute or trimming hold (ship loader). A for other workstations Sustained Crouching/ Kneeling Climbing Stairs <5m O Accessing ship loader. Up to 5 flights. Climbing Ladders <1m O 1-2s flight; 8-10 (Ship loaders). Crawling Balancing Throwing Overhead Reach <15s O When operating air conditioning controls overhead (ship loader). Exposure to Elements 5m O When travelling to operating equipment Uneven Surfaces 5m O When walking throughout the yard Proximity to moving objects Vibration (upper extremity) 5m O When traveling throughout the yard to access operating equipment. Vibration (whole body) 2h C Minor vibration when operating Ship loader. Frequency Ratings: V: varies (see comments) : ever R: Rare - ot daily or up to 1% of shift (<5mins/day) O: Occasional - 1%-33% of shift (up to 2.5hrs) F: Frequent - 34%-67% of shift (2.5-5hrs) C: Constant ->67% of shift (>5hrs) ErgoRisk 2008 Page 11 of 11