2. 2
2
Presentation Contents
• 4 major projects (introduction, my role, professional
growth)
– Major Hazard Facility (MHF)
– M2 Transformer Temperature Alarms
– M2 Paper Break Camera System
– Recovery Boiler’s 5 & 6 (R5/6) Superheater Tube Temperature
Probes
• Training / experiance
• Life in the Valley
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3
MHF
Introduction
• Australian Paper (Maryvale mill) is a MHF
• Safety Case
– How we manage safety at our MHF
My Role
• Finding and tagging ~100 untagged MHF assets
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4
MHF
My Role
• Managed the updating of BECA marked piping and
instrumentation diagrams (P&IDs) show all MHF assets
• Added previously unrecorded MHF assets to instrument
calibration system (Caltrack)
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5
MHF
My Role
• Documented ‘unreachable’ MHF assets
– Created work requests for area assistance
• Attend MHF meetings to report progress
– Worked within WorkSafe MHF licence renewal deadline
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Professional Growth
• Read P&IDs
• Locate assets
• Maryvale mill
• Safety
– Personal protective equipment (PPE)
– Signing into areas
• MHF
– Identification of MHF locations & critical assets
MHF
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My Role
• Investigated old switching type indicators
• Sourced and purchased new site standard WIKA
indicator/transmitters
• Documentation
– Loop connection diagrams
– Junction box drawings
• Installation
• Distributed Control System (DCS)
– Logic
– Human Machine Interface (HMI) Graphics
• Commissioning
M2 Transformer Temperature Alarms
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M2 Paper Break Camera System
Introduction
• Making paper is not a perfect process
• Paper breaks
– Hard to diagnose (insects, falling debris, dripping, inconsistent pulp
from the head box etc.)
– Unplanned downtime expense
– Camera system
• Portable trial camera system (WEBVISION)
Purchased and
installed at M2
Decided to
reinstall at M2
Moved to other paper machines
Reinstallation
at M2
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Justification for Reinstallation
M2 Paper Break Camera System
M2 unplanned downtime cost $3388/hour
M2 average breaks per day (2011) 3.72 (rose to ~6 in 2012)
M2 average break time 12 minutes
Average break cost $677.60/break
M2 paper machine production 290 days/year
Saving assuming one break per day reduction $196,504/year
Project cost $30,000
Return on investment (ROI) 555%
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My Role
• Read available documentation
• Diagnosed reason that camera system was not functioning:
– Sourced and replaced broken switch to power up WEBVISION system.
– Fixed non functioning capture computers
• Power supply replaced with a spare
• HDD formatted and imaged with working capture unit’s HDD
• Swapped single input video card with dual input card from M4
• Wrote a scope of work
– Extracted drawings from WEBVISION documentation and organise boilermakers to make up
brackets for cameras and lights
– Assisted electricians with installation
• Prepare cameras (power/video connections, housing, focus, aperture, exposure
zoom)
• Create/updated company documentation
• Training and handover
M2 Paper Break Camera System
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Professional Growth
• Cameras
– Aperture
– Exposure
– Focus
– Lighting
– Fault finding
• Better estimate installation times
• Process of getting work done
• Communication with trades
M2 Paper Break Camera System
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• Old
• New
R5/6 Superheater Tube Temperature Probes
Bailey DCS
ABB DCS
Temperature
transmitter
HMI
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My Role
• Ascertain what work had already been completed and what
was left to do
• Prepare wiring diagrams for remaining work
R5/6 Superheater Tube Temperature Probes
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My Role
• Prepare loop connection diagrams for each loop (135)
R5/6 Superheater Tube Temperature Probes
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My Role
• Source quotes for remaining work
– Relocation of 89 loops from R5 and
46 loops from R6
• Manage contractors work
• Commission
– Check wiring/cabling/ferrules are correct
– Programming of transmitters and making
sure each loop is functioning correctly
– Enabling new DCS programming and linking
to operators graphics (HMI)
R5/6 Superheater Tube Temperature Probes
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Professional Growth
• Wiring diagrams and loop connection diagrams are
essential for:
– Installation
– Decommissioning
– System analysis and modification
– Fault finding
• Temperature sensors
• Manage contractors work
• Bailey and ABB DCS
R5/6 Superheater Tube Temperature Probes
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• CMMS (PBS4)
• Thermal imaging
• DC motor maintenance
• DCS
– METSO
– ABB
• Electrical Equipment in Hazardous Areas (EEHA)
• Cardiopulmonary resuscitation (CPR)
• Job Safety Analysis (JSA)
• Transformer Oil Sampling
Training / Experience
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• Netball – 2 seasons (Churchill)
• Badminton – 2 seasons (Traralgon)
• Indoor cricket – 2nd seasons (Traralgon)
• Golf – AP Golf Day
• Latrobe Young Professionals (LYP) group events
• Fishing at Lake Hyland
Life in the Valley
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Staff
• Daryl Adams - E/I Engineer - HV, SESO
• Alex ‘Zac’ Crewe - Power/Recovery E/I Engineer
• Steven Gooda - DCS Engineer
• Jeff Buckett – Head of Maintenance - E/I
• Andrew Sun - Asset Management Engineer
• Muditha Hasthanayake - M1 & M2 E/I Engineer
• Milinda Senanayake - Graduate E/I Engineer
• Tom Hagley - M3 E/I Engineer
• Edward Trickett – General Manager - Paper
• Trevor Niejalke - M1/M2/M3 E/I Superintendent
• Anthony Beckett - M5 Production Superintendent
• Alan Jenkinson - M5 E/I Engineer
• Raymond Smith - 2011 IBL Mechanical Engineering Student
• Brendan Jilbert - M1/M2 Machine Manager
Acknowledgements
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Trades/Technicians
• David Lothian - M1/2/3 E/I
• Bill Vansambeek - DCS Technician
• Andrew Daly - E/I Central Workshop Planner
• Rodney Hewat - E/I Central Workshop L/H & Acting SESO
• Ben Bowen - Central Workshop E/I
• Rudy Bence, Contractor – VB & Co planner
• Nick Calla - M1/M2/M3 E/I Planner
• Craig Bassi - HP Technician
• Brian Spiteri – Boilermakers
Young Professionals
Acknowledgements
