JOB 1: lead out roll locking pin Flashcards
What safety precautions should be taken when working on slippery surfaces in this area?
Remove the cause of the slippery area, production cleaned the area with a jet wash before work commenced
What issue occurred with the lead-out roll top wire roll locking mechanism?
drive side locking pin was not changing positions from the cylinder meaning the lead out roll was not locking into position. This was then simulated in the DCS to prevent roll movements.
upon initial inspection the cylinder was found to be leaking this meant that the cylinder did not have any differential pressure so couldn’t move into the locked position
Why did the drive side (DS) pin fail to lock while the front side (FS) pin moved into position?
cylinder DS was damaged and not holding pressure meaning a pressure differential was never generated to switch the cylinder over.
What troubleshooting steps were taken to diagnose the cylinder movement issue?
before our work began an engineer had changed the airlines over on the cylinder, as no movement occurred the cylinder was either passing or not holding pressure. this proved the manifold was okay. was no spare available for change at this point.
carried out a visual inspection/observation when starting our job, found the cylinder to be cracked on the extend/locked side.
Why was the Festo part number not immediately available from the Voith drawings?
drawing had not been updated since 2012
was the manufacturer drawing and not the palm installation drawing
working environment is hot dirty and wet. this meant that the faceplate details of the cylinder were not visible or readable.
How was the supplier involved in resolving the issue with the replacement cylinder?
contacted by our supervisor to discuss possible replacement and to confirm the spare we decided to order was the correct type
What role did simulation play in obtaining locked position feedback from the FS sensor?
allowed the machine to continue running safely until the shutdown. by interlocking the FS will a simulation, all roll movements were inhibited,
Why was only the locked position simulated, and not the unlocked sensor input?
by simulating the locked position it stops roll movements. unlocked would be an que for roll movements within the logic.
What paperwork (PCI) was created for the logic changes, and where was it documented?
PCI is a document used for the recording and planing of logic changes on the paper machine. This outlines the issue on the locking pin and its resolution
What condition was the faulty cylinder in upon initial inspection?
Upon our initial we found that the cylinder was cooreded and cracked. This meant that the cylinder was not holding pressure to creat a differential to lock the pin in place. It was decided to replace the cylinder
Why is the cylinder replacement planned for an appropriate shutdown rather than immediate replacement?
We did not have an appropriate replacement in stock and was waiting for a delivery, whilst this was happening it Was determined by production that the issue was runnable with a simulation to prevent roll movements.
What are the key responsibilities of employer under the HASAW 1974?
To provide a safe working environment
To have appropriate work documents when assigning jobs, this includes Work orders, PTA,RA
To provide safety protocols and work guidelines through SSOW
Reporting and investigation of health and safety incidents
Provide training to employees
How does the risk assessment process help in maintaining a safe workplace?
Allows you to identify and mitigate any hazard and risk that present themselves protecting the safety of employees
Allows a company to implement control measures and safety protocols
Allows for a continuous improvement of health and safety
Reduces risk to employees
What are SSOW and OPL and how are they implemented at Palm?
SSOW is structured approach to ensure workplace safety it involves the planning,organising and control of activities outlining a standard of practice and guidance on tasks.
OPL’s are less detailed SSOW and cover. More specific tasks
Both are part of the yearly training plan for employees
Why is it important to complete a PTA before a job in a industrial environment?
Allows you to assess the working area and identify the risks that my present themselves, measures cab then be taken to reduces the probability of injuries or exposure
PTA are importation as industrial environments are always changing
Give the employee time to sow down and think of the job at hand, allowing them to come up with a safe and methodological approach to the job.
Compliance with legal requirements
Promotes workplace sfaety
How does COSHH training contribute to workplace safety?
Allows the employee to accurately identify chemical hazards
Provides the information on how to access the hazdata sheets which provides information on the PPE required, health risks, potential risks, emergency procedures etc.
What des the role of PPE play in ensuring worker safety and what specific PPE was worn for this task
PPE is the final layer ofprotection against a hard
Provides physical protection from injury by creating a physical barrier between person and hazard
Comlicance with safety regulations and promotes safety culture
How door isolation procedures contribute to workplace safety when working with electrical equipment?
Isolations provide a phycial barrier between a person and electrical risks
Ensures the equipment is safet to work on
Procedural documentation means guidelines and standards are set in stone maeaning safety standards are maintained
Isolation training is provided to ensure it is done correctly
Isolations ensures the equipment can not be energised whilst the work is being carried out
What types of training are required before completing work on palm machinery?
Competency is proven before lone working is to be completed
Health and safety training is completed this includes, COOSH, manual handling, risk identification etc.
Why is it necessary to follow specific legislation such as Electricity a work regulations 1989 in an industrial setting?
Legal requirement
Primary objective is the safety of workers who work with electrical systems reducing the risks of shock, burns etc,
Legislation mandates proper safety measures
Protects personnel and equipment
How does the management of health and safety at work regulations 1999 impact daily operations in a workplace?
Accident reporting and investigation
Risk and hazard identification -managers manage the associated risks and hazards
Provide employees training to ensure safety
Implementing measures to reduce risk
Have an appointed duty holder to ensure safety and continued improvement
What are the key tasks included in the maintenance process?
Identify the cause of the locking pin failure
Carry out isolations
Remove cylinder
Reinstall cylinder
Deisolated
Test
Why is it important to document work completed, fault locations and tools used?
Can create a historical set of data for others and allows you to track faults on a specified machine or component
Informs supervisors of faults identified and work carried out. Allowing this job to be handed over smoothly
Legal requirement
What documents were printed before starting the maintenance work?
Drawings
Isolations
PTA
Work order
Why was it necessary to speak to the production supervisor before accessing the lead out roll?
Working within the electrical department SSOW outlines th procedure for isolations. This requires us to receive production approval for all work.
Prevents lost time and machine down time.
What PPE is required for this job and Why?
Hi-vis - increased visability, so they can see you on the machine whilst they are washing down the machine
Bump cap_ shut down requirement due to increased work load
Work wear - general protection
Hearing protection: work area is loud
Glasses: protect eyes
What risks were identified during the PTA and how were they mitigated?
Slippery surface was cleaned by production and inspected by us before work commenced. Allowing us to decide its safe to work whilst carrying out the PTA
Why must isolation be carried out with permission from production management?
reduce production interference so the machine will continue to run
Allows the operates to know what work is going on on there machine
Improves safety
How was the isolation process documented, and why is it important to follow the one man one lock rue?
Isolation card documents the job, identification numbers, isolation type, work, permission to
Isolation sheets used for personal locks
One man one lock rules means every man on a job mus lock onto the master lock box, ensuring jo safety
What issue was discovered during the reed switch isolation and how was it corrected?
When the isolation occurred we discovered the reed switches still had power. As a result we gathered the drawings and compared them to the isolation sheet, this allowed us to realise the wrong cr panel was noted down on the isolation sheet.
Updated the supervisor in charge of the job and modified the isolation paperwork
Carried out a isolation before checking the isolations again.
What steps were taken to ensure the airlines were properly marked before disonnection
Marked the airlines with 1 or 2 dots and the air fitting with the corresponding mark
Why was it necessary to measure the distance of the reed switches before removing them?
They switch over in the correct position and feedback to the DCS the pin position . If this is incorrect it may over or under extend, or interlock the logic
What modifications were needed to align the new cylinder with the existing set up?
Rotated the cylinder 180 so the airline mountings had the same ordination- this also allowed us to fit the existing reed switches
The new cylinder was a new version of the old cylinder as it was redundant
What steps were taken to securely fasten the new cylinder in place?
Placed the locking pin in the correct position before refitting the cylinder
Used a spanner to lock the cylinder shaft in place with a locking nut to ensure stability
Refastened the main body fixing bolts of the flanger in an opposing pattern o ensure even pressure distribution
Why was the reed sensors reinstalled based on earlier measurements?
The reed sensors operate based on magnetism, if they were positioned incorrectly feedback tot he dcs would be ocnorect and the cylinder could extend or retract to far/little.
By not having the sensors in the correct position the system could interlock as it isn’t eyeing the lock in the logic
Setting this up correctly minimises downtime
How was th3 function of the magnetic reed switch tested
Functionality was tested through he activation of the sensor, we unmounted them and slide them up and down the cylinder- they switched in line with the piston
What issues was discovered with the unlocking sensor (B23) bad how was it resolved?
The unlocking sensor was not switching when moved to the activation point. This was resolved through unit substitution and re-tested.
Why was it important to confirm deisolations with production?
So they are aware the work has been completed and allows them torts all of the alarms and faults that occurred as a result of the isolation?
Ensures no one is in the area when it occurs
Complainers with procedures /ssow
Why was it necessary to update the work order and complete a work log?
By doing so you keep a record of the issue at hand and its reolustion for suture reference
Lega requirement to hold record
Officially hands work back ocer
What is the lead out rolls role in the process?
Lead out roll is a centrered crown roll meaning its diameter is larger in the middle then outside
Keeps the felt under tension as the bottom wire uses a vacuume
