JOB 2: FRS TP conveyor testing Flashcards
What is the primary function of the Finish Roll Store (FRS)?
Storage area for finished rolls prepared to be shipped out to customers
Why was the FRS system taken out of service in 2014?
Operation errors/lack of communication between shipping and wrapping line
What is the main goal of reinstating the FRS system?
to reduce the loading times of the shipping department
What specific tests need to be performed on the FRS tunnel balcony TP conveyors?
Functionality testing: making sure the conveyor moves in both directions without faults.
I/O: converyors stop when the role is in the correct position. this will also confirm the health of the sensor
Visual inspections: any visible signs of damage etc.
How is the functionality of the TP conveyors verified during testing?
Visual: checked for any obvious signs of damage.
watched to see if the conveyor functioned as required
I/O: we are able to visually see the input come into the I/O rack and it perform the required function
What is the purpose of the IO testing for the TP conveyors?
prove the functionality of the sensors and conveyor
How are the reflective sensors tested to ensure proper operation?
Visual: checked for no obvious signs of damage
Why is a physical inspection of sensors and reflectors necessary?
if they didn’t notice the roll it would drive itself off the end of the conveyor and off the balcony. Health and safety concern
if they were damaged it would interlock the system preventing it from working as the sensor inputs form and blocks and triggers within the automation process.
What happens if issues are identified during the testing process?
appropriate measures are taken to rectify the issue, often following the 6 point fault finding procedure
How does reinstating the FRS system contribute to reducing shipping times?
currently rolls destined for the same lorry are located in different storage bays. relocation will allow them to be moved between bays so they are stored locally to one another reducing the time spend driving between bays
rolls will be relocated overnight to outfeed conveyors for first shipments of the next day
How does the Door and Laser system contribute to workplace safety?
provides a physical barrier between personnel and the moving machinery by preventing access through the door until it is safe to do so.
The light gates when triggered cause an emergency stop causing the crane to interlock and stop. this prevents any continued roll or conveyor movements. You can pass through the light gate when the crane is parked up.
Which specific SSOW and OPL guidelines were followed during the described job?
carried out isolations in accordance to the working in the electrical maintenance department and wrapping line door entry.
No testing was done live in accordance to the working in the electrical department
What specific health and safety training was completed before carrying out conveyor testing and inverter changes?
Manual handling, Health and safety induction training, isolation procedures
documentation was attached to the work order which was read before commencing with the work, this included isolations and safe entry
What PPE was required for the described job, and why was each item necessary?
Hearing protection - to reduce exposure to loud noise, hearing protection is required in this area
Safety glasses - site policy, this area has swarf and metal filings everywhere so this will protect the eyes
Work clothes - steel toe caps, protective work trousers and appropriate t -shirt.
Gloves - protect from sharps
Which key legislation and regulations were followed during the work process?
Health and Safety at Work 1974- paperwork, risk assessments, PTA, Work plan, followed written safety guidance.
PPe- worn
PUWER - All test equipment was inspected to GS38
Manual handling - lifted and moved the inverter in accordance to the manual handling training I received.
What are the key responsibilities of employers under the Health and Safety at Work Act 1974 at Palm Paper?
- to provide a safe working environment through the proper maintenance of machinery and through the creation of procedural guidelines in the form of safe systems of work
- Ensure that work plans are formated to minimise risk to employees
- have documented safety procedures
- provide training to individuals
what is the purpose of conducing a pre-task assessment?
- allows you to analyse the risks that may present themselves and take the required precautions to limit them
- allows you to plan ahead on the job and ome up with a safe and methodological approach to the work
- legal requirement
why is regular training essential for maintaining workplace safety?
- regular training is essential in maintaining workplace safety as it puts safety at the forefront of your mind when carrying out work
- encourages a safety first mentality and environment
-allows you to accurately mitigate risks - competency through regular training is a legal requirement and in turn reduces chances of injury
Hoe do PPE regulations ensure worker safety in industrial enviroments?
-ensures a baselines of safety when carrying out tasks
- reduces the chance of injury or long term exposure
what is the purpose of the control of substances hazardous to health training?
- the identification of chemicals and how to safely handle them by knowing how to access the required information on things like PPE, exposure procedures, clean up procedures, risks, health implications etc
-understand the procedure for reporting chemical issues
How do risk assessments help in identifying and mitigating workplace hazards?
- Hazards are the issue. Risk is the chance of exposure.
- risks assessments allow an individual to identify a risk and plan the manner in which to reduce the chances of injury or exposure.
what does RIDDOR stand for and why is it important in workplace safety?
- Reporting of injurie, disease and dangerous occurrences
- Means injuries and incidents are reported to the HSE and investigated thoroughly
- allows for the continuous growth of H&S measures
- allows for trends to be observed and mitigated
- improves health and safety culture
-WE have a system in place to report any H&S incidents and injuries
How do the Electricity at Work Regulations 1989 impact electrical maintenance procedures?
- Legal requirement set to ensure safety
-sets clear responsibilities for employers and employees to reduce hazards - ensures safe installation and maintenance of machinery, regular checks+maintenace
-sets out competency and safety standards
-prevents electrical risks with design requirements
-safe isolation procedures etc
Why is compliance with the Working at Height Regulations 2005 crucial in an industrial setting?
- Legal requirement
- majority of serious or fatal injuries ae rlated to falls from height
- ensures risks are properly managed
- provides guidelines on fall systems to manage risk
-proper equipment and training
Why was the task split into smaller sections, and how was the work organized with shipping and the wrapping line?
Split into smaller sections to limit the impact on shipping by having all the cranes parked up at the same time. when bay 1 was being accessed both chances in storage area 1 were parked up
What specific PPE was required for the maintenance tasks on Day 1, and how was this determined?
HEARING PROTECTION
GLASSES
WOTK CLOTHES
GLOVES
- Determined through SSOW, PTA that was completed and pre-existing knowledge and experience in the area.
What is the purpose of a Pre-Task Assessment (PTA), and what did it include during the maintenance tasks?
-Allows you to analyse the risks that present themselves and take the required precautions
- allows you to pre-plan your work thinking of a safe and methodological approach to the work
- legal requirement
- this PTA included isolations plan, cleaning, trip hazards, dead testing and PPE worn.
What was the issue with Bay 7 TP conveyor during the functional testing, and how was it addressed?
TP conveyor would not travel in either direction and immediately came up with a saturation fault on the inverter. This is a terminal fault indicating a short circuit or overload of the brake resistor
How did the testing of the IO system ensure that the reflective sensors were working correctly during the testing of the conveyors?
I/O test proved the sensors were sending an input signal to the I/O rack
Breaking the sensors proved the systems safe to run as it stopped transportation
What steps were taken to replace the inverter in Bay 7 TP Conveyor, and what tools were needed?
Unit substitution of inverter took place
Required reprogramming and downloading the original fault diagnostic buffer
1 locate spare
2 download parameters
3 gather fault history
4 isolate
5 disconnect and remove
6 install and reconnect
7 deisolate
8 reprogrammed
9 file to upload comparison
10 functionality testing
How was the electrical isolation and lockout procedure carried out during the inverter replacement in Bay 7?
-generated isolation tag that was signed for by production
- let wrapping line and shipping now the isolation was about to take place
- isolated and completed paperwork
-placed key and paperwork into the lock box and then followed the one man one lock isolation procedure
- completed paperwork
What safety measures were implemented when accessing the balcony areas for testing and maintenance of the conveyors?
Gained access to the balcony following the agreed to procedure outlined in the sow. This involves parking up the crane and entering through the disabled door and gate.
What was the outcome of the inverter replacement in Bay 7, and how was the testing process completed post-replacement?
Bay 7 inverter replacement went successfully as proven during testing
Followed the same testing procedure as previously outlined
What steps were taken to confirm the inverter was safe to work on before removal?
Carried out an isolation and dead test to ensure the equipment wasn’t live and disconnected
How were the saved inverter parameters re-uploaded after the replacement, and why was this important?
Parameters determine the function of the inverter allowing it to perform its duties. The most important parameter is its bus address as this allows bus control of the system and reports any feedback to the DCS. This is part of the cyclic profibus function
Also. Incorrect parameters can damage the equipment as it could have a lower ramping time etc-
What actions were taken after completing the maintenance tasks to ensure the work area was secured and operations resumed?
- tidied work area
- shut and rest the safety gate and cranes
- let shipping and wrapping line know the work was completed and what we had achieved
- updated work order with completed works
- emailed asset care the records of what we had installed and the service/fault diagnostic file
What was the final step in the maintenance process, and how was the task documented?
Updated the work order detailing every aspect of the job
Emailed assets care with the records of the installed device and the service file
Why was asset care informed about the inverter replacement, and what details were included in the report?
Inverters are often sent away to be reformed and serviced and this file helps with that
Includes type number, l number,a page,software and fault history
What steps were taken at the end of Day 2 to ensure tools were stored and the work area was left tidy?
General end of maintenance tasks
What is the next step after the maintenance, as stated in the “Going Forward” section?
WMS are required to functional test the system. This is the system as a whole not just the individual hardware components
