Job 6: MCB1 Consistency Meter Flashcards
Why does the consistency meter require replacement?
Initial investigation found the MCB1 consistency meter is frozen at 9.4% and requires replacement
How does the consistency unit read the viscosity of the product?
BTG consistency unit measures the viscosity of a product by observing the resistance to rotation of a spindle submerged in the sample. This resistance is directly proportional to the product’s viscosity, and the unit calculates the viscosity from this torque measurement. It provides continuous, real-time monitoring of the product’s consistency to help optimize the manufacturing process.
What were the keys steps in the pre-shut work for the tcu replacement?
Disconnect and remove the unit
Install new cdu unit
No new cable or management needed
Place external signal cable in bag
What are the key responsibilities of the employer under the health and safety at work act 1974?(5)
Provide a safe working environment by maintaining all machinery and equipment
Minimise risks by having appropriate documentation and planning
Provide key training skills to reduce risks
Conduct risk assessment and mitigate the hazards
Develop and maintain written health and safety practices
What Ppe was used on this job? 5
Steel toe caps
Hearing protection
Eye protection
Hi vis
Work trousers and top
Gloves and brush to apply cutting fluid (dermatitis risk reduced)
Why is electrical isolation critical in this type of maintenance work?
Provides a barrier between an individual and the work being carried out preventing accidental re-energisation of the equipment reducing risks of electrical shock etc
Ensure maintenance Can be performed safely
Compliance with safety standards
Preventing short circuits protecting equipment
Why was new bracketry needed for the CDM unit
The units were different sizes and the existing bracketry wouldn’t support the new units
Made large enough to accommodate additional units going forward
Explain the process of drilling and tapping the holes for the new equipment?
Marked out the centre of the holes
Centre punched
Applied cutting fluid to drill bits
Drilled a pilot hole
Drilled out to 8.5mm for m10
Applied cutting fluid to tap
Tapped out hole for m10. 1 clock 1/4 anti
What steps were taken to ensure the correct reconnections?
Completed a disconnection sheet and reattached as disconnected
Had print outs of the drawings to use as a guide
Performed the tug test
Cable tied existing cables to pre existing management for support
What is a dead test and why is it performed
A dead test is undertaken after an isolation to ensure no livebworking takes place
Ensures the safety of the personnel and equipment
Reduces risk associated with shock, burns and renergisation
How was communication handled with stakeholders, such as the dip operator? (Isolations, desolations, going forward)
Isolations ;
Production permission is required for an isolation as it effects production
The isolation required the simulation to be removed from DCS this was communicated to the dip operator so they knew to remove it for isolation conformation
Desolation:
Updates the operator and supervisor of the work that had been undertaken and the position we were in on the job
Let them know the unit was to remain isolated until the consistency unit is fitted on the shutdown
Going forward:
Updated the work order on the work that had been completed!
What documentation was printed before starting the job
Work orders
Pre task assessment
Drawings
Isolation sheet
How was the work order updated after the task was completed?
Informed the supervisor of all the work that was completed. This should always include the issue, findings during investigation, resolution, testing, parts use and any other notable information. The details should be implemented as if the next person on the job wasn’t involved
What actions were taken to test the new install cdu unit?
Desolated the circuit breaker on F15 to energise the unit
Green light came on to show the unit was powered and healthy
What are the next steps in terms of the MCC tray and profibus coupler isolations
These are to remain isolated until the consistency unit is fitted and calibrated
What is the significance of the CFC change from Valmet to BTG?
CFC is a device code that allows the DCS to control a unit! Without the correct cfc the profibus unit can not communicate with the device
Accylcic communication- call and respond
