2012/2013 IBL Experience

Dion Botha - Electrical Engineering Student

22

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

33

MHFIntroduction• 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

44

MHFMy 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)

55

MHFMy Role• Documented ‘unreachable’ MHF assets

– Created work requests for area assistance• Attend MHF meetings to report progress

– Worked within WorkSafe MHF licence renewal deadline

66

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

77

M2 Transformer Temperature AlarmsIntroduction

88

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

99

At Transformers

M2 Transformer Temperature Alarms

Before After

1010

Wiring to DCS I/O

M2 Transformer Temperature Alarms

1111

DCS HMI

M2 Transformer Temperature Alarms

1212

DCS HMI

M2 Transformer Temperature Alarms

1313

Professional Growth• Transformers• Temperature switching indicators and transmitters• Thread Standards• Metso DNA DCS

M2 Transformer Temperature Alarms

1414

M2 Paper Break Camera SystemIntroduction• 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 machinesReinstallation

at M2

1515

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%

1616

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

1717

M2 Paper Break Camera System

Before After

Field Racks and Instrument Air

1818

M2 Paper Break Camera SystemCameras and Lights

1919

Control Station

M2 Paper Break Camera System

2020

Operators Station

M2 Paper Break Camera System

2121

M2 Paper Break Camera SystemCamera Locations

2222

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

2323

R5/6 Superheater Tube Temperature ProbesIntroduction

24°C200°C240°C280°C320°C

12.4mV12.9mV13.6mV14.2mV

HMI(Operators

Station)…

2424

• Old

• New

R5/6 Superheater Tube Temperature Probes

Bailey DCS

ABB DCSTemperature transmitter

HMI

2525

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

2626

My Role• Prepare loop connection diagrams for each loop (135)

R5/6 Superheater Tube Temperature Probes

2727

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

2828

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

2929

• 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

3030

• 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

3131

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

3232

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

Questions