Date post: | 05-Apr-2017 |
Category: |
Documents |
Upload: | dion-botha |
View: | 102 times |
Download: | 0 times |
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