Plan and carry out a conveyor pulley bearing changeout

What is going on

The Mount Errol Quarries October shutdown includes replacing the head and tail pulley bearings on conveyor one and realigning the drive. The bearings have been received under REC-26-0887. The work is carried out under the customer's isolation permit system with Ironbark personal locks on the group lock box, and the laser alignment kit at Gladstone is due for calibration before the shutdown. Bree Sutherland, the Maintenance Services Manager, wants the isolation plan, the JSA and the changeout method prepared before mobilisation, and then wants the changeout carried out and recorded on the job card with the alignment readings and condition findings.

Your brief

Prepare the isolation plan and job safety analysis for the bearing changeout, confirm parts, equipment and your own competencies are ready, carry out the isolation, changeout and alignment to procedure, and record the work, readings and condition findings against the job card.

Work through it

You do not need to do it all. Doing a few of these will show you what the work is like. Your ticks and notes stay on this device.

• Read the Mount Errol Quarries October Shutdown Plan and the Isolation and Lockout Procedure and list every energy source and isolation point for conveyor one, including stored energy in the take-up and the drive.
• Prepare a Job Safety Analysis for the pulley bearing changeout covering isolation, lifting the pulley, bearing removal and fitting, alignment and reinstatement, and name the permits required.
• Check the Materials and Certificate Register for the bearings under REC-26-0887 and the Plant and Equipment Register for the laser alignment kit and hydraulic torque tools, and raise any item that is not ready with the supervisor.
• Check your own site induction, isolation training and any expiring competency in the Training and Competency Matrix and report gaps to the supervisor.
• Carry out the isolation with personal locks on the group lock box, test for dead, and record the isolation on job card JC-26-0420.
• Remove and fit the bearings using the correct tools, check shaft and housing condition, and align the drive with the laser kit, recording before and after readings.
• Complete the reinstatement checks, remove locks under the procedure, and record condition findings and recommended follow-up work on the job card.
• Report any incident, hazard or near miss during the task in the WHS Incident and Hazard Register.

What someone in this role would produce

• Isolation plan listing energy sources and isolation points for conveyor one
• Job Safety Analysis for the bearing changeout
• Alignment readings before and after, with the condition report
• Job card JC-26-0420 updated with isolation record, hours and findings