Coordinate the forming fabric change at the October shutdown

You are the Acting Shift Supervisor coordinating a paper machine clothing change.

Simulated workplaceIntermediate missionCAQA Riverside Pulp and Paper

What is going on

The forming fabric on the paper machine is showing edge wear at the drive side and its change is locked into the 36-hour October shutdown starting 17 October. The new fabric is on site and its serial number must be confirmed. The change must be completed inside ten hours because a press roll change and a dryer hood inspection follow it. The crane and lifting gear need current inspection tags, section drives, showers, stock and vacuum must be isolated and locked, and the dryer hood inspection needs a confined space permit. The crew includes two operators who have never done a fabric change. The Paper Machine Shift Supervisor has asked you to coordinate the whole task.

Mick Delaney, Paper Machine Shift Supervisor
Subject: Forming fabric change, 17 October, you are coordinating

The forming fabric is showing edge wear and the change is locked in for the October shutdown. I want you to coordinate it: confirm the new fabric and its serial number, get the crane and lifting gear inspections, write the job safety analysis, raise the permits including the confined space permit for the dryer hood inspection that follows, and run the toolbox talk on the day. Use the clothing change procedure step by step. We have 36 hours for the whole shutdown, so the fabric change needs to be done inside ten.

Your brief

Plan, prepare and direct the forming fabric change in accordance with the Paper Machine Clothing Change Procedure and the Permit to Work and Isolation Policy, with a job safety analysis, permits, isolations, a toolbox talk, a task sequence with times, and complete records in the Permit to Work Register, the Production Shift Log and the Maintenance Work Orders.

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 Paper Machine Clothing Change Procedure and the Permit to Work and Isolation Policy, and list every isolation, permit and inspection required before the old fabric is touched.
Review work order WO-26-3290 and update it with the new fabric serial number, the crane and lifting gear inspection status and the confirmed task window.
Prepare a job safety analysis for the fabric change that covers the removal of the cantilever beams, the crane lifts, the cutting of the old fabric and the tensioning of the new fabric, with controls for each step.
Raise the permits in the Permit to Work Register for the fabric change isolations and the confined space entry for the dryer hood inspection, listing the isolation points and the locks for each entrant.
Complete a Toolbox Talk Record for the shutdown crew that covers plant status, the task sequence, hazards and controls, the live permits and the roles of the two inexperienced operators.
Write the task sequence with target times for each step from machine stop to return to service inside ten hours, and state the checks you will make before isolations are removed.
Create a Production Shift Log record for the shutdown shift recording the change, the serial numbers, the downtime and any problems, and describe what you would do if the fabric tracked off on start-up.

My notes: what did I enjoy, and what surprised me?

What someone in this role would produce

Isolation, permit and inspection checklist
Updated work order WO-26-3290
Job safety analysis
Permit to Work Register entries
Toolbox Talk Record, task sequence and Production Shift Log record

Printing this is a record of what you explored. It is not a certificate or a qualification.