Run stock preparation and rectify a refiner freeness drift

You are a Process Operator on stock preparation, C panel night shift.

Simulated workplaceIntermediate missionCAQA Riverside Pulp and Paper

What is going on

Day shift logged refiner 2 running at high plate load with freeness drifting low, and a work order has been raised for a plate inspection at the next machine stop. The paper machine is running 140 gsm fluting and needs machine chest consistency held at 3.2 per cent and freeness within the setpoint band for the grade. Part way through your shift the freeness drifts below the band, the machine chest agitator has been isolated because a coupling guard was found missing after maintenance, and the wet end reports a break at the couch. You have the distributed control system, the setpoint sheet, the shift log and the maintenance work orders.

Grant Oyelaran, Production Manager
Subject: Refiner 2 and freeness drift on C panel

Tahlia logged refiner 2 running with high plate load and freeness drifting low on day shift. You are on stock prep tonight. Run the stock preparation system to the setpoint sheet, watch refiner 2 closely, and if the drift continues work through the operational problem method: check the data, isolate the likely cause, adjust within your authority and log everything. Make sure the work order for the plate inspection is complete and accurate so the planners can schedule it. Handover to me at 06:00.

Your brief

Operate the stock preparation system to the grade setpoints for the shift, identify and rectify the freeness drift within your authority using the site problem method, manage the agitator isolation safely, and record production, adjustments, problems and handover in 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 Quality Policy testing section and the Permit to Work and Isolation Policy and list the process tests you must take on shift and the rules that apply while the agitator is isolated.
Review the day shift stock preparation record and work order WO-26-3312, and write a start of shift plan for monitoring refiner 2 and the machine chest.
Record hourly consistency and freeness readings for the shift as a table, showing the point where freeness leaves the band.
Work through the operational problem method for the freeness drift: list possible causes, check each against your data, and record the cause you identify and the adjustment you make within your authority.
Describe how you kept the machine chest within specification with the agitator isolated and what you told the wet end and the supervisor.
Update work order WO-26-3312 with your observations and update work order WO-26-3316 for the guard, so that maintenance has accurate information.
Create a Production Shift Log record for stock preparation with production, adjustments, problems, work orders raised and a clear handover to the Production Manager.

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

What someone in this role would produce

Start of shift monitoring plan
Hourly readings table
Operational problem analysis with cause and adjustment
Updated Maintenance Work Orders
Production Shift Log record with handover

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