Isolate the primary jaw crusher for a liner change

You are a maintenance fitter and permit holder at Wattle Creek Quarry.

Simulated workplaceIntermediate missionCAQA Deepridge Resources

What is going on

The primary jaw crusher CR01 at Wattle Creek is scheduled for a liner change on 17 September 2026 with a crew of three. The Maintenance Superintendent wants the isolation permit raised in the Permit to Work and Isolation Register, every energy source identified from the isolation drawing, a job hazard analysis prepared with the crew and the lock box process explained before she issues the permit. A guard was found missing on conveyor CV03 after a belt change earlier in the month, so the return to service check is under scrutiny. The crusher has electrical, hydraulic and gravitational energy sources and a feeder upstream that must also be locked.

Deb Marchetti, Maintenance Superintendent
Subject: Jaw crusher CR01 liner change, permit and isolation

The primary jaw crusher CR01 at Wattle Creek is coming down on Thursday for a liner change. I want you to raise the isolation permit in the Permit to Work and Isolation Register, identify every energy source from the isolation drawing, prepare the job hazard analysis with the crew and walk me through the lock box process before I issue the permit. Read the Isolation and Permit to Work Procedure first. The missing guard on CV03 last week is a reminder that the return to service check matters as much as the isolation.

Your brief

Plan and document the isolation of CR01 to the Isolation and Permit to Work Procedure: identify energy sources, raise the permit, prepare the job hazard analysis with the crew, explain the lock box and test for dead steps, and set out the return to service checks including guarding.

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 Isolation and Permit to Work Procedure and list every step from raising the permit to returning the plant to service.
From the crusher description, identify each energy source (electrical, hydraulic, stored, gravitational and upstream feed) and the isolation point for each.
Raise the isolation permit in the Permit to Work and Isolation Register with the plant, the isolations, the crew and the validity.
Prepare the Job Hazard Analysis Form for the liner change with the crew, covering lifting the liners, working inside the crusher and the confined space assessment.
Describe the lock box process for a crew of three and what happens if one fitter is called away mid-task.
Explain the test for dead and try to start steps and who witnesses them before the permit is issued.
Write the return to service checklist including guard refit, tool count and the operations handover, and record the permit closure in the register.
A fitter arrives after the permit is issued and is not on the permit: describe what must happen before they can work on the crusher.

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

What someone in this role would produce

Energy source and isolation point table
Isolation permit raised in the register
Completed Job Hazard Analysis Form
Return to service checklist and permit closure

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