Sandvik Mining and Construction Pty Ltd

Transcription

1 JSEA 1.16 TASK DESCRIPTION FREQUENCY WEIGHT Strangler valve test 250hrs and 2000 hrs ALL PERSONNEL MUST BE TRAINED AND AUTHORISED TO OPERATE THE ED7 OTHER RELEVANT JSEA DATE Issued Manager s Rules. JSEA ED /04/2007 PERSONAL PROTECTIVE EQUIPMENT TOOLS/EQUIPMENT ENVIRONMENTAL CONTROLS Safety Glasses Dry sorb or other similar material to be at hand Danger Tags 7/16, 9/16, ¾ & 15/16 spanners Waste to be placed into controlled disposal bins Out Of Service Tags ½ drive ratchet & socket set Scrap metal to be placed in controlled recycle bins Standard issue personal protective equipment Tachometer Oily rags to be placed in controlled waste bins Hearing protection Saturated dry sorb is to be cleaned up and placed in Relevant material safety data sheets waste bins NOTE!! Specific Information Regarding Task Step. High Risk = 1 to 6 WARNING!! Safety Alert Regarding to Task Step Medium Risk = 7 to 15 INFO!! General Information Regarding to Task Step Low Risk = 16 to 25 Risk Ranking Table Probability Consequence A B C D E PROBABILITY CONSEQUENCE A: Common or repeating occurrence 1 Fatality or permanent disability. B: Known to occur or has happened 2 Serious lost time or illness. C: Could occur or heard of it happening 3 Moderate lost time or illness. D: Not likely to occur. 4 Minor lost time or illness E: Practically impossible 5 No lost time NOTE!! The JSEA ED has been determined to be a low / medium risk task after the controls have been put into place. A.B.N Non Conformance Report or Incident Report to be Completed for Any Recognized Defect, Incident or Event. Rev. 02, 20/04/07

2 1. Position machine for maintenance in non As per manager s rules and regulations. Death or D1 7 hazardous zone. crush As per JSEA ED During test machine will be operated with safety shutdown system disabled. Test must be conducted in NON HAZARDOUS ZONE. 2. Isolate machine. As per manager s rules and regulations. As per JSEA ED Close Low Water Make Up Test Valve Ensure all PPE is worn. 913 has no makeup tank so this step is not required. Refer Photos 4. Open Low Water Level Valve Ensure all PPE is worn. Allow water to run out until it has stopped running. DO NOT close valve until test is completed. Ensure that water running on ground does not create slip hazard. Refer Photos 5. Remove Exhaust gas test port plugs and adaptors on downpipe. 6. Disable all low water shutdown valves (Humphrey Valves) On machines fitted with Catalytic convertor remove raw gas and treated gas test points. Remove adaptors to increase size of hole. Disable Humphrey valves by plugging and capping exhaust ports on both valves. The exhaust port is the centre port on Humphrey valves Trip, slip, fall Trip, slip, fall Finger trap Finger trap A.B.N Non Conformance Report or Incident Report to be Completed for Any Recognized Defect, Incident or Event. Rev. 02, 20/04/07

3 7. Start machine and run at Ensure all PPE is worn. Death or D1 7 - Idle for 250 hour or monthly service Make sure everyone is clear of the test area. crush rpm for 2000 hour or yearly service Warning! Operating the emergency shutdown system whilst the engine is running may result in damage to engine components which may include the turbocharger, crackshaft seal, head gasket, and other seals and gaskets. In addition there is the risk of water ingress into the engine due to the potential vacuum created in the downpipe and exhaust conditioner. The test procedure outlined reduces the risk of water entry into the engine, however water may still enter the engine during the tests, and damage to the engine may still result even without water ingress. Due to the inherent risks associated with emergency shutoff valves, Sandvik are unable to warrant the engine package for damage caused by test or emergency operation of the emergency shutdown system 8. Operate Diesel Engine Shutdown System (Strangler Valve). Reset Diesel Engine Shutdown System (Strangler Valve) Ensure all PPE is worn. Make sure everyone is clear of the test area. 9. Close Low Water Level Valve Ensure all PPE is worn. Refer Photos Record time from operation of shutdown system to engine stopped. Visually check that Strangler Valve has reopened. (Actuation cylinder rod will be extended when open) 10. Open Low Water Make Up Test Valve Ensure all PPE is worn. 913 has no Makeup Tank. On 913 refill scrubber at this step. Refer Photos Death or crush Finger trap D1 7 A.B.N Non Conformance Report or Incident Report to be Completed for Any Recognized Defect, Incident or Event. Rev. 02, 20/04/07

4 11. Replace exhaust gas test port plugs and On machines fitted with Catalytic convertor replace raw gas and Finger trap adaptors. treated gas test point adaptors and plugs. Machine MUST NOT be operated with test points open 12. Reconnect 2 low water shutdown valves Machine MUST NOT be operated with low water shutdown valves Finger trap (Humphrey Valves). disabled. 13. Conduct low water shutdown test Refer operators manual for low water shutdown test procedure 14. Optional High Idle Test This test can be performed during Code D inspection Warning! Due to high risk of engine damage this test is not recommended. Warning! Operating the emergency shutdown system whilst the engine is running may result in damage to engine components which may include the turbocharger, crackshaft seal, head gasket, and other seals and gaskets. Due to the inherent risks associated with emergency shutoff valves, Sandvik are unable to warrant the engine package for damage caused by test or emergency operation of the emergency shutdown system 15. Set up for high idle test as per steps 1 and 2 of this JSEA Refer steps 1 and 2 of this JSEA 16. Remove exhaust downpipe This is removed as part of Code D inspection Finger trap 17. Run machine at high idle Wear hearing protection to protect against noise of unrestricted exhaust. Ensure area is clear of other personel when conducting test. Death or crush D1 7 A.B.N Non Conformance Report or Incident Report to be Completed for Any Recognized Defect, Incident or Event. Rev. 02, 20/04/07

5 18. Operate Diesel Engine Shutdown System (Strangler Valve) Damage to engine due to water ingress from exhaust coditioner may result if downpipe is not removed. Death or crush D1 7 Record time from Operation of Diesel Engine Shutdown system until engine stops. 19. Reset Diesel Engine Shutdown System Check Diesel Engine Shutdown actuating cylinder extends when reset. Person Name: Date: Comments or Problems: A.B.N Non Conformance Report or Incident Report to be Completed for Any Recognized Defect, Incident or Event. Rev. 02, 20/04/07

6 Raw Emission Gas Test Point Treated Gas Test Point Drain Valve Low Water Level Valve Water make up Test Valve 3126 Engine on ED7 and ED10 LHD A.B.N Non Conformance Report or Incident Report to be Completed for Any Recognized Defect, Incident or Event. Rev. 02, 20/04/07

7 Water Makeup Test Valve Low Water Level Valve Water fill point 3306 Engine on 913-6LHD, 130 LHD and 936 Chock Carrier Low water level valve Scrubber drain valve 3304 Engine on 913 LHD A.B.N Non Conformance Report or Incident Report to be Completed for Any Recognized Defect, Incident or Event. Rev. 02, 20/04/07