PROJECT / 05
Solving pulveriser wear measurement challenges
A repeatable way to capture internal pulveriser wear without confined-space entry for measurement.
The brief
Before the laser-scanning method was introduced, maintenance personnel entered the pulveriser as a confined space and used calipers to measure wear on the grinding balls and rings. These measurements were needed to track component life and plan future overhauls. The challenge was to obtain reliable measurements while reducing the need for personnel to enter the vessel.
Design approach & deliverables
I developed a method from an idea to scan internal grinding components from outside the vessel. The captured geometry was used to determine ball diameter and ring wear, which was then entered into the existing wear-life spreadsheet for trending and maintenance forecasts.
The result
The method reduced the need for confined-space entry during measurement, shortened the task and became part of routine site activity. The project was recognised as a QGSF Safety Innovator finalist and received an individual innovation award.
Selected work from Ted Watson’s professional portfolio.