Gypsum Technologies (Gyptech) is a global company specialising in the manufacture of wallboard-making plants and machinery for the building sector. With offices in Canada, North America, Europe, and South America, providing cutting-edge solutions in the wallboard production industry.
Gyptech faced a complex challenge in ensuring the safety and efficiency of a new plant intended to be completed in sequential stages. Each stage required comprehensive validation to ensure it could be safely livened, tested, and validated before entering wet commissioning. The validation process needed to be detailed yet understandable for both Gyptech engineers and executive-level Winstone Wallboards (WWB) staff, who required an overview for strategic decision-making. Additionally, WWB writers needed timely information to develop Standard Operating Procedures (SOPs) for employees during wet commissioning.
TEG Risk was engaged on the recommendation of WWB, who had previously worked with TEG Risk at their Auckland site. TEG Risk’s familiarity with WWB’s machinery, processes, and associated risks made them an ideal choice for this project. Our team, equipped with significant industry experience, trade qualifications, Certified Machinery Safety Expert (CMSE) certifications, and TÜV certification, provided the necessary expertise to address Gyptech’s needs effectively.
To achieve a comprehensive response, TEG Risk implemented a multi-phase approach, minimising duplicated labour and optimising on-site validation activities: design phase, functional testing, fault testing, as-built machinery inspection, reporting.
Design Phase
Gyptech and TEG Risk agreed on a modular, reusable design for the safety software, comprising standardised subsystems for various device types (e.g., emergency stops, gates). This modular approach meant that each subsystem needed validation only once, allowing subsequent instances to be verified through white box testing. High diagnostic coverage was achieved by:
- Wiring digital safety I/O 1:1 to the controller.
- Using dual-channel devices with discrepancy checking.
- Safety devices could detect short circuits by self-diagnosis or by the safety controller.
Functional Testing
TEG Risk monitored Gyptech’s standard full functional testing process to prove the outcome. In instances where TEG Risk could not attend, a competent representative from WWB supervised the process. Each machinery zone was tested to ensure everything in the zone stopped.
Fault Testing
Specific safety functions were audited to prove their diagnostics and fault messaging was operational. The auditing was undertaken as fault testing, which involved random audits of one device type per controller to ensure the safety control system reacted appropriately. Devices tested included:
- Hard-wired E-stop buttons
- Ethernet-based gate bolting/locking devices
- Hard-wired interlocking/locking devices
- Plug-in enabling devices
- Dual safety contactors
- PowerFlex 5 and 7 series VFDs
- Kinetix 5700 servo drives
Once fault functionality was confirmed, a combination of white box testing and code analysis was used to verify the design’s modularity and reusability.
Physical Inspection
Inspections ensured that interlocking devices were fit for purpose, reset devices had a clear view of the area, and control panels provided suitable views and controls. This step ensured the machinery was intuitive, simple to use, and reliable.
Reporting
Given the need for a quick turnaround, same-day or next-day email reports were sent to Gyptech. The content of these reports included:
- an executive summary for high-level stakeholders,
- detailed scope, findings, and conclusions for technical reference,
- specific actions for addressing non-compliances,
- highlighting residual risks for immediate SOP creation and signage.
Several challenges arose during the project. The complexity and scale was challenging with validation of around 1200 safety input/output devices and 15000 safety functions. Various locations and time zones required meticulous coordination, as preliminary work was conducted remotely between New Zealand and Canada. There were also operational constraints, with the need for site visits and assessments to not disrupt plant operations, which typically ran two shifts daily, six days a week.
The project delivered several significant benefits for WWB, including enhanced safety, efficient processes, clear communication, cost savings, and timely SOP development. The comprehensive validation process significantly increased operator safety during wet commissioning. The use of modular design and standardised testing procedures minimised downtime and labour costs, making the processes more efficient. Effective communication with executives and stakeholders ensured informed decision-making throughout the project. Immediate reporting allowed WWB writers to swiftly develop the necessary standard operating procedures (SOPs), ensuring operational readiness. Additionally, by minimising downtime and optimising validation processes, the project achieved substantial cost savings.
This machine safety project between Gyptech and TEG Risk underscores the essential role of expert validation in enhancing safety and operational efficiency. Through careful planning, modular design, and comprehensive testing, TEG Risk successfully addressed Gyptech’s challenges. The positive results highlight the importance of specialised expertise in achieving industry-leading outcomes.
Looking to ensure safety and compliance across multiple sites and machines? TEG Risk are experienced at undertaking machine safety projects at scale across Australia and New Zealand, call Hamish today to find out more.