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	Tower cleaning (Cardox)
	Contact:  Palmer.Melvin@dol.gov

Home   1. Plugged Tower   Chain off all tower access poi...    Assemble crew   Control room activates kiln di...    Assign task   Raise elevator and lock-out   All workers donn "hot suits"   Remove tires from fourth floor...    Contact control for "by-pass" ...    Start conveyor belt to prevent...    Assure both doors on tire chut...    Inspect calciner and feed pipe...    Start unplugging process   Take down barrier chains at al...    2. Preparation Work   Ensure all safety precautions ...    Identifty ports to be shot   Call Supervisor   3. Cleanup   Turn off warning light switch ...    Loosen splindle valve while st...    Remove both heads at each ends   Remove generator   Place tube in vertical positio...    Clean tube with bore brush and...    Place tube back in storage rac...    Clean detonator head with wire...    Shut off CO2 bottle, install s...    Turn air cannons back on and f...    Return all equipment to proper...    4. Execute   Drill   Load   Shoot

Tower cleaning (Cardox) 1. Plugged Tower These are actions that must be done in addition to established procedures for cleaning tower. Extreme hot flame and materials and other hazardous conditions exist. Chain off all tower access points Assemble crew Control room activates kiln discharge end warning lights Potential harzard exists of hot material being flushed out. Assign task All crew members must maintain radio contact at all times, and keep each other informed of possible hazards, and of their location. Raise elevator and lock-out All workers donn "hot suits" Remove tires from fourth floor tire conveyor belt. Contact control for "by-pass" on tire belt and doors Start conveyor belt to prevent it from burning . Assure both doors on tire chute are closed Inspect calciner and feed pipe for plugged location Start unplugging process Unplugging process may consist of "water laser", "air lance", or "Cardox", in extreme conditions. Take down barrier chains at all access areas 2. Preparation Work Ensure all safety precautions are met Ensure strobe lights are on. Discharge and shut off air cannons. Donn necessary PPE, (drillers and installers) FR, hood with face shields. Hats, coats and gloves. Hearing protection Must be a minimum of two persons present before opening port. Perform area workplace examination. No one is to enter the area without getting permission from the shift supervisor. Identifty ports to be shot Explain buildup identification process/procedure. Call Supervisor Supervisor unlocks generator magazine and inventories generator usage upon completion, and re- locks magazine upon completion. 3. Cleanup Turn off warning light switch when shooting is completed Loosen splindle valve while still in assembly stand Remove both heads at each ends Remove generator Spent generator goes into trash Misfire generator goes into kiln Place tube in vertical position Clean tube with bore brush and blow out with compressed air. Place tube back in storage rack Clean detonator head with wire wheel Shut off CO2 bottle, install safety cap Turn air cannons back on and fire Return all equipment to proper storage areas. 4. Execute Drill Remove cap Obtain drill Pneumatic drills and hoses are located on each level (3rd, 3 1/2, and 4th. floors) on retractable hose reels. Make certain that hoses do not become a tripping hazard and all connections are pinned to prevent whipping action. Make certain drilling depth is a minumum of 17-inches. Ascertain that drilling procedure is as straight as possible, ( tube will not lock in collar if not properly aligned). Use extreme caution in blow back mode when clearing hole. (Extremely hot material may be present). Retract drill Load Load tube Tube loading will be done concurrently by other crew member per JBC training. Show JBC video. Go into Cardox room, turn on CO2 bottle Visually examine Cardox tube Make sure mating surfaces are clean and true. Install tube in assembly stand Install copper gasket and shear discs, and then select appropiate discharge head Rounded edge of shear disc should be against copper gasket. Install generator and detonation head on other end Generator end of tube is chromed polished end. Use Impact wrench on both ends to tighten with three short bursts Check continuity with Ohm meter to ensure good connection (low resistance) Zero to three ohms is good. Three to five marginal. Above five not acceptable. Install tube into fill station Open spindle valve three-quarters turn Open CO2 fill station valve Open air pump ball valve. Pump cycles until it almost stalls Close spindle valve ( hand tight) Shut pump hand valve and CO2 hand valve off. Open bleed-off valve ( bleeds off bottle pressure in lines). Carry tube to collar stand on proper floor. Shoot Install locking collar and safety cap and chain on tube Wrench tighten Lay out detonation wire and shunt Shunt wires at detonation end  Secure tube in port to be shot Turn clockwise one-quarter turn until stops Insert wires (probes) into tube Un-shunt detonation wire and check continuity Be sure to use permissible blasters ohmmeter (yellow or orange in color) Clear entire blast area Connect wires to detonator One crew member sounds alarm Radio transmission (fire in the hole) Initiate firing sequence Charge detonator Hold button until green light appears. Fire Press detonate button immediately after warning alarm stops. Misfire Do not remove tube at this time Disconnect and shunt wires Slowly open spindle valve to bleed off pressure while tube is still locked into vessel. Tube is still under full pressure. Remove wires from detonator Remove tube with locking collar still attached Handle with extreme caution as tube will be hot. Re-install cap on port Remove locking collar Return tube to Cardox room Put tube back in assembly stand

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