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Conveyorman Pit "B"

Conveyorman Pit "B"
Start of Shift Activities Fire-Up "B" Pit Berm & Highwall Inspection in "B" Pit "B" Pit Inspection(Belts & Feeder) Inspect FC16 Conveyor Belt Inspect FC15 Conveyor Belt Inspection of MCC (Motor Control Center) for "B" Pit Inspect FC14 Conveyor Belt Inspect FC13 Conveyor Belt Inspect FC12 Conveyor Belt Inspect FC12 MCC Preventative Maintenance Housekeeping Spill Response Unplug Transfer Points Belt Training Belt Splicing End of Shift Activities
1. Start of Shift Activities
Clock-In
Don PPE
Steel Toed Boots
Rubber or Leather
gloves
Work Gloves/Welding Gloves
Safety Glasses
Clear
Shaded
Hard Hat
Hearing Protection
Where Required and noted with signs. Both plugs and muffs are available based on individual preference.
Obtain Communication (Radio)
Get radio from charger
Put on channel #1
Turn Radio On
Listen for the audible beep
Secure Radio in pocket or holder
Talk to Supervisor
Discuss any special tasks or duties
Discuss turn-over information from maintenance shift
Attend Safety Meeting
Wednesday's at 6:30 am
Obtain the detailed checklist for the Pre-operational Vehicle Inspection
Red tag and inform shop mechanic if defects are found on any safety items
Check Park Brake
Set brake and attempt to move while in third gear
Conduct in safe place
Check Service Brakes
Check Fluids
Check Oil
Check Coolant
Check Power steering
Check Windshield wiper
Check Fuel
Ensure that the correct type of fuel is used
Check Brake
Check Lights
Cleanliness
Operational
Check Back-up alarm
If defective, red tag and inform shop mechanic
Check Horn
Check Wipers
Check Seat belt
Red Tag all Safety Defects
Check Windows and glass
Check Mirrors
Conduct a Visual Check of Battery Cables
Check Belts for wear/cracking
Check Welder and Welding Leads
Check Tire Condition
Check Fire Extinguisher
Check Oxygen/Acetylene Bottles
Check if full
check to make sure they are secure
Check hose,gauge and torch condition
Check gauges for cracks and grease
Ensure that both cylinder valves are closed, oxygen first, bleed the pressure, and loosen both regulator valves
Refer to Employee Safety Handbook
Check for proper housekeeping
Ensure that chocks are present
2. Fire-Up "B" Pit
Radio "A" Pit Conveyorman to start when he is ready
Inspect to ensure that conveyors are operating, while in vehicle
Check for proper belt tracking
Check splices
Look for General Malfunctions
Check for misalignment
Look for smoke
Listen for unusual noises
Check for slipping
Inspect Guarding
Always put guards back in place when finished; shut down operation if guard needs replaced or fixed
Notice Gearbox problems
Look for leaks, heat, and noises
Check V-belts
Ensure start-up alarm is working by listening for it
Inspect and Start Trash Pump
check oil
fill up with gas
prime the pump
remove cap
fill with water and leave cap off
Turn on Switch
Pull the Choke
Pull the Start Cord
Turn off Choke after pump starts
Check for circulation on pump(observe water gushing from pump cap area)
Turn on/off switch to off position
Replace prime cap
Turn switch back on
Pull start cord to start pump
Ensure Material Flow
Observe the transfer points
Ensure material is flowing on belts
Check for spillage
Check for blockage
Look for General Malfunctions
Check for Misalignment
Look for Smoke
Listen for Unusual Noises
Check for Slipping
Inspect Guarding
Shut down operation to repair or replace defective guarding
Look for any gearbox problems
Check V-belts
3. Berm & Highwall Inspection in "B" Pit
Obtain and Follow Workplace Examination Checklist
If any defects are found, contact supervisor and/or loader operator. Refer to MSHA's and Company Policy
Observe and follow all posted safety signs
Check Berms
Check areas of the pond, highwall, and feeder ramp berms
Ensure they are mid-axle height to the largest equipment on roadway
This is a back up check for the loader operator
Check Pit Floor (rocks & steel)
This is a backup check for the loader operator
Check highwall
Check height
This is a backup check for the loader operator
Check angle of repose
This is a backup check for the loader operator
Check for undercuts
This is a backup check for the loader operator
Notify the loader and Marion operator that Conveyorman is in the area
Loader and Marion operators have the right-of-way at all times; stay away from the travel path of Marion
4. "B" Pit Inspection(Belts & Feeder)
Check for proper guarding
Shut down operation to repair or replace defective guarding
Check Belts
Check Rollers
Check Bearings
Check Gear Box
Check Head Pulley
Check Tail Pulley
Check Wipers
Check for water flow at belly of the feeder belt
Reduces heat build-up and helps clean stray material
Check Grizzly Pump
Check for hydraulic leaks
Refer to Glacier's Environmental Response Plan
Check fluid level on hydraulic pump
Refer to Glacier's Environmental Response Plan; check the site glass for proper fluid level
5. Inspect FC16 Conveyor Belt
Check Tail Pulley Area
Check the impact rubber for cracks, lagging, and alignment
Ensure that skirting is secured
Check for wear
Check tail bearing
Check for heat and unusual noises
Check tail pulley
Visual Inspection
Check for proper guarding
Shut down operation to repair or replace defective guarding; ensure that it is secure and in place; no contact with moving parts
Head Pulley Area
Check for proper guarding
Shut down operation to repair or replace defective guarding; ensure that it is secure and in place; no contact with moving parts
Check Head Pulley
Check for cracks, lagging and alignment
Check Bearings
Check Gear Box
Check for leaks, over-heating and unusual noise
Check Wiper
Check for contact to the belt
Check Snubber Pulley
Check for cracks and wear
Check Motor
Check for heat and unusual noise;check electrical connections; check for proper bushing and bare wires
Check V-Belts
Check for alignment, wear, tension
Inspect FC16 Mid-Section
Check for bad rollers
Proper spinning, holes, rollers aren't cutting the belt or return roller brackets
Inspect E-Stop Cords
Check for proper tension
Check for proper box mounting
6. Inspect FC15 Conveyor Belt
Check Tail Pulley Area
Check the impact rubber for cracks, lagging, and alignment
Ensure that skirting is secured
Check for wear
Check tail bearing
Check tail pulley
Visual inspection
Check for proper guarding
Shut down operation to repair or replace defective guarding; ensure that it is secure and in place; no contact with moving parts
Head Pulley Area
Check for proper guarding
Shut down operation to repair or replace defective guarding; ensure that it is secure and in place; no contact with moving parts
Check Head Pulley
Check for cracks, lagging and alignment
Check bearings
Check Gear Box
Check for leaks, over-heating and unusual noise
Check Wiper
Check for contact to the belt
Check Snubber Pulley
Check for cracks and wear
Check Motor
Check for heat and unusual noise;check electrical connections; check for proper bushing and bare wires
Check V-Belts
Check for alignment, wear & tension
Inspect FC15 Mid-Section
Check for bad rollers
Proper spinning, holes, rollers aren't cutting the belt or return roller brackets
Inspect E-Stop Cords
Check for proper tension
Check for proper box mounting
7. Inspection of MCC (Motor Control Center) for "B" Pit
Inspect fire extinguisher
Inspect housekeeping
Remove all combustible materials from the MCC
Ensure that lock out tag out board is maintained
Check for hazardous electrical conditions
Check lights and light covers
Check cable installation
Check labels
Check cover plates
8. Inspect FC14 Conveyor Belt
Check Tail Pulley Area
Check the impact rubber for cracks, lagging, and alignment
Ensure that skirt is secured
Check for wear
Check tail bearing
Inspect cable and sheaves for the gravity take-up
Insure that trolley is on track
Check tail pulley
Visual Inspection
Check for proper guarding
Shut down operation to repair or replace defective guarding; ensure that it is secure and in place; no contact with moving parts
Check Head Pulley Area
Check for proper guarding
Shut down operation to repair or replace defective guarding; ensure that it is secure and in place; no contact with moving parts
Check Head Pulley
Check for cracks, lagging and alignment
Check bearings
Check for over-heating and unusual noise
Check Gear Box
Check for leaks, over-heating and unusual noise
Check Wiper
Check for contact to the belt
Check Snubber Pulley
Check for cracks and wear
Check Motor
Check for heat and unusual noise;check electrical connections; check for proper bushing and bare wires
Check V-Belts
Check for alignment, wear, tension
Inspect FC14 Mid-Section
Check for bad rollers
Proper spinning, holes, rollers aren't cutting the belt or return roller brackets
Inspect E-Stop Cords
Check for proper tension
Check for proper box mounting
9. Inspect FC13 Conveyor Belt
Check Tail Pulley Area
Check the impact rubber for cracks, lagging, and alignment
Ensure that skirting is secured
Check for wear
Check tail bearing
Check tail pulley
Visual inspection
Check for proper guarding
Shut down operation to repair or replace defective guarding; ensure that it is secure and in place; no contact with moving parts
Check Head Pulley Area
Check for proper guarding
Shut down operation to repair or replace defective guarding; ensure that it is secure and in place; no contact with moving parts
Check Head Pulley
Check for cracks, lagging and alignment
Check bearings
Check for over-heating and unusual noise
Check Gear Box
Check for leaks, noise, over-heating
Check Wiper
Check for contact to the belt
Check Snubber Pulley
Check for cracks and wear
Check Motor
Check for heat and unusual noise;check electrical connections; check for proper bushing and bare wires
Check V-Belts
Check for alignment, wear, tension
Inspect FC13 Mid-Section
Check for bad rollers
Proper spinning, holes, rollers aren't cutting the belt or return roller brackets
Inspect E-Stop Cords
Check for proper tension
Check for proper box mounting
10. Inspect FC12 Conveyor Belt
Check Tail Pulley Area
Check the impact rubber for cracks, lagging, and alignment
Ensure that skirting is secured
Check for wear
Check tail bearing
Check tail pulley
Visual inspection
Check for proper guarding
Shut down operation to repair or replace defective guarding; ensure that it is secure and in place; no contact with moving parts
Check Head Pulley Area
Check for proper guarding
Shut down operation to repair or replace defective guarding; ensure that it is secure and in place; no contact with moving parts
Check Head Pulley
Check for cracks, lagging and alignment
Check bearings
Check for over-heating and unusual noise
Check Gear Box
Check for leaks, over-heating and unusual noise
Check Wiper
Check for contact to the belt
Check Snubber Pulley
Check for cracks and wear
Check Motor
Check for heat and unusual noise;check electrical connections; check for proper bushing and bare wires
Check V-Belts
Check for alignment, wear, tension
Inspect FC12 Mid-Section
Check all rollers
Proper spinning, holes, rollers aren't cutting the belt or return brackets
Inspect lighting in tunnel
Ensure that lights are working and guards are in place
Inspect housekeeping
Check for clear walkway and no accumulation of extra materials
Inspect E-Stop Cords
Check for proper tension
Check for proper box mounting
11. Inspect FC12 MCC
Inspect fire extinguisher
Inspect housekeeping
Remove all combustible materials from the MCC
Ensure that lock out tag out board is maintained
Check for hazardous electrical conditions
Check lights and light covers
Check cable installation
Check labels
Check cover plates
12. Preventative Maintenance
Obtain grease from the oil container
Oil container is in shop
Fill grease gun
Follow grease schedule
Grease the bearings that are listed
Inspect the grease lines and zerk fittings
If broken line is discovered repair if accessible. If not accessible make appropriate note on PM sheet
Look for visible grease around the bearing
This ensures that the bearing is properly lubricated. The old grease is pushed out and new grease is inserted
13. Housekeeping
Obtain water truck
Conveyorman must be properly task trained prior to operating the water truck
Ensure that wheels are properly chocked
Start water truck to build air on truck
Turn valve on to start water to fill water truck up
Valve is located at the bottom of the water stand pipe
Turn off water when truck is full
To prevent spillage. If spillage occurs halt water check flow path, if entering the slough, estimate the cleanliness and volume of the water and immediately notify plant manager
Proceed to "B" pit via "A" pit roadway
If gate is locked contact supervisor
Proceed in low gear when traveling down the hill
Refer to site map and policy
Proceed to areas that require cleanup
Go to the dirtiest area first
Refer to work area exam
Park truck in a safe area
Set parking brake
to prevent unexpected movement
Engage PTO
to start the pump
Engage throttle to maximum
To provide maximum water pressure
chock wheels
Remove and un-wind water hose
Lay out hose in the proper area before opening water valve
Open valve on rear of truck slowly
Grab the end of the water hose
Discharge end
Open the hose nozzle slowly
To maintain control of the hose
Clean transfer points thoroughly as possible
Do not spray water directly on bearings or electrical motors/equipment
Roll up water hose
Remove and store wheel chocks
Store chocks in storage box on rear of truck
Re-set throttle to idle
This is done to disengage the PTO and to prevent equipment damage
Turn off pump by disengaging PTO
Do this when water pressure drops for the first time
Disengage parking brake
Return to water stand and repeat fill up procedures
When traveling "B" pit roadway, beware of potential slippery road conditions
Do not follow other persons or equipment up roadway
Proceed to any other areas that need to be cleaned after water truck is filled again
Refer to work place examination for areas that require clean up
14. Spill Response
Ensure personal and co-worker safety
Determine the source of the spill and halt if possible
Refer to company policy
Collect appropriate cleanup/containment materials
Containment materials are at the shop: diapers, booms (worse case use berms or cover with soil)
Contain, limit, or stop the spill
Notify the supervisor immediately
If supervisor is not available use environmental call-out and response plan sheet until someone is contacted
Determine the type, approximate time, location and quantity of the spill
Bag contaminated soil and clean-up materials
Place in proper container
15. Unplug Transfer Points
Shut down the two preceding, and following belts of the plugged area
Prevents injury and equipment damage
Lock-out and tag-out the belts that were turned off
Follow the company policy regarding lock and tag out procedures
Analyze and discuss the task prior to beginning work
To gain consensus in the safest and most effective way to correct the problem
Obtain tools, equipment and/or safety items that are required to make the proper repair
May need fall protection and/or confined space permit
Remove the accessible material
Hose out Material-Step 1
This is the first step that must be taken
Hose out as much material as possible from the top first
Unplug from the top-Step 2
Dislodge as much material as possible
If this step is not successful then dislodge as much material as possible from the bottom
Unplug from the bottom-Step 3
Remove the back door and dislodge as much material as possible
Miner should use caution when opening door because of falling material hazards
Entering transfer point-Step 4
Obtain a confined space entry permit from the MCC room
Obtain a cell phone from the shop
Obtain (multi-gas) sniffer, located at the shop
Obtain life line from the shop
Obtain ladder
Fill out confined space permit
Ensure that there is an attendant and/or entry supervisor at the rock box before entry
Without an attendant you can't enter the confined space
Take gas test and document readings (done by attendant)
No entry permitted if outside the gas parameters
Inspect and put on safety harness
Complete inspection documents
Locate and hook up the life line to the appropriate attachment point
Position and tie off the ladder
See company policy on ladders
Attach lanyard to the attachment point
Devices will be capable of supporting 5000 pounds or more
Place pry bar in box
Descend ladder
Maintain three points of contact. Do not carry tools while descending or ascending the ladder
Take and record another gas test (done by the attendant)
Dislodge materials
If unsuccessful contact supervisor and assess the condition
Exit the confined space
Remove ladder and clean up all tools and materials and return them to the appropriate areas
Complete the confined space permit (done by attendant/supervisor)
Permit is placed in time box
Remove the lock out/tag out devices
Follow company policy regarding lock out procedures
Energize the circuits
16. Belt Training
Training Bottom
Determine which direction the belt is misaligned
Obtain 2 lb sledge hammer
Strike the return roller bracket in the direction of the belt travel to train the belt away from you; (or)
Strike the roller bracket in the opposite direction of the belt travel to train the belt toward you
Observe the belt alignment for several rotations before attempting to adjust again
Training Top
Determine which direction the belt is misaligned
Obtain 2 lb sledge hammer
Strike the troughing roller in the direction of the belt travel to train the belt away from you; (or)
Strike the troughing roller in the opposite direction of the belt travel to train the belt toward you
Observe the belt alignment for several rotations before attempting to adjust again
Training Tail
Apply grease to the take-up side misaligned
Observe the belt
For several rotations before attempting to adjust again
17. Belt Splicing
Spot the belt
Position the splice in a safe location of the top side of belt
Assess the position of the splice and make adjustments if necessary
Lock/tag-out Belt
Refer to company policy
Obtain the following tools needed to splice belt:
Template to determine belt and clips size
Four Clamp bars and four glometers
Two 3 ton com-a-longs
Check for bent hooks, safety latch and damage to the chain
Impact gun
Be certain it has been ground tested
Flex-Co splicing tools
Driver, spoon, cutters, and breaker
Bucket of Flex-Cos
Splicing board
Razor knife
Requires sharp blade
Straight edge or square
Claw hammer
Extension cord
Be certain it has been ground tested
Face shield
To be used when grinding
4.5 inch Grinder
Be certain that it has been ground tested, and has guard
Inspect tools needed to splice belt
Obtain, inspect, and use fall protection
To be used when there is a danger of falling
Place the required tools at or near the location of the splice
Install belt clamps
Leave enough room to space the clamps as far as the com-a-longs will permit
Position and tension both com-a-longs simultaneously
Position splice board under belt and on top of the com-a-long chain
The board should be centered on the existing splice
Cut out the old splice using a straight edge
The cut needs to be straight
Install splicing template
Drill holes
Remove Template
Install Flex-Cos (Clips) on both sides
Realign both side of the belt
Install caps and nuts
Tighten nuts with a nut driver
Break off the studs using a breaker tool
Grind and clean to remove sharp edges
Use face shield
Loosen the com-a-longs simultaneously
Remove the com-a-longs
Remove clamps
Remove splice board
Clean up and re-store tools
Remove locks and tags
18. End of Shift Activities
Signal the loader operator to stop feeding the plant
At appropriate time
Proceed to the control tower
Turn off the power to feeder, FC16, 15, 14, 13, and FC12
Ensure that the belts are cleaned off prior to turning off power
Remove power in proper sequence
Pick up the loader operator if required
Shut and lock the gate if the last person out
The permit requires that no activity occurs after 6:00 PM
Park service truck on the line
Chock tires when parked on line
Post-Op the service truck (Company Policy)
Lock tool box
Check oxygen and acetylene bottles
Replace if necessary, make sure that they are bled off and secured
Note any damage that may have occurred during the shift
Leave the vehicle in operational condition for the next individual
Return PPE to locker
Replace any unusable PPE
Place radio in charger
Turn in paperwork
Grease schedule
Pre-Op
"B" Pit Inspection Sheet
Safety Harness Inspection
Clock out
Go home in the condition you came in