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Hydrate Helper
Contact:  Palmer.Melvin@dol.gov
1. Beginning of Shift
Conduct a Self Assessment
Clock In
Drive to the change/lunch room
Park car
Proceed to change room
Change clothes (if needed)
Collect and put on PPE
Collect Hard Hat
Collect Safety Glasses
Collect Safety shoes
Collect Ear plugs
Collect Gloves
Proceed to the pump floor
Start visual inspection of the plant
Look at housekeeping
Accumulation of lime
Look for slip and trip hazards
Listen for unusual noises
Check for guards that are not in place
Ensure that machinery is properly operating
Check for unusual smells
Check for trip hazards
Check Hand Rails
Check Stairs
Check Walkways
Notify the maintenance supervisor immediately if any unsafe conditions are found.
Write up a work order on any other defective conditions that are found
Attend briefing with the hydrate helper leaving
Receive status of the trucks and railcars loaded
Discuss the ongoing maintenance
Talk to the operator
Discuss silo levels
Discuss moisture levels
< .7 % moisture load in trucks
>.7 % moisture bagged
Ensure that he don't need anything
2. Load Bulk Trucks
Continue Visual Inspection
This inspection is a continuation of the items listed in the "Beginning of Shift" duty
Coordinate the loading of the trucks with the bagging operation
Assist the baggers with the crossover belt if needed
Communicate with truck driver to ensure that they know that you will be on the truck
Ensure that the truck driver has his brakes set and the pressure is released from inside trailer
Obtain and put on PPE
Body Harness
Dust Mask
Goggles
Inspect the ladder for slip, trip and fall hazards and/or broken rungs
Climb ladder to load out shack
Attach retractable lanyard to the harness
Position the truck where the spout is between the center loading holes
To ensure that all lids can be accessed without adjusting truck position
Lower the ramp
Walk out onto the truck
Open the lids
Open latches starting near the hinge
Release the latch with the safety catch last
In case there is pressure inside the tank which may cause the lid to "fly up"
Return to the ramp
Proceed to load out shack
Reposition the truck
Use directional lights: if lights are not working use hand signals
Lower the spout into the first loading hole
May have to return to the ramp to ensure that the spout goes in the loading hole
Remove the retractable lanyard from the harness
Turn on the vibrator on loading spout
Turn on the load out screw
Turn on the load out elevator
Ensure that the elevator is operating
Look for the turning shaft at the bottom of the elevator
Turn on the #2 silo discharge screw
Ensure that the screw is running
Look for the turning shaft at the end of the screw
Notify the operator if the screw is not turning
Fill hole to the proper level
Hole is full when a steady stream of dust is coming from the spout and the hole
Turn off the #2 silo discharge screw
Turn off the elevator
Turn off the load out screw
Turn off the vibrator
Raise the load out spout
Reposition the truck
Use directional lights; if lights are not work use hand signals.
Listen for the air brakes on the truck to ensure that the brakes are set
Obtain the sample can
In load out shack
Re-attach the retractable lanyard to the harness
Return to the top of truck
Fill the sample can from the first load out hole
Run the sample if needed for that truck
Only run one sample from each truck
Close the first truck lid
Ensure that all the latches are properly secured
Follow the same loading process for the remaining holes
Shut down loading operation after last hole
Shut down the silo discharge screw
Allow system to run until cleared
Shut down elevator
Shut down the load out screw
Turn off the vibrator
Raise the load out spout all the way up
Position the truck with the spout between the two center holes
Ensure all lids and latches are closed
Blow off the top of the truck using air lance
Company policy, it's required that the trucks are blown off after loading
Return to the load out shack
Remove the retractable lanyard
Ensure that the ramp is raised up
Climb down the ladder to the ground
Remove the body harness and store in proper place
Notify the truck driver that the loading process is over
Proceed to the rail scale check out shack
Fill out bill of lading
Give bill of lading to the truck driver
3. Load Train Cars
Continue Visual Inspection
This inspection is a continuation of the items listed in the "Beginning of Shift" duty
Coordinate the loading of the rail car with the bagging operation
Assist the baggers with the crossover belt if needed
Check to ensure that the load out ramp and spout are in the fully raised position
Obtain the loader
CAT 966
Conduct a Pre-shift inspection of the loader
Use the Pre-Op check sheet inside the loader. Company policy
Climb inside loader
Put on seat belt
Company policy
Start up loader
Fill out the Pre-Op inspection check sheet
Company policy
Proceed to the rail cars
Drop bucket to the ground
Company policy
Set the brakes on the loader
Company policy
Ensure that the loader is in neutral
Company policy
Dismount the loader
Check for proper brake tension on the rail cars
Pull on brake chain system to ensure tightness
If more than one car, check the brake systems on all cars
Check the knuckle of the car that you are going to hook to ensuring that it is open
Check the knuckle on the loader to ensure that it is open
Mount the loader
Put on seat belt
Company policy
Raise the bucket
Release park brake on the loader
Set the lock on the knuckle in the loader
Push the switch next to the seat forward
Back up to the train car until the knuckle is engaged
Proceed to the load out station
Spot the car on the center hole using the alignment marks on the wall
Align your right shoulder with the painted marks on the wall
Gray for seven hole cars
Orange for six hole cars
Unhook the rail car from the loader
Push switch next to seat to the rear of the loader
Park the loader in a safe location away from the dust
Use parking procedure
Obtain paperwork and seals
Paperwork and seals located in lock up
Start train car profile paperwork
Record car number, seal numbers, and empty car weight on the profile
Car weight and number located on the car
Obtain and put on PPE
Body Harness
Dust Mask
Goggles
Inspect the ladder for slip, trip and fall hazards and/or broken rungs
Climb ladder to load out shack
Attach retractable lanyard to the harness
Lower the ramp
Walk out onto the rail car
Open lids 1-4
Open latches starting near the hinge
Release the latch with the safety catch last
In case there is pressure inside the tank which may cause the lid to "fly up"
Return to the ramp
Proceed to load out shack
Lower the spout into the first loading hole
May have to return to the ramp to ensure that the spout goes in the loading hole
Remove the lanyard from the harness
Turn on the vibrator on loading spout
To ensure that the spout don't plug
Turn on the load out screw
Turn on the load out elevator
Ensure that the elevator is operating
Look for the turning shaft at the bottom of the elevator
Turn on the #2 silo discharge screw
Ensure that the screw is running
Look for the turning shaft at the end of the screw
Notify the operator if the screw is not turning
Fill hole to the proper level
Hole is full when a steady stream of dust is coming from the spout and the hole
Turn off the #2 silo discharge screw
Turn off the elevator
Turn off the load out screw
Turn off the vibrator
Raise the load out spout
Raise the ramp in the fully raised position
Climb down ladder to the ground
Obtain the loader
Connect the loader to the rail car using the connection procedures
Reposition rail cars to the next paint marks
Leave the loader attached to the rail cars and repeat loading process for holes 2-4
Obtain three sample cans
In load out shack
Re-attach the retractable lanyard to the harness
Return to the top of the rail car
Fill the sample can from the first and fourth holes
Use one can for each hole
Close lids and attach seals on holes 1-4 after hole #4 is filled
Attaching seals are Company policy
Clean off the top of the rail car using compressed air and air lance
Only clean the area around the loaded holes 1-4
Follow the same loading process for the remaining holes
Shut down loading operation after last hole
Shut down the silo discharge screw
Allow system to run until cleared
Shut down elevator
Shut down the load out screw
Turn off the vibrator
Raise the load out spout up
Take a sample from the last load out hole
A total of three samples per car
Close and attach seal to the remaining lids
Ensure that all latches are secured
Company Policy
Clean off the top of the car using air lance
Company policy, failure may cause disciplinary action; railroad policy
Return to load out shack
Remove the retractable lanyard
Raise ramp all the way up
Climb down the ladder to the ground
Remove the body harness and store in proper place
Check the position of the track switch
Ensure that the rail switch flag is cross ways with the track
Return to the loader
Move the rail car through the switch
Use first gear
Stop and exit the loader
Ensure that proper parking procedures are followed
Turn the rail switch back to where the flag is parallel to the rails
Return to the loader
Unhook the loader from the rail car using switch inside loader
Move the loader to the other end of the car
Couple the loader to the car
Pull through the switch and onto the scale
Record the gross weight of the rail car on the profile report
Note the weight on the digital scale read out monitor
Exit the loader
Inspect the area around the rail cars and loader to ensure all persons are clear
Open any closed couplers on loaded train cars that may be present on the track
Couplers are opened by lifting the bar on the end of the rail car
Return to the loader
Sound the loader horn before moving
Back the car in the reverse direction off of the scale
Couple the car to any additional cars and move past the switch at least 2 car lengths to allow the next car to clear
If there is more than one car, the brakes may have to be released enough to move the loaded cars forward
Stop and park the loader using the proper procedures
Exit the loader
Ensure that the brake is fully set on at least one rail car
Get in the loader
Unhook the car from the loader using the proper procedure
Park loader in designated area
Company Policy
Obtain the three full sample cans and proceed to the lab
Run all required tests
Moisture %
Viscosity
Pack Set
Company Policy
Record all results on the profile report and lab log
Company Policy
Ensure that the profile is complete
Take profile report to the pump control room
4. Fill Tanner Gas
Continue Visual Inspection
This inspection is a continuation of the items listed in the "Beginning of Shift" duty
Obtain and put on PPE
Face shield or goggles
Rubber Gloves
Ensure that the correct container is used
Blue 5 gallon bucket stored beneath the tank
Proceed to the oil house (If needed)
Locate the 55 gallon drum of methanol
Ensure that all caps are closed and tight
Place drum on the dolly
Lay drum on its side with the pour spout down
Place the 5 gallon bucket under the spout
Open the small cap on the top of the drum
Remove the lid from the 5 gallon bucket
Open the spout on the drum slowly
Open to the correct flow rate to eliminate splashing
Close spout when the bucket is full
Put lid back on 5 gallon bucket
Put small lid back on air flow hole and hand tighten
Stand the drum back to the vertical position
Proceed back to the tanner gas tank with the bucket
Open air lines to the main pipe
Close both valves to the tanner gas tank
Up to 120lbs. air pressure
Remove the plug on the fill pipe
Open the valve on the fill pipe (slowly)
Dump the methanol into the fill pipe until full
Close valve on the fill pipe
Replace the plug in the end of the fill pipe
Open both valves on the bypass pipe
Close the valve to the main line
Repeat steps to refill 5 gallon bucket if needed
5 gallon should remain full to be used if needed
Replace 5 gallon bucket under tanner tank
5. Run Samples
Continue Visual Inspection
This inspection is a continuation of the items listed in the "Beginning of Shift" duty
Follow the written procedure for determining the Moisture (%) content
The written procedure is in lab
There will be one sample per truck and three samples per rail car
Follow the written procedure for determining the viscosity of the sample
The written procedure is in lab
There will be one sample per truck and three samples per rail car
Notify operator if viscosity is less than 110,000
Communicate with operator on additive feed dial settings to be used
Begin application of additive when notified by operator
Proceed to Devils Hole
Check feed pipe and clear if necessary
Set dial to appropriate settings
Turn toggle switch to on position
Proceed to additive hopper
Place a bag of additive on the grate above the hopper
Break bag open and dump into hopper
Repeat adding additive as needed
Additional additive in the warehouse
Place empty bags into dumpster next to the bagger shack
Follow the written procedure for the Pack Set test
The written procedure is on the bottom and back of the train car profile sheet
There will be one sample per truck and three samples per rail car
Record all test results on the lab sheet report
Company policy may cause disciplinary action if not done.
Combine all remaining samples from each rail car into one bucket and leave in the lab
Tag samples with car numbers, date and initial
Company policy; may cause disciplinary action if not done
6. Dump the Reject Hopper
Continue Visual Inspection
This inspection is a continuation of the items listed in the "Beginning of Shift" duty
Close the air gate above the hopper
Obtain the Forklift
Conduct a pre-operational inspection on the forklift
Company Policy; possible disciplinary action
Fill out the pre-op form
Company Policy; possible disciplinary action
Get on the forklift
Put on seatbelt
Company Policy; possible disciplinary action
Start forklift
Raise forks
Four to six inches
Release parking brake
Proceed to hopper
Lift hopper onto forks
Carry hopper to dump site
Watch for screws,elevator, persons,beams, pipes etc.
Stop fork lift and set park brake at dump site
Raise hopper about three feet from the ground
Tilt the mast forward
Dismount forklift
Raise the dump latch on hopper
Get back on forklift
Raise the load to dump the hopper
Tilt the mast back to vertical
Lower the hopper to the ground
Dismount forklift
Check latch to ensure hopper is properly secured
Remount the forklift
Raise load four to six inches off the ground
Release the park brake
Drive hopper back to the dirt devil
Set hopper in place
Return forklift to designated area
Company Policy
Set park brake and lower forks
Company Policy
Shut off forklift
Proceed to and open air gate
Only open gate half way
7. General Cleanup
Continue Visual Inspection
This inspection is a continuation of the items listed in the "Beginning of Shift" duty
Obtain and put on PPE
Gloves
Glasses
Dust Mask
Inspect the condition of hand tools
Wheelbarrow
Shovel
Brooms
If defects are found turn them into a supervisor for replacement
Obtain Bobcat if needed
Inspect before use
Fill out pre-operational check sheet
Tape off lower level before sweeping or blowing off upper level
Clean up the Hydrate area
Clean up Main Floor
Clean up Pump Floor
Clean off Top of Silos
Clean off Top Separators
Clean up Devils Hole
The pump must be shut off before clean up is done in the Devils Hole
Clean up with two persons
Clean up Below the Hydrator
Clean up around the load out
Clean up around train tracks
Part of the job description
Put away all tools in designated areas when finished
8. General Maintenance
Continue Visual Inspection
This inspection is a continuation of the items listed in the "Beginning of Shift" duty
Obtain tools
Get grease gun
Get rags
Get screw driver
Get extra tube of grease
Greasing
Follow lubrication schedule as posted in the control room
Check condition of the V-belts
If worn or in poor condition, write a work order
Replace broken or missing V-belts
Notify the operator
Lock and tag out motor after the operator has shut down motor circuit
Follow company lock and tag out policy
Obtain tools
Crescent wrench
9/16" wrench
Screw driver
hammer
Remove the guard
Check the V-belt for the size
Obtain the replacement V-belt
Belt room
Fill out inventory sheet in belt room (quantity, size and what you put on)
Install the new V-belt
Loosen the torque arm or adjust motor to shorten belt span
Remove any existing belts that may be on pulley
Install the new belts over the pulley
Adjust the torque arm or motor to the proper tension
Tighten the torque and/or motor locking nuts
Install guard
Company policy states that nothing is started without the guard properly in place
Remove lock and tag
Put tools away
Energize motor
Check top and bottom elevator bearings
Check Load out elevator
Check Silo feed elevator
Check Reject elevator
Check Collector elevator
Check surge bin elevator
Ensure that the balls are in the bearing, shaft is centered within the two bearings, seals are in place, shaft is not spinning inside the bearing, and ensure that the bearing is getting grease (check on a daily basis)
Check to ensure the operation of the screw conveyors (Tail Bearings)
Check the surge bin feed screw
Check the surge bin discharge screw
Check the #1 and #2 clean out screws
Check the collector discharge screw
Check the #1 separator feed screw
Check the #1 separator product screw
Check the #1 separator reject screw
Check the #2 separator feed screw
Check the #2 separator product screw
Check the #2 separator reject screw
Check the micro pulverizing screw (dirt devil)
Check the silo feed screw
Ensure that the balls are in the bearing, seals are in place, ensure that the shaft is not spinning inside the bearing, and ensure that the bearing is getting grease (Check on a daily basis)
Check top separator Bearings
Check #1 separator bearing
Check #2 separator bearing
Ensure that the balls are in the bearing, seals are in place, ensure that the shaft is not spinning inside the bearing, ensure that the bearing is getting grease, and remove lime build-up if necessary (Check on a daily basis)
9. End of Shift
Ensure that the reject hopper is empty
follow the dumping of reject hopper job steps
To be done within 1/2 hour of the end of the shift
Ensure that samples have been run
If samples have not been run advise incoming hydrate helper. If not done it may be grounds for disciplinary action.
Ensure that all reports and paperwork have been completed
Railcar profile report
Pre-Op inspection report
Any work orders
Tool orders list
Parts orders
Wait for proper relief
Brief incoming hydrate helper
Discuss what train cars are done or half done
Advise of trucks loaded
Advise of any break downs or maintenance issues
Advise of the condition of the lime
Discuss any other potential problems
Return to lunchroom
Change clothes
Clock out
About
Title
Hydrate Helper
Subject
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Company
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Author
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Version
151
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