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Hydrate Helper

Hydrate Helper
Beginning of Shift Load Bulk Trucks Load Train Cars Fill Tanner Gas Run Samples Dump the Reject Hopper General Cleanup General Maintenance End of Shift
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 Priority 2
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 Priority 2
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 Priority 2
Receive status of the trucks and railcars loaded
Discuss the ongoing maintenance
Talk to the operator Priority 2
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 Priority 2
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 Priority 2
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 Priority 3
Ensure that the truck driver has his brakes set and the pressure is released from inside trailer Priority 3
Obtain and put on PPE Priority 3
Body Harness
Dust Mask
Goggles
Inspect the ladder for slip, trip and fall hazards and/or broken rungs Priority 3
Climb ladder to load out shack Priority 3
Attach retractable lanyard to the harness Priority 3
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 Priority 3
Walk out onto the truck Priority 3
Open the lids Priority 3
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 Priority 3
Proceed to load out shack Priority 3
Reposition the truck Priority 3
Use directional lights: if lights are not working use hand signals
Lower the spout into the first loading hole Priority 3
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 Priority 3
Turn on the load out screw Priority 3
Turn on the load out elevator Priority 3
Ensure that the elevator is operating Priority 2
Look for the turning shaft at the bottom of the elevator
Turn on the #2 silo discharge screw Priority 3
Ensure that the screw is running Priority 2
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 Priority 2
Hole is full when a steady stream of dust is coming from the spout and the hole
Turn off the #2 silo discharge screw Priority 3
Turn off the elevator Priority 3
Turn off the load out screw Priority 3
Turn off the vibrator
Raise the load out spout Priority 3
Reposition the truck Priority 3
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 Priority 3
Obtain the sample can
In load out shack
Re-attach the retractable lanyard to the harness Priority 3
Return to the top of truck Priority 3
Fill the sample can from the first load out hole Priority 3
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 Priority 3
Shut down loading operation after last hole Priority 3
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 Priority 3
Blow off the top of the truck using air lance Priority 3
Company policy, it's required that the trucks are blown off after loading
Return to the load out shack Priority 3
Remove the retractable lanyard Priority 3
Ensure that the ramp is raised up Priority 3
Climb down the ladder to the ground Priority 3
Remove the body harness and store in proper place
Notify the truck driver that the loading process is over Priority 3
Proceed to the rail scale check out shack Priority 3
Fill out bill of lading Priority 3
Give bill of lading to the truck driver Priority 3
3. Load Train Cars
Continue Visual Inspection Priority 2
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 Priority 2
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 Priority 3
Obtain the loader Priority 3
CAT 966
Conduct a Pre-shift inspection of the loader Priority 3
Use the Pre-Op check sheet inside the loader. Company policy
Climb inside loader Priority 3
Put on seat belt Priority 3
Company policy
Start up loader Priority 3
Fill out the Pre-Op inspection check sheet Priority 3
Company policy
Proceed to the rail cars Priority 3
Drop bucket to the ground Priority 3
Company policy
Set the brakes on the loader Priority 3
Company policy
Ensure that the loader is in neutral Priority 3
Company policy
Dismount the loader Priority 3
Check for proper brake tension on the rail cars Priority 3
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 Priority 3
Put on seat belt Priority 3
Company policy
Raise the bucket Priority 2
Release park brake on the loader Priority 3
Set the lock on the knuckle in the loader Priority 3
Push the switch next to the seat forward
Back up to the train car until the knuckle is engaged Priority 3
Proceed to the load out station Priority 3
Spot the car on the center hole using the alignment marks on the wall Priority 3
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 Priority 3
Paperwork and seals located in lock up
Start train car profile paperwork Priority 3
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 Priority 3
Body Harness
Dust Mask
Goggles
Inspect the ladder for slip, trip and fall hazards and/or broken rungs Priority 3
Climb ladder to load out shack Priority 3
Attach retractable lanyard to the harness Priority 3
Lower the ramp Priority 3
Walk out onto the rail car Priority 3
Open lids 1-4 Priority 3
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 Priority 3
Proceed to load out shack Priority 3
Lower the spout into the first loading hole Priority 3
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 Priority 3
To ensure that the spout don't plug
Turn on the load out screw Priority 3
Turn on the load out elevator Priority 3
Ensure that the elevator is operating Priority 2
Look for the turning shaft at the bottom of the elevator
Turn on the #2 silo discharge screw Priority 3
Ensure that the screw is running Priority 2
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 Priority 2
Hole is full when a steady stream of dust is coming from the spout and the hole
Turn off the #2 silo discharge screw Priority 3
Turn off the elevator Priority 3
Turn off the load out screw Priority 3
Turn off the vibrator
Raise the load out spout Priority 3
Raise the ramp in the fully raised position Priority 3
Climb down ladder to the ground Priority 3
Obtain the loader Priority 3
Connect the loader to the rail car using the connection procedures Priority 3
Reposition rail cars to the next paint marks Priority 3
Leave the loader attached to the rail cars and repeat loading process for holes 2-4 Priority 2
Obtain three sample cans Priority 3
In load out shack
Re-attach the retractable lanyard to the harness Priority 3
Return to the top of the rail car Priority 3
Fill the sample can from the first and fourth holes Priority 3
Use one can for each hole
Close lids and attach seals on holes 1-4 after hole #4 is filled Priority 3
Attaching seals are Company policy
Clean off the top of the rail car using compressed air and air lance Priority 3
Only clean the area around the loaded holes 1-4
Follow the same loading process for the remaining holes Priority 3
Shut down loading operation after last hole Priority 3
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 Priority 3
A total of three samples per car
Close and attach seal to the remaining lids Priority 3
Ensure that all latches are secured Priority 3
Company Policy
Clean off the top of the car using air lance Priority 3
Company policy, failure may cause disciplinary action; railroad policy
Return to load out shack Priority 3
Remove the retractable lanyard Priority 3
Raise ramp all the way up Priority 3
Climb down the ladder to the ground Priority 3
Remove the body harness and store in proper place
Check the position of the track switch Priority 3
Ensure that the rail switch flag is cross ways with the track
Return to the loader Priority 3
Move the rail car through the switch Priority 3
Use first gear
Stop and exit the loader Priority 3
Ensure that proper parking procedures are followed
Turn the rail switch back to where the flag is parallel to the rails Priority 3
Return to the loader Priority 3
Unhook the loader from the rail car using switch inside loader Priority 3
Move the loader to the other end of the car Priority 3
Couple the loader to the car Priority 3
Pull through the switch and onto the scale Priority 3
Record the gross weight of the rail car on the profile report Priority 3
Note the weight on the digital scale read out monitor
Exit the loader Priority 3
Inspect the area around the rail cars and loader to ensure all persons are clear Priority 3
Open any closed couplers on loaded train cars that may be present on the track Priority 3
Couplers are opened by lifting the bar on the end of the rail car
Return to the loader Priority 3
Sound the loader horn before moving Priority 3
Back the car in the reverse direction off of the scale Priority 3
Couple the car to any additional cars and move past the switch at least 2 car lengths to allow the next car to clear Priority 3
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 Priority 3
Exit the loader Priority 3
Ensure that the brake is fully set on at least one rail car Priority 3
Get in the loader Priority 3
Unhook the car from the loader using the proper procedure Priority 3
Park loader in designated area Priority 3
Company Policy
Obtain the three full sample cans and proceed to the lab Priority 3
Run all required tests Priority 3
Moisture %
Viscosity
Pack Set
Company Policy
Record all results on the profile report and lab log Priority 3
Company Policy
Ensure that the profile is complete
Take profile report to the pump control room
4. Fill Tanner Gas
Continue Visual Inspection Priority 2
This inspection is a continuation of the items listed in the "Beginning of Shift" duty
Obtain and put on PPE Priority 3
Face shield or goggles
Rubber Gloves
Ensure that the correct container is used Priority 2
Blue 5 gallon bucket stored beneath the tank
Proceed to the oil house (If needed) Priority 3
Locate the 55 gallon drum of methanol Priority 3
Ensure that all caps are closed and tight Priority 3
Place drum on the dolly Priority 3
Lay drum on its side with the pour spout down Priority 3
Place the 5 gallon bucket under the spout Priority 3
Open the small cap on the top of the drum Priority 3
Remove the lid from the 5 gallon bucket Priority 3
Open the spout on the drum slowly Priority 3
Open to the correct flow rate to eliminate splashing
Close spout when the bucket is full Priority 3
Put lid back on 5 gallon bucket Priority 3
Put small lid back on air flow hole and hand tighten Priority 3
Stand the drum back to the vertical position Priority 3
Proceed back to the tanner gas tank with the bucket Priority 3
Open air lines to the main pipe Priority 3
Close both valves to the tanner gas tank Priority 3
Up to 120lbs. air pressure
Remove the plug on the fill pipe Priority 3
Open the valve on the fill pipe (slowly) Priority 3
Dump the methanol into the fill pipe until full Priority 3
Close valve on the fill pipe Priority 3
Replace the plug in the end of the fill pipe Priority 3
Open both valves on the bypass pipe Priority 3
Close the valve to the main line Priority 3
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 Priority 2
5. Run Samples
Continue Visual Inspection Priority 2
This inspection is a continuation of the items listed in the "Beginning of Shift" duty
Follow the written procedure for determining the Moisture (%) content Priority 3
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 Priority 3
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 Priority 3
Communicate with operator on additive feed dial settings to be used Priority 3
Begin application of additive when notified by operator Priority 3
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 Priority 3
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 Priority 3
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 Priority 3
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 Priority 2
This inspection is a continuation of the items listed in the "Beginning of Shift" duty
Close the air gate above the hopper Priority 3
Obtain the Forklift Priority 3
Conduct a pre-operational inspection on the forklift Priority 3
Company Policy; possible disciplinary action
Fill out the pre-op form Priority 3
Company Policy; possible disciplinary action
Get on the forklift Priority 3
Put on seatbelt Priority 3
Company Policy; possible disciplinary action
Start forklift Priority 3
Raise forks Priority 3
Four to six inches
Release parking brake Priority 3
Proceed to hopper Priority 3
Lift hopper onto forks Priority 3
Carry hopper to dump site Priority 3
Watch for screws,elevator, persons,beams, pipes etc.
Stop fork lift and set park brake at dump site Priority 3
Raise hopper about three feet from the ground Priority 3
Tilt the mast forward Priority 3
Dismount forklift Priority 3
Raise the dump latch on hopper Priority 3
Get back on forklift Priority 3
Raise the load to dump the hopper Priority 3
Tilt the mast back to vertical Priority 3
Lower the hopper to the ground Priority 3
Dismount forklift Priority 3
Check latch to ensure hopper is properly secured Priority 3
Remount the forklift Priority 3
Raise load four to six inches off the ground Priority 3
Release the park brake Priority 3
Drive hopper back to the dirt devil Priority 3
Set hopper in place Priority 3
Return forklift to designated area Priority 3
Company Policy
Set park brake and lower forks Priority 3
Company Policy
Shut off forklift Priority 2
Proceed to and open air gate Priority 3
Only open gate half way
7. General Cleanup
Continue Visual Inspection Priority 2
This inspection is a continuation of the items listed in the "Beginning of Shift" duty
Obtain and put on PPE Priority 3
Gloves
Glasses
Dust Mask
Inspect the condition of hand tools Priority 2
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 Priority 3
Clean up the Hydrate area Priority 2
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 Priority 2
8. General Maintenance
Continue Visual Inspection Priority 2
This inspection is a continuation of the items listed in the "Beginning of Shift" duty
Obtain tools Priority 3
Get grease gun
Get rags
Get screw driver
Get extra tube of grease
Greasing Priority 3
Follow lubrication schedule as posted in the control room
Check condition of the V-belts Priority 2
If worn or in poor condition, write a work order
Replace broken or missing V-belts Priority 3
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 Priority 2
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) Priority 2
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 Priority 2
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 Priority 2
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 Priority 3
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 Priority 3
Railcar profile report
Pre-Op inspection report
Any work orders
Tool orders list
Parts orders
Wait for proper relief Priority 3
Brief incoming hydrate helper Priority 2
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