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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 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 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 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 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 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 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 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) 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