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Roller Mill Tire Change

Roller Mill Tire Change
Planning Execute Start-Up Prep Work
1. Planning
Planning Meeting
Weekly Inspection
Wear Measurement ( Maintenance Engineer )
Follow Mill lock-out procedure
Use pin measurement template
Check Data to make sure within constraints ( 0 - 1 5/8" wear )
Data Warrants change out contact Maintenance & Production
Determine which tire is to be replaced.
Write work order (SAP System) STD
Give assignment to appropriate Supervisor
Data Warrants Immediate change out contact Maintenance & Production
Determine which tire is to be replaced.
Write work order (SAP System) RED
Give assignment to appropriate Supervisor
Assign Maintenance Supervisor
Assign Crew
Define Tasks
Check Inventory
Schedule Crane
2. Execute
Crew meeting
Hand out work orders
Scan into Kronos
Hold tailgate meeting
Assign job tasks and duties
Two of team goes to mill via pickup
Assigned to clear mill table
Pre-shift inspection
Follow company operating procedures
Two of team gather tools via pickup
Two one-ton come-alongs, and two 1/2 by 3' chokers
Pre-shift inspection
Follow company operating procedures
Supervisor assigns clean up duties to specific individuals.
Return crane to staging area, air lines re-organized, tools in gang box, shut off oxygen/acetelyene bottles, hoses purged, protective valve covers in place, gases evacuated from ring of fire, clear hazards, police area and dispose of unwanted items in the appropriate containers, scrap tires to bone yard (remove the pallet and discard in wood waste), return cribbing to warehouse area, return comealongs and chokers to storeroom and note any defects/damages to equipment at that time.
Crew supervisor calls control room to allow bypass and field permit of roller mill
Clear mill table
Open man door
Chain off opening
Call control room and verify roller mill ID fan is running, and dampers are set on zero
Hook up air lance
Raise rollers hydraulically per indicator light (one man stays at door opening)
Verify roller position with Teammate
Hydraulic man positions himself to start roller mill locally
Use verbal communication between crew members prior to starting mill
Push start button to start mill
Door man starts air lance, cleaning off table ( clockwise )
Must point air lance in direction of table rotation, to avoid lance contacting table and kicking back against operator.  Takes ~ 5 minutes to complete this operation.
Hydraulic man shuts down mill locally, maintain stop button to avoid restart
Shut off 4 ram hydraulic valves to maintain up-position of rollers
Lock out/tag out
Supervisor calls control room and notifies it that mill circuit breakers are being locked out
Supervisor will close guillotine gate at kiln ID fan
Installs lock at MCC center at lower level of pre-heat tower
While at lower level, lock out feed belt conveyor S-225
Locks out triple gate
Locks out hydraulic system for roller mill
Supervisor goes to 5th floor of preheat tower,to locally close off guillotine gate S-252
Supervisor returns to first floor of pre-heat tower MCC, pulls breaker, and locks out S-252
Supervisor then goes to second level of pre-heat tower MCC
Goes to mill motor switch gear
Verify with amp meter that motor is not energized
Trips mill drive motor starter
Pull handle of breaker to off position
Installs MCC lock
Goes to Roller Mill ID fan
Verify that Amp meter is at zero
Trips ID fan motor starter
Pull handle of breaker to off position
Installs MCC lock
Store the Lock-out keys in lock-out box
Locks-out lock-out box
Supervisor calls control room for a bump start
This is done to check that the right equipment has been locked-out.
Supervisor fills out S-230 lockout procedure form
Crew members install personal locks
Crew members do pre-job safety inspection
Address any potential hazards observed prior to starting work.
Fill out daily job site inspection form
Open journal door
Properly place 8-foot ladder
Discuss three points of contact
Show ladder safety video
Workers put on fall protection
Loosen nuts with 3/4 inch impact wrench.(top and sides of door)
Once harnessed in place instruct co-worker to hand 3/4 inch impact wrench up to co-worker.
Turn latches 90 degrees.
Lower impact wrench to co-worker.
Decend and remove ladder from working area.
Remove thermocouple from journal bearing
Thermocouple should  only be hand tightened.
Attach safety removal tabs on door to journal yoke
Loosen nuts on lower edge of door
Use hoists to remove walkway and railings beside journals to accommodate journal yoke
Install temporary railings
Attach clevises on 15-ton monorail hoists to picking eyes on yoke assembly
One hoist attached approximately 20 degree from vertical.
One hoist attached vertical.
Monitor cables for proper tension
Attach 1/2-inch choker and comealongs to hydraulic cylinder connecting rods
Ataches connecting rods to yoke assembly.
Remove taper pin lock cap screws and insert one cap screw in threaded pusher hole to break taper lock.
Insert threaded slide hammer into pin threaded center hole.
Remove pins (north and south)
Utilize hoist , comealong, and slide hammer in unison to remove pin. (Pins weight approximately sixty pounds each).
Once the pin is out of the taper fit, it takes two people to lower the pin to ground level.
Remind workers to use proper lifting techniques.
Utilize hoist to ensure safe removal of pin to prevent lifting injuries.
Relax the connecting rods with the comealongs already in place.
Position one mechanic on the north hoist pendant and one on the south hoist pendant.
Maintain eye contact to ensure consistent and safe lifting.
The mechanic on the 20 degrees off vertical hoist begins lifting while other mechanic maintains proper tension on other line.
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Ensure there is tension on the line when at stops.
When the 20 degree offset line becomes vertical, it maintains tension while the other hoist lowers the journal to the I-Beam stops below the removed grating
Tire Removal (Top)
Position the 8' extension ladder over journal, ascend ladder and attach to retractable fall protection.
Co-worker hands air lance to worker in upper position.
Clean ring retainer holes (approx. 20)
Necessary to have face shield, goggles, dust mask, and normal PPE.
Fellow workers should evacuate building while air lancing is taking place. (To avoid dust and projectile injury)
Get 3/4" air impact wrench from co-worker and remove the (20) ring retainer bolts.
Attach mobile crane to retainer ring.
Execute pre-shift inspection.
Attach I-Bolts 180 degrees apart through threaded picking holes.
Chokers must be a minimum of 6' in length and matching.
Worker on top of journal apparatus descends ladder and removes it from area.
Swing out handrails
Designated signaler posted to communicate with the crane operator.
Signals crane operator to add light tension to line.
Position mechanics(2) on opposite sides of journal with 8 lb sledge hammers.
Impact retainer ring with sledge hammers to loosen ring from shoulder while maintaining tension on line.
Apply tether line to eye holes prior to tapping to maintain lift control of ring.
Worker should maintain tension on the tether line.
Lift ring with crane and position outside on ground out of work area.
Close Handrails
Detach crane from ring.
Two mechanics attach spreader bar to crane.
Two mechanics obtain ring of fire.
Center ring on tire and attach propane and air hoses to proper connectors.
Ensure the ring of fire is centered on tire to optimize heat transfer.
Mechanic positions ladder to ascend onto top of journal, with proper fall protection to attach spreader bar.
Attach spreader bar to top tire via two threaded holes on opposite sides.
Ensure the spreader bar is level for equal pull and maintain a constant tension.
Mechanic descends ladder and removes from direct work area.
Ignite ring of fire.
Mechanic opens propane valve slightly while another mechanic is igniting flame.  Adjust both air and propane to obtain proper mixture of gas.
Proper air/gas mixture shows a flame detached from nozzles approx. 1" (blue flame).
Start heat check.
Use a heat pencil or infrared meter to verify the removal temperature is 250 degrees Fahrenheit (do not exceed).
Lift Tire
Swing out handrails
Signal crane operator to lift.
Execute a constant lift when separation begins to occur between tires.
Shut off propane/air valves.
Pivot arms on ring of fire and lower.
Continue lifting tire off of journal and lower to ground outside.
Ensure all workers are clear of the active crane radius..
If tire is to be discarded, place on pallet.
If tire is to be re-installed, place on cribbing
Close Handrails
Detach spreader bar from removed tire.
Tire Removal (Bottom)
Two mechanics center ring of fire on tire
Ensure the ring of fire is centered on tire to optimize heat transfer.
Attach spreader bar to bottom tire via two threaded holes on opposite sides.
Ensure the spreader bar is level for equal pull and maintain a constant tension.
Ignite ring of fire.
Mechanic opens propane valve slightly while another mechanic is igniting flame.  Adjust both air and propane to obtain proper mixture of gas.
Proper air/gas mixture shows a flame detached from nozzles approx. 1" (blue flame).
Start heat check.
Use a heat pencil or infrared meter to verify the removal temperature is 250 degrees fahrenheit (do not exceed).
Lift Tire
Swing out handrails
Signal crane operator to lift.
Execute a constant lift when separation begins to occur between tires.
Shut off propane/air valves.
Pivot arms on ring of fire and lower.
Continue lifting tire off of journal and lower to ground outside.
Ensure all workers are clear of the active crane radius.
If tire is to be discarded, place on pallet.
If tire is to be re-installed, place on cribbing.
Close Handrails
Detach spreader bar from crane.
New Tire Installation
Clean and de burr the key on hub.
Use sandpaper or emery cloth.
If uncleanable then replace key with one inch keystock.
To be done while heating the spare tire and removing the crane block from the removed tire.
Put loc-tite on the entire circumference of the hub face.
Loc-tite is used to alleviate pressure from the inner split retainer ring.
To be done while heating the spare tire and removing the crane block from the removed tire.
Attach spreader bar to new tire via two threaded holes on opposite sides.
Ensure the spreader bar is level for equal pull and maintain a constant tension.
Ignite ring of fire.
Execute when the bottom tire being removed is being heated.
Mechanic opens propane valve slightly while another mechanic is igniting flame.  Adjust both air and propane to obtain proper mixture of gas.
Proper air/gas mixture shows a flame detached from nozzles approx. 1" (blue flame).
Start heat check.
Use a heat pencil or infrared meter to verify the removal temperature is 250 degrees fahrenheit (do not exceed).
Lift Tire
Shut off propane/air valves.
Remove ring of fire.
Attach spreader bar to crane.
Swing out handrails
Signal crane operator to lift.
Execute a constant lift when separation begins to occur between tires.
Lift tire off cribbing and raise into position above journal, lower into place
Ensure all workers are clear of the active crane radius.
One mechanic should be guiding the tire keyway onto key.
It is critical that tire and spreader bar are level to ensure that during installation the tire does not get stuck.
Maintain level when lowering the tire into place over keyway. (Very Critical)
There should not be any gap between the tire and the split retainer because the split retainer may have broken bolts or a bent boss.
Close Handrails
Detach spreader bar from installed tire.
Re-install top tire
Determine which used tire to reinstall
Attach spreader bar to tire to reinstall via two threaded holes on opposite sides.
Ensure the spreader bar is level for equal pull and maintain a constant tension
Install ring of fire
Make certain that ring of fire is centered over tire.
Clean key way prior to heating tire
Be aware of temperature of tire.
Ignite ring of fire.
Mechanic opens propane valve slightly while another mechanic is igniting flame.  Adjust both air and propane to obtain proper mixture of gas.
Proper air/gas mixture shows a flame detached from nozzles approx. 1" (blue flame).
Start heat check.
Use a heat pencil or infrared meter to verify the removal temperature is 250 degrees fahrenheit (do not exceed).
Lift Tire
Shut off propane/air valves.
Remove ring of fire.
Attach spreader bar to crane.
Swing out handrails
Signal crane operator to lift.
Lift tire off cribbing and raise into position above journal, lower into place
Ensure all workers are clear of the active crane radius.
One mechanic should be guiding the tire keyway onto key.
It is critical that tire and spreader bar are level to ensure that during installation the tire does not get stuck.
Maintain level when lowering the tire into place over keyway. (Very Critical)
There should not be any gap between the tire and the split retainer because the split retainer may have broken bolts or a bent boss.
Close Handrails
Detach spreader bar from installed tire.
Swing spreader bar out of work area and place outside on pallet
Attach crane to retainer ring chokers
Swing out handrails
Lift retaining ring in place on hub
Align bolt holes with hub
Close Handrails
Tighten Retainer Bolts
Position ladder and ascend to top of journal
Attach harness to retractable fall protection
Obtain 3/4" impact wrench from co-worker
Tighten bolts in a 90 degree spread pattern
Ensure the ring is being tightened down evenly.
Lower impact wrench to co-worker
Do not lower using air line.
Descend from journal and remove ladder
Close Journal Door
One mechanic positioned on N and one on S at crane pendants
Maintain tension on the vertical line while lifting with the 20 degree offset until vertical.
Lift with the vertical and maintain tension on 20 degree offset.
Position the hydraulic connecting rods with attached comealongs until eyelet alignment is met.
Lift North pin into place
Remind workers to use proper lifting techniques.
Utilize hoist to ensure safe insertion of pin to prevent lifting injuries.
Use of slide hammer may be necessary to get the pin into position.
Install taper lock bushing by tightening bolts in a 90 degree spread pattern.
Lift South pin into place
Remind workers to use proper lifting techniques.
Utilize hoist to ensure safe insertion of pin to prevent lifting injuries.
Install taper lock bushing by tightening bolts in a 90 degree spread pattern.
Remove comealongs off arms.
Remove hoists from yoke and secure out of the way.
Replace grated walkways and handrails.
Mechanic position ladder to ascend to top of yoke with proper fall protection in place.
Obtain 3/4 ton comealong from coworker.
Attach to eyelet approx. 3' above door opening on mill body and load chain attached to door eyelet.
Put a strain on the comealong to support the door.
Co-worker removes bolts from the safety tabs.
Position door with comealong for height and to secure for tightening.
When positioning door, replace gasket if needed.
Harnessed mechanic is handed 3/4" impact wrench.
Tighten all bolts within reach.
Mechanic descends and removes ladder.
Mechanic below tightens remaining bolts on door.
Call for oiler to check journal oil and add as needed.
Mechanic re-install thermocouple on journal.
Close mill access door and tighten all bolts.
Make sure safety chains are removed prior to closing.
Open 2 hydraulic valves per cylinder at the cylinders.
3. Start-Up
Notify appropriate supervisor upon job completion if not at site.
Supervisor instructs for personal locks to be removed.
Supervisor completes a post-job site inspection.
Supervisor removes MCC lock from roller mill lock box.
Supervisor notifies control room that he/she will be closing out breakers.
Supervisor removes all locks and energizes the breakers that were locked out.
Supervisor to 5th floor preheat tower to S-252 Guillotine Gate and opens.
Supervisor goes to 2nd floor preheat tower to S-251 Guillotine Gate.
Notify control room that he/she is going to open S-251 Guillotine Gate and it may affect airflow.
Open S-251 Guillotine Gate.
Supervisor returns to MCC and returns locks to their respective positions in the Roller Mill Lock-Out Box
Supervisor calls control room to inquire about any possible abnormals in the Roller Mill Circuit.
If none, mill is released to production to start.
Supervisor is positioned in Roller Mill area to ensure everything starts up properly.
4. Prep Work
Stage replacement Tire in proper location
Use 8000 lb Fork Lift
Perform pre shift inspection
Ensure proper operator certification
Place on 8 X 8 wood cribbing using metal spacers
Set up of cribbing and metal spacing must include enough for two tires.
Do not discard shipping pallet as it will be used in removal of old tire.
Clean cosmoline off tire
Utilizes face shield, rubber gloves, apron & spill protection
Chase threads in tire for picking eyes
Install Spreader bar
Hang ring of fire on tire
Insure heating nozzles centered on the tire face
Pre Job Safety Inspection
As Assigned
Environmental Hazards
Crane inspections - mobile and overhead
Check for 4-part block on mobile crane
Inspect rigging equipment
Inspect air hoses, gas lines, gauges, electrical checks
Inspect gang box
Sockets, impact (3/4), sledges, 2 -  1 1/4 clevis, air hose adaptor
Check fire extinguisher availibility
Check 200 gallon Propane tank - 40 % minimum
Stage mobile crane - 1 day prior to use
Pre-op inspection
Flag work area
Ensure proper operator certification
Production crew grinds out the mill
Pull feed - 30 minutes prior to shut down
Monitor mill bearing temperatures
Shut off mill