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Sand Dredge Operator (Spider No. 2)
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1. 3. Dredge Startup
Remove window guards
Enter operators compartment
Can remove life-jacket
Get in seat
Check diary/log
Check alarm/warnings
take necessary action
Start oil cooler pump
Start service water pump
Start cutter pump
allow time delay during starting sequence to limit peak power demand
Do not start cutter if oil temperature is below 80 degrees
Check cutter system charge pressure
Minimum 250 psi - maximum 400 psi
start system hydraulic pump and wait for normal starting pressure
allow time delay during starting sequence to limit peak power demand
start jet pump (if needed)
allow time delay during starting sequence to limit peak power demand
turn on controls
This activates the controls on operator's chair
check all instruments
log on to plant computer
lower ladder
swing dredge port to starboard to check cable slack
Failure to do this could get swing cables caught in cutter
turn cutter on (forward)
contact plant prior to pumping fresh water
enable the dc drive
Check operation of maximizer
Check indicator light on dash
Check vacuum change
Look for air bubbles
throttle the underwater pump up to priming speed slowly
Contact plant operator to tell them fresh water is coming
throttle underwater pump up to operating speed
lower ladder to mining face
Notify plant operator that you are sending material
2. 4. Mining
establish instrument baseline readings ON WATER (flow, vacuum and discharge pressure)
Check cutter pressure
approximately 1500 psi
Check for vacuum
should be above water vacuum
Check for discharge pressure
above water base line
set auto flow control
normally at 19
based on pipe size, density of material, pipe length, distance
start starboard swing winch
adjust swing speed to maximize cutter pressure, swing pressure or vacuum
get to end of swing and change direction
adjust swing speed to maintain vacuum
this is a clean up pass
may return quicker than mining pass
continuously monitor instruments
get to the end of swing and stop
advance a few feet or lower ladder
refer to mine plan
repeat cycle
Inspect oil filter bypass gages
Filtration return filter, ladder swing return filter, cutter return filter, cutter charge filter
maintain communications with plant personnel
Lack of communication is a factor in a large number of injuries and fatalities
monitor plant computer (CSR)
monitor production rate/flow
Monitor TOTAL TONS PER HOUR
Monitor concrete sand: tons per hour
Monitor mason sand: tons per hour
Monitor specialized sand: tons per hour
monitor for proper operation of tanks
clean cutter head as needed
a rise in vacuum without a rise in production would indicate a plugging condition (suction mouth)
use jet pump only when needed for the following conditions:
if you cannot maintain maximum vacuum
to help clean cutter
use water cannon on deck to cut the bank above water
Never operate if not needed (conserve energy costs)
water direction must be manually selected with switch on dash
3. 5. Dredge Shutdown
Swing dredge to port side of cut
raise ladder to fresh water
pump water to clear materials from pipeline (approximately 15 minutes)
Observe instruments for return to baseline readings
flow, vacuum and discharge pressure
notify plant operator dredge is shutting down
throttle down underwater pump to zero
disable underwater pump
Shut cutter direction off
shut jet pump down
raise ladder to safety chain
tighten up swing cables
shut down system hydraulics
shut cutter hydraulic pump down
shut oil cooling pump off
turn off controls
log off of plant computer
Install window guards
Make necessary entries in diary/log
allow service water pump to continue operating
pump is left running to allow flushing of vacuum, depth and discharge sensors
Exit operators compartment
Wear life jacket and hard hat
4. 6. End of shift Activities
Begin on starboard side
Check for slip/trip hazards
Check for icing in the winter months (use calcium/propane torch if necessary)
Check all handrails
loose cables
broken, bent uprights
openings are chained off
toe boards in place
Check service water pump and jet pump
packing
suction
physical damage
U-bolts along the ladder
Check electrical room
Check air conditioning/heating system
Check static oil tanks
look at oil canisters mounted on ladder
oil levels
color of oil
Check hydraulic room
check for hydraulic leaks
check hydraulic oil levels
Use site glass
look for oil level between high and low marks
Add oil if needed
ISO 32 OR ISO 45 AS NEEDED
check filter indicator
should be in the green with unit not running
drain water from air compressor tank
visually examine pump motors for damage, missing bolts
visually inspect hydraulic hoses, valves
Obtain grease gun
grease trunion pins (starboard and port)
check keeper bolt
grease packing gland and two bearings on service water pump
grease two bearings on jet pump
Check stern winch
Check for leaks
Check wire rope for bird nesting
Check winch mounting nuts/bolts
If loose, re-tighten or replace with Grade 5 or better nuts/bolts
Check and grease fair leads
inspect port side deck
Check all handrails
loose cables
broken, bent uprights
openings are chained off
toe boards in place
Check for slip/trip hazards
grease upper ladder hoist sheave
climb steps to ladder at bow of dredge
Use 3-point contact
travel down port side of ladder to cutter
Use 3-point contact
check oil lines for leaks
check water lines for leaks and bulges
check swing cables for broken wires and flattening
check for missing/loose nuts/bolts
check suction pipe for physical damage, nuts/bolts in place
check port-side swing block for wear
grease port side swing block
Grease lower travel sheave block
check cutter gear for leaks, loose/missing bolts
check cutter tubes for leaks, loose/missing bolts
travel back up starboard side of ladder
Use 3-point contact
check starboard swing block for wear
grease starboard swing block
check starboard swing cable for broken wires, flattening
Check suction pipe for physical damage, nuts/bolts in place
inspect bolts on maximizer (loose, missing)
Check lift chains and lifting eyes on hoist block (upper and lower)
check sheaves for wear
check for loose/bent connectors
Check ladder winch
Check for leaks
Check wire rope
Check winch mounting nuts/bolts
If loose, re-tighten or replace with Grade 5 or better nuts/bolts
Check shackle dead end of cable
check pin tightness/beckett
Ensure clean out lid is in place and tight on suction side of dredge pump
examine vacuum sensors for physical damage
flush vacuum and depth sensors
open both valves
ensure both valves are closed after flushing sensors
examine underwater pump
check for missing nuts/bolts
check for oil leaks
shaft seals
hose
drain plug
check for holes in pump shell
check pump packing and adjust if necessary
Check 90-degree elbow for wear/holes
Check the spool piece behind the 90-degree elbow for wear/holes
examine torque tubes
check shim packs
check taper locks
check for paint wear
check for water leaks and cracks
check intermediate bearings and seals
examine swing cable fair leads (port and starboard side)
check for wear
check for rotation
grease swing cable fair leads until you have a show of grease
Examine discharge pipe along the ladder
Check for wear
Check for leaks
Check for clamp bolts
Examine swing winches
Check for leaks
Check wire rope for bird nesting
Check winch mounting nuts/bolts
If loose, re-tighten or replace with Grade 5 or better nuts/bolts
Check Lufkin gear box
Check for leaks
Check coupling
Check oil level
oil should be visible in site glass
Should look like oil - not milk (milky color indicates water in oil)
Check mounting nuts/bolts
Check manual temperature gage
Check pressure gage
should be at zero
Check wiring on electronic temperature gage
Check dc drive motor
check mounting nuts/bolts
If loose, re-tighten or replace with Grade 5 or better nuts/bolts
check temperature
should be warm at all times
check bolts in coupling between gear box and motor
check for unusual odors (burnt smell)
Check dc blower motor
check mounting nuts/bolts
If loose, re-tighten or replace with Grade 5 or better nuts/bolts
Complete "dredge daily lubrication and maintenance report
fill out log book/diary for shift
shut service pump off
close all windows
lock all doors
Board the boat
no smoking on the boat
use 3-point contact
pump off rain water
ensure oar/paddle is on boat
check fire extinguisher
when using small boat, return fire extinguisher to locker
5. 7. Non-Routine Activities, Emergency/Unusual Situations
Maintain communications with plant personnel (follow posted instructions for contacting company personnel and regulatory agencies)
Be prepared to provide information such as who is injured, location of victim, hazards in the area, extent of injuries (provide location if call is placed to 911 from dredge phone, plant phone or cell)
NOTE: 2nd work boat to be used as a rescue vehicle if necessary
Medical and fire emergencies
Call 911
Be prepared to provide information such as who is injured, location of victim, hazards in the area, extent of injuries (provide location if call is placed to 911 from dredge phone, plant phone or cell)
NOTE: 2nd work boat to be used as a rescue vehicle if necessary
Location of first aid supplies
Located on dredge in the electrical room, at plants, office
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Weather conditions
Lightening
Run material at a lighter load
Stay in the operator's cab
Shut down when/if instructed
Snow/icing
Wear PPE
Maintain 3-point contact
Clear decks
Man overboard
Know the location of the life preserver
Throw the preserver to the victim
Plugged discharge line (when in full production load)
Caused by sloughing of material, cave-in
Raise ladder up to pump fresh water
These steps will unplug the discharge 90% of the time
Speed dredge pump up to maximum rpm's
Open up maximizer valve
Observe instruments (discharge pressure, vacuum gage, and flow rate)
Feel for cavitations
Look for drop in tail line pressure
Look for increase in flow rate
Contact supervisor if plugged line persists
Plugged discharge line (Power Failure or any interruption in the dredging process)
Could be a rupture in the pipe line
These steps will unplug the discharge 90% of the time
Wait for power to come back on
Restart dredge
Rise ladder to fresh water
Slowly increase underwater pump rpm
Maintain a lower rpm
Maintain discharge pressure at 30 psi
Check flow gage for increase
If you observe an increase in flow gage, bring rpm's up slowly to increase pressure/flow
Repeat until line is clear
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Sand Dredge Operator (Spider No. 2)
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