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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 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 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 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 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 Untitled 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