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Tower cleaning (Cardox)

Tower cleaning (Cardox)
Plugged Tower Preparation Work Cleanup Execute
1. Plugged Tower
These are actions that must be done in addition to established procedures for cleaning tower.
Extreme hot flame and materials and other hazardous conditions exist.
Chain off all tower access points
Assemble crew
Control room activates kiln discharge end warning lights
Potential harzard exists of hot material being flushed out.
Assign task
All crew members must maintain radio contact at all times, and keep each other informed of possible hazards, and of their location.
Raise elevator and lock-out
All workers donn "hot suits"
Remove tires from fourth floor tire conveyor belt.
Contact control for "by-pass" on tire belt and doors
Start conveyor belt to prevent it from burning .
Assure both doors on tire chute are closed
Inspect calciner and feed pipe for plugged location
Start unplugging process
Unplugging process may consist of "water laser", "air lance", or "Cardox", in extreme conditions.
Take down barrier chains at all access areas
2. Preparation Work
Ensure all safety precautions are met
Ensure strobe lights are on.
Discharge and shut off air cannons.
Donn necessary PPE, (drillers and installers) FR, hood with face shields. Hats, coats and gloves. Hearing protection
Must be a minimum of two persons present before opening port.
Perform area workplace examination.
No one is to enter the area without getting permission from the shift supervisor.
Identifty ports to be shot
Explain buildup identification process/procedure.
Call Supervisor
Supervisor unlocks generator magazine and inventories generator usage upon completion, and re- locks magazine upon completion.
3. Cleanup
Turn off warning light switch when shooting is completed
Loosen splindle valve while still in assembly stand
Remove both heads at each ends
Remove generator
Spent generator goes into trash
Misfire generator goes into kiln
Place tube in vertical position
Clean tube with bore brush and blow out with compressed air.
Place tube back in storage rack
Clean detonator head with wire wheel
Shut off CO2 bottle, install safety cap
Turn air cannons back on and fire
Return all equipment to proper storage areas.
4. Execute
Remove cap
Obtain drill
Pneumatic drills and hoses are located on each level (3rd, 3 1/2, and 4th. floors) on retractable hose reels.
Make certain that hoses do not become a tripping hazard and all connections are pinned to prevent whipping action.
Make certain drilling depth is a minumum of 17-inches.
Ascertain that drilling procedure is as straight as possible, ( tube will not lock in collar if not properly aligned).
Use extreme caution in blow back mode when clearing hole. (Extremely hot material may be present).
Retract drill
Load tube
Tube loading will be done concurrently by other crew member per JBC training.
Show JBC video.
Go into Cardox room, turn on CO2 bottle
Visually examine Cardox tube
Make sure mating surfaces are clean and true.
Install tube in assembly stand
Install copper gasket and shear discs, and then select appropiate discharge head
Rounded edge of shear disc should be against copper gasket.
Install generator and detonation head on other end
Generator end of tube is chromed polished end.
Use Impact wrench on both ends to tighten with three short bursts
Check continuity with Ohm meter to ensure good connection (low resistance)
Zero to three ohms is good.
Three to five marginal.
Above five not acceptable.
Install tube into fill station
Open spindle valve three-quarters turn
Open CO2 fill station valve
Open air pump ball valve.
Pump cycles until it almost stalls
Close spindle valve ( hand tight)
Shut pump hand valve and CO2 hand valve off.
Open bleed-off valve ( bleeds off bottle pressure in lines).
Carry tube to collar stand on proper floor.
Install locking collar and safety cap and chain on tube
Wrench tighten
Lay out detonation wire and shunt
Shunt wires at detonation end 
Secure tube in port to be shot
Turn clockwise one-quarter turn until stops
Insert wires (probes) into tube
Un-shunt detonation wire and check continuity
Be sure to use permissible blasters ohmmeter (yellow or orange in color)
Clear entire blast area
Connect wires to detonator
One crew member sounds alarm
Radio transmission (fire in the hole)
Initiate firing sequence
Charge detonator
Hold button until green light appears.
Press detonate button immediately after warning alarm stops.
Do not remove tube at this time
Disconnect and shunt wires
Slowly open spindle valve to bleed off pressure while tube is still locked into vessel.
Tube is still under full pressure.
Remove wires from detonator
Remove tube with locking collar still attached
Handle with extreme caution as tube will be hot.
Re-install cap on port
Remove locking collar
Return tube to Cardox room
Put tube back in assembly stand