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Plant Maintenance Conveyor Belt Change-out

Plant Maintenance Conveyor Belt Change-out
Start of Shift (Pre-Plan) Activities Perform the Job Clean-up End of Shift
1. Start of Shift (Pre-Plan) Activities
Check in (Time Clock)
Put on work clothes
Steel tip shoes Priority 2
Must be minimum 6" boot
Report to lunch room
Receive job assignment from supervisor
Obtain work order
Work order number for time card and for charge card
Equipment number
Work order description
Who originated the work order
Discuss special instructions as needed Priority 2
Discuss safety issues of job Priority 2
Inquire if job area has been cleaned
Walk to shop
Watch for traffic
Watch for wet/icy surfaces Priority 2
Obtain PPE located in shop Priority 2
Get hard hat Priority 2
Get hearing protection
Ear plugs
Get gloves
Get respiratory protection
Get safety glasses Priority 2
Get safety locks Priority 3
Receive further job instructions from lead person (Clip process/Vulcanizing process)
Assign mobile equipment
Pre-shift inspection
Show Pre-Operational power point presentations
Repair truck
Obtain materials and parts Priority 2
Complete charge out slips
Turn charge slips into store house
Use forklift to remove conveyor belt (24") from storage area
Prefer using forklift
Get belt clips (190 type clips)
Explain why this size/type of clip is used
Get belt tape
Obtain tools Priority 2
Minimum of 3 plant radios required
Two belt clamps/blocks
24 inch, 190 template
Framing square
Four come-a-longs
One chain wrench (3 ton)
Two 5/8-inch x 4 ft. slings
Two chains (3/4 inch)
Two 1/2-inch drive electric impact wrenches
#1 belt punch
#1 nut driver
Two stud breaker bars
One 4 1/2-inch electric grinder
Face shield
One claw hammer
Two utility knives with spare blade
Combination wrench set
Socket Set (1/2-inch drive)
Light cord with gfci
Shaft and bearing assembly
Two clevises
Two 5/16 chains
1/2-inch cable (min. 25 ft.)
Six 1/2-inch cable clamps
Danger tape
Torch and burning goggles
Belt clevises
Two 2" x 12" x 36" boards/planks
One spool 3/4" hemp rope
Punch quick connect for impact wrench
Tool bag
Each person is responsible for their own tool bag
Call Central Control Priority 3
Review company policy
Report names
Report clock numbers
Report equipment I.D. being worked on Priority 2
Report what job description
Have control room place crt. #1, belt #1 and #2 in the "jog" mode
Perform mobile equipment pre-shift inspection Priority 2
Fill out pre-shift inspection check list
Report or correct any problems Priority 2
Refuel equipment as needed
Discuss HazCom regulations
Load materials and tools onto truck
Load belt onto forklift or gradall Priority 2
Discuss qualifications to operate equipment
Proceed to job site
Observe speed limit
Watch for foot traffic
Watch for equipment right-of-way Priority 2
Stay 40 feet from mobile equipment while walking
Beware of restricted areas
2. Perform the Job
Arrive at job site
Observe work area upon approach
Park truck in safe area
Chock wheels
Perform work place examination
Correct or report safety defects Priority 2
Verify that crew is at correct belt by visual observation
Lock equipment out Priority 3
Each individual applies his/her own locks
Review company lock out policy
Apply locks on crt. #1 belt #1
Try to jog belt #1 to make sure belt will not start
Apply locks on crt. #1 belt #2 Priority 3
Try to jog belt #2 to make sure belt will not start
Unload tools at tail pulley at belt #2 Priority 2
All tools except 3-ton chain wrench and 3/4" chain
Bring adjustable wrenches
Remove wheel chocks and drive to head pulley area
Park truck and chock wheels
Unload tools at gravity take-up
Remove the gravity take-up guards Priority 2
Install the chain on beam above the center line of the gravity take-up weight
Connect 3-ton chain wrench to the chain Priority 2
Verify safety latches on hooks
Weight limitations in effect
Connect the chain wrench lifting hook into the gravity weight take-up lug
Verify safety latches on hooks
Lift the gravity take-up into the halfway position using the 3-ton chain wrench Priority 2
Explain this procedure
Close the gravity take-up guards
Back off tension on belt scrapers
Remove chocks and drive back to tail pulley
Park truck and chock wheels
Use forklift/gradall to put belt into position at tail pulley area for installation
Install shaft/bearing assembly into the core of the new belt
Verify belt is not hung backward
Install the two 5/16" chains to the overhead beams
Minimum 5/16"
Watch your loading capacity
Hook one come-a-long to each chain
Close safety latches on hooks
Install one clevis to each bearing
Connect each come-a-long lifting hook to each clevises
Close safety latches on hooks
Use come-a-long to lift new belt about 6 inches off floor
Remove guards from tail pulley area
Remove skirting from tail chute
Install belt clamp at Grimmies bridge
Explain that hemp rope can be used here. Do not use rope on incline belt
Remove belt covers, if necessary
Connect two come-a-longs to the belt clamp
Close safety latches on hooks
Install two cables around the next set of idlers
Connect come-a-longs into the two cables
Close safety latches on hooks
Explain when necessary why chains are used instead of cables
Tension the come-a-longs
Install the plank underneath the bottom of the top belt
Set the framing square on the belt top cover and square it with the belt above the plank
Use the utility knife to cut the belt using the framing square as your guide cutting away from your body
Pull the non-clamp belt end through the tail pulley
Cut bands on new belt
Stay clear - explain danger of release energy
Pull and feed the new belt end over the tail pulley and through the wall to the old belt end
Square the new belt end up to the old belt end
Install planks under both belt ends
Using the top part of belt clip, mark six sets of holes evenly spaced across belt ends
Use the electric impact wrench with a #1 punch and quick connector to punch holes into the belt ends
Install clips through bottom side of belt ends through the punch holes
Install top of belt clips and nuts
Tighten each nut using the impact wrench and nut driver
Make sure clip ends are countersunk in top cover of belt ends
Use breaker bars to break stud from all six clips
Remove come-a-longs, belt clamp, planks, and both cables
Install belt clevis on old return end of belt using 1/2" bolts
Holes must be punched prior to attaching the clevis
Tighten the bolts on belt clevis
Install one end of the 25' cable through the belt clevis cable
Use three 1/2" cable clamps to fasten a loop around the belt clevis cable
Explain properly installed clamps
Danger tape all affected areas
Contact pay loader operator using plant radio
Make a loop in the cable fastening with three 1/2" cable clamps
Reinforce cable clamps proper installation/configuration
Connect the loop of the cable to pay loader's hitch pin
All personnel must remove locks from belt #2
Verify that radios are working properly
Spot personnel to the proper location all with radio using Channel 3
Still need to have people (possibly more people) to communicate without radios
Assign one to tail pulley
Assign one head pulley
Assign one with splice
Assign one outside with pay loader
Verify communication with each person Priority 2
Put the disconnect switch into "On" position
Stand to the side of the disconnect switch throwing switch while facing away from it
Verify that safety lanyard is operating by using "jog"
Explain safety switch procedure
Reset safety lanyard
Call to make sure that all personnel are clear and ready to pull belt Priority 2
Explain procedure of removing old belt
Begin "pulling" belt using radio communication between "jogging" and "pulling" with pay loader
Continue the "pulling" process until the new belt is all the way around
Lock #2 belt out Priority 2
All personnel install their locks
Disconnect the cable from the pay loader's hitch pin
Release pay loader operator
Disconnect cable and belt clevis from belt
Place cable and belt clevis on truck
Cut the old belt from the new belt
Feed new belt through tail pulley to other end of new belt
Install one belt clamp on each end of belt
Explain this process on distances between belt clamps
Install come-a-longs to belt clamps
Close safety latches on hooks
Use come-a-longs to remove belt slack
Place plank under the top belt
Square belt ends
Explain this procedure
Nail one end of belt to the plank
Install splicing template
Explain this procedure
Install holes in belt through template
Explain this procedure
Remove template from belt
Put clips into one end of belt
Follow manufacturer's procedures
Turn template upside down and slide onto bolt of clips to line up with holes
Take other end of belt and install clips into holes
Install top half of clips with nuts (hand tight)
Install belt tape to seal the joint
Ensure splice is square
Tighten all nuts on clips with impact wrench
Explain the procedure
Use breaker bars to break off all clip bolts
Grind the clips with a 4 1/2" disc grinder
Must wear full face shield
Grind bolts flush with nuts
Remove nail from belt
Remove planks from belt
Remove the belt blocks and come-a-longs
Install skirting and guards on tail pulley Priority 2
Reinstall all belt covers
Go to the drive end of belt and lower gravity take-up
Remove chains and chain wrench
Install guards at gravity take-up Priority 2
Re-tension belt scrapers
Explain this procedure
Remove all locks
Belt #1
Belt #2
Put disconnect switch to the "On" position
Stand to the side of the disconnect switch throwing switch while facing away from it
"Jog" and "train" belt
Check and replace all bad idlers, as needed
Lock belt out before any idler replacement is started
Release system to Central Control
3. Clean-up
Gather all tools up and load them on the truck
If torches were used, gases must be bled Priority 2
Show video
Before moving truck, ensure chocks are removed
Pick up all debris
Clean up old belt
Roll up and move with gradall/forklift
Clean up, remove new belt on roll, and return to belt storage location
Remove danger tape
Perform workplace inspection
Correct any deficiencies Priority 2
Ensure all locks are off
Ensure all disconnects/lanyards have been place in the "on" position
Call Central Control
Report names
Report numbers
Report equipment I.D.
Verify "ready" light
Return to shop
Park truck in front of shop
Chock truck wheels
Remove debris from truck and place into proper containers
Unload tools/equipment from truck
Visual inspection of your tools
Replace/repair damaged tools
Store tools in proper location
Remove chocks from wheels
Drive truck to wash rack
Clean truck
Blow off/high pressure wash
Drive truck back to shop
Chock wheels
Ensure personal and company tool boxes are locked
4. End of Shift
Ensure that all parts have been charged out and slips turned in
Fill out work order and explain the work performed
Fill out time card
Place all paperwork into box in front of shop
Notify supervisor of job completion
Root cause analysis meeting
Hold job critique meeting
Improve job efficiency
Improve job safety
Abnormal conditions dictate discussions
Shower up
Check out