+-----------------------------------+----------------------------------+
| **Company Name:**                 | **Equipment/Job Identification:  |
|                                   | Roller Mill Tire Change**        |
|                                   |                                  |
|                                   | **Type of Equipment: Roller      |
|                                   | Mill**                           |
|                                   |                                  |
|                                   | **Make: Raymond**                |
|                                   |                                  |
|                                   | **Model:**                       |
|                                   |                                  |
|                                   | **Year:**                        |
|                                   |                                  |
|                                   | **Use:**                         |
+-----------------------------------+----------------------------------+
| **Mine Name:**                    |                                  |
+-----------------------------------+----------------------------------+
| **Date of Analysis:**             |                                  |
+-----------------------------------+----------------------------------+

# Duty 1: Planning

Objective: The learner will explain the importance of the planning
meeting in determining work to be accomplished. The learner will explain
and interpret information received in the planning meeting to the
trainer. The learner will explain each job step, why it is conducted,
any associated risk, and how to implement appropriate controls. Planning
activities include the following duties:

+--------------------+---+--------------+--------+-------+---------------+
| **Job Steps**      | * |              | **Impo | **Sa  | **Pr          |
|                    | * |              | rtance | tisfa | ocedures/Risk |
|                    | I |              | Ran    | ctory | Resolution/** |
|                    | m |              | king** | or**  |               |
|                    | p |              |        |       | **Not         |
|                    | o |              | **1    | **    | es/Comments** |
|                    | r |              | =Impor | Needs |               |
|                    | t |              | tant** | W     |               |
|                    | a |              |        | ork** |               |
|                    | n |              | **     |       |               |
|                    | c |              | 2=Very |       |               |
|                    | e |              | Impor  |       |               |
|                    | N |              | tant** |       |               |
|                    | a |              |        |       |               |
|                    | r |              | **     |       |               |
|                    | r |              | 3=Crit |       |               |
|                    | a |              | ical** |       |               |
|                    | t |              |        |       |               |
|                    | i |              |        |       |               |
|                    | v |              |        |       |               |
|                    | e |              |        |       |               |
|                    | * |              |        |       |               |
|                    | * |              |        |       |               |
|                    |   |              |        |       |               |
|                    | * |              |        |       |               |
|                    | * |              |        |       |               |
|                    | ( |              |        |       |               |
|                    | C |              |        |       |               |
|                    | o |              |        |       |               |
|                    | n |              |        |       |               |
|                    | s |              |        |       |               |
|                    | i |              |        |       |               |
|                    | d |              |        |       |               |
|                    | e |              |        |       |               |
|                    | r |              |        |       |               |
|                    | S |              |        |       |               |
|                    | a |              |        |       |               |
|                    | f |              |        |       |               |
|                    | e |              |        |       |               |
|                    | t |              |        |       |               |
|                    | y |              |        |       |               |
|                    | , |              |        |       |               |
|                    | P |              |        |       |               |
|                    | r |              |        |       |               |
|                    | o |              |        |       |               |
|                    | d |              |        |       |               |
|                    | u |              |        |       |               |
|                    | c |              |        |       |               |
|                    | t |              |        |       |               |
|                    | i |              |        |       |               |
|                    | o |              |        |       |               |
|                    | n |              |        |       |               |
|                    | , |              |        |       |               |
|                    | M |              |        |       |               |
|                    | a |              |        |       |               |
|                    | i |              |        |       |               |
|                    | n |              |        |       |               |
|                    | t |              |        |       |               |
|                    | e |              |        |       |               |
|                    | n |              |        |       |               |
|                    | a |              |        |       |               |
|                    | n |              |        |       |               |
|                    | c |              |        |       |               |
|                    | e |              |        |       |               |
|                    | ) |              |        |       |               |
|                    | * |              |        |       |               |
|                    | * |              |        |       |               |
+====================+===+==============+========+=======+===============+
| Planning Meeting   |   |              |        |       |               |
+--------------------+---+--------------+--------+-------+---------------+
| ##                 |   |              |        |       | Critical to   |
|  Weekly Inspection |   |              |        |       | production    |
|                    |   |              |        |       | loss          |
+--------------------+---+--------------+--------+-------+---------------+
| -   Wear           |   |              |        |       |               |
|     Measurement    |   |              |        |       |               |
|     (Maintenance   |   |              |        |       |               |
|     Engineer)      |   |              |        |       |               |
+--------------------+---+--------------+--------+-------+---------------+
| a.  Follow Mill    |   |              |        |       | Review        |
|     lock-out       |   |              |        |       | company       |
|     procedure      |   |              |        |       | lock-out      |
|                    |   |              |        |       | procedures.   |
+--------------------+---+--------------+--------+-------+---------------+
| b.  Use pin        |   |              |        |       |               |
|     measurement    |   |              |        |       |               |
|     template       |   |              |        |       |               |
+--------------------+---+--------------+--------+-------+---------------+
| c.  Check data to  |   |              |        |       |               |
|     make sure      |   |              |        |       |               |
|                    |   |              |        |       |               |
| within constraints |   |              |        |       |               |
| (0-1 5/8" wear)    |   |              |        |       |               |
+--------------------+---+--------------+--------+-------+---------------+
| d)  Locks out      |   |              |        |       |               |
|     hydraulic      |   |              |        |       |               |
|     system for     |   |              |        |       |               |
|                    |   |              |        |       |               |
| > roller mill      |   |              |        |       |               |
+--------------------+---+--------------+--------+-------+---------------+
| -   Supervisor     |   |              |        |       | Explain       |
|     goes to 5^th^  |   |              |        |       | temperature   |
|     floor of       |   |              |        |       | hazards       |
|     preheat tower  |   |              |        |       |               |
|     to locally     |   |              |        |       |               |
|     closes off     |   |              |        |       |               |
|     guillotine     |   |              |        |       |               |
|     gate S-252     |   |              |        |       |               |
+--------------------+---+--------------+--------+-------+---------------+
| -   Supervisor     |   |              |        |       |               |
|     returns to     |   |              |        |       |               |
|     first floor of |   |              |        |       |               |
|     preheat tower  |   |              |        |       |               |
|     MCC, pulls     |   |              |        |       |               |
|     breaker, and   |   |              |        |       |               |
|     locks out      |   |              |        |       |               |
|     S-252          |   |              |        |       |               |
+--------------------+---+--------------+--------+-------+---------------+
| -   Supervisor     |   |              |        |       |               |
|     then goes to   |   |              |        |       |               |
|     second level   |   |              |        |       |               |
|     of pre-heat    |   |              |        |       |               |
|     tower MCC      |   |              |        |       |               |
+--------------------+---+--------------+--------+-------+---------------+
| a)  Goes to mill   |   |              |        |       | Review        |
|     motor switch   |   |              |        |       | company       |
|     gear           |   |              |        |       | lock-out      |
|                    |   |              |        |       | procedures    |
| > 1\) Verify with  |   |              |        |       |               |
| > ammeter that     |   |              |        |       |               |
| > motor is not     |   |              |        |       |               |
| > energized        |   |              |        |       |               |
| >                  |   |              |        |       |               |
| > 2\) Trips mill   |   |              |        |       |               |
| > drive motor      |   |              |        |       |               |
| > starter          |   |              |        |       |               |
| >                  |   |              |        |       |               |
| > 3\) Pull handle  |   |              |        |       |               |
| > of breaker to    |   |              |        |       |               |
| > off position     |   |              |        |       |               |
| >                  |   |              |        |       |               |
| > 4\) Installs MCC |   |              |        |       |               |
| > lock             |   |              |        |       |               |
+--------------------+---+--------------+--------+-------+---------------+
| b)  Goes to Roller |   |              |        |       | Review        |
|     Mill ID fan    |   |              |        |       | company       |
|                    |   |              |        |       | policies and  |
| > 1\) Verify that  |   |              |        |       | procedures    |
| > ammeter is at    |   |              |        |       |               |
| > zero             |   |              |        |       |               |
| >                  |   |              |        |       |               |
| > 2\) Trips ID fan |   |              |        |       |               |
| > motor starter    |   |              |        |       |               |
| >                  |   |              |        |       |               |
| > 3\) Pull handle  |   |              |        |       |               |
| > of breaker to    |   |              |        |       |               |
| > off position     |   |              |        |       |               |
| >                  |   |              |        |       |               |
| > 4\) Installs MCC |   |              |        |       |               |
| > lock             |   |              |        |       |               |
+--------------------+---+--------------+--------+-------+---------------+
| c)  Store the      |   |              |        |       | Review        |
|     lock-out keys  |   |              |        |       | company       |
|     in lock-out    |   |              |        |       | policies and  |
|                    |   |              |        |       | procedures    |
| > box              |   |              |        |       |               |
| >                  |   |              |        |       |               |
| > 1\) Locks out    |   |              |        |       |               |
| > lock-out box     |   |              |        |       |               |
+--------------------+---+--------------+--------+-------+---------------+
| d\) Supervisor     |   |              |        |       | This is done  |
| calls control room |   |              |        |       | to check that |
| for a              |   |              |        |       | the right     |
|                    |   |              |        |       | equipment has |
| bump start         |   |              |        |       | been          |
|                    |   |              |        |       | locked-out.   |
| 1\) Supervisor     |   |              |        |       |               |
| fills out S-230    |   |              |        |       |               |
|                    |   |              |        |       |               |
| lockout procedure  |   |              |        |       |               |
| form               |   |              |        |       |               |
+--------------------+---+--------------+--------+-------+---------------+
| -   Crew members   |   |              |        |       | Review lock   |
|     install        |   |              |        |       | out           |
|     personal locks |   |              |        |       | procedures    |
+--------------------+---+--------------+--------+-------+---------------+
| **Crew members do  |   |              |        |       | Address any   |
| pre-job safety     |   |              |        |       | potential     |
| inspection**       |   |              |        |       | hazards       |
|                    |   |              |        |       | observed      |
|                    |   |              |        |       | prior to      |
|                    |   |              |        |       | starting      |
|                    |   |              |        |       | work.         |
+--------------------+---+--------------+--------+-------+---------------+
| -   Fill out daily |   |              |        |       |               |
|     job site       |   |              |        |       |               |
|     inspection     |   |              |        |       |               |
|     form           |   |              |        |       |               |
+--------------------+---+--------------+--------+-------+---------------+
| **Open journal     |   |              |        |       |               |
| door**             |   |              |        |       |               |
+--------------------+---+--------------+--------+-------+---------------+
| -   Properly place |   |              |        |       | Discuss three |
|     8-foot ladder  |   |              |        |       | points of     |
|                    |   |              |        |       | contact.      |
|                    |   |              |        |       |               |
|                    |   |              |        |       | Show ladder   |
|                    |   |              |        |       | safety video  |
+--------------------+---+--------------+--------+-------+---------------+
| -   Workers put on |   |              |        |       | Review        |
|     fall           |   |              |        |       | company       |
|     protection     |   |              |        |       | policy        |
+--------------------+---+--------------+--------+-------+---------------+
| -   Loosen nuts    |   |              |        |       | Once          |
|     with ¾ inch    |   |              |        |       | harnessed in  |
|     impact wrench  |   |              |        |       | place         |
|     (top and sides |   |              |        |       | instruct      |
|     of door)       |   |              |        |       | co-worker to  |
|                    |   |              |        |       | hand 3/4 inch |
|                    |   |              |        |       | impact wrench |
|                    |   |              |        |       | up to         |
|                    |   |              |        |       | co-worker.    |
|                    |   |              |        |       |               |
|                    |   |              |        |       | Turn latches  |
|                    |   |              |        |       | 90 degrees.   |
|                    |   |              |        |       |               |
|                    |   |              |        |       | Lower impact  |
|                    |   |              |        |       | wrench to     |
|                    |   |              |        |       | co-worker.    |
|                    |   |              |        |       |               |
|                    |   |              |        |       | Descend and   |
|                    |   |              |        |       | remove ladder |
|                    |   |              |        |       | from working  |
|                    |   |              |        |       | area.         |
+--------------------+---+--------------+--------+-------+---------------+
| -   Remove         |   |              |        |       | Thermocouple  |
|     thermocouple   |   |              |        |       | should        |
|     from journal   |   |              |        |       | normally only |
|     bearing        |   |              |        |       | be hand       |
|                    |   |              |        |       | tightened     |
+--------------------+---+--------------+--------+-------+---------------+
| -   Attach safety  |   |              |        |       |               |
|     removal tabs   |   |              |        |       |               |
|     on door to     |   |              |        |       |               |
|     journal yoke   |   |              |        |       |               |
+--------------------+---+--------------+--------+-------+---------------+
| -   Loosen nuts on |   |              |        |       |               |
|     lower edge of  |   |              |        |       |               |
|     door           |   |              |        |       |               |
+--------------------+---+--------------+--------+-------+---------------+
| -   Use hoist to   |   |              |        |       |               |
|     remove walkway |   |              |        |       |               |
|     & railing      |   |              |        |       |               |
|     beside         |   |              |        |       |               |
|     journals to    |   |              |        |       |               |
|     accommodate    |   |              |        |       |               |
|     journal yoke.  |   |              |        |       |               |
+--------------------+---+--------------+--------+-------+---------------+
| -   Install        |   |              |        |       |               |
|     temporary      |   |              |        |       |               |
|     railings       |   |              |        |       |               |
+--------------------+---+--------------+--------+-------+---------------+
| -   Attach         |   |              |        |       | One hoist     |
|     clevises on    |   |              |        |       | attached      |
|     15-ton         |   |              |        |       | approximately |
|     monorail       |   |              |        |       | 20 degree     |
|     hoists to      |   |              |        |       | from          |
|     picking eyes   |   |              |        |       | vertical.     |
|     on yoke        |   |              |        |       |               |
|     assembly       |   |              |        |       | One hoist     |
|                    |   |              |        |       | attached      |
|                    |   |              |        |       | vertical.     |
|                    |   |              |        |       |               |
|                    |   |              |        |       | Monitor       |
|                    |   |              |        |       | cables for    |
|                    |   |              |        |       | proper        |
|                    |   |              |        |       | tension.      |
+--------------------+---+--------------+--------+-------+---------------+
| -   Attach ½-inch  |   |              |        |       | Attach        |
|     choker and     |   |              |        |       | connecting    |
|     come-a-longs   |   |              |        |       | rods to yoke  |
|     to hydraulic   |   |              |        |       | assembly      |
|     cylinder       |   |              |        |       |               |
|     connecting     |   |              |        |       |               |
|     rods.          |   |              |        |       |               |
+--------------------+---+--------------+--------+-------+---------------+
| -   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,   |   |              |        |       | Utilize       |
|     (north and     |   |              |        |       | hoist,        |
|     south)         |   |              |        |       | come-a-long,  |
|                    |   |              |        |       | 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 it 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  |   |              |        |       |               |
|     come-a-longs   |   |              |        |       |               |
|     already in     |   |              |        |       |               |
|     place.         |   |              |        |       |               |
+--------------------+---+--------------+--------+-------+---------------+
| -   Position one   |   |              |        |       | Maintain eye  |
|     mechanic on    |   |              |        |       | contact to    |
|     the north      |   |              |        |       | ensure        |
|     hoist pendant  |   |              |        |       | consistent    |
|     and one on the |   |              |        |       | and safe      |
|     south hoist    |   |              |        |       | lifting.      |
|     pendant.       |   |              |        |       |               |
+--------------------+---+--------------+--------+-------+---------------+
| -   The mechanic   |   |              |        |       | .             |
|     on the 20      |   |              |        |       |               |
|     degrees off    |   |              |        |       | .             |
|     vertical hoist |   |              |        |       |               |
|     begins lifting |   |              |        |       |               |
|     while other    |   |              |        |       |               |
|     mechanic       |   |              |        |       |               |
|     maintains      |   |              |        |       |               |
|     proper tension |   |              |        |       |               |
|     on other line. |   |              |        |       |               |
+--------------------+---+--------------+--------+-------+---------------+
| -   When the 20    |   |              |        |       | Ensure there  |
|     degree offset  |   |              |        |       | is tension on |
|     line becomes   |   |              |        |       | the line when |
|     vertical, it   |   |              |        |       | at stops      |
|     maintains      |   |              |        |       |               |
|     tension while  |   |              |        |       |               |
|     the other      |   |              |        |       |               |
|     hoist lowers   |   |              |        |       |               |
|     the journal to |   |              |        |       |               |
|     the I-Beam     |   |              |        |       |               |
|     stops below    |   |              |        |       |               |
|     the removed    |   |              |        |       |               |
|     grating        |   |              |        |       |               |
+--------------------+---+--------------+--------+-------+---------------+
| **Tire Removal     |   |              |        |       |               |
| (Top)**            |   |              |        |       |               |
+--------------------+---+--------------+--------+-------+---------------+
| -   Position the   |   |              |        |       | Review        |
|     8' extension   |   |              |        |       | company       |
|     ladder over    |   |              |        |       | policies      |
|     journal,       |   |              |        |       |               |
|     ascend ladder  |   |              |        |       |               |
|     and attach to  |   |              |        |       |               |
|     retractable    |   |              |        |       |               |
|     fall           |   |              |        |       |               |
|     protection     |   |              |        |       |               |
+--------------------+---+--------------+--------+-------+---------------+
| -   Co-worker      |   |              |        |       | Necessary to  |
|     hands air      |   |              |        |       | have face     |
|     lance to       |   |              |        |       | shield,       |
|     worker in      |   |              |        |       | goggles, dust |
|     upper position |   |              |        |       | mask, and     |
|                    |   |              |        |       | normal PPE.   |
+--------------------+---+--------------+--------+-------+---------------+
| -   Clean ring     |   |              |        |       | Fellow        |
|     retainer holes |   |              |        |       | workers       |
|     (approx. 20)   |   |              |        |       | should        |
|                    |   |              |        |       | evacuate      |
|                    |   |              |        |       | building      |
|                    |   |              |        |       | while air     |
|                    |   |              |        |       | lancing is    |
|                    |   |              |        |       | taking place. |
|                    |   |              |        |       | (To avoid     |
|                    |   |              |        |       | dust and      |
|                    |   |              |        |       | projectile    |
|                    |   |              |        |       | injury)       |
+--------------------+---+--------------+--------+-------+---------------+
| -   Get ¾" air     |   |              |        |       |               |
|     impact wrench  |   |              |        |       |               |
|     from co-worker |   |              |        |       |               |
|     and removes    |   |              |        |       |               |
|     the (20) ring  |   |              |        |       |               |
|     retainer       |   |              |        |       |               |
|     bolts.         |   |              |        |       |               |
+--------------------+---+--------------+--------+-------+---------------+
| -   Attach mobile  |   |              |        |       | Execute       |
|     crane to       |   |              |        |       | pre-shift     |
|     retainer ring  |   |              |        |       | inspection.   |
|                    |   |              |        |       |               |
| a)  Attach I-Bolts |   |              |        |       | Chokers must  |
|     180 degrees    |   |              |        |       | be minimum of |
|     apart through  |   |              |        |       | 6' in length  |
|     threaded       |   |              |        |       | and matching. |
|     picking holes  |   |              |        |       |               |
+--------------------+---+--------------+--------+-------+---------------+
| -   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       |   |              |        |       |               |
|                    |   |              |        |       |               |
| > a\) Signals      |   |              |        |       |               |
| > crane operator   |   |              |        |       |               |
| > to add light     |   |              |        |       |               |
| > tension to line. |   |              |        |       |               |
+--------------------+---+--------------+--------+-------+---------------+
| -   Position       |   |              |        |       | Apply tether  |
|     mechanics (2)  |   |              |        |       | lines to eye  |
|     on opposite    |   |              |        |       | holes prior   |
|     sides of       |   |              |        |       | to tapping to |
|     journal with 8 |   |              |        |       | maintain lift |
|     lb. sledge     |   |              |        |       | control of    |
|     hammers.       |   |              |        |       | ring.         |
|                    |   |              |        |       |               |
| > a\) Impact       |   |              |        |       | Worker should |
| > retainer ring    |   |              |        |       | maintain      |
| > with sledge      |   |              |        |       | tension on    |
| > hammers to       |   |              |        |       | the tether    |
| > loosen rig from  |   |              |        |       | line.         |
| > shoulder while   |   |              |        |       |               |
| > maintaining      |   |              |        |       |               |
| > tension          |   |              |        |       |               |
+--------------------+---+--------------+--------+-------+---------------+
| -   Lift ring with |   |              |        |       | Review        |
|     crane and      |   |              |        |       | company       |
|     position       |   |              |        |       | procedures    |
|     outside on     |   |              |        |       |               |
|     ground out of  |   |              |        |       | Place as      |
|     work area.     |   |              |        |       | determine     |
|                    |   |              |        |       | during crew   |
|                    |   |              |        |       | meeting       |
+--------------------+---+--------------+--------+-------+---------------+
| -   Close          |   |              |        |       | Review        |
|     handrails      |   |              |        |       | company       |
|                    |   |              |        |       | procedures    |
+--------------------+---+--------------+--------+-------+---------------+
| -   Detach crane   |   |              |        |       |               |
|     from ring.     |   |              |        |       |               |
+--------------------+---+--------------+--------+-------+---------------+
| -   Two mechanics  |   |              |        |       |               |
|     attach         |   |              |        |       |               |
|     spreader bar   |   |              |        |       |               |
|     to crane.      |   |              |        |       |               |
+--------------------+---+--------------+--------+-------+---------------+
| -   Two mechanics  |   |              |        |       | Ensure the    |
|     obtain ring of |   |              |        |       | ring of fire  |
|     fire           |   |              |        |       | is centered   |
|                    |   |              |        |       | on tire to    |
| > a\) Center ring  |   |              |        |       | optimize heat |
| > on tire and      |   |              |        |       | transfer.     |
| > attach propane   |   |              |        |       |               |
| > and air hoses to |   |              |        |       |               |
| > proper           |   |              |        |       |               |
| > connectors.      |   |              |        |       |               |
+--------------------+---+--------------+--------+-------+---------------+
| -   Mechanic       |   |              |        |       | Review        |
|     positions      |   |              |        |       | company       |
|     ladder to      |   |              |        |       | procedures    |
|     ascend onto    |   |              |        |       |               |
|     top of         |   |              |        |       |               |
|     journal, with  |   |              |        |       |               |
|     proper fall    |   |              |        |       |               |
|     protection to  |   |              |        |       |               |
|     attach         |   |              |        |       |               |
|     spreader bar.  |   |              |        |       |               |
+--------------------+---+--------------+--------+-------+---------------+
| -   Attach         |   |              |        |       | Ensure the    |
|     spreader bar   |   |              |        |       | spreader bar  |
|     to top tire    |   |              |        |       | is level for  |
|     via two        |   |              |        |       | equal pull    |
|     threaded holes |   |              |        |       | and maintain  |
|     on opposite    |   |              |        |       | a constant    |
|     sides.         |   |              |        |       | tension.      |
+--------------------+---+--------------+--------+-------+---------------+
| -   Mechanic       |   |              |        |       |               |
|     descends       |   |              |        |       |               |
|     ladder and     |   |              |        |       |               |
|     removes from   |   |              |        |       |               |
|     direct work    |   |              |        |       |               |
|     area.          |   |              |        |       |               |
+--------------------+---+--------------+--------+-------+---------------+
| -   Ignite ring of |   |              |        |       | Mechanic      |
|     fire.          |   |              |        |       | 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     |   |              |        |       | Use a heat    |
|     check          |   |              |        |       | pencil or     |
|                    |   |              |        |       | infrared      |
|                    |   |              |        |       | meter to      |
|                    |   |              |        |       | verify the    |
|                    |   |              |        |       | removal       |
|                    |   |              |        |       | temperature   |
|                    |   |              |        |       | is 250        |
|                    |   |              |        |       | degrees       |
|                    |   |              |        |       | Fahrenheit    |
|                    |   |              |        |       | (do not       |
|                    |   |              |        |       | exceed).      |
+--------------------+---+--------------+--------+-------+---------------+
| -   Lift tire      |   |              |        |       | Execute a     |
|                    |   |              |        |       | constant lift |
| > a\) Swing out    |   |              |        |       | when          |
| > handrails        |   |              |        |       | separation    |
|                    |   |              |        |       | begins to     |
| b)  Signal crane   |   |              |        |       | occur between |
|     operator to    |   |              |        |       | tires.        |
|     lift           |   |              |        |       |               |
|                    |   |              |        |       | Explain       |
| c)  Shut off       |   |              |        |       | hazards       |
|     propane/air    |   |              |        |       |               |
|     valves.        |   |              |        |       | Ensure all    |
|                    |   |              |        |       | workers are   |
| d)  Pivot arms on  |   |              |        |       | clear of the  |
|     ring of fire   |   |              |        |       | active crane  |
|     and lower      |   |              |        |       | radius        |
|                    |   |              |        |       |               |
| e)  Continue       |   |              |        |       | If tire is to |
|     lifting tire   |   |              |        |       | be discarded, |
|     off of journal |   |              |        |       | place on      |
|     and lower to   |   |              |        |       | pallet        |
|     ground         |   |              |        |       |               |
|     outside.       |   |              |        |       | If tire is to |
|                    |   |              |        |       | be            |
|                    |   |              |        |       | re-installed, |
|                    |   |              |        |       | place on      |
|                    |   |              |        |       | cribbing.     |
+--------------------+---+--------------+--------+-------+---------------+
| -   Detach         |   |              |        |       |               |
|     spreader bar   |   |              |        |       |               |
|     from removed   |   |              |        |       |               |
|     tire.          |   |              |        |       |               |
+--------------------+---+--------------+--------+-------+---------------+
| **Tire Removal     |   |              |        |       |               |
| (Bottom)**         |   |              |        |       |               |
+--------------------+---+--------------+--------+-------+---------------+
| -   Two mechanics  |   |              |        |       | Ensure the    |
|     center ring on |   |              |        |       | ring of fire  |
|     tire.          |   |              |        |       | is centered   |
|                    |   |              |        |       | on tire to    |
|                    |   |              |        |       | optimize heat |
|                    |   |              |        |       | transfer.     |
+--------------------+---+--------------+--------+-------+---------------+
| -   Attach         |   |              |        |       | Ensure the    |
|     spreader bar   |   |              |        |       | spreader bar  |
|     to bottom tire |   |              |        |       | is level for  |
|     via two        |   |              |        |       | equal pull    |
|     threaded holes |   |              |        |       | and maintain  |
|     on opposite    |   |              |        |       | a constant    |
|     sides.         |   |              |        |       | tension.      |
+--------------------+---+--------------+--------+-------+---------------+
| -   Ignite ring of |   |              |        |       | Mechanic      |
|     fire.          |   |              |        |       | 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     |   |              |        |       | Use a heat    |
|     check          |   |              |        |       | pencil or     |
|                    |   |              |        |       | infrared      |
|                    |   |              |        |       | meter to      |
|                    |   |              |        |       | verify the    |
|                    |   |              |        |       | removal       |
|                    |   |              |        |       | temperature   |
|                    |   |              |        |       | is 250        |
|                    |   |              |        |       | degrees       |
|                    |   |              |        |       | Fahrenheit    |
|                    |   |              |        |       | (do not       |
|                    |   |              |        |       | exceed).      |
+--------------------+---+--------------+--------+-------+---------------+
| -   Lift tire      |   |              |        |       | Execute a     |
|                    |   |              |        |       | constant lift |
| > a\) Swing out    |   |              |        |       | when          |
| > handrails        |   |              |        |       | separation    |
| >                  |   |              |        |       | begins to     |
| > b Signal crane   |   |              |        |       | occur between |
| > operator to lift |   |              |        |       | tires.        |
|                    |   |              |        |       |               |
| a)  Shut off       |   |              |        |       | Explain       |
|     propane/air    |   |              |        |       | hazards       |
|     valves.        |   |              |        |       |               |
|                    |   |              |        |       | Ensure all    |
| b)  Pivot arms on  |   |              |        |       | workers are   |
|     ring of fire   |   |              |        |       | clear of the  |
|     and lower      |   |              |        |       | active crane  |
|                    |   |              |        |       | radius        |
| c)  Continue       |   |              |        |       |               |
|     lifting tire   |   |              |        |       | If tire is to |
|     off of journal |   |              |        |       | be discarded, |
|     and lower to   |   |              |        |       | place on      |
|     ground         |   |              |        |       | pallet        |
|     outside.       |   |              |        |       |               |
|                    |   |              |        |       | If tire is to |
| f\) Close          |   |              |        |       | be            |
| handrails          |   |              |        |       | re-installed, |
|                    |   |              |        |       | place on      |
|                    |   |              |        |       | cribbing.     |
+--------------------+---+--------------+--------+-------+---------------+
| -   Detach         |   |              |        |       |               |
|     spreader bar   |   |              |        |       |               |
|     from crane.    |   |              |        |       |               |
+--------------------+---+--------------+--------+-------+---------------+
| **New Tire         |   |              |        |       |               |
| Installation**     |   |              |        |       |               |
+--------------------+---+--------------+--------+-------+---------------+
| -   Clean and      |   |              |        |       | Use sandpaper |
|     de-burr the    |   |              |        |       | or emery      |
|     key on hub     |   |              |        |       | cloth.        |
|                    |   |              |        |       |               |
|                    |   |              |        |       | If            |
|                    |   |              |        |       | uncleanable   |
|                    |   |              |        |       | then replace  |
|                    |   |              |        |       | key with one  |
|                    |   |              |        |       | inch key      |
|                    |   |              |        |       | stock.        |
|                    |   |              |        |       |               |
|                    |   |              |        |       | To be done    |
|                    |   |              |        |       | while heating |
|                    |   |              |        |       | the spare     |
|                    |   |              |        |       | tire and      |
|                    |   |              |        |       | removing the  |
|                    |   |              |        |       | crane block   |
|                    |   |              |        |       | from the      |
|                    |   |              |        |       | removed tire. |
+--------------------+---+--------------+--------+-------+---------------+
| -   Put Loc-Tite   |   |              |        |       | Loc-Tite is   |
|     on the entire  |   |              |        |       | used to       |
|     circumference  |   |              |        |       | alleviate     |
|     of the hub     |   |              |        |       | pressure from |
|     face.          |   |              |        |       | the inner     |
|                    |   |              |        |       | split         |
|                    |   |              |        |       | retainer      |
|                    |   |              |        |       | ring.         |
|                    |   |              |        |       |               |
|                    |   |              |        |       | To be done    |
|                    |   |              |        |       | while heating |
|                    |   |              |        |       | the spare     |
|                    |   |              |        |       | tire and      |
|                    |   |              |        |       | removing the  |
|                    |   |              |        |       | crane block   |
|                    |   |              |        |       | from the      |
|                    |   |              |        |       | removed tire. |
+--------------------+---+--------------+--------+-------+---------------+
| -   Attach         |   |              |        |       | Ensure the    |
|     spreader bar   |   |              |        |       | spreader bar  |
|     to new tire    |   |              |        |       | is level for  |
|     via two        |   |              |        |       | equal pull    |
|     threaded holes |   |              |        |       | and maintain  |
|     on opposite    |   |              |        |       | a constant    |
|     sides.         |   |              |        |       | tension.      |
+--------------------+---+--------------+--------+-------+---------------+
| -   Ignite ring of |   |              |        |       | Execute when  |
|     fire.          |   |              |        |       | 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     |   |              |        |       | Use a heat    |
|     check          |   |              |        |       | pencil or     |
|                    |   |              |        |       | infrared      |
|                    |   |              |        |       | meter to      |
|                    |   |              |        |       | verify the    |
|                    |   |              |        |       | removal       |
|                    |   |              |        |       | temperature   |
|                    |   |              |        |       | is 250        |
|                    |   |              |        |       | degrees       |
|                    |   |              |        |       | Fahrenheit    |
|                    |   |              |        |       | (do not       |
|                    |   |              |        |       | exceed).      |
+--------------------+---+--------------+--------+-------+---------------+
| -   Lift tire      |   |              |        |       | Explain       |
|                    |   |              |        |       | hazards       |
| a)  Shut off       |   |              |        |       |               |
|     propane/air    |   |              |        |       | Execute a     |
|     valves.        |   |              |        |       | constant lift |
|                    |   |              |        |       | when          |
| b)  Remove ring of |   |              |        |       | separation    |
|     fire           |   |              |        |       | begins to     |
|                    |   |              |        |       | occur between |
| c)  Attach         |   |              |        |       | tires         |
|     spreader bar   |   |              |        |       |               |
|     to crane       |   |              |        |       | Ensure all    |
|                    |   |              |        |       | workers are   |
| d)  Swing out      |   |              |        |       | clear of the  |
|     handrails      |   |              |        |       | active crane  |
|                    |   |              |        |       | radius        |
| e)  Signal crane   |   |              |        |       |               |
|     operator to    |   |              |        |       | One mechanic  |
|     lift           |   |              |        |       | should be     |
|                    |   |              |        |       | guiding the   |
| f)  Lift tire off  |   |              |        |       | tire keyway   |
|     cribbing and   |   |              |        |       | onto key.     |
|     raise into     |   |              |        |       |               |
|     position above |   |              |        |       | It is         |
|     journal, then  |   |              |        |       | critical that |
|     lower into     |   |              |        |       | tire and      |
|     place.         |   |              |        |       | spreader bar  |
|                    |   |              |        |       | is level to   |
| g\) Close          |   |              |        |       | ensure that   |
| handrails          |   |              |        |       | 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.    |
+--------------------+---+--------------+--------+-------+---------------+
| -   Detach         |   |              |        |       |               |
|     spreader bar   |   |              |        |       |               |
|     from installed |   |              |        |       |               |
|     tire.          |   |              |        |       |               |
+--------------------+---+--------------+--------+-------+---------------+
| Re-install top     |   |              |        |       |               |
| tire               |   |              |        |       |               |
+--------------------+---+--------------+--------+-------+---------------+
| -   Determine      |   |              |        |       |               |
|     which used     |   |              |        |       |               |
|     tire to        |   |              |        |       |               |
|     reinstall      |   |              |        |       |               |
+--------------------+---+--------------+--------+-------+---------------+
| -   Attach         |   |              |        |       | Ensure the    |
|     spreader bar   |   |              |        |       | spreader bar  |
|     to tire to     |   |              |        |       | is level for  |
|     reinstall via  |   |              |        |       | equal pull    |
|     two threaded   |   |              |        |       | and maintain  |
|     holes on       |   |              |        |       | a constant    |
|     opposite       |   |              |        |       | tension.      |
|     sides.         |   |              |        |       |               |
+--------------------+---+--------------+--------+-------+---------------+
| -   Install ring   |   |              |        |       | Make certain  |
|     of fire        |   |              |        |       | that ring of  |
|                    |   |              |        |       | fire is       |
|                    |   |              |        |       | centered over |
|                    |   |              |        |       | tire.         |
+--------------------+---+--------------+--------+-------+---------------+
| -   Clean key way  |   |              |        |       | Be aware of   |
|     prior to       |   |              |        |       | temperature   |
|     heating tire   |   |              |        |       | of fire.      |
+--------------------+---+--------------+--------+-------+---------------+
| -   Ignite ring of |   |              |        |       | Mechanic      |
|     fire.          |   |              |        |       | 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     |   |              |        |       | Use a heat    |
|     check          |   |              |        |       | pencil or     |
|                    |   |              |        |       | infrared      |
|                    |   |              |        |       | meter to      |
|                    |   |              |        |       | verify the    |
|                    |   |              |        |       | removal       |
|                    |   |              |        |       | temperature   |
|                    |   |              |        |       | is 250        |
|                    |   |              |        |       | degrees       |
|                    |   |              |        |       | Fahrenheit    |
|                    |   |              |        |       | (do not       |
|                    |   |              |        |       | exceed).      |
+--------------------+---+--------------+--------+-------+---------------+
| -   Lift tire      |   |              |        |       | Explain       |
|                    |   |              |        |       | hazards       |
| a)  Shut off       |   |              |        |       |               |
|     propane/air    |   |              |        |       | Ensure all    |
|     valves.        |   |              |        |       | workers are   |
|                    |   |              |        |       | clear of the  |
| b)  Remove ring of |   |              |        |       | active crane  |
|     fire           |   |              |        |       | radius        |
|                    |   |              |        |       |               |
| c)  Attach         |   |              |        |       | One mechanic  |
|     spreader bar   |   |              |        |       | should be     |
|     to crane       |   |              |        |       | guiding the   |
|                    |   |              |        |       | tire keyway   |
| d)  Swing out      |   |              |        |       | onto key.     |
|     handrails      |   |              |        |       |               |
|                    |   |              |        |       | It is         |
| e)  Signal crane   |   |              |        |       | critical that |
|     operator to    |   |              |        |       | tire and      |
|     lift           |   |              |        |       | spreader bar  |
|                    |   |              |        |       | is level to   |
| f)  Lift tire off  |   |              |        |       | ensure that   |
|     cribbing and   |   |              |        |       | during        |
|     raise into     |   |              |        |       | installation  |
|     position above |   |              |        |       | the tire does |
|     journal, then  |   |              |        |       | not get       |
|     lower into     |   |              |        |       | stuck.        |
|     place.         |   |              |        |       |               |
|                    |   |              |        |       | Maintain      |
| g\) Close          |   |              |        |       | level when    |
| handrails          |   |              |        |       | lowering the  |
|                    |   |              |        |       | tire into     |
|                    |   |              |        |       | place over    |
|                    |   |              |        |       | keyway. (Very |
|                    |   |              |        |       | Critical)     |
+--------------------+---+--------------+--------+-------+---------------+
| -   Detach         |   |              |        |       |               |
|     spreader bar   |   |              |        |       |               |
|     from installed |   |              |        |       |               |
|     tire.          |   |              |        |       |               |
+--------------------+---+--------------+--------+-------+---------------+
| -   Swing spreader |   |              |        |       | Explain       |
|     bar out of     |   |              |        |       | hazards       |
|     work area and  |   |              |        |       |               |
|     place outside  |   |              |        |       |               |
|     on pallet      |   |              |        |       |               |
+--------------------+---+--------------+--------+-------+---------------+
| -   Attach crane   |   |              |        |       |               |
|     to retainer    |   |              |        |       |               |
|     ring chokers   |   |              |        |       |               |
+--------------------+---+--------------+--------+-------+---------------+
| -   Swing out      |   |              |        |       |               |
|     handrails      |   |              |        |       |               |
+--------------------+---+--------------+--------+-------+---------------+
| -   Lift retaining |   |              |        |       | Align bolt    |
|     ring in place  |   |              |        |       | holes with    |
|     on hub         |   |              |        |       | hub           |
+--------------------+---+--------------+--------+-------+---------------+
| -   Close          |   |              |        |       | Explain       |
|     handrails      |   |              |        |       | hazards       |
+--------------------+---+--------------+--------+-------+---------------+
| -   Tighten        |   |              |        |       | Explain       |
|     Retainer bolts |   |              |        |       | hazards       |
|                    |   |              |        |       |               |
| a)  Position       |   |              |        |       | Ensure the    |
|     ladder and     |   |              |        |       | ring is being |
|     ascend to top  |   |              |        |       | tightened     |
|     of journal     |   |              |        |       | down evenly   |
|                    |   |              |        |       |               |
| b)  Attach harness |   |              |        |       | Do not lower  |
|     to retractable |   |              |        |       | using air     |
|     fall           |   |              |        |       | line          |
|     protection     |   |              |        |       |               |
|                    |   |              |        |       |               |
| c)  Obtain ¾"      |   |              |        |       |               |
|     impact wrench  |   |              |        |       |               |
|     from co-worker |   |              |        |       |               |
|                    |   |              |        |       |               |
| d)  Tighten bolts  |   |              |        |       |               |
|     in a 90 degree |   |              |        |       |               |
|     spread pattern |   |              |        |       |               |
|                    |   |              |        |       |               |
| e)  Lower impact   |   |              |        |       |               |
|     wrench to      |   |              |        |       |               |
|     co-worker      |   |              |        |       |               |
|                    |   |              |        |       |               |
| f)  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  |   |              |        |       |               |
|                    |   |              |        |       |               |
| > a\) Position the |   |              |        |       |               |
| > hydraulic        |   |              |        |       |               |
| > connecting rods  |   |              |        |       |               |
| > with attached    |   |              |        |       |               |
| > come-a-longs     |   |              |        |       |               |
| > until eyelet     |   |              |        |       |               |
| > alignment is     |   |              |        |       |               |
| > met.             |   |              |        |       |               |
+--------------------+---+--------------+--------+-------+---------------+
| -   Lift North pin |   |              |        |       | Remind        |
|     into place     |   |              |        |       | 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.       |   |              |        |       |               |
+--------------------+---+--------------+--------+-------+---------------+
| -   Remove         |   |              |        |       |               |
|     come-a-longs   |   |              |        |       |               |
|     off arms       |   |              |        |       |               |
+--------------------+---+--------------+--------+-------+---------------+
| -   Remove hoists  |   |              |        |       |               |
|     from yoke and  |   |              |        |       |               |
|     secure out of  |   |              |        |       |               |
|     the way        |   |              |        |       |               |
+--------------------+---+--------------+--------+-------+---------------+
| -   Replace grated |   |              |        |       | Explain       |
|     walkways and   |   |              |        |       | hazards       |
|     handrails      |   |              |        |       |               |
+--------------------+---+--------------+--------+-------+---------------+
| -   Mechanic       |   |              |        |       | Explain       |
|     position       |   |              |        |       | hazards       |
|     ladder to      |   |              |        |       |               |
|     ascend to top  |   |              |        |       |               |
|     of yoke with   |   |              |        |       |               |
|     proper fall    |   |              |        |       |               |
|     protection in  |   |              |        |       |               |
|     place.         |   |              |        |       |               |
+--------------------+---+--------------+--------+-------+---------------+
| -   Obtain ¾ ton   |   |              |        |       |               |
|     come-a-long    |   |              |        |       |               |
|     from coworker. |   |              |        |       |               |
|                    |   |              |        |       |               |
| a)  Attach to      |   |              |        |       |               |
|     eyelet approx. |   |              |        |       |               |
|     3' above door  |   |              |        |       |               |
|     opening on     |   |              |        |       |               |
|     mill body and  |   |              |        |       |               |
|     load chain     |   |              |        |       |               |
|     attached to    |   |              |        |       |               |
|     door eyelet.   |   |              |        |       |               |
|                    |   |              |        |       |               |
| b)  Put a strain   |   |              |        |       |               |
|     on the         |   |              |        |       |               |
|     come-a-long to |   |              |        |       |               |
|     support the    |   |              |        |       |               |
|     door.          |   |              |        |       |               |
+--------------------+---+--------------+--------+-------+---------------+
| -   Co-worker      |   |              |        |       |               |
|     removes bolts  |   |              |        |       |               |
|     from the       |   |              |        |       |               |
|     safety tabs.   |   |              |        |       |               |
+--------------------+---+--------------+--------+-------+---------------+
| -   Position door  |   |              |        |       | When          |
|     with           |   |              |        |       | positioning   |
|     come-a-long    |   |              |        |       | door, replace |
|     for height and |   |              |        |       | gasket if     |
|     to secure for  |   |              |        |       | needed.       |
|     tightening     |   |              |        |       |               |
+--------------------+---+--------------+--------+-------+---------------+
| -   Harnessed      |   |              |        |       |               |
|     mechanic is    |   |              |        |       |               |
|     handed ¾"      |   |              |        |       |               |
|     impact wrench  |   |              |        |       |               |
|                    |   |              |        |       |               |
| > a\) 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 shall |   |              |        |       |               |
|     re-install     |   |              |        |       |               |
|     thermocouple   |   |              |        |       |               |
|     on journal.    |   |              |        |       |               |
+--------------------+---+--------------+--------+-------+---------------+
| -   Close mill     |   |              |        |       | Make sure     |
|     access door    |   |              |        |       | safety chains |
|     and tighten    |   |              |        |       | are removed   |
|     all bolts      |   |              |        |       | prior to      |
|                    |   |              |        |       | closing.      |
+--------------------+---+--------------+--------+-------+---------------+
| -   Open 2         |   |              |        |       |               |
|     hydraulic      |   |              |        |       |               |
|     valves per     |   |              |        |       |               |
|     cylinder at    |   |              |        |       |               |
|     the cylinders. |   |              |        |       |               |
+--------------------+---+--------------+--------+-------+---------------+

# 

# Duty 4: Startup

Objective: The Learner will demonstrate how to safely startup the roller
mill circuit. The learner will demonstrate the proper procedure for a
startup. The learner will also explain and demonstrate other job steps
listed, and explain why they are conducted, any associated risk, and how
to implement appropriate controls. The proper startup procedure will
include the following job steps and activities:

+--------------------+------------------+--------+------+-------------+
| **Job Steps**      | **Importance     | **Impo | **   | **Proc      |
|                    | Narrative**      | rtance | Sati | edures/Risk |
|                    |                  | Narra  | sfac | Re          |
|                    | **(Consider      | tive** | tory | solution/** |
|                    | Safety,          |        | or   |             |
|                    | Production, and  | **1    | N    | **Notes     |
|                    | Maintenance)**   | =Impor | eeds | /Comments** |
|                    |                  | tant** | Wo   |             |
|                    |                  |        | rk** |             |
|                    |                  | **     |      |             |
|                    |                  | 2=Very |      |             |
|                    |                  | Impor  |      |             |
|                    |                  | tant** |      |             |
|                    |                  |        |      |             |
|                    |                  | **     |      |             |
|                    |                  | 3=Crit |      |             |
|                    |                  | ical** |      |             |
+====================+==================+========+======+=============+
| **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  |                  |        |      | Explain     |
|     5^th^ floor of |                  |        |      | production  |
|     preheat tower  |                  |        |      | hazards     |
|     to S-252       |                  |        |      |             |
|     Guillotine     |                  |        |      |             |
|     Gate and       |                  |        |      |             |
|     opens.         |                  |        |      |             |
+--------------------+------------------+--------+------+-------------+
| -   Supervisor     |                  |        |      | Explain     |
|     goes to 2^nd^  |                  |        |      | production  |
|     floor preheat  |                  |        |      | hazards     |
|     tower to S-251 |                  |        |      |             |
|     Guillotine     |                  |        |      |             |
|     Gate and       |                  |        |      |             |
|     opens.         |                  |        |      |             |
|                    |                  |        |      |             |
|     a.  Notify     |                  |        |      |             |
|         control    |                  |        |      |             |
|         room that  |                  |        |      |             |
|         he/she is  |                  |        |      |             |
|         going to   |                  |        |      |             |
|         open S-251 |                  |        |      |             |
|         Guillotine |                  |        |      |             |
|         Gate and   |                  |        |      |             |
|         it may     |                  |        |      |             |
|         affect     |                  |        |      |             |
|         airflow    |                  |        |      |             |
|                    |                  |        |      |             |
|     b.  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   |                  |        |      |             |
|     abnormal in    |                  |        |      |             |
|     the Roller     |                  |        |      |             |
|     Mill Circuit   |                  |        |      |             |
|                    |                  |        |      |             |
| > a\) If none,     |                  |        |      |             |
| > mill is released |                  |        |      |             |
| > to production to |                  |        |      |             |
| > start            |                  |        |      |             |
+--------------------+------------------+--------+------+-------------+
| -   Supervisor is  |                  |        |      | Production  |
|     positioned in  |                  |        |      | hazards     |
|     Roller Mill    |                  |        |      |             |
|     area to ensure |                  |        |      |             |
|     everything     |                  |        |      |             |
|     starts up      |                  |        |      |             |
|     properly       |                  |        |      |             |
+--------------------+------------------+--------+------+-------------+