CHAPTER 37: EQUIPMENT TRAINING CERTIFICATION

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1 CHAPTER 37: EQUIPMENT TRAINING CERTIFICATION

2 EQUIPMENT TRAINING CERTIFICATION INTRODUCTION Prior to any JTT worker operating a piece of equipment, they must be properly trained on the applicable piece of equipment. In order to find out whether a worker has been trained on a specific piece of equipment, contact the local JTT Manpower/Safety Manager. Once it is determined that a worker needs specific training, the JTT training process requires the following two steps: 1. Review of the equipment s operation manual and successful passage of the corresponding written tests to confirm understanding of operational procedures; and 2. Hands-on review by a qualified operator to ensure proper operation For copies of the operator tests and observation reports that are to be administered prior to any worker operating equipment on a JTT site, see the following pages. 444

3 Air Driven Screw Feed Drill Insure to review the proper Instruction manual with the employee prior to giving this test. If the employee demonstrates understanding of the safety procedures by successfully passing the test, observe the worker to insure the safety procedures as outlined in the manual are properly implemented. If 1. Only experienced operators or trainees under the direct supervision of an experienced operator who have reviewed and are failure with the safe operating instructions and have been approved by J.T. Thorpe supervision should operate this equipment. 2. The maximum air pressure allowed for operating the drill is 90 PSIG. 3. The use of hearing protection is required when operating this drill. 4. Pressure regulars are to be used on the air lines to limit air pressure to the proper operating pressure. 5. Proper safety gear to be worn when using the drill includes: a. Safety Glasses b. Fire Retardant Coveralls (regardless if required by customer or not) c. Hearing Protection d. Only A&C are correct 445

4 Batch Mix Gunning Rig (Micon) Insure to review the proper Instruction manual with the employee prior to giving this test. If the employee demonstrates understanding of the safety procedures by successfully passing the test, observe the worker to insure the safety procedures as outlined in the manual are properly implemented. If 1. Only experienced operators or trainees under the direct supervision of an experienced operator who have reviewed and are familiar with the safe operating instructions and have been approved by J.T. Thorpe supervision should operate this equipment. 2. The Allentown Model guniting machine training must be completed prior to operating the Batch Mix Gunning Rig. 3. It is OK to lift the mixer grate while the motor is operating if you are only going to remove minor build up of material at the top of the mixing hopper. 4. Care should be taken to prevent build-up of concrete on the lower conveyor pulley. A maintenance door is provided for ease of access for cleaning. This cleaning should only be done when the engine is off. 5. To clear a plug it is safe to first stop the air motor, partially close the main air supply valve and then strike the hose before and after the plug with a mallet or hammer. Prior to doing this however, make sure the nozzle man has the nozzle firmly braced in the event the hose will whip when the plug releases. 6. To insure no premature wear on the clutch, make sure the clutch is fully engaged when operating the machine. 7. What possible safety controls are in place to prevent access to the mixer while the paddles are rotating? (Circle all that apply) a. Hasp with padlock on grating, with key connected to ignition of Micon Rig b. Siren sounds when grating is raised during operation c. Motor kill switch activated when grating is raised d. None, no hazards exist 446

5 ALLENTOWN Operator Test Insure to review the proper Instruction manual with the employee prior to giving this test. If the employee demonstrates understanding of the safety procedures by successfully passing the test, observe the worker to insure the safety procedures as outlined in the manual are properly implemented. If Name: : 1. When should the Allentown be inspected: a. At the beginning of the job b. At the end of the job c. Only in the yard d. At the beginning of each shift 2. Only Certified, Trained and Qualified Operators are allowed to operate the Allentown equipment. 3. If the Air Motor Safety Control Assembly gets in the way of the operation or cleaning of the Allentown, it is OK to remove it, as long as you put it back on at the end of the job. 4. If you do not have the correct parts to repair the Allentown, it is OK to use tie wire, duct tape or other means to keep the machine running, as long as you get the job done. 5. What type of lubricant do you use for the air motor? a. 10 Weight Motor Oil b. Synthetic Oil c. Graphite d. Grease 6. What type of bolts are used on the Allentown? a. Carbon Steel b. Stainless Steel c. Grade 8 d. Cast Iron 7. When a plug up occurs, what is the first step you must take in order to clear the plug? a. Turn off the Air Compressor b. Turn off the Air Valve c. Run for Cover d. Turn off the Material Feed Wheel 447

6 8. If there is another shift after yours, it is OK to leave the material in the gun for the next shift? 9. There is no need to wear a respirator while operating the Allentown. 10. What is the ideal moisture content for Gunite Material a. 2 to 4 percent b. 6 to 7 percent c. 3 to 5 percent d. 1 to 3 percent 11. When cleaning the machine feed wheel of debris, the proper tool is: a. Your finger b. Small air line and screwdriver/chisel c. Don t clean it, let the warehouse deal with it 12. The control system to operate the feed wheel during cleaning requires the operator to: a. Push one button b. Concurrently push two buttons 13. Overriding the safety control system to speed-up cleanout and improve shift production will result in: a. Accolades from your Superintendent b. Gift card from the Project Manager c. Immediate termination Trained By: : Signed: Allentown Operator I acknowledge that I have received, read and understand the Allentown Instruction Manual for safe Allentown Operations. I also understand that it is my responsibility as a J.T. Thorpe & Son, Inc. employee to comply with these rules and procedures at all times while operating and maintaining the Allentown. Name (Print) Signature 448

7 Allentown Piccola 020 Rotary Gun Reed Gun Insure to review the proper Instruction manual with the employee prior to giving this test. If the employee demonstrates understanding of the safety procedures by successfully passing the test, observe the worker to insure the safety procedures as outlined in the manual are properly implemented. If 1. Only experienced operators or trainees under the direct supervision of an experienced operator who have reviewed and are failure with the safe operating instructions and have been approved by J.T. Thorpe supervision should operate this equipment. 2. The Allentown Piccola 020 Rotary Gun does not need to be inspected when it is first used if it has been inspected and found in good condition during the prior shift or day. 3. You do not need to wear safety glasses when operating the Allentown Piccola 020 Rotary Gun due to the fact that this equipment operates at a maximum pressure of 125 PSI and this is not enough pressure to cause injury. 4. Safety screens must be in placed on the hopper whenever this equipment is operated. These screens must be in place due the rotating stirring spider and feed rotors inside the hoper can cause serious injury including amputation. 5. A V belt is used to transfer power from the motor to the gear box. A belt guard is provided for this V belt, but this guard may be removed while the machine is running if repairs or tensioning is needed to keep the job running. 6. To clear a plug it is safe to first stop the air motor, partially close the main air supply valve and then strike the hose before and after the plug with a mallet or hammer. Prior to doing this however, make sure the nozzleman has the nozzle firmly braced in the event the hose will whip when the plug releases. 7. It is okay to remove the hopper safety screen during operation to breakup large pieces of refractory during operation. 449

8 Anchor/Mortar Mixer Insure to review the proper Instruction manual with the employee prior to giving this test. If the employee demonstrates understanding of the safety procedures by successfully passing the test, observe the worker to insure the safety procedures as outlined in the manual are properly implemented. If 1. If dry material is left on mixer grating, is it OK to slam the grating down to remove the material? YES NO 2. What is the proper PPE to be worn while operating the mixer? a. Safety glasses b. Safety glasses and ear plugs c. Safety glasses, ear plugs, and half face respirator with 2097 HEPA filters d. None of the above 3. Do I need to concern myself with anyone in the area while pouring or dumping material from the mixer hopper? YES NO 4. When dumping the mixer hopper, are there any exposed moving parts that I should be concerned with? YES NO 450

9 SAW OPERATING SAFETY PROCEDURES Insure to review the Brick Saw safety training outline with bricklayer prior to giving this test. If the bricklayer demonstrates understanding of the safety procedures by successfully passing the test, observe the worker to insure the safety procedures as outlined in the outline are properly implemented. If 1. It is OK to operate a brick saw without a pre-job inspection if the saw operated properly the day before. 2. If the polarity of the electrical connection is not correct, the bricklayer may open up the electrical connection box and change the wires as long as the saw is not connected to the power feed. 3. You may not wear loose fitting clothing or gloves when operating the brick saw. 4. You must wear hearing protection anytime the brick saw is being used, no exceptions. 5. When cutting a brick, you should always have a tight grip on the brick and it is proper to try and push from the back side of the brick when cutting operations are being performed. 6. If the saw blade is starting to bind and show wear, it is OK to continue cutting brick if there are only a few cuts necessary to finish out the day. 7 If at any time when operating the brick saw you feel an electrical shock, shut down the saw and report the problem to your supervisor. 451

10 CHIPPING GUN Insure to review the Brick Saw safety training outline with bricklayer prior to giving this test. If the bricklayer demonstrates understanding of the safety procedures by successfully passing the test, observe the worker to insure the safety procedures as outlined in the outline are properly implemented. If 1. What is the mandatory PPE to be worn while operating a chipping gun? a. Hard hat, safety glasses, steel toed boots, dust mask b. Safety glasses, half face respirator, steel toed boots, long sleeved shirt c. Long sleeve shirt, hard hat, full face respirator, ear plugs, steel toed boots, gloves d. Too hot to wear PPE 2. Is it OK to hold the chisel shank while operating the chipping hammer? YES NO 3. Prior to operation, it is my responsibility to inspect the chipping hammer. 4. Can the chisel shank eject from the chipping hammer if the retainer spring is not secured? YES NO 5. Under normal conditions, how much air pressure is required to operate a chipping gun? a psi b psi c psi d psi 6. If the chipping hammer does not have an inline oilier and I add too much oil, could this pose an unsafe condition? YES NO 7. When changing out the chisel shank, are you required to turn off the air supply? YES NO 8. It is OK to operate a chipping hammer while work is being done below you. 9. Should I be concerned with the working environment while operating a chipping hammer? YES NO 452

11 10. If my chipping hammer malfunctions, what should I do? a. Take the time to get the necessary parts and work on it myself b. Set it in the corner and don t worry about it c. Turn the air supply off and notify my foreman, and he/she will get me another chipping hammer. d. None of the above 453

12 POWER CONVEYOR Insure to review the Brick Saw safety training outline with bricklayer prior to giving this test. If the bricklayer demonstrates understanding of the safety procedures by successfully passing the test, observe the worker to insure the safety procedures as outlined in the outline are properly implemented. If 1. Only experienced operators or trainees under the direct supervision of an experienced operator who have reviewed and are familiar with the safe operating instructions and have been approved by J.T. Thorpe supervision should operate this equipment. 2. Before turning the electric motor on, you should sound an All Clear call to be sure that no material or parts are on the belt. 3. Before turning the electric motor on, you should be sure no one is touching the conveyor frame or belt. 1. Belt tension and tracking must be adjusted before and periodically during operation of the conveyor. 2. To properly adjust the belt tracking: a. Keep the belt flowing in the center of the frame b. The tracking should be adjusted at both ends of the conveyor c. Be re-adjusted when drive direction is changed d. All the above are correct. 6. You do not need to be concerned about spacing material on the conveyor belt during use. 7. To adjust the belt if it is slipping, turn the adjustment bolt clockwise. 8. Keep hair, loose clothing, and hands out of the conveyor drive belts. 454

13 FLEMING MIXER Insure to review the Brick Saw safety training outline with bricklayer prior to giving this test. If the bricklayer demonstrates understanding of the safety procedures by successfully passing the test, observe the worker to insure the safety procedures as outlined in the outline are properly implemented. If 1. It is required to lock out the Mixer prior to cleaning the paddles or making any adjustments. 2. When setting the mixer on a scaffold, the proper rating for that scaffold should be: a. Light duty scaffold b. Medium duty scaffold c. Heavy duty scaffold d. The scaffold rating does not matter 3. What is the proper PPE to be worn while operating the mixer? a. Safety glasses b. Safety glasses and ear plugs c. Safety glasses, ear plugs and a half face respirator with 2097 HEPA filters d. None of the above 4. It is OK to operate this mixer with the guards removed and the safety switch made inoperable if the mixer is easier and more convenient to operate. 5. The Fleming mixer has automatic machinery which operates by itself. You do not need to be concerned about this equipment starting when the machine is shut down. 455

14 HOBART MIXER Insure to review the Brick Saw safety training outline with bricklayer prior to giving this test. If the bricklayer demonstrates understanding of the safety procedures by successfully passing the test, observe the worker to insure the safety procedures as outlined in the outline are properly implemented. If 1. Only experienced operators or trainees under the direct supervision of an experienced operator who have reviewed and are familiar with the safe operating instructions and have been approved by J.T. Thorpe supervision should operate this equipment. 2. The Hobart Mixer does not need to be inspected when it is first used if it has been inspected and found in good condition during the prior shift or day. 3. You do not need to wear safety glasses when operating the Hobart, due to the fact that the material being mixed is wet. 4. You are required to keep hands, clothing, and tools out of the beater when the Hobart is in operation. 5. The bowl guard needs to be in place before operating the Hobart. 6. Changing speed of the mixer can be done while the mixer is in operation. 456

15 HPC 3300 Refractory Mixer/Pump Insure to review the Brick Saw safety training outline with bricklayer prior to giving this test. If the bricklayer demonstrates understanding of the safety procedures by successfully passing the test, observe the worker to insure the safety procedures as outlined in the outline are properly implemented. If 1. It is required to lock out the Mixer and pump prior to cleaning the paddles. 2. It is okay to remove the grating above the agitator hopper or mixxing hopper to gain access during operation. 3. Prior to start up, you should: a. Check fluid levels b. Ensure guards are in place c. Inspect discharge lines and couplings to ensure they are securely attached d. Break hose at pump and pour in sufficient slurry e. All of the above 4. What is the proper PPE to be worn while operating the mixer? a. Safety glasses b. Safety glasses and ear plugs c. Safety glasses, ear plugs, and half face respirator with 2097 HEPA filters d. None of the above 5. You should never place your hand in the pump discharge unless the power is off and locked in that position. 457

16 J.T. Thorpe & Son, Inc. Equipment Training Employee: Signature: Types of Equipment Allentown Piccola/Reed Gunite Machine Allentown N-Type Gunite Machine Allentown Micon Rig Fleming Mixer Anchor/Mortar Mixer Hobart Mixer Air Drill Brick Saw Refractory Pump/Mixer Chipping Guns Electric Conveyor of Training of Observation Insert date of training (i.e. reviewed) operations manual, tests and observation to indicate completion. False certification is punishable under section 110(a) and (f) of the Federal Mine Safety and Health Act. I certify that the above training has been completed. Safety Manager: Signature: 458

17 JTT Equipment Safety Training Audit Form This form is designed to document Name of Equipment Operated: Name of Operator Observed: Operator Observed: JTT Qualified Person Observing: Equipment set up Knew procedrues for pre inspection LEAKS/DAMAGE YES NO Comments Knew equipment lock out procedures prior to starting operation Guards in place Equipment set up Had machine properly set up Lines and cords kept off ground as much as possible Initial Operation Inspection Check for wear, proper connections and guards in place Drive Belts Check condition Grease Grease all fittings Oil Refill if needed Used proper PPE when operating equipment Motor Run and listen for damage prior to star House Keeping maintained Hoses and cords off ground, bags and other debris kept off ground, area clear of other materials. Safety Devices Check that these are in place prior to operation Clean Machine Knew procedrues for cleaning Turned off equipment as needed /lock out power General Comments: Signature of Qualified Person: 459

18 Equipment Inspection Form Equipment Inspected: Inspected: Person Inspecting: Items Needing Repair:

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