Bulk Store Ferret and Cleaning PDF

## TASK 09: LOADING AND OFFLOADING OF THE FERRET ### Steps: 1. Inspect Ferret and Road Trucks, Prepare for Loading. * Inspect Ferret and Road Trucks for compliance. * Refer to check list. * Reason: To prevent unexpected breakdowns which is time consuming and costly. * To...

## TASK 09: LOADING AND OFFLOADING OF THE FERRET ### Steps: 1. Inspect Ferret and Road Trucks, Prepare for Loading. * Inspect Ferret and Road Trucks for compliance. * Refer to check list. * Reason: To prevent unexpected breakdowns which is time consuming and costly. * To keep Ferret/trucks roadworthy and ensure that the offloading valves and top hatch are in a good working condition at all times. 2. Load Product from Hoppers * Receive certificate of analysis from the Bulk loader and proceed to the selected hopper at PPAN. * To load and transport Porous prill Ammonium Nitrate to the Bulk Store or to Anfex. * Prevent loading product from the wrong hopper. This will mean that you may load the wrong product for storage in the Bulk Store, which can cause customer complaints, and time delay, which is costly. 3. Position Ferret/Bulk Truck Below Loading Chute of the Selected Hopper * By driving the Ferret/Truck forwards or in reverse until the top hatch is below the loading chute. * To ensure that there are no spillages when the Ferret is loaded, if the Ferret/Bulk Truck is not under the loading chute the product will not run into the Ferret/Bulk Truck and can spill into the road which will make the road surface slippery and unsafe. The product can only be used as sweepings. All spillages are a cost to the company. * Check that the Ferret/bulk truck are empty. * Any product in the Ferret/bulk truck may result in mixing two different products which will result in customer complaints.. 4. Lower the Loading Sock into the Loading Hatch of the Ferret/Bulk Truck. * Lower the sock into the loading hatch of the Ferret/Bulk Truck. * To get the product to run into the Ferret/Bulk truck. * If the sock is not properly aligned with the loading hatch, it will spill into the road, which will cause the surface to be slippery and unsafe. 5. Open the Pneumatic Slide Valve at Bottom of the Selected Hopper * Make sure the flaps on hoppers D and E are in the right position for road loading. * If the flaps are not in the right position it will cause spillages. * Change the pneumatic switch to the open position. * To open the pneumatic slide valve and allow the product to flow through into the Ferret/Bulk Truck. Fill the Ferret/Bulk Truck with Ammonium Nitrate prills. * If the product flows into the Ferret/Bulk Truck without spilling, keep the slide valve open until full. * If you open the slide valve and no product flows through, this is an indication that the product inside the hopper could have formed lumps which will clog up the outlet of the hopper valve. Start the vibrators to loosen the product inside the hopper. * To ensure a free flow of the product into the Ferret the lumps must be cleared from the outlet. * If product cannot be loosened after starting the vibrators then use a rubberised hammer to hit the hoppers. 6. Close the Pneumatic Air Valve when the Ferret is Full * Change the pneumatic switch to the closed position. * To close the pneumatic slide valve. * Close the valve. * To stop the flow of product into the Ferret/Bulk Truck. * To prevent the Ferret/ Bulk Truck from overflowing which can cause spillage and sweepings. 7. Proceed to Weighbridge and Weigh the Full Ferret * Park the Ferret on top of the weighbridge * To get the weight of the product inside the Ferret. * To be able to keep count of the product being transported to the Bulk Store. 8. Obtain Weighbridge Ticket from the Weighbridge Operator * Weigh the full Ferret and receive the weighbridge ticket. * Weighbridge operator to record source weight and destination of Ferret load. * For traceability and record purposes. 9. Proceed to the Off Loading Poing and Offload Ferret (Bulkstore) * Park Ferret directly above offloading hatch at H301 conveyor. * To offload the Ferret without spillage. * If the Ferret is not directly above the hatch, the product will run onto the floor, which will cause the floor to be slippery and unsafe. * It will also create an effluent problem during the rainy season due to product being washed into the weak effluent system. * Check with Bulk Store operator if the conveyor H301 system is on line. * To convey the product to the selected bay in the Bulk Store. * If the system is off line the product will spill onto the floor inside the tunnel below the road. This will cause an unsafe condition and wasting of good product. * Open the offloading valve at the bottom of the Ferret. * If the system is on line, offload the product until the Ferret/Bulk Truck is empty. Valve must be opened just enough not to overflow H301 conveyor, which will cause spillages and the floor will be slippery and unsafe. ## TASK 10: CLEANING INSIDE HOPPERS ### Steps: 1. Start up Cleaning * Wear correct PPE and safety harness before entering Hoppers * Check that you have the correct PPE and good conditional safety harness. * If you do not have the right PPE do not commence with your work. * Inspect the hopper to ensure that it is empty and open at the bottom. * Check the position of the fines accumulated inside the hopper. * If there is some product remain inside the hopper and the hopper is still closed at the bottom, don't enter. * Test oxygen level using oxygen meter reading. * Check and ensure that there is enough air flow into the hopper before entering. The oxygen level reading on the meter must at least be 18% before anyone can enter the vessel. * If the air level is not do not enter inside the hopper. * Ensure that enough space for ladder to grip when inserted. * Check if the space where the ladder will be placed is clear of any product. * If there is no enough space to place the ladder, do not inset the ladder. * Stop and lock 306 conveyor using lock out set. * Check the conveyor by pressing the start switch. * If there is any potential of product flow into the hopper, don't commence cleaning task. * Insert the inspected labelled ladder inside the hopper * Check if the ladder is firm, gripped and well secured before using it. ### Steps: 1. Enter the hopper with standby monitoring at the entrance chute/manhole. 2. Start cleaning the hopper using rubber hummer. * Beware of lumps that might fall while cleaning. * Check the flow of fines during cleaning to ensure that outlet loading pipe is not blocked by lumps during cleaning process. * If the fines are not going out into the bin placed at loading chute, stop and report to your Team Manager. ## TASK 11: RECLAIMING FINES FROM BAY 11 ### Steps: 1. Inspect the Bay * Inspect the bay to ensure that it is accessible before any work is undertaken. * Check the position of the moving arm scrapper whether it is in the way of bay 11. * Ensure that there is enough space in the bay to move around. * Check the space where the scooper will be travelling. If there is sufficient space available then continue with the off-loading process next to bay 10. * The driver of the scooper must have someone on standby to give the driver directions as when to stop if the scooper is close to the edge. * Check and inspect the scooper before entering bulk store * If there is no enough space at the bay, there could be potential of accidents to Risk assess the job. * Check for leaks, cleanliness correct tyre threading etc. * If any of these conditions are not met do not commence with the work.