C Test Area 4 Mosaic

Front 1

When cleaning the Chain Mills it is necessary to lock out the Primary Elevator

Back 1

True

Front 2

What problem is created if the condensate cannot leave the pre heater

Back 2

Condensate will collect in the coils and pre heater will start to hammer and may cause coils to break

Front 3

Is a safety harness required for all chain mills cleaning

Back 3

Yes

Front 4

Briefly explain how to rack out the 2300 volt switch gear in the XYZ motor control center

Back 4

Verify equipment is off

Go to proper MCC

Put on flash gear

Turn power control switch on the panel to the off position

Stand on hinge side of door

Make sure the area is clear of all personnel

Rack switch gear with proper tool

Tag with proper tag

Front 5

What PPE must be worn while cleaning the dryer feed chute

Back 5

Lanyard & harness

Front 6

Name 2 reasons for not being eligible for progression

Back 6

Breaking safety rules and not showing up for work

Front 7

Is a Confined Space Permitted required to enter the Cyclones

Back 7

True

Front 8

If a cyclone hopper bladder is missing, excessive dust will likely carry over to the scrubbers and air ducts could plug

Back 8

True

Front 9

If there is excessive fines mixed in with the product going to the cooler, you would expect to find

Back 9

Blinded products screens

Front 10

If the product going to the cooler has excessive oversized mixed in, you would expect to find

Back 10

Holes in the scalping screens

Front 11

If a conveyor belt wear out of training you would expect to find

Back 11

Build up on rollers

Front 12

Why would the scalping screen vibrators be cut off

Back 12

Never cut the scalping screen vibrators off during normal operation

Front 13

What is the purpose of the chains in the Cyclones

Back 13

To keep the bottom of the cyclones open

Front 14

What fuel does the Bobcat and payloader use

Back 14

Diesel

Front 15

What should be done when the payloader are Bobcats starts leaking oil or grease

Back 15

Stop the equipment and have it repaired and notify supervisor

Front 16

The daily service check sheet is required on the payloader but not the skid steer

Back 16

False

Front 17

Safety belts are to be used on the pay loader and skid steer when the unit is being operated

Back 17

True

Front 18

The backup alarm on the skid steer and pay loader must be working at all times

Back 18

True

Front 19

The gases from the pre neutralizer and granulator are pulled into what scrubber system by the what fan

Back 19

Fume fume

Front 20

What is the importance of using pond water in place of fresh water when possible

Back 20

To conserve fresh water supply and to help control pond water levels

Front 21

What results from not having seal water on a pump

Back 21

The seal will go out, spill material and damage pump

Front 22

How often are safety showers and eyewash stations inspected

Back 22

Every week

Front 23

Explain the functions of the following equipment cyclones, chain mills, scrap reclaim systems, West End scrubbers

Back 23

Cyclones recover dust, chain Mills break up over sized feed, scrap reclaim systems to reclaim fines and product back into the system, West End scrubbers to reclaim dust from West End

Front 24

briefly describe the lock and tag out procedure

Back 24

Verify equipment is off, and rack out breaker, then tag with proper tag, then lock with your assigned lock, check field switch

Front 25

Briefly describe the procedure to put the steam preheater in service

Back 25

Make sure drain valve is closed, open the preheater condensate discharge valve, open up preheater steam valve

Front 26

Where does the preheater condensate discharge to

Back 26

Condensate collection tank on West End z train then to condensate collection tank at a map

Front 27

What is the purpose of the steam preheater

Back 27

To conserve on natural gas usage

Front 28

The fines bin for Y & Z is fed from which scrap reclaim elevator

Back 28

Y train scrap elevator

Front 29

The belts eating from the above bin are interlocked with what equipment

Back 29

Z train granulator and Y train granulator

Front 30

Y train scrap reclaim elevator can discharged into what two places

Back 30

5th floor fines bin and Y train dryer feed chute

Front 31

Briefly describe the procedure for changing X or Y product from B to A shipping warehouse

Back 31

Start D 3 belt. check hoppers for blockage and proper gate position. Set interlock to D 3. start D4 . Start D5. Contact operator to shut down product elevator. Go to y or X MCC. Rack and tagged product elevator. Switch pancake to D 5. Set interlock to a shipping. Remove locks. contact operator to start product system. Then check products system for spillage.

Front 32

What is the purpose of the interlock flip switch between d2 and d3 belts

Back 32

To interlock d2 or d3 to d4. If d2 or D three stops the entire product system will shut down. This prevents both product loss and equipment damage

Front 33

Where are the electrical breakers located for d1 and D3 product belts

Back 33

"A" shipping

Front 34

Where is the electrical breaker located for d5 product belt

Back 34

Y train MCC

Front 35

Where is the electrical breaker located 4 d 2 product belt

Back 35

Z train MCC

Front 36

What are the three common causes or reasons why a conveyor belt will not start

Back 36

Flag down, belt overloaded, motion switch

Front 37

How often are the emergency stop pull cables for all the conveyors checked

Back 37

Monthly

Front 38

When the Z train product conveyor is reverse, the dry side operator needs to check the belt for

Back 38

Check belt for train and spillage

Front 39

Describe the dry side operators clean up areas

Back 39

Dryer feed chute, under the dryer feed conveyor and complete aging conveyor area including tail pulley and stairs on both sides, also assist shift in their assigned clean up areas

Front 40

What is the purpose of the two sets of water strainers on the west end scrubbers

Back 40

When one strainer becomes plugged, the other can be put into service without shutting down system

Front 41

What areas of the plant does the west end scrubber pull from

Back 41

Aging conveyor, dryer feed conveyor and product system

Front 42

One tank of UAN will raise the storage tank level to what percent

Back 42

9%

Front 43

An blank is a mishap caused by an unsafe act and or condition

Back 43

Accident

Front 44

Where is the electrical switch gear for locking out the lump crusher for cleaning

Back 44

At the lump crusher platform disconnect or the MCC

Front 45

Where are the shelter in place kits located in area 4

Back 45

Day crew break room, XY Z control room, a map control room, dry side office conference room, maintenance break room

Front 46

Where can you find MSDS information and area 4

Back 46

MSDS information can be found on the company intranet from any computer in area 4. Area specific MSDS can be found in the operating procedures

Front 47

Give the number and location of the emergency Direction stations in the area 4

Back 47

17 is located north east of XYZ. 7 is located southeast corner of XYZ. 5 is located north east side of a map. 6 is located a map maintenance shop

Front 48

Name at least five different locations of our five or ten minute escape packs

Back 48

A map control room. A map lab. A map breakroom. Top of 532 acid tank. a map sub coolers. utility breakroom. Ammonia unloading station. Ammonia transfer pumps. d ammonia bullet top. XYZ breakroom. XYZ lab. XYZ control room. XYZ freight elevator. top of X train primary elevator. Top of Y train primary elevator. top of Z train primary elevator. Y train 5th floor stairway. Y train 4th floor stairway. Y train 3rd floor stairway

Front 49

We are required to shut the plants down to clean or top chain mills

Back 49

True

Front 50

Area 4 SCBA units are inspected blank and after each use

Back 50

Monthly

Front 51

Where are the interlock flip switches for X & Y product elevator located

Back 51

X train MCC , Y train MCC on the product elevator switch gear

Front 52

List of PPE required when inside the pre neutralizer red zone

Back 52

Goggles, face shield, long as it coat buttoned up, chemical resistant acid gloves

Front 53

What could cause heat and fumes to come out of the west end of the dryer

Back 53

Plugged dryer down leg and dryer exit temperature is too high

Front 54

Starting at Y train feeders , name the equipment parts of plant in order, to move feed into the south end of a shipping

Back 54

Y train feeders. Product screens. Product pipe. Cooler. Cooler discharge belt. Product elevator. D 5. D4. D 2. D1. Shuttle belt

Front 55

While Y train is running map, how are fines move to y train

Back 55

Payloader

Front 56

Should XY & Z train be runnin DAP, how r fines moved to the trains

Back 56

Loader feeding from bottom floor of XYZ and from B shipping on the fines return system

Front 57

What should be done to secure the lump crusher before cleaning it

Back 57

Lock and tag it out at the disconnect and check the field switch

Front 58

What is the purpose of the interlock system

Back 58

Protective equipment and minimize spillage

Front 59

What is the main reason why all of the screen vibrators should be working properly

Back 59

Because vibrators are crucial in making the screens work efficiently

Front 60

What is the main reason that the metal doors on the cyclone hopper bladders should stay closed

Back 60

To keep cold air and moisture from getting into the discharge pipe

Front 61

What is the purpose of the retaining screens on the fifth floor of XY & Z trains

Back 61

To slow down the feed for better distribution and screening

Front 62

What is the location of the quenching air fans on XY & Z trains

Back 62

On the bottom floor

Front 63

Why is it important that all conveyor belts stay in train

Back 63

To reduce and or eliminate spillage, to keep the belt from scraping on metal housing and guarding thus damaging the belt and to keep the belt from getting into a bind and kicking out the motor

Front 64

In general, non processed freshwater should not be used for wash down purposes

Back 64

True

Front 65

Leaving at shift change before seeing your relief man without supervisor approval is a violation of company policy and can be punishable up to termination

Back 65

True

Front 66

How often should be shift floors be cleaned and swept

Back 66

Every day the shift is working

Front 67

Who is responsible for a dry side spill that happens during a shift

Back 67

The shift that had the spill

Front 68

Who is responsible for a spill that found early in the shift, but not reported to the supervisor

Back 68

The shift that found the spill

Front 69

Who is responsible for a spill that is found and reported at the beginning of the shift

Back 69

The previous shift

Front 70

Your release man has left you in bad shape several times lately. You have talked to him but the problem doesn't go away. What should you do

Back 70

Report it to your supervisor

Front 71

If metal is in the lump crusher, the plant must shut down in order to get it out

Back 71

True

Front 72

How often should be West End strippers be checked

Back 72

Every 2 hours

Front 73

A hazard permit is required when taking off the down leg of a scrubber

Back 73

True

Front 74

A hazard permit is required when opening up the chain mills

Back 74

False

Front 75

A hazard permit is required when taking the blank off the bottom of the fume seal pot

Back 75

True

Front 76

What fan pulls dust from the screen that is XYZ

Back 76

Dust fan

Front 77

What's an post us from the screens at a map

Back 77

Dryer fan

Front 78

Where does the granulator drip chute discharge to on XY & Z trains

Back 78

The bottom floor

Front 79

Where does the granulator drip chute discharge to at a map

Back 79

The secondary elevator

Front 80

Where are the fume cyclones located

Back 80

There are no fume cyclones

Front 81

What is the total number of cyclones on each train at XYZ

Back 81

10

Front 82

Where does the product feeder bypass chute discharge to

Back 82

The mill house

Front 83

Where is the dryer bypass switch located for XYZ train

Back 83

In the MCC, on the dryer motor switch gear panel

Front 84

Where do the oversized shoots at XYZ or a map discharged to

Back 84

The chain or cage mills

Front 85

Where do they cage mills at a map discharge to

Back 85

The secondary elevator

Front 86

The XYZ product tunnel belt discharges directly onto the B shipping shuttle belt

Back 86

True

Front 87

According to company policy, any person entering a confined space must sign the confined space permit for that vessel before entering

Back 87

True

Front 88

When checking out your dry side system at the end of a shift, you find that a cyclone bladder has come off. What should you do

Back 88

With the help of a fellow operator and tools, put it back on immediately

Front 89

What is the purpose of the product feeder belts at XY & Z

Back 89

To feed product and fines to the products screens and to control the recycle load