Guidelines for Spring Startup

Mar. 05, 2019

As the weather shows the first signs of warming up, it’s time for crushing plants to start warming back up!

The process of seasonal startup is important to get correct. The proper startup processes go a long way toward increasing safety levels at a crushing site, and they contribute toward preparing a site for success and maximum production.

 Ready to get things moving this spring? Here’s some tips on the seasonal startup process from our experts:

 1. Check all safety equipment.

This is the first step in the startup process because safety is always the first priority on a crushing site. This typically entails: 

Checking fire extinguishers and make sure they are in place and haven’t expired past their date of recommended use. 

Checking first aid kits to make sure equipment is stocked and up to date.

Checking safety equipment on machinery. This includes reviewing emergency stops, pull cords, and safety guarding on conveyors to make sure that everything is operational.

If anything is missing or out of date, it should be replaced before continuing in startup procedures. Ensuring that safety equipment is updated and functional is a good precaution against incident. 

2. Complete and update any paperwork and training.

Next, it’s important to make sure that all paperwork and trainings are current.

Are all site personnel up to date on MSHA and OSHA trainings? Is the corresponding paperwork completed?

On Mellott crushing sites, we mandate annual refresher trainings to ensure compliance, and confirm that all of our site personnel are current on necessary paperwork.

3. Ensure safe conditions at the crushing site.

With paperwork and training up to date, the next step is to ensure safe conditions at the crushing site itself.

There are a variety of things to look for here. 

Checking access roads. Make sure that there haven’t been rock-falls or other events that have impeded road access during the winter months. Confirm that all needed roads are open.

Check safety conditions in the pit area. Make sure that there isn’t standing water or fallen debris that would delay operations.

Check that berms are up to height. Ensure that weather conditions and erosion over the course of the offseason haven’t displaced or washed out berms. 

4. Check crushing equipment.

After reviewing pit conditions, it’s finally time to check the crushing equipment itself. Like cars that sit through seasons without use, crushers need to be reviewed before they can be trusted to perform at maximum capacity again.

Here are a few things to check for at standard crushing sites:

Check oils and fluids. Ensure that there hasn’t been a leak over the offseason, and confirm that all levels are appropriately topped off.

Check cones for debris. Make sure that cones are clear of any ice or debris that would impede functionality.

Check belt conditions. Check transfer and discharge points to ensure they are free of ice and debris.

There are also a few concerns specific to mobile Equipment:

Check tire conditions. Make sure that air pressure is up to manufactures specifications

Check mobile equipment fluids. Inspect fuel, antifreeze, and oil levels to prepare the mobile equipment for daily production. 

5. Start things up.

Finally, your crushing site is ready to be brought back to life! 

Test the startup siren to make sure it works. Then start up all the individual pieces of the plant to make sure that everything is running properly.

You don’t want to start running at full capacity; make sure to start slow and work up to full speed. While the time to full production will vary across plants and production materials, it’s generally best to work up to full capacity over a full day.

Want to Learn More About Operational Crushing Processes?

Following these guidelines will help you start your spring season off right.

Want more help maximizing efficiency in crushing processes?

At Mellott Company, we offer inspections and equipment servicing to ensure that you’ll be running at optimum efficiency when it matters most – and that you’ll able to gear up for the upcoming crushing season safely. 

To be prepared for your next season, get in touch with us at 800.634.5634 and we can discuss your specific needs.

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