30, 36, 42 Die & Cool Plug Removal
What: A checklist to remove the die and cool plug for 30”, 36”, and 42”
When: During diameter change
Why Use: To create a consistent process that covers necessary checks to ensure a speedy start-up
Keys: Install new gaskets & O-rings at every diameter change
Removal Steps
- Turn thermolator off and all associated water inlet and outlet valves, drain water lines
- Remove all plumbing from cool plug and place in a safe space so as not to bend the piping
- Using straps remove cool plug being careful to have straps and crane in the correct orientation.
- Place cool plug in designated storage box with straps.
- Using the crane and the large self-leveling tackle block begin to rig your chains.
- Use the 20 ton (largest) chain hoist with the longest (20 foot) chain coupled to the hoist on one side of the tackle block. Use the short 10 foot chain on the other side of the tackle bock
- Loosen the rear most heater band for the outer wall (closest to die stand) find the correct eye bolt and washers for the rear lift point. Install eye bolt making sure that there is no play
- Place long chain around the front of the die use a 1×6 wood board between die and chain.
- Connect chain to eye bolt on the rear of the die using the appropriate d-ring (10 ton or larger)
- Center crane over die. Using the crane and chain hoist together, put the same amount of pressure on the rear chain and front chain (the tackle block will appear level)
- Turn off both inner and outer wall control panels. Find all heater band wires for the die and unplug them from the control panel and wrap them safely and securely around the die itself.
- Begin removing the bolts that connect the die to the die stand.
- Once all 10 bolts are out and ACCOUNTED FOR the die may be removed and stored
- Clean the die stand of all debris from previous production. It is vital to have a clean matting surface so as not to have any leaks
- Clean all material residue off die stand and rear of die while the material is still hot and pliable. Remove the aluminum O-rings from rear of hot die.