COATER OPERATIONS MODULE
Description:
Coater Training is designed to teach the learner how to operate several very complex systems in the
back end of the roofing manufacturing process. This intensive training covers at several weeks of
training that incorporates classroom instruction, structured on-the-job training and activities with the
instructor. This is followed by a six-month period for Phase Two with a mentor. The Phase Two
process will include monthly feedback sessions with the mentor. This interactive course uses
classroom activities, floor demonstrations and worksheets, performance checklists, and assessments.
This course also targets the more intangible areas of safety, back-end leadership, troubleshooting,
decision-making, and quality management.
Course Prerequisites:
Participants need to have completed the following courses: ―Computer 1,‖ ―Downtime Editor,‖
―Quality Testing Training,‖ ―Information Systems,‖ ―Cooling Section Operations,‖ ―Granule
Operations,‖ all Level 1 non-technical training, all required orientation courses and obtain supervisor
approval.
Grading Requirements:
Your grade is based on the short quizzes, performance checklists, and multiple assignments including
worksheets and completion of situational scenarios. Full attendance is required.
Accreditation:
If you wish, you may take this course for credit. You need to complete a Clackamas Community
College registration form for course MN 119 for eight (8) credits.
Logistics:
You will begin this series with an overview of the entire learning process. We will walk through the
tabs / modules and talk about the purpose of each. You will notice that tabs 1 – 8 have quizzes. Tabs
nine, Operations and ten, Troubleshooting, contain multiple activity-based assessments. These
training/assessments, such as start-up, shut down, changeover, and PMs will need to be scheduled as
the actual events come up. It is the learner’s responsibility to scan the schedule for these occurrences
and arrange for that section with your instructor.
Table of Contents:
Tab 1: Overview
Tab 2: Filler System
Tab 3: Coating System
Tab 4: Filled Coating System
Tab 5: Coater System
Tab 6: Weight Control, Shadowline Application and Granule Valve
Tab 7: Line Speed Control
Tab 8: Hot Oil Systems
Tab 9: Coater Operations
Tab 10: Troubleshooting and Maintenance
TAB 2: FILLER SYSTEM
Objectives: Learners will be able to…
Describe all safety hazards, environmental controls and precautions
Describe the filler system process
Describe all filler system panel view screens, their purpose and use
Identify all filler system components in the systems and describe their functions
Describe how the filler is heated and how the system operates
Agenda Section Two: Filler System (8 hours)
1. Safety Hazards, Environmental Controls and Precautions
2. Filler System Overview—Process and Purpose
a. Filler Transfer System
b. Filler Silo
c. Upper Surge Bin
d. Filler Heater
e. Lower Surge Bin
f. Filler Heater System
3. Filler Silo
a. Filler Silo Process and Components
b. Classroom Worksheet
4. Filler Heater
a. Upper Surge Bin Components
b. Classroom Worksheet
c. Floor Activity—Upper Surge Bin Components
d. Filler Heater Process and Components
e. Classroom Worksheet
f. Heating Filler
5. Lower Surge Bin
a. Process and Components
b. Classroom Worksheet
6. Filler Panel View Screens
a. Main Menu Screen
b. Filler Silo Screen
c. Classroom Worksheet
d. Upper Surge Bin Screen
e. Classroom Worksheet
f. Upper Surge Bin, cont’d
g. Lower Filler Surge Bin Screen
h. Classroom Worksheet
i. Filler Transfer Screw Screen
j. Classroom Worksheet
k. Burner Control Screen
l. Classroom Worksheet
m. Filler System Status Screen
n. Classroom Worksheet
o. Vibration Screen
p. Classroom Worksheet
q. Filler System Screen
r. Classroom Worksheets
s. Filler System Autocontrol
t. Classroom Worksheet
u. Floor Activity—Putting the Filler System into Auto
v. Filler System Overview Screen
w. Classroom Worksheet
Assessment
TAB 3: COATING SYSTEM
Objectives: Learners will be able to…
Describe all safety hazards, environmental controls and precautions
Explain loss prevention
Describe the coating system process
Describe all coating system panel view screens, their purpose and use
Identify all coating system components in the systems and describe their functions
Describe how the asphalt coating is heated and how the system operates
NOTE: This training will eventually replace the Roofing Asphalt Operations Training.
Agenda Section Three: Coating System (24 hours)
1. Overview
2. Safety Hazards, Environmental Controls and Precautions
a. PPEs
b. Environmental systems—Ceco System
c. Loss Prevention Video Series and Notes
i. Explosion Hazards
ii. Vapor Space Monitoring
iii. Monitoring Tools
iv. Tank Inspection
v. Preheater Operation / Safety & Inspection
d. CO2 System
3. Coating System Overview—Process and Purpose
a. Purpose of the Coating System
b. Components of the Coating System
4. Components—Preheater Operations
a. Overview
b. Components
c. Gas Trains
d. Safety Controllers
e. Inspection Requirements
5. Classroom Activity—Illustrate the Coater System
6. Components: Pumps and Valves
7. Coating System Screen
8. Classroom Worksheet
9. Floor Exercise—Coating System
a. Part One: Locations
b. Part Two: Panel View
10. Coater System Under Normal Operation
11. Back Control Station—Coating System Panel Views
a. Main Menu Screen
b. Classroom Worksheet
c. Coating System Screen
d. Classroom Worksheet
e. Auto Valve Screen
f. Classroom Worksheet
g. Classroom Activity
h. Asphalt Pumps & Agitators Screen
i. Preheater Control Screen
j. Classroom Worksheet
k. Preheater Status Screen
l. Preheater Operations Cold Start-up Instructions
m. Pressure Switch Testing and Inspection
n. Agitators Control Screen
o. Temperature 3-way Valve Screen
p. Asphalt Unloading Screen
q. Floor Activity—Coating System and Operating at the Back Control Station
12. Processes for Operations—Shutdown and Start Up
a. Shutdown Process Checklist
b. Shutdown Process Checklist (Training Version)
c. Unscheduled Shutdown (Power Outage)
d. Start-up Process Checklist
e. Start-up Process Checklist (Training Version)
13. Switching Products Between Tanks
a. Process Worksheet
b. Performance Checklist
14. Troubleshooting the Coating System
Assessment
TAB 4: FILLED COATING SYSTEM
Objectives: Learners will be able to…
Describe all safety hazards, environmental controls and precautions
Describe the filled coating system process
Describe all filled coating system panel view screens, their purpose and use
Identify all filled coating system components in the systems and describe their functions
Agenda Section Four: Filled Coating System (24 hours)
1. Safety Hazards, Environmental Controls and Precautions
a. PPEs
b. Filled Coating Safety
c. Environmental Controls
d. Ceco Fume System
e. Dust Collectors
f. Spill Prevention and Reaction
g. CO2 System
2. Filled Coating System Overview—Process and Purpose
a. Process and Purpose
b. Classroom Worksheet
3. Floor Activity—Safety Hazards
4. Floor Activity—Component Identification
5. Classroom Worksheet
6. Filled Coating System
a. Asphalt / Filler Mixer
b. Surge Tank
c. Surge Tank Pump and Valves
d. Coater Pump and Valves
e. Coater Pan
f. Valves
g. 3-Way Valves
h. Filled Coating System—Pumps and Autovalves
i. Coating Valves Screens
ii. Backcoating Auto Control
iii. Return Coating Auto Control
iv. Top Coating Auto Control
v. Classroom Worksheet
vi. Auto Controls
vii. Classroom Worksheet
i. Floor Activity—Auto Valves
7. Filled Coating System—Mixing
8. Filled Coating Safety
9. Filled Coating Circulation Loop
a. Class Overview
b. Classroom Worksheet
10. Floor Activity—Filled Coating System: Components
11. Floor Activity—Filled Coating System Flow
12. Start up
a. Screens
b. Classroom Worksheets
13. Troubleshooting
a. Classroom Worksheet
b. Filled Coating Screen
c. Classroom Worksheets
i. Components
ii. Common Cause Problems
iii. Worksheet
iv. Impacts to Viscosity
14. Surge Tank
a. Surge Tank Screen
b. Classroom Worksheet—Surge Tank
15. Filled Coating Drives
a. Panel View Screen
b. Classroom Worksheet
16. Floor Activity—Coater Pump
17. Floor Activity—Filled Coating System Panel View
18. Cold Start Screen
a. Classroom Worksheet
19. Filled Coating Autofiller
a. Autofiller Screen
b. Classroom Activity—Complete the Product Specs
20. Tracking the Trends
a. Filler Trend Screen
b. Viscosity Trend Screen
c. Alarm History Screen
d. Floor Activity—Trend Analysis and Alarm History
21. Cost and Waste
Assessment
TAB 5: COATER SYSTEM
Objectives: Learners will be able to…
Describe all safety hazards, environmental controls and precautions
Describe the coater process
Describe how topcoating and backcoating work
Identify all coater components and describe their functions
Describe how the tracking systems work
Agenda Section Five: Coater System (8 hours)
1. Safety Hazards, Environmental Controls and Precautions
2. Coater Process Overview
a. Applying Filled Coating
b. Backcoating Application
c. Classroom Worksheet
d. Adjusting Backcoating
e. Using Control Charts
f. Floor Activity—Backcoating (use the charts at the back of Tab 5)
3. Topcoating
a. Topcoating Components
b. Gauging the Thickness of Topcoating
4. Tracking
a. Coater Fife Tracker
b. Backfall Tracker
c. Tejax Sheet Width Adjustment Dial
Assessments
TAB 6: WEIGHT CONTROL, SHADOWLINE APPLICATION, AND GRANULE VALVE
Objectives: Learners will be able to…
Describe all safety hazards in the weight control and shadowline processes
Describe and use the Centurion System Controls for product weight: panel view screen, adjust
comp numbers and product change and startup.
Describe and operate the Weight Control process
Use all Weight Control panel view screens, describe their purpose and potential problems
Identify all Weight Control components in the systems and describe their functions
Describe how the Weight Control system operates
Work with the manual weight control switches when process is out of control
Pre-class reading:
You need to read the Centurion Systems Operating manual located at the back of Tab 6. This
overview information is essential to your success.
Agenda Section Six: Weight Control, Shadowline Application and Granule Valve (16 hours)
1. Overview
2. Safety Hazards
3. Product Weight Specifications
4. Centurion System
a. Classroom Worksheet—Centurion Systems
b. Weight Control Components
c. Product Change Methods at the Centurion Weight Control System
d. Composition Number
e. Scanner Start-up Procedure
f. Power Outages
g. Floor Activity—Weight Control Overview and Centurion Controller
h. Floor Activity—Centurion Control Panel
i. Floor Activity—Product Change
5. Weight Control System
a. Weight Control Systems Screen
b. Classroom Worksheet
c. Weight Variable Screen
d. UCLs and LCLs
e. Viscosity Variable Screen
f. Classroom Worksheet
g. Product Weights and Costs
6. Panel Views
a. Both Actuator Screen
b. Front Actuator Screen
c. Back Actuator Screen
d. Manual Switches
e. Floor Activity—Using the Panel View Screens and Making Decisions
i. Manual Switches
ii. Accessing and Using the Weight Control System Screen
iii. Accessing and Using the Weight Variable Screen
iv. Accessing and Using the Viscosity Variable Screen
v. Accessing and Using the Both Actuator Screen
vi. Accessing and Using the Front Actuator Screen
vii. Accessing and Using the Back Actuator Screen
7. Shadowline Application
a. Shadowline Applicators Screen
b. Oakpro 30 Shadowline
c. Oakpro 40 Shadowline
d. Oakpro 50 Shadowline
e. Classroom Activity—Shadowline Application
f. Shadow Applicator Setup Screen
g. Shadow Monitor Screen
h. Floor Activity—Shadowline Application
8. Overview of Granule Valve
a. Overview course objectives and agenda
b. Overview course activities
c. Class Registration (if offered for college credit)
d. ASSESSMENT PROCESS
e. Warm ups
f. Theory of Operation
g. Safety
9. Granule Valve Operations Manual
a. Condensed Operating Instructions
b. Setup of Blend Boxes and Chutes
c. Floor Activity—Identifying Blender Components and Safety
d. Performance Checklist—Installing Blend Boxes and Chutes
e. Complete Control Panel Operations
f. Classroom Activity—Navigating through the control screens
g. Tracker Setup, Adjustment, and Operations
h. Troubleshooting
i. Good Operations Checklist
j. Performance Checklist—Performing the Pre-Start up Checklist
10. Granule Valve Maintenance Manual
a. Routine maintenance
b. Gauge Measurement of Wear
c. Changing a Module
d. Replacing Wear Parts in the Module
e. Floor Activity—Granule Valve Routine Maintenance and Part Replacement
f. Classroom Activity—Replacing Wear Parts in the Module
g. Take Home Worksheet
11. Blender Shutdown and Power-up Procedures
12. Centurion Operating Manual
Assessment
TAB 7: LINE SPEED CONTROL
Objectives: Learners will be able to…
Describe all safety hazards, environmental controls and precautions
Describe the line speed control process
Describe all line speed control panel view screens, their purpose and use
Identify all line speed control components in the systems and describe their functions
Describe the tension control processes
Demonstrate sheet break and lace up procedures
Agenda Section Seven: Line Speed Control (8 hours)
1. Line Speed Control Overview—Process and Purpose
2. Safety Hazards, Environmental Controls and Precautions
3. Classroom Worksheet—Line Speed Control System Overview
4. Line Drives
5. Machine Controls
6. Drive Interaction
7. Modes of Operations
8. Line Speed Specifications by Product
9. Floor Activity—Line Speed Control Drives and Switches
a. Safety Hazards
b. Line Speed Display Analysis
10. Classroom Worksheet—Line Drive Troubleshooting
a. Root Cause Analysis
b. Situational Scenarios
11. Tension Control
12. Moving the Sheet When the Line is Down
a. Overview
b. Performance Checklist
13. Sheet Break and Lace up
a. Overview
b. Classroom Worksheet—Sheet Break Process
c. Classroom Worksheet—Lace-up Process
14. Performance Checklists
a. Sheet Breaks
b. Lace-up Procedures
Assessment
TAB 8: HOT OIL SYSTEMS
Objectives: Learners will be able to…
Describe all safety hazards, environmental controls and precautions of the hot oil system
Describe the hot oil system and processes
Describe all hot oil system panel view screens, their purpose and use
Identify all hot oil system components in the systems and describe their functions
Agenda Section Eight: Hot Oil Systems (6 hours)
1. Overview
2. Safety
a. Hot Oil Safety
b. Spill Prevention and Reaction
3. Classroom Worksheet—Hot Oil System Overview
4. Filled Coating Hot Oil System
a. Filled Coating Hot Oil Manifold #1
b. Classroom Worksheet
c. Filled Coating Hot Oil Manifold #2
d. Filled Coating Hot Oil Manifold #3
5. Hot Oil Valves for Pure Coating Loop
6. Hot Oil Temperature Controllers
7. Filled Sealant Hot Oil System
a. Overview
b. Classroom Worksheet
8. Coating / Laminate Hot Oil System
9. Hot Oil System Components
a. Components
b. Safety Hazards
10. Floor Activity—Hot Oil System
Assessment
TAB 9: COATER OPERATIONS
Objectives: Learners will be able to…
Describe all safety hazards, environmental controls and precautions
Describe the entire coater system and processes
Explain and perform all start-up and shut down actions using a checklist
Explain and perform all actions you take during normal operations
Explain each of the variables you need to manage during normal operations, the targets,
min/max and potential problems/solutions.
Explain and demonstrate how to monitor the and maintain the quality of the product
Explain and demonstrate how to monitor and maintain the quality of the process
Demonstrate the housekeeping standards and perform the housekeeping checklist
Demonstrate an integrated understanding of the entire system through review and situational
scenarios
NOTE: This module will be scheduled to coincide with actual operations including: startup,
changeover, shut down, and regular operations.
Agenda Section Nine: Coater Operations
(hours vary based on operations; this module will be scheduled over several days)
1. Overview
2. Warm-up: Based on what you’ve already learned, what are the things you must do, and when
do you do them when operating the coater?
3. Classroom Review Activity and Assessment
a. Part One—Major Components and Layout
b. Part Two—Safety Hazards
c. Part Three—Environmental Controls
d. Part Four—Systems Overview
4. Start-up Processes
a. Start-up Process Checklist
b. Performance Checklist—Start-up Process
c. Mixing Filler Percent During Start-up
d. Floor Activity—Start-up
5. Changeover Processes
a. Checklist—Managing the Backend During Changeover
b. Backfall Changeover—Laminates to 3-tab
c. Coater Changeover—3-tab to Laminates
d. Backfall Changeover—3-tab to Laminates
e. Cooling Section Changeover—3-tab to Laminates
f. Coater Changeover—Laminates to 3-tab
g. Blender Changeover—3-tab to Laminates
h. Backend Changeover—Checklists / Performance Checklists
6. Shut down Process
a. Shutdown Process Checklists
b. Performance Checklists
7. Housekeeping
a. Cleaning walkthrough
b. Shift housekeeping Standards Checklist
c. Floor Activity—Housekeeping checklist
8. Normal Operations and Monitoring Quality of Product and Processes
a. Cheat Chart for Managing Variables
b. Situational Scenarios
9. Quality in operating
a. Dimensions
b. Product Spec Sheets
TAB 10: TROUBLESHOOTING AND MAINTENANCE
Objectives: Learners will be able to…
Describe all safety hazards, environmental controls and precautions in completing the uptime
and downtime PMs.
Determine if the PM requires Lock out Tag out, Confined Space Training, Hot Work Permit,
Roof Access Permit or Line Breaking Permit and identify where in the process this occurs
Describe the processes for each of the PMs (daily uptime, downtime, quarterly and annual)
Demonstrate the Daily Task List
Demonstrate common PMs.
Determine correct response to hypothetical situations that may occur.
Analyze common issues for root causes and actions to resolve the problems.
NOTE: This module will need to be scheduled to coincide with the actual activities. You need to be
scanning the schedule for these activities and work with your instructor to schedule the
training. Because of this the time will vary for this module.
Agenda Section Ten: Troubleshooting and Maintenance
1. Overview
2. Troubleshooting—Issues Analysis
a. Classroom Worksheets
i. Viscosity Issues
ii. Tracking Issues
iii. Weight Variation
iv. Backcoating
v. Level Control
vi. Stickers
vii. Granule Coverage
viii. Granule Alignment and segregation
3. Classroom Activity—Situational Scenarios for Integrating Variables and Demonstrating
Judgment and Decision-making
4. Maintenance Overview
5. Safety Procedure Checklists
6. Daily Task List for Coater
a. Floor Activity—Performing the Daily Task List
b. Classroom Worksheet—Daily Task List for Coater
7. Lodding Scraper Set-up Procedure
a. Uptime PM task list
b. Classroom Worksheet—Lodding Scraper Set-up Procedure – Uptime PM Task List
c. Floor Demonstration
8. Filled Coating
a. Downtime PM task list
b. Classroom Worksheet—Filled Coating - Downtime PM Task List
c. Floor Demonstration
9. Coater Downtime
a. PM task list
b. Classroom Worksheet—Coater Downtime - PM Task List
c. Floor demonstration
10. Mixer & Surge Tank
a. Quarterly Downtime PM Task List
b. ClassroomWorksheet—Mixer & Surge Tank - Quarterly Downtime PM Task List
11. Simulation for Paddle Wear Judgment
12. Hydro Blasting
a. Set-up of Coater Pan Procedure Downtime PM Task List
b. Classroom Worksheet—Set-up for Hydro Blasting of Coater Pan Procedure -
Downtime PM Task List
13. Home Work Assignment—Leadership at the Backend
Training Evaluation
Final Assessment