5. plant maintenance

7/31/2019 5. Plant Maintenance

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By: Seah Chong MengTetra Pak Dairy, Beverage & Prepared FoodSoya & Tea Centre

Soya Training

9 10 June 2010VinaSoy

Plant Maintenance


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PERFORATED DISC MILL


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Working Principle


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Mashing

Pulping

Grinding

Emulsifying

Working Principle


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The pressure of the cooling / sealingliquid must be 0.5 to 1 bar higher thanproduct outlet pressure. Flow is about 1to 4 liters/min.

Check and clean filter monthly

Maintenance & Operation cooling liquid

Pressure Gauge

PressureRegulator

Regulating Valve


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Maintenance Greasing of Main Motors

GreasingNipples


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After >2000 hours of operation, the knife, disc and cam-ring worn out

New Disc, Knife and Cam ring

The disc can be turn over when it is worn on one side


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DONT WAIT FOR THIS TO HAPPEN


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COLLOID MILLWITH FINE CUT STATOR/ROTOR


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WorkingPrinciple

FINE CROSSCUT ROTORSTATOR


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Grinding

Homogenizing

Dispersing Emulsifying

Working Principle


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The pressure of the cooling /sealing liquid must be 0.5 to 1bar higher than product outlet

pressure. Flow is about 1 to 4liters/min.

Check and clean filter monthly

Maintenance & Operation cooling liquid


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Adjustingthegrin

dingG

ap

Gap 150~200 micron


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Decrease Gap

Holding Handle

Scale

Hand Wheel

Increase Gap

Adjustingthegrin

dingGap


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Maintenance Stator & Rotor and Lubrication

Stator/Rotor will be worn after long usage. Can be sent back to

factory for re-sharpening.

Stator/Rotor to be changed when worn out.

Yield will decrease due to bigger particle size from worn rotorand stator


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New Fine Cut Rotor & Stator

THE SMALL EDGES ARE PUPOSELY CHIPPED OFF TOPREVENT IT FROM BREAKING DURING NORMAL OPERATION


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DONT WAIT FOR THIS TO HAPPEN


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Vibrations In the Mills

Causes:-Cavitations worn stator of M2, wrong M4 gap

-Overloading too much beans, small gap

-Over pressure wrong back pressure setting,system design

Remedy:

-Cavitations - ensure sufficient feed or increasesystem backpressure

-Overloading - reduce beans capacity, increase gap

-Over pressure - reduce system back pressure


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DETAILED MAINTENANCE INSTRUCTIONSFOR BOTH MILLS CAN BE FOUND IN THEOPERATION AND MAINTENANCE MANUAL

PLEASE READ IT - BEFORE YOU CARRYOUT ANYMAINTENANCE WORK


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NETZSCH MOHNOPUMPS


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Working Principle


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Maintenance - General


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The Rotors are Reduced Rotors

The motor and gearbox ALSO need maintenance

Before you carryout any maintenance work, READ the instructionsfound in Section 7 to 10 of the O&M Manual


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FLASH COOLER


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Working Principle

Cooling Water

Outlet

Cooling water

To vacuum pumpInlet

Product


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Maintenance

Change O ring

De-scaling of Condenseris necessary if thecooling water is Hard


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STEAM INJECTOR


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Working Principle


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Steam injector Optimizing running time andtemperature control by gap setting using spacer 7, 8,9 10 and11

S7 T=2.0 mmS8 T=2.5 mm

S9 T=3.0 mmS10 T=3.5 mmS11 T=4.0 mm

Maintenance Optimization


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Instruments


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Tetra Alwin Soy Instruments

Check for Correct Function Quarterly

Calibrate Annually


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Calibration of Pressure Transmitter Do not attempt to calibrate the

sensor on site. The PLCprogram is set according toits calibrated range

The pressure transmitters forthe flash cooler has a rangefrom -1 to 1 bar so YOU MUSTNOT ZERO IT.


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Decanter


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Maintenance &Operational

Guide


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Daily Operational Checkpoints

Cleanliness. Look for oil spills, grease spots, liquid spills etc

Check machine vibration

Check bearing and general machine noiseLook for loose nuts, bolts or screws etc. Tighten if necessary

Check temperature of grease lubricated main bearings

Look for oil leaks from gearboxCheck conveyor torque

Check flexible connections for deterioration and leaks

Check general condition of vibration isolators


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Weekly - Check the CIP Nozzles

Ensure that there is no blockage

SAFETY FIRST


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SAFETY FIRST

1. ENSURE ELECTRIC POWER IS CUT-OFF TO MACHINE

2. ENSURE MACHINE HAS COME TOA STANDSTILL BEFORE OPENINGCOVER

3. LOCATE GREASING POINT BYLOOKING OUT FOR THIS SYMBOL

LUBRICATION SCHEDULE


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LUBRICATION SCHEDULEACCORDING TO SERVICE BULLETIN SB_9807_3

Main Bearings

Standard time interval for lubrication of main bearings is 300 operatinghours for operation temperatures less then 70 degrees C and 150operating hours for higher then 70 degrees C.

Foodec 310T it is 12 grams or 8 strokes per lubrication

(1.5gm/stroke with standard Alfa Laval grease gun)

Conveyor BearingsThe conveyor bearings should be lubricated after every CIP cycle.

Foodec 310T it is 2.4 grams or ~2 strokes per lubrication

(1.5gm/stroke with standard Alfa Laval grease gun)PLEASE REFER TO SERVICE BULLETIN FOR COMPLETELUBRICATION GUIDE

L b i t M i & C B i


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Conveyor Bearing

Grease: Texaco

Lubricate when machine at

standstill

Main Bearing

Grease: SKF LGHP2

Lubricate when bearing

temperature is below 80

degrees C and at low speed

Lubricate Main & Conveyor Bearings

Always use the recommended lubricants


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Lubricate Main & Conveyor Bearings

Conveyor Bearing

Grease: TexacoLubricate when machine at

standstill

Always use the recommended lubricants

Main Bearing

Grease: SKF LGHP2

Lubricate when bearing

temperature is below 80

degrees C and at low speed

3 5 kN DD G b R ti 1 52


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3.5 kNm DD Gearbox Ratio 1:52

Consult your local Alfa Laval Service

Centre for service & repair of gearbox


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Monthly - Remove feed tube and check for

clogging in feed inlet and cleanliness


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Venting is Important

CAUSE EFFECT

Oth I t t Ch k i t


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Other Important Checkpoints

Check V Belt Tensions every 2000 HrsChange V Belts every 16000 Hrs

Check Seating Torque of Main Bearing Pillow Block Bolts 4000 Hrs

Check for Corrosion Inside Casing and Bowl Exterior 1000 HrsCheck Bushings at Solid Discharge for Wear 1000 Hrs

Check Function of Emergency Stop 2000 Hrs

Check Function of Vibration Switch 2000 Hrs

Check Function of Cover Switch 2000 Hrs

Change Gearbox Oil 2000 Hrs

Plan for Intermediate and Major Service -

Remember the Motors Also Needs Servicing 2000 Hrs

REFER TO OM FOR COMPLETE

MAINTENANCE INSTRUCTIONS


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Thank You

5. plant maintenance

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