workinstruction for maintenance &pest control etc

7/30/2019 Workinstruction for Maintenance &Pest Control Etc.

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THE NILGIRI DAIRY FARM PVT LTD

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WORK INSTRUCTIONS

RO PLANT - PROCESS:

a) 3litre of hypo chlorine is mixed with 37 liter of water in one tank.

b) After mixing, it is transferred to sand filter in which 9500litre of water

can be stored..

c) First it is filtered by sand and with filters layers inside. So that, if the

input is 2kg then output is 1.9kg. This water is taken in small beaker for testing. It should have 0.2 ppm chlorine in water.

d) After sand filter, water is transferred to carbon filter; its overallcapacity is 40kg. Half of the tank contain carbon and filter layers.

e) Water is transferred from top; it crosses carbon, filters and settlesdown. Its purity is confirmed by taking test.

f) Water is purified but taste is not changed. After all these process, ittastes salty if bore well water is salty.

g) From carbon filter tank, water is transferred to 2 tanks. In first tank 2.5 kg of watcol is added in 37.5litre water and in second tank, 10kg

of hydrochloric acid in 30kg of water.

h) From these 2 tanks, water is mixed and passed through pipe in the

third tank. Its capacity is 10,000litre. From third tank, water istransferred to membrane.

i) If 9500litre water is transferred then the output will be 4000litre. In

this membrane, taste of water is changed and its ph is maintained at

5.5-6 and 0ppm. The remaining 5500litre water is sent as waste water.

Prepared by Checked by Approved by Page no:




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j) At last from membrane, water is pumped to degasser where large

number of filter is kept. The filtered and purified water is maintainedat 7.5-8ph.

k) The waste water rejected contains 6000ppm, bore well water contain

1500-1600ppm and RO pure water 0ppm with ph 7.5-8.

Cleaning: To clean all the tanks, backwashing by pure water is done for 10 hrs.

Membrane is cleaned weekly once with 2litre of hydrochloric acid in 300lite of pure water.





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BOILER - PROCESS:

In boiler room, diesel tank, boiler and temperature controller panel is kept. In dieseltank 17.5 liter diesel and 500 liter furnace oil is mixed and combination of these two is used

every day. Boiler has a capacity of 600kg i.e. for 1hr 600litre of water is used. Water from RO

plant with ph 0-5 is transferred to boiler. Water is stored in bottom and stream from boiling water is produced at top. In temperature controller panel Fill, off, fire, three switches is present.

a. While starting boiler, water valve, diesel valve should be kept open. Switch on to

fill, water is pumped. Allow water to run for 3 minutes. So that coil is covered

with water, then switch on to fire.

b. After 5minutes allow stream to come out. Temperature is maintained at 120°c

then it is passed for line service. If boiler is running for 8hrs, stop boiler. Close

the entire valve. Put Bolton for 6-8kg pressure.

c. So that scales in coil is removed and water is kept for cooling. Maximum

temperature is maintained at 160-170°c.

d. For safety measures another boiler is kept. Its capacity is 600kg.For this, furnaceoil tank is used nearly it stores 1000ltr.Water from RO plant may have 0-5ppm.If

it exists more than 5ppm; sharpener machine is used.110ltr of resin is in

sharpener. In this, 15kg salt and 30ltr RO water is mixed. In order to control morethan 5ppm in water, this process is used. For 1/2hr water is sent out to reduce its

hardness. After that take sample and test it for ppm, if it is less than 5, close the

valve and transfer water to service tank which hold 5000ltr water, from there to

boiler and the process repeated. Boiler is mainly used to get stream. This stream plays a vital role in pasteurization of milk, to prepare paneer, curd, set curd,

cheese, ghee.

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AIR COMPRESSOR:

In this room 2 compressors is used. First compressor has 7.5 hp and secondcompressor has 15hp. In case of air compressor, if it attains 10kg pressure then there is an

automated cut off of the power. Once it attains 7 kg pressure then power will switch on.

Air compressor plays a vital role in milk pasteurization, for packing curd, set curd, yoghurt, for

mould pressing in preparing cheese like mozzarella, cheddar.

REFRIGERATION:

IBT tank is important in this section.

• 2 tanks are used. Each has a capacity of 35000ltr water.

• Inside the tank coil is present; where ammonia gas is passed, outside purified water is

kept to get cool.

• It runs at 30kg pressure.

• In this refrigeration compressor, condenser, accumulator is important.

• First ammonia gas is taken in receiver; from there it is sent to condenser

accumulator inside coil in tanks.

• So that the water becomes ice i.e. -2° to -4° chill. In that ammonia becomes liquid.

• It is again transferred to compressor because of its 160°-170°c, it become gas.

• It is sent to condenser nearly 5°c less from compressor. From there to receiver

accumulator tank.

• This process continues; meanwhile ammonia gas in receiver is checked.

• If two compressors is in use then two condenser and two cooling tower is used. Each

cooling tower can hold 300ltr of water. Cooling tower is kept on when compressor starts

running.

• From IBT tank ammonia is sent to compressor and then condenser. There is a connection

between condenser and cooling tower.

• Cooling tower reduces the temperature of ammonia from160°-170°. At last it is sent toreceiver. Once again the process is repeated. Engine oil in compressor is weekly checked.

This chill temperature plays a vital role in storage of milk, curd set curd, cheese, paneer.





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PROCEDURE FOR EFFLUENT TREATMENT PLANT:

PRIMARY TREATMENT:

The raw effluent is primarily treated for removing and coarse matter and fat by screening

and fat separation followed by equalization to dampen the fluctuations in the characteristics of

the effluent and to homogenize the effluent concentration.

SECONDARY TREATMENT:

The secondary treatment comprises of conventional extended aeration activated sludge process.

PROCESS DESCTIPTION:

Stream -1 whey effluent with a design flow of 10 KLD is proposed to be gravitated

through an under ground pipe net work, in to an independent ETP comprising of a bar screen in

SS, followed by a collection sump of 1 day storage which will be provided with 1 no. agitator and acid / alkali dosing tanks. The neutralized effluent will be pumped in to a UASB reactor at a

constant flow rate. These pre-treated effluent from UASB is carried over at the inlet of stream –

2 ETP, with BOD of around 3000 mg/l, & COD of 11,000 mg/l.

Stream -2 wash effluent: The combined process effluent (stream -1 & stream -2, with a

design flow of 100 KLD (stream -1 = 10 KLD = stream -2 = 90 KLD) will be further treated by atwo stage extended aeration activated sludge plant. Out of the above mentioned flow of 100

KLD, the existing ETP can handle 15 KLD of process effluent & design BOD of 3000 mg/l

being the outlet of UASB, along with 2 KLD domestic effluents classified as stream -3. Balance83 KLD of stream-1 + stream-2 (100-17 =83 KLD) is proposed to be treated in an new ETP

which will be gravitated into a bar screen, equalization/ neutralization tank where lime is added

for PH correction if necessary, & will be treated by two stage extended aeration activated sludge

process followed by filtration & chlorination. The entire treated effluent will be disposed on ownland for gardening.

UNITWISE OPERATION INSTRUCTIONS:

A) BAR SCREEN:

The basic function of the bar screen is to remove coarse organic matter. Therefore the

plant maintenance staff carry out the routine inspection of the bar screen and remove the





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screenings manually that may be retained on the bar screen manually with the hand rake

provided. The removed screening is collected and periodically disposed.

B)EQUALISATION TANK:

The raw effluent is taken to equalization tank for dampening the fluctuations in thecharacteristics of the effluent. One number of agitators is provided to keep the contents of

the equalization tank in suspension and in mixed state. The effluent from the equalization

tank is pumped to aeration tank for further biological treatment

C) CONSTANT HEAD TANK:

Constant head tank is made up of mild steel and is internally lined with fiber-reinforced plastic to avoid direct contact of the chlorine/polyelectrolyte being dosed with MS tank,

there by increasing its life span. It is provided with the PVC tapered valve connected with

stainless steel operating knob, so that the dosage can be varied according to therequirements. Inlet of the tank is provided with polypropylene/ PVC float valve, so that

the chlorine, polyelectrolyte when gets filled up to the maximum capacity, further inflow

into the tank is automatically stopped.

D) AERATION TANK:

The plant personnel ensure the continuous operation of the surface aerators and alsomake sure that there is sufficient bleeding of mixed liquor suspended solids (settled

sludge from the clarifier) to the aeration tank.

Operation one sludge pump to return from the sludge clarifier back to the aeration tank.During the working shifts, operate this pump at regular intervals depending upon quantity

of sludge generated. At other times it is permissible to operate it intermittently.

The above operations are very essential to keep the biological mass in the aeration tank inliving condition. As the sludge contains the organisms responsible for biological activity.

Check the MLSS of the liquid in the aeration tank once a day.

D) CLARIFIER:

Clarifier being a part of extended aeration activated sludge process is essentially a setting

unit, where the active biomass is settled. The plant maintenance staff ensures that thesettled sludge in the clarifier is periodically returned to the aeration unit and the excess





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sludge is pumped to sludge drying beds. The tank is provided with a scraper arm which is

driven at a very slow speed by means of a motor connected through double reductiongear box. The sludge settled in the tank is pushed to the central sludge pit by means of a

slow moving scraper arm. Then the sludge is finally pumped out to aeration tank or

sludge drying beds depending on the site conditions.

E) ACTIVATED CARBON FILTER:

The treated water is pumped into the carbon filter from clarified water sump by means of

a filter feed for further polishing. Filtered water can be used for gardening. Carbon filter can be operated by following the illustrations given below:

Before starting the filter feed pump, filter valves are checked and brought to thefollowing positions:

Filter inlet valve (V1) openFilter outlet valve (V2) closed

Back wash inlet valve (V3) closed

Back wash outlet drain valve (V4) closedAir vents valve (V5) open

Start filters feed pumps and allow treated water into the filter. Watch the inlet pressure gauge. As

soon as the filter is full, the pressure gauge reading will rise. Air valve on top of the filter will

release the air from inside the filter with a hissing sound and then will close by itself.Immediately on observing the rise in inlet pressure, the filter outlet is opened. Filtration is nowon.

BACKWASHING THE FILTER:

Backwashing the filter to wash out the dirt, accumulating on top of the filter bed

is an essential part of the operation routine. The frequency of backwashing depends uponthe turbidity of the water to be filtered. As soon as the clarified water is fairly clear, the

backwashing operation may be stopped.

The operation process of backwashing is:1. First stop the pumps.

2. Close the filter inlet valve and filter outlet valve.

3. Open the backwash drain valve.4. proceed to backwash the filter as follows:

a) Ensure that the settled water sump is full.





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b) Start pumps and observe the rise in the inlet pressure.

c) Immediately open the backwash inlet valve until the outlet pressure

gauge reading shows 20 ft or 8.5 psi.

5. Backwashing is now on. The clarified water will enter the filter in the reverse

direction at a high rate. This will loosen and carry the accumulated dirt on the

filter bed upwards into the backwash tray and the dirty water will be washed fromthe backwash drain pipe. Usually, the backwashing is indicated when the waste

water coming out of the drain is almost clear. The drain water is led to waste and

not returned to the treated water sump.6. Close the backwash inlet valve. Immediately on completion of backwash stop the

pumps to avoid the unnecessary wastage.7. The filter can now be restarted for normal operation.





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WORK INSTRUCTION FOR PEST CONTROL:

1. PIED PIPER SERVICES (Rodent Control) doing work for once in 15 days interval.2. This is a treatment against rats, bandicoots and mice’s.

3. In this treatment ROBAN CAKE: PPS, BROMADIOLONE 0.005% is used.

4. In treatment, if found dead rats inside/outside premises, it is taken outside and burned/ buried.

5. Once in a month GOLDSEAL SERVICES is done.

6. This treatment is against cockroaches and black/red ants only.

7. This treatment is also for outside premises.8. We install RODA BOXES around the outside premises for rodent control.

9. Gel i.e., FIPRONIL, PHENYL PYRAZOLE is applied for cockroaches.10. Weekly twice IFM SERVICE is carried out for flies.

11. In this treatment CYPHENOTHRIN/DELTAMETHRIN 2% is used.

12. Every end of the month inspection is done. Technicians guide workers also.

13. The chemicals used for this treatment is safe for human beings & surroundings, Alsoapproved by the Indian government.





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WORK INSTRUCTION FOR ELECTRICIAN:

Daily check the KEB reading.

Daily check transformer and fuse.

Check the voltage (440v R.Y.B)

Check all main switch, fuse.

Check amperes.

Check all current line.

Check I.B.T panel box, fuse, loose connection, contactor and load relay.

Check air compressor & motor’s panel box loose connection, contactors relay checking.

In RO plant check panel box, loose connection, motor, ampere, and bearing.

In AC check panel box.

In AC check air and gas leakage.

In ETP check panel box, all motors, baring, amperes, voltages, loose connection.

In milk packing machine, check panel box, all motors, baring, amperes, voltages, loose

connection.

In D.C generator check panel box, loose connection, meter reading and time.

In D.C generator check water in the battery level and check charging.

Check boiler reading time and diesel level and oil.

Check the controls of UPS battery.





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RULES TO BE FOLLOWED BEFORE WORKING

PERSONNEL HYGIENE

• Trim the nails; sanitize your hands in iodophore solution before and after handling of

operation

Sanitize your hands after touching unclean vessels, hand shake, coughing, sneezing, and

using toilets.

Avoid spitting and coughing near the processing equipment.

Daily wear clean clothes.

Wear cap and gloves inside the processing hall, storage area and wear mouth guard if

required.

Wear bandage for wounds.

Not to smoke, chew tobacco/ gum in the factory premises.

Cut the hair properly.





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GENERAL HYGIENE

Keep the floor and walls clean.

Keep the lighting fitting clean.

• Ensure that walls are kept clean against cob-webs

Clean the equipments thoroughly.

Clean the floor with detergents mob with disinfectant.

Keep the drainage always clean.

Clean the foot mat daily.

• Clean the dustbins daily.





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HANDLING METHOD OF ACIDS, CAUSTIC & DETERGENTS

Take detergent solution without spillage.

Take caustic without spillage.

Wear hand glows while handling acid

Wear the coat, goggle, shoes and mouth guard while handling acid.

Close the acid container tightly.

Use acid pump for emptying the required quantity

Use the prescribed vessel for handling acid.





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PROCEDURE FOR MILK DUMPING AND MILK TANK UNLOADING

• Unload the can from the vehicle

• Open the can lid, by lid opener.

• Check the milk for quality.

• Clean the can lid thorough detergent solution (1:2) and clean it in can lid tank by water.

• Pour the milk in weighing tank and note the milk quantity.

• Take the milk sample and transfer the milk to dump tank.

•Clean the empty cans thorough can washer by soda solution and thorough steam (70˚C)

• Receive the Cleaned cans (thorough washing soda solution 4kg in 400liter at 70˚C) in can

conveyor and load the can in the respective route vehicle.

• Chill the dump tank milk thorough chiller (<6˚C) and store in the clean storage tank.





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• Ensure CIP system is complete for milk reception equipment.

• Clean the raw milk chiller twice a week by dismantling it.

MILK RECEPTION – UNLOADING ROUTE MILK

a) Operate the can conveyor.

b) Ensure the milk vehicles are parked in the correct position.

c) Unload the can from vehicle with reference to trip sheet and agent code number.

d) Open the can lid by lid opener

e) Clean the lid in lid cleaning tank.

f) Pour the milk in weighing tank and keep the can in the can washer conveyor.

TANKER MILK

a) Park the Milk tanker in the milk reception bay.

b) Open the milk tanker compartment door and plunge the milk and take sample.





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c) On Quality acceptance chill the milk trough milk chiller.

d) After milk reception, clean the milk tanker (1:2 detergent solutions) & check the PH inlaboratory.

e) Finally sanitize with iodophore (75PPM) solution for 5 minutes. Ensure the cleanliness of milk tanker is effective.

RECEPTION AREA CLEANING WORK INSTRUCTIONS

a) Keep the reception dock clean.

b) Ensure reception dock is free from pest.

c) Clean the area if milk spillage occurs.

d) Clean the dustbins on shift basics.

e) Keep the can conveyor, weighing bowl and dump tank can washer clean and tidy. Close

the dump tank and weighing bowl when not in use.

f) Clean the can washer and can conveyor by detergent solution (1:2) once the milk reception is complete.

g) Sanitize the hands by iodophore solution and handle the milk.

h) Ensure the route vehicle and milk tankers are clean and tidy.





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VECHICLE CLEANING INSPECTION PROCEDURE

PROCUREMENT VEHICLE

1. Every route vehicle should be properly covered.

2. Every route vehicle platform should be cleaned and kept smooth.

3. Every Can should be in closed condition with proper lids

4. Vehicle outside and inside should be cleaned and free from dust and smell

MILK TANKERS

1. Milk road tanker outside should be cleaned.

2. Each compartment door should be cleaned and closed properly.

3. Valve section door should be closed with S.S. box.





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4. Inside wall condition should be smooth and free from dust and smell.

PROCEDURE FOR CAN WASH

Ensure effective cleaning of can washer.

Take 400liter of water and mix 4 kg of washing soda in can washing tank.

Keep the can in the can conveyor for cleaning.

Adjust the steam and water line for cleaning requirement.

Switch on the can conveyor.

Ensure the effective cleaning of can in the can washer.

Clean the can lid with detergent solution.

Close the can with can lid after cleaning.

Load the can in the vehicle.





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Put off the can conveyor and close the steam and water line.

Drain the washing soda solution once the can washing is complete.


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