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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
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