Equipment Operating Procedures

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Equipment Operation Procedures 1 Purpose: These procedures are established to ensure that equipment operators carry out their tasks correctly, and to prevent production and safety accidents resulting from improper operation of the equipment. 2 Scope Applicable to the operation of production equipment. 3 Responsibilities 3.1 The Production Department is responsible for drafting equipment operation procedures. 3.2 Operators in each position are responsible for operating the equipment in accordance with the equipment operation procedures. 4 Operating Requirements 4.1 Operation of Centrifugal Pumps 4.1.1 Before starting, check the oil level in the bearing housing; it should be at a level of 1-2 mm above the center line of the oil gauge. Also, verify that the motor rotates in the correct direction, that the coupling turns smoothly without any obstruction, and that the washer is intact. 4.1.2 For mechanically sealed units with water cooling, the cooling water should be turned on before startup. Self-cooling pumps should be started after the liquid feed is introduced into the pump casing; it is strictly prohibited to operate them with no liquid inside the casing. 4.1.3 After startup, regularly check that the oil temperature does not exceed 75°C, that the oil is clean, and that there is no noise. 4.1.4 If any fault is detected, the machine should be stopped immediately for maintenance; it must not be operated while faulty. 4.1.5 To shut down the pump, first close the feed valve, then stop the motor, and subsequently turn off the cooling water. If the ambient temperature is below the freezing point of the liquid, it is necessary to drain the remaining liquid from within the pump casing. If the pump is not to be used for an extended period, it should be disassembled, cleaned thoroughly, and reassembled. 4.2 Operating procedures for the reducer 4.2.1 Before starting up, check whether the lubricating oil or grease in the reducer is at the proper level, and ensure that the bolts of all couplings are tight. 4.2.2 Check whether the holder of the reducer is secure; manually rotate it to check for any jamming or noise. 4.2.3 After verification shows no issues, start the machine and monitor the oil level, oil temperature, and noise; stop the machine immediately for inspection if any abnormalities are detected. 4.2.4 The lubricating oil should be replaced at least once every six months, while the grease should be replaced once a year (for new machines, the lubricating oil should be changed within 36 hours). 4.3 Use of the grinder 4.3.1 Preparations before startup 4.3.1.1 Open the cover to check whether the rotor is loose or deformed. 4.3.1.2 Check whether the screws on the machine housing are tightened. 4.3.1.3 Check whether the motor base is loose or displaced. 4.3.1.4 Manually rotate the pulley to check for any jamming or looseness in the transmission components. 4.3.1.5 Check whether the belt is damaged or slipping on the pulley. 4.3.1.6 Check whether the rotation direction of the large and small cages is correct; opposite directions are acceptable ； Install the pulley cover. 4.3.2 Starting up and operation 4.3.2.1 After completing the preparatory work mentioned above, start the steamer basket motor to run under no-load conditions, while paying attention to its operating status. 4.3.2.2 If there is an abnormal sound, the power supply should be turned off immediately to determine the cause. If there are no abnormalities, the large cage motor can be turned on. 4.3.2.3 It is also acceptable to use just one motor under special process requirements. 4.3.2.4 Pay regular attention to the sounds of various bearings and belts, etc., to prevent accidents. 4.3.2.5 Pay attention to whether there is any powder leakage during the operation with material in the device; note down the location so that it can be sealed after the machine stops. 4.3.3 Shutdown 4.3.3.1 Ensure that the screen machine has stopped before shutting down. 4.3.3.2 After stopping, clean the magnetic rod. 4.4 Operation of the belt conveyor 4.4.1 Preparations before startup 4.4.1.1 Before starting the machine, in addition to conducting a thorough maintenance check of all its components, it is also necessary to ensure that there are no people or other debris on the belt. A signal to start driving can be given only after checking that there are no problems. When multiple belts are connected in series, they are started in sequence from the discharge end to the feed end. 4.4.2 Startup 4.4.2.1 After starting, let it run idly for 3–5 minutes; only once all components are confirmed to be functioning properly can it operate under load. 4.4.2.2 After the conveyor belt starts operating, the operators must remain focused and stay at their posts; those responsible for monitoring the belt should conduct regular inspections along its length to identify any issues and address them promptly. 4.4.2.3 If the belt is found to be misaligned, slipping, or jumping during operation, the machine should be stopped immediately; a mechanic must adjust the position of the electric drum before the machine can be used again. 4.4.3 Shutdown 4.4.3.1 Before preparing for shutdown, the feeding of material onto the conveyor belt should be stopped first. 4.4.3.2 The motor may be stopped only after all the material on the conveyor belt has been conveyed away. 4.5 Operation of the fan 4.5.1 Preparations before starting the fan 4.5.1.1 Check the clearance dimensions of various parts of the fan, as well as to ensure that there is no collision or friction between the moving parts and the fixed parts. 4.5.1.2 No one shall stand in the radial direction of the impeller or near the coupling to avoid danger; a protective cover should be installed on the coupling. 4.5.1.3 Check whether the electrical wiring and instruments are correct. 4.5.1.4 Check whether the cooling section is functioning properly. 4.5.2 Once the fan is started and operating at the specified load, the temperature rise of the bearings shall not exceed 40 degrees. 4.5.3 Emergency shutdown of the fan 4.5.3.1 When intense noise is detected from the fan. 4.5.3.2 The temperature of the bearing rises sharply. 4.5.3.3 When the fan experiences severe vibration and impact. 4.6 Use of the drying drum 4.6.1 Before feeding material, check whether the nozzle holder and nozzle angle are appropriate, and conduct tests for leaks by passing water and air respectively. 4.6.2 Check whether the reducer is in good condition, and whether the oil level in the gears and the puller’s oil tank is appropriate. 4.6.3 Check whether the ventilation openings at the furnace head and furnace tail are at the opening levels required by the process, and ensure that the flange screws are tightened properly. 4.6.4 Check whether all instruments and on-site measuring devices are functioning properly. 4.6.4 Before starting up, warn the people nearby the equipment not to approach it, especially the gear ring area; the equipment can be started only after the start-up signal is given. 4.6.5 Lay the bed layer according to the process requirements. 4.6.6 In the event of a long-term shutdown, have an electrician reverse the wiring of the motor; the operator should then rotate the drum in the opposite direction to discharge the material, thereby preventing it from clumping inside the drum due to moisture. 4.7 Operation of the vibrating screen 4.7.1 Check whether the connection to the vibration motor is secure and whether the bolts are tight. 4.7.2 Check whether the screen is damaged, and whether the rubber strips around it are properly pressed and secured. 4.7.3 Only after the above checks show no issues can it be started briefly to observe the vibration level and the presence of any noise. If the amplitude is uniform and there is no noise, and these conditions meet the production requirements, then it can be started for normal operation. 4.7.4 Stop the machine when no material is being screened by the vibrating screen. 4.7.5 Check the condition of the vibrating screen at least twice per shift, and record the inspection results in the process records. 4.8 Bag filters 4.8.1 During long periods of shutdown, the cover should be opened to check whether the filter bags are damaged. 4.8.2 Before use, check whether the auger reducer and air shutter are functioning properly. 4.8.3 The pressure of the purge compressed air should be between 0.4 and 0.6 MPa; check whether the solenoid valve is functioning properly. 4.8.4 Whether the manholes and other cover plates are properly closed. 4.8.5 First start the bag filter auger and purge system, then start the dust removal fan and other equipment. 4.8.6 When shutting down, wait for other devices and the dust removal fan to be turned off before shutting off the bag filter. 4.8.7 Check the condition of the bag; if there are lumps in it, remove them and clean the bag, and if the bag is damaged, replace it immediately with a spare one. 4.9 Use of agitation 4.9.1 Check whether the oil level in the reducer is at the midpoint indicated by the oil gauge, whether the bolts of the coupling are tightened, and whether the supports are secure. 4.9.2 Check whether the connection between the motor and the reducer is loose. 4.9.3 Reverse rotation of the mixer is strictly prohibited (the direction depends on the rotation direction of the mixing screw). 4.9.4 After verification, start the machine and operate it, paying attention to the oil level, oil temperature, and noise levels; stop the machine immediately for inspection if any abnormalities are detected. 4.9.5 After mixing evenly, stop stirring. 4.10 Use of the bucket elevator 4.10.1 Preparations before startup 4.10.1.1 Open the cover to check whether the chain and buckets are loose or deformed. 4.10.1.2 Check whether the screws on the machine housing are tightened. 4.10.1.3 Check whether the motor base is loose or displaced, and inspect the oil level in the reducer and the motor. 4.10.1.4 Manually rotate the pulley or sprocket to check for any jamming or looseness in the transmission components. 4.10.1.5 Check whether the belt is damaged or slipping on the pulley. 4.10.1.6 Check the motor direction; reverse rotation is strictly prohibited. 4.10.1.7 Adjust the counterweight or positioning screw to the optimal position. 4.10.2 Starting up and operation 4.10.2.1 After completing the preparatory work mentioned above, start the motor to operate under no-load conditions, while paying attention to its operating status. 4.10.2.2 Regularly pay attention to the sounds emitted by bearings, belts, and chains, etc., to take preventive measures. 4.10.2.3 Add material to the equipment only after it is running steadily; never add material before starting it up. 4.10.3 Shutdown 4.10.3.1 Stop feeding the conveyor. 4.10.3.2 Stop the machine after the material is discharged at the outlet. 4.11 Use of the leaf filter 4.11.1 Check whether the oil level in the tank is at 2/3 of the level indicated by the sight glass, and whether the circuit is connected. 4.11.2 Filter in accordance with the process procedure. 4.11.3 Opening the cover 4.11.3.1 Open the safety valve to release the pressure inside the filter and start the hydraulic pump. 4.11.3.2 Pull the locking handle; once the locking ring has been fully pulled apart, release the handling to return it to the stopped position. 4.11.3.3 Pull the filter screen inlet and outlet handle; once the filter screen has been fully pulled out, pull the handle back to the stop position. 4.11.3.4 Shut down the hydraulic pump. 4.11.4 Clean the filter screen in accordance with the process requirements. 4.11.5 Closing the cover 4.11.5.1 Start the hydraulic pump, move the handle for inserting the filter screen in and out; once the filter screen is fully inserted, return the handle to its resting position. 4.11.5.2 Pull the locking handle; once the locking ring has fully engaged (with the main oil circuit pressure at 6–10 MPa), the locking handle returns to its resting position. 4.11.5.3 Screw on the outlet valve, i.e., insert the anti-rotation pin, close the vent valve, and the filtration tank is now sealed. 4.11.5.4 Shut down the hydraulic pump. It is strictly prohibited to release the lock when there is pressure and material inside the filter! ! !