SOP for Preventive & Routine Maintenance for Rapid Mixer Granulator

OBJECTIVE

1. To reduce downtime.
2. To minimize breakdown time and maintenance costs of equipment to obtain optimum performance.

SCOPE

General maintenance for long intervals (yearly/monthly) and short intervals (weekly/daily). 

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RESPONSIBILITY

Maintenance personnel: Responsible for carrying out the maintenance work and rectifying any anomalies.

Operators: For carrying out daily routine checks and reporting to the maintenance department for any unusual observations, vibrations, and performance.

Production manager and production supervisors: To make the machine available for maintenance in time before the machine comes to a standstill.

PROCEDURE

Routine maintenance: Daily

Check the following prior to operating the machine

• The interlocking system. When the lid is open.

1. The main motor will not operate.
2. The chopper motor will not operate.
3. The discharge valve will not operate.

• The access panel on the machine base is properly secured.
• The main impeller is properly mounted and bolted to the drive shaft.
• The chopper is properly mounted and bolted to the drive shaft.
• Sufficient air pressure is available to the shaft seals and the pneumatic cylinder of the discharge valve (6 to 8) BART.
• Excessive vibration or unusual sound from the machine or its control should be investigated and attended at once.

Routine maintenance: Weekly

• Check the mixer cone impeller and chopper
• Remove the impeller and chopper and thoroughly clean the shaft seal.
• Replace the seal if excessive wear is observed.
• Check and ensure that the impeller and the chopper are neither too tightly fit on their respective shafts nor too loose.
• Check the operation of the discharge valve,

1. The rubber plunger seal is not loose and is in position to ensure an effective seal, if not replaced.
2. The plunger opens and closes easily and movement does not take more than 3 seconds.
3. The face of the plunger is sitting flush with the mixer cone internally and does not penetrate inside causing damage to the main blade.

• Clean the filter cloth inside the dome of the lid.
• Check all interlocking for proper functioning.
• Grease all bearings in the motor with the recommended grease.
• Check the gearbox oil level; top it up with recommended oil (EP.90.)
• Check the tightness of - Belts and fastenings.

ALSO READ: Design Qualification for Rapid Mixer Granulator

Safety of the operator:

• Always use proper tools; always pull the spanner to prevent possible slippage of the wrench which could cause damage to corners on nuts, bolts, sockets, and screws and possible injury to wounds.
• A hoist is recommended for lifting anything weighing over 13kg.
• Always use leg muscles when lifting objects/parts of the machine. Mere back muscles.
• Make certain there is no oil or water on the flow.
• Always wear safety glasses/goggles when using welding grasses, blazing, and grinding.
• Make certain that electrical connections and air connections are disconnected from the source.

Safety of equipment

• Never over-tighten bolts, nuts, or screws, as this will affect or ruin machine parts.
• Never under-tighten bolts, nuts, and screws as this will also ruin machine parts
• Always tighten bolts, nuts,
• And screws in a correct sequence.
• Make certain all connections are tightened before operating the machine.
• Before operating the machine make certain all moving parts are protected by guards. And guards are properly put in place.
• Make certain machine alignment is ok.

Safety of contents

• Always ensure the accuracy and care given to the installation and adjustments of various parts of the system are correct.
• Always review safety as a reminder of the hazards that may be present when working with equipment and suppliers as there is no exception to the rule that “the safe way is the right way”.

ABBREVIATIONS

R.M.G- Rapid Mixer Granulator.

EP – Extreme pressure.

ANNEXURE

Nil

REVISION HISTORY

Nil

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