BREAKDOWN RECTIFICATION OF TRAY DRYER

1.0 PURPOSE:
    
    To  describe  a  standard operating procedure  for  breakdown rectification of tray dryer.
    
2.0    SCOPE:
    
    The standard operating procedure describes in detail the method of  breakdown  rectification of tray dryer.  The breakdown  rectification includes, rectification of motor pulley and fan  pulley, replacement of bearings of fan shaft and motor, replacement  of  fan  shaft/fan, rectification of burnt motor and replacement of  V-Belts.
    
3.0    RESPONSIBILITY:
    
    The responsibility of carrying out breakdown  rectification  of dryer  lies  with the staff of rank not lower than  the  junior utility operator of maintenance department.
    
    The  responsibility of preparing, reviewing  and approving  the  standard  operating  procedure lies with the  Manager  -  Maintenance,  Head of Production and Head of QAD respectively.
    
4.0    METHOD:
    
4.1    Rectification of motor pulley and fan pulley:
    
4.1.1    Isolate the equipment electrically.
    
4.1.2    Remove the motor from the equipment
    
4.1.3    Carry out the replacement of pulley as per SOP REPLACEMENT OF DAMAGED COUPLINGS/PULLEYS OF REACTORS, PUMPS, MOTORS AND GEAR BOXES. in case of motor pulley damage.
    
4.1.4    Loosen the first plumber block and remove the same.
    
4.1.5    Loosen the second plumber block.
    
4.1.6    Remove the V-belt.
    
4.1.7    Remove  the  damaged pulley from the fan shaft  and  place  new pulley.
    
4.1.8    Fix the V-belt.
    
4.1.9    Tighten the second plumber block.
    
4.1.10    Fix the first plumber block.
    
4.1.11    Restore the power supply to the equipment
    
4.1.12    Record the details in the equipment history card.
    
4.2    Replacement of bearings of fan shaft and motor:
    
4.2.1    Replacement of bearings of fan shaft.
    
4.2.1.1    Isolate the equipment electrically and remove the  guard.
    
4.2.1.2    Loosen the first plumber lock and remove it from the shaft.
    
4.2.1.3    Remove the pulley from the fan shaft.
    
4.2.1.4    Loosen  the second plumber block and remove it from  the  fan shaft.
    
4.2.1.5    Insert the second plumber block with new bearing and  fix  it in its original position.
    
4.2.1.6    Insert  the  pulley, fix it to the fan shaft and fix  the  V-belt.   Insert  the  first plumber block and fix  it  in  its original position.  Fix the guard.
    
4.2.1.7    Restore the power supply to the equipment.
    
4.2.1.8    Record the details in the equipment history card.
    
4.2.2    Replacement of motor bearings:
    
4.2.2.1    Isolate the equipment electrically.
    
4.2.2.2    Remove  the  guard and motor from the equipment.   Remove  V-belt.
    
4.2.2.3    Carry  out  the  replacement  of  bearings  as  per  SOP  REPLACEMENT OF  BEARINGS OF  PROCESS / UTILITIES / LABORATORY EQUIPMENT.
    
4.2.2.4    Place the motor on the equipment, fix the V-belt and fix  the motor to the equipment and fix the guard.
    
4.2.2.5    Restore  the power supply to the equipment.
    
4.2.2.6    Record the details in the equipment history card.
    
4.3    Replacement of fan shaft/fan:
    
4.3.1    Isolate the equipment electrically.
    
4.3.2    Remove guard.
    
4.3.3    Loosen the plumber blocks.
    
4.3.4    Remove V-belt.
    
4.3.5    Remove fan side mesh.
    
4.3.6    Remove fan by hitting from back side.
    
4.3.7    Remove  shaft along with the plumber blocks and  pulley  from the equipment.
    
4.3.8    Remove  first plumber block, pulley and second plumber  block from the shaft.
    
4.3.9    Replace the old fan shaft with new one.
    
    
4.3.10    Fix second plumber block, pulley and insert v-belt.
    
4.3.11    Fix the first plumber block.
    
4.3.12    Replace the old fan with new one and fix the mesh.
    
4.3.13    Fix the guard
    
4.3.14    Restore the power supply to the equipment.
    
4.3.15    Record the details in the equipment history card.
    
4.4    Rectification of burnt motor.
    
4.4.1    Isolate the equipment electrically.
    
4.4.2    Remove the guard and V-belt.
    
4.4.3    Remove the motor from the equipment.

4.4.4    Send  the motor for rewinding  as per SOP SENDING  OUT  EQUIPMENT  FOR RECTIFICATION TO THE OUTSIDE AGENCY..
    
4.4.5    After receiving the, fix it to the equipment.
    
4.4.6    Fix the V-belt and the guard.
    
    
4.4.7    Restore the power supply to the equipment.
    
4.4.8    Record the details in the equipment history card.
    
4.5    Replacement of V-belts of dryer:
    
4.5.1    Isolate the equipment electrically.
    
4.5.2    Remove guard.
    
4.5.3    Loosen first plumber block bolts.
    
4.5.4    Replace the damaged V-belt with new one.
    
4.5.5    Fix the first plumber block.
    
4.5.6    Fix the guard.
    
4.5.7    Restore the power supply to the equipment.
    
4.6    Main door Gasket leak:
    
4.6.1    Isolate the equipment electrically.
    
4.6.2    Check the main door gasket, if it is hardened replace it with new gasket
    
    
4.6.3    Check the door hinges, if damaged replace them.
    
4.6.4    Check the twisting of door due to heat, if so, straighten it.
    
4.7    Steam Calorifier leak:
    
4.7.1    Isolate the equipment electrically.
    
4.7.2    Dismantle the steam calorifier.
    
4.7.3    Rectify the calorifier leaks by welding.  If the calorifier Damages beyond the repair replace with new one.
    
4.7.4    Restore the power supply to the equipment.
    
4.7.5    Record the details in the equipment history card.
    
5.0    RECORDING:
    
    Responsibility of recording the breakdown  rectification in  the  history card  lies with the staff of  rank  not lower than the maintenance supervisor.     
          

Breakdown rectification, engineering, v-belt