BREAKDOWN RECTIFICATION OF REACTORS

1.0 PURPOSE:
         
    To  describe  a  standard operating procedure  for  breakdown    rectification of reactors.
    
2.0    SCOPE:
    
    The standard operating procedure describes in detail the method  of breakdown  rectification of reactors.
    
3.0    RESPONSIBILITY:
    
    The  responsibility  of  breakdown   rectification  of  various    reactors lies with the  staff of rank not lower than maintenance  supervisor 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:
    
4.1.0    Agitator failure or shaft failure: 

4.1.1    This  can happen due to overload, misalignment of  agitator  or   shaft, solidification of mass, corrosion or erosion.  

4.1.2    Take out the agitator or shaft, repair/replace and fix it  back   as per SOP REPAIRING/REPLACING THE AGITATOR/SHAFT OF REACTORS 

4.2.0    Damage of jacket: 

4.2.1    This can happen due to more heating or cooling medium  pressure   or due to corrosion.

4.2.2    The  jacket damage is of two types one is minor and another  is    major.  

4.2.2.1    Minor damage:

4.2.2.1a    Repair the portion that is damaged as per SOP WELDING  THE DAMAGED JACKET OF REACTOR.
4.2.2.2    Major damage:

4.2.2.2a    Get the jacket replaced as per SOP SENDING  OUT  EQUIPMENT  FOR RECTIFICATION TO THE OUTSIDE AGENCY..

4.3.0    Gear box problems:

The  possible gear box problems are oil seal leakage,  bearings    damage, worn out gears and damaged gaskets.

4.3.1    If   oil  seal  leaks,  replace  the  oil  seal  as   per   SOP  REPLACEMENT OF OIL SEALS OF GEAR BOXES.

4.3.2    If  bearings  are  damaged, replace the  bearings  as  per  SOP REPLACEMENT OF  BEARINGS OF  PROCESS / UTILITIES / LABORATORY EQUIPMENT.

4.3.3    If gears are worn-out, send the gear box for repairs as per SOP SENDING  OUT  EQUIPMENT  FOR RECTIFICATION TO THE OUTSIDE AGENCY.

4.3.4    If  gaskets  are  damaged,  replace the same  as  per  SOP  REPLACEMENT OF GASKETS OF PIPE LINES/PUMPS.

4.4.0    Coupling bolts damage/V-belts damage/worn-out gland packing:

4.4.1    Due to  misalignment of shafts, coupling bolts will be normally  damaged.

4.4.2    After  rectification  of  misalignment of  shafts  replace  the  damaged coupling bolts as per SOP REPLACEMENT OF COUPLING BOLTS OF REACTORS. 

4.4.3    If  V-belts  are  damaged,  replace the same  as  per  SOP  REPLACEMENT OF V-BELTS OF REACTORS, VACUUM PUMPS, COMPRESSORS, AIR COMPRESSORS, CENTRIFUGES, BLOWER ETC..

4.4.4    If  gland packing is worn-out, replace the same as per SOP replacement  of gland packing of pumps and reactors.

4.5.0    Burning of motor/damage of motor bearings:

4.5.1    If motor is burnt out, get the motor rewound.

4.5.2    If motor bearings are damaged, replace the same as per SOP REPLACEMENT OF  BEARINGS OF  PROCESS / UTILITIES / LABORATORY EQUIPMENT. 

5.0    RECORDING:

    The responsibility of recording breakdown rectification in  the   history card  as per SOP lies with staff of rank not lower than   the maintenance Engineer.

Breakdown rectification, engineering, jacket of reactor