BREAKDOWN RECTIFICATION OF SIFTER

1.0 PURPOSE:   

    To  describe  a  standard operating procedure  for  breakdown rectification of sifter.    
2.0    SCOPE:    
    The standard operating procedure describes in detail the method of breakdown  rectification of sifter and  includes replacement of motor bearings, rectification of burnt motor, replacement of motor  pulley and sifter shaft pulley, replacement  of  spider, replacement  of  sieve, replacement  of   sifter  bearings  and replacement of V-belts.
    
3.0    RESPONSIBILITY:
    
    The responsibility of carrying out breakdown  rectification  of sifter  lies with the staff of rank not lower than  the  junior utility operator.
    
    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    Replacement of motor bearings:
    
4.1.1    Isolate the equipment electrically.
    
4.1.2    Separate the motor from the  equipment. 

4.1.3    Carry   out   the   replacement  of   bearings   as   per   SOP REPLACEMENT OF  BEARINGS OF  PROCESS / UTILITIES / LABORATORY EQUIPMENT.
    
4.1.4    Fix the motor to the equipment. 
    
4.1.5    Restore the power supply to the equipment. 
    
4.1.6    Record the bearings replacement data in the equipment history card.
    
4.2    Rectification of burnt motor:
    
4.2.1    Isolate  the equipment  electrically. 
    
4.2.2    Separate the motor from the equipment.
    
4.2.3    Send the motor to the outside agency as per SOP SENDING  OUT  EQUIPMENT  FOR RECTIFICATION TO THE OUTSIDE AGENCY.for rewinding.
    
4.2.4    After receving back, check the motor functioning in no load condition and fix the motor to the equipment
    
4.2.5    Restore the power supply to the equipment.
    
4.2.6    Record the details in the equipment history card.
    
4.3    Replacement of motor shaft pulley and sifter shaft pulley:
    
4.3.1    Isolate the equipment electrically.
    
4.3.2    Carry out  replacement of pulley as per SOP REPLACEMENT OF DAMAGED COUPLINGS/PULLEYS OF REACTORS, PUMPS, MOTORS AND GEAR BOXES.
    
4.3.3    Restore the power supply to the equipment.
    
4.3.4    Record the replacement data in the equipment history card.
    
    
4.4    Replacement of spider:
    
4.4.1    Isolate the equipment electrically.

4.4.2    Loosen the motor support bolts/bottom bearing housing bolts.
    
4.4.3    Slowly hit the motor support bracket/bearing housing down wards using hammer.
    
4.4.4    Replace the spider.
    
4.4.5    Bring  the motor support bracket/bottom bearing housing to  the original position and tighten the bolts.
    
4.4.6    Restore the power supply to the equipment
    
4.5    Replacement of sieve:
    
4.5.1    Isolate the equipment electrically.
    
4.5.2    Loosen the sieve holder bolts.
    
4.5.3    Remove the sieve holder from the equipment
    
4.5.4    Replace the old sieve with new one.
    
4.5.5    Place the sieve holder and tighten the bolts.
    
4.5.6    Restore the power supply to the equipment.
    
    
4.6    Replacement of sifter bearings:
    
4.6.1    Isolate the equipment electrically.
    
4.6.2    Separate  the  motor and spider from  the equipment  if  it  is direct  drive.   If it is belt drive loosen the  motor  support  bolts and remove the V-belt.
    
4.6.3    Separate sieve holder from the equipment.
    
4.6.4    Separate  the bearing housing from the equipment.  In  case  of  belt drive separate the upper bearing housing and lower bearing  housing from the equipment.
    
4.6.5    Take  out  the pulleys and bearing covers and then  remove  old bearings, clean the bearing housing with  cotton waste.  If the  shaft  of any bearing housing is found worn-out at the  bearing seating area and/or shaft is found bent, replace the shaft with new one.
    
4.6.6    Insert  the new bearings in their respective places  and  apply Bearing  grease.
    
4.6.7    Fix the bearing covers and pulleys in their respective places.
    
4.6.8    Fix the bearing housing.  In case of belt drive, fix the  upper bearing housing and the lower bearing housing.
    
4.6.9    Check  the old spider.  If it is damaged  replace it with   new one and fix the motor in case of direct drive.  Keep V-belt  on pulleys  and adjust the motor for the medium tightness  of  the V-belt and fix the motor support bolts in case of belt drive.
    
4.6.10    Fix the sieve holder to the equipment.
    
4.6.11    Restore the power supply to the equipment.
    
    
4.6.12    Record the bearings replacement details in the equipment history card.
    
4.7    Replacement of damaged V-belts:
    
4.7.1    Isolate the equipment electrically.
    
4.7.2    Loosen the motor support bolts.
    
4.7.3    Remove old V-belt and place new V-belt.
    
4.7.4    Adjust the motor for the medium tightness of the V-belt and fix the motor support.
    
4.7.5    Restore the power  supply to the equipment.
    
4.8    Insufficient vibration of sieve holder:
    
4.8.1    Isolate the equipment electrically.
    
4.8.2    Dismantle the sieve and sieve holder.

4.8.3    Adjust  the balancing mechanism for sufficient vibration
    
4.8.4    Replace the rubber cushion padings, if found damaged.
    
4.8.5    Assemble the sieve and sieve holder.
    
4.8.6    Restore the power supply to the equipment.    
    
5.0    RECORDING:

   The responsibility of recording the breakdown  rectification in the   history card  lies with the staff of rank not lower  than the maintenance supervisor.
    

Breakdown rectificatio, engineering, pulleys of reactors, pumps