The purpose of this (Standard Operating Procedure) SOP For Preventive Maintenance of De-dusting Tunnel is to provide guidelines and instructions for the preventive maintenance of the De-dusting Tunnel to ensure its optimal performance, cleanliness, and compliance with quality standards during the de-dusting process.
SOP for Preventive Maintenance of De-dusting Tunnel
- OBJECTIVE:
- To lay down the Procedure for preventive maintenance of de-dusting tunnel installed in warehouse material receiving area.
- SCOPE:
- This SOP is applicable to preventive maintenance of de-dusting tunnel installed in warehouse material receiving area.
- RESPONSIBILITY:
- Technician/ Officer engineering shall be responsible for proper execution of preventive maintenance as per SOP.
- Engineering – Head shall be responsible for reviewing the SOP and for ensuring proper execution of preventive maintenance
- ACCOUNTABILITY:
- Engineering – Head shall be accountable for proper implementation of the SOP.
- DEFINITIONS:
- Nil
- PROCEDURE:
- Preventive maintenance shall be executed as per the SOP No.: SOP/EN/XXXYYY- Execution of Preventive Maintenance.
- Ensure that the spare parts are available at the time of preventive maintenance.
- Preventive Maintenance – Mechanical
- Checking of Door Gaskets
- Check the condition of door gaskets for any damaged (cut, deforms size and shape change).
- Insert the spring and then gasket in the gasket groove.
- Checking shall be done monthly.
- Checking of internal of de-dusting tunnel
- Check the condition of internal of de-dusting tunnel for any dent; surface finish; if required repair the same.
- Clean the internal surface with the lint free cloth and cleaning solvent.
- Checking shall be done monthly.
- Checking of air curtains
- Physically check the condition of air curtains for damaged; cutting if required replace the same.
- Checking shall be done monthly.
- Checking of rollers
- Physically check the condition of roller; and free movement.
- Check the movement of rollers with the limit switches.
- Checking shall be done monthly.
- Checking of blower damper
- Check the closing and opening of the blower damper.
- Check for the gasket if required replaces the same.
- Checking shall be done monthly.
- Checking of installed instruments
- Ensure that the installed instruments are calibrated.
- Check the end connections of the all instruments; if required tighten the same.
- Checking shall be done half yearly.
- Checking of all air filters
- Check the condition of all air filters.
- If there are stubborn impurities sticking on to the padding then a gentle knock on the mesh can dislodge the stuck particles.
- If this does not work then highly compressed air blown through the mesh can help in removing the stuck particles.
SOP For Preventive Maintenance of De-dusting Tunnel:
- Preventive Maintenance – Electrical
- Checking of terminations and wiring
- Ensure that the power supply to the machine is switched OFF.
- Visually check all the power and control wiring and terminations in the electrical panel and for control elements mounted on the machine for any loose connection and damage.
- Check and ensure by using the screwdriver that all the wires are properly tightened at the distribution terminals inside the electrical panel and on the terminals of all the control elements.
- Checking shall be done six monthly.
- Checking and maintenance of contactors
- Switch OFF the Electrical supply to the Machine.
- Remove all the power and control wires from the contactor terminals.
- Remove dust from control panel with help of air blower.
- Remove the contactor from the panel and visually check all the contacts for the signs of pitting and deposit of carbon on the contacts.
- Clean the contacts, terminals and all the moving parts of the contactor by spraying contactor cleaner.
- Replace the contacts if found damaged / welded.
- Put back the contactor in the panel and re-terminate all the power and control wires properly to their original locations.
- Checking of contactors shall be done six monthly.
- Checking and lubrication of blower motor bearings
- Switch OFF the main Electrical Supply to the machine.
- Open the motor terminal box and remove the power connections.
- Open the foundation bolts of the motor and take it out from the Base frame.
- Open the fan cover and remove the cooling fan.
- Dismantle the end plates of the motor and take the rotor carefully out, from the stator
- Visually inspect the bearings, rotor and end plates for any sign of mechanical damage. If found any, replace / rectify the same.
- Manually rotate the bearings and check for any abnormal sound. If the bearings have worn-out replace the same, otherwise lubricate the bearings by all-purpose extreme pressure, high temperature grease.
- Reassemble the motor and re-terminate the power cable.
- Place the motor to its foundation and tighten the bolts.
- Checking of bearings shall be done once in a year.
SOP For Preventive Maintenance of De-dusting Tunnel:
- Checking of motor
- Check the insulation resistance of motor winding with the help of megger.
- Check the phase continuity and winding continuity of motor with the help of tong tester.
- Physically check the motor terminal box and terminal connections.
- Check the voltage drawn by motor with the help of multimeter
- Check the current drawn by motor with the help of tong tester.
- Physically check the direction of rotation; it should be as per recommended direction.
- Checking shall be done after every six month.
- Checking of earth connection
- Check earthing wire and thimble for any damage. If observed any replace the same.
- Tighten the earth connection with appropriate tool.
- Checking shall be done six monthly.
- Checking of tube lights
- Ensure that the fluorescent lamp for luminous intensity.
- Replace the fluorescent lamp, if observed light is less.
- Checking shall be done on six monthly.
- Post Preventive Maintenance – Check List
- Record the Preventive Maintenance details as per the Format No.: SOP/EN/XXXYYY “Preventive Maintenance Checklist & Record for De-dusting Tunnel”.
- Whenever any modifications and major works are carried out to the equipment, the same shall be mentioned in the equipment history card as per the respective SOP.
- Connect the equipment main power supply and start the equipment.
- Ensure that the equipment is running smoothly, without any abnormality.
- If any abnormality is observed in the above, same will be attended in co-ordination with User department Head.
- ABBREVIATIONS:
- CRF No. : Change Request Form number
- CFL : Chloro Fluorescent Light / Lamp.
- QA : Quality Assurance
- SOP : Standard Operating procedure
- REFERENCES:
- Nil.
- DISTRIBUTION LIST:
- SOP shall be distributed to following departments Quality Assurance, Engineering as per user request.
- ANNEXURES:
- Preventive maintenance checklist & record for de-dusting tunnel. : SOP/EN/XXXYYY
SOP For Preventive Maintenance of De-dusting Tunnel:
PREVENTIVE MAINTENANCE CHECKLIST & RECORD FOR DE-DUSTING TUNNEL
| Equipment Name | Location | ||
| Equipment ID | Frequency |
| Check List | Check | Remark |
| Monthly Check List | ||
| Checking and cleaning of internal surface of the de-dusting tunnel. | ||
| Checking and cleaning of the internal surface of the de-dusting tunnel. | ||
| Checking of air curtains. | ||
| Checking of rollers for free movement. | ||
| Checking of blower damper. | ||
| Check the blower motor for Lubrication. | ||
| Half Yearly Check List | ||
| Checking of installed instrument. | ||
| Checking of terminations and wiring. | ||
| Half-Yearly Check List | ||
| Checking of contactors. | ||
| Checking of CFL tube light for luminous intensity | ||
| Checking of earth connections. | ||
| Yearly Check List | ||
| Checking of bearings shall be done once in a year. |
