SOP for Barrel Filling Machine PDF

AkzoNobel India Limited Metal Coatings STANDARD OPERATING PROCEDURE MANUAL – OPERATIONS Section No.: SOP.PRD.020 Ref. ISO 9001 & AN HSES Manual...

AkzoNobel India Limited Metal Coatings STANDARD OPERATING PROCEDURE MANUAL – OPERATIONS Section No.: SOP.PRD.020 Ref. ISO 9001 & AN HSES Manual Review Date: 08/01/2025 Issue Date: 27/07/2022 Page No.: 1 of 13 Rev No.2 BARREL FILLING MACHINE Sl. no Rev 1.0 PURPOSE To lay down instructions for safe operating of Barrel filling machine. 2.0 SCOPE This procedure is applicable to filter material through filter unit & filling in Barrel through barrel filling machine 3.0 DEFINATIONS / ABBREVIATIONS *PA/TA Trained & Authorized Person QO Quality Officer PO Production Officer PM Production manager ETF Emergency Task Force *TA- Trained and authorized person is the person who has got proper training of doing the particular activity and is validated for the same. 4.0 RESPONSIBILITIES Responsibility Activity Primary Secondary Information Reference Safe operating of PA/TA PO PM Equipment Manual filter machines. 5.0 HAZARD Static Fire Hazard -– Failure of continuity of portable earthing & bonding clamp can 5.1 cause a fire.  PA to always ensure to apply Earthing and Bonding during the filling operation LOPC with Filter Bag / Bucket Filter / AODD Pump-  Ensure the filter bag is properly set into the bucket filter, as incorrect packing can 5.2 cause leakage. Tighten the bucket filter securely, and verify that all connections of the AODD pump are properly fixed to prevent any leakage. 5.3 Electrocution –  Ensure there are no exposed wires. All control panel and operating panel cables Reviewed by : Manoj Taywade Approved by : Dipenkumar Patel  AkzoNobel India Limited Metal Coatings STANDARD OPERATING PROCEDURE MANUAL – OPERATIONS Section No.: SOP.PRD.020 Ref. ISO 9001 & AN HSES Manual Review Date: 08/01/2025 Issue Date: 27/07/2022 Page No.: 2 of 13 Rev No.2 BARREL FILLING MACHINE must have proper glanding as per standards to prevent the risk of electrocution. Fire Due to Electrical component in Zone area – 5.4  All electrical panels should be complied as the Zone requirement. LOPC from the Barrel filling machine lance – 5.5  Filling lance and infeed actuator valve will operate on the set point which is acting on the Loadcell value. PA to correctly enter the set point and Engineering department has to check Lance on a weekly basis for its working. Line of fire (Movable sleeve) –  The sleeve of the filling machine should remain in the left-hand side rest position. 5.6 Line of fire (Material movement) –  TA to ensure not to keep all the pallets on the line of fire and has to keep it on the reserved places, where warehouse operators can come and pic the same. Impact load on the Barrel – 5.7  In case of misalignment of the barrel bunk, ensure the lance assembly returns to its normal position. Ergonomic Risk Hazard –  Ensure that all manual handling is performed in accordance with established best practices for safe manual handling. 5.8 PPEs: 5.9 Safety Shoes, High Visibility Jackets, Safety Goggle & Helmet – All the Time Cut Resistance Gloves - while handling Wooden pallet, Empty drums, Filled drums, Reviewed by : Manoj Taywade Approved by : Dipenkumar Patel  AkzoNobel India Limited Metal Coatings STANDARD OPERATING PROCEDURE MANUAL – OPERATIONS Section No.: SOP.PRD.020 Ref. ISO 9001 & AN HSES Manual Review Date: 08/01/2025 Issue Date: 27/07/2022 Page No.: 3 of 13 Rev No.2 BARREL FILLING MACHINE HOPT, Barrel tilter. Vapor mask, Long sleeves and Nitrile Gloves - when in Contact with Chemical Hygiene – 5.10  Avoid moisture (water) and dust to enter the barrel and filling line Slips, Trips, and Falls (STF): 1- Ensure that empty metal pallets, Velcro Belts, and other materials are kept in appropriate positions out of pathways after use. 2- Maintain three-point contact when ascending or descending platforms and always keep your eyes on the path. Ensure working floor is dry, no liquid spillage. Electrical Shock - Handling Battery Charger Plug & Sockets:  Handling Battery Charger plug & sockets – Only trained personnel should operate the stacker. 6.0 METHOD 6.1 INITIAL START UP Filter machine assembly contains the following accessories… a. Diaphragm pump b. Filter unit (with provision for fixing filter bag) c. Connecting Hose Pipes 6.1.1 6.1.2 Use proper PPEs as per mention during operation. 6.1.3 Ensure the filter unit is cleaned by opening the filter unit casing. 6.1.4 Check for any residual solvent in the filter machine. Reviewed by : Manoj Taywade Approved by : Dipenkumar Patel  AkzoNobel India Limited Metal Coatings STANDARD OPERATING PROCEDURE MANUAL – OPERATIONS Section No.: SOP.PRD.020 Ref. ISO 9001 & AN HSES Manual Review Date: 08/01/2025 Issue Date: 27/07/2022 Page No.: 4 of 13 Rev No.2 BARREL FILLING MACHINE 6.1.5 Check the pump strainer by opening and inspecting, if not clean, clean it. Place the filter bag (as specified in the process instructions / batch sheet) into the filter 6.1.6 unit such that it fits the strainer mesh. 6.1.7 If a bag is already in use, ensure that it is clean and free from clogs. 6.1.8 Ensure the O – Ring condition before closing the lid, check all the o rings in the assembly 6.1.9 Tighten the eye bolts of the filter unit lid such that no leakage can happen from the sides. 6.1.10 Fix the barrel filling machine airline connection to the diaphragm pump Ensure the pressure of the compressed air is around 4 – 6 Kg/Cm2, if the pressure is 6.1.11 less, inform maintenance to correct it Position the outlet of the filter machine assembly over the spout of the container such that 6.1.12 no spillage can occur during operation. 6.1.13 Connect the inlet pipe of the diaphragm pump to the outlet valve of the vessel or blender. 6.1.14 Ensure all connections are made properly. 6.1.15 Attach a static discharge clip to the filter machine assembly. Connect the outlet pipe of the diaphragm pump to the inlet valve of the barrel filling 6.1.16 machine 6.1.17 Switch on the power for control panel. Press F5 to go on home screen and login for the process For login follow bellow process 1. Press F1 to go log in screen 2. Press 1 in Level 3. Press 1000 in PSW 4. Then press enter key to complete log in 5. Then press F5 to go to the home screen. 6.1.18 Reviewed by : Manoj Taywade Approved by : Dipenkumar Patel  AkzoNobel India Limited Metal Coatings STANDARD OPERATING PROCEDURE MANUAL – OPERATIONS Section No.: SOP.PRD.020 Ref. ISO 9001 & AN HSES Manual Review Date: 08/01/2025 Issue Date: 27/07/2022 Page No.: 5 of 13 Rev No.2 BARREL FILLING MACHINE Check gross weight and net weight should be zero or in tolerance level (+/-0.2 Kg), if not then do zero 6.1.19 For doing Zero follow the below process 6.1.20 1. Press F5 button in display source to go in Metrological screen 2. Then Press F4 for Zero. 3. Then press home button and then F5 to go main display screen and then check again net and gross weight should be zero. 6.1.21 System put on manual mode by switching switch in manual mode on control panel. check lance up down by switching switch in operating panel. If found ok, then again switch on the auto mode on control panel 6.1.22 Reviewed by : Manoj Taywade Approved by : Dipenkumar Patel  AkzoNobel India Limited Metal Coatings STANDARD OPERATING PROCEDURE MANUAL – OPERATIONS Section No.: SOP.PRD.020 Ref. ISO 9001 & AN HSES Manual Review Date: 08/01/2025 Issue Date: 27/07/2022 Page No.: 6 of 13 Rev No.2 BARREL FILLING MACHINE Ensure recipe as per filling instruction mention in batch card Ensure the following parameters are to be programed in the controller for operation 1. Fill target. 2. Fill fine target. 3. Fill super fine target. 4. In-flight value. 5. Empty drum weight (Single drum with pallet) 6. Tolerance 7. Empty pallet weight. 8. No of drums on pallet 6.1.23 For recipe edit / selection follow below process 1. Go to the home screen 2. Press F1 for data entry page 3. Then add recipe no 6.1.24 4. Press F5 for next 5. Add recipe detail and press F5 for addition data. 6. Press F1 for write if you have done any changes in recipe. 7. Then press F5 for home scree. 8. Do same process again to cross check recipe you have entered and successfully save into the system and confirm for the same. Reviewed by : Manoj Taywade Approved by : Dipenkumar Patel  AkzoNobel India Limited Metal Coatings STANDARD OPERATING PROCEDURE MANUAL – OPERATIONS Section No.: SOP.PRD.020 Ref. ISO 9001 & AN HSES Manual Review Date: 08/01/2025 Issue Date: 27/07/2022 Page No.: 7 of 13 Rev No.2 BARREL FILLING MACHINE Ensure barrel filling machine sleeve to its rest position toward left hand side and switch on breaker switch in control panel it will hold the sleeve at position. 6.1.25 Empty drums with pallet to be placed on the weighing platform scale manually Places pallet with 4 empty barrels to the weighing scale and check any alarm shows for “Above tolerance” and “Below tolerance”, if ok then move to the next stage. 6.1.26 If not ok then go to the recipe setting and correct the setting If the empty drum weight in the weighing scale is within the tolerance the controller “Tare” 6.1.27 the empty drum with pallet weight. 6.1.28 Ensure barrel bunk should be toward the center and if not then arrange it Switch off breaker switch in control panel and adjust filling nozzle to the barrel bunk and 6.1.29 switch On breaker switch in operating panel which will hold the Sleeve assembly. Reviewed by : Manoj Taywade Approved by : Dipenkumar Patel  AkzoNobel India Limited Metal Coatings STANDARD OPERATING PROCEDURE MANUAL – OPERATIONS Section No.: SOP.PRD.020 Ref. ISO 9001 & AN HSES Manual Review Date: 08/01/2025 Issue Date: 27/07/2022 Page No.: 8 of 13 Rev No.2 BARREL FILLING MACHINE Attached earthing clamp to the barrel in which filling activity has been performed and check earth monitoring system should be green 6.1.30 Adjust Local exhaust ventilation (LEV) close to the filling stand and switch on power supply for LEV and ensure LEV system should be on before work began. For adjusting LEV system use rotating knob provide for the system Press Start button to fill the barrel. if the filling nozzle hits the drum during lance down 6.1.31 then lance automatically goes up with a massage “Bunk Wrong”. At that time adjust filling nozzle and then re-start again. 6.1.32 Ensure Filling should be stopped on the set point as per selected recipe. After filling first drum then adjust filling nozzle to the second drum, remove earthing cable 6.1.33 from first drum and attached to the second drum and press start push button to start filling and follow same process for third and fourth barrel. After completing 4-barrel filling repeat the same process for next pallet till complete batch 6.1.34 quantity After batch completion remove the pallet and abort the system 6.1.35 6.1.36 For aborting the system follow bellow steps 6.1.37 Go to the home screen then press F1 for data entry page and then press F4 for Abort. 6.1.37 For batch flushing select batch flushing recipe and start the process. 6.1.38 After blender flushing abort the process as mentioned in 6.1.35 After batch completion before removing hose from filling line depressurize line by using 6.1.39 valve provided after bucket filter and place bucket bellow depressurized valve. While removing hatch guard during warm and clod blender cleaning take permit to open 6.1.40 hatch guard Reviewed by : Manoj Taywade Approved by : Dipenkumar Patel  AkzoNobel India Limited Metal Coatings STANDARD OPERATING PROCEDURE MANUAL – OPERATIONS Section No.: SOP.PRD.020 Ref. ISO 9001 & AN HSES Manual Review Date: 08/01/2025 Issue Date: 27/07/2022 Page No.: 9 of 13 Rev No.2 BARREL FILLING MACHINE 6.1.41 After filling activity done clean all equipment thoroughly and check for contamination 6.2 OPERATIONS LIMITS: - 6.2.1 Use Proper PPEs before starting the operation. Observe closely on all joints for leakage, if there is any leakage, stop the filtration 6.2.2 immediately by pushing emergency switch button. Ensure static discharge clips are attached to the filter machine assembly and to the 6.2.3 container where material is being filled. Maximum capacity of weighing scale was 1500 Kg, insure before batch filling total weight 6.2.4 after filling with barrel and pallet should not cross 1500 Kg 6.2.5 Product temp should be 50 º C to 55 º C before batch filling 6.2.6 Ensure Air pressure 4 Kg/Cm2 After complete filling 1 barrel earthing clamp should be removed and connect to the 6.2.7 second barrel before start filling 6.2.8 Before opening the lid of the filter unit, ensure pressure is zero. Ensure before batch filling fume Extraction system should be in on condition and use 6.2.9 mandatory PPEs during this. TEMPORARY OPERATIONS: 1. While filling of paint material and material will not come from vessel/blender then check physical stock in vessel/blender 6.3 2. Filter bag can jam, replace it or clean if possible. 3. Air pressure went down then stop work and inform to maintenance. 4. In case of Spillage, immediate inform to superior and start to clean and collect spilled material in separate container 6.4 EMERGENCY OPERATION – Fire Alarm or Spillage 1. In case any abnormality is noticed or in the event of any incident turn off the 6.4.1 machine by pushing emergency shut off switch. Reviewed by : Manoj Taywade Approved by : Dipenkumar Patel  AkzoNobel India Limited Metal Coatings STANDARD OPERATING PROCEDURE MANUAL – OPERATIONS Section No.: SOP.PRD.020 Ref. ISO 9001 & AN HSES Manual Review Date: 08/01/2025 Issue Date: 27/07/2022 Page No.: 10 of 13 Rev No.2 BARREL FILLING MACHINE 2. Report the matter to the line manager and / or HSES staff and act as per the instruction. In case of any splash / exposure wash with copious amount of water and inform Shift 6.4.2 officer. Consult medical centre if required. Operator should be evacuated along with secondary labours who are working on filling 6.4.3 operation to the assembly point. 6.5 CAUTION POINTS 6.5.1 Adjust required nos. of barrel as specified in the recipe set in the system. After power failure when power resume if you have not done any change then start push 6.5.2 button and continue the process but if you have done any changes on weighing scale or in system then abort the system and start new process Machine should run only in auto mode and manual mode should be used only to check 6.5.3 lance movement. 6.5.4 Ensure the fume exhaust is ON. Wrong Recipe –  Special care to be taken while selecting recipe. The recipe to be selected after 6.5.5 checking filling quantity mention in batch card. Wrong recipe selection can lead to wrong batch filled, and LOPC may happen. Cleaning off barrel filling machine – 6.5.6  Ensure that filling machine cleaned properly and no residue for previous batch. Contaminated filling machine can lead to loss of batch. Spill/leakages from filling machine – 6.5.7  Ensure filling machine valves and nozzle are closed properly. Leakage valve can lead to spill of product from filling machine. Impact of Quality – 6.5.8  Wrong labels and filling quantity can lead to damage product quality. Reviewed by : Manoj Taywade Approved by : Dipenkumar Patel  AkzoNobel India Limited Metal Coatings STANDARD OPERATING PROCEDURE MANUAL – OPERATIONS Section No.: SOP.PRD.020 Ref. ISO 9001 & AN HSES Manual Review Date: 08/01/2025 Issue Date: 27/07/2022 Page No.: 11 of 13 Rev No.2 BARREL FILLING MACHINE Earthing & Bonding – 6.5.9  Ensure that all the weighing machine and filling assemble should be connect with earthing and bonding before starting the work on machine. In case of any deviation do not start the machine and inform to shift officer Filter Bag- 6.5.10  Wrong filter bag can lead to quality damage and product loss. 6.6 EMERGENCY SHUTDOWN 6.6.1 In case of a fire: Refer Emergency response plan. In case of a loss of containment: Push emergency button raise alarm Inform Shift In 6.6.2 charge. Attempt control of leakage using cotton rags available. Collect spill as per the procedure. In case of external emergency, the process may be stopped at any point, to be resumed 6.6.3 later as per the original sequence. Follow emergency evacuation procedure. 6.7 NORMAL SHUTDOWN. 6.7.1 Drain complete material from filling machine Transfer the material in a container and label it with product code, date, batch no. and 6.7.2 indicate.as ullage quantity, if material come bellow full SKU quanitity 6.7.3 The material will be used in the next batch of the same product. 6.7.4 Use solvent for cleaning and clean vessel with cleaning solvent Remove cleaning solvent through barrel filling machine and clean barrel filling machine 6.7.5 assembly. 6.7.6 Remove the inlet line of the filter machine assembly from the vessel. 6.7.7 Drain remaining hold up quantity available in filling line through valve 6.7.8 Transfer the solvent used for cleaning the filter machine into the designated area 6.7.9 Open the filter unit and remove the filter bag. 6.7.10 Move the filter machine sleeve assembly to the ideal position. Reviewed by : Manoj Taywade Approved by : Dipenkumar Patel  AkzoNobel India Limited Metal Coatings STANDARD OPERATING PROCEDURE MANUAL – OPERATIONS Section No.: SOP.PRD.020 Ref. ISO 9001 & AN HSES Manual Review Date: 08/01/2025 Issue Date: 27/07/2022 Page No.: 12 of 13 Rev No.2 BARREL FILLING MACHINE 6.7.11 Switch of power and push emergency switch. STARTUP AFTER EMERGENCY SHUT DOWN 1.Released the emergency switch. 6.8 2. Go to the home screen and abort system and restart process as per normal operation process MEASURES IN CASE OF LOSS OF UTILITY Electricity- In case of power failure, when power resume release emergency & complete remaining work if you have not done any change in filling station & if you have done 6.9 change then abort the process and restart process as per normal operation process. Air Pressure- In case of low pressure and no pressure inform to engineering person and when pressure resume complete remaining work as per process 6.10 AUTHORIZATION FOR WORK Under breakdown machine can be operated by trained and authorized person and this 6.10.1 operation requires maintenance of acquired competence. 6.10.2 Unsupervised operation can only be done by Trained & Authorized Person. Required PSF for this Process 6.11 Required LSR for this Process Reviewed by : Manoj Taywade Approved by : Dipenkumar Patel  AkzoNobel India Limited Metal Coatings STANDARD OPERATING PROCEDURE MANUAL – OPERATIONS Section No.: SOP.PRD.020 Ref. ISO 9001 & AN HSES Manual Review Date: 08/01/2025 Issue Date: 27/07/2022 Page No.: 13 of 13 Rev No.2 BARREL FILLING MACHINE Reviewed by : Manoj Taywade Approved by : Dipenkumar Patel