SOP for Operation of Air Compressor and Drier PDF

HATSUN AGRO PRODUCT LIMITED Issue No / Date 01/ 14.10.2024 FRESH CHILLED DIVISION Rev No / Date 00 SOP FOR OPERATION OF AIR Doc No: HAP/FCD/ENGG/SOP/OP/58...

HATSUN AGRO PRODUCT LIMITED Issue No / Date 01/ 14.10.2024 FRESH CHILLED DIVISION Rev No / Date 00 SOP FOR OPERATION OF AIR Doc No: HAP/FCD/ENGG/SOP/OP/58 COMPRESSOR AND DRIER Purpose: To lay down the procedure for operation of Air Compressor and drier Scope: The scope is applicable for Air Compressor and Drier in the Fresh Division. Responsibility: Maintenance technician – Responsible for executing Operations of Air Compressor and Drier as per the SOP. Supervisor – Monitoring the entire process Engineering Manager – Accountability Abbreviations: PPE – Personal Protective Equipment SAP – Systems, Applications & Products in Data Processing PM – Preventive Maintenance 1.0 SAFETY, HEALTH & ENVIRONMENT (SHE) RELATED HAZARDS, CONSEQUENCES, & PRECAUTIONS: Hazards Consequences Precaution 1.Noise during operation Ear injury Use Ear plugs / Ear muffs. 2.Hitting during Serious head injury on movement around the Wear safety helmet with chinstrap. hitting on the structures. equipment Ensure proper housekeeping. 3.Oil / water spillage in Physical injury Use safety shoes, Safety helmet & Safety floor goggles Prepared by Verified by Approved by Page no Signature 1 Of 11 Name K. Muthukumar G. Kesavan N. Aravindraj  HATSUN AGRO PRODUCT LIMITED Issue No / Date 01/ 14.10.2024 FRESH CHILLED DIVISION Rev No / Date 00 SOP FOR OPERATION OF AIR Doc No: HAP/FCD/ENGG/SOP/OP/58 COMPRESSOR AND DRIER 4.Hot surface contacts Hot burns Use cotton gloves 5.Cold surface contacts Cold burns Use Low temperature gloves 1.1 PPEs: 2.0 PROCEDURE: 2.1 The compressed air system consists of oil type screw compressors, air receivers and air dryers. The compressor compresses the ambient air; 2.2 2.3 Outlet is connected to the air Dryer which is in series. Outlets of air Dryer are connected to the air Receiver. The air dryer works on Pressure Dew Point Temperature of -1 degree Centigrade To 3 °C, where the moisture is being removed through the internal refrigeration system. Prepared by Verified by Approved by Page no Signature 2 Of 11 Name K. Muthukumar G. Kesavan N. Aravindraj  HATSUN AGRO PRODUCT LIMITED Issue No / Date 01/ 14.10.2024 FRESH CHILLED DIVISION Rev No / Date 00 SOP FOR OPERATION OF AIR Doc No: HAP/FCD/ENGG/SOP/OP/58 COMPRESSOR AND DRIER 2.4 2.5 The oil and moisture free air from the air dryer, which passes through the HEPA filter, which is suitable for 450 CFM air handling capacity, and gives the particle size of 1 micron on its outlet. 2.6 2.7 The condition of filtering element in the HEPA filters are represented in two bands, Yellow represents filter in good condition and red represents filter in bad condition, which needs replacement. 2.8 Prepared by Verified by Approved by Page no Signature 3 Of 11 Name K. Muthukumar G. Kesavan N. Aravindraj  HATSUN AGRO PRODUCT LIMITED Issue No / Date 01/ 14.10.2024 FRESH CHILLED DIVISION Rev No / Date 00 SOP FOR OPERATION OF AIR Doc No: HAP/FCD/ENGG/SOP/OP/58 COMPRESSOR AND DRIER 2.9 Process Flow Diagram Compressed Air Air filter (8µ size) Screw element (85±5ºC) Oil separator Air cooler (water separator and auto drain valve) Air dryer Air receiver UD 220 + Filter Plant Use Prepared by Verified by Approved by Page no Signature 4 Of 11 Name K. Muthukumar G. Kesavan N. Aravindraj  HATSUN AGRO PRODUCT LIMITED Issue No / Date 01/ 14.10.2024 FRESH CHILLED DIVISION Rev No / Date 00 SOP FOR OPERATION OF AIR Doc No: HAP/FCD/ENGG/SOP/OP/58 COMPRESSOR AND DRIER 3.0 OPERATION OF COMPRESSED AIR SYSTEM 3.1 Power Supply 3.1.1 Switch ON the Main Feeder of MCC8 3.1.2 Switch ON the Air compressor Feeder. Prepared by Verified by Approved by Page no Signature 5 Of 11 Name K. Muthukumar G. Kesavan N. Aravindraj  HATSUN AGRO PRODUCT LIMITED Issue No / Date 01/ 14.10.2024 FRESH CHILLED DIVISION Rev No / Date 00 SOP FOR OPERATION OF AIR Doc No: HAP/FCD/ENGG/SOP/OP/58 COMPRESSOR AND DRIER 3.1.3Release all emergency stop buttons in Air compressors. 3.1.4 Dew point temperature of Dryer until the temperature reaches its set point (3°C.) or below. This should never go below -1 °C. 3.1.5 Check the condensate Auto drain valve. It should always be open. Prepared by Verified by Approved by Page no Signature 6 Of 11 Name K. Muthukumar G. Kesavan N. Aravindraj  HATSUN AGRO PRODUCT LIMITED Issue No / Date 01/ 14.10.2024 FRESH CHILLED DIVISION Rev No / Date 00 SOP FOR OPERATION OF AIR Doc No: HAP/FCD/ENGG/SOP/OP/58 COMPRESSOR AND DRIER 3.1.6 Check the discharge valve of receiver. It should be open. 3.1.7 Check the oil level in Oil separators. Maintain the Upper line level. 3.1.8 Check for any other leakage of oil in bottom of Oil separator. Prepared by Verified by Approved by Page no Signature 7 Of 11 Name K. Muthukumar G. Kesavan N. Aravindraj  HATSUN AGRO PRODUCT LIMITED Issue No / Date 01/ 14.10.2024 FRESH CHILLED DIVISION Rev No / Date 00 SOP FOR OPERATION OF AIR Doc No: HAP/FCD/ENGG/SOP/OP/58 COMPRESSOR AND DRIER 3.1.9 Check the proper working of Electronically. Check that display is showing all the parameters. 3.1.10 Check for alarms if any (red LED glowing) then rectify the problem. 3.1.11Acknowledge the alarm by pressing the reset button (F3). Prepared by Verified by Approved by Page no Signature 8 Of 11 Name K. Muthukumar G. Kesavan N. Aravindraj  HATSUN AGRO PRODUCT LIMITED Issue No / Date 01/ 14.10.2024 FRESH CHILLED DIVISION Rev No / Date 00 SOP FOR OPERATION OF AIR Doc No: HAP/FCD/ENGG/SOP/OP/58 COMPRESSOR AND DRIER 3.1.12 If reset button is not available on main screen then go to status by pressing MAIN SCREEN button (F1). There again press SHOW button (F2). Now reset button will be available there (F3). Press F3 to ACK. Alarm. 4.0 Starting Procedure: 4.1 Go to main screen by pressing F1 functional key on Electronically control board 4.2 Start the compressor by pressing the I button on control panel. 4.3 The compressor starts compressing and delivers air to plant through Air receiver. Prepared by Verified by Approved by Page no Signature 9 Of 11 Name K. Muthukumar G. Kesavan N. Aravindraj  HATSUN AGRO PRODUCT LIMITED Issue No / Date 01/ 14.10.2024 FRESH CHILLED DIVISION Rev No / Date 00 SOP FOR OPERATION OF AIR Doc No: HAP/FCD/ENGG/SOP/OP/58 COMPRESSOR AND DRIER 4.4 As the reading of Out let air pressure in display reaches to unloading pressure, the compressor will automatically unload. If the receiver pressure goes down to loading pressure, the compressor again starts loading till the unloading pressure reaches. 5.0 Stopping Procedure 5.1 Electronikon control board O Button click then Stopped the Compressor. Prepared by Verified by Approved by Page no Signature 10 Of 11 Name K. Muthukumar G. Kesavan N. Aravindraj  HATSUN AGRO PRODUCT LIMITED Issue No / Date 01/ 14.10.2024 FRESH CHILLED DIVISION Rev No / Date 00 SOP FOR OPERATION OF AIR Doc No: HAP/FCD/ENGG/SOP/OP/58 COMPRESSOR AND DRIER 5.2 Close the Air compressor Discharge Valve. 6.0 Reference Document: Document Name Document Reference Air Compressor Log book HAP/FCD/ENGG/UTL/R/10 Prepared by Verified by Approved by Page no Signature 11 Of 11 Name K. Muthukumar G. Kesavan N. Aravindraj