PPM or Planned Preventitive Maintenance is exactly what is says on the tin. To be proactive in maintenance to avoid the breakdown nightmare. To ensure that the your equipment runs to its optimum specification reliably, it is important that the equipment is correctly maintained. Most of the maintenance requires visual inspections on a daily or weekly basis, but you should refer to the manufacturer’s recommendations on maintenance periods for specific parts. The inspections below are the minimum recommendations for a liquid process / CIP Set, if successive inspections reveal issues the maintenance regime should be increased/adjusted as appropriate.
Below is a rough guide to checks that you could implement into your maintenance schedule
** Health and Safety ** please ensure the line is empty before breaking any pipework and appropriate PPE is worn
Planned Preventative Maintenance
- Filters should be checked and cleaned as appropriate once a day. (ensure isolation before check)
- A visual inspection of the mechanical equipment and pipework whilst the machine is running to ensure that there are no leaks or excessive vibration that may lead to loosening of process connections.
- Ensure that the air regulator on the side of the control panel is free from moisture and listen for any signs of air leakage from the compressed air lines.
- From the screen review the alarms log for any alarms relating to out of tolerance on any of the instrumentation, record and review for weekly maintenance comparisons.
- Check any oil levels
- Check the operation of the emergency stop and tank lid safety circuit – Note that the operation of this may affect other running processes such as remote routing.
- Open the dirt leg drain valve on the steam circuit to remove any particulate build up.
- Check the condition of the stored liqueur from the tank hatch (Pre-rinse, Detergent and water) and the conditions of the vessel internals. If excessive soiling is present such as floating deposits, then either manually dump and replenish individual tanks or run a self-clean.
- Check the condition of the stored liqueur from the tank drain valves if excessive heavy deposits are present then either manually dump and replenish individual tanks or run a full self-clean.
- Visual inspection of all external instrumentation and control elements for signs of damage, ingress or malfunction.
- Check the control panels for any signs of moisture ingress and rectify as appropriate.
- Check the condition of the ventilation filters on the control panel for build-up of dust and clean as appropriate.
- Check the tightness of all process connections.
- Check and clean the filters in the steam traps.
- Check the tightness of all electrical connections on all internal panel equipment and external control and instrumentation parts.
- Calibration of all instrumentation by an industry recognised specialist – depending upon the process some instrumentation may need calibration every 6 months
- Replacement of Divert Valve and Pump Seals, every 2/3 years all valve seals will require replacing
Hysyscare is a division within Hysysco that offers bespoke aftercare packages, spare parts & breakdown support.
We recommend all service kits used are genuine OEM spares where possible as this will maximise the life of the equipment.
Please note for SPX/GEA/Tetra/Bardiani/Kieselmann etc. very little stock is held in the UK and it would be advisable to hold at least one seal for each item of equipment on your plant. If you would like a site survey to identify critical parts of your plant please contact Becki on 01427 613 942 / firstname.lastname@example.org
Hysysco/Hysyscare can support your plant with care packages covering maintenance to replace seals, emergency call out, as a care package customer we hold stock for the items covered under the agreement at our stores
For emergency call out as detailed a description of the faults &/symptoms helps us diagnose faster. If it’s not working how is it not working?
- Not responding? What was the equipment doing prior to the fault? Production? Clean?
- Something happening that shouldn’t be?
- Noises or smells that don’t usually occur?
- Was it a one off or has it been happening over a period? Has it got worse?
- Has a site engineer looked? What were their findings?
If the issue maybe something software related, we would recommend that the customer installs a method of remote access which will permit access to our PLC and HMI for remote fault finding whilst we are off site. As a minimum we would recommend that the location containing the equipment be equipped with a reliable telephone line, so that we can at least talk with staff whilst they are in front of the equipment.
- Nature of the fault – as detailed a description as possible.
- Current step number that the program is running – Which may be gained from the screen.
- Current circuit that is being cleaned – Which can be gained from the screen.
- Details of any alarms that cannot be cleared – Which can be gained from the screen.
- Number of incidence’s – Has this happened before?
- What (if any) corrective actions have been taken to rectify the fault already.