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Summary of Contents for Pro Mach STOCK RETORT SA-146
- Page 1 PERFORMANCE, PACKAGED MAINTENANCE MANUAL RETORT 1 MODEL SA-146 SERIAL NUMBER(S):...
- Page 2 PERFORMANCE, PACKAGED 2 IMPORTANT! THE FOLLOWING MANUAL SHOULD BE KEPT IN A PLACE OF EASY ACCESS AND ALL ITS OPERATORS AND MAINTENANCE PERSONNEL SHOULD HAVE KNOWLEDGE OF IT. BEFORE OPERATING THE RETORT, READ THE INSTRUCTIONS CAREFULLY AND RESPECT ITS INDICATIONS OF USE. ...
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Page 3: Table Of Contents
PERFORMANCE, PACKAGED Contents: Maintenance .............................. 4 Periodic Maintenance Operations...................... 4 Cleaning Operations and Preventive Maintenance .................. 5 Cleaning Spray Nozzles .......................... 6 Cleaning the Valves .......................... 6 Cleaning the Filters Inside of the Retort .................... 7 Cleaning the Recirculation Water Distribution Tray ................ 7 Cleaning the Recirculation Water Circuit .................... 7 Revision of the Basket Loading and Unloading Track ................ 8 Opening Security Valves ........................ 8 Cleaning Water Level .......................... 8 3 Cleaning the Collector .......................... 8 Sanitation Procedures ........................... 9 Troubleshooting ............................ 9 Heating Temperature Deviations...................... 9 Cooling Temperature Deviations ...................... 10 Control Pressure Deviations ........................ 10 Specific Valve Fault .......................... 11 ... -
Page 4: Maintenance
PERFORMANCE, PACKAGED MAINTENANCE. PERIODIC MAINTENANCE OPERATIONS Take into consideration the following precautions when repairing or conducting routine maintenance on the retort: Make sure the retort cannot accidentally be switched on before performing any maintenance and/or repair work on the retort. Use padlocks to lock the door and to lock the main switch on the electric panel Use the PPE specified in your company's health and safety plan. Wear protective footwear, helmets, hearing devices and safety goggles at all times during the maintenance and/or repair activities When very large or heavy objects must be handled, use hoisting/lifting equipment, such as bridge cranes and/or forklifts that can handle these weights Only use spare parts or repair methods that authorized by Stock America, LLC when replacing or repairing parts of the retort. If needed, please contact Stock America, LLC before making repairs. The retort must be installed correctly to guarantee the correct operation of the unit Check the facility and installation to ensure area(s) are safe to work in after carrying out maintenance tasks or ... -
Page 5: Cleaning Operations And Preventive Maintenance
PERFORMANCE, PACKAGED Monthly Clean the interior and exterior filters and collector Clean the distribution tray Inspect all electrical terminals in panels and motors. Tighten as needed. Inspect all sensors to ensure they have been fixed and fitted correctly. Tighten as needed. Check all air connections have been connected correctly and there are no air leaks. Reconnect the connections as required. Check all spliced joints. Replace the gasket if needed Inspect the pump seal. Replace if needed Check for leaks in the Heat exchanger. Replace the gaskets if needed Check the pneumatic valves open correctly Annually Check the safety valves function at the loading pressure Check the general condition of the control panel Check the welds of the pressure equipment. In particular, check the doors, plate of the cylindrical body and tubes inserted into the cylindrical body. Inspect the steam inlet tube. Clean as needed. General pump maintenance 5 ... -
Page 6: Cleaning Spray Nozzles
PERFORMANCE, PACKAGED CLEANING SPRAY NOZZLES Due to their small cross section they are positioned to distribute the water uniformly. If you have conducted a quality water analysis and you find you have “hard water”, the nozzles can be blocked (i.e. lime) and the water will not distribute correctly. To avoid this, at least 1 time each 6 months (in stop period) take off the pipes of the nozzles (Unscrew the showers and place in a slightly acid solution bath. Contact your water quality company for recommendations. When the nozzles and the pipes are dry, they should be struck lightly with rubber mallet in an effort to loosen any lime which may be present. Reinstall as needed taking into account how the nozzles were removed. CLEANING THE VALVES. Pneumatic valves may become partially or totally obstructed due to lime or small particles carried through the pipes. Follow these steps for their cleaning (see illustration for details): STEP 1. Unscrew the 4 screws which join the lower body and the top body. Once done, pull up the top body and separate from the lower body. STEP 2. Insert the upper body into a container with nitric acid as shown in the drawing below for 10 to 15 minutes. Make sure to not submerge below the point indicated by the dotted line. The nitric acid container must be narrower 6 than “part 1”. Once finished, rinse the mechanism submerged in nitric acid several times with clean water in order to neutralize the acid. STEP 3. With a brush dipped in nitric acid, coat the seating inside the lower body as shown in point B. Repeat this several times until the seating is completely clean and then rinse with clean water. STEP 4. Once the two parts of the valve are clean, reassemble the two parts of the valve. STEP 1 STEP 2 STEP 3 Top Body ... -
Page 7: Cleaning The Filters Inside Of The Retort
PERFORMANCE, PACKAGED CLEANING THE FILTERS INSIDE OF THE RETORT. It is necessary to clean the bottom inside of the retort once every work day and preferably at the end of the last shift or between two shifts if operating 24 hours a day. To do this, press the outlet valve button on the control panel (manual mode) and clean the walls and especially the back of the retort with a hose or a pressurized spray pistol. This is necessary in order to rinse out as much residue as possible, preventing it from passing through the filter. INSIDE FILTERS: Stock America recommends cleaning the filters once a month. To do this, an operator must remove the top screws from each of the filters, remove them from the retort and clean them thoroughly with a pressurized spray gun (or a hose). Return the filter to its original positions and tighten the screws. OUTSIDE FILTER: located before the recirculation pump. Stock America recommends to clean once a week. To do this, a operator will have to unscrews the screws on the flange of the filter, remove the filter and clean by pressure water pistol. Return the filter to its original positions and tighten the screws. CLEANING THE RECIRCULATION WATER DISTRIBUTION TRAY. It is necessary to clean the distribution tray approximately once every 15 days. To do this, unscrew the screws found at tray level behind the door. Stock America recommends leaving a basket inside the retort as a support and to aid the operator in removing the tray. Once outside the retort, clean with pressurized water (or a hose). 7 ... -
Page 8: Revision Of The Basket Loading And Unloading Track
PERFORMANCE, PACKAGED REVISION OF THE BASKET LOADING AND UNLOADING TRACK. The automatic basket loading chain and its track do not require lubrication. They have been designed to operate in damp environments and at extreme temperatures. The chain track should be kept clean of foreign objects. Following the standard recommended cleaning procedures from Stock America will prevent any issues. On a weekly basis, it will be necessary tightened the chains to prevent wear of the sprocket. An operator will have to fit the tensile placed in the front part of the retort. OPENING SECURITY VALVES IS VERY IMPORTANT! The security valves, located on the top of the machine, must be opened at least once a week to prevent them from seizing up (as a result of retort inactivity) in the event they are needed. To do this, move the valve levers up and down several times. 8 CLEANING WATER LEVEL. It is not necessary to clean the cylinder, although it is recommended once a year. To do this, remove it and let water flow ... -
Page 9: Sanitation Procedures
PERFORMANCE, PACKAGED SANITATION PROCEDURES. Stock America recommends cleaning the bottom inside of the retort once every work day preferably at the end of the last shift or between two shifts if operating 24 hours a day. For this, all that is required is one cycle with water only. If there is excess dirt and is necessary to include detergents, these will have to be neutral. In this case, a cycle of cleanliness will be done by the detergent and then three cycles of water only. When inside the retort, some containers may brake and product and contains may be seen within the retort. If this occurs, please take the following steps: 1. Stop the machine and process by corresponding Safety Procedure for Entering a confined space 2. Open all the drain valves in manual mode from the control panel 3. With special cleaning equipment (pressure and manual cleaning) take out the liquid and solid waste The exterior of the machine must be in optimal condition TROUBLE SHOOTING The most common problems detected in the retort are: HEATING TEMPERATURE DEVIATIONS 9 Issue: 1. The RTD temperature (temperature resistor) does not match with the reading of the digital calibrated thermometer (DTG) ... -
Page 10: Cooling Temperature Deviations
PERFORMANCE, PACKAGED 3. Insufficient supply of steam – Check the input pressure to ensure it is set to a minimum of 85 psi of steam entering the heater. a. Check to make sure the steam modulating valve is opened 100%. Make sure the check valve is not blocked. b. Make sure there are no obstructing elements at the condensate outlet and the condensate flows freely. c. If the RTD probe has been calibrated correctly, with the digital thermometer, adjust the input compensation parameter in the meter to make it match with the value shown on the HMI. COOLING TEMPERATURE DEVIATIONS Issue: 1. Cooling time exceeded and alarms Solution: 1. On the HMI, check the cooling water inlet valve which controls the temperature. If there is an error in the process variable, check the connections. Note: this must only be performed by qualified staff. a. -
Page 11: Specific Valve Fault
PERFORMANCE, PACKAGED SPECIFIC VALVE FAULT Issue: 1. The valve/actuator does not open/close correctly 2. There is a short‐circuit in the actuator of the modulating valve 3. The actuator does not generate the adequate torque 4. The valve with the positioning device is jammed 5. The valve is mechanically blocked 6. Worn actuator gaskets and no torque is generated 7. Erratic valve control 8. The valve does not respond 9. The process control deviates from the adjustment point 10. The valve is leaking through the gasket, with no instrument signal 11. The valve is leaking through the rod Solution: 1. Start on the HMI cancellation screen and try to move the valve manually (25‐50‐75‐100%) 2. Check the blown fuse indicator on the panel to detect short‐circuits 3. Check the input air pressure to ensure 85 psi (6 kg/cm2) is supplied to the valve controller 4. Confirm the air is being supplied from the valve collector with a positioning device on the panel towards the 11 ... -
Page 12: Flow Reduction
PERFORMANCE, PACKAGED FLOW REDUCTION Issue: 1. Water filters clogged inside the retort 2. The pump is not operating 3. The pump is operating, but is cavitating 4. Differential pressure switch error 5. Flow discharge system blocked Solution: 1. Remove the baskets from the retort and continue to follow the safety procedures to disconnect the retort and access the vessel, in accordance with the plant's procedures. Inspect all filters on the lower part and make sure that all waste has been removed. Clean/replace the filters as needed. 2. The control panel is receiving no power: a. Inspect the pump's motor guard (make sure there are no thermal faults) b. Current overload of the pump not connected ‐ restore and control the current readings to the correct range c. Make sure that the pump start‐up device is not failing 3. The water level is too low ‐ check the water level sensor 12 a. If the water level is correct, inspect the pump rotor b. Make sure the level of consumption of the pump is correct and that there are no motor failures 4. Read the screen and make sure the indicator of the differential pressure switch is active a. -
Page 13: Recommended Spare Parts List
PERFORMANCE, PACKAGED RECOMMENDED SPARE PARTS LIST: PART DESCRIPTION: PRICE: Door Seal Pump Seal Kit Check Valve 2" Packing Gland Seal Check Valve 1.5" Circulation Loop Strainer DN125 Circulation Loop Strainer DN100 Spray Nozzle (qty 10) Positioner Trolly Lock Sensor Trolly Pressent Sensor 13 Door Lock Sensor ...
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