SHUT DOWN & START UP PROCEDURES FOR SHUT

DOWN PERIOD OF 3 TO 4 MONTHS.

EQUIPMENT:

AMMONIA COMPRESSORS:

SHUT DOWN PROCEDURES:

 The refrigerant must be pumped to the receiver for storage by keeping the
receiver outlet valve closed till the compressor suction pr. gauge reads zero.
 The ammonia receiver inlet and out let valves are closed.
 Ensure the compressor is not opened in vacuum condition, as it will draw air & dirt
into the system.
 Dismantle the V-belts.
 De-scale cylinder jackets/oil cooler S & T Heat exchanger if necessary.

START UP PROCEDURES:

 Ensure all the pressure gauges are calibrated.

 Ensure cooling tower water supply for jacket cooling & oil cooler.
 Leak test to be undertaken by applying nitrogen up to 250 PSI for about 1 hour and
Pr. Gauge to be monitored continuously for any loss of pressure along with soap
test.
 The nitrogen has to be vented out thro a purge valve in the system.
 The system to be vacuumed thro the discharge pr.guage line keeping the discharge
valve closed, with indication from suction Pr.guage.
 The compressor to be run on no load to check all the parameters like oil pressure,
loading & unloading , belt tensioning etc.
 The receiver valves to be opened and the suction valve of compressor to be crack
open and compressor to be run for 1 hr before full loading.
 The oil pressure should be a minimum of 1. 5 times more than the suction pressure
during running under load.
 Sulphur test to be done to detect any ammonia leak for all the valves.
 Motor resistance check to be done by Megger.
 Check motor & compressor parameters at full load.
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 SHUT DOWN & START UP PROCEDURES FOR SHUT
DOWN PERIOD OF 3 TO 4 MONTHS.

EQUIPMENT:

Unitanks/BBT:

SHUT DOWN PROCEDURES:

 Complete refrigerant to be drained out from Jackets and through water

circulation to be done to ensure complete removal of refrigerant.

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EQUIPMENT:

AIR COMPRESSORS:

SHUT DOWN PROCEDURES:

 Suction filter to be cleaned and covered properly.

 Air receiver to be completely drained.

 After cooler/intercooler to be cleaned for any scaling.

 Drive belts to be dismantled.

 De-scale cylinder jackets if necessary.

START UP PROCEDURES:

 Suction & Discharge valves to be opened and cleaned.

 Loading and unloading mechanism to be checked.

 Oil pressure & level to be checked.

 Belt tension to be checked.

 Run compressor in unload condition for an Hour.

 After loading ensure cut in /cut off pressures is as per set point and check safety
valve set pressure.

 Check motor parameters at full load.

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SHUT DOWN & START UP PROCEDURES FOR SHUT

DOWN PERIOD OF 3 TO 4 MONTHS.

EQUIPMENT:

DIESEL GENERATORS:

SHUT DOWN PROCEDURES:

 Battery to be disconnected.

 Heat exchanger to be descaled.

 Cooling tower cleaning to be done & V –belt to be dismantled.

START UP PROCEDURES:

 Batteries to be recharged.

 Cooling tower fan/motor and belts to checked.

 Engine to be run on no load for 30 mins and oil pressure, water temperature and
RPM to be monitored.

 Alternatively engine to be started and run every second day for a period of 10 mins,
to maintain the battery in charged condition.

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 SHUT DOWN & START UP PROCEDURES FOR SHUT
DOWN PERIOD OF 3 TO 4 MONTHS.

EQUIPMENT:

FILLER:

SHUT DOWN PROCEDURES:

 Caustic CIP should be done after last production.

 Machine to be cleaned with water & air.

 All CIP cups to be mounted on the filling valves.

 All change parts should be covered and stored properly.

 Grease to be applied on crowner external column to avoid rusting.

 Grease to be flushed in the Bowl & Crowner height adjustment screws and both the
bowl & crowner to be raised & lowered to the min and max level.

 Water condensate to be drained from gear box, all the gears to be cleaned and
fresh grease to be applied.

 Flush out oil contained air from lift cylinders. Open the drain plug on the air ring
and flush with fresh air and fill up fresh oil.

 Grease to be flushed from crowner cylinder.

 All utility main valves to be shut.

START UP PROCEDURES:

 Feed fresh grease to all manual grease points.

 Move bowl & crowner to min –max height.

 All grease lubrication pipes to be manually cleaned.

 Fresh grease to be filled to auto lubrication container and oil to gear box.

 All filling valve rubber parts to be replaced if m/c is shutdown for more than 3
months.

 Filler to be run in inching mode, for 10 minutes immediately after re start.

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 SHUT DOWN & START UP PROCEDURES FOR SHUT
DOWN PERIOD OF 3 TO 4 MONTHS.

EQUIPMENT:

WASHER:

SHUT DOWN PROCEDURES:

 Caustic zones to be drained out .Clean up bottom and top jets manual manually from
inside and outside. Ensure all nozzles are cleaned.

 Pre & Post caustic zones to be drained and cleaned with pressurized jets.

 Clean the chain and rollers.

 Apply normal hydraulic oil on entire chain.

 Refill the caustic zones with water – add 0.5% caustic and mix up properly.

 Clean infeed & Discharge gear mechanism & apply fresh grease on all gears and
cover it with plastic film.

 Cover all motors with plastic films.

 Paint the post caustic zones from inside.

 Flush out the grease and add fresh grease in all manual greasing points provided.

 Cover all cardon shafts joints with plastic films.

 Clean the condensate traps manually.

 Close all utility main valves & power supply switch in the panel.

START UP PROCEDURES:

 Check all the pump shafts are free to rotate & run the m/c in no load condition.

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 SHUT DOWN & START UP PROCEDURES FOR SHUT
DOWN PERIOD OF 3 TO 4 MONTHS.

EQUIPMENT:

PACKER:

SHUT DOWN PROCEDURES:

 Flush out the grease and add the fresh grease in all the manual greasing points
provided on the machine.

 Close all the utility main valves.

 Close main power supply switch in the panel.

 Cover entire machine with plastic film.

START UP PROCEDURES:

 Ensure main air line is completely drained of condensate.

 Check for air leaks in all PU piping and bottle holders.

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WTP:

SHUT DOWN PROCEDURES:

 Ensure all the media like resins in softener & DM plant are filled with soft water
and DM water respectively.

 The resins should not be left dry as they are prone to get cracked.

 OEM guidance to be taken for shutting down RO Plant to prevent damage to

Membranes.

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 SHUT DOWN & START UP PROCEDURES FOR SHUT
DOWN PERIOD OF 3 TO 4 MONTHS.

EQUIPMENT:

LABELLER:

SHUT DOWN PROCEDURES:

 Machine to be thoroughly cleaned after last production.

 Glue pumps to be cleaned and flushed with hot water.

 Gripper cylinders to be cleaned and lubricated.

 All change parts to be stored properly.

 Oil to be drained from both the labeling aggregates and bottle table, and fresh oil
to be filled.

 All bottle holders to be cleaned and lubricated.

 Machine to be covered with plastic sheets.

 Ensure machine center column & screw is lubricated and move the column to max
and min level.

START UP PROCEDURES:

 Rotate the machine in inching mode for 5 minutes.

 Ensure oil circulation to the bottle table from oil sump.

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 SHUT DOWN & START UP PROCEDURES FOR SHUT
DOWN PERIOD OF 3 TO 4 MONTHS.

EQUIPMENT:

BOILER:

SHUT DOWN PROCEDURES:

 The tubes & fire side surfaces to be cleaned /brushed to remove all soot. Air to be
blown to dry out the tubes and remove loose soot.

 A light coat of SAE 40 oil to be applied to the fire side surfaces

 Drain the water thoroughly, and dry it out.

 Wipe the water from internal surfaces with the help of cloth.

 Place trays of unsalted lime (11 kg/m3 volume) or Silica Gel (2.7 kg/m3) inside the
boiler drum to absorb any moisture. Then close the door, manholes, dampers etc
tightly so that no ingress of moisture or air can take place. The lime/silica gel
should be replaced whenever it becomes mushy.

 The chimney stack to be disconnected or the damper to be closed.

 Water service tanks, pumps and all pipings should also be dried out and all openings
to be closed properly.

START UP PROCEDURES:

 Ensure the feed water is full and water quality is as per specs.

 Ensure that all safety systems & alarms are working.

 Open the air vent valve & keep the main steam valve closed.

 Keep the ID, SFD & FD fan dampers in minimum position.

 Check & ensure oil level /pressure and required stroke length of Hydraulic power
pack.

 Prepare the fuel bed with fuel and diesel and set it on fire.

 After the bed catches fire, gradually open the dampers.

 Put all switches in Auto mode.

 Close the vent valve after the boiler reaches 1.5 kg.cm2. The steam valve can be
opened after sufficient pressure for process is attained.