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Land O'Lakes - Dryers > Dryers > Flashcards

Dryers Flashcards

1
Q

Shift Overview

What are the five questions you should ask when getting turnover from the previous crew?

A
  1. What product is the dryer running?
  2. What’s the level in the CT silo, SP2, or the feed tank?
  3. What’s the powder destination (bin)?
  4. Is the powder in spec?
  5. Have there been any problems or deviations?
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2
Q

Shift Overview

You’ve got the turnover from the previous shift; what are the other two tasks to be completed at the start of the shift?

A
  1. Get shift paperwork ready. Fill out a new chart so it is ready to be replaced at midnight (Niro only). Get any CIP paperwork ready.
  2. Begin the Dryer set and sample the powder.
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3
Q

Shift Overview

What are the 8 routine tasks to be completed during the shift?

A
  1. Continue hourly sets and samples.
  2. Pull calibration samples for the lab as required.
  3. Once an hour, walk the dryer and check for any plugs or issues with the dryer. Ensure all rotary valves and motors are running. Ensure the Cargo Caire is operational (R1 and R2 only).
  4. Be looking out for water, air, and product leaks during your shift.
  5. Clean up any messes that are found.
  6. Ensure that the area is clean. Floor mats, buckets, and brushes are properly stored. Hoses are rolled up and stored where they belong. All lines and ports are capped.
  7. Any line circuit that is being used for product transfer must be disconnected from CIP sources when not used for CIP.
  8. Change the temperature chart at midnight (Niro only).
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4
Q

Shift Overview

What are the 4 end of shift tasks?

A
  1. Ensure that the Dryer area is in a cleanly state. Recheck those areas while looking for the items listed in the During Shift section.
  2. Update the white board with any necessary information for turnover.
  3. Ensure all CIP paperwork is completed, and CP Toolkit is filled out.
  4. Leave your area in the condition you would want to receive it!
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5
Q

Drying Basics

What are the qualities the surrounding air should have in order to dry food?

A

The air should be hot, dry, and moving.

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6
Q

Drying Basics

Why should the air be dry?

A

So that it can absorb the moisture from the food.

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7
Q

Drying Basics

Why should the air be hot?

A

Heating the air around the product causes it to dry more quickly.

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8
Q

Drying Basics

Why should the air be moving?

A

If the air is not moving across the food it cannot get rid of the water vapor that it has collected. A fan or air blower is needed to keep the air circulating.

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9
Q

Drying Basics

What is drying?

A

Removing the the water from the food product into the surrounding air.

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10
Q

Powder Specifications

What is LHNF and what are its specs?

A

Low Heat Non Fat Dry Milk

Butterfat less than 1.00%, Max 1.25%

Moisture less than 4.00%

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11
Q

Powder Specifications

What is MHBM and what are its specs?

A

Medium Heat Buttermilk

Butterfat greater than 4.50%

Moisture between 3.00% and 4.00%

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12
Q

Powder Specifications

What is 26% WDM and what are its specs?

A

26% Whole Dry Milk

Butterfat greater than 28.50%

Moisture between 2.00% and 3.00%

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13
Q

Powder Specifications

What is 28.5% WDM and what are its specs?

A

28.5% Whole Dry Milk

Butterfat greater than 28.50%

Moisture between 2.00% and 3.00%

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14
Q

Powder Specifications

What are the WPN settings for Low, Medium, and High heat?

A

Low Heat greater than 5.99

Medium heat between 1.5 and 5.99

High heat less than 1.5

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15
Q

Product Pre-Start Checklist for Niro

What are the 10 steps of the checklist?

A
  1. Are the nozzles assembled with the correct orifice for the product run?
  2. Have the nozzles been attached to the wands and installed into the dryer?
  3. Are the 2 steam valves and chill water valve (Fan Room) in the open position?
  4. Is the condense silo connected to the silo’s outlet line? Is the condense silo port connected to SP2’s transfer line? (Wiegand operator will usually connect these, but verify with the operator that they are connected.)
  5. Is SP1/SP2’s transfer line connected to SP2?
  6. Is SP2’s feedline and filters connected to the HPP feedline?
  7. Is the exhaust stack open?
  8. Check the 7 items on the Allen Bradley panel.
  9. Check the 9 items on the Niro panel.
  10. Are the fluid bed dampers set for both the hot and cold sections.
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16
Q

Product Pre-Start Checklist for Niro

What are the 7 items to check on the Allen Bradley panel?

A
  1. Powder Transfer Blower
  2. Dust Collector Fan
  3. Powder Transfer Rotary Valve
  4. Sifter Motors
  5. Hopper Discharge Rotary Valve
  6. Conveying Air Blower
  7. Fluid Bed Rotary Valve
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17
Q

Product Pre-Start Checklist for Niro

What are the 9 items to check on the Niro panel?

A
  1. Cyclone Rappers
  2. Baghouse Rappers
  3. Baghouse Backpulses
  4. Exhaust Fan
  5. Supply Fan
  6. VF Fan
  7. Cooling Neck Fan
  8. Combustion Fan
  9. HPP Oil Pump
18
Q

Niro Startup and Operation

What are the 6 overall phases of startup and operation?

A
  1. Nozzle Assembly
  2. Installation of Nozzles
  3. Pre-start Connections and Checks
  4. Dryer Fan, Motor, and Rotary Valve Startup
  5. Lighting the Burner
  6. Product Operation
19
Q

Niro Startup and Operation

What are the 9 steps of nozzle assembly?

A
  1. Layout and inspect nozzle components.
  2. Place the smaller gasket into the inset in the bottom of the nozzle body.
  3. Place an orifice on top of the gasket in the nozzle body. Ensure that the flat side of the orifice is facing down.
    3a) Use orifice #121 for LHW and BM product runs.
    3b) Use orifice #91 for LHNF product runs.
  4. Place a swirl plate on top of the orifice. Make sure the swirl plate is on top of the inner lip of the nozzle body, is flat, and will spin.
    4a) use the swirl plate SG for all product runs.
  5. Place a cap on top of the swirl plate in the center.
  6. Apply a light amount of anti-seize compound to either the nozzle body or screw pin threads.
  7. Insert the screw pin with the four-point side down into the nozzle body until the cut out edges of the screw pin are just above the edges of the nozzle body. Ensure that the screw pin is fitted directly over the cap.
  8. If the screw pin edges are not just above the edge of the nozzle body, then the screw pin is not directly over the cap. Remove the screw pin and re-center the cap. Then repeat step 7.
  9. Using an adjustable wrench, place the completed nozzle body in the vise located by the sink, and lightly tighten the screw pin.
20
Q

Niro Startup and Operation

What are the 7 steps of nozzle installation?

A
  1. Remove caps from wand entry ports.
  2. Place nozzle wand on the holding fixture on the nozzle deck railing.
  3. Use RTU and a Wipe-All towel to sanitize the entire wand.
  4. Install the nozzle onto the wand and tighten with the provided tool taking care to not over tighten.
  5. Clamp the wand flange to the deck port with the provided clamps.
  6. Repeat steps 1-5 for the remaining 2 nozzles and wands.
  7. Coming down from installing nozzles go into the VF Fan room and turn on the 3 steam valves located on the CIP room side of the VF fan duct. The handle should be pointing towards the floor in the ON position.
21
Q

Niro Startup and Operation

What are the 3 steps of pre-start connections and checks?

A
  1. Hook up the CT Tank that the product is in that is to be dried under the tank. Hook the stinger on the Weigand Plate to the CT tank port, and the SP2 port, plus the bottom valve airline in from the CT tank previously hooked up.
  2. On the Allen Bradley Screen in the Niro, push F16 to return to the Main Menu screen. Press the F2 key to access the Niro operations screen. Press the F1 key to start transferring the product to be dried from the CT tank to SP2.
  3. Unhook the line from SP2 and the feed line from the CIP lines out at the strainers. Hook the line from SP2 and the feed together.
22
Q

Niro Startup and Operation

What are the 7 steps of dryer fan, motor, and rotary valve startup?

A
  1. Go to the Allen Bradley screen on the wall. Push the F16 key to call up the Main Menu screen. Push the F4 key to call up the Niro Sifter Operations screen. Push F1 to start the Niro Sifter System. It will automatically start the Powder Transfer Blower, Dust Collector Fan, Powder Transfer Rotary Valve, Sifter Motors, Hopper Discharge Rotary Valve, Conveying Air Blower, and Fluid Bed Rotary Valve.
  2. On the Allen-Bradley screen return to the Main Menu screen via the F16 key. Press F2 to access the Niro Operations screen.
  3. Turn the Cyclones and Bag House Rapper switch on Make sure Bag House Pulse jet switch is on. Set the fluid bed dampers to 9 for the hot section and 8 for the cold section.
  4. On the control panel, turn the exhaust stack switch to open. Watch the Dryer Map screen above the control panel. When the top green light on the stack lights up the stack is open.
  5. On the control panel, push the exhaust start, supply start, VF supply start, neck cool fan starts, combustion air fan starts, vacuum pump start, HPP oil pump start, VF motor start, and the hot water set pump start. DO NOT start the HIGH-PRESSURE pump. The East and West cyclone rotary valves and cyclone blower will start automatically when starting main fans.
  6. Below the magnehelic gauges on the control panel, on the right-side end, the supply and exhaust fan controls are located. On the exhaust fan Honeywell control, press the increase button and hold it. While holding the increase button, press and release the decrease button 1 time.
  7. While increasing the exhaust fan control, watch the chamber pressure indicator magnehelic gauge located in the top left corner of the gauges. Increase the supply fan control to keep the gauge reading around 0 (zero). When the exhaust fan speed is around 50%, switch the exhaust control to automatic. Turn the supply fan slowly up to 75 amps. Watch the chamber pressure while increasing both to avoid any major over or under pressure of the chamber to avoid damage to the chamber blow out doors.
23
Q

Niro Startup and Operation

What are the 6 steps to lighting the burner?

A
  1. Make sure furnace temperature control is set at 205 degrees. Make sure dryer outlet temperature valve is set between 8% and 10%. Press the start burner button. Look at the box located on the back wall on the left side of the MCC room door. The left side top 3 lights should turn on when the start burner button is pushed. After approximately 2 minutes the right side top end bulb will light up indicating the burner is lit.
  2. Set the starting output of the high-pressure pump to 14%.
  3. Purge the feedline of air and prepare to start the high pressure pump.
  4. Start raising the burner inlet temperature up to about 230 to 240, where the outlet temp starts getting to 200 degrees Fahrenheit.
  5. Ensure that the HPP is ready to start on feed.
  6. When the outlet temperature reaches 208, bump the inlet temperature up by 30 degrees, so that the inlet temperature set point is roughly between 270 and 285. In rapid succession start the HPP in manual mode (not Auto) at preset output of 14%.
24
Q

Niro Startup and Operation

What are the 19 steps of product operation?

A
  1. Wait for the feed to hit the nozzle and observe the inlet temperature as it starts increasing. Observe that the nozzle pressure is at about 1100 +- 100 on 1 nozzle. Observe that the outlet temperature will drop a little, and the goal is that it won’t drop below 195F due to the rapid inlet temperature bump that was applied shortly prior to starting the HPP. All the while keep the HPP in manual at 14%.
  2. During this transition, we’re just observing over the course of at least 30 seconds, up to maybe a minute or two.
  3. We need to verify that feed hits the nozzle, that the burner starts increasing temperature, and that we see a temperature change of the chamber outlet air.
  4. If the HPP faults out, then ensure you shut off the burner. If the burner faults, then shut down the HPP.
  5. If the outlet temperature increases further above 208, just wait for it to start going back down, assuming you’ve observed that feed hit the nozzle.
  6. It’s ok if the outlet temperature goes up to 220 and even 230, as long as it comes down within a minute or two. The outlet temp will likely not increase this high before it starts decreasing.
  7. It’s ok if the outlet temperature goes down to 195, and even 190, but if it appears clear that its rate of decrease will bring the outlet temp down into the 180s, you should jump to the next step.
  8. Go to the next step after expected observations are confirmed, and make sure to give the process enough time to make this transition before you make any setpoint changes or mode changes to anything.
  9. Still, as in the previous steop, keeping the HPP in manual at 14%– after the transition to starting the HPP, you will likely have a lower outlet temperature than 205. Therefore, you should increase the inlet temperature set point.
    9a) By the amount of your discretion (in steps of 5 degrees at least).
    9b) Wait at least 30 seconds.
    9c) Observe the outlet temperature increase. If it’s at or above 205, go to the next step. If it’s still below 205, go to 9a).
  10. Now that the outlet temperature is at or above 205, while the HPP has been in manual at 14% this whole time, it’s now time to put it in auto. You can at this point know for sure that the HPP output will only increase in order to hold the 205F setpoint, thereby ensuring that the nozzle pressure doesn’t ever go below 1000 psi during startup.
  11. Continue with raising the inlet temperature in increments of at least 5F, every 30 seconds.
    11a) Use judgement to ensure the outlet temperature controller is keeping up with the rate of increase in the burner, to inform you if you’re raising the inlet temperature too fast over time. A 10-degree lag is ok (if outlet temp is at 215, while HPP is ramping up in response to an increasing inlet temp).
    11b) Keep an eye on the nozzle pressure this whole time, and as soon as the pressure gets up above 4000 psi open the next nozzle.
    11c) Continue with this procedure as you ramp to production and open the 3rd nozzle at 4000 psi as well.
  12. After arriving at target feed rate for the run, you will likely be at around 380 to 400F, but that’s likely because the total solids in the feed hasn’t increased to the desired production level of 49-51%. You will, over the next 20 to 40 minutes or so, have to periodically lower the inlet temperature in order to not let the feed rate increase too high.
  13. Double check the supply fan current draw is 75 Amps. If it’s off, now that you’re at full production temperature, change it so that it’s at 75 Amps.
  14. Final set points for all items will vary depending on which product is being run on the dryer (LHNF, BM, LHW). Review posted job aids for those set points.
  15. Once the outlet temperature has leveled-out and is holding near the set point, walk to the top of the dyer and check for leaks and that the nozzle spray is correct.
  16. Pull several samples from the automatic sampler within the first hour and test them on the Perten for moisture and fat. Refer to LAB-250 for Perten operation. Also, run a test for scorched particles. Refer to LAB-259 for testing product scorch. Adjust the dryer settings (inlet temperature, outlet temperature, fluid bed temperature, and fan speeds) to meed and maintain the customer and LOL specifications (See Powder Specifications).
  17. Samples must be pulled a minimum of once every hour of operation or more often if there are problems with the dryer or the previous sample is out of specification.
  18. A walk through of the dryer must be completed for every hour that the dryer is on product. Inspect and look for the following items during each walk:
    18a) Check for plugs in the cyclones, fluid bed, chamber, and sifter.
    18b) Look for water, air, and product leaks during the walk. Fix them if possible. If you cannot repair the problem then notify maintenance, supervisor, or lead.
    18c) Clean up any messes that are found (powder, condense, water, etc)
    18d) Ensure the levels are clean. Floor mats, buckets, and brushes are properly stored. Hoses are rolled up and stored where they belong. All lines and ports are capped if not in use.
  19. All facets of dryer operation will be recorded on the Niro Dryer Log Sheet (For #027) with a minimum of one set every two hours.
25
Q

Niro Hourly Checks

What 7 items are to be checked on the ground floor every hour?

A
  1. Secondary Drop Tube- use the mallet to tap the cyclone sides to ensure that powder is not backing up.
  2. South End of the Fluid Bed- Use the mallet to tap the sides to ensure that powder is not backing up. Always check the bed springs on the fluid bed. If the springs are compressed more than usual, then the fluid bed may be backing up.
  3. Open the fluid bed doors and check that the powder level is normal.
  4. Sifter Bag- if the bag is full, then remove it and place a new one on the drop tube. Ensure that the bag is properly labelled.
  5. Baghouse Sack- if the sack is full, then remove it and place a new one on the drop tube.
  6. HPP- check the seals for leaking milk. If the seals are leaking, then notify maintenance that they will need replaced after CIP and make a note on the dryer board so that seals are not missed.
  7. Night shift only! At midnight, change to SP2/CIP 16’s temperature recording chart.
26
Q

Niro Hourly Checks

What are the two items to be checked on cyclone mid-level every hour?

A
  1. Look through the cyclone boot and ensure that powder is flowing through the line. Use the mallet to tap the drop tube if needed.
  2. Clean up any powder on the floor.
27
Q

Niro Hourly Checks

What should be checked in the fan room every hour?

A

Ensure all filters are in place, motors are running, and that all filter cabinets are tightly closed.

28
Q

Niro Hourly Checks

What 3 items should be checked on the cyclone 24’ level every hour?

A
  1. Use the mallet to tap the cyclone sides to ensure that powder is not backing up.
  2. Ensure that the baghouse rotary valve is running.
  3. Clean up any powder or standing water on the floor.
29
Q

Niro Hourly Checks

What 3 items should be checked on the 54’ level every hour?

A
  1. Listen to the baghouse back pulses to ensure they are firing.
  2. Take note of any air leaks on the back pulses and get them fixed.
  3. Clean up any powder on the floor.
30
Q

Niro Hourly Checks

What 2 items should be checked on the top level every hour?

A
  1. Check the top of the chamber to ensure the wands and hoses are not leaking.
  2. Clean up any powder on the floor or condense on the chamber deck.
31
Q

Niro Hourly Checks

What are the 7 hourly items of sets and powder sampling?

A
  1. Complete Rogers 1 Log Sheet Form #029.
  2. Pull a powder sample from the auto sampler and test on the Perten.
  3. Run a scorch on the powder sample.
  4. Enter Perten and scorch results into the In-Process Log.
  5. Maintain the Perten and the sampling counter by quickly cleaning the area after each sample.
  6. If dryer adjustments are needed to maintain in spec powder, then make those adjustments to the dryer. Use Moisture and Drying Rate Ajustment Guidelines (TJA-032) as a reference for possible adjustments.
  7. Pull calibration samples for the lab as necessary. Follow Process-783 or Post 180 for sampling guidelines.
32
Q

Moisture and Drying Rate Adjustment Guidelines

Fill in the blank:
Priority should be getting _____ in specification. Then, adjust ______ ____ based on ____ ____ levels.

A

Priority should be getting moisture in specification. Then, adjust drying rate based on feed tank levels.

33
Q

Moisture and Drying Rate Adjustment Guidelines

What are the 6 possible adjustments with low moisture and low drying rate?

A
  1. Decrease outlet temp, but remain greater than 170F.
  2. Decrease fluid bed inlet temp.
  3. Increase fluid bed fan speed.
  4. Increase feed rate.
  5. Increase inlet air temp, but remain less than 410F.
  6. Increase inlet fan speed.
34
Q

Moisture and Drying Rate Adjustment Guidelines

What are the 3 possible adjustments with low moisture and an acceptable drying rate?

A
  1. Decrease outlet temp, but remain greater than 170F.
  2. Decrease fluid bed inlet temp.
  3. Increase fluid bed fan speed.
35
Q

Moisture and Drying Rate Adjustment Guidelines

What are the 6 possible adjustments with low moisture and a high drying rate?

A
  1. Decrease outlet temp, but remain greater than 170F
  2. Decrease fluid bed inlet temp.
  3. Increase fluid bed fan speed.
  4. Decrease feed rate.
  5. Decrease inlet air temp.
  6. Decrease inlet fan speed.
36
Q

Moisture and Drying Rate Adjustment Guidelines

What are the 3 possible adjustments with in spec moisture and low drying rate?

A
  1. increase feed rate.
  2. Increase inlet air temp, but remain less than 410F.
  3. Increase inlet fan speed.
37
Q

Moisture and Drying Rate Adjustment Guidelines

What are the possible adjustments for in spec moisture and an acceptable drying rate?

A

No adjustments are necessary

38
Q

Moisture and Drying Rate Adjustment Guidelines

What are the 3 possible adjustments with in spec moisture and high drying rate?

A
  1. Decrease feed rate.
  2. Decrease inlet air temp.
  3. Decrease inlet fan speed.
39
Q

Moisture and Drying Rate Adjustment Guidelines

What are the 6 possible adjustments for high moisture and low drying rate?

A
  1. Increase outlet temp, but remain less than 200F.
  2. Increase fluid bed inlet temp.
  3. Decrease fluid bed fan speed.
  4. Increase feed rate.
  5. Increase inlet air temp, but remain less than 410F.
  6. Increase inlet fan speed.
40
Q

Moisture and Drying Rate Adjustment Guidelines

What are the 3 possible adjustments for high moisture with an acceptable drying rate?

A
  1. Increase outlet temp, but remain less than 200F.
  2. Increase fluid bed inlet temp.
  3. Decrease fluid bed fan speed.
41
Q

Moisture and Drying Rate Adjustment Guidelines

What are the 6 possible adjustments for high moisture with a high drying rate?

A
  1. Increase outlet temp, but remain less than 200F.
  2. Increase fluid bed inlet temp.
  3. Decrease fluid bed fan speed.
  4. Decrease feed rate.
  5. Decrease inlet air temp.
  6. Decrease inlet fan speed.

Land O'Lakes - Dryers (4 decks)

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