grain storage/handling facilities livestock feed … · 2013-10-03 · processing equipment, dust...

GRAIN STORAGE/HANDLING FACILITIES LIVESTOCK FEED MILLING FACILITIES

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Appendix 9 Grain Storage/Handling Facilities & Livestock Feed Milling Facilities

All grain storage and handling and livestock feed milling facilities shall be inspected by on an annual basis.

Check all mechanical and safety control equipment associated with dryers, grain stream processing equipment, dust collection equipment, and bucket elevators before start-up each Monday morning. During peak harvest season, check bearings, bucket elevator leg(s), and conveyors each day before start-up.

Perform lubrication and other appropriate maintenance in accordance with the manufacturer’s recommendations or more often if prior operating records indicate that it is necessary.

The following pages may be used as check sheets. Make copies of the individual inspection forms and use them whenever you perform a check on machinery and equipment or whenever you are doing routine maintenance activities or conducting repairs.

Identify each facility and note the appropriate date of the inspection/maintenance/repair activity on each line item that is checked. Comment on the condition of equipment where appropriate. Note the date by which repairs must be made or completed.

Complete and forward an Inspection and Preventive Maintenance Work Order Form to the appropriate supervisor. A second copy must also be forwarded to the Main Office for review and placed in an appropriate, permanent safety file for future reference.

Follow Lockout and Tagout Procedures to prevent the inadvertent start up of equipment during maintenance, repair, and inspection activities.

In the event that cutting, welding, or brazing activities are required, observe Hot Work Permit procedures.

In the event that entry is required into a confined space, follow the appropriate Confined Space Entry procedure, assemble the necessary rescue personnel and equipment, post observers, and evaluate the space for conditions which create a hazardous atmosphere, engulfment hazard, entrapment hazard, and/or entanglement hazard.

Inspection and Preventive Maintenance Work Order


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(This form is to be used when specific repairs and/or maintenance activities are required.) Observe all Lockout/Tagout, Confined Space Entry, and Hot Work Permit procedures at all times.

Company Name: Date:

Date of initial assignment: Date to be completed:

1. Type or equipment or process:

Serial or other identification number on piece of equipment:

Location of equipment:

Activity assigned to: By:

2. Describe the inspection, maintenance, or repair activity to be completed:

List any specific instructions (include specific procedures to be followed):

3. Inspection/maintenance/repairs completed (Date): (Time)

Number of employees involved: Number of employee man-hours:

Remarks (include warranty, minimum service interval, other follow-up):

Signature of employee(s) involved: ___________________________

(Return this form to the supervisor’s office for filing when work is completed.)

Company Location: Date:


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Follow lockout and tagout procedures to prevent inadvertent start up of equipment during inspection, maintenance, or repairs.

To be completed prior to the beginning of each drying season. Identify all potential problem areas.

Item Checked YES? NO? Date Corrected?

Grain Dryer(s) general N/A N/A N/A

Check/grease bearings?

Check gear box oil level?

Condition of drive belts/chains/sheaves/sprockets?

Screens cleaned?

Plenum chamber(s) clean and free of debris?

Ignitors/burners operating properly?

Grain dryer(s) unloading augers N/A N/A N/A



Drive belts/sheaves/chains/sprockets?

Safety shields in place?

Grain dryer bucket elevator dry grain leg(s) N/A N/A N/A

Check/grease bearings --- top and bottom?


Check motor and motor mount?

Drive belt/sheaves?

Condition of leg belt/alignment/cups intact?


Grain dryer bucket elevator wet grain leg(s) N/A N/A N/A



Check motor and motor mount?

Drive belts/sheaves?

Condition of leg belt/alignment/cups intact?

Item Checked YES? NO? Date Corrected?


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Grain dryer(s) electrical N/A N/A N/A


High/low pressure switches?

Limit switches?

Main thermostat?

Ignition system?

Blower fan(s)?

Condition of wiring/conduit/connections/switches?

Grain dryer(s) mechanical N/A N/A N/A

Variable speed drive?

Check column screens for holes?

Interior/exterior clean and free from debris?

All doors secure and no air leakage?

Fire extinguishers properly mounted/protected/inspected?

Grain dryer(s) wet grain leveling auger N/A N/A N/A



Drive belt(s)/sheaves?

Motor and motor mount?

Check for holes in auger tube?

Auger flighting?

Company Name: Date: Inspected by: GRAIN DRYER CHECKLIST


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Item Checked OK? Comments

Exterior N/A N/A

Openings to heating/cooling sections accessible without use of tools?

Dryer anchored to withstand high winds?

Anchor bolts/welds checked for wear?

Area near dryer(s) free from combustibles/debris?

Electrical N/A N/A

No breakage or exposed wires on conduit?

Electrical system properly grounded?

Electrical control panel housing weather tight?

Master power switch located in main electrical panel?

Power lines above/near dryer properly supported?

High-limit switch in plenum chamber?

Fire Protection

Local fire department familiar with dryer operation?

Dry chemical portable fire extinguisher in place/identified?

Fire stop located in wet grain fill spout?

Exhaust detection system operational?

Housekeeping

Doors/opening permit inspection/cleaning/maintenance?

Interior screens cleaned?

Exterior screens cleaned?

Louvers cleaned?

Regular dryer cleaning scheduled and posted at:

Interior screens every hours? Exterior screens every hours? Plenum chamber checked & cleaned for trash buildup every hours?

Grain dryer(s) housekeeping continued

Drying compartments/chambers


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All bolts and screws in columns tight?

Missing bolts/screws replaced?

No worn, rusted areas, or holes in column(s)?

Air lines clear?

Thermostatic control equipment operational?

Gauges operational?

Thermometers operational?

Hidden areas (under drags/augers/chains) clean?

Feed rolls free of debris/in good condition?

Heat and air source N/A N/A

No worn spots or leaks in fuel line(s)?

All connections tight?

Fan bearings/drives in good condition?

Air screens tight?

Air screens free from holes?

Pressure or sail switch in place?

Stock handling equipment

Cups secure/belts properly aligned?

V-belts on drives in good condition?

Bearings on conveyors/augers/drags in good condition?

Bearings clean and lubricated?

Drives on conveyors/augers/drags in good condition?

Emergency control equipment tested and operational?

All other controls tested and operational?


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Company Name: Location:

Date: GRAIN ELEVATOR #

Follow lockout and tagout procedures to prevent inadvertent start up of equipment during inspection, maintenance, or repairs.


Leg # N/A N/A



Condition of leg belt?

Belt buckets in place/in good condition?

Head pulley lagging condition?

Leg # N/A N/A






Leg # N/A N/A






Grain screener/scalper # N/A N/A



Drive belt(s)/chains?


Grain screener/scalper # N/A N/A


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Grain screener/scalper # continued


Manlift N/A N/A



Check cable condition?

Gates/doors/floor openings?

Top bin conveyor # N/A N/A



Drive belt(s)/chain?


Conveyor cover bolted in place?













Tunnel (basement) bin conveyor # N/A N/A



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Top drag conveyor # N/A N/A






Top drag conveyor # N/A N/A







Bottom drag conveyor # N/A N/A



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Bottom drag conveyor # N/A N/A






Dryer - wet leg # N/A N/A





Belt cups intact?


Dryer - dry leg # N/A N/A






Belt cups intact?


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Dryer - distribution auger N/A N/A

Check/grease bearings --- front and rear?





Aeration fan # Bin # N/A N/A





















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Equipment Check & Service Report Bucket Elevator

Facility: Location: Date: Inspected by: Make: Model: Capacity: Drive: Motor: Phase/Voltage: Serial # All items are in good working condition unless noted. Repair work and parts that have been replaced or need to be replaced should be noted.


Cups - damaged/loose/missing?

Cup bolts - loose/missing/damaged?

Belt condition - cuts/tears/frays/edge/wear on back of belt?

Belt splice - tight?

Belt take-up tension?

Belt alignment?

Inspection doors secure?

Truck/casing - wear/holes/rust?

Trunk/casing - belt and cup clearance?

Head pulley - lagging/set screws/alignment/shaft condition/bearings mounts secure?

Head housing/crown wear?

Head linings?

Throat wear/lining plate wear/throat clear of obstructions?

Drive installation/alignment/mounting?

Drive lubrication?

Alignment drive belt/chain?

Condition belt and sheaves?

Condition chain and sprockets?

Guards - condition/in place?



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Motor mount?

Exposed wires?

Oil level in gear boxes?

Boot pulley - alignment/take-ups/shaft condition/set screws/bearing mounts secure?

Boot section clear of obstructions and tramp material?

Guy wires - cable - clamps - anchors; condition/secure?

Explosion vents?

Dust fan and ducting?

Test motion detector?

Test dust suppression system?

Test alignment warning system?

Test bearing monitors?

Note item, repairs made/needed, parts/supplies used/needed, etc.


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Equipment Check & Service Report Grain Cleaner Facility: Location: Date: Inspected by: Make: Model: Capacity: Drive: Motor: Phase/Voltage: Serial # All items are in good working condition unless noted. Repair work and parts that have been replaced or need to be replaced should be noted.


Screen --- tension/worn/clean?

Inlet spout --- worn/clear of debris?

Fines spout --- worn/clear of obstructions?

Bypass --- clear/operable?

Drive belts --- condition/tension?

Reducer drive --- lubrication/condition?

Bearings --- lubrication/condition?

Motor bearings --- lubrication/condition?

Electrical wiring/junction box/conduit/etc.?

Suspension cables (toggle arms)?

Suspension springs?

Safety devices operable?

Check for vibration and/or unusual noise?

Cracks in frame/support structure?



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Equipment Check & Service Report Truck Lift Facility: Location: Date: Inspected by: Make: Model: Capacity: Drive: Motor: Phase/Voltage: Serial # All items are in good working condition unless noted. Repair work and parts that have been replaced or need to be replaced should be noted.


Frame --- condition?

Shafts --- condition?

Track and trolleys --- condition?

Sheaves --- condition/secure?

Cable drum --- condition?

Set screws --- secure?

Cables/clamps/thimble --- condition & secure?

Cradle --- condition?

Cradle sheaves --- condition?

Lubrication of bearings?

Supports --- condition?

Shaft coupling & guard condition (if applicable)?

Motor & gears --- condition?

Oil level in gear box?

Controls operate properly?

Top limit switch operational?

Sign: No smoking within 75 feet?

Sign: No standing behind truck?



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Equipment Check & Service Report Manlift

Facility: Location:

Date: Inspected by:

Make: Model: Capacity:

Drive: Motor: Phase/Voltage: Serial #

All items are in good working condition unless noted. Repair work and parts that have been replaced or need to be replaced should be noted.


Cage --- condition of gate/frame/body?

Top limit switch?

Control switch?

Cable attachment to cage?

Cable condition?

Hand rope --- secure/condition?

Counterweight --- inspection access?

Counterweight --- attachment to cable?

Counterweight --- condition?

Traction wheel?

Traction wheel shaft?

Traction wheel bearings?

Reduction drive?

Motor & drive mount assembly?

Motor?

Motor brake?

Overspeed brake?

Overspeed brake rope?

Intermediate entry switches?

Conduit & wiring?

Lubrication?

Gates at landings?



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Equipment Check & Service Report Belt Conveyors Facility: Location: Date: Inspected by: Make: Model: Capacity: Drive: Motor: Phase/Voltage: Serial # All items are in good working condition unless noted. Repair work and parts that have been replaced or need to be replaced should be noted.


Head pulley - lagging/set screws/alignment/shaft condition/bearing mounts/secure?

Loading hood - condition/alignment?

Gear drive --- oil level/mounting secure?

Condition of drive belt or chain/sheaves/sprockets/set screws/secure?

Motor & Mount --- secure?

Guards --- condition/in place?

Conveyor belt --- condition/splice?

Idlers --- alignment/flat/lubricated?

Trough --- condition?

Tail pulley --- alignment/take-ups/shaft condition/set screws/bearing mounts?

Unloading hood --- condition/alignment?

Electrical interlocks & alarms/conduit/wiring?

Dust build up under conveyor/ on supports/drive pulleys/motor?

Grain spillage & buildup?

Trippers --- condition/alignment

Pulleys & gears/Controls

Chain or belt drives/Discharge spouting

Friction drive wheels/Set screws - secure


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Equipment Check & Service Report Drag Conveyors Facility: Location: Date: Inspected by: Make: Model: Capacity: Drive: Motor: Phase/Voltage: Serial # All items are in good working condition unless noted. Repair work and parts that have been replaced or need to be replaced should be noted.


Head shaft --- condition/set screws/bearings lubricated/sprocket alignment & condition/bearing mounts secure?

Inlet --- condition/wear on splitter?


Motor & mount --- secure?

Condition of belts/sheaves or chains/sprockets?

Alignment of belt/chain?

Guards --- condition in place?

Drag chain --- condition (links/pins/accessories)?

Flights (paddles) missing/condition/secure?

Chain tension?

Return angles --- condition?

Housing --- condition/weather tight?

Drops --- conditions/operation?

Tail shaft --- condition/set screws tight/sprocket alignment/sprocket condition/bearing mounts secure/bearings lubricated?

Take-ups --- condition/operation

Electrical wiring/conduit?

Safety switches?



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Equipment Check & Service Report Screw Augers Facility: Location: Date: Inspected by: Make: Model: Capacity: Drive: Motor: Phase/Voltage: Serial # All items are in good working condition unless noted. Repair work and parts that have been replaced or need to be replaced should be noted.



Motor & mount secure?

Condition --- belts/sheaves or chains/sprockets?

Alignment of belt or chain?

Guards --- condition and in place?

Bearing lubrication?

Cover --- secure/weather tight?

Trough --- alignment/wear?

Flighting --- alignment/damaged/worn/loose on pipe/coupling bolt hole condition (max. 1/8-inch of play)?

Drop (outlets) --- wear/location?

Hanger bearing(s) --- secure/condition/max. 1/8-inch play?

Coupling shaft --- condition?

Coupling bolts --- secure?

Internal collars --- secure?

Tail plate --- condition?

Tail bearing --- condition/secure/set screws tight/lubricated?

Seal (if needed)?

Fee of buildup or foreign material?

Thrust washer (if needed)?



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Equipment Check & Service Report Distributor(s) Facility: Location: Date: Inspected by: Make: Model: Capacity: Drive: Motor: Phase/Voltage: Serial # All items are in good working condition unless noted. Repair work and parts that have been replaced or need to be replaced should be noted.


Free movement?

Inlet collar/throat wear?

Baffles & inner parts --- condition?

Turn or swing spout --- wear/alignment?

Pivot points --- wear/lubrication?

Outlet ducts --- wear/alignment?

Position lock --- condition?

Controls --- operable/cables/sheaves/clamps?

Control handle --- proper operation?

Position indicator?

Electrical connections/wiring/conduit --- condition?

Support & mounting?



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Equipment Check & Service Report Electrical Facility: Location: Date: Inspected by:

All items are in good working condition unless noted. Repair work and parts that have been replaced or need to be replaced should be noted.


Outside N/A N/A

Aerial wires clear of obstructions?

Aerial wires insulated?

Conduit sealed and secure?

Enclosures watertight and secure?

Enclosures free of dust and debris?

Inside

All junction box covers sealed and in place?

All conduit sealed and in place?

All flex joints sealed and secure?

All plug-in receptacles (enclosed type)?

Lights free of dust and enclosures in place?

Switches labeled?

Switch covers in place?

Check for any evidence of short circuits or overloads?

Notify licensed electrician on any questionable conditions?

Electrical room --- clean/dry?



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Equipment Check & Service Report General Facility: Location: Date: Inspected by: All items are in good working condition unless noted. Repair work and parts that have been replaced or need to be replaced should be noted.


Exits marked and NO SMOKING signs posted?

First Aid Kits available at:

Free of any evidence of pests and bird nests?

Aircraft warning lights operable?

All roofs --- free of leaks?

All doors --- secure and operable?

Weeds and brush clear?

Area drainage adequate?

Exterior paint condition: Good Satisfactory Poor

Outside area clear of spilled grain?

Loading tracks clear of car cleanouts?

Blind & dangerous intersections & railroad crossings are marked?

Ladder rungs --- looseness/toe clearance (7 inches)/evenly spaced?

Ladder rails --- straight/secure?

Ladder brackets --- secure?

Steps and/or walkways --- secure?

Steps and/or walkways --- holes in floor/hand rails secure?

Ladder, steps, walkways --- clear/free of buildup (ice, snow, dirt, grain, etc.)?

Dump pit(s) --- grate in place/good condition?

Dump pit(s) --- outside --- covers in good condition/lift working?

Dump pit(s) --- gates and controls in adjustment?

Dump pit(s) --- clean/free of buildup?

Dump pit(s) --- adequate clearance from trucks?



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Equipment Check & Service Report Dust Filters Facility: Location: Date: Inspected by: Make: Model: Capacity: Drive: Motor: Phase/Voltage: Serial # All items are in good working condition unless noted. Repair work and parts that have been replaced or need to be replaced should be noted.


Bags --- caking/rips/proper insulation?

Bearings --- inside and outside (reverse pulse)?

Cams and springs --- on reverse pulse?

Magnehelic reading in 2 to 4 inch range?

Clearance of vanes to wall in rotary valves?

Diaphragms and solenoids in air-operated systems?

Air leaks or a drop in air pressure in air operated systems?

Drain compressed air system (should be done nightly)?

Start and stop system operating properly to allow purging?

All drives for belt/chain and sheave/sprocket --- tension & wear?

Blower fans and their V-belts --- proper operation?

Check and lubricate bearings?


grain storage/handling facilities livestock feed … · 2013-10-03 · processing equipment, dust...

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