vrt safety maint training service manual brasil foods.pdf

8/20/2019 VRT Safety Maint Training Service Manual Brasil Foods.pdf

1/45

VRT FREEZER SYSTEM

SAFETY, MAINTENANCE & SERVICETRAINING MANUAL

Prepared by:

GEA Refrigeration North America, Inc.Section: GEA Intec

4319 South Alston Avenue, Suite 105Durham, NC 27713, USAPhone: +1 919 433-0131

Fax: +1 919 433-0140

Refrigeration Technologies


2/45

VRT Safety & MaintenanceTraining Manual

Page 2 of 45

GEA Refrigeration North America, InSection: GEA Int

4319 South Alston Avenue, Suite 10Durham, NC 27713, US

Phone: +1 919 433-01Fax: +1 919 433-01

Refrigeration Technologies

TABLE OF CONTENTS

SECTION 1 ............................................................................................................ SAFETY PROCEDURES

SECTION 2 .............................................................................................................. GENERAL OVERVIEW

SECTION 3 ................................................................................................................................. GLOSSARY

SECTION 4 ............................................................................................... VRT MAINTENANCE PROGRAM

SECTION 5 .................................................................................................................. SERVICE PROGRAM


3/45

VRT Safety, Maintenance &Service Training Manual

Page 3 of 45



Phone: +1 919 433-01Fax: +1 919 433-01

Refrigeration Technologie

SECTION 1

INTEC – VRT SAFETY PROCEDURES

CONTENTS:

VRT SAFETY - GENERAL ............................................................................................. 4

TERMS OF LIABILITY ..................................................................................................... 4GENERAL PROCEDURES ............................................................................................. 5ELECTRICAL SUPPLY ................................................................................................... 7CLEANING ...................................................................................................................... 7PRODUCTION PREMISES ............................................................................................. 8SIGNPLATES / MARKINGS ............................................................................................ 9EVACUATION ................................................................................................................. 9VRT FREEZERS / CHILLERS - GENERAL INFORMATION ......................................... 10VRT OPERATION ......................................................................................................... 11

VRT ENCLOSURE - ENTRY PROCEDURE ................................................................ 12

VRT ENTRY - OPERATORS DURING NORMAL PRODUCTION ................................. 12VRT ENTRY - MAINTENANCE PERSONNEL .............................................................. 14VRT ENTRY - GENERAL PRECAUTIONS.................................................................... 16


4/45


Page 4 of 45



Phone: +1 919 433-01Fax: +1 919 433-01


VVRRTT SSAAFFEETTYY -- GGEENNEERRAALL

T T E E R R M M S S O O F F LLI I AAB B I I LLI I T T Y Y

1 This Safety Manual applies to equipment supplied and installed by GEA Intec

2 The owner of the plant is obliged to ensure compliance with this safety manual

3 Equipment supplied by Intec shall be installed in premises which designconforms to national regulations

4 Equipment supplied by Intec complies at the time of delivery with the provisions inforce in accordance with the Order Agreement

5 Equipment supplied by another supplier that is connected to equipment suppliedby Intec shall comply with the provisions in force in accordance with the OrderAgreement

6 Do not connect equipment supplied by another supplier to equipment supplied byIntec without consulting with Intec as to its compatibility


5/45


Page 5 of 45



Phone: +1 919 433-01Fax: +1 919 433-01


G G E E N N E E R R AALL P P R R O O C C E E D D U U R R E E S S

These procedures also require the following to be in place:

• buildings, production equipment, refrigeration plant etc. are designed and built inaccordance with the regulations currently in force

• compliance with the regulations that govern protective clothing

Safety Notes

1 The owner is responsible for ensuring that staff operating the VRT and associatedproduction equipment are suitable for such duties and possess the necessary

skills and equipment

2 Only undamaged tools suitable for the intended purpose shall be used in anyoperations

3 Do not start up the plant until you have read and understood the Operating andSafety Instructions and are familiar with and understand the location and functionof the various components

4 Alarm and indicator lamps are to be observed and obeyed

5 Areas, system sections or components or their equivalents which are locked may

not be modified without special consent

6 The plant is never to be operated outside the specifications of the supplier or itsoperational settings

7 Plant safety monitors or protective equipment must never be rendered inoperativeor removed by such means as by-passing or bridging, dismantling, or setting tooperational values outside those permitted

8 Never place fingers, hands or any other part of the body in equipment which is inoperation or can start automatically

9 Bear in mind the danger of loose clothing or long unprotected hair catching inmoving parts of the machinery

10 Never remove information, warning or prohibition signs from the plant. A missing orworn sign shall be replaced immediately

11 Do not start up the plant without drawing this to the attention of the other staff


6/45


Page 6 of 45



Phone: +1 919 433-01Fax: +1 919 433-01


12 Work involving heat or a naked flame, e.g. cutting or welding, always requires awelding permit or other specific permission

13 There must be no direct connection (passage way) between the machine roomand any other area in which an open flame or hot surfaces are present. Thisincludes burners, boilers and similar equipment

14 Smoking in the machine room is prohibited

15 The plant shall be continually maintained and monitored in a reliable manner suchthat its condition conforms to that laid down in the regulations

16 Only staff who have been approved and trained, and have received authorised

orders may work on the refrigerant/ evaporator system.

17 Work on refrigeration plant is to be done in compliance with the rules andprovisions of the Local or National Code or Standards or refrigeration norms or theequivalent

18 Note that the noise levels inside the VRT enclosure may cause damage to hearingif the fans are operating. Employees must wear hearing protection

19 Use only walkways and a type-approved ladder in accordance with the instructionsof the supplier when working on and inside the plant

20 Abnormal activity such as noise, vibration, knocking etc. shall be reported ATONCE for expert appraisal

21 Do not start up the plant if any component or part of a system is defective orincorrect.

22 Before doing any work make sure that the machine is locked out in accordancewith the instructions in this manual


7/45


Page 7 of 45



Phone: +1 919 433-01Fax: +1 919 433-01


E E LLE E C C T T R R I I C C AALL S S U U P P P P LLY Y

1 Only staff who have been approved and trained, and have received orders may

work on the electrical system. Work is to be undertaken in accordance with localprovisions and regulations

2 If this work does not require the supervision of an electrical contractor, liability lieswith the person doing the work, or if the latter does not posses the necessaryexpertise, with the person who ordered the work

3 Check in particular electric heating cables in freezer doors to ensure that they arein good condition. A damaged cable is a potential cause of fire and may constitutea lethal danger

4 Electrical work may be performed only by duly authorised and trained personnelwho are assigned to such work

5 Before any electrical work commences, the power supply of the unit is to beswitched off by the main circuit breaker and secured / locked in the off position

6 There is still current in the lighting circuit even when the main VRT circuit breakeris switched off

C C LLE E AAN N I I N N G G

1 Cleaning may be done only by staff who have been approved and trained, andhave received orders

2 Cleaning is to be done in accordance with the instructions issued

3 Cleaning is always to be done only when the plant is shut down and disconnectedfrom the power supply

4 If protective guards or other protective equipment has to be removed duringcleaning, it must be re-fitted immediately once cleaning has been done


8/45


Page 8 of 45



Phone: +1 919 433-01Fax: +1 919 433-01


P P R R O O D D U U C C T T I I O O N N P P R R E E M M I I S S E E S S

1 Only staff who have been approved and trained, and have received orders may bepresent on the production premises

2 The term production premises embraces both the individual VRT / ConveyorSystem and the premises on which it is sited

3 All machine units shall be easily accessible and have clearly marked emergencystopping devices

4 Production premises shall be built in accordance with the regulations relating tohygiene, fire, the environment, etc.

5 Production premises and unit shall be kept clean of dirt and oil and refrigerantspillage

6 Inflammable material other than that required for production may not be kept onthe production premises or in the unit.

7 Note that during production there are very cold surfaces on the VRT - which canbe as low as -40°F

8 The operating position, evacuation routes and gangways are to be kept accessibleand free

9 Observe local rules in respect of protective clothing and equipment

10 Unless the local regulations otherwise provide, at least the following must bepresent at a suitable site:

• fire extinguisher• hearing protectors• visible/audible signal device for alarms in the event of refrigerant leakage or

other emergency

• emergency lighting

• first aid kit


9/45


Page 9 of 45



Phone: +1 919 433-01Fax: +1 919 433-01


S S I I G G N N P P LLAAT T E E S S / / M M AAR R K K I I N N G G S S

1 Note: The following may be overruled by local or national regulations:

2 Emergency stopping devices are to be clearly marked.

3 Piping to be clearly marked in respect of flow direction and nature of contents, e.g.NH3 gas, HCFC 22 liquid, etc.

4 All evacuation routes to be clearly marked with illuminated signs in accordancewith local rules

5 Projecting parts of equipment are to be marked or provided with protective lining

6 Machines that contain substances that can burn, explode or are a health hazardshall be clearly marked with sign plates

7 Fire-fighting equipment to be clearly marked in respect of type and location

E E V V AAC C U U AAT T I I O O N N

Note: The following may be overruled by local or national regulations.

1 At suitable sites on the production premises there shall be:

•

a diagram of evacuation routes• a description of how to alert the emergency services• location of manual alarms and emergency release devices• location of main sectioning valves and sectioning doors• assembly site after evacuation

2 Evacuation routes from production premises are to be clearly marked

3 In immediate vicinity of a production unit containing media that can cause a fire,explosion or health hazard, there is to be an evacuation chart stating the following:

• health hazards from escaping media

• necessary protective equipment and its location• assembly site after evacuation• measures to be taken in the event of fire or an escape of media

• how to act in air containing media if the latter is a health hazard


10/45


Page 10 of 45



Phone: +1 919 433-01Fax: +1 919 433-01


V V R R T T F F R R E E E E Z Z E E R R S S / / C C H H I I LLLLE E R R S S - - G G E E N N E E R R AALL I I N N F F O O R R M M AAT T I I O O N N S S a a f f e e t t y y s s t t a a r r t t s s w w i i t t h h Y Y O O U U ! !

1 Always follow the operating / safety instructions and precautions

2 Perform no task for which you are not authorised, qualified or trained

3 The VRT must be kept clean and may not be used for storage of any objects notdirectly required for care of equipment

4 Emergency stop push buttons are located inside the freezer and outside. Pushingany one of these buttons switches off all functions of the VRT except for the

lighting5 VRT doors intended for personnel must not be blocked, but must be easily

accessible at all times

6 Drain hatches for water in the VRT must not be blocked, but must be easilyaccessible at all times

7 Under no circumstances may the freezer be exposed to fire or open flame

8 Operating Manual and Safety Manual must be available

9 Only duly authorised and trained personnel who are responsible for operation mayenter the VRT

10 Appropriate personnel protective clothing is to be worn on entering the VRT


11/45


Page 11 of 45



Phone: +1 919 433-01Fax: +1 919 433-01


V V R R T T O O P P E E R R AAT T I I O O N N

The VRT consists of carriers, conveyors, motors, chains and other moving parts whichare capable of causing various types of injury or damage

1 Never put the unit into operation before you have read and understood theoperation and safety instructions. You must also know and understand the locationand function of the various components

2 The unit's safety devices and equipment must not be removed, disconnected,bypassed, dismantled or set outside prescribed operating limits

3 Loose clothing or long, unprotected hair may get caught in the moving parts of themachinery. Never put fingers, hands, or other parts of the body in equipment that

is in operation or that can start automatically

4 Know where all the emergency stop buttons are and how they work

5 Suitable protective clothing, e.g. safety goggles, gloves, shoes, helmets andhearing protection is to be worn at all times when working with the VRT

6 Only duly authorised and trained personnel who are responsible for operation mayenter the freezer

7 Note Low Temperature Environment:•

Low temperatures• Frozen metal surfaces• High air velocity

8 Moist skin sticks immediately to cold metal surfaces and severe injuries may result.Do not wear wet clothing which may also stick to cold metal surfaces

9 Extremely low air temperatures may cause frostbite and possible fatal hypothermiaeven on short exposure

10 The nose, cheeks, ears and hands should be especially checked for signs of frostinjury (e.g. white spots) or numbness


12/45


Page 12 of 45



Phone: +1 919 433-01Fax: +1 919 433-01


VVRRTT EENNCCLLOOSSUURREE -- EENNTTRRYY PPRROOCCEEDDUURREE

The procedures outlined below applies to all people specifically trained as VRToperators and authorized to enter the VRT enclosure during normal production

V V R R T T E E N N T T R R Y Y - - O O P P E E R R AAT T O O R R S S D D U U R R I I N N G G N N O O R R M M AALL P P R R O O D D U U C C T T I I O O N N

As could be required to clear a product jam.

RECORD ENTRY / EXIT • by writing your name and entry / exit times in the logbook provided. After exiting the cause of thestoppage should also be written into the log book

• by informing a trained work mate

CARRY A RADIO • at all times with communication established with anoperator on the outside

STOP & DISABLE • push the E-Stop button on the operator console

• turn the main key-switch from the AUTO to the OFFposition and withdraw the key (the key can only be

withdrawn in the off position ) - take the key with you

• open the external enclosure door(this action also removes all control and motor powerto internal VRT components - same as pushing E- Stop )

• when inside push the internal E-Stop button locatednearest your area of work


13/45


Page 13 of 45



Phone: +1 919 433-01Fax: +1 919 433-01


ENABLE & RESTART • release the internal E-Stop

•

open the enclosure door and with door open insert thekey (taken earlier from main Auto / Off / Manual switch )into the internal door reset switch and toggle once.

• remove the key and exit closing the door behind you

• release the E-Stop on the operator console

• push the Reset push-button and acknowledge anyalarms on the SCADA.

• insert the key into the main key-switch and turn to the

AUTO POSITION

Note: All control and motor power will remain physicallyisolated until:First: the internal door reset switch has been activatedand thenSecond: the key is inserted into the main key-switchand the switch is turned to AUTOThen and only then will power be re-applied tocomponents provided that also:

- all doors are closed

- all E-Stop buttons have been released- all VRT alarms have been cleared

• a start up lamp and audible alarm will soundimmediately prior to the VRT re-starting andcomponent movement commencing


14/45


Page 14 of 45



Phone: +1 919 433-01Fax: +1 919 433-01


V V R R T T E E N N T T R R Y Y - - M M AAI I N N T T E E N N AAN N C C E E P P E E R R S S O O N N N N E E LL

As could be required to change out an electric motor

RECORD ENTRY /EXIT

• by writing your name and entry / exit times in the logbook provided. After exiting the cause of the stoppageshould also be written into the log book

• by informing a trained work mate

CARRY A RADIO • at all times with communication established with an

operator on the outside

STOP & DISABLE • push the E-Stop button on the operator console

• turn the main key-switch from the AUTO to the OFFposition and withdraw the key (the key can only bewithdrawn in the off position ) - take the key with you

• when inside push the internal E-Stop button locatednearest your area of work

DISCONNECT • the main MCP breaker and lock out

• the local motor isolator(s) and lock out

all lock outs should only be done with tagged padlocksunique to each maintenance worker or electrician

RE CONNECT Once work has been completed:

• local motor isolators and switch MCP main breakerback on and then proceed back into the VRT


15/45


Page 15 of 45



Phone: +1 919 433-01Fax: +1 919 433-01


ENABLE &RESTART

• release the internal E-Stop

•

open the enclosure door and with door open insert thekey (taken earlier from main Auto / Off / Manual switch )into the internal door reset switch and toggle once.

• remove the key and exit closing the door behind you.

• release the E-Stop on the operator console

• push the Reset push-button and acknowledge anyalarms on the SCADA.

• insert the key into the main key-switch and turn to the

AUTO POSITION

Note: All control and motor power will remain physicallyisolated until:First: the internal door reset switch has been activatedand thenSecond: the key is inserted into the main key-switchand the switch is turned to AUTOThen and only then will power be re-applied tocomponents provided that also:

- all doors are closed

- all E-Stop buttons have been released- all VRT alarms have been cleared

• a start up lamp and audible alarm will soundimmediately prior to the VRT re-starting andcomponent movement commencing


16/45


Page 16 of 45



Phone: +1 919 433-01Fax: +1 919 433-01


V V R R T T E E N N T T R R Y Y - - G G E E N N E E R R AALL P P R R E E C C AAU U T T I I O O N N S S

NEVER • ride on the VRT cradles or stand on any VRTcomponents while in operation

• use the rack structure as a ladder - always useapproved ladders and safety harnesses

AVOID AFTER THE VRT HAS BEEN STOPPED AND LOCKEDOUT:

• standing under the carriers or cradle

• lying half way out of the rack structure at the load ortransfer ends

• standing inside the sweeparm cross bracing

• walking on conveyor surfaces

• walking unsupported on any structural members

CLOTHING • suitable for the cold must be worn inside the VRT -

including suit, gloves, headgear and boots

TIME • spent inside the VRT should be kept to a minimum -take regular breaks outside if prolonged work isrequired inside

This section introduces the two main controls in the VRT Control Room that are used to

operate the VRT:

• the Operator Console, and• the Operator Interface.


17/45


Page 17 of 45



Phone: +1 919 433-01Fax: +1 919 433-01


11..11 O O p p e e r r a a t t o o r r C C o o n n s s o o l l e e

The Operator Console is mounted on the desk in the Control Room, next to thecomputer. It has the following controls:

• VRT ON-OFF key-switch sets the operating mode of the VRT.• EMERGENCY STOP button stops all the motors inside the VRT.• VFD MODE key-switch is used to set up the SEW Variable Frequency

Drives (referred to as VFDs).

• RESET button clears the alarms and messages on the Operator Interface,and restarts the system after an Emergency Stop.

• MANUAL EXT-RET switch is used to operate VRT components in Manual.


18/45


Page 18 of 45



Phone: +1 919 433-01Fax: +1 919 433-01


SECTION 2

GENERAL OVERVIEW

Variable Retention Time Chilling and Freezing

• The Intec VRT is a tray blast freezer andchiller.

• The VRT has multiple load levels. Product isstored on shelves in the levels.

• Each level can be assigned a unique retentiontime whereby product in that level is

discharged once the retention time has

elapsed, allowing a range of product to be

frozen or chilled at different rates.

• Incoming product is sorted into conveyor linesaccording to predetermined retention times,

product type or packaging size. From the

infeed conveyors, it is transferred into a load

level. For example if product was sorted

according to its retention time, then product

with a four hour retention time can be loaded

into one level, product with a five hour

retention time into another level and so on.


19/45


Page 19 of 45



Phone: +1 919 433-01Fax: +1 919 433-01


The VRT Cycle

Shelves • The VRT consists of a number of storage, or

load levels. The number of levels is fixed

and is determined by the capacity

requirements of the machine.

• Each level contains a set number of shelvesdepending on the size of the machine.

• Product is accumulated outside the VRT inshelf lots. A shelf lot is the number of cases

of a particular size that can fit onto a shelf.

• Once product enters the VRT, it is arrangedautomatically into a pattern to optimize air

flow and shelf area.

• Once the product is loaded onto the shelf,the VRT then transfers the shelf into a load

level where the product and the shelf remain

until the product has meet its predetermined

retention time.


20/45


Page 20 of 45



Phone: +1 919 433-01Fax: +1 919 433-01


The VRT Cycle

Infeed Accumulation Conveyors • Cased product from the production lines is fed automatically into the

VRT via the arrangement of low pressure roller and belt conveyors.

• Once product reaches the VRT end of the conveyors, product ismetered into the VRT using the NxA, NxB & NxC brake spacer

conveyors.

• As product travel across the NxC brake belt onto the NxB curve, aspeed differential between the conveyors creates a gap between the

cases. This gap is maintained across the NxB to NxA belt.

• From time to time, it will be necessary to accumulate product outsidethe VRT on the accumulation conveyors.

• Accumulation starts on the NxD conveyor. Once cases haveaccumulated the full length of the NxD conveyor, a photoeye senses

the section of conveyor is full and shuts off the motor. Product then

begins accumulating on the NxE conveyor and the sequence repeats

itself along the length of the system.

• Once the VRT starts loading, product is released off the NxD ontothe brake spacer conveyors. There is a short interval between NxD

starting and NxE starting to ensure down stream cases have time to

clear the s stem. The start-u se uence re eats itself alon the len th


21/45


Page 21 of 45



Phone: +1 919 433-01Fax: +1 919 433-01


The VRT CycleH Conveyor & F Sweeparm

• As product is spaced off the NxA belt, apredetermined gap is set between cases as

they are loaded onto the H conveyor. This

gap ensure airflow between the cases.

• Once 14 cases have loaded onto the Hconveyor, the F sweeparm indexes the casesoff the H conveyor onto the surge table.

The F Arm retracts and another row of 14

cases is loaded onto the H conveyor.

• The F Arm extends again sweeping thesecond row onto the surge table before

retracting.

• A third row is then loaded onto the Hconveyor, at which time the F Arm will

extend and sweep all three rows (42 cases)

onto an empty shelf on the C Cradle.


22/45


Page 22 of 45



Phone: +1 919 433-01Fax: +1 919 433-01


The VRT Cycle

Elevator System

• The Elevator system comprises of twocradles, the C Cradle at the load end and the

D Cradle at the transfer end.

• The two cradles are mechanically linked bythe line shafts that run down either side of

the machine. The line shafts are driven by

the E Motors. These motors are

electronically linked to provide synchronous

operation.• The C Cradle will always be at the same

elevation as the D Cradle and vice versus.

• The Cradles are suspended from a topsprocket assembly and have counterweights

attached to the top chains to offset their

load.

• The elevators are raised and lowered by thebottom chains which wrap around the

underside of the lineshafts.


23/45


Page 23 of 45



Phone: +1 919 433-01Fax: +1 919 433-01


The VRT Cycle

Cradles and Pushers

• The Cradles support the shelf as it iselevated between the conveyors and the load

levels.

• On each side of the cradle is a pusherassembly. The pusher assemblies connect to

the pusher beam which pushes the shelf into

the rack structure.

• When a shelf is pushed into a level at oneend of the rack-structure, the last shelf is

pushed out of the same level at the opposite

end of the rack-structure.

• The opposite cradle latches the shelf, andthen retracts lightly pulling the shelf clear of

the other shelves and the rack structure.

• Both the C and the D Cradle work in exactlythe same manner allowing shelves to be

pushed into any level from either end.


24/45


Page 24 of 45



Phone: +1 919 433-01Fax: +1 919 433-01


The VRT Cycle

G Arm, I Conveyor & Gap Table

• After the VRT unloads a shelf of timed-outproduct from the load level, the D-Cradle takes it

to the I1-Conveyor level.

• The G Sweeparm transfers the product off theshelf onto the outfeed conveyor and outfeed gap

table.

• In order to separate the product, one row ofproduct remains on the outfeed conveyor while

two rows are placed on the gap table. The gaptable then moves back clear of the I conveyor.

The I conveyor runs discharging the cases from

the VRT onto the O1A discharge conveyor.

• Once the first row is clear of the I conveyor, theGap table moves forward and one of the two rows

is pushed onto the I conveyor by the G1B

sweeparm. The I conveyor runs discharging

product from the VRT. Once clear, the last row is

transferred off the gap table onto the I conveyor

and is in turn discharged from the VRT.


25/45


Page 25 of 45



Phone: +1 919 433-01Fax: +1 919 433-01


The VRT Cycle

Discharge Conveyors

• Product is discharged off the I1 conveyoronto the O1 discharge conveyors. The

conveyors stream product out to the VRT,

down a decline belt and out into the stack

off / manual palletizing area where the

product is manually stacked onto pallets.


26/45


Page 26 of 45



Phone: +1 919 433-01Fax: +1 919 433-01


The VRT System

SCADA PC

• SCADA - Supervisor Control and DataAcquisition.

• The Scada PC is the Human MachineInterface. It allows operators to input data

into the system as well as view component

status via the many mimic screens.• In conjunction with the Operator Station it

allows an operator to select and manually

control any of the machine components

discussed previously.


27/45


Page 27 of 45



Phone: +1 919 433-01Fax: +1 919 433-01


The VRT System

Operator Station • The operator control station comprises of

the following switches and push buttons.

• Emergency Stop Button - pressing this willimmediately stop the machine.

• Master Key. This key allows the machineto be switched between Manual, Automatic

and Off modes.

• Reset Button - Used to reset the machineafter the emergency button has been

pressed and to reset the machine after a

fault.

• Extend/Retract Selector Switch - Allowscomponents selected on the SCADA to

extend/retract, raise or lower under manual

control.

• Set Up Key Switch - allows components tobe referenced to a known position in case

of certain faults.

• Fan On/Off Switch. Allows the operators


28/45


Page 28 of 45



Phone: +1 919 433-01Fax: +1 919 433-01


The VRT System

Motor Control Panel

• The Motor Control Panel (MCP) houses theProgrammable Logic Controller which

controls the machine operation.

• The MCP also houses the VariableFrequency Drives which control the position

and speed characteristics of the motors.• The MCP distributes incoming power to the

various drives and motor starters and

ancillary components.

• The MCP must only be opened by trainedelectrical technicians.


29/45


Page 29 of 45



Phone: +1 919 433-01Fax: +1 919 433-01


SECTION 3

GLOSSARY

Accumulating Conveyors.

Designated N1,N2,and N3,N4. N1, N2 are the bottom lines feeding H1 level,

N3,N4 are the upper lines feeding H2 level.

Each category of product is identified as it comes off the production line and

accumulated on its own low line pressure live roller conveyor into shelf-sized lots

ready for loading onto the VRT Infeed Conveyor.

Under normal operation, as the product arrives it will be loaded directly onto the

VRT Infeed Conveyor and the Accumulation Conveyor will only accumulate

product once the Infeed Conveyor is full and is waiting to load product onto an

empty shelf on the C Cradle.

Product is conveyed and accumulated prior to the brake spacer wide side leading.

Brake Spacer and K Transfer Conveyors.

Designated N1B, N1A, K1B, K1A & N2B, N2A, K2B & K2A.

A brake/spacer conveyor meters product off the end of the accumulation conveyor,

counting cases off the spacer belt onto K1B.

Once the required number of cases are counted onto the K1B conveyor, the cases

are transferred onto K1A.

Once cases have transferred onto K1A, a new batch of product will be counted

onto K1B.

H1 and H2 Pushers.

Designated H1P & H2P.


30/45


Page 30 of 45



Phone: +1 919 433-01Fax: +1 919 433-01


Once a slug of product has transferred onto K1A or K2A, the H1 Pusher will

extend and push the row of product off the K1A conveyor onto the H1 Conveyor.

H1 and H2 Infeed Conveyors.

Designated H1 and H2.

The H Conveyors are designed to accommodate product in shelf lots.

Product is pushed off the K1A transfer conveyor onto the H1 infeed belt in rows.

The H1 conveyor then indexes the width of the row plus an additional amount to

allow air to flow between the rows of product.

The H Conveyor is comprised of a galvanized steel frame. Product is conveyed onthe frame on Intralox plastic conveyor belt. The conveyor is driven by a shaft

mounted SEW AC Servo motor.

The motor speed and position is controlled by an SEW Movidrive IPOS controller

in the motor control panel.

Infeed Sweeparms

Designated F1 and F2. F1 sweeps product off H1, F2 sweeps product off H2.

The Infeed Sweeparm sweeps a row of product off the H Conveyor onto an empty

shelf on the C Cradle.

The Infeed Sweeparms consist of a mechanical pusher, driven by a motor gearbox

unit direct coupled to a cross shaft. Using a chain drive, the sweeparm traverses

forward and reverse. The cross shaft is driven by an SEW AC Servo motor direct

coupled to the cross shaft.




31/45


Page 31 of 45



Phone: +1 919 433-01Fax: +1 919 433-01


Cradles

The C Cradle is the cradle at the load end.

The D Cradle is the cradle at the unload end.

The Cradles are the vertically moving platforms that raise or lower the shelves,

either to be loaded, unloaded, or inserted into a level. The Cradles consist of a

main frame supported at each end by End Beams. The End Beams are connected

to the Elevator Chains, which drive the cradle up, or down.

Pushers.

A Pushers are mounted on the C Cradle.

B Pushers are mounted on the D Cradle.

The Pushers are the drive mechanisms located on the cradles that push the shelves

into the rack structure. They consist of two separate electric motors mounted on

the End Beams on each of the cradles. They drive the Pusher Beam forward via a

chain drive assembly.

During normal operation the A Pushers on the C Cradle will extend, pushing ashelf into the Rack Structure. As a shelf is pushed into the Rack Structure, a shelf

at the opposite end is pushed out of the rack structure onto the opposing D Cradle.

Once the pushers on the C Cradle have fully extended, the B Pushers on the

opposing D Cradle with move forward seeking the shelf. Photoeyes mounted in

the Pusher Beam will sense the shelf as the latches ride up over the pusher plates

mounted on the corners of the shelf. Once the shelf is latched, the Pushers on both

cradles retract.

Once the D Cradle B Pushers have latched the shelf they will retract to the

retracted position, pulling the latched shelf clear of the other shelves and the rack

structure. The C Cradle A Pushers retract to the latch position.


32/45


Page 32 of 45



Phone: +1 919 433-01Fax: +1 919 433-01


Latches

The latches are attached to the Pusher Beams. The latches are a profiled steel

hook used to latch the shelf so that it can be pulled away from the other shelvesand the Rack Structure. When a shelf is pushed through the structure, the

receiving pushers move forward to seek the shelf. The front edge of the latch rides

up over the shelf pusher plates, dropping into position shortly before the shelf seek

movement finishes.

When the Pushers extend, the latch plunger rides up on a guide lifting the latch

clear of the pusher plates so that the shelf is not dragged back out of the rack

structure.

EELLEEVVAATTOORRSS

Designated Elevator Master and Elevator Slave.

The two motors drive the lineshafts, which raise and lower the cradles.

The two motors are electronically synchronized with one unit running in the

opposite direction to the other unit.

The lineshafts are connected to the cradles via the upper and lower elevator

chains. The upper chains support the cradles and counterweights from the top

shafts. The lower chains drive the cradles up and down.

The line shafts run the full length of the VRT rack structure and connect the C and

D Cradles together ensuring the cradles move in unison.


33/45


Page 33 of 45



Phone: +1 919 433-01Fax: +1 919 433-01


Outfeed Sweeparm

Designated G1.

The Outfeed Sweeparm is the mechanism which sweeps a shelf load of frozen or

chilled product off the full shelf on D Cradle onto the Outfeed Conveyor and

Outfeed Gap Table.

The Outfeed Sweeparm consists of a mechanical pusher, driven by a motor

gearbox unit direct coupled to a cross shaft. Using a chain drive, the sweeparm

traverses forward and reverse. The cross shaft is driven by an SEW AC Servo

motor direct coupled to the cross shaft.

The motor speed and position is controlled by an SEW Movidrive IPOS controllerin the motor control panel.

Outfeed Conveyors

Designated I1, O1A & I2 & O2A Conveyor.

Once the G Arm sweeps product onto the I1 Conveyor, the I1A discharges the

complete shelf slot onto the O1A conveyor.

The speed differential between the I1A and O1A conveyor increases the gap

between the rows of product which allows the shelf lot to be singulated into a

single row to be sent to palletizing.

The I Conveyor is comprised of a galvanized steel frame. Product is conveyed on

the frame on Intralox plastic conveyor belt. The conveyor is driven by a shaft

mounted SEW AC Servo motor.




34/45


Page 34 of 45



Phone: +1 919 433-01Fax: +1 919 433-01


Load End

The Load End is the end of the VRT Freezer closest to the control room. It

contains all of the components required to load product into and out of the VRTFreezer.

Unload End

The Unload End is the end of the VRT Freezer closest to the evaporator coils. The

Unload cradle or D Cradle unloads frozen product from the VRT Freezer and also

transfers shelves out of the load levels into the return level.

Rack Structure

The Rack Structure consists of the main structural columns and beams plus the

rack beams, the parallel flange channels that support the shelves within the rack

structure. It is a multi-level structure into which shelves are injected for horizontal

movement within the VRT. Push a shelf into a level at one end, and another shelf

will be pushed out at the opposite end.

The sides and top of the rack structure is covered in corrugated metal cladding to

ensure that the air flow can only pass over the product. The cladding between the

evaporator coils and the rack structure is known as the plenum.

Shelves

The shelves, or moveable platforms, are used to move product through the VRT.

The shelves consist of galvanized steel frames with a corrugated steel profile top

surface. The shelves slide along the rack beam on UHMW wear strips.

Catenary

The Catenary, which consists of the plastic drag chain and electrical cables, is

attached to the end beams on the cradles at one end and mounted mid height on the


35/45


Page 35 of 45



Phone: +1 919 433-01Fax: +1 919 433-01


adjacent columns at the other. The plastic drag chain protects the electrical cables

from accidental damage. The electrical cables on one side of the tunnel provide

power for the electric motors. The other side provides all power and return signal

wires for the control devices used on the cradles.

Levels

A number, starting from 1 and working up the tunnel to level 32 designates each

level of shelves.

Rows are the number of shelves deep per level, i.e., each level has 15 shelves per

level, or 15 rows.

Certain levels are also known by the level at which an Infeed Conveyor or Outfeed

Conveyor are located at, such as the Infeed level or Outfeed level.

The Infeed and Outfeed Conveyors are pitched at multiples of the level spacing,

and the top of the conveyor rollers are level with the top of the decking when a

shelf sits in the corresponding level.

Return Level

A level is assigned within the control sequence of the program, to be used to

return empty shelves from the unload end to the load end of the tunnel. It is

designated the Return Level and cannot be assigned to receive incoming product.

All empty shelves normally return through the Return Level before they can be

loaded with new product.


36/45


Page 36 of 45



Phone: +1 919 433-01Fax: +1 919 433-01


SECTION 4

VRT Preventative Maintenance Program

Daily (Nominal 8-16 machine hours)

VRT General

Walk around VRT and inspect floor for:

• Signs of wear, i.e, metal or pastic shavings;

• Oil leaks;

• Broken electrical cables;

• Spilt product;

• Obvious damage or signs of misalignment;

C & D Cradles

• Remove old grease from runners and apply new grease.

• Oil pusher chains - if required;

• Check operation of latch pin and latch plunger - if required;

• Check Cradles are level and shelf on cradle is level with shelf in structure;

Reference

• A Pushers;

• B Pushers;

• Elevators.

Every Week (Nominal 100 machine hours)

VRT General

• Check that all sensors are secure, in good condition and correctly aligned;

• Check that all sensor QD leads are secure and in good condition;


37/45


Page 37 of 45



Phone: +1 919 433-01Fax: +1 919 433-01


C & D Cradles

• Remove old grease from runners and apply new grease - if required;

• Oil pusher chains - if required; • Lubricate latch pin and latch plunger - if required;

• Inspect latch plunger for wear and ensure latch plunger moves freely;

• Lubricate latch plunger and latch plunger ramp - if required;

• Check transfer plate is secure, straight and clean;

• Ensure sensors are clean, secure and aligned correctly;

Elevator

• Check gearbox seals for signs of leakage;

• Ensure cradles and counterweights are level;

• Inspect elevator chains for signs of uneven or excessive wear;


F & G Arms

• Remove old grease from runners and apply new grease;

• Check bearing and sprocket set screws are tight;


H & I Conveyors

• Check bearing set screws are tight;


H & I Transfer Pushers

• Check tension of pusher chains, and adjust if necessary;Check pusherchains for sufficient lubrication, and grease/oil if necessary

N & K Conveyors

• Check bearing set screws are tight;



38/45


Page 38 of 45



Phone: +1 919 433-01Fax: +1 919 433-01


Every Month (Nominal 500 machine hours)

Electrical Components

• Clean Fan Air filters On VRT and Conveyor MCPs and ensure adequate

ventilation;• Check that all sensors are secure, in good condition and correctly aligned;


C & D Cradles

• Inspect tension of pusher chains and adjust as required;

• Inspect reaction block pads and pusher wear pads for signs of wear;

Elevator

• Chains - inspect for lubrication and oil if required;

• Ensure cradle and counterweights are level;

• Check lineshaft bearings set screws are tight;

F & G Arms

• Inspect drive chains and oil if required;

H & I Conveyors

• Check tension / condition of Intralox belts;


• Check tension of pusher chains, and adjust if necessary;

• Check pusher chains for sufficient lubrication, and grease/oil if necessary

N & K Conveyors

• Check tension / condition & tracking of Intralox belts and sprockets;

Every 2 Months (Nominal 1000 machine hours)

VRT General



• Check reference position of all components;

• Physically check that all motors are rigidly mounted.


39/45


Page 39 of 45



Phone: +1 919 433-01Fax: +1 919 433-01


C & D Cradles

• Check gearbox oil levels and top up if necessary;

• Check sprockets for wear and position & ensure clamping units are secure;

• Grease idle sprocket shafts;

Elevator

• Inspect upper bearings for signs of movement, wear or cracking;

• Check sprockets for wear and position

• Inspect tension of safety wire and adjust as necessary;

• Inspect chains for adjustment and adjust as necessary;


F & G Arms• Check gearbox oil levels and top up if necessary;

• Inspect tension of drive chains and adjust if required;

• Grease bearing units as possible (not sealed);

• Inspect wheels / runners for signs of wear;

H & I Conveyors

• Grease bearing units as possible;



• Grease bearing units;


N & K Conveyors

• Grease bearing units

• Check gearbox oil levels and top up if necessary:


C & D Cradles

• Check reaction block plastic bearing surfaces for wear - replace if necessary

• Grease runners if necessary


40/45


Page 40 of 45



Phone: +1 919 433-01Fax: +1 919 433-01


F & G Arms

• Check bearing surfaces for wear

• Replace if necessary


• Check UHMW plastic bearing surfaces and rollers for wear

• Replace if necessary

• Grease runners if necessary

SEW Gearboxes

• Check oil quantity and top up to oil level plug if necessary

Roller Bearings• Apply 3 x shots of grease from a grease gun



• Test Movidrive Battery backup (Refer to operating instructions).

• Test UPS Battery backup (Refer to operating instructions).

• Check Electrical Connections MCP’s

• Clean Electrical MCP’s.

VRT General


• Physically check that all motors are rigidly mounted;


• Check that all sensor QD leads are secure and in good condition.

C & D Cradles

• Change Gearbox Oil.

• Take oil samples for analysis if appearance dictates.


41/45


Page 41 of 45



Phone: +1 919 433-01Fax: +1 919 433-01


Elevator

• Check motor brake gaps and adjust if required (SEW Technician).

Every 24 Months (Nominal 12,000 machine hours)


• Test Movidrive Battery backup.(Refer to operating instructions section 9.1.1)

• Test UPS Battery backup(Refer to operating instructions section 9.1.2).


• Clean Electrical MCP’s

VRT General





C & D Cradles

• Inspect Electric Motors (SEW Technician).

Elevator


F & G Arms


H & I Conveyors


H & I Transfer Pushers• Inspect Electric Motors (SEW Technician).

N & K Conveyors



42/45


Page 42 of 45



Phone: +1 919 433-01Fax: +1 919 433-01


Every 5 Years (Nominal 30,000 machine hours)






VRT General





C & D Cradles

• Replace Bronze Bushes on Rear Shafts and Latches

• Replace Nylon Reaction Block Pads, UHMW Pusher Wear Pads.

Elevator


F & G Arms


H & I Conveyors




N & K Conveyors



43/45


Page 43 of 45



Phone: +1 919 433-01Fax: +1 919 433-01


Every 10 Years (Nominal 60,000 machine hours)






VRT General





Elevator

• Replace Elevator Chains;

• Replace Elevator Bearings.

ANNUAL MAINTENANCE BUDGET ESTIMATES:

GEA INTEC recommends an annual budget for Maintenance & Spare Parts for year 1through year 8 of the VRT System at $5,000.00 per year. This is mainly for lowtemperature lubrication and other miscellaneous parts. Year 9 should include a fullmechanical audit of the system and a budget for year 10 somewhere between $50,000to $80,000. This allowance would include for new elevator chains, sprockets, shaftsand other miscellaneous components that may need to be replaced or upgradeddepending on the production wear and tear of any system ( how hard it works/cycletime ) and is also tied directly to the PM and Maintenance disciplines of each Company.

The uptime and reliability of each individual VRT System is greatly enhanced by aproper In-house PM Program and even further enhanced by participating in the GEAINTEC Service Program. This Program is customized per installation / customer anddriven by the expertise and disciplines of their Maintenance Staffs and Management. Itis minimally one complete audit and re-training exercise per year, but can be as oftenas three visits per year.


44/45


Page 44 of 45



Phone: +1 919 433-01Fax: +1 919 433-01


SECTION 5

SSEERRVVIICCEE PPRROOGGRRAAMM

YEAR 1 PROGRAM:

• Four ( 4 ) Service visits are included for a period of 12 months following theTake-Over Test.

• Each Service visit is based on a seven ( 7 ) day window, including travel days.• Service Visits need to be scheduled and confirmed fourteen ( 14 ) in advance.

• Costs for the Service Labor is included, but all other associated Travel andLiving expenses are not:

a. Airfaresb. Ground transportationc. Hoteld. Fuele. Per Diem - $80.00 USD per Day

POST YEAR 1 PROGRAMS:

GEA INTEC – SCHEDULE OF SERVICE CHARGES 2012

DAILY RATES: ONSITE SUPPORT

Daily Rate, Monday - Friday International $1800 USD / day Daily Rate, Weekends International $2,100 USD / day Daily Rate, Holidays International $2,500 USD / day

TRAVEL AND LIVING EXPENSES

Expenses (Airfare, auto, hotel, fuel, etc.) Cost +10%Per Diem: International $80.00 USD / Day


45/45

VRT Safety, Maintenance &Service Training Manual Refrigeration Technologie

MINIMUM CHARGE OUT TIME

A minimum charge out time of 3 hours shall apply for any phone, online ordial-up technical support unless a Service Support Contract is in place, thencharges will be real time.

DESCRIPTION OF CHARGES

Remote Support is described as any communication between the clientand a service technician while the service tech is not at the client’s facility.As long as the service tech can identify and correct any issues via phone,

VPN or dial-up, remote support rates will apply. Onsite Support is described as any visit to a client’s facility by a servicetechnician. Daily charges start the day of departure and end on the day ofreturn. A day is considered not more than 10 hours from 12:00am to11:59pm per calendar day. If more than 10 hours is required anadditional day will be charged. No technician will be allowed to be at aclient’s facility more than 16 hours per calendar day.

Please contact Jim Chamblee (Regional Service Manager, East Coast) with anyquestions or to enquire about a Service Support Contract.

Mobile: (919) 943-0355EMAIL: [email protected]

Office: (919) 433-0131FAX: (919) 433-0140

Please also review the attached COMPREHENSIVE SERVICE PLAN program.

vrt safety maint training service manual brasil foods.pdf

Documents