Daily Electrical Report (FEB'2012)

Date Machine name/Place Faults

01.02.12

Motor tripped.Water found CIP caustic transfer inside the motor due to seal pump leakage. Compressor tripped.Drier AF comp. ADT control card burnt. Mixture ratio range problem L1 paramix Anton paar CO2 volume problem Alarm saving problem Mixture ratio range problem L1 paramix Anton paar CO2 volume problem Alarm saving problem Valve not opend Blower motor not run Conveyer modification Solenoied valve not open ADT control card burnt Sensor didnt sence the new crown Caustic concentrate inside the pipe & caustic drum Level fluctuation problem Syrup pump tripped

02.02.12 L1 filler ETP GRB Conveyer 04.02.12 Padovan CIP AF comp. Date code m/c

Unicorn CIP 06.02.12 CO2 Plant L1 paramix

Submersible pump Send for servicing L3 conveyer L3 bent tube detector L-2 bottle inspection shed FSR return pump Blower Sensor installation Balast & switch burnt

07.02.12

Motor tripped.Water found inside the motor due to seal leakage. L-2 video jet Bad Printing quality CO2 line solenoid valve not L-3 C/C buffer tank open

07.02.12

L-3 SMI

Machine tripped showing Masssage "general Shut down." Bad Printing quality servicing

L-3 Alpha Jet 08.02.12 Auto clave Husky Plant

Piovan Chiller tripped due to temp sensor problem. L-1 Shrink wrapper Panel A/C servicing Auto clave servicing 09.02.12 AF comp. L-3 Alpha Jet Shrink film plant 11.02.12 ADT tripped Bad Printing quality

Lighting New submersible pump Husky Submersible start frequently due to low pump reservation L402 (Imaje 9040) not print. L4 date coding Ink come outside of the gutter L2 filler inspection switch problem shade Husky Submersible Old pump is not sufficient pump L3 warmer MPCB problem Syrup room L-3 vent tube detector L1 filler capper hopper IR dryer AF comp.(860) Syrup room Water treatment plant AC problem Installation capper hopper motor not run correctly due to sensor adjustment. Refregerent gas pressure low Water pump tripped AC problem

12.02.12

Pump no.-11 & 25 not run Refregerent gas pressure low Incubetor servicing ETP breaker installation

13.02.12

IR dryer

QC lab Substation

13.02.12

L-3 vent tube detector L4 date coding L2 Carbocooler buffer tank 14.02.12 Cooline chiller pump

Installation New Imaje 9030 date code machine installation Solenoid valve malfunctioning Supply pressure reduce

QC lab L-1 tunnel Heater FM room ETP plant WTP Pump House 15.02.12 RM store L-1 tunnel Heater Sugar conveyer Finished Syrup Room L4 date coding L4 conveyer 16.02.12 Finished Syrup Room QC lab Online UPS Workshop

Incubetar servicing Cooling fan installation A/C power socket burnt Lighting Water heater Pump-15 tripped Lighting Heater problem Celing fan problem AC problem Imaje 9040 tripped showing "Gutter recuparation fault" Motor didnt run due to conveyer displacement AC problem Incubater New Battery Installation Welding machine power card problem Heater problem

L-1 tunnel Heater 18.02.12

L-4 Imaje 9040 QC lab Unicorn CIP

Ink came outside the gutter Incubator Agitator Motor not run

GRB flow mix pump Coil damaged motor

L-2 vent tube detector L-2 inspection shade 19.02.12 Raw Syrup Room WTP SMI FM room FSR Room L-2 pasturizer 20.02.12 L-2 celing fan L-3 Labeller L-3 vent tube detector UPS 22.2.12 L-1 warmer L-1 tunnel Heater LP comp. Imaje 9040 23.02.13 L-2 Carbocooler Online UPS IR compresser

Installation switch problem Cable dresing Pump no.-11 not run Output chain drive stopped A/C power socket burnt A/C servicing Solenoid valve not work in auto mode Not run Panel AC tripped Cable installation Not charged Temperatur controller installation Heater problem Maintenance Hired machine Water level sensor problem Charging problem Maintenance

Daily Electrical Report (FEB'2012)

Job Description Dismantle the motor,checked coil & found ok. Changed the seal, heated the armature & refited. No load current-3.1,3.1,3.2 (Rated current-5.5A) Take out the defective ADT. This comp. is not in service now. Present status

KHS expert NEO is trying to solve these problem.

Continue..

Neo cant increase the mixture ratio range. There is leakage inside the anton paar CO2 measuring module. Changed 3 pcs diaphragms. Modify the program. checked & changed one 24dc solenoied. Checked & changed defective auxiliary contact. Rated current-2.8A, Running current-2.2A Prepared one new Control box.Installed new cable tray, control panel & connected the motor with control panel. Replaced the defective solenoied card. Replaced the defective ADT. Adjust the sensor & bring a new optical fiber photo sensor adapter for high speed printing at L4. Dismantle caustic dosing pump, pipe line & clean the caustic solution drum by hot water. After cleaning the whole dosing system dosing has been run automatically. Connect the agitator motor. Tried to stable the re-boiler by changing some PID value of Lean MEA & rich MEA pump but no improvement. Checked the motor & control circuit. Magnetic contactor sizzed. Made it free & run the motor. Installed the pump, Checked & connected the motor. Insulation resistance-200Mohm(p-p), 100Mohm(p-b). Take out the blower from line-3. Sensor installation & wiring is going on. Replaced the shade. Repaired the burnt shade with new wiring. Replaced the motor. Dismantle the motor,checked coil & found ok. Changed the seal, heated the armature, refited. Wash the head & adjust the sensor & head. Checked coil & valve, cleaned plunger. Solved Solved Ok. Solved Now its working good. Now alarm is saved. Solved Solved

Solved Solved Solved

Solved Need to consult with expert. Solved Solved Done

Checked all control circuit, communication cable & found a fuse Solved. Now machine is burnt inside optical communication module. Changed the burnt fuse. running. Expert checked the machine, changed the motherboard but found no improvement. Now the machine is running on "Auto Refresh" mode. Printing is done by Imaje 9030. Heater is checked by connecting 2 pin power socket. Coil is ok but found water leakage with heater connection. Checked & temperory manage to run the chiller. Installed the old panel A/C into shrink wrapper machine. After servicing, handed over the auto clave to QC department. Took apart the ADT and checked for leakage but ok. Reset the ADT & run the comp. Expert again checked the machine and suggested to changed the ink tank. Installed 2 nos. metal halide lamp at shrink film plant. Disconnected the new pump and set back the pressure switch connection to old pump. Contact with imaje expert and carried out the suggested procedure several times. But no improvement. replaced the toggle switch. Again connect the new pump. MPCB was under rated. Replaced the defective MPCB. Checked all AC & tried to repair one today. Changed compressor, refregerant gas. Wirinig and sensor installation completed. But could not connect emergency switch connection as line was running. Adjust the sensor & increase the time in timer. Third party checheked for leakage. Checked motor connection & found defective magnetic contactor. Replaced the defective magnetic contactor 3 Nos. AC servicing completed. Replaced 2 compressor, charged refregent in one compressor & clean outdoor, indoor unit. This machine is under maintenance. solved Need to purchase a new sensor Ok. Ok. Now it is running This machine is now running. Complete Now old one is running.

Need to call expert. Ok. Under observation Ok. Ok. Continue.. solved Continue.. solved Ok.

Run the alternate pump-10 first then checked control circuit & adjust solved the float switch.Production stopped 15 mins due to this problem. Charged refregerant as they found no leakage. Now it is running. Under observation

Checked control circuit & found burnt temperature controller in one machine. Trying to service this controller. Other machine has control Continue.. card problem (could not get nutral connection). Trying to solve this problem. Made copper bar for 300A MCCB terminal connection. Continue..

Need CIP to connect the sensors with existing control circuit. A new Imaje 9030 date code machine has been installed for high speed printing at L-4. Checked & servicing carried out of the solenoid valve. Supply pressure reduced to 1-1.5 bar due air problem at sucktion line. Made the pump air free. Motor rated current 10A, now running current 5.5A & pressure 6 bar

Continue.. Now kept as stand by. Ok. solved

Checked all control circuit but could not possible to run the machine correctly. This machine can be modified by using a temperature Need to consult with EM. controller & solied state relay to control the temperature. installed two metal body cooling fan on L-1 heater. replaced the power socket. Connected two 200W incandicent bulb. Checked 7 found one heater coil burnt. tripped due to pump side jamming. Mechanical servicing carried out. Now the motor takes normal running current. RM store lighting is going on. Need more tubelight shade. First changed the power cable. But after few hours heater burnt. Need to find the problem during CIP. Now it heated by other two coil. Repaired one & set it back. Repaired leakage of AC-5, vaccumed & charged refregernt gas. Also charged refregerent gas into AC-3. Wash the head & reset the fault. After adjusting the conveyor, run the motor Checked AC-2 & found leakage. Trying to replace the outdoor unit. Modification work going on.One of the circuit is replaced by temperature controller, magnetic contactor & a thermocouple. Installed 96 pcs new battery in 40 KVA online UPS. Checked & found dry soldering. Carried out solderring properly. Ok. Ok. Ok. Other two are heating now.

Continue.. Continue.. Ok. Continue.. Kept as stand by solved Continue.. Continue.. Need to checked by expert solved

Take out the heater box, Checked coil resistance & found 23ohms Need to find out the at both coil. But insulation resistance differ. So, refited the good one. cause during CIP. Another coil was kept at tools room as it sparked. Cleaned the head & kept it as stand by. Repaired one machine & sent it to QC lab for their observation. Overload relay found faulty. Changed the overload relay. Rewinding completed, varnished the coil, Checked coil resistance & found 2.3ohms from each coil. Assambled & ran the motor. Motor vibrate & made abnormal sound. ok Under observation solved Need to contact with rewinding party.

Installed one more relay & reset switch & completed wiring. Give direct connection as new switch was not available. Carried out cable dressing at raw syrup room. Checked & found problem in float switch. Servicing carried out. Reset the drive. Replaced the power socket with a breaker. Solved the leakage problem of FSR A/C-2. As production started, so ran it manualy. Checked & found the coil burnt. AC tripped due to air block. Clean the AC carefully. Replaced 3 core wire by 4 core for DC nutral. Checked and found that charging card still faulty. Prepared the controller for installation. It t will be installed during CIP. Replaced the coil. Clean the panel, checked & tightened all the connection. Servicing carried out of a solenoid valve. Sent back the hired machine. Checked & found loose contact of the level sensor. Checked by third party. Didnt find out the problem. Clean the panel, checked & tightened all the connection

Need CIP to adjust the sensor Need to change the switch ok ok. ok ok ok Need to find out the cause during CIP. Need to install another fan ok ok Need to repair. Continue.. solved ok ok ok Not solved ok

Work done by

Manik,Matin

Shahnuzzaman, Matin Third party, Nur Alam

Sharif, Barun Manik

Sharif, Barun Habib Shahnuzzaman, Matin

Shahnuzzaman, Matin

Sharif, Anis Mahfuz, Anis Maniruzzaman Anis, Barun Mahfuz Mahfuz, Barun Khokon Latif, Ripon Barun Maniruzzaman Shahnuzzaman, Matin matin Maniruzzaman Sharif, Anis Anis, Barun Anis

Mahfuz, Barun

Habib Sharif Sharif, Barun Shanuzzaman, Matin

Sharif Habib, Ripon Sharif, Ripon Habib Shahnuzzaman Maniruzzaman Maniruzzaman Mahfuz, anis Mahfuz, Anis Maniruzzaman Sharif Sharif habib habib Barun

anis Third party, Sharif Manik,Latif