START-UP CHECKLIST FOR CAT 1 COOKER

  • It is important that these tasks are always carried out. Whoever checks and signs each task shall be responsible for ensuring that it has been completed correctly

  • Select which cooker is being started up

  • Enter the date and time the cooker is being started up

  • 1. Ensure no isolations or maintenance work is being carried out on all machinery involved with the line to be started from raw material through to cake discharge screws to the line trailer. Before starting any machinery, ensure the runner has walked around and checked that no work is taking place on or around machinery that is to be started I e painting, general cleaning etc. In the event of a restart after a shutdown, due to a breakdown, ensure the isolations have been removed and the electrician / fitter has checked direction / rotation of machinery once the repair has been carried out, also ensure a walk around of machinery to be restarted, is carried out by the runner.

  • 2. Confirm with the maintenance department that no isolations are in place on the equipment to be started (Scan QR code at the isolation bench to confirm & signed for by a maintenance department member)

  • Sign off for No. 2

  • 3. NC fan on 95 %, condenser fans on automatic (signed by control room operator)

  • 4. Start oxidiser – oxidiser check list (signed by start-up runner)

  • 5. Make sure that the Fire Extinguishing System is set to Auto/Manual (Scan QR code at location & signed by control room operator)

  • Sign off for No. 5

  • 6. Start crushing material, fill bin under crusher and above the cooker (signed by control room operator)

  • 7. Open damper up (signed by control room operator)

  • 8. Open valve on ram feed screw (signed by control room operator)

  • 9. Shut drain valve on cooker shaft (Signed by start-up runner)

  • 10. Start cooker shaft motor and cooling fan (signed by control room operator)

  • 11. Start dosing pump (signed by control room operator)

  • 12. Fill the cooker to desired level (signed by control room operator)

  • 13. Shut the gate leading to cooker platform

  • 14. Open steam valves to 20%-30% (signed by control room operator)

  • 15. Once the oxidiser is warmed up (around 2 hours from cold), start opening crown valves by opening closest one to the cooker first (signed by start-up runner)

  • 16. Slowly open the second one – let the pipework warm up before opening fully (Scan QR code at location & signed by start-up runner)

  • Sign off for No. 16

  • 17. Check condense coming out of the cooker by the drain pipe. If it`s milky, drain until clear. If it stays milky or getting worse, empty the cooker and shut down. Close the valve after inspection (Scan QR code at location & signed by start-up runner)

  • 18. Start zero-flash pump (signed by control room operator)

  • 19. Ramp the oxidiser up (signed by start-up runner)

  • 20. Fill the cooker 3-4 tonne at a time and let some of it evaporate before adding more material (signed by control room operator)

  • 21. Judging by temperatures and cooker level start tallow system and system screws around 30 minutes before discharging, leave only discharge screw off (signed by control room operator)

  • 22. Warm the sedimenter lines up and the sedimenter itself using steam, return the valves to normal positions (Signed by start-up runner)

  • 23. Warm press pump lines up using steam, return the valves to normal positions

  • 24.Warm shakers and decanters lines up using steam, return the valves to normal positions

  • 25. Warm storage pump line up using steam

  • 26. Warm prime pump line up using steam and open the valve to it

  • 27. Shut all steam when ready to start discharging and return valves to normal positions (signed by start-up runner)

  • 28. Turn on the sedimenter discharge srew magnet (signed by start-up runner)

  • 29. Start discharge (signed by control room operator)

  • 30. Start milling section screws (signed by control room operator)

  • 31. Start desired press on 10% feeding in and slowly build up the speed. (signed by control room operator)

  • 32. Check that water comes on all presses by opening the water valve in control room for couple of seconds (signed by start-up runner)

  • Enter the date and time the cooker is being started up

  • 1. Ensure no isolations or maintenance work is being carried out on all machinery involved with the line to be started from raw material through to cake discharge screws to the line trailer. Before starting any machinery, ensure the runner has walked around and checked that no work is taking place on or around machinery that is to be started I e painting, general cleaning etc. In the event of a restart after a shutdown, due to a breakdown, ensure the isolations have been removed and the electrician / fitter has checked direction / rotation of machinery once the repair has been carried out, also ensure a walk around of machinery to be restarted, is carried out by the runner.

  • 2. Confirm with the maintenance department that no isolations are in place on the equipment to be started (Scan QR code at the isolation bench to confirm & signed for by a maintenance department member)

  • Sign off for No. 2

  • 3. NC fan on 95 %, condenser fans on automatic (signed by control room operator)

  • 4. Start oxidiser – oxidiser check list (signed by start-up runner)

  • 5. Make sure that the Fire Extinguishing System is set to Auto/Manual (Scan QR code at location & signed by control room operator)

  • Sign off for No. 5

  • 6. Start crushing material, fill bin under crusher and above the cooker (signed by control room operator)

  • 7. Open damper up (signed by control room operator)

  • 8. Open valve on ram feed screw (signed by control room operator)

  • 9. Shut drain valve on cooker shaft (Signed by start-up runner)

  • 10. Start cooker shaft motor and cooling fan (signed by control room operator)

  • 11. Start dosing pump (signed by control room operator)

  • 12. Fill the cooker to desired level (signed by control room operator)

  • 13. Shut the gate leading to cooker platform

  • 14. Open steam valves to 20%-30% (signed by control room operator)

  • 15. Once the oxidiser is warmed up (around 2 hours from cold), start opening crown valves by opening closest one to the cooker first (signed by start-up runner)

  • 16. Slowly open the second one – let the pipework warm up before opening fully (Scan QR code at location & signed by start-up runner)

  • Sign off for No. 16

  • 17. Check condense coming out of the cooker by the drain pipe. If it`s milky, drain until clear. If it stays milky or getting worse, empty the cooker and shut down. Close the valve after inspection (Scan QR code at location & signed by start-up runner)

  • 18. Start zero-flash pump (signed by control room operator)

  • 19. Ramp the oxidiser up (signed by start-up runner)

  • 20. Fill the cooker 3-4 tonne at a time and let some of it evaporate before adding more material (signed by control room operator)

  • 21. Judging by temperatures and cooker level start tallow system and system screws around 30 minutes before discharging, leave only discharge screw off (signed by control room operator)

  • 22. Warm the sedimenter lines up and the sedimenter itself using steam, return the valves to normal positions (Signed by start-up runner)

  • 23. Warm press pump lines up using steam, return the valves to normal positions

  • 24.Warm shakers and decanters lines up using steam, return the valves to normal positions

  • 25. Warm storage pump line up using steam

  • 26. Warm prime pump line up using steam and open the valve to it

  • 27. Shut all steam when ready to start discharging and return valves to normal positions (signed by start-up runner)

  • 28. Start discharge (signed by control room operator)

  • 29. Start milling section screws (signed by control room operator)

  • 30. Start desired press on 10% feeding in and slowly build up the speed. (signed by control room operator)

  • 31. Check that water comes on all presses by opening the water valve in control room for couple of seconds (signed by start-up runner)

  • Enter the date and time the cooker is being started up

  • 1. Ensure no isolations or maintenance work is being carried out on all machinery involved with the line to be started from raw material through to cake discharge screws to the line trailer. Before starting any machinery, ensure the runner has walked around and checked that no work is taking place on or around machinery that is to be started I e painting, general cleaning etc. In the event of a restart after a shutdown, due to a breakdown, ensure the isolations have been removed and the electrician / fitter has checked direction / rotation of machinery once the repair has been carried out, also ensure a walk around of machinery to be restarted, is carried out by the runner.

  • 2. Confirm with the maintenance department that no isolations are in place on the equipment to be started (Scan QR code at the isolation bench to confirm & signed for by a maintenance department member)

  • Sign off for No. 2

  • 3. Start oxidiser – oxidiser check list (signed by start-up runner)

  • 4. Make sure that the Fire Extinguishing System is set to Auto/Manual (Scan QR code at location & signed by control room operator)

  • Sign off for No. 4

  • 5. Start crushing material, fill bin under crusher and above the cooker (signed by control room operator)

  • 6. Open damper up (signed by control room operator)

  • 7. Open valve on ram feed screw (signed by control room operator)

  • 8. Shut drain valve on cooker shaft (Signed by start-up runner)

  • 9. Start cooker shaft motor and cooling fan (signed by control room operator)

  • 10. Start dosing pump (signed by control room operator)

  • 11. Fill the cooker to desired level (signed by control room operator)

  • 12. Shut the gate leading to cooker platform

  • 13. Open steam valves to 20%-30% (signed by control room operator)

  • 14. Once the oxidiser is warmed up (around 2 hours from cold), start opening crown valves by opening closest one to the cooker first (signed by start-up runner)

  • 15. Slowly open the second one – let the pipework warm up before opening fully (Scan QR code at location & signed by start-up runner)

  • Sign off for No. 15

  • 16. Check condense coming out of the cooker by the drain pipe. If it`s milky, drain until clear. If it stays milky or getting worse, empty the cooker and shut down. Close the valve after inspection (Scan QR code at location & signed by start-up runner)

  • 17. Start zero-flash pump (signed by control room operator)

  • 18. Ramp the oxidiser up (signed by start-up runner)

  • 19. Fill the cooker 3-4 tonne at a time and let some of it evaporate before adding more material (signed by control room operator)

  • 20. Judging by temperatures and cooker level start tallow system and system screws around 30 minutes before discharging, leave only discharge screw off (signed by control room operator)

  • 21. Turn on the sedimenter discharge screw magnet (signed by start-up runner)

  • 22. Warm the sedimenter lines up and the sedimenter itself using steam, return the valves to normal positions (Signed by start-up runner)

  • 23. Warm prime pump line up using steam

  • 24. Shut all steam when ready to start discharging and return valves to normal positions (signed by start-up runner)

  • 25. Start discharge (signed by control room operator)

  • Enter the date and time the cooker is being started up

  • 1. Ensure no isolations or maintenance work is being carried out on all machinery involved with the line to be started from raw material through to cake discharge screws to the line trailer. Before starting any machinery, ensure the runner has walked around and checked that no work is taking place on or around machinery that is to be started I e painting, general cleaning etc. In the event of a restart after a shutdown, due to a breakdown, ensure the isolations have been removed and the electrician / fitter has checked direction / rotation of machinery once the repair has been carried out, also ensure a walk around of machinery to be restarted, is carried out by the runner.

  • 2. Confirm with the maintenance department that no isolations are in place on the equipment to be started (Scan QR code at the isolation bench to confirm & signed for by a maintenance department member)

  • Sign off for No. 2

  • 3. Start oxidiser – oxidiser check list (signed by start-up runner)

  • 4. Make sure that the Fire Extinguishing System is set to Auto/Manual (Scan QR code at location & signed by control room operator)

  • Sign off for No. 4

  • 5. Start crushing material, fill bin under crusher and above the cooker (signed by control room operator)

  • 6. Open damper up (signed by control room operator)

  • 7. Open valve on ram feed screw (signed by control room operator)

  • 8. Shut drain valve on cooker shaft (Signed by start-up runner)

  • 9. Start cooker shaft motor and cooling fan (signed by control room operator)

  • 10. Start dosing pump (signed by control room operator)

  • 11. Fill the cooker to desired level (signed by control room operator)

  • 12. Shut the gate leading to cooker platform

  • 13. Open steam valves to 20%-30% (signed by control room operator)

  • 14. Once the oxidiser is warmed up (around 2 hours from cold), start opening crown valves by opening closest one to the cooker first (signed by start-up runner)

  • 15. Slowly open the second one – let the pipework warm up before opening fully (Scan QR code at location & signed by start-up runner)

  • Sign off for No. 15

  • 16. Check condense coming out of the cooker by the drain pipe. If it`s milky, drain until clear. If it stays milky or getting worse, empty the cooker and shut down. Close the valve after inspection (Scan QR code at location & signed by start-up runner)

  • 17. Start zero-flash pump (signed by control room operator)

  • 18. Ramp the oxidiser up (signed by start-up runner)

  • 19. Fill the cooker 3-4 tonne at a time and let some of it evaporate before adding more material (signed by control room operator)

  • 20. Judging by temperatures and cooker level start tallow system and system screws around 30 minutes before discharging, leave only discharge screw off (signed by control room operator)

  • 21. Warm the sedimenter lines up and the sedimenter itself using steam, return the valves to normal positions (Signed by start-up runner)

  • 22. Warm prime pump line up using steam

  • 23. Shut all steam when ready to start discharging and return valves to normal positions (signed by start-up runner)

  • 24. Start discharge (signed by control room operator)

Cooker Start-up Sign Off

  • Any Additional Comments

  • Managerial Sign Off

  • Cooker Start-up Sign Off by Manager / Supervisor (I confirm that the cooker has been started safely and in a correct manner )

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