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Category 3 - Cooker 1 - Start-up Check- List
Category 3 - Cooker 1 - Start-up Check- List
Darren Challinor

Category 3 - Cooker 1 - Start-up Check- List

Cooker 1- Start-up Check-List

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Free Category 3 - Cooker 1 - Start-up Check- List Checklist

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Title Page

  • Conducted on

  • Prepared by

  • Location

  • START UP CHECKLIST FOR LINE 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 the Control Room Operator, this must be re-selected if part way through a start-up the operator has changed for any reason

    • Nick Tunnicliffe
    • Daniel Wood
    • Darren Challinor
    • Robbie Evans
    • Piotr Misiak
    • Gordon Foulkes
    • Shane Law
    • Tyler Scragg
    • Robert Sargeant
    • Simon James
    • Colin Tatton
    • Chris Betteny
    • Matthew Walwyn
    • Trainee

  • Nick Tunnicliffe

  • Daniel Wood

  • Darren Challinor

  • Robbie Evans

  • Piotr Misiak

  • Gordon Foulkes

  • Shane Law

  • Tyler Scragg

  • Robert Sargeant

  • Simon James

  • Colin Tatton

  • Chris Betteny

  • Trainee Name

  • Select the Cook House Runner , this must be re-selected if part way through a start-up the Runner has changed for any reason

    • Nick Tunnicliffe
    • Daniel Wood
    • Darren Challinor
    • Robbie Evans
    • Piotr Misiak
    • Gordon Foulkes
    • Shane Law
    • Tyler Scragg
    • Robert Sargeant
    • Simon James
    • Colin Tatton
    • Chris Betteny
    • Matthew Walwyn
    • Trainee

  • Daniel Wood

  • Darren Challinor

  • Robbie Evans

  • Piotr Misiak

  • Gordon Foulkes

  • Shane Law

  • Tyler Scragg

  • Robert Sargeant

  • Simon James

  • Colin Tatton

  • Chris Bettany

  • Trainee Name

  • 1.Managerial Signature required- Ensure that there is no work taking place on the RAW MATERIAL line that will be used to feed line 1 COOKER the COOKER itself and associated PRESSING system & TALLOW system.

  • 2. Confirm that no isolations are in place on the equipment to be started (Scan the QR code at the isolation bench to confirm)

  • Sign off for no. 2 Signature required from the Maintenance Department - Electrician or Fitter.

  • 3.Check the boilers are up to pressure, and the boiler operator is aware of which cooker is starting. SIGNED BY RUNNER.

  • 4.Ensure that the condense drain is closed ready for start up.

  • Sign off for No. 4 SIGNED BY RUNNER.

  • 5.Ensure that the cooker hood hatches,cooker front door, and control wheel hatch are closed and secured, also check that the air is on to the cooker gate. SIGNED BY RUNNER.

  • 6.Set all Tallow lines to production positions and clear through with steam - Sedimenter, Press Pump, Prime Pump, Product Pump, Shaker Lines. SIGNED BY RUNNER.

  • N.B - Steam may be required on the low level feed screw if we have had freezing temperatures or at the start of the production week. ( Damage to the chain or motor could occur).

  • 7.Ensure that the vacuum line is open,and the vacuum pot is drained and closed. SIGNED BY RUNNER.

  • 8.Open the cooker shaft drain valve to the floor and ensure the zero flash and steam traps are closed (Scan the QR code at location)

  • Sign off for No. 8 SIGNED BY RUNNER.

  • Enter the date and time cooker 1, is ready to be started up, after all the previous checks have been completed.

  • 9.NOTE - The control room operator must remain in the control room for their 4 hour session (Unless suitable cover has been arranged) , the control room must not be left unmanned.

  • Sign off for No. 9. SIGNED BY OPERATOR.

  • 10.Set the NC fan (Vacuum) 50%, and start the NC fan, Condenser Fans, once up to speed put the NC (Vacuum) fan in Auto. SIGNED BY OPERATOR.

  • 11. Start oil bearing cooler C4, Cooker shaft C3, Low level feed screw C2 & Sight glass screw C3a. SIGNED BY OPERATOR.

  • 12.Set the Modulating steam valve to 10% open. SIGNED BY OPERATOR.

  • 13.Instruct the runner to go to the steam landing and slowly open cooker 1 crown valve (main steam valve) to a maximum of 3 turns, and allow steam condensate to drain for 30 minutes via the cooker shaft drain, check regularly until drain runs clear. (If liquid is still milky after this time contact the manager) SIGNED BY RUNNER.

  • 14.Select the Raw Material section that you are going to be using.

    • Raw Material section 1
    • Raw Material section 2

  • 15.Open cooker feed bin valve A8, open Rotary pump valve A7. SIGNED BY OPERATOR.

  • 16.Turn on Rotary pump A6,Rotary pump feed screw A5, crusher bin screws A4a,A4b. SIGNED BY OPERATOR.

  • Turn on Crusher A3, Incline screw to crusher A2 & Hopper screws A1a,A1b. SIGNED BY OPERATOR.

  • 17.Fill the Cooker feed bin until you see the % level rise. And then turn the Rotary pump (A6) off, all the system will then go into standby.SIGNED BY OPERATOR.

  • 15.Open cooker feed bin valve B10, open Rotary pump vale B8. SIGNED BY OPERATOR.

  • 16.Turn on Rotary pump B7,Rotary pump feed screw B6, Crusher bin screws B5a,B5b. SIGNED BY OPERATOR.

  • 17.Turn on Crusher bin feed screw B4, Turn on the Crusher B3. SIGNED BY OPERATOR.

  • 18.Turn on the incline screw to the Crusher B2, Turn on the Hopper screws B1a,B1b,B1c,B1d. SIGNED BY OPERATOR.

  • 19.Fill the Cooker feed bin until you see the % level rise.And then turn the Rotary pump (B7) off, all the system will then go into standby.SIGNED BY OPERATOR.

  • 20.Once the cooker drain is running clear instruct the runner to close the drain valve, open the Johnson valve fully, and then go to the main steam landing and open cooker 1 steam crown valve.( runner to confirm he has carried out the task) SIGNED BY RUNNER

  • 21. turn on the zero flash pump C5 (you will have to wait for sufficient bar pressure (2.2bar) before it will run) and then put the zero flash into Auto on page 9.SIGNED BY OPERATOR.

  • 22. Once the back end temperature reaches 95 Degrees C, commence feeding the cooker. SIGNED BY OPERATOR.

  • Enter the time & date feeding the cooker started.

  • 23. Turn on the cooker feed bin screws C1 & C1a and then turn on the Rotary pump. Set Cooker feed to 10%. SIGNED BY OPERATOR.

  • 24. Gradually open the steam modulating valve and increase the cooker in feed, in 5% increments. Until the temperature reaches its set point and the in-feed has reached 60% (this is a guide only and feed may vary depending on material mix). SIGNED BY OPERATOR.

  • 25. confirm that the cooker is feeding correctly and the temperature set point has been reached and is now in Auto. ( This would be a good time to send the runner to blow the sight glass). SIGNED BY OPERATOR.

  • 26.Ensure that there is a meal trailer in the line, if not please request one to be put in. SIGNED BY OPERATOR.

  • when the cooker is 20 minutes away from discharging please start up all the other associated plant.

  • 27.Start the meal trailer section, select the correct screw direction arrow then turn M4,M3,M2,M1. SIGNED BY OPERATOR.

  • 28. Start up Press section, D1,D2,D2a,D11,D10,D12,D9 & turn on the Dupps Scrubber System V3,V3a. SIGNED BY OPERATOR.

  • 29. select the presses you are going to run.

    • F Press
    • E Press
    • D Press

  • F Press-Turn on the press, set the feed screw set point to 5%, SIGNED BY OPERATOR.

  • F Press-Ensure that there are set point values inserted for the Choke, Feed screw high Amps & the water valve. SIGNED BY OPERATOR.

  • E Press-Turn on the press, set the feed screw set point to 5%, SIGNED BY OPERATOR.

  • E Press-Ensure that there are set point values inserted for the Choke, Feed screw high Amps & the water valve.SIGNED BY OPERATOR.

  • D Press-Turn on the press, set the feed screw set point to 5%, SIGNED BY OPERATOR.

  • D Press-Ensure that there are set point values inserted for the Choke, Feed screw high Amps & the water valve.SIGNED BY OPERATOR.

  • Sign off to No.29 SIGNED BY OPERATOR.

  • 30. Ask the runner to confirm which Decanter will be used and to ensure the valves are set accordingly.

    • T4 Decanter
    • T5 Decanter

  • Confirm which Decanter will be started. SIGNED BY RUNNER.

  • 31. Ask the runner to confirm which shaker will be used, and to set the valves accordingly.

    • T1 Shaker
    • T2 Shaker

  • Confirm which shaker will be used. SIGNED BY RUNNER.

  • Start up the Tallow section

  • 32.Turn on the Decanter (T4 or T5) & The Decanter fines screw T7 & Decanter Feed pump T3 (shaker pump) Turn on Shaker Screen motors (T1 / T2).SIGNED BY OPERATOR.

  • 33. Start the Prime pump T8 & Product pump T6 and then turn on Fresh air fans, T8a & T9. SIGNED BY OPERATOR.

  • 34. When the cooker is almost ready to discharge instruct the runner to check that the lines are set to production. SIGNED BY RUNNER

  • 35. Instruct the Runner to close the floor drain valves on the press pump and decanter tank. also ensure the sedimenter floor valve is closed. SIGNED BY RUNNER

  • Start up discharge conveyor system on Page 4

  • 36. start screws C10,C9,C8,C8a,C7. & start sedimenter pump C11. SIGNED BY OPERATOR.

  • 37. Start the control Wheel C6, and then enter 10% on the discharge, open the Cooker gate C3i, (build up the discharge % at a steady rate) SIGNED BY OPERATOR.

  • The cooker is now discharging allow the Buffer bin to fill up to 40% before processing down the presses

  • 38.Turn on the Hydraulic power pack (D13) for the chokes and the turn on the chokes ( the chokes will normally only come on once sufficient material is going through the press) SIGNED BY OPERATOR.

  • 39. Turn on the feed screw to the presses and start processing greaves through the press system, the feed rate can be increased steadily whilst carefully monitoring the press Amp. SIGNED BY OPERATOR.

  • N.B The material on start up is generally not the best so it is good practice to have a few Dolavs at the front of the presses to catch the poor quality material until it gets better and then send to trailer.

  • 40. I confirm that all parts of the process are operating normally. SIGNED BY OPERATOR.

  • Control Room & Runner Sign Off To Confirm All Tasks Have Been Completed Correctly

  • Control Room Operator

  • Runner

  • Managerial Sign Off

  • Any Additional Comments

  • Manager/Assistant Signature

Category 3 - Cooker 1 - Start-up Check- List
Darren Challinor

Category 3 - Cooker 1 - Start-up Check- List

Cooker 1- Start-up Check-List

Use this Template
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