• SHUTDOWN CHECKLIST FOR SUPER COOKER 1.

  • 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 Shut-down the operator has changed

  • Nick Tunnicliffe

  • Daniel Wood

  • Darren Challinor

  • Robbie Evans

  • Piotr Misiak

  • Gordon Foulkes

  • Shane Law

  • Tyler Scragg

  • Robert Sargeant

  • Simon James

  • Colin Tatton

  • Chris Bettany

  • Matthew Walwyn

  • Trainee Name

  • Select the Cookhouse Runner this must be re-selected if part way through a Shut-down the Runner has changed

  • Nick Tunnicliffe

  • Daniel Wood

  • Darren Challinor

  • Robbie Evans

  • Piotr Misiak

  • Gordon Foulkes

  • Shane Law

  • Tyler Scragg

  • Robert Sargeant

  • Simon James

  • Colin Tatton

  • Chris Bettany

  • Matthew Walwyn

  • Trainee Name

  • Select the reason for the Cooker shutdown

  • Enter the time the shutdown started

  • Select which Raw material section is going to be shutdown

  • 1. when the hopper is empty turn off the screws A1a & A1b

  • 2. When the incline screw is empty turn off A2

  • 3. Wait for the Crusher to clear of material and the turn off A3

  • 4.Empty the contents of the crusher bin and the turn off the screws A4a,A4b

  • 5.Turn off the Rotary pump feed screw A5 & the Rotary pump A6

  • 6.Close the Rotary pump valve A7 and then close the cooker valve A8

  • 7. Check the cooker feed bin C1b, is empty via % level and then turn the bin screws off C1,C1a.

  • 1. when the hopper is empty turn off the screws B1a,B1b,B1c,B1d

  • 2. When the incline screw is empty turn off B2

  • 3. Wait for the Crusher to clear of material and the turn off B3

  • 4.Empty the contents of the crusher bin and the turn off the (Kebab screw) B4 and the bins screws B5a,B5b

  • 5.Turn off the Rotary pump feed screw B6 the Rotary pump B7

  • 6.Close the Rotary pump valve B8 and then close the cooker valve B10

  • 7. Check the cooker feed bin C1b, is empty via % level and then turn the bin screws off C1,C1a.

  • Select the Date and Time for when the cooker started to empty down

  • 8.Set the cooker Feed % to zero. SIGNED BY CONTROL ROOM OPERATOR.

  • 9.Set the modulating steam valve to zero % & Instruct the runner to shut the crown valve, on the main steam deck.. SIGNED BY CONTROL ROOM OPERATOR

  • 10. runner to take a picture of the Main crown valve after closing

  • 10a Sign off for number 10SIGNED BY RUNNER.

  • 11. Instruct the runner to slowly open the cooker shaft drain valve at the front of the cooker. SIGNED BY RUNNER.

  • 12. Inform the boiler man/maintenance that the main steam has been turned off. SIGNED BY CONTROL ROOM OPERATOR

  • 13. Take the zero flash out of Auto and reduce to zero % (the zero flash will turn off automatically when the bar pressure has dropped) SIGNED BY CONTROL ROOM OPERATOR.

  • 14. Override the cooker gate. SIGNED BY CONTROL ROOM OPERATOR.

  • 15. Control room operator to take a picture of the cooker temperature from page 4.

  • 15a.Sign off for number 15 by CONTROL ROOM OPERATOR.

  • 16.Empty material out of the cooker for the set time given by your Manager. SIGNED BY CONTROL ROOM OPERATOR.

  • 17.Instruct the runner to half fill a Dolav with cake. SIGNED BY CONTROL ROOM OPERATOR.

  • 18..After sufficient material has been emptied out of the cooker move onto the next step.

  • Select the Time and Date for when discharging from the cooker stopped.

  • 19.close the cooker gate C3i & take the gate out of override. SIGNED BY CONTROL ROOM OPERATOR.

  • 20.let the control wheel empty out for a couple of minutes before reducing the discharge %.SIGNED BY CONTROL ROOM OPERATOR.

  • 21.Set the discharge % to zero and then turn the control wheel C6 off.SIGNED BY CONTROL ROOM OPERATOR.

  • 22.Instruct the runner to empty the contents of the sedimenter over to the shakers and then blow all the lines through with steam.SIGNED BY RUNNER.

  • 23.instruct the runner to wash through the decanter and shaker system for at least 15 minutes until water is clear, and clear the product pump and prime pump lines with steam.SIGNED BY RUNNER.

  • 24.Stop the cooker shaft C3.SIGNED BY CONTROL ROOM OPERATOR.

  • 25.Stop the low level feed screw C2.SIGNED BY CONTROL ROOM OPERATOR.

  • 26.Stop sight glass feed screw C3a.SIGNED BY CONTROL ROOM OPERATOR.

  • 27.Stop the bearing oil cooler C4.SIGNED BY CONTROL ROOM OPERATOR.

  • 28.Stop the sedimenter pump, and instruct the runner to wash out the sedimenter & screen check for any damage .SIGNED BY RUNNER

  • 29.Observe the press feed chutes using the CCTV, when the rerun system is empty and no longer feeding material into the presses stop the press feed screws and set to zero %.SIGNED BY CONTROL ROOM OPERATOR.

  • 30. Instruct the runner to clean the press magnets then introduce 3/4 buckets of dry cake into presses, to clear the presses.SIGNED BY RUNNER.

  • 31.Turn off motors, on page 4, C7, C8,C8a,C9, C10.SIGNED BY CONTROL ROOM OPERATOR.

  • 32.stop the presses when the runner confirms they are clear.SIGNED BY CONTROL ROOM OPERATOR.

  • 33.Instruct the runner to clear the press pump line with steam and then to wash through the press pump with water, and then check the press pump screen for any damage.SIGNED BY RUNNER.

  • 34. Turn all motors off on page 5. D1,D2,D2a,D9,D10,D11,D12 Turn the chokes off on the presses and then turn D13 off. SIGNED BY CONTROL ROOM OPERATOR.

  • 35. Turn all meal conveyor screws off, M1,M2,M3,M4. SIGNED BY CONTROL ROOM OPERATOR.

  • 36.Instruct the runner to check if the water is running clear on the decanter.SIGNED BY RUNNER.

  • 37.The runner to turn the water off on the decanter if the water is running clear.SIGNED BY RUNNER.

  • 38. Turn off the Prime pump T8, Product pump T6, Turn off the Decanter feed pump(T3) and Decanter(T4 or T5), Turn off Shaker motors (T1 & T2) & the fresh air fans T8a,T9. SIGNED BY CONTROL ROOM OPERATOR.

  • 39. Turn off the NC fan and all condenser fans V1c,V1b,V1a & C12. SIGNED BY CONTROL ROOM OPERATOR.

  • 40.Change the Vacuum % to zero on page 9.SIGNED BY CONTROL ROOM OPERATOR.

  • 41.Stop the Dupps scrubber motor & pump on page 8. Instruct the runner to empty and refresh if dirty.SIGNED BY CONTROL ROOM OPERATOR.

  • 42.instruct the runner to clear all tallow lines for a second time and ensure all service steam is off. SIGNED BY RUNNER

  • 43.Close the Johnson valve and leave the cooker drain valve fully open.SIGNED BY RUNNER.

  • 44. Open all the condense lines and leave open. SIGNED BY RUNNER.

  • 45. Control room operator to check through all the SCARDA pages and ensure all plant equipment is shutdown. SIGNED BY CONTROL ROOM OPERATOR.

  • 46.Take a picture of the cooker temperatures off page 4.SIGNED BY CONTROL ROOM OPERATOR.

  • Cooker Shutdown Sign Off

  • Any additional comments.

  • Control room operator to sign that he has shutdown the plant correctly

  • Runner to sign that he has completed all the tasks correctly

  • Managerial Sign Off by Manager/Assistant.

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