SMP Rotary Feeder

SMP No: TL-SMP-34-01
Revision: 01
Effective: August 1, 2020
Supersedes: TL-SMP-34-00 (July 1, 2009)
Prepared by: Shyam Kumar Gujarathi

Power O&M
Approved by: K. Narayanan
Standard Maintenance Procedure for Rotary Feeder

TL-SMP-34-01
1. HAZARD IDENTIFICATION AND ASSESSMENT OF RISK & OPPORTUNITY (HIARO) NO:
2. SUMMARY OF THE OBJECTIVE

This document is created to provide the information to job execution team for carrying out maintenance
with best quality and safety.
3. RECOMMENDED SAFETY PPEs
S.N. Name Function

01 Safety Element Head Protection
02 Safety Shoes Foot Protection
03 Safety Goggles Eye protection

Protection from
04 Nose Mask
dust
05 Hand Gloves Hand Protection
06 Safety Belt Fall Protection
07 Ear plug Hearing Protection
Other specific PPE’s recommended in

08
HIARO to be used
4. FIELD CHECKS FOR SAFE MAINTENANCE
Work Permit No. :- Checks

S.N. Checks Reasons Yes No
1 Adequate Illumination Inadequate illumination causes accident
2 Proper Ventilation Easy breathing & relief from early fatigue
3 Any slippery agent on floor To avoid any accident/ incident
4 Cross checked LOTO & tag To avoid any un safe act
STANDARD MAINTENANCE PROCEDURE FOR ROTARY FEEDER
5. TROUBLE SHOOTING CAN HELP WHEN YOU SUSPECT A PROBLEM
Problem Possible cause Correction
Rotor not centered in valve housing Center rotor.
Particulate or foreign object caught Reverse rotor to remove object. If this does not
between rotor and housing work, remove valve from service and disassemble.
Valve rotor does
not turn freely, Too much particulate feed to valve
Reduce feed rate or use larger valve size.
binds, or chatters inlet
Remove excessive moisture or use rotor with

Excessive particulate caking on valve
beveled blades and two cutter blades and/or coated
housing
valve housing.
Bearings need Grease Grease bearings, replace if necessary
Excessive noise Rotor has shifted Inspect rotor and realign
Drive chain is rubbing on chain guard Reposition chain or sprockets and chain
Remove excessive moisture from upstream

Excessive Excessive moisture in product. particulate or use rotor with beveled blades and two
particulate caking cutter blades and/or coated valve housing.
on valve housing Rotor may be turning in the wrong
Reverse valve rotation.
direction (for beveled blades)
Check fuse or breaker size required based on motor

Improper fuse or breaker size
FLA rating.
Check motor wiring per diagram on motor

Motor improperly wired
nameplate.
Motor stops
running Wrong voltage supplied to motor Check motor nameplate.
Safety interlock activated Check control panel wiring to motor.
See probable causes above for valve See remedies above for valve rotor does not turn
rotor does not turn freely, binds., freely, binds, or chatters.
Reducer problem Check reducer operation.

Motor runs but
valve not turning Broken or misaligned drive chain,
Inspect drive components and adjust or repair.
sprocket, or shaft key
May need steeper inlet hopper or anti-bridging

Particulate not free flowing
devices like bin flow aerators or vibrator.
Light particulate and/or high pressure Connect the valve housing air vent to a surge hopper
Particulate bridges
differential across valve rotor above valve or a dust control suction line.
above valve inlet
Check rotor and housing for out of roundness.
Excessive rotor/housing clearances Replace rotor and/or housing as required with
tighter tolerances (reduced clearance).
TL-SMP-34-01 Effective: August 1, 2020 Page 2 of 5

Shaft and Hole tolerance chart
Over Dia
3 6 10 18 30 40 50 65 80 100 120 140 160 180 200 225 250 280
from
Up to
6 10 18 30 40 50 65 80 100 120 140 160 180 200 225 250 280 315
Incl.-MM
Shaft - 0 0 0 0 0 0 0 0 0 0
h7 -0.012 -0.015 -0.018 -0.021 -0.025 -0.03 -0.035 -0.04 -0.046 -0.052
0.012 0.015 0.018 0.021 0.025 0.03 0.035 0.04 0.046 0.052
Hole- H7
0 0 0 0 0 0 0 0 0 0
Bearing installation
S.N. Activities
1 Remove the old bearing with the help of bearing puller
Check shaft OD in bearing siting area with respect to bearing ID and make it require tolerance as per
2
chart
3 Check the levelling of rotor with master level and align using shim at plumber block base
4 Check top and bottom plumber block half contact with bearing outer race by blue matching.
4 Check the plumber block and maintain recommended interference.
Straight bearings above 50mm ID should be heated to
5 100°C for is ZZ category, 120°C for other bearings. No heating is required for taper bore bearing.
NOTE: Temperature above 120°C not allowed.
6 Bearing lock-nut tightness to be ensured as per clearance chart. Ensure proper surface of lock nut.
7 Install oil seal/ Dust seal/Gauge glass/ Grease nipple with proper care.
Mechanical seal installation

S.N. Activities
1 Clean the staffing box and shaft at seal location
2 Check and clean sleeve and remove all damaged 'O' rings and fix new rubber 'O' rings.
3 Lap the mating face and check the blue match
4 Fix the stationary mating part O-ring with seal flange.
5 Check and noted the max spring compression of seal externally
6 Fix the rotary part of seal on sleeve and set the adequate seal spring pressure.
7 Fix the seal cooling water line if applicable.
Coupling installation and alignment

S.N. Activities
1 Check the shaft OD at coupling siting area with respect to coupling ID.
2 Check the coupling bore and keyway and make it require tolerance.
3 Heat the coupling max140°C and fix the coupling without hammering.
5 Before alignment ensure drive and driven should not have any push or pull force by piping/cable
4 Check the soft foot error and correct it if required
Fix the two dial for axial and one for radial. Fix alignment clamps on prime mover also ensured clamp is
5
rigid enough. Dial gauge should move freely in full range of its scale.
Do axial and redial alignment with minimum number of shims. Take the TIR and make correction by the
6 shim as per calculation. TIR should be checked in all bolt tightened condition and recheck the reading
and confirm the same.
7 Remove the alignment clamp dial and fix the coupling and lubricant.
Maintenance Management Systems
Equipment Name: Rotary Feeder
Types: M1- Checks, M2- Minor, M3- Major Maintenance
S.N. Maintenance Activities Yes No N/A Remarks
A M1, M2, M3- Common Checks

1 Is foundation base frame sufficiently massive?
2 Check for any mechanical “looseness”.
3 Checking the condition of drive sprocket and chain
4 Is the chain guard securing?
5 Check static oil level drive gearbox
6 If grease lubricated, make sure not over packed.
7 Check the cleanness of grease nipple for bearings
8 Check the adequate grease of all bearing
9 Check the air purging cleaning of Rotor.
10 Check the packing gland condition for any leak.
11 Can the rotor be easily turned with (relative) ease,

and without metallic sounds
12 Check Motor drawing current
S. N. Maintenance Activities Checks Yes No
B M2- Minor
1 Check any jamming/coating inside feeder No Jamming
2 Check the gap between rotor and outer casing Accepted Gap
3 Check shaft condition for any crack/bending No Damage
4 Check vane condition for any bending No Damage
5 Check condition of drive chain lock pin Good Condition
6 Check Motor drawing current Current will be normal

S. N. Maintenance Activities Checks Yes No
C M3- Major Maintenance
1 Overhauling of feeder Full Overhauling
2 Check bearings condition Replace if require
3 Check shaft condition for any crack/bending No Damage
4 Check rotor-body clearance Replace if require
5 Take drop test. Permissible Limit
6 Check Motor drawing current Current will be normal
Name of Maintenance Engineer:
Department :
Contact No. :
Permit Details:

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SMP No: TL-SMP-34-01

Effective: August 1, 2020

Supersedes: TL-SMP-34-00 (July 1, 2009)

Prepared by: Shyam Kumar Gujarathi

Standard Maintenance Procedure for Rotary Feeder

1. HAZARD IDENTIFICATION AND ASSESSMENT OF RISK & OPPORTUNITY (HIARO) NO:

2. SUMMARY OF THE OBJECTIVE

3. RECOMMENDED SAFETY PPEs

S.N. Name Function

02 Safety Shoes Foot Protection

03 Safety Goggles Eye protection

06 Safety Belt Fall Protection

07 Ear plug Hearing Protection

Other specific PPE’s recommended in

4. FIELD CHECKS FOR SAFE MAINTENANCE

Work Permit No. :- Checks

Problem Possible cause Correction

Rotor not centered in valve housing Center rotor.

Remove excessive moisture or use rotor with

Bearings need Grease Grease bearings, replace if necessary

Excessive noise Rotor has shifted Inspect rotor and realign

Remove excessive moisture from upstream

Check fuse or breaker size required based on motor

Check motor wiring per diagram on motor

Safety interlock activated Check control panel wiring to motor.

Reducer problem Check reducer operation.

May need steeper inlet hopper or anti-bridging

TL-SMP-34-01 Effective: August 1, 2020 Page 2 of 5

Mechanical seal installation

Coupling installation and alignment

A M1, M2, M3- Common Checks

11 Can the rotor be easily turned with (relative) ease,

S. N. Maintenance Activities Checks Yes No

1 Check any jamming/coating inside feeder No Jamming

3 Check shaft condition for any crack/bending No Damage

4 Check vane condition for any bending No Damage

5 Check condition of drive chain lock pin Good Condition

6 Check Motor drawing current Current will be normal

TL-SMP-34-01 Effective: August 1, 2020 Page 4 of 5

C M3- Major Maintenance

1 Overhauling of feeder Full Overhauling

2 Check bearings condition Replace if require

3 Check shaft condition for any crack/bending No Damage

4 Check rotor-body clearance Replace if require

5 Take drop test. Permissible Limit

6 Check Motor drawing current Current will be normal

Name of Maintenance Engineer:

TL-SMP-34-01 Effective: August 1, 2020 Page 5 of 5

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