Document V3qbKZYOjMkVKpzxOdroRLgRN

OPALON COMPOUND TENTATIVE OPERATING INSTRUCTTORS FOR NORTH AND SOUTH MILL ROLLS August 10, 1953 B. E. Steinkuhler RSV0024002 TABLE OF CONTENTS 530.00 - Procedure for North and South Mill Rolls - Opalon Compound Line 531.00 Objective 532.00 Summary 533.00 Equipment 534.00 Operating Details 534.10 Control Panels 534.20 Start -Up 534.30 Milling Operation 534.40 Shut-Dovn 53^*50 Operating Difficulties 534.60 Emergencies 534.70 Clean ing 535*00 Discussion 536.00 Safety 537*00 Records RSV0024003 531.00 - Objective This procedure d scribes the operation of the North and South mill r 11s as part of the Opalon compounding line. It is has d on the tentative process issued on April 28, 1953, by Research entitled "Opalon Dry Blending and Compounding." It Includes operation of tvo belt oonveyors (Banbury to South mill and South mill to North mill) and one roller conveyor (North roll to cooling tank). RSV0024004 2 5^2.00 - Summary Th fused stock is discharged from the Banbury xtfa the belt conveyor t> the South mill roll. A by-pass chute is provided for discharging directly to the North mill roll if desired. The purpose of the South mill Ib to blend the fused stock from the Banbury into a homogeneous mass. The operator achieves this by cutting the stock back and forth. The stock is then removed by a set of knives as a continuous ribbon and conveyed to the North mill. The North mill vill serve primarily as a stock reservoir for the cooling and cutting section of the line. The stock is removed as a continuous ribbon and is carried over a roller conveyor to the cooling tank. RSV0024005 -3 - 533.00 - Equipment Se Plastics Division Engineering Report 85D for a complete description of equipment. The major Items are listed as follovs: Equipment No, Name and Manufacturer Description 01-436 Conveyor, Banbury to South Mill, Pembroke See Pembroke Conveyor drawing dated 5/12/53 and Monsanto drawing D-6228. 01-440 South Compounding Mill, Farrel-Birmingham 22m x 60", F-B-drawing number 2-1779. 01-444 Strip Conveyor, South Mill to North Mill, Pembroke See Pembroke Conveyor drawing dated 5/12 /53 and Monsanto drawing D-6228. 01-448 North Compounding Mill, Farrel- Birmingham 22" x 6D", F-B drawing number 2-1779. ----"-- Strip Conveyor, North Mill to Cooling Tank Standard roller conveyor 12" wide by f'-o" long, seven idling rollers. RSV0024006 -5 - `o 4. When the oil temperature has reached 90F and the oil pressure is at least 12-15 psig, close the steam valve to the oil tank, 5. The cold water valve 17 (located above west end of rolls) for the oil cooling coils should be opened to maintain an oil temperature of 120F to 140F. 6. Start the motor ventilation system (switch on south wall, first floor of 85B). 7. Start the mill rolls by pressing the start button on the instrument panel, 8. Check the safety bar. The rolls should stop within approximately four inches of travel. If the safety bar is not functioning properly, do not operate the mill roll. 9. Turn the roll temperature control instruments on. Isolate the steam control valves by checking valves 3, 4, 5 and 6 as being closed. 10. Open the steam by-pass valves (7 and 8) slightly to allow a small flow of steam. 11. Open vlaves 9, 11, 13 and 15 at the steam traps. Check to insure that trap by-pass valves 10 and 14 are closed. 12. Check to insure that drain valves 12 and 16 are closed. 13. Heat the rolls to specified temperature at the rate of 20 to 30C per hour. 14. The tentative specified roll temperatures are: a. South mill - front 125C rear 120C b. North mill - front 125C rear 120C 15. When the rolls have reached the desired temperatures, close steam by-pass valves 7 and 8. Open the valves before and after the steam control valves (3, 4, 5, and 6). 16. Check the instrument set temperature as prescribed in step 14. 17. Start the Banbury conveyor which will carry the stock from the Banbury to the South mill. 18. Start the mill conveyor which will carry the stock strip from the South mill to the North mill. RSV0024008 -6 - 19. Push the button to signal the Banbury operator for the batch. Notei If the mill rolls must be shut down for periods exceeding 20 minutes while at temperatures of 90C or higher, raise the stock: guides 1/8 inch before attempting to start again. 584.80 - Milling Operations A, South Mill 1. When the fused Banbury batch is dropped to the roll nips, guide the stock to form a blanket around the front roll. 2. Work the stock only enough to obtain a homogeneous compound by cutting it back and forth. 3. Adjust the roll spacings to give a ribbon 1/4 inch in thickness. 4. Place the stripping knives against the face of the front roll (left side) to remove a continuous ribbon. Guide this ribbon to the mill conveyor. Note: The width of the strip removed will depeDd upon the desired production rate. 5. Work the stock over to the left side of the rolls and ring the Banbury operator for another batch. 6. When the batch is dropped, work it Into a homogeneous blanket on the right side of the roll. 7. Operation from batch to batch will then be routine. The mill roll operator will have to keep close watch to insure that a sufficient reservoir of stock is maintained on the North mill roll, 8. Check stock temperature frequently with a needle pyrometer. The stock temperature should not exceed 310P. B. North Mill 1. The strip stock from the South mill should be banded on th front roll. Very little working of stock should be required on this mill. 2. Adjust the roll spacings to give a ribbon 3/16 inch in thickness. 3. Place the stripping knives against the face of the front roll (left side) to remove a continuous ribbon. Guide this ribbon over the roller conveyor to the cooling section. RSV0024009 -7 - Note: Approximate width of strip from Worth roll versus pounds per hour (67 ft./min, and specific gravity of 1.375) is as follows: 5" x 3/16" = 2250#/hr. 4" x 3/16" - 1800#/hr. 4. Check stock temperature frequently with a needle pyrometer. The stock temperature should not exceed 310F* 534,40 - Shut-Down 1. Shut off steam to rolls and open the drain valves. Do not apply cold vater to the rolls. 2. Stop the Banbury conveyor and the mill conveyor. 3. When the rolls have cooled to 90C, stop the mill motor and lubricating pump, 4. Turn off the power to the roll temperature recording controllers. 5. Close the valve for the cooling water to the oil tank. 534.50 - Operating Difficulties A. Foreign Material If foreign objects drop onto the rolls, stop the mill motor. Open the roll nips and remove the object. If it is necessary to work above the roll crown near the nips, lock out the mill motor disconnect switch. If the stock is contaminated, remove it from the rolls in slabs and hang on drums to cool. B. Off-Color Batch 1. Cut the ribbon feed to the strip conveyor. 2. Remove the batch in slabs. 3. Hang the slabson fiber drums to cool. 4. When the mills are clear, signal the Banbury operator for the next batch. C. Un -Fused Batch 1. Attempt to fuse the batch on the rolls by working with other fused stock. 2. If the premix is in specification, the Banbury mixer should properly fused the batches. If this condition persists, the Banbury operator and assistant foreman should be notified. RSV0024010 -8 534.60 - Emergencies Smoke or Fire from MQ.1 Motor or Mill Area 1, Stop motor by pressing button on panel. 2. Call fire department. 3o Use the COg fire extinguishers. Do not use water. 534.70 - Cleaning 1. Follov the lockout procedure outlined in the "Safety*1 section. 2. Clean the conveyor from the Banbury. 3. Clean premix and color off the mill roll hood and overhead. 4. Wipe any premix and color off the rolls and saddles. Dioctyl phthalate may be used. 5. Sveep all loose material from the stock pan. RSV0024011 -9 - 535.00 - Discussion }a. Compounding Stock Temperature One of the important justifications for the Banbury-mill roll compounding line is improved product quality. Results of Research investigations indicate that compound produced by the Banburymill roll method is superior to extrusion compounded material. The major reason is the lover stock temperatures (310F or less) encountered in the Banbury-mill roll process versus the high stock temperatures (360-400F) encountered in the extrusion compounding process. Therefore, stock temperatures should be maintained at the lowest levels consistent with satisfactory compounding of premix into a homogeneous product. B. Contamination This is a most important factor that must be kept under control. Contamination of any nature can't be tolerated in the production of either electrical or profile compounds. C. Mill Roll Lubrication The mill roll bearings are lubricated by circulating oil that should be maintained at 120-140F and approximately 15 psig. Manual adjustment of the valve controlling the cooling water to the oil tank will be required. Recent experience with the mill rolls in the Farrel calender line indicated that oil temperatures might rise to at least 150F. The bearings are also equipped with cooling water facilities. However, Farrel engineers have recently recommended that the cooling water should not be used. D. Milling Rates The width of the strips removed from the mill rolls will depend upon the desired production rates. The following approximate figures are calculated using a compound specific gravity of 1.375* 1. South mill - operating at roll surface speed of 101 feet per minute. 2.5" * lA" = 2250#/hr. 2" x 1/4" = 1800#/hr. 2. North mill - operating at roll surface speed of 67 feet per minute . fl 5 4 t x x 3/16" 3/16" = 2250#/hr. = 1800#/hr. RSV0024012 10 Uniformity of pellet size is desirable. Therefore, the ribbon thickness of 3/16 inch from the North mill should be adhered to. The operator should check the thickness frequently. RSV0024013 -3 - 543.00 - Equipment fcee Plastics Division Engineering Report 85D for a complete description of equipment. The major items are listed as follows: Equipment No. Name and Manufacturer Description 01-450 Strip Cooling Tank See Monsanto drawing D-6226. -- Belt Conveyor Pull Section, Driven by 1/2 H.P. Cooling Tank to Dicer, Pembroke Varldrive motor. 01-452 Dicer, Cumberland Cumberland drawing number A-18001 01-454 Product Screening Rote* shaker. Day. Pitted with perforated metal sheet, circular openings 3/8 inch in diameter. 01-456 Conveyor, Product to Bagout Hopper Includes Buffalo Electric Blower, size 5 1/2, type E, and associated piping and hoppers. See Monsanto drawing numbers C-4104-1 to C-4104-12, inclusive. Also C-4110, C-4100, A-4225, C-4108, C-4117, C1-4109, B-2248 and C-4115. 01-458 Bag Packer, St. Regis Paper Co. Machine number 6471, type 301 FB. RSV0024014 11 536.00 - Safety A. safety Equipment 1. Fire extinguishers. 2. Safety bars for opening rolls. 3. R-1000 AD type respirators for use in areas containing premix dust o 4. R-31 type respirators for use in areas containing harmful fumes. 5. Gloves, etc. B. Safe Practices 1. Keep hands below the crown of the rolls at all times. Do not attempt to retrieve any object falling into the stock or nips while the mill is running. Stop the mill immediately. 2. The mill rolls are provided vith safety bars. These must be checked once per shift. The rolls should stop vithin four Inches of travel. 3. The mill motor disconnect switch must be locked out according to Plant Bulletin E-210 whenever the mill rolls are shut down for cleaning or maintenance. Obtain the lock from the assistant foreman, 4. Gloves must be worn when working with heated equipment or hot stock, 5. Dioctyl phthalate is the only solvent that can be used for cleaning purposes. 6. Use extreme care in handling knives for cutting stock. RSV002401.5 12 537*00 - Records There are no formal records for the mill roll operator to keep. Hovever, the mill roll operator shall he responsible for changing the charts at 6:00 A.M. on each operating day for the roll temperature controllers. These charts should be forwarded to the Assistant Foreman at the end of the shift. RSV0024016 FIGURE 1 NORTH AND SOUTH MILL ROLLS OPALON COMPOUND LINE 8/10/53 B.E.S. water I C O HDtNMTS SOUTH MILL ROLL INSTRUMENT PANEL FRONT ROLL TEMP. fC.) 1, 1 IT ^! REAR roll TEMP, ("c) NORTH MILL ROLL IfrSTfttJMENT PAtf&L cRONT ROLL TEMP. fO.) o_ o REAP ROLL TEMP, ffj L/Ch'r C| START wj3 Tc P . \_ UART ^ STOP j0(i J START j' STMT ; srcp iQ STOP t; LUBE PUM.P BAuP'JhJ CON V. NULL C.ONV. MIUMOTOR PAN6`JR'> aP. siORAt. ' C uir.PT C Start ^ STOP L USE PUMP O J&i c START c STOP NULL MO T oR \ RSV0024017