Hindustan Zinc Limited

RD Mill

SMP for Filter High Flow Valve Replacement

Doc No. : HZL/ZSRP/Zone 1/SMP/RDM/Mill/13 Date of First Issue : 25/05/2016
Revision Number : R2 Last Revision on : 20/06/2019

SMP FOR Filter

High Flow Valve Replacement

Anup Das, AM(Mech.)

Prepared by :
Applicable to RD-Mill
Signature:
Vivian Dutt , Engineering Head, RD Mill
Reviewed by :
Signature :
Sunil Sampla , Mill Head, RD Mine
Approved by :
Signature :
Ram Murari , Unit Head, RD Mine
Approved by :
Signature :

1
 Hindustan Zinc Limited
RD Mill

SMP for Filter High Flow Valve Replacement

Doc No. : HZL/ZSRP/Zone 1/SMP/RDM/Mill/13 Date of First Issue : 25/05/2016
Revision Number : R2 Last Revision on : 20/06/2019

A. Purpose – To minimize the risk of accident/hazard/fatality during Filter high flow valve disc replacement
B. Scope – High flow valve disc replacement replacement of 3 nos Zn Product Filter and a Pb Product Filter
C. Competency Skill and Knowledge
 VTC Trained fitter, welder, helper with ITI or 4 years of experience

D. PREREQUISITES:-
1. Basic Qualification – Experience as Fitter, Mechanic, Welder.
2. Basic Safety Training – VTC Training as per HZL rules
3. Mandatory PPEs – Safety Helmet, Safety Shoes, Dust Mask, Reflector Jacket, Hand Gloves.
4. Tools / Equipment’s –
 General Tools.

D. Activities :
PTW and LOTOTO
i. Cold work permit to be taken for the job.
ii. Electrical isolation of the filter drum is to be taken.
iii. Compressed air line valve to be closed and product line valve to be closed.
iv. Trial out to be Electrical isolation to be done before starting work.

1. Filter to be stopped after cleaning the material stuck on the cloth.

2. Stop the valve on the high flow valve airline. Remove the high flow valve assembly by removing the
spring loaded mountings and flange at filtrate pump suction line.
3. Check the condition of the disc. If the disc surface is damaged, it is to be sent for repairs and new
disc to be fitted.
4. Remove the disc by removing the 8 nos mounting bolts at the periphery and 4 nos at the center.
5. Apply water jet inside each vacuum pipelines to clean any material stuck inside to remove chocking.
6. Inspect the mounting surface of the disc. Apply a rubber sheet cut exactly in the shape of the disc if
there is any damage on the surface.
7. Fix the new disc and tighten the mounting bolts. After tightening, check the surface of disc. The
surface should be absolutely flat. If there is any irregularity, the disc will not function and air blown
inside the discharge end sectors will be sucked by the vacuum pump. Cover the head of the
countersunk mounting bolts with sealant to protect them from corrosion.
8. After that, clean the high flow valve air pipe to remove any stuck up material.
9. Check the high flow valve mounting metal disc, the surfaces of air pocket on the valve body for any
sign of erosion. If there is any damage, repair it. Then, fit the valve.
10. Fit the suction line of the filtrate pump at the end of High flow valve.
11. Remove all tools, surrender the permit and remove power isolation.