PRESTASI FLOUR MILL(M) SDN BHD

WORK INSTRUCTION

TITLE: TO CONTROL CLEANING IN

BULK LOADING TANKER

DOCUMENT NO:

W I N - M - 0 3

ESTABLISHED DATE : 25th Jun 2019

TOTAL PAGES : 27

PREPARED BY APPROVED BY

NAME : Lim Yew Hung NAME : Wai Choon Sing

POSITION: Mechanical Engineer POSITION: Head of Maintenance
DATE : DATE :
 PRESTASI FLOUR MILL (M) SDN BHD
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LOADING TANKER
Approved by: Head of
Rev No: 3 Date: 25th Jun 2019 Prepared by: Mechanical Engineer
Maintenance

Effective
Rev. Description Reference
Date

Re-zero version number due to updating entire manual and procedures

0 1-12-2013 including standardize document number assigned to ease documentation
maintenance.

To consolidate the previous 100% tanker cleaning procedure into

1 08-08-2016
current work instruction
2 18-1-2017 Add in Fluidising cup cleaning Page 9 to page 10
3 25-6-2019 Revised procedure for fluidising cleaning process
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LOADING TANKER
Approved by: Head of
Rev No: 3 Date: 25th Jun 2019 Prepared by: Mechanical Engineer
Maintenance

OBJECTIVE
This procedure is for 100% cleaning for the tanker

SCOPE

To ensure the tanker is hygienic before loading of flour.

DEFINITION
Low risk Residue flour at tanker wall.
Slight layer of harden flour at the tanker wall.
(All of the above is common)

High risk Weevil found at after cleaning sample.

Foreign material found in the tanker after cleaning sample being sheave.

Dirty Flour Flour from tanker after cleaning.

Clean Flour Flour used for flushing.

EQUIPMENTS

1. A new unit of portable fresh air blower 300mm diameter.

2. Blind range to cover up blow line to prevent infestation during pipe cleaning processes.

3. Food grade pan, brush and stainless steel scraper.

4. Tools for opening pipe flange.

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LOADING TANKER
Approved by: Head of
Rev No: 3 Date: 25th Jun 2019 Prepared by: Mechanical Engineer
Maintenance

5. Clean flour for after cleaning flushing.

6. Hardness for whose working on top of tanker (Work at Height)

PROCEDURES

1. Received work order (through SAP) from QC/Logistic for the tanker 100% cleaning
request.

2. Tanker cleaning check list (DOC No: PFM/QC/R33) pass to tanker cleaning PIC before
the cleaning activities start.

3. The tanker will have to be park at the tanker cleaning bay as request.
Cleaning of the inside tanker will be carried out from 9.00am to 5.00pm. (Low activities of
weevils)

4. If blow pipe is needed to be dismantle for cleaning all the flange attached to the tanker
have to be closed with blind flange.

5. The dismantle pipe will be soak in water to loosen up the flour for easy cleaning. (min 3
hours soaking time)

6. The fresh air blower fan will be installed at the top of the hatch hole for forced ventilation
into the tanker

7. The cleaning of the tanker will be from top to bottom. The hatch cover will be the first to
be clean follow by the tanker body.

8. During cleaning inside tanker cleaning awareness to look out for weevil or other
abnormal foreign object must be observed.

9. When the inside tanker is cleaned, the hatch is closed, and the blow pipe will be
installed.

10. The blow pipe has to be fully dry before installing to the tanker.

11. After installing the pipe, the tanker is ready for blowing out the dirty flour and these will
be collected for sample to be used for sheaving to check for weevil and foreign object.

12. From the sheaving of the dirty flour, the result will be recorded in the checklist.
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LOADING TANKER
Approved by: Head of
Rev No: 3 Date: 25th Jun 2019 Prepared by: Mechanical Engineer
Maintenance

13. Clean flour is pour into the individual hatch (5 no’s) and 1 bag are pour into each hatch
for flushing. These clean flour are collected and goes through sheaving for any weevil or
foreign object.

14. If there is no discrepancy, the tanker will have released for loading. All work carried out
and any finding will be documented in the checklist.

In the event when there is a discovery of discrepancy, the management will be inform for
further action.

Example for further action

Discrepancy Further action

Weevil Fumigation of tanker
Foreign object Inform management and at the same
time check for source, rectify and follow-
up
Procedure:

1. Blow the residue flour inside dirty tanker into the hopper.
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LOADING TANKER
Approved by: Head of
Rev No: 3 Date: 25th Jun 2019 Prepared by: Mechanical Engineer
Maintenance

2. Take sample of the dirty flour. Sample should be recorded with tanker registration,
date before and after

3. After parking the tanker, put a road blocker at the tanker’s tyres
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LOADING TANKER
Approved by: Head of
Rev No: 3 Date: 25th Jun 2019 Prepared by: Mechanical Engineer
Maintenance

4. Take out the blower’s filer from prime mover’s blower and clean it with compressor
air
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LOADING TANKER
Approved by: Head of
Rev No: 3 Date: 25th Jun 2019 Prepared by: Mechanical Engineer
Maintenance

5. Open the breather at the end of the tanker to release the air inside the tanker
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LOADING TANKER
Approved by: Head of
Rev No: 3 Date: 25th Jun 2019 Prepared by: Mechanical Engineer
Maintenance

6. Hang the blow pipe with rope

7. Used allen key to open cup

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LOADING TANKER
Approved by: Head of
Rev No: 3 Date: 25th Jun 2019 Prepared by: Mechanical Engineer
Maintenance

8. Remove the fluidising rubber from the cup

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LOADING TANKER
Approved by: Head of
Rev No: 3 Date: 25th Jun 2019 Prepared by: Mechanical Engineer
Maintenance

9. Remove residual of flour from cup

10. Cleaning cup, hose and remove residual if any

11. Clean the fludising rubber with water (Top and Bottom)
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Approved by: Head of
Rev No: 3 Date: 25th Jun 2019 Prepared by: Mechanical Engineer
Maintenance

12. Installed back the cup

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LOADING TANKER
Approved by: Head of
Rev No: 3 Date: 25th Jun 2019 Prepared by: Mechanical Engineer
Maintenance

13. Dismantle the blow pipe by open the bolt and nut at flange using air impact wrench

14. Also dismantle the intermediate pipe

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LOADING TANKER
Approved by: Head of
Rev No: 3 Date: 25th Jun 2019 Prepared by: Mechanical Engineer
Maintenance

15. Cover the bottom hole of tanker with canvas

16. Soak all the dismantle pipe inside the water for 2 hours
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LOADING TANKER
Approved by: Head of
Rev No: 3 Date: 25th Jun 2019 Prepared by: Mechanical Engineer
Maintenance

17. Scrap all the residue flour inside the pipe

18. Drying the water inside the pipe under the sun light. Wrapping with wrapping films for
all opening to prevent any weevil or dust enter inside the piping.
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LOADING TANKER
Approved by: Head of
Rev No: 3 Date: 25th Jun 2019 Prepared by: Mechanical Engineer
Maintenance

19. Also take out all the butterfly valve and soak it inside water for 2 hour, then place it
vertical position let it dry. Check the condition of the seal of butterfly valve, change
the seal if found defect.

20. Blow in fresh air into the tanker for 15 minutes, then only enter the tanker for
cleaning.
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LOADING TANKER
Approved by: Head of
Rev No: 3 Date: 25th Jun 2019 Prepared by: Mechanical Engineer
Maintenance

21. Open hatch and clean the residue flour. Need care as not to drop residue flour into
tanker.

22. Put the ladder into each manhole tanker. Worker go into the tanker and clean the
internal body.
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LOADING TANKER
Approved by: Head of
Rev No: 3 Date: 25th Jun 2019 Prepared by: Mechanical Engineer
Maintenance

23. Scrap all the residue flour on the internal body of the tanker with scrapper
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LOADING TANKER
Approved by: Head of
Rev No: 3 Date: 25th Jun 2019 Prepared by: Mechanical Engineer
Maintenance

24. All the residue flour will drop down onto the bottom of tanker. Then, swept away all
the residue flour.
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LOADING TANKER
Approved by: Head of
Rev No: 3 Date: 25th Jun 2019 Prepared by: Mechanical Engineer
Maintenance

25. Remove the cover of strainer and check for any foreign material it should be non.
Clean the strainer with water and let it dry. Check the condition of strainer. If found
any defect, replace it.
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LOADING TANKER
Approved by: Head of
Rev No: 3 Date: 25th Jun 2019 Prepared by: Mechanical Engineer
Maintenance

26. Open the cover to retrieve the magnet. Remove the residue flour and check for any
iron.

27. Take out the flexible hose and clean with cloth and check for any defect.
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Approved by: Head of
Rev No: 3 Date: 25th Jun 2019 Prepared by: Mechanical Engineer
Maintenance

28. Fix back all the mechanical part into the tanker after cleaning.

29. Do flushing by pouring the clean flour into each of the tanker’s hatch. Pour 2 bag Per
Hole. Blow it into the clean hopper. Bag with flour should be open before going up to
the tanker manhole.
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Approved by: Head of
Rev No: 3 Date: 25th Jun 2019 Prepared by: Mechanical Engineer
Maintenance

30. After blowing into the clean flour collect sample from the clean flour tank for checking
(QC Department). Sample should be recorded with Tanker Registration Number,
Date and After Cleaning.

31. Any defect found when 100% cleaning, replace with new spare part.
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Approved by: Head of
Rev No: 3 Date: 25th Jun 2019 Prepared by: Mechanical Engineer
Maintenance
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Approved by: Head of
Rev No: 3 Date: 25th Jun 2019 Prepared by: Mechanical Engineer
Maintenance
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Approved by: Head of
Rev No: 3 Date: 25th Jun 2019 Prepared by: Mechanical Engineer
Maintenance
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Approved by: Head of
Rev No: 3 Date: 25th Jun 2019 Prepared by: Mechanical Engineer
Maintenance
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Approved by: Head of
Rev No: 3 Date: 25th Jun 2019 Prepared by: Mechanical Engineer
Maintenance

32. After done 100% cleaning, record down the tanker down with tanker registration
number, date and time inside the book.