Alexander Dade

All samples

Cooling wind failure

Troubleshooting SOP for a glass manufacturing plant

Context

One procedure from the library I built for a new glass manufacturing facility, written with engineers, technicians, and developers. The library let operators handle issues that used to wait for an engineer.

This one guides a technical reader through diagnosing a fault that can be in the software or in the equipment.

Tools: Ignition SCADA, Azure DevOps, Photoshop

What to notice

  • The first step lists symptoms and causes, so the reader knows what they're looking at before they act.
  • Numbered steps carry the sequence. Bullets carry the checks inside each step.
  • Step numbers are bold and larger, so the reader can find their place on a plant floor.
  • Active voice keeps instructions direct: “check for any alarms,” not “the alarms should be checked.”
  • Photos carry callouts that point to the critical part.

The document

Cooling wind failure

See the following to diagnose and respond to a cooling wind failure.

  1. Know the symptoms and causes.

    Common symptoms of cooling wind failure:

    • Cooling wind fan error message at the operator station.
    • High radar gauge temperature alarm.

    Cooling wind can be lost for several reasons:

    • Blower wheel obstruction
    • Clogged filter
    • Bearing failure
    • Motor failure
  2. At the operator station:
    • Check for any alarms.
    • Alarms are shown at the top of the screen.
    Operator station screen with a red alarm bar across the top, above tabs for Main Overview, Stilling Chamber, Melter Spout, and two zones.
  3. Physically check the cooling wind fan.
    • Check if the filter is clogged.
    • Check if the fan is running as expected by looking through the perforated guard at the shaft.
    • Check the wiring and duct connections.

    If you hear squealing or screeching noises:

    • There may be a motor or bearing issue.
    Photo of the cooling wind fan motor and housing on a grated platform, with a callout labeled Cooling Wind Fan.
  4. Check the wiring and duct connections.
    • If the cooling wind fan is running but the radar gauges still report high temperatures, physically inspect the cooling wind ducts.
    • Check each duct and connection.