1. PURPOSE:
To establish the system for the maintenance of electrical equipments and to ensure that the equipments are available continuously for preventive maintenance.
2. SCOPE:
This is applicable to the preventive & breakdown Maintenance of electrical equipment of Foil.
3. DEFINITIONS:
Dy.General Manager - Deputy General Manager Asst.Manager - Assistant Manager
PMI - Preventive Maintenance Incharge I.D. No. - Identification Number
P.M - Preventive Maintenance 4. RESPONSIBILITY:
4.1 Head of department is over all responsible for implementing this procedure. 4.2 Personal performing breakdown maintenance shall not carry out preventive
maintenance.
4.3 Individual responsibilities of specific activities are described here after. 5. PROCESS INPUT:
5.1 Work instruction for carrying out maintenance activities. 5.2 Intimation of breakdown by work order
5.3 P.M.Slippage Record 5.4 P.M.Schedule
5.5 PM Checklist
5.6 P.M.Schedule cum check sheet
A. Preventive maintenance: -Sr.
No. Activity Responsibility Ref. Doc.
1 All the equipments requiring periodic maintenance will be identified and a list will be prepared.
Asst.Manager FQMNT02F01
2 A unique I.D.No. Will be given to them. Asst.Manager FQMNT02F01
3
The frequency of maintenance will be decided on the basis of
• Manufacture recommendation Decided by maintenance Department
Asst.Manager Operation & Maintenance Manual FQMNT02F06 4
The P.M. schedule/P.M.Schedule cum check sheet will be made as per the identified frequency above.
Asst.Manager FQMNT02F06 FQMNT02F18
5
The equipment will be spared and the preventive maintenance will be carried out as per P.M check list/ P.M.Schedule cum check sheet & relevant work instruction.
Asst.Manager/PMI/ Sr.Formen/ Foreman FQMNT02F07, FQMNT02W03, FQMNT02W10, FQMNT02W12 FQMNT02F18, FQMNT02W05 6
The P.M. checklist / P.M.Schedule cum check sheet will be filled up after
completing maintenance. PMI
FQMNT02F07, FQMNT02F18
7
In case of any schedule getting delayed due to any reasons or preventive action if not carried out, should be recorded in the P.M slippage record.
PMI FQMNT02F08
8
Review the P.M. schedule at least Six monthly for types of checks & frequency on the basis of its effectiveness.
Asst.Manager/PMI FQMNT02F03, FQMNT02F04
9 Review the P.M.slippage record monthly & to avoid the frequency of slippage. Asst.Manager/PMI FQMNT02F08
equipment, follow the respective work instruction/Vendor instruction manual and
filled the over hauling check list. Foreman
maintenance manual, FQMNT02W09, FQMNT02W07 FQMNT02F19 11
Operation of DG SET, Circuit breaker, 66KVSwithyard,HT Capacitor bank and power changeover done as per work
instruction. Shift foreman
FQMNT02W01 FQMNT02W02 FQMNT02W04 FQMNT02W08 FQMNT02W11 B. BREAKDOWN: -Sr.
No. Activity Responsibility Ref. Doc.
1 Receiving work order from user department regarding breakdown of any equipment. Shift Incharge 2 Review the problem and allocate the job to
concern person.
Asst.Manager/ Shift Incharge 3 Carry out the breakdown maintenance. As
per work instruction.
Sr.Forman/ Shift
Incharge/Foreman FQMNT02W06 4 Prepare daily breakdown report and sent copy to Dy.GM (Mech) & GM (F&A). Sr.Forman /Foreman FQMNT02F03
5
Prepare monthly breakdown report and sent copy to V.P. (foils), all Deptt. Heads, MIS & PPC.
Sr.Forman
/Foreman FQMNT02F04 7. PROCESS OUT PUTS:
7.1. Continue availability of machine.
7.2. Relevant reports & records of equipments. 7.3 P.M.Slippage Record.
8. PROCESS MONITORING: Sr.
1 Review of P.M. schedule. Six monthly Asst.Manager 2 Review P.M.slippage record. Monthly Asst.Manager
9. RECORDS:
Sr.No. Record No. Record Title Retention period Location authorityDisposal 1 FQMNT02F01 COMPREHENSIVE EQUIPMENT LIST Till the equipment Last ELECTRICAL SHOP FLOOR Dy. General Manager 2 FQMNT02F02 EQUIPMENT HISTORY RECORD Till the equipme nt Last ELECTRICAL SHOP FLOOR, MSDS&ERS Dy. General Manager 3 FQMNT02F03 DAILY BREAKDOWN REPORT Six
Months ELECTRICAL SHOP FLOOR
Dy. General Manager 4 FQMNT02F04 MONTHLY BREAKDOWN REPORT
1Year ELECTRICAL SHOP FLOOR
Dy. General Manager 5 FQMNT02F05 MAJOR BREAKDOWN ANALYSIS REPORT
1Year ELECTRICAL SHOP FLOOR
Dy. General Manager
6 FQMNT02F06 PM SCHEDULE 1Year ELECTRICAL SHOP FLOOR/MSDS
Dy. General Manager
7 FQMNT02F07 FQMNT02F07/ 01 FQMNT02F07/ 02 FQMNT02F07/ 03 FQMNT02F07/ 04 FQMNT02F07/ 05 FQMNT02F07/ 06 FQMNT02F07/ 07 FQMNT02F07/ 08 FQMNT02F07/ 09 FQMNT02F07/ 10 FQMNT02F07/ 11 FQMNT02F07/ 12 FQMNT02F07/ 13 FQMNT02F07/ 14 FQMNT02F07/ 15 FQMNT02F07/ 16 FQMNT02F07/ 17 FQMNT02F07/ 18 FQMNT02F07/ 19 FQMNT02F07/ 20 FQMNT02F07/ 21 FQMNT02F07/ 22 FQMNT02F07/ 23 FQMNT02F07/ 24 FQMNT02F07/ 25 FQMNT02F07/ 26 FQMNT02F07/ 27 FQMNT02F07/ 28 FQMNT02F07/ 29 FQMNT02F07/ 30 FQMNT02F07/ 31 P.M.CHECK LIST:-MILL M50 MILL M51 MILL M52 MILL Q4 MILL Q5 CRANE # 1 CRANE # 2 CRANE # 3 CRANE # 4 CRANE # 5 CRANE # 6 CRANE # 7 CRANE # 8 CRANE # 4A REWIND LINE # 1 REWIND LINE # 2 REWIND LINE # 3 BAILING PRESS ROLL GRINDER ANN. FURNACE # 1 ANN. FURNACE # 2 ANN. FURNACE # 3 ANN. FURNACE # 4 OVEN # 1 OVEN # 2 OVEN # 3 SEPARATOR # 25 SEPARATOR # 26 DOWN ENDER FUME EXH. SYSTEM H G SLITTER 1Year ELECTRICAL SHOP FLOOR/MSDS Dy. General Manager
Approved By: Issued By: Edition No. 01 FQMNT02F07/ 32 FQMNT02F07/ 33 FQMNT02F07/ 34 FQMNT02F07/ 35 FQMNT02F07/ 36 FQMNT02F07/ 37 FQMNT02F07/ 38 FQMNT02F07/ 39 FQMNT02F07/ 40 FQMNT02F07/ 41 FQMNT02F07/ 42 FQMNT02F07/ 43 FQMNT02F07/ 44 M G SLITTER L G SLITTER DOCTOR REWINDER DRY BOND LAM. PRINTING MACHINE EXTRUDER COATER MAIN PUMP HOUSE COOLING TOWER NITROGEN GEN. FIRE HYDRANT W.T.P. VENT. SYSTEM COMP. HOUSE 1 Year ELECTRICAL SHOP FLOOR/MSDS Dy. General Manager
8 FQMNT02F08 P.M.SLIPPAGE RECORD 1Year
ELECTRICAL SHOPFLOOR/ MSDS Dy. General Manager 9 FQMNT02F09 WORK ORDER 3 Month ERS& MSDSECR Q4/Q5,
Dy. General Manager 10 FQMNT02F10 WORK PERMIT 3Month ERS& MSDSECR Q4/Q5,
Dy. General Manager 11 FQMNT02F11 OVERHAULING SCHEDULE 1 Year MSDS / ERS
Dy. General Manager 12 FQMNT02F12 SHIFT LOG BOOK 1YEAR CONTROL Q4/Q5
ROOM Dy. General Manager 13 FQMNT02F13 DAILY ENERGY GENERATION /CONSUMPTION REPORT Six Months MSDS Dy. General Manager 14 FQMNT02F14 STATEMENT SHOWING ENERGY GENERATED & CONSUMED INCLUDING CONSUMPTION OF DIESEL
1Year MSDS Dy. General
Manager
15 FQMNT02F15 DG LOG BOOK 1Year MSDS Dy. General
Manager 16 FQMNT02F16 ANALYSIS OF
MOTOR FAILURE 1Year ERS Dy. General Manager 17 FQMNT02F17 ELECTRICAL POWER CONSUMPTION REPORT 1Year ELECTRICAL SHOP FLOOR Dy. General Manager 18 FQMNT02F18 FQMNT02F18/ 01 FQMNT02F18/ 02 FQMNT02F18/ 03 FQMNT02F18/ 04 FQMNT02F18/ 05 FQMNT02F18/ 06 FQMNT02F18/ 07 FQMNT02F18/ 08 PM SCHEDULE CUM CHECK SHEET: -LT air circuit breaker 66 kv CT, PT, CVT & LA
LT APFC panel, HT capacitor bank & reactor
Battery bank & battery charger 11 kv & 132 kv MOCB 11 kv T.M.G. ACB 11 kv ABB (indoor & outdoor) & Siemens VCB 66 kv Sf6 circuit breaker 22 kv Sf6 circuit breaker 11 kv, 22 kv & 66 kv isolators
1Year MSDS Dy. General
10. REFERENCE :
Sr.No. Document no. Work instruction
1 FQMNT 02W01 OPERATION OF D.G.SET
2 FQMNT 02W02 OPERATION OF 66KV SWITCH YARD
3 FQMNT 02W03 OPERATION AND MAINTENANCE OF BATTERY BANK 4 FQMNT 02W04 OPERATION OF H.T CAPACITOR BANK
5 FQMNT 02W05 OPERATION AND MAINTENANCE OF TRANSFORMER
6 FQMNT 02W06 BREAKDOWN MAINTENANCE
7 FQMNT 02W07 OVER HAULING OF D.C. MOTOR 8 FQMNT 02W08 POWER CHANGE OVER
9 FQMNT 02W09 OVER HAULING OF A.C. SLIPRING MOTOR 10 FQMNT 02W10 MAINTENANCE OF DIESEL GENERATOR 11 FQMNT 02W11 OPERATION OF CIRCUIT BREAKER 12 FQMNT 02W12 PREVENTIVE MAINTENANCE FQMNT02F18/ 12 FQMNT02F18/ 13 FQMNT02F18/ 14 FQMNT02F18/ 15
Power & distribution transformer
415 v, 125 kva DG set Sub- station (monthly)
Sub- station (fortnight) 1Year MSDS Dy. General Manager
19 FQMNT02F19 OVER HAULING
CHECK LIST 3 Years ERS
Dy. General Manager
