AWT NIZAMPUR CEMENT PLANT

PREVENTIVE MAINTENANCE SCHEDULE OF

OIL FIRING
MAIN/ML/4/025
ISSUE-1
1 of 36
S.NO Detail of Activities 3M 6M Y
1 Check suction /discharge valves
2 Clean the filter of pump
3 Check rotation of motor
4 Check temprature of fuel oil
5 Check alignment of pump/motor
6 Start pump & listen any abnormal sound
7 Check vibration of motor/pump
8 Check foundation of bolts
9 Check pressure /temp of guages
10 Tight gland in case of oil leakage
1 Rotate manually the pump
2 Check alignment of pump/motor
3 Check abnormal noise/vibration of the pump
4 Check foundation of bolts
5 Check all pressure /temp guages
6 Check suction /discharge valves
1 Check suction /discharge valves
2 Rotate pump manually
3 Check noise of pump
4 Check vibration of motor/pump
5 Check pressure /temp of guages
1 Check suction /discharge valves
2 Rotate pump manually
3 Start pump & listen any abnormal sound
4 Tight foundation bolts
5 Check pressure /temp of guages
1 Check alignment of pump
2 Check noise & vibration
3 Check foundation bolts
4 Check pressure guages
5 Check suction /discharge valves
1 Check alignment of pump & motor
2 Check sound of the pump & motor
3 Tight foundation bolts of pump & motor
4 Adjust gland in case of oil leakage
5 Check pressure of pump on pressure guages
6 Check vibration of pump & motor with vibrometer
7 Check temprature of F.O
8 Check amp & volt of motor
9 Clean the filter of pump
10 Check suction /discharge valves
1 Check nozzle of boiler
2 Check fuel adjustment plate
3 Check fuel adjustment wheel
4 Check actuator
5 Check diaphargm valve
6 Check secondary air pressure
Thermal oil Boiler
Low Pressure Unloading Pump
Oil filling up pumps
Fuel oil circulation pumps
Thermal oil ciculation pump
Diesel oil Service pump
High pressure pump
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AWT NIZAMPUR CEMENT PLANT
PREVENTIVE MAINTENANCE SCHEDULE OF
OIL FIRING
MAIN/ML/4/025
ISSUE-1
2 of 36
S.NO Detail of Activities 3M 6M Y
7 Check air damper
8 Check all flexible pipes
9 Check atomizer/orifice plate
10 Check overall working of boiler compressor
11 Check exhaust gas analysis
12 Check CO,O2,O/O with orsat operator
13 Check inside condition of boiler
14 Check inlet /out let pressure
15 Check fuel pump pressure
16 Check all the valves
17 Check cleaning of boiler
1 Check oil storage tanks no.1 & 2
2 Check main supply & discharge valve
3 Check overall condition of suction heater
4 Check all temprature guages
5 Check all pressure guages
6 Check oil storage float guage
7 Check heat exchanger & cleaner
8 Check fuel oil circulation loop
9 Check all thermal oil valves
10 Check all fuel oil valves
11 Check all pipelines
12 Check all valves of the thermal oil of the system
13 Check all fuel oil valves of the system
14 Check H.E valves
Signature of DM/AM/JO:_________________________________
Area Equipment
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AWT NIZAMPUR CEMENT PLANT
PREVENTIVE MAINTENANCE SCHEDULE OF
WATER SUPPLY
MAIN/ML/4/026
ISSUE-1
3 OF 36
S.NO Detail of Activities 3M 6M Y
1 Bridge welding ,supports,foundation,intake wall structure
1 Vibration,temprature,gland adjustment
2 Delevery pressure check
3 Amp of motor & voltage
4 Check all valves at intake well
5 Tightening of bolts
6 Inspection of pipe line from intake well to treatment station
7 Flush the line
1 Check the sand of filter bed efficiency
2 Check the sealing of storage ,tank,crank/foreign matter
3 Check presettling tank accumulation level
4 Check sedimantation tank accumulation level
1 Temprature of pump & motor
2 Check the pressure
3 Check the Amp/Voltage
4 Check the vib,noise,alignment
5 Cleaning the suction valve
1 Check the pressure ,voltage,amp
2 Check the vib,noise,temprature
3 Check the suction valve
1 Temprature of pump & motor
2 Check pressure ,gland,pusher adjustment
3 Check ampere& voltage
4 Check vib,noise,alignment
5 Check water cleaning by P.filter
6 Temprature of supply and return
7 Gate valve,pressure guages/leakage
8 Check the pipe line in/out of pressure filter & cooling tower
9 Check the pump foundation bolts
10 Check the butter fly & NR valve
11 Check the pipe line supply and return of plant
12 Check the hot & cold water tank crack ,bottom,sealing,forwegin mater
1 Check spray & cleaning of spray nozzle
2 Check ampere,voltage,noise
1 Check temp,pump & motor
2 Check pressure & gland adjustment
3 Check amp,voltage
4 Check vibration ,noise
5 Pressure guages of suc/dis valve
6 Check the cooling tower spray nozzle
7 Check pipe line to crusher
1 Check temp of pump & motor
2 Check pressure & gland adjustment
3 Check amp,voltage
4 Check vibration ,noise alignment
Water pump for alum
Recirculation Pump Station
Cooling Tower
Crusher Pump
Intake Well
Turbine at intake well
Treatment Station
Back wash pump
Raw Mill
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AWT NIZAMPUR CEMENT PLANT
PREVENTIVE MAINTENANCE SCHEDULE OF
WATER SUPPLY
MAIN/ML/4/026
ISSUE-1
4 OF 36
S.NO Detail of Activities 3M 6M Y
Intake Well 5 Inspection of all kinds of valve N.R.V etc
6 Check the pressure guages
1 Check temp of pump & motor
2 Check pressure & gland adjustment
3 Check amp,voltage
4 Check vibration ,noise alignment
5 Inspection of all kinds of valve N.R.V etc
6 Check the pressure guages
1 Check temp of pump & motor
2 Check pressure & gland adjustment
3 Check amp,voltage
4 Inspection of all kinds of valve N.R.V etc
Check the pressure guages
1 Check the pipe lines,valves,pressure guages etc
1 Check temp of pump & motor
2 Check pressure & gland adjustment
3 Check amp,voltage
4 Inspection of all kinds of valve N.R.V etc
Check the pressure guages
1 Check the pipe line ,valve,pressure guages
1 Check the pipe line all kinds of valves,pressure guages
Signature of DM/AM/JO:__________________________
Cooler pump station
Compressor Station
W/Supply line of C.Mill,P.Plant
Condition tower pump station
Preheater pump 15 CW
Kiln Area
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AWT NIZAMPUR CEMENT PLANT
PREVENTIVE MAINTENANCE SCHEDULE OF
CRUSHER AREA
MAIN/ML/4/019
ISSUE-1
5 of 3
S.NO Detail of Activities 3M 6M Y
1 Dismentle cover of drive & driven shafts bearings ,clean ,check roller
bearings & re-fill grease .Record bearing clearance
2 Check /measure driven wheel wear rebuild if required
3 Check magnetic plug of drive unit if metal pieces are found analyse the
nature of particles ,if suspected for excessive wear of gear teeth or bearing
,dismentle gear & fixed out wear part & replace if necessary
4 Check coupling allignment & realign/record dated
5 Check chain links,pins/replaced,repair report to arrange spares
6 Check bearing of roller /replace if required
7 Replaced worn out rolers,prepare report for spare arrangement
8 Replace oil of gear box /flash before refill
9 Replace worn out chutes /lining plates
10 Check & measure apron plates thickness & record
11 Check the shaft levels(Drive,driven re-adjust if required)
12 Replace oil of planetary gear box
1 Reverse hammers
2 Check main bearing.Clean & measure clearance & fill oil
3 Check feed roller bearings by opening covers record clearance for bearing
and shaft clean & re-fill
4 Check rubber pads & plates for feed rollers if damaged replace
5 Check rubber pads & counter weight system ,if necessary replace pad &
repair weight system
6 Check rubber coupling and pins of main motor /main shaft
7 Replace hammers
8 Replace shaft seals (main shaft,feed roller shaft)
9 Dismantle motor cooling fan clean all the filters ,bearings checking
10 Check hydraulic oil system /operate
11 Clean hydraulic oil pi[pes fitting fill new oil
12 Clean feed roller gear box,beariong housing fill new oil,/replace seals if
required
13 Replace impact plates
14 Replace grate plates
15 Replace feed roller liners
16 Clean oil pipe of motor bearing ,oil station ,valves,fitting ,fill new oil
17 Replace shell inner plates (alternative year)
18 Adjust impact plates & grate plates carriage initial position
19 Repair all the chutes ,fix new liner
1 Dismenle cover of drive & driven shafts bearings ,chain ,check roller bearing
& refill grease ,Record bearing clearance
2 Check /measure driven wheel wear rebuild ,if required
3 Check magnetic plug of drive unit if metal pieces are found analyse the
nature of particles ,if suspected for excessive wear of gear teeth or bearing
dismentle gear & replace worn out paqrts ,record observations
4 Check coupling alignment /relign record data
5 Check chain links ,pins in detail prepare report to arrange spare '
6 Check bearing of roller /replace if required
7 Replace worn out rollers .Prepair report for spare arrangement
8 Replace oil of gear box & planetry gear box
9 Replace worn out chutes/links
10 Check /measure apron plates thickness,record,prepare note for spare
plates required
Apron Feeder(Limestone)(02.01)
Hammer Crusher(02.03)
Apron Feeder (Shale)(02.02)
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AWT NIZAMPUR CEMENT PLANT
PREVENTIVE MAINTENANCE SCHEDULE OF
CRUSHER AREA
MAIN/ML/4/019
ISSUE-1
6 of 3
S.NO Detail of Activities 3M 6M Y
Apron Feeder(Limestone)(02.01) 11 Check the shaft level drive,driven adjust,if required
12 Clean grease tank & grease pipes completely & fill new grease
13 Replace grease pumps washers & O rings ,also overl haul grease distributor
14 Replace bearings of grease tank shaper
15 Fix new plunger of grease pumps II.
1 Check bearings of all the drums by opening covers
2 Replace chutes/liners(both ends)
3 Check pull wire rope for proper operation
4 Replace worn out rollers
5 Replace (both parts damaged with new belt pieces hot vulcanizing
6 Replace rubber liners of drums
7 Replace coupling pins /rubbe rof drum/gear box & check alignment
8 Check oil level of gear box
9 Check sound/vib/temp oil leakage of gear shafts
10 Replace oil of gear box
11 Replace oil seals /worn out bearings /parts
12 Over haul oil pump ,replace worn out parts seals ,O ring bearings etc
13 Machine brake drum(if required)
14 Clean magnetic plug
1 Replace liners of chute if required
2 Replace oil gear box
3 Replace coupling pins ,bushes & re-align
4 Clean all the bearing /replace ,if required
1 Remove all the bags ,clean & re-fix,replace worn out bags
2 Check impeller of fan ,if worn out replace
3 Replace worn out coupling pins & connecting rods
4 Replace fan bearings
5 Replace all the bags
1 Check bearing of all the drum by opening covers of the bearings,check
clearance ,record observation ,refill grease ,if required replace bearings
2 Replace chutes/liners(both ends)
3 Replace worn out rollers
4 Replace (both parts damaged with new belt pieces hot vulcanizing
5 Replace rubber liners of drums
6 Replace coupling pins/bushing of drum gear box & check alignment
7 Replace oil of gear box
8 Replace oil seals /worn out bearings /parts
9 Over haul oil pump ,replace worn out parts
10 Machine brake drum(if required)
11 Check alignment of fluid coupling & motor
12 Replace rubber bushing of fluid coupling
13 Replace oil of fluid coupling
14 Clean magnetic plug
1 a)Check & record condition of wheels bearing & pins ,replace if damaged
I)Traveling wheels 8No.
ii)Pressing wheel ! No
iii)Driving drum & tail drum of boom belt conveyor
iv)Boom belt pivot bearings
b)Clean oil unit of hydraulic system& refill
Belt Conveyor(02.04)
Bag Filter(Uni-Type)(02.12)
Belt Conveyor(05.01)
Stacker(05.02)
Long Belt Conveyor(02.09)
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AWT NIZAMPUR CEMENT PLANT
PREVENTIVE MAINTENANCE SCHEDULE OF
CRUSHER AREA
MAIN/ML/4/019
ISSUE-1
7 of 3
S.NO Detail of Activities 3M 6M Y
Apron Feeder(Limestone)(02.01) c)Clean all the oil pipes ,valves,fitting.Replace worn out "O"rings
d)Replace bearings of cable real drum
e)Repair/inspect cable real gear box motor ,clutch system
2 Replace oil of fluid coupling of:
a)Driving system
b)Belt conveyor gear box
c)Boom belt conveyor gear box
d)Brake pump/actuator unit of driving system
3 a)Replace belt boom belt conveyor
b)Repair /rebuild/replace traveling wheels
c)Clean/ Check hydraulic jack
d)Adjust counter weight system of boom belt conveyor
e)Check oil pumps of hydraulic system,replace worn out parts I.e gears
plates,seals etc
Signature of AM/JO(Crusher):_______________________
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AWT NIZAMPUR CEMENT PLANT
PREVENTIVE MAINTENANCE SCHEDULE OF
CRUSHER AREA
MAIN/ML/4/019
ISSUE-1
8 of 3
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AWT NIZAMPUR CEMENT PLANT
PREVENTIVE MAINTENANCE SCHEDULE OF
CRUSHER AREA
MAIN/ML/4/019
ISSUE-1
9 of 3
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AWT NIZAMPUR CEMENT PLANT
PREVENTIVE MAINTENANCE SCHEDULE OF
CRUSHER AREA
MAIN/ML/4/019
ISSUE-1
10 of 3
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MAIN/ML/4/024
PREVENTIVE MAINTENANCE SCHEDULE Issue-1
(Compressors) 1 of 1
S.NO Detail of Activities
1 2 3 1 2 3
1 Check all pressure ,temp guages etc
2 Oil filter cleaning
3 Tightening of all kinds of bolts
4 Tightening of motor foundation bolts
5 Air filter cleaning
6 Check water cooling system leakage/valves
without dismentling
7 Check V-belt tension /alignment
8 Clean intake & discharge valve
9 Check lubricant change if necessary
10 Check silencer & air filter
11 Check performance of compressor
12 Check mirror surface of cylinder
13 Check guide ring change if necessary
14 Check piston ring
15
Check radia fit clearance between connection rod
big end bushing & crank journal
16
Check wear tear of connecting rod small end
sleeve & cross head pin
17 Cleaning of water cooler,cooling jacket
18 Chenge lubrication in frame ,clean oil receiver
19 Check all parts wear /tear
20 Remove water scale from all parts
21 Clean oil filter/oil filter screen
Eq.No:02.07(compressor)
Crusher Area
1 Oil filter clean/check
2 oil change (oil change after 2500 Hrs)
Qty=35 Ltr,Grade=AWS-68 Hyspin
4 Oil filter clean/check
5 Oil filter change(10 M)
change of oil filter after 10000 Hrs(5 years)
6 Air filter clean/check
Air filter change
7 Overall efficiency of compressor
check full pressure development
8 Check vibration of both end bearing
9 Separation tank
Check liquid carry over to check efficiency
10 Radiator check & clean
Check safeties of compressor
Signature of DM/AM/JO:_______________________
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Remarks
C.Mill(compressor) Kiln(compressor)
AWT NIZAMPUR CEMENT PLANT
3M 6M Y
AWT NIZAMPUR CEMENT PLANT
PREVENTIVE MAINTENANCE SCHEDULE OF
PACKING PLANT
MAIN/ML/4/023
ISSUE-1
12 OF 36
S.NO Detail of Activities 3M 6M Y
1 Motorised Gate
Internal inspection of gear reducer
Condition of cam rod(replace if required)
2 Air operated Gate (Pneumatic)
Cylinder condition
Screw gate inspection(inside)
3 Air Slide Gate
Canvas inspection
Replacement of canvas & thorough inspection of gate
1 Internal inspection of geared motor
2 Clean & check drive sprockets bearing
3 Clean & check tail sprocket bearings
4 Lubricate drive chains
5 Replacement of rubber joints
1 Clean inlet filters
2 Measure coupling gap/Check alignment
3 Test safety valve by blowing off.Check blower off pressure
4 Check bearing clearance /record
5 Check rotor clearance /record,if required replace bearings
6 Re-align motor & blower
7 Replace rubber bushing of coupling pins
8 Check gear train & oil seals.replace seals if required
9 Replace ment of bearings (particularly ball bearings)
10 Adjustment of rotor clearance
1 Check air chamber of air slide & blower duct for dust /clogging etc
2 Check wear of impeller & record observation
3 Check air slide cloth /replace ,if required
4 Repair all the inlet/outlet chutes
1 Check rotory valve condition
2 Check flag valve movement
3 Check purging system (complete)
4 Inspect bags through toop doors,replace damaged
5 Check jacks & replace damaged seal
6 Check diaphargm valves,replace damaged diaphargm
7 Check welding cracks between air & dust chamber
1 Check condition of buckets & chain
2 Check driving & drivesn sprocket(note down wear)
3 Replace worn out segment of drive sprockets & driven sprocket
4 Replace damaged worn out buckets
5 Check chains for wear & alongation,replace alongated chain(pairs)
6 Replace coupling pins & bushing of motor & gearbox
7 Open top bearing & bottom bush ,clean check condition &replace
8 Replace fluid coupling bearings as per condition
1 Check bearing condition
2 Main frame cracks/condition
3 Mesh condition
4 Inspection /replacement of mesh
Vibrating Screen(Eq.No:26.02)
Silo Discharge Gate(Eq.No:25.23)
Air Distributor(Eq.No:25.17)
Roots Blower(Eq.No:25.18)1,2,3
Air Slides(Eq.No:25.19,25.20)
Bag Filters(Eq.No:25.20,25.21,25.27,26.22)
Bucket Elevator(Eq.No:26.01)
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AWT NIZAMPUR CEMENT PLANT
PREVENTIVE MAINTENANCE SCHEDULE OF
PACKING PLANT
MAIN/ML/4/023
ISSUE-1
13 OF 36
S.NO Detail of Activities 3M 6M Y
Silo Discharge Gate(Eq.No:25.23) 5 Inspection & replacement of bearings
1 Overhauling & inspection of screw gate
1 Internal inspection of gear reducer
2 Rotor inspection
3 Inspection /replacement of sprocket
4 Inspection/replacement of bearings
1 Inspection /replacement of v-belt/w-belt of main G.box &turbine box
2 Inside inspection of drive gear box/replacement of bearing
3 Inspection of main bearing bottom side
4 Pneumatic cylinders
Inspection /replacement of pneumatic cylinderskits I.e through off cylinders
three way cylinder,bag holding cylinder
5 Turbine box
Inspection/cleaning replacement of impeller bearing
Inspection /replacement of seals
Insperction/replacement of impeller
Inspection of impeller shaft(wearness)
Inspection /replacement of bag stool(wear.cut,springs)
1 Check bearing of all the drum by opening covers of the bearings,check
clearance ,record observation,refill grease,if required replace bearings
2 Replace worn out rollers
3 Replace belt with new belt
4 Internal inspection of geared motor
5 Inspect & replace chain& sprocket of drive& drive side
1 Inspect & replace chainif required
2 Inspect & replace sprockets(drive ,driven)
3 Internal; inspection of drive gear box
4 Check condition of rollers(replace if required)
1 Internal inspection of gear box
2 Coupling condition
3 Condition of cutters
4 Inspect & replace v-belt
5 Roller movement /condition
6 Open bearing housing ,inspect and replace bearings if requirwed
1 Inspect & replace sprockets and chain
2 Open bearing housing Check and replace,regrease bearing if required
3 Internal inspection of geared motor
1 Inspection /replacement of belt conveyor
2 Inspection/replacement of bearings
3 Internal inspection of drive system
4 Tooth belt replacement
5 Replaceemnt/inspection drive & driven v-belt pullies
1 Internal inspection of gear box
2 Inspection/replacement of chute chsange mechanism rod
3 Replacement of bearings of teflon rollers if required
Bag Destroyer(Eq.No:26.12)
Roller Conveyor(Eq.No:26.13)
Bag weigh Checker(BWC)(Eq.No:26.14)
Bag transfer Chute(Eq.No:26.15)
Screw Gate(Eq.No:26.04)
Rotory Feeder(Eq.No:26.05)
Roto Packer(Eq.No:26.06)
Belt Conveyor(Discharge & alignment belts)(Eq.No:26.08,26.10)
Bag cleaning device(Eq.No:26.11)
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AWT NIZAMPUR CEMENT PLANT
PREVENTIVE MAINTENANCE SCHEDULE OF
PACKING PLANT
MAIN/ML/4/023
ISSUE-1
14 OF 36
S.NO Detail of Activities 3M 6M Y
Silo Discharge Gate(Eq.No:25.23)
1 Check bearing of all the drum by opening covers of the bearings,check
clearance ,record observation,refill grease,if required replace bearings
2 Replace worn out rollers
3 Replace belt with new belt
4 Replace rubber liner of drum
5 Internal inspection of geared motor
Frame drive system
1 Inside inspection of gear box
2 Inspect/replace chain & sprocket
3 Free travel of conv.& condition of wheels/oil
Belt Conveyor system
1 Check bearing of all the drum by opening covers of the bearings,check
clearance ,record observation,refill grease,if required replace bearings
2 Replace worn out rollers
3 Replace belt with new belt
4 Replace rubber liner of drum
5 Internal inspection of electro drum
Hoisting system
1 Inside inspection of gear box
2 Inspect brake condition
3 Inspect wire rope condition ^& replace if required
4 Inspection of clamps for wire ropes
1 Inspect & over haul hoist mechanism
2 Inspect for working condition& repair if needed
1 Inspect & overhaul hoist mechanism
2 Inspect for working condition& repair if needed
3 Check condition of wire rope
Signature of DM/AM/JO:_______________________________
Manual operated hoist(Eq.No:26.24,26.25)
Electrical operated hoist(Eq.No:26.26)
Belt Conveyor(Eq.No:26.16,26.17)
Mobile Loader Conveyor(Eq.No:26.19)
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AWT NIZAMPUR CEMENT PLANT
PREVENTIVE MAINTENANCE SCHEDULE OF
PACKING PLANT
MAIN/ML/4/023
ISSUE-1
15 OF 36
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AWT NIZAMPUR CEMENT PLANT
PREVENTIVE MAINTENANCE SCHEDULE OF
PACKING PLANT
MAIN/ML/4/023
ISSUE-1
16 OF 36
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AWT NIZAMPUR CEMENT PLANT
PREVENTIVE MAINTENANCE SCHEDULE OF
PACKING PLANT
MAIN/ML/4/023
ISSUE-1
17 OF 36
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AWTAWT NIZAMPUR CEMENT PLANT
PREVENTIVE MAINTENANCE SCHEDULE OF
CEMENT MILL AREA
MAIN/ML/4/022
ISSUE-1
18 OF 36
S.NO Detail of Activities 3M 6M Y
1 Replace belt skirts
2 Replace liners of chute from belt apron
3 Clean all the bearing /replace if required
4 Check complete belt from drive drum side(wear,cut,defects)
1 Replace belt skirts
2 Replace liners of chute from belt apron
3 Clean all the bearing /replace if required
4 Check complete belt from drive drum side(wear,cut,defects)
1 Check jacks operation& replace damaged seal
2 Check rotory valve chain & sprocket chain & sprocket conditions if needed replace
3 Check rotory valve inside condition blades wearness & clearance B/W housing & rotor
4 Check purging system(complete)& replace damaged diaphragms
5 Inspect bags through top doors ,replace damaged bags
6 Remove all the bags,clean & re-fix,replace worn out bags
7 Check main body bolts/welding cracks
8 Inspect blower of dust deposit,if so clean
9 Check impeller of fan,if worn out replace
1 Replace belt skirts
2 Replace liners of chute from belt apron
3 Clean all the bearing /replace if required
4 Check complete belt from drive drum side(wear,cut,defects)
5 Replace rubber bushing/pins if required
6 Replace coupling pins,bushes & re-align
1 Replace belt skirts
2 Replace liners of chute from belt apron
3 Clean all the bearing /replace if required
4 Check complete belt from drive drum side(wear,cut,defects)
1 Check coupling of shaker motor
2 Open bag filter door & inspect from inside,remove all the bags,clean & refix
replace worn out bags
3 Replace V-belts
4 Check rotory valve condition
5 Check roller chain of rotory valve
6 Check main body bolts/welding cracks
7 Check impeller of fan ,if worn out replace
8 Check & replace worn out pins of shaker
1 Check condition of apron feeder ,chain,all bolts ,rollers
2 Check all the lubrication points by dismantling from grease points operate
pump& check flow of grease
3 Dismantle cover of drive & driven shaft bearing ,clean,check roller bearing &
refill grease.record bearing clearance
4 Check shaft level(drive & driven readjust if required)
5 Check/measure drive& driven wheel wear rebuild if required
6 Check coupling alignment & relign/record dated
7 Check chain links,pins/replace ,repair report to arrange spares
8 Replace worn out rollers.Prepare report for spares arrangement
9 Replace worn out chutes /lining plates
Apron Feeder(Eq.No:22.15)
Belt Conveyor(Eq.No:22.07)
Belt Conveyor(Eq.No:22.08)1 & 2
Bag filter (Pulse jet type)(Eq.No:22.09)1,2,3
Belt Conveyor(Eq.No:22.11)
Bag Filter(Uni bag)(Eq.No:22.14)
Belt Conveyor(Eq.No:22.13)
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AWTAWT NIZAMPUR CEMENT PLANT
PREVENTIVE MAINTENANCE SCHEDULE OF
CEMENT MILL AREA
MAIN/ML/4/022
ISSUE-1
19 OF 36
S.NO Detail of Activities 3M 6M Y
Belt Conveyor(Eq.No:22.07) 10 Internal inspection of geared motor
1 Check main bearing ,clean & measure clearance & fill oil
2 Measure & record wear of hammers
3 Check gaps between hammers & grate plates (25 ~ 30mm) adjust if more
4 Reverse hammers if one side has worn beyond range
5 Replace hammers as per condition
6 Replace braker plates if required
7 Replace grate plates if required
8 Replace liner plates (Alternatie year)
9 Replace V-belts if splitting & cracks have been occurred
10 Inspect V-belt pullies wearness of v-grooves etc & alignment
1 Replace belt skirts
2 Replace liners of chute from belt apron
3 Clean all the bearing /replace if required
4 Check complete belt from drive drum side(wear,cut,defects)
1 Check coupling of shaker motor
2 Open bag filter door & inspect from inside,remove all the bags,clean & refix
replace worn out bags
3 Replace V-belts
4 Check rotory valve condition
5 Check roller chain of rotory valve
6 Check main body bolts/welding cracks
7 Check impeller of fan ,if worn out replace
8 Check & replace worn out pins of shaker
1 Check coupling of shaker motor
2 Open bag filter door & inspect from inside,remove all the bags,clean & refix
6 Check main body bolts/welding cracks
7 Check impeller of fan ,if worn out replace
8 Check & replace worn out pins of shaker
1 Adjust belt /replace if damaged
2 Replace rubber skirts & worn out parts
3 Repair hopper /chutes etc
4 Clean rollers and check for abnormal wear & movement
5 Clean bearings of DS & NDS and refill new grease
6 Internal inspection of gear box
1 Adjust belt /replace if damaged
2 Replace rubber skirts & worn out parts
3 Repair hopper /chutes etc
4 Clean rollers and check for abnormal wear & movement
5 Clean bearings of DS & NDS and refill new grease
6 Internal inspection of gear box
1 Check coupling of shaker motor
2 Open bag filter door & inspect from inside,remove all the bags,clean & refix
replace worn out bags
3 Replace V-belts
4 Check rotory valve condition
5 Check roller chain of rotory valve
Hammer Crusher(Eq.No:22.16)
Belt Conveyor(Eq.No:22.17)
Bag Filter(Uni bag)(Eq.No:22.18)
Bag Filter(Uni bag)(Eq.No:22.20)
Weighing Feeder(Eq.No:24.01)
Weighing Feeder(Eq.No:24.02)
Bag Filter(Uni bag)(Eq.No:24.03)
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AWTAWT NIZAMPUR CEMENT PLANT
PREVENTIVE MAINTENANCE SCHEDULE OF
CEMENT MILL AREA
MAIN/ML/4/022
ISSUE-1
20 OF 36
S.NO Detail of Activities 3M 6M Y
Belt Conveyor(Eq.No:22.07) 6 Check main body bolts/welding cracks
7 Check impeller of fan ,if worn out replace
8 Check & replace worn out pins of shaker
1 Check drive mechanism I.e geared motor ,roller chain,sprockets
2 Clean all the bearing /replace if required
3 Check complete belt from drive drum side(wear,cut,defects)
4 Check magnetic mechanism for functioning
5 Replace sprockets & roller chain
1 Check ,record,chains for wear & elongation,replace elongated chain(pairs)
2 Replace coupling pins & bushing of motor & gear box
3 Open top & bottom bearing ,clean ,check condition and replace if required
4 Thoroughly inspect the casing for leakage & wear etc
5 Replace deformed/de-shaped buckets
6 Internal inspection of gwear box
7 Check condition of drive & driven wheel & note down wear rebuild if necessary
1 Replace belt skirts
2 Replace liners of chute from belt apron
3 Clean all the bearing /replace if required
4 Check complete belt from drive drum side(wear,cut,defects)
5 Check functioning of magnetic detector for metal pieces
1 Internal inspection of hydraulic pump
2 Clean all hydraulic filters
3 Inspection of hydraulic pump coupling
4 Check pressure guages for crrect functioning
5 Check both rollers of DS & NDS .Clean and refill the grease
1 Check v-belt condition(splitting ,cracks etc)if required replace
2 Gear box inside inspection
3 Roller lubrication condition
4 Inspect main bearing of both rollers DS & NDS .clean and refill grease
5 Check centralised lubricating system
1 Check condition of clutch by engaging and disengaging in stoppage
2 Internal inspection of gear box(bearings,gear contact,pinion position etc)
3 Check functioning of hydraulic brake ,check leather liner replace if required
4 Check pins,bushes & alignment of coupling
5 Replace coupling pins & bushing of motor & gear box
1 Check tooth contact of gears & pinion condition
2 Check bearings condition & note contact angle for metal bearings
3 Check coupling of gear box and mill
4 Check alignment of torsion shaft
1 internal inspection of mill of both chamber & check
I)Shell liner.ii)Diaphragm platesiii)Side liner at inlet & discharge side
Replace damaged /crack liner & diaphragm plates
2 Check all bolts of liner ,if loose ,tight
1 Clean oil cooler(insummer season twice in a year)
Belt Conveyor(Eq.No:24.08)
Roller Press(Eq.No:24.10)
Rollers Drive System
Cement Mill (Eq.No:24.12)
Magnetic Separator(Eq.No:24.05)
Bucket Elevator(Eq.No:24.07)
Auxiliary Drive
Mian Gear Box
Mill Shell
Lubrication Unit(Turnion bearings & main gear box)
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AWTAWT NIZAMPUR CEMENT PLANT
PREVENTIVE MAINTENANCE SCHEDULE OF
CEMENT MILL AREA
MAIN/ML/4/022
ISSUE-1
21 OF 36
S.NO Detail of Activities 3M 6M Y
Belt Conveyor(Eq.No:22.07) 2 Overhaul the lubrication pumps of both oil station low pressure & HP pump
3 Check coupling condotion of lubrication pumps & replace bush if required
4 Check functioning of all P& T guages installed at lubrication pump station
5 Valves/valve wheels condition for operation
1 Check air slide cloth/replace if required and record observation for next year
2 Sealing of joints tightening of bolts
3 Clean air chamber from dust deposit
4 Check wear of impeller & record observation
1 Check ,record,chains for wear & elongation,replace elongated chain(pairs)
2 Replace coupling pins & bushing of motor & gear box
3 Open top & bottom bearing ,clean ,check condition and replace if required
4 Thoroughly inspect the casing for leakage & wear etc
5 Replace deformed/de-shaped buckets
6 Internal inspection of gwear box
7 Check condition of drive & driven wheel & note down wear rebuild if necessary
1 Check air slide cloth/replace if required and record observation for next year
2 Sealing of joints tightening of bolts
3 Clean air chamber from dust deposit
4 Check wear of impeller & record observation
1 Inspection of coupling(pins,bushes etc)
2 Gear box inside inspection(Bearings,gears,pinion etc)
3 Check movement of double flap gate
4 Inside inspection of O-Sepa separator
5 Wearness of guide vanes& moveable blades,inside body condition
6 Check detached & worn ceramic liner,fix new liners
7 Inspection of inside bearing ,clean and refill grease
8 Inspection of both lower dampers wearness of blades
9 Check opening closing of louver dampers ,if jam remove the fault
1 Internal inspection of rotory valve
2 Check drive chain & sprocket condition of rotory valve
3 Replace drive chain
4 Replace bearings if required
1 Replace belt skirts
2 Replace liners of chute from belt apron
3 Clean all the bearing /replace if required
4 Check complete belt from drive drum side(wear,cut,defects)
1 Check mechanical mechanism of weigh scale & repair if needed
1 Replace belt skirts
2 Replace liners of chute from belt apron
3 Clean all the bearing /replace if required
4 Check complete belt from drive drum side(wear,cut,defects)
1 Check purging system (complete)
2 Inspect bags through top doors replace damaged bags
3 Remove all the bags ,clean ,& refix ,replace worn out bags
4 Check jacks operation and replace damaged seal
Air Slide & fan(Eq.No:24.14,24.15)
Bucket Elevator(Eq.No:24.17)
Air Slide & fan(Eq.No:24.18,24.19)
O-Sepa air separator(Eq.No:24.20)
Bag filter (Pulse jet type)(Eq.No:22.29)
Rotory Valve(Eq.No:24.24)
Belt Conveyor(Eq.No:22.25)
Weigh Scale(Eq.No:24.26&24.28)
Belt Conveyor(Eq.No:22.27)
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AWTAWT NIZAMPUR CEMENT PLANT
PREVENTIVE MAINTENANCE SCHEDULE OF
CEMENT MILL AREA
MAIN/ML/4/022
ISSUE-1
22 OF 36
S.NO Detail of Activities 3M 6M Y
Belt Conveyor(Eq.No:22.07) 5 Check diaphragm valves,replace damaged diaphragm
6 Check main body bolts/welding
7 Check canvas condition
8 Inspect blower for dust deposit,if so clean
9 Check impeller of air slide fan ,if worn out replace
10 Check discharge flap gate for proper functioning
1 Sealing of joints tightening of bolts
2 Check lower suction of air slide & blower duct for dust /clogging etc
3 Check wear of impeller & record observation
1 Inspect impellerr for wear /clogging
2 Check all the flange for sealing & tightening of bolts
3 Check/calibrate flap dampers,record,indicate valve and actual
4 Check alignment of coupling ,motor&fans&record
5 Replacement coupling bushes/pins
6 Check suction & delivery ducts for clogging ,choking,sticking of material
7 Repair all the water valves,glands etc
1 Check air slide cloth/replace if required and record observation for next year
2 Sealing of joints tightening of bolts
3 Clean air chamber from dust deposit
4 Check wear of impeller & record observation
1 Check rotory valve chain& sprocket
2 Check purging system (complete)
3 Inspect bags through top doors replace damaged bags
4 Remove all the bags ,clean ,& refix ,replace worn out bags
5 Check jacks operation and replace damaged seal
6 Check diaphragm valves,replace damaged diaphragm
7 Check main body bolts/welding
8 Inside inspection of impeller of BF fan
9 Check bearing of fan & rotory valve,clean,refill with fresh lubricant
1 Inspect sealing of all joints ,tight bolts
2 Check sealing of inspection doors
3 Check butterfly valve for its quick functioning
4 Inspect air & meal feed pipes wear/blockage etc
5 Inspect lower chamber of air lift for leakage ,back flow material etc
6 Check canvas cloth
1 Re-align motor & blower
2 Replace rubber bushing of coupling pins
3 Check gear train & oil seals ,replace oil seals,if required
4 Replacement of bearings(particularly ball bearings)
5 Adjustment of rotor clearance
6 Replacement of filtering media of air filters
1 Check jacks operation
2 Rotory valve chain
3 Rotory valve sprocket
4 Check rotory valve condition
5 Check purging system (complete)
6 Inspect bags through top doors replace damaged bags
Fan(Eq.No:24.30)
Mill Fan(Eq.No:24.31)
Air Slide & fan(Eq.No:24.32,24.33)
Bag filter (Pulse jet type)(Eq.No:24.35)
Air Lift(Eq.No:25.01)
Roots Blower(Eq.No:25.02)1 & 2
Bag filter (Pulse jet type)(Eq.No:25.04)
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PREVENTIVE MAINTENANCE SCHEDULE OF
CEMENT MILL AREA
MAIN/ML/4/022
ISSUE-1
23 OF 36
S.NO Detail of Activities 3M 6M Y
Belt Conveyor(Eq.No:22.07) 7 Remove all the bags ,clean ,& refix ,replace worn out bags
8 Check jacks and replace damaged seals
9 Check diaphragm valves,replace damaged diaphragm
10 Main body bolts/welding
11 Inspect blower for dust deposit,if so clean
12 Check impeller of fan,if worn out ,replace
1 Check air slide cloth/replace if required and record observation for next year
2 Sealing of joints tightening of bolts
3 Clean air chamber from dust deposit
4 Check wear of impeller & record observation
1 Check jacks operation & replace damaged seals
2 Check rotory valve chain& sprocket & replace if required
3 Check purging system (complete) & replace damaged diaphragm
4 Inspect bags through top doors replace damaged bags
5 Remove all the bags ,clean ,& refix ,replace worn out bags
6 Check main body bolts/welding
7 Inspect blower for dust deposit,if so clean
8 Check impeller of fan,if worn out ,replace
9 Check screw conveyor & its bearings,clean refill new grease(in case of 25.06)
10 Internal inspection of geared motor of discharging device screw conveyor Eq#25.06
1 Check manual gate for smooth functioning
2 Check mechanical system of motorised gate repair if necessary
Signature of AM/JO(C.Mill):_____________________________
Air Slide & fan(Eq.No:25.08,25.09)
Bag filter (Pulse jet type)(Eq.No:25.06 & 25.10, 1 & 2))
Silo top gates at silo # 1,2,3
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AWT NIZAMPUR CEMENT PLANT
PREVENTIVE MAINTENANCE SCHEDULE OF
KILN AREA
MAIN/ML/4/021
ISSUE-1
24 of 36
S.NO Detail of Activities 3M 6M Y
1 Check & record safety valve operation
2 Replace V-belts & re-align
3 Overhauling of roots blower
a)Check bearing clearance &condition,replace if required
b)Check rotor clearance & record
c)Dismantle roots blower drive cover & check gear train & bearings
d)Adjust rotor clearance if required
4 Change oil
5 Clean all the air pipes & motorised valves
6 Re-align motor & blower
7 Replace rubber bushing of coupling pins
1 Check drive sprockets bearing
2 Check tail sprockets bearings
1 Clean/inspect compressed air lines
2 Check/repair pneumatic jack
1 Check wear of impeller & record observation
2 Check air slide cloth/replace if required
3 Repair all the inlet/outlet chutes
1 Condition of buckets & chain
2 Driving sprocket(note down wear)
3 Replace worn out segment of drive sprocket & driven sprocket
4 Replace damaged worn out buckets
5 Check,chains for wear & elongation,replace elongated chain(pairs)
6 Replace oil of drive unit
7 Replace coupling pins & bushing of motor & gear box
8 Open top & bottom bearing ,clean,check condition and replace
1 Check wear of impeller & record observation
2 Check air slide cloth/replace if required
3 Repair all the inlet/outlet chutes
1 Clean/inspect compressed air lines
2 Check /repair pneumatic jack
1 Check & record safety valve operation
2 Replace V-belts & re-align
3 Overhauling of roots blower
a)Check bearing clearance &condition,replace if required
b)Check rotor clearance & record
c)Dismantle roots blower drive cover & check gear train & bearings
d)Adjust rotor clearance if required
4 Change oil
5 Clean all the air pipes & motorised valves
6 Re-align motor & blower
7 Replace rubber bushing of coupling pins
8 Clean suction filter of roots blower in every planned shut down
1 Check rotory valve condition
2 Check flap valve movement
Feed bin Discharge Gate(Eq.No:13.24)1 & 2
Roots Blower(Eq.No:13.25)
Pulse Jet bag filter(Eq.No:13.26)
Roots Blower(Eq.No:13.14)1 & 2.(13.13)1 & 2
Air Distributor(Eq.No:13.15)
Silo extraction gate(Eq.No:13.16)1 & 2
Air Slide(Eq.No:13.17,13.18,13.19)
Bucket Elevator(Eq.No:13.20)1 & 2
Air Slide(Eq.No:13.21,13.22)
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AWT NIZAMPUR CEMENT PLANT
PREVENTIVE MAINTENANCE SCHEDULE OF
KILN AREA
MAIN/ML/4/021
ISSUE-1
25 of 36
S.NO Detail of Activities 3M 6M Y
Roots Blower(Eq.No:13.14)1 & 2.(13.13)1 & 2 3 Check purging system (complete)
4 Inspect bags through top doors,replace damaged
5 Check jacks and replace damaged seal
6 Check door sealing ,replace if required
7 Check diaphragm valves ,replace damaged diaphragm
8 Check welding cracks between air and dust chamber
1 Check suction of fan for clogging etc
2 Check air chamber of air slide & blower duct for dust/clogging etc
3 Check wear of impeller & record observation
4 Check air slide cloth/replace if required
5 Repair all the inlet/outlet chutes
1 Inspect canvas cloth & screen on the cloth
2 Inspect air & meal feed pipes wear/blockage etc.replace /repair
3 Inspect blower chamber of air lift for leakage ,back flow material etc
1 Check & record safety valve operation
2 Replace V-belts & re-align
3 Overhauling of roots blower
a)Check bearing clearance &condition,replace if required
b)Check rotor clearance & record
c)Dismantle roots blower drive cover & check gear train & bearings
d)Adjust rotor clearance if required
4 Change oil
5 Clean all the air pipes & motorised valves
6 Re-align motor & blower
7 Replace rubber bushing of coupling pins
1 Check rotory valve condition
2 Check flap valve movement
3 Check purging system (complete)
4 Inspect bags through top doors,replace damaged
5 Check jacks and replace damaged seal
6 Check door sealing ,replace if required
7 Check diaphragm valves ,replace damaged diaphragm
8 Check welding cracks between air and dust chamber
1 Check suction & delivery ductfor clogging ,choking etc
2 Check all the flanges for seal & tightening of bolts
3 Inspect bearings by removing covers,measure clearance,recrd observations
measurement
4 Check motor & fan alignment & record
5 Replace coupling bushes
6 Replace oil station oil
7 Clean all the station pipes,valves,filter tank etc
8 Replace fan bearing /motor bearings(Depending on condition)
9 Check flap damper for wear & rwepair
10 Check wear impeller ,do hard sufring if required
1 Check & record pinion ,girth gear ,rod clearance &backlash,record
2 Clean all the pipes & valves of oil station of thrust roller
3 Replace oil of oil station
4 Replace oil filter
Roots Blower(Eq.No:13.33)1 & 2
Air Slide(Eq.No:13.29,13.30)
Air Lift(Eq.No:13.32)
Pulse Jet bag filter(Eq.No:13.34)
Kiln IDF(Eq.No:15.03)
Kiln(Eq.No:15.06)
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PREVENTIVE MAINTENANCE SCHEDULE OF
KILN AREA
MAIN/ML/4/021
ISSUE-1
26 of 36
S.NO Detail of Activities 3M 6M Y
Roots Blower(Eq.No:13.14)1 & 2.(13.13)1 & 2 5 Check & record tyre & shell gap
6 Inspection of kiln main drive gear box and record observation
7 Check levels of kiln foundation from elevation marks
8 Clean grease pipes,pneumatic cylinders etc
9 Replace wearing parts of inlet seal
10 Replace nose ring liners S.S
11 Clean bearing housing & liner of all the 12 bearings of supporting roller,for
this purpose jack up the kiln ,remove liner and inspect ,record observation
12 Check pins of girth gear ,spring plates replaced if requiored
13 To check kiln alignment perform lead wire test using Dia =3mm
14 Adjust/inspect all supporting roller lubrication tray
1 Internal inspection of drive gear boxes of 1st & 2nd line grate
2 Inspect(during stoppage)and replace if required
I)General condition of moveable &fixed plates particularly 1st three rows of
grate 1st & 1st plates at fan side of each row
ii)Condition of T-bolts
iii)Free movement of carriage wheels
iv)Gap between carriage rail/wheel,if so fix shims under carriage wheel
v)Check chamber sealing/repair,if required
vi)Check all the fastners of fixed girders moveable frames
vii)Check all the grease pipe for roller disconnect & check flow of grease
3 Replace bushing of transmission shafts of 1st stage & 2nd stage
4 Check condition of bearings of transmission shaft,clean &fill new grease
5 Replace oil of 1st & 2nd stage gearbox
6 Replace grate plates of 1st stage(Depending on condition)
7 Inspect & replace outlet grate bars(grizzly bars)
8 Adjust moving frame of 1st & 2nd grate ,put shims under wheel support
9 Inspect hammer for wear & record position
10 Replace/reverse hammer if needed
11 Clean & check bearing of hammer crusher record observation
12 Replace V-belts & re-align
13 Replace moveable & fixed plates depending on condition &fix new T-bolts
14 Replace rails of moveable carriage if worn out
15 Replace liners of chutes
Drag chain of grate cooler
1 Clean bearings,check clearance,record and re-lubricate
2 Replace worn out guide blocks
3 Replace bearing(if required inspect & record)
4 Replace drive/driven sprockets,if required.Record observation for next year
5 Replace drive chain
6 Replace oilof motorized gear box
1 Inspect bearing by opening the covers of bearing housings,clean bearings
measure clearance.Check condition of lock nut & sleeve
2 Replace v-belt
3 Replace(DS & NDS)bearings of cooler fan # 5,6&7
4 Replace drive side bearings of cooler fan # 1,2,3 &4
5 Replace non drive side bearings of cooler fan # 1,2,3&4 after 9month
6 Replace impeller if required & record observation
7 Inspect V-belt pulley condition & replace if requiored
8 Check damper for free movement of all cooler fans
1 Internal inspection of drive gear boxes of 1st & 2nd line grate
Cooler Fans(7 Nos)(Eq.No:15.12 ~ 15.18)
Pan Conveyor(Eq.No:15.25)
Grate Cooler(Eq.No:15.11)
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PREVENTIVE MAINTENANCE SCHEDULE OF
KILN AREA
MAIN/ML/4/021
ISSUE-1
27 of 36
S.NO Detail of Activities 3M 6M Y
Roots Blower(Eq.No:13.14)1 & 2.(13.13)1 & 2 2 Check for completeness/loose,toothed segment and tight retaining nuts
3 Check fixing screw for proper fit (at random)if severalscrew loose, all the
screws have to be retighten of conveying elements
4 Check rollers for smooth run heavy running or jammed,replace jamed rollers
5 Check chain tension & movement of rollers on rail,adjust chain ,if required
6 Check liners of chutes for wear &replace if required
7 Inspect fluid coupling & replace bearings if needed
8 Replace coupling bushes of all couplings
1 Inspect hangers & diffuser plates at inlet
2 Check/remove broken electrodes
3 Fix new hammer/brackets etc for rapping system
4 Check expansion doors for safe operation
5 Check coupling of rapping shaft from inside
6 Check hanger frames for cathode plates & anode for correct distance /adjust
if requirwed
7 Replace oil of rapping devices(all)
8 Replace all the broken /removed electrodes
9 Replace lifting chains of electrode frame
10 Replace bearings of lifting system & pins
11 Insulate/seal all the ducts flanges etc
12 Replace faulty insulator
13 Test and check all the safety instrument & re-calibrate
14 Correct deformed electrical frames and adjust correct distance
1 Check motor gear box & gear box conveyor coupling & record observation
2 Observe bearing condition by opening the covers,measure clearance &
record drive ,driven side
3 Check & record wear of drive & driven drum
4 Check guide blacks of chain(top bottom) and adjust ,if required
5 Adjust chain length,if required
6 Replace oil ofg gear boxes
7 Replace chain assembly complete
8 Replace bearing if required
9 Repair/hard surface drive driven drum
10 Replace /guide blocks
11 Replace bushing of motor gear box coupling
12 Repair worn out parts of conveyor & chutes
1 Remove all the hang bearings,measure size,& record replace all the bearings
2 Replace screw flange bolts/pins(at drive side)
3 Clean bearings both sides record observation replace if required
4 Replace oil of gear box
5 Re-align gear box & motor & conveyor
6 Repair worn out chute/conveyor etc
7 Inspect worms of conveyor for wear record observation for next year
1 Open observation window & fan casing and check for dust deposit on impeller
condition,repair/record observations
2 Open bearing housing ,clean ,inspect bearing,record clearance,replace bearing
3 Replace coupling pins motor & fan
4 Replace lub oil of bearings
5 Re-align motor & fan if required
6 Ep fan hub bolts & wear of impeller should be checked in every planned
Screw Conveyor(Eq.No:15.20)
EP Drag chain
EP Fan(Eq.No:15.21)
Cooler EP(Electrostatic precipitator)(Eq.No:15.19)
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PREVENTIVE MAINTENANCE SCHEDULE OF
KILN AREA
MAIN/ML/4/021
ISSUE-1
28 of 36
S.NO Detail of Activities 3M 6M Y
Roots Blower(Eq.No:13.14)1 & 2.(13.13)1 & 2 shut down schedule
1 Check rotory valve condition
2 Check flap valve movement
3 Check purging system complete
4 Inspect bags through top doors,replace damaged
5 Check jacks and replace damaged seal
6 Check door sealing ,replace if required
7 Check welding cracks between air and dust chamber
Signature of DM/AM/JO:_________________________________
Pulse jet bag filter(Eq.No:22.06)
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PREVENTIVE MAINTENANCE SCHEDULE OF
RAW MILL AREA
MAIN/ML/4/020
ISSUE-1
29 of 36
S.NO Detail of activities 3M 6M Y
1 Cleane & re-lubricate bearing/replace ,if required
I)Traveling wheels
ii)Traveling gears
iii)Rack chain drive system
iv)Rack chain side roller
v)Bridge side rollers
vi)Rack lifting winch
2 Measure & record thickness of drive driven sprocket
3 Replace coupling pins of rack driving system,traveling system& scraper chain drive
4 Replace brake shoes of traveling system
5 Align gear box,motor & driven shafts of :
1)Traveling system
2)Rack drive system
3)Scraper chain drive
6 Replace liners of drop chute
7 Replace oil of fluid coupling of scraper chain
8 Replace oil of traveling system gear box,rack drive system & scraper chain
drive system
9 Repair/adjust cable real drum drive system(4 sets)
10 Replace bearing of cable drum drive /holding shaft & non return bearing
11 Replace scraper chain assembly complete
12 Replace wear parts of all buckets I.e scrapers & harrows
13 Replace buckets as per condition
14 Replace segments of driving/driven sprockets
15 Replace bearings of:
I)Traveling wheels
ii)Rack wheels
iii)Side wheels of racks
iv)Side wheels of bridge
v)Bearings of traveling gears
vi)Check condition of bearings before change
16 Dismantle complete rack chain ,carry out through inspection.if worn or damaged replace
17 Inspect driving sprocket of rack chain if required ,replace
1 Replaace belt skirts
2 Replace oil of gear box
3 Clean all the bearings
1 Check condition of magnetic coil & current.Also check vibration & calibrate with
current
2 Replace /repair worn out tray
3 Replace rubber skirts of chutes
4 Remove all the spring plates,replace broken,/damaged & re-fix with addition of new
plates.Record initial current at various vibration levels
1 Replaace belt skirts
2 Replace oil of gear box
3 Clean all the bearings
Reclaimer (05.03)
Belt conveyor(05.04)
Vibrating feeder(05.10)
Belt conveyor(05.06)
Bag Filter(Uni type)(05.07)
3M:QUARTERLY,6M:6MONTHLY,
Y:YEARLY
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AWT NIZAMPUR CEMENT PLANT
PREVENTIVE MAINTENANCE SCHEDULE OF
RAW MILL AREA
MAIN/ML/4/020
ISSUE-1
30 of 36
S.NO Detail of activities 3M 6M Y
Reclaimer (05.03) 1 Remove all the bags ,clean & re-fix ,replace worn out bags
2 Replace worn out coupling pins & connecting rods
3 Check impeller of fan ,if worn out ,replace
4 Replace fan bearings if required
5 Replace all the bags
1 Remove all the bags ,clean & re-fix ,replace worn out bags
2 Replace worn out coupling pins & connecting rods
3 Check impeller of fan ,if worn out ,replace
4 Replace fan bearings if required
5 Replace all the bags
1 Replaace belt skirts
2 Replace oil of gear box
3 Clean all the bearings
1 Remove all the bags ,clean & re-fix ,replace worn out bags
2 Replace worn out coupling pins & connecting rods
3 Check impeller of fan ,if worn out ,replace
4 Replace fan bearings if required
5 Replace all the bags
1 Replaace belt skirts
2 Replace oil of gear box
3 Clean all the bearings,replace if required
4 Replace liners of chute from belt apron
5 Replace coupling pins,bushes & re-align
1 Remove all the bags ,clean & re-fix ,replace worn out bags
2 Replace worn out coupling pins & connecting rods
3 Check impeller of fan ,if worn out ,replace
4 Replace fan bearings if required
5 Replace all the bags
1 Remove all the bags ,clean & re-fix ,replace worn out bags
2 Replace worn out coupling pins & connecting rods
3 Check impeller of fan ,if worn out ,replace
4 Replace fan bearings if required
5 Replace all the bags
1 Replaace belt skirts
2 Replace oil of gear box
3 Clean all the bearings
1 Replaace belt skirts
2 Replace oil of gear box
3 Clean all the bearings,replace if required
4 Replace liners of chute from belt apron
5 Replace coupling pins,bushes & re-align
Belt conveyor(05.19)
Belt conveyor(05.11)
Bag Filter(Uni type)(05.12)
Belt conveyor(05.13)
Bag Filter(Uni type)(05.14)
Bag Filter(Uni type)(05.15)
Belt conveyor(05.16)
Bag Filter(Uni type)(05.08)
3M:QUARTERLY,6M:6MONTHLY,
Y:YEARLY
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PREVENTIVE MAINTENANCE SCHEDULE OF
RAW MILL AREA
MAIN/ML/4/020
ISSUE-1
31 of 36
S.NO Detail of activities 3M 6M Y
Reclaimer (05.03)
1 Remove all the bags ,clean & re-fix ,replace worn out bags
2 Replace worn out coupling pins & connecting rods
3 Check impeller of fan ,if worn out ,replace
4 Replace fan bearings if required
5 Replace all the bags
6 Replace V-belt if required
1 Check condition of magnetic coil & current.Also check vibration & calibrate with
current
2 Replace /repair worn out tray
3 Replace rubber skirts of chutes
4 Remove all the spring plates,replace broken,/damaged & re-fix with addition of new
plates.Record initial current at various vibration levels
1 Remove all the bags ,clean & re-fix ,replace worn out bags
2 Replace worn out coupling pins & connecting rods
3 Check impeller of fan ,if worn out ,replace
4 Replace fan bearings if required
5 Replace all the bags
1 Replaace belt skirts
2 Replace oil of gear box
3 Clean all the bearings,replace if required
4 Replace liners of chute from belt apron
5 Replace coupling pins,bushes & re-align
1 Remove all the bags ,clean & re-fix ,replace worn out bags
2 Replace worn out coupling pins & connecting rods
3 Check impeller of fan ,if worn out ,replace
4 Replace fan bearings if required
5 Replace all the bags
1 Replaace belt skirts
2 Replace oil of gear box
3 Clean all the bearings,replace if required
4 Replace liners of chute from belt apron
5 Replace coupling pins,bushes & re-align
1 Remove all the bags ,clean & re-fix ,replace worn out bags
2 Replace worn out coupling pins & connecting rods
3 Check impeller of fan ,if worn out ,replace
4 Replace fan bearings if required
5 Replace all the bags
6 Replace v-belt if required
1 Dismantle cover of drive & driven shafts bearing,clean & check roller bearing &
refill grease.Record for clearance
2 Check /measure driven wheel wear rebuild if required
Bag Filter(Uni type)(05.20)
Vibrating feeder(05.23)
Bag Filter(Uni type)(05.29)
Apron feeder(05.05)
Bag Filter(Uni type)(05.24)
Belt conveyor(05.25)
Bag Filter(Uni type)(05.26)
Belt conveyor(05.28)
3M:QUARTERLY,6M:6MONTHLY,
Y:YEARLY
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RAW MILL AREA
MAIN/ML/4/020
ISSUE-1
32 of 36
S.NO Detail of activities 3M 6M Y
Reclaimer (05.03) 3 Check couplin alignment & realign/record dated
4 Check chain links ,pins/replace ,prepair report to arrange spares
5 Check bearing of roller /replace if required
6 Replace worn out rollers.Prepare report for spares arrangement
7 Replace oil of geared motor/flush before refill
8 Replace worn out chutes/lining plates
9 Check and measure apron plates thickness/reccord .Prepare note for spare
plates required
10 Check the shaft levels ,drive ,driven re-adjust if required with addition of new plates
.Record initial current at various vibration levels
1 Replace oil of gear box
2 Adjust belt/replace ,if damaged
3 Replace rubberskirts & worn out parts
4 Repair hopper/chutes etc
5 Inside inspection of gear box
6 Inspect drive & driven roller bearings ,replace if required
1 Replace oil of gear box
2 Adjust belt/replace ,if damaged
3 Replace rubberskirts & worn out parts
4 Repair hopper/chutes etc
5 Inside inspection of gear box
6 Inspect drive & driven roller bearings ,replace if required
1 Replace oil of gear box
2 Adjust belt/replace ,if damaged
3 Replace rubberskirts & worn out parts
4 Repair hopper/chutes etc
5 Inside inspection of gear box
6 Inspect drive & driven roller bearings ,replace if required
1 Replace oil of gear box
2 Adjust belt/replace ,if damaged
3 Replace rubberskirts & worn out parts
4 Repair hopper/chutes etc
5 Inside inspection of gear box
6 Inspect drive & driven roller bearings ,replace if required
1 Check coupling of shaker motor
2 Open bag filter door & inspect from inside
3 Check main body bolts/welding
4 Check impeller of fan ,if worn out replace
5 Check & replace worn out pins of shaker
1 Replaace belt skirts
2 Clean all the bearings,replace if required
3 Replace liners of chute from belt apron
4 Replace coupling pins,bushes & re-align
Weighing Feeder(12.02)
Weighing Feeder(12.03)
Weighing Feeder(12.04)
Weighing Feeder(12.06)
Bag filter(Uni type)(12.07)
Belt conveyor(12.08)
3M:QUARTERLY,6M:6MONTHLY,
Y:YEARLY
Legend:
Activity performed
Activity not performed
AWT NIZAMPUR CEMENT PLANT
PREVENTIVE MAINTENANCE SCHEDULE OF
RAW MILL AREA
MAIN/ML/4/020
ISSUE-1
33 of 36
S.NO Detail of activities 3M 6M Y
Reclaimer (05.03) 5 Check complete belt from drive drum side(wear,cut,defects)
6 Replace rubber bushing /pins if required
1 Replace oil seals & O-rings of oil pumps
2 Inspect flaps of lock vale & repair if worn out
3 Clean control valves & replace "O"-rings
4 Check bearing condition of jacks pivot & record
5 Replace oil of oil station
6 Replace liners of flaps & chutes
7 Replace jack pivot bearings
8 Clean all the oil pipe
9 Repair the jacks for leakage/seals etc
10 Repair oil pumps/I.e side plates/seals etc
1 Clean & inspect impeller of air fan
2 Check & record condition of liners of air nozzle,liners for grinding table and liners
for grinding rollers
3 Replace oil of main motor bearing
4 Inspect the condition of bearing of grinding rollers & record
5 Cleaning of all oil pipes,oil tank,control valves etc,Replace worn out parts
"O"ring seals
6 Replace oil of tension system
7 Replace air sealing fan bearings
8 Clean all the oil lines,valves & filters
9 R%eplace oil, flush gear box reservoir
10 Replace oil seals of pumps
11 Replace coupling pins/bush auxiliary drive
12 Clean pipes,valves,oil tank of classifier oil station
13 Replace oil of classifier oil station
14 Check/repair oil pumps /replace oil seal,"O" ring etc
15 Replace oil of grinding roller
16 Replace oil filter of hydraulic tension system
17 Replace liners of grinding bed,grinding rollers,air duct etc
18 Replace oil filter of classifier oil station
19 Replace bearings of classifier shaft(inspect & record)
1 Inspect of clog/checking sticking of material
2 Check for worn out parts specially Spherical & cone section
3 Replace sealing of observation door
4 Check pressure instruments & pipes
5 Replace /repair wear resistant material(if damaged)
1 Rooter inspection
2 Cleaning/inspection of bearing replace if required
1 Inspect impeller for wear /clogging
2 Check all the flange for sealing & tightening of bolts
3 Check/calibrate flap dampers,record,indicate value & actual
4 Check alignment of couplingmo0tor & fan & record
Cyclone(12.15)
Rotory feeder(12.16)
Mill Fan(12.17)
Feed Gate(12.12)
Loesche Mill(12.13)
3M:QUARTERLY,6M:6MONTHLY,
Y:YEARLY
Legend:
Activity performed
Activity not performed
AWT NIZAMPUR CEMENT PLANT
PREVENTIVE MAINTENANCE SCHEDULE OF
RAW MILL AREA
MAIN/ML/4/020
ISSUE-1
34 of 36
S.NO Detail of activities 3M 6M Y
Reclaimer (05.03) 5 Replace coupling bushes/pins
6 Inspect & clean DS & NDS bearings and refill oil
1 Check lower section of air slide & blower duct for dust/clogging etc
2 Check wear of impeller & record observation
3 Check air slide cloth/replace if required and record observation for next year
4 Repair all the inlet/outlet chutes
1 Blower ,Bearing
2 Check suction of blower for clogging etc
3 Lubricate bearings
4 Check foundation bolts,casing bolts & motor of blower
1 Check correct members of inlet shaking device
2 Check spray nozzle for choking contaminationetc & inlet bend duct
3 Inspection bottom hopper ,checking clean,if required
4 Replace oil of geared motor of screw conveyor
5 Check bearing/replace if requiored & record clearance
6 Remove all the hang bearings ,measure size & record.Replace all the belts
7 Replace screw flange bolts/pins(at drive side)
8 Inspect worms of conveyor for wear ,record observation for next year
1 Remove all the hang bearings ,measure size & record.Replace all the felts
2 Replace screw flange bolts/pins(at drive side)
3 Clean bearings both sides,record observation ,replace if required
4 Replace of gear box
5 Re-align gear box & motor conveyor etc
6 Repair worn out chute/conveyor etc
7 Inspect worms of conveyor for wear ,record observation for next year
1 Inspect hangers & diffuser plates at inlet
2 Check /remove broken electrodes
3 Fix new hammer/brackets etc for rapping system if required
4 Check expansion doors for safe operation
5 Check coupling of rapping shaft from inside
6 Check hanger frames for cathode plates & anode for correct distance/adjust if required
7 Replace oil of rapping devices(all)
8 Replace all the broken /removed electrodes
9 Fix new hammer ,Replace pins when required
10 Replace lifting chains of electrode frame
11 Replace bearings of lifting system & pins
12 Insulate /seal all the ducts flanges etc
13 Test & check all the safety instrument & re-lubricate
14 Correct deformed electrical frames and adjust correct distance
15 Observe bearing condition by opening the covers,measure clearance & record
drive driven side
16 Check & record wear of drive &driven drum
17 Check guide blocks of chain(top bottom)and adjust,if required
18 Adjust chain length,if required
Air Slide(12.18,12.19)
Fan(12.20)
Conditioning tower(16.01)
Screw Conveyor(16.07)
E.P(Raw Mill)(16.03)
3M:QUARTERLY,6M:6MONTHLY,
Y:YEARLY
Legend:
Activity performed
Activity not performed
AWT NIZAMPUR CEMENT PLANT
PREVENTIVE MAINTENANCE SCHEDULE OF
RAW MILL AREA
MAIN/ML/4/020
ISSUE-1
35 of 36
S.NO Detail of activities 3M 6M Y
Reclaimer (05.03) 19 Replace oil of gear boxes
20 Replace chain assembly complete
21 Replace bearings if required
22 Repair/hard surface drive driven drum
23 Replace guide blocks
24 Replace bushing of motor gear box coupling
25 Repair worn out part of conveyor & chutes
1 Open observation window & fan casing and check for dust deposit on impeller &
wear condition,repair /record the observation
2 Open bearing housing,clean,inspect bearing ,record clearance,replace bearing,
if requiered
3 Replace coupling pins motor & gear box
4 Replace lub oil of bearings
5 Adjust flap valve,lubricate
6 Re-align motor & fan if required
1 Replace worn out segment of drive sprockets & driven sprocket
2 Replace damaged worn out buckets
3 Check,record,chains for wear & elongation,replace elongated chain (pairs)
4 Replacve oil of drive unit
5 Replace coupling pins & bushings of motor & gear box
6 Open top & bottom bearing,clean ,check condition and replace(record observation)
1 Remove all the bags ,clean & re-fix ,replace worn out bags
2 Replace worn out coupling pins & connecting rods
3 Check impeller of fan ,if worn out ,replace
4 Replace fan bearings if required
5 Replace all the bags
6 Replace v-belt if required
1 Remove all the hang bearings ,measure size & record.Replace all the felts
2 Replace screw flange bolts/pins(at drive side)
3 Clean bearings both sides,record observation ,replace if required
4 Replace of gear box
5 Re-align gear box & motor conveyor etc
6 Repair worn out chute/conveyor etc
7 Inspect worms of conveyor for wear ,record observation for next year
1 Inspect air filter cloth
2 Inspect air & meal feed pipes wear/blockage etc,replacwe /repair
3 Inspect lower chamber of air lift for leakage,back flow material etc
4 Replace filter cloth
5 Replace/repair worn out pipes
1 Change oil
2 Clean all the air pipes & mootrized valves
3 Re-align motor & blower
4 Replace rubber bushing of coupling pins
Fan(Raw Mill E.P)(16.05)
Bucket Elevator(16.09)
Bag Filter(16.14)
Screw Conveyor(16.08,16.06,16.13)
Air Lift(13.01)
Roots Blower(13.02)
3M:QUARTERLY,6M:6MONTHLY,
Y:YEARLY
Legend:
Activity performed
Activity not performed
AWT NIZAMPUR CEMENT PLANT
PREVENTIVE MAINTENANCE SCHEDULE OF
RAW MILL AREA
MAIN/ML/4/020
ISSUE-1
36 of 36
S.NO Detail of activities 3M 6M Y
Reclaimer (05.03) 5 Check gear train &oil seals.Replace seals,if required
6 Replacement of bearings(particularly all bearings)
7 Adjustment of rotor clearance
1 Check coupling of shaker motor
2 Open bag filter door & inspect from inside
3 Replace v-belt
4 Check rotory valve internal condition I.e liner ,blades etc
5 Check roller chain of rotory valve & replace if required
6 Check main body bolts/welding
7 Check impeller of fan ,if worn out ,replace
8 Check & replace worn out pins of shaker
1 Inspect impeller for wear/clogging
2 Check all the flange for sealing & tightening of bolts
1 Check lower section of air slide & blower duct for dust/clogging etc
2 Check wear of impeller & record observation
3 Check air slide cloth/replace if required and record observation for next year
4 Repair all the inlet/outlet chutes
1 Check lower section of air slide & blower duct for dust/clogging etc
2 Check wear of impeller & record observation
3 Check air slide cloth/replace if required and record observation for next year
4 Repair all the inlet/outlet chutes
1 Inspect impeller for wear/clogging
2 Check all the flange for sealing & tightening of bolts
1 Check jacks operation & replace damaged seal
2 Check rotory valve chain ,sprocket & replace if required
3 Check purging system complete & replace damaged diaphragm
4 Inspect bags through top doors,replace damaged bags
5 Remove all the bags ,clean & re-fix ,replace worn out bags
6 Check main body bolts/welding
7 Inspect blower for dust deposit ,if so clean
8 Check impeller of fan ,if worn out ,replace
9 Check screw conveyor & its bearings,clean refill new grease(in case of 25.06)
10 Internal inspection of geared motor of discharging device screw conveyor Eq # 25.06
1 Inspect impeller for wear/clogging
2 Check all the flange for sealing & tightening of bolts
Signature of DM/AM/JO:________________________________
Fan(13.11)
Air Slide(13.06)
Air Slide(13.08)
Fan(13.09)
Bag filter(Pulse jet type)(13.10)
Bag Filter(Pulse jet type)(13.03)
Fan(13.04)
3M:QUARTERLY,6M:6MONTHLY,
Y:YEARLY
Legend:
Activity performed
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