POWERCON

MAINTENANCE MANUAL

POWERCON EQUIPMENTS
MANUFACTURERS OF UNIT & BULK MATERIAL HANDLING SYSTEMS.

REGD.OFFICE- GARDENIA CO-OP. HSG. SOC. PHASE -1, BLDG. C1 #22 WADAGON SHERI. PUNE
-411014
WORKS- PLOT NO-182 SECTOR 10, PCNTDA MIDC BHOSARI PUNE -411026
020-27035035 / 09822292753
MAHARASHTRA- INDIA.

SCREW FEEDERS

CLIENT- M/S THYSEEN KRUPP INDUSTRIES

(INDIA) PVT. LIMITED.

CUSTOMER- M/S TATA CHEMEICAL LIMITED.

MITHAPUR –GUJRAT –INDIA.

PROJECT -1X200 TPH CFBC BOILER-HPB 04

SCOPE OF SUPPLY

Design Manufacture and supply of screw feeders and systems for

handling Esp., Lime stone and Cyclone ash.

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MAINTENANCE MANUAL

SWITCH OFF POWER

BEFORE CARRYING OUT ANY

ROUTINE MAINTENANCE

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SAFETY GUIDELINES FOR THE INSTALLATION & MAINTAINENCE OF

POWERCON EQUIPMENTS

RECOMMENDATION FOR REDUCING HAZARDS WHEN INSTALLLING

EQUIPMENT

MOUNTING – Foundations and supports must provide an adequate anchorage

POWERCON’ S machine and any ancillary equipment to which it may be connected.
Subsidence or Subsequent movement of the machine during operation will result in
excessive wear of both haulage chain and casing. Details on identification and the correct
initial alignment of the machine and supports are dealt within detail in the main part of
manual.

LIFTING – Due to the essential bulky nature of most of the component parts
involved in the erection of a plant of this kind, lifting gar will be extensively used. In
correct lifting technique will not only result in damage to the product, but also
possible injury to the operative. Always sling the load correctly using any lifting
points, which may be provided. Never exceed the S. W. L point, which must be
marked on all types of lifting gear.

ELECTRICAL CABLING – all cabling must be carried in a manner, which in all

respects meets the requirements appropriate local and national regulation. Always check
and follow all special requirements demanded by site condition or user specification.
The cross sectional area of cables and wires must be adequate to carry the required
current without raising their temperature above the recommended limit and without
exceeding the allowable voltage drop. Always allow adequate ventilation around the
machine giving special attention to the ambient operating temperature, type of enclosure,
and any other source of heat. All connections, including those of earthen conductors,
must be secured against accidental loosening.

GAURDS - properly designed guard affording complete protecting for all shaft
extensions, couplings and drives are an integral part of all POWERCON Machine. If, by
client’s request, the machine is supplied without drives, the onus is placed upon the client
to supply fit, adequate guarding once the drive is installed. Always isolate the machine
electrically before component, trained person taking al l appropriate precautions to
prevent any accidental contact with the moving parts of the machine must perform
removing any guard and never leave moving parts doors or panels.

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MAINTENANCE MANUAL

CARELESS USE OF THE MACHINERY SUPPLIED ON THIS PLANT CAN PROVE HAZARDOUS

CORRECT INITIAL DESIGN, FOLLOWED BY ACCURATE INSTALLATION AND REGULER

MAINTENANCE WILL ALL COMBINE TO ENSURE THAT ANY POTENTIAL DANGERS
INHERENT IN THIS TYPE OF MACHINE ARE MINIMISED

POWERCON EQUIPMENT HAS REDUCED SOME OF THESE POTENTIAL DANGERS BY

CORRECT DESIGN AND MANUFACTURE. HOWEVER THE INSTALLATION AND
SUBSEQUENT RUNNING OF THIS EQUIPMENT IS VERY LARGELY OUTSIDE OF REDLER
CONTROD. THIS THEREFORE PLACES AN OBLIGATION UPON THE USER TO INSTALL
AND OPERATE THIS PLANT IN SUCH A WAY AS TO MAXIMISE SAFETY AT ALL TIMES.

THE FOLLOWING GUIDELINES HAVE BEEN PREPARED WITH THE FOREGOING IN MIND.
BY READING, AND WHERE APPROPRIATE, ACTING UPON THESE RECOMMENDATIONS
THE CHANCES OF PREVENTING THE OCCURRENCE OF A HAZARDOUS INCIDENCE WILL
BE GREATLY IMPROVED.

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 FUNCTIONING OF EQUIPMENTS.

The POWERCON make conveyors an effective screw feeder must have the inlet filled
at all times. The design of the flight pitches under the inlet will control the product draw
down in the inlet and subsequent product loading in the conveying portion of the housing
after the inlet. There will always be a section of shroud after the inlet. This creates a
round conveying path that the screw draws through. With this round conveying path the
screw can only convey the material that has fallen into the flight pocket in the inlet.
Material flow into the inlet of the screw feeder is also critical. The screw feeder can not
meter material out of the inlet unless the material uniformly fills the flight pockets in the
inlet.

On a screw feeder, product degradation, product compaction and equipment wear are all
considerations. Particular care needs to be taken with the layout of the progressive pitch
flights through the inlet and under the shroud as well as the length and shape of the
displacement pipe sleeve or cone in the inlet section.

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 CONTENTS

A. List of Equipments.
1. Screw Feeder for Handling Cyclone ash.
2. Screw Feeder for Handling Esp. ash.
3. Screw Feeder for Handling Lime Stone.
4. Expansion Joints.
5. Y chute Assembly for Esp. Screw feeder.
6. Slide gates.

B. Technical Specifications of Indidual Equipments.

1. Screw Feeder for Handling Cyclone ash.
2. Screw Feeder for Handling Esp. ash.
3. Screw Feeder for Handling Lime Stone.
4. Expansion Joints.
5. Y chute Assembly for Esp. Screw feeder.
6. Slide gates.
C. General arrangements drawing for Indidual Equipments.

1. Screw Feeder for Handling Cyclone ash.

2. Screw Feeder for Handling Esp. ash.
3. Screw Feeder for Handling Lime Stone.
4. Expansion Joints.
5. Y chute Assembly for Esp. Screw feeder.
6. Slide gates.

D. Details of Internal assemblies Drag. for Maintenance.( Common For all Screw)
E. List of commissioning checks
F. Routine Safety precautions and Maintenance checks.
G. Predicable Maintenance chart
H. Trouble shooting
I. Lubrication chart & lubrication points.
J. Dismantling and reassembly of Equipments.
K. Spare part list.

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RECOMMENDATIONS FOR REDUCING HAZARDS DURING MAINTENANCE

It must be stressed that only qualified personnel familiar with the construction and
operation of this plant, and who are aware of the inherent dangers associated with this
type of equipment should be permitted access to these machines. This is of particular
importance when considering inspection maintenance or adjustment.
A well planned and executed maintenance schedule is essential to the satisfactory and
safe operation of this plant. The user should establish a maintenance programmed with
the assistance of the POWERCON installation and maintenance manual. Additional rules
and regulations for operation and safety must be drawn up and made known to all
personal that will be associated with the running of this plant. Any recommendations or
mandatory legislation referring to health and safety at work must be considered when
drawing up such rules.
During the normal operation of this plant all inspection doors covers and protective
guards must be secured in their proper place.
All maintenance work must be performed with the machine isolated electrically. Suitable
warning signs must be prominently displayed and all precautions taken to prevent the
power from being accidentally restored to the machine. This is of even greater
importance if the maintenance work is being carried out of sight of the starter operator.
All starting and stopping devices must be clearly indicated and easily accessible
particularly all emergency stop.
Free and unhindered access should be allowed to all lubrication points. It is
recommended that these are painted to a standard pattern. After using lubricating oils or
greases, always ensure that work stations and passageways are kept clear and clean. To
ensure access to the machines all authorized passageways should be indicated in a clear
manner with gangways provided over all the machines where necessary. It must be
strictly forbidden to cross over or under a machine except at the points specially provided
for that purpose.
All overload and cutout devices which may be fitted to the machines must be regularly
checked to ensure their correct and trouble free working. This is particularly important if
explosion doors are fitted to any parts of the machine. When the POWERCON
Machine/plant has been delivered and installed it must be remembered that it has been
designed to perform a specific task under accepted conditions. These conditions of work
must not be altered without prior consultation with Powercon equipment. When spares are
required the machine serial number together with the description of the spare parts and its
reference number should always be quoted in all correspondence.

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COMMISSIONING CHECKS

It must be emphasized that only qualified personnel familiar with the construction and
operation of this plant and who are aware of the inherent dangers associated with this
type of equipment should be permitted access to this machine. This is particularly
important when considering inspection or adjustment. A well planned and executed
maintenance schedule must be initiated after commissioning to ensure the satisfactory of
this plant.

1. Drive
1.1 Ensure that the bedplate is accurately aligned and securely bolted down.
1.2 Check the direction of rotation as mentioned on the equipments.
1.3 Check the lubricant levels in the gearbox and fluid coupling (if fitted).
2. Electricals
2.1 Ensure that the motor is wired for proper start-up.
2.2 Ensure that the Zero Speed unit is correctly installed wired and providing a
signal (if fitted).
2.3 Check that all emergency stop buttons and any audio/visual alarm systems are
correctly wired and functioning.
3. General
3.1Check to ensure that the casing sections are all correctly aligned and securely
bolted together.
3.2Ensure that all inspection doors are correctly fitted and secure.
3.3Ensure that all guards and covers are correctly fitted and secure.

4“Dry” Commissioning
4.1Start the machine and check and record the ammeter reading.
4.2Check the screw speed and compare with the figure quoted on the General
Arrangement Drawing...
4.3 ISOLATE THE MACHINE ELECTRICALLY and check the free
movement of the conveyor screw. The rubbing, abnormal sound should be
eliminated before start load trial. If there are no abnormal conditions, the
Equipments are ready for USE.

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ROUTINE SAFETY PRECAUTIONS AND MAINTENANCE
CHECKS

1) Never undertake any routine maintenance checks on moving machinery without

first isolating the machine. Take all precautions necessary to prevent the
accidental restoring of power to the machine particularly if maintenance work is
taking place out of the starter operator.
2) Only qualified personnel familiar with the construction and operation of this plant
and who are aware of the inherent dangers associated with this type of equipment
should be permitted access to this machine (s).
3) Using the POWERCON Maintenance chart for assistance establish a regular and
carefully executed maintenance schedule there by helping to extend the
satisfactory and safe operation of this plant.
4) Use only recommended lubricants when “topping up” or during planned oil
changes. Never mix different oils or greases.
5) Record the ammeter readings and check for any significant changes that may
occur ascertain the cause of the fluctuations and rectify.
6) Regularly check all bearings for signs of over heating and/or rough running.
Check that the shaft and bearing seals are showing no signs of wear and are still
preventing the ingress of dirt and reign material into the bearing housing.

.
7) Regularly check the trough clearance to ensure it remains correctly fitted and
undamaged. Compacted material must not be allowed to build up between the
trough and screw dim...
8) Check all machine drives and make any corrective adjustments necessary.
9) Regularly check and test all emergency stop devices stop rotation sensors and
audio/visual alarm systems.
10) Always ensure all inspection doors covers and guards are correctly and securely
re-fitted after undertaking any routine maintenance.
11) Ensure all structural fasteners remain secure.
12) Regularly inspect all areas of the plant where the combined effects of wear
corrosion or accidental damage maybe impairing the working efficiency of the
plant. Replace all badly worn parts and refurbish all surfaces where the paint
finish is showing signs of deterioration.

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TROUBLE SHOOTING –

1. High current – Drawing by Motor –

If the conveyors motor is drawing abnormal current during normal course of

operation , please check up the alignment of related in put coupling in between motor
and gear box. Before that checkup the no load current of motor i.e. run the motor
without any unit coupling. If the motor gives still high current than –check up
electrically.

2. Nose level increase in Geared Unit –

The noise level in geared unit may also increase because of disturbance in
aligemement in between main screw shaft and out put shaft of Geared unit. Make sure
the proper alignment in between screw shaft and out put of geared unit. Before that
checkup the unit for idle condition along with motor , if the noise level is abnormal
than , refer to the supplier of Geared unit if the unit is under guarantee period.

3. Abnormal vibration-
The abnormal vibration is due to miss alignment in between coupling areas like motor
to gear box or gear box to main screw shafts. Check proper aliment step by step and
find out the misalignment area. The vibration could be because on imbalance in screw
shaft area. The same can be rectified by balancing the screw shaft.

4. Jamming of Screw –
The Jamming of screw may cause because of uncontrolled in put of material , i.e.
sudden over loading , Discharge area may got choke up etc. Open the cover and find
out the reason above and run the equipment once again gradually.

5. Heavy wear tear to trough –

The trough wear could only because of rubbing of screw shaft to main trough due to
misaligemenment or bend of main screw. After opening the main trough cover, check up
the run out of main screw. And find the reason of rubbing of trough , if the shaft is
run out , should get repaired etc.

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MAINTENANCE MANUAL

LUBRICATION POINTS-

The units are generally supplied duly grease and oil filled up while dispatching
the material , but during transships at idle period of actual utilization of equipment,
the oil or grease levels / qty may not be sufficient. So while commissioning the
equipment it is always advisable to check up oil and grease levels respectively in
geared unit and Plummer block and bearing assemblies.

The following items should be checkup for proper lubrication-

1. PLUMMER BLOC AT DRIVE and NON DRIVE END ASSLY-

Normally drive end assembly Plummer blocks are supplied with proper grease qty,
but due to dust , high atmospheric temperature the qty may reduce , so qty should be
top up with opening of Plummer block assembly or should be top up by grease
gun. The recommended grease grade is SERVO makes GEM RR 3 for bearing.

2. GEAR BOX UNIT –

Normally Gear box assembly are supplied with proper oil qty, but due to
leakage in transits or leakage in body in course of time the oil level get reduced
to the required level. Also the visciocity of oil gets change due to continuous use ,
So it is advisable to maintain and replace the lubricant oil periodically as
recommended in Maintenance chart. The proper oil level can be visualized by
indicating level glass gauge or immersion gauge level indicator. The oil level can be
top up within running by opening the top cover inlet. Avoid high level of lubricant ,
this will increase the heat inside unit due to unwanted rotation of oil.
The recommended oil grade is SERVO make MESH 320.

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MAINTENANCE MANUAL

DISMENTALING & REASSEMBALIES-

The units can be dismantle in annual maintenance schedule by following steps –

1. Isolate the machine electrically.

2. Decouple the coupling – in between input and out put shaft by proper unscrew of
grub screw and using bearing puller. Thus the geared unit and Motor can be
separated from main assemblies.
3. By removing Plummer block and Spherical roller bearing using proper
instruments like bearing puller etc the bearing can be take out.
4. Once the bearing with housing are taken out of main screw , The end plate
cover of either side i.e. drive or non Drive side the main screw can be slide
down completely out of trough.
5. The dismantling sequence should be used to reversely to assemble the equipment.

By normally checks unit should put once again on Load.

Please refer Sketch Showing dismantling of equipments.

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POWERCON EQUIPMENTS
Redg.Office – GARDENIA CO-OP HSG.SCO, PHASE -1 BLDG. C1 FLAT NO- 22 WADAGON
SHERI.PUNE -411014. (MAHARAHTRA- INDIA)
PHONE- 020- 27035035 / 09822292753.
E MAIL – anilkshirsagar@vsnl.net.

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