STANDARD MAINTENANCE PROCEDURE

Jaypee Nigrie Super Thermal Power Plant

2 X 660 MW IPP
SMP FOR BELT CONVEYOR/ FEEDER
Revision No.: 00
Doc No.: JPVL/PMPL/CHP/002 Effective Date: Page 1 of 7
Revision Date: 13.12.2014

STANDARD MAINTENANCE
PROCEDURE
FOR

BELT CONVEYOR/FEEDER

Prepared by (PMPL): Reviewed by (PMPL): Reviewed by (Jaypee): Approved by (Jaypee):

Signature: Signature: Signature: Signature:

Name: Name: Name: Name:

Desg.: Desg.: Desg.: Desg.:
 STANDARD MAINTENANCE PROCEDURE
Jaypee Nigrie Super Thermal Power Plant
2 X 660 MW IPP
SMP FOR BELT CONVEYOR/ FEEDER
Revision No.: 00
Doc No.: JPVL/PMPL/CHP/002 Effective Date: Page 2 of 7
Revision Date: 13.12.2014

List of Contents

1. Definition
2. Work Instructions
3. Quality Check
4. Check before Release of Permit
5. Re-Commissioning Procedure
1.0 Responsibility
2.0 Manpower Required
3.0 Duration
4.0 Other Department to be Intimated
5.0 Details of Hazard Involve
6.0 Safety Precaution Required
7.0 Permit Type
8.0 Permit Approving Authority
9.0 Tools Required
10.0 Materials Required
11.0 Frequency of Maintenance

Prepared by (PMPL): Reviewed by (PMPL): Reviewed by (Jaypee): Approved by (Jaypee):

Signature: Signature: Signature: Signature:

Name: Name: Name: Name:

Desg.: Desg.: Desg.: Desg.:
 STANDARD MAINTENANCE PROCEDURE
Jaypee Nigrie Super Thermal Power Plant
2 X 660 MW IPP
SMP FOR BELT CONVEYOR/ FEEDER
Revision No.: 00
Doc No.: JPVL/PMPL/CHP/002 Effective Date: Page 3 of 7
Revision Date: 13.12.2014

GENERAL SPECIFICATION OF BELT CONVEYOR/FEEDER:

Prepared by (PMPL): Reviewed by (PMPL): Reviewed by (Jaypee): Approved by (Jaypee):

Signature: Signature: Signature: Signature:

Name: Name: Name: Name:

Desg.: Desg.: Desg.: Desg.:
 STANDARD MAINTENANCE PROCEDURE
Jaypee Nigrie Super Thermal Power Plant
2 X 660 MW IPP
SMP FOR BELT CONVEYOR/ FEEDER
Revision No.: 00
Doc No.: JPVL/PMPL/CHP/002 Effective Date: Page 4 of 7
Revision Date: 13.12.2014

1. DEFINITION: Applicable for Belt Conveyor/ Feeder permit to work

2. WORK INSTRUCTIONS :

1. Take permit after checking following points

 Belt conveyor/ feeder is isolated electrically and mechanically
 No materials on the belt
2. Check for any leakage from gear box/ fluid coupling and its oil level. If required, oil
top up to be done.
3. All coupling bolts are to be checked.
4. Check the idler conditions- jammed/damage/missing, repair the same.
5. Check the skirt rubber , adjust/replace if required,
6. Check the “V” Scrapper. adjust / replace If required.
7. Check deflector plate condition.
8. Check Conveyor joint and its edge, Repair /replace if required.
9. Check Hold back condition, oil level to be checked/top up if required.
10. Check/top up oil in gearbox and clean the breather plug.
11. Check /adjust belt tension.
12. Train the MS Belt, if required.
13. Check Gear box, Fluid couplings, Hold backs, pin bush.
14. Greasing of all the bearings by pump.
15. Deflectors to be checked.
16. H.S/L.S coupling bolts/bushes to be checked and if required replaced.
17. Check the conveyor belt condition for patch/ edge condition.
18. Check the belt feeder skirt rubber/spill nil condition. Adjustment/Replace spill nil.
19. Idler condition checking.
20. Belt feeder scrapper adjustment.
21. Check the receiving chute liner condition, Repair/replace if required
22. Gear box foundation bolts & others to be tightened.
23. Take up screw servicing
24. Gap to be measured. greasing to be done.
25. If brg. found damaged same to be replaced.
26. Flap gate coal leakage to be checked and stopped.( Damage flap gate patching to be
done).
27. Take up guide clamp/plate to checked and fixed for alignment.
28. All P/B bolts to be tightened .

Prepared by (PMPL): Reviewed by (PMPL): Reviewed by (Jaypee): Approved by (Jaypee):

Signature: Signature: Signature: Signature:

Name: Name: Name: Name:

Desg.: Desg.: Desg.: Desg.:
 STANDARD MAINTENANCE PROCEDURE
Jaypee Nigrie Super Thermal Power Plant
2 X 660 MW IPP
SMP FOR BELT CONVEYOR/ FEEDER
Revision No.: 00
Doc No.: JPVL/PMPL/CHP/002 Effective Date: Page 5 of 7
Revision Date: 13.12.2014

29. All bearings clearance to be measured, labyrinth seal & lock nut to be tightened &
greased by PP.
30. Check bolt tightness of drive unit.
31. Check pulley lagging for distortion.
32. Check deflector pulley bearings condition and grease it. Also check for any shift in
shaft of deflector pulley. Replace deflector pulley bearing if required.
33. Check belt scrapper condition and adjustment/replacement if required.
34. Check skirt rubber condition and adjust/replace as per requirement.
35. Gear box cooling water line and valve to be checked and leakages to be arrested.
36. Check condition of counter weight rope
37. All Pulley brg. Clearance is to be measured & greased. Damaged brg to be replaced
if required.
38. Grease flap gate bearings & operation to be ensured.
39. Check/repair/replace deflector in the chutes.
40. Check take up pulley wire rope and lubricate.
41. Adjust labyrinth seal of pulley P/block.
42. Check guide clamp & replace.
43. Check ZSS, Pull Cord, Sway switch, calibrate/replace if required
44. Fill the check list.
45. Surrender the permit and ask operation depts. to normalize.
46. Check for leakages and attend if any, after taking permit.
47. Remove all T&P and clean the area
48. Cancel the permit (PTW).

3. QUALITY CHECKS:

 All the parameters, activities are maintained within

4. CHECKS BEFORE RELEASE OF PERMIT:

 All Tools & materials and manpower are removed.

 Clean the maintenance area properly.
 Ensure safety protection cover / guards are fitted in its position.

Prepared by (PMPL): Reviewed by (PMPL): Reviewed by (Jaypee): Approved by (Jaypee):

Signature: Signature: Signature: Signature:

Name: Name: Name: Name:

Desg.: Desg.: Desg.: Desg.:
 STANDARD MAINTENANCE PROCEDURE
Jaypee Nigrie Super Thermal Power Plant
2 X 660 MW IPP
SMP FOR BELT CONVEYOR/ FEEDER
Revision No.: 00
Doc No.: JPVL/PMPL/CHP/002 Effective Date: Page 6 of 7
Revision Date: 13.12.2014

5.RE-COMMISSIONING PROCEDURE:
 Return PTW.
 Normalize isolations after release of PTW

1.0 RESPONSIBILITY Mechanical Engineers

2.0 MAN POWER REQUIRED: 1 Engineer, 1 Technicians, 2 Helper, 1 Rigger
3.0 DURATION: 7days.
4.0 OTHER DEPARTMENT TO BE INTIMATED: (Main Plant Operation /E&I
/Mech.)
5.0 DETAILS OF HAZARD INVOLVE
 Fall/ Slip due to oily surface.
 Fire.
 Failure of lifting tools & tackles.
 Exposure to high noise.
 Contact with hot surface.

6.0 SAFETY PRECAUTION REQUIRED:

 Keep the fire extinguishers ready within reachable limit for any exigency.
 Ceramic hand gloves to be used while handling thrust collar / hot surface. (OHSAS)
 Ensure use of periodically tested proper lifting tools & tackles.
 Use of earplug is mandatory along with other general PPEs.
 Boiler suit to be worn while working.
 Ensure proper illumination.
 Ensure good housekeeping of maintenance bay. (EMS)
 Put barricade tapes around the equipment under maintenance.

7.0 PERMIT TYPE: Permit To Work Order.

8.0 PERMIT APPROVING AUTHORITY: Shift- In-Charge (Main Control Room)

9.0 TOOLS REQUIRED:-

SL. NO. TYPE OF THE TOOL SPECIFICATION QUANTITY
1 Spanner Set (Ring/DE) 8 – 36 mm 1 set
2 Hammer 2 kg 1 No

Prepared by (PMPL): Reviewed by (PMPL): Reviewed by (Jaypee): Approved by (Jaypee):

Signature: Signature: Signature: Signature:

Name: Name: Name: Name:

Desg.: Desg.: Desg.: Desg.:
 STANDARD MAINTENANCE PROCEDURE
Jaypee Nigrie Super Thermal Power Plant
2 X 660 MW IPP
SMP FOR BELT CONVEYOR/ FEEDER
Revision No.: 00
Doc No.: JPVL/PMPL/CHP/002 Effective Date: Page 7 of 7
Revision Date: 13.12.2014

3 Screw Driver Medium 1 No

4 Allen Key Set 1 No
5 Vernier Callipers 0-150 mm 1 No
6 Dial Gauge with magnetic base 0-10 mm 1 No
7 Inside/Outside Micrometer 0-150 mm 1 No
8 Chisel Medium 1 No
9 Centre Punch 1 No

10.0 MATERIALS REQUIRED:-

SL. NO. TYPE OF THE MATERIAL QUANTITY

1 Oil gasket As per requirement
2 Teflon Tape 1 Roll
3 Copper Rod 1 No
4 Emery paper-400 8 Nos.
5 WD-40 2 Nos.
6 Diesel 2liter
7 Wire bush 1 No
8 Hand gloves 6 Nos.
9 Cotton waste 2 kg

11.0 FREQUENCY OF MAINTENANCE: PM/ Annual Outage / In case of failures /

when required.

Prepared by (PMPL): Reviewed by (PMPL): Reviewed by (Jaypee): Approved by (Jaypee):

Signature: Signature: Signature: Signature:

Name: Name: Name: Name:

Desg.: Desg.: Desg.: Desg.: