KCL / APPC SECTION :KILN

CREW TIME /
SL Qty FREQUEN
M/C NAME/ACTIVITY NAME UNIT OCC
NO (Nos) CY
(MINS)
OPERATOR HELPER

GCT & PUMPS 4

1 Suction pipe & filtter inspection yearly 1 1 1 120
2 Check spray nozzle condition daily 1 1 1 120
3 Pump set or motor replacement yearly 1 1 5 240
4 Over hauling of water pump set yearly 1 2 6 720
5 Maintenance of filteration system yearly 1 1 1 240
6 Check GCT screw gear box oil level & coupling bolts weekly 1 1 1 120
7 GCT Screw bearing checked & greased yearly 2 1 1 240
8 Check GCT discharge rotory lock and chain condition yearly 1 1 1 180

Note:
UNIT: DAILY/WEEKLY/MONTHLY
FREQ: HOW MANY TIMES THEY ARE DOING ON THAT UNIT
CREW: MAN POWER ENGAGED FOR THE ACTIVITY (HEAD COUNT)
TIME/ OCCURENCE: HOW MUCH TIME TAKEN FOR THAT ACTIVITY
KCL / APPC SECTION :KILN

CREW TIME /
SL Qty FREQUEN
M/C NAME/ACTIVITY NAME UNIT OCC
NO (Nos) CY
(MINS)
OPERATOR HELPER

Fans 23
1 Check fan vibration & any abnormality daily 1 1 1 120
2 Check v-belt condition weekly 2 1 1 120
3 Bearings to be check & greased yearly 2 4 8 240
4 Check tyre & coupling bolts condition yearly 2 4 8 240
5 Impeller to be check yearly 2 1 5 240
6 Check bearing oil level daily 1 1 1 120

Note:
UNIT: DAILY/WEEKLY/MONTHLY
FREQ: HOW MANY TIMES THEY ARE DOING ON THAT UNIT
CREW: MAN POWER ENGAGED FOR THE ACTIVITY (HEAD COUNT)
TIME/ OCCURENCE: HOW MUCH TIME TAKEN FOR THAT ACTIVITY
KCL / APPC SECTION :KILN

CREW TIME /
SL Qty FREQUEN
M/C NAME/ACTIVITY NAME UNIT OCC
NO (Nos) CY
(MINS)
OPERATOR HELPER

Push feeder 1
1 Check gear box oil level & any abnormality Daily 1 1 1 60
2 Eccentric coupling & bolt checked Daily 1 1 1 60
3 Connecting rod bearing & bush check/ replacement Monthly 1 1 3 180
4 Idler wheel bearings greasing Monthly 1 1 2 180
5 Gear box oil replacement Yearly 1 1 1 120
6 Feed chute wornout plate patching / replacement Yearly 1 1 4 240
7 Discharge chute wornout plate patching /replacement Yearly 1 1 4 240
8 Live frame wornout liners replacement Yearly 1 1 4 240

Note:
UNIT: DAILY/WEEKLY/MONTHLY
FREQ: HOW MANY TIMES THEY ARE DOING ON THAT UNIT
CREW: MAN POWER ENGAGED FOR THE ACTIVITY (HEAD COUNT)
TIME/ OCCURENCE: HOW MUCH TIME TAKEN FOR THAT ACTIVITY
KCL / APPC SECTION :KILN

CREW TIME /
SL Qty
M/C NAME/ACTIVITY NAME UNIT FREQUENCY OCC
NO (Nos)
(MINS)
FITTER HELPER

Bucket Elevators 6
1 Check gear box oil level daily 1 1 1 120
2 Check input & output coupling bolts yearly 2 1 3 240
3 Bearing to be check & greased yearly 2 1 3 240
4 Check bucket bolts & chain lock pins yearly 2 1 4 420
5 Check top & bottom sprockets condition yearly 2 1 4 420
6
7
8

Note:
UNIT: DAILY/WEEKLY/MONTHLY
FREQ: HOW MANY TIMES THEY ARE DOING ON THAT UNIT
CREW: MAN POWER ENGAGED FOR THE ACTIVITY (HEAD COUNT)
TIME/ OCCURENCE: HOW MUCH TIME TAKEN FOR THAT ACTIVITY
KCL / APPC SECTION :KILN

CREW TIME /
SL Qty
M/C NAME/ACTIVITY NAME UNIT FREQUENCY OCC
NO (Nos)
(MINS)
FITTER HELPER

coal mill 2
1 Check inlet & outlet bearings lubrication Daily 1 1 1 30
2 Check gear box oil level & any abnormality Daily 1 1 1 30
3 Coal mill gear box out put coupling bolts & bushes checked Weekly 1 1 2 60
4 Coal mill gear box input coupling tyre checked Weekly 1 1 1 60
5 Inlet & out let seal checked/ replacement Monthly 1 1 4 240
6 inlet & out let chute patching/ replacement Monthly 1 1 4 240
7 Coal mill linear plates checked Yearly 1 1 5 240
8 Coal mill pinion bearing check & greasing Yearly 1 1 4 240
9 Grith gear & pinion gear teeth condition checked Yearly 1 1 4 240
10 Grith gear & pinion gear root clearance & back lash checked Yearly 1 1 4 240

Note:
UNIT: DAILY/WEEKLY/MONTHLY
FREQ: HOW MANY TIMES THEY ARE DOING ON THAT UNIT
CREW: MAN POWER ENGAGED FOR THE ACTIVITY (HEAD COUNT)
TIME/ OCCURENCE: HOW MUCH TIME TAKEN FOR THAT ACTIVITY
KCL / APPC SECTION :KILN

CREW TIME /
SL Qty
M/C NAME/ACTIVITY NAME UNIT FREQUENCY OCC
NO (Nos)
(MINS)
FITTER HELPER

Feed table & classifier 4

1 Check gear box oil level & any abnormality Daily 1 1 1 60
2 Feed table gear box input & out put coupling bolts,tyre check Daily 1 1 1 60
3 Check coal classifier gear box oil level & leakage Daily 1 1 1 30
4 Classifier input & output coupling to be checked Daily 1 1 1 30
6 Feed table disc patching/ replacement Yearly 1 1 4 360
7 Classifier main bearing & coupling checked & greasing Yearly 1 2 8 720
8 Classifier rotor & blade checked/ replacement Yearly 1 2 8 720
9 Classifier cone patching/ replacement Yearly 1 1 5 360

Note:
UNIT: DAILY/WEEKLY/MONTHLY
FREQ: HOW MANY TIMES THEY ARE DOING ON THAT UNIT
CREW: MAN POWER ENGAGED FOR THE ACTIVITY (HEAD COUNT)
TIME/ OCCURENCE: HOW MUCH TIME TAKEN FOR THAT ACTIVITY
KCL / APPC SECTION KILN

CREW TIME /
SL Qty FREQUEN
M/C NAME/ACTIVITY NAME UNIT OCC
NO (Nos) CY
(MINS)
FITTER HELPER

LNV Cooler 2
1 Check hydraulic cylinder oil leakages Daily 1 1 1 20
2 check shuttle for any abnormal sound Daily 1 1 1 30
3 Check fixed side & moving side(hyd.cyl.) bracket bolts Monthly 1 1 3 180
4 Check shuttle seals & plates Yearly 1 20 80 3600
5 Check four joint mechanism bearings & pins condition Yearly 1 10 40 3600
6 Check stiffner bars & bolts condition Monthly 1 1 4 240
7 Check hydraulic pumps coupling condition Yearly 1 1 3 240
8 Check hydraulic hose pipe oil leakages Daily 1 1 1 20
9 Check cooler fixed compartement grade plates Yearly 1 1 4 360
10 Check clinker breaker rotor & hammers condition Yearly 1 1 4 360
11 Clinker breaker bearing checked & greased Yearly 1 1 3 240
12 Clinker breaker V-belts check/ replacement Yearly 1 1 3 240

Note:
UNIT: DAILY/WEEKLY/MONTHLY
FREQ: HOW MANY TIMES THEY ARE DOING ON THAT UNIT
CREW: MAN POWER ENGAGED FOR THE ACTIVITY (HEAD COUNT)
TIME/ OCCURENCE: HOW MUCH TIME TAKEN FOR THAT ACTIVITY
KCL / APPC SECTION :KILN

CREW TIME /
SL Qty FREQUEN
M/C NAME/ACTIVITY NAME UNIT OCC
NO (Nos) CY
(MINS)
OPERATOR HELPER

Supporting Rollers 12
1 Supporting rollers bearings temperature to check Daily 1 1 1 60
2 Supporting rollers oil level & leakages check/ arrested Daily 1 1 1 20
3 Oil tray & oil buckets check Daily 1 1 1 20
4 Disc bolts to be check Daily 1 1 1 20
5 Supporting Roller diameter check/ replacement yearly 1 4 16 840

Note:
UNIT: DAILY/WEEKLY/MONTHLY
FREQ: HOW MANY TIMES THEY ARE DOING ON THAT UNIT
CREW: MAN POWER ENGAGED FOR THE ACTIVITY (HEAD COUNT)
TIME/ OCCURENCE: HOW MUCH TIME TAKEN FOR THAT ACTIVITY
KCL / APPC SECTION :KILN

CREW TIME /
SL Qty
M/C NAME/ACTIVITY NAME UNIT FREQUENCY OCC
NO (Nos)
(MINS)
operator HELPER

Coal crusher 1
1 Check v-belt condition Daily 1 1 1 20
2 Check input tyre condition Daily 1 1 1 20
3 Linear plates checked & bolt tightening Weekly 1 1 2 60
4 Rotor bearing checking & greasing Monthly 1 1 3 120
5 Hammers & rotor condition to be checked Monthly 1 1 5 360
6 Jack shaft pulley bearing checked & greased Monthly 1 1 3 120
7 Feed chute plate patching/ replacement Yearly 1 1 4 360
8 Discharge chute plate replacement Yearly 1 1 4 360
9 Coal crusher back side linear plate checked/ replacement Yearly 1 1 4 240
10 Rotor pulley & jack shaft pulley checked/ replacement Yearly 1 1 4 360

Note:
UNIT: DAILY/WEEKLY/MONTHLY
FREQ: HOW MANY TIMES THEY ARE DOING ON THAT UNIT
CREW: MAN POWER ENGAGED FOR THE ACTIVITY (HEAD COUNT)
TIME/ OCCURENCE: HOW MUCH TIME TAKEN FOR THAT ACTIVITY
KCL / APPC SECTION :KILN

CREW TIME /
SL Qty FREQUEN
M/C NAME/ACTIVITY NAME UNIT OCC
NO (Nos) CY
(MINS)
FITTER HELPER

Kiln 2
1 Check chair pad & stoppers condition Daily 1 1 1 30
2 Check guide roller condition Daily 1 1 1 20
3 Check grith gear joint bolts Daily 1 1 1 30
4 kiln inlet seal bolts & spring to be checked Daily 1 1 1 20
5 Main motor gear box oil level & leakages to be checked Daily 1 1 1 20
6 kiln inlet seal to be checked/ replacement yearly 1 1 4 360
7 kiln outlet seal to be checked/ replacement yearly 1 1 4 360
8 Burner pipe checked/ replacement yearly 1 1 8 360
9 Torsion shaft coupling & bolts checked/ replacement yearly 1 1 6 240
10 Gear box input coupling checked/ replacement yearly 1 1 3 240
11 Pinion bearing condtion check/ replacement yearly 1 1 5 240
12 Grith gear teeth & pinion gear teeth to be checked yearly 1 1 4 240
13 Grith gear & pinion backlash & root clearance checked yearly 1 1 4 240
14 kiln inlet tongue plates to be check/replacement yearly 1 1 4 360
15 kiln tyre air gap & shimming check yearly 1 1 4 240
16 Tip casting segment condition checking/replacement yearly 1 3 18 1080

Note:
UNIT: DAILY/WEEKLY/MONTHLY
FREQ: HOW MANY TIMES THEY ARE DOING ON THAT UNIT
CREW: MAN POWER ENGAGED FOR THE ACTIVITY (HEAD COUNT)
TIME/ OCCURENCE: HOW MUCH TIME TAKEN FOR THAT ACTIVITY
KCL / APPC SECTION : KILN

CREW TIME /
SL Qty FREQUEN
M/C NAME/ACTIVITY NAME UNIT OCC
NO (Nos) CY
(MINS)
OPERATER HELPER
Conveyor belts : 9
1 Belt idlers cleaning & belt adjustment in centre Daily 1 1 1 120
2 Belt rotating drums cleaning Daily 1 1 1 60
3 Couplings & bolts inspection & fixing if required Weekly 1 1 1 90
4 Belt patchings & joints inpection / repairing Monthly 1 2 4 360
5 Drive gear box oil level inspection and topup Weekly 1 1 180
6 Conveyor scrapers adjustment / replacement Monthly 1 1 1 60
7 Replacement of damaged troughing,impact and return idlers Yearly 8 1 4 360
8 Belt vulconizing joint Yearly 16 2 6 360
9 Belt drum bearing greasing & replacement if required Yearly 10 1 4 240
10 Belt replacement Yearly 2 2 8 420

Note:
UNIT: DAILY/WEEKLY/MONTHLY
FREQ: HOW MANY TIMES THEY ARE DOING ON THAT UNIT
CREW: MAN POWER ENGAGED FOR THE ACTIVITY (HEAD COUNT)
TIME/ OCCURENCE: HOW MUCH TIME TAKEN FOR THAT ACTIVITY
KCL / APPC SECTION :KILN

CREW TIME /
SL Qty FREQUEN
M/C NAME/ACTIVITY NAME UNIT OCC
NO (Nos) CY
(MINS)
OPERATOR HELPER

Enmasses Conveyor 6
1 Check geared unit oil level daily 1 1 1 20
2 Check chain links condition weekly 1 1 1 120
3 Check head & tail sprocket condition yearly 1 1 4 240
4 Head & Tail sprocket bearing checked & greased yearly 1 1 4 240
5 Bottom & Top flat check/ replacement yearly 1 1 4 360
6
7
8

Note:
UNIT: DAILY/WEEKLY/MONTHLY
FREQ: HOW MANY TIMES THEY ARE DOING ON THAT UNIT
CREW: MAN POWER ENGAGED FOR THE ACTIVITY (HEAD COUNT)
TIME/ OCCURENCE: HOW MUCH TIME TAKEN FOR THAT ACTIVITY
KCL / APPC SECTION :KILN

CREW TIME /
SL Qty FREQUEN
M/C NAME/ACTIVITY NAME UNIT OCC
NO (Nos) CY
(MINS)
OPERATOR HELPER

PS PUMP 4
1 Check air pressure & any leakages Daily 1 1 1 20
2 Check bearing temperature Daily 1 1 1 20
3 Check flap valve condition Monthly 1 1 2 60
4 Check screw & barrel bushes condition & replacement Yearly 1 1 4 360
5 DE & NDE bearings & oilseals checked/ replacement Yearly 1 1 4 360
6
7
8

Note:
UNIT: DAILY/WEEKLY/MONTHLY
FREQ: HOW MANY TIMES THEY ARE DOING ON THAT UNIT
CREW: MAN POWER ENGAGED FOR THE ACTIVITY (HEAD COUNT)
TIME/ OCCURENCE: HOW MUCH TIME TAKEN FOR THAT ACTIVITY
KCL / APPC SECTION :KILN

CREW TIME /
SL Qty FREQUEN
M/C NAME/ACTIVITY NAME UNIT OCC
NO (Nos) CY
(MINS)
OPERATOR HELPER

DPC 4
1 Check gear box oil & leakages Daily 1 1 20
2 Fluid coupling oillevel check/ replacement Weakly 1 1 60
3 Check chain links & pins Weakly 1 1 1 60
4 Check Tail & Head sprocket condition/replacement Monthly 1 1 4 180
5 Buckets bolts & wheels check & replacement Monthly 1 1 4 120
6 Head & tail sprocket bearing checked & greased Yearly 4 1 3 120
7
8

Note:
UNIT: DAILY/WEEKLY/MONTHLY
FREQ: HOW MANY TIMES THEY ARE DOING ON THAT UNIT
CREW: MAN POWER ENGAGED FOR THE ACTIVITY (HEAD COUNT)
TIME/ OCCURENCE: HOW MUCH TIME TAKEN FOR THAT ACTIVITY
KCL / APPC SECTION :KILN

CREW TIME /
SL Qty FREQUEN
M/C NAME/ACTIVITY NAME UNIT OCC
NO (Nos) CY
(MINS)
OPERATOR HELPER

Weigh feeders-2 & screws-16 18

1 Check gear box oil & leakages Daily 1 1 30
2 Check input & output coupling bolts & tyre Weakly 1 1 1 60
3 Check belt drum & bearing condtion Monthly 1 1 2 60
4 Belt joint check/ replacement Yearly 1 1 4 240
5 Screw & vanes check/ replacement Yearly 2 1 4 240
6 Screw bearings check & greased Yearly 2 1 2 120
7
8

Note:
UNIT: DAILY/WEEKLY/MONTHLY
FREQ: HOW MANY TIMES THEY ARE DOING ON THAT UNIT
CREW: MAN POWER ENGAGED FOR THE ACTIVITY (HEAD COUNT)
TIME/ OCCURENCE: HOW MUCH TIME TAKEN FOR THAT ACTIVITY
KCL / APPC SECTION :KILN

CREW TIME /
SL Qty FREQUEN
M/C NAME/ACTIVITY NAME UNIT OCC
NO (Nos) CY
(MINS)
OPERATOR HELPER

Air Slide boxes & blowers 14

1 Check for any leakages Daily 1 1 30
2 Check fan vibration & any abnormality Daily 1 1 1 30
3 Check air slide air pressure Daily 1 1 1 30
4 Check coupling tyre & bolts condition Weekly 1 1 1 60
5 Air Slide cloth check/ replacement Monthly 1 1 4 360
6 airslide chutes (feed & discharge ) check/ patch Yearly 1 1 4 240
7
8

Note:
UNIT: DAILY/WEEKLY/MONTHLY
FREQ: HOW MANY TIMES THEY ARE DOING ON THAT UNIT
CREW: MAN POWER ENGAGED FOR THE ACTIVITY (HEAD COUNT)
TIME/ OCCURENCE: HOW MUCH TIME TAKEN FOR THAT ACTIVITY