1)Pyro Section

Blending Silo 340 BS1:

1. Ensure all the air slide fixing arrangement in the silo

2. Check the airline leakage the which is connecting to the internal air slide
should be arrest
3. Ensure the garbage cleaning in the silo after close the man hole doors
4. Before close the manhole door, Ensure all the discharge opening to be
cleaned
5. Ensure the bucket elevator discharge air slide common one, connected with
distribution chamber and equally distributed to connected air slide (6 No’s)
dropping at around the silo
6. Ensure the aeration be given to distribution chamber and other air slide (410
BL1 & 410 BL2)
7. Ensure blower to be commissioned. Direction, Amps to be checked
8. Fan discharge pipeline, valve should be keep in open condition
9. Commission the silo aeration blowers, check the direction, ‘V’ belts guarding
etc., Ensure vibration abnormal noise and temperature etc.,
10. Silo aeration discharge pipe line valves to be opened, NRV fixing
arrangement and safety valve setting to be observed
11. Ensure the silo extraction, manual gate opening and closing, motorized
shut off valve opening and closing to be done
12. Please ensure the aeration time settings for silo with instrumentation
(of all solenoid valves) in the system (time and operation)
13. Ensure the blending silo high level indicators and low level indicators

Bucket Elevator 410 BE 1:

1. Elevator discharge to air slide to 420 RA 1 rotary air lock to be commissioned

2. Check the motor direction, Amps, Rotation etc.,
3. Gear box oil level, Vibration, Temperature, noise etc.,
4. Coupling guard, zero speed switch to be inspected.

Kiln Feed Bin 410 BI1:

5. Ensure inside of the bin air slide cloth fixing arrangement and air line
leakages to be arrest.
6. Ensure the aeration blowers 410 BL3 & 410 BL4 to be commissioned. Check
the ‘V’ belts, direction of motor pulley safety guards etc.,
7. Ensure the discharge line, safety valve setting, NRV and discharge valve
should be open condition
8. Empty bin load cells inspection, calibration to be ensure
9. Ensure bin high level and low level indication.
10. Ensure bin venting system etc.,
11. Endure the bin discharge air slide aeration, manual slide gate, dozing
valve open/close limits to be commissioned.
 12. SFM connection, calibration and its venting system to be fine tunes.
410 FM1, 410 FM2
13. SFM discharge air slide and its blower to be commissioned
14. 410 SM1 sampling screw geared motor connection and direction to be
checked (Oil to be filled for geared motors)
Preheater
Twin Cyclones 420 CN1A & 1B, Cyclones 420 CN2, 420 CN3, 420 CN4, 420
CN5:

1. Check all cyclone external welding, bolting etc.,

2. Inside brick lining, castable works to be inspected
3. Immersion tubes to be fixed to be checked
4. All cyclone inlet temperature, pressure tap and outlet temperature, pressure
tap fixing arrangement inspection
5. Cyclone cone level indicators to be cross check
6. Mill feed chute flaps to be inspected before taking the kiln feed. All feed
chutes to keep in open condition (Please tight the flap handlers with rope)
7. All the cyclone doors must be closed with castable and rope to be fixed
8. Ensure all the feed chute should be free of flow
9. Ensure the silo venting system, bag filters, RAV and bag filter fan etc.,

Calciner 420 CL1, Mixing Chamber 420 DA 2, TAD 420 TA1:

1. Ensure the brick lining and castable work completion and inspection
2. Inlet area O2 and CO analyzer sample probe fixing arrangement etc.,
3. PC coal firing to be inspected
4. Kiln inlet temperature RTD and pressure points to be kept on line
5. Ensure the TA damper 420 DA3 operation up and down limits etc
6. TAD brick lining to be inspected
7. TAD expansion joints lockings to be removed
8. TAD settling hopper manual gate to be closed
9. TAD below manual gate double flap to be kept online to be inspected
10. For all blaster airline connection, exhaust valves, control panel initially
manually to be operated

Kiln outlet Nose ring cooling Fan alignment, Motor Direction, Coupling Guard, Shaft
guard fixing to ensure before trial run.

Kiln Firing Hood, Burner Pipe, PA Fan etc.:

1. Endure Burner pipe fixing arrangement should be centre of the kiln

2. Ensure coal cc connection
3. Ensure primary air fan to be commissioned. Change the alignment of fan and
motor, empty motor take rain run check the direction, coupling guard to be
fixed.
4. Ensure the Diesel tank filling, Ensure the leakage. Diesel pump to be taken
trial. Ensure the direction of the pump, by closing the bypass valve set the
pump system pressure. 5kg or more.
5. Ensure when kiln to start all auxiliary drives, cooling fan, compressor,
hydraulic system. Everything should be made individual trial runs before light
up everything should be boxed. Check inlet sea arrangement, outlet TAD
damper positioning, PA fan, oil pumps, coal system etc., girth gear
lubrication system, gear box lubrication system etc.,
Preheater Fan 360 FN1:

1. Ensure the empty motor trial run, Amps, load direction to be checked
2. Preheater fan inlet damper to be commissioned. It should be in closed
condition when we go for trial run.
3. LRS to be commissioned
4. Fan bearings to be inspected DE- fixing NDE side, floating around minimum
30 mm (Free end)
5. Check all connections; Bolt tightening, expansion joint inlet and outlet.
6. Check bearing vibration connector, Temperature probes for bearings
7. Ensure the Impeller rotation

Kiln 430 KL1:

1. Ensure the kiln welding, inlet and outlet seal arrangement, kiln outlet tip
castings, brick lining, kiln inlet segments to be inspected properly.
2. Ensure the kiln tyres chair pads, gap, migration, stopper blocks welding to be
checked
3. Ensure kiln support roller bearings 12 nos’s, thrust gap, oil servo mesh 680,
bearing oil scooping buckets, inlet and outlet level water through bearings to
be inspected
4. Supporting roller jack bolts to be lubricated band with plastic paper further
adjustment
5. Ensure no leakages from the supporting roller bearings
6. Ensure all shell cooling fans to be commissioned, check the direction of the
fan axial flow fans
7. Check the kiln girth gear and pinion. Root clearance, backlash connected
area to be fixed. Apply grease cyplattin 300 grease paste on the firth gear
and pinion. Ensure girth gear spray system to be commissioned set grease
spray on time and off time
8. Check kiln main gear box alignment, gear box oil filling, gear box lubrication
oil system at 2.5 bar to be commissioned. Empty motor trial run to be taken,
check the direction of motor suitable gear box input marking.
9. Check kiln auxiliary gear box, oil level, clutch system, Auxiliary motor trial
run, Direction of rotation, LPB etc.,
10. Ensure the input coupling guard, Torsion shaft guard, Auxiliary
coupling guard etc.,
11. Ensure the kiln main drive motor (DC drive VFC) run the empty motor
up to maximum extent.
12. Ensure the speedometer is working behind the motor (Taco meter)
13. Ensure the kiln hydraulic thrust roller arrangement fixing bolts,
Cylinder, Hose connection and power pack system to be commissioned.
When the up and down taking time ensure kiln should run with auxiliary
drive.
14. Before kiln rotation small quantity of lubrication oil to put on the
supporting roller shaft.
15. Ensure hydraulic thrust power pack hydraulic oil to be filled for cylinder
operation.
Clinker Cooler 440 GC1 :

1. Ensure all cooler parts, side wall plates tightened

2. Ensure all compartment doors to be closed
3. Cooler drives gear box oil filling, bearings lubrication. Ensure motor direction
etc.,
4. Set the centralized lubrication system
5. Clinker crusher, grinding path, curtain chain firing arrangement, ensure
clinker crusher direction, ’V’ pulley guard etc., Load Amps to be noted
6. Ensure clinker crusher bearing temperature RTD and vibration sensors etc.,
7. Bottom discharge hoppers, double flap valves, cylinders, air line leakages to
be arrested. Flap valves sequence of operation to be made

Cooler Fans 440 FN1, 440 FN2, 440 FN3, 440 FN4, 440 FN5: