ROTARY PLANT SHUT DOWN JOB SCHEDULE - DECEMBER 2020

SUPPORTING
S.NO SHUT DOWN JOB DESCRIPTION DEPARTMENT DAY TEAM

Crusher Section
Trolley: limit switch checking, JB connection tightening/dressing, Cable dressing. DAY 3 TAWSEEF
1
All belt conveyers: JB connection tightening/dressing, ZSS, Pull Cord rope and Belt sway DAY 3 TAWSEEF
checking/replacement,Cable dressing.
2
3  Apron feeder: VFD pannel dressing/cleaning/contactor checking. Parameter list update DAY 3 TAWSEEF

4 Protection guards for installed Vibro sensors and all R.T.D’s. Mechanical DAY 2 MUZAFFAR

5 I/O panel cable dressing / cleaning./ SERVER CLEANING DAY 2 MUZAFFAR

JBs connection tightening/cleaning and covering with polyethylene stretch cling
6
7 Belt weigher maintenance and calibration. Parameter List Update DAY 2 TAWSEEF

8 Bin weighing system maintenence and calibration. Parameter List Update DAY2 TAWSEEF
Pull Chord Electrical connection scheme - revamping / standradisation Mechnical DAY 1 MUZAFFAR

9
Purge Feed Back/ Healthy Feed back for Bag filter to CCR DAY 1 TAWSEEF

10
Bag filtersMaintenance - pannel connection tightening/dressing/cleaning - Purging cycle testing, diaphram DAY1 TAWSEEF
replacement if required

11
Raw Mill Section
All belt conveyers: JB connection tightening/dressing, ZSS, Pull Cord rope and Belt sway
checking/replacement,Cable dressing.
1
Damper actuators operation and cross checking of end limit indication/travel time/interlock along with Process
Process Engineer.
2
Folaphone maintenance and cross check along with Process Engineer Process
3
Maintenance / Calibration of all Weigh feeders. Parameter List Update DAY 2 SAFEER/TAJAMUL
4
AC Drives Panel for all weighfeedersdressing/cleaning/contactor checking. Parameter List Update DAY 1 SAFEER/TAJAMUL
5
Vibro sensors / Vibro Controller maintenance / replacemnet if required - Cros check with Mechanical Mechanical DAY 1 SAFEER/TAJAMUL
6
 Lubrication Systems cycle operation to be checked and tested along with mechnical Mechanical
7
Bag filtersMaintenance - pannel connection tightening/dressing/cleaning - Purging cycle testing, diaphram
replacement if required
8
Installation of DP switch in Bag Filters / cable laying. Purge Feed Back/ Healthy Feed back for Bag filter to Mechanical/DYNAMIC SHOWKET
CCR
9
Maintenance for all Bucket elevators boot level and BDS.
10
RTDs and Thermocouples connection tightening/dressing/cleaning -calibration
11
JBs connection tightening/cleaning and proper covering with polyethylene stretch cling
12
Maintenance and Calibration of SFM Reject. Parameter List Update
13
Dressing and Ferruling of I/O panels.
14
Change of auxiliary contactors in O-Sepa and RA fan panels, replacement if required
15
Pull Chord Electrical connection scheme - revamping / standradisation DAY 4 SHOWKET
16
Change of geared motor of 351WF2
17
Iron ore / Silca weighfeeder panel interchange as per drawings and data sheet. Parameter List Update DAY1 & DAY3 SHOWKET
18
RABH

Checking of Solenoid valves, limit switches,proxies for puppet valves Mechanical DAY 4 MUZAFFAR
1
Cable revamping/relocation and proper dressing DAY 4 MUZAFFAR
2
Screw conveyers ZSS checking, cable dressing,conduit replacement and proper covering with polyethylene
stretch cling
3
Damper actuators operation and cross checking of end limit indication/travel time/interlock along with Process
Process Engineer.
4
JBs connection tightening/cleaning and proper covering with polyethylene stretch cling DAY 5 MUZAFFAR
5
Change of fresh air damper actuator / wiring on demand of Process and mechanical Process,Mechanical DAY 5 MUZAFFAR
6
HNL Polution equipment upgradiation as per HNL recommendation and CPCB norms
7

8 Cleaning of stack analszer panel and probes, Relocate probe in chimney as per CPCB norms
Blending Silo
1 Checking and Calibration of all motorized gates, pneumatic gates and butterfly valves. Mechanical DAY 5 TAWSEEF

2 Blending Silo actuators replacement/checking Mechanical DAY 5 TAWSEEF

3 Bag filters pannel connection tightening/dressing/cleaning - Purging cycle testing DAY 5 TAWSEEF
4 Checking and Calibration of SFM and Bin weigh system. Parameter List Update DAY 6 TAWSEEF
5 Checking of Position transmitters of actuators 411DV1-DV6 and take in line. DAY 6 TAWSEEF
Installation of DP switch in Bag Filters / cable laying. Purge Feed Back/ Healthy Feed back for Bag filter to Mechanical/DYNAMIC TAWSEEF
CCR
6 DAY 6
Pre heater ,Kiln and Cooler Area
1 Checking of 421SG5 and SG6 limits along mechanical DAY 4 SAFER/ TAJAMUL
2 All pyro thermocouple and draft checking DAY 4 SAFER/ TAJAMUL
3 All blasters checking, along with process Process DAY 4 SAFER/ TAJAMUL
4 Installation of panel fans in cooler fan panel and RABH fan panel. DAY 5 SAFER/ TAJAMUL
5 Pre heater fan Vibro sensors checking change if required DAY 5 SAFER/ TAJAMUL
6 Preheater fan damper 441DA1 checking Process DAY 5 SAFER/ TAJAMUL
7 Checking of Girth Gear spray system Mechanical DAY 5 SAFER/ TAJAMUL
8 Checking of Roller temperature RTDs.
9 Checking Hood draft. Transmitter
10 Water cooler system checking of pressure switch. DAY 6 SAFER/ TAJAMUL
12 Checking Cooler Flaps. DAY 6 SAFER/ TAJAMUL
13 Checking of cooler grate thermocouples replacement Process DAY 6 SAFER/ TAJAMUL
14 Checking of compartment pressure points. DAY 6 SAFER/ TAJAMUL
15 Checking of all cooler fans drives. DAY 7 SAFER/ TAJAMUL
16 Checking of cooler great drives. DAY 7 SAFER/ TAJAMUL
17 Checking of ESP field / ESP hopper level sensors. / New controller installation
18 Checking of DBC and diverting gate 491 DG1
20 Checking of ESP fan drive, vibro sensor, barring temperatures and damper.
21 Checking of temperature scanner of cooler fans
22 Dressing of cables and Ferruling of I/O panels.
23 Checking the Emergency Limit switch of DBC 491DB1
24 Checking of all bag filters. (Change of diaphragm or solenoid) DAY 6 SHOWKET
Installation of DP switch in Bag Filters / cable laying. Purge Feed Back/ Healthy Feed back for Bag filter to
CCR
25 Mechanical SHOWKET
Checking and change of Kiln Floating limit switches. Compare with LVDT. To be checked and tested along
26 with mechnical Mechanical DAY 6 SHOWKET
27 HNL Polution equipment upgradiation as per HNL recommendation and CPCB norms
28 Change of drives in cooler fans 471 FN3 110 KW to 90 KW as per motor specification Electrical DAY 8 SAFER/ TAJAMUL
29 Installation of flow meters in cooler fans SERVICE ENGINER SAFER/ TAJAMUL
Coal Firing ,Coal Mill Area
1 Checking of Fine coal Weigh feeder, Calibration if required.Parameter List Update DAY 7 TAWSEEF
2 Bin weight Checking and zero correction.Parameter List Update DAY 7 TAWSEEF
3 Checking all limit switches and solenoids of firing group pneumatic gates. change if required DAY 6 MUZAFFAR
4 Checking of limits of bag filter pneumatic gates (4B1 SD1 &SD2). Mechanical
5 JB dressing, Conduit, ZSS, Pull Cord and Belt Sway of all belt conveyers.
6 Checking of all the Damper actuators and cross checking along with process Engineer. Process
7 Checking of coal crusher area and ZSS of crusher.
8 Checking of all bag filters. (Change of diaphragm or solenoid) DAY 7 MUZAFFAR
Checking and correcting all instruments of LQ’s, main drive and others. To be checked and tested along with
9 mechnical Mechanical
10 Checking of all the RTD in coal mill area.
11 All JBs properly cleaned, connection tightened and properly covered.
12 Checking, alignment and calibration of Raw coal weigh feeders.
13 Maintenance of all Weigh-feeder, AC Drives Panel.Parameter List Update DAY 7 MUZAFFAR
14  Change of panel fan in ac drives if requiredParameter List Update
15 Cleaning and checking of all the PLC Panels.
16 Checking and calibration of hopper level sensor.
Installation of DP switch in Bag Filters / cable laying. Purge Feed Back/ Healthy Feed back for Bag filter to
CCR
MECHNICAL/DYNAMICDAY 8 MUZAFFAR
ROLL PRESS
1 Magnetic Separator 521MS1 panel checking, control transformer change DAY 9 MUZAFAR
2 Metal Detector 521MD1 maintenance DAY 9 MUZAFAR
3 Belt Weigher (521 BW1 &BW2) maintenance and calibration.Parameter List Update DAY 9 TAWSEEF
4 Testing / Maintenance of proportional control valve in hydraulic system Mechanical
5 Checking of LVDTs and testing along with mechnical Mechanical
Checking of all equipments of roll press lubrication system.(RTD's, flows switches etc. ) to be checked and
6 tested along with mechnical Mechanical
7 Checking of all equipments of roll press gear box system.(flow switches, pressure switches etc)
8 Bin weight Checking and zero correction. DAY 9 TAWSEEF
9  Checking of 521SG2 and SG3 gate postioner.
Checking of all equipments of hydraulic gate system 521SG1. (Solenoids, Proxies etc ) To be checked and
10 tested along with mechnical Mechanical
11 Maintenance and Calibration of all Weigh-feeders.Parameter List Update
12 Replacement of drive in Weigh-feeders 511WF3, 531WF3.
13 Maintenance of AC Drives Panels.
14 Checking of all equipments of pneumatic gate system.(Solenoids, Proxies etc )
15  JB Dressing, Conduit, ZSS, Pull Cord and Belt Sway of all Belt conveyers.
16 Cleaning and Checking of all the PLC Panels.
17 Checking of all bag filters. (Change of diaphragm or solenoid)
Installation of DP switch in Bag Filters / cable laying. Purge Feed Back/ Healthy Feed back for Bag filter to
CCR

18 Checking of all boot levels and BDS of elevators

19 Checking and Cleaning of all I/O panels in MCC 10 and 11
CEMENT MILL
1 Checking of all the Damper actuators and cross checking along with process Engineer. Process
2 Checking of all the RTD, convert in to analog DAY 8 &DAY 9 SHOWKET
3 Checking of all LQ’s. To be checked and tested along with mechnical Mechanical
4 Maintenance and calibration of all Weigh-feeders.Parameter List Update
5 Maintenance of AC Drives Panels.Parameter List Update
6  Maintenance of Silo level sensors
7  JB dressing, conduit, ZSS, Pull Cord and Belt Sway of all belt conveyers.
8 Cleaning and checking of all the PLC Panels.
9 Checking of bag filters.(Change of diaphragm or solenoid)
Installation of DP switch in Bag Filters / cable laying. Purge Feed Back/ Healthy Feed back for Bag filter to
CCR
DAY 10 SHOWKET
10   Checking of all boot levels and BDS of elevators
11   Checking and Cleaning of all I/O panels in MCC 10 and 11
12   Checking RTD in CEMENT mill O-Sepa 541 SR1, change if required
13 Checking of pholophone and cross check with process Process
14 All JBs properly cleaned, connection tightened and properly covered.
15 Change of geared motor of 511WF3 Mechanical
GRINDING UNITS
1 Checking of all the RTD
2 Checking of all LQ’s. To be checked and tested along with mechnical Mechanical
3 Maintenance and calibration of all Weigh-feeders.Parameter List Update
4 Maintenance of AC Drives Panels.Parameter List Update
5 JB dressing, conduit, ZSS, Pull Cord and Belt Sway of all belt conveyers.
6 Cleaning and checking of all the PLC Panels.
7 Checking of bag filters.(Change of diaphragm or solenoid)
Installation of DP switch in Bag Filters / cable laying. Purge Feed Back/ Healthy Feed back for Bag filter to
CCR

8 Checking of all boot levels and BDS of elevators

9 Checking and Cleaning of all I/O panels in MCC
10 Checking of pholophone and cross check with process
11  Checking of all equipments of AIR LIFT system.(solenoids, proxies, gates etc )
PACKING SECTION

1 Checking , maintenance, cleaning and calibration of all spouts of packing machine.Parameter List Update DAY 10 SAFEER/TAJAMUL
2 Check / Change of solenoids and filters of packing machine DAY 10 SAFEER/TAJAMUL
3 JB dressing, conduit, ZSS, Pull Cord and Belt Sway of all belt conveyers.
4 Cleaning and checking of all the PLC Panels.
5 Checking of all boot levels and BDS of elevators
6 Checking , maintenance, cleaning of truck loader
7 Proper UPS Power distribution DAY 11 SAFEER/TAJAMUL
8 Installation of new packer controllers
PLC
1 Cleaning and maintenance of Servers,Engineering station and CCR Opstations. DAY 13 SAFEER/TAJAMUL
Replacement of PLC battries.
2  Checking and cleaning of PLC panels.
3 Cleaning and checking of UPS Panel.
4 Checking and Cleaning of all I/O panels in MCC
5 Proper UPS Power distribution (Installation of New Panel) DAY 12 SHOWKET

SERVICES ENGINEERS
HNL for recommissioning of stack analyser Upgradiation
L&T Engineer for new Pannel installation Kiln Dc drive Upgradiation
ABB Gas Analyser O2 / PLC installation Upgradiation
FLSA - Packer Controllers Upgradiation
Hind Rectifier for checking of ESP Fields Upgradiation

Material Requisition
DESCRIPTION Req No. PO.No. Status as on 17-11-
2020
Vibro Sensors Req No 4843 N.A
Diaphragm Or Solenoid For Bag Filters Req No 5166, N.A
5167
Geared Motor Of 351WF2 And 511WF3 Req No 4851 N.A
Panel Cooling Fan In RABH AC Drive PO No. 4560 N.A
Position Transmitters Of Actuators 411DV1-DV6 PO No. 5626 N.A
Kiln Floating Limit Switches Req No 5164 N.A
Flow Meters In Cooler Fans PO No.4167 N.A
Panel Cooling Fan In existing Kiln DC Drive Req No. 1782 N.A
UPS Power Distribution (Installation Of New Panel) Dynamic N.A
Electricals
Change Of Panel Fan In Ac Drives PO No 5625 N.A
Magnetic Separator 521MS1 Panel Checking, Control Transformer Change PO No 3979 N.A
Change Of Drive In Weigh-Feeders 511WF3, 531WF3. PO No 5476 N.A
RTD To Analog Module Converter - Reckers Req No.5163 N.A
Metal Detector PO No 1980 N.A
VFD Cement Mill Osepa 250 KW Against VSK 250 N.A
KW VFD
D.C Drive Kiln 200 KW N.A
Department Tools Multimeter,Clamp N.A
meter, vibro
controller,screw
driver
7- Core cable 1.5sqmm for bag filter upgradiation set,blower,drill,DP
Req:5206 N.A
calibrator,telephon
Pyrometer communication cable M16-12 DIL Cable eReq:4865
tool box N.A

ABB Gas Analysers- MAGNOS /PLC N.A

 MAINTANANCE SCHEDULE ( DECEMBER 2020 )
LOCATION ACTIVITIES DAY 1 2 3 4 5
Crusher Section

Raw mill

RABH

Blending Silo

Preheater,Kiln & cooler

Roll Press

Cement Mill
Grinding Unit
Packing
PLC
CHEDULE ( DECEMBER 2020 )
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