ESS CHECK POINT FOR COAL MILL- 1

FREQ
SL.NO. CHECK POINTS
Weekly
RAW COAL HOPPER / ROD GATE
1 CHECK THE RAW COAL HOPPER FOR ANY LEAKAGE W
2 CHECK THE PIN GATE ROD FOR ANY BEND
3 CHECK THE FRENESS OF ROD GATE
4 CHECK THE PIN GATE SEATING BUSH WELDING INSPECTION

WEIGH FEEDER

1
General inspection of pulleys and bearings

2
Check the idlers condition for any damage or wear
3 Check Gear motor
4 Check input coupling condition
5 Check pulley bearing condition
6 Check pulley lagging
7 Check belt condition W

8
Check idler condition
9
Check carrying & weighing idlers condition
10 Check skirt rubber W
11 Check chute internal condition
12 Check the tensioning arrangement
ROTARY AIR LOCK( GRAVEL GATE)
1
Check rotor condition for wear or damage
2
Check the gearbox/gear motor Condition & Coupling.
3
General inspection of coupling and bush any wear

4
Check the RAL DE & NDE Bearing and housing
5 Check the DE & NDE Glande
6 Check the Rotor blade with housing clearence
7 Check the casing for any leakages
STATIC SAPERATOR
1 Check the blade condition
 check the blade holding pipe for any wear
2

3 check the bolts of blade

VRM (COAL MILL)

1 W
INSPECT THE GUIDE BRACKET BOLT.
2 W
INSPECT THE GUIDE PIN BOLTS .

3 W
INSPECT THE TIE ROD SEAL PLATE BOLTS
4 W
INSPECT THE WALL LINER & ITS BOLTS.
5 W
INSPECT THE ROLLER ASSYMBLY HOOK BOLTS
6 W
INSPECT THE TIE ROD FOR ANY WEAR IN THE EYE PORTION.
7 INSPECT THE SCRAPPER PLATE W
8 INSPECT THE INSULATION RING JOINTS & ITS BOLTS W
9 INSPECT THE ANY LEAKAGES IN THE MILL BODY (DOME ) W
10 INSPECT THE OIL LAVEL IN SEAL LUBRICATION TANK W

11 W
INSPECT THE ANY LEAKAGES IN SEAL AIR BLOWER PIPE LINE

12 W
TAKE THE WEAR READING OF ROLLER SHELL

13 W
TAKE WEAR READING OF TABEL LINER
14 INSPECT THE OIL LAVEL OF ALL ROLLER ASSYMBLY. W
15 INSPECT THE ANY LEAKAGES IN THE ROLLER ASSYMBLY. w
16 INSPECT THE TIE ROD SEALING BELLOW w
17 INSPECT FELT PACKING FOR ANY LEKAGES IN BOWL.
18
INSPECT THE MILL OUTLET DUCT DISTANCE PIECE LEAKAGES .
19 COUPLING BOLT & BUSH INSPECTION

MAIN GEAR BOX (COAL MILL)

1 Check the gear box internal inspection
2 Check the auxillary drive condition
3 Visual check of pipe condition & its clamping
4 Check the pin bush coupling bolt and bush any wear
5 Check the breather cleaning
6 Check the segment pads condition

GEAR BOX LUBRICATION SYSTEM (COAL MILL)

1 INSPECT THE OIL FILTER IN MAIN LINE
2 INSPECT THE WATER FILTER
3 INSPECT THE ANY LEAKAGES IN THE OIL PIPE LINE W
4 INSPECT THE ANY LEAKAGES IN WATER PIPE LINE W
5 INSPECT THE LEAKAGES IN OIL STORAGE TANK. W
6 Check the heat exchanger tubes for ang lekages.
7 check the pump condition
HYDRAULIC UNIT SYSTEM (COAL MILL)

1
check the pump condition

2
Check the accmulator Nitrogen Pressure.
3
Check the filter any contnamination and replaced
4
Check the hose condition
5 W
INSPECT THE CYLINDER BASE BOLTS.

6
INSPECT THE CHECK VALVE

7
INSPECT THE NON RETURN VALVE.

DUST COLLECTOR (PC & MAIN)

1
Check the bags condition
2
Check for tightening of inspection / roof door bolts
3
Check for proper functioning of solenoid valve
4
General inspection for any air leakages
5
check the purging system.
6
check dust collector inlet and outlet duct condition
7 Check the inlet / outlet expansion joint condition

8 Check the cages condition

FAN
1 Check for any coating on blade or wear
2 Check the bearing housing condition
3 Check shaft sealing plate
5 Check Bearing for Clearance
6 Check foundation bolts / casing bolts
7 Check coupling condition
8 Check impeller for any wear or damage
9 check casing condition
10 check fan inlet and outlet expansion joints for any damage
11 check damper valve opening for suction
12 Check the inlet cone condition
13 Check the casing internal bolts condition for any wear
SCREW CONVEYOR ( BELOW AYDC HOPER )

1
Check the Hanger Bearing , Journal & Bearing Housing for any wear.
2 check for any wear of screw flights
3 check for wear of gland packing any leakage
4 check the hanger bearing journal bolt
5 Check the de & nde bearing and housing condition.
6 Check the Geared Motor condition
7 Check the Coupling and bush condition
FINE COAL BIN
1 Check the PC & Main Bin for any coating inside the bin.
2 Check the Bin airation system solenoid valve diaphragam.
3 Check the filter plate for bin airation.
4 Check the hose pipe for any lekages
5 Check the bin condition
6 Check the nozzle condition
7 Check the rapture disc condition
8 Check the MS bin any waer
9 Check the SS bin any wear

AYDC DUST COLLECTOR

1 INSPCT THE AIR PURZZING PIPE LINE w
2 INSPCT THE RECIVER CONNECTING WIRE BRAIDED HOSE PIPE w
3 INSPECT THE ALL CHAMBERS FOR ANY BAG DAMAGES
4 INSPECT THE AIR DUCT FOR ANY COAL ACCUMLATION.
5 INSPECT THE PRESSURE GAUGE.
6 INSPECT AIR RECIVER TANK FOR ANY LEAKAGES.
7 INSPECT THE PURZZING PIPE LINE HOLDING CLAMP.
8 INSPECT THE HOPPER LEAKAGES
9 INSPECT THE BUFFER PLATE
10 INSPECT THE AYDC INLET DUCT LEAKGES .
11 INSPECT THE AYDC OUTLET DUCT LEAKGES.
12 INSPECT INLET FLAP OPERATION
13 INSPECT THE OUTLET DUCT FLAP OPERATION
14 INSPECT THE DOOR SEALING RUBBER PACKING
15 INSPECT THE DIAPHGRAM
16 INSPECT THE SOLINOID VALVE.

SEAL AIR BLOWER

1 INSPECT THE HOUSING BOLT
2 INSPECT THE MOTOR BASE BOLT
3 INSPECT THE V BELT QUALITY OF BLOWER
4 INSPECT THE SUCTION FILTER QUALITY . W
5 INSPECT THE DRIVE SIDE BEARING
6 INSPECT THE NON DRIVE SIDE BEARING
7 INSPECT THE IMPELLAR

REJECTION BELT
1 INSPECT THE BELT JOINT
2 INSPECT THE SCRET RUBBER QUALITY
3 INSPECT THE JACK BOLT CONSDITION
4 INSPECT THE HEAD DRUM BEARING BASE BOLT
5 INSPECT THE TAIL DRUM BEARING HOUSING BASE BOLT
6 INSPCT THE TAIL DRUM BEARINGS
7 INSPECT THE HEAD DRUM BEARING

POLDAS
1 INSPECT THE CONVEYING NOZZLE FOR ANY WEAR
2 INSPECT THE CONTROL VALVE SPINDAL FOR WEAR
3 INSPECT THE CONTROL VALVE SEATING FOR WEAR
4 INSPECT THE BIN AERATION CLOTH QUALITY
5 INSPECT THE NON METALIC EXPANSION BELLOW FOR ANY DAMAGE
6 INSPECT THE FLAP FOR ANY WEAR
7 INSPECT THE CONVEYING PIPE FOR ANY DAMAGE.
OAL MILL- 1

FREQUENCY
Forthnight Monthly Quarterly Half yearly Yearly

Q
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 ESS CHECK POINT FOR COAL MILL- 2

FREQUENCY
SL.NO. CHECK POINTS
Weekly Forthnight Monthly

RAW COAL HOPPER / ROD GATE

1 W
CHECK THE RAW COAL HOPPER FOR ANY LEAKAGE

2
CHECK THE PIN GATE ROD FOR ANY BEND

3 M
CHECK THE FRENESS OF ROD GATE

4
CHECK THE PIN GATE SEATING BUSH WELDING INSPECTION

DRAG CHAIN

1 CHECK THE CHAIN TENSION w

2 INSPECT THE DRAG PLATE WEAR TEAIR m

3 INSPECT THE GUIDE RAIL CONDITION. m

4 INSPECT THE LINER PLATE . w

5 INSPECT THE TAIL DRUM BEARINGS

6 INSPECT THE HEAD DRUM BEARINGS

7 INSPECT THE TAIL DRUM ADJUSTMENT JACK BOLT m

ROTARY AIR LOCK( GRAVEL GATE)

1
Check rotor condition for wear or damage
2
Check the gearbox/gear motor Condition & Coupling.

3
General inspection of coupling and bush any wear

4
Check the RAL DE & NDE Bearing and housing
5
Check the DE & NDE Glande
Check the Rotor blade with housing clearence
6

7 Check the casing for any leakages M

CLASSIFER
1 M
INSPECT THE CLASSIFER BLADE
2
INSPECT THE TIE ROD ADJUSTMENT ROD CASING PIPE WEAR
3 M
INSPECT THE COUPLING BOLT OF CLASSIFER
4
INSPECT THE MOTOR BASE BOLT
5 M
INSPECT CLASSIFER OUTLET DUCT LEAKAGES
6
INSPECT THE BOTTOM BEARING
7
INSPECT THE BOTTOM BEARING GREASING PIPE LINE.
8
INSPECT COUPLING BOLT
9
INSPECT THE TOP BEARING

VRM (COAL MILL)

1 W
INSPECT THE GUIDE BRACKET BOLT.
2 W
INSPECT THE GUIDE PIN BOLTS .
3 W
INSPECT THE TIE ROD SEAL PLATE BOLTS
4 W
INSPECT THE WALL LINER & ITS BOLTS.
5 W
INSPECT THE ROLLER ASSYMBLY HOOK BOLTS
6 W
INSPECT THE TIE ROD FOR ANY WEAR IN THE EYE PORTION.
7 W
INSPECT THE SCRAPPER PLATE
8 W
INSPECT THE INSULATION RING JOINTS & ITS BOLTS
9 W
INSPECT THE ANY LEAKAGES IN THE MILL BODY (DOME )
10 W
INSPECT THE OIL LAVEL IN SEAL LUBRICATION TANK
11 W
INSPECT THE ANY LEAKAGES IN SEAL AIR BLOWER PIPE LINE
12 W
TAKE THE WEAR READING OF ROLLER SHELL
13 W
TAKE WEAR READING OF TABEL LINER
14 W
INSPECT THE OIL LAVEL OF ALL ROLLER ASSYMBLY.
15 w
INSPECT THE ANY LEAKAGES IN THE ROLLER ASSYMBLY.
16 w
INSPECT THE TIE ROD SEALING BELLOW
17 M
INSPECT FELT PACKING FOR ANY LEKAGES IN BOWL.
18 M
INSPECT THE MILL OUTLET DUCT DISTANCE PIECE LEAKAGES .
19 M
COUPLING BOLT & BUSH INSPECTION

MAIN GEAR BOX (COAL MILL)

1
Check the gear box internal inspection
2
Check the auxillary drive condition
3
Visual check of pipe condition & its clamping
4
Check the pin bush coupling bolt and bush any wear
5 M
Check the breather cleaning
6
Check the segment pads condition

GEAR BOX LUBRICATION SYSTEM (COAL MILL)

1 M
INSPECT THE OIL FILTER IN MAIN LINE
2 M
INSPECT THE WATER FILTER
3 W
INSPECT THE ANY LEAKAGES IN THE OIL PIPE LINE
4 W
INSPECT THE ANY LEAKAGES IN WATER PIPE LINE
5 W
INSPECT THE LEAKAGES IN OIL STORAGE TANK.
6 M
Check the heat exchanger tubes for ang lekages.
7
check the pump condition
HYDRAULIC UNIT SYSTEM (COAL MILL)

1
check the pump condition
2
Check the accmulator Nitrogen Pressure.
3
Check the filter any contnamination and replaced
4 M
Check the hose condition
5 W
INSPECT THE CYLINDER BASE BOLTS.
6
INSPECT THE CHECK VALVE
7
INSPECT THE NON RETURN VALVE.

DUST COLLECTOR (PC & MAIN)

1
Check the bags condition
2 M
Check for tightening of inspection / roof door bolts
3
Check for proper functioning of solenoid valve

4 M
General inspection for any air leakages
5 M
check the purging system.

6
check dust collector inlet and outlet duct condition

7 Check the inlet / outlet expansion joint condition

8 Check the cages condition

FAN

1
Check for any coating on blade or wear
2
Check the bearing housing condition

3
Check shaft sealing plate

5
Check Bearing for Clearance

6
Check foundation bolts / casing bolts

7
Check coupling condition

8 M
Check impeller for any wear or damage

9
check casing condition
check fan inlet and outlet expansion joints for any damage
10

11
check damper valve opening for suction

12
Check the inlet cone condition

13
Check the casing internal bolts condition for any wear

SCREW CONVEYOR ( BELOW AYDC HOPER )

1 Check the Hanger Bearing , Journal & Bearing Housing for

any wear.

2
check for any wear of screw flights

3
check for wear of gland packing any leakage

4
check the hanger bearing journal bolt

5
Check the de & nde bearing and housing condition.
6
Check the Geared Motor condition
7
Check the Coupling and bush condition

FINE COAL BIN

1
Check the PC & Main Bin for any coating inside the bin.

2
Check the Bin airation system solenoid valve diaphragam.

3
Check the filter plate for bin airation.

4
Check the hose pipe for any lekages

5
Check the bin condition

6
Check the nozzle condition

7
Check the rapture disc condition

8
Check the MS bin any waer

9
Check the SS bin any wear

AYDC DUST COLLECTOR

1 w
INSPCT THE AIR PURZZING PIPE LINE
2 w
INSPCT THE RECIVER CONNECTING WIRE BRAIDED HOSE PIPE
3 M
INSPECT THE ALL CHAMBERS FOR ANY BAG DAMAGES
4 M
INSPECT THE AIR DUCT FOR ANY COAL ACCUMLATION.
5 M
INSPECT THE PRESSURE GAUGE.
6 M
INSPECT AIR RECIVER TANK FOR ANY LEAKAGES.
7 M
INSPECT THE PURZZING PIPE LINE HOLDING CLAMP.
8
INSPECT THE HOPPER LEAKAGES
9
INSPECT THE BUFFER PLATE
10
INSPECT THE AYDC INLET DUCT LEAKGES .
11
INSPECT THE AYDC OUTLET DUCT LEAKGES.
12
INSPECT INLET FLAP OPERATION
13
INSPECT THE OUTLET DUCT FLAP OPERATION
14
INSPECT THE DOOR SEALING RUBBER PACKING
15
INSPECT THE DIAPHGRAM M
16
INSPECT THE SOLINOID VALVE.

SEAL AIR BLOWER

1
INSPECT THE HOUSING BOLT M
2
INSPECT THE MOTOR BASE BOLT M
3
INSPECT THE V BELT QUALITY OF BLOWER M
4 W
INSPECT THE SUCTION FILTER QUALITY .
5
INSPECT THE DRIVE SIDE BEARING
6
INSPECT THE NON DRIVE SIDE BEARING
7
INSPECT THE IMPELLAR

REJECTION BELT
1
INSPECT THE BELT JOINT M
2
INSPECT THE SCRET RUBBER QUALITY M
3
INSPECT THE JACK BOLT CONSDITION M
4
INSPECT THE HEAD DRUM BEARING BASE BOLT
5
INSPECT THE TAIL DRUM BEARING HOUSING BASE BOLT
6
INSPCT THE TAIL DRUM BEARINGS
7
INSPECT THE HEAD DRUM BEARING
 ROTOSCALE (Main and PC)

1
Check the Rotor Condition.
2 Check the blow out Nozzle for Wear.
3 Check the Gear Box Condiition.
4 Check the Gear Box Drive belt condition.
5 Check the Drive & Driven Spocket for wear or damage.
6 Check the Upper Sealing Plate for any Wear.
7 Check the Gap of the Rotor.
8 Check the Bottom Sealing Plate for any Wear.
Check the expansion bellow/metallic exp. Joint condition
9
FREQUENCY
Quarterly Half yearly Yearly

H
 H

Q
 Y

y
 H

Q
Q

Q y

H
 Y

H
 H

Q
 Y
Y
Y
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Q
 ESS CHECK POINTS FOR KILN - 2

FREQUENCY
SL.NO. CHECK POINTS
Weekly Forthnight Monthly
KILN FEED BIN

Inspect the bottom bin cloth

1
Inspect the bin aeration
2
Inspect the venting pipe line condition.
3
SOLID FLOW METER

Inspect the cloth of solid flow meter

1
Inspect the any lekages in the casing
2
Inspect the calibration of solid flow meter
3
Inspect the aeration pipe line leakages
4
Inspect the chain condition inside solid flow meter
5
KILN FEED ROTOR SCALE

Check the rotor housing condition any wear

1
Check the upper housing plate and lower housing plate any wear
2
Check the condition of the seal for drive shaft
3
Check the condition of the compenastor any crack
4
Check the geared motor condition
5
check the rotor shaft
6
Dosing valve (Pneumatic/ motorised)

Check the dosing valve cloth

1
Inspect the dozzing valve actuator/Pneumatc cylinder
2
Check for smooth operation of gate
3
Check the condition of manual disengaging lever
4
Check the locking of gate with the shaft
5
Check for proper sealing of the gate
6
check the coupling and its bush
7
 CYCLONE. (PRE-HEATER)

Check the Dip tube for any Damage.

1
Check the Dip tube holding clamp
2
Check the Cyclone for any damage.
3
Check the distribution box, dispertion plate
4
Check the pendulum flap and bearing condition
5
Check the metalic expansion joint condition
6
check the dividing gate
7

8 Check the cyclone feed pipe condition.

Belt Bucket elevator

Check the head drum bearing

1
Check the tail drum bush bearing
2
Check drum for damage
3
Check tensioning device for function, damage, wear
4
Check conveying belt for damage
5
Check conveying belt clamp connection General cond.
6
Check tightening torque of clamp bolts
7
Check buckets & Holding bolts (Visual check)
8
Check torque support for damage
9
Check friction liner
10
Check whether any wires are exposed near the clamping
11 connection.
Check the Hardness of belt near the belt clamping connection
12
Check the condition of belt behind the rubber strip & hardness.
13
Check whether bucket fixing holes are enlarged or cracks
14 developed.
Check the auxillary drive condition
15
AIR SLIDE BLOWER

Check the bearing and housing condition

1
Check for impeller coating and condition
2
check the blower foundation bolts
3
 Inlet suction filter cleaning
4 M
check the damper
5
Air slide box

Check for cloth condition

1
Check for casing tightening bolts
2
Check casing condition
3
Check the air slide aeration pipe for any damage.
4
Divertor

Check the bearing condition

1
Check for proper functioning
2
General inspection of pneumatic cylinder / motorised actuator
3
Check flap condition for wear or damage
4
Slide gate

Check for proper functioning

1 M
General inspection of pneumatic cylinder / screw (manual)
2
Check slide plate condition for wear or damage
3
Check the condition of support roller.
4
check the glant rope for any damage.
5
Rotary air lock

Check rotor condition for wear or damage

1
Check the gearbox/gear motor Condition & Coupling.
2
General inspection of coupling
3
Check the RAL DE & NDE Bearing.
4
Check the DE & NDE Glande
5

6 Check the Rotor blade with housing clearence

Dust collector

Check the bag condition

1
Check for tightening of inspection / roof door bolts
2
Check for proper functioning of solenoid valve
3 M
 General inspection for any air leakages
4 M
check the purging system.
5
check dust collector inlet and outlet duct condition
6
Check the inlet / outlet expansion joint condition
7
Check the bags condition
8
Check the cages condition
9
KILN INLET SEAL

1 Inspect the graphite Blocks

2 Inspect the bottom portion wire rope condition M

3 Inspect the top portion wire rope condition M

4 Inspect the welding jionts of the hub casing

5 inspect the joint bolt of the hub casing
6 inspect the V-Belt condition of the blower
7 inspect the v- pulley condition.
8 inspect the fan base bolt & base frame condition.
KILN OUTLET SEAL (PNEUMATIC)

1 INSPECT THE ALL CYCLINDERS FOR ANY LEKAGES

2 INSPECT THE SEAL ROPE
3 INSPECT SEAL PLATE
4 INSPECT SEALING PLATE
5 INSPECT THE SEAL PLATE BOLT ( CSK)
6 INSPECT THE INLET SEAL GREASE POINT M

7 INSPECT THE HOSE PIPE OF CYCLINDER M

KILN
1 INSPECT THE SUPPORTING ROLLER SHAFT
2 INSPECT THE SUPPORTING ROLLER SEAL FOR LEAKAGES
3 INSPECT THE SUPPORTING ROLLER BASE BOLTS
4 INSPECT THE SUPPORTING ROLLER HOUSING
5 INSPECT THE TYRE SLIPPAGES
6 INSPECT THE TYRE RETAINER RING JOINTS
7 INSPECT THE SUPPORTING ROLLER TYRE FOR ANY CRACK
8 INSPECT THE WATER PIPE LINE OF SUPPORTING ROLLER
9 INSPECT THE RETURN LINE WATER PIPE LINE
10 INSPECT THE GIRT GEAR JOINT BOLTS
11 INSPECT THE GEARTH GEAR TEETH FOR ANY CRACK
12 INSPECT THE PINION TEETH
13 INSPECT THE PINION SHAFT
14 INSPECT THE GIRTH GEAR SPRAY SYSTEM NOZZLES
15 INSPECT THE GIRTH GEAR SPRAY S/Y PUMP
16 INSPECT THE GIRTH GEAR SPRAY S/Y FILTTERS
17 INSPECT THE GIRTH GEAR SPRAY PATTERN
18 INSPECT THE MAIN DRIVE GEAR BOX
19 INSPECT THE GEAR BOX WATER PIPE LINE
20 INSPECT THE WATER FILTER IN WATER PIPE LINE OF SUPPORTING ROLLER
21 INSPECT THE OIL LEAKAGES IN GEAR BOX
22 INSPECT THE GEAR BOX LUBRICATION PUMP
23 INSPECT THE GEAR BOX COUPLING BOLT
24 INSPECT THE COUPLINGS
25 INSPECT TORSHION SHAFT COUPLING BOLTS & COUPLING
26 INSPECT THE NOSE RING BLOWER

KILN MAIN DRIVE GEAR BOX

Check the gear box internal inspection

1
check the brether
2
check the coupling .
3
check the torsion shaft .
4
check the torsion shaft coupling bolt & its teeth.
5
 check gear box base bolt.
6
Check the centrifugal breake
7
Condition of break liners
8
Check the out put flexible coupling for any bush worn out.
9
check the internal pipe line
10
KILN MAIN DRIVE GEAR BOX LUBRICATION SYSTEM

Pump flange bolts tightness.

1
check the coupling .
2
check the coupling spider
3
check the leakages from the pump.
4
Check the oil Filter (Dual Filter)
5
Check the breather cleaning
6
Inspection and cleaning of tubes for heat exchanger
7
GRATE COOLER

1 INSPECT THE UNDER GRATE COOLER PLATE T BOLT TIGHTNESS

2 INSPECT THE GEAR BOX BREATHER
3 INSPECT THE TAPER BLOCK & ITS BOLT
4 INSPECT THE GUIDE ROLLER & ITS BOLT
5 INSPECT THE RING FEEDER BOLT OF COOLER DRIVE SHAFT
6 INSPECT THE SEAL PLATE THICKNESS
7 INSPECT THE DRIVE CHAIN
8 INSPECT THE BOGGE WHEEL TAPER BLOCK
9 INSPECT THE COUPLING & ITS BOLT
INSPECT THE MOVING BEAM FOR ANY CRACK.
10
INSPCT THE SIDE CASTING
11
INSPECT THE COOLER PLATE FOR WEAR AND CRACK
12
INSPECT THE CURTAIN CHAIN THICKNESS
13
INSPECT THE CURTAIN CHAIN HOLDING BEAMS WELDING
14
FAN
 Check for any coating or wear
1
Check the bearing and housing condition
2
Check shaft sealing plate
3
Check cooling disc condition
4
Check Bearing for Clearance
5
Check foundation bolts / casing bolts
6
Check coupling condition
7
Check impeller for any wear or damage
8
check casing condition
9
check fan inlet and outlet expansion joints for any damage
10
Check the inlet cone condition
11
Check the casing internal bolts condition for any wear
12
Clinker Breaker

check the rotor disc thickness

1
check the grizzaly bar thickness and bend
2
check the side wall liner plate
3
check the casing wall liner plate
4
check the rotor disc thickness
5
check the hammer pin & its locking any wear and bend
6
Inspect the drive & non drive side bearing
7
Inspect the v belt condition
8
Inspect the pully any wear
9
Inspect the fluid coupling and oil level
10
Inspect housing base bolt
11
Deep pan conveyor

Check the Frames, steel structure and Machine parts for any sign
1 of corrosion, Deformation of subassemblies and Welding seams
for cracks.
Check the nut locks for completeness and function of connecting
2 element.
Check the Pedestal Bearing(Head Drum) & Flanged Bearing( Tail
3 Drum) Condition .
Check the Drive Sprocket for slip-free chain transported
4
 Check the drive sprocket or segments worn out.
5
Check the Tension Roller Sprocket is the chain transported in a
6 slip-free way.
Check the tensioning roller sprocket or segment worn out.
7
Check does the tensioning roller sprocket take up the chain
8 sufficiently.
Check the Chain & bucket damage or wear and tear be detected.
9
Check the Wheels functional and sufficiently lubricated.
10
Check whether chain is runing centrally.
11
Check the wire ropes been fastened correctly.
12
Check the wire rope worn off or do they show any mechanical
13 damage.
Check the Rope Pulley for any damage.
14
Check the bucket bolts and bucket condition
15
Check the rail condition
16
Check the bucket wheel bolts and free rotation
17
WATER SPARY SYSTEM

1 Check the pump condition

Check the gland conditin

2

3 Check the pneumatic ball valve proper functioning

4 Check the air filter regulator M

5 Check for coupling and spider condition

6 CHECH THE NOZZLE PIPE LINE THICKNESS.

7 CHECK THE NOZZLE TIP W
8 CHECK THE HOSE PIPE FOR LEAKAGE W

GAS CONDITION TOWER

1 CHECK THE WATER SPRAY PATTERN W
2 CHECK THE WATER SPARY LANCER TIP CONDITION F
3 CHECK THE LANCER CONDITION M
4 CHECK THE WATER FILTER M
5 CHECK THE ON/OFF VALVE CONDITION
6 CHECK THE HOSE CONDITION M
7 CHECK THE PROTECTION PIPE THICKNESS
8 CHECK THE WATER PUMP
9 CHECK THE DRIVE & NON DRIVE SIDE BEARING
10 CHECK THE PUMP DRIVE & NON DRIVE SIDE GLANT M
11 CHECK THE COUPLING CONDITION.
12 CHECK THE COUPLING BOLTS & BUSHS
 AIR BLASTER
1 CHECK THE AIR BLASTER NOZZLE
2 CHECK THE SAFTEY VALVE OF AIR BLASTER
3 CHECK THE QUICK EXHAUST VALVE BODY
4 CHECK THE QUICK EXHAUST VALVE DIAPHGRAM M
5 CHECK THE HOSE PIPE M
6 CHECK THE AIR PIPE LINE M
7 CHCEK THE PISTON M
8 CHECK THE PISTON RUBBER PAD M
FREQUENCY
Quarterly Half yearly Yearly

H
 Y

H
H

H Y

H
 H

Y
 Y

H
 Y

Y
H

Y
 Y

Q
Q

Y
H
Q

Q
Q
 H
Q
Q
 ESS CHECK POINTS FOR KILN - 1

FREQUENCY
SL.NO. CHECK POINTS
Weekly Forthnight Monthly
KILN FEED BIN

Inspect the bottom bin cloth

1
Inspect the bin aeration
2
Inspect the venting pipe line condition.
3
IMPACT FLOW METER

Inspect the impact plate thickness

1
inspect the casing for leakages
2
inspect the casing bolts tightning for any lekages
3
inspect the calibration
4
KILN FEED AERO POLE

check the bottom pneumatic gate

1
check the by pass pneumatic gate
2
check the bottom air slide cloth
3
check the conveying pipe line .
4
check the hose pipe for leakages
5
check the aeration pipe line lekages.
6
Dosing valve (Pneumatic/ motorised)

Check the dosing valve cloth

1
Inspect the dozzing valve actuator/Pneumatc cylinder
2
Check for smooth operation of gate
3
Check the condition of manual disengaging lever
4
Check the locking of gate with the shaft
5
Check for proper sealing of the gate
6
check the coupling and its bush
7
 CYCLONE. (PRE-HEATER)

Check the Dip tube for any Damage.

1
Check the Dip tube holding clamp
2
Check the Cyclone for any damage.
3
Check the distribution box, dispertion plate
4
Check the pendulum flap and bearing condition
5
Check the metalic expansion joint condition
6
check the dividing gate
7

8 Check the cyclone feed pipe condition.

Belt Bucket elevator

Check the head drum bearing

1
Check the tail drum bush bearing
2
Check drum for damage
3
Check tensioning device for function, damage, wear
4
Check conveying belt for damage
5
Check conveying belt clamp connection General cond.
6
Check tightening torque of clamp bolts
7
Check buckets & Holding bolts (Visual check)
8
Check torque support for damage
9
Check friction liner
10
Check whether any wires are exposed near the clamping
11 connection.
Check the Hardness of belt near the belt clamping connection
12
Check the condition of belt behind the rubber strip & hardness.
13
Check whether bucket fixing holes are enlarged or cracks
14 developed.
Check the auxillary drive condition
15
AIR SLIDE BLOWER
 Check the bearing and housing condition
1
Check for impeller coating and condition
2
check the blower foundation bolts
3
Inlet suction filter cleaning
4 M
check the damper
5
Air slide box

Check for cloth condition

1
Check for casing tightening bolts
2
Check casing condition
3
Check the air slide aeration pipe for any damage.
4
Divertor

Check the bearing condition

1
Check for proper functioning
2
General inspection of pneumatic cylinder / motorised actuator
3
Check flap condition for wear or damage
4
Slide gate

Check for proper functioning

1 M
General inspection of pneumatic cylinder / screw (manual)
2
Check slide plate condition for wear or damage
3
Check the condition of support roller.
4
check the glant rope for any damage.
5
Rotary air lock

Check rotor condition for wear or damage

1
Check the gearbox/gear motor Condition & Coupling.
2
General inspection of coupling
3
Check the RAL DE & NDE Bearing.
4
Check the DE & NDE Glande
5
6 Check the Rotor blade with housing clearence

Dust collector

Check the bag condition

1
Check for tightening of inspection / roof door bolts
2
Check for proper functioning of solenoid valve
3 M
General inspection for any air leakages
4 M
check the purging system.
5
check dust collector inlet and outlet duct condition
6
Check the inlet / outlet expansion joint condition
7
Check the bags condition
8
Check the cages condition
9
KILN INLET SEAL(pneumatic)

1 INSPECT THE ALL CYCLINDERS FOR ANY LEKAGES

2 INSPECT THE SEAL ROPE
3 INSPECT SEAL PLATE
4 INSPECT SEALING PLATE
5 INSPECT THE SEAL PLATE BOLT ( CSK)
6 INSPECT THE INLET SEAL GREASE POINT
7 INSPECT THE AIR PIPE OF CYCLINDER
8
KILN OUTLET SEAL (laminar)

1 INSPECT THE LAMINAR PLATE FOR ANY DAMAGE

2 INSPECT THE LAMINAR PLATE HOLDING BOLT
3 INSPECT THE LAMINAR PLATE HOLDING ROPE
4 INSPECT THE DUST SPILLAGE HOPPER FOR ANY WELDING CRACK
5 INSPECT THE DUST CONVEING PIPE LINE
6 INSPECT THE KOUL SHELL THICKNESS
 KILN
1 INSPECT THE SUPPORTING ROLLER SHAFT
2 INSPECT THE SUPPORTING ROLLER SEAL FOR LEAKAGES
3 INSPECT THE SUPPORTING ROLLER BASE BOLTS
4 INSPECT THE SUPPORTING ROLLER HOUSING
5 INSPECT THE TYRE SLIPPAGES
6 INSPECT THE TYRE RETAINER RING JOINTS
7 INSPECT THE SUPPORTING ROLLER TYRE FOR ANY CRACK
8 INSPECT THE WATER PIPE LINE OF SUPPORTING ROLLER
9 INSPECT THE RETURN LINE WATER PIPE LINE
10 INSPECT THE GIRT GEAR JOINT BOLTS
11 INSPECT THE GEARTH GEAR TEETH FOR ANY CRACK
12 INSPECT THE PINION TEETH
13 INSPECT THE PINION SHAFT
14 INSPECT THE GIRTH GEAR SPRAY SYSTEM NOZZLES
15 INSPECT THE GIRTH GEAR SPRAY S/Y PUMP
16 INSPECT THE GIRTH GEAR SPRAY S/Y FILTTERS
17 INSPECT THE GIRTH GEAR SPRAY PATTERN
18 INSPECT THE MAIN DRIVE GEAR BOX
19 INSPECT THE GEAR BOX WATER PIPE LINE
20 INSPECT THE WATER FILTER IN WATER PIPE LINE OF SUPPORTING
ROLLER
21 INSPECT THE OIL LEAKAGES IN GEAR BOX
22 INSPECT THE GEAR BOX LUBRICATION PUMP
23 INSPECT THE GEAR BOX COUPLING BOLT
24 INSPECT THE COUPLINGS
25 INSPECT TORSHION SHAFT COUPLING BOLTS & COUPLING
26 INSPECT THE NOSE RING BLOWER
 KILN MAIN DRIVE GEAR BOX

Check the gear box internal inspection

1
check the brether
2
check the coupling .
3
check the torsion shaft .
4
check the torsion shaft coupling bolt & its teeth.
5
check gear box base bolt.
6
Check the centrifugal breake
7
Condition of break liners
8
Check the out put flexible coupling for any bush worn out.
9
check the internal pipe line
10
GRATE COOLER

1 INSPECT THE UNDER GRATE COOLER PLATE T BOLT TIGHTNESS

2 INSPECT THE GEAR BOX BREATHER
3 INSPECT THE TAPER BLOCK & ITS BOLT
4 INSPECT THE GUIDE ROLLER & ITS BOLT
5 INSPECT THE RING FEEDER BOLT OF COOLER DRIVE SHAFT
6 INSPECT THE SEAL PLATE THICKNESS
7 INSPECT THE DRIVE CHAIN
8 INSPECT THE BOGGE WHEEL TAPER BLOCK
9 INSPECT THE COUPLING & ITS BOLT
INSPECT THE MOVING BEAM FOR ANY CRACK.
10
INSPCT THE SIDE CASTING
11
INSPECT THE COOLER PLATE FOR WEAR AND CRACK
12
INSPECT THE CURTAIN CHAIN THICKNESS
13
 INSPECT THE CURTAIN CHAIN HOLDING BEAMS WELDING
14
FAN

Check for any coating or wear

1
Check the bearing and housing condition
2
Check shaft sealing plate
3
Check cooling disc condition
4
Check Bearing for Clearance
5
Check foundation bolts / casing bolts
6
Check coupling condition
7
Check impeller for any wear or damage
8
check casing condition
9
check fan inlet and outlet expansion joints for any damage
10
Check the inlet cone condition
11
Check the casing internal bolts condition for any wear
12
Clinker Breaker

check the rotor disc thickness

1
check the grizzaly bar thickness and bend
2
check the side wall liner plate
3
check the casing wall liner plate
4
check the rotor disc thickness
5
check the hammer pin & its locking any wear and bend
6
Inspect the drive & non drive side bearing
7
Inspect the v belt condition
8
Inspect the pully any wear
9
Inspect the fluid coupling and oil level
10
Inspect housing base bolt
11
Deep pan conveyor
 Check the Frames, steel structure and Machine parts for any sign of
1 corrosion, Deformation of subassemblies and Welding seams for
cracks.
Check the nut locks for completeness and function of connecting
2 element.
Check the Pedestal Bearing(Head Drum) & Flanged Bearing( Tail
3 Drum) Condition .
Check the Drive Sprocket for slip-free chain transported
4
Check the drive sprocket or segments worn out.
5
Check the Tension Roller Sprocket is the chain transported in a slip-
6 free way.
Check the tensioning roller sprocket or segment worn out.
7
Check does the tensioning roller sprocket take up the chain
8 sufficiently.
Check the Chain & bucket damage or wear and tear be detected.
9
Check the Wheels functional and sufficiently lubricated.
10
Check whether chain is runing centrally.
11
Check the wire ropes been fastened correctly.
12
Check the wire rope worn off or do they show any mechanical
13 damage.
Check the Rope Pulley for any damage.
14
Check the bucket bolts and bucket condition
15
Check the rail condition
16
Check the bucket wheel bolts and free rotation
17
WATER SPARY SYSTEM

1 Check the pump condition

Check the gland conditin

2

3 Check the pneumatic ball valve proper functioning

4 Check the air filter regulator M

5 Check for coupling and spider condition

CHECH THE NOZZLE PIPE LINE THICKNESS.

6
CHECK THE NOZZLE TIP
7 W
CHECK THE HOSE PIPE FOR LEAKAGE
8 W
 GAS CONDITION TOWER

CHECK THE WATER SPRAY PATTERN

1 W
CHECK THE WATER SPARY LANCER TIP CONDITION
2 F
CHECK THE LANCER CONDITION
3 M
CHECK THE WATER FILTER
4 M
CHECK THE ON/OFF VALVE CONDITION
5
CHECK THE HOSE CONDITION
6 M
CHECK THE PROTECTION PIPE THICKNESS
7
CHECK THE WATER PUMP
8
CHECK THE DRIVE & NON DRIVE SIDE BEARING
9
CHECK THE PUMP DRIVE & NON DRIVE SIDE GLANT
10 M
CHECK THE COUPLING CONDITION.
11
CHECK THE COUPLING BOLTS & BUSHS
12

AIR BLASTER
1 CHECK THE AIR BLASTER NOZZLE
2 CHECK THE SAFTEY VALVE OF AIR BLASTER
3 CHECK THE QUICK EXHAUST VALVE BODY
4 CHECK THE QUICK EXHAUST VALVE DIAPHGRAM M
5 CHECK THE HOSE PIPE M
6 CHECK THE AIR PIPE LINE M
7 CHCEK THE PISTON M
8 CHECK THE PISTON RUBBER PAD M
FREQUENCY
Quarterly Half yearly Yearly

H
 Y

H
H

H Y

H
 Y

Y
 Y

Y
 Y

Y
 Y

H
 Y

Q
Q

H
Q
Q