MAINTENANCE 2020-21
Name of the Plant
CPCL LPG Plant Location : Manali
SECTION:1 PREVENTIVE MAINTENANCE LOG BOOK
SR:NO Equipment Name Spare used
1. Fiber Optic Cable
2. Valve Spindle.
3. Gun Pin.
4. Load Cell Cable MAK-III
5. Pneumatic cyl 50-Dia seal kit
6. Mounting Plate.
7. Mouth Washer.
8. Nylon Roller.
9. O-Ring Green.
10.Pipe For Filling Head.
11.Power and communication cable.
12.Rubber Suspension Bush.
13.U-seal for Filling Machine.
14.Reflector.
15.Spring For new gun.
16.Spring For Old Gun.
17.Stabilizer.
18.Center column Seal Kit
19.Load cell.
20.Centering Arm.
21.Ball Bushing.
22.Bearing 6016-2Z
23.CUC Key pad MK-II
24.Gas stop valve Pad.
25.T-Connector Cable.
1 CAROUSEL- 2 No's
Month : November-2021
Details of repair/service Preventive Maintenance Schedule
1. Carousel-1 fiber optic cable damaged, so 1. During Sunday Maintenance we done the servic
replaced With 1 Nos of new cable. for introduction & Ejection unit for Both the
2. 5/2 valve serviced in F/M :NO:10 in carousel- carousel.
1 replaced. 2.Preventive Log Book is Maintained in Daily bases.
3. During service of Filling gun some of filling 3.Carousel cleaning was done in regular bases.
gun pin was damaged so replaced withnew one. 4.Filling Machine Alignment was done for Proper
4. Carousel-2 Check scale load cell cable
Clamping of cylinder.
damaged, So replaced with 1 no of new cable.
5. For both the carousel-1&2 Introduction & 5.Carousel wheel Greasing was done in weekely
Ejection Serviced and new seal kit was replaced bases for both the carousel.
during sunday maintenance. 6.Calibration for the check scale is done at the start
6. To adjust the centering of Filling machine we of shift.
used this plate in carosuel-1&2 some of filling
machine plate is having some problem so
replaced during sunday maintenance.
7. During Service of pneumatic filling gu0n
some of the guns the seal is damaged , So
replaced with new one.
8. Existing Nylon Roller in the double & single
stopper is fully damaged, So replace with the
new one.
9. During service of non-Pneumatic Filling gun
we have replaced this O-ring.
10. In Filling machine some of the LPG hose
connecting bend Pipe ferrul damage is there so
replaced with new one.
11. Filling Machine no: 18 in carousel-1 cable
damaged so replaced with the new one.
12. To maintain the filling accuracy we need to
replace the damage Bush in filling machine.
13. During gun service we used to replace the
damage O-rings.
14. To identy the Filling machine we used this
reflector as a sensor is damaged so replaced with
new one,
15. For proper functioning of filling we used to
replaced the new spring.
16. For Proper centering of Filling Gun we used
this stabilizer.
17.Carousel-1 Center Column leak on (06-08-
2021) So replaced with New service kit along
with the 2 nos od bearing.
18.Carousel-2 Static Check scale load cell
problem so replace with 1 nos of New load cell.
19. For proper centering of cylinders in Filling
machine we have replaced 16 nos of new
centering arm in both carousels.
20.Carousel-1 introduction ball bushing is
repaced with 2 nos of new one.
21.Carousel-2 Wheel bearing of 2 nos is replaced
with new one.
22.Carousel filling machine CUC card replaced
with 1 nos of new one.
23.Carousel-2 fillling machine gas stop valve
 22.Bearing 6016-2Z 10. In Filling machine some of the LPG hose
23.CUC Key pad MK-II connecting bend Pipe ferrul damage is there so
24.Gas stop valve Pad. replaced with new one.
25.T-Connector Cable. 11. Filling Machine no: 18 in carousel-1 cable
damaged so replaced with the new one.
12. To maintain the filling accuracy we need to
replace the damage Bush in filling machine.
13. During gun service we used to replace the
damage O-rings.
14. To identy the Filling machine we used this
reflector as a sensor is damaged so replaced with
new one,
15. For proper functioning of filling we used to
replaced the new spring.
16. For Proper centering of Filling Gun we used
this stabilizer.
1 CAROUSEL- 2 No's 17.Carousel-1 Center Column leak on (06-08-
2021) So replaced with New service kit along
with the 2 nos od bearing.
18.Carousel-2 Static Check scale load cell
problem so replace with 1 nos of New load cell.
19. For proper centering of cylinders in Filling
machine we have replaced 16 nos of new
centering arm in both carousels.
20.Carousel-1 introduction ball bushing is
repaced with 2 nos of new one.
21.Carousel-2 Wheel bearing of 2 nos is replaced
with new one.
22.Carousel filling machine CUC card replaced
with 1 nos of new one.
23.Carousel-2 fillling machine gas stop valve
pad replaced in 2 nos.
24.Carousel-2 filling machine no:17
communication problem checked found T-
connector cable cut so replaced with 1 nos of
cable.
 1.Valve Detent.
2.Tapper Roller
2 VCM- 1 No
1. Preventiv Maintenance carried on
Sunday maintenance.
3 AUTO WEIGHT CORRECTION UNIT- 2 No's
1. Cleaning, calibration and gun
service done on regular bases.
4 Online Valve GD(GAS DETECTOR)- 2 No's
1.Pressure Transmitter PTPD
2.Cleaning, calibration and gun service damage so replaces with new one.
done on regular bases.
3.Angle joint.
5 Online PT ( PRESSURE TESTER)- 2 No's
4.PT Nozzle
1. Preventive maintenance and cleaning of 1.Daily preventive log book is maintained
machine is carried on regular bases. 2.Cleaning of VCM has been done in daily bases.
2. Valve detent of 6 nos new is replaced in 3. LPG hose Hydro testing done all hose found ok.
valve socket.
3. Sealing Bell limit switch tapper roller is
damaged so replaced with 1 nos of new one.
1. General Servise of equipment is done. 1.Daily calibration of the machine is carried out 2 hrs
2. Cleaning has been done during Sunday once.
maintenance. 2.Cleaning of machine is done in daily bases.
3.Alignment for the clamping of cylinder is done on
daily bases.
4.Machine sensor Cleaning is done in daily bases.
1.Alignment is done for proper functining of 1.Daily calibration of the machine is carried out 2 hrs
equipment. once.
2.Cleaning is done on regular bases. 2.Cleaning of machine is done in daily bases.
3.Alignment for the clamping of cylinder is done on
daily bases.
4.Machine sensor Cleaning is done in daily bases.
1.PT-1 Head pressure transmitter diaphragm 1.Daily calibration of the machine is carried out 2 hrs
once.
2.Alignment is done for proper functining of 2.Cleaning of machine is done in daily bases.
equipment. 3.Alignment for the clamping of cylinder is done on
3.Cleaning is done on regular bases. daily bases.
4.Machine sensor Cleaning is done in daily bases.

6 CONVEYOR
7 HOT AIR SEALING UNIT ( 2 No's)
8 BLOWER - 1 no
9 MSV(V-101,V-102,V-103,V-104)
BULK PUMP- 4 No's
10
(P-101,P102,P103,P104)
11 BOTTLING PUMP(P-105,P-106)
1.Majour conveyor maintenance work
was carried out for the HAS-2
2.Brown soap solution.
3.U-213 bearing
4.collection tray
5.Conveyor strip
6.Conveyor supporting angle.
7.Cutting Wheel
8.Duplex chain link
9.Duples sprocket 17 teeth
10.Duplex sprocket 26 teeth
11.1" Duplex chain link
12.14 Teeth head sprocket.
13.Rubber sheet
14.L-150 Spider
15.Tail sprocket 8 teeth
16.Tail sprocket shaft
1. Preventiv Maintenance carried on
Sunday maintenance.
1. Preventive maintenace is carried out in
regular bases.
1.LPG pipe line painting is done for
both Liquid & Vapour line.
1. Daily cleaning work for all the
Pumps is done.
2. Trial Run for all the pumps is
carried out on daily.
1. Daily cleaning work for all the
Pumps is done.
2. Trial Run for all the pumps is
carried out on daily.
1.Conveyor track before HAS-1 was newly changed 1.Lubrication of the conveyor bearing has been done
on sunday maintenance work (25/07/2021) track of 8 once in a week.
meter along with the drive section was replaced. 2.The soap tray for the drive unit is been cleaned
2.Soap solution for the conveyor lubrication-12
drums/ month once in a week.
3. Duplex sprocket of 2 nos of 17 Teeth and the 26 3.Cleaning of test bath every 4 days.
teeth sprocket drive units. 4.Drive unit oil check done on daily basis.
4. 1 Nos of collection tray replaced. 5.Drive unit spider checked on daily basis.
5 30 Meter conveyor strip is used.
6. 1 new diverter has been replaced.
7. Carousel -2 Test bath E-plate welding work
carried.
8.7 No's of 8 teeth sprocket
9. Drive units shaft no's - 1 nos
10. Supporting angle - 6 meters.
11.U-213 Bearing - 1 no's
12.Cutting wheel- 46 nos
13.Weding rod packet used for welding work-5 nos
14.Spider for the drive unit-4 nos
1.Preventive log book for the HAS is being followed.
1. General Servise of equipment is done. 2.Draining of the FRL unit is done on daily basis.
3.Regular monitorng of the temperature of HAS
2. Cleaning has been done during Sunday
units
maintenance.
1.Daily preventive log book is maintained.
NIL
1.Preventive Maintenance is done for all the bulles.
NIL
1.SS-46 oil is refilled in the bearing chamber. 1.We are maintaining the preventive log book for the
2. LPG pipe line painting is done for pump pump and it has been filled in regular basis.
suction line. 2.Oil top up for the bearing housing and the seal
cooling oil topup.
3.Cleaning of the pumps on weekly basis.
4.Strainer cleaning done for all pumps.
1.SS-46 oil is refilled in the bearing chamber. 1.We are maintaining the preventive log book for the
2.LPG pipe line painting is done for pump pump and it has been filled in regular basis.
suction line. 2.Oil top up for the bearing housing and the seal
cooling oil topup.
3.Cleaning of the pumps on weekly basis.
4.Strainer cleaning done for all pumps.
 1. AMC LAST VISIT for 2 air
compressor(19-07-2021)
2.Filter Eliment
3.Lube Oil (Roto).
12 AIR COMPRESSOR 4.Oil filter Eliment.
1. AMC Visit for 201-(29/06/2021)
2. AMC Visit for 202-(07/07/2021)
13 FIRE ENGINE(P-201,P-202,P-203) 3. AMC Visit for 203-(25-01-2021)
1.During AMC all the preventive 1.AMC report has been file.
maintenance check is carried out normal 2.Recommended to put the oil filter in out let of the
running. discharge line.
2. B-check for both the compresor is carried
out (Filter eliment, oil is replaced for both the
air compressor)
1. Strainer cleaning takes place for all the 1.Daily trail run for the fire engine - 15 mins
three engines. 2.Log book has been filled in regular bases.
2. NRV Service work takes place for all the
threee engines.
 1.AMC Visit for all the Pumps- Recommendation during visit: 1.Daily trail run for the fire engine - 15 mins
(10/12/2020) 1. Observed pump P-202 Lower casing foot 2.Log book has been filled in regular bases.
and base frame is in rusted condition.
2. Pump P-203 Observed frame is in Rusted
Condition.
3. Base frame damaged lead to the
14 FIRE ENGINE PUMP - 201, 202, 203 misalignment of pump and engine.Base
frame need to be replaced immediately and
also Pump P-202 Casing to be replaced.
4. Need to Overhauled the pump No:202 &
203 to improve the pump performance.

1. General Servise of equipment is done. 1.Log book has been filled in regular bases.
1. Preventiv Maintenance carried on
15 Jockey Pump 2. Cleaning has been done during Sunday
Sunday maintenance.
maintenance.
Stainer cleaning dates:
Sr.no Equipment Name Last cleaning date Next due date Remarks
1 Bulk pump-101 6/22/2021 9/21/2021 Stainer is in good condition
2 Bulk pump-102 6/23/2021 9/22/2021 Stainer is in good condition
3 Bulk pump-103 6/24/2021 9/23/2021 Stainer is in good condition
4 Bulk pump-104 6/22/2021 9/21/2021 Stainer is in good condition
5 Bottling pump-105 6/24/2021 9/23/2021 Stainer is in good condition
6 Bottling pump-106 6/23/2021 9/22/2021 Stainer is in good condition
7 Carousel-1 11-07.2021 10/10/2021 Stainer is in good condition
8 carousel-2 11-07.2021 10/10/2021 Stainer is in good condition
9 Fire Engine-201 6/8/2021 9/7/2021 Stainer is in good condition
10 Fire Engine-202 6/9/2021 9/8/2021 Stainer is in good condition
11 Fire Engine-203 6/10/2021 9/9/2021 Stainer is in good condition
12 DV-ROOM:101 6/23/2021 9/22/2021 Stainer is in good condition
13 DV-ROOM:102 7/11/2021 10/10/2021 Stainer is in good condition
14 DV-ROOM:103 7/11/2021 10/10/2021 Stainer is in good condition
15 DV-ROOM:104 7/11/2021 10/10/2021 Stainer is in good condition
16 DV-ROOM:105 7/11/2021 10/10/2021 Stainer is in good condition
17 PLT LINE 6/19/2021 9/18/2021 Stainer is in good condition
LPG Hose Hydrotesting Dates:

All hoses are fine (Druing changing of new loading

7/19/2021 11/18/2021
arm all NEW LPG hose is replaced in all bays.
1 Gantry bays 1-8 (16 nos of hose)
2 Purging unit (4 nos of hose) 7/20/2021 11/19/2021 All hoses are fine
3 VCM Machine (2 nos of hose) 7/20/2021 11/19/2021 All hoses are fine
4 Auto Weight Correction Unit- (4 nos of hose) 7/21/2021 11/20/2021 All hoses are fine
5 Carousel-1 (48 nos of hose) 7/18/2021 11/17/2021
6 Carousel-2 (48 nos of hose) 7/18/2021 11/17/2021
7 Evacuation unit (4 nos of hoses) 7/22/2021 11/21/2021 All hoses are fine
8 ST-Shed degasing unit(5 nos of hose) 7/22/2021 11/21/2021 All hoses are fine
Fire Hose Hydrotesting Dates:

1 Fire hose Bulk ( 22 nos of hoses) 6/12/2021 12/11/2021 1. 2 Hoses are failed in the Hydro testing coupling
leak observed in the hose, So replaced with new one.
2 Fire hose Bottling ( 26 nos of hoses) 6/12/2021 12/11/2021 1. 2 Hoses are failed in the Hydro testing in pin leak
in the hose,So replaced with the new one.
Calibration :
Calibration done.
1 Pressure gauge(152 nos ) 19-02-2021 & 20-02-2021 7/18/2021 Found 11 nos of pressure gauge failed in the
calibration replace with new one.
2 Torque Wrench 7/1/2020 7/1/2021 Calibration done.