Annual Maintenance Contract Schedule for Paddle Feeder

Plant: GDK OC3 CHP | Area : RG-2

Item / Work Description : AMC For Energo make PF-1

AMC ORDER Visit No: Visit Date:

NO :

CONTENTS

1. Intent of AMC
2. Equipment Information
3. Hydraulics Checklist
4. Transmission Checklist
5. Electrical and C&I Checklist
6. Overall Machine Checklist

AMC for Energo make PF-1 | GDK OC3 CHP | RG-2 Page 1
 Annual Maintenance Contract Schedule for Paddle Feeder
Plant: GDK OC3 CHP | Area : RG-2
Item / Work Description : AMC For Energo make PF-1

AMC ORDER Visit No: Visit Date:

NO :

1.0 Intent of AMC

 The Intent of AMC Shall be to review maintenance schedules for proper maintenance
as per the OEM’s Manual.
 The proposed AMC is for service only. The required spares will be provided by SCCL.
 For carrying out the maintenance, required manpower (technical and non-technical)
will be provided by SCCL.
 The AMC Report shall cover present practices/status/recommendations w.r.t
Operation and maintenance, preventive maintenance, spares/consumable
replacement and other aspects for maintaining the availability of Rated Capacity for
sustained Commercial Operation.
 The team of comprises of specialists in Electronics, Hydraulics, PLC, Gear Boxes and
Overall Machining Assembly of Paddle Feeder.

AMC for Energo make PF-1 | GDK OC3 CHP | RG-2 Page 2
 Annual Maintenance Contract Schedule for Paddle Feeder
Plant: GDK OC3 CHP | Area : RG-2
Item / Work Description : AMC For Energo make PF-1

AMC ORDER Visit No: Visit Date:

NO :

2.0 Equipment Information:

 Capacity : 1200 TPH (Nominal)
600-1500 TPH (Variable)

 Material : R.O.M. Crushed Coal

 Bulk Density : 0.8-1.1 T/Cu.M
 Material size : (-) 250 mm
 Maximum moisture : 7 to 10%
content
 Travel Length : 110 M
 Arrangement for : Through Hydraulic Drive
capacity Variation

 Paddle Wheel
Diameter : 3600MM
No. of Blades : 6
Drive Arrangement : Hydraulic Drive
Arrangement
 Travel Arrangement
No. of travel wheels : 4
Drive arrangement : Through Geared Motor
 Power supply
arrangement : Through festoon cable
arrangement

AMC for Energo make PF-1 | GDK OC3 CHP | RG-2 Page 3
 Annual Maintenance Contract Schedule for Paddle Feeder
Plant: GDK OC3 CHP | Area : RG-2
Item / Work Description : AMC For Energo make PF-1

AMC ORDER Visit No: Visit Date:

NO :

3.0 Hydraulics Checklist

A)Visual checks YES NO NA Remark
1) Cleanliness of system
Criteria: System should be clean & dust free
2) Oil level in the tank
Criteria: Above 75% of level capacity
3) Condition of oil
Criteria:Should be free of water/moisture/contamination
4)Present temp. of oil in the tank
Criteria: In between 35 to 60 deg.C
5) All components in their resepctive position
Criteria: All in their res.location un altered/good condition as per CKT.
6) External leakages
Criteria : No leakage
7) All Safety Interlocks working

B) Physcical/Operational
1) Hydraulic Pump
a.Pump & Motor coupling condition (Any worn out sign)
b.Pump Noise in Idle & load condition (Judgemental)
For Close loop pump (c & d)
c.Boost pressure (Between 25 to 35 bar) Mention actual value
d.Pressure in A & B line in idle condition (Boost pressure) Mention actual
e.Pump internal leakage Open loop pumps (Measure at working pressure)
Criteria : below 5 %of rated flow
2) Valves
Criteria: Valve function as desired & as per ckt logic
3) Filters:
a. Pr.line filter(check & replace if choked)
Criteria: Existing element good/replace
b. Rtn.line filter(check & replace if choked)
Criteria: Existing element good/replace
c. Re-circulation filter(check & replace if choked)
Criteria: Existing element good/replace
4)Cylinder
a) External oil leakage
Criteria : No leakage
b) Preper function
Criteria: Operation
5)Hyd.Motor
a) External oil leakage
Criteria : No leakage
b) Internal leakage
Criteria : below 5 %of rated flow at working pressure
C) Functional test YES NO NA Remark
a. Pumps
Criteria : As desired/Circuit
b. Valves (Pressure/flow/DC/Prop/ etc)

AMC for Energo make PF-1 | GDK OC3 CHP | RG-2 Page 4
 Annual Maintenance Contract Schedule for Paddle Feeder
Plant: GDK OC3 CHP | Area : RG-2
Item / Work Description : AMC For Energo make PF-1

AMC ORDER Visit No: Visit Date:

NO :

Criteria: As desired/circuit/logic
c.Actuators (Cylinders/Motors)
Criteria: As desired/circuit/logic

Ovr all working of system as desired

Readings:
Pump Boost pressure(close loop) Unit As per ckt Actual Remarks
Load pressure (A line close loop) Bar
Load pressure (B line close loop) Bar
Line pressure (open loop) Bar
Cylinder speed Bar
Motor speed (Variable) mm/sec
Stocks
Whether required spares maintained at Customer YES NO

Spares replaced during visit

Description Qnty.

Specific findings if any:

Any problem reported in the sytem/Attended

Recommandations (From M/s Rexroth)

Plan for next visit (Date):

For M/s Bosch Rexroth India Ltd. For Customer (Auth.Signatory)

AMC for Energo make PF-1 | GDK OC3 CHP | RG-2 Page 5
 Annual Maintenance Contract Schedule for Paddle Feeder
Plant: GDK OC3 CHP | Area : RG-2
Item / Work Description : AMC For Energo make PF-1

AMC ORDER Visit No: Visit Date:

NO :

Srare list wala mail add

4.0 Transmission Checklist

AMC for Energo make PF-1 | GDK OC3 CHP | RG-2 Page 6
 Annual Maintenance Contract Schedule for Paddle Feeder
Plant: GDK OC3 CHP | Area : RG-2
Item / Work Description : AMC For Energo make PF-1

AMC ORDER Visit No: Visit Date:

NO :

5.0 Electrical and C&I Checklist

1 For PLC Panels Remarks

AMC for Energo make PF-1 | GDK OC3 CHP | RG-2 Page 7
 Annual Maintenance Contract Schedule for Paddle Feeder
Plant: GDK OC3 CHP | Area : RG-2
Item / Work Description : AMC For Energo make PF-1

AMC ORDER Visit No: Visit Date:

NO :

a) To check the operation of PLC system

b) To check the programming and logic of the system
c) To check the operation of Switchgear Component
d) To remove the dust and cleaning of the equipments.
2 For the supply:
List out the switchgear component required as mandatory
a)
spares
b) List out the PLC spares required as mandatory spares

6.0 Overall Machine Checklist

Operation

AMC for Energo make PF-1 | GDK OC3 CHP | RG-2 Page 8
 Annual Maintenance Contract Schedule for Paddle Feeder
Plant: GDK OC3 CHP | Area : RG-2
Item / Work Description : AMC For Energo make PF-1

AMC ORDER Visit No: Visit Date:

NO :

S.No Check List Description Status Remarks

1. Starter cum Control Speed variation of Travel Drive
Panel and Paddle Wheel
2. Travel Drive Speed 1.2m/min to 2.4m/min
3. Rotation of Plough Clockwise direction both in
Wheel forward and reverse direction of
the travel motion.
4. Capacity 1200 TPH
5. Travel limit switches Travel drive shall be fully
automatic and self-reversing by
means of travel limit switches
Reversal shall occur at either
end of a pre-determined
operating zone.
6. Plough Wheel Jamming The Plough feeder automatically
Condition reverses its long travel and
rotates the Plough wheel to
withdraw.
7. Travel Drive Span 110 meters
8. Supply from LT Panel to Three phase 550 V/440V
the Local control panel
of Plough feeder.
9. Festoon cable condition Properly Insulated and hanged
at right position.

Maintenance

1.
2.

AMC for Energo make PF-1 | GDK OC3 CHP | RG-2 Page 9
 Annual Maintenance Contract Schedule for Paddle Feeder
Plant: GDK OC3 CHP | Area : RG-2
Item / Work Description : AMC For Energo make PF-1

AMC ORDER Visit No: Visit Date:

NO :

3.

4.

5.
6.
7.
8.
9.
10.
11.
12.
13.
14.

AMC for Energo make PF-1 | GDK OC3 CHP | RG-2 Page 10
 Annual Maintenance Contract Schedule for Paddle Feeder
Plant: GDK OC3 CHP | Area : RG-2
Item / Work Description : AMC For Energo make PF-1

AMC ORDER Visit No: Visit Date:

NO :

10. Alignment of Blade

11. Bolts tightness of blade
arm from blade hub
12. liner plate wear details

S.No Check List Acceptable Actual Remarks

Range/Value Range/Value
TRAVEL DRIVE ASSEMBLY (DRIVE SIDE- CARRIAGE STRUCTURE)
13. Wheel bearing to be
checked visually for any
dust
14. Bolts tightness of
bearing housing &
bearing cover
15. Alignment of wheels
16. Alignment of floating
shaft 1 & 2
17. Visual check of gear

AMC for Energo make PF-1 | GDK OC3 CHP | RG-2 Page 11
 Annual Maintenance Contract Schedule for Paddle Feeder
Plant: GDK OC3 CHP | Area : RG-2
Item / Work Description : AMC For Energo make PF-1

AMC ORDER Visit No: Visit Date:

NO :

coupling teeth
TRAVEL DRIVE ASSEMBLY (NON DRIVE SIDE-DUST COLLECTOR)
18. Wheel bearing to be
checked visually for any
dust
19. Bolts tightness of
bearing housing &
bearing cover
20. Alignment of wheels
COMMON CHECK
21. Visual check for rust
formation in fabricated
structure

AMC for Energo make PF-1 | GDK OC3 CHP | RG-2 Page 12
 Annual Maintenance Contract Schedule for Paddle Feeder
Plant: GDK OC3 CHP | Area : RG-2
Item / Work Description : AMC For Energo make PF-1

AMC ORDER Visit No: Visit Date:

NO :

AMC for Energo make PF-1 | GDK OC3 CHP | RG-2 Page 13