AREAWISE STANDARD OPERATING PROCEDURES

CONTENTS
 General Area Introduction
 Equipment related to workshop
 Area Flow sheet
 General Parameters to be asked while working in the area
 Equipment General checklist

IRON ORE PELLETIZATION PROCESS PELLET PLANT

 AREA 301-302 AND 408 TRANSFER STATION
 Area 301 and 408- Raw Material Receiving workshop and Product transfer
station
1. Equipment's Involved
o PT1-1,2 Conveyor
o 301 BIN
o PT4-1, PT5-1 Conveyor
o TT3-1,2 Conveyor Drive and TT3-2 Diverter gate
2. Parameters to be asked.
o PT1-2 conveyor Frequency
o 301 Bin level
o Both conveyors current
o TT3-2 conveyor diverter gate position (Towards PT4-1 or towards CVF-41 conveyor side)
3. General Check List
o Belt Condition
o Conveyor Tracking condition
o Conveyor Drive physical condition like temperature, vibration.
o Primary and secondary scrapper condition
o Discharge chute inspection if blockage is found need to be cleaned.
o Idlers status, Pulley’s condition and any spillages found near snub pulley area need to be
cleaned.

IRON ORE PELLETIZATION PROCESS PELLET PLANT

 Area 302- Pre-Proportioning Workshop.
1. Equipment's Involved
o C1 Conveyor
o V-Ploughs
o Disc Feeders
o Weigh Feeders
o D1 Conveyor Tail End
o 6 Bins
2. Parameters to be asked.
o Conveyors and weigh feeders Current
o All 6 Bin levels and Type of material loaded
o Disc Feeder and weigh feeders frequency
o Disc Feeder Current
3. General Check List
o Belt Condition
o Conveyor Tracking condition
o Conveyor Drive physical condition like temperature, vibration, Coupling abnormality if any, drive break
shoes etc.,
o Primary and secondary scrapper condition
o Discharge chute inspection if blockage is found need to be cleaned.
o Idlers status, Pulley’s condition and any spillages found near snub pulley area need to be cleaned.
o V-Ploughs Polymers condition if any plough is passing or not operated properly
o Disc Feeder Drive and coupling condition
IRON ORE PELLETIZATION PROCESS PELLET PLANT
 Area 303- Concentrate Drying workshop .
1. Equipment's Involved
o D1,D2.D3 and PT2-1 Conveyors
o V-Plough
o Rotary Dryer with HAG system
o Combustion Fans-2 nos
o D1 de duster system
o Chain Scrapper conveyor, RAV
2. Parameters to be asked.
o Conveyors Current
o Concentrate inlet and outlet moisture, Furnace inlet and outlet temperature, Furnace inlet and outlet Pressures,
Combustion fan Pressure, Natural Gas line inlet and outlet pressure.
o De-duster fan frequency, damper opening status, Fan Current, Bag filter inlet and outlet pressure and temperatures,
Purging line Pressure, Fan Bearing temperatures.
3. General Check List
o Belt Condition
o Conveyor Tracking condition
o Conveyor Drive physical condition like temperature, vibration, Coupling abnormality if any, drive break
shoes, All pulleys bearings condition etc.,
o Primary and secondary scrappers condition
o Discharge chute inspection if blockage is found need to be cleaned.
o Idlers status, Pulley’s condition and any spillages found near snub pulley area need to be cleaned.
o V-Plough Polymers condition if plough is passing or not operated properly
o Dryer Grease lub pump and greasing points inspection, Dryer floating inspection.
o De duster fan bearings temperature, Chain Scrapper conveyor drive and scrapper condition. RAV operation

IRON ORE PELLETIZATION PROCESS PELLET PLANT

Iron Ore Concentrate Received from
yard conveyors.

PT1-1

C1 Conveyor
PT1-2

Disc Feeders Bin Hoppers

Weigh Feeders

D-1 Conveyor

Drying bypass D-2 Conveyor

Rotary Dryer
PT2-1 Conveyor

IRON ORE PELLETIZATION PROCESS PELLET PLANT

 V-Plough

Combustion air HAG Unit D2 Conveyor D1 Conveyor

DRYER

PT2-1
D3 Conveyor Conveyor

H1 Conveyor

IRON ORE PELLETIZATION PROCESS PELLET PLANT

 Area 504 – Bentonite Grinding workshop .
1. Equipment's Involved
o Vertical Grinding Mill, Mill Whizzer/Separator, Weigh Feeder, HAG unit, System Fan.
o Lubrication and Hydraulic System
o Bag Filter, RAV, Pneumatic Conveying System, B1 Cleated Conveyor
2. Parameters to be asked.
o Mill Inlet and Outlet Temperature, Base Pressure, Mill Outlet pressure, Separator Frequency, Mill inlet hot air duct valve opening
o Weigh Feeder Feed rate, Raw bentonite and powder bentonite bin levels.
o System Fan Frequency, Damper Opening, Fan Bearing temperatures.
o Natural Gas line inlet and outlet pressure, HAG furnace temperature,
o Bag filter inlet/outlet pressure and temperatures, Purging line Pressure,
o Lubrication pump pressure.
3. General Check List
o Lubrication and hydraulic system oil sump levels, pumps physical condition, Pressure, Oil temperature, Valve positions in lub system oil
leakages in lube line, Water line pressure to heat exchanger, water leakages if any.
o Check the valve positions of Hot air inlet line valve.
o Ensure that mill is running in smooth condition without any abnormal sound & with normal current rating
o Check the Bag filter ensure that the purging is taking place in all the chambers.
o Ensure that the hydraulic pump should be stopped after the grinding rollers area operated for up and down
o Check Pneumatic conveying system operation like feeding and conveying operation, Dome seal valve condition.
o Check For any leakages from the pneumatic conveying line or at dome seal valve or at manual knife gate valve.

IRON ORE PELLETIZATION PROCESS PELLET PLANT

 Area 304- Proportioning Workshop.
1. Equipment's Involved
o H-1,H-2,M-1 Conveyors
o Roller Screen
o Weigh Feeders-10 nos
o 4 nos Bag filters for Lime, Bentonite, Anthracite, and Dust bins
o HPGR
2. Parameters to be asked.
o HPGR- Roller Speed, Pressure
o All 6 Bin levels and Type of material loaded
o Disc Feeder and weigh feeders frequency
o Disc Feeder Current
3. General Check List
o Belt Condition
o Conveyor Tracking condition
o Conveyor Drive physical condition like temperature, vibration, Coupling abnormality if any,
drive break shoes etc.,
o Primary and secondary scrapper condition
o Discharge chute inspection if blockage is found need to be cleaned.
o Idlers status, Pulley’s condition and any spillages found near snub pulley area need to be
cleaned.
IRON ORE PELLETIZATION PROCESS PELLET PLANT
 Area 306 and 104 - Mixer Workshop.
1. Equipment's Involved
o P1,PT3-1 and PT3-2 Conveyors
o Mixer
o De-dusters 2,3, and 4.
2. Parameters to be asked.
o Related Conveyors Current
o Mixer Weight Set point, Rotor and Pan Drive Currents, Hydraulic oil flow, Mixer Gate opening,
o De-duster fan frequency, damper opening status, Fan Current, Bag filter inlet and outlet pressure and
temperatures, Purging line Pressure, Fan Bearing temperatures.
o De-dusting system-3 duct motorized valve status.
o Fans/Motor Drive and Non drive end bearings vibration and temp.,

3. General Check List

o Belt Condition
o Conveyor Tracking condition
o Conveyor Drive physical condition like temperature, vibration, Coupling abnormality if any,
o Primary and secondary scrapper condition
o Discharge chute inspection if blockage is found need to be cleaned.
o Idlers status, Pulley’s condition and any spillages found near snub pulley area need to be cleaned.
o De duster fan bearings temperature, Vibration, RAV running status in de-duster 2, Pneumatic conveying
system operation like conveying and feeding cycle, conveying pressure and instrument air pressure,
Check compressed air storage tank pressure gauges.

IRON ORE PELLETIZATION PROCESS PELLET PLANT

 Area 201- Pelletizing Workshop.
1. Equipment's Involved
o P2, P3-P10, L1, L6-L7 Conveyors
o Motorized V- ploughs
o Roller Screens 1-8
o Weigh Feeders 1-8
o Pelletizing Discs 1-8
o Grease Lubrication System
2. Parameters to be asked.
o Disc Parameters like Disc or weigh feeder feed set point and feed back, P1 Moisture, Bentonite set point,
o All 8 Bin levels
o Grease lubrication status.
o Weigh feeders frequency
o Disc Current
o L1 and Recycle TPH
o Ask for V ploughs operation
3. General Check List
o Check Pelletizing disc bed scrappers, water nozzle blockage, rim scrappers, disc abnormal sound etc.,
o Check for Roller screen rollers material build up need to be cleaned, roller screen discharge fines chute cleaning need to be
checked and cleaned at regular interval of time.
o Roller screen gaps need to be monitored at regular interval of time in order to avoid any sized or undersized pellets passing.
o Once in a shift need to check V-plough operation, and also check passing of material from ploughs.
o Belt Condition
o Conveyor Tracking condition
o Conveyor Drive physical condition like temperature, vibration, Coupling abnormality if any, drive break shoes etc.,
o Primary and secondary scrapper condition
o Check for any spillages found near snub pulley area need to be cleaned.

IRON ORE PELLETIZATION PROCESS PELLET PLANT

 Area 101- Travelling Grate Workshop.
1. Equipment's Involved
o Reciprocating conveyor, Wide Belt 1-2, L 2-5 Conveyors
o Roller Screen
o Hydraulic station for Reciprocating conveyor
o Travelling Grate Machine
o Grease Lubrication System
o DD valves
o Wind box dampers
o Hearth Layer Gate
o Grate Bar rapper device
o Combustion, Hood seal and Pilot air Fans, D4 De-dusting system
2. Parameters to be monitored.
o Reciprocating Conveyor frequency and Current, Frequency of hydraulic cylinder operation per minute.
o Hydraulic station parameters like, Pump pressure, temperature, main hydraulic pump and washing pump currents,
o TG Current, TG Feed, Speed, Hearth layer Height, Bed Height set point and levels(North, Middle and South) Heath
layer bin level, Machine discharge bin level, Burn Thru temp., DR main Temp., Top Temp., Firing Zones Temp set
point and feed backs., Cooling Zone-2 temp., Cross verify Burners CV feed back from CCR., UDD, DD, PH zone
hood and w/b Temp.,
o TG recirculating water flow and line pressure .
o S1 and S2 conveyor sector gate opening and water spray nozzle operating temp set point.
o Combustion air pressure
o DDV operation count and status of valve operating during that time period.
o Combustion, Hood seal and Pilot air fans Damper opening feed back.
o De-dusting Fan damper opening/Closing set point and feed back
o De-duster fan drive temp., vibration.

IRON ORE PELLETIZATION PROCESS PELLET PLANT

3. General Check List
o Check all the feed end station conveyors for belt joint, tracking, skirt rubber damages scrappers condition,
Material spillages if any.
o Check Roller screen for increase in roller gap, grooves formation and rollers pedestal blocks grease points.
o Check Recirculating water flow from each water collecting boxes.
o Check Pallet cars center casting, grate bars, side wall, spring seal bars, pallet car body temp.,
o Check Pallet cars ( 15-20 cars) in a shift for grate bars choke, grate bars condition, End grate bar lock missing
status.
o Inspection of furnace north and south side Drop seal bars, Hood seal boxes for any water leakages.
o Check False wind boxes and feed end carrying/return side spillages if any.
o Check All the wind boxes for any material buildup and operation of DV in auto mode functioning normal or not.
o Check TG discharge end for any pallet car-car gaps and accordingly operate tipping wheel hydraulic cylinder.
o Check grate bars rapping device by operating once in every shift.
o Once in every shift check Combustion, Hood seal and Pilot Fans for normal operation.
o Check TG grease lubrication once in every shift for any blockage points in the system.
o Check Discharge end rotary chute for any material blockages and clear the same.

IRON ORE PELLETIZATION PROCESS PELLET PLANT

 Area 102- Process Fans.
1. Equipment's Involved
o Process Fans
o Lubrication system
o Auxiliary Drives
2. Parameters to be Asked to CCR and monitored.
o All the process fans Damper openings
o Lubrication Pump pressure, temperature, and current.
o Fans Current, Speed ,Inlet and outlet temperature and pressure.
o Heat exchanger water valves opening status and line pressure.
o Fans/Motor Drive and Non drive end bearings vibration and temp.

3. General Check List.

o Check damper opening condition physically.
o Lubrication pumps oil pressure, DP, oil flow to the bearings, and oil levels in lubrication tank and
fan bearing housings.
o Check for Fan Impeller, bearing housing and Lubrication pumps abnormality if any.
o Check for the filters which are online.
o Fans bearings housing oil leakages.
o Process fans cloth type or metallic type bellow damages for any false air entry.
o Check whether manual valve of pump discharge to heat exchanger is opened or closed.
o Lubrication pumps oil flow discharge valve after filters need to be checked.
o Overhead tanks lubrication oil flow need to be checked.

IRON ORE PELLETIZATION PROCESS PELLET PLANT

 Area 103,602 and 603 – Screening system and Utility work shops.
1. Equipment's Involved
o Vibrating Screen, Lime Coating system
o S1-4, PT7-1,TT3-1 Conveyors
o Cross Ploughs, S-1,2,3 conveyor Motorized Hydraulic actuator gates.
o Circulation water pumps 3 nos., Lifting water pumps 2 nos., Cooling tower system, RO unit, Floor Sprinkling water pumps 2
nos., Balling disc process water pumps 2 nos., Fire fighting system.
2. Parameters to be Asked to CCR and monitored.
o Vibrating screen motor current, screen running status
o TT3-1 conveyor TPH, L3 conveyor TPH.
o S4 conveyor direction of rotation ( Reverse/Forward)
o Pumps current, Circulating water pump flow, Lifting water pump flow, Pool Levels, RO unit running status, Pressure filters
healthiness status, Pressure Filters outlet flow.
o Cooling tower fans running status, Balling disc pump running status and its flow.
3. General Check List.
o Check Belt Condition, Conveyor Tracking condition, Primary and secondary scrapper condition
o Conveyor Drive physical condition like temperature, vibration, Coupling abnormality if any, drive break shoes etc.,
o Check for any spillages found near snub pulley area need to be cleaned.
o Check Screen area spillages, Cloth condition, Vibrating screen V-belt condition, Hydraulic motorized gates operation.
o Check Compressor alarms in display, water pressure in line for compressor, Proper functioning of Loading and unloading
cycle, All valves of running air dryers need to be opened, Pressure in dryer filters, Drain flushing water in pit.
o Check running water pumps pressure, flow and motor/pump vibration and temp., Check Pool levels physically once in a
shift.
o RO unit pumps running condition, Anti scalant and Flocculent levels, system alarms, make sure the electric actuator
valves related to RO unit are operating properly.
o In lime coating system check RAV rotation, screw conveyor discharge material is going proper or not, also check lime
concentration solution is coating the pellets properly or not clean the discharge tray if it is blocked.

IRON ORE PELLETIZATION PROCESS PELLET PLANT