This project is

submitted by
CHANDAN KUMAR
ELECTRICAL BRANCH
79 ROLL NO. (029 B. ROLL
NO.)
SIXTH SEMESTER
2010-2013 SEC.

FROM K.K. POLYTECHNIC

DHANBAD

AN OVERVIEW OF
BOKARO STEEL PLANT

# INTRODUCTION :The GENERAL MAINT.-ELECT department is a part

of Central Electrical Maintenance. It is situated
near the Steel gate towards CEZ gate. Its task is to
ensure smooth running of electrical equipments of
Shops of the plant. And also to avoid costly
stoppage
and
achieving
quality
product
economically.
Since in the giant organization where bulk of machinery works
simultaneously and the production is flow based, any
interruption will directly affect the production of not only
particular shop, but of whole plant. There in order to avoid such
condition maintenance department provides the necessary help
and guidance.
#

OBJECTIVES :1 To
maintain
healthiness
of
electrical
equipments.
2 To improve and enhance the functioning of
electrical equipment by carrying out capital
repair and revamping jobs in major production
shops.

3 To repair and improve the availability of

Motors, Welding transformers, Control &
lighting transformers, Rectifier units, Battery
Chargers, Vibro-Feeder and Electro Magnetic
Rollers in the plant.
4 To maintain zero accident.
# SECTIONS:Since the department is catering to the Electrical Maintenance
Requirement of all the major shops.
The department is organized in to two zones :1. Repair zone : The repair zone group is the group which is
directly responsible for the repair of electrical
equipments of different shops of the plant like
Coke Oven, BF, Sl. Mill SMS-I & II, HSM,
HRCF, CRM, PEB, GM-Mech, CR(M), HMM,CCS,OG, SP, RMHP etc.
Repair Zone consists following
subsections: -

1. Testing Section,
2. Dismantling & Assembly Section,
3. Welding Transformer, Battery Charger & Rectifier
Section.
4. Motor rewinding section,
5. Control & Lighting Transformer repair section,

6. Vibro-Feeder & EMR assembly repair section.

2. Services Zone :
The service group provides necessary
assistance to the maintenance group of the
maintenance shops to carry out maint./repair of
jobs during shop shut-down & capital repairs
effectively. The capital repairs are carried out
mostly in HSM, Sl. Mill.
#

NATURE OF WORK :# Rewinding of Induction Motors up to 30 KW.

# Maint./ Repair of Lighting and Control
Transformers of whole plant.
# Maintenance & Repair of Rectifier Units,
Battery Chargers and Stabilizers.
# Maint./ Repair of Welding Machine, MG Set
and Multipoint Welding Machine.
# Maint./ Repair of EMR Assembly of HRCF &
Vibro Feeder of SP.
# Maint./ Repair of Roller Table Motors of HSM
during regular Shop Shut down and Capital
Repair and during Capital repair..

# Maint./ Repair of Ingot Buggy Trolley Lines of

Sl. Mill during regular Shop Shut down and
Capital Repair.
# Fabrication of Resistance Box Panels &Trolley
line Brackets for SMS 2.
#

REPAIR SERVICES OFFERED AREA :1. SLABBING MILL :- Maintenance/Repair of

ingot buggy trolley lines/reactors of
main drive motors, bus
bars during shop shut down & capital repair.

2. H.S.M. :- Maintenance/Repair of charging &

discharging side roughing motors, roller
table motors, delay table motors,
reactor and bus-bar of finishing main
drive motors during shop shut
down & capital repairs.

3 S.M.S.-II :- Fabrication of brackets for

Resistance-Box for Hot Metal Cranes.
4 Rewinding of slag car motors of BF, SMS-I & II,
Scarfing crane motors of Slabbing

Mill specially and other motors up to 22kw of

other shops of the plant.
5.
Rewinding/
revamping
of
welding
transformers, Rectifiers, Control & lighting
Transformers,Stabilizer, Battery Chargers etc.
6. Repair of Electro Magnetic Rollers of HRCF&
Vibro-Feeder of Sinter Plant.
7. Repair & maintenance of crane in workshop.
# STORE :In order to ensure uninterrupted supply of all
tools, tackles other maintenance equipments &
consumables materials, the deptt. maintains its
own stores. The store is equipped with all the
necessary tools and tackles, wires, insulators,
welding equipments, cutting equipments, oxygen
and acetylene cylinder etc.
# Other Activities :i) Quality Circle
ii) Suggestion Scheme
ii) Safety Consciousness
iii) Training Programme

HEAVY MAINTENANCE (ELECT.)

GENERAL
The basic function of this section of Electrical
Maintenance Department is to repair and
maintenance of all electrical machines above 200
KW in the plant. In addition to the maintenance and
repairs of electrical machines, this department is
also responsible for attending to breakdown on
these machines. There are about 703 machines of
capacity 200 KW and above in 4 MT stage , LT ,HT&
DC.

ZONES AND SECTIONS

Heavy Maint.(Elect.) is divided into the following

five zones & one central workshop.

Thermal Power Plant

It covers the repairs and maintenance of electrical

machines in Pump House Nos. 1 and 3 including
canal pump house of water management
department.

Sintering Plant Zone

It covers the repair and maintenance of big
electrical machines in CO, BPP, Sintering Plant.
Blast Furnace, Refractory, RM & MHP and D.N.W.
Hot Strip Mill Zone
It covers the maintenance of electrical machines of
capacity 200 KW in Hot Strip Mill, Slabbing Mill, Air
Blower Station. And the Pump Houses 2,8,9 and 10
in the mill area.
Cold Rolling Mill Zone
It consist of the maintenance of electrical machines
sof capacity 200 KW in HRCF, SSD, CRM, Gas
Booster Station and Central Compressor Plant No.2.
SMS Zone:
It covers SMS-I, SMS-2, Oxygen Plant & CCP-I,
Traffic and PH-4.

Central Workshop:
It is for centralized medium repair/ breakdown
repair jobs required to be done for the various
heavy maintenance zones of the department.
MAJOR JOBS OF THE DEPARTMENT
This department undertakes the following major
jobs in the
various zones.Medium Routine maintenance and
inspection of all electrical machines above 200 KW
Repairs of electrical machine above 200 KW.
Breakdown Repairs of electrical machine above
200 KW
Alignment with
machines after
Repairs.

mechanism of the electrical

Medium Repairs and Capital

Balancing of armature and rotor at site

Maints. of large spare armature, rotor & large
coupling mounting
Condition monitoring of large electrical drives and
connected equipment's by vibration and shock
Pulse measurement, analysis.

UNPLANNED JOBS
Some unplanned jobs are also carried out to
facilitate the work of other departments like
removal of coupling, alignment and commissioning
etc. with approval from GM(Elect).

SPECIAL JOBS
HME specializes in the following jobs which require
skill and precision.
Alignment of Vertical Pump motors of 1000 KW to
5000 KW rating which requires considerable skill,
time and man-power.
Alignment of machines with rigid couplings.
Scrapping and matching of sliding friction
bearing segments.
Scrapping and matching of Mill Main Drive
bearings having a dia. as high as 900 mm.
Repair of synchronous motor poles, their
removal and fixing back after repair and
balancing of rotor if needed.
Balancing of rotor at site.
Condition monitoring of large Electrical Drives
and connected equipment's by vibrations and
shock pulse measurement and analysis of
defects and liquidation.

MAINTENANCE PROCEDURE

Routine Maintenance & Inspection

The following jobs are carried out during Routine
Maintenance Inspection
i) Checking, operation of motor with special regard
to working of bearings, brush gear ventilation,
motor heating and vibrations.
ii) Insulation Resistance of Windings.
iii) Checking
maintenance.

of

bandages

(iv) Change of bearing

Greasing of bearings

during

lubricant

if

winding
required.

(v)Checking of brush gear, replacement of worn out

parts i.e. brushes, holders etc.
(vi) Checking and cleaning of commutators
(vii) Tightening of all nuts bolts and fixtures.
(viii) Terminal leads to be checked
(ix)

Foundation bolts to be checked

(x) Checking of coolers (Heat exchangers which

are mounted on motors)

Medium Repair
Important jobs carried out during Medium Repairs
are listed below
i)

Same
as
for
routine
checking
and
maintenance
ii) Removal of Motor and thorough checking of
stator and rotor winding
iii) Maintenance of windings, drying and
varnishing, rewinding and rewinding if
required
iv) Maintenance of slip rings/commutators,
matching of slip rings
v) Re-insulation of jumpers/terminal leads if
required and commutators if required
vi) Checking resistance of winding, quality of
joints and resoldering.
vii) Measurement of bearing clearance, air gap
and adjustment
viii) Repair of shaft necks, coupling seating and
end shields if necessary
ix) Replacement of bearing if necessary
x) Checking alignment with mechanism and
rectification.

xi) Measurement
of
vibration
and
rectification/balancing
xii) Checking magnetic axis and adjustment.

CAPITAL REPAIR
It consists of the following jobs :
Complete dismantling of units and their
thorough checking
Same as for medium repair
Cleaning of windings and determining
condition of body insulation and inter-turn
insulation by testing procedure. Partial
repair or complete repair rewinding if
necessary.
Rewinding changing and insulation of
jumpers, terminals insulating block for
jumpers and charging terminal boards.
Drying,
impregnating
and
varnishing
windings
Replacement of bearings.
Full replacement of brushes, brush holders
and insulation parts of brush gear
Renewal
of
surfaces
of
slip
rings/commutator
Restoration of shaft surfaces under bearing
and couplings to size.

 Repair of key ways

Repair of end shield, fan land covers.
Repair of motor body, foundation and
fixtures
Paintings
Core repairing/staggering of core
Re-caging of rotor bars
Replacement of rotor shaft.
FREQUENCY OF MAINTENANCE
It is decided depending on the criticality of job,
environmental conditions, type of machine, its
location and maintenance. For
CGT jobs the frequency is once in 3 months ,
whereas in DC machines it is once in 2 months. For
critical drives this frequency is reduced as per
application. .For MR plans AC motors are taken
once in 3 yrs and DC motors are taken once in 4
years.

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THANK
YOU