1.

PURPOSE: To establish the system for the maintenance of electrical equipments and to ensure that the equipments are available continuously for preventive maintenance. 2. SCOPE: This is applicable to the preventive & breakdown Maintenance of electrical equipment of Foil. 3. DEFINITIONS: Dy. General Manager Asst. Manager PMI I .D. No. P.M 4. RESPONSIBILITY: 4.1 4.2 4.3 Head of department is over all responsible for implementing this procedure. Personal performing breakdown maintenance shall not carry out preventive maintenance. Individual responsibilities of specific activities are described here after. Deputy General Manager Assistant Manager Preventive Maintenance Incharge Identification Number Preventive Maintenance

5. PROCESS INPUT: 5.1 5.2 5.3 5.4 5.5 5.6 Work instruction for carrying out maintenance activities. Intimation of breakdown by work order P.M. Slippage Record P.M. Schedule PM Checklist P.M. Schedule cum check sheet

6. PROCESS DESCRIPTION & INTERFACES: A: Preventive maintenance Sr. No. 1 2 3 Activity All the equipments requiring periodic maintenance will be identified and a list will be prepared. A unique I.D.No. Will be given to them. The frequency of maintenance will be decided on the basis of Manufacture recommendation Decided by maintenance Department The P.M. schedule/P.M.Schedule cum check sheet will be made as per the identified frequency above. The equipment will be spared and the preventive maintenance will be carried out as per P.M check list/ P.M.Schedule cum check sheet & relevant work instruction. The P.M. checklist / P.M.Schedule cum check sheet will be filled up after completing maintenance. In case of any schedule getting delayed due to any reasons or preventive action if not carried out, should be recorded in the P.M slippage record. Review the P.M. schedule at least Six monthly for types of checks & frequency on the basis of its effectiveness. Review the P.M.slippage record monthly & to avoid the frequency of slippage. In a case of overhauling required, for the equipment, follow the respective work instruction/Vendor instruction manual and filled the over hauling check list. Operation of DG SET, Circuit breaker, 66KVSwithyard,HT Capacitor bank and power changeover done as per work instruction. Responsibility Asst.Manager Asst.Manager Asst.Manager Ref. Doc. FQMNT02F01 FQMNT02F01 Operation & Maintenance Manual
FQMNT02F06
FQMNT02F06 FQMNT02F18
FQMNT02F07, FQMNT02W03, FQMNT02W10, FQMNT02W12 FQMNT02F18, FQMNT02W05

Asst.Manager Asst.Manager/PMI/ Sr.Formen/ Foreman PMI

FQMNT02F07, FQMNT02F18

PMI

FQMNT02F08

8 9

Asst.Manager/PMI Asst.Manager/ PMI Sr. Foreman/ Foreman

FQMNT02F03, FQMNT02F04 FQMNT02F08 Operating and maintenance manual, FQMNT02W09, FQMNT02W07

10

11

Shift foreman

FQMNT02F19 FQMNT02W01 FQMNT02W02 FQMNT02W04 FQMNT02W08 FQMNT02W11

B. Sr. No. 1 2 3 4 5

BREAKDOWN: Activity Receiving work order from user department regarding breakdown of any equipment. Review the problem and allocate the job to concern person. Carry out the breakdown maintenance. As per work instruction. Prepare daily breakdown report and sent copy to Dy.GM (Mech) & GM (F&A). Prepare monthly breakdown report and sent copy to V.P. (foils), all Deptt. Heads, MIS & PPC. Responsibility Shift Incharge Asst.Manager/ Shift Incharge Sr.Forman/ Shift Incharge/Foreman Sr.Forman /Foreman Sr.Forman /Foreman Ref. Doc.

FQMNT02W06
FQMNT02F03 FQMNT02F04

7. PROCESS OUT PUTS: 7.1. Continue availability of machine. 7.2. Relevant reports & records of equipments. 7.3 P.M.Slippage Record. 8. PROCESS MONITORING: Sr. No. 1 2 Description Review of P.M. schedule. Review P.M.slippage record. Frequency Six monthly Monthly Responsibility Asst.Manager Asst.Manager

9. RECORDS: Sr.No. 1 2 3 4 Record No. FQMNT02F01 FQMNT02F02 FQMNT02F03 FQMNT02F04 Record Title COMPREHENSIV E EQUIPMENT LIST EQUIPMENT HISTORY RECORD DAILY BREAKDOWN REPORT MONTHLY BREAKDOWN REPORT MAJOR BREAKDOWN ANALYSIS REPORT PM SCHEDULE Retention period Till the equipment Last Till the equipme nt Last Six Months 1Year Location ELECTRICAL SHOP FLOOR ELECTRICAL SHOP FLOOR, MSDS&ERS ELECTRICAL SHOP FLOOR ELECTRICAL SHOP FLOOR ELECTRICAL SHOP FLOOR ELECTRICAL SHOP FLOOR/MSDS Disposal authority Dy. General Manager Dy. General Manager Dy. General Manager Dy. General Manager Dy. General Manager Dy. General Manager

FQMNT02F05

1Year

FQMNT02F06

1Year

FQMNT02F07
FQMNT02F07/ 01 FQMNT02F07/ 02 FQMNT02F07/ 03 FQMNT02F07/ 04 FQMNT02F07/ 05 FQMNT02F07/ 06 FQMNT02F07/ 07 FQMNT02F07/ 08 FQMNT02F07/ 09 FQMNT02F07/ 10 FQMNT02F07/ 11 FQMNT02F07/ 12 FQMNT02F07/ 13 FQMNT02F07/ 14 FQMNT02F07/ 15 FQMNT02F07/ 16 FQMNT02F07/ 17 FQMNT02F07/ 18 FQMNT02F07/ 19 FQMNT02F07/ 20 FQMNT02F07/ 21 FQMNT02F07/ 22 FQMNT02F07/ 23 FQMNT02F07/ 24 FQMNT02F07/ 25 FQMNT02F07/ 26 FQMNT02F07/ 27 FQMNT02F07/ 28 FQMNT02F07/ 29 FQMNT02F07/ 30 FQMNT02F07/ 31

P.M.CHECK LIST:MILL M50 MILL M51 MILL M52 MILL Q4 MILL Q5 CRANE # 1 CRANE # 2 CRANE # 3 CRANE # 4 CRANE # 5 CRANE # 6 CRANE # 7 CRANE # 8 CRANE # 4A REWIND LINE # 1 REWIND LINE # 2 REWIND LINE # 3 BAILING PRESS ROLL GRINDER ANN. FURNACE # 1 ANN. FURNACE # 2 ANN. FURNACE # 3 ANN. FURNACE # 4 OVEN # 1 OVEN # 2 OVEN # 3 SEPARATOR # 25 SEPARATOR # 26 DOWN ENDER FUME EXH. SYSTEM H G SLITTER

1Year

ELECTRICAL SHOP FLOOR/MSDS

Dy. General Manager

FQMNT02F07/ 32 FQMNT02F07/ 33 FQMNT02F07/ 34 FQMNT02F07/ 35 FQMNT02F07/ 36 FQMNT02F07/ 37 FQMNT02F07/ 38 FQMNT02F07/ 39 FQMNT02F07/ 40 FQMNT02F07/ 41 FQMNT02F07/ 42 FQMNT02F07/ 43 FQMNT02F07/ 44

M G SLITTER L G SLITTER DOCTOR REWINDER DRY BOND LAM. PRINTING MACHINE EXTRUDER COATER MAIN PUMP HOUSE COOLING TOWER NITROGEN GEN. FIRE HYDRANT W.T.P. VENT. SYSTEM COMP. HOUSE

1 Year

ELECTRICAL SHOP FLOOR/MSDS

Dy. General Manager

8 9 10 14 11 12 15 13 16

FQMNT02F08 FQMNT02F09

P.M.SLIPPAGE RECORD WORK ORDER

1Year 3 Month 3Month 1Year 1 Year 1YEAR 1Year Six Months 1Year

FQMNT02F10 WORK PERMIT FQMNT02F14 STATEMENT SHOWING ENERGY OVERHAULING FQMNT02F11 GENERATED & SCHEDULE CONSUMED FQMNT02F12 INCLUDING BOOK SHIFT LOG CONSUMPTION OF DIESEL FQMNT02F15 DG DAILY ENERGY LOG BOOK GENERATION FQMNT02F13 /CONSUMPTION REPORT FQMNT02F16 ANALYSIS OF MOTOR FAILURE ELECTRICAL POWER CONSUMPTION REPORT PM SCHEDULE CUM CHECK SHEET: LT air circuit breaker 66 kv CT, PT, CVT & LA LT APFC panel, HT capacitor bank & reactor Battery bank & battery charger 11 kv & 132 kv MOCB 11 kv T.M.G. ACB 11 kv ABB (indoor & outdoor) & Siemens VCB 66 kv Sf6 circuit breaker 22 kv Sf6 circuit breaker 11 kv, 22 kv & 66 kv isolators 11 kv, 1500 kva DG set

ELECTRICAL SHOPFLOOR/ MSDS ECR Q4/Q5, ERS& MSDS ECR Q4/Q5, MSDS ERS& MSDS MSDS / ERS Q4/Q5 CONTROL ROOM MSDS MSDS ERS

Dy. General Manager Dy. General Manager Dy. General Dy. General Manager Manager Dy. General Manager Dy. General Manager Dy. General Dy. General Manager Manager Dy. General Manager Dy. General Manager

17 18

FQMNT02F17 FQMNT02F18
FQMNT02F18/ 01 FQMNT02F18/ 02 FQMNT02F18/ 03 FQMNT02F18/ 04 FQMNT02F18/ 05 FQMNT02F18/ 06 FQMNT02F18/ 07 FQMNT02F18/ 08 FQMNT02F18/ 09 FQMNT02F18/ 10 FQMNT02F18/ 11

1Year

ELECTRICAL SHOP FLOOR

1Year

MSDS

Dy. General Manager

FQMNT02F18/ 12 FQMNT02F18/ 13 FQMNT02F18/ 14 FQMNT02F18/ 15

Power & distribution transformer 415 v, 125 kva DG set Sub- station (monthly) Sub- station (fortnight)

1Year

MSDS

Dy. General Manager Dy. General Manager

19

FQMNT02F19

OVER HAULING CHECK LIST

3 Years

ERS

10. REFERENCE : Sr.No. 1 2 3 4 5 6 7 8 9 10 11 12 Document no. FQMNT 02W01 FQMNT 02W02 FQMNT 02W03 FQMNT 02W04 FQMNT 02W05 FQMNT 02W06 FQMNT 02W07 FQMNT 02W08 FQMNT 02W09 FQMNT 02W10 FQMNT 02W11 FQMNT 02W12 Work instruction OPERATION OF D.G.SET OPERATION OF 66KV SWITCH YARD OPERATION AND MAINTENANCE OF BATTERY BANK OPERATION OF H.T CAPACITOR BANK OPERATION AND MAINTENANCE OF TRANSFORMER BREAKDOWN MAINTENANCE OVER HAULING OF D.C. MOTOR POWER CHANGE OVER OVER HAULING OF A.C. SLIPRING MOTOR MAINTENANCE OF DIESEL GENERATOR OPERATION OF CIRCUIT BREAKER PREVENTIVE MAINTENANCE