QUALITY MANAGEMENT PROCEDURE / Doc. No. : F Q MNT 02 P

ELECTRICAL MAINTENANCE

/ Page No. : 1 of 8
  1. PURPOSE:

To establish the system for the maintenance of electrical equipments and to ensure that the equipments are available continuously for preventive maintenance.

  1. SCOPE:

This is applicable to the preventive & breakdown Maintenance of electrical equipment of Foil.

  1. DEFINITIONS:

Dy.General Manager - Deputy General Manager

Asst.Manager - Assistant Manager

PMI - Preventive Maintenance Incharge

I.D. No. - Identification Number

P.M - Preventive Maintenance

  1. RESPONSIBILITY:

4.1Head of department is over all responsible for implementing this procedure.

4.2Personal performing breakdown maintenance shall not carry out preventive maintenance.

4.3Individual responsibilities of specific activities are described here after.

  1. PROCESS INPUT:

5.1Work instruction for carrying out maintenance activities.

5.2Intimation of breakdown by work order

5.3P.M.Slippage Record

5.4P.M.Schedule

5.5PM Checklist

5.6P.M.Schedule cum check sheet

  1. PROCESS DESCRIPTION & INTERFACES:
  2. Preventive maintenance: -

Sr. No. / Activity / Responsibility / Ref. Doc.
1 /

All the equipments requiring periodic maintenance will be identified and a list will be prepared.

/

Asst.Manager

/ FQMNT02F01
2 /

A unique I.D.No. Will be given to them.

/

Asst.Manager

/ FQMNT02F01
3 /

The frequency of maintenance will be decided on the basis of

  • Manufacture recommendation
Decided by maintenance Department /

Asst.Manager

/ Operation & Maintenance Manual FQMNT02F06
4 / The P.M. schedule/P.M.Schedule cum check sheet will be made as per the identified frequency above. /

Asst.Manager

/ FQMNT02F06 FQMNT02F18
5 / 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. /

Asst.Manager/PMI/ Sr.Formen/

Foreman

/ FQMNT02F07, FQMNT02W03, FQMNT02W10, FQMNT02W12 FQMNT02F18,
FQMNT02W05
6 / The P.M. checklist / P.M.Schedule cum check sheet will be filled up after completing maintenance. /

PMI

/ FQMNT02F07, FQMNT02F18
7 / 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. /

PMI

/ FQMNT02F08
8 / Review the P.M. schedule at least Six monthly for types of checks & frequency on the basis of its effectiveness. /

Asst.Manager/PMI

/ FQMNT02F03, FQMNT02F04
9 / Review the P.M.slippage record monthly & to avoid the frequency of slippage. / Asst.Manager/
PMI / FQMNT02F08
10 / In a case of overhauling required, for the equipment, follow the respective work instruction/Vendor instruction manual and filled the over hauling check list. / Sr. Foreman/ Foreman / Operating and maintenance manual, FQMNT02W09, FQMNT02W07
FQMNT02F19
11 / Operation of DG SET, Circuit breaker, 66KVSwithyard,HT Capacitor bank and power changeover done as per work instruction. / Shift foreman / FQMNT02W01
FQMNT02W02
FQMNT02W04
FQMNT02W08 FQMNT02W11

B. BREAKDOWN: -

Sr. No. /
Activity
/ Responsibility / Ref. Doc.
1 / Receiving work order from user department regarding breakdown of any equipment. / Shift Incharge
2 / Review the problem and allocate the job to concern person. / Asst.Manager/
Shift Incharge
3 / Carry out the breakdown maintenance. As per work instruction. / Sr.Forman/ Shift Incharge/Foreman / FQMNT02W06
4 / Prepare daily breakdown report and sent copy to Dy.GM (Mech) & GM (F&A). / Sr.Forman /Foreman / FQMNT02F03
5 / Prepare monthly breakdown report and sent copy to V.P. (foils), all Deptt. Heads, MIS & PPC. / Sr.Forman /Foreman / FQMNT02F04
  1. PROCESS OUT PUTS:
  2. Continue availability of machine.
  3. Relevant reports & records of equipments.
  4. P.M.Slippage Record.
  1. PROCESS MONITORING:

Sr. No. / Description /

Frequency

/ Responsibility
1 /

Review of P.M. schedule.

/

Six monthly

/ Asst.Manager
2 /

Review P.M.slippage record.

/

Monthly

/ Asst.Manager
  1. RECORDS:

Sr.No. / Record No. / Record Title / Retention period / Location / Disposal authority
1 / FQMNT02F01 / COMPREHENSIVE EQUIPMENT LIST / Till the equipment Last / ELECTRICAL SHOP FLOOR / Dy. General Manager
2 / FQMNT02F02 / EQUIPMENT HISTORY RECORD / Till the equipme
nt Last / ELECTRICAL SHOP FLOOR, MSDS&ERS / Dy. General Manager
3 / FQMNT02F03 / DAILY BREAKDOWN REPORT / Six Months / ELECTRICAL SHOP FLOOR / Dy. General Manager
4 / FQMNT02F04 / MONTHLY BREAKDOWN REPORT / 1Year / ELECTRICAL SHOP FLOOR / Dy. General Manager
5 / FQMNT02F05 / MAJOR BREAKDOWN ANALYSIS REPORT / 1Year / ELECTRICAL SHOP FLOOR / Dy. General Manager
6 / FQMNT02F06 / PM SCHEDULE / 1Year / ELECTRICAL SHOP FLOOR/MSDS / Dy. General Manager
7 / 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 / FQMNT02F08 / P.M.SLIPPAGE RECORD / 1Year / ELECTRICAL SHOPFLOOR/MSDS / Dy. General Manager
9 / FQMNT02F09 / WORK ORDER / 3 Month / ECR Q4/Q5, ERS& MSDS / Dy. General Manager
10 / FQMNT02F10 / WORK PERMIT / 3Month / ECR Q4/Q5, ERS& MSDS / Dy. General Manager
11 / FQMNT02F11 / OVERHAULING SCHEDULE / 1 Year / MSDS / ERS / Dy. General Manager
12 / FQMNT02F12 / SHIFT LOG BOOK / 1YEAR / Q4/Q5 CONTROL ROOM / Dy. General Manager
13 / FQMNT02F13 / DAILY ENERGY GENERATION /CONSUMPTION REPORT / Six Months / MSDS / Dy. General Manager
14 / FQMNT02F14 / STATEMENT SHOWING ENERGY GENERATED & CONSUMED INCLUDING CONSUMPTION OF DIESEL / 1Year / MSDS / Dy. General Manager
15 / FQMNT02F15 / DG LOG BOOK / 1Year / MSDS / Dy. General Manager
16 / FQMNT02F16 / ANALYSIS OF MOTOR FAILURE / 1Year / ERS / Dy. General Manager
17 / FQMNT02F17 / ELECTRICAL POWER CONSUMPTION REPORT / 1Year / ELECTRICAL SHOP FLOOR / Dy. General Manager
18 / FQMNT02F18
FQMNT02F18/ 01
FQMNT02F18/ 02
FQMNT02F18/ 03
FQMNT02F18/ 04
FQMNT02F18/ 05
FQMNT02F18/ 06
FQMNT02F18/ 07
FQMNT02F18/ 08
FQMNT02F18/ 09
FQMNT02F18/ 10
FQMNT02F18/ 11 / 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 / 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
19 / FQMNT02F19 / OVER HAULING CHECK LIST / 3 Years / ERS / Dy. General Manager

10. REFERENCE :

Sr.No. / Document no. / Work instruction
1 / FQMNT 02W01 / OPERATION OF D.G.SET
2 / FQMNT 02W02 / OPERATION OF 66KV SWITCH YARD
3 / FQMNT 02W03 / OPERATION AND MAINTENANCE OF BATTERY BANK
4 / FQMNT 02W04 / OPERATION OF H.T CAPACITOR BANK
5 / FQMNT 02W05 / OPERATION AND MAINTENANCE OF TRANSFORMER
6 / FQMNT 02W06 / BREAKDOWN MAINTENANCE
7 / FQMNT 02W07 / OVER HAULING OF D.C. MOTOR
8 / FQMNT 02W08 / POWER CHANGE OVER
9 / FQMNT 02W09 / OVER HAULING OF A.C. SLIPRING MOTOR
10 / FQMNT 02W10 / MAINTENANCE OF DIESEL GENERATOR
11 / FQMNT 02W11 / OPERATION OF CIRCUIT BREAKER
12 / FQMNT 02W12 / PREVENTIVE MAINTENANCE
Approved By: / Issued By: / Edition No. 01
Date: 01. 12. 2001 / Date: 01.12. 2001 / Revision No. 02