DAILY DOWNTIME REPORT FOR APRIL-2018

DEPARTMENT: ELECTRICAL

Total Down
S.No. Date Shift Area Name of the Equipment from to Time in Reasons for Down Time Time in
Min Min.
1 4-Apr-18 A Utilities 51,52 and 53 Mould Cooling Blowers 11:07AM 11:12AM 5 Analog Input Signal Problem So rectified
2 5-Apr-18 B Coldend 56 - Line divider Infeed Conveyor 8:00PM 9:00PM 60 Motor Nde Side Bearing abnormal Sound So replaced
3 9-Apr-18 B Hotend 46 hotend coating M/C 7:00PM 07:30PM 30 Circulation Blower Bearing jammed So replaced
4 18-Apr-18 A Utilities 57 Mould Cooling Blower 1:50PM 2:00PM 10 Tripped due to power fluctuation So resetted
5 24-Apr-18 B ACL Shrink tunnel hood 7:00PM 7:30PM 30 Temperature problem So rectified
6 24-Apr-18 B ACL Shrink tunnel hood 8:20PM 9:20PM 60 Limit Switch Problem So rectified
Production Effected (Min.) 15 Non Production (Min.) 180 195 1.07
External 0
% Down
Time

0.0025
0
 DAILY DOWNTIME REPORT FOR M
DEPARTMENT: ELECTRICAL

S.No. Date Shift Area Name of the Equipment from

1 3-May-18 B Utilities All F-4 IS M/C are stopped 2:40 PM

2 12-May-18 A Coldend 41 packing M/C 12:50 PM

3 12-May-18 A Coldend 41 packing M/C Green belt conveyor 1:50 PM
4 12-May-18 B Coldend 54 packing M/C 5:10 PM
5 12-May-18 C Coldend 41 packing M/C 3:00 PM
6 14-May-18 B Lehr 57 Lehr 6:50 PM
7 14-May-18 C Coldend 45 LHS Packing M/C 11:40 PM
8 19-May-18 A Lehr 43 Lehr 1:45 PM
9 20-May-18 A Coldend 45 LHS Packing M/C 7:50 AM
10 23-May-18 C Coldend 45 LHS Packing M/C 4:30 AM
11 29-May-18 B Plant 43,46 & 47 MCBs & 41,43 & 46 Lehrs 9:25 PM
tripped
12 30-May-18 A M.R Shop Compressor 6:00 PM
Production Effected (Min.) 80 Non Production (Min.) 250
REPORT FOR MAY-2018
Total Down
% Down
to Time in Reasons for Down Time Time in
Time
Min Min.
Transformer-1 & Cameron compressor HT breakers
3:50 PM 70
tripped due to rain water
1:05 PM 15 Side Heater Coil Failed So replaced
2:00 PM 10 MCB failed So replaced
5:25 PM 15 Endsealer contactor problem So rectified
4:00 PM 60 Side Heater Coil Failed So replaced
6:55 PM 5 Panel Board MCB stopped So Started
12:10 AM 30 Panel Start Cable Cutt Off problem So rectified
1:50 PM 5 Drive Over heat fault So fan arranged
8:05 AM 15 End Sealer cable cutt off problem So rectified
5:00 AM 30 Panel Start Cable Cutt Off problem So rectified
9:40 PM 15 Power Fluctuation So started

7:00 PM 60 Pressure Switch and Contactor Problem So rectified

Total 330 5.71 0.0128
External 30 0.0672
 DAILY DOWNTIME REPORT FOR JUNE-2018
DEPARTMENT: ELECTRICAL

Total Down
% Down
S.No. Date Shift Area Name of the Equipment from to Time in Reasons for Down Time Time in
Time
Min Min.
11:50 AM 12:00AM
1 7-Jun-18 A Production 41 Control room systems restarted. 20 Cables Insulation failed due to rain Water.
04:35 PM 04:45 PM

2 9-Jun-18 B Production 44 Cross conveyor 6:45 PM 7:15 PM 30 Bearing Failed So replaced

3 26-Jun-18 C Coldend 45 packing M/C (L.H.S) 2:40 AM 2:50 AM 10 End Sealer cable cutt off problem So rectified

4 28-Jun-18 B Production 42 Cross Conveyor 5:45 PM 6:15 PM 30 Cable melted So rectified

Production Effected
60 Non Production (Min.) 30 Total 90 4.29 0.0099
(Min.)
External 0 0
 DAILY DOWNTIME REPORT FOR JULY-2018
DEPARTMENT: ELECTRICAL

Total Down
% Down
S.No. Date Shift Area Name of the Equipment from to Time in Reasons for Down Time Time in
Time
Min Min.
1 5-Jul-18 A Cold end 57 packing Machine 6:30 AM 7:00 AM 30 Heaters cable cutt off So rectified

2 15-Jul-18 C Cold end 58 packing Machine 4:50 AM 7:30 AM 160 Auto sensor failed So replaced another sensor

3 22-Jul-18 A Cold end 57 packing Machine 8:30 AM 8:45 AM 15 End sealer Thermo Couple problem So Rectified

Tunnel Incoming Cable cutt off and Control wiring

4 22-Jul-18 C Cold end 57 packing Machine 3:30 AM 4:50 AM 80
problem So rectified
Production Effected
0 Non Production (Min.) 285 Total 285 0.00 0.0000
(Min.)
External 0 0
 DAILY DOWNTIME REPORT FOR AUGUST-2018
DEPARTMENT: ELECTRICAL

Total Down
S.No. Date Shift Area Name of the Equipment from to Time in Reasons for Down Time Time in
Min Min.
F5 process equipments affected due to Un
1 1-Aug-18 B Plant F5 all IS M/C 8:40 PM 9:00 PM 20 authorised Operation of solar panel by solar
team
2 3-Aug-18 B Production 54 I/S Machine 7:30 PM 7:40 PM 10 Due to power Fluctuation So started

3 14-Aug-18 B Coldend 53 packing M/C 9:20 PM 9:35 PM 15 I/C supply Cable cutt off problem So rectified

4 21-Aug-18 A Coldend 58 packing M/C 10:45 AM 11:05 AM 20 NC block failed So rectified

5 24-Aug-18 B Coldend 58 packing M/C 3:20 PM 3:40 PM 20 Matrix sensor damaged So replaced
6 28-Aug-18 B Plant F5 all IS M/C 4:40 PM 4:50 PM 10 I/C supply failed due to EB Power Failure
Production Effected
0 Non Production (Min.) Total 95 0.00
(Min.)
External 60
% Down
Time

0.0000
0.1344
 DAILY DOWNTIME REPORT FOR SEPTEMBER-2018
DEPARTMENT: ELECTRICAL

Total Down
S.No. Date Shift Area Name of the Equipment from to Time Reasons for Down Time Timein
in Min Min.
1 6-Sep-18 A Coldend 58 packing M/C 8:40 AM 9:00 AM 20 End sealer Sensor failed So replaced.

2 17-Sep-18 A Coldend 57 Packing M/C 8:30 AM 9:00 AM 30 Tunnel Blower Motor bearing problem So replaced.

3 24-Sep-18 A Production 58 Cross Conveyor 6:30 AM 6:35 AM 5 Tripped with Overload fault So resetted.
4 25-Sep-18 A Production 47 MCB (42 IS M/C) 6:15 AM 6:20 AM 5 Tripped with Overload fault So resetted.
132 KV Line conductor snapped Due to thunder
26-Sep-18 B 5:10 PM _
5 Plant Power failure _ storms SO line repair works carried and power
27-Sep-18 A _ 12:50 PM
restored.
6 27-Sep-18 C Lehr 44 Lehr 2:10 AM 2:40 AM 30 Burner Cable shorted So rectified and started.
6:52 PM 6:57 PM 5
7 29-Sep-18 B Pruduction FGB NO -2 (F-V) Star Delta timer problem So FGB No-1 Started.
9:13 PM 9:18 AM 5
8 29-Sep-18 B Coldend 45 Packing M/C 8:50 PM 10:30 PM 100 Pusher sollenoid malfunctioning so rectified
9 29-Sep-18 C Coldend 53 Packing M/C 10:30 PM 11:30 PM 60 I/C Switch failed So replaced
10 30-Sep-18 A Coldend Goods Lift NO-2 10:40 AM 11:20 AM 40 Level adjustment purpose one channel welded
Production Effected (Min.) 20 Non Production (Min.) 280 Total 300 2.38
1200 External 1200
 %
Down
Time

0.0055
2.7778
 DAILY DOWNTIME REPORT FOR OCTOBER-2018
DEPARTMENT: ELECTRICAL

Total Down
Name of the
S.No. Date Shift Area from to Time in Reasons for Down Time Timein
Equipment
Min Min.

1 1-Oct-18 A Production 45 MCB 10:00 AM 10:05 AM 5 Drive stopped without alaram and fault.
2 2-Oct-18 A Coldend 41 Packing M/C 9:35 AM 9:45 AM 10 SMPS Failed So replaced.
3 2-Oct-18 A Packing Goods Lift NO-4 12:25 PM 1:45 PM 20 Level problem So adjusted.

4 3-Oct-18 B Packing Goods Lift NO-4 8:00 PM 10:00 PM 120 Tripped with Overload fault So resetted.

5 5-Oct-18 B Coldend 56 PLC Conveyor 9:00 PM 9:40 PM 40 56 PLC cable damaged So replaced.
6 8-Oct-18 C Coldend 58 Packing M/C 11:45 PM 12:30 AM 45 Auto Sensor failed So replaced.
7 9-Oct-18 C Plant F4 - PLANT 12:10 AM 1:10 AM 60 10 MVA transformer Tripped.
8 10-Oct-18 A Plant F4 - PLANT 6:30 AM 7:00 AM 30 10 MVA transformer Tripped.

8 12-Oct-18 C Coldend 42 Hotend Coating M/C 12:20 AM 1:20 AM 60 Circulation Blower Failed So replaced

10 13-Oct-18 B Coldend 56 RCP Case Conveyor 4:30 PM 5:15 PM 45 Motor cable got failed So changed.
11 20-Oct-18 B Coldend 41 Wrapping M/C 9:00 PM 9:50 PM 50 41 Wrapping M/C y-phase supply problem, rectified.

12 21-Oct-18 A Coldend 44 Poly pack tunnel 12:45 PM 1:00 PM 15 Blower Motor bearing problem So replaced.

13 23-Oct-18 B Plant All IS M/C 5:50 PM 6:20 PM 30 Compressors tripped due to voltage drop.
14 27-Oct-18 A Production 43 Lehr 12:00 PM 12:10 PM 10 43 Lehr belt drive fan got failed So replaced.

Production Effected (Min.) 105 Non Production (Min.) 435 Total 540 12.32
External 60
 %
Down
Time

0.0276
0.1344
 DAILY DOWNTIME REPORT FOR NOVE
DEPARTMENT: ELECTRICAL

S.No. Date Shift Area Name of the Equipment from

1 3-Nov-18 C Coldend 45 Packing M/C 12:25 AM

2 4-Nov-18 C Coldend 56 Packing Tunnel 4:45 AM

3 5-Nov-18 C Coldend 51 Packing M/C 3:15 AM

4 6-Nov-18 B Coldend 52 Packing M/C 8:00 PM

5 19-Nov-18 B Coldend 58 Packing M/C 5:40 PM

6 20-Nov-18 B Coldend 51 Packing M/C 6:30 PM

7 21-Nov-18 B Production 46 Lehr 4:15 PM

8 24-Nov-18 B Production 43 Lehr 4:40 PM

9 25-Nov-18 A Production 45 Hotend Coating M/C 10:43 AM

10 25-Nov-18 C Coldend 58 Packing M/C 3:00 AM

11 26-Nov-18 A Coldend 58 Packing M/C 9:40 AM

7:10 AM
12 30-Nov-18 A Production 47 MCB
7:30 AM
Production Effected (Min.) 60 Non Production (Min.) 350
ORT FOR NOVEMBER-2018
Total Down
% Down
to Time in Reasons for Down Time Time in
Time
Min Min.
12:50 AM 25 End sealer Cable Cutt Off problem So rectified.
Tunnel On/Off Switch Internally Shorted So MCB
5:05 AM 20
arranged and running given.
Tunnel heaters not getting ON Control Wiring Problem
4:10 AM 55
So Rectified.
Heater SSR got Failed and Control Circuit Problem So
10:00 AM 120
rectified.
6:10 PM 30 Pusher Up Sensor Failed So replaced.
6:50 PM 20 Tunnel Y-Phase Cable Problem So Rectified.

4:20 PM 5 Emergency stopped in HMI So resetted and Started.

Drive showing rpm and load but belt not rotating.its

5:00 PM 20
slipping problem.

11:08 AM 25 Circulation Blower Tripped So resetted and Started.

Pusher Down Sensor and Solenoid Coil Failed So

4:00AM 60
replaced.
10:00 AM 20 Pusher Down Sensor Failed So replaced.
7:15 AM
10 Over load Tripped So resetted and Started
7:35 AM
Total 410 4.29 0.0099
External 0.00 0.0000
 DAILY DOWNTIME REPORT FOR DECEMB
DEPARTMENT: ELECTRICAL

Total
Name of the
S.No. Date Shift Area from to Time in
Equipment
Min

1 2-Dec-18 A Production 52 Cross Conveyor 1:40 PM 2:20 PM 45

2 3-Dec-18 C Coldend 58 Packing M/C 12:10 AM 12:25 AM 15
3 5-Dec-18 A Production 46 LWN Blower 7:50 AM 7:55 AM 5

4 11-Dec-18 A Plant Plant 11:03 AM 11:18 AM 15

5 12-Dec-18 A Coldend 45 LHS Packing M/C 12:30 PM 1:00 PM 30

6 12-Dec-18 B Production 54 Cross Conveyor 7:30 PM 7:40 PM 10

7 12-Dec-18 C Production 54 Cross Conveyor 4:10 AM 5:00 AM 50

8 13-Dec-18 C Coldend 41 M-1 S/L Motor 2:40 AM 2:50 AM 10

9 15-Dec-18 A Production 41 MCB 6:30 AM 6:40 AM 10

10 16-Dec-18 A Coldend 57 packing M/C 8:00 AM 8:50 AM 50

11 17-Dec-18 A Coldend 52 packing M/C tunnel 1:00 PM 1:50 PM 50

12 17-Dec-18 B Coldend 46 Coldend Coating M/C 6:00 PM 6:35 PM 35

13 19-Dec-18 B Plant Plant 3:10 PM 3:30 PM 20

14 19-Dec-18 C Production 41 LWN Blower 12:34 AM 12:39 AM 5
15 20-Dec-18 A Plant Plant 6:25 AM 7:25 AM 60
IR Compressor 4,
16 20-Dec-18 B Production 3:40 PM 3:50 PM 10
54,55 and 56 IS M/C
IR Compressor 4,
17 20-Dec-18 C Production 2:50 AM 3:00 AM 10
54,55 and 56 IS M/C
IR Compressor 5,
18 21-Dec-18 B Production 6:50 PM 7:20 PM 30
54,55 and 56 IS M/C
19 22-Dec-18 B Production F-4 IS M/C 4:40 PM 4:50 PM 10
20 23-Dec-18 A Production 41 LWN Blower 9:05 AM 9:10 AM 5
21 23-Dec-18 C Coldend 51 Packing M/C tunnel 10:10 PM 11:00 PM 50
22 23-Dec-18 C Coldend 57 packing M/C 10:00 PM 11:00 PM 60
23 26-Dec-18 C Production F-5 IS M/C 3:10 AM 3:25 AM 15
24 28-Dec-18 A Coldend 42 Packing M/C tunnel 6:00 AM 8:00 AM 120
Production Effected (Min.) 300 Non Production (Min.) 420 Total 720
OR DECEMBER-2018
Down %
Reasons for Down Time Timein Down
Min. Time

Motor Bearing Failed So Motor replaced

Pusher Down Sensor Damaged So replaced.
Un Known person stopped So started
132KV SF6 Breaker tripped due to solar I/C Cable
problem
Tunnel emergency circuit problem So rectified

Drive tripped with overload fault resetted

Drive tripped with overload fault resetted

VFD got failed So replaced
Tripped with Overload Fault So speed reduced and
started.
Fuse and UP wind sensor problem So rectified
Tunnel blower jammed so replaced

Motor Jammed problem So replaced.

Supply problem So arranged.

No alarm And tripp Indication So Started.
Power failure

56 UPS Supply Problem

56 UPS Supply Problem

56 UPS Supply Change Over To Booster UPS

Supply.
F 4 Emegecy breaker strucked So replaced.
Automatically stopped No alarm.
Motor Winding Failed So replaced.
Aux relay problem So rectified
51 UPS Supply Problem
Blower Bearing Failed So Replaced.
37.41 0.0838
External 75 0.1680