Power from knowledge

KSK Mahanadi Power Company Ltd.

KMPCL/MAINT/DAU/01
6 X 600 MW Power Plant
SMP FOR BA HP PUMP
Issue No: 1 Issue Date: Revision: 1 Revision Date: 29.07.13 File no: Page 1 of 7

STANDARD MAINTANENCE PROCEDURE

FOR

DRY ASH UNLOADER

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Power from knowledge
KSK Mahanadi Power Company Ltd.
KMPCL/MAINT/DAU/01
6 X 600 MW Power Plant
SMP FOR BA HP PUMP
Issue No: 1 Issue Date: Revision: 1 Revision Date: 29.07.13 File no: Page 2 of 7

OBJECTIVE

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Power from knowledge
KSK Mahanadi Power Company Ltd.
KMPCL/MAINT/DAU/01
6 X 600 MW Power Plant
SMP FOR BA HP PUMP
Issue No: 1 Issue Date: Revision: 1 Revision Date: 29.07.13 File no: Page 3 of 7

The purpose of this work instruction is to explain the procedure for carrying out Overhaul of
DRY ASH UNLOADER

1. DRY ASH UNLOADER

The details of the DRY ASH UNLOADER are as follows :

Make: ZHENJIANG AUXILIARY MACHINERY FOR POWER STATION PLANT;TYPE: ZSJ 200B;
Capacity: 200TPH;

DETAILED INSTRUCTION
Sr. Activity Responsibility

No.
I Overhaul to be done as per Checklist

1 Before commencing dismantling operations, ensure that the

following tools and tackles are available:

 A crane / chain pulley block suitable for handling the weight of

pumping unit.
 A selection of ring and open-ended spanners in Metric sizes.
 Eyebolts in Metric sizes.
 Hardwood and metal packing blocks.
 Miscellaneous tools including a set of Allen keys, drills, pin drivers,
files etc.
 Extractor / puller for bearing and coupling.
.
After a long service, wear will occur in parts of the pump necessitating
the renewal of the parts. Those most likely to be affected are impeller,
Wear Rings, Bearings, and Sleeves.

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Power from knowledge
KSK Mahanadi Power Company Ltd.
KMPCL/MAINT/DAU/01
6 X 600 MW Power Plant
SMP FOR BA HP PUMP
Issue No: 1 Issue Date: Revision: 1 Revision Date: 29.07.13 File no: Page 4 of 7

DRY ASH UNLOADER

Prepared by: Reviewed by: Approved by:

Signature: Signature: Signature:
Name: Name: Name:
Designation: Designation: Designation:
Power from knowledge
KSK Mahanadi Power Company Ltd.
KMPCL/MAINT/DAU/01
6 X 600 MW Power Plant
SMP FOR BA HP PUMP
Issue No: 1 Issue Date: Revision: 1 Revision Date: 29.07.13 File no: Page 5 of 7

Construction Drawing For Dry Ash Unloader

Main part of unloading spout

 Telescopic device
 Control system
 Pulse filter

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Power from knowledge
KSK Mahanadi Power Company Ltd.
KMPCL/MAINT/DAU/01
6 X 600 MW Power Plant
SMP FOR BA HP PUMP
Issue No: 1 Issue Date: Revision: 1 Revision Date: 29.07.13 File no: Page 6 of 7

Prepared by: Reviewed by: Approved by:

Signature: Signature: Signature:
Name: Name: Name:
Designation: Designation: Designation:
Power from knowledge
KSK Mahanadi Power Company Ltd.
KMPCL/MAINT/DAU/01
6 X 600 MW Power Plant
SMP FOR BA HP PUMP
Issue No: 1 Issue Date: Revision: 1 Revision Date: 29.07.13 File no: Page 7 of 7

REVIEW DATE:-
SMP WILL BE REVIEWED IN EVERY SIX MONTH FROM THE DATE OF
ISSUE BASED ON ACTUAL PROBLEM FACED AND SHALL BE UPDATED
ACCORDINGLY.
MECHANICAL MAINTANENCE TEAM WILL VISIT THE EQUIPMENT
TWICE IN A WEEK & IF ANY ABNORMALITY NAMELY (VIBRATION,
ABNORMAL SOUND, TEMPERATURE RISE, BELT TIGHTNESS ETC) OF
EQUIPMENT IS OBSERVED AND THEN THE SAME WILL BE RECTIFIED
WITHIN PRESCRIBED TIME PERIOD.

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Signature: Signature: Signature:
Name: Name: Name:
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 Power from knowledge
KSK Mahanadi Power Company Ltd.
KMPCL/MAINT/DAU/01
6 X 600 MW Power Plant
SMP FOR BA HP PUMP
Issue No: 1 Issue Date: Revision: 1 Revision Date: 29.07.13 File no: Page 8 of 7

DO’s & DONT’s :

DO’s :

1. Ensure relevant equipment/system PTW is available before starting the work.

2. Ensure relevant equipment/system is electrically isolated before starting the work, if applicable.

3. Ensure relevant air/water valves are fully closed for the equipment/system before starting the work.

4. Provide Danger Boards before starting the work involving dismantling of any equipment/system.

5. Ensure proper follow-up of all statutory requirements & hazard norms.

6. Ensure proper follow-up of all plant practices, existing regulations, prescribed procedures & general
safety prior to carry out any work.

7. While replacing any spares/oil, ensure that the same must be as per OEM recommendation.

8. After overhauling of any equipment, ensure proper preservation of spares/oil.

9. Always use the special tools as recommended by OEM for certain equipments like HCSD Pump.

DONT’s :

1. Don’t start the work without presence of Safety Personnel in case fire / other hazards are involved.

2. Don’t use hammer / heating for removing bearings / gears.

3. Don’t use tools & tackles which are not calibrated / certified by relevant authority.

4. Don’t start the work in Pressure Vessels/Pressure Line/Water Line, unless it is completely de-
pressurised.

5. Don’t start the work, especially at height, without proper PPE’s.

6. Don’t start the work, without presence of skilled personnel/expert.

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Signature: Signature: Signature:
Name: Name: Name:
Designation: Designation: Designation: