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Ess Check Ponts of Kiln & Coal Mill-1 &2 28.07.2011
Ess Check Ponts of Kiln & Coal Mill-1 &2 28.07.2011
FREQ
SL.NO. CHECK POINTS
Weekly
RAW COAL HOPPER / ROD GATE
1 CHECK THE RAW COAL HOPPER FOR ANY LEAKAGE W
2 CHECK THE PIN GATE ROD FOR ANY BEND
3 CHECK THE FRENESS OF ROD GATE
4 CHECK THE PIN GATE SEATING BUSH WELDING INSPECTION
WEIGH FEEDER
1
General inspection of pulleys and bearings
2
Check the idlers condition for any damage or wear
3 Check Gear motor
4 Check input coupling condition
5 Check pulley bearing condition
6 Check pulley lagging
7 Check belt condition W
8
Check idler condition
9
Check carrying & weighing idlers condition
10 Check skirt rubber W
11 Check chute internal condition
12 Check the tensioning arrangement
ROTARY AIR LOCK( GRAVEL GATE)
1
Check rotor condition for wear or damage
2
Check the gearbox/gear motor Condition & Coupling.
3
General inspection of coupling and bush any wear
4
Check the RAL DE & NDE Bearing and housing
5 Check the DE & NDE Glande
6 Check the Rotor blade with housing clearence
7 Check the casing for any leakages
STATIC SAPERATOR
1 Check the blade condition
check the blade holding pipe for any wear
2
1 W
INSPECT THE GUIDE BRACKET BOLT.
2 W
INSPECT THE GUIDE PIN BOLTS .
3 W
INSPECT THE TIE ROD SEAL PLATE BOLTS
4 W
INSPECT THE WALL LINER & ITS BOLTS.
5 W
INSPECT THE ROLLER ASSYMBLY HOOK BOLTS
6 W
INSPECT THE TIE ROD FOR ANY WEAR IN THE EYE PORTION.
7 INSPECT THE SCRAPPER PLATE W
8 INSPECT THE INSULATION RING JOINTS & ITS BOLTS W
9 INSPECT THE ANY LEAKAGES IN THE MILL BODY (DOME ) W
10 INSPECT THE OIL LAVEL IN SEAL LUBRICATION TANK W
11 W
INSPECT THE ANY LEAKAGES IN SEAL AIR BLOWER PIPE LINE
12 W
TAKE THE WEAR READING OF ROLLER SHELL
13 W
TAKE WEAR READING OF TABEL LINER
14 INSPECT THE OIL LAVEL OF ALL ROLLER ASSYMBLY. W
15 INSPECT THE ANY LEAKAGES IN THE ROLLER ASSYMBLY. w
16 INSPECT THE TIE ROD SEALING BELLOW w
17 INSPECT FELT PACKING FOR ANY LEKAGES IN BOWL.
18
INSPECT THE MILL OUTLET DUCT DISTANCE PIECE LEAKAGES .
19 COUPLING BOLT & BUSH INSPECTION
1
check the pump condition
2
Check the accmulator Nitrogen Pressure.
3
Check the filter any contnamination and replaced
4
Check the hose condition
5 W
INSPECT THE CYLINDER BASE BOLTS.
6
INSPECT THE CHECK VALVE
7
INSPECT THE NON RETURN VALVE.
1
Check the bags condition
2
Check for tightening of inspection / roof door bolts
3
Check for proper functioning of solenoid valve
4
General inspection for any air leakages
5
check the purging system.
6
check dust collector inlet and outlet duct condition
7 Check the inlet / outlet expansion joint condition
FAN
1 Check for any coating on blade or wear
2 Check the bearing housing condition
3 Check shaft sealing plate
5 Check Bearing for Clearance
6 Check foundation bolts / casing bolts
7 Check coupling condition
8 Check impeller for any wear or damage
9 check casing condition
10 check fan inlet and outlet expansion joints for any damage
11 check damper valve opening for suction
12 Check the inlet cone condition
13 Check the casing internal bolts condition for any wear
SCREW CONVEYOR ( BELOW AYDC HOPER )
1
Check the Hanger Bearing , Journal & Bearing Housing for any wear.
2 check for any wear of screw flights
3 check for wear of gland packing any leakage
4 check the hanger bearing journal bolt
5 Check the de & nde bearing and housing condition.
6 Check the Geared Motor condition
7 Check the Coupling and bush condition
FINE COAL BIN
1 Check the PC & Main Bin for any coating inside the bin.
2 Check the Bin airation system solenoid valve diaphragam.
3 Check the filter plate for bin airation.
4 Check the hose pipe for any lekages
5 Check the bin condition
6 Check the nozzle condition
7 Check the rapture disc condition
8 Check the MS bin any waer
9 Check the SS bin any wear
REJECTION BELT
1 INSPECT THE BELT JOINT
2 INSPECT THE SCRET RUBBER QUALITY
3 INSPECT THE JACK BOLT CONSDITION
4 INSPECT THE HEAD DRUM BEARING BASE BOLT
5 INSPECT THE TAIL DRUM BEARING HOUSING BASE BOLT
6 INSPCT THE TAIL DRUM BEARINGS
7 INSPECT THE HEAD DRUM BEARING
POLDAS
1 INSPECT THE CONVEYING NOZZLE FOR ANY WEAR
2 INSPECT THE CONTROL VALVE SPINDAL FOR WEAR
3 INSPECT THE CONTROL VALVE SEATING FOR WEAR
4 INSPECT THE BIN AERATION CLOTH QUALITY
5 INSPECT THE NON METALIC EXPANSION BELLOW FOR ANY DAMAGE
6 INSPECT THE FLAP FOR ANY WEAR
7 INSPECT THE CONVEYING PIPE FOR ANY DAMAGE.
OAL MILL- 1
FREQUENCY
Forthnight Monthly Quarterly Half yearly Yearly
Q
M
Q
H
H
H
Q
Q
H
Q
H
M
Q
Q
Y
Y
Q
Y
H
M
y
M
M
M
H
Q
Q
Q y
Q
H
Q
M
Q
H
H
Y
Y
H
Q
Q
H
Y
H
Y
Q
H
Y
Y
H
Y
Y
Y
M
M
M
M
M
H
H
Y
Y
H
H
Q
M
Q
M
M
M
Q
Q
Q
M
M
M
Q
Q
Q
Q
H
Q
Q
Q
H
H
H
Q
ESS CHECK POINT FOR COAL MILL- 2
FREQUENCY
SL.NO. CHECK POINTS
Weekly Forthnight Monthly
1 W
CHECK THE RAW COAL HOPPER FOR ANY LEAKAGE
2
CHECK THE PIN GATE ROD FOR ANY BEND
3 M
CHECK THE FRENESS OF ROD GATE
4
CHECK THE PIN GATE SEATING BUSH WELDING INSPECTION
DRAG CHAIN
1
Check rotor condition for wear or damage
2
Check the gearbox/gear motor Condition & Coupling.
3
General inspection of coupling and bush any wear
4
Check the RAL DE & NDE Bearing and housing
5
Check the DE & NDE Glande
Check the Rotor blade with housing clearence
6
CLASSIFER
1 M
INSPECT THE CLASSIFER BLADE
2
INSPECT THE TIE ROD ADJUSTMENT ROD CASING PIPE WEAR
3 M
INSPECT THE COUPLING BOLT OF CLASSIFER
4
INSPECT THE MOTOR BASE BOLT
5 M
INSPECT CLASSIFER OUTLET DUCT LEAKAGES
6
INSPECT THE BOTTOM BEARING
7
INSPECT THE BOTTOM BEARING GREASING PIPE LINE.
8
INSPECT COUPLING BOLT
9
INSPECT THE TOP BEARING
1
Check the gear box internal inspection
2
Check the auxillary drive condition
3
Visual check of pipe condition & its clamping
4
Check the pin bush coupling bolt and bush any wear
5 M
Check the breather cleaning
6
Check the segment pads condition
1 M
INSPECT THE OIL FILTER IN MAIN LINE
2 M
INSPECT THE WATER FILTER
3 W
INSPECT THE ANY LEAKAGES IN THE OIL PIPE LINE
4 W
INSPECT THE ANY LEAKAGES IN WATER PIPE LINE
5 W
INSPECT THE LEAKAGES IN OIL STORAGE TANK.
6 M
Check the heat exchanger tubes for ang lekages.
7
check the pump condition
HYDRAULIC UNIT SYSTEM (COAL MILL)
1
check the pump condition
2
Check the accmulator Nitrogen Pressure.
3
Check the filter any contnamination and replaced
4 M
Check the hose condition
5 W
INSPECT THE CYLINDER BASE BOLTS.
6
INSPECT THE CHECK VALVE
7
INSPECT THE NON RETURN VALVE.
1
Check the bags condition
2 M
Check for tightening of inspection / roof door bolts
3
Check for proper functioning of solenoid valve
4 M
General inspection for any air leakages
5 M
check the purging system.
6
check dust collector inlet and outlet duct condition
FAN
1
Check for any coating on blade or wear
2
Check the bearing housing condition
3
Check shaft sealing plate
5
Check Bearing for Clearance
6
Check foundation bolts / casing bolts
7
Check coupling condition
8 M
Check impeller for any wear or damage
9
check casing condition
check fan inlet and outlet expansion joints for any damage
10
11
check damper valve opening for suction
12
Check the inlet cone condition
13
Check the casing internal bolts condition for any wear
2
check for any wear of screw flights
3
check for wear of gland packing any leakage
4
check the hanger bearing journal bolt
5
Check the de & nde bearing and housing condition.
6
Check the Geared Motor condition
7
Check the Coupling and bush condition
1
Check the PC & Main Bin for any coating inside the bin.
2
Check the Bin airation system solenoid valve diaphragam.
3
Check the filter plate for bin airation.
4
Check the hose pipe for any lekages
5
Check the bin condition
6
Check the nozzle condition
7
Check the rapture disc condition
8
Check the MS bin any waer
9
Check the SS bin any wear
REJECTION BELT
1
INSPECT THE BELT JOINT M
2
INSPECT THE SCRET RUBBER QUALITY M
3
INSPECT THE JACK BOLT CONSDITION M
4
INSPECT THE HEAD DRUM BEARING BASE BOLT
5
INSPECT THE TAIL DRUM BEARING HOUSING BASE BOLT
6
INSPCT THE TAIL DRUM BEARINGS
7
INSPECT THE HEAD DRUM BEARING
ROTOSCALE (Main and PC)
1
Check the Rotor Condition.
2 Check the blow out Nozzle for Wear.
3 Check the Gear Box Condiition.
4 Check the Gear Box Drive belt condition.
5 Check the Drive & Driven Spocket for wear or damage.
6 Check the Upper Sealing Plate for any Wear.
7 Check the Gap of the Rotor.
8 Check the Bottom Sealing Plate for any Wear.
Check the expansion bellow/metallic exp. Joint condition
9
FREQUENCY
Quarterly Half yearly Yearly
H
H
Q
Y
y
H
Q
Q
Q y
H
Y
H
H
Q
Y
Y
Y
H
Y
Y
Q
Y
Q
ESS CHECK POINTS FOR KILN - 2
FREQUENCY
SL.NO. CHECK POINTS
Weekly Forthnight Monthly
KILN FEED BIN
Dust collector
KILN
1 INSPECT THE SUPPORTING ROLLER SHAFT
2 INSPECT THE SUPPORTING ROLLER SEAL FOR LEAKAGES
3 INSPECT THE SUPPORTING ROLLER BASE BOLTS
4 INSPECT THE SUPPORTING ROLLER HOUSING
5 INSPECT THE TYRE SLIPPAGES
6 INSPECT THE TYRE RETAINER RING JOINTS
7 INSPECT THE SUPPORTING ROLLER TYRE FOR ANY CRACK
8 INSPECT THE WATER PIPE LINE OF SUPPORTING ROLLER
9 INSPECT THE RETURN LINE WATER PIPE LINE
10 INSPECT THE GIRT GEAR JOINT BOLTS
11 INSPECT THE GEARTH GEAR TEETH FOR ANY CRACK
12 INSPECT THE PINION TEETH
13 INSPECT THE PINION SHAFT
14 INSPECT THE GIRTH GEAR SPRAY SYSTEM NOZZLES
15 INSPECT THE GIRTH GEAR SPRAY S/Y PUMP
16 INSPECT THE GIRTH GEAR SPRAY S/Y FILTTERS
17 INSPECT THE GIRTH GEAR SPRAY PATTERN
18 INSPECT THE MAIN DRIVE GEAR BOX
19 INSPECT THE GEAR BOX WATER PIPE LINE
20 INSPECT THE WATER FILTER IN WATER PIPE LINE OF SUPPORTING ROLLER
21 INSPECT THE OIL LEAKAGES IN GEAR BOX
22 INSPECT THE GEAR BOX LUBRICATION PUMP
23 INSPECT THE GEAR BOX COUPLING BOLT
24 INSPECT THE COUPLINGS
25 INSPECT TORSHION SHAFT COUPLING BOLTS & COUPLING
26 INSPECT THE NOSE RING BLOWER
Check the Frames, steel structure and Machine parts for any sign
1 of corrosion, Deformation of subassemblies and Welding seams
for cracks.
Check the nut locks for completeness and function of connecting
2 element.
Check the Pedestal Bearing(Head Drum) & Flanged Bearing( Tail
3 Drum) Condition .
Check the Drive Sprocket for slip-free chain transported
4
Check the drive sprocket or segments worn out.
5
Check the Tension Roller Sprocket is the chain transported in a
6 slip-free way.
Check the tensioning roller sprocket or segment worn out.
7
Check does the tensioning roller sprocket take up the chain
8 sufficiently.
Check the Chain & bucket damage or wear and tear be detected.
9
Check the Wheels functional and sufficiently lubricated.
10
Check whether chain is runing centrally.
11
Check the wire ropes been fastened correctly.
12
Check the wire rope worn off or do they show any mechanical
13 damage.
Check the Rope Pulley for any damage.
14
Check the bucket bolts and bucket condition
15
Check the rail condition
16
Check the bucket wheel bolts and free rotation
17
WATER SPARY SYSTEM
H
Y
H
H
H Y
H
H
Y
Y
H
Y
Y
H
Y
Y
Q
Q
Y
H
Q
Q
Q
H
Q
Q
ESS CHECK POINTS FOR KILN - 1
FREQUENCY
SL.NO. CHECK POINTS
Weekly Forthnight Monthly
KILN FEED BIN
Dust collector
AIR BLASTER
1 CHECK THE AIR BLASTER NOZZLE
2 CHECK THE SAFTEY VALVE OF AIR BLASTER
3 CHECK THE QUICK EXHAUST VALVE BODY
4 CHECK THE QUICK EXHAUST VALVE DIAPHGRAM M
5 CHECK THE HOSE PIPE M
6 CHECK THE AIR PIPE LINE M
7 CHCEK THE PISTON M
8 CHECK THE PISTON RUBBER PAD M
FREQUENCY
Quarterly Half yearly Yearly
H
Y
H
H
H Y
H
Y
Y
Y
Y
Y
Y
Y
H
Y
Q
Q
H
Q
Q