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IMS DEPARTMENTAL MANUAL
Department: O&M / BMD-Rotary Machines
Issue 01, Issue Date: 01.12.2020
Page 1 of 20
Department Functional Manual – BMD-RM/O&M कु डगी
(ISO 9001:2015, ISO 14001:2015 and ISO 45001:2018) Kudgi
DFM/BMD-RM/01 Issue No. 01
INDEX
Chapte
Description Page No.
r No.
1. Amendment Record sheet 3
2. Terms & Definitions 4-5
3. Departmental organization chart 6
4. Responsibilities and authorities 7-10
5. Department Brief (Inputs, operational activities, Outputs) 11-12
6. List of procedures 13
7. List of work instructions and JSA 14-17
8. List of forms and formats 18
9. Legal and other Requirements 19
10. List of external origin documents 20
Page 2 of 20
Department Functional Manual – BMD-RM/O&M कु डगी
(ISO 9001:2015, ISO 14001:2015 and ISO 45001:2018) Kudgi
DFM/BMD-RM/01 Issue No. 01
Page 3 of 20
Department Functional Manual – BMD-RM/O&M कु डगी
(ISO 9001:2015, ISO 14001:2015 and ISO 45001:2018) Kudgi
DFM/BMD-RM/01 Issue No. 01
Page 4 of 20
Department Functional Manual – BMD-RM/O&M कु डगी
(ISO 9001:2015, ISO 14001:2015 and ISO 45001:2018) Kudgi
DFM/BMD-RM/01 Issue No. 01
I/c: In charge
SAP: It is a networked on-line system in which all the defects and maintenance activities
are initiated, planned, executed and recorded.
PTW: It stands for “Permit to work” and is a document, which states that, the equipment
on which, the maintenance is to be carried out has been isolated electrically & from
process and is safe for working.
LWC: It stands for “Limited work certificate” and is a document which states that the
equipment on which the maintenance is to be carried out without any isolation.
WORKSHOP / LAB JOB ORDER CARD: It is a format in which all the details of the
instrument to be calibrated are entered. It also contains the results of calibration.
SRV: “Store Requisition Voucher”, it is a SAP format for getting the material issued from
central Stores.
AI: “Environment Aspects & Impacts”, it is a matrix for identifying the environmental
Aspects of activities.
Page 5 of 20
Department Functional Manual – BMD-RM/O&M कु डगी
(ISO 9001:2015, ISO 14001:2015 and ISO 45001:2018) Kudgi
DFM/BMD-RM/01 Issue No. 01
HOD (BMD)
Section Incharge
Section Incharge
(BMD-RM & Mills)
BMD-Pressure Parts
(DFM is maintained separately)
Area Manager
Area Manager (BMD-Mills)
(BMD-RM)
Shift Engineer
(Group-A, Group-B, Group-C , Group-D)
Page 6 of 20
Department Functional Manual – BMD-RM/O&M कु डगी
(ISO 9001:2015, ISO 14001:2015 and ISO 45001:2018) Kudgi
DFM/BMD-RM/01 Issue No. 01
Page 7 of 20
Department Functional Manual – BMD-RM/O&M कु डगी
(ISO 9001:2015, ISO 14001:2015 and ISO 45001:2018) Kudgi
DFM/BMD-RM/01 Issue No. 01
Page 8 of 20
Department Functional Manual – BMD-RM/O&M कु डगी
(ISO 9001:2015, ISO 14001:2015 and ISO 45001:2018) Kudgi
DFM/BMD-RM/01 Issue No. 01
Page 9 of 20
Department Functional Manual – BMD-RM/O&M कु डगी
(ISO 9001:2015, ISO 14001:2015 and ISO 45001:2018) Kudgi
DFM/BMD-RM/01 Issue No. 01
Page 10 of 20
Department Functional Manual – BMD-RM/O&M कु डगी
(ISO 9001:2015, ISO 14001:2015 and ISO 45001:2018) Kudgi
DFM/BMD-RM/01 Issue No. 01
RCA &
implementation of Self /
Reliability
SAP reports Breakdown details corrective actions to HOD (BMD)
report
avoid recurrence & HOD (Maintenance)
occurrence
Periodical
Preparation of pre-
maintenance plan for
shutdown checklist,
boiler & aux.
Arrangement of PM reports,
Spare parts
spares, tools& tackles, Pre-shutdown
Contract manpower
Arrangement of checklists
PM Outsourced processes Self/MTP/
manpower, Operational
schedules (Vibration analysis, HOD(Maintenance)
Coordination with data
PMI, Calibration,
sourced processes, Post light up
Radiography, Dynamic
Pre-commissioning data
balancing, UT, stress
checks,
relieving)
Operational checks
Thermography
Preparation of pre-
shutdown checklist, Post light up
Spare parts Arrangement of data
Contract manpower spares, tools& tackles,
Overhaul of Outsourced processes Arrangement of Partial loss
Self/MTP/EEMG/
Boiler and (Vibration analysis, manpower, reduction plans
Operation
accessories PMI, Calibration, Coordination with
Oil sample analysis, sourced processes, Overhauling
DPT testing) Pre-commissioning reports
checks, Operational
checks
Page 11 of 20
Department Functional Manual – BMD-RM/O&M कु डगी
(ISO 9001:2015, ISO 14001:2015 and ISO 45001:2018) Kudgi
DFM/BMD-RM/01 Issue No. 01
1. To achieve targeted availability of units and reduce Partial Loss due to BMD Rotary
Machines
2. To minimize the loss due to forced outage
3. To ensure zero incident/accident by strictly adhering to safe operating procedures and
Compliance of Safety Observations.
4. To comply with statutory environmental norms.
(a)RM equipment failures are investigated for root cause for corrective and
preventive actions.
(b)The section in charge compiles viable corrective and preventive actions and form
an action plan for failure reduction (Once in a year before overhauls)
(c)The action plan is implemented as per approval.
SAP software is used for day-to-day maintenance and material management activities.
Page 12 of 20
Department Functional Manual – BMD-RM/O&M कु डगी
(ISO 9001:2015, ISO 14001:2015 and ISO 45001:2018) Kudgi
DFM/BMD-RM/01 Issue No. 01
6. List of procedures
Re
Sl. Storage Retention Storage
Document Name Doc No v Revision date
No media period location
No
Nil
Location management instruction for specific jobs identified. Such LMI’s are maintained
and audited regularly.
Sl.
No. Doc. Ref. No. Title/Purpose of the LMI Issue No. Issue Date
LMI-Kudgi-OGN-OPS-MECH-011- Control of PFA Agglomerate Emissions from Rev.2 22-08-2020
1 066 Coal Fired Power Stations
LMI-Kudgi-OGN-OPS-Mech-051- O&M Guidelines for Variable Pitch Axial Fans Rev.0 12-10-2020
2 131
LMI-Kudgi-OGN-OPS-MECH-052- Guidelines for Coal Mill Maintenance Rev.0 19-10-2020
3 134
Page 13 of 20
Department Functional Manual – BMD-RM/O&M कु डगी
(ISO 9001:2015, ISO 14001:2015 and ISO 45001:2018) Kudgi
DFM/BMD-RM/01 Issue No. 01
Re
Sl. Storage Revision Retentio Storage
Document Name Doc No v
No media date n period location
No
PM OF ID FAN LUBE OIL Soft 01.12.202 BMD
1 KUDGI/BMD/RM/WI-1 0 3 Years
PUMP copy 0 Intranet
PM OF PA/FD FAN LUBE OIL Soft 01.12.202 BMD
2 KUDGI/BMD/RM/WI-2 0 3 Years
PUMP copy 0 Intranet
PM OF SAPH/PAPH GUIDE
Soft 01.12.202 BMD
3 BEARING/SUPPORT BEARING KUDGI/BMD/RM/WI-3 copy
0
0
3 Years
Intranet
LOS
PM OF PURGE AIR FAN / Soft 01.12.202 BMD
4 KUDGI/BMD/RM/WI-4 0 3 Years
SCANNER AIR FAN copy 0 Intranet
APH SOOT BLOWER PM Soft 01.12.202 BMD
5 KUDGI/BMD/RM/WI-5 0 3 Years
WORKS copy 0 Intranet
FAN LUBE OIL/CONTROL OIL Soft 01.12.202 BMD
6 KUDGI/BMD/RM/WI-6 0 3 Years
FILTER CLEANING copy 0 Intranet
PM OF ID FAN SEAL AIR Soft 01.12.202 BMD
7 KUDGI/BMD/RM/WI-7 0 3 Years
FAN/FILTER CLEANING copy 0 Intranet
Soft 01.12.202 BMD
8 PM OF MILL SEAL AIR FAN KUDGI/BMD/RM/WI-8 copy
0
0
3 Years
Intranet
ID/FD/PA FAN LUBE OIL Soft 01.12.202 BMD
9 KUDGI/BMD/RM/WI-9 0 3 Years
TOPUP copy 0 Intranet
Soft 01.12.202 BMD
10 APH LUBE OIL TOPUP KUDGI/BMD/RM/WI-10 copy
0
0
3 Years
Intranet
Soft 01.12.202 BMD
11 BIAS DAMPER OIL TOPUP KUDGI/BMD/RM/WI-11 copy
0
0
3 Years
Intranet
Soft 01.12.202 BMD
12 PM OF APH AIR MOTOR KUDGI/BMD/RM/WI-12 copy
0
0
3 Years
Intranet
PM OF APH RDU Soft 01.12.202 BMD
13 KUDGI/BMD/RM/WI-13 0 3 Years
(SAPH/PAPH) copy 0 Intranet
APH soot blower pressure Soft 01.12.202 BMD
14 KUDGI/BMD/RM/WI-14 0 3 Years
setting copy 0 Intranet
DAMPER OR GATE JAMMING Soft 01.12.202 BMD
15 KUDGI/BMD/RM/WI-15 0 3 Years
or NOT OPERATING copy 0 Intranet
Reverse rotation of ID FAN Soft 01.12.202 BMD
16 KUDGI/BMD/RM/WI-16 0 3 Years
SEAL AIR FAN copy 0 Intranet
PURGE AIR FAN / SCANNER
AIR FAN discharge damper Soft 01.12.202 BMD
17 KUDGI/BMD/RM/WI-17 0 3 Years
passing / motor decoupling / copy 0 Intranet
high vibration
Bias damper Soft 01.12.202 BMD
18 KUDGI/BMD/RM/WI-18 0 3 Years
jamming/internal inspection copy 0 Intranet
Page 14 of 20
Department Functional Manual – BMD-RM/O&M कु डगी
(ISO 9001:2015, ISO 14001:2015 and ISO 45001:2018) Kudgi
DFM/BMD-RM/01 Issue No. 01
Re
Sl. Storage Revision Retentio Storage
Document Name Doc No v
No media date n period location
No
PM Jobs of Mills (Model: KUDGI/BMD/MILL/ Soft 01.12.202 BMD
19 0 3 Years
Loesche 35.3D) WI-1 copy 0 Intranet
PM Jobs of Gravimetric KUDGI/BMD/MILL/ 01.12.202 BMD
20 Soft copy 0 3 Years
Feeders WI-2 0 Intranet
Chockage removal in MRS
01.12.202 BMD
21 system / Normalizing MRS KUDGI/BMD/MILL/WI Soft copy 0
0
3 Years
Intranet
system -3
PM Job of Mill Reject 01.12.202 BMD
22 KUDGI/BMD/MILL/WI Soft copy 0 3 Years
Compressor 0 Intranet
-4
FEEDER DISCHARGE CHUTE 01.12.202 BMD
23 KUDGI/BMD/MILL/WI Soft copy 0 3 Years
PATCHING (496G) 0 Intranet
-5
Page 15 of 20
Department Functional Manual – BMD-RM/O&M कु डगी
(ISO 9001:2015, ISO 14001:2015 and ISO 45001:2018) Kudgi
DFM/BMD-RM/01 Issue No. 01
Page 16 of 20
Department Functional Manual – BMD-RM/O&M कु डगी
(ISO 9001:2015, ISO 14001:2015 and ISO 45001:2018) Kudgi
DFM/BMD-RM/01 Issue No. 01
COAL FEEDER
KUDGI/BMD/MILLS/ Soft 01.12.202 BMD
26 BELT(CONVENTIONA 0 3 Years
JSA-5 copy 0 Intranet
L) REPLACEMENT
COAL FEEDER TAIL
KUDGI/BMD/MILLS/ Soft 01.12.202 BMD
27 PULLEY 0 3 Years
JSA-6 copy 0 Intranet
REPLACEMENT
COAL FEEDER HEAD
KUDGI/BMD/MILLS/ Soft 01.12.202 BMD
28 PULLEY 0 3 Years
JSA-7 copy 0 Intranet
REPLACEMENT
MILL REJECT
COMPRESSOR KUDGI/BMD/MILLS/ Soft 01.12.202 BMD
29 0 3 Years
PM/COOLER JSA-8 copy 0 Intranet
CLEANING
Page 17 of 20
Department Functional Manual – BMD-RM/O&M कु डगी
(ISO 9001:2015, ISO 14001:2015 and ISO 45001:2018) Kudgi
DFM/BMD-RM/01 Issue No. 01
Page 18 of 20
Department Functional Manual – BMD-RM/O&M कु डगी
(ISO 9001:2015, ISO 14001:2015 and ISO 45001:2018) Kudgi
DFM/BMD-RM/01 Issue No. 01
Page 19 of 20
Department Functional Manual – BMD-RM/O&M कु डगी
(ISO 9001:2015, ISO 14001:2015 and ISO 45001:2018) Kudgi
DFM/BMD-RM/01 Issue No. 01
Storage
Document media Rev. Revision Retention Storage
S. No. Document Name
No (Hard / No date period location
Soft)
1 Nil
Page 20 of 20