DALMIA CEMENT (B) LIMITED, KADAPA

Instrumentation Department
Issue No:02 Rev No:01 Effective Date: 01.07.2016 K-P-1.0
MAINTENANCE SYSTEM

1.0 PURPOSE :
To ensure effective maintenance of plant and equipment.

2.0 SCOPE :
Covers equipment and machinery of cement manufacturing.

3.0 RESPONSIBILITY:

3.1 Instrumentation head assisted by functional personnel, are responsible for the continual
implementation of the Maintenance system.
4.0 SYSTEM DESCRIPTION:

4.1 The maintenance system shall be used to ensure planning, scheduling and monitoring of
the
jobs to increase the equipment availability, effective utilization of the manpower and time
etc.

4.2 Plant maintenance, shall be broadly classified as Preventive Maintenance, Predictive

maintenance and Corrective maintenance.
Preventive maintenance strategies are time based at the specified time. maintenance
activities as detailed by theOEM /One's own experience /Previous Learning’s are taken up &
shall be completed.
Predictive maintenance are based on the change of behavior of the equipment.
Corrective maintenance is based on measurements and user inputs of abnormality or
breakdown.

4.3 Spares required for maintaining equipment shall be procured by raising the Purchase
through SAP & Purchase order generated by the purchase dept.

4.4 The equipment / part drawings/documents shall be developed, for which the OEM's have
not supplied, as per the availability /during shutdowns / breakdowns, when the parts are
removed.

4.5 Availability of drawing s / Approved plans & its traceability:-

All the connected drawings,OEM manuals are made available in drawing office & also
updated time to time.

1
This doc. is valid only until it is viewed in General drive of DCBL local area network.The unsigned print out of the same shall be
treated “Invalid doc.” For print out of the same contact MR.
 DALMIA CEMENT (B) LIMITED, KADAPA

Instrumentation Department
Issue No:02 Rev No:01 Effective Date: 01.07.2016 H-P-1.0

4.6 While carrying out planned maintenance, the required Safety measures such as line
Clearances, Height permits, confined space permits, excavations permits shall be taken &
implemented.
4.7 Equipment Inspection Checklist
The concerned section Engineers shall be responsible for filling daily checklists at the
required frequency by taking plant rounds. The equipment status as per the checklist shall
be cross verified by the concerned section heads & shall initiate corrective / preventive
actions for the same.
4.7.1 Types of Preventive Maintenance Plans:
a. Time based.
b. Periodic Maintenance schedules
c. Based on condition monitoring
4.8 The list of transactions and usage configured under the standard system, are given below :

4.8.1 Technical systems are :

4.8.1.1 Functional locations:
Various sections in the plant shall be configured as Functional Locations. For eg. The
Limestone crusher, Raw material handling, Raw mill, Coal Mill, Pyro-process, Cement Mill,
Packing Plant and Utilities.
4.8.1.2 Operating parameters of the Equipments:
i) Operating parameters shall be configured to :
a. Record measurement for equipment parameters, on-Line at CCR.
b. Maintenance Planning on exceeding specified threshold values.

5.0 Maintenance History and recording in the system.

The equipment history are maintained in Excel file by respective department are kept in common
folder in I-drive.
6.0 Maintaince Budget Planning & its formats:-
Approved Inst. Budget copy is available with Inst. HOD & section wise Budget is available
with respective section incharge.This Budget status is reviewed on monthly basis.

7.0 Reports / Records Developed Or Maintained:-

a.OEM engineers visit & his inspections are recorded in MOM.
b. Any major software/Programming change is recorded and backup kept .

8.0 OPERATIONAL DETAILS :

2
This doc. is valid only until it is viewed in General drive of DCBL local area network.The unsigned print out of the same shall be
treated “Invalid doc.” For print out of the same contact MR.
 DALMIA CEMENT (B) LIMITED, KADAPA

Instrumentation Department
Issue No:02 Rev No:01 Effective Date: 01.07.2016 H-P-1.0

8.1 The system shall be operated by the concerned engineers of the respective departments, to
ensure the preventive maintenance of equipments.

8.1.1 Procedure for predictive maintenance & its Annual Plan:-

Monthly once all the weighing equipments calibration data are taken by respective section in
charge .If necessary twice in a month taken for critical equipment. Plan accordingly for the
corrective actions either in weekly maintenance or in major shutdown jobs.

8.2 Each machine/equipment shall be designated by a number in the system specified to a

particular functional location.
8.2.1 Reporting of maintenance Planning :
Production dept will provide the details of the stoppages like Equipment, start time, stop
time and duration of Breakdown. These malfunctions are to be completed by the concerned
section engineers, with Why-Why Analysis,wherever applicable. All other Malfunctions are
to be recorded & completed by respective section incharges

Equipment Inspection.

Daily Checklist.
Technical Cell
Observations

Pending job list

Man Power Spares Planning/
Planning. Procuring
Action Plan

Short term Long term

planning planning
(weekly (shutdown
maintenance) jobs)

3
This doc. is valid only until it is viewed in General drive of DCBL local area network.The unsigned print out of the same shall be
Off On Off -Line
treated “Invalid doc.” For print out of the same contact MR. On -Line
-Line -Line
 DALMIA CEMENT (B) LIMITED, KADAPA

Instrumentation Department
Issue No:02 Rev No:01 Effective Date: 01.07.2016 H-P-1.0

8.4 Monitoring of Malfunctions:

8.4.1 Monitoring of malfunctions shall be carried out on weekly basis by the concerned
HOD(Maint) of respective areas.
Action on notifications for abnormalities of critical equipments like MV Drive, Plant automation and
related equipments can be taken during planned stoppage / shutdown. If the abnormalities
observed are serious in nature, same will be rectified by stopping the equipments. However, in
case of abnormalities which can wait,actions will be taken during the next available planned
stoppage. Such notifications shall be closed mentioning the probable date of rectification during
next available shutdown.

8.4.2 The corrective actions taken on the malfunctions shall be entered with relevant details like
activities carried out,skill used,etc. and the notifications shall be closed.

8.5 Reasons for breakdown based on cause and task

8.6 Detailed breakdown analysis is available in the form of "Why-Why Analysis", which is
generated in the Excel sheet,concerned dept.

9.0 PROCESS INPUTS :

INPUT SOURCE REVIEW CRITERIA

1) Equipment under
Maint.Schedule Plant Equipments Maint. Schedule

2) Malfunction reports Abnormality in Eqpt. Type of Abnormality,

Time for rectification.
3) Maintenance Crew with
Required accessories. Management Adequate Manpower,
Tools etc.
4) Manpower (Oprn. & Maint.) HRD As per the requirement

10.0 PROCESS OUTPUTS :

4
This doc. is valid only until it is viewed in General drive of DCBL local area network.The unsigned print out of the same shall be
treated “Invalid doc.” For print out of the same contact MR.
 DALMIA CEMENT (B) LIMITED, KADAPA

Instrumentation Department
Issue No:02 Rev No:01 Effective Date: 01.07.2016 H-P-1.0

10.1 Equipment with desired working conditions.

10.1.2 Equipment with restored condition.

10.3 Records of completed PM history, Why-Why Analysis, major repair Reports.

11.0 RECORDS:

SL.No Description Doc. No. Resp. Retention

Period
1 Equipment-wise K-P-1.0-F-16 Section in Life Time
maintenance history in the charge
system
2 Site developed drawings Section in Life Time
charge
3 OEM manuals Drawing Office life time
Incharge.
4 Plant Section wise Why- K-P-1.0-F-1 Section 3 year
Why Analysis reports incharge/Technic
al cell.
5 Equipment checklist of each LSC K-P-1.0-F-3I section incharge 6 Months
section RMH K-P-1.0-F-4I
RM K-P-1.0-F-5I
CLM K-P-1.0-F-6I
KILN K-P-1.0-F-7I
CM K-P-1.0-F-8I
PP K-P-1.0-F-9I
CC K-P-1.0-F-10I
Packer wt K-P-1.0-F-11I
PA system K-P-1.0-F-12I
Telephone K-P-1.0-F-13I
WeighbridgeK-P-1.0-F-14I
X Ray ,Robo Lab
K-P-1.0-F-15I
6 SOP of the activity SOP/INST/--- General Drive Life Time
7 Waste management system K-P-1.01-W-1 Life Time

5
This doc. is valid only until it is viewed in General drive of DCBL local area network.The unsigned print out of the same shall be
treated “Invalid doc.” For print out of the same contact MR.
 DALMIA CEMENT (B) LIMITED, KADAPA

Instrumentation Department
Issue No:02 Rev No:01 Effective Date: 01.07.2016 H-P-1.0

6
This doc. is valid only until it is viewed in General drive of DCBL local area network.The unsigned print out of the same shall be
treated “Invalid doc.” For print out of the same contact MR.