EQUIPMENT LIST FOR SAP PM MODULE

SI.NO. PLANT DECSRPTION NAME OF THE SECTION DCS TAG NO

1 SCL CRUSHER

B1M105

E1M105A

2 CEMENT GRINDING AND PACKING UNIT CLINKER EXTRACTION SYSTEM

3 MTEPL ROLLER PRESS 541 RP1

4 SCML CRUSHER 211HP1

211AF1
EQUIPMENT NAME
LIME STONE DUMP HOPPER EX.

APRON FEEDER

SPILLAGE CONVEYOR EX.

BELT CONVEYOR EX.

ROLLER PRESS EX.

LIME STONE DUMP HOPPER EX.

APRON FEEDER EX.

 SAMPLE

SI.NO. DCS TAG NO. FUNCTIONAL LOCATION EQUIPMENT NAME

RAW COAL HANDLING SYSTEM COAL TIPPLER

RAW COAL DUMP HOPPER

RECIPROCATING FEEDER

BELT CONVEYOR - CR-1

1 361FN2 VRM RM56.4 RAW MILL FAN

 SAMPLE TASK LIST FOR SAP PM MODULE

SUB EQUIPMENT TYPE OF TASK

CONVEYOR BELT

DRIVE SYSTEM

TAIL PULLEY

BEND PULLEY

ACCESSORIES

IMPELLER CHECK POINT WITH TOOL

CHECK POINT WITHOUT TOOL
CHECK POINT WITHOUT TOOL

CASING AND EXP. JOINT ASSEMBLY CHECK POINT WITHOUT TOOL

CHECK POINT WITHOUT TOOL
CHECK POINT WITHOUT TOOL

COUPLING CHECK POINT WITHOUT TOOL

CHECK POINT WITHOUT TOOL

DE BEARING ASSEMBLY CHECK POINT WITHOUT TOOL

CHECK POINT WITH TOOL
CHECK POINT WITH TOOL
CHECK POINT WITHOUT TOOL

NDE BEARING ASSEMBLY CHECK POINT WITHOUT TOOL

CHECK POINT WITH TOOL
CHECK POINT WITH TOOL
CHECK POINT WITHOUT TOOL

DAMPER ASSEMBLY CHECK POINT WITH TOOL

CHECK POINT WITH TOOL
CHECK POINT WITH TOOL
CHECK POINT WITH TOOL
CHECK POINT WITH TOOL
LE

TASK LIST FREQUENCY

Check for wear of vanes 6M

Check for cracks on hub and shaft 3M
Check for coating on vanes M

Check for casing puncture / welding cracks/ wear M

Check for false air entry from casing / flange joints M
Check exp. Joint cloth condition M
Check for shaft sealing plate condition

Check for coupling bolt and bush condition Q

Check for coupling condition Q

Check bearing physical condition (inner race/outer race/cage/rolling elements) Q

Check bearing clearance Q
Check for foundation and housing bolts condition M
Check conditoin of locating ring if any Q

Check bearing physical condition (inner race/outer race/cage/rolling elements) Q

Check bearing clearance Q
Check for foundation and housing bolts condition M
Check conditoin of locating ring if any Q

Check for free rotation / full closing / full open H

Check for worn out / damage of damper flap H
Check for flaps bearing condition H
Lubrication fo flap bearings Q
Check actuator and lever condition Q
 LIMITS

6-8 MM
NO PHYSICAL CRACK
FREE FROM COATING

NO PHYSICAL CRACK / DAMAGE

 SAMPLE

SI.NO. DCS TAG NO. FUNCTIONAL LOCATION EQUIPMENT NAME

PRIMARY CRUSHER LS DUMP HOPPER

APRON FEEDER

LS CRUSHER - PRIMARY
1 361FN2 VRM RM56.4
211 BELT CONVEYEOR
 SAMPLE TASK LIST FOR SAP PM MODULE

SUB EQUIPMENT TYPE OF TASK

SPILLAGE CONVEYOR

LS CRUSHER
 DRIVE SYSTEM

Tail Pulley

Conveyor Belt and Accessories

NDE BEARING ASSEMBLY CHECK POINT WITHOUT TOOL

CHECK POINT WITH TOOL
CHECK POINT WITH TOOL
CHECK POINT WITHOUT TOOL

DAMPER ASSEMBLY CHECK POINT WITH TOOL

CHECK POINT WITH TOOL
CHECK POINT WITH TOOL
CHECK POINT WITH TOOL
CHECK POINT WITH TOOL
LE

TASK LIST FREQUENCY

Visual checking of Bearing condition Daily

Visual condition of Chain / Links Daily

Bull Gears. Daily

Gearbox [Noise / Vibration / Temp / Lub.] Daily

Drive [Coupling / V Belt / Foundation Bolt / Vib.] Daily

Visual condition of Pans Daily

Material build up/ accumulation / spillage in and around the conveyor Daily
Fouling & rubbing of components Daily
Rotation of inner labyrinth seals with shaft. Daily
Temperature of Plumber Blocks Daily

Daily
Free rotation moving parts such as Track Rollers

Daily
Free rotation moving parts such as Return Rollers
Motor current Daily
Running of Apron Conveyor on NO LOAD – Motor Current reading Monthly
Running of Apron Conveyor on NO LOAD – Abnormal sound Monthly
Sprocket chian tension Monthly
To ensure NO Packing of material on below parts: Monthly
Sprocket Monthly
Track link assembly Monthly
Idlers Monthly
Bushings Monthly
Gap between conveyor flights wear pad & top face Monthly
Change over of Lubricant Monthly

Drive Shaft plumber Block Monthly

Counter shaft plumber Block Monthly
Tail Shaft Take-up Blocks Monthly
Gear coupling Monthly

Geared Motor for Gears Monthly

Check DE Bearing clearance Quarterly
Gap between conveyor flights wear pad & top face of the rail exists Yearly
Free rotation of all Track rollers on LOAD/NO LOAD Yearly
Free rotation of return rollers & position of return roller w.r.t. Yearly
conveyor flights slide plates
Center of sprocket w.r.t. Link assembly Yearly
Meshing pattern of Bull Gear & Pinion teeth Yearly
Backlash & Root Gap of Bull Gear & Pinion Yearly
Check Temperature at No load Yearly
Check Vibration at No Load Yearly
Check Undesirable sound at No Load Yearly
Check Temperature at load Yearly
Check Vibration at Load Yearly
Check Undesirable sound at Load Yearly
Horizontal & vertical distance between. Conveyor flights slide plates against skirt Yearly
board/discharge Chute liner plates while moving
Check Motor current at No Load Yearly
Check Motor current at Load Yearly
Cleaning of locking assembly areas on both sprocket hub & Yearly
Idlers
Wear measurement of Apron Conveyor Yearly

Check for condition of housing liners Fortnight

Check condition of Blow Bars weekly
Check condition of hard faced surfaces Monthly
Check condition of locking of the blow bars weekly
Check locking assembly tightness weekly
Check impact arm suspension arrangement (spindle, pins and lock plates) weekly
Check for free movement of the Impact arm weekly
Check the condition of grinding path weekly
Check for free movement of the assembly Fortnight
Check drive tension V-belts Fortnight
Check tightness of blots of slide rails of drive Fortnight
Check for condition of coupling Monthly
Check tightness of locking assembly weekly
Check all fasteners for tightness Fortnight
Check for oil leakages through hydraulic system pipe lines weekly
Check condition of hydraulic pipe lines weekly
Check condition of hoses weekly
Check for leakage through seals at cylinder weekly
Check condition of oil Quarterly

Gearbox internals inspection and oil condition checking Yearly

Drive alignment checking and condition inspection Yearly
Head Pulley drum and lagging condition Monthly
Bearing inspection for clearance and condition FOR HEAD PULLEY Half Yearly
Conduct UT test to shaft for crack detection Yearly
Check gearbox oil condition Yearly

Bearing inspection for clearance and condition for Tail Pulley Half Yearly
Tail Pulley drum and lagging condition Monthly
Conduct UT test to shaft for crack detection Yearly

Check belt joint condition Weekly

Check belt wear and physical condition Monthly
Check carrying, return and self aligning idlers condition Weekly
Belt scraper and skirt rubber condition. Weekly
Spillage/Leakage. Daily

Check bearing physical condition (inner race/outer race/cage/rolling elements) Q

Check bearing clearance Q
Check for foundation and housing bolts condition M
Check conditoin of locating ring if any Q

Check for free rotation / full closing / full open H

Check for worn out / damage of damper flap H
Check for flaps bearing condition H
Lubrication fo flap bearings Q
Check actuator and lever condition Q
 LIMITS

Normal temp and vibration

proper lubrication and all are
intact

Proper lubrication and non

abnormal sound during meshing

Normal temp and vibration

All are in tact and no looseness

No cracks and all fixing bolts are in tact

Free from obstrcutions
No abnormal sound
Same speed
Normal temp and vibration

Free from jam and no physical

damage and abnormal sound

Free from jam and no physical

damage and abnormal sound

Visual
Visual
Visual
Visual
2 to 2.5mm

Interval of 4months - Grease

HP 2/mp- 2 or equivalent

Interval of 6months-
Servomesh 460 Oil or
Equivalent
 2mm to 2.5mm
Visual

Visual
As per GA
Visual
As per PBSM
Max. 10deg.
Vibration measuring m/c
Visual
Max. 10deg.
Vibration measuring m/c
Visual

20-25mm
As per GA-Spec.
As per GA-Spec.

As per wear chart

 SAMPLE TAS

SI.NO. DCS TAG NO. FUNCTIONAL LOCATION EQUIPMENT NAME

Belt Conveyor
1 361FN2 VRM RM56.4

211 BELT CONVEYEOR

 SAMPLE TASK LIST FOR SAP PM MODULE

SUB EQUIPMENT TYPE OF TASK

Drive system

Head Pulley

Tail Pulley

Bend Pulley

Tensioning System

Belt and accessories

SPILLAGE CONVEYOR

LS CRUSHER

DRIVE SYSTEM

Tail Pulley
 Conveyor Belt and Accessories

NDE BEARING ASSEMBLY CHECK POINT WITHOUT TOOL

CHECK POINT WITH TOOL
CHECK POINT WITH TOOL
CHECK POINT WITHOUT TOOL

DAMPER ASSEMBLY CHECK POINT WITH TOOL

CHECK POINT WITH TOOL
CHECK POINT WITH TOOL
CHECK POINT WITH TOOL
CHECK POINT WITH TOOL
LE

TASK LIST FREQUENCY

Gearbox [Noise / Vibration / Temp / Lub.] Daily
Drive [Coupling / V Belt / Foundation Bolt / Vib.] Daily

Visual condition of Pans Daily

Material build up/ accumulation / spillage in and around the conveyor Daily
Fouling & rubbing of components Daily
Rotation of inner labyrinth seals with shaft. Daily

Check visual condition of gearbox M

Check condition of coupling M
Check internals condition of coupling Q
Visual internal inspection of Gearbox Q
Checking of axial/radial play for gearbox internals Y
Check oil condition of gearbox oil Y

Check visual condition of pulley lagging M

To conduct UT test for shaft for crack detection Y
Check bearing clearance Y
Check bearing and accessories condition Y
Check Plumber block bolts tightness

Check pysical condition of belt joint W

Check belt for wear M
Check for idlers condition and replacement if required W

Temperature of Plumber Blocks Daily

Motor current Daily
Running of Apron Conveyor on NO LOAD – Motor Current reading Monthly
Running of Apron Conveyor on NO LOAD – Abnormal sound Monthly
Sprocket chian tension Monthly
To ensure NO Packing of material on below parts: Monthly
Sprocket Monthly
Track link assembly Monthly
Idlers Monthly
Bushings Monthly
Gap between conveyor flights wear pad & top face Monthly
Change over of Lubricant Monthly

Drive Shaft plumber Block Monthly

Counter shaft plumber Block Monthly
Tail Shaft Take-up Blocks Monthly
Gear coupling Monthly

Geared Motor for Gears Monthly

Check DE Bearing clearance Quarterly

Gap between conveyor flights wear pad & top face of the rail exists Yearly
Free rotation of all Track rollers on LOAD/NO LOAD Yearly
Free rotation of return rollers & position of return roller w.r.t. Yearly
conveyor flights slide plates
Center of sprocket w.r.t. Link assembly Yearly
Meshing pattern of Bull Gear & Pinion teeth Yearly
Backlash & Root Gap of Bull Gear & Pinion Yearly
Check Temperature at No load Yearly
Check Vibration at No Load Yearly
Check Undesirable sound at No Load Yearly
Check Temperature at load Yearly
Check Vibration at Load Yearly
Check Undesirable sound at Load Yearly
Horizontal & vertical distance between. Conveyor flights slide plates against skirt Yearly
board/discharge Chute liner plates while moving
Check Motor current at No Load Yearly
Check Motor current at Load Yearly
Cleaning of locking assembly areas on both sprocket hub & Yearly
Idlers
Wear measurement of Apron Conveyor Yearly

Check for condition of housing liners Fortnight

Check condition of Blow Bars weekly
Check condition of hard faced surfaces Monthly
Check condition of locking of the blow bars weekly
Check locking assembly tightness weekly
Check impact arm suspension arrangement (spindle, pins and lock plates) weekly
Check for free movement of the Impact arm weekly
Check the condition of grinding path weekly
Check for free movement of the assembly Fortnight
Check drive tension V-belts Fortnight
Check tightness of blots of slide rails of drive Fortnight
Check for condition of coupling Monthly
Check tightness of locking assembly weekly
Check all fasteners for tightness Fortnight
Check for oil leakages through hydraulic system pipe lines weekly
Check condition of hydraulic pipe lines weekly
Check condition of hoses weekly
Check for leakage through seals at cylinder weekly
Check condition of oil Quarterly

Gearbox internals inspection and oil condition checking Yearly

Drive alignment checking and condition inspection Yearly
Head Pulley drum and lagging condition Monthly
Bearing inspection for clearance and condition FOR HEAD PULLEY Half Yearly
Conduct UT test to shaft for crack detection Yearly
Check gearbox oil condition Yearly

Bearing inspection for clearance and condition for Tail Pulley Half Yearly
Tail Pulley drum and lagging condition Monthly
Conduct UT test to shaft for crack detection Yearly
Check belt joint condition Weekly
Check belt wear and physical condition Monthly
Check carrying, return and self aligning idlers condition Weekly
Belt scraper and skirt rubber condition. Weekly
Spillage/Leakage. Daily

Check bearing physical condition (inner race/outer race/cage/rolling elements) Q

Check bearing clearance Q
Check for foundation and housing bolts condition M
Check conditoin of locating ring if any Q

Check for free rotation / full closing / full open H

Check for worn out / damage of damper flap H
Check for flaps bearing condition H
Lubrication fo flap bearings Q
Check actuator and lever condition Q
 LIMITS
Normal temp and vibration
All are in tact and no looseness

No cracks and all fixing bolts are in tact

Free from obstrcutions
No abnormal sound
Same speed
 Normal temp and vibration

Visual
Visual
Visual
Visual
2 to 2.5mm

Interval of 4months - Grease

HP 2/mp- 2 or equivalent

Interval of 6months-
Servomesh 460 Oil or
Equivalent

2mm to 2.5mm
Visual

Visual
As per GA
Visual
As per PBSM
Max. 10deg.
Vibration measuring m/c
Visual
Max. 10deg.
Vibration measuring m/c
Visual
 20-25mm
As per GA-Spec.
As per GA-Spec.

As per wear chart