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QUALITY MANAGEMENT PROCEDURE ELECTRICAL MAINTENANCE 1.

PURPOSE:

Doc. No. : F Q MNT 02 P Page No. : 1 of 8

To establish the system for the maintenance of electrical equipments and to ensure that the equipments are available continuously for preventive maintenance. 2. SCOPE: This is applicable to the preventive & breakdown Maintenance of electrical equipment of Foil. 3. DEFINITIONS: Dy.General Manager Asst.Manager PMI I.D. No. P.M 4. RESPONSIBILITY: 4.1 4.2 4.3 Head of department is over all responsible for implementing this procedure. Personal performing breakdown maintenance shall not carry out preventive maintenance. Individual responsibilities of specific activities are described here after. Deputy General Manager Assistant Manager Preventive Maintenance Incharge Identification Number Preventive Maintenance

5. PROCESS INPUT: 5.1 5.2 5.3 5.4 5.5 5.6 Work instruction for carrying out maintenance activities. Intimation of breakdown by work order P.M.Slippage Record P.M.Schedule PM Checklist P.M.Schedule cum check sheet

6. PROCESS DESCRIPTION & INTERFACES:


Approved By: Issued By: Edition No. 01

Date: 01. 12. 2001

Date: 01.12. 2001

Revision No. 02

QUALITY MANAGEMENT PROCEDURE ELECTRICAL MAINTENANCE A. Sr. No. 1 2 3 Preventive maintenance: Activity All the equipments requiring periodic maintenance will be identified and a list will be prepared. A unique I.D.No. Will be given to them. The frequency of maintenance will be decided on the basis of Manufacture recommendation Decided by maintenance Department The P.M. schedule/P.M.Schedule cum check sheet will be made as per the identified frequency above. The equipment will be spared and the preventive maintenance will be carried out as per P.M check list/ P.M.Schedule cum check sheet & relevant work instruction. The P.M. checklist / P.M.Schedule cum check sheet will be filled up after completing maintenance. In case of any schedule getting delayed due to any reasons or preventive action if not carried out, should be recorded in the P.M slippage record. Review the P.M. schedule at least Six monthly for types of checks & frequency on the basis of its effectiveness. Review the P.M.slippage record monthly & to avoid the frequency of slippage. In a case of overhauling required, for the
Issued By:

Doc. No. : F Q MNT 02 P Page No. : 2 of 8

Responsibility Asst.Manager Asst.Manager Asst.Manager

Ref. Doc. FQMNT02F01 FQMNT02F01 Operation & Maintenance Manual


FQMNT02F06
FQMNT02F06 FQMNT02F18
FQMNT02F07, FQMNT02W03, FQMNT02W10, FQMNT02W12 FQMNT02F18, FQMNT02W05

Asst.Manager Asst.Manager/PMI/ Sr.Formen/ Foreman PMI

FQMNT02F07, FQMNT02F18

PMI

FQMNT02F08

Asst.Manager/PMI Asst.Manager/ PMI Sr. Foreman/


Edition No. 01

FQMNT02F03, FQMNT02F04 FQMNT02F08 Operating and

9 10

Approved By:

Date: 01. 12. 2001

Date: 01.12. 2001

Revision No. 02

QUALITY MANAGEMENT PROCEDURE ELECTRICAL MAINTENANCE

Doc. No. : F Q MNT 02 P Page No. : 3 of 8


maintenance manual, FQMNT02W09, FQMNT02W07

equipment, follow the respective work instruction/Vendor instruction manual and filled the over hauling check list. Operation of DG SET, Circuit breaker, 66KVSwithyard,HT Capacitor bank and power changeover done as per work instruction. BREAKDOWN: Activity

Foreman

FQMNT02F19 Shift foreman FQMNT02W01 FQMNT02W02 FQMNT02W04 FQMNT02W08 FQMNT02W11

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B. Sr. No. 1

Responsibility

Ref. Doc.

Receiving work order from user department Shift Incharge regarding breakdown of any equipment. Review the problem and allocate the job to Asst.Manager/ 2 concern person. Shift Incharge Carry out the breakdown maintenance. As Sr.Forman/ Shift 3 per work instruction. Incharge/Foreman Prepare daily breakdown report and sent Sr.Forman 4 copy to Dy.GM (Mech) & GM (F&A). /Foreman Prepare monthly breakdown report and sent Sr.Forman 5 copy to V.P. (foils), all Deptt. Heads, MIS /Foreman & PPC. 7. PROCESS OUT PUTS: 7.1. Continue availability of machine. 7.2. Relevant reports & records of equipments. 7.3 P.M.Slippage Record. 8. PROCESS MONITORING: Sr. No.
Approved By:

FQMNT02W06
FQMNT02F03 FQMNT02F04

Description
Issued By:

Frequency
Edition No. 01

Responsibility

Date: 01. 12. 2001

Date: 01.12. 2001

Revision No. 02

QUALITY MANAGEMENT PROCEDURE ELECTRICAL MAINTENANCE

Doc. No. : F Q MNT 02 P Page No. : 4 of 8

1 2

Review of P.M. schedule. Review P.M.slippage record. 9. RECORDS:

Six monthly Monthly

Asst.Manager Asst.Manager

Sr.No. 1 2 3 4

Record No. FQMNT02F01 FQMNT02F02 FQMNT02F03 FQMNT02F04

Record Title COMPREHENSIV E EQUIPMENT LIST EQUIPMENT HISTORY RECORD DAILY BREAKDOWN REPORT MONTHLY BREAKDOWN REPORT MAJOR BREAKDOWN ANALYSIS REPORT PM SCHEDULE

Retention period Till the equipment Last Till the equipme nt Last Six Months 1Year

Location ELECTRICAL SHOP FLOOR ELECTRICAL SHOP FLOOR, MSDS&ERS ELECTRICAL SHOP FLOOR ELECTRICAL SHOP FLOOR ELECTRICAL SHOP FLOOR ELECTRICAL SHOP FLOOR/MSDS

Disposal authority Dy. General Manager Dy. General Manager Dy. General Manager Dy. General Manager Dy. General Manager Dy. General Manager

FQMNT02F05

1Year

FQMNT02F06

1Year

Approved By:

Issued By:

Edition No. 01

Date: 01. 12. 2001

Date: 01.12. 2001

Revision No. 02

QUALITY MANAGEMENT PROCEDURE ELECTRICAL MAINTENANCE

Doc. No. : F Q MNT 02 P Page No. : 5 of 8

FQMNT02F07
FQMNT02F07/ 01 FQMNT02F07/ 02 FQMNT02F07/ 03 FQMNT02F07/ 04 FQMNT02F07/ 05 FQMNT02F07/ 06 FQMNT02F07/ 07 FQMNT02F07/ 08 FQMNT02F07/ 09 FQMNT02F07/ 10 FQMNT02F07/ 11 FQMNT02F07/ 12 FQMNT02F07/ 13 FQMNT02F07/ 14 FQMNT02F07/ 15 FQMNT02F07/ 16 FQMNT02F07/ 17 FQMNT02F07/ 18 FQMNT02F07/ 19 FQMNT02F07/ 20 FQMNT02F07/ 21 FQMNT02F07/ 22 FQMNT02F07/ 23 FQMNT02F07/ 24 FQMNT02F07/ 25 FQMNT02F07/ 26 FQMNT02F07/ 27 FQMNT02F07/ 28 FQMNT02F07/ 29 FQMNT02F07/ 30 FQMNT02F07/ 31

P.M.CHECK LIST:MILL M50 MILL M51 MILL M52 MILL Q4 MILL Q5 CRANE # 1 CRANE # 2 CRANE # 3 CRANE # 4 CRANE # 5 CRANE # 6 CRANE # 7 CRANE # 8 CRANE # 4A REWIND LINE # 1 REWIND LINE # 2 REWIND LINE # 3 BAILING PRESS ROLL GRINDER ANN. FURNACE # 1 ANN. FURNACE # 2 ANN. FURNACE # 3 ANN. FURNACE # 4 OVEN # 1 OVEN # 2 OVEN # 3 SEPARATOR # 25 SEPARATOR # 26 DOWN ENDER FUME EXH. SYSTEM H G SLITTER

1Year

ELECTRICAL SHOP FLOOR/MSDS

Dy. General Manager

Approved By:

Issued By:

Edition No. 01

Date: 01. 12. 2001

Date: 01.12. 2001

Revision No. 02

QUALITY MANAGEMENT PROCEDURE ELECTRICAL MAINTENANCE

Doc. No. : F Q MNT 02 P Page No. : 6 of 8

14

15 8 16 9 17 10 18 11 12

FQMNT02F07/ 32 M G SLITTER 1 Year FQMNT02F07/ 33 L G SLITTER FQMNT02F07/ 34 DOCTOR REWINDER FQMNT02F07/ 35 DRY BOND LAM. FQMNT02F14 36STATEMENT MACHINE 1Year FQMNT02F07/ PRINTING FQMNT02F07/ 37SHOWING ENERGY EXTRUDER COATER FQMNT02F07/ 38GENERATED &HOUSE MAIN PUMP FQMNT02F07/ 39CONSUMED TOWER COOLING FQMNT02F07/ 40INCLUDING GEN. NITROGEN FQMNT02F07/ 41CONSUMPTION OF FIRE HYDRANT FQMNT02F07/ 42 W.T.P. DIESEL FQMNT02F07/ 43 VENT. SYSTEM FQMNT02F15 44DG COMP. HOUSE LOG BOOK 1Year FQMNT02F07/

ELECTRICAL SHOP FLOOR/MSDS MSDS

Dy. General Manager Dy. General Manager

MSDS

P.M.SLIPPAGE FQMNT02F08 RECORD FQMNT02F16 ANALYSIS OF MOTOR FAILURE FQMNT02F09 WORK ORDER FQMNT02F17 ELECTRICAL POWER FQMNT02F10 CONSUMPTION WORK PERMIT REPORT FQMNT02F18 PM SCHEDULE CUM OVERHAULING CHECK SHEET: FQMNT02F11 LT air circuit breaker FQMNT02F18/ SCHEDULE
01 FQMNT02F18/ 02 FQMNT02F12 FQMNT02F18/ 03 FQMNT02F18/ 04 FQMNT02F13

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FQMNT02F18/ 05 FQMNT02F18/ 06 FQMNT02F18/ Approved By: 07 FQMNT02F18/ 08 FQMNT02F18/ Date:09 12. 2001 01. FQMNT02F18/ 10 FQMNT02F18/ 11

66 kv CT, PT, CVT & LA LT APFC panel, HT SHIFT LOG BOOK capacitor bank & reactor Battery bank & DAILY ENERGY battery charger GENERATION 11 kv & 132 kv MOCB /CONSUMPTION 11 kv T.M.G. ACB REPORT 11 kv ABB (indoor & outdoor) & Siemens VCB 66 kv Sf6 circuit breaker Issued By: 22 kv Sf6 circuit breaker 11 kv, 22 kv & 66 kv isolators 11 kv, 1500 kva DG Date: 01.12. 2001 set

ELECTRICAL 1Year SHOPFLOOR/ General 1Year ERS Dy. General MSDS Manager Manager Dy. ECR Q4/Q5, 3 Month General ERS& MSDS Dy. General 1Year ELECTRICAL Manager SHOP FLOOR Manager Dy. ECR Q4/Q5, 3Month General ERS& MSDS Manager 1Year MSDS Dy. General Dy. Manager 1 Year MSDS / ERS General Manager Q4/Q5 Dy. 1YEAR CONTROL General ROOM Manager Six Months Dy. General Manager

Dy. General Manager Dy.

MSDS

Edition No. 01

Revision No. 02

QUALITY MANAGEMENT PROCEDURE ELECTRICAL MAINTENANCE


FQMNT02F18/ 12 FQMNT02F18/ 13 FQMNT02F18/ 14 FQMNT02F18/ 15 Power & distribution transformer 415 v, 125 kva DG set Sub- station (monthly) Sub- station (fortnight)

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1Year

MSDS

Dy. General Manager

19

FQMNT02F19

OVER HAULING CHECK LIST

3 Years

ERS

Dy. General Manager

10. REFERENCE : Sr.No. 1 2 3 4 5 6 7 8 9 10 11 12 Document no. FQMNT 02W01 FQMNT 02W02 FQMNT 02W03 FQMNT 02W04 FQMNT 02W05 FQMNT 02W06 FQMNT 02W07 FQMNT 02W08 FQMNT 02W09 FQMNT 02W10 FQMNT 02W11 FQMNT 02W12 Work instruction OPERATION OF D.G.SET OPERATION OF 66KV SWITCH YARD OPERATION AND MAINTENANCE OF BATTERY BANK OPERATION OF H.T CAPACITOR BANK OPERATION AND MAINTENANCE OF TRANSFORMER BREAKDOWN MAINTENANCE OVER HAULING OF D.C. MOTOR POWER CHANGE OVER OVER HAULING OF A.C. SLIPRING MOTOR MAINTENANCE OF DIESEL GENERATOR OPERATION OF CIRCUIT BREAKER PREVENTIVE MAINTENANCE

Approved By:

Issued By:

Edition No. 01

Date: 01. 12. 2001

Date: 01.12. 2001

Revision No. 02

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