IN PELLETIZATION SECTION THERE ARE FOLLOWING SERIES:-

B6.033 ROLLER CONVEYORB6.032 OSCILLATING CONVEYORB6.030 BELT CONVEYORG1.001 INDURATING MACHINEB6.052 BELT CONVEYORB6.034 BELT CONVEYORB6.035 BELT CONVEYORB6.037 BELT CONVEYORB6.050 BELT CONVEYOR

G1.001 INDURATING MACHINEH2.004 WET SCRUBBERG1.065WEIGH FEEDERG1.066WEIGH FEEDERG4.001BELT CONVEYORG4.004 BELT CONVEYORG4.002 PROCESS SCREENH2.013/2 WET SCRUBBERG6.004 H/L BINGREEN PELLETS FROM B6.033H2.013/1 WET SCRUBBER

Consumers in Pelletising Section

SRNOUNITNUMBERDESCRIPTIONKWRPM1A6.001UNLOADING PUMP-17.52A6.002UNLOADING PUMP-27.53A6.003UNLOADING PUMP-37.54A6.004UNLOADING PUMP-47.55A6.009TRANSFER PUMP-13714706A6.010TRANSFER PUMP-23714707A6.012DAY TANK HEATER1088A6.013DRAIN PUMP-1 (NEAR OIL RECEIVING STATION)3.714409A6.014RING MAIN PUMP-122148510A6.015RING MAIN PUMP-222148511A6.016HEATER14412A6.017HEATER14413A6.018HEATER14414A6.028DRAIN PUMP-1 (INSIDE OIL UNLOADING STATION ROOM)3.71440

SR NOUNIT NUMBERDESCRIPTIONKWRPM15A6.029DRAIN PUMP-1 (NEAR G1.001)3.7144016B6.001ASCENDING BELT CONVEYOR45150017B6.001/1SOLENOID VALVE FOR PLOUGH50VA-18B6.001/2BELT CONVEYOR7.519B6.002ASCENDING BELT CONVEYOR37150020B6.009FLUFFER5.5150021B6.010/1BALLING DISC-1125146022B6.010/2SOLENOID VALVE FOR WATER, BALLING DISC50VA-23B6.010/3GREASE PUMP, ROLLER SUPPORT0.25100024B6.010/4GREASE PUMP, GEAR RIM AND PINION0.2591025B6.011REVERSIBLE BELT CONVEYOR3.7143026B6.015FLUFFER5.5150027B6.016/1BALLING DISC-2125150028B6.016/2SOLENOID VALVE FOR WATER, BALLING DISC50VA-

SR NOUNIT NUMBERDESCRIPTIONKWRPM29B6.016/3GREASE PUMP, ROLLER SUPPORT0.25100030B6.016/4GREASE PUMP, GEAR RIM AND PINION0.2591031B6.017REVERSIBLE BELT CONVEYOR3.7144032B6.021FLUFFER5.5150033B6.022/1BALLING DISC-3125150034B6.022/2SOLENOID VALVE FOR WATER, BALLING DISC50VA-35B6.022/3GREASE PUMP, ROLLER SUPPORT0.25100036B6.022/4GREASE PUMP, GEAR RIM AND PINION0.2591037B6.023REVERSIBLE BELT CONVEYOR3.7144038B6.027FLUFFER5.5150039B6.028/1BALLING DISC-4125150040B6.028/2SOLENOID VALVE FOR WATER, BALLING DISC50VA-41B6.028/3GREASE PUMP, ROLLER SUPPORT0.25100042B6.028/4GREASE PUMP, GEAR RIM AND PINION0.25910

SR NOUNIT NUMBERDESCRIPTIONKWRPM43B6.029REVERSIBLE BELT CONVEYOR3.7144044B6.030BELT CONVEYOR11150045B6.032OSCILLATING BELT CONVEYOR5.5150046B6.032/1HYDRAULIC OIL PUMP30147047B6.032/10SOLENOID VALVE50VA-48B6.032/11PACER MOTOR0.549B6.032/2HYDRAULIC OIL PUMP30147050B6.032/3OIL PREHEATER351B6.032/4, B6.032/9SOLENOID VALVE50VA-52B6.033ROLLER CONVEYORS1.51400/4753B6.034BELT CONVEYOR5.5144054B6.035BELT CONVEYOR7.5144055B6.037BELT CONVEYOR11150056B6.040ASCENDING BELT CONVEYOR30150057B6.040/1SOLENOID VALVE FOR PLOUGH50VA-

SR NOUNIT NUMBERDESCRIPTIONKWRPM58B6.041CRANE, UNDER SLUNG, ABOVE BALLING DISC, TOWARDS MCC SIDE, CONSOLIDATED, TYPE: HEOT-76165 (1 PAGE), CONTROL: 42 VOLT, MAIN HOIST11.563-59B6.041CREEP HOIST1.007160B6.041CROSS TRAVEL0.447661B6.041LONG TRAVEL-10.447662B6.041LONG TRAVEL-20.447663B6.042CRANE, UNDER SLUNG, ABOVE BALLING DISC, TOWARDS OIL UNLOADING SIDE, CONSOLIDATED, TYPE: HEOT-76165 (1 PAGE), CONTROL: 42 VOLT, MAIN HOIST11.563-64B6.042CREEP HOIST1.007165B6.042CROSS TRAVEL0.447666B6.042LONG TRAVEL-10.447667B6.042LONG TRAVEL-20.447668B6.050BELT CONVEYOR, VFD7.5969

SR NOUNIT NUMBERDESCRIPTIONKWRPM69B6.052BELT CONVEYOR5.5144070G1.002HEARTH LAYER GATE1.51400/4771G1.003HEARTH LAYER GATE, EMERGENCY1.5140072G1.004GREASE PUMP, MOTOR-1, LUBRICATION SYSTEM1.5140073G1.005GREASE PUMP, MOTOR-2, LUBRICATION SYSTEM1.5150074G1.006GRATE BAR CLEANING DEVICE0.554.575G1.007CROSS VIBRO FEEDER5.596076G1.010BUTTERFLY DAMPER1.1280077G1.011BUTTERFLY DAMPER1.1280078G1.012BUTTERFLY DAMPER1.1280079G1.013BUTTERFLY DAMPER1.1280080G1.014BUTTERFLY DAMPER1.1280081G1.015BUTTERFLY DAMPER1.1280082G1.016BUTTERFLY DAMPER1.12800

SR NOUNIT NUMBERDESCRIPTIONKWRPM83G1.018BUTTERFLY DAMPER1.1280084G1.020/060PLATTKO TIMER, DOUBLE PENDULUM VALVE300VA85G1.068ELEVATOR, NEAR G4.007, 7.5/5 TON, CONSOLIDATED HOIST, POONA, CONTROL: 42 VOLT, MAIN HOIST10.071140086G1.068MICRO MOTOR0.671470087G1.068TRAVEL MOTOR0.671470088G1.069ELECTRIC HOIST, NEAR G3.011, 3.5 TON, CONSOLIDATED PSG INDUSTRIES, MAIN HOIST10.071142089G1.069MICRO HOIST0.671490G1.069TROLLEY MOTOR0.447670091G1.070ELECTRIC HOIST, PELLET CAR, 10 TON, R.STAHL, STUTTGART, W-3120, TYPE: N425-244/1L2+FG, TYPE: SWH-320-023, CONTROL: 220 VOLT, LIFTING MOTOR121420

SR NOUNIT NUMBERDESCRIPTIONKWRPM92G1.070FINE LIFTING MOTOR1137093G1.070TRAVELLING MOTOR0.570094G1.070/1EOT CRANE, PELLET CAR, 3 TON, 14.5 MTR SPAN, EDDY CRANES ENGINEERS PVT LTD, PUNE, CONTROL: 110 VOLT, HOIST MOTOR11.1995G1.070/1MICRO HOIST MOTOR2.23896G1.070/1CROSS TRAVEL MOTOR0.37397G1.072CENTRIFUGAL PUMP TO COOLING TOWER22146598G1.073CENTRIFUGAL PUMP TO COOLING TOWER22150099G1.074COOLING TOWER FAN301500100G1.075COOLING TOWER FAN301500101G1.077ROOM DRAINAGE PUMP. 35 GRID STANDBY DEWATERING PUMP7.51500102G1.078ROOM DRAINAGE PUMP (MPB-50 GRID)7.51500

SR NOUNIT NUMBERDESCRIPTIONKWRPM103G1.080CENTRIFUGAL PUMP FROM COOLING TOWER751500104G1.081CENTRIFUGAL PUMP FROM COOLING TOWER751500105G1.082LSR PUMP15106G1.083LSR PUMP15107G1.090VERTICAL SUMP PUMP (COOLING TOWER)7.51500108G2.008/1ATOMIZING AIR FAN2001490109G2.008/2STARTER MOTOR0.125720/30110G2.009/1ATOMIZING AIR FAN2001490111G2.009/2STARTER MOTOR0.125720/30112G2.010/1BUTTERFLY DAMPER0.1-113G2.011/1BUTTERFLY DAMPER0.1-114G2.012/2FUEL OIL PREHEATER297-115G2.015/2FUEL OIL PREHEATER297-116G2.016/2FUEL OIL PREHEATER297-

SR NOUNIT NUMBERDESCRIPTIONKWRPM117G2.017/1FUEL OIL PUMP18.51500118G2.017/2FOOT HEATING1.5-119G2.018/1FUEL OIL PUMP18.51500120G2.018/2FOOT HEATING1.5-121G2.020/1COMBUSTION AIR FAN1251500122G2.021/1COMBUSTION AIR FAN1251480123G2.025HEATING FEEDER42124G2.039/1BUTTERFLY DAMPER0.1125G2.040/1BUTTERFLY DAMPER0.1126G2.047/1PURGE AIR FAN453000127G2.048/1BUTTERFLY DAMPER0.1128G2.058INSTRUMENT AIR1129G3.001/1GUIDE VANE2.2470/300130G3.006BUTTERFLY DAMPER1.12800131G3.007/1GUIDE VANE2.2470/300132G3.007/2AUXILIARY OIL PUMP3.71500

SR NOUNIT NUMBERDESCRIPTIONKWRPM133G3.007/6SOLENOID VALVE FOR STARTER50VA134G3.010BUTTERFLY DAMPER1.12800135G3.011/1GUIDE VANE1.12800136G3.011/2AUXILIARY OIL PUMP2.21500137G3.016BUTTERFLY DAMPER1.12800138G3.017/1GUIDE VANE2.2470/350139G3.017/2AUXILIARY OIL PUMP3.71500140G3.021BUTTERFLY DAMPER1.12800141G3.022/1BUTTERFLY DAMPER1.12800142G3.022/2BUTTERFLY DAMPER1.12800143G3.023SEALING AIR FAN111000144G3.028BUTTERFLY DAMPER1.12800145G4.001BELT CONVEYOR301470146G4.001/1BELT CONVEYOR5.51440147G4.002VIBRATING SCREEN45750

SR NOUNIT NUMBERDESCRIPTIONKWRPM148G4.003EOT CRANE, ABOVE SCREENING STATION, NEAR G4.004 HEAD END, 5 TON, CONSOLIDATED, HOIST MOTOR6.7141400149G4.003MICRO MOTOR0.4476700150G4.003TROLLEY MOTOR0.4476700151G4.004ASCENDING BELT CONVEYOR371500152G4.004/1SOLENOID VALVE WATER INJECTION50VA153G4.004/2SOLENOID VALVE WATER INJECTION50VA154G5.001BELT CONVEYOR3.71500155G5.002BELT CONVEYOR3.71000156G5.007BELT CONVEYOR3.71500157G5.018ELECTRIC HOIST, SCREENING STATION, 3.5 TON, CONSOLIDATED, HOIST MOTOR10.0711400158G5.018MICRO MOTOR

SR NOUNIT NUMBERDESCRIPTIONKWRPM159G5.018TROLLEY MOTOR0.6714700160G6.001BELT CONVEYOR (VFD)7.5969161G6.002ASCENDING BELT CONVEYOR451480162G6.003BELT CONVEYOR5.51500163G8.002BELT CONVEYOR, FOR PELLET EMERGENCY STOCK PILE151500164G8.003BELT CONVEYOR151460165G8.010BELT CONVEYOR18.51485166H1.004/1GUIDE VANE2.2470167H1.004/2AUXILIARY OIL PUMP3.71440168H1.004/6SOLENOID VALVE FOR STARTER50VA169H1.007/1DOUBLE PENDULUM VALVE50VA170H1.016REDUCER CONVEYOR7.5965/12171H1.017AGITATOR2.21400172H1.019SLURRY PUMP111460173H2.004WET SCRUBBER FAN301460

SR NOUNIT NUMBERDESCRIPTIONKWRPM174H2.013/1WET SCRUBBER FAN160990175H2.013/2WET SCRUBBER FAN751475176H2.015/1SLURRY PUMP151460177H2.015/2SLURRY PUMP15146017860.902.11PANEL-56A (OIL RECEIVING STATION HEATERS AND UNLOADING PUMPS)30017960.903.17/3DEWATERING PUMP, MPB 35 GRID7.5150018060.903.24BURNER EQUIPMENT, PREHEATING10A18160.903.25BURNER EQUIPMENT, FIRING10A18260.904.31PANEL-56, (OIL UNLOADING STATION, UNLOADING PUMPS)300183-SEA WATER PUMP SUPPLY (OUTSIDE JETTY NEAR G4.002), MOTOR NO.1451480184-SEA WATER PUMP SUPPLY (OUTSIDE JETTY NEAR G4.002), MOTOR NO.2451480

SR NOUNIT NUMBERDESCRIPTIONKWRPM185-SEA WATER PUMP SUPPLY (OUTSIDE JETTY NEAR G4.002), MOTOR NO.3451480186-NEW COMPRESSOR, INGERSOL RAND, MODEL: 7100, FOR BALLING DISC111460187-VERTICAL COMPRESSOR NO.2301500188-RTD PANEL10A

THE EQUIPMENTS USED IN PELLETIZING SECTION ARE:-1. BELT CONVEYORS,2. PUMPS,3. FANS,4. WET SCRUBBERS,5. HEATERS.6. ALL PROCESS FANS

DIFFERENT TYPES OF MOTORSMOTORDC MOTORAC MOTORSHUNTCOMPOUNDSERIES3PHASE1 PHASESQUIRREL CAGESQUIRREL CAGESLIP RING

IN PELLETIZING PLANT DC MOTORS, 3 PHASE SQUIRREL CAGE MOTORS AND SLIP-RING INDUCTION MOTORS ARE USED.

FOR B6.008, B6.018, B6.024, G1.001, G1.065 ANDG1.066 ARE DC MOTORS AND LOOKED AFTER BY INSTRUMENTATION DEPARTMENT.

FOR ATOMIZING AIR FANS G2.008/1 AND G2.009/1, COOLING WATER PUMPS G1.080/1 AND G1.081/1 ARE SLIP-RING INDUCTION MOTORS.

G2.008/1 AND G2.009/1 ARE LIQUID RESISTANCE STARTERS AND G1.080/1 AND G1.081/1 USE OIL IMMERSED RESISTANCE STARTERS.

ALL OTHER MOTORS ARE 3 PHASE SQUIRREL CAGE INDUCTION MOTORS.

A6.012, A6.016, A6.017, A6.018, G2.012/2, G2.015/2 AND G2.016/2 ARE HEATERS.

PROCEDURE FOR DAILY INSPECTIONTO CHECK BODY TEMPERATURE Keep hand on the body of the equipment for 50 sec. if you can hold your hand for 50sec or above then the temperature is normal, if you remove your hand before 50sec, then the temperature is abnormal. Action to be taken if abnormal.

TO CHECK ABNORMAL SOUND OF BEARING

Keep and touch a connector screw driver to the body of equipment at drive or non drive end and if you listen a low hissing noise at the handle by keeping your ear near the handle, then it is normal, if there is some heavy variable noise, then it is abnormal. Action to be taken if abnormal.

TO CHECK AIR VENTILATIONCheck any block in motor cooling fan cover through fins, and if block is there it means it is abnormal, if there is no blockade then it is normal. Action to be taken if abnormal.

PROCEDURE FOR QUARTERLY INSPECTION

T.B INSPECTION( TERMINAL BOX)

Check the tightness of connection after taking shutdownCleaning of T.B if dust accumulatedIf any burning/abnormality is there take action for repairs

IN CASE OF SLIP-RING INDUCTION MOTORS, ALONG WITH TB INSPECTION, CHECK THE FOLLOWING:-

CHECK SLIP-RINGS AND CARBON BRUSHES.

CLEAN SLIP-RINGS WITH EMERY PAPER, IF SURFACE IS FOUND NOT SMOOTH.

REPLACE THE CARBON BRUSHES, IF NECESSARY.

CHECK OIL IMMERSED RESISTANCES AND RESISTANCE CONTROL PANEL, IN CASE OF OIL IMMERSED RESISTANCE BOX.

CHECK LRS CONNECTION, ELECTROLITE LEVEL ETC.

CHECK PH VALUE OF ELECTROLITE, WHICH IS MAINTAINED 11-12 IN OUR PLANT.

INSPECTION OF HEATERS:-

CHECK ALL HEATERS BY REMOVING ALL THE CONNECTIONS. REPLACE DAMAGED HEATERS.

REPLACE DAMAGED INTERCONNECTING BUS BARS.

CHECK HEATER CONTROL PANEL. POWER CIRCUIT AND CONTROL CIRCUIT.

REPLACE BLOWN FUSES, BURNT WIRES ETC.

SWITCH BOX INSPECTION

Switch to be put OFF and opened after taking shutdownCheck the connection tightnessCleaning of switch box if dust accumulated If any abnormality is there take action for repairs

STARTER INSPECTION

Check connections of control wires in each terminal after taking shutdownCheck connection of power cables in each terminalCheck power contactor fixed & moving contacts Check O/L relay connection and its current settingCheck Aux contactor (control) connectionIf any abnormality is there action to be taken for repairsCleaning of starter box/panel to be done if dust accumulated

JUNCTION BOX INSPECTION

Open junction box cover after taking shutdownCable connection tightness to be checkedCleaning to be done if dust accumulation ( with cotton cloth)If any abnormality is there then action to be taken for repairs

MCC TRAY INSPECTION

Check sliding contact and its connection after taking shutdown and removing tray outChecking & cleaning of power contactor & its fixed and moving contactsCheck all control wires connection Check all power cable connectionsCheck O/L relay and its current settingCheck power fuses

Check MCBs Check Aux contacts and its connectionsCleaning tray and cabinet with air blower and cotton clothChecking of tray in test positionIf any abnormality is there then action to be taken for repairsPut tray in service position and put the power fuses and all MCBs to be made ON

LCB INSPECTION

Open the LCB front cover after taking shutdownCheck all the controls wire connection in elemex connector, D/I switch and impulse switchCheck and inspect the de/interlock switch & impulse switch operationCleaning of box if there is dust accumulationIf any abnormality is there, then action to be taken for repairsLCB cover to be put back after inspection

AUXILARY EQUIPMENT INSPECTIONPULL CHORD SWITCH INSPECTION

Open the coverCheck limit switch NO & NC operation & check continuity by operating the leverCleaning of switches if dust accumulatesPut the cover and fix itIf any abnormality is there, then action to be taken for repairs

ZERO SPEED SWITCH INSPECTION

Check the connection in the junction boxSensor and sensing plate to be cleanedSensor to sensing plate gap to be checked (10mm)Check Sensor is fitted firmly with mounting plateIf any abnormality is there, then action to be taken for repairs

PROCEDURE FOR HALF YEARLY INSPECTIONGREASING OF MOTOR

Motor to be greased in both NDE & DE side with hand operated greasing gun with proper nipple or plugLithon EP-2 grease to be usedPut the grease(grease quantity) as per frame size and KW of the motor and observe noise change before and after greasing

PROCEDURE FOR YEARLY INSPECTIONMOTOR IR VALUE CHECKING

Power cables should be isolated from the motor after taking shutdownMotor IR value should be taken only with 500V megger (higher rated should not be used for LT motor)Motor,phase to phase & phase to earth value to be noted

CABLE IR VALUE CHECKING

Power cable to be isolated from the motor and starter after taking shutdownPower cable IR value should be taken only with 500V megger as per cable grading (higher rating should not be used i.e. above 1KV)phase to phase & phase to earth megger values to be noted

MOTOR SERVICING

Motor to be dismantledCleaning of the partsBearing replacement if worn outAssembling of motorMeggering,trial and current measuring and notingPainting if required , tagging the motorDate of servicing to be notedCheck the resistance value of motor winding & to be noted

TROUBLESHOOTING

Check O/L relay in MCC tray (starter) with lamp testing. Inform production dept.Check power fuses, if it is blown due to any flashovers or motor burning, then rectify the faultCheck and reset O/L relay. Check the current after starting and note it.if O/L relay is frequently tripping without taking load. then check the relay

TRIPPED ON (60V DC) PC

Check in control gear any tripping of PCCheck any earth fault in control circuitCheck the earthing point by 60 v DC test lamp as per drawing, Rectify the faultReset PC & Give clearance for starting the equipmentIf working circuit is healthy but PC tripping, check PC

TRIPPED ON SINGLE POLE MCB IN MCC TRAY

Check control circuit in MCC tray for earth fault Trace the earth fault by 60V DC test lamp as per drawing & rectify the fault & reset the MCBReset the MCB & clearance to be given to start the equipment. If MCB is not resetting, check MCB

TRIPPED ON CONTROL CARD FEED BACK PROBLEM

Check control circuit as per drawing If it is control card contact problem, remove it and check contact is ok.If card contact is not ok, then replace the card and give clearance to start the equipment.

TRIPPED ON 3 POLE MCB IN MCC TRAY

Check the control circuit 220V AC as per drawingTrace the earth fault by 220V AC test lamp and check the power contactor coil. Rectify the fault. Reset it & start the equipment.If MCB is not resetting even though earth fault is not there, then check 3 pole MCB.

TRIPPED ON A PULL CHORD SWITCH

Check delock path in MCC tray for supply if not found then check at LCB.check pull chord switch for NC contact by operating the switch. If it is ok then give clearance for starting. If it is malfunctioning, check the limit switchIf it is malfunctioning due to mechanisms, check mechanisms

TRIPPED ON SPEED SENSOR

Check the 60V DC control path in marshalling rack after starting the equipmentIf control path is not available in marshalling rack then check speed sensor at siteIf sensor output supply of indication is not available. Then check sensor to sensing plate gap. Adjust the gap and check it (10mm) if it is ok then start itAfter adjusting gap also it is tripping then check any missing of sensing plate. if plate is missing then plate to be welded with mechanical helpEven After the above rectification if it is tripping again then check zero speed sensor.

SAFETY OF EQUIPMENTAll electrical equipment should be grounded (earthed) by connecting earthing strips & cables to the body. if we want to work on a electrical equipment, we should take shut down permit.

After taking permit, power fuses should be removed & control MCBs should be put off. One copy should be pasted on particular consumer in MCC panel tray.

After completion of work shutdown to be cleared & fuses should be put back & normalized

THANK YOU