Risk Analysis, Quality Assurance, ISO 9001 and …



1. PURPOSE:

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 - Deputy General Manager

Asst.Manager - Assistant Manager

PMI - Preventive Maintenance Incharge

I.D. No. - Identification Number

P.M - Preventive Maintenance

4. RESPONSIBILITY:

1. Head of department is over all responsible for implementing this procedure.

2. Personal performing breakdown maintenance shall not carry out preventive maintenance.

3. Individual responsibilities of specific activities are described here after.

5. PROCESS INPUT:

1. Work instruction for carrying out maintenance activities.

2. Intimation of breakdown by work order

3. P.M.Slippage Record

4. P.M.Schedule

5. PM Checklist

6. P.M.Schedule cum check sheet

6. PROCESS DESCRIPTION & INTERFACES:

1 Preventive maintenance: -

|Sr. No. |Activity |Responsibility |Ref. Doc. |

|1 |All the equipments requiring periodic maintenance will be |Asst.Manager |FQMNT02F01 |

| |identified and a list will be prepared. | | |

|2 |A unique I.D.No. Will be given to them. |Asst.Manager |FQMNT02F01 |

|3 |The frequency of maintenance will be decided on the basis of |Asst.Manager |Operation & Maintenance |

| |Manufacture recommendation | |Manual FQMNT02F06 |

| |Decided by maintenance Department | | |

|4 |The P.M. schedule/P.M.Schedule cum check sheet will be made as per|Asst.Manager |FQMNT02F06 FQMNT02F18 |

| |the identified frequency above. | | |

|5 |The equipment will be spared and the preventive maintenance will |Asst.Manager/PMI/ Sr.Formen/ |FQMNT02F07, FQMNT02W03, |

| |be carried out as per P.M check list/ P.M.Schedule cum check sheet|Foreman |FQMNT02W10, FQMNT02W12 |

| |& relevant work instruction. | |FQMNT02F18, |

| | | |FQMNT02W05 |

|6 |The P.M. checklist / P.M.Schedule cum check sheet will be filled |PMI |FQMNT02F07, FQMNT02F18 |

| |up after completing maintenance. | | |

|7 |In case of any schedule getting delayed due to any reasons or |PMI |FQMNT02F08 |

| |preventive action if not carried out, should be recorded in the | | |

| |P.M slippage record. | | |

|8 |Review the P.M. schedule at least Six monthly for types of checks |Asst.Manager/PMI |FQMNT02F03, FQMNT02F04 |

| |& frequency on the basis of its effectiveness. | | |

|9 |Review the P.M.slippage record monthly & to avoid the frequency of|Asst.Manager/ |FQMNT02F08 |

| |slippage. |PMI | |

|10 |In a case of overhauling required, for the equipment, follow the |Sr. Foreman/ Foreman |Operating and maintenance |

| |respective work instruction/Vendor instruction manual and filled | |manual, FQMNT02W09, |

| |the over hauling check list. | |FQMNT02W07 |

| | | |FQMNT02F19 |

| |Operation of DG SET, Circuit breaker, 66KVSwithyard,HT Capacitor | | |

|11 |bank and power changeover done as per work instruction. |Shift foreman |FQMNT02W01 |

| | | |FQMNT02W02 |

| | | |FQMNT02W04 |

| | | |FQMNT02W08 FQMNT02W11 |

B. BREAKDOWN: -

|Sr. No. |Activity |Responsibility |Ref. Doc. |

|1 |Receiving work order from user department regarding breakdown of |Shift Incharge | |

| |any equipment. | | |

|2 |Review the problem and allocate the job to concern person. |Asst.Manager/ | |

| | |Shift Incharge | |

|3 |Carry out the breakdown maintenance. As per work instruction. |Sr.Forman/ Shift |FQMNT02W06 |

| | |Incharge/Foreman | |

|4 |Prepare daily breakdown report and sent copy to Dy.GM (Mech) & GM |Sr.Forman /Foreman |FQMNT02F03 |

| |(F&A). | | |

|5 |Prepare monthly breakdown report and sent copy to V.P. (foils), |Sr.Forman /Foreman |FQMNT02F04 |

| |all Deptt. Heads, MIS & PPC. | | |

7. PROCESS OUT PUTS:

1. Continue availability of machine.

2. Relevant reports & records of equipments.

3. P.M.Slippage Record.

8. PROCESS MONITORING:

|Sr. No. |Description |Frequency |Responsibility |

|1 |Review of P.M. schedule. |Six monthly |Asst.Manager |

|2 | Review P.M.slippage record. |Monthly |Asst.Manager |

9. RECORDS:

|Sr.No. |Record No. |Record Title |Retention period |Location |Disposal authority|

|1 |FQMNT02F01 |COMPREHENSIVE EQUIPMENT LIST |Till the equipment|ELECTRICAL SHOP FLOOR |Dy. General |

| | | |Last | |Manager |

|2 |FQMNT02F02 |EQUIPMENT HISTORY RECORD |Till the equipme |ELECTRICAL SHOP FLOOR, |Dy. General |

| | | |nt Last |MSDS&ERS |Manager |

|3 |FQMNT02F03 |DAILY BREAKDOWN REPORT |Six Months |ELECTRICAL SHOP FLOOR |Dy. General |

| | | | | |Manager |

|4 |FQMNT02F04 |MONTHLY BREAKDOWN REPORT |1Year |ELECTRICAL SHOP FLOOR |Dy. General |

| | | | | |Manager |

|5 |FQMNT02F05 |MAJOR BREAKDOWN ANALYSIS REPORT|1Year |ELECTRICAL SHOP FLOOR |Dy. General |

| | | | | |Manager |

|6 |FQMNT02F06 |PM SCHEDULE |1Year |ELECTRICAL SHOP FLOOR/MSDS |Dy. General |

| | | | | |Manager |

|7 | FQMNT02F07 |P.M.CHECK LIST:- | | | |

| |FQMNT02F07/ 01 |MILL M50 | | | |

| |FQMNT02F07/ 02 |MILL M51 | | | |

| |FQMNT02F07/ 03 |MILL M52 | | | |

| |FQMNT02F07/ 04 |MILL Q4 | | | |

| |FQMNT02F07/ 05 |MILL Q5 | | | |

| |FQMNT02F07/ 06 |CRANE # 1 | | | |

| |FQMNT02F07/ 07 |CRANE # 2 | | | |

| |FQMNT02F07/ 08 |CRANE # 3 | | | |

| |FQMNT02F07/ 09 |CRANE # 4 | | | |

| |FQMNT02F07/ 10 |CRANE # 5 | | | |

| |FQMNT02F07/ 11 |CRANE # 6 | | | |

| |FQMNT02F07/ 12 |CRANE # 7 | | | |

| |FQMNT02F07/ 13 |CRANE # 8 |1Year |ELECTRICAL SHOP FLOOR/MSDS|Dy. General |

| |FQMNT02F07/ 14 |CRANE # 4A | | |Manager |

| |FQMNT02F07/ 15 |REWIND LINE # 1 | | | |

| |FQMNT02F07/ 16 |REWIND LINE # 2 | | | |

| |FQMNT02F07/ 17 |REWIND LINE # 3 | | | |

| |FQMNT02F07/ 18 |BAILING PRESS | | | |

| |FQMNT02F07/ 19 |ROLL GRINDER | | | |

| |FQMNT02F07/ 20 |ANN. FURNACE # 1 | | | |

| |FQMNT02F07/ 21 |ANN. FURNACE # 2 | | | |

| |FQMNT02F07/ 22 |ANN. FURNACE # 3 | | | |

| |FQMNT02F07/ 23 |ANN. FURNACE # 4 | | | |

| |FQMNT02F07/ 24 |OVEN # 1 | | | |

| |FQMNT02F07/ 25 |OVEN # 2 | | | |

| |FQMNT02F07/ 26 |OVEN # 3 | | | |

| |FQMNT02F07/ 27 |SEPARATOR # 25 | | | |

| |FQMNT02F07/ 28 |SEPARATOR # 26 | | | |

| |FQMNT02F07/ 29 |DOWN ENDER | | | |

| |FQMNT02F07/ 30 |FUME EXH. SYSTEM | | | |

| |FQMNT02F07/ 31 |H G SLITTER | | | |

| | | | | | |

| |FQMNT02F07/ 32 |M G SLITTER |1 Year |ELECTRICAL SHOP FLOOR/MSDS|Dy. |

| |FQMNT02F07/ 33 |L G SLITTER | | |General |

| |FQMNT02F07/ 34 |DOCTOR REWINDER | | |Manager |

| |FQMNT02F07/ 35 |DRY BOND LAM. | | | |

| |FQMNT02F07/ 36 |PRINTING MACHINE | | | |

| |FQMNT02F07/ 37 |EXTRUDER COATER | | | |

| |FQMNT02F07/ 38 |MAIN PUMP HOUSE | | | |

| |FQMNT02F07/ 39 |COOLING TOWER | | | |

| |FQMNT02F07/ 40 |NITROGEN GEN. | | | |

| |FQMNT02F07/ 41 |FIRE HYDRANT | | | |

| |FQMNT02F07/ 42 |W.T.P. | | | |

| |FQMNT02F07/ 43 FQMNT02F07/ 44 |VENT. SYSTEM | | | |

| | |COMP. HOUSE | | | |

|8 |FQMNT02F08 |P.M.SLIPPAGE RECORD |1Year |ELECTRICAL SHOPFLOOR/MSDS |Dy. General Manager|

|9 |FQMNT02F09 |WORK ORDER |3 Month |ECR Q4/Q5, ERS& MSDS |Dy. General Manager|

|10 |FQMNT02F10 |WORK PERMIT |3Month |ECR Q4/Q5, ERS& MSDS |Dy. General Manager|

|11 |FQMNT02F11 |OVERHAULING SCHEDULE |1 Year |MSDS / ERS |Dy. General Manager|

|12 |FQMNT02F12 |SHIFT LOG BOOK |1YEAR |Q4/Q5 CONTROL ROOM |Dy. General Manager|

|13 |FQMNT02F13 |DAILY ENERGY GENERATION /CONSUMPTION |Six Months |MSDS |Dy. General Manager|

| | |REPORT | | | |

|14 |FQMNT02F14 |STATEMENT SHOWING ENERGY GENERATED & |1Year |MSDS |Dy. General Manager |

| | |CONSUMED INCLUDING CONSUMPTION OF | | | |

| | |DIESEL | | | |

|15 |FQMNT02F15 |DG LOG BOOK |1Year |MSDS |Dy. General Manager |

|16 |FQMNT02F16 |ANALYSIS OF MOTOR FAILURE |1Year |ERS |Dy. General Manager |

|17 |FQMNT02F17 |ELECTRICAL POWER CONSUMPTION REPORT |1Year |ELECTRICAL SHOP FLOOR |Dy. General Manager |

|18 |FQMNT02F18 |PM SCHEDULE CUM CHECK SHEET: - |1Year |MSDS |Dy. General Manager |

| | |LT air circuit breaker | | | |

| |FQMNT02F18/ 01 |66 kv CT, PT, CVT & LA | | | |

| |FQMNT02F18/ 02 |LT APFC panel, HT capacitor bank & | | | |

| |FQMNT02F18/ 03 |reactor | | | |

| | |Battery bank & battery charger | | | |

| |FQMNT02F18/ 04 |11 kv & 132 kv MOCB | | | |

| | |11 kv T.M.G. ACB | | | |

| |FQMNT02F18/ 05 |11 kv ABB (indoor & outdoor) & | | | |

| |FQMNT02F18/ 06 |Siemens VCB | | | |

| |FQMNT02F18/ 07 |66 kv Sf6 circuit breaker | | | |

| | |22 kv Sf6 circuit breaker | | | |

| |FQMNT02F18/ 08 |11 kv, 22 kv & 66 kv isolators | | | |

| |FQMNT02F18/ 09 |11 kv, 1500 kva DG set | | | |

| |FQMNT02F18/ 10 | | | | |

| | | | | | |

| |FQMNT02F18/ 11 | | | | |

| |FQMNT02F18/ 12 |Power & distribution transformer |1Year |MSDS |Dy. General Manager |

| | |415 v, 125 kva DG set | | | |

| |FQMNT02F18/ 13 |Sub- station (monthly) | | | |

| |FQMNT02F18/ 14 |Sub- station (fortnight) | | | |

| |FQMNT02F18/ 15 | | | | |

|19 |FQMNT02F19 |OVER HAULING CHECK LIST |3 Years |ERS |Dy. General Manager |

10. REFERENCE :

|Sr.No. |Document no. |Work instruction |

|1 |FQMNT 02W01 |OPERATION OF D.G.SET |

|2 |FQMNT 02W02 |OPERATION OF 66KV SWITCH YARD |

|3 |FQMNT 02W03 |OPERATION AND MAINTENANCE OF BATTERY BANK |

|4 |FQMNT 02W04 |OPERATION OF H.T CAPACITOR BANK |

|5 |FQMNT 02W05 |OPERATION AND MAINTENANCE OF TRANSFORMER |

|6 |FQMNT 02W06 |BREAKDOWN MAINTENANCE |

|7 |FQMNT 02W07 |OVER HAULING OF D.C. MOTOR |

|8 |FQMNT 02W08 |POWER CHANGE OVER |

|9 |FQMNT 02W09 |OVER HAULING OF A.C. SLIPRING MOTOR |

|10 |FQMNT 02W10 |MAINTENANCE OF DIESEL GENERATOR |

|11 |FQMNT 02W11 |OPERATION OF CIRCUIT BREAKER |

|12 |FQMNT 02W12 |PREVENTIVE MAINTENANCE |

................
................

In order to avoid copyright disputes, this page is only a partial summary.

Google Online Preview   Download