CA Final Rev

Criticality
Sr. NO Equipment Code Equipment Description CATEGORY

Score
1 BF3-FURN-BLT FURNANCE BLT SYSTEM BLT 648

2 SP-COOL-TESP TAIL ESP ESP 648
3 SP-SS-HESP HEAD ESP ESP 648
4 BF3-O2N2-MAC MAIN AIR COMPRESSOR COMPRESSOR 486
6 BF3-CH-DM CAST HOUSE DRILL MACHINE DRILL MACHINE 432
7 BF3-CH-MUDGUN CAST HOUSE MUDGUN MACHINE MUDGUN 432
8 432
BF3-HMH-CRANE HOT METAL HANDLING CRANE-100/20CRANE
T
9 BF3-RMHS-C7 RMHS CONVEYOR C7 CONVEYOR 432
12 SP-SS-MAIN-FAN MAIN EXHAUST FAN FAN 324
13 SP-SS-SM SINTERING MACHINE SINTER MACHINE 324
14 SP-SS-SRC SINGLE ROLL CRUSHER SRC 324
17 BF3-O2N2-CB COLD BOX EQUIPMENT COLD BOX 216
18 BF3-CH-CRANE CAST HOUSE CRANE-16 T CRANE 144
19 BF3-CH-MUDPWPK CAST HOUSE POWER PACK POWER PACK 144
21 BF3-GCS-GDCEQ GDC EQUIPMENTS GDC 144
28 96
BF3-COMP-REG2 DEHUMIDIFIER AND REGENERATION UNIT-2
REGENRATOR
29 BF3-GCS-BKT BUCKET ELEVATOR BUCKET ELEVATOR 96
38 SP-COOL-ABC SINTER COOLER SINTER COOLER 96
39 BF3-O2N2-COMP PRODUCT COMPRESSOR COMPRESSOR 72
40 72
BF3-O2N2-PPU AIR PRECOOLING & PRE-PURIFICATIONPURIFICATION
44 SP-PROP-BWF BELT WEIGH FEEDER BELT WEIGH FEEDER 24
45 SP-SS-CA-FAN COMBUSTION AIR FAN FAN 9
47 BF3-HT-PCC-PNL 11KV BF HT PCC PANEL ELECTRICAL PANEL 72
48 BF3-HT-BLR-PNL 11KV BLOWER HT PANEL ELECTRICAL PANEL 72
49 BF3-HT-CWPS-PNL 11KV HT CWPS PANEL ELECTRICAL PANEL 108
50 BF3-BL-PANEL BLOWER PANEL ELECTRICAL PANEL 144
51 BF3-O2N2-DCS DISTRIBUTED CONTROL SYSTEM DCS 96
53 SP-SS-HESP-TRAFO1 HEAD ESP TRANSFORMER 1 TRANSFORMER 144
60 BF3-O2N2-MCC O2N2 PLANT MCC ROOM ELECTRICAL PANEL 128
61 SP-SS-11KV-PANEL SINTER 11KV PANEL ELECTRICAL PANEL 216
64 BF3-SH-TRANS STOCKHOUSE TRANSFORMER TRANSFORMER 36
67 SP-SS-TESP-TRAFO1 TAIL ESP TRANSFORMER 1 TRANSFORMER 72
70 BF3-PUMP-TRANS TRANSFORMER TRANSFORMER 36
71 BF3-FURN-TRANS TRANSFORMER TRANSFORMER 36
Summary
Mechanical Electrical Inst
SCHEDUL
Criticality status STATUS CA ideal CA actual CA ideal CA actual CA ideal
E
condition condition condition condition condition
Most Critical YES APRIL Not Done Done Not Done Done Done Done
Most Critical YES APRIL Not Done Done Not Done Done Done NA
Most Critical YES MAY Not Done Done Not Done Done Done Done
Critical YES APRIL Not Done Done Not Done NA NA NA
Critical YES JULY Not Done Done Not Done Done Done NA
Critical YES JUNE Not Done Done Not Done Done Done Done
Critical YES MAY Not Done Done Not Done Done Done Done
Critical YES MAY Not Done Done Not Done Done Done Done
Critical YES JUNE Not Done Done Not Done Done Done Done
Critical YES JULY Not Done Done Not Done Done Done Done
Critical YES AUG Not Done Done Done Not Done Not Done Done
Critical YES APRIL Not Done Done Not Done Done Done Done
Critical YES JULY Not Done Done Not Done Done Done Done
Critical YES APRIL Not Done Done Not Done Not Done Not Done Done
Critical YES APRIL Not Done Done Not Done Done Done Done
Critical YES APRIL Not Done Done Not Done NA NA NA

Critical YES APRIL Not Done Done Not Done Not Done Not Done Done
Critical YES JUNE Not Done Not Done Not Done Not Done Not Done Done
Critical YES APRIL Not Done NA NA Done Done NA
Critical YES APRIL Not Done NA NA Done Done Done
Critical YES MAY Not Done NA NA Done Done NA
0 0 0 0 0 0
Inst
CA actual
condition
Done
Done
Done
Done
NA
NA
NA
Done
Done
Done
Done
NA
NA
Done
Done
Done
Done
Done
Done
Done
Done
Done
Done
NA
Done
Done
NA
NA
NA
NA
Done
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
0
CONDITION APPRAISAL OF AIR DRYER AND REGENA
EQUIPMENT: SUB EQUIPMENTS COMPONENT
BF3-COMP-REG2 BF3-COMP-REG2 HEATER FOR DRYER
BF3-COMP-REG2 BF3-COMP-REG2 DIAPHRAGM VALVE 1

BF3-COMP-REG2 BF3-COMP-REG2 NRV 1
BF3-COMP-REG2 BF3-COMP-REG2 NRV 2
BF3-COMP-REG2 BF3-COMP-REG2 DRAIN VALVE
BF3-COMP-REG2 BF3-COMP-REG2 DRAIN VALVE
MICRO CONTROLLER
BF3-COMP-REG2
THERMOCOUPLE
SOLENOID VALVE
ION APPRAISAL OF AIR DRYER AND REGENARTION UNIT
DESCRIPTION / DIMENSION TYPE

TOOLS
OF CHECK
REQUIRED
(RUN CHECK / STOP CHECK / SHUTDOWN)
CHECK FOR COIL RESISTANCE MULTIMETER STOP CHECK
CHECK FOR DIAPHRAGM CONDITIONSPANNERS STOP CHECK

CHECK FOR PASSING OF VALVE SPANNERS STOP CHECK
CHECK FOR FUNCTIONING WRT TIMEOPERATION/STOP WATCH RUN CHECK
CHECK FOR COMMAND TO BED CHANMULTI METER RUN CHECK

CHECK FOR TEMPARATURE OF BED MULTI METER, SPANER RUN CHECK
CHECK FOR BED CHANGE OVER MULTI METER, SPANER RUN CHECK
DATE-AUG 09, 2018
ACTUAL CONDITION
IDEAL CONDITION ACTION REQUIRED
OBSERVED
300Ω-500Ω 396Ω
SEATED IN GROOVES AND
NO PHYSICAL DAMAGE AND WELL NO DAMAGE
DIAPHRAGM MINOR
NO PHYSICAL DAMAGE AND WELL DAMAGE FROM EDGE VALVE TO BE REPLACED
NO PASSING OF VALVE VALVE NOT PASSING
01 CYCLE EVERY 10MIN 01 CYCLE EVERY 15MIN CYCLE TIME TO BE CORRECTED
NO FAULTS FOUND ON
CONTROLLER SHOULD BE HELTHY CONTROLLER
TEMPARATURE >35 DEGREE TEMPARATURE >35 DEGREE
NO AIR PASSING AND COIL DAMAGCOIL WORKING OK
EQUIPMENT: SUB EQUIPMENTS
BF3-O2N2-MAC BF3-O2N2-MAC
C
COMPONENT ITEM CODE SPECIFICATION
ELEMENT OIL FILTER 5115010003

(USE 24107997)
IGV - DIAPHRAGM FOR MAC 5915010001
BOV –DIAPHRAGM FOR MAC 5915010003
LUBE OIL PUMP MAIN FOR MAC 5115010010
PRE LUBE OIL PUMP WITH MOTOR,MAC 5115010011
MAIN OIL PUMP (MOP) COUPLING 5202080029

, SIZE L-99 MAKE LOVE JOY
AUXILLARY OIL PUMP (AOP) COUPLING, TRANSMISSION 0804010058
, L100, LOVE JOY.
OIL COOLER UNIT OF MAC 5915010002
FLEXIBLE COUPLING, 804070063 6GBH-160 FOR MAC

1ST COOLER F/ MAC- 5115010016
CENTAC 3CIIP/ C90MX3
2ND COOLER F/ MAC- 5115010017
CENTAC - 3CIIP/ C90MX3
AFTER COOLER F/ MAC 5115010018
CENTAC 3CIIP/ C90MX3
1ST STAGE SUCTION AIR FILTER 5915010041
F/ MAC O2N2
2ND STAGE SUCTION AIR FILTER 5915010042
F/ MAC O2N2
3RD STAGE SUCTION AIR FILTER 5915010043
F/ MAC O2N2
ASSEMBLY ROTOR STG-1 5915010008 PART NO.23779499
ASSEMBLY ROTOR STG-2
5915010009 PART NO. 23779507
ASSEMBLY ROTOR STG-3 5915010010 PART NO. 23779572
HT PANEL BUSBARS
HT PANEL BUSBARS
HT PANEL EARTHING
HT PANEL BUSBAR HORIZONTAL AND

VERTICAL INSULATOR
HT FCMA SOFTSTARTER
HT NUMERICAL PROTECTIVE RELAY
HT CABLES
HT CABLES
POTENTIAL TRANSFORMER
CURRENT TRANSFORMER
HT Motor Windings
Terminal Box
HT VACUUM ISOLATION CONTACTOR
HT VACUUM BYPASS CONTACTOR
LT Auxiliary oil Pump Motor Windings
Auxiliary oil Pump Terminal Box

Auxiliary oil Pump Power Contactor
Auxiliary oil Pump Overload Relay
Vibration Transmitter
Oil DPT
RTD
power and feed back cable
pressure switch
Relay
DI ,DOCard,DCS , IM modules
SMPS
VNET Cable
CODITION APPRAISAL OF MAC
DESCRIPTION / DIMENSION TOOLS REQUIRED
CHECK PRESSURE DIFFERENCE FOR

CLOGGING DP GAUGE
CHECK FOR AIR LEAKAGE VISUAL
CHECK FOR AIR LEAKAGE VISUAL
CHECK FOR PRESSURE AT DISCHARGE VISUAL AT DCS
CHECK FOR PRESSURE AT DISCHARGE VISUAL AT DCS
CHECK FOR PHYSICAL DAMAGE VISUAL
CHECK FOR WATER AND OIL OUTLET TEMP VISUAL AT DCS AND FIELD GAUGE
CHECK FOR WATER AND AIR OUTLET TEMP VISUAL AT DCS AND FIELD GAUGE
CLOGGING DP GAUGE
CLOGGING DP GAUGE
CLOGGING DP GAUGE
CHECK DISCHARGE PRESSURE AT DCS

Check for proper tigteness of the busbar

and busbar support insulator. It should SPANNERS / TORQUE
have sufficient stiffness to be supported in WRENCH
air by insulated pillars.
Check for proper cleanliness of the busbar
insulator and panel body. It should be
generally uninsulated, and should be VISUAL / COTTON CLOTHE
proper insulation between busbar and
switchgear panel through busbar insualtor.
Check for megger value of Busbar and

HT MEGGER
panel body.
Check for proper interlocking of earth

switch and HT Breaker. Also, check for
VISUAL
interlocking of earth switch and panel
back door.
Check for high electrical & mechanical

strength used in electrical panels to
support the copper busbar. Check for VISUAL
megger value between insulator and panel
body.
To protect an electrical circuit from

damage caused by excess current from an
VISUAL, COTTON CLOTHE,
overload or short circuit. Its basic function
MULTIMETER
is to interrupt current flow after a fault is
detected.
To detect the fault and initiates the

SECONDARY INJECTION
operation of circuit breaker to isolate the
CURRENT AND VOLTAGE
defective element from the rest of the
TEST KIT
system.
Check for proper tigteness of the power SPANNERS / TORQUE

cable and HT Breaker Terminals. WRENCH
Check for megger value of HT Cable

MEGGER
phase to phae and phase to earth.
MEGGER
Check for partial discharge test of HT

TAN-DELTA TEST KIT
Cable for HT Cable insualtion testing.
Check for tighteness of connections and

measure the correct voltage and indication
VISUAL / SECONDARY
shown in the meter.
INJECTION CURRENT AND
Also, check for tripping of the HT
VOLTAGE TEST KIT
Numerical Relay by Secondary Injection
kit.

measure the correct current shown in the
VISUAL / SECONDARY
meter.
INJECTION CURRENT AND
VOLTAGE TEST KIT
Numerical Relay by Secondary Injection
kit.
To form magnetic field when

energized with current to produce
Megger & Multimeter
torque. Check for winding resistance
and megger value of Motor.
Check for TAN DELTA of the motor. TAN-DELTA TEST KIT
Check for proper tigteness of the

Spanners
power cable to the HT Motor
Check for physical condition of
vacuum bottles and its terminals.
Visual, Spanners, Screw
Check for contactor rating and
Drivers, Allen Key,
tighteness of contactor terminals.
Multimeter
Check for coil resistance of the
contactor.
Check for physical condition of

vacuum bottles and its terminals.
Visual, Spanners, Screw
Drivers, Allen Key,
Multimeter
contactor.

Megger & Multimeter

Spanners
tighteness of contactor terminals. Spanners, Screw Drivers,
Check for coil resistance of the Allen Key, Multimeter
contactor.
Check for overload relay range and

setting of relay current for motor Visual
tripping.
Check for Healthness of Mac

vibration at Different Stages VISUAL, Multimeter
CHECK FOR Differencial oil PRESSURE AT oil
Filter VISUAL, Multimeter
Check For MAC Discharge Air
Tempararture VISUAL, Multimeter
checking healthyness Run Motor. Multimeter,Tester
check healthyness of contact change

Multimeter,Tester
over by operaing with oil pressure
checking healthyness by Run Motor. Multimeter,Tester

check supply voltage and output
Multimeter,Tester
Voltage .
TYPE OF CHECK
(RUN CHECK / STOP IDEAL CONDITION ACTUAL CONDITION OBSERVED
CHECK /
SHUTDOWN)
RUN CHECK SHOULD BE <1BAR

STOP CHECK NO LEAKAGE
RUN CHECK SHOULD BE >1.34BAR
STOP CHECK NO DAMAGE
RUN CHECK WATER-<45*C, OIL-<49*C

RUN CHECK WATER-<40*C, AIR-<49*C
RUN CHECK DP SHOULD BE <0.2MMWC
RUN CHECK DP SHOULD BE <15MMWC
RUN CHECK DP SHOULD BE <12MMWC


Tightened with 12mm
high tensile stainless No looseness of the bolts and
SHUTDOWN
steel bolts with flat connecting links checked by torque
CHECK
washers and nuts by wrench.
Torque Wrench.
Insulators should be
installed properly to hold Insulators were installed properly and
SHUTDOWN
and support busbars. was clean. No oxydation observed
CHECK
Insulators should be between insulator and bubar.
clean.
Resistance between panel

SHUTDOWN Resistance between panel to busbar is
to busbar should be ˃ 20
CHECK 1200 mega ohms.
mega ohms.
Earthing should be Earthing is connected to the body and

RUN CHECK
healthy. to the Earth Pit.
Vertical and Horizontal

insulators should provide
high electrical and Vertical and Horizontal insulators
SHUTDOWN
mechanical strength to strength to the busbars are good. Also,
CHECK
the busbars. Also, megger value is 1200 mega Ohms.
megger value should be ˃
20 mega Ohms.
HT Softstarter should be
HT Softstarter found clean. There is
SHUTDOWN clean. There should not
no moisture or wear and rusting of
CHECK be any moisture or wear
contacts.
and rusting of contacts.
HT Breaker Numerical
Relay tripping should be HT Breaker Numerical Relay tripping
SHUTDOWN healthy to trip the is healthy to trip the breaker on the
CHECK breaker on the faults faults described in the relay on
described in the relay on prescribed values.
prescribed values.
Tightened with 12mm
high tensile stainless No looseness of the bolts and
SHUTDOWN
steel bolts with flat connecting links checked by torque
CHECK
washers and nuts by wrench.
Torque Wrench.
Insulation resistance
SHUTDOWN between Phase to Phase Insulation resistance between Phase to
CHECK should be > 20 Mega Phase is 1000 Ohms
Ohms
SHUTDOWN between Phase to Earth Insulation resistance between Phase to
CHECK should be > 20 Mega Earth is 1000Mega Ohms
Ohms
TAN-DELTA test of HT
SHUTDOWN TAN-DELTA test of HT Cable is
Cable should be < 0.004
CHECK 0.0019
absolute.
PT connections should be
tight and should
1. measure correct
PT connections are tight and display
voltage on the relay or
correct voltage on the relay. Indication
meter.
SHUTDOWN of voltage on the panel is shown.
2. provide indication of
CHECK Trippig of the HT Breaker through HT
voltage on the panel.
Relay on Over voltage / Under
3. trip the HT Breaker
Voltage is healthy.
through HT Relay on
Over voltage / Under
Voltage.
CT connections should
be tight and should
1. measure current CT connections are tight and display
accurately on the relay or accurate current on the relay. Trippig
SHUTDOWN
meter. of the HT Breaker through HT Relay
CHECK
2. trip the HT Breaker on Over curent / CIR / ITOC / DMT is
through HT Relay on healthy.
Over curent / CIR / ITOC
/ DMT.
Winding Resistances
should be balanced of
all three phases, i.e., No abnormal difference in winding
less than 5 ohms. resistances. Winding resistance of
Shut Down check Megger values all three phases is 0.7 ohms.
shouldbe above 5 Megger values are 2 Giga ohms
megaohms from all and in healthy condition.
three phases to
ground.
TAN-DELTA test of HT
SHUTDOWN TAN-DELTA test of HT Motor is
Motor should be < 0.04
CHECK 0.004
absolute.
Tightened with 16mm No looseness of 16 mm Chrome
Shut Down check Chrome Vanadium Vanadium bolts and connecting
Bolts. links.
Proper tighteness of
foundation of
contactor and at
terminals. No looseness in fitting of
No abnormalities to contactor and connection of
SHUTDOWN
be seen for the cables to power contactor and
CHECK
contacts and proper its contacts. Coil resistance of
fitting to be done. contactor checked 18 ohms.
Coil resistance
should be between 10
ohms - 30 ohms.
foundation of
contactor and at
SHUTDOWN
CHECK
fitting to be done. contactor checked 18.2 ohms.
Coil resistance
should be between 10
ohms - 30 ohms.
Winding Resistances
all three phases, i.e., No abnormal difference in winding
less than 10 ohms. resistances. Winding resistance of
Shut Down check Megger values all three phases is 9.7 ohms.
shouldbe above 5 Megger values are 200 Mega ohms
megaohms from all and in healthy condition.
three phases to
ground.
Tightened with 8 mm No looseness of 8 mm Chrome

Shut Down check Chrome Vanadium Vanadium bolts and connecting
Bolts. links.
foundation of
contactor and at
SHUTDOWN
CHECK
fitting to be done. contactor checked 28 ohms.
Coil resistance
should be between
20 ohms - 30 ohms.
Relay settings:
Inspected Relay Range = 6 -10 A
SHUTDOWN Relay Range = 6 -10
Relay setting = 7A
CHECK A
Running Current = 6.0 A
Relay setting = 7A
RUN CHECK SHOULD BE <1 mill No Abnormalities found
RUN CHECK SHOULD BE >1.34BAR No Leakages or Damage
RUN CHECK No Abnormalities found

Physical check or
Run check No damage
damage of cable
Physical check or
Run check No damage
damage of coil
Physical check or
Run check contact damage of No damage
coil using multimeter
Run check Physical check No damage

ACTION REQUIRED
CONDITION APPRAISAL O
Sub SPEC
EQUIPMENT: Equipme COMPONENT Item Code IFICA DESCRIPTION / DIMENSION
nts TION
BF3-O2N2-CB MAIN HEAT EXCHANGER CHECK FOR OUTLET TEMP
BF3-O2N2-CB DISTILLATION COLUMN CHECK FOR OUTLET TEMP
BF3-O2N2-CB DISTILLATION COLUMN CHECK FOR OUTLET PURITY

NDITION APPRAISAL OF COLD BOX
TYPE OF
CHECK (RUN
CHECK /
TOOLS REQUIRED IDEAL CONDITION ACTUAL CONDITION OBSERVED
STOP
CHECK /
SHUTDOWN)
RUN CHECK SHOULD BE BETWEEN

DCS 10-35*C
RUN CHECK SHOULD BE BETWEEN (-

DCS 180 TO -197*C)
DCS RUN CHECK SHOULD BE >90%

ACTION REQUIRED
EQUIPMENT SUB EQUIPMENTS COMPONENT
BF3-O2N2-COMP O2N2-GOX V BELTS 8V 2350 ,FOR OXYGEN COMPRESSOR SIZE

BF3-O2N2-COMP O2N2-GOX OIL FILTER F/O2 COMPRESOR, MODEL-SR11006
BF3-O2N2-COMP O2N2-GOX 1ST STAGE SUCTION VALVE
BF3-O2N2-COMP O2N2-GOX 1ST STAGE SUCTION VALVE
BF3-O2N2-COMP O2N2-GOX 1ST STAGE DISCHARGE VALVE
BF3-O2N2-COMP O2N2-GOX 1ST STAGE DISCHARGE VALVE
BF3-O2N2-COMP O2N2-GOX 2ND STAGE SUCTION VALVE
BF3-O2N2-COMP O2N2-GOX 2ND STAGE SUCTION VALVE
BF3-O2N2-COMP O2N2-GOX 2ND STAGE DISCHARGE VALVE
BF3-O2N2-COMP O2N2-GOX 2ND STAGE DISCHARGE VALVE
BF3-O2N2-COMP O2N2-GOX 1ST STAGE PISTON RING
BF3-O2N2-COMP O2N2-GOX 2ND STAGE PISTON RING
BF3-O2N2-COMP O2N2-GOX AUXILLARY OIL PUMP WITH MOTOR DULY ASSEMB
BF3-O2N2-COMP O2N2-GOX MAIN OIL PUMP GOX COMP
BF3-O2N2-COMP O2N2-GOX INTER COOLER F/ GOX-MODEL NO SR11006
BF3-O2N2-COMP O2N2-GOX AFTER COOLER F/ GOX-MODEL NO SR11006
BF3-O2N2-COMP O2N2-GOX DRIVE PULLEY FOR OXYGEN COMPRESSOR
BF3-O2N2-COMP O2N2-GOX LT Motor Windings
BF3-O2N2-COMP O2N2-GOX Terminal Box
BF3-O2N2-COMP O2N2-GOX GOX SOFTSTARTER
Command and Feed back cable
Relay
DI ,DOCard,PLC , IM modules
SMPS
BF3-O2N2-COMP O2N2-GOX
Profibus Cable
GOX COMP CW INLET TEMP
GOX C SUCTION SNUBBER PRESS
GOX C 1ST STG DIS (LEFT AND RIGHT) TEMP
GOX COMP 2ND STG DIS TEMP
GOX COMP OIL PRESS

CONDITION APPRAISAL OF PRODUCT COMP.
ITEM CODE SPECIFICATION DESCRIPTION / DIMENSION TOOLS REQUIRED
0802990034 CHECK FOR WEAROUT AND DAMA VISUAL

5915030004 CHECK FOR DP AT GAUGE
5115030001 CHECK FOR TEMP RISE VISUAL
5115030001 CHECK FOR GAS LEAKAGE VISUAL
5115030005 CHECK FOR DAMAGE VISUAL
5115030007 CHECK FOR DAMAGE VISUAL
5115030013 CHECK FOR PRESSURE AT DISCHARGVISUAL AT DCS
5915020010 CHECK FOR PRESSURE AT DISCHARGVISUAL AT DCS
5915030015 CHECK FOR WATER AND AIR OUTLEVISUAL AT DCS AND FIEL
5915030016 CHECK FOR WATER AND AIR OUTLEVISUAL AT DCS AND FIEL
0812990004 CHECK FOR PHYSICAL DAMAGE VISUAL
To form magnetic field

when energized with current
Megger &
to produce torque. Check for
Multimeter
winding resistance and
megger value of Motor.
Check for proper tigteness of

the power cable to the LT Spanners
Motor
Check for cleaning and Cotton clothe,

tighteness of power and control spanners, Screw
cable. driver
checking healthyness by
Multimeter,Tester
Run the Belt Conveyor
operating DOL starter of Multimeter,Tester
conveyor.
operating DOL starter of
conveyor/ by activating Multimeter,Tester
pull cord, BSS, ZSS and
LCS Box.
check supply voltage and
Multimeter,Tester
output Voltage
Multimeter,Tester
Run the Belt Conveyor
Multimeter,Tester
CHECK FOR WATER INLET PRE
Multimeter,Tester
CHECK FOR DP OF DISCHARGE
Multimeter,Tester
ND RIGHT) TEMP CHECK FOR DISCHARGE TEMP A
Multimeter,Tester
CHECK FOR DISCHARGE TEMP AT
Multimeter,Tester
CHECK OIL LUBRICATING OIL
T COMP.
TYPE OF CHECK (RUN

CHECK / STOP CHECK / IDEAL CONDITION
SHUTDOWN)
STOP CHECK NO WEAROUT AND DAMAGE
RUN CHECK SHOULD BE<1BAR
RUN CHECK TEMP <35*C
SHUTDOWN NO DAMAGE
SHUTDOWN NO DAMAGE
STOP CHECK NO PHYSICAL DAMAGE
Winding Resistances should

be balanced of all three
phases, i.e., less than 5
Shut Down check ohms.
Megger values shouldbe
above 5 megaohms from all
three phases to ground.
Tightened with 10 mm
Shut Down check
Chrome Vanadium Bolts.
Softstarter should clean.

SHUTDOWN CHECK Check the tighteness of the
power and control cable.
Physical check or damage

Run check
of cable
Check for healthiness of
Run check NO - NC contacts during
operation.
Run check Physical check
Run check
temp <40*C
Run check
PRESSURE <0.16 bar
Run check
temp <110*C
Run check
temp <110*C
Run check
pressURE >2 bar
ACTUAL CONDITION OBSERVED ACTION REQUIRED
No abnormal difference in
winding resistances. Winding
resistance of all three phases is
5.4 ohms. Megger values are 500
mega ohms and in healthy
condition.
No looseness of 10 mm Chrome
Vanadium bolts and connecting
links.
Softstarter is clean. Tighteness of

the power and control cable is
normal.
No abnormalities found
No abnormalities found in
switching of contacts during
operation.
CONDITION APPRAIS
Sub
EQUIPMENT: Equipments COMPONENT Item Code SPECIFICATION
BF3-O2N2-PPU PPU AFTER FILTER -F/O2N2 5915010036 CHECK FOR Dp

BF3-O2N2-PPU HEATER NUT ASSEMBLY 5115050001
BF3-O2N2-PPU HEATER NUT ASSEMBLY 5115050001
BF3-O2N2-PPU MOLECULAR SIEVE ADSORBENT 3101310063 13X BEADS PPU
BF3-O2N2-PPU ACTIVATED ALUMINA ADSORBE 3101310062 F-200
CONDITION APPRAISAL OF PPU
TYPE OF
CHECK (RUN
DESCRIPTION / DIMENSION TOOLS REQUIRED CHECK / STOP IDEAL CONDITION
CHECK /
SHUTDOWN)
CHECK FOR Dp VISUAL at dcs RUN CHECK <50MILIBAR

CHECK FOR TEMP. VISUAL at dcs RUN CHECK >150*C
CHECK FOR CURRENT AT FIELD RUN CHECK 70-80A
CHECK FOR OUTLET CO2 PPM VISUAL at dcs RUN CHECK SHOULD BE <0.5PPM
CHECK FOR OUTLET CO2 PPM VISUAL at dcs RUN CHECK SHOULD BE <0.5PPM
ACTUAL
ACTION
CONDITION REQUIRED
OBSERVED
COND
EQUIPMENT Sub Equipments COMPONENT Item Code
5102000132
BLT Bleeder valve Bleeder valve seat
5102000110
BLT Bleeder valve Bleeder valve seal
5102000133
BLT Bleeder valve Bleeder valve cap
Hydraulic cylinder for 5103990046

BLT Bleeder valve bleeder valve
2511010018
BLT Relief valve Relief vv sealing seal
5103990067
BLT Relief valve silencer f/relief v/v
Relief valve hydraulic 5109000066

BLT Relief valve cylinder
2511010017
BLT Equlization valve Eq v/v seating seal
Eq valve hydraulic 5109000067

BLT Equlization valve cylinder
Spring loded Nitrogen
BLT Equlization valve v/v DN 65 5107000050
cylinder of 5102000128
BLT Burden Stop Valve Hydraulic
Burden stop valve
for Burden stop 5102000156
BLT Burden Stop Valve Gate
valve (flap)
5102000129
Hydraulic cylinder for
BLT Upper sealing valve Upper sealing valve
5102000111
Upper sealing valve V/V plate for Upper
BLT sealing valve
5102000158
Upper sealing valve Holding arm for Upper
BLT sealing valve flap
for Upper sealing 5102000112

BLT Upper sealing valve Seal
valve flap
Upper sealing valve Links for Upper sealing

BLT valve
Upper sealing valve Upper Sealing valve

BLT arm
5102000129
Hydraulic cylinder for
BLT Lower sealing valve Lower sealing valve
v/v plate for Lower 5102000111

BLT Lower sealing valve sealing valve
Seal for Lower sealing 5102000112
BLT Lower sealing valve valve flap
stock rod gear box with

BLT stock rod O2N2 SIDE motor ,bob,chain,
complete assembly
5102000141
stock rod gear box with

BLT stock rod PCM SIDE motor ,bob,chain,
complete assembly
5102000141
Burden flow Gear box for Burden 5102000117
BLT regulating Flow Regulating Valve
valve/Gama drive (BFRV)
Burden flow Coupling for Burden

BLT regulating Flow Regulating Valve
Coupling bolts for

Burden flow Burden Flow
BLT regulating Regulating Valve
Burden flow
BLT regulating Valve plate for BFRV 5102000156
valve/Gama drive
Burden flow
BLT regulating Drive Shaft for BFRV
valve/Gama drive
Burden flow Non Drive Shaft for

BLT regulating BFRV
valve/Gama drive
Distributor/Beta Beta drive Primary 5102000124
BLT drive Gear box with motor
Distributor/Beta Encoder feedback 5102000140
BLT drive pinion
Distributor/Beta Intermediate gear box
BLT drive of Beta drive
BLT Alpha drive Alpha drive Arms
Alpha drive gear box 5102000123
BLT Alpha drive with motor full
assembly
Secondary Alpha drive
BLT Alpha drive gear box
pinion F/alpha drive 806990070
BLT Alpha drive gear box
BLT Alpha drive Alpha drive arms pins
Linear plate for burden

BLT BURDEN TANK tank
RECEIVING HOPPER Linear plate for

BLT receiving hopper
BELL LESS TOP

BLT HYDRAULIC LT Motor Windings
MOTOR#1
BELL LESS TOP
BLT HYDRAULIC Terminal Box
MOTOR#1
BELL LESS TOP

HYDRAULIC
BLT Power Contactor
MOTOR#1
FEEDER
BELL LESS TOP

HYDRAULIC
BLT Overload Relay
MOTOR#1
FEEDER
BELL LESS TOP

BLT HYDRAULIC LT Motor Windings
MOTOR#2
BELL LESS TOP

BLT HYDRAULIC Terminal Box
MOTOR#2
BELL LESS TOP

HYDRAULIC
BLT Power Contactor
MOTOR#2
FEEDER
BELL LESS TOP
HYDRAULIC
BLT Overload Relay
MOTOR#2
FEEDER
Burden flow
BLT regulating LT Motor Windings
valve/Gama drive
Burden flow
BLT regulating Terminal Box
valve/Gama drive
Burden flow
BLT regulating Servo Drive
valve/Gama drive
Burden flow
BLT regulating Power cable
valve/Gama drive
Distributor/Beta Distributor Motor

BLT
drive Windings
Distributor/Beta Distributor motor

BLT
drive Terminal Box
Distributor/Beta Gear Oil Pump
BLT
drive Motor Windings
Distributor/Beta Cooling Fan motor

BLT
drive winding
Distributor motor
Distributor/Beta
BLT Variable Frequency
drive
Drive
Distributor/Beta Distributor motor

BLT
drive Power cable
Distributor/Beta Gear Oil Power

BLT
drive Contactor
Distributor/Beta Cooling Fan Power
BLT
drive Contactor
BLT Alpha drive LT Motor Windings
BLT Alpha drive Terminal Box
BLT Alpha drive Servo Drive
BLT Alpha drive Power cable

STOCK ROD BF
STOCK ROD BF
CONTROL ROOM
BLT CONTROL ROOM
SIDE SIDE Motor
SIDE
Windings
STOCK ROD BF
STOCK ROD
BLT CONTROL ROOM
Terminal Box
SIDE
STOCK ROD BF STOCK ROD

BLT CONTROL ROOM Thruster Brake
SIDE Motor Windings
STOCK ROD BF
Cooling Fan motor
BLT CONTROL ROOM
winding
SIDE
STOCK ROD BF
STOCK ROD Motor
BLT CONTROL ROOM
Sanmotion DC Drive
SIDE
STOCK ROD BF
STOCK ROD motor
BLT CONTROL ROOM
Power cable
SIDE

BLT CONTROL ROOM Thruster Brake
SIDE Power Contactor
STOCK ROD BF
STOCK ROD Cooling
BLT CONTROL ROOM
Fan Power Contactor
SIDE
STOCK ROD BF Tap

STOCK ROD BF
BLT Hole SIDE Motor
Tap Hole SIDE
Windings

BLT
Tap Hole SIDE Terminal Box
STOCK ROD
STOCK ROD BF
BLT Thruster Brake
Tap Hole SIDE
Motor Windings
STOCK ROD BF Cooling Fan motor

BLT
Tap Hole SIDE winding
STOCK ROD BF STOCK ROD Motor

BLT
Tap Hole SIDE Sanmotion DC Drive
STOCK ROD BF STOCK ROD motor

BLT
Tap Hole SIDE Power cable
STOCK ROD
STOCK ROD BF
BLT Thruster Brake
Tap Hole SIDE
Power Contactor
STOCK ROD BF STOCK ROD Cooling

BLT
Tap Hole SIDE Fan Power Contactor
Proximity switch
power and feed back

cable
Bleeder Valve, solenoid coil

BLT Relief valve,
Equalizing valve ,
USV, BSV, LSV, Relay
DI ,DOCard,PLC , IM
modules
SMPS
Profibus Cable
Proximity switch
BLT BFRV, CHUTE

power and feed back
cable
BLT BFRV, CHUTE Relay
DI ,DO,AO Card PLC

, IM modules
SMPS
Proximity switch
power and feed back

cable
BLT Stock Rod Relay
DI ,DO Card PLC ,

IM modules
SMPS
Proximity switch
power and feed back

cable
BLT Distributor Relay
DI ,DO Card PLC ,

IM modules
SMPS
power and feed back

cable
pressure switch
Relay
BLT BLT Hydraulic Motor
DI ,DOCard,PLC , IM
modules
BLT BLT Hydraulic Motor
SMPS failure
Profibus Cable
CONDITION APPRAISAL as on 24.04.2017
SPECIFICATION DESCRIPTION / DIMENSION TOOLS REQUIRED
DN 550mm VISUAL
Bleeder valve CHECK FOR VALVE SEAT DAMAGE
DN 550mm VISUAL
Bleeder valve CHECK FOR VALVE SEAL DAMAGE
DN 550mm VISUAL
Bleeder valve CHECK FOR PHYSICAL DAMAGE IN CAP
VISUAL
125 x 90 x 350 CHECK FOR CYLINDER LEAKAGE and operation
OD 380 x ID 330x CHECK FOR SEAL SEATING AND DEFORMATION

id 310x W24
NOISE/SOUND
CHECK FOR SOUND METER
VISUAL
80 x 45 x 200 CHECK FOR CYLINDER LEAKAGE
od 320 x id 265 x id OPERATIONAL
235 x w 25 CHECK FOR SEALING BY EQUALIZING
VISUAL
CHECK FOR OPEARTION AND LPASSING OF OPERATIONAL
DN 65 VALVE
VISUAL
VISUAL
CHECK FOR WEAR AND DAMAGE
VISUAL
VISUAL
DN 700 CHECK FOR PLATE WEAR AND DAMAGE
VISUAL
CHECK FOR CRACKS AND DEFORMATION
CHECK FOR SEAL SEATING AND DEFORMATION
VISUAL
VISUAL
VISUAL
80 x 45 x500 CHECK FOR CYLINDER LEAKAGE
VISUAL
CHECK FOR PLATE WEAR AND DAMAGE
CHECK FOR SEAL SEATING AND DEFORMATION
VISUAL AT SITE AND

AT PLC
Chines CHECK BY TRIAL FOR SMOOTH OPERATION
VISUAL AT SITE AND

AT PLC
Chines CHECK BY TRIAL FOR SMOOTH OPERATION
BWEY 53-289 CHECK FOR INERNAL GEAR DAMAGE SPANNERS
W 51-06-08 CHECK FOR CRACKS AND DEFORMATION SPANNERS
W 51-06-08 CHECK FOR CRACKS AND DEFORMATION SPANNERS

CHECK FOR LEAKAGES AND ABNORMAL

W 31-44-00 VISUAL
SOUND
CHECK FOR PENION WEAR SPANNERS
XLD6-35-5.5 CHECK FOR INERNAL GEAR DAMAGE SPANNERS
CHECK FOR LEAKAGES AND ABNORMAL

W31-16-00 VISUAL
SOUND
CHECK FOR INERNAL GEAR DAMAGE SPANNERS
CHECK FOR PENION WEAR SPANNERS
CHECK FOR WEAR SPANNERS
CHECK FOR WEAR AND DAMAGE VISUAL
CHECK FOR WEAR AND DAMAGE VISUAL
To form magnetic field when energized

with current to produce torque. Check for Megger &
winding resistance and megger value of Multimeter
Motor.
Check for proper tigteness of the power
Spanners
cable to the LT Motor
Check for contactor rating and tighteness Spanners, Screw

of contactor terminals. Check for coil Drivers, Allen Key,
resistance of the contactor. Multimeter
Check for overload relay range and setting

Visual
of relay current for motor tripping.

Motor.

Spanners

Visual

Motor.

Spanners
To receive a command signal from a

control system, amplifies the signal, and Clamp Meter
transmits electric current to a servo Screw Drivers
motor in order to produce motion Visual
proportional to the command signal.
To transport electrical energy from the

Megger &
source of the electricity to the motor or
Multimeter
device.

Motor.

Spanners
Motor.

Motor.
To check for power connections

tighteness, load monitoring and drive
Clamp Meter
cooling fan sound and vibration.
Screw Drivers
To check for motor parameters feeded into
Visual
the Drive.
Motor FLC = 14.3A
To check for cable insulation greater than

Megger &
100 megaohms and continuity of cable
Multimeter
cores.


Motor.

Spanners
To receive a command signal from a

control system, amplifies the signal, and Clamp Meter
transmits electric current to a servo Screw Drivers
motor in order to produce motion Visual
proportional to the command signal.
To transport electrical energy from the

Megger &
source of the electricity to the motor or
Multimeter
device.
Motor.

Spanners

Motor.

Motor.

Clamp Meter
Screw Drivers
Visual
the DriveField FLC = 2.01 A
Armature FLC = 12.5 A
Megger &
Multimeter
cores.



Motor.

Spanners
Motor.

Motor.

Clamp Meter
Screw Drivers
Visual
the DriveField FLC = 2.01 A

Megger &
Multimeter
cores.

checking healthyness by operating valve. Multimeter, Tester
check coil Resistance Multimeter, Tester
check supply voltage and output Voltage Multimeter, Tester

checking healthyness by operating valve. Multimeter,Tester
check healthyness of contact change over

Multimeter,Tester
by operaing with pressure

check supply voltage and output Voltage Multimeter,Tester

TYPE OF
CHECK (RUN
CHECK / IDEAL CONDITION ACTUAL CONDITION OBSERVED
STOP
CHECK /
SHUTDOWN)
ShutDown No Deformation Deformed to be changed
ShutDown No Deformation
ShutDown No body damage
RUN CHECK NO LEAKAGE
ShutDown No Wear & Deformation
RUN CHECK SOUND <75DB
RUN CHECK SHOULD BE EQUALIZING
RUN CHECK NO LEAKAGE AND SMOOTH

OPERATION
ShutDown NO HOLES & Deformation

ShutDown NO CRACKS AND DAMAGE
RUN CHECK SMOOTH OPERATION
RUN CHECK SMOOTH OPERATION
NO INTERNAL TEETH
ShutDown DAMAGES

ShutDown NO PHYSICAL DAMAGE
RUN CHECK NO ABNORMAL SOUND AND

LEAKAGE
NO INTERNAL TEETH
ShutDown DAMAGES
RUN CHECK NO ABNORMAL SOUND AND

LEAKAGE
NO INTERNAL TEETH
ShutDown DAMAGES
NO WEAR AND DISPLACED

ShutDown LINERS
NO WEAR AND DISPLACED
ShutDown LINERS
Winding Resistances
should be balanced of all No abnormal difference in winding
three phases, i.e., less than resistances. Winding resistance of all
Shut Down
10 ohms. three phases is 7.1 ohms. Megger values
check
Megger values shouldbe are 500 mega ohms and in healthy
above 5 megaohms from condition.
all three phases to ground.
Shut Down Tightened with 10 mm No looseness of 10 mm Chrome
check Chrome Vanadium Bolts. Vanadium bolts and connecting links.
foundation of contactor.
No abnormalities to be No looseness in fitting of contactor and
SHUTDOW seen for the contacts and connection of cables to power contactor
N CHECK proper fitting to be done. and its contacts. Coil resistance of
Coil resistance should be contactor checked 25 ohms.
between 20 ohms - 30
ohms.
Relay settings: Inspected Relay Range = 48-54A

SHUTDOW
Relay Range = 48-54A Relay setting = 48A
N CHECK
Relay setting = 48A Running Current = 18 A
Winding Resistances
should be balanced of all No abnormal difference in winding
three phases, i.e., less than resistances. Winding resistance of all
Shut Down
10 ohms. three phases is 7.5 ohms. Megger
check
Megger values shouldbe values are 500 mega ohms and in
above 5 megaohms from healthy condition.
Shut Down Tightened with 10 mm No looseness of 10 mm Chrome

check Chrome Vanadium Bolts. Vanadium bolts and connecting links.
Coil resistance should be contactor checked 25.4 ohms.
ohms.
Relay settings: Inspected Relay Range = 48-54A
SHUTDOW
Relay Range = 48-54A Relay setting = 48A
N CHECK
Relay setting = 48A Running Current = 35 A
Winding Resistances
should be balanced of all
Winding resistances of all three are 46
three phases, i.e., less than
Shut Down ohms. Megger values are 10.8 mega
50 ohms.
check ohms phase to ground and are in
Megger values should be
healthy condition.
above 5 megaohms from
Brazing of cable to motor

Shut Down Brazing of connector with cable
and encoder connector
check checked. No abnormalities found.
properly done.
To check for power

Power connections tighteness on the
connections tighteness,
drive, load checking and drive cooling
SHUTDOW load monitoring and drive
fan vibration and abnormal sound
N CHECK cooling fan abnormal
checked. No abnormalities found.
sound and vibration.
Running Currnet = 2.2A
Motor FLC = 32A
To check for cable

Power cable insulation checked
SHUTDOW insulation greater than
through megger 850 megaohms.
N CHECK 100 megaohms and
Continuity of cable cores are normal.
continuity of cable cores.
Winding Resistances
Winding resistances of all three are 6.2
Shut Down ohms. Megger values are 800 mega
10 ohms.
healthy condition.
Shut Down Tightened with 10mm No looseness of the bolts and

check chrome vanadium Bolts. connecting links.
Winding Resistances
10 ohms.
healthy condition.
Check for cooling fan

motor winding resistance
Cooling fan motor winding resistance
should be in between 50
Shut Down 56 ohms and meger value is 55
ohms - 60 ohms and
check megaohms and continuity of power
megger should be greater
cable checked.
than 50 megaohms and
power cable.
To check for power

load monitoring and drive
cooling fan sound and
Shut Down fan vibration and sound checked.
vibration.
check Motor parameters feeded into the drive
To check for motor
parameters feeded into
Running Current = 4.6A
the Drive.
Motor FLC = 14.3A
To check for cable

Shut Down insulation greater than
check 100 megaohms and
ohms.
ohms.
Winding Resistances
Shut Down ohms. Megger values are 11 mega ohms
50 ohms.
check phase to ground and are in healthy
condition.
Brazing of cable to motor

Shut Down Brazing of connector with cable
and encoder connector
check checked. No abnormalities found.
properly done.
To check for power

SHUTDOW load monitoring and drive
fan vibration and abnormal sound
N CHECK cooling fan abnormal
Running Currnet = 1.9A
Motor FLC = 32A
To check for cable

SHUTDOW insulation greater than
N CHECK 100 megaohms and
Winding Resistances
10 ohms.
healthy condition.

Winding Resistances
10 ohms.
healthy condition.

ohms - 60 ohms and
cable checked.
power cable.
To check for power

fan vibration and sound checked.
Shut Down vibration.
Motor parameters feeded into the drive
check To check for motor
Drive Field RC = 2.01 A
the DriveField FLC = 2.01
Armature RC = 4.7 A
A
To check for cable
ohms.
ohms.
Winding Resistances
10 ohms.
healthy condition.

Winding Resistances
10 ohms.
healthy condition.

ohms - 60 ohms and
cable checked.
power cable.
To check for power

fan vibration and sound checked.
Shut Down vibration.
Motor parameters feeded into the drive
check To check for motor
Drive Field RC = 2.01 A
the DriveField FLC = 2.01
Armature RC = 4.9 A
A
To check for cable

ohms.
ohms.
Physical check or damage of

Run check No damage
sensor

Run check No damage
cable
Run check No damage
coil
Physical check or contact
Run check damage of coil using No damage
multimeter

Run check No damage
sensor
Run check No damage
cable
multimeter

Run check No damage
sensor
Run check No damage
cable
multimeter

Run check No damage
sensor
Run check No damage
cable
multimeter

Run check No damage
of cable
Run check No damage
of coil
multimeter


ACTION
REQUIRED
EQUIPMENT: Sub Equipments COMPONENT
SP-COOL-TESP SP-COOL-TESP TAIL ESP REDUCER CATHODE

SP-COOL-TESP SP-COOL-TESP TAIL ESP ASSEMBLY OF HAMMERS CATHODE
TAIL ESP HAMMER SHAFTSUPPORTING BASE
SP-COOL-TESP SP-COOL-TESP CATHODE
SP-COOL-TESP SP-COOL-TESP TAIL ESP SHAFT JOIN SLEEVE
SP-COOL-TESP SP-COOL-TESP TAIL ESP SHAFT-1 CATHODE
SP-COOL-TESP SP-COOL-TESP TAIL ESP REDUCER ANODE
SP-COOL-TESP SP-COOL-TESP TAIL ESP HAMMERS ANODE
SP-COOL-TESP SP-COOL-TESP TAIL ESP HAMMER SHAFTSUPPORTING BASE ANODE
SP-COOL-TESP SP-COOL-TESP TAIL ESP SHAFT JOIN SLEEVE

SP-COOL-TESP SP-COOL-TESP TAIL ESP SHAFT-1 ANODE
SP-COOL-TESP SP-COOL-TESP U CLAMP FOR TAIL ESP -SP
SP-COOL-TESP SP-COOL-TESP FABRIC CLOTH,FOR TAIL ESP PIPE INLET
SP-COOL-TESP SP-COOL-TESP FABRIC CLOTH,FOR TAIL ESP PIPE OUTLET
SP-COOL-TESP SP-COOL-TESP Geared motor motor for screw conveyor
SP-COOL-TESP SP-COOL-TESP EXPANSION BELLOW FOR TAIL ESP - SP
SP-COOL-TESP SP-COOL-TESP TAIL ESP CHEN DRIVE REDUCER
SP-COOL-TESP SP-COOL-TESP
RELAY
SP-COOL-TESP SP-COOL-TESP CAMMAND & FEEDBACK CABLE
SP-COOL-TESP SP-COOL-TESP
DI ,DO, AI, AO Card, PLC , IM modules
SP-COOL-TESP SP-COOL-TESP SMPS
SP-COOL-TESP SP-COOL-TESP Profibus Cable
CONDITION APPRAISAL OF TAIL ESP

CHECK FOR HAMMER WEAROUT VISUAL
CHECK FOR BOLT TIGHTNESS AND RUSTING SPANNERS


checking healthyness by operating DOL starter of motor. Multimeter,Tester

checking healthyness by Run the motor Multimeter,Tester
checking healthyness by operating DOL starter of motor and run feedback. Multimeter,Tester
checking of commnunication on SCADA sytem and on PLC card Multimeter,Tester
IL ESP
TYPE OF CHECK (RUN

SHUTDOWN)
STOP CHECK NO PHYSICAL DAMAGE TO BODY

STOP CHECK NO WEAROUT OF HAMMERS
STOP CHECK BOLTS SHOULD NOT BE RUSTED AND SHOULD BE TIGHT

STOP CHECK NO CRACKS AND DAMAGE

STOP CHECK NO TORNOUT IN CLOTH
STOP CHECK NO TORNOUT IN CLOTH
STOP CHECK LINKS SHOULD NOTBE DAMAGED
Run check Check for healthiness of NO - NC contacts during operation.

Run check Physical check or damage of cable

No abnormalities found in switching of

contacts during operation.
SP-SS-HESP SP-SS-HESP HEAD ESP VIBRATING HAMMER ASSEMBLY,CATHODE

SP-SS-HESP SP-SS-HESP HEAD ESP REDUCER, CATHODE
SP-SS-HESP SP-SS-HESP HEAD ESP CATHODE SHAFT-1
SP-SS-HESP SP-SS-HESP HEAD ESP SHAFT JOIN SLEEVE CATHODE
SP-SS-HESP SP-SS-HESP HEAD ESP HAMMER SUPPORT BASE CATHODE
SP-SS-HESP SP-SS-HESP HEAD ESP PULL PIN COUPL.
SP-SS-HESP SP-SS-HESP HEAD ESP VIBRATING HAMMER ASSEMBLY,ANODE
SP-SS-HESP SP-SS-HESP HEAD ESP REDUCER, ANODE
SP-SS-HESP SP-SS-HESP HEAD ESP ANODE SHAFT-1
SP-SS-HESP SP-SS-HESP HEAD ESP HAMMER SUPPORT BASE ANODE
SP-SS-HESP SP-SS-HESP HEAD ESP SHAFT JOIN SLEEVE ANODE
SP-SS-HESP SP-SS-HESP EMITTING ELECTRODE FOR HEAD ESP -CATHODE
SP-SS-HESP SP-SS-HESP DUST COLLECTING PLATE FOR HEAD ESP anode
SP-SS-HESP SP-SS-HESP DUPLEX CHAIN
SP-SS-HESP SP-SS-HESP SPROCKET BIG
SP-SS-HESP SP-SS-HESP SPROCKET SMALL
SP-SS-HESP SP-SS-HESP SLIDE GATE TYPE-SZ-400 FOR HEAD ESP-SP
SP-SS-HESP SP-SS-HESP U BOLT FOR HEAD ESP HAMMER-SP
SP-SS-HESP SP-SS-HESP
RELAY
SP-SS-HESP SP-SS-HESP CAMMAND & FEEDBACK CABLE
SP-SS-HESP SP-SS-HESP
DI ,DO Card, PLC , IM modules
SP-SS-HESP SP-SS-HESP SMPS
SP-SS-HESP SP-SS-HESP Profibus Cable
CONDITION APPRAISAL OF HEAD ESP
Item Code SPECIFICATION
5114000047
5114000041 SP,DN-CTD130-08
5114000042 ,SP,DN-CTD130-08
5114000043 ,SP,DN-CTD130-08
5114000044 ,SP,DN-CTD130-08
5114000045 ,SP,DN-CTD130-08
5114000056 ,SP,CTD130-10
5114000054 (2),SP
5114000046 ,SP,CTD130-08
5114000047
5114000048 SP,DN-CTD 130-10
5114000049 ,SP,CTD 130-10
5114000050 ,SP,CTD 130-10
5114000051 ,SP,CTD 130-10
5114000052 ,SP,CTD 130-10
5114000053 (1),SP
5114000056 ,SP,CTD130-10
1902010031
5114040017
5114040003
5114010021
5114010020
5114040019
0609010002
CONDITION APPRAISAL OF HEAD ESP

CHECK FOR WEAR &CRACKS IN HUB SPANNERS
CHECK FOR BEND & DISLOCATED CATODE VISUAL
CHECK FOR BEND & DISLOCATED CATODE VISUAL
CHECK FOR CHAIN LINKS DEFORMATION VISUAL
CHECK FOR DAMAGED THEETH VISUAL
CHECK FOR DAMAGED THEETH VISUAL
CHECK FOR SMOOTH OPENING AND CLOSING OPERATING

TYPE OF CHECK
(RUN CHECK / IDEAL CONDITION
STOP CHECK /
SHUTDOWN)
STOP CHECK face width should not be less than 40% of original size
STOP CHECK NO CRACKS AND WEAROUT IN HUB
STOP CHECK NO BEND AND DISLOCATED CATHODE
STOP CHECK NO BEND AND DISLOCATED CATHODE
STOP CHECK NO DEFORMED LINKS
STOP CHECK NO DAMAGED TEETHS
STOP CHECK NO DAMAGED TEETHS
STOP CHECK SMOOTH OPENING AND CLOSING


No abnormalities found in switching of contacts

during operation.
CON
DRUM NO.1 BEARING FOR DRUM NO. 1 (22236CA)
DRUM NO.1 PLUMMER BLOCK FOR DRUM NO. 1
DRUM NO.2 BEARING FOR DRUM NO. 2
DRUM NO.6 PLUMMER BLOCK FOR DRUM NO. 6 (GTU)
DRUM NO.7 BEARING FOR DRUM NO. 7 (22228 CA)

DRUM NO.10 PLUMMER BLOCK FOR DRUM NO. 10 (GTU)
DRUM NO.13 BEARING FOR DRUM NO. 13 (22236CA)
TEFLON BUSH / COUPLING PIN
SPIDER FOR CONVEYOR NO 1 INPUT COUPLING

COUPLING
COUPLING,
OUTPUT COUPLING
FUSIBLE PLUG -
FLUID COUPLING CPLG
GEAR BOX 1
GEARBOX
GEAR BOX 2
PLUMMER BLOCK FOR CB1 GTU DRUM

PLUMMER BLOCK
PLUMMER BLOCK F/ DRIVE DRUM -
Brake drum
BRAKE DRUM Brake drum coupling
Brake drum coupling
HOLDBACK HOLD BACK FOR SH CB1
SH CB#1 Drive 1 MOTOR SH CB#1 Motor Windings

SH CB#1 Drive 1 MOTOR SH CB#1 Terminal Box
SH CB#1 Drive 1 MOTOR SH CB#1 Thruster Brake Motor

THRUSTER BRAKE Windings
SH CB#1 Drive 1 COOLING SH CB#1 Cooling Pump motor

PUMP MOTOR winding
SH CB#1 Soft Starter
SH CB#1 Power Contactor
SH CB#1 Overload Relay
SH CB#1 cooling pump Power

STOCK HOUSE CB1/1 BELT Contactor
BF3-SH-CB1 PANEL
BF3-SH-CB1 PANEL
SH CB#1 cooling pump

AUXILIARY CONTACTOR
SH CB#1 Thruster brake

AUXILIARY CONTACTOR
SH CB#1 Thruster brake Power

Contactor
Speed sensor probe
ZERO SPEED SWITCH 1 & 2

Zero speed device
BELT SWAY BELT SWAY SWITCH
PULL CORD PULL CORD SWITCH

SH CB#1 Drive 2 MOTOR SH CB#1 Motor Windings
SH CB#1 Drive 2 MOTOR SH CB#1 Terminal Box
SH CB#1 Drive 2 MOTOR SH CB#1 Thruster Brake Motor

THRUSTER BRAKE Windings
SH CB#1 Drive 2 COOLING SH CB#1 Cooling Pump motor

PUMP MOTOR winding
SH CB#1 Soft Starter
SH CB#1 Power Contactor
SH CB#1 Overload Relay
STOCK HOUSE CB1/1 BELT

PANEL
SH CB#1 cooling pump Power
STOCK HOUSE CB1/1 BELT Contactor
PANEL
SH CB#1 cooling pump

AUXILIARY CONTACTOR
SH CB#1 Thruster brake

AUXILIARY CONTACTOR
SH CB#1 Thruster brake Power

Contactor
CONDITION APPRAISAL OF SH CB#1 (B
SPANNERS AND FILLER

CHECK FOR BEARING CLEARANCE GAUGE
CHECK FOR PHYSICAL DAMAGE AND BOLTS TIGHTNESS SPANNERS
SPANNERS AND FILLER

SPANNERS AND FILLER

SPANNERS AND FILLER

SPANNERS AND FILLER

SPANNERS AND FILLER

SPANNERS AND FILLER

SPANNERS AND FILLER

SPANNERS AND FILLER


SPANNERS AND FILLER
SPANNERS AND FILLER

SPANNERS AND FILLER

SPANNERS AND FILLER

CHECK FOR PHYSICAL DAMAGE OF SPIDER SPANNERS
CHECK FOR PHYSICAL DAMAGE OF COUPLING SPANNERS

CHECK FOR PHYSICAL DAMAGE OF GEARBOX SPANNERS
CHECK FOR PHYSICAL DAMAGE OF GEARBOX SPANNERS
CHECK FOR PHYSICAL DAMAGE SPANNERS

CHECK FOR PHYSICAL DAMAGE OF TEETHS SPANNERS
To form magnetic field when energized with

Megger &
current to produce torque. Check for winding
Multimeter
resistance and megger value of Motor.
Check for proper tigteness of the power cable to
Spanners
the LT Motor

Megger &
Multimeter

Megger &
Multimeter
Clamp Meter
To drive the motor smoothly without inrush flow
Screw Drivers
of current during starting.
Visual
Check for contactor rating and tighteness of Spanners, Screw

contactor terminals. Check for coil resistance of Drivers, Allen Key,
the contactor. Multimeter
Check for overload relay range and setting of relay

Visual
current for motor tripping.

The auxiliary contactor is often used in a logic
circuit, or for some other part of the control Visual
scheme.

scheme.

To detect the speed of the conveyor and provides a

Visual
pulse to the zero speed switch.
To detect the stoppage or unacceptably slow Multimeter, Screw

movement of a rotating conveyor tail end pulley. Driver
For detecting the sway or deviation of belt

conveyors, and sends out an alarm signal and an
Multimeter, Screw
emergency stop signal.
Driver
Suited to be used for belt breakage and materials
falling prevention due to the belt sway.
Check rope when operated for safety tripping

switch for conveyor belts. When the rope is pulled Multimeter, Screw
the lever of the pc unit is operated which in turn, Driver
actuates a switch, thereby the conveyor is stopped.
Megger &
Multimeter

Spanners
the LT Motor

Megger &
Multimeter

Megger &
Multimeter
Clamp Meter
To drive the motor smoothly without inrush flow
Screw Drivers
of current during starting.
Visual


Visual

scheme.

scheme.

F SH CB#1 (BF3-SH-CB1)
TYPE OF CHECK (RUN CHECK / STOP IDEAL CONDITION
CHECK / SHUTDOWN)
STOP CHECK CLEARANCE <0.70MM
NO PHYSICAL DAMAGE AND NO RUSTED

STOP CHECK BOLTS

STOP CHECK BOLTS

STOP CHECK BOLTS

STOP CHECK BOLTS

STOP CHECK BOLTS

STOP CHECK BOLTS

STOP CHECK BOLTS

STOP CHECK BOLTS

STOP CHECK BOLTS

STOP CHECK BOLTS

STOP CHECK BOLTS

STOP CHECK BOLTS
STOP CHECK NO PHYSICAL DAMAGE AND NO RUSTED

BOLTS

STOP CHECK BOLTS

STOP CHECK BOLTS
STOP CHECK
BOLTS
Winding Resistances should be

balanced of all three phases,
i.e., less than 1 ohms.
Shut Down check
Megger values shouldbe above
5 megaohms from all three
phases to ground.
Shut Down check Tightened with spanner set.

Shut Down check
Megger values should be above
phases to ground.
Cooling pump motor to be fit

Shut Down check
properly on the shaft

tighteness, load monitoring and
Shut Down check drive cooling fan abnormal
Motor FLC = 313 A
Proper tighteness of foundation

of contactor.
No abnormalities to be seen for
SHUTDOWN CHECK the contacts and proper fitting
to be done.
Coil resistance should be 42-43
ohms.
Relay settings:
SHUTDOWN CHECK BOCR Relay = 1.4A; O time=2s;
D time=6s
of contactor.
to be done.
ohms.
The auxiliary contctactor is
used to provide tripping
SHUTDOWN CHECK indication whenever the lube
oil pump will trip or power
fails.
fails.

of contactor.
to be done.
Coil resistance should be
between 20 ohms - 30 ohms.
To check for continuous

SHUTDOWN CHECK sensing of the speed of the
conveyor.
To check for NO - NC contacts

through a relay according to
SHUTDOWN CHECK
Time and Speed adjustable
settings.
To check for healthiness of NO

SHUTDOWN CHECK
- NC contacts during operation.
To check for healthiness of NO

SHUTDOWN CHECK
- NC contacts during operation.
Shut Down check
phases to ground.

Shut Down check
Megger values should be above
phases to ground.
Cooling pump motor to be fit

Shut Down check
properly on the shaft

tighteness, load monitoring and
Shut Down check drive cooling fan abnormal
Motor FLC = 313 A

of contactor.
to be done.
ohms.
Relay settings:
SHUTDOWN CHECK BOCR Relay = 1.4A; O time=2s;
D time=6s
of contactor.
to be done.
ohms.

fails.
fails.

of contactor.
to be done.
between 20 ohms - 30 ohms.
0.8 ohms. Megger values are
400 mega ohms and in healthy
condition.
No looseness of the bolts and
connecting links.
Winding resistances of all three

are 9.2 ohms. Megger values
are 250 mega ohms phase to
ground and are in healthy
condition.
No looseness found in fitting of

cooling fan to the shaft.
Power connections tighteness

on the drive, load checking and
drive cooling fan vibration and
abnormal sound checked. No
abnormalities found.
No looseness in fitting of
contactor and connection of
cables to power contactor and
its contacts. Coil resistance is
42 ohms.
Inspected BOCR Relay = 1.4A;

O time=2s; D time=6s
42 ohms.
Indication for tripping of lube
oil pump is healthy.

its contacts. Coil resistance of
contactor checked 22 ohms.
sensing of speed probe.
No any abnormalities found in

open - close contacts through
relay during running of
conveyor according to speed
and time settings.
operation.
operation.
condition.

connecting links.
Winding resistances of all three

are 9.7 ohms. Megger values
are 300 mega ohms phase to
ground and are in healthy
condition.
No looseness found in fitting of

cooling fan to the shaft.
Power connections tighteness

on the drive, load checking and
drive cooling fan vibration and
abnormal sound checked. No
Running Current = 110 A
44 ohms.
Inspected BOCR Relay = 1.4A;

O time=2s; D time=6s
42 ohms.


its contacts. Coil resistance of
Drifter complete set

BF3-CSTHEQ-DM BF3-CSTHEQ-DM
BF3-CSTHEQ-DM BF3-CSTHEQ-DM Carraige Movement chain

BF3-CSTHEQ-DM BF3-CSTHEQ-DM chain mounting roller pins
BF3-CSTHEQ-DM BF3-CSTHEQ-DM chain mounting rollers
BF3-CSTHEQ-DM BF3-CSTHEQ-DM chain sprocket

BF3-CSTHEQ-DM BF3-CSTHEQ-DM chain tensioning unit
BF3-CSTHEQ-DM BF3-CSTHEQ-DM hooking frame
BF3-CSTHEQ-DM BF3-CSTHEQ-DM Drill mc Boom
BF3-CH-MUDPWPK-PMP-
BF3-CSTHEQ-DM Motor Windings
MTR1
BF3-CH-MUDPWPK-PMP-
BF3-CSTHEQ-DM Terminal Box
MTR1
BF3-CSTHEQ-DM BF3-CH-MUDPWPK-PNL Power Contactor

BF3-CSTHEQ-DM BF3-CH-MUDPWPK-PNL Overload Relay
BF3-CH-MUDPWPK-PMP-
BF3-CSTHEQ-DM Motor Windings
MTR2
BF3-CH-MUDPWPK-PMP-
MTR2
BF3-CH-MUDPWPK-PMP-
BF3-CSTHEQ-DM MTR3 Motor Windings
BF3-CH-MUDPWPK-PMP-
MTR3

TOOLS
Item Code DESCRIPTION / DIMENSION REQUIRED
5103020172
CHECK FOR OPERATIONS OF HAMMERING VISUAL
CHECK FOR OIL LEAKAGE VISUAL
5103020123 CHECK CHAIN LINKS FOR DAMAGE VISUAL
5103020115 CHECK FOR PIN DAMAGE VISUAL
5103020115 CHECK FOR ROLLERS BUSH WEAROUT VISUAL
5103020170 CHECK FOR TEETH DAMAGE OF SPROCKET SPANNERS

1908000044 CHECK FOR ROLLER DAMAGE & THREAD DAMAGE SPANNERS
5103020115 CHECK FOR PHYSICAL DAMAGE OF FRAME VISUAL
5103020115 CHECK FOR PHYSICAL DAMAGE OF BOOM VISUAL

Megger &
Multimeter

Spanners
the LT Motor
Spanners,
Check for contactor rating and tighteness of
Screw Drivers,
contactor terminals. Check for coil resistance of
Allen Key,
the contactor.
Multimeter
Visual

Megger &
Multimeter

Spanners
the LT Motor
Spanners,
Screw Drivers,
Allen Key,
the contactor.
Multimeter

Visual

Megger &
Multimeter

Spanners
the LT Motor
Spanners,
Screw Drivers,
Allen Key,
the contactor.
Multimeter

Visual
TYPE OF
CHECK (RUN
CHECK / IDEAL CONDITION
STOP
CHECK /
SHUTDOWN)
RUN CHECK SHOULD BE HAMMERING WITHOUT STUCKING

RUN CHECK NO OIL LEAKAGE
STOP CHECK NO DMAMAGED LINKS IN CHAIN
STOP CHECK NO WEAROUT AND DAMAGE TO PINS
RUN CHECK NO WEARED BUSH
NO WEARED OF BUSHES & NO DAMAGE OF
STOP CHECK TEETHS
STOP CHECK NO THREAD & ROLLERS DAMAGE
STOP CHECK NO PHYSICAL DAMAGE OF FRAME
STOP CHECK NO PHYSICAL DAMAGE OF BOOM
Winding Resistances should be balanced of all

Shut Down three phases, i.e., less than 10 ohms.
check Megger values shouldbe above 5 megaohms
from all three phases to ground.
Shut Down Tightened with 10mm Chrome Vanadium

check Bolts.
Contactor rarting to be 150 A. Proper

tighteness of foundation of contactor.
Shut Down
No abnormalities to be seen for the contacts
check and proper fitting to be done.
Coil resistance should be 35-45 ohms.
Relay Range :
Shut Down (90 - 150)A
check Relay settings = 90A
FLC = 103A


check Bolts.

Shut Down
Relay Range :
FLC = 103A


check Bolts.
Shut Down
Relay Range :
FLC = 103A
ACTUAL CONDITION ACTION
OBSERVED REQUIRED
winding resistances.
Winding resistance of all
three phases is 5.6 ohms.
Megger values are 1000
condition.
No looseness of 10mm
Chrome Vanadium bolts and
connecting links.
Contactor rarting is 150 A.
cables to power contactor
and its contacts. Coil
resistance is 42 ohms.
Checked Relay Range :
(90 - 150)A
Relay settings = 90A
RC = 69.3A
condition.
connecting links.

resistance is 43.2 ohms.

(90 - 150)A
RC = 68.0A
condition.
connecting links.

(90 - 150)A
RC = 69.4A
EQUIPMENT: Sub Equipments
BF3-CH-MUDGUNBF3-CH-MUDGUN
BF3-CH-MUDGUNBF3-CH-MUDPWPK-PMP-MTR1
BF3-CH-MUDGUNBF3-CH-MUDPWPK-PNL
TOOLS
COMPONENT
REQUIRED
Mud barrel VISUAL CHECK

Mudgun Swell joint flang bolts SPANNER
Mudgun indicater Rope VERNIER
Motor Windings Megger & Multimet
Terminal Box Spanners
Power Contactor Spanners, Screw Dri
Overload Relay Visual


TYPE OF CHECK (RUN
SHUTDOWN)
STOP CHECK NO MAJOR MUD LEAKAGE TO BE FOUND
STOP CHECK NO BOLTS DAMAGE
STOP CHECK SHOULD BE >5.4MM
Winding Resistances should be balanced of all three phases,

Shut Down check
Megger values shouldbe above 5 megaohms from all three p
Shut Down check Tightened with 10mm Chrome Vanadium Bolt
Contactor rarting to be 150 A. Proper tighteness of foundatio

Shut Down check No abnormalities to be seen for the contacts and proper fitti
Relay Range :
(90 - 150)A
Shut Down check
FLC = 103A

Shut Down check

Relay Range :
(90 - 150)A
Shut Down check
FLC = 103A

Shut Down check

Relay Range :
(90 - 150)A
Shut Down check
FLC = 103A
OBSERVED REQUIRED
2 Bolts slipped while tighness

checking
thickness 5.2MM and dry rope
resistance of all three phases is 5.6
ohms. Megger values are 1000
condition.
No looseness of 10mm Chrome
links.
Contactor rarting is 150 A. No

looseness in fitting of contactor
and connection of cables to power
contactor and its contacts. Coil

(90 - 150)A
RC = 69.3A
condition.
links.

(90 - 150)A
RC = 68.0A
condition.
links.


(90 - 150)A
RC = 69.4A
CONDITION
APPRAISAL OF
HOT METAL
HANDLING
CRANE
BF3-HMH- EHMH-CRANE-MH-
CRANE GB
CRANE GB
CRANE GB
CRANE GB
CRANE GB
CRANE GB
BF3-HMH- EHMH-CRANE-LT-
CRANE GB1
CRANE GB1
CRANE GB1
CRANE GB2
CRANE GB2
CRANE GB2
CRANE GB2
CRANE GB2
CRANE GB2
BF3-HMH- EHMH-CRANE-CT-
CRANE GB
CRANE GB
CRANE GB
CRANE GB
CRANE GB
CRANE GB
CRANE GB
BF3-HMH- EHMH-CRANE-AH-
CRANE GB
CRANE GB
CRANE GB
CRANE GB
BF3-HMH- HMH CRANE

CRANE PROTECTIVE PANEL
BF3-HMH- HMH CRANE

BF3-HMH- HMH CRANE

BF3-HMH- HMH CRANE
BF3-HMH- HMH CRANE

BF3-HMH- BF3-HMH-CRANE-
CRANE PNL
CRANE MTR
CRANE MTR
BF3-HMH- HMH-CRNE-MH-
CRANE MTR-RB
CRANE MTR
CRANE MTR
CRANE PNL
CRANE PNL
CRANE PNL
CRANE PNL
CRANE PNL
CRANE PNL
CRANE PNL
CRANE PNL
CRANE PNL
CRANE PNL
CRANE BRK1
CRANE BRK1
CRANE BRK1
CRANE PNL
EHMH-CRANE-MH-
BRK2
CRANE BRK2
CRANE BRK2
CRANE MTR
CRANE MTR
BF3-HMH- HMH-CRNE-AH-
CRANE MTR-RB
CRANE MTR
CRANE MTR
CRANE PNL
CRANE PNL
CRANE PNL
CRANE PNL
CRANE PNL
CRANE PNL
CRANE PNL
CRANE PNL
CRANE PNL
CRANE PNL
CRANE PNL
CRANE BRK1
CRANE BRK1
CRANE PNL
CRANE PNL
CRANE BRK2
CRANE BRK2
CRANE MTR1
CRANE MTR1
CRANE MTR2
CRANE MTR2
CRANE MTR
BF3-HMH- HMH-CRNE-LT-MTR-
CRANE RB
BF3-HMH- HMH-CRNE-LT-MTR-
CRANE RB
BF3-HMH- HMH-CRNE-CT-
CRANE MTR-RB
CRANE MTR1
CRANE MTR2
CRANE MTR
CRANE MTR1
CRANE MTR2
CRANE MTR
CRANE PNL
CRANE PNL
CRANE PNL2
CRANE PNL
CRANE PNL2
CRANE PNL
CRANE PNL1
CRANE PNL
CRANE PNL
CRANE PNL
CRANE PNL
CRANE PNL
CRANE PNL
CRANE PNL
CRANE PNL
CRANE PNL
CRANE PNL
CRANE PNL
CRANE PNL
CRANE BRK1
CRANE BRK1
CRANE BRK1
CRANE BRK1
CRANE BRK1
CRANE BRK2
CRANE BRK2
CRANE BRK2
CRANE BRK1
CRANE BRK2
CRANE BRK
CRANE BRK
CRANE BRK
CRANE BRK
COMPONENT
EXTENTION SHAFT
TOP PULLEY ASSEMBLEY WITH SHAFT
SNATCH BOX PULLEY
PULLEY BLOCK WITH HOOK,
100T J HOOK FOR LADDLE LIFTING,
THIMBLE32 MM
GEAR BOX LT
EXTENTION SHAFT G.B.OUT TO WHEEL

IN COUPLING LHG107
EXTENTION SHAFT MOTOR TO G.B. IN
COUPLING LHG103
GEAR BOX LT
GEAR BOX INPUT SHAFT COUPLING

LHG103
GEAR BOX OUT PUT SHAFT COUPLING
LHG107
WHEEL INPUT SHAFT COUPLING
LHG107
EXTENTION SHAFT G.B.OUT TO WHEEL
IN COUPLING LHG107
EXTENTION SHAFT MOTOR TO G.B. IN
COUPLING LHG103
GEAR BOX CT
G.B. OUT PUT SHAFT BOTH SIDE

COUPLING LHG107
WHEEL INPUT SHAFT COUPLING
LHG107
EXTENTION SHAFT GEAR BOX O/P TO
WHEEL I/P BOTH SIDE LHG-107
G.B. IN PUT SHAFT COUPLINGLHG103
EXTENTION SHAFT MOTOR SIDE

COUPLINGLHG102
EXTENTION SHAFT GEAR BOX SIDE
COUPLINGLHG-103
EXTENTION SHAFT (MOTOR OUT
G.B.INPUT) COUPLING LHG103
GEAR BOX AUX HOIST WITH DRUM20 T
HOIST
20T CRANE TOP PULLEY ASSEMBLEY
20T PULLEY BLOCK WITH HOOK
SFU, 1000 A
MAIN POWER CONTACTOR
PHASE INDICATION LAMP

CURRENT TRANSFORMER
CONTROL TRANSFORMER
HMH CRANE DOOR Limit Switch
Motor Windings
Slip Rings
Resistance Box
Carbon Brush
Terminal Box
SFU, 400 A
Power Contactor (Hoist and Lower)
Resistance Contactor (Hoist and Lower)
Stator Overload Relay with Kit

Rotor Overload Relay with Kit
Electronic Timer ON / OFF Delay
Rotary Limit Switch
Main Hoist Gravity Limit Switch
Main Hoist Master Controller Joystic
Thruster brake 1 Power Contactor
Thruster brake 1 Overload Relay
Thrustor Motor
Brake Shoe and Liner
Thrustor Motor

Motor Windings
Slip Rings
Resistance Box
Carbon Brush
Terminal Box
SFU, 160 A
Power Contactor (Hoist and Lower)
Resistance Contactor (Hoist and Lower)
Stator Overload Relay
Rotor Overload Relay
Rotary Limit Switch
AH Gravity Limit Switch
AH Master Controller Joystic

Thrustor Motor

Thrustor Motor
Motor Windings LT 1
Slip Rings LT 1
Motor Windings LT 2
Slip Rings LT 2
Slip Rings CT
Resistance Box LT 1
Resistance Box LT 2
Resistance Box CT
Carbon Brush LT1
Carbon Brush LT2
Carbon Brush CT
Terminal Box LT1
Terminal Box LT2
Terminal Box CT
LT SFU, 160 A
Power Contactor LT1 (Forward & Reverse)
Power Contactor LT2 (Forward & Reverse)
Resistance Contactor LT1 (Forward &

Reverse)
Resistance Contactor LT2 (Forward &
Reverse)
Stator Overload Relay LT1
Rotor Overload Relay LT1
Rotor Overload Relay LT2
Stator Overload Relay LT2
Lever type LT Forward / Reverse Limit

Switch
CT SFU, 63 A
Power Contactor CT (Forward & Reverse)
Resistance Contactor CT (Forward &

Reverse)
Rotor Overload Relay CT
Stator Overload Relay CT
Lever type CT Forward / Reverse Limit

Switch
CT Master Controller Joystick

Thruster brake Power Contactor
Thruster brake Overload Relay
Thrustor Motor LT1

Thrustor Motor LT2
Brake Shoe and Liner LT1
Brake Shoe and Liner LT2

Thrustor Motor CT
Brake Shoe and Liner CT

TOOLS
DESCRIPTION / DIMENSION
REQUIRED
CHECK FOR CRAKS AND DAMAGE IN SHAFT VISUAL
CHECK FOR CRAKS AND DAMAGE IN SHAFT

VISUAL
AND BODY
CHECK FOR CRACKS AND DAMAGE VISUAL
CHECK FOR BASE WELDING CONDITION VISUAL
CHECK FOR INTERNAL GEAR DAMAGES BY

SPANNERS
OPENING TOP COVER

SPANNERS
OPENING TOP COVER

SPANNERS
OPENING TOP COVER

SPANNERS
OPENING TOP COVER
VISUAL /
Check for fuse rating and continuity of input /
MULTIMETE
output terminals.
R
Spanners,
For switching a power circuit with higher current Screw Drivers,
ratings Allen Key,
Multimeter
Check for indication of input voltage of the

VISUAL
panel.
Check for tighteness of connections and measure
VISUAL
the correct current shown in the meter.
To check for connections and power rating of

Spanners /
transformer. Input and output voltage should be
Multimeter
415 / 110 VAC
VISUAL /
Check for switching NO / NC Contact as per set
MULTIMETE
value during Crane operation.
R
To form magnetic field when energized with Megger &

current to produce torque. Multimeter
To allow the transmission of power and electrical

signals from a stationary to a rotating structure.
It can be used in any electromechanical system Visual
that requires rotation while transmitting power
or signals.
To check for multiple resistors hooked up to one

or multiple switches and is designed to provide
Megger &
multiple electrical resistances. To vary desired
Multimeter
speed by varying the resistances. Also, to provide
initial torque to the motor.
To conduct current between stationary wires and
moving parts, most commonly in a rotating Visual
shaft.
Allows the power cable to be fixed with the

motor windings cable properly insulated,
clamped and sealed connector to provide greater
Spanners
protecton from short circuiting of cables.
Check for cable termination tighteness and
properly glanding done.
VISUAL /
MULTIMETE
output terminals.
R
Spanners,
ratings Allen Key,
Multimeter
Spanners,
ratings Allen Key,
Multimeter
Check for overload relay range and setting of

Visual
relay current for motor tripping.
Visual
Check for Timer ON / OFF switching as per set

Visual
value.
VISUAL /
MULTIMETE
value during hoisting and lowering operation.
R
VISUAL /
MULTIMETE
value during hoisting operation.
R
Check for switching NO / NC Contact as per set VISUAL /

value during hoisting operation. Check for wear MULTIMETE
and tear of contacts. R
Spanners,
Screw Drivers,
Allen Key,
the contactor.
Multimeter

Visual
To drive the pump and delivers working fluid

under the piston axially in the guided path, and
Megger &
delivers thrust or force required to operate the
Multimeter
attached devise (like thruster brake) via the
piston rod and the eye-lug attached to it.
Spanners,
Screw Driver,
To provide friction for braking of rotary drum
Plier, Vernier
when motor is stopped.
Calliper
Visual
Spanners,
Screw Drivers,
Allen Key,
the contactor.
Multimeter

Visual

Megger &
Multimeter
Spanners,
Screw Driver,
Plier, Vernier
Calliper
Visual

or signals.
To check for multiple resistors hooked up to one

or multiple switches and is designed to provide
Megger &
multiple electrical resistances. To vary desired
Multimeter
speed by varying the resistances. Also, to provide
initial torque to the motor.

shaft.

Spanners
VISUAL /
MULTIMETE
output terminals.
R
Spanners,
ratings Allen Key,
Multimeter
Spanners,
ratings Allen Key,
Multimeter

Visual
Check for overload relay range and setting of Megger &

relay current for motor tripping. Multimeter

Visual
value.
VISUAL /
MULTIMETE
value during hoisting and lowering operation.
R
VISUAL /
MULTIMETE
R

Spanners,
Screw Drivers,
Allen Key,
the contactor.
Multimeter

Visual

Megger &
Multimeter
Spanners,
Screw Driver,
Plier, Vernier
Calliper
Visual
Spanners,
Screw Drivers,
Allen Key,
the contactor.
Multimeter
Visual

Megger &
Multimeter
Spanners,
Screw Driver,
Plier, Vernier
Calliper
Visual


or signals.

or signals.

or signals.
It is an equipment that contains multiple

resistors hooked up to one or multiple switches
and is designed to provide multiple electrical Megger &
resistances. To vary desired speed by varying the Multimeter
resistances. Also, to provide initial torque to the
motor.

motor.
motor.

shaft.
shaft.
shaft.

Spanners

Spanners

Spanners
VISUAL /
MULTIMETE
output terminals.
R
Spanners,
ratings Allen Key,
Multimeter
Spanners,
ratings Allen Key,
Multimeter
Spanners,
ratings Allen Key,
Multimeter
Spanners,
ratings Allen Key,
Multimeter

Visual
Check for overload relay range and setting of Megger &

relay current for motor tripping. Multimeter
Relays are protective devices that are designed to

cut power if the motor draws too much current Visual
for an extended period of time.


Visual
value.
VISUAL /
MULTIMETE
R
VISUAL /
MULTIMETE
output terminals.
R
Spanners,
ratings Allen Key,
Multimeter
Spanners,
ratings Allen Key,
Multimeter



Visual
value.
VISUAL /
MULTIMETE
R

Spanners,
Screw Drivers,
Allen Key,
the contactor.
Multimeter

Visual

Megger &
Multimeter
Spanners,
Screw Drivers,
Allen Key,
the contactor.
Multimeter

Visual
Megger &
Multimeter
Spanners,
Screw Drivers,
Allen Key,
the contactor.
Multimeter

Visual
Spanners,
Screw Driver,
Plier, Vernier
Calliper
Visual
Spanners,
Screw Driver,
Plier, Vernier
Calliper
Visual
Spanners,
Screw Drivers,
Allen Key,
the contactor.
Multimeter

Visual

Megger &
Multimeter
Spanners,
Screw Driver,
Plier, Vernier
Calliper
Visual
date
TYPE OF CHECK
(RUN CHECK /
IDEAL CONDITION
STOP CHECK /
SHUTDOWN)
NO CRACKS AND
STOP CHECK
DAMAGE
NO CRACKS AND
STOP CHECK
DAMAGE
NO CRACKS AND
STOP CHECK
DAMAGE
NO CRACKS AND
STOP CHECK
DAMAGE
NO CRACKS AND
STOP CHECK
DAMAGE
NO CRACKS AND
STOP CHECK
DAMAGE
NO DAMAGES IN GEAR
STOP CHECK
TEETHS
NO CRACKS AND
STOP CHECK
DAMAGE
NO CRACKS AND
STOP CHECK
DAMAGE
NO DAMAGES IN GEAR
STOP CHECK
TEETHS
NO CRACKS AND
STOP CHECK
DAMAGE
NO CRACKS AND
STOP CHECK
DAMAGE
NO CRACKS AND
STOP CHECK
DAMAGE
NO CRACKS AND
STOP CHECK
DAMAGE
NO CRACKS AND
STOP CHECK
DAMAGE
NO DAMAGES IN GEAR
STOP CHECK
TEETHS
NO CRACKS AND
STOP CHECK
DAMAGE
NO CRACKS AND
STOP CHECK
DAMAGE
NO CRACKS AND
STOP CHECK
DAMAGE
NO CRACKS AND
STOP CHECK
DAMAGE
NO CRACKS AND
STOP CHECK
DAMAGE
NO CRACKS AND
STOP CHECK
DAMAGE
NO CRACKS AND
STOP CHECK
DAMAGE
NO DAMAGES IN GEAR
STOP CHECK
TEETHS
NO CRACKS AND
STOP CHECK
DAMAGE
NO CRACKS AND
STOP CHECK
DAMAGE
SFU Unit should be clean.

SHUTDOWN Check for fuse taing and
CHECK continuity of fuse input /
output terminals.
Contactor rating to be
3TF68, 630 A. Proper
tighteness of foundation of
contactor.
SHUTDOWN
No abnormalities to be seen
CHECK
for the contacts and proper
fitting to be done.
20-30 ohms.
Indication lamp should

RUN CHECK indicate input phase voltage
of HMH crane.
CT connections should be
tight and should measure
RUN CHECK
current accurately on the
ammeter.
Control transformer
SHUTDOWN connections should be tight.
CHECK Input and output voltage
should be 415 / 110 VAC
HMH Crane should stop

RUN CHECK during operation when limit
switch operated.

SHUTDOWN
ohms.
CHECK
Should be uniform
throughout surface without
SHUTDOWN
wear and cuts. Slip ring
CHECK
should be 10mm. It should
not less than 2mm.
Condition of the resistance

plates should be good and
the values of the resistance
SHUTDOWN box should match with rotor
CHECK rating plate.
Power = 110 KW
Rotor Voltage = 388V AC
Rotor Current = 172A
Thickness and smooth
SHUTDOWN surface at the contact with
CHECK the slipring. No wear and
tear.
SHUTDOWN Tightened with 10mm

CHECK Chrome Vanadium Bolts.

output terminals.
contactor.
SHUTDOWN
CHECK
fitting to be done.
20-30 ohms.
contactor.
SHUTDOWN
CHECK
fitting to be done.
20-30 ohms.
Relay Range :
(160 - 250)A
RUN CHECK
FLC = 172A
Relay Range :
(160 - 250)A
RUN CHECK
FLC = 209A
Timer should change its
RUN CHECK contact NO / NC as per time
set. Time set 1 sec
Main Hoist Motor should
stop running during
RUN CHECK
hoisting and lowering
operation.
Main Hoist Motor should

RUN CHECK stop running during
hoisting operation.
Master controller
connections should be tight
RUN CHECK
and contacts should be
healthy.
3TF31, 12 A. Proper
contactor.
SHUTDOWN
CHECK
fitting to be done.
20-30 ohms.
Relay Range :
(1 - 1.6)A
RUN CHECK
Relay settings = 1.4A
FLC = 1.0A

SHUTDOWN
ohms.
CHECK
Check for proper allignment
of both sides brake shoes.
Thickness of Brake liner is
SHUTDOWN
12mm. It should not be less
CHECK
than 9 mm. If it is less, then
it should go for
replacement.
3TF31, 12 A. Proper
contactor.
SHUTDOWN
CHECK
fitting to be done.
20-30 ohms.
Relay Range :
(1 - 1.6)A
RUN CHECK
FLC = 1.0A

SHUTDOWN
ohms.
CHECK

SHUTDOWN
CHECK
it should go for
replacement.
SHUTDOWN
ohms.
CHECK
Should be uniform
SHUTDOWN
CHECK
not less than 2mm.

CHECK rating plate.
Power = 37 KW
Rotor Current = 70A

SHUTDOWN
surface at the contact with
CHECK
the slipring.


output terminals.
contactor.
SHUTDOWN
CHECK
fitting to be done.
20-30 ohms.
3TF49, 85 A. Proper
contactor.
SHUTDOWN
CHECK
fitting to be done.
20-30 ohms.
Relay Range :
(70 - 90)A
RUN CHECK
FLC = 70A
Relay Range :
(70 - 90)A
RUN CHECK
FLC = 70A
set. Time set 1 sec
Aux. Hoist Motor should
stop running during
RUN CHECK
hoisting and lowering
operation.
Aux. Hoist Motor should
RUN CHECK stop running during
hoisting operation.
Master controller
RUN CHECK
healthy.
3TF31, 12 A. Proper
contactor.
SHUTDOWN
CHECK
fitting to be done.
20-30 ohms.
Relay Range :
(1 - 1.6)A
RUN CHECK
FLC = 1.0A

SHUTDOWN
ohms.
CHECK

SHUTDOWN
CHECK
it should go for
replacement.
3TF31, 12 A. Proper
contactor.
SHUTDOWN
CHECK
fitting to be done.
20-30 ohms.
Relay Range :
(1 - 1.6)A
RUN CHECK
FLC = 1.0A

SHUTDOWN
ohms.
CHECK

SHUTDOWN
CHECK
it should go for
replacement.

SHUTDOWN
ohms.
CHECK
Should be uniform
SHUTDOWN
CHECK
not less than 2mm.
SHUTDOWN
ohms.
CHECK
Should be uniform
SHUTDOWN
CHECK
not less than 2mm.
Should be uniform
SHUTDOWN
CHECK
not less than 2mm.

CHECK rating plate.
Power = 30 KW
Rotor Current = 68.8A

CHECK rating plate.
Power = 30 KW
CHECK rating plate.
Power = 15 KW

SHUTDOWN
CHECK
the slipring.
SHUTDOWN
CHECK
the slipring.
SHUTDOWN
CHECK
the slipring.



output terminals.
contactor.
SHUTDOWN
CHECK
fitting to be done.
20-30 ohms.
contactor.
SHUTDOWN
CHECK
fitting to be done.
20-30 ohms.
3TF49, 85 A. Proper
contactor.
SHUTDOWN
CHECK
fitting to be done.
20-30 ohms.
3TF49, 85 A. Proper
contactor.
SHUTDOWN
CHECK
fitting to be done.
20-30 ohms.
Relay Range :
(50 - 63)A
RUN CHECK
FLC = 58.4A
Relay Range :
(63-80)A
RUN CHECK
FLC = 68.5A
Relay Range :
(63-80)A
Run check
FLC = 68.5A
Relay Range :
(50 - 63)A
Run check
FLC = 58.4A
set. Time set 1 sec
Motor should stop running
RUN CHECK during limit switch
operation.

output terminals.
3TF47, 63 A. Proper
contactor.
SHUTDOWN
CHECK
fitting to be done.
20-30 ohms.
3TF47, 63 A. Proper
contactor.
SHUTDOWN
CHECK
fitting to be done.
20-30 ohms.
Relay Range :
(40 - 57)A
Run check
FLC = 46.5A
Relay Range :
(25 - 40)A
Run check
FLC = 30.85A
set. Time set 1 sec
Motor should stop running
RUN CHECK during limit switch
operation.
Master controller
RUN CHECK
healthy.
3TF31, 12 A. Proper
contactor.
SHUTDOWN
CHECK
fitting to be done.
20-30 ohms.
Relay Range :
(0.4 - 0.63 ) A
RUN CHECK
FLC = 0.6A

SHUTDOWN
ohms.
CHECK
3TF31, 12 A. Proper
contactor.
SHUTDOWN
CHECK
fitting to be done.
20-30 ohms.
Relay Range :
(0.4 - 0.63 ) A
RUN CHECK
FLC = 0.6A
SHUTDOWN
ohms.
CHECK
3TF31, 12 A. Proper
contactor.
SHUTDOWN
CHECK
fitting to be done.
20-30 ohms.
Relay Range :
(0.4 - 0.63 ) A
RUN CHECK
FLC = 0.6A

SHUTDOWN
CHECK
it should go for
replacement.

SHUTDOWN
CHECK
it should go for
replacement.
3TF31, 12 A. Proper
contactor.
SHUTDOWN
CHECK
fitting to be done.
20-30 ohms.
Relay Range :
(0.4 - 0.63 ) A
RUN CHECK
FLC = 0.6A

SHUTDOWN
ohms.
CHECK

SHUTDOWN
CHECK
it should go for
replacement.
17.04.2018
ACTUAL CONDITION
ACTION REQUIRED
OBSERVED
no cracks
top pully groove damaged top pulley to be changed
pulley damaged from side Snatch box pully to be replaced
no damage
J-hook getting rotated from its

position , locking arrangement J-hook to be replaced
damaged
no damage
no damage
SFU Unit is clean. Fuse taing and
continuity of fuse input / output
terminals are normal
Contactor rating is 3TF68, 630 A. No

looseness in fitting of contactor and
connection of cables to power
Indication lamp indicates input

phase voltage of HMH crane.
CT connections are tight and display
accurate current on the ammeter.
Control transformer connections are

tight. Input and output voltage
measured is 415 / 110 VAC
HMH Crane stop during operation

when limit switch operated.
No abnormal difference in winding

resistances.
Winding resistances of all three are
mega ohms phase to ground and are
in healthy condition.
Throughout Smooth surface of the

ring inspected. Thickness 8mm.
Condition of the resistance plates

and resistance values are in healthy
condition.
Power = 110 KW
Rotor Current = 172A
Throughout Smooth surface and
thickness of the ring seen visually.

links.



Relay Range :
(160 - 250)A
RC = 95A
Relay Range :
(160 - 250)A
RC = 145A
Timer change its contact NO / NC as

per time set. Time set 1 sec
Main Hoist Motor stop running

during hoisting and lowering
operation.
Main Hoist Motor stop running

during hoisting operation.
Master controller connections are

tight and contacts are healthy.

Relay Range :
(1 - 1.6)A
RC = 1.2A

resistances.
ohms. Megger values are 1000 mega
ohms phase to ground and are in
healthy condition.
No any abnormalities found in the
allignment of brake shoe and
decaying of liner. Condition of the
revit is checked weekly which is fitted
4mm gap from liner.

Relay Range :
(1 - 1.6)A
RC = 0.8A

resistances.
healthy condition.

4mm gap from liner.
resistances.


condition.
Power = 37 KW
Rotor Current = 70A


links.


Relay Range :
(70 - 90)A
RC = 39A
Relay Range :
(70 - 90)A
RC = 41.2A

Aux. Hoist Motor stop running

during hoisting and lowering
operation.
Aux. Hoist Motor stop running

during hoisting operation.

Relay Range :
(1 - 1.6)A
RC = 1.2A

resistances.

4mm gap from liner.

Relay Range :
(1 - 1.6)A
RC = 1.2A

resistances.

4mm gap from liner.

resistances.

resistances.



condition.
Power = 30 KW

condition.
Power = 30 KW
condition.
Power = 15 KW




links.

links.

links.



Relay Range :
(50 - 63)A
RC = 36A
Relay Range :
(63-80)A
RC = 36.5A
Relay Range :
(63-80)A
RC = 36.5A
Relay Range :
(50 - 63)A
RC = 36A

Motor stop running during limit

switch operation.


Relay Range :
(40 - 57)A
RC = 25A
Relay Range :
(25 - 40)A
RC = 19A


switch operation.

Relay Range :
(0.4 - 0.63 ) A
RC = 0.6A

resistances.
healthy condition.

Relay Range :
(0.4 - 0.63 ) A
RC = 0.6A
resistances.
healthy condition.

Relay Range :
(0.4 - 0.63 ) A
RC = 0.6A

4mm gap from liner.

4mm gap from liner.
Relay Range :
(0.4 - 0.63 ) A
RC = 0.6A

resistances.
healthy condition.

4mm gap from liner.
CONDITION APPR
BF3-RMHS-C7 Head Drum HEAD DRUM BEARING
BF3-RMHS-C7 Head Drum PLUMMER BLOCK FOR HEAD DRUM
BF3-RMHS-C7 Head snub pulley HEAD END SNUB PULLEY BEARING
BF3-RMHS-C7 Head snub pulley PLUMMER BLOCK FOR HEAD END SNUB PULLEY
BF3-RMHS-C7 GTU BEND PULLEY GTU BEND PULLEY BEARING
BF3-RMHS-C7 GTU BEND PULLEY PLUMMER BLOCK FOR GTU BEND PULLEY
BF3-RMHS-C7 GTU BEND PULLEY GTU BEND PULLEY#2 BEARING
BF3-RMHS-C7 GTU BEND PULLEY PLUMMER BLOCK FOR GTU BEND PULLEY#2
BF3-RMHS-C7 GTU PULLEY GTU PULLEY BEARING
BF3-RMHS-C7 GTU PULLEY PLUMMER BLOCK FOR GTU PULLEY
BF3-RMHS-C7 PRESS DRUM BEARING FOR PRESS DRUM 22312
BF3-RMHS-C7 PRESS DRUM PLUMMER BLOCK FOR PRESS DRUM
BF3-RMHS-C7 TAIL DRUM TAIL DRUM BEARING

BF3-RMHS-C7 TAIL DRUM PLUMMER BLOCK FOR TAIL DRUM
BF3-RMHS-C7 PRESS PULLEY TEND PRESS PULLEY BEARING
BF3-RMHS-C7 INPUT COUPLING TEFLON BUSH - COUPLING PIN
BF3-RMHS-C7 INPUT COUPLING INPUT COUPLING SPIDER OF CONVEYOR 7 -BF3
BF3-RMHS-C7 INPUT COUPLING COUPLING, YOX II Z 500
BF3-RMHS-C7 OUTPUT COUPLING OUTPUT COUPLING
BF3-RMHS-C7 OUTPUT COUPLING Pin bush for coupling
BF3-RMHS-C7 GEARBOX GEAR BOX
RMHS CB#7
BF3-RMHS-C7 RMHS CB#7 Motor Windings
MOTOR DRIVE 1
RMHS CB#7
BF3-RMHS-C7 RMHS CB#7 Terminal Box
MOTOR DRIVE 1
BF3-RMHS-C7 RMHS CB#7 Soft Starter
RMHS CB#7 BELT

PANEL DRIVE 1
BF3-RMHS-C7 RMHS CB#7 Power Contactor
BF3-RMHS-C7 Speed sensor probe
ZERO SPEED
SWITCH
BF3-RMHS-C7 Zero speed device
BF3-RMHS-C7 BELT SWAY BELT SWAY SWITCH
BF3-RMHS-C7 PULL CORD PULL CORD SWITCH
RMHS CB#7
BF3-RMHS-C7 RMHS CB#7 Motor Windings
MOTOR DRIVE 2
RMHS CB#7
BF3-RMHS-C7 RMHS CB#7 Terminal Box
MOTOR DRIVE 2
BF3-RMHS-C7 RMHS CB#7 Soft Starter
RMHS CB#7 BELT

PANEL DRIVE 2
BF3-RMHS-C7 RMHS CB#7 Power Contactor
Relay
BF3-RMHS-C7
DI ,DOCard,PLC , IM modules
SMPS
Profibus Cable
CONDITION APPRAISAL OF CONVEYOR CB#7 (BF3-RMHS-C7)
Item Code SPECIFICATION DESCRIPTION / DIMENSION
0921020076 /BEARING,ROLLER,22232 CHECK FOR BEARING CLEARANCE

CA/W33
0941010128 (PLUMMER BLOCK CNVYR CHECK FOR PHYSICAL DAMAGE AND BOLTS TIGHTNESS
DRUM-TYPE 2, SL NO 1, OF
DRAWING 2220-02404 B)
0921020062 CHECK FOR BEARING CLEARANCE
22224 CA/W33
(PLUMMER BLOCK
5231990093 F/DRUM OF CONVEYOR-SL CHECK FOR PHYSICAL DAMAGE AND BOLTS TIGHTNESS
NO 8, OF DRAWING 2220-
02404 B)
/BEARING BALL 1316
(PLUMMER BLOCK
02404 B)
CHECK FOR BEARING CLEARANCE
CHECK FOR PHYSICAL DAMAGE AND BOLTS TIGHTNESS

/BEARING BALL 21316
(PLUMMER BLOCK
02404 B)
(PLUMMER BLOCK
02404 B)
22224 CA
(PLUMMER BLOCK
02404 B)
/
0921030052 BEARING,22312,SPHERICA CHECK FOR BEARING CLEARANCE
L ROLLER
Ø40XL64-SP, PIN FOR

0806990036 OUTPUT COUPLING OF CHECK FOR BUSH WEAR AND DAMAGE
CONVEYOR GEAR BOX AS
PER DRG NO 2220-
01697B
0804990109 CHECK FOR SPIDER WEAR AND DAMAGE
ф75 ф55 Z0110101176,

0804090056
TYPE: FLUID INPUT SPIDER CHECK FOR PHYSICAL DAMAGE AND BOLTS TIGHTNESS
COUPLING.
0804030060 CHECK FOR PHYSICAL DAMAGE AND BOLTS TIGHTNESS
( UB630)
UB 630
ZSY400-40-IV (90 KW)

current to produce torque. Check for
winding resistance and megger value of
Motor.

To drive the motor smoothly without inrush
flow of current during starting.

contactor terminals. Check for coil
resistance of the contactor.
To detect the speed of the conveyor and

provides a pulse to the zero speed switch.
To detect the stoppage or unacceptably slow

movement of a rotating conveyor tail end
pulley.
For detecting the sway or deviation of belt
conveyors, and sends out an alarm signal
and an emergency stop signal.
Suited to be used for belt breakage and
materials falling prevention due to the belt
sway.
Check rope when operated for safety

tripping switch for conveyor belts. When the
rope is pulled the lever of the pc unit is
operated which in turn, actuates a switch,
thereby the conveyor is stopped.

current to produce torque. Check for
Motor.

To drive the motor smoothly without inrush
flow of current during starting.

contactor terminals. Check for coil
checking healthyness by Run the Belt

Conveyor
checking healthyness by operating DOL

starter of conveyor.

starter of conveyor/ by activating pull cord,
BSS, ZSS and LCS Box.
check supply voltage and output Voltage
checking healthyness by operating valve.

TYPE OF CHECK
(RUN CHECK / STOP
TOOLS REQUIRED IDEAL CONDITION
CHECK /
SHUTDOWN)
SPANNERS AND FILLER STOP CHECK CLEARANCE <0.70MM
GAUGE
NO PHYSICAL DAMAGE AND BOLTS

SPANNERS STOP CHECK SHOULD NOT BE RUSTED

GAUGE


GAUGE


GAUGE
GAUGE


GAUGE


GAUGE

GAUGE
SPANNERS STOP CHECK NO WEAR AND DAMAGE
SPANNERS STOP CHECK NO WEAR AND DAMAGE
SPANNERS STOP CHECK NO DAMAGE
SPANNERS STOP CHECK NO DAMAGE BOLTS NOT RUSTED
Winding Resistances
three phases, i.e., less
Megger & Shut Down than 1 ohms.
Multimeter check Megger values shouldbe
all three phases to
ground.
Shut Down Tightened with spanner

Spanners
check set.
To check for power
Clamp Meter load monitoring and
Shut Down
Screw Drivers drive cooling fan
check
Visual abnormal sound and
vibration.
Motor FLC = 153 A
Spanners, Screw No abnormalities to be
SHUTDOWN
Drivers, Allen Key, seen for the contacts and
CHECK
Multimeter proper fitting to be done.
42-43 ohms.

SHUTDOWN
Visual sensing of the speed of
CHECK
the conveyor.
To check for NO - NC
Multimeter, Screw SHUTDOWN contacts through a relay
Driver CHECK according to Time and
Speed adjustable settings.
To check for healthiness
Multimeter, Screw SHUTDOWN
of NO - NC contacts
Driver CHECK
during operation.

Multimeter, Screw SHUTDOWN
of NO - NC contacts
Driver CHECK
during operation.
Winding Resistances
Megger & Shut Down than 1 ohms.
Multimeter check Megger values shouldbe
all three phases to
ground.
Shut Down Tightened with spanner

Spanners
check set.
To check for power
Clamp Meter load monitoring and
Shut Down
Screw Drivers drive cooling fan
check
Visual abnormal sound and
vibration.
Motor FLC = 153 A
Spanners, Screw No abnormalities to be
SHUTDOWN
Drivers, Allen Key, seen for the contacts and
CHECK
Multimeter proper fitting to be done.
42-43 ohms.

Multimeter,Tester Run check
of cable
Check for healthiness of

Multimeter,Tester Run check NO - NC contacts during
operation.
Multimeter,Tester Run check Physical check

ACTUAL CONDITION ACTION REQUIRED
OBSERVED
No abnormal
difference in winding
resistances. Winding
resistance of all three
phases is 1.8 ohms.
Megger values are
1000 mega ohms and
No looseness of the
bolts and connecting
links.
Power connections
tighteness on the
drive, load checking
and drive cooling fan
vibration and
abnormal sound
checked. No
Running Current =
61.0 A
No looseness in
fitting of contactor
and connection of
cables to power
contactor and its
contacts. Coil
resistance is 42
ohms.
No abnormalities
found in sensing of
speed probe.
No any abnormalities
found in open - close
contacts through
relay during running
of conveyor
according to speed
and time settings.
No abnormalities
found in switching of
contacts during
operation.
No abnormalities
contacts during
operation.
No abnormal
resistances. Winding
resistance of all three
phases is 0.8 ohms.
Megger values are
800 mega ohms and
No looseness of the
links.
Power connections
tighteness on the
drive, load checking
and drive cooling fan
vibration and
abnormal sound
checked. No
Running Current =
100.5 A
No looseness in
fitting of contactor
and connection of
cables to power
contactor and its
contacts. Coil
resistance is 40
ohms.
No abnormalities
found
No abnormalities
contacts during
operation.
No abnormalities
found
No abnormalities
found
No abnormalities
found
BF3-BL-BL1
INLET V/V
BF3-BL-BL1
BF3-BL-BL1
ANTI SURGE V/V
BF3-BL-BL1
BF3-BL-BL1
BLEEDER V/V
BF3-BL-BL1
BF3-BL-BL1
OUTLET V/V
BF3-BL-BL1
BF3-BL-BL1
NRV
BF3-BL-BL1
BF3-BL-BL1
BF3-BL-BL1
SNORT V/V
BF3-BL-BL1
BF3-BL-BL1 HEAT EXCHANGER
BF3-BL-BL1
COUPLINGS
BF3-BL-BL1
BF3-BL-BL1 BLOWER EQUIPMENTS
BF3-BL-BL1 BLOWER EQUIPMENTS

COMMISSIONING
BF3-BL-BL1
SPARES
COMMISSIONING
BF3-BL-BL1
SPARES
MAIN MOTOR- BLOWER

BF3-BL-BL1
1
MAIN MOTOR- BLOWER

BF3-BL-BL1
1
MAIN MOTOR- BLOWER

BF3-BL-BL1
1 HT CABLE
MAIN MOTOR- BLOWER
1 HT PANEL
MAIN MOTOR- BLOWER
1 SOFT STARTER PANEL
BF3-BL-BL1
MAIN MOTOR- BLOWER

1 BYPASS BREAKER
PANEL
MAIN MOTOR- BLOWER
1 OUTLET DISCHARGE
VALVE MOTOR
MAIN MOTOR- BLOWER
1 OUTLET DISCHARGE
VALVE MOTOR
MAIN MOTOR- BLOWER

1 OUTLET DISCHARGE
VALVE PANEL
MAIN MOTOR- BLOWER

1 OUTLET DISCHARGE
VALVE PANEL
MAIN MOTOR- BLOWER

1 OUTLET DISCHARGE
VALVE PANEL
MAIN MOTOR- BLOWER

1 INLET VALVE MOTOR
MAIN MOTOR- BLOWER

1 INLET VALVE MOTOR
MAIN MOTOR- BLOWER

1 INLET VALVE PANEL
MAIN MOTOR- BLOWER

1 INLET VALVE PANEL
MAIN MOTOR- BLOWER

1 BLEED VALVE MOTOR
MAIN MOTOR- BLOWER
1 BLEED VALVE MOTOR
MAIN MOTOR- BLOWER

1 BLEED VALVE PANEL
MAIN MOTOR- BLOWER

1 BLEED VALVE PANEL
BLOWER #1 LUBE OIL

PUMP #1 Motor
BLOWER #1 LUBE OIL

PUMP #1 Motor
BLOWER #1 LUBE OIL

PUMP #1 Panel
BLOWER #1 LUBE OIL

PUMP #1 Panel
BLOWER #1 LUBE OIL

PUMP #1 Panel
BLOWER #1 LUBE OIL

PUMP #2 Motor
BLOWER #1 LUBE OIL

PUMP #2 Motor
BLOWER #1 LUBE OIL
PUMP 2 Panel
BLOWER #1 LUBE OIL

PUMP #2 Panel
BLOWER #1 LUBE OIL

PUMP #2 Panel
Blower #1Barring Gear

Motor

Motor

Motor

Panel
BLOWER #1 MOTOR
SPACE HEATER
COMPONENT Item Code SPECIFICATION
INLET VALVE FOR BLOWER DN 1400 (IVC) 5044810037

ACTUATOR FOR INLET VALVE FOR
DN 1400
BLOWER
ANTISURGE VALVE 5044810033 DN 400
ACTUATOR FOR ANTISURGE VALVE DN 400
BLEEDER VALVE FOR BLOWER DN 450 5044810036

ACTUATOR FOR BLEEDER VALVE FOR
DN 450
BLOWER
OUTLET VALVE FOR BLOWER 5044810034 DN 1000
ACTUATOR FOR OUTLET VALVE FOR
BLOWER
NON RETURN VALVE FOR BLOWER 5044810035 DN 1000
ACTUATOR FOR NON RETURN VALVE
FOR BLOWER
SNORT VALVE 5109000051 DN 1000 ASSEMBLY
ACTUATOR FOR SNORT VALVE
GEAR BOX FOR SNORT VALVE ACTUATOR 5088110165
HEAT EXCHANGER FOR BLOWER OIL

COOLING
PIN-BUSH F/BLOWER OUTPUT COUPLING 0804030095 HS6280
PIN-BUSH F/BLOWER INPUT COUPLING 0804030096 HB1520
3WAY VALVE FOR BLOWER OIL STATION 7129030107
BARRING GEAR ASSEMBLY 5961010011

BLOWER BEARING DE
BLOWER BEARING NDE
HT Motor Windings
Terminal Box
HT CABLES
HT PANEL BUSBARS
HT PANEL EARTH SWITCH
HT PANEL EARTHING
HT PANEL SPACE HEATER

VERTICAL INSULATOR
HT BREAKER

HT CABLES
CURRENT TRANSFORMER
HT PANEL BUSBARS
HT PANEL EARTHING

VERTICAL INSULATOR
HT SOFTSTARTER
HT CABLES
CURRENT TRANSFORMER
HT PANEL BUSBARS
HT PANEL BUSBARS
HT PANEL EARTHING

VERTICAL INSULATOR
HT BREAKER
HT CABLES
CURRENT TRANSFORMER
LT Motor Windings
Terminal Box
Power Contactor
Overload Relay
Internal OPEN / CLOSE Limit Switch 10 A
LT Motor Windings
Terminal Box
Power Contactor
LT Motor Windings
Terminal Box
Power Contactor
LT Motor Windings
Terminal Box
BLOWER #1 LUBE OIL PUMP #1

CONTACTOR

OVERLOAD RELAY

AUXILIARY CONTACTOR
LT Motor Windings
Terminal Box
CONTACTOR

OVERLOAD RELAY

AUXILIARY CONTACTOR
LT Motor Windings
Terminal Box
Blower Barring gear Engage /

10 A
Disengage Lever type Limit Switch
BLOWER #1 BARRING GEAR MOTOR

CONTACTOR
BLOWER #1 BARRING GEAR MOTOR

SOFTSTARTER
BLOWER #1 MOTOR SPACE HEATER

CONTACTOR
CONDITION APPRAISAL OF BLOWER#1
TYPE OF CHECK
(RUN CHECK /
STOP CHECK /
SHUTDOWN)
CHECK FOR VALVE BODY AND
SPANNERS STOP CHECK
DISC DAMAGE
CHECK FOR OPERATION OF
VISUAL RUN CHECK
ACTUATOR BY OPERATING
SPANNERS STOP CHECK
DISC DAMAGE
VISUAL RUN CHECK
SPANNERS STOP CHECK
DISC DAMAGE
VISUAL RUN CHECK
SPANNERS STOP CHECK
DISC DAMAGE
VISUAL RUN CHECK
SPANNERS STOP CHECK
DISC DAMAGE
VISUAL RUN CHECK
SPANNERS STOP CHECK
DISC DAMAGE
VISUAL RUN CHECK
CHECK FOR PHYSICAL DAMAGE
VISUAL STOP CHECK
OF GEARBOX AND BOLTS
CHECK FOR THE PRESSURE AND

TEMPERATURE AT INLET AND VISUAL RUN CHECK
OUTLET OF OIL AND WATER

SPANNERS STOP CHECK
OF COUPLING AND PIN BUSH

SPANNERS STOP CHECK
OF COUPLING AND PIN BUSH
CHECK FOR OPERATION AND
VISUAL RUN CHECK
LEAKAGE OF VALVE
CHECK FOR OIL LEVEL OF
BARRING GEAR ASSEMBLY BY SPANNERS STOP CHECK
OPENING
CHECK FOR BEARING
WITH SPANNER STOP CHECK
CLEARANCE
CHECK FOR BEARING
WITH SPANNER STOP CHECK
CLEARANCE
Megger &
torque. Check for winding Shut Down check
Multimeter
resistance and megger value of
Motor.
Check for TAN DELTA of the TAN-DELTA TEST
SHUTDOWN CHECK
motor. KIT

Spanners Shut Down check

SPANNERS /
power cable and HT Breaker SHUTDOWN CHECK
TORQUE WRENCH
Terminals.
SHUTDOWN CHECK
MEGGER
SHUTDOWN CHECK
Check for partial discharge test of HT TAN-DELTA TEST

SHUTDOWN CHECK
Cable for HT Cable insualtion testing. KIT

busbar and busbar support insulator. It SPANNERS /
SHUTDOWN CHECK
should have sufficient stiffness to be TORQUE WRENCH
supported in air by insulated pillars.
Check for proper cleanliness of the

busbar insulator and panel body. It
should be generally uninsulated, and VISUAL / COTTON
SHUTDOWN CHECK
should be proper insulation between CLOTHE
busbar and switchgear panel through
busbar insualtor.
Check for megger value of Busbar
HT MEGGER SHUTDOWN CHECK
and panel body.

switch and HT Breaker. Also, check
VISUAL SHUTDOWN CHECK
for interlocking of earth switch and
panel back door.
Check for earthing of the Panel body. VISUAL RUN CHECK

Check for Oxydation of busbars and
LEAKAGE TESTER RUN CHECK
insulators due to moisture content.
Check for high electrical &

mechanical strength used in electrical
panels to support the copper busbar. VISUAL SHUTDOWN CHECK
Check for megger value between
insulator and panel body.
VISUAL, COTTON
CLOTHE, CRC,
damage caused by excess current
DIELECTRIC
from an overload or short circuit. Its SHUTDOWN CHECK
ISOPLEX & SHELL
basic function is to interrupt current
TELLUS 32 GREASE,
flow after a fault is detected.
HT MEGGER
To detect the fault and initiates the SECONDARY

operation of circuit breaker to isolate INJECTION
SHUTDOWN CHECK
the defective element from the rest of CURRENT AND
the system. VOLTAGE TEST KIT
SPANNERS /
TORQUE WRENCH
Terminals.

MEGGER SHUTDOWN CHECK

SHUTDOWN CHECK
Check for tighteness of connections

VISUAL /
and measure the correct voltage and
SECONDARY
indication shown in the meter.
INJECTION SHUTDOWN CHECK
CURRENT AND
Numerical Relay by Secondary
VOLTAGE TEST KIT
Injection kit.

VISUAL /
and measure the correct current
SECONDARY
shown in the meter.
CURRENT AND
VOLTAGE TEST KIT
Injection kit.

SHUTDOWN CHECK

SHUTDOWN CHECK
busbar insualtor.
and panel body.
VISUAL RUN CHECK
panel back door.
Check for earthing of the Panel body. LEAKAGE TESTER RUN CHECK
damage caused by excess current VISUAL, COTTON
from an overload or short circuit. Its CLOTHE, SHUTDOWN CHECK
basic function is to interrupt current MULTIMETER
SHUTDOWN CHECK
SPANNERS /
TORQUE WRENCH
Terminals.


SHUTDOWN CHECK

VISUAL /
SECONDARY
CURRENT AND
VOLTAGE TEST KIT
Injection kit.

VISUAL /
SECONDARY
shown in the meter.
CURRENT AND
VOLTAGE TEST KIT
Injection kit.

SHUTDOWN CHECK
SHUTDOWN CHECK
busbar insualtor.
and panel body.

panel back door.
Check for earthing of the Panel body. VISUAL RUN CHECK

LEAKAGE TESTER RUN CHECK

VISUAL, COTTON
CLOTHE, CRC,
DIELECTRIC
from an overload or short circuit. Its SHUTDOWN CHECK
ISOPLEX & SHELL
TELLUS 32 GREASE,
HT MEGGER
TELLUS 32 GREASE,
HT MEGGER

SHUTDOWN CHECK
SPANNERS /
TORQUE WRENCH
Terminals.


SHUTDOWN CHECK

VISUAL /
SECONDARY
CURRENT AND
VOLTAGE TEST KIT
Injection kit.

VISUAL /
SECONDARY
shown in the meter.
CURRENT AND
VOLTAGE TEST KIT
Injection kit.

energized with current to
Megger &
produce torque. Check for Shut Down check
Multimeter
winding resistance and megger
value of Motor.
the power cable to the LT Motor

Spanners, Screw
tighteness of contactor SHUTDOWN
Drivers, Allen Key,
terminals. Check for coil CHECK
Multimeter
Check for overload relay range

SHUTDOWN
and setting of relay current for Visual
CHECK
motor tripping.
Check for switching NO / NC

VISUAL /
Contact as per set value during RUN CHECK
MULTIMETER
hoisting operation.

Megger &
Multimeter
value of Motor.


Spanners, Screw
Drivers, Allen Key,
Multimeter

VISUAL /
MULTIMETER
hoisting operation.
Megger &
Multimeter
value of Motor.

Spanners, Screw
Drivers, Allen Key,
Multimeter

VISUAL /
MULTIMETER
hoisting operation.
Megger &
Multimeter
value of Motor.


Spanners, Screw
Drivers, Allen Key, SHUTDOWN CHECK
Multimeter
contactor.

setting of relay current for motor Visual RUN CHECK
tripping.
The auxiliary contactor is often used

in a logic circuit, or for some other Visual SHUTDOWN CHECK
part of the control scheme.

Megger &
Multimeter
value of Motor.

Spanners, Screw
Multimeter
contactor.

setting of relay current for motor Visual SHUTDOWN CHECK
tripping.
The auxiliary contactor is often used

in a logic circuit, or for some other Visual SHUTDOWN CHECK

Megger &
Multimeter
value of Motor.


VISUAL /
MULTIMETER
hoisting operation.

Spanners, Screw
Multimeter
contactor.
Softstarter is a device which controls

the acceleration of an electric motor Cotton clothe,
SHUTDOWN CHECK
by means of controlling the applied spanners, Screw driver
voltage.

Spanners, Screw
Multimeter
contactor.
IDEAL CONDITION
NO DAMAGE IN DISC AND BODY OF VALVE

SHOULD BE OPERATION SMOOTHLY WITHIN
OPEN AND CLOSE LIMITS
NO DAMAGE IN DISC AND BODY O VALVE
NO PHYSICAL DAMAGE AND NO RUSTED BOLTS
INLET TEMP <30*C, OUT LET TEMP <45*C WATER,
SHOULD BE OPERATIONG WITHIN RANGE AND

NO LEAKGE
OIL SHOULD BE WITHIN INDICATED LIMIT

CLEARANCE <0.15MM
CLEARANCE <0.15MM

three phases, i.e., less than 5 ohms.
Megger values shouldbe above 5 megaohms from
TAN-DELTA test of HT Motor should be < 0.04

absolute.
Tightened with 16mm Chrome Vanadium Bolts.
Tightened with 12mm high tensile stainless steel bolts

with flat washers and nuts by Torque Wrench.
Insulation resistance between Phase to Phase should be

> 20 Mega Ohms
Insulation resistance between Phase to Earth should be
> 20 Mega Ohms
TAN-DELTA test of HT Cable should be < 0.004

absolute.

Insulators should be installed properly to hold and

support busbars. Insulators should be clean.
Resistance between panel to busbar should be ˃ 20

mega ohms.
Interlock of Earth Switch and HT Breaker should be
healthy. HT Breaker should not Rack In during Earth
Switch operated condition. Also, Back Door of HT
Panel should not be open when earth switch is not
operated.
Earthing should be healthy.

No oxydation and moisture inside panel. Space Heater
current should be < 1 A
Vertical and Horizontal insulators should provide high

electrical and mechanical strength to the busbars. Also,
megger value should be ˃ 20 mega Ohms.
HT Breaker should be clean. There should not be any

moisture or wear and rusting of contacts.
Proper lubrication of all moving parts of mechanism.
Proper operation of gear box mechanism.
Proper operation of Test / Service auxiliary switch
operation.
Proper closing and tripping mechanism of breaker both
electrically and manually.
Proper spring charging operation of limit switch.
Condition of contact arm assembly of breaker should
be proper.
Vacuum inside bottles should be normal.
Insulation resistance between Upper & Lower contacts
should be > 1 T Ohms
> 1 T Ohms
> 1 T Ohms
Timing of CB during Close should be in ms of all three
phases.
Timing of CB during Open should be in ms of all three
phases.
Timing of CB during Close / Open should be in ms of
all three phases.
Contact Resistance between Upper and Lower contacts

should be in micro ohms of all three phases.
HVAC Test for 15 KV should withstand for min. of all

three phases.
HT Breaker Numerical Relay tripping should be

healthy to trip the breaker on the faults described in the
relay on prescribed values.

> 20 Mega Ohms
> 20 Mega Ohms

absolute.
PT connections should be tight and should

1. measure correct voltage on the relay or meter.
2. provide indication of voltage on the panel.
3. trip the HT Breaker through HT Relay on Over
voltage / Under Voltage.
CT connections should be tight and should

1. measure current accurately on the relay or meter.
curent / CIR / ITOC / DMT.



mega ohms.

HT Softstarter should be clean. There should not be any

Thyristors Resistances of all three phases of HT
Softstarter should be in 2 digit nos.



> 20 Mega Ohms
> 20 Mega Ohms

absolute.




mega ohms.
Interlock of Earth Switch and HT Breaker should be
healthy. HT Breaker should not Rack In during Earth
Panel should not be open when earth switch is not
operated.


HT Breaker should be clean. There should not be any

Proper lubrication of all moving parts of mechanism.
Proper operation of Test / Service auxiliary switch
operation.
Proper closing and tripping mechanism of breaker both
Proper spring charging operation of limit switch.
Condition of contact arm assembly of breaker should
be proper.
Insulation resistance between Upper & Lower contacts
> 1 T Ohms
> 1 T Ohms
Timing of CB during Close should be in ms of all three
phases.
Timing of CB during Open should be in ms of all three
phases.
Timing of CB during Close / Open should be in ms of
all three phases.
Contact Resistance between Upper and Lower contacts

should be in micro ohms of all three phases.
HVAC Test for 15 KV should withstand for min. of all

three phases.



> 20 Mega Ohms
> 20 Mega Ohms

absolute.



Megger values shouldbe above 5 megaohms
Tightened with 10 mm Chrome Vanadium
Bolts.
Proper tighteness of foundation of contactor.

and proper fitting to be done.
Coil resistance should be between 20 ohms -
30 ohms.
Relay settings:
Relay Range = 4-10A
Relay setting = 6.4A
Motor should stop running during limit switch

operation.


Bolts.

Coil resistance should be between 15 ohms - 30
ohms.

operation.

Bolts.

Coil resistance should be between 15 ohms - 30
ohms.

operation.


Bolts.
Contactor rarting to be 32A. Proper tighteness of

No abnormalities to be seen for the contacts and
proper fitting to be done.
Relay Range :
23 A - 32 A
FLC = 27.5A
The auxiliary contctactor is used to provide tripping

indication whenever the lube oil pump will trip or
power fails.


Bolts.
Relay Range :
23 A - 32 A
FLC = 27.5A
The auxiliary contctactor is used to provide tripping

indication whenever the lube oil pump will trip or
power fails.


Bolts.

operation.

Softstarter should clean. Check the tighteness of the

power and control cable.

ACTION
ACTUAL CONDITION OBSERVED
REQUIRED
resistances. Winding resistance of all three
phases is 0.7 ohms. Megger values are 2 Giga
ohms and in healthy condition.
TAN-DELTA test of HT Motor is 0.0028
No looseness of 16 mm Chrome Vanadium

bolts and connecting links.
No looseness of the bolts and connecting links

checked by torque wrench.
Insulation resistance between Phase to Phase is

1000 Ohms
Insulation resistance between Phase to Earth is
1000Mega Ohms
TAN-DELTA test of HT Cable is 0.0018

Insulators were installed properly and was clean.

No oxydation observed between insulator and
bubar.
Resistance between panel to busbar is 1000 mega

ohms.
Interlock of Earth Switch and HT Breaker is
healthy. HT Breaker do not Rack In during Earth
Panel has not been open when earth switch is not
operated.
Earthing is connected to the body and to the Earth
Pit.
No oxydation and moisture inside panel. Space
Heater current is 0.3 A
Vertical and Horizontal insulators strength to the

busbars are good. Also, megger value is 1000 mega
Ohms.
HT Breaker found clean. There is no moisture or

wear and rusting of contacts.
Lubrication of all moving parts of mechanism is
normal.
Operation of gear box mechanism is normal.
Operation of Test / Service auxiliary switch
operation is proper.
Closing and tripping mechanism of breaker both
electrically and manually is proper.
Spring charging operation of limit switch is
normal.
Condition of contact arm assembly of breaker is
proper.
Vacuum inside bottles is normal.
Insulation resistance between Upper & Lower
contacts is > 1 T Ohms
Insulation resistance between Phase to Phase is > 1
T Ohms
Insulation resistance between Phase to Earth is > 1
T Ohms
Timing of CB during Close is 48 ms of all three
phases.
Timing of CB during Open is 41 ms of all three
phases.
Timing of CB during Close / Open is 21 ms of all
three phases.
Contact Resistance between Upper and Lower

contacts is 45 micro ohms of all three phases.
HVAC Test for 15 KV withstand for min. of all

three phases.
HT Breaker Numerical Relay tripping is healthy to

trip the breaker on the faults described in the relay
on prescribed values.

1100 Ohms
1000Mega Ohms
PT connections are tight and display correct

voltage on the relay. Indication of voltage on the
panel is shown. Trippig of the HT Breaker through
HT Relay on Over voltage / Under Voltage is
healthy.
CT connections are tight and display accurate

current on the relay. Trippig of the HT Breaker
through HT Relay on Over curent / CIR / ITOC /
DMT is healthy.


bubar.

ohms.

Pit.

Ohms.
HT Softstarter found clean. There is no moisture or

All thyristors resistances are in double digit nos.
between 11 to 13 ohms.



1000 Ohms
1000Mega Ohms

healthy.

DMT is healthy.

bubar.

ohms.
healthy. HT Breaker do not Rack In during Earth
Panel has not been open when earth switch is not
operated.
Pit.


Ohms.
HT Breaker found clean. There is no moisture or

Lubrication of all moving parts of mechanism is
normal.
Closing and tripping mechanism of breaker both
electrically and manually is proper.
normal.
Condition of contact arm assembly of breaker is
proper.
Insulation resistance between Phase to Phase is > 1
T Ohms
Insulation resistance between Phase to Earth is > 1
T Ohms
Timing of CB during Close is 48 ms of all three
phases.
Timing of CB during Open is 41 ms of all three
phases.
Timing of CB during Close / Open is 21 ms of all
three phases.


three phases.



1100 Ohms
1000Mega Ohms

healthy.

DMT is healthy.

phases is 7.1 ohms. Megger values are 500
mega ohms and in healthy condition.
No looseness in fitting of contactor and

connection of cables to power contactor
and its contacts. Coil resistance of
Inspected Relay Range = 4-10A

Motor stop running during limit switch

operation.




operation.



operation.

phases is 9.5 ohms. Megger values are
1000 mega ohms and in healthy condition.

Contactor rarting is 32A. No looseness in fitting of

contactor and connection of cables to power
contactor and its contacts. Coil resistance is 39
ohms.

23 A - 32 A
RC = 12.2A
Indication for tripping of lube oil pump is healthy.


contactor and its contacts. Coil resistance is 39.5
ohms.

23 A - 32 A
RC = 14.2A
Indication for tripping of lube oil pump is healthy.



operation.

contactor and its contacts. Coil resistance is 41
ohms.
Softstarter is clean. Tighteness of the power and

control cable is normal.

contactor and its contacts. Coil resistance is 29.2
ohms.
Equipment Sub Equipments COMPONENT
INLET VALVE FOR BLOWER DN

1400 (IVC)
INLET V/V
ACTUATOR FOR INLET VALVE
FOR BLOWER
ANTISURGE VALVE
ANTI SURGE V/V ACTUATOR FOR ANTISURGE
VALVE
BLEEDER VALVE FOR BLOWER
DN 450
BLEEDER V/V
ACTUATOR FOR BLEEDER VALVE
FOR BLOWER
OUTLET VALVE FOR BLOWER
OUTLET V/V ACTUATOR FOR OUTLET VALVE
FOR BLOWER
NON RETURN VALVE FOR
BLOWER
NRV
ACTUATOR FOR NON RETURN
VALVE FOR BLOWER
SNORT VALVE
ACTUATOR FOR SNORT VALVE
SNORT V/V
GEAR BOX FOR SNORT VALVE
ACTUATOR
HEAT EXCHANGER HEAT EXCHANGER FOR BLOWER

OIL COOLING
PIN-BUSH F/BLOWER OUTPUT
COUPLING
COUPLINGS
PIN-BUSH F/BLOWER INPUT
COUPLING
3WAY VALVE FOR BLOWER OIL
BLOWER EQUIPMENTS STATION
BLOWER EQUIPMENTS BARRING GEAR ASSEMBLY
COMMISSIONING SPARES BLOWER BEARING DE
COMMISSIONING SPARES BLOWER BEARING NDE
MAIN MOTOR- BLOWER
HT Motor Windings
2
MAIN MOTOR- BLOWER

Terminal Box
2
MAIN MOTOR- BLOWER

HT CABLES
2 HT CABLE
HT PANEL BUSBARS
HT PANEL EARTHING

HT PANEL BUSBAR
HORIZONTAL AND
VERTICAL INSULATOR
HT BREAKER
MAIN MOTOR-
BLOWER 2 HT PANEL
HT NUMERICAL
PROTECTIVE RELAY
HT CABLES
CURRENT TRANSFORMER
HT PANEL BUSBARS
HT PANEL EARTHING
HT PANEL BUSBAR
HORIZONTAL AND
VERTICAL INSULATOR
HT SOFTSTARTER
MAIN MOTOR-
BLOWER 2 SOFT HT NUMERICAL
STARTER PANEL PROTECTIVE RELAY
HT CABLES
CURRENT TRANSFORMER
BF3-BL-BL2
HT PANEL BUSBARS
HT PANEL EARTHING
HT PANEL BUSBAR
HORIZONTAL AND
VERTICAL INSULATOR
HT BREAKER
MAIN MOTOR-
BLOWER 2 BYPASS
BREAKER PANEL
HT NUMERICAL
PROTECTIVE RELAY
HT CABLES
CURRENT TRANSFORMER
MAIN MOTOR-
BLOWER 2 OUTLET
DISCHARGE VALVE
LT Motor Windings
MOTOR
MAIN MOTOR-
BLOWER 2 OUTLET
DISCHARGE VALVE
Terminal Box
MOTOR
MAIN MOTOR-
BLOWER 2 OUTLET
DISCHARGE VALVE
Power Contactor
PANEL
MAIN MOTOR-
BLOWER 2 OUTLET
DISCHARGE VALVE
Overload Relay
PANEL
MAIN MOTOR-
BLOWER 2 OUTLET Internal OPEN / CLOSE
DISCHARGE VALVE Limit Switch
PANEL
MAIN MOTOR-
BLOWER 2 INLET LT Motor Windings
VALVE MOTOR
MAIN MOTOR-
BLOWER 2 INLET Terminal Box
VALVE MOTOR
MAIN MOTOR-
BLOWER 2 INLET Power Contactor
VALVE PANEL
MAIN MOTOR-
Internal OPEN / CLOSE
BLOWER 2 INLET
VALVE PANEL Limit Switch
MAIN MOTOR-
BLOWER 2 BLEED LT Motor Windings
VALVE MOTOR
MAIN MOTOR-
BLOWER 2 BLEED Terminal Box
VALVE MOTOR
MAIN MOTOR-
BLOWER 2 BLEED Power Contactor
VALVE PANEL
MAIN MOTOR-
Internal OPEN / CLOSE
BLOWER 2 BLEED
BLOWER #2 LUBE OIL

PUMP #2 Motor
LT Motor Windings
BLOWER #2 LUBE OIL

PUMP #2 Motor
Terminal Box
BLOWER #2 LUBE OIL BLOWER #2 LUBE OIL PUMP

PUMP 2 Panel #2 CONTACTOR

PUMP #2 Panel #2 OVERLOAD RELAY

PUMP #2 Panel #2 AUXILIARY CONTACTOR
Blower #2 Barring Gear
Motor
LT Motor Windings
Blower #2 Barring Gear

Motor
Terminal Box
Blower #2 Barring Gear BLOWER #2 BARRING GEAR

Motor MOTOR CONTACTOR
Blower Barring gear

Blower #2 Barring Gear Engage / Disengage Lever
type Limit Switch
Blower #2 Barring Gear BLOWER #2 BARRING GEAR

Panel MOTOR SOFTSTARTER
BLOWER #2 MOTOR BLOWER #2 MOTOR SPACE

SPACE HEATER HEATER CONTACTOR
CON
Item Code SPECIFICATION
5044810037
DN 1400
5044810033 DN 400
DN 400
5044810036
DN 450
5044810034 DN 1000
5044810035
DN 1000
5109000051 DN 1000 ASSEMBLY
5088110165
0804030095 HS6280
0804030096 HB1520
7129030107
5961010011
10 A
10 A
10 A
10 A
CONDITION APPRAISAL OF BLOWER#2
CHECK FOR VALVE BODY AND DISC DAMAGE SPANNERS
CHECK FOR OPERATION OF ACTUATOR BY OPERATING VISUAL



CHECK FOR PHYSICAL DAMAGE OF GEARBOX AND BOLTS VISUAL

CHECK FOR THE PRESSURE AND TEMPERATURE AT INLET AND OUTLET
OF OIL AND WATER VISUAL
CHECK FOR PHYSICAL DAMAGE OF COUPLING AND PIN BUSH SPANNERS
CHECK FOR PHYSICAL DAMAGE OF COUPLING AND PIN BUSH SPANNERS
CHECK FOR OPERATION AND LEAKAGE OF VALVE VISUAL

CHECK FOR OIL LEVEL OF BARRING GEAR ASSEMBLY BY OPENING SPANNERS
CHECK FOR BEARING CLEARANCE WITH SPANNER
CHECK FOR BEARING CLEARANCE WITH SPANNER
To form magnetic field when energized with current to
produce torque. Check for winding resistance and Megger & Multimeter
Check for TAN DELTA of the motor. TAN-DELTA TEST KIT
Check for proper tigteness of the power cable to the HT

Spanners
Motor
Check for proper tigteness of the power cable and HT SPANNERS / TORQUE
Breaker Terminals. WRENCH
Check for megger value of HT Cable phase to phae and

MEGGER
phase to earth.
Check for partial discharge test of HT Cable for HT Cable

TAN-DELTA TEST KIT
insualtion testing.
Check for proper tigteness of the busbar and busbar support
SPANNERS / TORQUE
insulator. It should have sufficient stiffness to be supported
WRENCH
in air by insulated pillars.
Check for proper cleanliness of the busbar insulator and
panel body. It should be generally uninsulated, and should VISUAL / COTTON
be proper insulation between busbar and switchgear panel CLOTHE
through busbar insualtor.
Check for megger value of Busbar and panel body. HT MEGGER
Check for proper interlocking of earth switch and HT

Breaker. Also, check for interlocking of earth switch and VISUAL
panel back door.
Check for earthing of the Panel body. VISUAL
Check for Oxydation of busbars and insulators due to

LEAKAGE TESTER
moisture content.
Check for high electrical & mechanical strength used in
electrical panels to support the copper busbar. Check for VISUAL
megger value between insulator and panel body.
VISUAL, COTTON
To protect an electrical circuit from damage caused by CLOTHE, CRC,
excess current from an overload or short circuit. Its basic DIELECTRIC ISOPLEX
function is to interrupt current flow after a fault is detected. & SHELL TELLUS 32
GREASE, HT MEGGER
SECONDARY
To detect the fault and initiates the operation of circuit
INJECTION CURRENT
breaker to isolate the defective element from the rest of the
AND VOLTAGE TEST
system.
KIT

MEGGER
phase to earth.

TAN-DELTA TEST KIT
insualtion testing.
Check for tighteness of connections and measure the correct VISUAL / SECONDARY
voltage and indication shown in the meter. INJECTION CURRENT
Also, check for tripping of the HT Numerical Relay by AND VOLTAGE TEST
Secondary Injection kit. KIT
current shown in the meter. INJECTION CURRENT

SPANNERS / TORQUE
WRENCH

panel back door.
Check for earthing of the Panel body. LEAKAGE TESTER

To protect an electrical circuit from damage caused by VISUAL, COTTON
excess current from an overload or short circuit. Its basic CLOTHE,
function is to interrupt current flow after a fault is detected. MULTIMETER
SECONDARY
INJECTION CURRENT
AND VOLTAGE TEST
system.
KIT

MEGGER
phase to earth.

TAN-DELTA TEST KIT
insualtion testing.

SPANNERS / TORQUE
WRENCH

panel back door.
Check for Oxydation of busbars and insulators due to

LEAKAGE TESTER
moisture content.

VISUAL, COTTON
To protect an electrical circuit from damage caused by CLOTHE, CRC,
excess current from an overload or short circuit. Its basic DIELECTRIC ISOPLEX
function is to interrupt current flow after a fault is detected. & SHELL TELLUS 32
GREASE, HT MEGGER
SECONDARY
INJECTION CURRENT
AND VOLTAGE TEST
system.
KIT

MEGGER
phase to earth.

TAN-DELTA TEST KIT
insualtion testing.

current to produce torque. Check for winding Megger & Multimeter
Spanners
the LT Motor


Visual

value during hoisting operation. MULTIMETER


Spanners
the LT Motor



Spanners
the LT Motor




Spanners
the LT Motor
Check for contactor rating and tighteness of contactor Spanners, Screw Drivers,
terminals. Check for coil resistance of the contactor. Allen Key, Multimeter
Check for overload relay range and setting of relay current

Visual
for motor tripping.
The auxiliary contactor is often used in a logic circuit, or for

Visual
some other part of the control scheme.

Spanners
the LT Motor

Softstarter is a device which controls the acceleration of an Cotton clothe, spanners,

electric motor by means of controlling the applied voltage. Screw driver
OWER#2
TYPE OF CHECK (RUN CHECK / IDEAL CONDITION

STOP CHECK / SHUTDOWN)
NO DAMAGE IN DISC AND BODY OF VALVE

STOP CHECK
SHOULD BE OPERATION SMOOTHLY WITHIN OPEN
RUN CHECK AND CLOSE LIMITS
STOP CHECK NO DAMAGE IN DISC AND BODY O VALVE

STOP CHECK

STOP CHECK

AND CLOSE LIMITS
RUN CHECK

STOP CHECK
INLET TEMP <30*C, OUT LET TEMP <45*C WATER,

RUN CHECK

STOP CHECK

STOP CHECK
SHOULD BE OPERATIONG WITHIN RANGE AND NO
RUN CHECK LEAKGE
STOP CHECK OIL SHOULD BE WITHIN INDICATED LIMIT
Winding Resistances should be balanced
of all three phases, i.e., less than 5 ohms.
Shut Down check Megger values shouldbe above 5
megaohms from all three phases to
ground.
TAN-DELTA test of HT Motor should be <

SHUTDOWN CHECK
0.04 absolute.
Tightened with 16mm Chrome

Shut Down check
Vanadium Bolts.
Tightened with 12mm high tensile stainless

SHUTDOWN CHECK steel bolts with flat washers and nuts by
Torque Wrench.
Insulation resistance between Phase to Phase
SHUTDOWN CHECK
should be > 20 Mega Ohms
Insulation resistance between Phase to Earth

SHUTDOWN CHECK
TAN-DELTA test of HT Cable should be <

SHUTDOWN CHECK
0.004 absolute.
Torque Wrench.
Insulators should be installed properly to

SHUTDOWN CHECK hold and support busbars. Insulators should
be clean.
Resistance between panel to busbar should

SHUTDOWN CHECK
be ˃ 20 mega ohms.
Interlock of Earth Switch and HT Breaker
should be healthy. HT Breaker should not
Rack In during Earth Switch operated
SHUTDOWN CHECK
condition. Also, Back Door of HT Panel
should not be open when earth switch is not
operated.
RUN CHECK Earthing should be healthy.
No oxydation and moisture inside panel.

RUN CHECK
Space Heater current should be < 1 A
Vertical and Horizontal insulators should
provide high electrical and mechanical
SHUTDOWN CHECK
strength to the busbars. Also, megger value
should be ˃ 20 mega Ohms.
HT Breaker should be clean. There should
not be any moisture or wear and rusting of
contacts.
Proper lubrication of all moving parts of
mechanism.
Proper operation of Test / Service auxiliary
switch operation.
Proper closing and tripping mechanism of
breaker both electrically and manually.
Proper spring charging operation of limit
switch.
Condition of contact arm assembly of
breaker should be proper.
SHUTDOWN CHECK Insulation resistance between Upper &
Lower contacts should be > 1 T Ohms
Timing of CB during Close should be in ms
of all three phases.
Timing of CB during Open should be in ms
Timing of CB during Close / Open should
be in ms of all three phases.
Contact Resistance between Upper and
Lower contacts should be in micro ohms of
all three phases.
HVAC Test for 15 KV should withstand for
min. of all three phases.
HT Breaker Numerical Relay tripping
should be healthy to trip the breaker on the
SHUTDOWN CHECK
faults described in the relay on prescribed
values.
Torque Wrench.
SHUTDOWN CHECK
SHUTDOWN CHECK
0.004 absolute.

1. measure correct voltage on the relay or
meter.
SHUTDOWN CHECK
3. trip the HT Breaker through HT Relay on
Over voltage / Under Voltage.

1. measure current accurately on the relay or
SHUTDOWN CHECK meter.
Over curent / CIR / ITOC / DMT.

Torque Wrench.

be clean.

SHUTDOWN CHECK
be ˃ 20 mega ohms.

RUN CHECK
SHUTDOWN CHECK
HT Softstarter should be clean. There should
SHUTDOWN CHECK contacts.
Thyristors Resistances of all three phases of
HT Softstarter should be in 2 digit nos.
SHUTDOWN CHECK
values.
Torque Wrench.
SHUTDOWN CHECK
SHUTDOWN CHECK
0.004 absolute.

meter.
SHUTDOWN CHECK


Torque Wrench.

be clean.

SHUTDOWN CHECK
be ˃ 20 mega ohms.
Interlock of Earth Switch and HT Breaker
should be healthy. HT Breaker should not
SHUTDOWN CHECK
condition. Also, Back Door of HT Panel
should not be open when earth switch is not
operated.

RUN CHECK
SHUTDOWN CHECK
HT Breaker should be clean. There should
contacts.
Proper lubrication of all moving parts of
mechanism.
Proper operation of Test / Service auxiliary
switch operation.
breaker both electrically and manually.
Proper spring charging operation of limit
switch.
SHUTDOWN CHECK Insulation resistance between Upper &
Lower contacts should be > 1 T Ohms
Timing of CB during Close should be in ms
Timing of CB during Open should be in ms
Timing of CB during Close / Open should
be in ms of all three phases.
Lower contacts should be in micro ohms of
all three phases.
HVAC Test for 15 KV should withstand for
SHUTDOWN CHECK
values.
Torque Wrench.
SHUTDOWN CHECK
SHUTDOWN CHECK
0.004 absolute.

meter.
SHUTDOWN CHECK


balanced of all three phases, i.e., less
than 10 ohms.
Shut Down check
Megger values shouldbe above 5
ground.
Tightened with 10 mm Chrome
Shut Down check
Vanadium Bolts.
Proper tighteness of foundation of

contactor.
No abnormalities to be seen for the
SHUTDOWN CHECK contacts and proper fitting to be
done.
Coil resistance should be between 20
ohms - 30 ohms.
Relay settings:
SHUTDOWN CHECK Relay Range = 4-10A
Motor should stop running during

RUN CHECK
limit switch operation.

than 10 ohms.
Shut Down check
ground.

Shut Down check
Vanadium Bolts.

contactor.
done.
ohms - 30 ohms.

RUN CHECK
than 10 ohms.
Shut Down check
ground.

Shut Down check
Vanadium Bolts.

contactor.
done.
ohms - 30 ohms.

RUN CHECK

than 10 ohms.
Shut Down check
ground.

Shut Down check
Vanadium Bolts.
Contactor rarting to be 32A. Proper

SHUTDOWN CHECK No abnormalities to be seen for the contacts
Relay Range :
23 A - 32 A
SHUTDOWN CHECK
FLC = 27.5A
The auxiliary contctactor is used to provide
SHUTDOWN CHECK tripping indication whenever the lube oil
pump will trip or power fails.
than 10 ohms.
Shut Down check
ground.

Shut Down check
Vanadium Bolts.


RUN CHECK
Softstarter should clean. Check the

SHUTDOWN CHECK
tighteness of the power and control cable.

Giga ohms and in healthy condition.
TAN-DELTA test of HT Motor is 0.0022



1000 Ohms

1000Mega Ohms

Insulators were installed properly and was

clean. No oxydation observed between
insulator and bubar.
Resistance between panel to busbar is 1000

mega ohms.

healthy. HT Breaker do not Rack In during
Earth Switch operated condition. Also, Back
Door of HT Panel has not been open when
earth switch is not operated.
Earthing is connected to the body and to the

Earth Pit.
Vertical and Horizontal insulators strength to
the busbars are good. Also, megger value is
1000 mega Ohms.
HT Breaker found clean. There is no moisture

or wear and rusting of contacts.
Lubrication of all moving parts of mechanism

is normal.
Closing and tripping mechanism of breaker
both electrically and manually is proper.
normal.
Condition of contact arm assembly of breaker
is proper.
> 1 T Ohms
> 1 T Ohms
Timing of CB during Close is 48 ms of all
three phases.
Timing of CB during Open is 41 ms of all
three phases.
Timing of CB during Close / Open is 21 ms of
all three phases.


three phases.
HT Breaker Numerical Relay tripping is

healthy to trip the breaker on the faults

1100 Ohms
1000Mega Ohms

voltage on the relay. Indication of voltage on
the panel is shown. Trippig of the HT Breaker
through HT Relay on Over voltage / Under
Voltage is healthy.

through HT Relay on Over curent / CIR /
ITOC / DMT is healthy.



mega ohms.

Earth Pit.


1000 mega Ohms.
HT Softstarter found clean. There is no
All thyristors resistances are in double digit

nos. between 11 to 13 ohms.



1000 Ohms
1000Mega Ohms

Voltage is healthy.




mega ohms.
healthy. HT Breaker do not Rack In during
Earth Switch operated condition. Also, Back
Door of HT Panel has not been open when

Earth Pit.

1000 mega Ohms.
HT Breaker found clean. There is no moisture

or wear and rusting of contacts.
Lubrication of all moving parts of mechanism

is normal.
Closing and tripping mechanism of breaker
both electrically and manually is proper.
normal.
Condition of contact arm assembly of breaker
is proper.
> 1 T Ohms
> 1 T Ohms
Timing of CB during Close is 48 ms of all
three phases.
Timing of CB during Open is 41 ms of all
three phases.
Timing of CB during Close / Open is 21 ms of
all three phases.


three phases.



1100 Ohms
1000Mega Ohms

Voltage is healthy.


resistances. Winding resistance of all
three phases is 7.1 ohms. Megger values
are 500 mega ohms and in healthy
condition.
Vanadium bolts and connecting links.

Inspected Relay Range = 4-10A


operation.

condition.


operation.
condition.


operation.

three phases is 9.5 ohms. Megger
values are 1000 mega ohms and in
healthy condition.
Contactor rarting is 32A. No looseness in

fitting of contactor and connection of cables to
power contactor and its contacts. Coil

23 A - 32 A
RC = 13.7A
Indication for tripping of lube oil pump is

healthy.
healthy condition.


operation.
Softstarter is clean. Tighteness of the power

and control cable is normal.

SP-SS-MAIN-FAN LUBRICATION ASSEMBLY FILTER SPL -50
SP-SS-MAIN-FAN LUBRICATION ASSEMBLY TUBE TYPE OIL COOLER,
SP-SS-MAIN-FAN LUBRICATION ASSEMBLY LABYRINTH SEAL

SP-SS-MAIN-FAN LUBRICATION ASSEMBLY OIL PUMP MAIN FAN
SP-SS-MAIN-FAN FAN ROTATNG ASMBLY EXHAUST FAN
SP-SS-MAIN-FAN FAN FIXED (THRUST)BEARING
SP-SS-MAIN-FAN FAN FREE(SUPPORT) BEARING
SP-SS-MAIN-FAN FAN COUPLING BOLT W/NUT
SP-SS-MAIN-FAN FAN RELAY

SP-SS-MAIN-FAN FAN CAMMAND & FEEDBACK CABLE
SP-SS-MAIN-FAN FAN DI ,DO, AI, AO Card, PLC , IM modules

SP-SS-MAIN-FAN FAN SMPS
SP-SS-MAIN-FAN FAN Profibus Cable
SP-SS-MAIN-FAN FAN VIBRATION TRANSMITTER
SP-SS-MAIN-FAN FAN RTD
SP-SS-MAIN-FAN FAN PRESSURE TRANSMITTER
CONDITION APPRAISAL OF MAIN
Item Code SPECIFICATIONS
5114000016 , LATUS RECTUM (MM)-50

5114010008 MODEL-2CFE-14
5114000039 SP DRG NO 2220-02131 B

5114000128 POWER PACK - SP
5114040001 HEAD END ESP
0940000038 Φ180 FAN 7500JZ-SP
0940000039 Φ 180 FAN7500JZ-SP
804990093 FOR HEAD ESP FAN
CONDITION APPRAISAL OF MAIN EXHAUST FAN
CHECK FOR CLOGGING SPANNERS

CHECK FOR INLET TEMP AND OUTLET TEMP OF WATER VISUAL AT GAUGE
CHECK FOR INLET TEMP AND OUTLET TEMP OF OIL VISUAL AT GAUGE
CHECK FOR LEAKAGE FROM SEAL VISUAL
CHECK FOR PRESSURE AT OUTLET OF PUMP VISUAL AT GAUGE
CHECK FOR IMPELLOR WEAROUT & DAMAGE VISUAL
CHECK FOR CLEARANCE OF BEARING LEAD WIRE
CHECK FOR CLEARANCE OF BEARING LEAD WIRE
CHECK FOR CRACKS AND DAMAGE SPANNERS

checking of fan beraing vibration Multimeter,Tester
checking of motor winding, moter bearing & fan bearing temperature Multimeter,Tester
checking of fan bearing lubrication oil pressure Multimeter,Tester
TYPE OF CHECK
(RUN CHECK / IDEAL CONDITION
STOP CHECK /
SHUTDOWN)
STOP CHECK NO CLOGGING IN FILTER

RUN CHECK INLET <31*C OUTLET TEMP <40*C
RUN CHECK INLET <45*C OUTLET TEMP <35*C
RUN CHECK NO LEAKAGE FROM SEAL
RUN CHECK BETWEEN 0.10mpa TO 0.30mPA
STOP CHECK NO WEAROUT AND DAMAGE AT FINS
Check for healthiness of NO - NC contacts during
Run check operation.

No abnormalities found in switching of contacts during operation.

APPRAISAL OF SINTER MACHINE
EQUIPMENT: Sub
Equipments COMPONENT Item Code
SP-SS-SM SP-SS-SM GEARBOX SINTER M/C, RDC TRIPLE RING RED 5114000006
SP-SS-SM SP-SS-SM Drive Sprocket journal bearing 0940000021
SP-SS-SM SP-SS-SM HEAD END BEARING BLOCK 5114000122
SP-SS-SM SP-SS-SM Driven Sprocket Journal bearing 0940000022
SP-SS-SM SP-SS-SM TAIL END BEARING BLOCK 5114000123
SP-SS-SM SP-SS-SM SPROCKET TEETH 75M2 SINTER MACHINE 5114000001
SP-SS-SM SP-SS-SM SINTER PALLET PRESSURE ROLLER 5114000035
SP-SS-SM SP-SS-SM SINTER PALLET CARS 5114000030
SP-SS-SM SP-SS-SM SINTER PALLET CARS
SP-SS-SM SP-SS-SM HEAD N TAIL END SEALING PLATE F/ SP 5114040023
SP-SS-SM SP-SS-SM Rail Clamp Fastner 0601010186
SP-SS-SM SP-SS-SM ROTARY CHUTE FOR SINTER MACHINE 75M3-SP 5114000115
SP-SS-SM SP-SS-SM Pulley of tensioning device 0811900014
SP-SS-SM SP-SS-SM
RELAY
SP-SS-SM SP-SS-SM CAMMAND & FEEDBACK CABLE
SP-SS-SM SP-SS-SM
SP-SS-SM SP-SS-SM SMPS
SP-SS-SM SP-SS-SM Profibus Cable
SPECIFICATION DESCRIPTION / DIMENSION

( dia-400,L-350,T-20) CHECK FOR CLEARANCE OF BEARING
(dia-280,L-280,T-20) CHECK FOR CLEARANCE OF BEARING
CHECK FOR FACE WIDTH WEAR OUT
CHECK FOR FREE MOVEMENT OF ROLLERS
CHECK FOR WHEEL MOVEMENT
CHECK FOR SIDE WALL COND.
CHECK FOR WEAROUT AND DAMAGE
M24x150 CHECK FOR BOLT TIGHTNESS AND RUSTING
CHECK FOR WHEEL MOVEMENT
CHECK FOR CRACKS AND DAMAGE
checking healthyness by operating DOL starter of motor.

checking healthyness by Run the motor
checking healthyness by operating DOL starter of motor and run feedback.

checking of commnunication on SCADA sytem and on PLC card
TOOLS REQUIRED TYPE OF CHECK (RUN CHECK / IDEAL CONDITION
VISUAL STOP CHECK NO PHYSICAL DAMAGE TO BODY
LEAD WIRE STOP CHECK CLEARANCE <1MM
LEAD WIRE STOP CHECK CLEARANCE <1MM
VISUAL STOP CHECK FACE WIDTH SHOULD BE 230MM-250MM
VISUAL RUN CHECK ROLLERS SHOULD BE ROTATING
VISUAL RUN CHECK WHEEL SHOULD BE ROTATING
VISUAL RUN CHECK SIDE WALL SHOULD NOT BE BEND
VISUAL STOP CHECK SHOULD NOT BE DAMAGED AND WORNOUT
SPANNERS STOP CHECK BOLTS SHOULD BE TIGHT AND RUSTFREE
VISUAL STOP CHECK WHEEL SHOULD BE ROTATING
VISUAL STOP CHECK SHOULD NOT BE DAMAGE
Check for healthiness of NO - NC contacts during
Multimeter,Tester Run check operation.
Multimeter,Tester Run check Physical check or damage of cable

ACTION
ACTUAL CONDITION OBSERVED REQUIRED

EQUIPMENT: Sub Equipments COMPONENT Item Code
SP-SS-SRC SP-SS-SRC GRIZZLY BAR 5114000011

SP-SS-SRC SP-SS-SRC GEARBOX 5114050016
SP-SS-SRC SP-SS-SRC SINGLE ROLL CRUSHER BEARING ASSEMBLEY,SP 5114050018
RIBBED V BELT 0802990030

SP-SS-SRC SP-SS-SRC
SP-SS-SRC SP-SS-SRC SINGLE ROLL CRUSHER DRIVE PULLEY 0812900003
SP-SS-SRC SP-SS-SRC SINGLE ROLL CRUSHER DRIVEN PULLEY 0812900004
CPLG 0804030067
SP-SS-SRC SP-SS-SRC
SP-SS-SRC SP-SS-SRC BUSH FOR PIN BUSH COUPLING 0804030094
SP-SS-SRC SP-SS-SRC MECHANICAL SEAL FOR ROATRY CATCHER 2516000010
SP-SS-SRC SP-SS-SRC SIDE LINER FOR SINGLE ROLL CRUSHER LHS 5114050043
SP-SS-SRC SP-SS-SRC SIDE LINER FOR SINGLE ROLL CRUSHER RHS 5114050044
SP-SS-SRC SP-SS-SRC CRUSH DECK FOR SINTER MACHINE 75M3-SP 5114000116
SP-SS-SRC SP-SS-SRC RELAY
SP-SS-SRC SP-SS-SRC CAMMAND & FEEDBACK CABLE
SP-SS-SRC SP-SS-SRC DI ,DO, AI Card, PLC , IM modules
SP-SS-SRC SP-SS-SRC SMPS
SP-SS-SRC SP-SS-SRC Profibus Cable

CONDITION APPRAISAL OF SINGLE ROLL CRUSH
Specification DESCRIPTION / DIMENSION
CHECK FOR DAMAGE/WEAR OUT

,MODEL ZL115-14-II CHECK FOR PHYSICAL DAMAGE
CHECK FOR CLEARANCE OF BEARING
20 PM 3350, SP(20 M-3350, V ribbed
belt m section, no of ribs -20) CHECK FOR DEFORMATOIN/DAMAGE
CHECK FOR GROOVE
CHECK FOR GROOVE
,PIN AND BUSH FLEXIBLE,UB 710,
(optional) CHECK FOR DAMAGE
UB 710 CHECK FOR WEAR OUT
CHECK FOR DISLODGE

checking healthyness by operating DOL starter of motor and run
feedback.

INGLE ROLL CRUSHER
TYPE OF CHECK
(RUN CHECK / STOP
CHECK /
SHUTDOWN)
VISUAL STOP CHECK NO DAMAGE/NO WEAR OUT
FILLER GUAGE STOP CHECK CLEARANCE <0.35MM
VISUAL STOP CHECK NO DEFORMATION/DAMAGE

VISUAL STOP CHECK NO DAMAGE TO GROOVE
VISUAL STOP CHECK NO DAMAGE TO GROOVE
VISUAL STOP CHECK NO DAMAGE

VERNIER STOP CHECK DIA SHOLD BE 38-40MM
SPANNER STOP CHECK SHOULD BE IN POSITOIN
Check for healthiness of NO - NC contacts
Multimeter,Tester Run check during operation.

No abnormalities found in switching of contacts during

operation.
CONDITIO
LT WHEEL DRIVE BEARING

BF3-CH-CRANE LT GB#1
LT WHEEL NON DRIVE
BF3-CH-CRANE LT GB#1 BEARING
GEAR BOX FOR LT

BF3-CH-CRANE LT GB#1 WHEEL INPUT SHAFT
Extention shaft
G.B.INPUT SHAFT
BF3-CH-CRANE LT GB#1 G.B, OUT PUT SHAFT
Extention shaft
COUPLING MOTOR TO GB
BF3-CH-CRANE LT GB#1 COUPLING GB TO WHEEL
LT WHEEL DRIVE BEARING

LT WHEEL NON DRIVE
BF3-CH-CRANE LT GB#2 BEARING
GEAR BOX FOR LT

WHEEL INPUT SHAFT
BF3-CH-CRANE LT GB#2 LHG106,
Extention shaft (G B OUT
BF3-CH-CRANE LT GB#2 wheel.INPut) LHG106,
G.B.INPUT SHAFT
BF3-CH-CRANE LT GB#2 ,RIGID,FS,RGR 102,
G.B, OUT PUT SHAFT
BF3-CH-CRANE LT GB#2 ,LHG106
Extention shaft (Motor OUT
BF3-CH-CRANE LT GB#2 G.B.INPut), LHG102
BF3-CH-CRANE LT GB#2 COUPLING GB TO WHEEL
GEAR BOX FOR CT

BF3-CH-CRANE CT-GB
G.B, OUT PUT SHAFT
BF3-CH-CRANE CT-GB ,RGR 103,
WHEEL INPUT SHAFT ,
BF3-CH-CRANE CT-GB RGR 103,
Extention shaft G.B.Out TO
BF3-CH-CRANE CT-GB Wheel INput) LHG103
G.B.IN PUT SHAFT LHG103

BF3-CH-CRANE CT-GB
BF3-CH-CRANE CT-GB
BF3-CH-CRANE CT-GB COUPLING GB TO WHEEL
BF3-CH-CRANE MAIN HOIST GB TOP PULLEY ASSEMBLY
16T MAIN HOIST GEARBOX

WITH DRUM
BF3-CH-CRANE MAIN HOIST GB
Extention shaft (Motor

OUTTO G.B.INPut) LHG103
BF3-CH-CRANE MAIN HOIST GB
BF3-CH-CRANE MAIN HOIST GB COUPLING
CH CRANE
BF3-CH-CRANE PROTECTIVE SFU, 250 A
PANEL
CH CRANE
MAIN POWER
BF3-CH-CRANE PROTECTIVE
CONTACTOR
PANEL
CH CRANE
PHASE INDICATION
LAMP
PANEL
CH CRANE
CURRENT
TRANSFORMER
PANEL
CH CRANE
CONTROL
TRANSFORMER
PANEL
CH CRANE
CH CRANE DOOR
Limit Switch
PANEL
CH-CRANE-MH-
BF3-CH-CRANE Motor Windings
MTR
CH-CRANE-MH-
BF3-CH-CRANE Slip Rings
MTR
CH-CRANE-MH-
BF3-CH-CRANE Resistance Box
MTR
CH-CRANE-MH-
BF3-CH-CRANE Carbon Brush
MTR
CH-CRANE-MH-
BF3-CH-CRANE Terminal Box
MTR
BF3-CH-CRANE-
BF3-CH-CRANE SFU, 160 A
PNL
BF3-CH-CRANE- Power Contactor

BF3-CH-CRANE
PNL (Hoist and Lower)
BF3-CH-CRANE- Resistance Contactor
BF3-CH-CRANE
PNL (Hoist and Lower)
BF3-CH-CRANE- Stator Overload Relay

BF3-CH-CRANE
PNL with Kit
BF3-CH-CRANE- Rotor Overload Relay

BF3-CH-CRANE
PNL with Kit
BF3-CH-CRANE- Electronic Timer ON /

BF3-CH-CRANE
PNL OFF Delay
BF3-CH-CRANE-
BF3-CH-CRANE Rotary Limit Switch
PNL
BF3-CH-CRANE- Main Hoist Gravity

BF3-CH-CRANE
PNL Limit Switch
BF3-CH-CRANE- Main Hoist Master
BF3-CH-CRANE
PNL Controller Joystic
BF3-CH-MH- Thruster brake 1

BF3-CH-CRANE
BRK1 Power Contactor
CH-CRANE-MH- Thruster brake 1

BF3-CH-CRANE
BRK1 Overload Relay
CH-CRANE-MH-
BF3-CH-CRANE Thrustor Motor
BRK1
CH-CRANE-MH-
BF3-CH-CRANE Brake Shoe and Liner
BRK1

BF3-CH-CRANE
BRK2 Power Contactor

BF3-CH-CRANE
BRK2 Overload Relay
CH-CRANE-MH-
BF3-CH-CRANE Thrustor Motor
BRK2
CH-CRANE-MH-
BF3-CH-CRANE Brake Shoe and Liner
BRK2
CH-CRANE-LT-
BF3-CH-CRANE Motor Windings LT 1
MTR1
CH-CRANE-LT-
BF3-CH-CRANE Slip Rings LT 1
MTR1
CH-CRANE-LT-
BF3-CH-CRANE Motor Windings LT 2
MTR2
CH-CRANE-LT-
BF3-CH-CRANE Slip Rings LT 2
MTR2
CH-CRANE-CT-
BF3-CH-CRANE Slip Rings CT
MTR
CH-CRNE-LT-
BF3-CH-CRANE Resistance Box LT 1
MTR-RB
CH-CRNE-LT-
BF3-CH-CRANE Resistance Box LT 2
MTR-RB
CH-CRNE-CT-
BF3-CH-CRANE Resistance Box CT
MTR-RB
CH-CRANE-LT-
BF3-CH-CRANE Carbon Brush LT1
MTR1
CH-CRANE-LT-
BF3-CH-CRANE Carbon Brush LT2
MTR2
CH-CRANE-CT-
BF3-CH-CRANE Carbon Brush CT
MTR
CH-CRANE-LT-
BF3-CH-CRANE Terminal Box LT1
MTR1
CH-CRANE-LT-
BF3-CH-CRANE Terminal Box LT2
MTR2
CH-CRANE-CT-
BF3-CH-CRANE Terminal Box CT
MTR
CH-CRANE-LT-
BF3-CH-CRANE LT SFU, 63 A
PNL
CH-CRANE-LT- Power Contactor LT1

BF3-CH-CRANE
PNL (Forward & Reverse)
CH-CRANE-LT- Power Contactor LT2
BF3-CH-CRANE
PNL2 (Forward & Reverse)
Resistance Contactor
CH-CRANE-LT-
BF3-CH-CRANE LT1 (Forward &
PNL
Reverse)
CH-CRANE-LT-
BF3-CH-CRANE LT2 (Forward &
PNL2
Reverse)
CH-CRANE-LT- Stator Overload Relay
BF3-CH-CRANE
PNL LT1
CH-CRANE-LT- Rotor Overload Relay

BF3-CH-CRANE
PNL1 LT1
CH-CRANE-LT- Rotor Overload Relay

BF3-CH-CRANE
PNL LT2
CH-CRANE-LT- Stator Overload Relay

BF3-CH-CRANE
PNL LT2
CH-CRANE-LT- Electronic Timer ON /

BF3-CH-CRANE
PNL OFF Delay
Lever type LT
CH-CRANE-LT-
BF3-CH-CRANE Forward / Reverse
PNL
Limit Switch
CH-CRANE-CT-
BF3-CH-CRANE CT SFU, 32 A
PNL
CH-CRANE-CT- Power Contactor CT
BF3-CH-CRANE
PNL (Forward & Reverse)
CH-CRANE-CT-
BF3-CH-CRANE CT (Forward &
PNL
Reverse)
CH-CRANE-CT- Rotor Overload Relay

BF3-CH-CRANE
PNL CT
CH-CRANE-CT- Stator Overload Relay

BF3-CH-CRANE
PNL CT
CH-CRANE-CT- Electronic Timer ON /
BF3-CH-CRANE
PNL OFF Delay
Lever type CT
CH-CRANE-CT-
BF3-CH-CRANE Forward / Reverse
PNL
Limit Switch
CH-CRANE-CT- CT Master Controller

BF3-CH-CRANE
PNL Joystick
CH-CRANE-LT- Thruster brake Power

BF3-CH-CRANE
BRK1 Contactor
CH-CRANE-LT- Thruster brake

BF3-CH-CRANE
BRK1 Overload Relay
CH-CRANE-LT-
BF3-CH-CRANE Thrustor Motor LT1
BRK1

BF3-CH-CRANE
BRK1 Contactor

BF3-CH-CRANE
BRK1 Overload Relay
CH-CRANE-LT-
BF3-CH-CRANE Thrustor Motor LT2
BRK2

BF3-CH-CRANE
BRK2 Contactor

BF3-CH-CRANE
BRK2 Overload Relay
CH-CRANE-LT- Brake Shoe and Liner

BF3-CH-CRANE
BRK1 LT1
CH-CRANE-LT- Brake Shoe and Liner
BF3-CH-CRANE
BRK2 LT2
CH-CRANE-CT- Thruster brake Power

BF3-CH-CRANE
BRK Contactor
CH-CRANE-CT- Thruster brake

BF3-CH-CRANE
BRK Overload Relay
CH-CRANE-CT-
BF3-CH-CRANE Thrustor Motor CT
BRK
CH-CRANE-CT- Brake Shoe and Liner
BF3-CH-CRANE
BRK CT
CONDITION APPRAISAL OF CAST HOUSE CRANE 16T
TYPE OF CHECK
SPECIFICATI DESCRIPTION / DIMENSION (RUN CHECK / STOP
Item Code TOOLS REQUIRED
ON CHECK /
SHUTDOWN)
BEARING TO BE CHECKED FOR

CLEARANCE FILLER GAUGE STOP CHECK
5116060034 CHECK FOR INTERNAL GEAR COND.

BY OPENING TOP FLANGE SPANNERS STOP CHECK
0804070061 LHG106, CHECK FOR PHYSICAL DAMAGE VISUAL STOP CHECK
(G B OUT
wheel.INPut)
0804070061 LHG106, CHECK FOR PHYSICAL DAMAGE VISUAL STOP CHECK
,
RIGID,FS,RGR
0804030072 102, CHECK FOR PHYSICAL DAMAGE VISUAL STOP CHECK
0844070061 ,LHG106 CHECK FOR PHYSICAL DAMAGE VISUAL STOP CHECK
(Motor OUT
G.B.INPut),
0804070030 LHG102 CHECK FOR PHYSICAL DAMAGE VISUAL STOP CHECK
CHECK FOR PHYSICAL DAMAGE SPANNERS STOP CHECK


0804070061 CHECK FOR PHYSICAL DAMAGE VISUAL STOP CHECK


0804070031
CHECK FOR PHYSICAL DAMAGE VISUAL STOP CHECK
0804070031

5116060096 CHECK FOR PHYSICAL DAMAGE SPANNERS STOP CHECK

0804070031
Check for fuse rating and VISUAL /

SHUTDOWN
250 A continuity of input / MULTIMETE
CHECK
output terminals. R
Spanners,
For switching a power
3TF54 Screw Drivers, SHUTDOWN
circuit with higher
00-0A Allen Key, CHECK
current ratings
Multimeter
Check for indication of

240 VAC VISUAL RUN CHECK
input voltage of the panel.
Check for tighteness of

connections and measure
150 / 5 A VISUAL RUN CHECK
the correct current shown
in the meter.
To check for connections

2 KVA, and power rating of
Spanners / SHUTDOWN
415 / 110 transformer. Input and
Multimeter CHECK
VAC output voltage should be
415 / 110 VAC
Check for switching NO /

VISUAL /
NC Contact as per set
10 A MULTIMETE RUN CHECK
value during Crane
R
operation.
when energized with Megger & SHUTDOWN
current to produce Multimeter CHECK
torque.
To allow the transmission

of power and electrical
signals from a stationary
to a rotating structure. It
SHUTDOWN
can be used in any Visual
CHECK
electromechanical system
that requires rotation
while transmitting power
or signals.
To check for multiple

resistors hooked up to
one or multiple switches
and is designed to provide
multiple electrical Megger & SHUTDOWN
resistances. To vary Multimeter CHECK
desired speed by varying
the resistances. Also, to
provide initial torque to
the motor.
To conduct current
between stationary wires
SHUTDOWN
and moving parts, most Visual
CHECK
commonly in a rotating
shaft.
Allows the power cable to
be fixed with the motor
windings cable properly
insulated, clamped and
sealed connector to
provide greater protecton SHUTDOWN
Spanners
from short circuiting of CHECK
cables.
Check for cable
termination tighteness
and properly glanding
done.

SHUTDOWN
CHECK
output terminals. R
Spanners,
Screw Drivers, SHUTDOWN
110 A circuit with higher
Allen Key, CHECK
current ratings
Multimeter
Spanners,
63 A circuit with higher
Allen Key, CHECK
current ratings
Multimeter
Check for overload relay

range and setting of relay
Visual RUN CHECK
current for motor
tripping.
Visual RUN CHECK
current for motor
tripping.
Check for Timer ON /

0.5 - 10
OFF switching as per set Visual RUN CHECK
sec
value.

VISUAL /
value during hoisting and
R
lowering operation.

VISUAL /
value during hoisting
R
operation.
NC Contact as per set VISUAL /
10 A value during hoisting MULTIMETE RUN CHECK
operation. Check for wear R
and tear of contacts.
Check for contactor rating

Spanners,
and tighteness of
contactor terminals.
Allen Key, CHECK
Check for coil resistance
Multimeter
of the contactor.

(1 - 1.6 ) A Visual RUN CHECK
current for motor
tripping.
To drive the pump and

delivers working fluid
under the piston axially in
the guided path, and
delivers thrust or force Megger & SHUTDOWN
required to operate the Multimeter CHECK
attached devise (like
thruster brake) via the
piston rod and the eye-lug
attached to it.
Spanners,
To provide friction for Screw Driver,
SHUTDOWN
braking of rotary drum Plier, Vernier
CHECK
when motor is stopped. Calliper
Visual

Spanners,
and tighteness of
Allen Key, CHECK
Multimeter
of the contactor.

Visual RUN CHECK
current for motor
tripping.

attached to it.
Spanners,
SHUTDOWN
CHECK
Visual

torque.

SHUTDOWN
CHECK
or signals.
torque.

SHUTDOWN
CHECK
or signals.

SHUTDOWN
CHECK
or signals.
It is an equipment that
contains multiple
Megger & SHUTDOWN
multiple electrical
Multimeter CHECK
resistances. To vary
the motor.
contains multiple
Megger & SHUTDOWN
multiple electrical
Multimeter CHECK
the motor.
contains multiple
Megger & SHUTDOWN
multiple electrical
Multimeter CHECK
the motor.
To conduct current
SHUTDOWN
CHECK
shaft.
To conduct current
SHUTDOWN
CHECK
shaft.
To conduct current
SHUTDOWN
CHECK
shaft.
sealed connector to
Spanners
cables.
Check for cable
done.

sealed connector to
Spanners
cables.
Check for cable
done.
sealed connector to
Spanners
cables.
Check for cable
done.

SHUTDOWN
CHECK
output terminals. R
Spanners,
circuit with higher
Allen Key, CHECK
current ratings
Multimeter
Spanners,
circuit with higher
Allen Key, CHECK
current ratings
Multimeter
Spanners,
circuit with higher
Allen Key, CHECK
current ratings
Multimeter
Spanners,
circuit with higher
Allen Key, CHECK
current ratings
Multimeter
Visual RUN CHECK
current for motor
tripping.
range and setting of relay Megger &
RUN CHECK
current for motor Multimeter
tripping.
Relays are protective

devices that are designed
to cut power if the motor
Visual Run check
draws too much current
for an extended period of
time.

Visual Run check
time.

0.5 - 10
sec
value.

VISUAL /
R
operation.

SHUTDOWN
CHECK
output terminals. R
Spanners,
circuit with higher
Allen Key, CHECK
current ratings
Multimeter
Spanners,
circuit with higher
Allen Key, CHECK
current ratings
Multimeter

Visual Run check
time.

Visual Run check
time.
0.5 - 10
sec
value.

VISUAL /
R
operation.

NC Contact as per set VISUAL /
10 A value during hoisting MULTIMETE RUN CHECK
operation. Check for wear R
and tear of contacts.

Spanners,
and tighteness of
Allen Key, CHECK
Multimeter
of the contactor.

(0.4 - range and setting of relay
Visual RUN CHECK
0.63 ) A current for motor
tripping.
attached to it.

Spanners,
and tighteness of
Allen Key, CHECK
Multimeter
of the contactor.

Visual RUN CHECK
tripping.
attached to it.

Spanners,
and tighteness of
Allen Key, CHECK
Multimeter
of the contactor.

Visual RUN CHECK
tripping.
Spanners,
SHUTDOWN
CHECK
Visual
Spanners,
SHUTDOWN
CHECK
Visual

Spanners,
and tighteness of
Allen Key, CHECK
Multimeter
of the contactor.

Visual RUN CHECK
tripping.

attached to it.
Spanners,
SHUTDOWN
CHECK
Visual
IDEAL CONDITION ACTUAL CONDITION OBSERVED ACTION REQUIRED
CLEARANCE <0.6MM
CLEARANCE <0.6MM
NO INTERNAL GEAR DAMAGE

NO PHYSICAL DAMAGE
NO PHYSICAL DAMAGE
NO PHYSICAL DAMAGE
NO PHYSICAL DAMAGE
NO PHYSICAL DAMAGE
NO CRACKS AND DAMAGE

CLEARANCE <0.6MM
CLEARANCE <0.6MM
NO PHYSICAL DAMAGE
NO PHYSICAL DAMAGE
NO PHYSICAL DAMAGE
NO PHYSICAL DAMAGE
NO PHYSICAL DAMAGE
NO PHYSICAL DAMAGE
NO PHYSICAL DAMAGE
NO PHYSICAL DAMAGE
NO PHYSICAL DAMAGE
NO PHYSICAL DAMAGE
NO PHYSICAL DAMAGE
SFU Unit should be
SFU Unit is clean. Fuse
clean. Check for fuse
taing and continuity of
fuse input / output
fuse input / output
terminals.
tighteness of Contactor rating is 3TF54,
foundation of 250 A. No looseness in
contactor. fitting of contactor and
No abnormalities to be connection of cables to
seen for the contacts power contactor and its
and proper fitting to be contacts. Coil resistance is
done. 30 ohms.
Coil resistance should
be 20-30 ohms.
Indication lamp should Indication lamp indicates

indicate input phase input phase voltage of
voltage of HMH crane. HMH crane.
CT connections should
be tight and should CT connections are tight
measure current and display accurate
accurately on the current on the ammeter.
ammeter.
Control transformer
Control transformer
connections should be
connections are tight.
tight. Input and output
Input and output voltage
voltage should be 415 /
measured is 415 / 110 VAC
110 VAC
CH Crane should stop CH Crane stop during

during operation when operation when limit
limit switch operated. switch operated.
Winding Resistances No abnormal difference in
should be balanced of winding resistances.
all three phases, i.e., Winding resistances of all
less than 5 ohms. three are 3.5 ohms.
Megger values Megger values are 1000
shouldbe above 5 mega ohms phase to
megaohms from all ground and are in healthy
three phases to ground. condition.
Should be uniform
throughout surface Throughout Smooth
without wear and cuts. surface of the ring
Slip ring should be inspected. Thickness
10mm. It should not 8mm.
less than 2mm.
Condition of the
resistance plates Condition of the resistance
should be good and the plates and resistance
values of the resistance values are in healthy
box should match with condition.
rotor rating plate.

Throughout Smooth
surface at the contact
surface and thickness of
with the slipring. No
the ring seen visually.
wear and tear.
Tightened with 10mm No looseness of 10mm
Chrome Vanadium Chrome Vanadium bolts
Bolts. and connecting links.
SFU Unit should be

fuse input / output
fuse input / output
terminals.
done. 25 ohms.
be 20-30 ohms.
3TF47, 63 A. Proper
done. 28 ohms.
be 20-30 ohms.
Relay Range : Relay Range :

(25-36)A (25-36)A
Relay settings = 20A Relay settings = 20A
FLC = 22.6A RC = 14.1A
(50-63)A (50-63)A
FLC = 28.1A RC = 13.9A
Timer should change
Timer change its contact
its contact NO / NC as
NO / NC as per time set.
per time set. Time set 1
Time set 1 sec
sec
Main Hoist Motor

Main Hoist Motor stop
should stop running
running during hoisting
during hoisting and
and lowering operation.
lowering operation.
Main Hoist Motor

Main Hoist Motor stop
should stop running
running during hoisting
during hoisting
operation.
operation.
Master controller
Master controller
connections are tight and
tight and contacts
contacts are healthy.
should be healthy.
3TF31, 12 A. Proper
done. 25 ohms.
be 20-30 ohms.

(1 - 1.6)A (1 - 1.6)A
Relay settings = 1.4A Relay settings = 1.4A
FLC = 1.0A RC = 1.2A
Winding Resistances
all three phases, i.e.,
Winding resistances of all
less than 10 ohms.
three are 9 ohms. Megger
Megger values
values are 1000 mega
shouldbe above 5
ohms phase to ground and
megaohms from all
are in healthy condition.
Check for proper
allignment of both No any abnormalities
sides brake shoes. found in the allignment of
Thickness of Brake brake shoe and decaying of
liner is 12mm. It should liner. Condition of the
not be less than 9 mm. revit is checked weekly
If it is less, then it which is fitted 4mm gap
should go for from liner.
replacement.
3TF31, 12 A. Proper
done. 25 ohms.
be 20-30 ohms.

(1 - 1.6)A (1 - 1.6)A
FLC = 1.0A RC = 0.8A
Winding Resistances
less than 10 ohms.
Megger values
values are 1000 mega
shouldbe above 5
ohms phase to ground and
megaohms from all
are in healthy condition.
Check for proper
replacement.

Should be uniform
8mm. It should not less 6mm.
than 2mm.
Should be uniform
than 2mm.
Should be uniform
than 2mm.
Condition of the
resistance plates Condition of the resistance
should be good and the plates and resistance
values of the resistance values are in healthy
box should match with condition.
rotor rating plate.
Condition of the
resistance plates
should be good and the
plates and resistance
values of the resistance
values are in healthy
box should match with
condition.
rotor rating plate.
Power = 30 KW
Power = 30 KW
Rotor Voltage = 212V
AC
Condition of the
resistance plates
should be good and the
plates and resistance
values of the resistance
values are in healthy
box should match with
condition.
rotor rating plate.
Power = 15 KW
Power = 15 KW
Rotor Voltage = 218V
AC
Thickness and smooth Throughout Smooth

surface at the contact surface and thickness of
with the slipring. the ring seen visually.



SFU Unit should be

fuse input / output
fuse input / output
terminals.
3TF47, 70 A. Proper
done. 28 ohms.
be 20-30 ohms.
3TF47, 70 A. Proper
done. 28.9 ohms.
be 20-30 ohms.
3TF34, 32 A. Proper
done. 29 ohms.
be 20-30 ohms.
3TF34, 32 A. Proper
done. 28.5 ohms.
be 20-30 ohms.
(12.5 - 20)A (12.5 - 20)A
FLC = 22.5A RC = 5.4A
(20-32)A (20-32)A
FLC = 27.6A RC = 5.1A

(20-32)A (20-32)A
FLC = 27.6A RC = 7.8A

(12.5 - 20)A (12.5 - 20)A
FLC = 22.5A RC = 9.4A
Timer should change

Time set 1 sec
sec
Motor should stop

Motor stop running during
running during limit
switch operation.
SFU Unit should be

fuse input / output
fuse input / output
terminals.
3TF33, 22 A. Proper
done. 28 ohms.
be 20-30 ohms.
3TF33, 22 A. Proper
done. 25 ohms.
be 20-30 ohms.

(12.5-20)A (12.5-20)A
FLC = 14.2A RC = 5.6A

(6.3-10)A (6.3-10)A
FLC = 9.03A RC = 5.4A
Timer should change
Time set 1 sec
sec
Motor should stop

Motor stop running during
running during limit
switch operation.
Master controller
Master controller
tight and contacts
contacts are healthy.
should be healthy.
3TF31, 12 A. Proper
done. 25 ohms.
be 20-30 ohms.

(0.4 - 0.63 ) A (0.4 - 0.63 ) A
FLC = 0.6A RC = 0.6A
Winding Resistances
less than 10 ohms.
Megger values
values are 800 mega ohms
shouldbe above 5
phase to ground and are in
megaohms from all
healthy condition.
3TF31, 12 A. Proper
done. 25 ohms.
be 20-30 ohms.

(0.4 - 0.63 ) A (0.4 - 0.63 ) A
FLC = 0.6A RC = 0.6A
Winding Resistances
less than 10 ohms.
Megger values
shouldbe above 5
megaohms from all
healthy condition.
3TF31, 12 A. Proper
done. 25 ohms.
be 20-30 ohms.

(0.4 - 0.63 ) A (0.4 - 0.63 ) A
FLC = 0.6A RC = 0.6A
Check for proper

replacement.
Check for proper
replacement.
3TF31, 12 A. Proper
done. 25 ohms.
be 20-30 ohms.

(0.4 - 0.63 ) A (0.4 - 0.63 ) A
FLC = 0.6A RC = 0.6A
Winding Resistances
less than 10 ohms.
Megger values
shouldbe above 5
megaohms from all
healthy condition.
Check for proper
replacement.
CONDITIO
COMPONEN
EQUIPMENT: Sub Equipments Item Code
T
BF3-CH- CSTH-MUDPWPK- Heat Exchanger 7701000328

MUDPWPK PMP1
Return line
BF3-CH- CSTH-MUDPWPK- filtre 7701000258
MUDPWPK PMP1
BF3-CH- CSTH-MUDPWPK- Coupling 5422020001

MUDPWPK PMP1
BF3-CH- CSTH-MUDPWPK- Flexible bellow 5395000013

MUDPWPK PMP1
BF3-CH-
Motor
BF3-CH-MUDGUN MUDPWPK-PMP-
Windings
MTR1
BF3-CH-
BF3-CH-MUDGUN MUDPWPK-PMP- Terminal Box
MTR1
BF3-CH- Power
BF3-CH-MUDGUN
MUDPWPK-PNL Contactor
BF3-CH-
BF3-CH-MUDGUN Overload Relay
MUDPWPK-PNL
BF3-CH-
Motor
Windings
MTR2
BF3-CH-
MTR2
BF3-CH- Power
BF3-CH-MUDGUN
BF3-CH-
MUDPWPK-PNL
BF3-CH-
Motor
Windings
MTR3
BF3-CH-
MTR3
BF3-CH- Power
BF3-CH-MUDGUN
BF3-CH-
MUDPWPK-PNL
BF3-CH-
BF3-CH-MUDGUN MUDPWPK- HOOTER
HOOTER
power and feed back

cable
pressure switch
Relay
BF3-CH-MUDGUN
DI ,DOCard,PLC ,
IM modules
SMPS failure
PLC , IM modules
Profibus Cable
CONDITION APPRAISAL OF MUDGUN POWER PACK
TYPE OF CHECK
DESCRIPTION / TOOLS (RUN CHECK / STOP
DIMENSION REQUIRED CHECK /
SHUTDOWN)
CHECK FOR TUBES

JAMMING SPANNER STOP CHECK
CHECK FOR FILTER

CHOKE VISUAL STOP CHECK
CHECK FOR
COUPLING DAMAGE SPANNER STOP CHECK
CHECK FOR BELLOW

DAMAGE VISUAL RUN CHECK

when energized with
current to produce Megger &
Shut Down check
torque. Check for Multimeter
Check for proper

tigteness of the power Spanners Shut Down check
Check for contactor
rating and tighteness Spanners,
of contactor terminals. Screw Drivers,
Shut Down check
Check for coil Allen Key,
resistance of the Multimeter
contactor.
Check for overload

relay range and setting
Visual Shut Down check
of relay current for
motor tripping.

when energized with
Shut Down check
Check for proper

Check for contactor
Shut Down check
contactor.
Check for overload

motor tripping.

when energized with
Shut Down check
Check for proper

Check for contactor
Shut Down check
contactor.
Check for overload

motor tripping.
Check for hooter motor

windings resistance Screw Driver /
STOP CHECK
and terminal Multimeter
tighteness connection.
checking healthyness Multimeter,Tes

Run check
by operating valve. ter
check healthyness of
Multimeter,Tes
contact change over by Run check
ter
operaing with pressure

Run check

Run check
check supply voltage Multimeter,Tes
Run check
and output Voltage ter
Run check
Run check
IDEAL CONDITION
OBSERVED REQUIRED
NO TUBES JAMMING &

DAMAGE
NO FILTER CHOKE
NO COUPLING
DAMAGE OR CRACK
NO BELLOW DAMAGE
Winding Resistances
than 10 ohms.
all three phases to
condition.
ground.
Tightened with 10mm
Chrome Vanadium bolts
and connecting links.
Contactor rarting to be
150 A. Proper tighteness
of foundation of
contactor.
contactor and connection
No abnormalities to be
of cables to power
seen for the contacts and
contactor and its contacts.
Coil resistance is 42 ohms.
35-45 ohms.
Relay Range : Checked Relay Range :

(90 - 150)A (90 - 150)A
FLC = 103A RC = 69.3A
Winding Resistances
than 10 ohms.
all three phases to
condition.
ground.
Tightened with 10mm
150 A. Proper tighteness Contactor rarting is 150 A.
of foundation of No looseness in fitting of
contactor. contactor and connection
No abnormalities to be of cables to power
seen for the contacts and contactor and its contacts.
proper fitting to be done. Coil resistance is 43.2
Coil resistance should be ohms.
35-45 ohms.

(90 - 150)A (90 - 150)A
FLC = 103A RC = 68.0A
Winding Resistances
than 10 ohms.
all three phases to
condition.
ground.
Tightened with 10mm
150 A. Proper tighteness Contactor rarting is 150 A.
of foundation of No looseness in fitting of
contactor. contactor and connection
No abnormalities to be of cables to power
seen for the contacts and contactor and its contacts.
proper fitting to be done. Coil resistance is 44.6
Coil resistance should be ohms.
35-45 ohms.

(90 - 150)A (90 - 150)A
FLC = 103A RC = 69.4A
Winding Resistances
than 40 ohms.
three phases is 38 ohms.
all three phases to
condition.
ground.

No damage
of cable

No damage
of coil

damage of coil using No damage
multimeter
Physical check No damage

BF3-HBS-HBS1
BF3-HBS-HBS1 HOT BLAST VALVE
BF3-HBS-HBS1

BF3-HBS-HBS1 BACK DRAFT VALVE

BF3-HBS-HBS1 BURNER VALVE

BF3-HBS-HBS1 Cold blast Valve
BF3-HBS-HBS1 Cold Blast bypass valve
BF3-HBS-HBS1 CHIMNEY VALVE

BF3-HBS-HBS1 CHIMNEY Bypass VALVE
BF3-HBS-HBS1 Air/Gas shut off valve
BF3-HBS-HBS1 Regulating valve
BF3-HBS-HBS1 Mixture Shut off valve

BF3-HBS-HBS1 Mixture regulating valve
BF3-HBS-HBS1 Goggle Valve
BF3-HBS-HBS1 HBS
HBS #1 AIR SHUT-OFF
BF3-HBS-HBS1
VALVE MOTOR
HBS #1 AIR SHUT-OFF

BF3-HBS-HBS1
VALVE MOTOR
HBS #1 AIR SHUT-OFF

BF3-HBS-HBS1
VALVE PANEL
HBS #1 AIR SHUT-OFF

BF3-HBS-HBS1
VALVE PANEL
HBS #1 AIR SHUT-OFF

BF3-HBS-HBS1
VALVE PANEL
HBS #1 GAS SHUT-OFF

BF3-HBS-HBS1
VALVE MOTOR
HBS #1 GAS SHUT-OFF

BF3-HBS-HBS1
VALVE MOTOR
HBS #1 GAS SHUT-OFF
BF3-HBS-HBS1
VALVE PANEL
HBS #1 GAS SHUT-OFF

BF3-HBS-HBS1
VALVE PANEL
HBS #1 GAS SHUT-OFF

BF3-HBS-HBS1
VALVE PANEL
BF3-HBS-HBS1 HBS SHELL

COMPONENT
HOT BLAST VALVE,
DISC FOR HOT BLAST VALVE
METAL JACKETED GASKET

CYLINDER FOR HOT BLAST VALVE -HBS,BF3
CHAIN FOR HBS VALVES
Simplex chain masterlink
Sprocket
Guide wheel
HT BOLT FOR FLANGE
METAL JACKETED GASKET-BONNET OF HBV-HBS
BACK DRAFT VALVE
METAL GASKET
CYLINDER FOR BACK DRAFT VALVE -HBS,BF3

HT BOLT FOR FLANGE
Simplex chain
Sprocket
Guide wheel
HT BOLTS
BURNER VALVE;
HYD.CYLINDER F/BURNER VALVE -HBS,BF3
METAL GASKET, GAS COMBUSTION VALVE, HBS
METAL JACKETED GASKET-BONNET-BURNER VALVE

Simplex chain
Sprocket
Guide wheel
COLD BLAST VALVE
HYD.CYLINDER F/COLD BLAST VALVE -HBS,BF3
METAL GASKET, COLD BLAST VALVE, HBS BF3
HT BOLTS FOR FLANGE
COLD BLAST bypass VALVE
HYD.CYLINDER F/COLD BLAST Bypass VALVE -HBS,BF3
CHIMNEY VALVE,
HYD.CYLINDER F/CHIMNEY VALVE -HBS,BF3
METAL CORE GASKET- CHIMNEY VALVE,HBS-BF3
HT BOLT
CHIMNEY bypass VALVE,
HYD.CYLINDER F/CHIMNEY bypassVALVE -HBS,BF3
SHUT OFF VALVE FOR AIR & GAS
ACTUATOR,FOR 700MM GAS/AIR SHUTOFF VALVE
SEAL OF GAS SHUTOF VALVE HBS BF3
HT BOLT & NUT
Gas / Air Regulating valve
HT BOLT & NUT
Metal GASKET,AIR/GAS REG. VLVE
MIXING AIR SHUTOFF VALVE,
Hydraulic cylinder MIXING AIR SHUTOFF VALVE
Bonnet gasket MIXING AIR SHUTOFF VALVE,DN700, BF3
GASKET,MIXING AIR SHUT OFF VALVE-HOT,HBS
GASKET,MIXING AIR SHUTOFF VALVE-COLD,HBS

HT BOLT & NUT
MIXING AIR REGULATING VALVE,
Goggle valve DN 1000
U Seal for Goggle valve
HBS burner bleeder valve
LT Motor Windings
Terminal Box
Power Contactor
Overload Relay
Internal OPEN / CLOSE Limit Switch
LT Motor Windings
Terminal Box
Power Contactor
Overload Relay
HBS SHELL
REFRACTORY BRICKS CONDITION

CONDITION APPRAISAL OF HBS #1 EQUIPMENTS
CHECK FOR BODY DAMAGE
CHECK FOR BODY TEMPERATURE
CHECK FOR DP OF STOVE
CHECK FOR DISC OUTLET WATER TEMP.
CHECK FOR LEAKAGE FROM GASKET SEATING

CHECK FOR CYLINDER LEAKAGE
CHECK FOR DAMAGE
CHECK FOR LINKS DAMAGE
CHECK FOR SPROCKET TEETH DAMAGE
CHECK FOR GUIDE WHEEL GROOVE DAMAGE
CHECK FOR RUSTING

CHECK FOR RUSTING
CHECK FOR DAMAGE
CHECK FOR RUSTING

CHECK FOR DAMAGE
CHECK FOR RUSTING
CHECK FOR VALVE LEAKAGE

CHECK FOR RUSTING
CHECK FOR OPERATION OF ACTUATOR
CHECK FOR LEAKAGE FROM SEAL SEATING
CHECK FOR RUSTING
CHECK FOR RUSTING

CHECK FOR RUSTING
CHECK FOR CORROSION
CHECK FOR OPEARTION OF VALVE
Check for proper tigteness of the power cable

to the LT Motor

contactor terminals. Check for coil resistance
of the contactor.



Check for proper tigteness of the power cable

to the LT Motor
of the contactor.


CHECK FOR HOT AREAS FOR INTERNAL

CASTING/REFRACTORY LAYER DEPLITION
CHECK FOR CHOAKING OF BRICKS

NDITION APPRAISAL OF HBS #1 EQUIPMENTS
TYPE OF CHECK (RUN CHECK /
TOOLS REQUIRED
VISUAL RUN CHECK
TEMPERATURE GUN RUN CHECK
VISUAL FROM PLC RUN CHECK
TEMPERATURE GUN RUN CHECK
VISUAL RUN CHECK

VISUAL RUN CHECK
VISUAL STOP CHECK
VISUAL STOP CHECK
VISUAL STOP CHECK
VISUAL STOP CHECK
VISUAL RUN CHECK
VISUAL RUN CHECK
VISUAL RUN CHECK
VISUAL RUN CHECK
VISUAL RUN CHECK

VISUAL RUN CHECK
VISUAL STOP CHECK
VISUAL STOP CHECK
VISUAL STOP CHECK
VISUAL STOP CHECK
VISUAL RUN CHECK
VISUAL RUN CHECK
VISUAL RUN CHECK
VISUAL RUN CHECK
VISUAL RUN CHECK

VISUAL STOP CHECK
VISUAL STOP CHECK
VISUAL STOP CHECK
VISUAL STOP CHECK
VISUAL RUN CHECK
VISUAL RUN CHECK
VISUAL RUN CHECK
VISUAL RUN CHECK
VISUAL RUN CHECK
VISUAL RUN CHECK
VISUAL RUN CHECK

VISUAL RUN CHECK
VISUAL RUN CHECK
VISUAL RUN CHECK
VISUAL RUN CHECK
VISUAL RUN CHECK
VISUAL RUN CHECK
VISUAL RUN CHECK
VISUAL RUN CHECK
VISUAL RUN CHECK
VISUAL RUN CHECK
VISUAL RUN CHECK
VISUAL RUN CHECK
VISUAL RUN CHECK
VISUAL RUN CHECK
VISUAL RUN CHECK
VISUAL RUN CHECK
VISUAL RUN CHECK

VISUAL RUN CHECK
VISUAL RUN CHECK
VISUAL RUN CHECK
VISUAL RUN CHECK
VISUAL RUN CHECK
Megger & Multimeter Shut Down check
Spanners, Screw Drivers, Allen

SHUTDOWN CHECK
Key, Multimeter
Visual SHUTDOWN CHECK
VISUAL / MULTIMETER RUN CHECK

Spanners, Screw Drivers, Allen
SHUTDOWN CHECK
Key, Multimeter
VISUAL / MULTIMETER RUN CHECK
THERMAL IMAGING CAMERS RUN CHECK
VISUAL INSPECTION S/D INSPECTION

IDEAL CONDITION ACTUAL CONDITION OBSERVED
NO BODY DAMAGE
TEMP <250*C
DP SHOULD BE
TEMP <45*C
NO LEAKAGE
NO LEAKAGE FROM CYLINDER
NO DAMAGE
NO DAMAGE
NO TEETH DAMAGE
NO DAMAGE
NO RUSTING
NO LEAKAGE
NO BODY DAMAGE
NO LEAKAGE

NO RUSTING
NO DAMAGE
NO DAMAGE
NO TEETH DAMAGE
NO DAMAGE
NO RUSTING
NO BODY DAMAGE
NO LEAKAGE
NO LEAKAGE
NO DAMAGE
NO DAMAGE
NO TEETH DAMAGE
NO DAMAGE
NO BODY DAMAGE
NO LEAKAGE
NO RUSTING
NO BODY DAMAGE
NO LEAKAGE
NO LEAKAGE
NO RUSTING
NO BODY DAMAGE
NO BODY DAMAGE
ACTUATOR SHOULD BE OPEARTING
WITHOUT JERKS
NO LEAKAGE
NO RUSTING
NO BODY DAMAGE
NO RUSTING
NO LEAKAGE
NO BODY DAMAGE
NO LEAKAGE
NO LEAKAGE
NO LEAKAGE
NO RUSTING
NO BODY DAMAGE
NO BODY DAMAGE
NO CORROSION
VALVE SHOULD NOT BE PASSING ON
CLOSING
than 10 ohms.
healthy condition.
ground.
Tightened with 8 mm Chrome No looseness of 8 mm Chrome

Vanadium Bolts. Vanadium bolts and connecting links.
Contactor rating to be LCID09, 09 A.

Contactor rating is LCID09, 09 A. No
contactor.
contacts and proper fitting to be done.
resistance of contactor checked 25
ohms.
ohms - 30 ohms.
Relay settings: Relay settings:

Relay Range = 2.5-4A Relay Range = 2.5-4A
Relay setting = 2.5A Relay setting = 2.5A
FC = 3 A Running Current = 2.2 A
Motor should stop running during Motor stop running during limit
limit switch operation. switch operation.
than 10 ohms.
healthy condition.
ground.
Tightened with 8 mm Chrome No looseness of 8 mm Chrome

Vanadium Bolts. Vanadium bolts and connecting links.
contactor.
ohms.
ohms - 30 ohms.

Relay setting = 2.5A Relay setting = 2.5A
FC = 3 A Running Current = 2.2 A
Motor should stop running during Motor stop running during limit
limit switch operation. switch operation.
THERMOGRAPHY REPORT
SHOULD BE NORMAL
BRICKS SHOULD NOT BE

CHOAKED
ACTION REQUIRED
BF3-HBS-HBS2
BF3-HBS-HBS2
BF3-HBS-HBS2 HBS
BF3-HBS-HBS2 HBS
BF3-HBS-HBS2
HBS #2 AIR SHUT-OFF
VALVE MOTOR
BF3-HBS-HBS2
HBS #2 AIR SHUT-OFF
VALVE MOTOR
BF3-HBS-HBS2
HBS #2 AIR SHUT-OFF
VALVE PANEL
BF3-HBS-HBS2
HBS #2 AIR SHUT-OFF
VALVE PANEL
BF3-HBS-HBS2
HBS #2 AIR SHUT-OFF
VALVE PANEL
BF3-HBS-HBS2
HBS #2 GAS SHUT-OFF
VALVE MOTOR
BF3-HBS-HBS2
HBS #2 GAS SHUT-OFF
VALVE MOTOR
BF3-HBS-HBS2
HBS #2 GAS SHUT-OFF
VALVE PANEL
BF3-HBS-HBS2
HBS #2 GAS SHUT-OFF
VALVE PANEL
BF3-HBS-HBS2
HBS #2 GAS SHUT-OFF
VALVE PANEL

CONDIT
COMPONENT Item Code
HOT BLAST VALVE, 5109000105
DISC FOR HOT BLAST VALVE 5109000106

METAL JACKETED GASKET 2502060005
CYLINDER FOR HOT BLAST VALVE -HBS,BF3 5109000060
CHAIN FOR HBS VALVES 5103020123
Simplex chain masterlink 5103020131
Sprocket
Guide wheel
HT BOLT FOR FLANGE 0601120201
METAL JACKETED GASKET-BONNET OF HBV- 2501030008
HBS
BACK DRAFT VALVE 5109000039
METAL GASKET 2501030003
CYLINDER FOR BACK DRAFT VALVE -HBS,BF3
HT BOLT FOR FLANGE 0601120201
Simplex chain 2116000028
Sprocket
Guide wheel
HT BOLTS 0601120184
BURNER VALVE; 5109000044
HYD.CYLINDER F/BURNER VALVE -HBS,BF3
METAL GASKET, GAS COMBUSTION VALVE, HBS 2501030004
METAL JACKETED GASKET-BONNET-BURNER VAL 2501030009
Simplex chain
Sprocket
Guide wheel
COLD BLAST VALVE 5109000041
HYD.CYLINDER F/COLD BLAST VALVE -HBS,BF3 5109000062
METAL GASKET, COLD BLAST VALVE, HBS BF3 2501030011
HT BOLTS FOR FLANGE 0601120181
COLD BLAST bypass VALVE 5014030010
HYD.CYLINDER F/COLD BLAST Bypass VALVE
-HBS,BF3
CHIMNEY VALVE, 5109000047
HYD.CYLINDER F/CHIMNEY VALVE -HBS,BF3
METAL CORE GASKET- CHIMNEY VALVE,HBS- 2502060007
BF3
HT BOLT 0601120201
CHIMNEY bypass VALVE, 5109000048
HYD.CYLINDER F/CHIMNEY bypassVALVE
-HBS,BF3
SHUT OFF VALVE FOR AIR & GAS 5109000046
ACTUATOR,FOR 700MM GAS/AIR SHUTOFF 5088000117
VALVE
SEAL OF GAS SHUTOF VALVE HBS BF3 5088000119
HT BOLT & NUT 0601120174
Gas / Air Regulating valve 5109000050
HT BOLT & NUT 5088110118
Metal GASKET,AIR/GAS REG. VLVE 2502060012
MIXING AIR SHUTOFF VALVE, 5109000042
Bonnet gasket MIXING AIR SHUTOFF
VALVE,DN700, BF3
GASKET,MIXING AIR SHUT OFF VALVE-HOT,HBS 2501030002
GASKET,MIXING AIR SHUTOFF VALVE-COLD,HBS 2501030007
HT BOLT & NUT 0601120201
MIXING AIR REGULATING VALVE, 5109000043
Goggle valve DN 1000 5107000039
U Seal for Goggle valve
HBS burner bleeder valve 5109000014
Metal GASKET: 770X700X4.5MM, AIR/GAS REG. 2502060012
VLVE
MIXING AIR SHUTOFF VALVE,DN700, BF3 5109000042
Bonnet gasket MIXING AIR SHUTOFF
VALVE,DN700, BF3
GASKET,MIXING AIR SHUT OFF VALVE-HOT,HBS 2501030002
GASKET,MIXING AIR SHUTOFF VALVE-COLD,HBS 2501030007
Disc COOLING HOSE 2" X 2.5 mtr 1702010742
M24X120 HT BOLT & NUT 0601120182
M30X130 HT BOLT & NUT 0601120201
MIXING AIR REGULATING VALVE,DN600, BF3 5109000043
Goggle valve DN 1000 5107000039
U Seal for Goggle valve DN 1000
HBS burner bleeder valve 5109000014
LT Motor Windings
Terminal Box
Power Contactor
Overload Relay
LT Motor Windings
Terminal Box
Power Contactor
Overload Relay
HBS SHELL
REFRACTORY BRICKS CONDITION

CONDITION APPRAISAL OF HBS #2 EQUIPMEN
DN1000,ASSEMBLYBF3(IND CHECK FOR BODY TEMPERATURE
IAN-FOURESS) CHECK FOR DP OF STOVE
DN1000(INDIAN-FOURESS) CHECK FOR DISC OUTLET WATER TEMP.
,1980X1895,HBV,HBS CHECK FOR LEAKAGE FROM GASKET SEATING
PITCH 31.75mm CHECK FOR DAMAGE
31.75mm CHECK FOR LINKS DAMAGE
CHECK FOR RUSTING
TYPE:GATE, DN700, BF3 CHECK FOR BODY DAMAGE
,BACK FLOW/DRAUGHT CHECK FOR LEAKAGE FROM GASKET SEATING
VALVE,HBS
CHECK FOR RUSTING
1" CHECK FOR DAMAGE
1" CHECK FOR LINKS DAMAGE
CHECK FOR RUSTING
TYPE:GATE; SIZE:700, BF3 CHECK FOR BODY DAMAGE
1" CHECK FOR DAMAGE
;TYPE:BTLF, DN900, BF3 CHECK FOR BODY DAMAGE
M24x110 CHECK FOR RUSTING
;TYPE:gate, DN250, BF3 CHECK FOR BODY DAMAGE
TYPE:CONNECTING, BF3 CHECK FOR VALVE LEAKAGE
M30X160 CHECK FOR RUSTING
TYPE:gate, DN250 BF3 CHECK FOR BODY DAMAGE
;DN 700, BF3 CHECK FOR BODY DAMAGE
CHECK FOR OPERATION OF ACTUATOR
CHECK FOR LEAKAGE FROM SEAL SEATING
Type: BTLF DN700, BF4 CHECK FOR BODY DAMAGE
: 770X700X4.5MM, CHECK FOR LEAKAGE FROM GASKET SEATING
DN700, BF3 CHECK FOR BODY DAMAGE
DN600, BF3 CHECK FOR BODY DAMAGE
DN 1000 CHECK FOR CORROSION
CHECK FOR OPEARTION OF VALVE

power cable to the LT Motor

contactor.

setting of relay current for motor
tripping.
Check for switching NO / NC Contact

10 A as per set value during hoisting
operation.


contactor.

setting of relay current for motor
tripping.
Check for switching NO / NC Contact

10 A as per set value during hoisting
operation.
CHECK FOR HOT AREAS FOR

INTERNAL CASTING/REFRACTORY
LAYER DEPLITION

F HBS #2 EQUIPMENTS
TYPE OF CHECK (RUN CHECK / IDEAL CONDITION ACTUAL CONDITION OBSERVED
VISUAL RUN CHECK NO BODY DAMAGE
TEMPERATURE GUN RUN CHECK TEMP <250*C
VISUAL FROM PLC RUN CHECK DP SHOULD BE
VISUAL RUN CHECK NO LEAKAGE
VISUAL RUN CHECK NO LEAKAGE FROM CYLINDER
VISUAL STOP CHECK NO TEETH DAMAGE
VISUAL RUN CHECK NO RUSTING
VISUAL RUN CHECK ACTUATOR SHOULD BE OPEARTING WITHOUT JERKS
VISUAL RUN CHECK NO CORROSION
VISUAL RUN CHECK VALVE SHOULD NOT BE PASSING ON CLOSING
Shut Down than 10 ohms.
Megger & Multimeter
check Megger values shouldbe above 5
ground.
Shut Down Tightened with 8 mm Chrome

Spanners
check Vanadium Bolts.

Spanners, Screw contactor.
SHUTDOWN
Drivers, Allen Key, No abnormalities to be seen for the
CHECK
Multimeter contacts and proper fitting to be done.
ohms - 30 ohms.
Relay settings:
SHUTDOWN Relay Range = 2.5-4A
Visual
CHECK Relay setting = 2.5A
FC = 3 A
VISUAL / Motor should stop running during

RUN CHECK
MULTIMETER limit switch operation.

Shut Down than 10 ohms.
Megger & Multimeter
check Megger values shouldbe above 5
ground.
Shut Down Tightened with 8 mm Chrome

Spanners
check Vanadium Bolts.
SHUTDOWN
CHECK
ohms - 30 ohms.
Relay settings:
Visual
FC = 3 A
VISUAL / Motor should stop running during

RUN CHECK
MULTIMETER limit switch operation.
THERMAL IMAGING THERMOGRAPHY REPORT

RUN CHECK
CAMERS SHOULD BE NORMAL
S/D BRICKS SHOULD NOT BE

VISUAL INSPECTION
INSPECTION CHOAKED
ACTION REQUIRED
healthy condition.

ohms.
Relay settings:
Relay Range = 2.5-4A

switch operation.

healthy condition.
ohms.
Relay settings:

switch operation.
BF3-HBS-HBS3
BF3-HBS-HBS3 HOT BLAST VALVE HOT BLAST VALVE,
BF3-HBS-HBS3
BF3-HBS-HBS3 HOT BLAST VALVE DISC FOR HOT BLAST VALVE
BF3-HBS-HBS3 HOT BLAST VALVE METAL JACKETED GASKET
CYLINDER FOR HOT BLAST
BF3-HBS-HBS3 HOT BLAST VALVE VALVE -HBS,BF3
BF3-HBS-HBS3 HOT BLAST VALVE CHAIN FOR HBS VALVES
BF3-HBS-HBS3 HOT BLAST VALVE Simplex chain masterlink
BF3-HBS-HBS3 HOT BLAST VALVE Sprocket
BF3-HBS-HBS3 HOT BLAST VALVE Guide wheel
BF3-HBS-HBS3 HOT BLAST VALVE HT BOLT FOR FLANGE
METAL JACKETED GASKET-
BF3-HBS-HBS3 HOT BLAST VALVE BONNET OF HBV-HBS
BF3-HBS-HBS3 BACK DRAFT VALVE BACK DRAFT VALVE
BF3-HBS-HBS3 BACK DRAFT VALVE METAL GASKET
CYLINDER FOR BACK
BF3-HBS-HBS3 BACK DRAFT VALVE DRAFT VALVE -HBS,BF3
BF3-HBS-HBS3 BACK DRAFT VALVE HT BOLT FOR FLANGE
BF3-HBS-HBS3 BACK DRAFT VALVE Simplex chain
BF3-HBS-HBS3 BACK DRAFT VALVE Simplex chain masterlink
BF3-HBS-HBS3 BACK DRAFT VALVE Sprocket
BF3-HBS-HBS3 BACK DRAFT VALVE Guide wheel
BF3-HBS-HBS3 BACK DRAFT VALVE HT BOLTS
BF3-HBS-HBS3 BURNER VALVE BURNER VALVE;
HYD.CYLINDER F/BURNER
VALVE
METAL-HBS,BF3
GASKET, GAS COMB
BF3-HBS-HBS3 BURNER VALVE USTION VALVE, HBS
BF3-HBS-HBS3 BURNER VALVE METAL JACKETED GASKET-B
BF3-HBS-HBS3 BURNER VALVE Simplex chain
BF3-HBS-HBS3 BURNER VALVE Simplex chain masterlink
BF3-HBS-HBS3 BURNER VALVE Sprocket
BF3-HBS-HBS3 BURNER VALVE Guide wheel
BF3-HBS-HBS3 Cold blast Valve COLD BLAST VALVE
HYD.CYLINDER F/COLD
BF3-HBS-HBS3 Cold blast Valve BLAST
METALVALVE
GASKET,-HBS,BF3
COLD
BLAST VALVE, HBS BF3
BF3-HBS-HBS3 Cold blast Valve HT BOLTS FOR FLANGE
BF3-HBS-HBS3 Cold Blast bypass valve COLD BLAST bypass
HYD.CYLINDER VALVE
F/COLD
BF3-HBS-HBS3 Cold Blast bypass valve BLAST Bypass VALVE
BF3-HBS-HBS3 CHIMNEY VALVE -HBS,BF3
CHIMNEY VALVE,
HYD.CYLINDER F/CHIMNEY
BF3-HBS-HBS3 CHIMNEY VALVE VALVE
METAL-HBS,BF3
CORE GASKET-
BF3-HBS-HBS3 CHIMNEY VALVE CHIMNEY VALVE,HBS-BF3
BF3-HBS-HBS3 CHIMNEY VALVE HT BOLT
BF3-HBS-HBS3 CHIMNEY Bypass VALVE CHIMNEY bypass VALVE,
HYD.CYLINDER F/CHIMNEY
BF3-HBS-HBS3 CHIMNEY Bypass VALVE bypassVALVE
SHUT OFF VALVE -HBS,BF3
FOR AIR &
BF3-HBS-HBS3 Air/Gas shut off valve ACTUATOR,FOR 700MM
GAS
BF3-HBS-HBS3 Air/Gas shut off valve GAS/AIR SHUTOFF
BF3-HBS-HBS3 Air/Gas shut off valve VALVE
SEAL OF GAS SHUTOF VALVE
BF3-HBS-HBS3 Air/Gas shut off valve HT BOLT & NUT
BF3-HBS-HBS3 Regulating valve Gas / Air Regulating valve
BF3-HBS-HBS3 Regulating valve HT BOLT & NUT
Metal GASKET,AIR/GAS REG.
BF3-HBS-HBS3 Regulating valve VLVE
BF3-HBS-HBS3 Mixture Shut off valve MIXING AIR SHUTOFF VALVE,
Hydraulic cylinder MIXING
BF3-HBS-HBS3 Mixture Shut off valve Bonnet gasket VALVE
MIXING AIR
AIR SHUTOFF
BF3-HBS-HBS3 Mixture Shut off valve SHUTOFF VALVE,DN700,
BF3-HBS-HBS3 Mixture Shut off valve BF3
GASKET,MIXING AIR SHUT OF
BF3-HBS-HBS3 Mixture Shut off valve GASKET,MIXING AIR SHUTOF
BF3-HBS-HBS3 Mixture Shut off valve HT BOLT & NUT
BF3-HBS-HBS3 Mixture regulating valve MIXING AIR REGULATING VAL
BF3-HBS-HBS3 Goggle Valve Goggle valve DN 1000
BF3-HBS-HBS3 Goggle Valve U Seal for Goggle valve
BF3-HBS-HBS3 HBS HBS
Metalburner
GASKET:bleeder valve
BF3-HBS-HBS3 Regulating valve 770X700X4.5MM, AIR/GAS
BF3-HBS-HBS3 Mixture Shut off valve REG. VLVE
MIXING AIR SHUTOFF VALVE,
Hydraulic cylinder MIXING
BF3-HBS-HBS3 Mixture Shut off valve Bonnet gasket VALVE
MIXING AIR
AIR SHUTOFF
BF3-HBS-HBS3 Mixture Shut off valve SHUTOFF VALVE,DN700,
BF3-HBS-HBS3 Mixture Shut off valve BF3
GASKET,MIXING AIR SHUT OF
BF3-HBS-HBS3 Mixture Shut off valve GASKET,MIXING AIR SHUTOF
Disc COOLING HOSE 2" X 2.5
mtr
BF3-HBS-HBS3 Mixture Shut off valve M24X120 HT BOLT & NUT
BF3-HBS-HBS3 Mixture Shut off valve M30X130 HT BOLT & NUT
BF3-HBS-HBS3 Mixture regulating valve MIXING AIR REGULATING VAL
BF3-HBS-HBS3 Goggle Valve Goggle valve DN 1000
U Seal for Goggle valve DN
BF3-HBS-HBS3 Goggle Valve 1000
BF3-HBS-HBS3 HBS HBS burner bleeder valve
HBS #3 AIR SHUT-OFF

BF3-HBS-HBS3
VALVE MOTOR
LT Motor Windings
HBS #3 AIR SHUT-OFF

BF3-HBS-HBS3
VALVE MOTOR
Terminal Box
HBS #3 AIR SHUT-OFF

BF3-HBS-HBS3
VALVE PANEL
Power Contactor
HBS #3 AIR SHUT-OFF

BF3-HBS-HBS3
VALVE PANEL
Overload Relay
BF3-HBS-HBS3
HBS #3 AIR SHUT-OFF Internal OPEN / CLOSE
HBS #3 GAS SHUT-OFF

BF3-HBS-HBS3
VALVE MOTOR
LT Motor Windings
HBS #3 GAS SHUT-OFF

BF3-HBS-HBS3
VALVE MOTOR
Terminal Box
HBS #3 GAS SHUT-OFF
BF3-HBS-HBS3
VALVE PANEL
Power Contactor
HBS #3 GAS SHUT-OFF

BF3-HBS-HBS3
VALVE PANEL
Overload Relay
BF3-HBS-HBS3
HBS #3 GAS SHUT-OFF Internal OPEN / CLOSE
BF3-HBS-HBS3 HBS SHELL HBS SHELL
REFRACTORY BRICKS
CONDITION
CONDITION APPRAISAL OF H
DESCRIPTION /
Item Code TOOLS REQUIRED
DIMENSION
5109000105 DN1000,ASSEMBLYBF CHECK FOR BODY TEMPERATURE
3(INDIAN-FOURESS) CHECK FOR DP OF STOVE
DN1000(INDIAN-
5109000106 CHECK FOR DISC OUTLET WATER TEMP.
FOURESS)
2502060005 ,1980X1895,HBV,HBS CHECK FOR LEAKAGE FROM GASKET SEATING
5109000060 CHECK FOR CYLINDER LEAKAGE
5103020123 PITCH 31.75mm CHECK FOR DAMAGE
5103020131 31.75mm CHECK FOR LINKS DAMAGE
0601120201 CHECK FOR RUSTING
2501030008 CHECK FOR LEAKAGE FROM GASKET SEATING
TYPE:GATE, DN700,
5109000039 ,BACK
BF3
2501030003 FLOW/DRAUGHT CHECK FOR LEAKAGE FROM GASKET SEATING
VALVE,HBS CHECK FOR CYLINDER LEAKAGE
2116000028 1" CHECK FOR DAMAGE
TYPE:GATE; SIZE:700, CHECK FOR BODY DAMAGE
5109000044 BF3
1" CHECK FOR DAMAGE
;TYPE:BTLF, DN900,
5109000041 CHECK FOR BODY DAMAGE
BF3
5109000062 CHECK FOR CYLINDER LEAKAGE
0601120181 M24x110 CHECK FOR RUSTING
;TYPE:gate, DN250,
BF3
TYPE:CONNECTING,
5109000047 CHECK FOR VALVE LEAKAGE
BF3
0601120201 M30X160 CHECK FOR RUSTING
5109000048 TYPE:gate, DN250 BF3 CHECK FOR BODY DAMAGE
5109000046 ;DN 700, BF3 CHECK FOR BODY DAMAGE
5088000117 CHECK FOR OPERATION OF ACTUATOR
5088000119 CHECK FOR LEAKAGE FROM SEAL SEATING
Type: BTLF DN700,
BF4
2502060012 : 770X700X4.5MM, CHECK FOR LEAKAGE FROM GASKET SEATING
5109000042 DN700, BF3 CHECK FOR BODY DAMAGE
5109000043 DN600, BF3 CHECK FOR BODY DAMAGE
DN 1000 CHECK FOR CORROSION
5109000014 CHECK FOR OPEARTION OF VALVE
2502060012
5109000042
2501030002
2501030007
1702010742
0601120182
0601120201
5109000043
5107000039
5109000014

with current to produce torque. Check for
Motor.

Check for contactor rating and tighteness

of contactor terminals. Check for coil

Check for switching NO / NC Contact as

10 A
per set value during hoisting operation.

Motor.



10 A
CHECK FOR HOT AREAS FOR

INTERNAL CASTING/REFRACTORY
LAYER DEPLITION

AISAL TYPE
OFOFHBS #1 EQUIPMENTS
CHECK (RUN
CHECK / STOP CHECK / IDEAL CONDITION ACTUAL CONDITION OBSERVED
SHUTDOWN)
VISUAL FROM PLC RUN CHECK DP SHOULD BE
VISUAL RUN CHECK ACTUATOR SHOULD BE OPEARTING WITHOUT JERKS
VISUAL RUN CHECK NO CORROSION
VISUAL RUN CHECK VALVE SHOULD NOT BE PASSING ON CLOSING
of all three phases, i.e., less than 10
Megger & ohms.
Shut Down check
Multimeter Megger values shouldbe above 5
ground.
Vanadium Bolts.

SHUTDOWN
CHECK
ohms - 30 ohms.
Relay settings:
Visual
FC = 3 A
VISUAL / Motor should stop running during limit

RUN CHECK
MULTIMETER switch operation.

Megger & ohms.
Shut Down check
ground.
Vanadium Bolts.
SHUTDOWN
CHECK
ohms - 30 ohms.
Relay settings:
Visual
FC = 3 A
VISUAL / Motor should stop running during limit

RUN CHECK
MULTIMETER switch operation.
THERMAL THERMOGRAPHY REPORT SHOULD

RUN CHECK
IMAGING CAMERS BE NORMAL
VISUAL S/D
BRICKS SHOULD NOT BE CHOAKED
INSPECTION INSPECTION
ACTION REQUIRED
condition.


Relay settings:

operation.

condition.

Relay settings:

operation.
CONDITION
Low Pressure pump PUMP PUMP DISCHARGE FLOW

Low Pressure pump PUMP PUMP DISCHARGE PRESSURE
Low Pressure pump PUMP Coupling(Indian) 0804070056
Low Pressure pump PUMP Pin bush assembly(Indian) 0804990103

Low Pressure pump PUMP Coupling bolt
Low Pressure pump PUMP Coupling bush
Low Pressure pump PUMP Bearing NDE/DE 0904030035
Low Pressure pump PUMP Impeller & Shaft
Low Pressure pump PUMP Mechanical seal
Low Pressure pump PUMP External circlip
Low Pressure pump PUMP MPP line filter
Low Pressure pump PUMP Wear ring
Low Pressure pump PUMP Outer spacer
Low Pressure pump PUMP Bearing sleeve
Low Pressure pump PUMP SUCTION VALVE
Low Pressure pump PUMP DISCHARGE VALVE
Low Pressure pump

Low Pressure pump SFU, 150 A
Panel
Low Pressure pump

Low Pressure pump MAIN POWER CONTACTOR
Panel
Low Pressure pump

Low Pressure pump CURRENT TRANSFORMER
Panel
Low Pressure pump
Low Pressure pump Motor Windings
Motor
Low Pressure pump

Low Pressure pump Terminal Box
Motor
Low Pressure pump

Low Pressure pump Overload Relay
Panel
CONDITION APPRAISAL OF LOW PRESSURE PUMP #01
TYPE OF CHECK
(RUN CHECK /
STOP CHECK /
SHUTDOWN)
DISCHARGE FLOW CHECKING VISUAL/TRIAL RUN CHECK
DISCHARGE PRESSURE CHECKING VISUAL/TRIAL RUN CHECK
CHECK FOR DAMAGE VISUAL STOP CHECK
check for wear and damage VISUAL STOP CHECK

Check for damage VISUAL STOP CHECK
CHECK FOR CLEARANCE USING FILLER GAUGE STOP CHECK

CHECK FOR CLEARANCE VERNIER STOP CHECK
check for clogging and leakage VISUAL STOP CHECK
CLOSING I/L V/V AND
check for passing CHECKING AT DRAIN STOP CHECK
VALVE
CLOSING O/L V/V AND

check for passing CHECKING AT DRAIN STOP CHECK
POINT
Check for fuse rating and continuity VISUAL / SHUTDOWN

of input / output terminals. MULTIMETER CHECK
Spanners, Screw
For switching a power circuit with SHUTDOWN
Drivers, Allen Key,
higher current ratings CHECK
Multimeter

and measure the correct current VISUAL RUN CHECK
shown in the meter.
SHUTDOWN
energized with current to produce Megger & Multimeter
CHECK
torque.
Allows the power cable to be fixed

with the motor windings cable
properly insulated, clamped and
sealed connector to provide greater
SHUTDOWN
protecton from short circuiting of Spanners
CHECK
cables.
Check for cable termination
tighteness and properly glanding
done.

setting of relay current for motor Visual Shut Down check
tripping.
PUMP #01
ACTION
REQUIRED
NO CRACKS
no damage
NO THREAD AND BODY DAMAGE

no damage
CLEARANCE <0.5MM
NO CAVITATION
2<DL<4
NO CRACKS
NO LEAKAGES
CLEARANCE <
NO PASSING
NO PASSING
SFU Unit should be clean. Check for fuse

SFU Unit is clean. Fuse taing and continuity of
taing and continuity of fuse input /
fuse input / output terminals are normal
output terminals.

Proper tighteness of foundation of Contactor rating is LCID11, 11 A. No looseness
contactor. in fitting of contactor and connection of cables
No abnormalities to be seen for the to power contactor and its contacts. Coil
contacts and proper fitting to be done. resistance is 40 ohms.
CT connections should be tight and

should measure current accurately on CT connections are tight and display accurate
the ammeter. CT rating should be 150 / current on the ammeter. CT rating is 150 / 5.
5.
resistances.
ohms.
Winding resistances of all three are 8.5 ohms.
Megger values are 1000 mega ohms phase to
ground and are in healthy condition.
ground.
Tightened with 8mm Chrome Vanadium No looseness of 8mm Chrome Vanadium bolts

(1-3.5)A (1-3.5)A
FLC = 62.5A RC = 60.0A
CONDITION APPRAISAL OF LOW
Sub
EQUIPMENT: Equipments COMPONENT Item Code

Low Pressure
Low Pressure pump pump Panel SFU, 150 A
Low Pressure
Low Pressure pump pump Panel MAIN POWER CONTACTOR
Low Pressure
Low Pressure pump pump Panel CURRENT TRANSFORMER
Low Pressure
Low Pressure pump pump Motor Motor Windings
Low Pressure
Low Pressure pump pump Motor Terminal Box
Low Pressure
Low Pressure pump pump Panel Overload Relay
NDITION APPRAISAL OF LOW PRESSURE PUMP #02
TYPE OF CHECK
TOOLS (RUN CHECK /
DESCRIPTION / DIMENSION IDEAL CONDITION
REQUIRED STOP CHECK /
SHUTDOWN)

CHECK FOR DAMAGE VISUAL STOP CHECK NO CRACKS
CHECK FOR DAMAGE VISUAL STOP CHECK no damage
check for wear and damage VISUAL STOP CHECK NO THREAD AND BODY DAMAGE
Check for damage VISUAL STOP CHECK no damage
CHECK FOR CLEARANCE USING FILLER GAU STOP CHECK CLEARANCE <0.5MM
check for wear and damage VISUAL STOP CHECK NO CAVITATION
CHECK FOR CLEARANCE VERNIER STOP CHECK 2<DL<4
Check for damage VISUAL STOP CHECK NO CRACKS
check for clogging and leakage VISUAL STOP CHECK NO LEAKAGES
CHECK FOR CLEARANCE VERNIER STOP CHECK CLEARANCE <
check for passing CLOSING I/L V/V A STOP CHECK NO PASSING
check for passing CLOSING O/L V/V ASTOP CHECK NO PASSING

Check for fuse rating and
VISUAL / SHUTDOWN Check for fuse taing and
continuity of input / output
MULTIMETER CHECK continuity of fuse input /
terminals.
output terminals.
Contactor rating to be LCID11,

11 A. Proper tighteness of
Spanners, Screw
For switching a power circuit SHUTDOWN No abnormalities to be seen for
Drivers, Allen
with higher current ratings CHECK the contacts and proper fitting
Key, Multimeter
to be done.
ohms.
Check for tighteness of CT connections should be tight
connections and measure the and should measure current
VISUAL RUN CHECK
correct current shown in the accurately on the ammeter. CT
meter. rating should be 150 / 5.

Megger & SHUTDOWN i.e., less than 10 ohms.
Multimeter CHECK Megger values shouldbe above
produce torque.
phases to ground.
Allows the power cable to be

fixed with the motor windings
cable properly insulated, clamped
and sealed connector to provide
SHUTDOWN Tightened with 8mm Chrome
greater protecton from short Spanners
CHECK Vanadium Bolts.
circuiting of cables.
done.
Relay Range :
Shut Down (1-3.5)A
check Relay settings = 3.1A
motor tripping.
FLC = 91.5A
OBSERVED REQUIRED
SFU Unit is clean.

Fuse taing and
continuity of fuse
input / output
Contactor rating is
LCID11, 11 A. No
looseness in fitting of
contactor and
connection of cables
to power contactor
resistance is 39.7
ohms.
CT connections are
tight and display
accurate current on
the ammeter. CT
rating is 150 / 5.
No abnormal
resistances.
Winding resistances
of all three are 8.5
ohms. Megger values
are 1000 mega ohms
phase to ground and
are in healthy
condition.
No looseness of 8mm
Chrome Vanadium
links.
Relay Range :
(1-3.5)A
RC = 90.0A
CONDITION APPRAISAL OF LOW
Sub

Low Pressure
Low Pressure pump pump Panel SFU, 150 A
Low Pressure
Low Pressure pump pump Panel MAIN POWER CONTACTOR
Low Pressure
Low Pressure pump pump Panel CURRENT TRANSFORMER
Low Pressure
Low Pressure pump pump Motor Motor Windings
Low Pressure
Low Pressure pump pump Motor Terminal Box
Low Pressure
Low Pressure pump pump Panel Overload Relay
NDITION APPRAISAL OF LOW PRESSURE PUMP #03
TYPE OF CHECK
TOOLS (RUN CHECK /
DESCRIPTION / DIMENSION IDEAL CONDITION
REQUIRED STOP CHECK /
SHUTDOWN)

CHECK FOR DAMAGE VISUAL STOP CHECK NO CRACKS
CHECK FOR DAMAGE VISUAL STOP CHECK no damage
check for wear and damage VISUAL STOP CHECK NO THREAD AND BODY DAMAGE
Check for damage VISUAL STOP CHECK no damage
CHECK FOR CLEARANCE USING FILLER GAU STOP CHECK CLEARANCE <0.5MM
check for wear and damage VISUAL STOP CHECK NO CAVITATION
CHECK FOR CLEARANCE VERNIER STOP CHECK 2<DL<4
Check for damage VISUAL STOP CHECK NO CRACKS
check for clogging and leakage VISUAL STOP CHECK NO LEAKAGES
CHECK FOR CLEARANCE VERNIER STOP CHECK CLEARANCE <
check for passing CLOSING I/L V/V A STOP CHECK NO PASSING
check for passing CLOSING O/L V/V ASTOP CHECK NO PASSING
Check for fuse rating and
VISUAL / SHUTDOWN Check for fuse taing and
continuity of input / output
MULTIMETER CHECK continuity of fuse input /
terminals.
output terminals.
Contactor rating to be LCID11,

Spanners, Screw
For switching a power circuit SHUTDOWN No abnormalities to be seen for
Drivers, Allen
with higher current ratings CHECK the contacts and proper fitting
Key, Multimeter
to be done.
ohms.
Check for tighteness of CT connections should be tight

connections and measure the and should measure current
VISUAL RUN CHECK
correct current shown in the accurately on the ammeter. CT
meter. rating should be 150 / 5.
Megger & SHUTDOWN i.e., less than 10 ohms.
Multimeter CHECK Megger values shouldbe above
produce torque.
phases to ground.
Allows the power cable to be

fixed with the motor windings
cable properly insulated, clamped
and sealed connector to provide
SHUTDOWN Tightened with 8mm Chrome
greater protecton from short Spanners
CHECK Vanadium Bolts.
circuiting of cables.
done.
Relay Range :
Shut Down (1-3.5)A
motor tripping.
FLC = 62.5A
OBSERVED REQUIRED
CONDITION APPRAISAL O
Sub
Medium Pressure pump PUMP PUMP DISCHARGE FLOW

Medium Pressure pump PUMP PUMP DISCHARGE PRESSURE
Medium Pressure pump PUMP Coupling(Indian) 0804070054
Medium Pressure pump PUMP Pin bush assembly(Indian) 0804990102
Medium Pressure pump PUMP Coupling bolt 0804990114
Medium Pressure pump PUMP Coupling bush 0804990078
Medium Pressure pump PUMP Bearing NDE/DE 0904030062
Medium Pressure pump PUMP Impeller & Shaft 5499000454
Medium Pressure pump PUMP Mechanical seal 5499000453
Medium Pressure pump PUMP External circlip 0652090037
Medium Pressure pump PUMP MPP line filter 0615020020
Medium Pressure pump PUMP Wear ring 5476020001
Medium Pressure pump PUMP Outer spacer 5476020002
Medium Pressure pump PUMP Bearing sleeve 5476020003
Medium Pressure pump PUMP SUCTION VALVE
Medium Pressure pump PUMP DISCHARGE VALVE
HT PANEL BUSBARS
HT PANEL EARTHING
HT PANEL BUSBAR
HORIZONTAL AND
VERTICAL INSULATOR
OUTGOIN HT BREAKER
G TO
MEDIUM
PRESSUR
E PUMP 1
PANEL
MEDIUM
PRESSURE PUMP
#1
HT NUMERICAL
PROTECTIVE RELAY
HT CABLES
CURRENT TRANSDUCER
POTENTIAL
TRANSFORMER
CURRENT TRANSFORMER
MAIN
MOTOR- HT Motor Windings
MPP 1
MAIN
MOTOR- Terminal Box
MPP 1
CONDITION APPRAISAL OF MEDIUM PRESSURE PUMP #01
TYPE OF CHECK
TOOLS (RUN CHECK /
DESCRIPTION / DIMENSION REQUIRED STOP CHECK /
SHUTDOWN)
CHECK FOR CLEARANCE USING FILLER GAU STOP CHECK
check for passing CLOSING I/L V/V A STOP CHECK
check for passing CLOSING O/L V/V ASTOP CHECK
busbar and busbar support insulator. SPANNERS /
SHUTDOWN
It should have sufficient stiffness to TORQUE
CHECK
be supported in air by insulated WRENCH
pillars.

VISUAL /
should be generally uninsulated, and SHUTDOWN
COTTON
should be proper insulation between CHECK
CLOTHE
busbar and switchgear panel
Check for megger value of Busbar SHUTDOWN

HT MEGGER
and panel body. CHECK
Check for proper interlocking of
earth switch and HT Breaker. Also, SHUTDOWN
VISUAL
check for interlocking of earth CHECK
switch and panel back door.
Check for earthing of the Panel

VISUAL RUN CHECK
body.
Check for Oxydation of busbars and LEAKAGE

RUN CHECK
insulators due to moisture content. TESTER

mechanical strength used in
electrical panels to support the SHUTDOWN
VISUAL
copper busbar. Check for megger CHECK
value between insulator and panel
body.
VISUAL,
COTTON
VISUAL,
COTTON
CLOTHE,
CRC,
DIELECTRIC SHUTDOWN
from an overload or short circuit. Its
ISOPLEX & CHECK
SHELL
TELLUS 32
GREASE, HT
MEGGER
SECONDARY
To detect the fault and initiates the INJECTION
operation of circuit breaker to CURRENT SHUTDOWN
isolate the defective element from AND CHECK
the rest of the system. VOLTAGE
TEST KIT
Check for proper tigteness of the SPANNERS /

SHUTDOWN
power cable and HT Breaker TORQUE
CHECK
Terminals. WRENCH
Check for megger value of HT

SHUTDOWN
Cable phase to phae and phase to MEGGER
CHECK
earth.
Check for partial discharge test of

TAN-DELTA SHUTDOWN
HT Cable for HT Cable insualtion
TEST KIT CHECK
testing.
Check for output current shown on VISUAL /

RUN CHECK
SCADA in Control Room. MULTIMTER
VISUAL /
SECONDARY
INJECTION
indication shown in the meter. SHUTDOWN
CURRENT
Also, check for tripping of the HT CHECK
AND
VOLTAGE
Injection kit.
TEST KIT
VISUAL /
SECONDARY
INJECTION
shown in the meter. SHUTDOWN
CURRENT
Also, check for tripping of the HT CHECK
AND
VOLTAGE
Injection kit.
TEST KIT
Megger & Shut Down
produce torque. Check for
Multimeter check
value of Motor.
Check for TAN DELTA of the TAN-DELTA SHUTDOWN

motor. TEST KIT CHECK
Check for proper tigteness of the Shut Down

Spanners
power cable to the HT Motor check
UMP #01

IDEAL CONDITION OBSERVED REQUIRED
NO CRACKS
no damage
no damage
CLEARANCE <0.5MM
NO CAVITATION
2<DL<4
NO CRACKS
NO LEAKAGES
CLEARANCE <
NO PASSING
NO PASSING
Tightened with 12mm high tensile

stainless steel bolts with flat
connecting links checked by
washers and nuts by Torque
torque wrench.
Wrench.
Insulators should be installed Insulators were installed

properly to hold and support properly and was clean. No
busbars. Insulators should be oxydation observed between
clean. insulator and bubar.
Resistance between panel to Resistance between panel to

busbar should be ˃ 20 mega ohms. busbar is 1000 mega ohms.
Interlock of Earth Switch and
Interlock of Earth Switch and HT
HT Breaker is healthy. HT
Breaker should be healthy. HT
Breaker do not Rack In
Breaker should not Rack In
during Earth Switch operated
during Earth Switch operated
condition. Also, Back Door
condition. Also, Back Door of HT
of HT Panel has not been
Panel should not be open when
open when earth switch is not
operated.
Earthing is connected to the

body and to the Earth Pit.
No oxydation and moisture inside No oxydation and moisture

panel. Space Heater current inside panel. Space Heater
should be < 1 A current is 0.3 A
Vertical and Horizontal insulators Vertical and Horizontal

should provide high electrical and insulators strength to the
mechanical strength to the busbars are good. Also,
busbars. Also, megger value megger value is 1000 mega
should be ˃ 20 mega Ohms. Ohms.
HT Breaker should be clean. HT Breaker found clean.

There should not be any moisture There is no moisture or wear
or wear and rusting of contacts. and rusting of contacts.
Lubrication of all moving

Proper lubrication of all moving
parts of mechanism is
parts of mechanism.
normal.
Proper operation of gear box Operation of gear box
mechanism. mechanism is normal.
Operation of Test / Service
Proper operation of Test / Service
auxiliary switch operation is
auxiliary switch operation.
proper.
Closing and tripping
Proper closing and tripping
mechanism of breaker both
electrically and manually is
proper.
Proper spring charging operation Spring charging operation of
of limit switch. limit switch is normal.
Condition of contact arm Condition of contact arm
assembly of breaker should be assembly of breaker is
proper. proper.
Vacuum inside bottles should be Vacuum inside bottles is
normal. normal.
Insulation resistance between Insulation resistance between
Upper & Lower contacts should Upper & Lower contacts is >
be > 1 T Ohms 1 T Ohms
Insulation resistance between
Phase to Phase should be > 1 T
Phase to Phase is > 1 T Ohms
Ohms
Phase to Earth should be > 1 T
Phase to Earth is > 1 T Ohms
Ohms
Timing of CB during Close
Timing of CB during Close is
should be in ms of all three
42 ms of all three phases.
phases.
Timing of CB during Open should Timing of CB during Open is

be in ms of all three phases. 39 ms of all three phases.
Timing of CB during Close / Timing of CB during Close /

Open should be in ms of all three Open is 18 ms of all three
phases. phases.
Contact Resistance between Contact Resistance between
Upper and Lower contacts should Upper and Lower contacts is
be in micro ohms of all three 45 micro ohms of all three
phases. phases.
HVAC Test for 15 KV should HVAC Test for 15 KV
withstand for min. of all three withstand for min. of all three
phases. phases.
HT Breaker Numerical Relay
tripping is healthy to trip the
tripping should be healthy to trip
breaker on the faults
the breaker on the faults described
described in the relay on
in the relay on prescribed values.
prescribed values.

torque wrench.
Wrench.
Phase to Phase should be > 20
Phase to Phase is 1200 Ohms
Mega Ohms
Phase to Earth should be > 20 Phase to Earth is 1000Mega
Mega Ohms Ohms
TAN-DELTA test of HT Cable TAN-DELTA test of HT

should be < 0.004 absolute. Cable is 0.0010
Output ma is checked on
To check for ma output of Current
transducer and showing
Transducer and should display on
current display on SCADA
SCADA in Control Room.
correctly.
PT connections should be tight

PT connections are tight and
and should
display correct voltage on the
1. measure correct voltage on the
relay. Indication of voltage
relay or meter.
on the panel is shown.
2. provide indication of voltage on
Trippig of the HT Breaker
the panel.
through HT Relay on Over
3. trip the HT Breaker through HT
voltage / Under Voltage is
healthy.
Voltage.
CT connections should be tight

CT connections are tight and
and should
display accurate current on
1. measure current accurately on
the relay. Trippig of the HT
the relay or meter.
Breaker through HT Relay on
Over curent / CIR / ITOC /
Relay on Over curent / CIR /
DMT is healthy.
ITOC / DMT.
Megger values are 2 Giga
ohms and in healthy
phases to ground.
condition.
TAN-DELTA test of HT Motor TAN-DELTA test of HT

should be < 0.04 absolute. Motor is 0.0018
No looseness of 16 mm
Vanadium Bolts.
CONDITION APP

HT PANEL BUSBARS
HT PANEL EARTHING
HT PANEL BUSBAR
HORIZONTAL AND
VERTICAL INSULATOR
OUTGOING TO HT BREAKER
MEDIUM
PRESSURE
PUMP 2 PANEL
MEDIUM PRESSURE
PUMP #2
OUTGOING TO HT BREAKER
MEDIUM
PRESSURE
PUMP 2 PANEL
MEDIUM PRESSURE
PUMP #2
HT NUMERICAL
PROTECTIVE RELAY
HT CABLES
CURRENT TRANSDUCER
POTENTIAL
TRANSFORMER
CURRENT TRANSFORMER
MAIN MOTOR-
HT Motor Windings
MPP 2
MAIN MOTOR-
Terminal Box
MPP 2
TYPE OF CHECK
TOOLS (RUN CHECK /
SHUTDOWN)
USING FILLER
CHECK FOR CLEARANCE STOP CHECK
GAUGE
CLOSING I/L V/V
check for passing AND CHECKING AT STOP CHECK
DRAIN VALVE
CLOSING O/L V/V

check for passing AND CHECKING AT STOP CHECK
DRAIN POINT

busbar and busbar support
SPANNERS /
insulator. It should have SHUTDOWN
TORQUE
sufficient stiffness to be CHECK
WRENCH
supported in air by insulated
pillars.
Check for proper cleanliness of

the busbar insulator and panel
body. It should be generally VISUAL /
SHUTDOWN
uninsulated, and should be COTTON
CHECK
proper insulation between busbar CLOTHE
and switchgear panel through
busbar insualtor.
Check for megger value of SHUTDOWN
HT MEGGER
Busbar and panel body. CHECK
earth switch and HT Breaker.
SHUTDOWN
Also, check for interlocking of VISUAL
CHECK
earth switch and panel back
door.

VISUAL RUN CHECK
body.
Check for Oxydation of busbars
LEAKAGE
and insulators due to moisture RUN CHECK
TESTER
content.
electrical panels to support the SHUTDOWN
VISUAL
copper busbar. Check for megger CHECK
value between insulator and
panel body.
VISUAL,
COTTON
To protect an electrical circuit CLOTHE,
from damage caused by excess CRC,
current from an overload or short DIELECTRIC SHUTDOWN
circuit. Its basic function is to ISOPLEX & CHECK
interrupt current flow after a SHELL
fault is detected. TELLUS 32
GREASE, HT
MEGGER
current from an overload or short DIELECTRIC SHUTDOWN
circuit. Its basic function is to ISOPLEX & CHECK
interrupt current flow after a SHELL
fault is detected. TELLUS 32
GREASE, HT
MEGGER
SECONDARY
To detect the fault and initiates INJECTION
the operation of circuit breaker CURRENT SHUTDOWN
to isolate the defective element AND CHECK
from the rest of the system. VOLTAGE
TEST KIT
Check for proper tigteness of the SPANNERS /
SHUTDOWN
power cable and HT Breaker TORQUE
CHECK
Terminals. WRENCH
SHUTDOWN
CHECK
earth.
Check for partial discharge test

TAN-DELTA SHUTDOWN
of HT Cable for HT Cable
TEST KIT CHECK
insualtion testing.
Check for output current shown VISUAL /

RUN CHECK
on SCADA in Control Room. MULTIMTER
Check for tighteness of VISUAL /
connections and measure the SECONDARY
correct voltage and indication INJECTION
SHUTDOWN
shown in the meter. CURRENT
CHECK
Also, check for tripping of the AND
HT Numerical Relay by VOLTAGE
Secondary Injection kit. TEST KIT
Check for tighteness of VISUAL /

connections and measure the SECONDARY
correct current shown in the INJECTION
SHUTDOWN
meter. CURRENT
CHECK
Also, check for tripping of the AND
HT Numerical Relay by VOLTAGE
Secondary Injection kit. TEST KIT

Megger & Shut Down
Multimeter check
Check for TAN DELTA of the TAN-DELTA SHUTDOWN

motor. TEST KIT CHECK
Shut Down
the power cable to the HT Spanners
check
Motor
PUMP #02
ACTION
IDEAL CONDITION ACTUAL CONDITION OBSERVED REQUIRED
NO CRACKS
no damage
no damage
CLEARANCE <0.5MM
NO CAVITATION
2<DL<4
NO CRACKS
NO LEAKAGES
CLEARANCE <
NO PASSING
NO PASSING
Tightened with 12mm high tensile No looseness of the bolts and

stainless steel bolts with flat washers connecting links checked by torque
and nuts by Torque Wrench. wrench.
Insulators should be installed properly Insulators were installed properly and

to hold and support busbars. Insulators was clean. No oxydation observed
should be clean. between insulator and bubar.
Resistance between panel to busbar Resistance between panel to busbar is

should be ˃ 20 mega ohms. 1000 mega ohms.
Interlock of Earth Switch and HT Interlock of Earth Switch and HT
Breaker should be healthy. HT Breaker Breaker is healthy. HT Breaker do not
should not Rack In during Earth Rack In during Earth Switch operated
Switch operated condition. Also, Back condition. Also, Back Door of HT
Door of HT Panel should not be open Panel has not been open when earth
when earth switch is not operated. switch is not operated.
Earthing is connected to the body and

to the Earth Pit.
No oxydation and moisture inside
panel. Space Heater current should be
panel. Space Heater current is 0.3 A
< 1A
Vertical and Horizontal insulators

should provide high electrical and
strength to the busbars are good.
mechanical strength to the busbars.
Also, megger value is 1000 mega
Also, megger value should be ˃ 20 Ohms.
mega Ohms.
HT Breaker should be clean. There HT Breaker found clean. There is no

should not be any moisture or wear moisture or wear and rusting of
and rusting of contacts. contacts.
Proper lubrication of all moving parts Lubrication of all moving parts of
of mechanism. mechanism is normal.
Proper operation of gear box Operation of gear box mechanism is
mechanism. normal.
Proper operation of Test / Service Operation of Test / Service auxiliary

auxiliary switch operation. switch operation is proper.
Proper closing and tripping mechanism Closing and tripping mechanism of

of breaker both electrically and breaker both electrically and
manually. manually is proper.
Proper spring charging operation of Spring charging operation of limit
limit switch. switch is normal.
Condition of contact arm assembly of Condition of contact arm assembly of
breaker should be proper. breaker is proper.
Vacuum inside bottles should be
normal.
Insulation resistance between Upper & Insulation resistance between Upper

Lower contacts should be > 1 T Ohms & Lower contacts is > 1 T Ohms
Insulation resistance between Phase to Insulation resistance between Phase
Phase should be > 1 T Ohms to Phase is > 1 T Ohms
Earth should be > 1 T Ohms to Earth is > 1 T Ohms
Timing of CB during Close should be Timing of CB during Close is 42 ms
in ms of all three phases. of all three phases.
Timing of CB during Open should be Timing of CB during Open is 39 ms
in ms of all three phases. of all three phases.
Timing of CB during Close / Open Timing of CB during Close / Open is
should be in ms of all three phases. 18 ms of all three phases.
Contact Resistance between Upper and Contact Resistance between Upper
Lower contacts should be in micro and Lower contacts is 45 micro ohms
ohms of all three phases. of all three phases.
HVAC Test for 15 KV should HVAC Test for 15 KV withstand for

withstand for min. of all three phases. min. of all three phases.
HT Breaker Numerical Relay tripping HT Breaker Numerical Relay tripping

should be healthy to trip the breaker on is healthy to trip the breaker on the
the faults described in the relay on faults described in the relay on
prescribed values. prescribed values.


Phase should be > 20 Mega Ohms to Phase is 1200 Ohms

Earth should be > 20 Mega Ohms to Earth is 1000Mega Ohms
TAN-DELTA test of HT Cable should TAN-DELTA test of HT Cable is

be < 0.004 absolute. 0.0018
To check for ma output of Current Output ma is checked on transducer

Transducer and should display on and showing current display on
SCADA in Control Room. SCADA correctly.
PT connections should be tight and
should
1. measure correct voltage on the relay
correct voltage on the relay.
or meter.
Indication of voltage on the panel is
2. provide indication of voltage on the
shown. Trippig of the HT Breaker
panel.
through HT Relay on Over voltage /
Under Voltage is healthy.
Voltage.

should CT connections are tight and display
1. measure current accurately on the accurate current on the relay. Trippig
relay or meter. of the HT Breaker through HT Relay
2. trip the HT Breaker through HT on Over curent / CIR / ITOC / DMT
Relay on Over curent / CIR / ITOC / is healthy.
DMT.

balanced of all three phases, i.e.,
less than 5 ohms.
ohms. Megger values are 2 Giga
ohms and in healthy condition.
ground.
TAN-DELTA test of HT Motor should TAN-DELTA test of HT Motor is
be < 0.04 absolute. 0.0021
Vanadium Bolts.
links.
COND
Sub

HT PANEL BUSBARS
HT PANEL EARTHING
HT PANEL BUSBAR
HORIZONTAL AND VERTICAL
INSULATOR
HT BREAKER
OUTGOIN
G TO
MEDIUM
PRESSUR
E PUMP 3
PANEL
MEDIUM PRESSURE
PUMP #3
HT NUMERICAL PROTECTIVE
RELAY
HT CABLES
CURRENT TRANSDUCER
CURRENT TRANSFORMER
MAIN
MOTOR- HT Motor Windings
MPP 3
MAIN
MOTOR- Terminal Box
MPP 3
DISCHARGE FLOW CHECKING VISUAL/TRIAL

DISCHARGE PRESSURE CHECKING VISUAL/TRIAL
CHECK FOR DAMAGE VISUAL
CHECK FOR DAMAGE VISUAL
check for wear and damage VISUAL
Check for damage VISUAL
CHECK FOR CLEARANCE USING FILLER GAUGE
check for wear and damage VISUAL
CHECK FOR CLEARANCE VERNIER
Check for damage VISUAL
check for clogging and leakage VISUAL
check for passing CLOSING I/L V/V AND CHECKING AT DRAIN VALVE
check for passing CLOSING O/L V/V AND CHECKING AT DRAIN POINT
busbar and busbar support insulator.
It should have sufficient stiffness to SPANNERS / TORQUE WRENCH
be supported in air by insulated
pillars.

should be generally uninsulated, and
VISUAL / COTTON CLOTHE
should be proper insulation between
busbar and switchgear panel

HT MEGGER
and panel body.
earth switch and HT Breaker. Also,
VISUAL
check for interlocking of earth
switch and panel back door.

VISUAL
body.

LEAKAGE TESTER

electrical panels to support the
VISUAL
copper busbar. Check for megger
value between insulator and panel
body.
damage caused by excess current VISUAL, COTTON CLOTHE, CRC,
from an overload or short circuit. Its DIELECTRIC ISOPLEX & SHELL TELLUS 32
basic function is to interrupt current GREASE, HT MEGGER
operation of circuit breaker to SECONDARY INJECTION CURRENT AND
isolate the defective element from VOLTAGE TEST KIT
the rest of the system.

power cable and HT Breaker SPANNERS / TORQUE WRENCH
Terminals.

earth.
Check for partial discharge test of

HT Cable for HT Cable insualtion TAN-DELTA TEST KIT
testing.
Check for output current shown on
VISUAL / MULTIMTER
SCADA in Control Room.

indication shown in the meter. VISUAL / SECONDARY INJECTION
Also, check for tripping of the HT CURRENT AND VOLTAGE TEST KIT
Injection kit.

shown in the meter. VISUAL / SECONDARY INJECTION
Also, check for tripping of the HT CURRENT AND VOLTAGE TEST KIT
Injection kit.

produce torque. Check for Megger & Multimeter
value of Motor.
Check for TAN DELTA of the
TAN-DELTA TEST KIT
motor.

Spanners
UMP #02
TYPE OF CHECK (RUN CHECK / ACTUAL CONDITION

IDEAL CONDITION
STOP CHECK / SHUTDOWN) OBSERVED
RUN CHECK
RUN CHECK
STOP CHECK NO CRACKS
STOP CHECK no damage
STOP CHECK NO THREAD AND BODY DAMAGE
STOP CHECK no damage
STOP CHECK NO CAVITATION
STOP CHECK 2<DL<4
STOP CHECK NO CRACKS
STOP CHECK NO LEAKAGES
STOP CHECK
STOP CHECK
STOP CHECK CLEARANCE <
STOP CHECK NO PASSING
STOP CHECK NO PASSING
No looseness of the
Tightened with 12mm high
bolts and
tensile stainless steel bolts with
SHUTDOWN CHECK connecting links
flat washers and nuts by Torque
checked by torque
Wrench.
wrench.
Insulators were
Insulators should be installed installed properly
properly to hold and support and was clean. No
SHUTDOWN CHECK
busbars. Insulators should be oxydation observed
clean. between insulator
and bubar.
Resistance between panel to Resistance between

SHUTDOWN CHECK busbar should be ˃ 20 mega panel to busbar is
ohms. 1000 mega ohms.
Interlock of Earth
Switch and HT
Interlock of Earth Switch and Breaker is healthy.
HT Breaker should be healthy. HT Breaker do not
HT Breaker should not Rack In Rack In during
during Earth Switch operated Earth Switch
SHUTDOWN CHECK
condition. Also, Back Door of operated condition.
HT Panel should not be open Also, Back Door of
when earth switch is not HT Panel has not
operated. been open when
earth switch is not
operated.
Earthing is
connected to the
body and to the
Earth Pit.
No oxydation and
No oxydation and moisture
moisture inside
RUN CHECK inside panel. Space Heater
panel. Space Heater
current is 0.3 A
Vertical and
Horizontal
insulators should provide high
insulators strength
electrical and mechanical
SHUTDOWN CHECK to the busbars are
strength to the busbars. Also,
good. Also, megger
megger value should be ˃ 20
mega Ohms.
value is 1000 mega
Ohms.
HT Breaker found
HT Breaker should be clean.
clean. There is no
There should not be any
moisture or wear
moisture or wear and rusting of
and rusting of
contacts.
contacts.
Lubrication of all
Proper lubrication of all moving moving parts of
parts of mechanism. mechanism is
normal.
Operation of gear
Proper operation of gear box
box mechanism is
mechanism.
normal.
Operation of Test /
Proper operation of Test /
Service auxiliary
Service auxiliary switch
switch operation is
operation.
proper.

mechanism of breaker both breaker both
electrically and manually. electrically and
manually is proper.
Spring charging
Proper spring charging operation
operation of limit
of limit switch.
switch is normal.
Condition of contact arm Condition of contact

assembly of breaker should be arm assembly of
proper. breaker is proper.
Vacuum inside bottles should be Vacuum inside

normal. bottles is normal.
SHUTDOWN CHECK Insulation resistance

between Upper &
Upper & Lower contacts should
Lower contacts is >
be > 1 T Ohms
1 T Ohms
between Phase to
Phase is > 1 T
Ohms
Ohms
Insulation resistance between Insulation resistance

Phase to Earth should be > 1 T between Phase to
Ohms Earth is > 1 T Ohms
Timing of CB
Timing of CB during Close
during Close is 42
ms of all three
phases.
phases.
Timing of CB
Timing of CB during Open
during Open is 39
ms of all three
phases.
phases.
Timing of CB
Timing of CB during Close /
during Close / Open
Open should be in ms of all
is 18 ms of all three
three phases.
phases.
Contact Resistance
Contact Resistance between
between Upper and
Upper and Lower contacts
Lower contacts is
should be in micro ohms of all
45 micro ohms of
three phases.
all three phases.
HVAC Test for 15

HVAC Test for 15 KV should
KV withstand for
withstand for min. of all three
min. of all three
phases.
phases.
HT Breaker
Numerical Relay
tripping is healthy
to trip the breaker
SHUTDOWN CHECK the breaker on the faults
on the faults
described in the relay on
described in the
prescribed values.
relay on prescribed
values.
No looseness of the
bolts and
tensile stainless steel bolts with
SHUTDOWN CHECK connecting links
flat washers and nuts by Torque
checked by torque
Wrench.
wrench.
Insulation resistance between Insulation resistance

SHUTDOWN CHECK Phase to Phase should be > 20 between Phase to
Mega Ohms Phase is 1200 Ohms
between Phase to
Phase to Earth should be > 20
Earth is 1000Mega
Mega Ohms
Ohms
TAN-DELTA test of HT Cable TAN-DELTA test of

SHUTDOWN CHECK
should be < 0.004 absolute. HT Cable is 0.0018
Output ma is
To check for ma output of checked on
Current Transducer and should transducer and
RUN CHECK
display on SCADA in Control showing current
Room. display on SCADA
correctly.
PT connections are
PT connections should be tight tight and display
and should correct voltage on
1. measure correct voltage on the relay. Indication
the relay or meter. of voltage on the
SHUTDOWN CHECK 2. provide indication of voltage panel is shown.
on the panel. Trippig of the HT
3. trip the HT Breaker through Breaker through HT
HT Relay on Over voltage / Relay on Over
Under Voltage. voltage / Under
Voltage is healthy.
CT connections are
CT connections should be tight tight and display
and should accurate current on
1. measure current accurately on the relay. Trippig of
SHUTDOWN CHECK the relay or meter. the HT Breaker
2. trip the HT Breaker through through HT Relay
HT Relay on Over curent / CIR / on Over curent /
ITOC / DMT. CIR / ITOC / DMT
is healthy.
No abnormal
difference in
winding
resistances.
Winding
phases, i.e., less than 5 ohms.
Shut Down check resistance of all
three phases is 0.7
ohms. Megger
values are 2 Giga
ohms and in
healthy condition.
TAN-DELTA test of HT Motor TAN-DELTA test of
SHUTDOWN CHECK
should be < 0.04 absolute. HT Motor is 0.0021
No looseness of 16
mm Chrome
Tightened with 16mm
Shut Down check Vanadium bolts
and connecting
links.
ACTION
REQUIRED
SP-COOL-ABC SP-COOL-ABC GEAR BOX SINTER COOLER

SP-COOL-ABC SP-COOL-ABC SINTER COOLER PALLET WHEEL
SP-COOL-ABC SP-COOL-ABC SINTER COOLER GUIDE WHEEL
SP-COOL-ABC SP-COOL-ABC SPROCKET,
SP-COOL-ABC SP-COOL-ABC SPROCKET
SP-COOL-ABC SP-COOL-ABC SINTER COOLER SUPPORT WHEEL
SP-COOL-ABC SP-COOL-ABC ROLLER CHAIN
SP-COOL-ABC SP-COOL-ABC SINTER COOLER SEALING RUBBER
SP-COOL-ABC SP-COOL-ABC SINTER COOLER SEALING RUBBER
SP-COOL-ABC SP-COOL-ABC FRICTION ROLLER
SP-COOL-ABC SP-COOL-ABC PALLET CAR ASSEMBLY FOR SINTER COOLER
SP-COOL-ABC SP-COOL-ABC PALLET CAR ASSEMBLY FOR SINTER COOLER
SP-COOL-ABC SP-COOL-ABC DRIVE FRICTION SPRING ASEMBLY
SP-COOL-ABC SP-COOL-ABC DEEPRAIL
SP-COOL-ABC SP-COOL-ABC
RELAY
SP-COOL-ABC SP-COOL-ABC CAMMAND & FEEDBACK CABLE
SP-COOL-ABC SP-COOL-ABC
SP-COOL-ABC SP-COOL-ABC SMPS
SP-COOL-ABC SP-COOL-ABC Profibus Cable
SP-COOL-ABC SP-COOL-ABC proximity switches
CONDITION APPRAISAL OF AIR BLAST COOLER

CHECK FOR JAMMING OF WHEEL VISUAL
CHECK FOR TEETH DAMAGE SPANNERS
CHECK FOR JAMMING OF WHEEL SPANNERS
CHECK FOR CHAIN LINKS DEFORMATION SPANNERS
CHECK FOR DAMAGE/WEAR OUT VISUAL
CHECK FOR DAMAGE/WEAR OUT VISUAL
CHECK FOR JAMMING OF ROLLER VISUAL
CHECK FOR WHEEL MOVEMENT VISUAL
CHECK FOR SIDE WALL COND. VISUAL
CHECK FOR ANY CRACK/DAMAGE TO SPRING VISUAL
CHECK FOR CRACKS AND WEAROUT VISUAL

feedback. Multimeter,Tester
ON APPRAISAL OF AIR BLAST COOLER
TYPE OF CHECK (RUN

SHUTDOWN)

RUN CHECK WHEEL SHOULD NOT BE JAMMED
STOP CHECK NO DAMAGE TO TEETH
STOP CHECK NO DAMAGE TO TEETH
STOP CHECK NO DEFORMED LINKS
RUN CHECK NO DAMAGE/WORN OUT
RUN CHECK NO DAMAGE/WORN OUT
RUN CHECK ROLLER SHOULD NOT BE JAMMED
RUN CHECK WHEEL SHOULD BE ROTATING
RUN CHECK SIDE WALL SHOULD NOT BE BEND
STOP CHECK NO DAMAGE TO SPRING
STOP CHECK NO CRACKS AND WEAR TO THE RAIL


No abnormalities found in switching of contacts during

operation.
CONDITION APPRAISAL OF RM
HEAD DRUM BEARING

HEAD DRUM
PLUMMER BLOCK FOR HEAD DRUM
HEAD END SNUB PULLEY BEARING

HEAD SNUB
PLUMMER BLOCK FOR HEAD END SNUB PULLEY
GTU BEND PULLEY BEARING

GTU BEND 1
PLUMMER BLOCK FOR GTU BEND PULLEY

GTU BEND 2
GTU PULLEY BEARING

GTU PULLEY
BF3-RMHS-C1 PLUMMER BLOCK FOR GTU PULLEY
TAIL DRUM BEARING

TAIL DRUM
PLUMMER BLOCK FOR TAIL DRUM
TEFLON BUSH / COUPLING
SPIDER FOR CONVEYOR

COUPLING INPUT COUPLING
INPUT COUPLING
OUTPUT COUPLING
Tyre for coupling
Pin bush for UB 360
GEARBOX GEAR BOX
RMHS CB#01
RMHS CB#01 Motor Windings
MOTOR
RMHS CB#01
RMHS CB#01 Terminal Box
MOTOR
RMHS CB#01
MOTOR Power Contactor
PANEL
RMHS CB#01
MOTOR Overload Relay with Kit
PANEL
Speed sensor probe
ZERO SPEED
SWITCH
Zero speed device
BF3-RMHS-
CB01
BF3-RMHS-
CB01
RMHS CB#01
HOOTER CONTACTOR
Hooter
RMHS CB#01
HOOTER
Hooter
Relay
BF3-RMHS-CB1 DI ,DOCard,PLC , IM modules
SMPS
PLC , IM modules
Profibus Cable
CONDITION APPRAISAL OF RMHS CB#1 (BF3-RMHS-C1)
TYPE OF CHECK (RUN CHECK /

DESCRIPTION / DIMENSION TOOLS REQUIRED STOP CHECK / SHUTDOWN)
CHECK FOR BEARING CLEARANCE SAPNNERS AND FILLER GAUGE STOP CHECK
CHECK FOR PHYSICAL DAMAGE AND BOLSPANNERS STOP CHECK







when energized with current
to produce torque. Check for Megger & Multimeter Shut Down check
the power cable to the LT Spanners Shut Down check
Motor

and tighteness of contactor Spanners, Screw Drivers,
SHUTDOWN CHECK
terminals. Check for coil Allen Key, Multimeter

range and setting of relay Visual RUN CHECK
To detect the speed of the

conveyor and provides a
pulse to the zero speed
switch.
To detect the stoppage or

unacceptably slow
Multimeter, Screw Driver SHUTDOWN CHECK
movement of a rotating
conveyor tail end pulley.
For detecting the sway or
deviation of belt conveyors,
and sends out an alarm
signal and an emergency
stop signal. Multimeter, Screw Driver SHUTDOWN CHECK
Suited to be used for belt
breakage and materials
falling prevention due to the
belt sway.
Check rope when operated

for safety tripping switch for
conveyor belts. When the
rope is pulled the lever of the
Multimeter, Screw Driver SHUTDOWN CHECK
pc unit is operated which in
turn, actuates a switch,
thereby the conveyor is
stopped.

and tighteness of contactor Spanners, Screw Drivers,
SHUTDOWN CHECK
terminals. Check for coil Allen Key, Multimeter
windings resistance and Screw Driver /
STOP CHECK
terminal tighteness Multimeter
connection.
checking healthyness by Run

the Belt Conveyor
operating DOL starter of Multimeter,Tester Run check
conveyor.
conveyor/ by activating pull Multimeter,Tester Run check
cord, BSS, ZSS and LCS
Box.
check supply voltage and
output Voltage
operating valve.
operating valve.
CLEARANCE <0.70MM
NO PHYSICAL DAMAGE AND NO
RUSTED BOLTS
CLEARANCE <0.70MM
RUSTED BOLTS
CLEARANCE <0.70MM
RUSTED BOLTS
CLEARANCE <0.70MM
RUSTED BOLTS
CLEARANCE <0.70MM
RUSTED BOLTS
CLEARANCE <0.70MM
RUSTED BOLTS
NO PHYSICAL DAMAGE
NO PHYSICAL DAMAGE
NO PHYSICAL DAMAGE
NO PHYSICAL DAMAGE
NO PHYSICAL DAMAGE
NO PHYSICAL DAMAGE
NO PHYSICAL DAMAGE
NO PHYSICAL DAMAGE
Winding Resistances
should be balanced of No abnormal difference in
all three phases, i.e., winding resistances.
less than 20 ohms. Winding resistance of all
Megger values three phases is 12.4 ohms.
shouldbe above 5 Megger values are 1200
megaohms from all mega ohms and in healthy
three phases to condition.
ground.
Tightened with No looseness of the bolts
spanner set. and connecting links.
LC1D40, 40 A. Proper
tighteness of Contactor rating is
foundation of LC1D40, 40 A. No
contactor. looseness in fitting of
No abnormalities to be contactor and connection
seen for the contacts of cables to power
and proper fitting to be contactor and its contacts.
done. Coil resistance is 42 ohms.
be 42-43 ohms.

(23-32)A (23-32)A
Relay settings = 23 A Relay settings = 23 A
FLC = 27.4 A RC = 10.3 A
To check for
continuous sensing of No abnormalities found in
the speed of the sensing of speed probe.
conveyor.
No any abnormalities
found in open - close
contacts through a
contacts through relay
relay according to
during running of conveyor
Time and Speed
according to speed and
adjustable settings.
time settings.
To check for
healthiness of NO - NC
switching of contacts
contacts during
during operation.
operation.
To check for
healthiness of NO - NC
switching of contacts
contacts during
during operation.
operation.
tighteness of Contactor rating is
foundation of LC1D09, 09 A. No
contactor. looseness in fitting of
No abnormalities to be contactor and connection
seen for the contacts of cables to power
and proper fitting to be contactor and its contacts.
done. Coil resistance is 42 ohms.
be 42-43 ohms.
Winding Resistances
should be balanced of No abnormal difference in
all three phases, i.e., winding resistances.
less than 40 ohms. Winding resistance of all
Megger values three phases is 38 ohms.
shouldbe above 5 Megger values are 100
megaohms from all mega ohms and in healthy
three phases to condition.
ground.
Physical check or
damage of cable
Check for healthiness No abnormalities found in
of NO - NC contacts switching of contacts
during operation. during operation.
Physical check No abnormalities found

CONDITION APP
HEAD DRUM BEARING 0921020120
HEAD DRUM
PLUMMER BLOCK FOR HEAD DRUM 5231990092
HEAD END SNUB PULLEY BEARING 0921020121
HEAD SNUB
PLUMMER BLOCK FOR HEAD END SNUB PULLEY 5231990089
TAIL DRUM BEARING 0921020062
BF3-RMHS-C9
TAIL DRUM
PLUMMER BLOCK FOR TAIL DRUM 5231990093
INPUT COUPLING 0804040045
PIN AND BUSH OF I/P COUPLING
COUPLING OUTPUT COUPLING 0804030060
PIN AND BUSH OF O/P COUPLING
tyre for coupling
GEARBOX GEAR BOX
RMHS CB#9
MOTOR
RMHS CB#9
MOTOR
RMHS CB#9
PANEL
RMHS CB#9
PANEL
Speed sensor probe
ZERO SPEED
SWITCH
Zero speed device

BF3-RMHS-CB09

RMHS CB#9
HOOTER CONTACTOR
Hooter
RMHS CB#9
HOOTER
Hooter
Relay
BF3-RMHS-CB9 DI ,DOCard,PLC , IM modules
SMPS
PLC , IM modules
Profibus Cable
ONDITION APPRAISAL OF RMHS CB#9(BF3-RMHS-C9)
22220 CA CHECK FOR BEARING CLEARANCE SPANNERS AND FILLER GAUGE
(PLUMMER BLOCK
F/DRUM OF CONVEYOR- CHECK FOR PHYSICAL DAMAGE AND BOLTS SPANNERS
SL NO 7, OF DRAWING
2220-02404 B)
22210 CHECK FOR BEARING CLEARANCE SPANNERS AND FILLER GAUGE

02404 B)(PLUMMER
BLOCK F/DRUM OF CHECK FOR PHYSICAL DAMAGE AND BOLTS SPANNERS
CONVEYOR-SL NO 4, OF
DRAWING 2220-
(PLUMMER BLOCK
SL NO 8, OF DRAWING
2220-02404 B)
(UT0080) CHECK FOR PHYSICAL DAMAGE SPANNERS

CHECK FOR PHYSICAL DAMAGE OF BUSH AND SPANNERS
PINS
(UB285) CHECK FOR PHYSICAL DAMAGE SPANNERS
CHECK FOR PHYSICAL DAMAGE OF BUSH AND SPANNERS
PINS
ZSY180-25 (11 KW) CHECK FOR PHYSICAL DAMAGE AND BOLTS SPANNERS

torque. Check for winding Megger & Multimeter
resistance and megger value of
Motor.

Spanners
Spanners, Screw
Drivers, Allen Key,
Multimeter
contactor.

motor tripping.

conveyor and provides a pulse to Visual
the zero speed switch.

Multimeter, Screw
unacceptably slow movement of a
Driver
rotating conveyor tail end pulley.

deviation of belt conveyors, and
sends out an alarm signal and an
Multimeter, Screw
Driver
Suited to be used for belt breakage
and materials falling prevention
due to the belt sway.
Check rope when operated for
safety tripping switch for conveyor
belts. When the rope is pulled the Multimeter, Screw
lever of the pc unit is operated Driver
which in turn, actuates a switch,
thereby the conveyor is stopped.

Spanners, Screw
Drivers, Allen Key,
Multimeter
contactor.
Check for hooter motor windings

Screw Driver /
resistance and terminal tighteness
Multimeter
connection.
checking healthyness by Run the

Multimeter,Tester
Belt Conveyor
checking healthyness by operating

Multimeter,Tester
DOL starter of conveyor.

DOL starter of conveyor/ by
Multimeter,Tester
activating pull cord, BSS, ZSS and
LCS Box.
Multimeter,Tester
Voltage
Multimeter,Tester
valve.
Multimeter,Tester
valve.
TYPE OF CHECK (RUN
SHUTDOWN)
STOP CHECK NO PHYSICAL DAMAGE AND NO RUSTED BOLTS

less than 20 ohms.
Shut Down check
megaohms from all three phases
to ground.

Contactor rating to be LC1D50, 50
A. Proper tighteness of foundation
of contactor.
SHUTDOWN No abnormalities to be seen for
CHECK the contacts and proper fitting to
be done.
ohms.
Relay Range :
(37-50)A
RUN CHECK
Relay settings = 30 A
FLC = 39.6A
SHUTDOWN To check for continuous sensing

CHECK of the speed of the conveyor.

SHUTDOWN
through a relay according to Time
CHECK
and Speed adjustable settings.
SHUTDOWN To check for healthiness of NO -

CHECK NC contacts during operation.

of contactor.
be done.
ohms.

less than 40 ohms.
STOP CHECK
to ground.
Check for healthiness of NO - NC

Run check

condition.

connecting links.
Contactor rating is LC1D50, 50 A.
cables to power contactor and its
contacts. Coil resistance is 42
ohms.
Relay Range :
(37-50)A
RC = 18.2 A

relay during running of conveyor
according to speed and time
settings.
operation.
operation.

ohms.
resistance of all three phases is 38
condition.
operation.
CONDITION APPRAISA
HEAD DRUM BEARING 0921020120
HEAD DRUM
PLUMMER BLOCK FOR HEAD DRUM 5231990092
HEAD END SNUB PULLEY BEARING 0921020121
HEAD SNUB PLUMMER BLOCK FOR HEAD END SNUB 5231990089

PULLEY
TAIL DRUM BEARING 0921020062
BF3-RMHS-C10
TAIL DRUM
PLUMMER BLOCK FOR TAIL DRUM 5231990093
INPUT COUPLING 0804040045
PIN AND BUSH OF I/P COUPLING
COUPLING OUTPUT COUPLING 0804030060
PIN AND BUSH OF O/P COUPLING
tyre for coupling
GEARBOX GEAR BOX
RMHS CB#10 RMHS CB#10 Motor

MOTOR Windings
RMHS CB#10 RMHS CB#10 Terminal

MOTOR Box
RMHS CB#10
PANEL
RMHS CB#10
PANEL
Speed sensor probe
ZERO SPEED
SWITCH
Zero speed device
BF3-RMHS-CB10

RMHS CB#10
HOOTER CONTACTOR
Hooter
RMHS CB#10
HOOTER
Hooter
Command and Feed back

cable
Relay
BF3-RMHS-CB9 DI ,DOCard
SMPS
PLC , IM modules
Profibus Cable
CONDITION APPRAISAL OF RMHS CB#10(BF3-RMHS-C10)
(PLUMMER BLOCK
SL NO 7, OF DRAWING
2220-02404 B)
22210 CHECK FOR BEARING CLEARANCE SPANNERS AND FILLER GAUGE

02404 B)(PLUMMER
BLOCK F/DRUM OF
CONVEYOR-SL NO 4, OF CHECK FOR PHYSICAL DAMAGE AND BOLTS SPANNERS
DRAWING 2220-
(PLUMMER BLOCK
SL NO 8, OF DRAWING
2220-02404 B)
(UT0080) CHECK FOR PHYSICAL DAMAGE SPANNERS
CHECK FOR PHYSICAL DAMAGE OF BUSH AND PINS SPANNERS
(UB285) CHECK FOR PHYSICAL DAMAGE SPANNERS
CHECK FOR PHYSICAL DAMAGE OF BUSH AND PINS SPANNERS
ZSY180-25 (11 KW) CHECK FOR PHYSICAL DAMAGE AND BOLTS SPANNERS

Megger & Multimeter

Spanners
Spanners, Screw
Drivers, Allen Key,
Multimeter
contactor.

setting of relay current for motor Visual
tripping.
To detect the speed of the conveyor

and provides a pulse to the zero speed Visual
switch.

Multimeter, Screw
Driver
For detecting the sway or deviation of

belt conveyors, and sends out an
alarm signal and an emergency stop
Multimeter, Screw
signal.
Driver
Suited to be used for belt breakage
and materials falling prevention due
to the belt sway.
Check rope when operated for safety

tripping switch for conveyor belts.
When the rope is pulled the lever of Multimeter, Screw
the pc unit is operated which in turn, Driver
actuates a switch, thereby the
conveyor is stopped.
Spanners, Screw
Drivers, Allen Key,
Multimeter
contactor.

Screw Driver /
resistance and terminal tighteness
Multimeter
connection.

Multimeter,Tester
Conveyor

Multimeter,Tester
DOL starter of conveyor.

DOL starter of conveyor/ by activating Multimeter,Tester
pull cord, BSS, ZSS and LCS Box.
Multimeter,Tester
Voltage
Multimeter,Tester
valve.
Multimeter,Tester
valve.
10)
TYPE OF CHECK (RUN
SHUTDOWN)

STOP CHECK BOLTS

STOP CHECK BOLTS

STOP CHECK BOLTS

STOP CHECK BOLTS

less than 20 ohms.
Shut Down check
to ground.

Contactor rating to be LC1D40,
be done.
ohms.
Relay Range :
(17-25)A
RUN CHECK
FLC = 20.4A


SHUTDOWN through a relay according to
CHECK Time and Speed adjustable
settings.


be done.
ohms.

less than 40 ohms.
STOP CHECK
to ground.

Run check
cable

Run check

condition.

connecting links.
ohms.
Relay Range :
(17-25)A
RC = 10.0 A

relay during running of conveyor
according to speed and time
settings.
operation.
operation.
ohms.
resistance of all three phases is 38
condition.
operation.
CONDITION AP
HEAD DRUM BEARING
HEAD DRUM
HEAD SNUB
GTU BEND
GTU BEND PULLEY#2 BEARING

GTU BEND 2
PLUMMER BLOCK FOR GTU BEND PULLEY#2
GTU PULLEY BEARING
GTU PULLEY
PLUMMER BLOCK FOR GTU PULLEY
TAIL DRUM BEARING
TAIL DRUM
BF3-RMHS-C11
BF3-RMHS-C11
TEFLON BUSH / COUPLING OUTPUT
COUPLING
I/P COUPLING SPIDER
INPUT COUPLING
OUTPUT COUPLING
GEARBOX GEAR BOX
TRIPPER TROLLEY DRUM BEARING
PLUMMER BLOCK FOR TRIPPER TROLLEY DRUM
TRIPPER TROLLEY WHEEL WITH SHAFT
TRIPPER TROLLEY WHEEL BEARING
GEAR BOX
DRIVE CHAIN
SPROCKET FOR GEARBOX CHAIN

TROLLEY DRIVE
SPROCKER FOR WHEEL CHAIN
PRESS PULLEY ASSEMBLY
PRESS PULLEY BEARING
PLUMMER BLOCK FOR PRESS PULLEY
ROLLER CHAIN,
RMHS CB#11
MOTOR
RMHS CB#11
MOTOR
RMHS CB#11
Power Contactor
MOTOR PANEL
RMHS CB#11
Overload Relay with Kit
MOTOR PANEL
Speed sensor probe
ZERO SPEED
SWITCH
Zero speed device
BF3-RMHS-CB11
BF3-RMHS-CB11
RMHS CB#11
RMHS CB#11 Trolley Motor Windings
Trolley MOTOR
RMHS CB#11
RMHS CB#11 Trolley Terminal Box
Trolley MOTOR
RMHS CB#11
Power Contactor
panel
RMHS CB#11
panel
RMHS CB#11
HOOTER CONTACTOR
Hooter
RMHS CB#11
HOOTER
Hooter
Relay
BF3-RMHS-CB9 DI ,DOCard
SMPS
PLC , IM modules
Profibus Cable
0921020120 (22220 CA) CHECK FOR BEARING CLEARANCE
(PLUMMER BLOCK
F/DRUM OF
5231990092 CONVEYOR-SL NO 7, CHECK FOR PHYSICAL DAMAGE AND BOLTS
OF DRAWING 2220-
02404 B)
(PLUMMER BLOCK
F/DRUM OF
OF DRAWING 2220-
02404 B)
0901020009 -1316 CHECK FOR BEARING CLEARANCE
(PLUMMER BLOCK
F/DRUM OF
OF DRAWING 2220-
02404 B)
CHECK FOR PHYSICAL DAMAGE AND BOLTS
(PLUMMER BLOCK
F/DRUM OF
OF DRAWING 2220-
02404 B)
(PLUMMER BLOCK
F/DRUM OF
OF DRAWING 2220-
02404 B)
PIN Ø30XL45-BF3,
PIN FOR OUTPUT
0806990032
COUPLING OF CHECK FOR PHYSICAL DAMAGE OF COUPLING
CONVEYOR GEAR BUSH
BOX AS PER DRG NO
2220- 01697B
0804990106
F/ CONVEYORS 6,9 CHECK FOR PHYSICAL DAMAGE OF COUPLING
&11 SPIDER
0804030056
TYPE PIN BUSH (UB CHECK FOR PHYSICAL DAMAGE OF COUPLING
162)
0804030064 (UB400) CHECK FOR PHYSICAL DAMAGE OF COUPLING
ZSY250-31.5 (30 KW) CHECK FOR PHYSICAL DAMAGE AND BOLTS
CHECK FOR WHEEL WEAR AND DAMAGE
5105020009 CHECK FOR DAMAGED LINKS AND PINS

(DUPLEX027F0233
0808020006 CHECK FOR SPROCKET TEETH
NO. OF TEETH-33)
(DUPLEX,C.S.,027F02
0808020005 21 NO. OF TEETH- CHECK FOR SPROCKET TEETH
21)
CHECK FOR PULLEY PHYSICAL
0921020035
(8000045803) 22214 E CHECK FOR BEARING CLEARANCE
DUPLEX,PITCH-
5105020009 CHECK FOR PHYSICAL DAMAGE
31.75MM,STCKHS

value of Motor.

contactor.

and setting of relay current for
motor tripping.

conveyor and provides a pulse to
the zero speed switch.


deviation of belt conveyors, and
sends out an alarm signal and an
breakage and materials falling
prevention due to the belt sway.
Check rope when operated for
safety tripping switch for
conveyor belts. When the rope is
pulled the lever of the pc unit is
operated which in turn, actuates
a switch, thereby the conveyor is
stopped.

value of Motor.


contactor.

and setting of relay current for
motor tripping.
contactor.

resistance and terminal
tighteness connection.
checking healthyness by Run the

Belt Conveyor
conveyor.
conveyor/ by activating pull cord,
Voltage
operating valve.
operating valve.
3-RMHS-C11)
TYPE OF CHECK (RUN

TOOLS REQUIRED CHECK / STOP CHECK / IDEAL CONDITION
SHUTDOWN)
SPANNERS AND FILLER GAUGE STOP CHECK CLEARANCE <0.50MM
SPANNERS STOP CHECK NO PHYSICAL DAMAGE AND NO RUSTED BOLTS

SPANNERS STOP CHECK NO PHYSICAL DAMAGE
VISUAL STOP CHECK NO ABNORMAL WEAR(GROOVES AND CRACKS)

AND DAMAGE
VISUAL STOP CHECK NO DAMAGED LINKS AND PINS
VISUAL STOP CHECK NO BROKEN OR DAMAGED TEETHS
VISUAL STOP CHECK NO PHYSICAL DAMAGE


less than 10 ohms.
to ground.
Spanners Shut Down check Tightened with spanner set.

of contactor.
Spanners, Screw Drivers, SHUTDOWN No abnormalities to be seen for
Allen Key, Multimeter CHECK the contacts and proper fitting to
be done.
ohms.
Relay Range :
(48-65)A
Visual RUN CHECK
FLC = 52.7A

Visual

SHUTDOWN
Multimeter, Screw Driver through a relay according to Time
CHECK
and Speed adjustable settings.

Multimeter, Screw Driver
Multimeter, Screw Driver

less than 10 ohms.
to ground.
Spanners Shut Down check Tightened with spanner set.

of contactor.
be done.
ohms.
Relay Range :
(23-32)A
Visual RUN CHECK
FLC = 28.9A
be done.
ohms.

Screw Driver / less than 40 ohms.
STOP CHECK
to ground.


No looseness of the bolts and connecting
links.
Contactor rating is LC1D65, 65 A. No

connection of cables to power contactor and
its contacts. Coil resistance is 42 ohms.
Relay Range :
(48-65)A
RC = 18.2 A
No abnormalities found in sensing of speed

probe.
No any abnormalities found in open - close

contacts through relay during running of
conveyor according to speed and time
settings.


No looseness of the bolts and connecting

links.

Relay Range :
(23-32)A
RC = 15A

phases is 38 ohms. Megger values are 100

ACTION REQUIRED
CONDITION
HEAD DRUM BEARING

HEAD DRUM

HEAD SNUB

GTU BEND
GTU BEND PULLEY#2 BEARING

GTU BEND 2
PLUMMER BLOCK FOR GTU BEND PULLEY#2
GTU PULLEY BEARING

GTU PULLEY
PLUMMER BLOCK FOR GTU PULLEY
TAIL DRUM BEARING

TAIL DRUM
TEFLON BUSH / COUPLING OUTPUT
BF3-RMHS-C12
I/P COUPLING SPIDER
COUPLING
INPUT COUPLING
OUTPUT COUPLING
GEARBOX GEAR BOX
TRIPPER TROLLEY DRUM BEARING
PLUMMER BLOCK FOR TRIPPER TROLLEY DRUM
TRIPPER TROLLEY WHEEL WITH SHAFT

TRIPPER TROLLEY WHEEL BEARING
GEAR BOX
TROLLEY DRIVE
DRIVE CHAIN
SPROCKET FOR GEARBOX CHAIN

SPROCKER FOR WHEEL CHAIN
PRESS PULLEY ASSEMBLY
PRESS PULLEY BEARING
PLUMMER BLOCK FOR PRESS PULLEY
ROLLER CHAIN,
RMHS CB#12
MOTOR
RMHS CB#12
MOTOR
RMHS CB#12
Power Contactor
MOTOR PANEL
RMHS CB#12
MOTOR PANEL
Speed sensor probe
ZERO SPEED
SWITCH
Zero speed device
BF3-RMHS-
CB12

RMHS CB#12
RMHS CB#12 Trolley Motor Windings
Trolley MOTOR
RMHS CB#12
RMHS CB#12 Trolley Terminal Box
Trolley MOTOR
RMHS CB#12
Power Contactor
panel
RMHS CB#12
panel
RMHS CB#12
HOOTER CONTACTOR
panel
RMHS CB#12
RMHS CB#12 Hooter
panel
5231990092
(PLUMMER BLOCK F/DRUM OF CONVEYOR-SL NO 7, OF CHECK FOR PHYSICAL DAMAGE AND
DRAWING 2220-02404 B) BOLTS
5231990090
(PLUMMER BLOCK F/DRUM OF CONVEYOR-SL NO 5, CHECK FOR PHYSICAL DAMAGE AND
OF DRAWING 2220-02404 B) BOLTS
5231990088
(PLUMMER BLOCK F/DRUM OF CONVEYOR-SL NO 3, CHECK FOR PHYSICAL DAMAGE AND
OF DRAWING 2220-02404 B) BOLTS
CHECK FOR PHYSICAL DAMAGE AND

BOLTS
5231990088
5231990092
0806990032
PIN Ø30XL45-BF3, PIN FOR OUTPUT COUPLING OF CHECK FOR PHYSICAL DAMAGE OF
CONVEYOR GEAR BOX AS PER DRG NO 2220- 01697B COUPLING BUSH
CHECK FOR PHYSICAL DAMAGE OF

0804990106 F/ CONVEYORS 6,9 &11 COUPLING SPIDER
0804030056 TYPE PIN BUSH (UB 162) COUPLING
0804030064 (UB400) COUPLING
ZSY250-31.5 (30 KW) BOLTS

BOLTS
CHECK FOR WHEEL WEAR AND
DAMAGE

BOLTS
5105020009
CHECK FOR DAMAGED LINKS AND
PINS
0808020006 (DUPLEX027F0233 NO. OF TEETH-33) CHECK FOR SPROCKET TEETH
0808020005 (DUPLEX,C.S.,027F0221 NO. OF TEETH-21) CHECK FOR SPROCKET TEETH
CHECK FOR PULLEY PHYSICAL
0921020035
(8000045803) 22214 E CHECK FOR BEARING CLEARANCE

BOLTS
5105020009 DUPLEX,PITCH-31.75MM,STCKHS CHECK FOR PHYSICAL DAMAGE

when energized with
current to produce torque.
Check for winding
resistance and megger
value of Motor.
Check for proper tigteness

of the power cable to the
LT Motor

and tighteness of
of the contactor.
current for motor
tripping.

conveyor and provides a
pulse to the zero speed
switch.

unacceptably slow
movement of a rotating
conveyor tail end pulley.

deviation of belt
conveyors, and sends out
an alarm signal and an
breakage and materials
falling prevention due to
the belt sway.
Check rope when

operated for safety
tripping switch for
conveyor belts. When the
rope is pulled the lever of
the pc unit is operated
which in turn, actuates a
switch, thereby the
conveyor is stopped.
when energized with
current to produce torque.
Check for winding
resistance and megger
value of Motor.
Check for proper tigteness

of the power cable to the
LT Motor

and tighteness of
of the contactor.

current for motor
tripping.

and tighteness of
of the contactor.
windings resistance and
terminal tighteness
connection.
-C12)
TYPE OF CHECK (RUN

TOOLS REQUIRED CHECK / STOP CHECK / IDEAL CONDITION
SHUTDOWN)

SPANNERS STOP CHECK RUSTED BOLTS






VISUAL STOP CHECK NO ABNORMAL WEAR(GROOVES AND CRACKS) AND DAM

VISUAL STOP CHECK NO DAMAGED LINKS AND PINS

SPANNERS STOP CHECK NO PHYSICAL DAMAGE AND NO

RUSTED BOLTS
Winding Resistances
less than 10 ohms.
above 5 megaohms
from all three phases to
ground.
Tightened with spanner

set.
tighteness of foundation
of contactor.
Spanners, Screw Drivers, SHUTDOWN No abnormalities to be
Allen Key, Multimeter CHECK seen for the contacts
and proper fitting to be
done.
be 42-43 ohms.
Relay Range :
(30-40)A
Visual RUN CHECK
FLC = 33.4 A

SHUTDOWN
Visual sensing of the speed of
CHECK
the conveyor.
contacts through a relay
SHUTDOWN
Multimeter, Screw Driver according to Time and
CHECK
Speed adjustable
settings.

SHUTDOWN
Multimeter, Screw Driver of NO - NC contacts
CHECK
during operation.

SHUTDOWN
Multimeter, Screw Driver of NO - NC contacts
CHECK
during operation.
Winding Resistances
less than 10 ohms.
above 5 megaohms
ground.
Tightened with spanner

set.
of contactor.
done.
be 42-43 ohms.
Relay Range :
(23-32)A
Visual RUN CHECK
FLC = 28.9A
of contactor.
done.
be 42-43 ohms.
Winding Resistances
Screw Driver / less than 40 ohms.
STOP CHECK
Multimeter Megger values shouldbe
above 5 megaohms
ground.
E AND NO RUSTED BOLTS
(GROOVES AND CRACKS) AND DAMAGE

E AND NO RUSTED BOLTS
AGED TEETHS
AGED TEETHS

healthy condition.

connecting links.

and its contacts. Coil resistance is 42
ohms.
Relay Range :
(30-40)A
RC = 11.3 A
No abnormalities found in sensing of

speed probe.
No any abnormalities found in open -

close contacts through relay during
running of conveyor according to speed
and time settings.


healthy condition.

connecting links.

ohms.
Relay Range :
(23-32)A
RC = 16.5A

ohms.
three phases is 37 ohms. Megger values
condition.
ACTION REQUIRED
LINK F/DRY BAG

BF3-GCS-SCRP BF3-GCS-SCRP FILTER SCRAPPER 5105020002
CONV
DRIVE CHAIN
BF3-GCS-SCRP BF3-GCS-SCRP 5105020010
ROLLER CHAIN,
SCRAPPER DRIVE
CHAIN MASTER LINK
SCRAPPER TAIL END

PLUMMER BLOCK
SCRAPPER GEAR
BOX
BF3-GCS-SCRP BF3-GCS-SCRP Head pulley bearing 0921020060
BF3-GCS-SCRP BF3-GCS-SCRP Tail pulley bearing 0921020014
GCS Scrapper
BF3-GCS-SCRP Motor Windings
Conveyor Motor
GCS Scrapper
BF3-GCS-SCRP Terminal Box
Conveyor Motor
GCS Scrapper
BF3-GCS-SCRP Power Contactor
Conveyor Panel
GCS Scrapper
BF3-GCS-SCRP Overload Relay with Kit
Conveyor Panel
CONDITION APPRAISAL OF GCP SCRAPPER CONVEYOR
SPECIFICATI DESCRIPTION /
TOOLS REQUIRED
ON DIMENSION
CHECK CONDITION OF LINKS

SPANNERS
BY OPENING TOP COVER
DUPLEX,PITCH
CHECK ROLLERS CONDITION SPANNERS
-38.1MM
CHECK FOR PHYSICAL

SPANNERS
CONDITION OF MASTER LINK
CHECK FOR PHYSICAL

SPANNERS
CONDITION OF MASTER LINK
CHECK FOR INTERNAL GEARS

SPANNERS
BY OPENING TOP COVER
22222 K + H322
CHECK FOR BEARING
(Bearing with FILLER GAUGE
CLEARANCE
sleeve)
22216K + H316 CHECK FOR BEARING

FILLER GAUGE
(Brg with sleeve) CLEARANCE

produce torque. Check for Megger & Multimeter
value of Motor.
Spanners

Spanners, Screw
Drivers, Allen Key,
Multimeter
contactor.

motor tripping.
PER CONVEYOR
TYPE OF
CHECK (RUN
CHECK / STOP IDEAL CONDITION
CHECK /
SHUTDOWN)
RUN
CHECK/STOP NO DAMAGED LINKS
CHECK
STOP CHECK NO DAMAGED CHAIN
STOP CHECK NO WEAR AND BODY DAMAGE
STOP CHECK NO INTERNAL GEAR DAMAGE

than 10 ohms.
Shut Down check
ground.
Contactor rating to be LC1D40, 40 A.

SHUTDOWN contactor.
CHECK No abnormalities to be seen for the
Relay Range :
(23-32)A
RUN CHECK
FLC = 27.0 A
OBSERVED REQUIRED
condition.
connecting links.
Contactor rating is LC1D40, 40

A. No looseness in fitting of
ohms.
Relay Range :
(23-32)A
RC = 9.4 A
VANE FEEDER GCP ASH

BF3-GCP-SRW BF3-GCP-SRW 5105020015
BUNKER
BF3-GCP-SRW BF3-GCP-SRW
VANE FEEDER GCP ASH
BUNKER
BF3-GCP-SRW BF3-GCP-SRW HUMIDIFIER BLADE 5105020002
HUMIDIFIER COUPLING
BF3-GCP-SRW BF3-GCP-SRW 0804990083
BUSH
BF3-GCP-SRW BF3-GCP-SRW
SCREW CONVEYOR GEAR
BOX
GCS Screw
BF3-GCP-SRW Conveyor Motor Windings
Motor
GCS Screw
BF3-GCP-SRW Conveyor Terminal Box
Motor
GCS Screw
BF3-GCP-SRW Conveyor Power Contactor
Panel
GCS Screw
BF3-GCP-SRW Conveyor Overload Relay with Kit
Panel
CONDITION APPRAISAL OF GCP SCREW CONVEYOR
TYPE OF CHECK
(RUN CHECK /
DESCRIPTION / DIMENSION TOOLS REQUIRED STOP CHECK /
SHUTDOWN)
CHECK FOR BODY DAMAGE VISUAL RUN CHECK
CHECK FOR FINS DAMAGE SPANNERS STOP CHECK
CHECK FOR BLADE WEAROUT MEASURING TAPE STOP CHECK
CHECK FOR PHYSICAL DAMAGE OF BUSH SPANNERS STOP CHECK
CHECK FOR ABNORMAL SOUND AND

PHYSICAL DAMAGE VISUAL/AUDIO RUN CHECK

Megger & Shut Down
Multimeter check
value of Motor.

Spanners
power cable to the LT Motor check
Check for contactor rating and Spanners,

tighteness of contactor Screw Drivers, SHUTDOWN
terminals. Check for coil Allen Key, CHECK

and setting of relay current for Visual RUN CHECK
motor tripping.
YOR
NO PHYSICAL DAMAGE TO BODY
NO DAMAGED FINS
BLADE WIDTH SHOULD BE >35MM
NO PHYSICAL DAMAGE TO BUSH
NO ABNORMAL SOUND AND NO PHYSICAL DAMAGE TO

BODY
Winding Resistances should be balanced No abnormal difference in

of all three phases, i.e., less than 10 winding resistances. Winding
ohms. resistance of all three phases is
Megger values shouldbe above 5 6.8 ohms. Megger values are
megaohms from all three phases to 1000 mega ohms and in healthy
ground. condition.

Tightened with spanner set.
connecting links.
Contactor rating to be LC1D40, 40 A. Contactor rating is LC1D40, 40

Proper tighteness of foundation of A. No looseness in fitting of
contactor. contactor and connection of
No abnormalities to be seen for the cables to power contactor and its
contacts and proper fitting to be done. contacts. Coil resistance is 42
Coil resistance should be 42-43 ohms. ohms.

(17-25)A (17-25)A
Relay settings = 15 A Relay settings = 15 A
FLC = 20.7A RC = 10.7 A
ACTION REQUIRED
BF3-GCS-GDCEQ BF3-GCS-GDCEQ V BELT

BF3-GCS-GDCEQ BF3-GCS-GDCEQ GDC UNLOAD
BF3-GCS-GDCEQ BF3-GCS-GDCEQ GDC UNLOAD
BF3-GCS-GDCEQ BF3-GCS-GDCEQ GDC Humidifier Bearing
BF3-GCS-GDCEQ BF3-GCS-GDCEQ
CLUTCH RING FOR GDC
ACTUATOR
BF3-GCS-GDCEQ BF3-GCS-GDCEQ Drive pulley B groove
BF3-GCS-GDCEQ BF3-GCS-GDCEQ Driven pulley B groove
BF3-GCS-GDCEQ BF3-GCS-GDCEQ GDC bleeder valve
BF3-GCS-GDCEQ BF3-GCS-GDCEQ GDC bleeder valve
BF3-GCS-GDCEQ BF3-GCS-GDCEQ GDC BUTTERFLY(BYPASS VALVE)
BF3-GCS-GDCEQ BF3-GCS-GDCEQ
Pneumatic cylinder for 400NB
valve
GDC DUST UNLOADING

BF3-GCS-GDCEQ
VALVE MOTOR
LT Motor Windings
GDC DUST UNLOADING

BF3-GCS-GDCEQ
VALVE MOTOR
Terminal Box
GDC DUST UNLOADING
BF3-GCS-GDCEQ
VALVE PANEL
Power Contactor
GDC DUST UNLOADING

BF3-GCS-GDCEQ
VALVE PANEL
Overload Relay
BF3-GCS-GDCEQ
GDC DUST UNLOADING Internal OPEN / CLOSE Limit
VALVE PANEL Switch
BF3-GCS-GDCEQ GDC Humidifier Motor Motor Windings
BF3-GCS-GDCEQ GDC Humidifier Motor Terminal Box
BF3-GCS-GDCEQ GDC Humidifier Panel Power Contactor
BF3-GCS-GDCEQ GDC Humidifier Panel Overload Relay with Kit

BF3-GCS-GDCEQ GDC Pulsator #1 Motor Motor Windings
BF3-GCS-GDCEQ GDC Pulsator #1 Motor Terminal Box
BF3-GCS-GDCEQ GDC Pulsator #2 Motor Motor Windings
BF3-GCS-GDCEQ GDC Pulsator #2 Motor Terminal Box
BF3-GCS-GDCEQ GDC Pulsator #1 Panel Power Contactor
BF3-GCS-GDCEQ GDC Pulsator #2 Panel Power Contactor

BF3-GCS-GDCEQ GDC Pulsator #1 Panel Overload Relay with Kit
BF3-GCS-GDCEQ GDC Pulsator #2 Panel Overload Relay with Kit
BF3-GCS-GDCEQ GDC Vane Feeder Motor Motor Windings
BF3-GCS-GDCEQ GDC Vane Feeder Motor Terminal Box
BF3-GCS-GDCEQ GDC Vane Feeder Panel Power Contactor
BF3-GCS-GDCEQ GDC Vane Feeder Panel Overload Relay with Kit
GDC Rupture Valve

BF3-GCS-GDCEQ Motor Windings
Winch Motor
GDC Rupture Valve
BF3-GCS-GDCEQ Terminal Box
Winch Motor
GDC Rupture Valve

BF3-GCS-GDCEQ Power Contactor
Winch Panel
GDC Rupture Valve

BF3-GCS-GDCEQ Overload Relay with Kit
Winch Panel
BF3-GCS-GDCEQ
GDC Rupture Valve Internal OPEN / CLOSE Limit
Winch Limit Switch Switch
Relay
GDC DUST UNLOADING VALVE
MOTOR
BF3-GCS-GDCEQ DI ,DOCard,PLC , IM modules
SMPS
Profibus Cable
GDC Pnematic Bypass valve solenoid coil

CONDITION APPRAISAL OF GDC EQUIPM
0802020120 , B-2159/B-85 CHECK FOR BELT WEAR AND CUTS

5107000048 DN 400 BALL VCHECK FOR SEALING OF VALVE BY OPERATION
5105020040 DN 400 BUTTER CHECK FOR SEALING OF VALVE BY OPERATION
0921010008 21316 CHECK FOR BEARING CLEARANCE
5088000111 CHECK FOR RING WERA/DMAGE
CHECK FOR PHYSICAL DAMAGE OF GROOVES

CHECK FOR PHYSICAL DAMAGE OF GROOVES
5107000028 DN 250 CHECK FOR SEALING OF VALVE BY OPERATION
7703000052 CHECK FOR LEAKAGE IN CYLINDER BY OPERATING

Motor.



10 A

Motor.



Motor.


Motor.





Motor.




Motor.



10 A

Conveyor

starter of conveyor.

starter of conveyor/ by activating pull cord,
checking healthyness by operating valve.
check coil Resistance

OF GDC EQUIPMENTS
TYPE OF CHECK
(RUN CHECK /
STOP CHECK /
SHUTDOWN)
VISUAL STOP CHECK NO CUTS AND WEARS ON BELT
VISUAL RUN CHECK VALVE SHOULD NOT BE PASSING
FILLER GAUGE STOP CHECK CLEARANCE SHOULD BE <0.50MM
SPANNERS STOP CHECK NO WEAR AND DAMAGE OF RINGS
VISUAL STOP CHECK NO PHYSICAL DAMAGE OF GROOVES

VISUAL STOP CHECK NO PHYSICAL DAMAGE OF GROOVES
VISUAL RUN CHECK NO LEAKGE AND DAMAGE OF CYLINDER
Winding Resistances should be balanced of

Megger & Shut Down all three phases, i.e., less than 10 ohms.
Multimeter check Megger values shouldbe above 5 megaohms
Shut Down Tightened with 8 mm Chrome Vanadium

Spanners
check Bolts.
Contactor rating to be LCID09, 09 A. Proper
Spanners, tighteness of foundation of contactor.
Screw Drivers, SHUTDOWN No abnormalities to be seen for the contacts
Allen Key, CHECK and proper fitting to be done.
Multimeter Coil resistance should be between 20 ohms -
30 ohms.
Relay settings:
Visual
FC = 3.3 A
VISUAL /
Motor should stop running during limit
MULTIMETE RUN CHECK
switch operation.
R

Shut Down
Spanners Tightened with spanner set.
check
Contactor rating to be LC1D40, 40 A. Proper

Spanners,
Allen Key, CHECK
Multimeter
Relay Range :
(12-18)A
Visual RUN CHECK
Relay settings = 14.0 A
FLC = 15.6A
Shut Down
check

Shut Down
check

Spanners,
Allen Key, CHECK
Multimeter

Spanners,
Allen Key, CHECK
Multimeter
Relay Range :
(0.1-0.63)A
Visual RUN CHECK
FLC = 0.5 A
Relay Range :
(0.1-0.63)A
Visual RUN CHECK
FLC = 0.5 A

Shut Down
check

Spanners,
Allen Key, CHECK
Multimeter
Relay Range :
(2.5-4)A
Visual RUN CHECK
FLC = 3.6A

Shut Down
check

Spanners,
Allen Key, CHECK
Multimeter
Relay Range :
(17-25)A
Visual RUN CHECK
FLC = 20.6A
VISUAL /
Motor should stop running during limit
MULTIMETE RUN CHECK
switch operation.
R
Multimeter,Test
er
Multimeter,Test Check for healthiness of NO - NC contacts

Run check
er during operation.
Multimeter,Test
er
Multimeter,Test
er
Multimeter,Test
er
Multimeter,
Run check Physical check or damage of coil
Tester

resistances. Winding resistance of
all three phases is 9.4 ohms.
Megger values are 500 mega ohms
and in healthy condition.
links.
Contactor rating is LCID09, 09 A.
No looseness in fitting of contactor
ohms.
Relay settings:

switch operation.


connecting links.

Relay Range :
(12-18)A
RC = 9.0 A

connecting links.


connecting links.


Relay Range :
(0.1-0.63)A
RC = 0.4 A
Relay Range :
(0.1-0.63)A
RC = 0.39 A


connecting links.

Relay Range :
(2.5-4)A
RC = 2.1 A

connecting links.

Relay Range :
(17-25)A
RC = 10.1 A

switch operation.
operation.
No damage
BF3-FLST-EQP Bellow 5103990072
BF3-FLST-EQP MCV 5107000038
BF3-FLST-EQP Shut off valve 5107000037
BF3-FLST-EQP Goggle valve 5107000039
BF3-FLST-EQP Bypass valve 400 mm
BF3-FLST-EQP Burner Tip
MOTORISED
CONTROL VALVE
CONTACTOR
FLARESTACK
MOTORISED MOTORISED
CONTROL CONTROL VALVE
VALVE OVERLOAD RELAY
MOTORISED
CONTROL VALVE
AUXILIARY PLA
RELAYS
FLARESTACK
GOGGLE VALVE
OPEN CONTACTOR
FLARESTACK
GOGGLE VALVE
CLOSE
CONTACTOR
FLARESTACK
GOGGLE VALVE
OVERLOAD RELAY
FLARESTACK
GOGGLE VALVE
AUXILIARY PLA
RELAYS
FLARESTACK
GOGGLE
VALVE
FLARESTACK
GOGGLE VALVE
CLAMP
CONTACTOR
FLARESTACK
GOGGLE VALVE
DECLAMP
CONTACTOR
FLARESTACK
GOGGLE VALVE
OVERLOAD RELAY
FLARESTACK
GOGGLE VALVE
AUXILIARY PLA
RELAYS
FLARESTACK
SHUT-OFF VALVE
OPEN CONTACTOR
FLARESTACK
SHUT-OFF VALVE
FLARESTACK CLOSE
SHUT-OFF CONTACTOR
VALVE
FLARESTACK
SHUT-OFF VALVE
OVERLOAD RELAY
FLARESTACK
SHUT-OFF VALVE
AUXILIARY PLA
RELAYS
Positioner
AI Card
AO Card
FLARE STACK PLC

EQUIPMENTS
IM Module
FLARSTACK
CONTR0LVALVE
CONTRL ROOM S/D
SMPS
FLARSTACK
CONTR0LVALVE
CONTRL ROOM S/D
UPS
Signal Cable
Pressure Regulator
Compressor
Impulse line
Relay
DI Card
DO Card
PLC
FLARSTACK
CONTR0LVALVE
CONTRL ROOM S/D
IM Module
SMPS
UPS
Signal Cable
FLARESTACK BFG Pressure Transmitter

LINE PRESSURE
FLARESTACK BFG Pressure Transmitter

LINE PRESSURE
Relay
DI Card
DO Card
PLC
FLARESTACK QUICK
OPEN VALVE
IM Module
SMPS
UPS
Signal Cable
FLARESTACK Thermo couple

BURNER1 TEMP
FLARESTACK Thermo couple

BURNER2 TEMP
FLARESTACK FLAME Thermo couple
TEMP
ISOLATION Ignition Transformer

TRANSFORMER
FLARESTACK LONG Solenoid valve

LIGHT VALVE
FLARESTACK LPG Pressure Transmitter

PRESSURE
CPU
PLC S7 200
FLARESTACK PILOT
Solenoid valve
VALVE
TYPE OF CHECK
TOOLS (RUN CHECK /
SHUTDOWN)
CHECK FOR PHYSICAL DAMAGE VISUAL RUN CHECK
CHECK FOR OPERATION VISUAL STOP CHECK
Spanners,
Screw
and tighteness of contactor SHUTDOWN
Drivers,
Allen Key,
Multimeter

SHUTDOWN
range and setting of relay Visual
CHECK
The auxiliary PLA Relays

are often used in a logic SHUTDOWN
Visual
circuit, or for some other CHECK
Spanners,
Screw
Drivers,
Allen Key,
Multimeter
Spanners,
Screw
Drivers,
Allen Key,
Multimeter

SHUTDOWN
CHECK

Visual
Spanners,
Screw
Drivers,
Allen Key,
Multimeter
Spanners,
Screw
Drivers,
Allen Key,
Multimeter

SHUTDOWN
CHECK

Visual
Spanners,
Screw
Drivers,
Allen Key,
Multimeter
Spanners,
Screw
Drivers,
Allen Key,
Multimeter

SHUTDOWN
CHECK

Visual
check for Positioner to

rotate control valve
SHUTDOWN
according to command Multi meter
CHECK
given by the PLC Analog
input
check for Feedback postion
Multi meter RUN,
of the valve
check for set position of the
Multi meter RUN
valve
check to Execute command
and Feedback According to
Multi meter RUN
set point by progamming
Logic
check for Communication
between PLC and Analog Multi meter RUN
Input and output Cards
check for Supply to
Communication and I/O Multi meter RUN
Cards
check for supply to PLC
Multi meter RUN
And SMPS
check for Command to

Positioner and get Feedback Multi meter RUN
from positioner to PLC
check Sufficient Pressure to

VIsual RUN
Positioner
check sufficient air to
VIsual RUN
operate Positioner
check Pressure up to
Regulator of the Positioner VIsual RUN
From Air Receiving Tank
check for Open/ Close

Multi meter RUN
command

Multi meter RUN
of the valve
Check for Open/ Close
Multi meter RUN
command
Multi meter RUN
Logic
check for Supply to
Cards
Multi meter RUN
And SMPS

To show the BFG Line Multi meter,

RUN
Pressure Spanner
To show the BFG Line Multi meter,
RUN
Pressure Spanner
check for Open/ Close
Multi meter RUN
command

Multi meter RUN
of the valve
Check for Open/ Close
Multi meter RUN
command
Multi meter RUN
Logic
check for Supply to
Cards
Multi meter RUN
And SMPS

Check for Burner # 1

Multi meter RUN
Temparature
Check for Burner #
Multi meter RUN
2Temparature
Check for Burner Flame
Multi meter RUN
Temparature
To provide spark for LPG SHUTDOWN
Multi meter
Firing for BFG Flare CHECK
Check for Valve opening of
Multi meter RUN
LPG Line
check for LPG Line
Multi meter RUN
pressure
Check for Healthyness of
Operation of LPG Firing
through Ignition Multi meter RUN
Transformer and Burner
Temparartures.
Check for Valve opening of
Multi meter RUN
LPG Line
NO PHYSICAL DAMAGE TO BELLOW
SHOULD BE OPERATING WITHOUT JERKS WITHIN

LIMITS SMOOTHLY
LIMITS SMOOTHLY
LIMITS SMOOTHLY
LIMITS SMOOTHLY
NO DAMAGE TO TIPS
Contactor rarting to be 9A. Proper Contactor rarting is 9A. No

tighteness of foundation of contactor. looseness in fitting of contactor
No abnormalities to be seen for the and connection of cables to power
contacts and proper fitting to be done. contactor and its contacts. Coil
Coil resistance should be between 20 ohms resistance of contactor checked 25
- 30 ohms. ohms.

Relay setting = 8A Relay setting = 8A
FLC = 8.3 A RUNNING CURRENT = 7A
The auxiliary PLA Relays are used to provide The auxiliary PLA Relays are used to
logic for interlocking. provide logic for interlocking.
Contactor rarting to be 9A. Proper Contactor rarting to be 9A. No

- 30 ohms. ohms.
- 30 ohms. ohms.
FLC = 3.4 RUNNING CURRENT = 2.8A

Coil resistance should be between 20 ohms resistance of contactor checked
- 30 ohms. 27.5 ohms.

- 30 ohms. 26.1 ohms.

- 30 ohms. 25.5 ohms.

- 30 ohms. 26.2 ohms.
No leakages found No leakages found
Get 4.00 mA Get 4.00 mA
Get 4.00 mA Get 4.00 mA
No fault LED will Glow No fault LED will Glow
Get 24 Volt output Get 24 Volt output

Get 230 Volt Get 230 Volt
No damage No damage
Pressure Showing 4.0 Kg/cm2 Pressure Showing 4.0 Kg/cm3
Provide 5.0 Kg/Cm2 Provide 5.0 Kg/Cm2
No leakages found No leakages found
No abnormalities to be seen for the No abnormalities to be seen for the

contacts. contacts.
Get 24 Volt output Get 24 Volt output
Get 230 Volt Get 230 Volt
No damage No damage
pressure between6 to 13 Kpa pressure between6 to 13 Kpa
pressure between6 to 13 Kpa pressure between6 to 13 Kpa

No abnormalities to be seen for the No abnormalities to be seen for the
contacts. contacts.
Voltage Between 23 to 25 Volt Voltage Between 23 to 25 Volt
Volatage Between 220 to 240 Volt Volatage Between 220 to 240 Volt
No damage No damage
Temparature between 300 to 650

Temparature between 300 to 650 Degree
Degree
Temparature between 300 to 650
Temparature between 300 to 650 Degree
Degree
Tempararture between 50 to 100
Tempararture between 50 to 100 Degree
Degree
Spark healthy ness check Spark healthy ness check
Coil should Energige on Plant
Coil should Energige on Plant Ruuning
Ruuning
pressure Between 50 to 250 Kpa pressure Between 50 to 250 Kpa
No falult LED should Glow on CPU No falult LED should Glow on CPU
Coil should Energige on Plant startup
Coil should Energige on Plant startup and After
and After flame get coil should de-
flame get coil should de-energige
energige
ACTION
REQUIRED
CONDITIO
LINK FOR BUCKETS OF

BF3-GCS-BKT BF3-GCS-BKT 5105020003
BUCKET ELEVATOR- DBF
BUCKET FR BUCKET
BF3-GCS-BKT BF3-GCS-BKT ELEVATOR-DRY BAG 5105020013
FILTER
PLUMMER BLOCK--TAIL
END BUCKET ELEVATOR
DRIVE
BF3-GCS-BKT BF3-GCS-BKT CHAIN,SIMPLEX,PITCH- 5112000094
38.1MM
Head pulley bearing
22224K
BF3-GCS-BKT BF3-GCS-BKT Tail pulley bearing item code
BF3-GCS-BKT BF3-GCS-BKT Bucket elevator Head drum item code
BF3-GCS-BKT BF3-GCS-BKT Bucket elevator Tail drum item code
GEAREDMOTOR GCP
BUCKET ELEVATOR
BF3-GCS-BKT BF3-GCS-BKT
Sprocket (drive) SPROCKET 0808010042
SIMPLEX
Sprocket (driven)
SPROCKET SIMPLEX
GCS Bucket
BF3-GCS-BKT Motor Windings
Elevator Motor
GCS Bucket
BF3-GCS-BKT Terminal Box
Elevator Motor
GCS Bucket
BF3-GCS-BKT Power Contactor
Elevator Panel
GCS Bucket
BF3-GCS-BKT Overload Relay with Kit
Elevator Panel
Command and Feed back

cable
Relay
BF3-GCS-BKT
DI ,DOCard,PLC , IM
modules
SMPS
Profibus Cable
CONDITION APPRAISAL OF GCP BUCKET ELEVATOR
TYPE OF CHECK
TOOLS (RUN CHECK / STOP
DESCRIPTION / DIMENSION REQUIRED CHECK /
SHUTDOWN)
CHECK FOR DAMAGED LINKS SPANNERS STOP CHECK
CHECK FOR DAMAGED BUCKET SPANNERS STOP CHECK
CHECK FOR DAMAGED LINKS VISUAL STOP CHECK
CHECK FOR BEARING CLEARANCE FILLER GAUGE STOP CHECK
CHECK FOR BEARING CLEARANCE FILLER GAUGE STOP CHECK

Megger & Shut Down
Multimeter check
value of Motor.
Spanners
power cable to the LT Motor check
Spanners,
Screw
Drivers, Allen
Key,
Multimeter

and setting of relay current for Visual RUN CHECK
motor tripping.
checking healthyness by Run the Multimeter,Te

Run check
Belt Conveyor ster
Multimeter,Te
operating DOL starter of Run check
ster
Elevator.
operating DOL starter of Multimeter,Te
Run check
conveyor/ by activating pull cord, ster
check supply voltage and output Multimeter,Te
Run check
Voltage ster
checking healthyness by Multimeter,Te
Run check
operating valve. ster
LEVATOR
NO DAMAGED LINKS
NO DAMAGED BUCKETS
NO PHYSICAL DAMAGE
NO DAMAGED LINKS
CLEARANCE <0.60MM
CLEARANCE <0.60MM
NO PHYSICAL DAMAGE
NO PHYSICAL DAMAGE
NO PHYSICAL DAMAGE
NO PHYSICAL DAMAGE
NO PHYSICAL DAMAGE
Winding Resistances should No abnormal difference

be balanced of all three in winding resistances.
phases, i.e., less than 10 Winding resistance of all
ohms. three phases is 6.8 ohms.
Megger values shouldbe Megger values are 1000
above 5 megaohms from all mega ohms and in
three phases to ground. healthy condition.
No looseness of the bolts
Tightened with spanner set.
Contactor rating is
LC1D32, 32 A. No
looseness in fitting of
contactor.
contactor and connection
of cables to power
contactor and its
fitting to be done.
contacts. Coil resistance
is 38 ohms.
30-43 ohms.

(12-18)A (12-18)A
Relay settings = 14.0 A Relay settings = 14.0 A
FLC = 14.3A RC = 9.2 A
cable
Check for healthiness of NO No abnormalities found

- NC contacts during in switching of contacts
operation. during operation.

SP-SS-CA-FAN COMBUSTION FAN ASSEMLEY (SP) 5114000020
SP-SS-CA-FAN COMBUSTION FAN ASSEMLEY (SP)
SP-SS-CA-FAN RELAY
SP-SS-CA-FAN CAMMAND & FEEDBACK CABLE
SP-SS-CA-FAN DI ,DO Card, PLC , IM modules
SP-SS-CA-FAN SMPS,
SP-SS-CA-FAN PRESSURE TRANSMITTER
SP-SS-CA-FAN Profibus Cable

NO DAMAGE/CRACK TO IMPELLER VISUAL
WIND VOLUME VISUAL AT PLC
check supply voltage and output Voltage, parameter setting,
checking of voltage & calibration

F CHECK (RUN CHECK / STOP CHECK / IDEAL
SHUTDOWN)
CONDITION ACTUAL CONDITION OBSERVED
STOP CHECK NO CRACKS AND DAMAGE ON IMPELLOR
RUN CHECK 3500-4000 M3/HR
Multimeter,Tester Run check Check for healthiness of NO - NC contacts during oper

ACTION REQUIRED
No abnormalities found in switching of contacts during operation.

CONDITION APP
Sub
SP-SS-FEED DRUM SP-SS-FEED DR FEED DRUM GEAR BOX 0806760022

SP-SS-FEED DRUM SP-SS-FEED DR FEEDDRUM GEARBOX PINION-SP 0806990046
SP-SS-FEED DRUM SP-SS-FEED DR Gear for Feed drum driven 0806990066
SP-SS-FEED DRUM SP-SS-FEED DR BEARING, 0921020091
SP-SS-FEED DRUM SP-SS-FEED DR Coupling input 0804040043
SP-SS-FEED DRUM SP-SS-FEED DR Feed Drum liner 5222000087
SP-SS-FEED DRUM SP-SS-FEED DR Sector gate rope 2111000064
CONDITION APPRAISAL OF FEEDDRUM
TYPE OF
CHECK (RUN
TOOLS CHECK /
SPECIFICATION DESCRIPTION / DIMENSION REQUIRED STOP
CHECK /
SHUTDOWN)
MODEL NO -ZSY250-100-1, SP CHECK FOR PHYSICAL DAMAGE VISUAL STOP CHECK

CHECK FOR TOOTH THICKNESS VERNIER STOP CHECK
CHECK FOR TOOTH THICKNESS VERNIER STOP CHECK
ROLLER,22234CCK/W33 CHECK FOR BEARING CLEARANCE FILLER GAUG STOP CHECK
UT 60 CHECK FOR BOLT TIGHTNESS OF C SPANNERS STOP CHECK
CHECK FOR THICKNESS VERNIER STOP CHECK
6mm CHECK FOR ROPE THICKNESS VERNIER STOP CHECK
ACTUAL ACTION
IDEAL CONDITION CONDITION REQUIRED
OBSERVED

SHOULD BE
SHOULD BE
SHOULD BE <0.70MM
BOLTS SHOULD BE TIGHT
SHOULD >08MM
SHOULD BE >5.4MM
CONDITION APPRAISAL OF
SP-SS-WBOX SP-SS-WBOX Geared motor 5114000102

SINTER MACHINE WIND 5114000144
SP-SS-WBOX SP-SS-WBOX BOX BELLOW
SINTER MACHINE WIND 5114000143
SP-SS-WBOX SP-SS-WBOX BOX BELLOW
SP-SS-WBOX SP-SS-WBOX GLAND PACKING, 2505000065
SP-SS-WBOX SP-SS-WBOX ROPE 2510040015
CONDITION APPRAISAL OF WINDBOX
TYPE OF
CHECK
(RUN
TOOLS CHECK
SPECIFICATION DESCRIPTION / DIMENSION REQUIRE STOP /
D CHECK /
SHUTDO
WN)
TYPE 1 CHECK FOR ANY LEAKAGE VISUAL RUN CHECK
TYPE 2 CHECK FOR ANY LEAKAGE VISUAL RUN CHECK

16 MM SQR,STYLE100 FXI CHECK FOR SHEARED/DAMAGEDSPANNER STOP CHEC
,ASBESTOS,SQUARE,12MM DIA,GRPHITED CHECK FOR SHEARED/DAMAGEDSPANNER STOP CHEC
ACTUAL
CONDITI ACTION
IDEAL CONDITION ON REQUIRE
OBSERVE D
D
NO LEAKAGE
NO LEAKAGE
FLANGE BOLT SHOULD BE TIGHT
FLANGE BOLT SHOULD BE TIGHT
SP-SS-7ROLL SP-SS-7ROLL ROLLERS OF 7 ROLL DISTRIBUTOR-SP
SP-SS-7ROLL SP-SS-7ROLL GEARED MOTOR OF 7 ROLL DISTRIBUTOR-SP
SP-SS-7ROLL SP-SS-7ROLL Spider of Coupling
SP-SS-7ROLL SP-SS-7ROLL COUPLING

CONDITION APPRAISAL OF 7ROLL DISTRIBUTOR
Item Code DESCRIPTION / DIMENSION TOOLS REQUIRED
5114000040 CHECK FOR SHELL DAMAGE VISUAL
3301020198 CHECK FOR PHYSICAL DAMAGE VISUAL
0804990108 CHECK FOR PHYSICAL DAMAGE SPANNERS
CHECK FOR CRACKS/DAMAGE IN HUB SPANNERS

DISTRIBUTOR
TYPE OF CHECK (RUN CHECK
/ STOP CHECK / IDEAL CONDITION
SHUTDOWN)
STOP CHECK NO DAMAGE TO SHELL OF ROLLERS

Sub
EQUIPMENT: COMPONENT Item Code
Equipments
SP-PROP-BWF SP-PROP-BWF Weigh feeder Gear box 5114060004

SP-PROP-BWF SP-PROP-BWF Carrying idler 5231010064
SP-PROP-BWF SP-PROP-BWF Load cell idler 5222900379/5222900380
SP-PROP-BWF SP-PROP-BWF Digester gear box 5114060005
SP-PROP-BWF SP-PROP-BWF PILLOW BLOCK 5222900359/5222900358
SP-PROP-BWF SP-PROP-BWF RAV GEAR BOX 5105020019

SP-PROP-BWF SP-PROP-BWF Head pulley 0812900006/0812900005
SP-PROP-BWF SP-PROP-BWF Tail pulley 5114050055/0812900007
SP-PROP-BWF SP-PROP-BWF Ecentric Bearing 0923090002
SP-PROP-BWF SP-PROP-BWF
RELAY
SP-PROP-BWF SP-PROP-BWF CAMMAND & FEEDBACK CABLE
SP-PROP-BWF SP-PROP-BWF
DI ,AO Card, PLC , IM modules
SP-PROP-BWF SP-PROP-BWF SMPS, BT820 CONTROLER
SP-PROP-BWF SP-PROP-BWF can bus Cable
SP-PROP-BWF SP-PROP-BWF Load cell
SP-PROP-BWF SP-PROP-BWF speed senor
CONDITION APPRAISAL OF BELT WEIGH FEEDER
SPECIFICATION
(650MMBELT)
(650/800MM BELT)
BWY22A-SP
, UCHA 207/, UCF 208 CD
PROP BIN 7,12,13- BYW18A-SP

800/650 mm belt
800/650 mm belt
RN206 MV23A
NDITION APPRAISAL OF BELT WEIGH FEEDER

CHECK FOR PHYSICAL DAMAGE OF IDLER SHELL
CHECK FOR PHYSICAL DAMAGE OF IDLER SHELL

CHECK FOR PHYSICAL DAMAGE OF PULLEY SHELL
CHECK FOR PHYSICAL DAMAGE OF PULLEY SHELL

checking healthyness by operating DOL starter of motor and run feedback.

check supply voltage and output Voltage, parameter setting,
check supply voltage and output Voltage and resistances
ER
TYPE OF
CHECK (RUN
CHECK /
TOOLS REQUIRED
STOP
CHECK /
SHUTDOWN)
SPANNERS STOP CHECK

VISUAL STOP CHECK
VISUAL STOP CHECK
SPANNERS STOP CHECK
SPANNERS STOP CHECK
SPANNERS STOP CHECK

VISUAL STOP CHECK
VISUAL STOP CHECK
SPANNERS AND FILLER GAUG STOP CHECK



NO PHYSICAL DAMAGE
NO PHYSICAL DAMAGE

NO PHYSICAL DAMAGE
NO PHYSICAL DAMAGE
CLEARANCE < 0.40MM
Check for healthiness of NO - NC contacts during operation. contacts during operation.
Physical check or damage of cable No abnormalities found

ACTION REQUIRED
HT PANEL BUSBARS
HT PANEL EARTHING
HT PANEL BUSBAR
HORIZONTAL AND
VERTICAL INSULATOR
HT BREAKER
OUTGOING TO
11 KV BF HT
O2N2 PLANT
PANEL ROOM
FROM PCC
HT NUMERICAL
PROTECTIVE RELAY
HT CABLES
POTENTIAL
TRANSFORMER
CURRENT TRANSFORMER
HT PANEL BUSBARS
HT PANEL BUSBARS
HT PANEL EARTHING
HT PANEL BUSBAR
HORIZONTAL AND
VERTICAL INSULATOR
HT BREAKER
OUTGOING TO
11 KV BF HT 1000KVAR
PANEL ROOM CAPACITOR
BANK
OUTGOING TO
11 KV BF HT 1000KVAR
PANEL ROOM CAPACITOR
BANK
HT CAPACITOR 1000
KVAR
HT NUMERICAL
PROTECTIVE RELAY
HT CABLES
POTENTIAL
TRANSFORMER
CURRENT TRANSFORMER
HT PANEL BUSBARS
HT PANEL EARTHING
HT PANEL BUSBAR
HORIZONTAL AND
VERTICAL INSULATOR
HT BREAKER
11 KV BF HT OUTGOING TO CA
PANEL ROOM FAN 1 FROM PCC
HT NUMERICAL
PROTECTIVE RELAY
HT CABLES
HT CABLES
POTENTIAL
TRANSFORMER
CURRENT TRANSFORMER
HT PANEL BUSBARS

HT PANEL EARTHING
HT PANEL BUSBAR
HORIZONTAL AND
VERTICAL INSULATOR
HT BREAKER
11 KV BF HT OUTGOING TO
PANEL ROOM CHDD FAN
HT NUMERICAL
PROTECTIVE RELAY
HT CABLES
POTENTIAL
TRANSFORMER
CURRENT TRANSFORMER
HT PANEL BUSBARS
HT PANEL EARTHING
HT PANEL BUSBAR
HORIZONTAL AND
VERTICAL INSULATOR
HT BREAKER
PANEL ROOM PCI ID FAN
HT NUMERICAL
PROTECTIVE RELAY
HT CABLES
POTENTIAL
TRANSFORMER
CURRENT TRANSFORMER
HT PANEL BUSBARS
HT PANEL EARTHING

HT PANEL BUSBAR
HORIZONTAL AND
VERTICAL INSULATOR
HT BREAKER
OUTGOING TO
11 KV BF HT MAIN CONTROL
PANEL ROOM B/D 1250KVA
TRANSFORMER 1
HT NUMERICAL
PROTECTIVE RELAY
HT CABLES
POTENTIAL
TRANSFORMER
CURRENT TRANSFORMER
HT PANEL BUSBARS
HT PANEL BUSBARS
HT PANEL EARTHING
HT PANEL BUSBAR
HORIZONTAL AND
VERTICAL INSULATOR
HT BREAKER
OUTGOING TO
11 KV BF HT STOCK HOUSE
PANEL ROOM 1250KVA
TRANSFORMER 1
OUTGOING TO
PANEL ROOM 1250KVA
TRANSFORMER 1
HT NUMERICAL
PROTECTIVE RELAY
HT CABLES
POTENTIAL
TRANSFORMER
CURRENT TRANSFORMER
HT PANEL BUSBARS
HT PANEL EARTHING
HT PANEL BUSBAR
HORIZONTAL AND
VERTICAL INSULATOR
HT BREAKER
OUTGOING TO
11 KV BF HT
CWPS PANEL
PANEL ROOM
SECTION 1
HT NUMERICAL
PROTECTIVE RELAY
HT CABLES
HT CABLES
POTENTIAL
TRANSFORMER
CURRENT TRANSFORMER
HT PANEL BUSBARS

HT PANEL EARTHING
HT PANEL BUSBAR
HORIZONTAL AND
VERTICAL INSULATOR
HT BREAKER
BF HT PCC PANEL
11 KV BF HT INCOMING
PANEL ROOM SUPPLY FROM
PP2
HT NUMERICAL
PROTECTIVE RELAY
HT CABLES
POTENTIAL
TRANSFORMER
CURRENT TRANSFORMER
HT PANEL BUSBARS
HT PANEL EARTHING
HT PANEL BUSBAR
HORIZONTAL AND
VERTICAL INSULATOR
HT BREAKER
11 KV BF HT PCC PANEL
PANEL ROOM BUSCOUPLER
HT NUMERICAL
PROTECTIVE RELAY
HT CABLES
POTENTIAL
TRANSFORMER
CURRENT TRANSFORMER
HT PANEL BUSBARS
HT PANEL EARTHING

HT PANEL BUSBAR
HORIZONTAL AND
VERTICAL INSULATOR
HT BREAKER
OUTGOING TO
PANEL ROOM 1250KVA
TRANSFORMER 2
HT NUMERICAL
PROTECTIVE RELAY
HT CABLES
POTENTIAL
TRANSFORMER
CURRENT TRANSFORMER
HT PANEL BUSBARS
HT PANEL BUSBARS
HT PANEL EARTHING
HT PANEL BUSBAR
HORIZONTAL AND
VERTICAL INSULATOR
HT BREAKER
OUTGOING TO
TRANSFORMER 2
OUTGOING TO
TRANSFORMER 2
HT NUMERICAL
PROTECTIVE RELAY
HT CABLES
POTENTIAL
TRANSFORMER
CURRENT TRANSFORMER
HT PANEL BUSBARS
HT PANEL EARTHING
HT PANEL BUSBAR
HORIZONTAL AND
VERTICAL INSULATOR
HT BREAKER
OUTGOING TO
11 KV BF HT
STOCK HOUSE
PANEL ROOM
DD FAN
HT NUMERICAL
PROTECTIVE RELAY
HT CABLES
HT CABLES
POTENTIAL
TRANSFORMER
CURRENT TRANSFORMER
HT PANEL BUSBARS

HT PANEL EARTHING
HT PANEL BUSBAR
HORIZONTAL AND
VERTICAL INSULATOR
HT BREAKER
PANEL ROOM HBS CA FAN 2
HT NUMERICAL
PROTECTIVE RELAY
HT CABLES
POTENTIAL
TRANSFORMER
CURRENT TRANSFORMER
HT PANEL BUSBARS
HT PANEL EARTHING
HT PANEL BUSBAR
HORIZONTAL AND
VERTICAL INSULATOR
HT BREAKER
OUTGOING TO
11 KV BF HT
CWPS PANEL
PANEL ROOM
SECTION 2
HT NUMERICAL
PROTECTIVE RELAY
HT CABLES
POTENTIAL
TRANSFORMER
CURRENT TRANSFORMER
HT PANEL BUSBARS
HT PANEL EARTHING

HT PANEL BUSBAR
HORIZONTAL AND
VERTICAL INSULATOR
HT BREAKER
PANEL ROOM SINTER PLANT
HT NUMERICAL
PROTECTIVE RELAY
HT CABLES
POTENTIAL
TRANSFORMER
CURRENT TRANSFORMER
HT PANEL BUSBARS
HT PANEL BUSBARS
HT PANEL EARTHING
HT PANEL BUSBAR
HORIZONTAL AND
VERTICAL INSULATOR
HT BREAKER
11 KV BF HT INCOMING FROM
PANEL ROOM PIP DG SUPPLY
11 KV BF HT INCOMING FROM
PANEL ROOM PIP DG SUPPLY
HT NUMERICAL
PROTECTIVE RELAY
HT CABLES
POTENTIAL
TRANSFORMER
CURRENT TRANSFORMER
TOOLS
REQUIRED
Check for proper tigteness of the busbar and

SPANNERS /
busbar support insulator. It should have
TORQUE
sufficient stiffness to be supported in air by
WRENCH
insulated pillars.

insulator and panel body. It should be VISUAL /
generally uninsulated, and should be proper COTTON
insulation between busbar and switchgear CLOTHE
panel through busbar insualtor.
Check for megger value of Busbar and panel

HT MEGGER
body.
Check for proper interlocking of earth switch

and HT Breaker. Also, check for interlocking VISUAL
of earth switch and panel back door.


strength used in electrical panels to support
VISUAL
the copper busbar. Check for megger value
between insulator and panel body.
VISUAL,
COTTON
To protect an electrical circuit from damage CLOTHE, CRC,
caused by excess current from an overload or DIELECTRIC
short circuit. Its basic function is to interrupt ISOPLEX &
current flow after a fault is detected. SHELL TELLUS
32 GREASE, HT
MEGGER
SECONDARY
To detect the fault and initiates the operation INJECTION
of circuit breaker to isolate the defective CURRENT AND
element from the rest of the system. VOLTAGE TEST
KIT
SPANNERS /
TORQUE
cable and HT Breaker Terminals.
WRENCH
Check for megger value of HT Cable phase

MEGGER
to phae and phase to earth.
Check for partial discharge test of HT Cable TAN-DELTA

for HT Cable insualtion testing. TEST KIT
VISUAL /
SECONDARY
INJECTION
shown in the meter.
CURRENT AND
Also, check for tripping of the HT Numerical
VOLTAGE TEST
Relay by Secondary Injection kit.
KIT
VISUAL /
SECONDARY
INJECTION
meter.
CURRENT AND
VOLTAGE TEST
KIT

SPANNERS /
TORQUE
WRENCH
insulated pillars.
HT MEGGER
body.



VISUAL
VISUAL,
COTTON
32 GREASE, HT
MEGGER
32 GREASE, HT
MEGGER
Check for megger value of HT Capacitor

HT MEGGER
terminal and panel body.
SECONDARY
KIT
SPANNERS /
TORQUE
WRENCH

MEGGER
VISUAL /
SECONDARY
INJECTION
shown in the meter.
CURRENT AND
VOLTAGE TEST
KIT
VISUAL /
SECONDARY
INJECTION
meter.
CURRENT AND
VOLTAGE TEST
KIT

SPANNERS /
TORQUE
WRENCH
insulated pillars.
HT MEGGER
body.



VISUAL
VISUAL,
COTTON
32 GREASE, HT
MEGGER
SECONDARY
KIT
SPANNERS /
TORQUE
WRENCH
MEGGER

VISUAL /
SECONDARY
INJECTION
shown in the meter.
CURRENT AND
VOLTAGE TEST
KIT
VISUAL /
SECONDARY
INJECTION
meter.
CURRENT AND
VOLTAGE TEST
KIT

SPANNERS /
TORQUE
WRENCH
insulated pillars.
HT MEGGER
body.



VISUAL
VISUAL,
COTTON
32 GREASE, HT
MEGGER
SECONDARY
KIT
SPANNERS /
TORQUE
WRENCH

MEGGER

VISUAL /
SECONDARY
INJECTION
shown in the meter.
CURRENT AND
VOLTAGE TEST
KIT
VISUAL /
SECONDARY
INJECTION
meter.
CURRENT AND
VOLTAGE TEST
KIT
SPANNERS /
TORQUE
WRENCH
insulated pillars.
HT MEGGER
body.



VISUAL
VISUAL,
COTTON
VISUAL,
COTTON
32 GREASE, HT
MEGGER
SECONDARY
KIT
SPANNERS /
TORQUE
WRENCH

MEGGER

VISUAL /
SECONDARY
INJECTION
shown in the meter.
CURRENT AND
VOLTAGE TEST
KIT
VISUAL /
SECONDARY
INJECTION
meter.
CURRENT AND
VOLTAGE TEST
KIT

SPANNERS /
TORQUE
WRENCH
insulated pillars.
HT MEGGER
body.


VISUAL
VISUAL,
COTTON
32 GREASE, HT
MEGGER
SECONDARY
KIT
SPANNERS /
TORQUE
WRENCH

MEGGER

VISUAL /
SECONDARY
INJECTION
shown in the meter.
CURRENT AND
VOLTAGE TEST
KIT
VISUAL /
SECONDARY
INJECTION
meter.
CURRENT AND
VOLTAGE TEST
KIT

SPANNERS /
TORQUE
WRENCH
insulated pillars.
HT MEGGER
body.



VISUAL
VISUAL,
COTTON
32 GREASE, HT
MEGGER
32 GREASE, HT
MEGGER
SECONDARY
KIT
SPANNERS /
TORQUE
WRENCH

MEGGER

VISUAL /
SECONDARY
INJECTION
shown in the meter.
CURRENT AND
VOLTAGE TEST
KIT
VISUAL /
SECONDARY
INJECTION
meter.
CURRENT AND
VOLTAGE TEST
KIT

SPANNERS /
TORQUE
WRENCH
insulated pillars.
HT MEGGER
body.



VISUAL
VISUAL,
COTTON
32 GREASE, HT
MEGGER
SECONDARY
KIT
SPANNERS /
TORQUE
WRENCH
MEGGER

VISUAL /
SECONDARY
INJECTION
shown in the meter.
CURRENT AND
VOLTAGE TEST
KIT
VISUAL /
SECONDARY
INJECTION
meter.
CURRENT AND
VOLTAGE TEST
KIT

SPANNERS /
TORQUE
WRENCH
insulated pillars.
HT MEGGER
body.



VISUAL
VISUAL,
COTTON
32 GREASE, HT
MEGGER
SECONDARY
KIT
SPANNERS /
TORQUE
WRENCH

MEGGER

VISUAL /
SECONDARY
INJECTION
shown in the meter.
CURRENT AND
VOLTAGE TEST
KIT
VISUAL /
SECONDARY
INJECTION
meter.
CURRENT AND
VOLTAGE TEST
KIT
SPANNERS /
TORQUE
WRENCH
insulated pillars.
HT MEGGER
body.



VISUAL
VISUAL,
COTTON
VISUAL,
COTTON
32 GREASE, HT
MEGGER
SECONDARY
KIT
SPANNERS /
TORQUE
WRENCH

MEGGER
VISUAL /
SECONDARY
INJECTION
shown in the meter.
CURRENT AND
VOLTAGE TEST
KIT
VISUAL /
SECONDARY
INJECTION
meter.
CURRENT AND
VOLTAGE TEST
KIT

SPANNERS /
TORQUE
WRENCH
insulated pillars.
HT MEGGER
body.


VISUAL
VISUAL,
COTTON
32 GREASE, HT
MEGGER
SECONDARY
KIT
SPANNERS /
TORQUE
WRENCH

MEGGER

VISUAL /
SECONDARY
INJECTION
shown in the meter.
CURRENT AND
VOLTAGE TEST
KIT
VISUAL /
SECONDARY
INJECTION
meter.
CURRENT AND
VOLTAGE TEST
KIT

SPANNERS /
TORQUE
WRENCH
insulated pillars.
HT MEGGER
body.



VISUAL
VISUAL,
COTTON
32 GREASE, HT
MEGGER
32 GREASE, HT
MEGGER
SECONDARY
KIT
SPANNERS /
TORQUE
WRENCH

MEGGER

VISUAL /
SECONDARY
INJECTION
shown in the meter.
CURRENT AND
VOLTAGE TEST
KIT
VISUAL /
SECONDARY
INJECTION
meter.
CURRENT AND
VOLTAGE TEST
KIT

SPANNERS /
TORQUE
WRENCH
insulated pillars.
HT MEGGER
body.



VISUAL
VISUAL,
COTTON
32 GREASE, HT
MEGGER
SECONDARY
KIT
SPANNERS /
TORQUE
WRENCH
MEGGER

VISUAL /
SECONDARY
INJECTION
shown in the meter.
CURRENT AND
VOLTAGE TEST
KIT
VISUAL /
SECONDARY
INJECTION
meter.
CURRENT AND
VOLTAGE TEST
KIT

SPANNERS /
TORQUE
WRENCH
insulated pillars.
HT MEGGER
body.



VISUAL
VISUAL,
COTTON
32 GREASE, HT
MEGGER
SECONDARY
KIT
SPANNERS /
TORQUE
WRENCH

MEGGER

VISUAL /
SECONDARY
INJECTION
shown in the meter.
CURRENT AND
VOLTAGE TEST
KIT
VISUAL /
SECONDARY
INJECTION
meter.
CURRENT AND
VOLTAGE TEST
KIT
SPANNERS /
TORQUE
WRENCH
insulated pillars.
HT MEGGER
body.



VISUAL
VISUAL,
COTTON
VISUAL,
COTTON
32 GREASE, HT
MEGGER
SECONDARY
KIT
SPANNERS /
TORQUE
WRENCH

MEGGER

VISUAL /
SECONDARY
INJECTION
shown in the meter.
CURRENT AND
VOLTAGE TEST
KIT
VISUAL /
SECONDARY
INJECTION
meter.
CURRENT AND
VOLTAGE TEST
KIT

SPANNERS /
TORQUE
WRENCH
insulated pillars.
HT MEGGER
body.


VISUAL
VISUAL,
COTTON
32 GREASE, HT
MEGGER
SECONDARY
KIT
SPANNERS /
TORQUE
WRENCH

MEGGER

VISUAL /
SECONDARY
INJECTION
shown in the meter.
CURRENT AND
VOLTAGE TEST
KIT
VISUAL /
SECONDARY
INJECTION
meter.
CURRENT AND
VOLTAGE TEST
KIT

SPANNERS /
TORQUE
WRENCH
insulated pillars.
HT MEGGER
body.



VISUAL
VISUAL,
COTTON
32 GREASE, HT
MEGGER
32 GREASE, HT
MEGGER
SECONDARY
KIT
SPANNERS /
TORQUE
WRENCH

MEGGER
VISUAL /
SECONDARY
INJECTION
shown in the meter.
CURRENT AND
VOLTAGE TEST
KIT
VISUAL /
SECONDARY
INJECTION
meter.
CURRENT AND
VOLTAGE TEST
KIT
TYPE OF CHECK (RUN
SHUTDOWN)

SHUTDOWN CHECK stainless steel bolts with flat washers
and nuts by Torque Wrench.
Insulators should be installed properly

SHUTDOWN CHECK to hold and support busbars.
Insulators should be clean.
Resistance between panel to busbar

SHUTDOWN CHECK
should be ˃ 20 mega ohms.

Breaker should not Rack In during
SHUTDOWN CHECK Earth Switch operated condition.
Also, Back Door of HT Panel should
not be open when earth switch is not
operated.

RUN CHECK panel. Space Heater current should be
< 1A

SHUTDOWN CHECK mechanical strength to the busbars.
Also, megger value should be ˃ 20
mega Ohms.
HT Breaker should be clean. There

should not be any moisture or wear
Proper lubrication of all moving parts
of mechanism.
mechanism.
Proper spring charging operation of
limit switch.
normal.
Insulation resistance between Upper
SHUTDOWN CHECK & Lower contacts should be > 1 T
Ohms
Insulation resistance between Phase

to Phase should be > 1 T Ohms

to Earth should be > 1 T Ohms
Timing of CB during Close should be

in ms of all three phases.
Timing of CB during Open should be
Timing of CB during Close / Open
should be in ms of all three phases.
Contact Resistance between Upper
and Lower contacts should be in
micro ohms of all three phases.

withstand for min. of all three phases.

should be healthy to trip the breaker
SHUTDOWN CHECK
on the faults described in the relay on
prescribed values.

to Phase should be > 20 Mega Ohms
SHUTDOWN CHECK
to Earth should be > 20 Mega Ohms
TAN-DELTA test of HT Cable should

SHUTDOWN CHECK
be < 0.004 absolute.
should
relay or meter.
SHUTDOWN CHECK 2. provide indication of voltage on the
panel.
Voltage.

should
1. measure current accurately on the
SHUTDOWN CHECK relay or meter.
Relay on Over curent / CIR / ITOC /
DMT.


SHUTDOWN CHECK
operated.

< 1A
mega Ohms.
of mechanism.
mechanism.
limit switch.
normal.
Ohms




SHUTDOWN CHECK

SHUTDOWN CHECK
prescribed values.


SHUTDOWN CHECK

should
relay or meter.
panel.
Voltage.
should
DMT.



SHUTDOWN CHECK
operated.

< 1A
mega Ohms.
of mechanism.
mechanism.
limit switch.
normal.
Ohms





SHUTDOWN CHECK
prescribed values.

SHUTDOWN CHECK

SHUTDOWN CHECK
should
relay or meter.
panel.
Voltage.

should
DMT.



SHUTDOWN CHECK
operated.

< 1A
mega Ohms.
of mechanism.
mechanism.
limit switch.
normal.
Ohms





SHUTDOWN CHECK
prescribed values.


SHUTDOWN CHECK

SHUTDOWN CHECK

should
relay or meter.
panel.
Voltage.

should
DMT.


SHUTDOWN CHECK
operated.

< 1A
mega Ohms.
of mechanism.
mechanism.
limit switch.
normal.
Ohms





SHUTDOWN CHECK
prescribed values.


SHUTDOWN CHECK

SHUTDOWN CHECK
should
relay or meter.
panel.
Voltage.

should
DMT.



SHUTDOWN CHECK
operated.

< 1A
mega Ohms.
of mechanism.
mechanism.
limit switch.
normal.
Ohms




SHUTDOWN CHECK
prescribed values.


SHUTDOWN CHECK

SHUTDOWN CHECK
should
relay or meter.
panel.
Voltage.

should
DMT.


SHUTDOWN CHECK
operated.

< 1A
mega Ohms.
of mechanism.
mechanism.
limit switch.
normal.
Ohms




SHUTDOWN CHECK
prescribed values.


SHUTDOWN CHECK

SHUTDOWN CHECK

should
relay or meter.
panel.
Voltage.
should
DMT.



SHUTDOWN CHECK
operated.

< 1A
mega Ohms.
of mechanism.
mechanism.
limit switch.
normal.
Ohms





SHUTDOWN CHECK
prescribed values.

SHUTDOWN CHECK

SHUTDOWN CHECK
should
relay or meter.
panel.
Voltage.

should
DMT.



SHUTDOWN CHECK
operated.

< 1A
mega Ohms.
of mechanism.
mechanism.
limit switch.
normal.
Ohms





SHUTDOWN CHECK
prescribed values.


SHUTDOWN CHECK

SHUTDOWN CHECK

should
relay or meter.
panel.
Voltage.

should
DMT.


SHUTDOWN CHECK
operated.

< 1A
mega Ohms.
of mechanism.
mechanism.
limit switch.
normal.
Ohms





SHUTDOWN CHECK
prescribed values.


SHUTDOWN CHECK
should
relay or meter.
panel.
Voltage.

should
DMT.



SHUTDOWN CHECK
operated.

< 1A
mega Ohms.
of mechanism.
mechanism.
limit switch.
normal.
Ohms




SHUTDOWN CHECK
prescribed values.


SHUTDOWN CHECK

SHUTDOWN CHECK
should
relay or meter.
panel.
Voltage.

should
DMT.


SHUTDOWN CHECK
operated.

< 1A
mega Ohms.
of mechanism.
mechanism.
limit switch.
normal.
Ohms




SHUTDOWN CHECK
prescribed values.


SHUTDOWN CHECK

SHUTDOWN CHECK

should
relay or meter.
panel.
Voltage.
should
DMT.



SHUTDOWN CHECK
operated.

< 1A
mega Ohms.
of mechanism.
mechanism.
limit switch.
normal.
Ohms





SHUTDOWN CHECK
prescribed values.

SHUTDOWN CHECK

SHUTDOWN CHECK
should
relay or meter.
panel.
Voltage.

should
DMT.



SHUTDOWN CHECK
operated.

< 1A
mega Ohms.
of mechanism.
mechanism.
limit switch.
normal.
Ohms





SHUTDOWN CHECK
prescribed values.


SHUTDOWN CHECK

SHUTDOWN CHECK

should
relay or meter.
panel.
Voltage.

should
DMT.


SHUTDOWN CHECK
operated.

< 1A
mega Ohms.
of mechanism.
mechanism.
limit switch.
normal.
Ohms





SHUTDOWN CHECK
prescribed values.


SHUTDOWN CHECK

SHUTDOWN CHECK
should
relay or meter.
panel.
Voltage.

should
DMT.



SHUTDOWN CHECK
operated.

< 1A
mega Ohms.
of mechanism.
mechanism.
limit switch.
normal.
Ohms




SHUTDOWN CHECK
prescribed values.


SHUTDOWN CHECK

SHUTDOWN CHECK
should
relay or meter.
panel.
Voltage.

should
DMT.


SHUTDOWN CHECK
operated.

< 1A
mega Ohms.
of mechanism.
mechanism.
limit switch.
normal.
Ohms




SHUTDOWN CHECK
prescribed values.


SHUTDOWN CHECK

should
relay or meter.
panel.
Voltage.
should
DMT.
ACTUAL CONDITION OBSERVED ACTION
ON 12.04.2018 REQUIRED

connecting links checked by torque
wrench.
Insulators were installed properly and

was clean. No oxydation observed
between insulator and bubar.
Resistance between panel to busbar is

1000 mega ohms.

Breaker is healthy. HT Breaker do not
Panel has not been open when earth
switch is not operated.

to the Earth Pit.


strength to the busbars are good. Also,
megger value is 1000 mega Ohms.
HT Breaker found clean. There is no

contacts.
Lubrication of all moving parts of
mechanism is normal.
Operation of gear box mechanism is
normal.
Operation of Test / Service auxiliary
switch operation is proper.
Closing and tripping mechanism of
breaker both electrically and manually
is proper.
Spring charging operation of limit
switch is normal.
breaker is proper.
Insulation resistance between Upper &

Lower contacts is > 1 T Ohms
Insulation resistance between Phase to

Phase is > 1 T Ohms

Earth is > 1 T Ohms
Timing of CB during Close is 41 ms of

all three phases.
Timing of CB during Open is 38 ms of
all three phases.
Timing of CB during Close / Open is 19
ms of all three phases.
Lower contacts is 38 micro ohms of all
three phases.
HVAC Test for 15 KV withstand for


is healthy to trip the breaker on the
faults described in the relay on
prescribed values.
wrench.

Phase is 1200 Ohms

Earth is 1000Mega Ohms
TAN-DELTA test of HT Cable is

0.0027

of voltage on the panel is shown.
Trippig of the HT Breaker through HT
Relay on Over voltage / Under Voltage
is healthy.

accurate current on the relay. Trippig of
the HT Breaker through HT Relay on
Over curent / CIR / ITOC / DMT is
healthy.

wrench.

1000 mega ohms.


to the Earth Pit.



contacts.
normal.
is proper.
switch is normal.
breaker is proper.


Phase is > 1 T Ohms
Earth is > 1 T Ohms

all three phases.
all three phases.
three phases.


1000 mega ohms.

prescribed values.

wrench.

Phase is 1200 Ohms


is healthy.
healthy.

wrench.


1000 mega ohms.


to the Earth Pit.



contacts.
normal.
is proper.
switch is normal.
breaker is proper.


Phase is > 1 T Ohms

Earth is > 1 T Ohms

all three phases.
all three phases.
three phases.


prescribed values.

wrench.
Phase is 1100 Ohms


0.0017

is healthy.

healthy.

wrench.


1000 mega ohms.

to the Earth Pit.



contacts.
normal.
is proper.
switch is normal.
breaker is proper.


Phase is > 1 T Ohms

Earth is > 1 T Ohms

all three phases.
all three phases.
three phases.


prescribed values.

wrench.

Phase is 1800 Ohms


0.00124

is healthy.

healthy.
wrench.


1000 mega ohms.


to the Earth Pit.



contacts.
normal.
is proper.
switch is normal.
breaker is proper.


Phase is > 1 T Ohms

Earth is > 1 T Ohms

all three phases.
all three phases.
three phases.


prescribed values.

wrench.

Phase is 1200 Ohms


0.0029
is healthy.

healthy.

wrench.


1000 mega ohms.


to the Earth Pit.


contacts.
normal.
is proper.
switch is normal.
breaker is proper.


Phase is > 1 T Ohms

Earth is > 1 T Ohms

all three phases.
all three phases.
three phases.

prescribed values.

wrench.

Phase is 1100 Ohms


0.0022

is healthy.

healthy.

wrench.

1000 mega ohms.


to the Earth Pit.



contacts.
normal.
is proper.
switch is normal.
breaker is proper.


Phase is > 1 T Ohms
Earth is > 1 T Ohms

all three phases.
all three phases.
three phases.


prescribed values.

wrench.

Phase is 1100 Ohms


0.0029

is healthy.
healthy.

wrench.


1000 mega ohms.


to the Earth Pit.



contacts.
normal.
is proper.
switch is normal.
breaker is proper.


Phase is > 1 T Ohms

Earth is > 1 T Ohms

all three phases.
all three phases.
three phases.


prescribed values.

wrench.
Phase is 1200 Ohms


0.0028

is healthy.

healthy.

wrench.


1000 mega ohms.

to the Earth Pit.



contacts.
normal.
is proper.
switch is normal.
breaker is proper.


Phase is > 1 T Ohms

Earth is > 1 T Ohms
Timing of CB during Close is39 ms of

all three phases.
all three phases.
three phases.


prescribed values.

wrench.

Phase is 1200 Ohms


0.0031

is healthy.

healthy.
wrench.


1000 mega ohms.


to the Earth Pit.



contacts.
normal.
is proper.
switch is normal.
breaker is proper.


Phase is > 1 T Ohms

Earth is > 1 T Ohms

all three phases.
all three phases.
three phases.


prescribed values.

wrench.

Phase is 1200 Ohms

is healthy.

healthy.

wrench.


1000 mega ohms.


to the Earth Pit.


contacts.
normal.
is proper.
switch is normal.
breaker is proper.


Phase is > 1 T Ohms

Earth is > 1 T Ohms

all three phases.
all three phases.
three phases.

prescribed values.

wrench.

Phase is 1500 Ohms


0.0030

is healthy.

healthy.

wrench.

1000 mega ohms.


to the Earth Pit.



contacts.
normal.
is proper.
switch is normal.
breaker is proper.


Phase is > 1 T Ohms
Earth is > 1 T Ohms

all three phases.
all three phases.
three phases.


prescribed values.

wrench.

Phase is 1200 Ohms


0.0020

is healthy.
healthy.

wrench.


1000 mega ohms.


to the Earth Pit.



contacts.
normal.
is proper.
switch is normal.
breaker is proper.


Phase is > 1 T Ohms

Earth is > 1 T Ohms

all three phases.
all three phases.
three phases.


prescribed values.

wrench.
Phase is 1700 Ohms


0.00173

is healthy.

healthy.

wrench.


1000 mega ohms.

to the Earth Pit.



contacts.
normal.
is proper.
switch is normal.
breaker is proper.


Phase is > 1 T Ohms

Earth is > 1 T Ohms

all three phases.
all three phases.
three phases.


prescribed values.

wrench.

Phase is 1000 Ohms


0.0019

is healthy.

healthy.
wrench.


1000 mega ohms.


to the Earth Pit.



contacts.
normal.
is proper.
switch is normal.
breaker is proper.


Phase is > 1 T Ohms

Earth is > 1 T Ohms

all three phases.
all three phases.
three phases.


prescribed values.

wrench.

Phase is 1200 Ohms


0.0021
is healthy.

healthy.

wrench.


1000 mega ohms.


to the Earth Pit.


contacts.
normal.
is proper.
switch is normal.
breaker is proper.


Phase is > 1 T Ohms

Earth is > 1 T Ohms

all three phases.
all three phases.
three phases.

prescribed values.

wrench.

Phase is 1000 Ohms


0.0025

is healthy.

healthy.

wrench.

1000 mega ohms.


to the Earth Pit.



contacts.
normal.
is proper.
switch is normal.
breaker is proper.


Phase is > 1 T Ohms
Earth is > 1 T Ohms

all three phases.
all three phases.
three phases.


prescribed values.

wrench.

Phase is 1200 Ohms


is healthy.
healthy.
Sub
EQUIPMENT: COMPONENT
Equipments
HT PANEL BUSBARS
HT PANEL EARTHING
HT PANEL BUSBAR
HORIZONTAL AND
VERTICAL INSULATOR
HT BREAKER
11 KV BF3 11KV
BLOWER HT BLOWER 1
PANEL ROOM OUTGOING
HT NUMERICAL
PROTECTIVE RELAY
HT CABLES
POTENTIAL
TRANSFORMER
CURRENT TRANSFORMER
HT PANEL BUSBARS
HT PANEL BUSBARS
HT PANEL EARTHING
HT PANEL BUSBAR
HORIZONTAL AND
VERTICAL INSULATOR
HT BREAKER
11 KV BF3 11KV
BLOWER HT BLOWER 2
PANEL ROOM OUTGOING
11 KV BF3 11KV
BLOWER HT BLOWER 2
PANEL ROOM OUTGOING
HT NUMERICAL
PROTECTIVE RELAY
HT CABLES
POTENTIAL
TRANSFORMER
CURRENT TRANSFORMER
HT PANEL BUSBARS
HT PANEL EARTHING
HT PANEL BUSBAR
HORIZONTAL AND
VERTICAL INSULATOR
HT BREAKER
BF3 11KV
BLOWER
11 KV
PANEL
BLOWER HT
1600KVAR
PANEL ROOM
CAPACITOR
BANK
HT CAPACITOR 1600
KVAR
HT NUMERICAL
PROTECTIVE RELAY
HT CABLES
POTENTIAL
TRANSFORMER
CURRENT TRANSFORMER
HT PANEL BUSBARS
HT PANEL EARTHING
HT PANEL BUSBAR
HORIZONTAL AND
VERTICAL INSULATOR
HT BREAKER
HT SOFTSTARTER
BF3 11KV
11 KV BLOWER 1
BLOWER HT SOFT
PANEL ROOM STARTER
PANEL
HT BYPASS BREAKER
HT BYPASS BREAKER
HT NUMERICAL
PROTECTIVE RELAY
HT CABLES
POTENTIAL
TRANSFORMER
CURRENT TRANSFORMER
HT PANEL BUSBARS
HT PANEL EARTHING

HT PANEL BUSBAR
HORIZONTAL AND
VERTICAL INSULATOR
HT BREAKER
BF3 11KV
HT SOFTSTARTER
BF3 11KV
11 KV BLOWER 2
BLOWER HT SOFT
PANEL ROOM STARTER
PANEL
HT BYPASS BREAKER
HT NUMERICAL
PROTECTIVE RELAY
HT CABLES
POTENTIAL
TRANSFORMER
CURRENT TRANSFORMER
HT PANEL BUSBARS
HT PANEL BUSBARS
HT PANEL EARTHING
HT PANEL BUSBAR
HORIZONTAL AND
VERTICAL INSULATOR
HT BREAKER
BLOWER
11KV HT
11 KV
PCC PANEL
BLOWER HT
INCOMING
PANEL ROOM
SUPPLY
FROM PP2
11KV HT
11 KV
PCC PANEL
BLOWER HT
INCOMING
PANEL ROOM
SUPPLY
FROM PP2
HT NUMERICAL
PROTECTIVE RELAY
HT CABLES
POTENTIAL
TRANSFORMER
CURRENT TRANSFORMER
TOOLS
REQUIRED

SPANNERS /
TORQUE
WRENCH
insulated pillars.


HT MEGGER
body.



VISUAL
VISUAL,
COTTON
32 GREASE, HT
MEGGER
SECONDARY
KIT
SPANNERS /
TORQUE
WRENCH

MEGGER

VISUAL /
SECONDARY
INJECTION
shown in the meter.
CURRENT AND
VOLTAGE TEST
KIT
VISUAL /
SECONDARY
INJECTION
meter.
CURRENT AND
VOLTAGE TEST
KIT

SPANNERS /
TORQUE
WRENCH
insulated pillars.
HT MEGGER
body.



VISUAL
VISUAL,
COTTON
32 GREASE, HT
MEGGER
32 GREASE, HT
MEGGER
SECONDARY
KIT
SPANNERS /
TORQUE
WRENCH

MEGGER
VISUAL /
SECONDARY
INJECTION
shown in the meter.
CURRENT AND
VOLTAGE TEST
KIT
VISUAL /
SECONDARY
INJECTION
meter.
CURRENT AND
VOLTAGE TEST
KIT

SPANNERS /
TORQUE
WRENCH
insulated pillars.
HT MEGGER
body.



VISUAL
VISUAL,
COTTON
32 GREASE, HT
MEGGER
Check for megger value of HT Capacitor

HT MEGGER
terminal and panel body.
SECONDARY
KIT
SPANNERS /
TORQUE
WRENCH

MEGGER
VISUAL /
SECONDARY
INJECTION
shown in the meter.
CURRENT AND
VOLTAGE TEST
KIT
VISUAL /
SECONDARY
INJECTION
meter.
CURRENT AND
VOLTAGE TEST
KIT

SPANNERS /
TORQUE
WRENCH
insulated pillars.
HT MEGGER
body.


VISUAL
VISUAL,
COTTON
32 GREASE, HT
MEGGER
Check for Resistance values of all thyristors Multimeter,
in each phase inside HT Softstarter. Lamp Test
VISUAL,
COTTON
32 GREASE, HT
MEGGER
32 GREASE, HT
MEGGER
SECONDARY
KIT
SPANNERS /
TORQUE
WRENCH

MEGGER

VISUAL /
SECONDARY
INJECTION
shown in the meter.
CURRENT AND
VOLTAGE TEST
KIT
VISUAL /
SECONDARY
INJECTION
meter.
CURRENT AND
VOLTAGE TEST
KIT

SPANNERS /
TORQUE
WRENCH
insulated pillars.
HT MEGGER
body.


VISUAL
VISUAL,
COTTON
32 GREASE, HT
MEGGER
Check for Resistance values of all thyristors Multimeter,
in each phase inside HT Softstarter. Lamp Test
VISUAL,
COTTON
32 GREASE, HT
MEGGER
SECONDARY
KIT
SPANNERS /
TORQUE
WRENCH

MEGGER

VISUAL /
SECONDARY
INJECTION
shown in the meter.
CURRENT AND
VOLTAGE TEST
KIT
VISUAL /
SECONDARY
INJECTION
meter.
CURRENT AND
VOLTAGE TEST
KIT

SPANNERS /
TORQUE
WRENCH
insulated pillars.
HT MEGGER
body.



VISUAL
VISUAL,
COTTON
32 GREASE, HT
MEGGER
32 GREASE, HT
MEGGER
SECONDARY
KIT
SPANNERS /
TORQUE
WRENCH

MEGGER

VISUAL /
SECONDARY
INJECTION
shown in the meter.
CURRENT AND
VOLTAGE TEST
KIT
VISUAL /
SECONDARY
INJECTION
meter.
CURRENT AND
VOLTAGE TEST
KIT
TYPE OF CHECK (RUN
SHUTDOWN)



SHUTDOWN CHECK

operated.

< 1A

mega Ohms.

of mechanism.
mechanism.
limit switch.
normal.
Ohms





SHUTDOWN CHECK
prescribed values.

SHUTDOWN CHECK

SHUTDOWN CHECK
should
relay or meter.
panel.
Voltage.

should
DMT.


SHUTDOWN CHECK
operated.

< 1A
mega Ohms.
of mechanism.
mechanism.
limit switch.
normal.
Ohms




SHUTDOWN CHECK
prescribed values.


SHUTDOWN CHECK

should
relay or meter.
panel.
Voltage.
should
DMT.



SHUTDOWN CHECK
operated.

< 1A
mega Ohms.
of mechanism.
mechanism.
limit switch.
normal.
Ohms





SHUTDOWN CHECK

SHUTDOWN CHECK
prescribed values.

SHUTDOWN CHECK

should
relay or meter.
panel.
Voltage.

should
DMT.



SHUTDOWN CHECK
operated.

< 1A
mega Ohms.
of mechanism.
mechanism.
limit switch.
normal.
Ohms



All ten thyristors in each phase

SHUTDOWN CHECK resistance should be in two digits


of mechanism.
mechanism.
limit switch.
SHUTDOWN CHECK Vacuum inside bottles should be
normal.
SHUTDOWN CHECK

& Lower contacts should be > 1 T
Ohms





SHUTDOWN CHECK
prescribed values.


SHUTDOWN CHECK

SHUTDOWN CHECK
should
relay or meter.
panel.
Voltage.

should
DMT.



SHUTDOWN CHECK
operated.

< 1A
mega Ohms.
of mechanism.
mechanism.
limit switch.
normal.
Ohms




SHUTDOWN CHECK resistance should be in two digits

of mechanism.
mechanism.
limit switch.
normal.
Ohms




SHUTDOWN CHECK
prescribed values.


SHUTDOWN CHECK

SHUTDOWN CHECK
should
relay or meter.
panel.
Voltage.

should
DMT.


SHUTDOWN CHECK
operated.

< 1A
mega Ohms.
of mechanism.
mechanism.
limit switch.
normal.
Ohms




SHUTDOWN CHECK
prescribed values.


SHUTDOWN CHECK

SHUTDOWN CHECK

should
relay or meter.
panel.
Voltage.
should
DMT.

wrench.


1000 mega ohms.


to the Earth Pit.



contacts.
normal.
is proper.
switch is normal.
breaker is proper.


Phase is > 1 T Ohms

Earth is > 1 T Ohms

all three phases.
all three phases.
three phases.


prescribed values.
wrench.

Phase is 1100 Ohms


0.0017

is healthy.

healthy.

wrench.

1000 mega ohms.


to the Earth Pit.



contacts.
normal.
is proper.
switch is normal.
breaker is proper.


Phase is > 1 T Ohms
Earth is > 1 T Ohms

all three phases.
all three phases.
three phases.


prescribed values.

wrench.

Phase is 1200 Ohms


is healthy.
healthy.

wrench.


1000 mega ohms.


to the Earth Pit.



contacts.
normal.
is proper.
switch is normal.
breaker is proper.


Phase is > 1 T Ohms

Earth is > 1 T Ohms

all three phases.
all three phases.
three phases.


1000 mega ohms.

prescribed values.
wrench.

Phase is 1100 Ohms


is healthy.

healthy.

wrench.


1000 mega ohms.

to the Earth Pit.



contacts.
normal.
is proper.
switch is normal.
breaker is proper.


Phase is > 1 T Ohms

Earth is > 1 T Ohms
all three phases.
all three phases.
three phases.


resistance are in two digits. All
thyristors are in range of 11 to 14 ohms.

contacts.

normal.
is proper.
switch is normal.
breaker is proper.

Phase is > 1 T Ohms

Earth is > 1 T Ohms

all three phases.
all three phases.
three phases.


prescribed values.

wrench.

Phase is 1800 Ohms


0.00124
is healthy.

healthy.

wrench.


1000 mega ohms.


to the Earth Pit.


contacts.
normal.
is proper.
switch is normal.
breaker is proper.


Phase is > 1 T Ohms

Earth is > 1 T Ohms

all three phases.
all three phases.
three phases.

resistance are in two digits. All
thyristors are in range of 11 to 14 ohms.

contacts.
normal.
is proper.
switch is normal.
breaker is proper.


Phase is > 1 T Ohms

Earth is > 1 T Ohms

all three phases.
all three phases.
three phases.

prescribed values.

wrench.

Phase is 1200 Ohms


0.0029

is healthy.

healthy.

wrench.

1000 mega ohms.


to the Earth Pit.



contacts.
normal.
is proper.
switch is normal.
breaker is proper.


Phase is > 1 T Ohms
Earth is > 1 T Ohms

all three phases.
all three phases.
three phases.


prescribed values.

wrench.

Phase is 1200 Ohms


0.0029

is healthy.
healthy.
Sub
Equipments
HT PANEL BUSBARS
HT PANEL EARTHING
HT PANEL BUSBAR
HORIZONTAL AND
VERTICAL INSULATOR
OUTGOING HT BREAKER
11 KV HT
TO MEDIUM
CWPS PANEL
PRESSURE
ROOM
PUMP 1
HT NUMERICAL
PROTECTIVE RELAY
HT CABLES
POTENTIAL
TRANSFORMER
CURRENT TRANSFORMER
HT PANEL BUSBARS
HT PANEL EARTHING
HT PANEL BUSBAR
HORIZONTAL AND
VERTICAL INSULATOR
HT BREAKER
OUTGOING
11 KV HT
TO MEDIUM
CWPS PANEL
PRESSURE
ROOM
PUMP 2
HT NUMERICAL
PROTECTIVE RELAY
HT CABLES
POTENTIAL
TRANSFORMER
CURRENT TRANSFORMER
HT PANEL BUSBARS
HT PANEL EARTHING

HT PANEL BUSBAR
HORIZONTAL AND
VERTICAL INSULATOR
HT BREAKER
OUTGOING
11 KV HT
TO MEDIUM
CWPS PANEL
PRESSURE
ROOM
PUMP 3
HT NUMERICAL
PROTECTIVE RELAY
HT CABLES
POTENTIAL
TRANSFORMER
CURRENT TRANSFORMER
HT PANEL BUSBARS
HT PANEL BUSBARS
HT PANEL EARTHING
HT PANEL BUSBAR
HORIZONTAL AND
VERTICAL INSULATOR
HT BREAKER
OUTGOING
11 KV HT
TO 2500KVA
CWPS PANEL
TRANSFOR
ROOM
MER 1
OUTGOING
11 KV HT
TO 2500KVA
CWPS PANEL
TRANSFOR
ROOM
MER 1
HT NUMERICAL
PROTECTIVE RELAY
HT CABLES
POTENTIAL
TRANSFORMER
CURRENT TRANSFORMER
HT PANEL BUSBARS
HT PANEL EARTHING
HT PANEL BUSBAR
HORIZONTAL AND
VERTICAL INSULATOR
HT BREAKER
OUTGOING
11 KV HT
TO 2500KVA
CWPS PANEL
TRANSFOR
ROOM
MER 2
HT NUMERICAL
PROTECTIVE RELAY
HT CABLES
HT CABLES
POTENTIAL
TRANSFORMER
CURRENT TRANSFORMER
TOOLS
REQUIRED

SPANNERS /
TORQUE
WRENCH
insulated pillars.


HT MEGGER
body.



VISUAL
VISUAL,
COTTON
32 GREASE, HT
MEGGER
SECONDARY
KIT
SPANNERS /
TORQUE
WRENCH

MEGGER

VISUAL /
SECONDARY
INJECTION
shown in the meter.
CURRENT AND
VOLTAGE TEST
KIT
VISUAL /
SECONDARY
INJECTION
meter.
CURRENT AND
VOLTAGE TEST
KIT
SPANNERS /
TORQUE
WRENCH
insulated pillars.
HT MEGGER
body.



VISUAL
VISUAL,
COTTON
VISUAL,
COTTON
32 GREASE, HT
MEGGER
SECONDARY
KIT
SPANNERS /
TORQUE
WRENCH

MEGGER

VISUAL /
SECONDARY
INJECTION
shown in the meter.
CURRENT AND
VOLTAGE TEST
KIT
VISUAL /
SECONDARY
INJECTION
meter.
CURRENT AND
VOLTAGE TEST
KIT

SPANNERS /
TORQUE
WRENCH
insulated pillars.
HT MEGGER
body.


VISUAL
VISUAL,
COTTON
32 GREASE, HT
MEGGER
SECONDARY
KIT
SPANNERS /
TORQUE
WRENCH

MEGGER

VISUAL /
SECONDARY
INJECTION
shown in the meter.
CURRENT AND
VOLTAGE TEST
KIT
VISUAL /
SECONDARY
INJECTION
meter.
CURRENT AND
VOLTAGE TEST
KIT

SPANNERS /
TORQUE
WRENCH
insulated pillars.
HT MEGGER
body.



VISUAL
VISUAL,
COTTON
32 GREASE, HT
MEGGER
32 GREASE, HT
MEGGER
SECONDARY
KIT
SPANNERS /
TORQUE
WRENCH

MEGGER

VISUAL /
SECONDARY
INJECTION
shown in the meter.
CURRENT AND
VOLTAGE TEST
KIT
VISUAL /
SECONDARY
INJECTION
meter.
CURRENT AND
VOLTAGE TEST
KIT

SPANNERS /
TORQUE
WRENCH
insulated pillars.
HT MEGGER
body.



VISUAL
VISUAL,
COTTON
32 GREASE, HT
MEGGER
SECONDARY
KIT
SPANNERS /
TORQUE
WRENCH
MEGGER

VISUAL /
SECONDARY
INJECTION
shown in the meter.
CURRENT AND
VOLTAGE TEST
KIT
VISUAL /
SECONDARY
INJECTION
meter.
CURRENT AND
VOLTAGE TEST
KIT
TYPE OF CHECK (RUN
SHUTDOWN)



SHUTDOWN CHECK

operated.

< 1A

mega Ohms.
of mechanism.
mechanism.
limit switch.
normal.
Ohms




SHUTDOWN CHECK
prescribed values.


SHUTDOWN CHECK

SHUTDOWN CHECK

should
relay or meter.
panel.
Voltage.

should
DMT.


SHUTDOWN CHECK
operated.

< 1A
mega Ohms.
of mechanism.
mechanism.
limit switch.
normal.
Ohms





SHUTDOWN CHECK
prescribed values.


SHUTDOWN CHECK

SHUTDOWN CHECK
should
relay or meter.
panel.
Voltage.

should
DMT.



SHUTDOWN CHECK
operated.

< 1A
mega Ohms.
of mechanism.
mechanism.
limit switch.
normal.
Ohms




SHUTDOWN CHECK
prescribed values.


SHUTDOWN CHECK

SHUTDOWN CHECK
should
relay or meter.
panel.
Voltage.

should
DMT.


SHUTDOWN CHECK
operated.

< 1A
mega Ohms.
of mechanism.
mechanism.
limit switch.
normal.
Ohms




SHUTDOWN CHECK
prescribed values.


SHUTDOWN CHECK

SHUTDOWN CHECK

should
relay or meter.
panel.
Voltage.
should
DMT.



SHUTDOWN CHECK
operated.

< 1A
mega Ohms.
of mechanism.
mechanism.
limit switch.
normal.
Ohms





SHUTDOWN CHECK
prescribed values.

SHUTDOWN CHECK

SHUTDOWN CHECK
should
relay or meter.
panel.
Voltage.

should
DMT.

wrench.


1000 mega ohms.


to the Earth Pit.


contacts.
normal.
is proper.
switch is normal.
breaker is proper.


Phase is > 1 T Ohms

Earth is > 1 T Ohms

all three phases.
all three phases.
three phases.

prescribed values.

wrench.

Phase is 1200 Ohms


0.0010

is healthy.

healthy.
wrench.


1000 mega ohms.


to the Earth Pit.



contacts.
normal.
is proper.
switch is normal.
breaker is proper.


Phase is > 1 T Ohms

Earth is > 1 T Ohms

all three phases.
all three phases.
three phases.


prescribed values.

wrench.

Phase is 1300 Ohms


0.0009
is healthy.

healthy.

wrench.


1000 mega ohms.


to the Earth Pit.


contacts.
normal.
is proper.
switch is normal.
breaker is proper.


Phase is > 1 T Ohms

Earth is > 1 T Ohms

all three phases.
all three phases.
three phases.

prescribed values.

wrench.

Phase is 1700 Ohms


is healthy.

healthy.

wrench.

1000 mega ohms.


to the Earth Pit.



contacts.
normal.
is proper.
switch is normal.
breaker is proper.


Phase is > 1 T Ohms
Earth is > 1 T Ohms

all three phases.
all three phases.
three phases.


prescribed values.

wrench.

Phase is 1500 Ohms


0.0010

is healthy.
healthy.

wrench.


1000 mega ohms.


to the Earth Pit.



contacts.
normal.
is proper.
switch is normal.
breaker is proper.


Phase is > 1 T Ohms

Earth is > 1 T Ohms

all three phases.
all three phases.
three phases.


prescribed values.

wrench.
Phase is 1700 Ohms


0.0031

is healthy.

healthy.
BLOWER #1 LUBE OIL

PUMP #1 CONTACTOR
BLOWER #1 LUBE OIL

PUMP #1 OVERLOAD
RELAY
BLOWER #1 LUBE OIL

PUMP #1 AUXILIARY
CONTACTOR
BLOWER #1 LUBE OIL

PUMP #2 CONTACTOR
BLOWER #1 LUBE OIL

PUMP #2 OVERLOAD
RELAY
BLOWER #1 LUBE OIL

PUMP #2 AUXILIARY
CONTACTOR
BLOWER #1 BARRING
GEAR MOTOR
CONTACTOR
BLOWER #1 BARRING
GEAR MOTOR
SOFTSTARTER
BLOWER #2 LUBE OIL

PUMP #1 CONTACTOR
BLOWER
ACCESSORIES
PANEL
BLOWER #2 LUBE OIL

PUMP #1 OVERLOAD
RELAY
BLOWER #2 LUBE OIL

PUMP #1 AUXILIARY
CONTACTOR
BLOWER #2 LUBE OIL

PUMP #2 CONTACTOR
BLOWER #2 LUBE OIL

PUMP #2 OVERLOAD
RELAY
BLOWER #2 LUBE OIL

PUMP #2 AUXILIARY
CONTACTOR
BLOWER #2 BARRING
GEAR MOTOR
CONTACTOR
BLOWER #2 BARRING
GEAR MOTOR
SOFTSTARTER
BLOWER #1 MOTOR
SPACE HEATER
CONTACTOR
BLOWER #2 MOTOR
SPACE HEATER
CONTACTOR
HT PANEL BUSBARS
HT PANEL EARTHING
HT PANEL BUSBAR
HORIZONTAL AND
HT CAPACITOR VERTICAL INSULATOR
PANEL
HT VACUUM CONTACTOR
HT CABLES
HT PANEL BUSBARS
HT PANEL EARTHING
HT PANEL BUSBAR
HORIZONTAL AND
VERTICAL INSULATOR
BLOWER HT HT BREAKER
PANEL
HT NUMERICAL
PROTECTIVE RELAY
HT CABLES
HT CABLES
POTENTIAL
TRANSFORMER
CURRENT TRANSFORMER
HT PANEL BUSBARS
HT PANEL EARTHING
HT PANEL BUSBAR
HORIZONTAL AND
VERTICAL INSULATOR
HT SOFTSTARTER
BLOWER 1 SOFT
STARTER PANEL
HT NUMERICAL
PROTECTIVE RELAY
BLOWER
PANEL HT CABLES
POTENTIAL
TRANSFORMER
CURRENT TRANSFORMER
HT PANEL BUSBARS
HT PANEL EARTHING
HT PANEL BUSBAR
HORIZONTAL AND
VERTICAL INSULATOR
HT SOFTSTARTER
BLOWER 2 SOFT
STARTER PANEL HT NUMERICAL
PROTECTIVE RELAY
STARTER PANEL
HT CABLES
POTENTIAL
TRANSFORMER
CURRENT TRANSFORMER
BLOWER SOFTSTARTER
UPS#1
BLOWER BLOWER SOFTSTARTER

SOFTSTARTER UPS#2
UPS
BLOWER
SOFTSTARTER
UPS
BLOWER SOFTSTARTER
CUBICLE CABINET
UNINTERRUPTIBLE
POWER SUPPLY
CENTRAL PROCESSING
UNIT
ON/OFF CONTROL
SYSTEM
OPEN LOOP CONTROL

SYSTEM
FEED FORWARD
CONTROL SYSTEM
CLOSE LOOP CONTROL

SYSTEM
BLOWER PLC
ANALOG INPUT MODULE
BLOWER PLC
ANALOG OUTPUT
MODULE
DIGITAL INPUT MODULE
DIGITAL OUTPUT
MODULE
COMMUNICATION
MODULE
HUMAN MACHINE
INTERFACE OR SCADA
UPS#1
BLOWER PLC
UPS
UPS#2
BLOWER #1 LUBE OIL

PUMP #1 RELAY
BLOWER #1 LUBE OIL

PUMP # 2 RELAY
BLOWER #1 BARRING
GEAR MOTOR RELAY
BLOWER #2 LUBE OIL

PUMP #1 RELAY
BLOWER #2 LUBE OIL

PUMP #2 RELAY
BLOWER #2 BARRING
GEAR MOTOR RELAY
BLOWER
ACCESSORIES
PANEL BLOWER #1 Bleed Valve
RELAY
ACCESSORIES
PANEL
BLOWER #2 Bleed Valve

RELAY
BLOWER #1 IGV RELAY
BLOWER #2 IGV RELAY
BLOWER #1OUTLET
VALVE RELAY
BLOWER #2 OUTLET
VALVE RELAY
Positioner
AI Card
AO Card
PLC
IM Module
SMPS
BLOWER # 1
ANTI SURGE
VALVE
UPS
Signal Cable
Pressure Regulator
Compressor
Impulse line
Relay
Relay
DI Card
DO Card
BLOWER # 1
BLEED VALVE PLC
IM Module
UPS
Signal Cable
Relay
DI Card
DO Card
BLOWER # 2
BLEED VALVE PLC
IM Module
UPS
Signal Cable
VIBRATION
TRANSMITTER
BLOWER
RTD
TOOLS
REQUIRED
Spanners,
Screw Drivers,
Allen Key,
of the contactor.
Multimeter

Visual
The auxiliary contactor is often used in a

logic circuit, or for some other part of the Visual
control scheme.
Spanners,
Screw Drivers,
Allen Key,
of the contactor.
Multimeter

Visual

control scheme.
Spanners,
Screw Drivers,
Allen Key,
of the contactor.
Multimeter
Softstarter is a device which controls the Cotton clothe,

acceleration of an electric motor by means of spanners, Screw
controlling the applied voltage. driver
Spanners,
Screw Drivers,
Allen Key,
of the contactor.
Multimeter

Visual

control scheme.
Spanners,
Screw Drivers,
Allen Key,
of the contactor.
Multimeter

Visual

control scheme.
Spanners,
Screw Drivers,
Allen Key,
of the contactor.
Multimeter
Softstarter is a device which controls the Cotton clothe,

acceleration of an electric motor by means of spanners, Screw
controlling the applied voltage. driver
Spanners,
Screw Drivers,
Allen Key,
of the contactor.
Multimeter
Spanners,
Screw Drivers,
Allen Key,
of the contactor.
Multimeter

SPANNERS /
TORQUE
WRENCH
insulated pillars.


HT MEGGER
body.

VISUAL
VISUAL,
COTTON
32 GREASE, HT
MEGGER
SPANNERS /
TORQUE
WRENCH

MEGGER
SPANNERS /
TORQUE
WRENCH
insulated pillars.


HT MEGGER
body.



VISUAL
VISUAL,
COTTON
32 GREASE, HT
MEGGER
SECONDARY
KIT
SPANNERS /
TORQUE
WRENCH
MEGGER

VISUAL /
SECONDARY
INJECTION
shown in the meter.
CURRENT AND
VOLTAGE TEST
KIT
VISUAL /
SECONDARY
INJECTION
meter.
CURRENT AND
VOLTAGE TEST
KIT

SPANNERS /
TORQUE
WRENCH
insulated pillars.


HT MEGGER
body.

LEAKAGE
Check for earthing of the Panel body.
TESTER

VISUAL
To protect an electrical circuit from damage VISUAL,

caused by excess current from an overload or COTTON
short circuit. Its basic function is to interrupt CLOTHE,
current flow after a fault is detected. MULTIMETER
SECONDARY
KIT
SPANNERS /
TORQUE
WRENCH

MEGGER

VISUAL /
SECONDARY
INJECTION
shown in the meter.
CURRENT AND
VOLTAGE TEST
KIT
VISUAL /
SECONDARY
INJECTION
meter.
CURRENT AND
VOLTAGE TEST
KIT

SPANNERS /
TORQUE
WRENCH
insulated pillars.
HT MEGGER
body.

LEAKAGE
Check for earthing of the Panel body.
TESTER

VISUAL
To protect an electrical circuit from damage VISUAL,

caused by excess current from an overload or COTTON
short circuit. Its basic function is to interrupt CLOTHE,
current flow after a fault is detected. MULTIMETER
SECONDARY
KIT
SPANNERS /
TORQUE
WRENCH

MEGGER

VISUAL /
SECONDARY
INJECTION
shown in the meter.
CURRENT AND
VOLTAGE TEST
KIT
VISUAL /
SECONDARY
INJECTION
meter.
CURRENT AND
VOLTAGE TEST
KIT
UPS provides emergency power to a load

when the input power source or mains power VISUAL
fails.

fails.
Blower Cubicle cabinet helps to synchronize
Blower UPS #1 & UPS #2 and Bypass VISUAL
supply.
Power Supply Unit distributes energy to the

Processor card and the I/O modules. It has a
+5V DC output supply which together with VISUAL /
an input-voltage supply (AC ready) and an MULTIMETER
output-voltage supply (DC ready) provides
power back-up to the system.
CPU controls or monitors all the components

which are distributed throughout the system.
VISUAL
It generally composed of the main memory,
control unit, and arithmetic-logic unit.
MULTIMETER /
ON / OFF Control System is two states fully
SOURCE
ON and Fully OFF
METER
Open Loop Control is to produce desired MULTIMETER /
response to the actuators independently SOURCE
calculates control outputs. METER
Feed forward control is implemented to
reduce the effect of Input disturbance on MULTIMETER /
process. A sensor in this system detects the SOURCE
disturbances or any load changes in the METER
process.
Close loop control system is implementd in MULTIMETER /
the output measurement as a feedback signal SOURCE
is found. METER
Analog input modules facilitate connection
of the controller to the analog signals of a
process. They are suitable for connecting
VISUAL /
analog sensors such as voltage and current
MULTIMETER
sensors, thermocouples, resistors and
resistance thermometers as well as analog
actuators.
Analog output modules convert a 16-bit

digital value into a current or a voltage and
VISUAL /
output this to the process. They are suitable
MULTIMETER
for controlling proportional valves or small
servo drives.
Digital input modules contain digital inputs

for the automation system. Digital sensors VISUAL /
and actuators can be connected to the MULTIMETER
automation system via these modules.
This digital output module transmits control

VISUAL /
signals of 24 VDC from the automation
MULTIMETER
device to the connected actuators.
The communication cards OR Modules are

used to realize the generalpurpose
VISUAL /
communication of field control station and
SOFTWARE
subsystems via serial links, so that the
subsystem may be controlled or monitored.
HMI OR SCADA monitor entire plant
parameters graphically and to log the data in
VISUAL /
plant database systems. Trend display of
SOFTWARE
various process parameters provides the
effective display and easy monitoring.

fails.

fails.
check for Relay heathyness of oil pump to Screw Drivers,

start Multimeter

start Multimeter
check for Relay heathyness of Barring Gear Screw Drivers,

Motor to start Multimeter

start Multimeter

start Multimeter
check for Relay heathyness of Barring Gear Screw Drivers,

check for Relay heathyness of Bleed Valve Screw Drivers,

check for Relay heathyness of Bleed Valve Screw Drivers,
check for Relay heathyness of IGV Motor to Screw Drivers,

start Multimeter
check for Relay heathyness of IGV Motor to Screw Drivers,

start Multimeter
check for Relay heathyness of OUTLET Screw Drivers,

VALVE Motor to start Multimeter
check for Relay heathyness of OUTLET Screw Drivers,

VALVE Motor to start Multimeter
check for Positioner to rotate control valve

according to command given by the PLC Multi meter
Analog input
check for Feedback postion of the valve Multi meter
check for set position of the valve Multi meter
check to Execute command and Feedback

Multi meter
According to set point by progamming Logic
check for Communication between PLC and

Multi meter
Analog Input and output Cards
check for Supply to Communication and I/O

Multi meter
Cards
check for supply to PLC And SMPS Multi meter
check for Command to Positioner and get

Multi meter
Feedback from positioner to PLC
check Sufficient Pressure to Positioner VIsual

check sufficient air to operate Positioner VIsual
check Pressure up to Regulator of the

VIsual
Positioner From Air Receiving Tank
check for Open/ Close command Multi meter
Check for Open/ Close command Multi meter

Multi meter

Multi meter

Multi meter
Check for Open/ Close command Multi meter

Multi meter

Multi meter

Multi meter
Check for vibration of compressor Multi meter
Check for Temparature of Motor winding,

Bearing of Blower,Gear Box and OIL Multi meter
Tempararture
TYPE OF CHECK (RUN
SHUTDOWN)
Contactor rarting to be 32A.

contactor.
SHUTDOWN CHECK
the contacts and proper fitting to
be done.
ohms.
Relay Range :
23 A - 32 A
SHUTDOWN CHECK
FLC = 27.5A
The auxiliary contctactor is used to

provide tripping indication whenever
SHUTDOWN CHECK
the lube oil pump will trip or power
fails.

contactor.
SHUTDOWN CHECK
be done.
ohms.
Relay Range :
23 A - 32 A
SHUTDOWN CHECK
FLC = 27.5A
SHUTDOWN CHECK
fails.
contactor.
SHUTDOWN CHECK
be done.
ohms.
SHUTDOWN CHECK tighteness of the power and
control cable.
contactor.
SHUTDOWN CHECK
be done.
ohms.
Relay Range :
23 A - 32 A
SHUTDOWN CHECK
FLC = 27.5A
SHUTDOWN CHECK
fails.

contactor.
SHUTDOWN CHECK
be done.
ohms.
Relay Range :
23 A - 32 A
SHUTDOWN CHECK
FLC = 27.5A
SHUTDOWN CHECK
fails.
contactor.
SHUTDOWN CHECK
be done.
ohms.
SHUTDOWN CHECK tighteness of the power and
control cable.
contactor.
SHUTDOWN CHECK
be done.
ohms.

contactor.
SHUTDOWN CHECK
be done.
ohms.



SHUTDOWN CHECK
operated.

mega Ohms.
HT Vacuum Contactor should be

clean. There should not be any
contacts.
Condition of contact should be proper.

normal.
SHUTDOWN CHECK Insulation resistance between Upper
& Lower contacts should be OL
Ohms
to Phase should be OL Ohms
to Earth should be OL Ohms


SHUTDOWN CHECK


SHUTDOWN CHECK

operated.

< 1A

mega Ohms.

of mechanism.
mechanism.
limit switch.
normal.
Ohms





SHUTDOWN CHECK
prescribed values.

SHUTDOWN CHECK

SHUTDOWN CHECK

should
relay or meter.
panel.
Voltage.

should
DMT.



SHUTDOWN CHECK

< 1A
mega Ohms.
HT Softstarter should be clean. There

SHUTDOWN CHECK
Thyristors Resistances of all three
phases of HT Softstarter should be in
2 digit nos.

SHUTDOWN CHECK
prescribed values.


SHUTDOWN CHECK

SHUTDOWN CHECK

should
relay or meter.
panel.
Voltage.
should
DMT.



SHUTDOWN CHECK

< 1A
mega Ohms.
HT Softstarter should be clean. There
SHUTDOWN CHECK
Thyristors Resistances of all three
phases of HT Softstarter should be in
2 digit nos.

SHUTDOWN CHECK
prescribed values.

SHUTDOWN CHECK

SHUTDOWN CHECK
should
relay or meter.
panel.
Voltage.

should
DMT.
Healthiness of Incoming Main Power,

Outgoing Power, Battery Voltage
SHUTDOWN CHECK Indication should be healthy.
Voltage should be 113 VDC and

Current should be <1.5 A


Healthiness of Incoming Main Power
Supply of UPS #1, Incoming Main
Power Supply of UPS #2 and Bypass
SHUTDOWN CHECK supply Indication should be healthy.

UPS should distribute voltage to CPU

STOP CHECK and I/O modules of +5 VDC and
should provide back up to the system.
CPU should control logic, monitor the

parameters and communicate to
different I/O modules. In
programming mode it should accept
the downloaded logic from a PC. In
RUN CHECK / STOP CHECK run mode, the GREEN LED should
continuously blink and it should
execute the program and operate the
process. It should be more reliable
and highly efficient to run the
program.
RUN CHECK Process System should be normal.

It should provide High-resolution and
high-precision module
for detecting currents and voltages It
should record temperatures
via resistance type
transmitters (RTD) including
characteristic-curve linearization.
RUN CHECK / STOP CHECK Analog input card should convert a
voltage or current (e.g. a signal that
can be anywhere from 0 to 20mA OR
0 to 10 VDC) into a digitally
equivalent number that can be
understood by the CPU. In run mode,
the GREEN LED should be
displayed.
It should provide High-speed

resolution and accuracy. It should
provide universal hybrid for the
RUN CHECK / STOP CHECK acquisition and output of currents
and voltages, i.e., 0 to 10 VDC OR 4
to 20 ma. In run mode, the GREEN
LED should be displayed.
It should record frequently required

signals of 24 VDC with high channel
RUN CHECK / STOP CHECK
density. In run mode, the GREEN
It should have Very fast module,

especially for isochronous
applications. It should have
Comprehensive control functions,
RUN CHECK / STOP CHECK in particular for use in a
process-oriented environment;
integrated diode for
redundant interconnection of
the outputs.
It should exchange messages in or
between modules. It should be
operational immediately and do not
have to be rewritten when another
RUN CHECK reader type is used. Communications
protocols cover authentication, error
detection and correction, and
signaling. In run mode, the GREEN
It should Control industrial processes
locally or at remote locations.
RUN CHECK
Monitor, gather, and process real-time
data very fast and accurate.





SHUTDOWN CHECK
the contacts.

SHUTDOWN CHECK
the contacts.

SHUTDOWN CHECK
the contacts.

SHUTDOWN CHECK
the contacts.

SHUTDOWN CHECK
the contacts.

SHUTDOWN CHECK
the contacts.

SHUTDOWN CHECK
the contacts.
SHUTDOWN CHECK
the contacts.

SHUTDOWN CHECK
the contacts.

SHUTDOWN CHECK
the contacts.

SHUTDOWN CHECK
the contacts.

SHUTDOWN CHECK
the contacts.
SHUTDOWN CHECK No leakages found
RUN, Get 4.00 mA
RUN Get 4.00 mA
RUN No fault LED will Glow
RUN Get 24 Volt output
RUN Get 230 Volt
RUN No damage
RUN Pressure Showing 4.0 Kg/cm2

RUN Provide 5.0 Kg/Cm2
RUN No leakages found

RUN the contacts.

RUN the contacts.
RUN Volatage Between 220 to 240 Volt
RUN No damage

RUN the contacts.

RUN Volatage Between 220 to 240 Volt
RUN No damage
SHUTDOWN CHECK No damage
SHUTDOWN CHECK No damage

Contactor rarting is 32A. No


23 A - 32 A
RC = 12.2A
Indication for tripping of lube oil pump

is healthy.


23 A - 32 A
RC = 13.2A

is healthy.

normal.


23 A - 32 A
RC = 13.2A

is healthy.


23 A - 32 A
RC = 13.7A

is healthy.

normal.



wrench.


1000 mega ohms.

to the Earth Pit.

HT Vacuum Contactor found clean.

There is no moisture or wear and
rusting of contacts.
Condition of contact is proper.

Lower contacts is OL Ohms

Phase is OL Ohms
Earth is OL Ohms
three phases.

wrench.

Phase is 1200 Ohms

wrench.


1000 mega ohms.


to the Earth Pit.



contacts.
normal.
is proper.
switch is normal.
breaker is proper.


Phase is > 1 T Ohms

Earth is > 1 T Ohms

all three phases.
all three phases.
three phases.


prescribed values.

wrench.
Phase is 1100 Ohms


0.0017

is healthy.

healthy.

wrench.


1000 mega ohms.

to the Earth Pit.


contacts.
All thyristors resistances are in double

digit nos. between 11 to 13 ohms.

prescribed values.

wrench.

Phase is 1000 Ohms


0.0029

is healthy.
healthy.

wrench.


1000 mega ohms.

to the Earth Pit.



contacts.
All thyristors resistances are in double

digit nos. between 11 to 13 ohms.

prescribed values.
wrench.

Phase is 1000 Ohms


0.0030

is healthy.

healthy.
Incoming Main Power, Outgoing

Power, Battery Voltage Indication is
healthy.
Voltage is 113 VDC and Current is 0.5

A

healthy.

A
Incoming Main Power Supply of UPS
#1, Incoming Main Power Supply of
UPS #2 and Bypass supply Indication is
healthy.

A
UPS is healthy and distributes +5 VDC

and provides back up to the system.
CPU reads and control logic, monitor

the parameters and communicate to
different I/O modules. In programming
mode it accepts the downloaded logic
from a PC. In run mode, GREEN led is
blinking continuously and it execute the
program and operate the process. It is
reliable and highly efficient to run the
program.
Process system is normal.

It has High-resolution and high-
precision module for detecting currents
and voltages. It record temperatures via
resistance type
Analog input card converts a voltage or
current (e.g. a signal that can be
anywhere from 0 to 20mA OR 0 to 10
VDC) into a digitally equivalent
number to the CPU. In run mode, the
GREEN LED is displayed.
It has High-speed resolution and

accuracy. It provides universal hybrid
for the acquisition and output of
currents and voltages, i.e., 0 to 10 VDC
OR 4 to 20 ma. In run mode, the
It records signals of 24 VDC with high

channel density. In run mode, the
It is very fast module, especially for

isochronous applications. It should
have Comprehensive control functions,
in particular for use in a
process-oriented environment.
It exchange messages in or between

modules. It operates immediately and
do not rewrite when another reader type
is used. Communications protocols
cover authentication, error detection
and correction, and signaling. In run
mode, the GREEN LED is displayed.
It controls industrial processes locally
or at remote locations. Monitor, gather,
and process real-time data very fast and
accurate.

healthy.

A

healthy.

A

contacts.

contacts.

contacts.

contacts.

contacts.

contacts.

contacts.
contacts.

contacts.

contacts.

contacts.

contacts.
Condition to
No leakages found
be maintained
Condition to
Get 4.00 mA
be maintained
Condition to
Get 4.00 mA
be maintained
Condition to
No fault LED will Glow
be maintained
Condition to
be maintained
Condition to
Get 24 Volt output
be maintained
Condition to
Get 230 Volt
be maintained
Condition to
No damage
be maintained
Condition to
Pressure Showing 4.0 Kg/cm3
be maintained
Condition to
Provide 5.0 Kg/Cm2
be maintained
Condition to
No leakages found
be maintained

Condition to
contacts.
be maintained

Condition to
contacts.
be maintained
Condition to
be maintained
Condition to
be maintained
Condition to
be maintained
Condition to
be maintained
Condition to
Volatage Between 220 to 240 Volt
be maintained
Condition to
No damage
be maintained

Condition to
contacts.
be maintained
Condition to
be maintained
Condition to
be maintained
Condition to
be maintained
Condition to
be maintained
Condition to
Volatage Between 220 to 240 Volt
be maintained
Condition to
No damage
be maintained
Condition to
No damage
be maintained
Condition to
No damage
be maintained
Sub
Equipments
CWPS
CWPS
TRANSFORMER TRANSFORMER TRANSFORMER OIL 102040004
#1
CWPS
CWPS
TRANSFORMER TRANSFORMER HT AND LT WINDINGS
#1
CWPS
CWPS
TRANSFORMER TRANSFORMER BREATHER 3101190015
#1
CWPS
CWPS
TRANSFORMER TRANSFORMER CONSERVATOR TANK
#1
CWPS
CWPS
TRANSFORMER TRANSFORMER BUCHOLTZ RELAY
#1
CWPS
CWPS
TRANSFORMER TRANSFORMER HT TERMINAL BOX
#1
CWPS
CWPS
TRANSFORMER TRANSFORMER LT TERMINAL BOX
#1
CWPS
CWPS
TRANSFORMER TRANSFORMER OFF LOAD TAP CHANGER
#1
CWPS
CWPS NEUTRAL EARTH ING EARTH PIT
TRANSFORMER TRANSFORMER CONNECTION
#1
CWPS
CWPS BODY EARTHING EARTH PIT
#1
CWPS
CWPS
#2
CWPS
CWPS
#2
CWPS
CWPS
#2
CWPS
CWPS
#2
CWPS
CWPS
#2
CWPS
CWPS
#2
CWPS
CWPS
#2
TRANSFORMER #2
CWPS
CWPS
#2
CWPS
CWPS NEUTRAL EARTH ING EARTH PIT
#2
CWPS
CWPS BODY EARTHING EARTH PIT
#2
TYPE OF CHECK
TOOLS (RUN CHECK /
SHUTDOWN)
VISUAL / OIL
TEMPERATURE &
FOR COOLING OF WINDING RUN CHECK
TRANSFORMER WINDINGS TEMPERATURE
GUAGE
SHUTDOWN
BDV TEST KIT CHECK
FOR INSULATION OF
TRANSFORMER WINDINGS SHUTDOWN
DGA TEST KIT CHECK
To form magnetic field when MEGGER / TAN- SHUTDOWN

energized with current to DELTA TEST KIT CHECK
produce SECONDARY EMF.
FOR INDICATION OF VISUAL RUN CHECK

TRANSFORMER HEALTINESS
TO PROVIDE ADEQUATE SPACE

FOR EXPANSION OF OIL WITHIN
THE TRANSFORMER. IT ACTS AS VISUAL / MOG RUN CHECK
A RESERVOIR FOR
TRANSFORMER INSULATING OIL.
FOR PROTECTION OF VISUAL RUN CHECK

TRASFORMER
Allows the HT power cable to be

fixed with TRANSFORMER
insulated, clamped and sealed
connector to provide greater SPANNERS /
protecton from short circuiting TORQUE
SHUTDOWN
of cables. CHECK
WRENCH
done.
HT power cable insulation

should be healthy to provide TAN-DELTA SHUTDOWN
uninterrupted power supply to TEST KIT CHECK
Power Transformer.
There should be no oxydation of VISUAL SHUTDOWN

bushings and cable lugs. CHECK
HT cable lugs should be proper
tight and condition should be SHUTDOWN
VISUAL
healthy. There should be no CHECK
worn out of lugs.
Allows the LT power cable to be

insulated, clamped and sealed SPANNERS /
connector to provide greater SHUTDOWN
protecton from short circuiting TORQUE CHECK
of cables. WRENCH
done.

LT cable lugs should be proper

VISUAL
worn out of lugs.
VOLTAGE TAP CHANGING OF SHUTDOWN

VISUAL
TRANSFORMER OFF LOAD CHECK
TO PROVIDE NEUTRAL
EARTHING OF THE VISUAL RUN CHECK
TRANSFORMER
TO PROVIDE BODY EARTHING OF VISUAL RUN CHECK

THE TRANSFORMER
FOR COOLING AND INSULATION VISUAL / OIL

TEMPERATURE RUN CHECK
OF TRANSFORMER WINDINGS GUAGE
SHUTDOWN
BDV TEST KIT CHECK
FOR INSULATION OF
TRANSFORMER WINDINGS
SHUTDOWN
DGA TEST KIT CHECK


A RESERVOIR FOR

TRASFORMER

of cables. WRENCH
done.

Power Transformer.


VISUAL
worn out of lugs.

protecton from short circuiting SPANNERS CHECK
of cables.
done.

LT cable lugs should be proper SPANNERS /
healthy. There should be no TORQUE
CHECK
worn out of lugs. WRENCH
VOLTAGE TAP CHANGING OF VISUAL

SHUTDOWN
TO PROVIDE NEUTRAL
TRANSFORMER

THE TRANSFORMER
ACTUAL CONDITION OBSERVED ON
IDEAL CONDITION 05.09.2018
OIL TEMPERATURE SHOULD BE WITHIN 30 OIL TEMPERATURE OF TRANSFORMER IS 42

TO 55 DEG CELCIUS DEG CELCIUS
BDV OF OIL SHOULD BE > 40 KV BDV OF OIL IS 65 KV
DISSOLVED GAS OF TRANSFORMER OIL DISSOLVED GAS OF TRANSFORMER OIL IS

SHOULD BE MINIMUM AS PER ISO MINIMUM AS PER ISO STANDARD
STANDARD
MEGGER VALUE SHOULD BE > 20 MEGA MEGGER VALUE IS 2000 MEGA OHMS AND
OHMS AND TAN-DELTA <0.02 absolute. TAN-DELTA 0.007
BREATHER COLOUR SHOULD BE BLUE BREATHER COLOUR IS BLUE
OIL LEVEL SHOULD BE WITHIN 55% TO 75% OIL LEVEL IS 70%
TRANSFORMER TRIPPING SHOULD BE TRANSFORMER TRIPPED BY BUCHOLTZ RELAY

HEALTHY BY BUCHOLTZ RELAY


be < 0.004 absolute. 0.0017
No oxydation or moisture of bushings and No oxydation or moisture of bushings and

cable lugs cable lugs
HT CABLE LUGS SHOULD BE PROPERLY HT CABLE LUGS ARE PROPERLY TIGHT AND
TIGHT AND CONDITION SHOULD BE CONDITION IS HEALTHY WITH NO WORN OUT.
HEALTHY WITH NO WORN OUT.


LT CABLE LUGS SHOULD BE PROPERLY TIGHT LT CABLE LUGS ARE PROPERLY TIGHT AND
AND CONDITION SHOULD BE HEALTHY WITH CONDITION IS HEALTHY WITH NO WORN OUT.
NO WORN OUT.
TAP CHANGER SHOULD BE IN WORKING TAP CHANGER IS IN WORKING CONDITION

CONDITION
EARTHING IS CONNECTED TO THE EARTH PIT

EARTHING SHOULD BE HEALTHY AND IS HEALTHY



STANDARD




be < 0.004 absolute. 0.0010

NO LOOSENESS OF BOLTS BOLTS ARE ALL TIGHT BY SPANNERS


CONDITION


ACTION REQUIRED
UNINTERRUPTIBLE
POWER SUPPLY
CENTRAL PROCESSING
UNIT
ON/OFF CONTROL
SYSTEM
OPEN LOOP CONTROL

SYSTEM
FEED FORWARD
CONTROL SYSTEM
CLOSE LOOP CONTROL

SYSTEM
ANALOG INPUT MODULE
DISTRIBUTED
CONTROL
SYSTEM
ANALOG OUTPUT
MODULE
DISTRIUTED
CONTROL
SYSTEM
DIGITAL INPUT MODULE

DIGITAL OUTPUT
MODULE
COMMUNICATION
MODULE
HUMAN MACHINE
INTERFACE OR SCADA
DCS HUMAN
HUMAN INTERFACE
INTERFACE
STATION
STATION
DCS UPS#1
DCS UPS
DCS UPS#2
DCS UPS#2
BF3-O2N2- O2N2-DCS-ANSR ONLINE ANALYSER-CO2

MAC
BF3-O2N2- O2N2-DCS-ANSR ONLINE ANALYSER-N2
MAC
BF3-O2N2- O2N2-DCS-ANSR ONLINE ANALYSER-O2
MAC
Power Supply Unit distributes energy to the

Processor card and the I/O modules. It has a
+5V DC output supply which together with VISUAL /
an input-voltage supply (AC ready) and an MULTIMETER
output-voltage supply (DC ready) provides
power back-up to the system.
CPU controls or monitors all the components

which are distributed throughout the system.
VISUAL
It generally composed of the main memory,
control unit, and arithmetic-logic unit.
ON / OFF Control System is two states fully MULTIMETER /

ON and Fully OFF SOURCE METER
Open Loop Control is to produce desired

MULTIMETER /
response to the actuators independently
SOURCE METER
calculates control outputs.
Feed forward control is implemented to

reduce the effect of Input disturbance on
MULTIMETER /
process. A sensor in this system detects the
SOURCE METER
disturbances or any load changes in the
process.
Close loop control system is implementd in
MULTIMETER /
the output measurement as a feedback signal
SOURCE METER
is found.
Analog input modules facilitate connection
of the controller to the analog signals of a
process. They are suitable for connecting
VISUAL /
analog sensors such as voltage and current
MULTIMETER
sensors, thermocouples, resistors and
resistance thermometers as well as analog
actuators.
Analog output modules convert a 16-bit

digital value into a current or a voltage and
VISUAL /
output this to the process. They are suitable
MULTIMETER
for controlling proportional valves or small
servo drives.
Digital input modules contain digital inputs

for the automation system. Digital sensors VISUAL /
and actuators can be connected to the MULTIMETER
automation system via these modules.
This digital output module transmits control
VISUAL /
signals of 24 VDC from the automation
MULTIMETER
device to the connected actuators.
The communication cards OR Modules are

used to realize the generalpurpose
VISUAL /
communication of field control station and
SOFTWARE
subsystems via serial links, so that the
subsystem may be controlled or monitored.
HMI OR SCADA monitor entire plant

parameters graphically and to log the data in
VISUAL /
plant database systems. Trend display of
SOFTWARE
various process parameters provides the
effective display and easy monitoring.
The human interface system programmed

for a project/plan is designed in such a way
VISUAL /
that it would be easy for the operator to
SOFTWARE
understand all the operations occurred in the
plant.

fails.

fails.
fails.
CHECK FOR PPM OF CO2 IN DRY AIR Multimeter
CHECK FOR PPM O2 IN GAN PRODUCT Multimeter
CHECK FOR %O2 IN GOX PRODUCT Multimeter

TYPE OF CHECK (RUN
SHUTDOWN)
UPS should distribute voltage to CPU

STOP CHECK and I/O modules of +5 VDC and
should provide back up to the system.
CPU should control logic, monitor the

parameters and communicate to
different I/O modules. In
programming mode it should accept
the downloaded logic from a PC. In
RUN CHECK / STOP CHECK run mode, the GREEN LED should
continuously blink and it should
execute the program and operate the
process. It should be more reliable
and highly efficient to run the
program.

It should provide High-resolution and
high-precision module
for detecting currents and voltages It
should record temperatures
via resistance type
RUN CHECK / STOP CHECK Analog input card should convert a
voltage or current (e.g. a signal that
can be anywhere from 0 to 20mA OR
0 to 10 VDC) into a digitally
equivalent number that can be
understood by the CPU. In run mode,
the GREEN LED should be
displayed.
It should provide High-speed

resolution and accuracy. It should
provide universal hybrid for the
RUN CHECK / STOP CHECK acquisition and output of currents
and voltages, i.e., 0 to 10 VDC OR 4
to 20 ma. In run mode, the GREEN
It should record frequently required

signals of 24 VDC with high channel
RUN CHECK / STOP CHECK
density. In run mode, the GREEN
It should have Very fast module,
especially for isochronous
applications. It should have
Comprehensive control functions,
RUN CHECK / STOP CHECK in particular for use in a
process-oriented environment;
integrated diode for
redundant interconnection of
the outputs.
It should exchange messages in or

between modules. It should be
operational immediately and do not
have to be rewritten when another
RUN CHECK reader type is used. Communications
protocols cover authentication, error
detection and correction, and
signaling. In run mode, the GREEN

RUN CHECK

RUN CHECK



SHUTDOWN CHECK
RUN CHECK 0.0 PPM
RUN CHECK 240 PPM
RUN CHECK 90.00%

UPS is healthy and distributes +5 VDC

and provides back up to the system.
CPU reads and control logic, monitor

the parameters and communicate to
different I/O modules. In programming
mode it accepts the downloaded logic
from a PC. In run mode, GREEN led is
blinking continuously and it execute the
program and operate the process. It is
reliable and highly efficient to run the
program.

It has High-resolution and high-
precision module for detecting currents
and voltages. It record temperatures via
resistance type
Analog input card converts a voltage or
current (e.g. a signal that can be
anywhere from 0 to 20mA OR 0 to 10
VDC) into a digitally equivalent
number to the CPU. In run mode, the
It has High-speed resolution and

accuracy. It provides universal hybrid
for the acquisition and output of
currents and voltages, i.e., 0 to 10 VDC
OR 4 to 20 ma. In run mode, the
It records signals of 24 VDC with high

channel density. In run mode, the
It is very fast module, especially for
isochronous applications. It should
have Comprehensive control functions,
in particular for use in a
process-oriented environment.
It exchange messages in or between

modules. It operates immediately and
do not rewrite when another reader type
is used. Communications protocols
cover authentication, error detection
and correction, and signaling. In run
mode, the GREEN LED is displayed.

accurate.

accurate.

healthy.

A

healthy.
A
0.0 PPM
150 PPM
90.00%
Sub
Equipments
MAIN CONTROL MAIN CONTROL

BUILDING
BUILDING TRANSFORMER OIL 102040004
TRANSFORMER TRANSFORMER
#1
MAIN CONTROL
MAIN CONTROL BUILDING
TRANSFORMER HT AND LT WINDINGS
BUILDING
TRANSFORMER #1
MAIN CONTROL
TRANSFORMER BREATHER
BUILDING 3101190015
TRANSFORMER #1
MAIN CONTROL
TRANSFORMER CONSERVATOR TANK
BUILDING
TRANSFORMER #1
MAIN CONTROL
TRANSFORMER BUCHOLTZ RELAY
BUILDING
TRANSFORMER #1

BUILDING
BUILDING HT TERMINAL BOX
#1
BUILDING TRANSFORMER HT TERMINAL BOX
TRANSFORMER #1

BUILDING
BUILDING LT TERMINAL BOX
#1
MAIN CONTROL
TRANSFORMER AIR BREAK SWITCH
BUILDING
TRANSFORMER #1
MAIN CONTROL
TRANSFORMER OFF LOAD TAP CHANGER
BUILDING
TRANSFORMER #1
MAIN CONTROL
MAIN CONTROL BUILDING NEUTRAL EARTH ING EARTH PIT
BUILDING TRANSFORMER CONNECTION
TRANSFORMER #1
MAIN CONTROL
MAIN CONTROL BUILDING BODY EARTHING EARTH PIT
TRANSFORMER #1
BUILDING
BUILDING TRANSFORMER OIL 102040004
#2
MAIN CONTROL
TRANSFORMER HT AND LT WINDINGS
BUILDING
TRANSFORMER #2
MAIN CONTROL
TRANSFORMER BREATHER
BUILDING 3101190015
TRANSFORMER #2
MAIN CONTROL
TRANSFORMER CONSERVATOR TANK
BUILDING
TRANSFORMER #2
MAIN CONTROL
TRANSFORMER BUCHOLTZ RELAY
BUILDING
TRANSFORMER #2

BUILDING
BUILDING HT TERMINAL BOX
#2
BUILDING
BUILDING LT TERMINAL BOX
#2
MAIN CONTROL
TRANSFORMER AIR BREAK SWITCH
BUILDING
TRANSFORMER #2
MAIN CONTROL
TRANSFORMER OFF LOAD TAP CHANGER
BUILDING
TRANSFORMER #2
MAIN CONTROL
MAIN CONTROL BUILDING NEUTRAL EARTH ING EARTH PIT
TRANSFORMER #2
MAIN CONTROL
MAIN CONTROL BUILDING BODY EARTHING EARTH PIT
TRANSFORMER #2
TYPE OF CHECK
TOOLS (RUN CHECK /
SHUTDOWN)
FOR COOLING AND INSULATION VISUAL / OIL RUN CHECK
OF TRANSFORMER WINDINGS TEMPERATURE
SHUTDOWN
BDV TEST KIT CHECK
FOR INSULATION OF
DGA TEST KIT CHECK



A RESERVOIR FOR

TRASFORMER

of cables. WRENCH
done.

Power Transformer.

VISUAL
worn out of lugs.

of cables. WRENCH
done.


VISUAL
worn out of lugs.
ISOLATION AS WELL AS
INTERLOCK BETWEEN SHUTDOWN
LIMIT SWITCH
TRANSFORMER AND HT CHECK
BREAKER

VISUAL
TO PROVIDE NEUTRAL
TRANSFORMER

THE TRANSFORMER
SHUTDOWN
BDV TEST KIT CHECK
FOR INSULATION OF
SHUTDOWN
DGA TEST KIT CHECK



A RESERVOIR FOR

TRASFORMER

of cables. WRENCH
done.

Power Transformer.

VISUAL
worn out of lugs.

of cables. WRENCH
done.


VISUAL
worn out of lugs.
LIMIT SWITCH
BREAKER

VISUAL
TO PROVIDE NEUTRAL
TRANSFORMER

THE TRANSFORMER
ACTUAL CONDITION OBSERVED ON ACTION
IDEAL CONDITION 05.09.2018 REQUIRED


STANDARD



be < 0.004 absolute. 0.0031


NO WORN OUT.
AIR BREAK SWITCH SHOULD BE IN WORKING AIR BREAK SWITCH IS IN WORKING

CONDITION CONDITION

CONDITION



STANDARD



be < 0.004 absolute. 0.0023



NO WORN OUT.

CONDITION CONDITION
TAP CHANGER SHOULD BE IN WORKING

TAP CHANGER IS IN WORKING CONDITION
CONDITION


HT PANEL BUSBARS
HT PANEL EARTHING
HT PANEL BUSBAR
HORIZONTAL AND
VERTICAL INSULATOR
HT BREAKER
HT BREAKER
INCOMER OF
O2N2 MCC
O2N2 FROM 11KV
PANEL ROOM
HT BLOWER PCC
HT NUMERICAL
PROTECTIVE MICOM
RELAY
HT CABLES
POTENTIAL
TRANSFORMER
CURRENT TRANSFORMER
HT PANEL BUSBARS
HT PANEL EARTHING
HT PANEL BUSBAR
HORIZONTAL AND
VERTICAL INSULATOR
HT BREAKER
MAIN AIR
O2N2 MCC
COMPRESSOR HT
PANEL ROOM
BREAKER
HT NUMERICAL
PROTECTIVE MICOM
RELAY
HT CABLES
POTENTIAL
TRANSFORMER
CURRENT TRANSFORMER
HT PANEL BUSBARS
HT PANEL EARTHING
HT PANEL BUSBAR
HORIZONTAL AND
VERTICAL INSULATOR
HT BREAKER
OUTGOING TO
O2N2 MCC
O2N2 11KV
PANEL ROOM
TRANSFORMER
HT NUMERICAL
PROTECTIVE MICOM
RELAY
HT CABLES
POTENTIAL
TRANSFORMER
CURRENT TRANSFORMER
LT PANEL BUSBARS
LT PANEL EARTHING
LT PANEL SPACE HEATER
LT PANEL BUSBAR
HORIZONTAL AND
VERTICAL INSULATOR
LT SIEMENS BREAKER
O2N2 MCC LT INCOMER OF

PANEL ROOM O2N2 MCC PANEL
LT PROTECTIVE RELAY
INCOMING LT CABLE
FROM O2N2
TRANSFORMER TO LT
BREAKER
POTENTIAL
TRANSFORMER
CURRENT TRANSFORMER
BATTERY CHARGER
BATTERIES 2V
BATTERY CHARGER
INCOMING POWER
SUPPLY INDICATOR
BATTERY CHARGER
ANALOG AMMETER
BATTERY CHARGER
ANALOG VOLTMETER
O2N2 MCC BATTERY

PANEL ROOM CHARGER PANEL
BATTERY CHARGER
O2N2 MCC BATTERY INCOMING VOLTAGE
PANEL ROOM CHARGER PANEL ANALOG VOLTMETER
LT PANEL EARTHING
LT PANEL BUSBAR
HORIZONTAL
PROTECTIVE RELAY
POTENTIAL
TRANSFORMER
CURRENT TRANSFORMER
TOOLS
REQUIRED

SPANNERS /
TORQUE
WRENCH
insulated pillars.


HT MEGGER
body.


VISUAL
VISUAL,
COTTON
VISUAL,
COTTON
32 GREASE, HT
MEGGER
SECONDARY
KIT
SPANNERS /
TORQUE
WRENCH

MEGGER
VISUAL /
SECONDARY
INJECTION
shown in the meter.
CURRENT AND
VOLTAGE TEST
KIT
VISUAL /
SECONDARY
INJECTION
meter.
CURRENT AND
VOLTAGE TEST
KIT

SPANNERS /
TORQUE
WRENCH
insulated pillars.
HT MEGGER
body.


VISUAL
VISUAL,
COTTON
32 GREASE, HT
MEGGER
SECONDARY
KIT
SPANNERS /
TORQUE
WRENCH

MEGGER

VISUAL /
SECONDARY
INJECTION
shown in the meter.
CURRENT AND
VOLTAGE TEST
KIT
VISUAL /
SECONDARY
INJECTION
meter.
CURRENT AND
VOLTAGE TEST
KIT

SPANNERS /
TORQUE
WRENCH
insulated pillars.
HT MEGGER
body.


VISUAL
VISUAL,
COTTON
32 GREASE, HT
MEGGER
SECONDARY
KIT
SPANNERS /
TORQUE
WRENCH

MEGGER

VISUAL /
SECONDARY
INJECTION
shown in the meter.
CURRENT AND
VOLTAGE TEST
KIT
VISUAL /
SECONDARY
INJECTION
meter.
CURRENT AND
VOLTAGE TEST
KIT

SPANNERS /
TORQUE
WRENCH
insulated pillars.
LT MEGGER
body.


VISUAL
VISUAL,
COTTON
32 GREASE, HT
MEGGER
SECONDARY
KIT
SPANNERS /
TORQUE
cable and LT Breaker Terminals.
WRENCH
Check for megger value of LT Cable phase

MEGGER
VISUAL /
SECONDARY
INJECTION
shown in the meter.
CURRENT AND
Also, check for tripping of the LT Numerical
VOLTAGE TEST
KIT
VISUAL /
SECONDARY
INJECTION
meter.
CURRENT AND
Also, check for tripping of the LT Numerical
VOLTAGE TEST
KIT
Battery charger is a device used to charge the

VISUAL
batteries.
A battery is a source of energy which

provides a voltage to get the current flowing CLAMPMETER
in a circuit.
To provide indication of incoming power

VISUAL
supply on the panel.
To indicate charging current of the battery. VISUAL
To indicate charging voltage of the battery. VISUAL

To indicate incoming voltage on th panel. VISUAL
To provive earthng of the Panel body. VISUAL

sufficient stiffness to be supported in air by VISUAL
insulated pillars. Check for megger value of
Busbar and panel body.
To detect the fault and initiates the operation

of circuit breaker to isolate the defective MANUAL
element from the rest of the system.

VISUAL
shown in the meter. Check for tripping of
charger during overvoltage.

measure the correct current shown in the VISUAL
meter.
TYPE OF CHECK (RUN
SHUTDOWN)



SHUTDOWN CHECK

< 1A

mega Ohms.

of mechanism.
mechanism.
SHUTDOWN CHECK
limit switch.
SHUTDOWN CHECK Condition of contact arm assembly of
normal.
Ohms




SHUTDOWN CHECK
prescribed values.


SHUTDOWN CHECK
should
relay or meter.
panel.
Voltage.

should
DMT.



SHUTDOWN CHECK

< 1A
mega Ohms.
of mechanism.
mechanism.
limit switch.
SHUTDOWN CHECK
normal.
Ohms




SHUTDOWN CHECK
prescribed values.


SHUTDOWN CHECK

SHUTDOWN CHECK
should
relay or meter.
panel.
Voltage.

should
DMT.



SHUTDOWN CHECK

< 1A
mega Ohms.
of mechanism.
mechanism.
limit switch.
SHUTDOWN CHECK
normal.
Ohms




SHUTDOWN CHECK
prescribed values.


SHUTDOWN CHECK

SHUTDOWN CHECK
should
relay or meter.
panel.
Voltage.

should
DMT.



SHUTDOWN CHECK

< 1A
mega Ohms.
of mechanism.
mechanism.
limit switch.
SHUTDOWN CHECK breaker should be proper.
normal.
& Lower contacts should be OL
Ohms

to Phase should be OL Ohms

to Earth should be OL Ohms

LT Breaker Relay tripping should be

healthy to trip the breaker on the
SHUTDOWN CHECK
prescribed values.


SHUTDOWN CHECK
should
relay or meter.
SHUTDOWN CHECK
panel.
3. trip the LT Breaker through Relay
on Over voltage / Under Voltage.

should
SHUTDOWN CHECK
relay or meter.
2. trip the LT Breaker through Relay
on Over curent / CIR / Ie.
Battery charger should provide

Trickle charge and Boost charge.
Trickle charging current < 2A.
Trickle charging voltage should be for
110 VDC should be 112 VDC.
RUN CHECK
Boost charging current > 2A.
Boost charging voltage should be for
110 VDC should be 114 to 115 VDC
VDC.
To provide the voltage to the

electrical equipments. Also, to
RUN CHECK / STOP CHECK provide voltage backup during power
failure. Voltage should be 110 VDC
for 6 hrs. during power failure.
Indication of incoming power supply

RUN CHECK
on the panel should be healthy.
Indication of charging current on the

RUN CHECK
panel should be healthy.
Indication of charging voltage on the

RUN CHECK
Indication of incoming voltage on the
RUN CHECK
Horizontal insulators should provide

high electrical and mechanical
SHUTDOWN CHECK
strength to the busbars. Also, megger
value should be ˃ 20 mega Ohms.
Relay tripping should be healthy to

SHUTDOWN CHECK trip the charger on Overvoltage /
Overtemperature / Overcurrent.

should
relay or meter.
SHUTDOWN CHECK
panel.
3. trip the charger through relay on
Over voltage

should
SHUTDOWN CHECK
ammeter.
2. trip the charger through Relay on
Over curent.

wrench.


1100 mega ohms.

to the Earth Pit.



contacts.
normal.
is proper.
switch is normal.
breaker is proper.


Phase is > 1 T Ohms

Earth is > 1 T Ohms

three phases.

prescribed values.

wrench.

Phase is 1200 Ohms

is healthy.

healthy.

wrench.


1100 mega ohms.
to the Earth Pit.



contacts.
normal.
is proper.
switch is normal.
breaker is proper.


Phase is > 1 T Ohms

Earth is > 1 T Ohms

three phases.

prescribed values.

wrench.

Phase is 1200 Ohms


0.0019
is healthy.

healthy.

wrench.


1000 mega ohms.
to the Earth Pit.



contacts.
normal.
is proper.
switch is normal.
breaker is proper.


Phase is > 1 T Ohms

Earth is > 1 T Ohms

three phases.

prescribed values.

wrench.

Phase is 1100 Ohms


0.0012
is healthy.

healthy.

wrench.


1000 mega ohms.
to the Earth Pit.



contacts.
normal.
is proper.
switch is normal.
breaker is proper.

Lower contacts is OL Ohms

Phase is OL Ohms

Earth is OL Ohms

three phases.
LT Breaker Relay tripping is healthy to

trip the breaker on the faults described

wrench.

Phase is 1800 Ohms

Trippig of the LT Breaker through
is healthy.

accurate current on the relay. Tripping
of the LT Breaker through Relay on
Over curent / CIR / Ie is healthy.
Trickle charging current is 0.5A.

Trickle charging voltage is 112 VDC.
Boost charging current is 5A.

Boost charging voltage is 115 VDC.
Voltage is 110 VDC for 6 hrs. during

power failure.
Indication of incoming power supply on

the panel is healthy.
Indication of charging current on the

panel is healthy.
Indication of charging voltage on the

panel is healthy.
Indication of incoming voltage on the
panel is healthy.

to the Earth Pit.
Horizontal insulators strength to the

busbars are good. Also, megger value is
500 mega Ohms.
Relay tripping is healthy to trip the

charger on Overvoltage /
Overtemperature / Overcurrent.

Trippig of the charger through Relay on
Over voltage is healthy.

accurate current on ammeter. Tripping
of the charger through Relay on Over
curent.
Sub
STOCK HOUSE
STOCK HOUSE
#1
STOCK HOUSE
STOCK HOUSE
#1
STOCK HOUSE
STOCK HOUSE
#1
STOCK HOUSE
STOCK HOUSE
#1
STOCK HOUSE
STOCK HOUSE
#1
STOCK HOUSE
STOCK HOUSE
#1
STOCK HOUSE
STOCK HOUSE
#1
STOCK HOUSE
STOCK HOUSE
TRANSFORMER TRANSFORMER AIR BREAK SWITCH
#1
STOCK HOUSE
STOCK HOUSE
#1
STOCK HOUSE
STOCK HOUSE NEUTRAL EARTH ING EARTH PIT
TRANSFORMER
TRANSFORMER CONNECTION
#1
STOCK HOUSE
STOCK HOUSE BODY EARTHING EARTH PIT
TRANSFORMER
#1
STOCK HOUSE
STOCK HOUSE
#2
STOCK HOUSE
STOCK HOUSE
#2
STOCK HOUSE
STOCK HOUSE
#2
STOCK HOUSE
STOCK HOUSE
#2
STOCK HOUSE
STOCK HOUSE
#2
STOCK HOUSE
STOCK HOUSE
#2
STOCK HOUSE
STOCK HOUSE
#2
STOCK HOUSE
STOCK HOUSE
#2
STOCK HOUSE
STOCK HOUSE
TRANSFORMER TRANSFORMER AIR BREAK SWITCH
#2
STOCK HOUSE
STOCK HOUSE
#2
STOCK HOUSE
STOCK HOUSE NEUTRAL EARTH ING EARTH PIT
TRANSFORMER
#2
STOCK HOUSE
STOCK HOUSE BODY EARTHING EARTH PIT
TRANSFORMER
#2
TYPE OF CHECK
TOOLS (RUN CHECK /
SHUTDOWN)
SHUTDOWN
BDV TEST KIT CHECK
FOR INSULATION OF
DGA TEST KIT CHECK



A RESERVOIR FOR

TRASFORMER

of cables. WRENCH
done.

Power Transformer.

VISUAL
worn out of lugs.

of cables. WRENCH
done.


VISUAL
worn out of lugs.
LIMIT SWITCH
BREAKER

VISUAL
TO PROVIDE NEUTRAL
TRANSFORMER

THE TRANSFORMER

SHUTDOWN
BDV TEST KIT CHECK
FOR INSULATION OF
SHUTDOWN
DGA TEST KIT CHECK


A RESERVOIR FOR

TRASFORMER

of cables. WRENCH
done.

Power Transformer.


VISUAL
worn out of lugs.

of cables. WRENCH
done.

VISUAL
worn out of lugs.
LIMIT SWITCH
BREAKER

VISUAL
TO PROVIDE NEUTRAL
TRANSFORMER

THE TRANSFORMER
ACTUAL CONDITION OBSERVED ON ACTION
IDEAL CONDITION 05.09.2018 REQUIRED


STANDARD



be < 0.004 absolute. 0.0014



NO WORN OUT.

CONDITION CONDITION

CONDITION




STANDARD



be < 0.004 absolute. 0.0017


NO WORN OUT.

CONDITION CONDITION

CONDITION


Sub
Equipments
HEAD ESP
HEAD ESP
NO 1
HEAD ESP
HEAD ESP
NO 1
HEAD ESP
HEAD ESP
NO 1
HEAD ESP
HEAD ESP
NO 1
HEAD ESP
HEAD ESP
TRANSFORMER TRANSFORMER ESP CONTROLLER
NO 1
HEAD ESP
HEAD ESP ESP PANEL KEPAD DISPLAY
TRANSFORMER TRANSFORMER UNIT
NO 1
HEAD ESP
HEAD ESP
TRANSFORMER TRANSFORMER ESP PANEL THYRISTOR
NO 1
HEAD ESP
HEAD ESP
TRANSFORMER TRANSFORMER HT TERMINAL INSULATOR
NO 1
HEAD ESP
HEAD ESP
NO 1
HEAD ESP
HEAD ESP
NO 1
HEAD ESP
HEAD ESP
TRANSFORMER TRANSFORMER ELECTRODES
NO 1
HEAD ESP
HEAD ESP BODY EARTHING EARTH PIT
NO 1
TYPE OF CHECK
TOOLS (RUN CHECK /
SHUTDOWN)
VISUAL / OIL
TEMPERATURE &
GUAGE
SHUTDOWN
BDV TEST KIT CHECK
FOR INSULATION OF
DGA TEST KIT CHECK



A RESERVOIR FOR
Controls the firing angle of the

thyristors by taking feedbacks
from transformer output
voltage,transformer oil VISUAL RUN CHECK
temperature and the parameters
set in the display unit by the
user.
This unit is interfaced with the

ESP Controller. It acts exclusively
as a bistable switch, conducting
when the gate receives a current
trigger, and continuing to VISUAL RUN CHECK
conduct until the voltage across
the device is reversed biased, or
until the voltage is removed (by
some other means)
This device controls the primary
voltage which is to be fed to
transformer primary winding. SHUTDOWN
The thyristor is being controlled VISUAL/SPANNERS CHECK
by controlling its firing angle by
the ESP controller.
Cylindrical Support Insulator

find application for ESP and
feature high alumina content
that makes these sustain
operating temp above 500°c.
Further, these cylindrical
Insulator also feature high
compressive and tensile strength
and are made available in
brown/white glaze finish.
Finding application for high SHUTDOWN
voltage ESPS, these are VISUAL
CHECK
developed using glass reinforced
polyester as well as aluminum
threads that assures in these
optimum durability support. It
also provide mechanical support
as well as electrically isolating
discharge electrodes from
collecting curtains
Axis insulator provide

mechanical support as well as
electrically isolating discharge SHUTDOWN
electrodes from collecting VISUAL
curtains as well as grounded ESP CHECK
casing because of their high
voltage.
SHUTDOWN
of cables. CHECK
WRENCH
done.

should be healthy to provide SHUTDOWN
uninterrupted power supply to MEGGER
CHECK
Power Transformer.


VISUAL
worn out of lugs.

of cables. WRENCH
done.


VISUAL
worn out of lugs.
Collecting Electrodes are the
collection surface made of sheet
metal on which the particulate
mater is collected after being
negatively charged within the
gas passage of the ESP. Designs VISUAL SHUTDOWN
of the plates vary from CHECK
manufacturer to manufacturer.
These plates are secured to the
ESP shell at ground potential and
serve as the positive anode of
the gas passage.
Emitting Electrodes, also knows

as Discharge Electrodes is the
heart os the ESP. These are High
Voltage internal and ionizes the
gases and creates the electrical
field. When the voltage breaks SHUTDOWN
the gas down at the surface of VISUAL CHECK
the electrode, it generates
corona power. This leads to
creation of corona tufts on the
surface of the electrode.
Negative polariy voltage is
applied to the electrode.

THE TRANSFORMER


STANDARD
Transformer output parameters i.e. KV , Ma

should be as per the required set values Transformer output parameters i.e. KV , Ma
which are set by the user . Hunting may are in the range of set values And are stable
occur of the set values if the load condition
varies
The display unit shows the transformer actual

values . Same compared with clamp meter
readings and the values are matching
The display unit should Display the actual primary voltage ----240V
values of transformer output parameters. primary current ---- 16
secondary voltage ----35 KV
secondary current ----350 mA
Thyristor is functioning correctly as the O/P
parameters are confirmed with clamp meters
Thyristor should conduct according to the primary voltage ----215V
input provided by the ESP Controller primary current ---- 48A
should be free from Excess Dust Dust accumulation cleaned . Insulator

accumulation and without any checked for any physical deformation .
physical deformation/damage Found ok
Insulator should be free from Excess Dust accumulation cleaned . Insulator

Dust accumulation and without any checked for any physical deformation .
physical deformation/damage. Found ok
meggar value of HT Cable should be

meggar value of HT Cable > 5 mohm
> 5 mohm



NO WORN OUT.
1. There should not be any physical 1. There is no physical deformation or damage
deformation or damage of electrodes of electrodes. ok
2. There should not be any Looseness of 2. All bolts tightness checked .ok.
Bolt. 3. Dust cleaned manually .ok.
3. free from Excess Dust Collection .

EARTHING SHOULD BE HEALTHY AND IS HEALTHY IE RESISTANCE SHOULD BE
LESS THAN 5 OHMS
ACTION REQUIRED
Sub
Equipments
HEAD ESP
HEAD ESP
NO 2
HEAD ESP
HEAD ESP
NO 2
HEAD ESP
HEAD ESP
NO 2
HEAD ESP
HEAD ESP
NO 2
HEAD ESP
HEAD ESP
NO 2
HEAD ESP
NO 2
HEAD ESP
HEAD ESP
NO 2
HEAD ESP
HEAD ESP
NO 2
HEAD ESP
HEAD ESP
NO 2
HEAD ESP
HEAD ESP
NO 2
HEAD ESP
HEAD ESP
NO 2
HEAD ESP
NO 2
TYPE OF CHECK
TOOLS (RUN CHECK /
SHUTDOWN)
VISUAL / OIL
TEMPERATURE &
GUAGE
SHUTDOWN
BDV TEST KIT CHECK
FOR INSULATION OF
DGA TEST KIT CHECK



A RESERVOIR FOR

user.

some other means)
the ESP controller.

CHECK
collecting curtains

voltage.
SHUTDOWN
of cables. CHECK
WRENCH
done.

CHECK
Power Transformer.


VISUAL
worn out of lugs.

of cables. WRENCH
done.


VISUAL
worn out of lugs.
the gas passage.


THE TRANSFORMER


STANDARD

varies




> 5 mohm



NO WORN OUT.

EARTHING SHOULD BE HEALTHY AND IS HEALTHY RESISTANCE SHOULD BE LESS
THAN 5 OHMS
ACTION REQUIRED
Sub
Equipments
HEAD ESP
HEAD ESP
NO 3
HEAD ESP
HEAD ESP
NO 3
HEAD ESP
HEAD ESP
NO 3
HEAD ESP
HEAD ESP
NO 3
HEAD ESP
HEAD ESP
NO 3
HEAD ESP
NO 3
HEAD ESP
HEAD ESP
NO 3
HEAD ESP
HEAD ESP
NO 3
HEAD ESP
HEAD ESP
NO 3
HEAD ESP
HEAD ESP
NO 3
HEAD ESP
HEAD ESP
NO 3
HEAD ESP
NO 3
TYPE OF CHECK
TOOLS (RUN CHECK /
SHUTDOWN)
VISUAL / OIL
TEMPERATURE &
GUAGE
SHUTDOWN
BDV TEST KIT CHECK
FOR INSULATION OF
DGA TEST KIT CHECK



A RESERVOIR FOR

user.

some other means)
the ESP controller.

CHECK
collecting curtains

voltage.
SHUTDOWN
of cables. CHECK
WRENCH
done.

CHECK
Power Transformer.


VISUAL
worn out of lugs.

of cables. WRENCH
done.


VISUAL
worn out of lugs.
the gas passage.


THE TRANSFORMER


STANDARD

varies




> 5 mohm



NO WORN OUT.

THAN 5 OHMS
ACTION REQUIRED
Sub
Equipments
TAIL ESP
HEAD ESP
NO 1
TAIL ESP
HEAD ESP
NO 1
TAIL ESP
HEAD ESP
NO 1
TAIL ESP
HEAD ESP
NO 1
TAIL ESP
HEAD ESP
NO 1
TAIL ESP
NO 1
TAIL ESP
HEAD ESP
NO 1
TAIL ESP
HEAD ESP
NO 1
TAIL ESP
HEAD ESP
NO 1
TAIL ESP
HEAD ESP
NO 1
TAIL ESP
HEAD ESP
NO 1
TAIL ESP
NO 1
TYPE OF CHECK
TOOLS (RUN CHECK /
SHUTDOWN)
VISUAL / OIL
TEMPERATURE &
GUAGE
SHUTDOWN
BDV TEST KIT CHECK
FOR INSULATION OF
DGA TEST KIT CHECK



A RESERVOIR FOR

user.

some other means)
the ESP controller.

CHECK
collecting curtains

voltage.
SHUTDOWN
of cables. CHECK
WRENCH
done.

CHECK
Power Transformer.


VISUAL
worn out of lugs.

of cables. WRENCH
done.


VISUAL
worn out of lugs.
the gas passage.


THE TRANSFORMER


STANDARD

varies




> 5 mohm



NO WORN OUT.

THAN 5 OHMS
ACTION REQUIRED
Sub
Equipments
TAIL ESP
HEAD ESP
NO 2
TAIL ESP
HEAD ESP
NO 2
TAIL ESP
HEAD ESP
NO 2
TAIL ESP
HEAD ESP
NO 2
TAIL ESP
HEAD ESP
NO 2
TAIL ESP
NO 2
TAIL ESP
HEAD ESP
NO 2
TAIL ESP
HEAD ESP
NO 2
TAIL ESP
HEAD ESP
NO 2
TAIL ESP
HEAD ESP
NO 2
TAIL ESP
HEAD ESP
NO 2
TAIL ESP
NO 2
TYPE OF CHECK
TOOLS (RUN CHECK /
SHUTDOWN)
VISUAL / OIL
TEMPERATURE &
GUAGE
SHUTDOWN
BDV TEST KIT CHECK
FOR INSULATION OF
DGA TEST KIT CHECK



A RESERVOIR FOR

user.

some other means)
the ESP controller.

CHECK
collecting curtains

voltage.
SHUTDOWN
of cables. CHECK
WRENCH
done.

CHECK
Power Transformer.


VISUAL
worn out of lugs.

of cables. WRENCH
done.


VISUAL
worn out of lugs.
the gas passage.


THE TRANSFORMER


STANDARD

varies




> 5 mohm



NO WORN OUT.

THAN 5 OHMS
ACTION REQUIRED
Sub
Equipments
TAIL ESP
HEAD ESP
NO 3
TAIL ESP
HEAD ESP
NO 3
TAIL ESP
HEAD ESP
NO 3
TAIL ESP
HEAD ESP
NO 3
TAIL ESP
HEAD ESP
NO 3
TAIL ESP
NO 3
TAIL ESP
HEAD ESP
NO 3
TAIL ESP
HEAD ESP
NO 3
TAIL ESP
HEAD ESP
NO 3
TAIL ESP
HEAD ESP
NO 3
TAIL ESP
HEAD ESP
NO 3
TAIL ESP
NO 3
TYPE OF CHECK
TOOLS (RUN CHECK /
SHUTDOWN)
VISUAL / OIL
TEMPERATURE &
GUAGE
SHUTDOWN
BDV TEST KIT CHECK
FOR INSULATION OF
DGA TEST KIT CHECK



A RESERVOIR FOR

user.

some other means)
the ESP controller.

CHECK
collecting curtains

voltage.
SHUTDOWN
of cables. CHECK
WRENCH
done.

CHECK
Power Transformer.


VISUAL
worn out of lugs.

of cables. WRENCH
done.


VISUAL
worn out of lugs.
the gas passage.


THE TRANSFORMER


STANDARD

varies




> 5 mohm



NO WORN OUT.

THAN 5 OHMS
ACTION REQUIRED
HT PANEL BUSBARS
HT PANEL EARTH
SWITCH
HT PANEL EARTHING
HT PANEL SPACE
HEATER
HT PANEL BUSBAR
HORIZONTAL AND
VERTICAL
INSULATOR
HT BREAKER
SP 11KV
SINTER 11KV INCOMER NO 1
PANEL FROM PP-
2(NPP)
HT NUMERICAL
PROTECTIVE RELAY
HT CABLES
POTENTIAL
TRANSFORMER
CURRENT
TRANSFORMER
HT PANEL BUSBARS
HT PANEL EARTH
SWITCH
HT PANEL EARTHING
HT PANEL SPACE
HEATER
HT PANEL BUSBAR
HORIZONTAL AND
VERTICAL
INSULATOR
SINTER MAIN HT BREAKER
SINTER 11KV SHOP
PANEL TRANSFORMER
NO 1
HT NUMERICAL
PROTECTIVE RELAY
HT CABLES
POTENTIAL
TRANSFORMER
CURRENT
TRANSFORMER
HT PANEL BUSBARS
HT PANEL EARTH
SWITCH
HT PANEL EARTHING
HT PANEL SPACE
HEATER
HT PANEL BUSBAR
HORIZONTAL AND
VERTICAL
INSULATOR
HT BREAKER
PROPORTIONIN
SINTER 11KV G
PANEL TRANSFORMER
NO 1
HT NUMERICAL
PROTECTIVE RELAY
HT CABLES
POTENTIAL
TRANSFORMER
CURRENT
TRANSFORMER
HT PANEL BUSBARS
HT PANEL EARTH
SWITCH
HT PANEL EARTHING
HT PANEL SPACE
HEATER
HT PANEL BUSBAR
HORIZONTAL AND
VERTICAL
INSULATOR
MAIN HT BREAKER
EXHAUST FAN
MAIN HT BREAKER
EXHAUST FAN
SINTER 11KV CHINESE
PANEL SOFTSTATER
OUTGOING
FEEDER
HT NUMERICAL
PROTECTIVE RELAY
HT CABLES
HT CABLES
POTENTIAL
TRANSFORMER
CURRENT
TRANSFORMER
HT PANEL BUSBARS
HT PANEL EARTH
SWITCH
HT PANEL EARTHING
HT PANEL SPACE
HEATER
HT PANEL BUSBAR
HORIZONTAL AND
VERTICAL
INSULATOR
HT BREAKER
SINTER 11KV CHILL FAN NO
PANEL 3
PANEL 3
HT NUMERICAL
PROTECTIVE RELAY
HT CABLES
POTENTIAL
TRANSFORMER
CURRENT
TRANSFORMER
HT PANEL BUSBARS
HT PANEL EARTH
SWITCH
HT PANEL EARTHING
HT PANEL SPACE
HEATER
HT PANEL BUSBAR
HORIZONTAL AND
VERTICAL
INSULATOR
HT BREAKER
PANEL 1
HT NUMERICAL
PROTECTIVE RELAY
HT CABLES
POTENTIAL
TRANSFORMER
CURRENT
TRANSFORMER
HT PANEL BUSBARS
HT PANEL EARTH
SWITCH
HT PANEL EARTHING
HT PANEL SPACE
HEATER
HT PANEL BUSBAR
HORIZONTAL AND
VERTICAL
INSULATOR
HT BREAKER
SINTER 11KV PROPORTIONIN
PANEL G ID FAN
HT NUMERICAL
PROTECTIVE RELAY
HT CABLES
POTENTIAL
TRANSFORMER
CURRENT
TRANSFORMER
HT PANEL BUSBARS
HT PANEL EARTH
SWITCH
HT PANEL EARTHING
HT PANEL SPACE
HEATER
HT PANEL BUSBAR
HORIZONTAL AND
VERTICAL
INSULATOR
HT BREAKER
SINTER 11KV HAMMER
PANEL CRUSHER NO 1
HT NUMERICAL
PROTECTIVE RELAY
HT CABLES
POTENTIAL
TRANSFORMER
CURRENT
TRANSFORMER
HT PANEL BUSBARS
HT PANEL BUSBARS
HT PANEL EARTH
SWITCH
HT PANEL EARTHING
HT PANEL SPACE
HEATER
HT PANEL BUSBAR
HORIZONTAL AND
VERTICAL
INSULATOR
MAIN HT BREAKER
EXHAUST FAN
SINTER 11KV INDIAN
PANEL SOFTSTATER
OUTGOING
FEEDER
HT NUMERICAL
PROTECTIVE RELAY
HT CABLES
HT CABLES
POTENTIAL
TRANSFORMER
CURRENT
TRANSFORMER
HT PANEL BUSBARS
HT PANEL EARTH
SWITCH
HT PANEL EARTHING
HT PANEL SPACE
HEATER
HT PANEL BUSBAR
HORIZONTAL AND
VERTICAL
INSULATOR
HT BREAKER
SINTER 11KV 11KV PT &
HT BREAKER
SINTER 11KV 11KV PT &
PANEL ARRESTER 1
HT NUMERICAL
PROTECTIVE RELAY
HT CABLES
HT CABLES
POTENTIAL
TRANSFORMER
CURRENT
TRANSFORMER
HT PANEL BUSBARS
HT PANEL EARTH
SWITCH
HT PANEL EARTHING
HT PANEL SPACE
HEATER
HT PANEL BUSBAR
HORIZONTAL AND
VERTICAL
INSULATOR
HT BREAKER
SP 11 KV
SINTER 11KV
BUSCOUPLER
PANEL
PANEL
HT NUMERICAL
PROTECTIVE RELAY
HT CABLES
POTENTIAL
TRANSFORMER
CURRENT
TRANSFORMER
HT PANEL BUSBARS
HT PANEL EARTH
SWITCH
HT PANEL EARTHING
HT PANEL SPACE
HEATER
HT PANEL BUSBAR
HORIZONTAL AND
VERTICAL
INSULATOR
HT BREAKER
SP 11 KV
SINTER 11KV SUBSTATION
PANEL TRANSFORMER
NO 1
HT NUMERICAL
PROTECTIVE RELAY
HT CABLES
POTENTIAL
TRANSFORMER
CURRENT
TRANSFORMER
HT PANEL BUSBARS
HT PANEL EARTH
SWITCH
HT PANEL EARTHING
HT PANEL SPACE
HEATER
HT PANEL BUSBAR
HORIZONTAL AND
VERTICAL
INSULATOR
HT BREAKER
SP 11 KV
SINTER 11KV SUBSTATION
PANEL TRANSFORMER
NO 2
HT NUMERICAL
PROTECTIVE RELAY
HT CABLES
POTENTIAL
TRANSFORMER
CURRENT
TRANSFORMER
HT PANEL BUSBARS
HT PANEL EARTH
SWITCH
HT PANEL EARTHING
HT PANEL SPACE
HEATER
HT PANEL BUSBAR
HORIZONTAL AND
VERTICAL
INSULATOR
HT BREAKER
SINTER MAIN
SINTER 11KV SHOP
PANEL TRANSFORMER
NO 2
HT NUMERICAL
PROTECTIVE RELAY
HT CABLES
POTENTIAL
TRANSFORMER
CURRENT
TRANSFORMER
HT PANEL BUSBARS
HT PANEL BUSBARS
HT PANEL EARTH
SWITCH
HT PANEL EARTHING
HT PANEL SPACE
HEATER
HT PANEL BUSBAR
HORIZONTAL AND
VERTICAL
INSULATOR
HT BREAKER
PROPORTIONIN
SINTER 11KV G
PANEL TRANSFORMER
NO 2
HT NUMERICAL
PROTECTIVE RELAY
HT CABLES
HT CABLES
POTENTIAL
TRANSFORMER
CURRENT
TRANSFORMER
HT PANEL BUSBARS
HT PANEL EARTH
SWITCH
HT PANEL EARTHING
HT PANEL SPACE
HEATER
HT PANEL BUSBAR
HORIZONTAL AND
VERTICAL
INSULATOR
HT BREAKER
HT BREAKER
PANEL 2
HT NUMERICAL
PROTECTIVE RELAY
HT CABLES
HT CABLES
POTENTIAL
TRANSFORMER
CURRENT
TRANSFORMER
HT PANEL BUSBARS
HT PANEL EARTH
SWITCH
HT PANEL EARTHING
HT PANEL SPACE
HEATER
HT PANEL BUSBAR
HORIZONTAL AND
VERTICAL
INSULATOR
HT BREAKER
SINTER 11KV SCREENING ID
PANEL FAN
PANEL FAN
HT NUMERICAL
PROTECTIVE RELAY
HT CABLES
POTENTIAL
TRANSFORMER
CURRENT
TRANSFORMER
HT PANEL BUSBARS
HT PANEL EARTH
SWITCH
HT PANEL EARTHING
HT PANEL SPACE
HEATER
HT PANEL BUSBAR
HORIZONTAL AND
VERTICAL
INSULATOR
HT BREAKER
SINTER 11KV TAIL ESP ID
PANEL FAN
HT NUMERICAL
PROTECTIVE RELAY
HT CABLES
POTENTIAL
TRANSFORMER
CURRENT
TRANSFORMER
HT PANEL BUSBARS
HT PANEL EARTH
SWITCH
HT PANEL EARTHING
HT PANEL SPACE
HEATER
HT PANEL BUSBAR
HORIZONTAL AND
VERTICAL
INSULATOR
HT BREAKER
SINTER 11KV HAMMER
PANEL CRUSHER NO 2
HT NUMERICAL
PROTECTIVE RELAY
HT CABLES
POTENTIAL
TRANSFORMER
CURRENT
TRANSFORMER
HT PANEL BUSBARS
HT PANEL EARTH
SWITCH
HT PANEL EARTHING
HT PANEL SPACE
HEATER
HT PANEL BUSBAR
HORIZONTAL AND
VERTICAL
INSULATOR
SP 11KV PT HT BREAKER
SINTER 11KV
AND
PANEL
ARRESTOR 2
HT NUMERICAL
PROTECTIVE RELAY
HT CABLES
POTENTIAL
TRANSFORMER
CURRENT
TRANSFORMER
HT PANEL BUSBARS
HT PANEL EARTH
SWITCH
HT PANEL EARTHING
HT PANEL SPACE
HEATER
HT PANEL BUSBAR
HORIZONTAL AND
VERTICAL
INSULATOR
HT BREAKER
SP 11 KV
HT BREAKER
SP 11 KV
11 KV BF HT BUSCOUPLER
PANEL ROOM CONNECT
SWITCH
HT NUMERICAL
PROTECTIVE RELAY
HT CABLES
HT CABLES
POTENTIAL
TRANSFORMER
CURRENT
TRANSFORMER
TYPE OF
CHECK (RUN
TOOLS CHECK /
REQUIRED STOP CHECK
/
SHUTDOWN)
SPANNERS /
Busbars typically housed inside switchgear SHUTDOWN
TORQUE
/ panel boards for local high current power CHECK
WRENCH
distribution. They are used to connect high
voltage equipment at electrical
switchyards, and low voltage equipments.
They are generally uninsulated, and have
sufficient stiffness to be supported in air by VISUAL /
insulated pillars. These features allow the SHUTDOWN
COTTON
ability to tap in at various points without CHECK
CLOTHE
creating a new joint. There should be
proper insulation between busbar and
switchgear panel through busbar Insulator.
SHUTDOWN
HT MEGGER
CHECK
Earth Switch is designed to ground

electrical circuit on both side of AC
Vacuum Circuit Breaker when the AC
SHUTDOWN
Vacuum Circuit Breaker is open. This VISUAL
CHECK
ensures the safety of the maintenance
personnel during maintenance and routine
checking.
To provide earthng of the Panel body. VISUAL RUN CHECK
HT Panel Space Heaters are designed to

LEAKAGE
maintain temperature and minimize RUN CHECK
TESTER
moisture inside electrical panel.
HT Panel Horizontal and Vertical

Insulators are for their high electrical &
mechanical strength used in electrical SHUTDOWN
VISUAL
panels to support the copper busbar. They CHECK
do not allow current to flow freely from
conductor (busbar) to body of the panel.
VISUAL,
COTTON
CLOTHE, CRC,
DIELECTRIC SHUTDOWN
ISOPLEX & CHECK
SHELL TELLUS
detected.
32 GREASE, HT
MEGGER
SECONDARY
INJECTION
operation of circuit breaker to isolate the SHUTDOWN
CURRENT AND
defective element from the rest of the CHECK
VOLTAGE TEST
system.
KIT
SPANNERS /
SHUTDOWN
TORQUE
Allows the electric power transmission at WRENCH CHECK
high voltage. Cable to be fixed with
Breaker Terminals properly insulated,
clamped and sealed connector to provide
greater protecton from short circuiting of
cables.
Cable joints and terminals must be
designed to control the high-voltage stress
to prevent breakdown of the insulation. SHUTDOWN
MEGGER
CHECK
TAN-DELTA SHUTDOWN
TEST KIT CHECK
PT used to reduce the voltage to lower

values and to provide isolation between VISUAL /
high voltage power network and the relays SECONDARY
and the other instruments that are INJECTION SHUTDOWN
connected to their secondaries. PT is used CURRENT AND CHECK
to measure voltage in high voltage circuits. VOLTAGE TEST
Also, it is used for protective purposes as KIT
input to relays in a power system
CT used to reduce the current to lower
VISUAL /
values and to provide isolation between
SECONDARY
high current and the relays and the other
INJECTION SHUTDOWN
instruments that are connected to their
CURRENT AND CHECK
secondaries. CT is used to measure current
VOLTAGE TEST
and also used for protective purposes as
KIT
Busbars typically housed inside switchgear

/ panel boards for local high current power SPANNERS /
SHUTDOWN
distribution. They are used to connect high TORQUE
CHECK
voltage equipment at electrical WRENCH
SHUTDOWN
insulated pillars. These features allow the COTTON
CHECK
ability to tap in at various points without CLOTHE
proper insulation between busbar and SHUTDOWN
HT MEGGER
switchgear panel through busbar Insulator. CHECK

SHUTDOWN
CHECK
checking.
To provive earthng of the Panel body. VISUAL RUN CHECK

LEAKAGE
TESTER

VISUAL
VISUAL,
COTTON
CLOTHE, CRC,
DIELECTRIC SHUTDOWN
ISOPLEX & CHECK
SHELL TELLUS
detected.
32 GREASE, HT
MEGGER
SECONDARY
INJECTION
CURRENT AND
VOLTAGE TEST
system.
KIT
Allows the electric power transmission at SPANNERS / SHUTDOWN

high voltage. Cable to be fixed with TORQUE
CHECK
Breaker Terminals properly insulated, WRENCH
cables.
Cable joints and terminals must be SHUTDOWN
MEGGER
designed to control the high-voltage stress CHECK
to prevent breakdown of the insulation.


VISUAL /
SECONDARY
INJECTION SHUTDOWN
CURRENT AND CHECK
VOLTAGE TEST
KIT
SHUTDOWN
CHECK
SHUTDOWN
CHECK
HT MEGGER

SHUTDOWN
CHECK
checking.

LEAKAGE
TESTER

VISUAL
VISUAL,
COTTON
CLOTHE, CRC,
DIELECTRIC SHUTDOWN
ISOPLEX & CHECK
SHELL TELLUS
detected.
32 GREASE, HT
MEGGER
SECONDARY
INJECTION
CURRENT AND
VOLTAGE TEST
system.
KIT
SPANNERS /
SHUTDOWN
TORQUE
cables. SHUTDOWN
MEGGER
Cable joints and terminals must be CHECK
TAN-DELTA SHUTDOWN
TEST KIT CHECK


VISUAL /
SECONDARY
INJECTION SHUTDOWN
CURRENT AND CHECK
VOLTAGE TEST
KIT

SHUTDOWN
CHECK
SHUTDOWN
CHECK
HT MEGGER
SHUTDOWN
CHECK
checking.

LEAKAGE
TESTER

VISUAL
VISUAL,
COTTON
CLOTHE, CRC,
DIELECTRIC SHUTDOWN
ISOPLEX & CHECK
VISUAL,
COTTON
CLOTHE, CRC,
DIELECTRIC SHUTDOWN
ISOPLEX & CHECK
SHELL TELLUS
detected.
32 GREASE, HT
MEGGER
SECONDARY
INJECTION
CURRENT AND
VOLTAGE TEST
system.
KIT
SPANNERS /
SHUTDOWN
TORQUE
cables. SHUTDOWN
MEGGER
cables. SHUTDOWN
MEGGER
TAN-DELTA SHUTDOWN
TEST KIT CHECK


VISUAL /
SECONDARY
INJECTION SHUTDOWN
CURRENT AND CHECK
VOLTAGE TEST
KIT

SHUTDOWN
CHECK
SHUTDOWN
CHECK
HT MEGGER

SHUTDOWN
CHECK
checking.

LEAKAGE
TESTER

VISUAL
VISUAL,
COTTON
CLOTHE, CRC,
DIELECTRIC SHUTDOWN
ISOPLEX & CHECK
SHELL TELLUS
detected.
32 GREASE, HT
MEGGER
SHELL TELLUS
detected.
32 GREASE, HT
MEGGER
SECONDARY
INJECTION
CURRENT AND
VOLTAGE TEST
system.
KIT
SPANNERS /
SHUTDOWN
TORQUE
cables. SHUTDOWN
MEGGER
TAN-DELTA SHUTDOWN
TEST KIT CHECK

VISUAL /
SECONDARY
INJECTION SHUTDOWN
CURRENT AND CHECK
VOLTAGE TEST
KIT

SHUTDOWN
CHECK
SHUTDOWN
CHECK
HT MEGGER

SHUTDOWN
CHECK
checking.

LEAKAGE
TESTER
VISUAL
VISUAL,
COTTON
CLOTHE, CRC,
DIELECTRIC SHUTDOWN
ISOPLEX & CHECK
SHELL TELLUS
detected.
32 GREASE, HT
MEGGER
SECONDARY
INJECTION
CURRENT AND
VOLTAGE TEST
system.
KIT
SPANNERS /
SHUTDOWN
TORQUE
cables. SHUTDOWN
MEGGER
TAN-DELTA SHUTDOWN
TEST KIT CHECK

VISUAL /
SECONDARY
INJECTION SHUTDOWN
CURRENT AND CHECK
VOLTAGE TEST
KIT

SHUTDOWN
CHECK
SHUTDOWN
CHECK
HT MEGGER

SHUTDOWN
CHECK
checking.

LEAKAGE
TESTER

VISUAL
VISUAL,
COTTON
CLOTHE, CRC,
DIELECTRIC SHUTDOWN
ISOPLEX & CHECK
SHELL TELLUS
detected.
32 GREASE, HT
MEGGER
SECONDARY
INJECTION
CURRENT AND
VOLTAGE TEST
system.
KIT
SPANNERS /
SHUTDOWN
TORQUE
cables. SHUTDOWN
MEGGER
TAN-DELTA SHUTDOWN
TEST KIT CHECK


VISUAL /
SECONDARY
INJECTION SHUTDOWN
CURRENT AND CHECK
VOLTAGE TEST
KIT
SHUTDOWN
CHECK
SHUTDOWN
CHECK
HT MEGGER

SHUTDOWN
CHECK
checking.

LEAKAGE
TESTER

VISUAL
VISUAL,
COTTON
CLOTHE, CRC,
DIELECTRIC SHUTDOWN
ISOPLEX & CHECK
SHELL TELLUS
detected.
32 GREASE, HT
MEGGER
SECONDARY
INJECTION
CURRENT AND
VOLTAGE TEST
system.
KIT
SPANNERS /
SHUTDOWN
TORQUE
cables. SHUTDOWN
MEGGER
TAN-DELTA SHUTDOWN
TEST KIT CHECK


VISUAL /
SECONDARY
INJECTION SHUTDOWN
CURRENT AND CHECK
VOLTAGE TEST
KIT

SHUTDOWN
CHECK
SHUTDOWN
CHECK
HT MEGGER

SHUTDOWN
CHECK
checking.

LEAKAGE
TESTER

VISUAL
VISUAL,
COTTON
CLOTHE, CRC,
DIELECTRIC SHUTDOWN
ISOPLEX & CHECK
SHELL TELLUS
detected.
32 GREASE, HT
MEGGER
SECONDARY
INJECTION
CURRENT AND
VOLTAGE TEST
system.
KIT
SPANNERS /
SHUTDOWN
TORQUE
cables.
Allows the electric power transmission at
cables. SHUTDOWN
MEGGER
TAN-DELTA SHUTDOWN
TEST KIT CHECK


VISUAL /
SECONDARY
INJECTION SHUTDOWN
CURRENT AND CHECK
VOLTAGE TEST
KIT

SHUTDOWN
CHECK
SHUTDOWN
CHECK
HT MEGGER
SHUTDOWN
CHECK
checking.

LEAKAGE
TESTER

VISUAL
VISUAL,
COTTON
CLOTHE, CRC,
DIELECTRIC SHUTDOWN
ISOPLEX & CHECK
VISUAL,
COTTON
CLOTHE, CRC,
DIELECTRIC SHUTDOWN
ISOPLEX & CHECK
SHELL TELLUS
detected.
32 GREASE, HT
MEGGER
SECONDARY
INJECTION
CURRENT AND
VOLTAGE TEST
system.
KIT

CHECK
cables.
MEGGER
cables.
MEGGER


VISUAL /
SECONDARY
INJECTION SHUTDOWN
CURRENT AND CHECK
VOLTAGE TEST
KIT

SHUTDOWN
CHECK
SHUTDOWN
CHECK
HT MEGGER

SHUTDOWN
CHECK
checking.

LEAKAGE
TESTER

VISUAL
VISUAL,
COTTON
CLOTHE, CRC,
DIELECTRIC SHUTDOWN
ISOPLEX & CHECK
SHELL TELLUS
detected.
32 GREASE, HT
MEGGER
SECONDARY
INJECTION
CURRENT AND
VOLTAGE TEST
system.
KIT
SPANNERS /
SHUTDOWN
TORQUE
cables. SHUTDOWN
MEGGER
TAN-DELTA SHUTDOWN
TEST KIT CHECK

VISUAL /
SECONDARY
INJECTION SHUTDOWN
CURRENT AND CHECK
VOLTAGE TEST
KIT

SHUTDOWN
CHECK
SHUTDOWN
CHECK
HT MEGGER

SHUTDOWN
CHECK
checking.

LEAKAGE
TESTER
VISUAL
VISUAL,
COTTON
CLOTHE, CRC,
DIELECTRIC SHUTDOWN
ISOPLEX & CHECK
SHELL TELLUS
detected.
32 GREASE, HT
MEGGER
SECONDARY
INJECTION
CURRENT AND
VOLTAGE TEST
system.
KIT
SPANNERS /
SHUTDOWN
TORQUE
cables. SHUTDOWN
MEGGER
TAN-DELTA SHUTDOWN
TEST KIT CHECK

VISUAL /
SECONDARY
INJECTION SHUTDOWN
CURRENT AND CHECK
VOLTAGE TEST
KIT

SHUTDOWN
CHECK
SHUTDOWN
CHECK
HT MEGGER

SHUTDOWN
CHECK
checking.

LEAKAGE
TESTER

VISUAL
VISUAL,
COTTON
CLOTHE, CRC,
DIELECTRIC SHUTDOWN
ISOPLEX & CHECK
SHELL TELLUS
detected.
32 GREASE, HT
MEGGER
SECONDARY
INJECTION
CURRENT AND
VOLTAGE TEST
system.
KIT
SPANNERS /
SHUTDOWN
TORQUE
cables. SHUTDOWN
MEGGER
TAN-DELTA SHUTDOWN
TEST KIT CHECK


VISUAL /
SECONDARY
INJECTION SHUTDOWN
CURRENT AND CHECK
VOLTAGE TEST
KIT
SHUTDOWN
CHECK
SHUTDOWN
CHECK
HT MEGGER

SHUTDOWN
CHECK
checking.

LEAKAGE
TESTER

VISUAL
VISUAL,
COTTON
CLOTHE, CRC,
DIELECTRIC SHUTDOWN
ISOPLEX & CHECK
SHELL TELLUS
detected.
32 GREASE, HT
MEGGER
SECONDARY
INJECTION
CURRENT AND
VOLTAGE TEST
system.
KIT
SPANNERS /
SHUTDOWN
TORQUE
cables. SHUTDOWN
MEGGER
TAN-DELTA SHUTDOWN
TEST KIT CHECK


VISUAL /
SECONDARY
INJECTION SHUTDOWN
CURRENT AND CHECK
VOLTAGE TEST
KIT

SHUTDOWN
CHECK
SHUTDOWN
CHECK
HT MEGGER

SHUTDOWN
CHECK
checking.

LEAKAGE
TESTER

VISUAL
VISUAL,
COTTON
CLOTHE, CRC,
DIELECTRIC SHUTDOWN
ISOPLEX & CHECK
SHELL TELLUS
detected.
32 GREASE, HT
MEGGER
SECONDARY
INJECTION
CURRENT AND
VOLTAGE TEST
system.
KIT
SPANNERS /
SHUTDOWN
TORQUE
cables.
Allows the electric power transmission at
cables. SHUTDOWN
MEGGER
TAN-DELTA SHUTDOWN
TEST KIT CHECK


VISUAL /
SECONDARY
INJECTION SHUTDOWN
CURRENT AND CHECK
VOLTAGE TEST
KIT

SHUTDOWN
CHECK
SHUTDOWN
CHECK
HT MEGGER
SHUTDOWN
CHECK
checking.

LEAKAGE
TESTER

VISUAL
VISUAL,
COTTON
CLOTHE, CRC,
DIELECTRIC SHUTDOWN
ISOPLEX & CHECK
VISUAL,
COTTON
CLOTHE, CRC,
DIELECTRIC SHUTDOWN
ISOPLEX & CHECK
SHELL TELLUS
detected.
32 GREASE, HT
MEGGER
SECONDARY
INJECTION
CURRENT AND
VOLTAGE TEST
system.
KIT
SPANNERS /
SHUTDOWN
TORQUE
cables. SHUTDOWN
MEGGER
cables. SHUTDOWN
MEGGER
TAN-DELTA SHUTDOWN
TEST KIT CHECK


VISUAL /
SECONDARY
INJECTION SHUTDOWN
CURRENT AND CHECK
VOLTAGE TEST
KIT

SHUTDOWN
CHECK
SHUTDOWN
CHECK
HT MEGGER

SHUTDOWN
CHECK
checking.

LEAKAGE
TESTER

VISUAL
VISUAL,
COTTON
CLOTHE, CRC,
DIELECTRIC SHUTDOWN
ISOPLEX & CHECK
SHELL TELLUS
detected.
32 GREASE, HT
MEGGER
SHELL TELLUS
detected.
32 GREASE, HT
MEGGER
SECONDARY
INJECTION
CURRENT AND
VOLTAGE TEST
system.
KIT

CHECK
cables.
MEGGER

VISUAL /
SECONDARY
INJECTION SHUTDOWN
CURRENT AND CHECK
VOLTAGE TEST
KIT

SHUTDOWN
CHECK
SHUTDOWN
CHECK
HT MEGGER

SHUTDOWN
CHECK
checking.

LEAKAGE
TESTER
VISUAL
VISUAL,
COTTON
CLOTHE, CRC,
DIELECTRIC SHUTDOWN
ISOPLEX & CHECK
SHELL TELLUS
detected.
32 GREASE, HT
MEGGER
SECONDARY
INJECTION
CURRENT AND
VOLTAGE TEST
system.
KIT

CHECK
cables.
MEGGER

VISUAL /
SECONDARY
INJECTION SHUTDOWN
CURRENT AND CHECK
VOLTAGE TEST
KIT

SHUTDOWN
CHECK
SHUTDOWN
CHECK
HT MEGGER

SHUTDOWN
CHECK
checking.

LEAKAGE
TESTER

VISUAL
VISUAL,
COTTON
CLOTHE, CRC,
DIELECTRIC SHUTDOWN
ISOPLEX & CHECK
SHELL TELLUS
detected.
32 GREASE, HT
MEGGER
SECONDARY
INJECTION
CURRENT AND
VOLTAGE TEST
system.
KIT

CHECK
cables.
MEGGER


VISUAL /
SECONDARY
INJECTION SHUTDOWN
CURRENT AND CHECK
VOLTAGE TEST
KIT
SHUTDOWN
CHECK
SHUTDOWN
CHECK
HT MEGGER

SHUTDOWN
CHECK
checking.

LEAKAGE
TESTER

VISUAL
VISUAL,
COTTON
CLOTHE, CRC,
DIELECTRIC SHUTDOWN
ISOPLEX & CHECK
SHELL TELLUS
detected.
32 GREASE, HT
MEGGER
SECONDARY
INJECTION
CURRENT AND
VOLTAGE TEST
system.
KIT
CHECK
cables.
MEGGER


VISUAL /
SECONDARY
INJECTION SHUTDOWN
CURRENT AND CHECK
VOLTAGE TEST
KIT

SHUTDOWN
CHECK
SHUTDOWN
CHECK
HT MEGGER
SHUTDOWN
CHECK
checking.

LEAKAGE
TESTER

VISUAL
VISUAL,
COTTON
CLOTHE, CRC,
DIELECTRIC SHUTDOWN
ISOPLEX & CHECK
VISUAL,
COTTON
CLOTHE, CRC,
DIELECTRIC SHUTDOWN
ISOPLEX & CHECK
SHELL TELLUS
detected.
32 GREASE, HT
MEGGER
SECONDARY
INJECTION
CURRENT AND
VOLTAGE TEST
system.
KIT
SPANNERS /
SHUTDOWN
TORQUE
cables. SHUTDOWN
MEGGER
cables. SHUTDOWN
MEGGER
TAN-DELTA SHUTDOWN
TEST KIT CHECK


VISUAL /
SECONDARY
INJECTION SHUTDOWN
CURRENT AND CHECK
VOLTAGE TEST
KIT
IDEAL CONDITION
OBSERVED ON 16.04.2018 REQUIRED

torque wrench.
Wrench.
Insulators were installed

Insulators should be installed
properly and was clean. No
properly to hold and support
oxydation observed between
busbars. Insulators should be clean.
insulator and busbar.
Resistance between panel to busbar Resistance between panel to

should be ˃ 20 mega ohms. busbar is 100 mega ohms.

Breaker do not Rack In during
Earth Switch operated
Earth Switch operated condition.
condition. Also, Back Door of
Also, Back Door of HT Panel
HT Panel has not been open
should not be open when earth
when earth switch is not
operated.


panel. Space Heater current should inside panel. Space Heater
be < 1 A current is 0.3 A

insulators strength to the
busbars are good. Also, megger
value is 100 mega Ohms.
mega Ohms.
HT Breaker should be clean. There HT Breaker found clean. There
should not be any moisture or wear is no moisture or wear and
and rusting of contacts. rusting of contacts.
Proper lubrication of all moving Lubrication of all moving parts

parts of mechanism. of mechanism is normal.

proper.
proper.
Proper spring charging operation of Spring charging operation of
limit switch. limit switch is normal.
Condition of contact arm assembly Condition of contact arm

of breaker should be proper. assembly of breaker is proper.

normal. normal.
Upper & Lower contacts should be Upper & Lower contacts is > 1
> 1 T Ohms T Ohms
Ohms
Ohms
Timing of CB during Close should Timing of CB during Close is



Open is 18 ms of all three
phases.
Contact Resistance between Upper Contact Resistance between
and Lower contacts should be in Upper and Lower contacts is 44
micro ohms of all three phases. micro ohms of all three phases.

phases. phases.
breaker on the faults described
in the relay on prescribed
values.

torque wrench.
Wrench.

Mega Ohms
Mega Ohms Ohms
TAN-DELTA test of HT Cable TAN-DELTA test of HT Cable
should be < 0.004 absolute. is 0.0027

should PT connections are tight and
1. measure correct voltage on the display correct voltage on the
relay or meter. relay. Indication of voltage on
2. provide indication of voltage on the panel is shown. Trippig of
the panel. the HT Breaker through HT
3. trip the HT Breaker through HT Relay on Over voltage / Under
Relay on Over voltage / Under Voltage is healthy.
Voltage.
should
display accurate current on the
relay. Trippig of the HT Breaker
the relay or meter.
curent / CIR / ITOC / DMT is
Relay on Over curent / CIR / ITOC
healthy.
/ DMT.

torque wrench.
Wrench.
operated.

mega Ohms.


proper.
proper.


normal. normal.
> 1 T Ohms T Ohms
Ohms
Ohms



phases.

phases. phases.
values.
torque wrench.
Wrench.
Mega Ohms
Mega Ohms Ohms

Voltage.

should
the relay or meter.
healthy.
/ DMT.
torque wrench.
Wrench.
operated.

mega Ohms.



proper.
proper.


normal. normal.
> 1 T Ohms T Ohms
Ohms
Ohms



phases.


phases. phases.
values.
torque wrench.
Wrench.
Mega Ohms
Mega Ohms Ohms
Voltage.

should
the relay or meter.
healthy.
/ DMT.

torque wrench.
Wrench.
operated.

mega Ohms.



proper.
proper.

normal. normal.
> 1 T Ohms T Ohms
Ohms
Ohms



phases.


phases. phases.
values.
torque wrench.
Wrench.
Mega Ohms
Mega Ohms Ohms
Voltage.

should
the relay or meter.
healthy.
/ DMT.

torque wrench.
Wrench.
operated.

mega Ohms.



proper.
proper.


normal. normal.
> 1 T Ohms T Ohms
Ohms
Ohms



phases.


phases. phases.
values.
torque wrench.
Wrench.
Mega Ohms
Mega Ohms Ohms
Voltage.

should
the relay or meter.
healthy.
/ DMT.

torque wrench.
Wrench.
operated.
mega Ohms.



proper.
proper.


normal. normal.
> 1 T Ohms T Ohms
Ohms
Ohms


phases.


phases. phases.
values.
torque wrench.
Wrench.
Mega Ohms
Mega Ohms Ohms

Voltage.
should
the relay or meter.
healthy.
/ DMT.

torque wrench.
Wrench.
operated.

mega Ohms.


proper.
proper.


normal. normal.
> 1 T Ohms T Ohms
Ohms
Ohms



phases.

phases. phases.
values.
torque wrench.
Wrench.
Mega Ohms
Mega Ohms Ohms

Voltage.

should
the relay or meter.
healthy.
/ DMT.
torque wrench.
Wrench.
operated.

mega Ohms.



proper.
proper.


normal. normal.
> 1 T Ohms T Ohms
Ohms
Ohms



phases.


phases. phases.
values.
torque wrench.
Wrench.
Mega Ohms
Mega Ohms Ohms
Voltage.

should
the relay or meter.
healthy.
/ DMT.

torque wrench.
Wrench.
operated.

mega Ohms.



proper.
proper.


normal. normal.
> 1 T Ohms T Ohms
Ohms
Ohms
Timing of CB during Close should Timing of CB during Close is39

be in ms of all three phases. ms of all three phases.


phases.


phases. phases.
values.
torque wrench.
Wrench.
Mega Ohms
Mega Ohms Ohms
Voltage.

should
the relay or meter.
healthy.
/ DMT.

torque wrench.
Wrench.
operated.

mega Ohms.



proper.
proper.

normal. normal.
> 1 T Ohms T Ohms
Ohms
Ohms



phases.


phases. phases.
values.
torque wrench.
Wrench.
Mega Ohms
Mega Ohms Ohms

Voltage.

should
the relay or meter.
healthy.
/ DMT.

torque wrench.
Wrench.
operated.

mega Ohms.



proper.
proper.


normal. normal.
> 1 T Ohms T Ohms
Ohms
Ohms


phases.


phases. phases.
values.
torque wrench.
Wrench.
Mega Ohms
Mega Ohms Ohms
Voltage.

should
the relay or meter.
healthy.
/ DMT.

torque wrench.
Wrench.
operated.
mega Ohms.



proper.
proper.


normal. normal.
> 1 T Ohms T Ohms
Ohms
Ohms


phases.


phases. phases.
values.
torque wrench.
Wrench.
Mega Ohms
Mega Ohms Ohms

Voltage.
should
the relay or meter.
healthy.
/ DMT.

torque wrench.
Wrench.
operated.

mega Ohms.


proper.
proper.


normal. normal.
> 1 T Ohms T Ohms
Ohms
Ohms



phases.

phases. phases.
values.
torque wrench.
Wrench.
Mega Ohms
Mega Ohms Ohms

Voltage.

should
the relay or meter.
healthy.
/ DMT.
torque wrench.
Wrench.
operated.

mega Ohms.



proper.
proper.


normal. normal.
> 1 T Ohms T Ohms
Ohms
Ohms



phases.


phases. phases.
values.
torque wrench.
Wrench.
Mega Ohms
Mega Ohms Ohms
Voltage.

should
the relay or meter.
healthy.
/ DMT.

torque wrench.
Wrench.
operated.

mega Ohms.



proper.
proper.


normal. normal.
> 1 T Ohms T Ohms
Ohms
Ohms



phases.


phases. phases.
values.
torque wrench.
Wrench.
Mega Ohms
Mega Ohms Ohms
Voltage.

should
the relay or meter.
healthy.
/ DMT.

torque wrench.
Wrench.
operated.

mega Ohms.



proper.
proper.

normal. normal.
> 1 T Ohms T Ohms
Ohms
Ohms



phases.


phases. phases.
values.
torque wrench.
Wrench.
Mega Ohms
Mega Ohms Ohms
Voltage.

should
the relay or meter.
healthy.
/ DMT.

torque wrench.
Wrench.
operated.

mega Ohms.



proper.
proper.


normal. normal.
> 1 T Ohms T Ohms
Ohms
Ohms



phases.


phases. phases.
values.
torque wrench.
Wrench.
Mega Ohms
Mega Ohms Ohms
Voltage.

should
the relay or meter.
healthy.
/ DMT.

torque wrench.
Wrench.
operated.
mega Ohms.



proper.
proper.


normal. normal.
> 1 T Ohms T Ohms
Ohms
Ohms


phases.


phases. phases.
values.
torque wrench.
Wrench.
Mega Ohms
Mega Ohms Ohms

Voltage.
should
the relay or meter.
healthy.
/ DMT.

torque wrench.
Wrench.
operated.

mega Ohms.


proper.
proper.


normal. normal.
> 1 T Ohms T Ohms
Ohms
Ohms



phases.

phases. phases.
values.
torque wrench.
Wrench.
Mega Ohms
Mega Ohms Ohms

Voltage.

should
the relay or meter.
healthy.
/ DMT.
torque wrench.
Wrench.
operated.

mega Ohms.



proper.
proper.


normal. normal.
> 1 T Ohms T Ohms
Ohms
Ohms



phases.


phases. phases.
values.
torque wrench.
Wrench.
Mega Ohms
Mega Ohms Ohms

Voltage.

should
the relay or meter.
healthy.
/ DMT.

torque wrench.
Wrench.
operated.

mega Ohms.



proper.
proper.

normal. normal.
> 1 T Ohms T Ohms
Ohms
Ohms



phases.


phases. phases.
values.
torque wrench.
Wrench.
Mega Ohms
Mega Ohms Ohms
Voltage.

should
the relay or meter.
healthy.
/ DMT.
Sub DESCRIPTION /
Equipments DIMENSION
switchgear / panel boards for
local high current power
distribution. They are used to
connect high voltage equipment
at electrical switchyards, and
low voltage equipments. They
are generally uninsulated, and
LT PANEL
have sufficient stiffness to be
BUSBARS
supported in air by insulated
pillars. These features allow the
ability to tap in at various points
without creating a new joint.
There should be proper
insulation between busbar and
switchgear panel through busbar
LT PANEL To provide earthng of the Panel

EARTHING body.
LT Panel Space Heaters are

LT PANEL SPACE designed to maintain
HEATER temperature and minimize
LT Panel Horizontal and Vertical

Insulators are for their high
LT PANEL
electrical & mechanical strength
BUSBAR
used in electrical panels to
HORIZONTAL
support the copper busbar. They
AND VERTICAL
do not allow current to flow
INSULATOR
freely from conductor (busbar)
to body of the panel.
SMS MCC
SMS MCC To protect an electrical circuit
PANEL
from damage caused by excess
current from an overload or
LT MCCB
short circuit. Its basic function is
to interrupt current flow after a
fault is detected.
SMS MCC
SMS MCC To protect an electrical circuit
PANEL
from damage caused by excess
current from an overload or
LT MCCB
short circuit. Its basic function is
to interrupt current flow after a
fault is detected.
Allows the electric power

transmission at low voltage.
Cable to be fixed with Breaker
Terminals properly insulated,
clamped and sealed connector to
LT CABLES provide greater protecton from
short circuiting of cables.
Cable joints and terminals must
be designed to control the low-
voltage stress to prevent
breakdown of the insulation.
Control transformer is used to

reduce the voltage to lower
values and to provide isolation
between different level of
voltage power network and the
CONTROL
relays and the other instruments
TRANSFORMER
that are connected to their
secondaries. it is used to
provide control supply
voltage(110Vac) to different
feeders connected to the MCC
CURRENT CT is used to measure current

TRANSFORMER and
TYPE OF CHECK
TOOLS (RUN CHECK / STOP
IDEAL CONDITION
REQUIRED CHECK /
SHUTDOWN)
SPANNERS / tensile stainless steel bolts
SHUTDOWN CHECK
TORQUE WRENCH with flat washers and nuts by
Torque Wrench.

VISUAL / COTTON properly to hold and support
SHUTDOWN CHECK
CLOTH busbars. Insulators should be
clean.
Resistance between panel to

LT MEGGER SHUTDOWN CHECK busbar should be ˃ 20 mega
ohms.
Panelshould be connected to
2 separate earth strips which
VISUAL RUN CHECK has to be connected to earth
pits having resistance less
than 5 ohms.

LEAKAGE TESTER RUN CHECK inside panel. Space Heater

insulators should provide
high electrical and
mechanical strength to the
busbars. Also, megger value
LT MCCB should be clean.

There should not be any
moisture or wear and rusting
of contacts.
VISUAL, COTTON
SHUTDOWN CHECK
CLOTH, CRC,
VISUAL, COTTON Proper operation of MCCB
SHUTDOWN CHECK
CLOTH, CRC, for trip/close operation


SPANNERS / tensile stainless steel bolts
SHUTDOWN CHECK
TORQUE WRENCH with flat washers and nuts by
Torque Wrench.
Phase to Phase should be >
20 Mega Ohms
Phase to Earth should be >
20 Mega Ohms
Control transformer
and should
VISUAL / CLAMP 1. measure correct voltage on
SHUTDOWN CHECK
METER the meter.
2. provide indication of
voltage on the panel.
CT connections should be
tight and should measure
VISUAL SHUTDOWN CHECK current accurately on the
meter.
ACTUAL CONDITION
OBSERVED ON ACTION REQUIRED
16.04.2018

and connecting links

Resistance between panel to

busbar is >100 mega ohms.
Panel is connected to earth

pits (2 no) having resistance
value of 1 ohms with 2
separate earth strips

inside panel. Space Heater
current is 0.3 A

busbars are good. Also,
megger value is >100 mega
Ohms.
HT Breaker found clean.

There is no moisture or wear
LT MCCB operation for
trip/close is proper
proper.

and connecting links
between Phase to Phase is
>100 Ohms
between Phase to Earth is >
100 Mega Ohms
Control transformer
display correct voltage on
the relay. Indication of
voltage on the panel is
shown.

display accurate current on
the meter.

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Criticality

Sr. NO Equipment Code Equipment Description CATEGORY

1 BF3-FURN-BLT FURNANCE BLT SYSTEM BLT 648

Critical YES APRIL Not Done Done Not Done NA NA NA

EQUIPMENT: SUB EQUIPMENTS COMPONENT

BF3-COMP-REG2 BF3-COMP-REG2 HEATER FOR DRYER

BF3-COMP-REG2 BF3-COMP-REG2 DIAPHRAGM VALVE 1

BF3-COMP-REG2 BF3-COMP-REG2 DIAPHRAGM VALVE 2

BF3-COMP-REG2 BF3-COMP-REG2 DIAPHRAGM VALVE 3

BF3-COMP-REG2 BF3-COMP-REG2 DIAPHRAGM VALVE 4

DESCRIPTION / DIMENSION TYPE

CHECK FOR COIL RESISTANCE MULTIMETER STOP CHECK

CHECK FOR DIAPHRAGM CONDITIONSPANNERS STOP CHECK

CHECK FOR DIAPHRAGM CONDITIONSPANNERS STOP CHECK

CHECK FOR DIAPHRAGM CONDITIONSPANNERS STOP CHECK

CHECK FOR DIAPHRAGM CONDITIONSPANNERS STOP CHECK

CHECK FOR COMMAND TO BED CHANMULTI METER RUN CHECK

COMPONENT ITEM CODE SPECIFICATION

ELEMENT OIL FILTER 5115010003

MAIN OIL PUMP (MOP) COUPLING 5202080029

FLEXIBLE COUPLING, 804070063 6GBH-160 FOR MAC

HT PANEL BUSBAR HORIZONTAL AND

HT NUMERICAL PROTECTIVE RELAY

HT VACUUM BYPASS CONTACTOR

LT Auxiliary oil Pump Motor Windings

Auxiliary oil Pump Terminal Box

Auxiliary oil Pump Overload Relay

DESCRIPTION / DIMENSION TOOLS REQUIRED

CHECK PRESSURE DIFFERENCE FOR

CHECK FOR PHYSICAL DAMAGE VISUAL

CHECK FOR PHYSICAL DAMAGE VISUAL

CHECK DISCHARGE PRESSURE AT DCS

Check for proper tigteness of the busbar

Check for megger value of Busbar and

Check for proper interlocking of earth

Check for high electrical & mechanical

To protect an electrical circuit from

To detect the fault and initiates the

Check for proper tigteness of the power SPANNERS / TORQUE

Check for megger value of HT Cable

Check for partial discharge test of HT

Check for tighteness of connections and

Check for tighteness of connections and

To form magnetic field when

Check for TAN DELTA of the motor. TAN-DELTA TEST KIT

Check for proper tigteness of the

Check for physical condition of

To form magnetic field when

Check for proper tigteness of the

Check for overload relay range and

Check for Healthness of Mac

check healthyness of contact change

checking healthyness by Run Motor. Multimeter,Tester

checking healthyness by Run Motor. Multimeter,Tester

RUN CHECK SHOULD BE <1BAR

STOP CHECK NO DAMAGE

STOP CHECK NO DAMAGE

RUN CHECK WATER-<45*C, OIL-<49*C

RUN CHECK WATER-<40*C, AIR-<49*C

RUN CHECK WATER-<40*C, AIR-<49*C

RUN CHECK WATER-<40*C, AIR-<49*C

RUN CHECK DP SHOULD BE <0.2MMWC

RUN CHECK DP SHOULD BE <15MMWC

RUN CHECK DP SHOULD BE <12MMWC

RUN CHECK WATER-<45C, OIL-<49C

RUN CHECK WATER-<40C, AIR-<49C

RUN CHECK WATER-<40C, AIR-<49C

RUN CHECK WATER-<40C, AIR-<49C