Document No. VSL/WRBM/WI/8.

1/007
QUALITY WORK INSTRUCTION Date of Preparation 10/06/2017
Maintenance For Re-Heating Furnace Revision No. & Date 00
Page No. 01
PREPARED BY: APPROVED BY: ISSUED BY:
Subhrajit Mohapatra HOD : T K Chakraborty HOD (ISO & TPM) Vinit Kumar

Reheating Furnace Hydraulic Equipment:

In reheating furnace hydraulic cylinders are installed at Kick off device (4 cylinders), Walking
beam (3 cylinders).
1. Check the tightness of Hydraulic line pipe clamps and hose fittings.
 Check the tightness of clamp bolts and hose fittings by using proper ring or DE spanners
as per site requirement.
 Tightening to be done in clock wise rotational direction.
 Do not use any extension to the spanners in order to avoid over tightness or slip of thread.
 While tightening the hose fittings if there is any leakage observed then note in defect
register. Appropriate action to be taken in the next possible shut down.
2. Clean the hydraulic cylinders for observing the minute leakages
 Clean the hydraulic cylinder with cloth, observe any seepage leakage. If found note it in
defect register. Appropriate action to be taken in the next possible shut down.
3. Check tightness of hydraulic cylinder fasteners and cylinder mounting fasteners
 Tighten the hydraulic cylinder body fasteners and mounting fasteners by using Allen key,
spanners etc.
4. Grease the hydraulic cylinders tunion bearings.
 Grease the hydraulic cylinder tunion bearings with the help of grease pump. EP-2 grease
should be used.
5. Check for any hydraulic leakage from the hyd. Cylinder cushioning adjusting point.
 Cushioning point should be carefully observed for any hydraulic leakage. If case of any
leakage try to arrest the leakage by tightening the check nut. In case leakage still exist
then note it in defect register. Appropriate action to be taken in the next possible shut
down.

Reheating Furnace Grease lubrication:

In reheating furnace centralized greasing is done to the plummer block of charging roller table,
discharging roller table, kick off device wheel, walking beam wheel and sliding mechanism of buffer.
1. Check the tightness of grease line pipe clamps and end fittings.
 Check the tightness of clamp bolts and grease fittings by using proper ring or DE
spanners as per site requirement.
 Tightening to be done in clock wise rotational direction.
 Do not use any extension to the spanners in order to avoid over tightness or slip of thread.
  While tightening the grease line fittings if there is any leakage observed then arrest the
leakage by changing the ferrule. Before opening the joint see the grease pump restart
time, or wait for the pause delay time. (Pause delay time is 1 Hr.)
2. Check proper quantity of grease is reaching to the end points(required greasing point)
 This operation to be carried out in short shut down. Grease point before plummer block
to be opened and observe grease is coming out or not. In case of no grease change the
grease distributer. The defect grease distributer to be overhauled offline and kept in store
for next time use.

Reheating Furnace Cooling water system:

In Reheating furnace cooling water system is supplied to walking beam, kick off device mechanism,
charging roller table, discharging roller table, Buffer, Doors.
1. Check the hoses and pipe line condition of cooled equipment for any joint leakages
 Check the water leakage from the pipe line, hose fitting, rotary union. For hose fitting
leakage tighten the hose swivel nut. For other leakage note it in defect register.
Appropriate action to be taken in the next possible shut down.

Reheating Furnace Door mechanism:

In Reheating furnace there are 3 nos. of doors. Charging, discharging and inspection door.
1. Door mechanism should be checked so that the doors opens and closes properly without
excessive force or noise.

Reheating Furnace Charging and Discharging roller table

In Reheating furnace there are 10 charging roller and 09 discharging rollers.

1. Check the oil level in the gear box, Visual inspection and take appropriate action.
 Take work permit to stop the gear motor of charging and discharging roller as per the
production plan.
 Open the over flow plug with Allen key.
 If oil level is up to the over flow point, oil level is OK. Close the plug.
 If oil level is not up to the over flow point then refill gear oil ISO VG 220 through filling
point up till oil reaches over flow point.
2. Check for any excessive vibration or abnormal noises.
 During running condition observe for any abnormal noise or vibration in gear motor, for
any abnormality situation discuss with electrical or other seniors
3. Greasing of rotary Union.
 Greasing of rotary union with the help of grease pump using EP-2 grease.
4. Check tightness of Rotary Union.
 Charging roller table rotary union is left hand thread so tightness to be done anti-clock
wise direction with DE spanner.
 Discharging roller table rotary union is right hand thread so tightness to be done clock
wise direction with DE Spanner.
Reheating Furnace Pneumatic system

1. Oil Level Checking in lubricator & refilling if required

 Check oil level in lubricator bowl if oil level is at min. level then refill servo system 32
oil to the bowl.
 Before opening the bowl for refilling oil shut off the pneumatic line input valve.
2. Check the tightness of Pneumatic line pipe clamps and hose fittings.
 Check the tightness of clamp bolts and hose fittings by using proper ring or DE spanners
as per site requirement.
 Tightening to be done in clock wise rotational direction.
 Do not use any extension to the spanners in order to avoid over tightness or slip of thread.
 Check the air leakage from the pipe line. Note it in defect register. Appropriate action to
be taken in the next possible shut down.
Reheating Furnace Kick off machine

1. Check the bolt tightness.

 Check the bolt tightness by using proper DE and Ring spanner.
 Tightening to be done in clock wise rotational direction.
2. Check the sliding door movement and door guide plate condition.
 Carefully observe the movement of sliding door for it’s up and down motion. If found
any abnormality note it in defect register. Appropriate action to be taken in the next
possible shut down.

Reheating Furnace Blowers

1. Check the coupling condition.

 Check the coupling condition of blower which is in offline.
 Tighten the coupling bolts.
2. Observe the temperature and vibration of Drive End and Non Drive End plummer block
 Check the temperature of DE and NDE plummer block note it in the observation sheet.
3. Greasing of drive and non drive end plummer block(4000 Running Hours)
 Greasing of Drive and non drive end plummer block with the help of grease pump using
EP-2 grease.
4. Check and if required rectify function of damper's actuator.
 Check the damper movement with respect to the actuator opening and closing, correct if
there is any obstruction in damper movement(free the damper movement.)
5. Grease to damper shaft bearings.
 Greasing of Damper shaft bearing with the help of grease pump using EP-2 grease.
6. Check the bolt tightness
 Check the bolt tightness by using proper DE and Ring spanner.
 Tightening to be done in clock wise rotational direction.
Reheating Furnace Skid

1. Inspect that bolts are tighten and there is no excessive vibration or noise.
 Check the bolt tightness by using proper DE and Ring spanner.
 Tightening to be done in clock wise rotational direction.