FG#6-MHS SHUTDOWN POST-MORTEM REPORT

(FROM 07/10/23 TO 15/10/23)

JOJOBERA CEMENT PLANT
 SHUTDOWN HIGHLIGHTS
•SAFETY – SHUTDOWN COMPLETED WITHOUT ANY MEDICAL INJURY,LTI
•NO MAJOR NON-COMPLIANCE REPORTED INSPITE OF LARGE NUMBER OF EXTERNAL
WORKFORCE DEPLOYMENT
1)FAI- 0 Nos
2)Near Miss during shutdown : - High - 0 Nos , Medium – 0 Nos, Low - 4 Nos.

•Total Job :
Mechanical:- Planned jobs- 89 nos. Actual Jobs- 46nos. , Completion – 52%
•VERTICAL START-UP OF PLANT

•Shutdown Days :
Planned: 06 days Actual: 09 days
Shutdown Planning VS Achieved Status for FG#6 MHS

FG#6 MHS Major Shutdown Job Planning

Sr. Equipment No Work Details Resources required Support
No required Material Availabilty Status

1. Reclaimer all three set sprocket replacement. 1. 2 set available, 1 set to be

2. Chain guide repair and replacement. replaced from old discraded 1. Not Completed
3. Chain link repair/replacement segment. 2. Completed
4. Bucket replacement/repair. 2. 3. Completed.
1 463 QR06 4. Completed.
5. All housing inspection 1. 16 mm plate- 3 ton. 3. Available.
6. All shaft UT testing. 4. 75 nos new available, 5. Not Completed
2. Buckets for replacement. 6. Not Completed
7. Sheave assembly greasing and inspection. 3. All rollers availability. rest to be repaired from old
8. Fron wheel bogie repair and replacement. ones. 7. Completed.
4. Ceramic Legging 8. Completed.
1. Return roller replacement. 1. Completed.
2 463 BC 08 2. Take up and Bend pulley legging. 2. Completed.
3. All damaged rollers replacement. 3. Completed.
4. Side skirt assy with rubber repair/replacement. 4. Not Completed

1. Screen Mesh replacement. 1. Completed.

3 463 VS 12 2. Mesh mounting frame repair. 2. Not Completed
3. Spring inpsection. 3. Completed.
4. Bearing Inspection. 4. Completed.
5. Side skirt rubber replacement of screen discharge. 5. Completed.

1. Belt replacement-155mtr-800mm BW 1. Not Completed

2. Take up and Bend pulley legging. 1. 800mm BW belt availability- 1. As per new lot receiving 2.Not Completed
4 463 BC 14
3. All rollers replacement. 155 mtr. status. 3. Completed.
4. Side skirt assy with rubber repair/replacement. 4. Not Completed
5. Discharge chute repair to BC 20. 5. Completed.
1. Belt replacement-155mtr-800mm BW 1. Completed.
5 463 BC 20 2. Take up and Bend pulley legging. 1. Completed 2. Completed.
3. All rollers replacement. 3. Completed.
4. Side skirt assy with rubber repair/replacement. 4. Not Completed
1. Incoming chute from BC 20 -mirror finish plate fixing.
6 462 BC 02 2. All damaged roller replacement. 1. Mirror finish Plate- 1500X 1. Not Completed
3. Side skirt mother plate modification for spillage control. 4000mm. 2. Completed.
2. MS plate 10/12 mm- 1 ton 3. Not Completed
1. Manual hopper 3 side plate cutting and height shortening
462 BC 02 Manual & Grizzly modification. Production- Area cleaning near
7 2. Manual feed hopper area all roller replacement.
Feed Hopper manual hopper 1. Not Completed
3. Cover plate near manual hopper to be strengthened. 2.Not Completed
3. Not Completed
Shutdown Planning VS Achieved Status for FG#6 MHS
FG#6 MHS Major Shutdown Job Planning
Sr. Equipment Resources Support Material
Work Details Status
No No required required Availabilty
1. Belt replacement-18mtr-1000mm BW 1. Completed
2. Pulley legging. 1. 1000mm BW belt. 2. Completed
8 462 BC 21 3. All damaged rollers replacement. 2. Plate-10/12mm- 3. Completed
4. Side skirt assy with rubber repair/replacement. 0.750ton 4. Completed
5. Incoming chute from BC 02 repair and modification 5. Completed
1. Belt replacement-25mtr-1000mm BW 1. Completed
2. Pulley legging. 1. 1000mm BW belt. 2. Completed
9 462 BC 22 3. All damaged rollers replacement. 2. Plate-10/12mm- 3. Completed
4. Side skirt assy with rubber repair/replacement. 1.5 ton 4. Completed
5. Discharge chute to Slag hopper modification 5. Completed
1. Belt replacement-25mtr-1000mm BW 1. Completed
2. Pulley legging. 2. Completed
3. All damaged rollers replacement. 6. Hardox plate- 3. Completed
10 462 BC 24 1-5 Completed
4. Side skirt assy with rubber repair/replacement. 3000X700m- 2 nos 4. Completed
5. Discharge chute to Clinker hopper modification. 5. Not Completed
6. Incoming chute modification. 6. Not Completed
1. Belt replacement-18mtr-1200mm BW
2. Pulley legging. 1. Completed
3. All damaged rollers replacement. 1. 3.15mm MS 2. Completed
11 462 BC 26
4. Side skirt assy with rubber repair/replacement. plate- .7ton 3. Completed
5. Discharge chute to LD Slag and Gypsum hopper 4. Not Completed
modification 5. Not Completed
1. Belt replacement-30mtr-1000mm BW 1. Completed
2. Pulley legging. 1. 1000mm BW belt. 2. Completed
12 462 BC 15
3. All damaged rollers replacement. 2. MS 12mm- .5 ton 3. Completed
4. Side skirt assy with rubber repair/replacement. 4. Completed
1. All Pulley legging. 1. Not Completed
2. All damaged rollers replacement. 2. Not Completed
13 562 BC 06 3. Side skirt assy with rubber repair/replacement. 1. Completed 3. Not Completed
4. Snub pulley area discharge modification. 4. Not Completed
5. Belt repalcement- 250mtr/800/900mm BW. 5. Not Completed
462 DC 18 &
14
20 Duct Line modification Not Completed
1. All shaft UT testing.(78 No's) 1. Not Completed
15 All conveyors 2. Bearing Housing Inspection and greasing. 2. Not Completed
3. All coupling inspection and greasing if required. 3. Not Completed
1. Belt replacement-35mtr-800mm BW. 1. Not Completed
16 622 BC 06 2. Damaged roller replacement. 2. Not Completed
3. Side skirt rubber replacement. 3. Not Completed
 Shutdown Planning VS Achieved Status for FG#6 MHS
FG#6 MHS Major Shutdown Job Planning
Sr. Support Material
Equipment No Work Details Resources required Status
No required Availabilty

17 622 BC 08 1. Damaged roller replacement. 1. Not Completed.

2. Side skirt rubber replacement. 2. Not Completed.

1. Not Completed.
18 622 BC 10 1. Damaged roller replacement. 2. Not Completed.
2. Side skirt rubber replacement.

1. Not Completed.
19 622 BC 12 1. Damaged roller replacement. 2. Not Completed.
2. Side skirt rubber replacement.

1. All Damaged roller replacement. 1. roller availability of 800,1000 1. Not Completed.

20 All conveyors &1200mm BW conveyors.
2. All side skirt rubber replacement 2. Not Completed.
2. Side skirt roll

1. All Pulley legging.

2. All damaged rollers replacement.
3. Side skirt assy with rubber 1. Not Completed.
21 452 BC 10 repair/replacement. 2. Not Completed.
4. Discharge chute modification. 3. Completed.
5. Snub pulley bearing with housing 4. Not Completed.
repalcement. 5. Completed.
6. Fluid coupling replacement/repair 6. Completed
1. Belt replacement
2. All Pulley legging. 1. Completed.
22 452 BC 28 3. All damaged rollers replacement. 2. Completed.
4. Side skirt assy with rubber 3. Completed.
repair/replacement. 4. Completed.
5. Discharge chute modification 5. Not Completed.
Clinker circuit Dust
23 Duct Line modification Not Completed
collector
 463QR06- RECLAIMER CHAIN AND BUCKET REPLACEMENT
 Objective : To improve Reliability and MTBF of FG#6 MHS feeding circuit.
 Best practices Followed:
1. Safe Execution of Job, Proper sequence of bucket opening followed.
2. Fixing of bucket also done at one place safely.
3. Pneumatic impact wrench & battery operated wrench were used for bucket bolt tightening for
faster execution. Torque tightening was verified by manual torque wrench at 20 buckets.
 Schedule: On schedule (Completed on Time)
 Key Learning :
1. Pneumatic impact wrench & battery operated wrench were used for bucket bolt tightening for
faster execution. Proper sequence of bucket opening followed at both location.
2. All damaged buckets replaced & with 560 nos. new fasteners.
 Improvement Opportunities (Way forward):
1. 65 nos. old bucket used due to only 60 nos new bucket procured and remaing 15 nos new bucket
from previous year procurement used.
2. Buckets fasteners were not provided with lock, it is single nut support. Already intimation given to
planning team.
3. Sprocket segment 3 no’s set to be replaced at one time.
463QR06- RECLAIMER CHAIN AND BUCKET REPLACEMENT

New chain Inserted

 462BC02 DISCHARGE CHUTE MODIFICATIONS
 Objective : To improve Reliability and MTBF of FG#6 VCM.
 Best practices Followed:
1. Safe Execution of Job, Proper tested tools and tackles used during chute modification.
2. Measurements of modifications taken and plate after cutting with proper marking shifted at site.
3. After plate fitting with tack weld, full welding done by one additional welder and parallel fitting
done.
 Schedule: On schedule (Completed on Time)
 Key Learning :
1. Deflection plate extension height to be increased to reduce fall height impact on side skirts.
 Improvement Opportunities (Way forward):
1. Both primary and secondary scraper need to procure to replace in coming opportunity
2. Inserted rubber belts towards back side need to inspect regularly for any damages.
462BC02 DISCHARGE CHUTE MODIFICATIONS

1. Chute plate worn out, and chute plate

modified to act as deflection plate for
material being discharged to 462 BC 21
2. Previously frequent spillage and dust
emission issue.
 462BC22 RECEIVING CHUTE MODIFICATIONS
 Objective : To improve Reliability and MTBF of FG#6 VCM.
 Best practices Followed:
1. Safe Execution of Job, Proper tested tools and tackles used during chute modification.
2. Measurements of modifications taken and plate after cutting with proper marking shifted at site.
3. After plate fitting with tack weld, full welding done by one additional welder and parallel fitting
done.
 Schedule: On schedule (Completed on Time)
 Key Learning :
1. Deflection plate extension height to be increased to reduce fall height impact on side skirts.
 Improvement Opportunities (Way forward):
1. Both primary and secondary scraper need to procure to replace in coming opportunity
2. Inserted rubber belts towards back side need to inspect regularly for any damages.
462BC22 DISCHARGE CHUTE MODIFICATIONS
• Chute increased by 1mtr to avoid
jamming of material in discharge
chute to Slag hopper-
• Previously frequent jam of chute
due to inclination issue.
 THANK YOU
OPERATIONAL
INTEGRITY ENTREPRENEURSHIP COLLABORATION CARE EXCELLENCE