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Boiler: Reliance Sugar and Chemical Industries PVT - LTD

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Reliance sugar and chemical industries pvt.ltd.

List of maintenance jobs


BOILER
working man power required
1 Bagasse elevator No.1 date days group wise work
Dismantling of rake & chain from site 10march-17march 7
Dismantling of chain componenets 25march-30march 5
sonelal ram, nabi alam, +1helper
Cleaning & checking of chain components 14april-16april 2
Assembly of chain components 3 17day-3manpower
Repair of rakes 2may-3may 1
Replacement of worn out runner & trough plates 3may-5may 2
dhirendra kushwaha, +1helper
Overhauling of head & tail shaft 6may-9may 3
Overhauling of drive units 10may-12may 3 9days-2manpower
Assembly of chain & rake at site 10 10days-4manpower sonelal ram, nabi alam, +2 helper
Fitting of drive & allignmet 2 2days-2manpower dhirendra kushwaha, +1helper
Trial 38
2 Bagasse elevator no.2
Dismantling of rake & chain from site 12march-22march 10
Dismantling of chain componenets 30marc-9april 8
sonelal ram, nabi alam, +1helper
Cleaning & checking of chain components 16april-19april 3
Assembly of chain components 5 26days-3manpower
Repair of rakes 13may-14may 1
Replacement of worn out runner & trough plates 15may-17may 3
dhirendra kushwaha, +1helper
Overhauling of head & tail shaft 18may-21may 4
Overhauling of drive units 21may-24may 4 12days-2manpower
Assembly of chain & rake at site 15 15days-4manpower sonelal ram, nabi alam, +2 helper
Fitting of drive & allignmet 2 2days-2manpower dhirendra kushwaha, +1helper
Trial 55
3 Excess bagasse carrier
Dismantling of rake & chain from site 15march-23march 8
Dismantling of chain componenets 9april-14april 5
sonelal ram, nabi alam, +1 helper
Cleaning & checking of chain components 19april-21april 2
Assembly of chain components 3 18days-3manpower
Repair of rakes 25may-26may 1
Replacement of worn out runner & trough plates 27may-28may 2
dhirendra kushwaha, +1helper
Overhauling of head & tail shaft 29may-3june 5
Overhauling of drive units 4june-7june 4 12days-2manpower
Assembly of chain & rake at site 10 10days-4manpower sonelal ram, nabi alam, +2 helper
Fitting of drive & allignmet 2 2days-2manpower dhirendra kushwaha, +1helper
Trial 42
4 Main Bagasse Carrier
Dismantling of rake & chain from site 15
Dismantling of chain componenets 10
sonelal ram, nabi alam, +2 helper
Cleaning & checking of chain components 5
Assembly of chain components 10 40days-4manpower
Repair of rakes 2
Replacement of worn out runner & trough plates 3
dhirendra kushwaha, +1helper
Overhauling of head & tail shaft 6
Overhauling of drive units 10 21days-2manpower
Assembly of chain & rake at site 15 15days-2manpower sonelal ram, nabi alam, +2 helper
Fitting of drive & allignmet 4 4days-2manpower dhirendra kushwaha, +1helper
Trial 80
5 Return bagasse carrier
Dismantling of rake & chain from site 20
Dismantling of chain componenets 10 sonelal ram, nabi alam, +2 helper,
Cleaning & checking of chain components 5 khalasi
Assembly of chain components 10 45days-4manpower
Repair of rakes 2
Replacement of worn out runner & trough plates 4
dhirendra kushwaha, +1helper
Overhauling of head & tail shaft 12
Overhauling of drive units 10 28days-2manp[ower
Assembly of chain & rake at site 15 15days-4manpower sonelal ram, nabi alam, +2 helper
Fitting of drive & allignmet 6 6days-2manpower dhirendra kushwaha, +1helper
Trial 94
6 Surplus bagasse carrier
Dismantling of rake & chain from site 20
Dismantling of chain componenets 10 sonelal ram, nabi alam, +2 helper,
Cleaning & checking of chain components 5 khalasi
Assembly of chain components 10
Repair of rakes 2
Replacement of worn out runner & trough plates 4 dhirendra kushwaha, +1helper, khalasi,
Overhauling of head & tail shaft 8 welder
Overhauling of drive units 10
Assembly of chain & rake at site 12 sonelal ram, nabi alam, +2 helper
Fitting of drive & allignmet 4 dhirendra kushwaha, +1helper
Trial 85
7 Boiler no.1 (IJT)
Dismantling of valves 15march-18march 3
Overhauling of mountings 18march-18may 60
dhramnath yadav, rambilash kushwaha,
Overhauling of steam stop valves & NRV 18may-26may 8
ramanand kushwaha, +3 helper
Overhauling of accessories 26may-02june 6
Overhauling of gauge glasses 02june-08june 6
Chemical cleaning
Mechanical cleaning of tubes
External cleaning of boiler contractor job
External cleaning of economizer
internal cleaning of air heater tubes 30
Replacement of leaky & weak tubes september
Dismantling of drum internal 01may-10may 10 rambilash kushwaha ,+3 helper
Hydraulic testing 2
Overhauling of travelling grate drive
Overhauling of Travelling grate head & tail shaft
Overhauling of travelling grate chain & grate bar dhramnath yadav, +4 helper
Overhauling of travelling grate sealing arrangement
Overhauling of travelling grate guides 01june-25aug. 85
Cleaning & painting of ducting
Overhauling of ID fan 11may-16may 6
Overhauling of FD fan 17may-22may 6
Overhauling of SA fan 23may-28may 6 ramanand kushwaha, +1helper, khalasi
Fitting of drive & allignment 28may-04june 6
Trial of fans 2
Overhauling of soot blowers 15 dhramnath yadav, +1 helper
Repair of blow down lines 12sept-14sept. 2 ramanand kushwaha, +1helper, welder
Refractory work in combustation chamber & furnace
contractor job
Repair of baffling
Overhauling of bagasse feeders with drive 4 nos 11may-25may 15 ramanand kushwaha, +1helper, khalasi
O/H of dampers ramanand kushwaha, +1helper, welder
Boiler lighting 1
Assembly of drum internal 15oct-22oct 8 rambilash kushwaha ,+3 helper
Repair of ducting 5
8 Boiler no. 2 282
Dismantling of valves 10
Overhauling of mountings 50
bishwanath neupane, rogai ram, +1
Overhauling of steam stop valves & NRV 8
helper
Overhauling of accessories 10
Overhauling of gauge glasses 10
Chemical cleaning
Mechanical cleaning of tubes
External cleaning of boiler contractor job
External cleaning of economiser
internal cleaning of air heater tubes
Replacement of leaky & weak tubes
Dismantling of drum internal 10
Hydraulic testing
Overhauling of dumping grate furnace 10
Repair of ducting
Cleaning & painting of ducting
harindra sah, awadh kishor giri, rambabu
Overhauling of ID fan 5
yada, +1 helper, khalasi
Overhauling of FD fan 5
harindra sah, awadh kishor giri, rambabu
yada, +1 helper, khalasi

Overhauling of SA fan 5
Fitting of drive & allignment 10
Trial of fans 1
Overhauling of soot blowers 10
Repair of blow down lines 2
Refractory work in combustation chamber & furnace
contractor job
Repair of baffling
Cleaning & painting of chimney
Overhauling of bagasse feeders with drive-3 nos 10 bishwanath neupane, rogai ram, +1
O/H of dampers 5 helper
Boiler lighting
Assembly of drum internal 7
9 Boiler no. 3 168
Dismantling of valves 10march-17march 7
Overhauling of mountings 18march-05may 50
harindra sah, awadh kishor giri, rambabu
Overhauling of steam stop valves & NRV 05may-12may 7
yada, +1 helper
Overhauling of accessories 13may-19may 6
Overhauling of gauge glasses 20may-30may 10
Chemical cleaning
Mechanical cleaning of tubes
External cleaning of boiler contractor job
External cleaning of economiser
internal cleaning of air heater tubes
Replacement of leaky & weak tubes
Dismantling of drum internal 30may-10june 10
Hydraulic testing september
Overhauling of dumping grate furnace 1aug-10aug 10
Repair of ducting
Cleaning & painting of ducting
bishwanath neupane, rogai ram, +1
Overhauling of ID fan 11june-16june 5
helper, khalasi, welder
Overhauling of FD fan 16june-21june 5
Overhauling of SA fan 21june-26june 5
Fitting of drive & allignment 15aug-25aug 10
Trial of fans
Overhauling of soot blowers 1aug-10aug 10
Repair of blow down lines 10aug-12aug 2
Refractory work in combustation chamber & furnace
contractor job
Repair of baffling
Cleaning & painting of chimney
Overhauling of bagasse feeders with drive-3 nos 26june-05july 10
O/H of dampers 5july-10july 5 harindra sah, awadh kishor giri, rambabu
Boiler lighting yada, +1 helper
Assembly of drum internal 7
10 Feed water system 159
Overhauling of valve feed tanks 10
Overhauling of valve deareator 23june-30june 7
Overhauling of valve feed pumps 30june-20july 20
Overhauling of boiler feed pump 6 nos 40
Overhauling of HP dosing pump 2 nos 10 rambilash kushwaha ,+1 helper
Overhauling of LP dosing pump 2 nos 10
Cleaning & painting of feed tank & dearator tank 20july-15august 25
Overhauling of feed water transfer pumps 2 nos 8
Fitting of drive & allignment 10
11 Steam header (IJT) 140
Overhauling of steam distribution header valves
Overhauling of steam line main valves
Overhauling of drain valves at header
dhramnath yadav, +1 helper
Overhauling of drain valaves in steam lines
Overhauling of drain valves in Ex/vapour line
Overheater of desuper heater valves 8june-23june 15
12 Steam Header(Tex)
Overhauling of steam distribution header valves
Overhauling of steam line main valves
Overhauling of drain valves at header bishwanath neupane, harindra sah, rogai
Overhauling of drain valaves in steam lines ram

35
bishwanath neupane, harindra sah, rogai
ram
Overhauling of drain valves in Ex/vapour line
Overheater of desuper heater valves 35
DM-Plant 60 upendra yadav,+1 helper
bagasse carrier post
1 sonelalram asst.fitter
2 nabi alam operator

3 dhirendra kushwaha asst.fitter


4 rambabau yadav welder
ijt boiler
5 rambilash kushwaha attendent
6 dhramnath yadav attendent
7 ramanand kushwaha attendent
8 satrudhan chaurasiya fireman

texmaco boiler
11 bishwanath neupane fitter
12 harindra sah fitter
13 rambabu yadav attendent
14 awadh kishor giri attendent
15 rogai ram attendent
16 shambhu yadav welder/feedpump
17 nagendra yadav supervisor
18 upendra yadav dm- incharge
19 anil tiwari khalasi
Reliance Sugar And C
Boiler House Equipment statu
S.n Equipments Name Running Problem Occurred Action Taken
Status
1 Bagasse elevator no.1 OK nill
2 Bagasse elevator no.2 OK nill
3 Main bagasse carrier OK mbc bearing damaged bearing changed

4 Return bagasse carrier OK double drive gearbox failure another drive taken in operation

5 Excess bagasse carrier OK 1nos. Rack broken rack replaced by spare


6 Surplus bagasse carrier not in operation

7 Texmaco boiler no.1 OK nill


with accessories

8 Texmaco boiler no.2 OK nill


with accessories

9 Ijt Boiler with OK water level indicator line valve repaired at the time of no cane
accessories leakage,

10 Feed station for IJT and OK nill


Texmaco Boiler
11 RCC chimney OK nill
12 MS chimney OK nill
13 DM plant OK
Reliance Sugar And Chemical Ind.Pvt.Ltd
Boiler House Equipment status with material requirement
Off season job Off season Material Requirement

general repair & mentinance


general repair & mentinance
general repair & mentinance MBC new chain required-200mtrs.,
duplex chain required

general repair & mentinance duplex chain, gearbox pinion

general repair & mentinance


general repair & mentinance

front wall is to be re-construction, refactory work,


insulation work, tube internal & external cleaning, drum
internal reparing work ( with general repair &
mentinance)

front wall is to be re-construction, refactory work,


insulation work, tube internal & external cleaning, drum
internal reparing work ( with general repair &
mentinance)

primary & secondary APH tube is to be chanced, APH tube, ss plate, valves
dearotar tank is to be repaired, refactory work,
insulation work, tube internal & external cleaning, drum
internal reparing work ( with general repair &
mentinance)

general repair & mentinance blancing dish, o-ring, bearings

servecing required
Seasonal Material requirement Remarks
Chain and chain spares
S.N Marerial Specification Requirement Unit Storestock Remarks
1 Pin for bagasse carrier 2000 Pcs
2 Bush for bagasse carrier 3500 Pcs
3 Roller for bagasse carrier nill Pcs
4 Split pin
a (ms)6x40mm 2000 Pcs bagasse carrier
b (ms)8x50mm 6000 Pcs For bagasse carrier
c SS 6x32mm 1000 Pcs For travelling grate chain
Special washer 1000
5 drive chain for MBC & 2.5"pitch 18 mtrs
RBC
6 drive chain for MBC & 2.5" pitch 15 pcs
RBC master link
7 chain for MBC 6" pitch 200 mtrs.
Packing and joint
1 Boiler
a. Gland packing metallic
3mm 4 roll
4mm 4 roll
5mm 4 roll
6mm 10 roll
8mm 6 roll
10mm 4 roll
12mm 4 roll
Joint sheet metalic
1.5mm 2 sheet
3mm 5 sheet
5mm 4 sheet

Refactory Items
firecrete super cement 7000 kg
calundun 2000 kg
accoset-50 1500 kg

oil seal for gearbox


60*80*10 8 pics.
42*63*9 14 pics.
42*63*10 14 pics.
175*250*37 10 pics.
52*70*10 10 pics.
35*60*12 8 pics.
50*70*10 10 pics.
35*57*10 10 pics.
45*55*7 10 pics.
32*42*7 10 pics.
250*300*37 8 pics.
250*375*50 8 pics.
100*135*13 8 pics.
65*90*13 8 pics.

copuling items
tyre for copuling
ph-292 2 pics.
ph-190 1 pics.
ph-250 2 pics.
ph-390 1 pics.
ph-126 6 pics.
tc-011 2 pics.
tc-09 2 pics.
valves items
diaphragm rubber sheet
25mm 10 pics.
40mm 12 pics.
50mm 8 pics.
gate valve size- 6 pics.
20NB,class-
800, schocket
welded type
gate valve size-1/2",class- 8 pcs
800
steam trap 1/2"- 10 pcs

gate valve size-1",class- 5 pics.


800, schoket
welded type
welding electrode
superbond ss no.10 10 kg
superbond ss no.12 20 kg
Tube cleaning items
flexible shaft 10mtrs. 8pcs
15mtrs 4pcs
s.no work is to be done
IJT boiler primary & secondary APH tube is to be changed. ( Tube size
1 63.5 mm OD, 2.03 mm THK, 2.57 mtr Length, 990 x2 nos), Material:-
BS 1775/64/ERW 11

2 IJT boiler furnace internal 'SS'-plate is to be changed


3 blow down line is to be changed
4 DM-plant servecing work is to be done
5 both texmaco boiler front wall re-construction work is to be done
6 mechanical cleaning work of all boiler tubes is to be done
7 refactory work of all boiler is to be done
8 insulation work of all heat loss area is to be done
9 elevetor no.2 double drive is to be installed
10 de-airator tank related all work is to be done
11 required instrumentation is to be installed
12 steam flow meter in fibriser turbine steam line is to be installed
13 steam flow meter in 3mw power turbine steam line is to be installed
14 RBC damaged gear is to be repaired
15 RBC & MBC drive area shade covering work is to be done
16 Ash handling system to be equiped with pneumatic cylinder & belt
conveyour

IBR Schedule-40 seamless pipe size-20 mm - 18 mtr, size-1/2"-


17 60mtrs
18 21-1 kg/cm2 saftey valve is to be installed
19 21-7 kg/cm2 saftey valve is to be installed

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