This document outlines the standard operating procedure for preventative maintenance of a 33KVA transformer. It details the inputs, responsibilities, description of activities, and outputs of the preventative maintenance process. Key steps include developing a maintenance schedule, isolating the transformer, inspecting and cleaning it, checking components, replacing parts as needed, and documenting the maintenance in logs upon completion. The goal is to properly maintain transformer equipment through regularly scheduled preventative maintenance.
This document outlines the standard operating procedure for preventative maintenance of a 33KVA transformer. It details the inputs, responsibilities, description of activities, and outputs of the preventative maintenance process. Key steps include developing a maintenance schedule, isolating the transformer, inspecting and cleaning it, checking components, replacing parts as needed, and documenting the maintenance in logs upon completion. The goal is to properly maintain transformer equipment through regularly scheduled preventative maintenance.
This document outlines the standard operating procedure for preventative maintenance of a 33KVA transformer. It details the inputs, responsibilities, description of activities, and outputs of the preventative maintenance process. Key steps include developing a maintenance schedule, isolating the transformer, inspecting and cleaning it, checking components, replacing parts as needed, and documenting the maintenance in logs upon completion. The goal is to properly maintain transformer equipment through regularly scheduled preventative maintenance.
This document outlines the standard operating procedure for preventative maintenance of a 33KVA transformer. It details the inputs, responsibilities, description of activities, and outputs of the preventative maintenance process. Key steps include developing a maintenance schedule, isolating the transformer, inspecting and cleaning it, checking components, replacing parts as needed, and documenting the maintenance in logs upon completion. The goal is to properly maintain transformer equipment through regularly scheduled preventative maintenance.
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Standard Operating Orient Refractories Limited
Procedure Issue No.01 Rev No.00 Issue date:1st Jan 2016 Revision Date: 1st Jan SOP Doc No.: ORL/EM/SOP/07 2016 Department: Electrical Activity: Preventive Maintenance Maintenance of 33KVA Transformer
Title : SOP for Preventive Maintenance of Transformer
PURPOSE:To carry out Preventive Maintenance of 33KVA Transformer
SCOPE: All Electrical Maintenance activities carried out by Electrical Department
Input : Sl. No. Inputs Source 1. Preventive Maintenance Schedule Electrical Maintenance 2. Equipment History Card Electrical Maintenance 3. Tool Set Electrical Maintenance 4. Spares Electrical Maintenance 5. Consumables (Cotton cloth) Electrical Maintenance 6. Transformer oil checking & change Store and Electrical Maintenance 7. Silica Gel checking & change Electrical Maintenance 8. Winding resistance checking ( By Electrical Maintenance Meggar) 9. Cleaning of transformer Electrical Maintenance 10. I/P & O/P Terminal checking Electrical Maintenance 11. Tap changer mechanism checking Electrical Maintenance 12. PPE (Gloves, Helmet, Shoes, Electrical Maintenance Goggles etc.) 13. Transformer Manuals Electrical Maintenance 14. Quality Manual, EMS Manual, QMS and EMS Document issued to Process flow chart department 15. Formats, Files, Check lists, Log As issued to department Books and Registers RESPONSIBILITY: Sl. No. Activity Responsibility 1. Finalization of Preventive Maintenance HOD/Sr. Manager/ Manager Schedule and assignment of Duties 2. Carrying out of Maintenance Activities Charge Hand and Electrician 3. Issue of Spares and Consumables Dy. Manager/ Sr. Foreman/ Asst. Foreman/ Supervisor 4. Receipt of Completion Certificate HOD/Sr. Manager/ Manager 5. Filling of Records & log book Supervisor /Shift Charge Hand
DESCRIPTION OF ACTIVES: 1. Preventive Maintenance 1. The Preventive maintenance schedule taken by electrical HOD/ Sr. Manager/ Manager. 2. Electrical HOD/ Sr. Manager/ Manager identify the actual schedule of the Prepared by(HOD) Approved By (Head-Opn) Issued by(M R-QMS)
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Standard Operating Orient Refractories Limited Procedure Issue No.01 Rev No.00 Issue date:1st Jan 2016 Revision Date: 1st Jan SOP Doc No.: ORL/EM/SOP/07 2016 Department: Electrical Activity: Preventive Maintenance Maintenance of 33KVA Transformer
preventive maintenance and assign the appropriate electrical person to carry out the job. 3. Shift Charge Hand/Electrician prior to starting any job, displays the board, “Transformer under Preventive Maintenance” on the Equipment and switch’ “OFF” the power of the transformer. 4. Connect the HT power cable to Earth through appropriate cable. 5. Shift Charge Hand/Electrician properly cleans the Transformer working area. 6. Appropriate tools for carrying out the maintenance activities are taken by the Shift Charge Hand/Electrician. 7. Electrical HOD/ Sr. Manager/ Manager based on the requirements identify appropriate spares and consumables gets it issued from the store by filling up the indent. 8. As per the requirement machine electrical drawings are taken by the Sr. Foreman/Supervisor from the electrical department. 9. For this appropriate work instruction as given of annexure to this SOP are used for carrying out maintenance activities such as Dismantling of HT Equipment, (Annexure 5), Assembly of HT Equipment (Annexure 6). 10. Electrical HOD/ Sr. Manager/ Manager ensures that the charge hand/electrician and other personnel involved in this activity wears required PPEs (HT Gloves, Helmet, Shoes, and Mouth Mask, etc.). 11. After preventive maintenance job completion checks the Transformer. 12. If the Transformer is working properly, removes the Board “Transformer under Preventive Maintenance” from the panel. 13. Collect all used items (such as used cloth, removed damage spare parts etc.) from the yard and dispose in the proper identified areas. 14. The waste generated from the maintenance activities is managed as per OCP on waste management/ Hazardous waste management. 15. The signature of electrical HOD/ Sr. Manager/ Manager is obtained after maintenance job completion for closing preventive schedule. 16. Details in the log book and respective equipment’s history cards are recorded by Supervisor /Shift Charge Hand. 17. Transformer check list is properly filed-up for further record in the designated file.
CROSS REFERENCE :
Aspect impact document no. AI/EL/06
Annexure 1 - Work Instruction for Dismantling of Equipment Annexure 2 - Work Instruction for Assembly of Equipment Annexure 3 - Work Instruction for Welding Annexure 4 - Work Instruction for Cutting Annexure 5 - Work Instruction for Grinding Annexure 6 - Work Instruction for Lubrication
Prepared by(HOD) Approved By (Head-Opn) Issued by(M R-QMS)
Signature Signature Signature
Standard Operating Orient Refractories Limited Procedure Issue No.01 Rev No.00 Issue date:1st Jan 2016 Revision Date: 1st Jan SOP Doc No.: ORL/EM/SOP/07 2016 Department: Electrical Activity: Preventive Maintenance Maintenance of 33KVA Transformer
Annexure 7 - Work Instruction for Change of Oil
Output: Sl. No. Output Location 1. Maintained Equipment Electrical Departments 2. Filled Formats, Files, Check lists and Electrical Department Registers 3. Logs and History Cards Electrical Department
Annexure 1 Work Instruction for Dismantling of Equipment
1. Shutdown of machine/equipment in consultation with the user department’s authorized
person. 2. Shutdown of electrical panel of the equipment. 3. Display of equipment under electrical maintenance tag. 4. Appropriate tools for carrying out the maintenance activities are taken. 5. Ensures that the supervisor/chargehand/electrician personnel involved in this activity. 6. Based on the requirements appropriate equipment/spares dismantling to be carried out.
Prepared by(HOD) Approved By (Head-Opn) Issued by(M R-QMS)
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Standard Operating Orient Refractories Limited Procedure Issue No.01 Rev No.00 Issue date:1st Jan 2016 Revision Date: 1st Jan SOP Doc No.: ORL/EM/SOP/07 2016 Department: Electrical Activity: Preventive Maintenance Maintenance of 33KVA Transformer
Annexure 2 Work Instruction for Assembly of Equipment
1. Assembly of the Equipment.
Shutdown of machine/equipment in consultation with the user department’s authorized
person. Shutdown of electrical panel of the equipment. Display of equipment under electrical maintenance tag. Appropriate tools for carrying out the maintenance activities are taken. Ensures that the supervisor/chargehand/electrician personnel involved in this activity wears required PPEs (Gloves, Helmet, Shoes, and Mouth Mask etc.) Based on the requirements appropriate equipment/spares assembly to be carried out.
2. Test Run of the Equipment.
Clean the equipment which to be maintain. Appropriate tools for carrying out the maintenance activities are taken. Ensures that the supervisor/chargehand/electrician personnel involved in this activity wears required PPEs (Gloves, Helmet, Shoes, and Mouth Mask etc.) Ensure that all connections have been screwed tight again. Check that all materials, tools, equipment, etc. that were required for maintenance and repair work been removed from the materials testing machine's working area. Ensure all safety devices such as MCB, Breakers, limit switches, proximity switches and the materials testing machine's EMERGENCY OFF button in perfect working order. Ensure all of the above work must be first correctly done free of error before the materials testing machine is to be used by the operating personnel.
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Standard Operating Orient Refractories Limited Procedure Issue No.01 Rev No.00 Issue date:1st Jan 2016 Revision Date: 1st Jan SOP Doc No.: ORL/EM/SOP/07 2016 Department: Electrical Activity: Preventive Maintenance Maintenance of 33KVA Transformer
Annexure 3 Work Instruction for Welding
1. Check the Welding cable for good condition and not to create a tripping hazard. 2. Keep area clean and free of grease, oil and other flammable material. 3. Before welding work make a visual inspection of all equipment for damage. 4. Ensure the earthen cable is properly fixed. 5. Check that the area is well ventilated and fume extracting passes available. 6. Faulty equipment not to be used. Immediately report suspect equipment to Supervisor/ Shift Incharge. 7. Carry out the Welding activity is carried out with appropriate welding electrode as per the fabrication drawing/ sample. Ensure proper current setting as per the welding requirement. Sl. No Type of Welding Type of Current Range Remarks recommended welding electrode
8. Ensure proper Fire Fighting equipment and Guard person as per the requirement. 9. Wear required PPEs (Gloves, Helmet, Shoes, and Mouth Mask, Goggles etc.). 10. HOD/supervisor checks and signs for work completion in the check-sheet. 11. Hang up welding cable and screen properly on the stand after completion of activity. 12. Complete the respective equipment logs, history cards
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Signature Signature Signature
Standard Operating Orient Refractories Limited Procedure Issue No.01 Rev No.00 Issue date:1st Jan 2016 Revision Date: 1st Jan SOP Doc No.: ORL/EM/SOP/07 2016 Department: Electrical Activity: Preventive Maintenance Maintenance of 33KVA Transformer
Annexure 4 Work Instruction for Cutting a. Check the Gas hoses for good condition and not to create a tripping hazard. b. Keep area clean and free of grease, oil and other flammable material. c. Before lighting up make a visual inspection of all equipment for damage. d. Check that the area is well ventilated and fume extracting passes available. e. Do not use Faulty equipment. Report suspect equipment to Supervisor/Shift Incharge. f. Carry out Gas Cutting activity as per the drawing/sample/ instruction from supervisor. Ensure proper flame setting. g. Ensure availability of proper Fire Fighting equipment and Guard person as per the requirement. h. Wear required PPEs (Gloves, Helmet, Shoes, and Mouth Mask, Goggles etc.). i. Supervisor checks the work completion and signs on the check-sheet. j. Hang up welding blowpipe and hoses properly on the trolley stand after completion of activity. k. Complete respective equipment logs, history cards after completion of work.
Prepared by(HOD) Approved By (Head-Opn) Issued by(M R-QMS)
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Standard Operating Orient Refractories Limited Procedure Issue No.01 Rev No.00 Issue date:1st Jan 2016 Revision Date: 1st Jan SOP Doc No.: ORL/EM/SOP/07 2016 Department: Electrical Activity: Preventive Maintenance Maintenance of 33KVA Transformer
Annexure 5 Work Instruction for Grinding
1. Use only in designated grinding area and erects screens if necessary.
2. Wears required PPEs (Gloves, Helmet, Shoes, and Mouth Mask, Goggles etc.). 3. Check the power cord, extension lead, plugs, sockets and power outlet for damage. 4. Ensure that the grinding disc, guard and attachments (including handle) are secure and correctly fitted. 5. Inspect the grinding disc for damage. Do not use damaged grinding disc. 6. Always inspect the work piece to ensure that there aren’t any items which might damage the grinding wheel or cause injury to the operator. 7. Secure and support the work piece using clamps, bench vices, etc. 8. Keep fingers and hands & power cords clear of the grinding disc. 9. Never make adjustments while the angle grinder is running. 10. Do not switch off the angle grinder when it is under load, except in an emergency. 11. Allow angle grinder to reach operating speed before applying to work piece & increase load gradually. 12. Do not lift or drag angle grinders by the cord. 13. Keep flexible electrical cords clear of oil, grease, machines and sources of heat. 14. Be aware of flying sparks. Hold grinder so that sparks fly away and flammable materials. 15. Do not leave the angle grinder running & only use the grinder when hand held. 16. Do not touch the work piece immediately after grinding operation as it may be extremely hot. 17. Clean bench and work area & place all waste material in bin. 18. Return angle grinder & rolled up extension leads to storage area. 19. Complete respective equipment logs, history cards after completion of work.
Prepared by(HOD) Approved By (Head-Opn) Issued by(M R-QMS)
Signature Signature Signature
Standard Operating Orient Refractories Limited Procedure Issue No.01 Rev No.00 Issue date:1st Jan 2016 Revision Date: 1st Jan SOP Doc No.: ORL/EM/SOP/07 2016 Department: Electrical Activity: Preventive Maintenance Maintenance of 33KVA Transformer
Annexure 6 Work Instruction for Lubrication
Prepared by(HOD) Approved By (Head-Opn) Issued by(M R-QMS)
Signature Signature Signature
Standard Operating Orient Refractories Limited Procedure Issue No.01 Rev No.00 Issue date:1st Jan 2016 Revision Date: 1st Jan SOP Doc No.: ORL/EM/SOP/07 2016 Department: Electrical Activity: Preventive Maintenance Maintenance of 33KVA Transformer
Annexure 7 Work Instruction for Change of Oil
Prepared by(HOD) Approved By (Head-Opn) Issued by(M R-QMS)
