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Sai Wardha Power Limited

Standard MaintenanceProcedure
For HYDRAULLIC SOV TESTING AND
CHECKING
Issue
No: 1

Issue Date:
14.08.2015

Revision:
00

Revision Date:

SWPL/C&I / SMP/I-148

Page 0 of 5

File no:

SAI WARDHA POWER LIMITED, 4X135 MW

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Standard Maintenance Procedure for

HYDRAULLIC SOV TESTING AND CHECKING

SMP/SCP No.

Revision

Date

Remarks / Reason
for Revision

SWPL/C&I / I /SMP

0
1

14.08.2015

AGENCY: McNally Bharat Engineering Company Limited.

Prepared By :
Area In-charge
Name

Pankaj ku.
Pradhan

Reviewed/Chec
ked By :
Dept. Head
G.C.Ghosh

Reviewed/Cleare
d By :
Site Head
R.L.Sanyal

E&I Head

Plant In charge

Signature
Designation

Manager

OWNER : Sai Wardha Power Limited, Warora

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Validated by :
Functional
Head (HO)*

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Sai Wardha Power Limited

Standard MaintenanceProcedure
For HYDRAULLIC SOV TESTING AND
CHECKING
Issue
No: 1

Issue Date:
14.08.2015

Revision:
00

Reviewed
by :
EIC / Dept.
Head

Revision Date:

Reviewed
&/
Approved
by :

File no:

Reviewed &
Approved
by:
Plant Head

Maintenanc
e Head
Name
Signature

1 | Page

Pralhad
Datir

Pralhad
Datir

SWPL/C&I / SMP/I-148

Rohit kumar
Upadhyaya

Reviewed
&
Approved
By :
Functional
Head (HO)

Page 1 of 5

Approved By
: Apex Body

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Standard MaintenanceProcedure
For HYDRAULLIC SOV TESTING AND
CHECKING
Issue
No: 1

Issue Date:
14.08.2015

Revision:
00

Revision Date:

File no:

SWPL/C&I / SMP/I-148

Page 2 of 5

STANDARD MAINTENANCE PROCEDURE

FOR
HYDRAULLIC SOV TESTING AND CHECKING

2 | Page

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Standard MaintenanceProcedure
For HYDRAULLIC SOV TESTING AND
CHECKING
Issue
No: 1

Issue Date:
14.08.2015

Revision:
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Revision Date:

SWPL/C&I / SMP/I-148

File no:

Page 3 of 5

INDEX
1.

Objective

2.

Technical Specification

3.

Responsibility

4.

Reference drawings / Manuals / Standards

5.

Permit- requiring special clearances / Otherwise

6.

Standard Maintenance Procedure-PM

7.

Safety Aspects

8.

Quality Checks / Validation

9.

Dos & Donts

10. Protocols/Records
11. Permit Closure & Trial / Clearance for regular Operation
12. Frequency
13. Conclusion

1.

OBJECTIVE
This Purpose of this document is to detail out the standard maintenance procedure for

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Standard MaintenanceProcedure
For HYDRAULLIC SOV TESTING AND
CHECKING
Issue
No: 1

Issue Date:
14.08.2015

Revision:
00

Revision Date:

File no:

SWPL/C&I / SMP/I-148

Page 4 of 5

setting of mill hydraulic system for establishing dynamic & static pressure, proportional
overflow valve and Directional Valve in Boiler to increase the reliability and ensure the
healthiness of instruments.

2. TECHNICAL SPECIFICATION
MODEL-ATOS E-ATR-6/250 908892
PRESSURE TRANSDUCER TYPE-E-ATR-6/250,
HAD 7446-B-250-110 SIGNAL-0-10V, UB-12-30VDC,
RANGE-0-250BAR
3. RESPONSIBILITY
Area In charge C&I Department (Agency)
1. To apply for permit as per the schedule.
2. Ensure necessary isolations before starting the work.
3. To ensure the completion of the activities as per the SMP and to check all the
parameters as per the check list.
4. Ensure housekeeping after completing the work.
5. Returning the permit.
Shift Manager Operation
1. To ensure availability of the equipment for maintenance as per planned time interval.
2. To ensure issuance of Work Permit complying with the safety requirements as
required.
3. To ensure Isolations done as per SOP.
4. Cancellation of the Work Permit after completion of the work.
5. Normalization of the system and trial run.
3.

REFERENCE DRAWINGS / MANUALS / STANDARDS

OEM Manuals : ATOS E-ATR-6/250 908892

4.

PERMIT Requiring special clearances / Otherwise

Not required

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Standard MaintenanceProcedure
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Issue
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5.

Issue Date:
14.08.2015

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Revision Date:

SWPL/C&I / SMP/I-148

File no:

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STANDARD MAINTAINENCE PROCEDURE

Physical status

Physical observation of steady/variable pressure.

Check the Steady/variable mode SOV

Check the Roller up/down SOV

Check the proportional valve status.

ACTIVITY 1: Setting of Static Loading Pressure

Proportional Valve MCB ON (24 VDC).

Local mode selected.

Oil Level Ok (equal to Hi or Less than Hi but not low).

Lifting lever of manual diverter valve perpendicular to it.

Loading mode in control panel invariable mode.

Adjust the system Pressure by setting the relief valve (R1) at the discharge
of pump and top in manual diverter valve assembly at 190 kg/cm2.

Take the loading mode to invariable or static mode from local panel.

Slowly adjust the relief valve (R4) below magnetic diverter valve so that
the static pressure comes to the desired set pressure.
ACTIVITY 2: Setting of Roller Lifting Pressure

Proportional Valve MCB ON (24 VDC).

Local mode selected.

Oil Level Ok (equal to Hi or Less than Hi but not low).

Lifting lever of manual diverter valve in centre position.

Loading mode in control panel in variable mode.

Lever L1 to manual diverter valve assembly.

Adjust the bottom relief valve (R2) in manual diverter valve assembly to
increase/decrease the roller lifting pressure. It should be set at 80 Kg/cm2.
ACTIVITY 3: Setting of Dynamic Loading Pressure

5 | Page

Proportional Valve MCB on.

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Standard MaintenanceProcedure
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Issue
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Issue Date:
14.08.2015

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Local mode selected.

Oil Level Ok (equal to Hi or Less than Hi but not low).

Lifting lever of manual diverter valve perpendicular to it.

Loading mode in control panel variable mode.

Open the driver card of the proportional valve assembly and unfold it to
view all the setting pots.

Give 0% command from DCS and adjust the zero pot (P1) in the driver
card to set the pressure at around 40 kg/cm2. To increase rotate in
clockwise and for decreasing it anti clockwise.

Give 100% command from DCS and adjust the span pot (P4) in the servo
card to set the pressure at around 140 kg/cm2. To increase rotate it in
clockwise and for decreasing it anti clockwise.
ACTIVITY 4: Air Venting of Pressure Line.

Proportional Valve MCB on.

Hydraulic Pump Off.

Local mode selected.

Oil Level Ok (equal to Hi or Less than Hi but not low).

Open Port p1, p2 and p3 on each three loading cylinder.

Keep it open till oil starts coming out of it.

Close and tighten the bolt and take trial run.

Return the PTW & REPORT in WO.

Write down all the observations and work carried out during the checking &
fills the HISTORY & CALIBRATION CARDS

6. SAFETY ASPECTS
a) Hazard Involved :
1. Slip hazard while isolating Blocking of SOV ports.
2. Oil Leakage while isolating & restoring SOV.
b) Precaution to be taken :
1. Obtain isolation of adjacent and connected equipment.
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SWPL/C&I / SMP/I-148

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Standard MaintenanceProcedure
For HYDRAULLIC SOV TESTING AND
CHECKING
Issue
No: 1

Issue Date:
14.08.2015

Revision:
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File no:

SWPL/C&I / SMP/I-148

Page 7 of 5

2. Do not leave loose tools, spanner, equipment etc. on floor.

3. Use personal protective equipment like safety helmet, safety shoes, safety belt,
safety goggle and hand gloves, dust mask.
c) SAFETY PPEs :
Helmet with chin strip, Ear Plugs, Safety Goggles, Hand Gloves, Nose masks, safety
harness etc.
7.

QUALITY CHECKS/VALIDATION
Ensure Oil quality within permissible limits

8.

DOS & DONTS

DOS

After removing SOV cover the port of blocks with cloths to avoid ingress of dust and
ash particles.

DONTS:
Dont put SOV block port in open condition.
Dont rap the proportional control card arrangement in oil merge cotton cloths.
Dont start any hydraulic pump unless and until all the nut and bolt are properly
tighten.
9.

PROTOCOLS/RECORDS
Record all maintenance activities in Standard format for future reference.

10. Permit Closure & Trial / Clearance for regular Operation

Ensure Operation of Mil in Static as well as in Dynamic mode and close the permit for
regular Mill operation.
7 | Page

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Standard MaintenanceProcedure
For HYDRAULLIC SOV TESTING AND
CHECKING
Issue
No: 1

Issue Date:
14.08.2015

Revision:
00

Revision Date:

File no:

SWPL/C&I / SMP/I-148

Page 8 of 5

11. FREQUENCY
1. Mill Overhaul : 10000 Mill running hours
2. Defect base
12. CONCLUSION
Adoption of Standard Maintenance Procedure to ensure the healthiness of mill hydraulics
system and availability of mill in dynamic mode operation.

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