Master Energy Planning Rev

Logo
Format No.
LOCATION : _____________
Master Energy Planning

Department / Section:
Department Head:
Source Of Energy:
S.No
Division/ Energy
Segment
Process Brief
Battery Limit
Day Bin to Mixer
Energy Use
Silica Feeder
Weighing Hopper
Fludization System for
Carbon Charging
List of Equipment
Screw Motor # 1
Load Cells
Fludization Pads
Solenoid Valves
Electrical AC Motors
Connected
Load KW
1.5
Wearing of Belts
Belt Loosening
Compound stuck up in
auto loader
Roller Jamming
Bearing Jamming
Prev Maint
Prev Maint
Prev Maint
Air Leakage
Audit
Pneumatic Cylinder
Loading Conveyors
4.5
Weighing Scale
Load cell
Polymer Charging- Loading

Conveyor to Mixer Chamber
Oil Charging- Oil Tank to Mixer

Oil Pump
Chamber
Purging System
Carbon Purging
Wearing Of Belts
Belt Loosening
Belt Offcentering and
Jamming
Solenoid Valve
( 10 Nos )
7.5
Oil Volume as per recipe

Oil Quality
Oil Temperature
Metering &
Accounting
System
Existing Controls
No Control
Prev Maint
Prev Maint
Moisture Separater
Prev Maint
No Control
Audit
55
STOCK LOADER
CHARGING SYSTEM Transfer
of Polymer,Carbon & Oil
Energy Variables
Moisture in Silica
Screw clearance
Gear box backlash
Moisture in Carbon
Damaged pads
Coil Resistance
PU Tube leakage in SOV
Refer Flow Diagram With Critical

Relevant Operation Controls Controls/Operation Log Book Format
% Of Total
Procedures / Work
Reference/ Performance Calculation
Energy
Instructions
Work Sheet of Energy Centric
Equipment.
No
2.04
Ref NoLIM/PRN-R/WI/MIX
LIM/PRN-R/MIX/PROCESS01
No
0.056
Prev Maint
Prev Maint
No
0.17
No Control
No
0.00
No
0.28
No
0.002
Time difference between

the operation of two
Timer is present
valves
No Control
Coil Resistance
Prev Maint
Air leakage from fitting
Dust Collector
Blowing System
Blower
HOPPER DOOR
Gear Box LUBRICATION

SYSTEM
Hydraulic Cylinder
37
LUBE PUMPS-Electrical
AC Motors
DUST SEAL LUBRICATION

SYSTEM
Prev Maint
Fan & Impellor Condition
Differential pressure
No Control
Jamming
Prev Maint
Line Damage
Prev Maint
Hydraulic Pressure
Leakages
Oil Contamination
Viscosity
Jamming
Compund Stuckup
Temperature
Water Flow
Oil Pressure
Oil Contamination
Oil Viscosity
2.2
Oil Contamination
Oil Pressure
Leakages
Hydraulic Cylinder
Solenoid Valve
Pr. Regulator
Prev Maint
Prev Maint
Prev Maint
Prev Maint
Heat Exchanger
Flow Switch
Pr. Switch
Prev Maint
Prev Maint
Hydraulic Pressure
Pr Regulator
Oil Leakages from Fitting
Prev Maint
Hose Pipe Leakage
No
Hopper Door to Discharge Door
No
0.00
No
0.15
No
0.08
No
0.00
Prev Maint
No
0.00
Hudraulic Pressure
Hose Leakages
Oil Contamination
Viscosity
Friction/Jamming
Hydraulic Power Pack
AC Motor
Mixer Rotor & Gear Box

Assy
55
MIXER 105
Cooling System for Motor Electrical AC Motors
TSS
2125
Prev Maint
No
2.04
Rotor Speed
Gear Box Clearance
Gear Box wear & tear
Oil Leakage from
Coupling
Batch Specific
Prev Maint
Energy Meter@
BNB5 TR
Coil Resistance
78.8
0.15
Hydraulic Pressure
Coil Resistance
Pr Regulator
Hydraulic Line Leakages Prev Maint
Compound Stuck up
No
0.00
18.5
Water Circulation
Pipeline Insulation
Leakage
Valve Failure
Prev Maint
No
0.69
Pumps & Heaters
10.9
Water Circulation
Pipeline Insulation
Leakage
Cooling Valve Failure
Line Jam
Prev Maint
0.4
Gear Box Lubrication
0.55
Temperature
Oil Pressure
Oil Contamination
Prev Maint
0.02
R.H.S. Screw
90
L.H.S Screw
90
TOP ROLL
ROLL TCU
Pumps & Heaters
ROLL LUBRICATION
0.21
ROLL NIP GAP

ADJUSTMENT
Uncontrolled Loading
ROLL FWD/REV
BOTTOM ROLL
TAKE AWAY CONVEYOR
DIP TANK
Pump-Electrical AC
Motors
0.75
COOL RACK
Fans-Electrical AC
Motors
7.5
Temp of Compound
WIGWAG
7.5
Wearing of Conveyor Belt

Rollers Jamming
Prev Maint
Belt Off-Centering
Belt Loose/tight
Discharge DOOR
Hydraulic Cylinder
Solenoid Valve
MIXER TCU
Pumps & Heaters
TSS TCU
No Contractor
Ref No- BNB 105 2/102-103
Operator
Ref No- BNB 105 2/102-103
Operator
Ref No- BNB 105 2/102-103
Operator
Ref No- BNB 105 2/102-103
Operator
Ref No- BNB 105 2/78
Operator
1.37
RAM & CONTROL

Mixing Chamber
Ref No- BNB 105 2/10- 98R5581001/1025
0.00
Prev Maint
Prev Maint
Prev Maint
No Control
No Control
No Control
Name of The Contractor/Service

Provider if Involved
Operator

BNB 105 2/83
Operator

BNB 105 2/83
Operator

BNB 105 2/83
Operator

BNB 105 2/83
Operator

BNB 105 2/83
Operator

BNB 105 2/83
Operator

BNB 105 2/83
Operator
3.34
Screw Speed
Screw Clearance
Friction
Oil Leakage
Batch Specific
Prev Maint
75
Roll Speed
Roll idle running
Batch Secific
Roll interlocking with
discharge door
Prev Maint
9.2
Water Circulation
Pipeline Insulation
Leakage
Prev Maint
0.34
0.008
Shear Pads
0.11
Compound Stuck up
No Control
between TSS & Calendar
0.15
75
Roll Speed
Roll idle running
2.2
3.34
Mixer TCU To Bottom Roll

Energy Meter @
MDB15 For TSS
Batch Secific
PLC
Prev Maint
2.78
2.78
BATCH OFF UNIT
Take Away Conveyor to

Wigwag Conveyor
TOTAL
2695.01
90.00
80.00
Energy Use
List of Equipment
Silica Feeder
Screw Motor # 1
STOCK LOADER
Loading Conveyors
Oil Pump
Solenoid Valve
( 10 Nos )
Carbon Purging
Dust Collector Blower
Gear Box LUBRICATION
SYSTEM
LUBE PUMPS-Electrical AC
Motors
Connected Load KW
70.00
55
1.5
4.5
7.5
5
50.00
40.00
37
4
DUST SEAL LUBRICATION

SYSTEM
AC Motor
Mixer Rotor & Gear Box Assy
2125
Cooling System for Motor

MIXER TCU
TSS TCU
R.H.S. Screw
L.H.S Screw
TOP ROLL
ROLL TCU
ROLL LUBRICATION
Pumps & Heaters
Pumps & Heaters
Pumps & Heaters
4
18.5
10.9
0.55
90
90
75
9.2
0.21
ROLL NIP GAP ADJUSTMENT
ROLL FWD/REV
BOTTOM ROLL
TAKE AWAY CONVEYOR
DIP TANK
COOL RACK
WIGWAG
Pump-Electrical AC Motors
Fans-Electrical AC Motors
60.00
2.2
55
3
4
75
2.2
0.75
7.5
7.5
30.00
20.00
10.00
0.00
Slippage
Bearing Damaged
Roller Jamming
Air Leakage at cylinder
Slurry Contamination
Prev Maint
Tank Cleaning after

regular intervals
Cooling Fans
Cooling Rack speed
Energy Meter For

Misc PCC16.4
0.082
0.028
0.28
0.28
99.82
Logo
LOCATION : _____________
Department Head:
Source Of Energy:
S.No
Division/ Energy
Segment
Process Brief
2
of Polymer
Dust Collector
Mixing Chamber
MIXER 106
Cooling System
MILLS
BATCH OFF UNIT
Mast
Battery Limit
Energy Use
List of Equipment
Polymer Conveyor
Chemical Charging
Conveyor
Weighing Scale
Load cell
Purging System
Carbon Purging
Solenoid Valve
(10 Nos.)
Blowing System
Blower
Polymer Charging-Polymer
Conveyor to Chemical
Charging Conveyor
Hydraulic Cylinder
HOPPER DOOR
Solenoid Valves
Gear Box
AC Motors
LUBRICATION SYSTEM
DUST SEAL
LUBRICATION SYSTEM
Hydraulic Cylinder
Hopper Door to Discharge Door
RAM & CONTROL

Solenoid Valve
HYDRAULIC POWER
PACK
Mixer Rotor & GearBox

Assembly
Cooling System For
Motor
Hydraulic Cylinder
DISCHARGE DOOR
Solenoid Valves
TCU
Mixer TCU
Pumps & Heaters
Dump Mill
Holding Mill
Sheeting Mill
Dump Mill to Sheeting Mill

Wigwag Conveyor
TAKE AWAY
CONVEYOR
DIP TANK
Pump-Electrical AC
Motors
COOL RACK
Fans-Electrical AC
Motors
WIGWAG
TOTAL
Connected
Load
KW
Energy Variables
Metering &
Accounting
System
Existing
Controls
2.5
Wearing Of Belts
Belt Loosening
Prev Maint
No
1.5
Wearing Of Belts
Belt Loosening
Prev Maint
No
37

Timer is present
valves
Prev Maint
Coil Resistance
Prev Maint
No
Hydraulic Pressure
Leakages
Oil Contamination
Viscosity
Jamming
Pr. Regulator
Prev Maint
No
Coil Resistance
Prev Maint
No
Heat Exchanger
Flow Switch
Pr. Switch
Prev Maint
Temperature
Water Flow
Oil Pressure
Oil Contamination
2.2
Oil Contamination
Oil Pressure
Prev Maint
No
Hydraulic Pressure
Pr Regulator
Prev Maint
No
Coil Resistance
Prev Maint
No
Prev Maint
No
Rotor Speed
Gear Box Clearance
Batch Specific
Prev Maint
Energy Meter @
BNB6 TR
Hydraulic Pressure
Leakages
Oil Contamination
Viscosity
Jamming
Pr. Regulator
Prev Maint
Coil Resistance
Prev Maint
13.5
Water Circulation
Pipeline Insulation
Leakage
Prev Maint
No
200
Mill Idle Running Time
No Control
Energy Meter @
MDB21
300
Viscosity of Compound
Gear Box Clearance
Process Specific
Prev Maint
Energy Meter @
MDB21
200
Mill Idle Running Time
No Control
No
55
2125
4
Hydraulic Pressure
Hose Leakages
Oil Contamination
Viscosity
Friction/Jamming
No

2.2
Prev Maint
Slippage
Tank Cleaning at
regular intervals
7.5
Temp of Compound
Cooling Fans
Cooling Rack
speed
7.5
Wearing of Conveyor Belt Prev Maint
0.75
2968.65
Energy Meter @
PCC 1
Energy Meter @
PCC 21.2 BNB6
Conveyor Panel
Relevant Operation Controls

% Of Total
Procedures / Work
Energy
Instructions
0.084
0.051
0.202
1.246
0.135
0.074
1.853
71.581
0.135
0.455
6.737
10.106
6.737
0.074
0.025
0.253
0.253
Format No.

Controls/Operation Log Book Format
Equipment.

Ref NoBNB 106 2/57

BNB 106 2/58
Contractor
Ref NoBNB 106 2/57

ATL/106/0167/01
Operator
Ref NoBNB 106 2/4

BNB 106 2/5
BNB 106 2/6
Operator
Ref NoBNB 106 2/4

BNB 106 2/5
BNB 106 2/6
Operator
Ref NoBNB 106 2/4

BNB 106 2/5
BNB 106 2/6
Operator
Ref NoBNB 106 2/4

BNB 106 2/5
BNB 106 2/6
Operator
Ref NoBNB 106 2/4

BNB 106 2/5
BNB 106 2/6
Operator
Ref NoBNB 106 2/17

BNB 106 2/19
BNB 106 2/21
Ref NoBNB 106 2/18
BNB 106 2/20
Operator
Ref NoBNB 106 2/33
Operator
Logo
LOCATION : _____________
Department Head:
Source Of Energy:
S.No
Division/ Energy
Segment
Process Brief

of Carbon,Polymer & Oil
Dust Collector
Dust Collector
Mixing Chamber
Cooling System
TSS
BATCH OFF UNIT
Mast
Battery Limit
Carbon Charging- DayBin to

Mixer Chamber
Polymer Charging- Loading

Conveyor to Mixer Chamber
Energy Use
Carbon Feeders 1-8

Weighing Hopper
Screw Motor # (8)

Load Cells
Solenoid Valves
Polymer Conveyor
Transfer Conveyor
Weighing Scale
Load cell
Oil Injection Pump
Electrical AC
Motors(2)
Oil Weighing Scale
Load cell
Carbon Purging
Solenoid Valve
Oil Charging- Oil Tank to Mixer

Chamber
Purging System
List of Equipment
Blowing System
Blower
Hydraulic Cylinder
HOPPER DOOR
Solenoid Valves
Gear Box
LUBRICATION SYSTEM AC Motors
DUST SEAL
LUBRICATION SYSTEM
Hopper Door to Dischage Door
RAM & CONTROL
Hydraulic Cylinder
Solenoid Valves
Hydraulic Power Pack AC Motor
Mixer Rotor-1 & Gear

Box Assly
Mixer Rotor-2 & Gear

Box Assly
MOTOR BLOWERS
Hydraulic Cylinder
DISCHARGE DOOR
Solenoid Valves
All Zones
TCU
Pumps & Heaters
TSS TCU
Pumps & Heaters
R.H.S. Screw
L.H.S Screw
TOP ROLL
ROLL TCU
Pumps & Heaters
ROLL LUBRICATION
ROLL NIP GAP

ADJUSTMENT
ROLL FWD/REV
MIXER TCU To Bottom Roll

Wigwag Conveyor
BOTTOM ROLL
TAKE AWAY
CONVEYOR
DIP TANK
Pump-Electrical AC
Motors
COOLING CONVEYOR
WIGWAG
TOTAL
Connected
Load
Energy Variables
Moisture
Separater
Prev Maint
24
Moisture in Carbon
Screw clearance
Coil Resistance
5.5
Wearing Of Belt
Prev Maint
5.5
Wearing Of Belt
Prev Maint
7.5
Oil Volume as per recipe

Oil Quality
Oil Temperature
Metering &
Accounting
System
Existing
Controls
No
Energy Meter @
PDB21.2.1 I/c
1F4Weighing &
Feeding PLC
Panel
No Control
Energy Meter @
PDB21.2.2 1F1
BNB7 Oil Pump

Timer is present
valves
Prev Maint
Coil Resistance
No
37

Power quality
Prev Maint
Hydraulic Pressure
Leakages
Oil Contamination
Viscosity
Jamming
Pr. Regulator
Prev Maint
Coil Resistance
Prev Maint
Temperature
Water Flow
Oil Pressure
Oil Contamination
5.5
Oil Contamination
Oil Pressure
Prev Maint
Hydraulic Pressure
Pr Regulator
Prev Maint
Coil Resistance
Prev Maint
Hudraulic Pressure
Hose Leakages
Oil Contamination
Viscosity
Friction/Jamming
Prev Maint
75
Heat Exchanger
Flow Switch
Pr. Switch
Prev Maint
Energy Mater @
PCC21.2 3F2
BNB7 MIXER Panel
No
Energy Meter @
BNB7 HT Feeder
2125
2125
No
Rotor Speed
Gear Box Clearance
Batch Specific
Prev Maint
Energy Meter @
BNB7 HT Feeder
Hydraulic Pressure
Leakages
Oil Contamination
Viscosity
Jamming
Pr. Regulator
Prev Maint
Coil Resistance
Prev Maint
18.5
Water Circulation
Pipeline Insulation
Leakage
Prev Maint
10.9
Water Circulation
Pipeline Insulation
Leakage
Prev Maint
Energy Meter @
PCC21.2 3F1 TSS
TCU
Temperature
0.55
90
Oil Pressure
Oil Contamination
Prev Maint
Screw Speed
Screw Clearance
Friction
Batch Specific
Prev Maint
75
Roll Speed
Roll idle running
Batch Secific
Prev Maint
Interlocking
9.2
Water Circulation
Pipeline Insulation
Leakage
Prev Maint
90
0.21
Shear Pads
Compound Stuck Up
No Control
between TSS & Calendar
Energy Meter For

TSS @ MDB14
75
Roll Speed
Roll idle running
Batch Secific
Prev Maint
Interlocking

2.2
Prev Maint
Slippage
Tank Cleaning on
regular basis
5.5
Temp of Compound
Cooling Fans
Cooling Rack
speed
5.5
Wearing of Conveyor Belt Prev Maint
0.75
4812.31
Energy Meter For

Misc @ PCC21.2
% Of Total Relevant Operation Controls

Energy
Procedures / Work Instructions
0.50
0.11
0.11
-
0.16
0.77
0.08
0.11
1.56
44.2
44.2
0.2
0.4
0.2
0.0
1.9
1.9
1.6
0.2
0.0
0.1
0.1
1.6
0.05
0.02
0.11
0.11
Format No.

Equipment.

Ref NoBNB 107 2/29
Contractor
Ref NoBNB 107 2/29
Operator
Ref NoBNB 107 2/78
Operator
Ref NoBNB 107 2/78
Ref NoBNB 107 2/7

BNB 107 2/8
BNB 107 2/9
Ref NoBNB 107 2/7

BNB 107 2/8
BNB 107 2/9
Ref NoBNB 107 2/7

BNB 107 2/8
BNB 107 2/9
Operator
Operator
Operator
Operator
Ref NoBNB 107 2/7

BNB 107 2/8
BNB 107 2/9
Ref NoBNB 107 TSS 2/51

BNB 107 TSS 2/52
BNB 107 TSS 2/53
Operator
Operator
Ref NoBNB 107 2/27

BNB 107 2/28
BNB 107 2/86
Operator
Logo
LOCATION : ____STOCK-1
Department / Section: PCR/STOCK-1/Extruder

Department Head:
Source Of Energy:
S.No
Division/ Energy
Segment
Process Brief
Duplex Extruder
It is Hot Feed Extrusion

Process,in this process
rubber compound is first fed
into Twin Mill/Single Mill and
then through feed mill it is
transferred to Extruder
where compound takes the
shape of die and converted
into Treads & Sidewalls
Master
Battery Limit
Energy Use
List of Equipment
Twin Mill Stock Loader

Conveyor,Cutter
Twin Mill/Cracker Mill
Twin Mill Lubrication
Collecting Mill/Single Mill Electrical AC Motors
Conveyors-From
Collecting to Feed Mill
Feed Mill
Cooling Blower For Feed

Mill
Hot Feed Extruder
Feed Mill Lubrication
Feed Conveyor
Hot Feed Extruder
Electrical DC Motors
HFE Lubrication
Cold Feed Extruder
Cushion Calendar
Feed Conveyor
Cold Feed Extruder
CFE BLOWER
Cushion Extruder Feed

Conveyor
Cushion Extruder
Cushion Calendar
TCU
Electrical AC
Motors,Heaters
Cushion Cal. Feed

Conveyor
Pull Out Conveyor
Die Heater
Shrinkage Conveyor
Paint Conveyor
Inclined Conveyor
Cooling Conveyor 6-9
Chiller Pump
Separating Conveyor
Sidewall Decline
Conveyor
Sidewall Blowoff
Conveyor
Winder Overhead
Conveyor
Winder-1 & Winder-2
Pull Out Conveyor to Cooling

Line
Decline Conveyor to Booking

Conveyor
SKIVER KNIFE MOTOR
SKIVER CONV
SKIVER CARRIAGE
RING BLOWER
RING BLOWER
SEPERATING CONV
BLOWER
BOOKING W/S
BOOKING CONV
TOTAL LOAD
Connected
Load
KW
Energy Variables
Existing
Controls
7.7
Wearing Of Belts
Tearing of Cutter edges
Compound Jamming in
between Coneyors and
roller
Prev Maint
400
Overloading Of
Compound
Nature
of Compound
Gear Box Clearance
Gear Box Wear & Tear
Idle Running
Stock Loader Knife not
working
Lubrication Pressure
drop,Mill Trpping
Best Work
Practices
No Control
Prev Maint
1.55
Temperature
Oil Pressure
Oil Contamination
Prev Maint
Metering &
Accounting
System
Energy Meter @
MDB18
250
Overloading Of
Compound
Gear Box Clearance
Best Work
Practices
Prev Maint
0.75
Wearing Of Belts
Prev Maint
290
1.65
Overloading Of
Compound
Gear Box Clearance
Pushout to Sheetout
Activity
Best Work
Practices
Prev Maint

Prev Maint
Temperature
Oil Pressure
Oil Contamination
Prev Maint
Wearing Of Belts
Loosening of Belts
195
Screw Speed
Temp of Compound
Temp of Extruder's
Barrel,Head & Screw
Compound Leakage
Process Specific
Prev Maint
1.5
Temperature
Oil Pressure
Oil Contamination
Prev Maint
Prev Maint
Energy Meter @
MDB14
Wearing Of Belts
Loosening of Belts
488
Screw Speed
Temp of Compound
Temp of Extruder's
Barrel,Head & Screw
Compound Leakage
7.5
Fan Condition
Prev Maint
Process Specific
Prev Maint
Prev Maint
Wearing Of Belts
Loosening of Belts
110
Screw Speed
Temp of Compound
Temp of Extruder's
Barrel,Head & Screw
Compound Leakage
Process Specific
Prev Maint
Calendar Speed
Process Specific
Prev Maint
Water Circulation
Pipeline Insulation
Leakage
Prev Maint
50
144
Wearing Of Belts
Loosening of Belts
Prev Maint
Prev Maint
Energy Meter @
PCC14.1
Wearing Of Belts
Loosening of Belts
Prev Maint
2.2
Wearing Of Belts
Loosening of Belts
Prev Maint
Wearing Of Belts
Loosening of Belts
Prev Maint
5.5
Wearing Of Belts
Loosening of Belts
Prev Maint
22
Wearing Of Belts
Loosening of Belts
Prev Maint
Energy Meter @
MDB 14 For
Entire Extruder
Line
0.55
55
Spray Nozzles
blocked/unblocked
Nozle Crrosion
For Bias Production all
nozzles to be opened
Cleaning of
Nozzles
Nozzles to be
Energy Meter @
replaced
PCC14.1
Opening /Closing
of Valves
2.2
Wearing Of Belts
Loosening of Belts
Prev Maint
2.2
Wearing Of Belts
Loosening of Belts
Prev Maint
1.1
Wearing Of Belts
Loosening of Belts
Prev Maint
1.5
Wearing Of Belts
Loosening of Belts
Prev Maint
1.5
Winder Motor Idle

Running
Interlocking
Energy Meter @
PCC 14.1
5.5
6.6
Knife Motor Idle Running Interlocking
Wearing Of Belts
Loosening of Belts
Prev Maint
4.4
Idle running
Interlocking
2.2
Fan Condition
Prev Maint
1.6
Fan Condition
Prev Maint
1.1
Fan Condition
Prev Maint
1.5
Wearing Of Belts
Loosening of Belts
Prev Maint
2.2
Wearing Of Belts
Loosening of Belts
Prev Maint
2082.5

Energy
0.37
19.21
0.07
Ref No.LIM/PRN-R/WI/EXT-D
LIM/PRN-R/EXT-D/PROCESS01
12.00
0.04
13.93%
0.19%
0.08
0.05
9.36
0.07
0.05
23.43
0.36
0.05
5.28
2.40
6.91
0.05
0.24
0.03
0.11
0.14
0.26
1.06
2.64
0.11
0.11
0.05
0.07
0.07
0.26
0.32
0.21
0.11
0.08
0.05
0.07
0.11
Format No.

Equipment.

Ref No.
DUP EXT 1/11,12,13,14
Operator
Ref No.
DUP EXT 1/11,12,13,14
Operator
Ref No.
DUP EXT 1/11,12,13,14
Operator
Ref No.
DUP EXT 1/11,12,13,14
Operator
Ref No.
DUP EXT 1/11,12,13,14
Operator
Ref No.
DUP EXT 1/11,12,13,14
Operator
Ref No.
DUP EXT 1/11,12,13,14
Operator
Ref No.
DUP EXT 1/11,12,13,14
Operator
Ref No.
DUP EXT 1/15,16
Operator
Ref No.
DUP EXT 1/15,16
Operator
Ref No.
DUP EXT 1/15,16
Operator
Ref No.
DUP EXT 1/15,16
Operator
Operator
Operator
Ref No.
DUP EXT 1/15,16
Operator
Operator
Ref No.
DUP EXT 1/21,19
Operator
Operator
Ref No.
DUP EXT 1/21,19
Operator
Operator
Operator
Ref No.
DUP EXT 1/27,24
Operator
Operator
Operator
Operator
Ref No.
DUP EXT 1/18
Operator
Operator
Operator
Operator
Ref No.
DUP EXT 1/22
Operator
Operator
Operator
Operator
Ref No.
DUP EXT 1/31,32,33
Operator
Operator
Operator
Operator
Ref No.
DUP EXT 1/28,29,30
Operator
Operator
Operator
Logo

Department Head:
Source Of Energy:
S.No
Division/ Energy
Segment
Process Brief
SRRD EXTRUDER
In this process rubber

compound is directly feed
into 150MM CFE & 200 MM
CFE ,compound is extruded
from 150MM and 200MM
screw die so as to take
specified shape.
This is used for making
treads & SideWall
This process starts from
compound going to CFE and
ends after compound leaves
booking area.
SRRD EXTRUDER
specified shape.
treads & SideWall
booking area.
Master
Battery Limit
Energy Use
List of Equipment
200MM EXTRUDER FEED

CONVEYOR
200 MM Extruder
200MM MAIN MOTOR

BLOWER
200MM GEARBOX
LUBRICATION
200 MM Cold Feed Extruder

150MM EXTRUDER FEED
to 150 MM Cold Feed
CONVEYOR
Extruder

to 150 MM Cold Feed
Extruder
TCU
Roller Die to Winder1 &

Winder2
150 mm extruder
150MM MAIN MOTOR

BLOWER
150MM GEARBOX
LUBRICATION MOTOR
HEAD HYDRAULIC UNIT
PUMPS ZONE 1 TO4
Zone Heating
Heaters
PUMPS ZONE 5 TO 12
ROLLER DIE MOTOR
INCLINE CONVEYOR
BLOWER AT INCLINE
CONVEYOR
BOOMRANG CONVEYOR
Cooling Conveyor 1-4
Roller Die to Winder1 &

Winder2
Pump 1401 & Pump

1402- One run at a time
DECLINE CONVEYOR
WATER BLOW OFF

CONVEYOR
WINDER 1
WINDER2
WINDER CHANGE OVER

CONVEYOR
SKIVER CONVEYOR
CUTTER CARRIAGE
SKIVER KNIFE
RING BLOWER
SHRINKAGE CONVEYOR 1 Electrical AC Motors

SHRINKAGE CONVEYOR 2
TO 6
SEPARATING CONVEYOR Electrical AC Motors
Skiver Unit to Scrap

Conveyor
BLOWER AT SEPARATING
CONVEYOR
Skiver Unit to Scrap

Conveyor
CONVEYOR
BOOKING CONVEYOR 1
BOOKING CONVEYOR 2
LINEAR WEIGHING SCALE

CONVEYOR
BOOKING WEIGHING
SCALE CONVEYOR
SCRAP CONVEYOR
TOTAL LOAD
Connected
Load
KW
Energy Variables
2.2
Wearing Of Belts
Loosening of Belts
386
Screw Speed
Temp of Compound
Temp of Extruder's
Barrel,Head & Screw
Compound Leakage
5.5
1.1
2.2
Fan Condition
Temperature
Oil Pressure
Oil Contamination
Wearing Of Belts
Loosening of Belts
Existing
Controls
Prev Maint
Process Specific
Prev Maint
Metering &
Accounting
System
Energy Meter @
PCC 21.1
Prev Maint
Prev Maint
Prev Maint
300
Screw Speed
Temp of Compound
Temp of Extruder's
Barrel,Head & Screw
Compound Leakage
Fan Condition
Process Specific
Prev Maint
Energy Meter @
MDB21
Prev Maint
1.1
Temperature
Oil Pressure
Oil Contamination
Prev Maint
11
Hudraulic Pressure
Hose Leakages
Oil Contamination
Viscosity
Friction/Jamming
Prev Maint
4.4
Water Contamination
No Control
144
Water Circulation
Temperature
controllers for
switching
heaters
17.6
Water Contamination
No Control
22
Roller Speed
2.2
Wearing Of Belts
Loosening of Belts
7.5
Fan Condition
Process Specific
Prev Maint
Prev Maint
Energy Meter @
PCC 21.1
0.75
Wearing Of Belts
Loosening of Belts
Prev Maint
16
Wearing Of Belts
Loosening of Belts
Prev Maint
Energy Meter @
PCC 21.1
22
Impellar Condition
Nozzle Blockage
Prev Maint
Cleaning
Energy Meter @
PCC 21.1
2.2
Wearing Of Belts
Loosening of Belts
Prev Maint
Energy Meter @
PCC 21.1-For
Misc.
1.5
Wearing Of Belts
Loosening of Belts
Prev Maint
Idle running
Interlocking
Idle running
Interlocking
2.2
Wearing Of Belts
Loosening of Belts
Prev Maint
6.7
Wearing Of Belts
Loosening of Belts
Prev Maint
4.3
Idle running
Interlocking
2.2
Idle running
Interlocking
1.6
Fan Condition
Prev Maint
0.5
Wearing Of Belts
Loosening of Belts
Prev Maint
0.75
Wearing Of Belts
Loosening of Belts
Prev Maint
1.5
Wearing Of Belts
Loosening of Belts
Prev Maint
7.5
Fan Condition
Prev Maint
1.6
Fan Condition
Prev Maint
1.5
Wearing Of Belts
Loosening of Belts
Prev Maint
1.5
Wearing Of Belts
Loosening of Belts
Prev Maint
1.5
Wearing Of Belts
Loosening of Belts
Prev Maint
1.5
Wearing Of Belts
Loosening of Belts
Prev Maint
1.5
Wearing Of Belts
Loosening of Belts
Prev Maint
996.6

Energy
0.22%
38.73%
0.55%
0.11%
0.22%
Ref No.LIM/PRN-R/WI/EXT-S
LIM/PRN-R/EXT-S/PROCESS01
30.10%
0.30%
0.11%
1.10%
0.44%
14.45%
1.77%
2.21%
0.22%
0.75%
0.08%
1.61%
2.21%
0.22%
0.15%
0.40%
0.40%
0.22%
0.67%
0.43%
0.22%
0.16%
0.05%
0.08%
0.15%
0.75%
0.16%
0.15%
0.15%
0.15%
0.15%
0.15%
Format No.

Equipment.

Ref No.
SRRD EXT 1/86-83
Operator
Ref No.
SRRD EXT 1/86-83
Operator
Ref No.
SRRD EXT 1/86-83
Operator
Ref No.
SRRD EXT 1/86-83
Operator
Ref No.
SRRD EXT 1/85
Operator
Ref No.
SRRD EXT 1/85
Operator
Ref No.
SRRD EXT 1/85
Operator
Ref No.
SRRD EXT 1/85
Operator
Ref No.
SRRD EXT 1/85
Operator
Ref No.
SRRD EXT 1/85
Operator
Ref No.
SRRD EXT 1/86-83
Operator
Ref No.
SRRD EXT 1/86-83
Operator
Ref No.
SRRD EXT 1/86-87
Operator
Ref No.
SRRD EXT 1/86-87
Operator
Logo

Department Head:
Source Of Energy:
S.No
Division/ Energy
Segment
Process Brief
KRUPP EXTRUDER

into CFE ,compound is
extruded from screw die so
as to take specified shape.
treads & SideWall
booking area.
KRUPP EXTRUDER

into CFE ,compound is
extruded from screw die so
as to take specified shape.
treads & SideWall
booking area.
Maste
Battery Limit
Energy Use
List of Equipment
UPPER EXTRUDER FEED

CONVEYOR
UPPER EXTRUDER
UPPER M/C GEAR BOX

LUBRICATION
UPPER M/C MAIN MOTOR

BLOWER
LOWER EXTRUDER FEED

CONVEYOR
LOWER EXTRUDER
Cold Feed Extruder-Upper

Extruder to Boxer Extruder
Cold Feed Extruder-Upper

Extruder to Boxer Extruder
LOWER M/C MAIN

MOTOR BLOWER
LOWER M/C GEAR BOX

LUBRICATION
BOXER EXTRUDER FEED

CONVEYOR
BOXER EXTRUDER
BOXER EXTRUDER GEAR

BOX LUBRICATION
Electrical AC MotorsPumps
TCU
Heaters(9 Zones)-2 in
Each
HYDRAULIC HEAD
CUSHION EXTRUDER
CUSHION EXTRUDER TCU Electrical AC Motors
CUSHION FEED
CONVEYOR
PULL OUT CONVEYOR
SHRINKAGE CONVEYOR
MARKER CONVEYOR
INCLINED CONVEYOR
COOLING CONVEYOR
CHILLER PUMP
COOLING LINE BLOWER
DECLINE CONVEYOR
BLOWER
BLOWER MOTOR FOR

S/W BLOW OFF
CONVEYOR
SKIVER CONVEYOR
ELECTRICAL AC
SERVO MOTOR
SKIVER KNIFE
Electrical AC SERVO
Motor
CUSHION CALENDAR TO
COOLING LINE
SKIVER CUTTER
CARRIAGE
SEPARATING CONVEYOR Electrical AC Motors
DECLINE CONVEYOR TO
BOOKING CONVEYOR
CONVEYOR
BOOKING CONVEYOR
WINDER 1
WINDER 2
WINDER CHANGE OVER

CONVEYOR
LINEAR WEIGHING SCALE

CONVEYOR
BOOKING WEIGHING
SCALE CONVEYOR
TOTAL
Connected
Load
KW
Energy Variables
Existing
Controls
2.2
Wearing Of Belts
Prev Maint
316
Screw Speed
Temp of Compound
Temp of Extruder's
Barrel,Head & Screw
Compound Leakage
Process Specific
Prev Maint
1.1
Oil Pressure
Oil Contamination
Fan Condition
Metering &
Accounting
System
Pr. Switch
Prev Maint
Prev Maint
1.1
Wearing Of Belts
Prev Maint
205
Screw Speed
Temp of Compound
Temp of Extruder's
Barrel,Head & Screw
Compound Leakage
Process Specific
Prev Maint
Energy Meter
@PCC 57 &
PCC13.5
0.37
0.75
75
0.37
Fan Condition
Oil Pressure
Oil Contamination
Prev Maint
Pr. Switch
Prev Maint
Wearing Of Belts
Belt Loosening
Prev Maint
Screw Speed
Temp of Compound
Temp of Extruder's
Barrel,Head & Screw
Compound Leakage
Process Specific
Prev Maint
Oil Pressure
Oil Contamination
Pr. Switch
Prev Maint
Energy Meter
@PCC13.5
8.865
Water Circulation
Pipeline Insulation
Leakage
Energy Meter
@PCC13.5
Prev Maint
162
7.5
40
0.75
Screw Speed
Temp of Compound
Temp of Extruder's
Barrel,Head & Screw
Compound Leakage
Process Specific
Prev Maint
Water Circulation
Pipeline Insulation
Leakage
Prev Maint
2.95
Wearing Of Belts
Belt Loosening
0.75
Wearing Of Belts
Belt Loosening
2.2
Wearing Of Belts
Belt Loosening
Prev Maint
2.2
Wearing Of Belts
Belt Loosening
Prev Maint
2.2
Wearing Of Belts
Belt Loosening
Prev Maint
Wearing Of Belts
Belt Loosening
Prev Maint
Prev Maint
Prev Maint
22
Impellor Condition
Nozzle Blockage
Fan Condition
Fan Condition
Prev Maint
Fan Condition
Idle Running
Prev Maint
Interlocking
15
22
7
5.2
Prev Maint
Cleaning
Prev Maint
Wearing Of Belt
Belt Loosening
Rollers Jamming
Prev Maint
Idle running
Interlocking
Energy Meter @
PCC13.5
4.6
Idle running
Interlocking
2.2
Wearing Of Belt
Belt Loosening
Rollers Jamming
Prev Maint
1.6
Fan Condition
Idle Running
Prev Maint
Interlocking
2.2
Wearing Of Belt
Belt Loosening
Rollers Jamming
Prev Maint
1.5
Idle running
Interlocking
1.5
Idle running
Interlocking
1.5
Wearing Of Belt
Belt Loosening
Rollers Jamming
Prev Maint
2.2
Wearing Of Belt
Belt Loosening
Rollers Jamming
Prev Maint
0.75
Wearing Of Belt
Belt Loosening
Rollers Jamming
Prev Maint
933.555

Energy
0.24
33.85
0.12
0.32
0.12
21.96
Ref No.LIM/PRN-R/WI/EXT-K
LIM/PRN-R/EXT-K/PROCESS01
0.32
0.04
0.08
8.03
0.04
0.95
17.35
0.80
4.28
0.08
0.32
0.08
0.24
0.24
0.24
0.43
1.61
2.36
0.32
2.36
0.75
0.56
0.49
0.24
0.17
0.24
0.16
0.16
0.16
0.24
0.08
Format No.

Equipment.

Ref No.
KRUPP EXT 1/1-2
Operator
Ref No.
KRUPP EXT 1/1-2-4-6
Operator
Ref No.
KRUPP EXT 1/1-2
Operator
Ref No.
KRUPP EXT 1/1-2-6
Operator
Ref No.
KRUPP EXT 1/45-47-51
Operator
Ref No.
Operator
Ref No.
Operator
Ref No.
Operator
Ref No.
Operator
Ref No.
Operator
Ref No.
Operator
Ref No.
KRUPP EXT 1/34
Operator
Ref No.
KRUPP EXT 1/34
Operator
Ref No.
KRUPP EXT 1/34
Operator
Ref No.
Operator
Ref No.
Operator
Ref No.
KRUPP EXT 1/38-43
Operator
Ref No.
KRUPP EXT 1/80-82
Operator
Logo
LOCATION : _____________
Department Head:
Source Of Energy:
S.No
Division/ Energy
Segment
Process Brief
STEEL TYRE CORD

CALENDAR
In this process,rubber is
calendared on fabric and
Steel wires - Both sides.
This coated fabric and steel
sheets are used to make
Body Plies and Steel Belts
respectively
Mas
Battery Limit
FABRIC
PRE-CALENDARING To
FABRIC CENTERING & EDGE
SPREADING SYSTEM
Energy Use
List of Equipment
Feed Roll Let Off
Tension Stand-1
Tension Stand-2
LET OFF Splice Station

Fabric Roll Accumulator

FABRIC
PRE-CALENDARING To
FABRIC CENTERING & EDGE
SPREADING SYSTEM
Oven Main Blower
Oven Exhaust
Pre & Post Accumulator

Centering System
Pre Oven Web Spreading

System
Pre Calendar Centering

System
Pre Calendar Spreading

System
Pre Calendar Edge

Spreading System
E-2 Mill (Cracker Mill)
E2 to E3 Mill Conveyor
E2 to E4 Mill Conveyor
E-3 Mill (Cracker Mill)
E-4 Mill (Feed Mill)
E4 Mill to CalendarUpper Conveyor Belt
MILLS To 4 Roll Calendar
E4 Mill to Calendar-Lower
Conveyor Belt
Lower Wig-Wag
Scrap Conveyor
ROLL 1-4 (4)
ROLL 1-4 (4) Blower
Gap Adj Roll-1(2) Gap

Adj Roll-2(2) Gap Adj
Roll-4(2)
Roll 1-4 TCU (4)
Calendar Bearing
Lubrication(2)
Calendar Gear-Box
Lubrication
Cross- Axis Roll

& 4)-2
(1
Pull Unit
Pull Unit Blower motor
Brake Pump Pull Unit
Cooling Drum
Cooling Drum Blower

motor
Brake Pump Cooling

Drum
Dancer Hydraulic
4 Roll Calendar to Wind Up

Unit
Accumulator Hydraulic
Centering unit of
Accumulator
Winder 1
Winder 2
Winder-1 Blower & Brake Electrical AC Motors

Winder-2 Blower & Brake Electrical AC Motors
Top Stock Guider D/S
Top Stock Guider W/S
Bottom Stock Guider D/S
Bottom Stock Guider W/S
Cutter Unit near Wind-up
Winder Position drive
(Wagon Translation)
TOTAL
Connected
Load
KW
Energy Variables
Existing
Controls
5.6
Speed
Clutch Engage/Disengage
Friction
No Control
Prev Maint
7.6
Speed
Roll Jamming
15
Speed
Roll Jamming
Metering &
Accounting
System
Process Specific
Prev Maint
Energy Meter
Process Specific @ PCC15.1 Let
Prev Maint
Off Unit
18.5
Hudraulic Pressure
Hose Leakages
Oil Contamination
Viscosity
Friction/Jamming
Prev Maint
18.5
Hudraulic Pressure
Hose Leakages
Oil Contamination
Viscosity
Friction/Jamming
Prev Maint
75
18.5

Bearing Greasing

Bearing Greasing
0.55
Speed
Roll Jamming
1.1
Speed
Roll Jamming
0.55
Speed
Roll Jamming
1.1
Speed
Roll Jamming
1.1
Speed
Roll Jamming
Prev Maint
Prev Maint
Process Specific
Prev Maint
Energy Meter
@ MDB15
Calendar Line
Process Specific
Prev Maint
Process Specific
Prev Maint
Process Specific
Prev Maint
Process Specific
Prev Maint
250
Overloading Of Compound Best Work

Practices
Gear Box Clearance
No Control
Prev Maint
0.55
Wearing Of Belts
Belt Loosening
Prev Maint
1.1
Wearing Of Belts
Belt Loosening
Prev Maint
Energy Meter
@ PCC16.2
250

Practices
Gear Box Clearance
No Control
Prev Maint
Energy Meter
@ PCC16.2
194

Practices
Gear Box Clearance
No Control
Prev Maint
Energy Meter
@ PCC15.1
1.7
Wearing Of Belts
Belt Loosening
Prev Maint
1.7
Wearing Of Belts
Belt Loosening
Prev Maint
0.75
Wearing Of Belts
Belt Loosening
Prev Maint
1.7
Wearing Of Belts
Belt Loosening
Prev Maint
288
Roll Speed
Roll idle running
Process Secific
Prev Maint
Interlocking
4.4
15
22

Bearing Greasing
Water Circulation
Pipeline Insulation
Leakage
Prev Maint
Shear Pads
Prev Maint
Oil Pressure
Oil Contamination
2.2
Oil Pressure
Oil Contamination
Pr. Switch
Prev Maint
Pr. Switch
Prev Maint
0.55
0.12
27.5
0.4
0.12
5.5
Speed
Idle Running
Bearing Greasing
Interlocking
Prev Maint
Oil Pressure
Oil Contamination
Pr. Switch
Prev Maint
Drum Speed
Chain Loosening
Sprocket teeth damaging
Prev Maint

Bearing Greasing
Prev Maint
Oil Pressure
Oil Contamination
Pr. Switch
Prev Maint
Hudraulic Pressure
Hose Leakages
Oil Contamination
Viscosity
Friction/Jamming
Prev Maint
7.5
0.37
Hudraulic Pressure
Hose Leakages
Oil Contamination
Viscosity
Friction/Jamming
Speed
Roll Jamming
Prev Maint
Process Specific
Prev Maint
26
Idle Running
Interlocking
26
Idle Running
Interlocking
0.52
Idle Running
Interlocking
0.52
Idle Running
Interlocking
1.1
Idle Running
Interlocking
1.1
Idle Running
Interlocking
1.1
Idle Running
Interlocking
1.1
Idle Running
Interlocking
3.45
Idle Running
Interlocking
1.1
Idle Running
Interlocking
1313.25

Energy Procedures / Work Instructions
Ref No.LIM/PRN-R/WI/FCAL
0.43%
LIM/PRN-R/FCAL/PROCESS01
0.58%
1.14%
1.41%
1.41%
5.71%
1.41%
0.04%
0.08%
0.04%
0.08%
0.08%
Ref No.LIM/PRN-R/WI/FCAL-SCAL
19.04%
LIM/PRN-R/FCAL-SCAL/PROCESS01
0.04%
0.08%
19.04%
14.77%
0.13%
0.13%
0.06%
0.13%
21.93%
0.34%
1.14%
1.68%
0.23%
0.17%
0.23%
0.53%
0.04%
0.01%
2.09%
0.03%
0.01%
0.42%
0.57%
0.03%
1.98%
1.98%
0.04%
0.04%
0.08%
0.08%
0.08%
0.08%
0.26%
0.08%
Format No.

Equipment.

Operator
Operator
Ref No
Stc 4/31-33-38
Operator
Operator
Operator
Ref No
Stc 4/42-43
Operator
Ref No
Stc 4/42-43
Operator
Operator
Operator
Operator
Ref No
Stc 4/28-29-31
Operator
Operator
Operator
Operator
Ref No
Stc 4/97-99
Operator
Ref No
Stc 4/97-99
Operator
Operator
Operator
Operator
Ref No
Stc 4/17-15
Operator
Operator
Operator
Operator
Operator
Operator
Ref No.
StC 4/95-1-43
Ref No.
StC 4/95-1-43
Operator
Operator
Operator
Operator
Operator
Operator
Operator
Operator
Operator
Operator
Ref No.
StC 4/36 -37-38
Ref No.
StC 4/36 -37-38
Operator
Operator
Operator
Operator
Operator
Operator
Operator
Operator
Operator
Operator
Operator
Operator
Logo
LOCATION : _____________
Department Head:
Source Of Energy:
Division/ Energy
Segment
S.No
Process Brief
Assembly Line
calendared .And this
calendared rubber is used
in making Inner Liner and
Gum-Edge
Ma
Battery Limit
Energy Use
List of Equipment
150MM EXTRUDER
150 MM TCU
150MM EXTRUDER Gear

Box Lubrication
150 mm extruder
Fwd/Rev Movement
Pnumatic Cylinder
Hydraulic System
Face Roll Calendar -1
Calendar -1 Knife
Pnumatic Cylinder
Nip-Gap Adjustment
Trimming Conveyor
Calendar-1 TCU
Face Roll Calendar -2
Calendar -2 Knife
Pneumatic Cylinder
Nip-Gap Adjustment
Calendar-2 to StandBy
Extruder
Trimming Conveyor
Calendar-2 TCU
1st Take Away Conveyor
90MM Extruder Feed

Conveyor
90 MM Extruder
Electrical DC Motor
Trimming Conveyor
Transfer Conveyor from

Extruder to Cal-2
Pneumatic Cylinder
2nd Take Away Conveyor Electrical AC Motors
Poly Loading Unit To Wind Up

Unit
Poly Loading Unit
Sponge Roller Unit
Pneumatic Cylinder
Chaffer Let-Off 1
Chaffer Let-Off 2
Chaffer Application
Conveyor
Chaffer Passing
Conveyor-1
Chaffer Passing
Conveyor-2
Cooling Conveyor 1,2
Laminating Conveyor
Surface Winder-1,2,3
Poly Loading Unit To Wind Up

Unit
Surface Winder-1,2,3
Pneumatic Cylinder
Booking Conveyor-1,2,3
3rd Conveyor Blower
Wind Up Unit
Pneumatic Cylinder
MHE IN-OUT
Pneumatic Cylinder
TOTAL
Connected
Load
Kw
Energy Variables
Existing
Controls
Metering &
% Of Total
Accounting
Energy
System
174
35.27
6.6
1.34
1.1
0.2229654
2.6
0.53
72.5
14.70
1.6
0.32
0
2.25
0.5
0
72.5
14.70
1.6
0.32
0
3.3
0.67
0
2.2
0.4459309
1.1
0.2229654
110
22.3
0
0.61
0
3
0.61
0.61
1.5
0.30
1.5
0.30
1.5
0.30
1.22
6.75
1.37
0
8.5
1.72
1.25
0.25
1.22
493.35
EnPIs
(Performance
Indicators)
Relevant Operation
Controls Procedures /
Work Instructions
Format No.

Equipment.

Logo
LOCATION : _____________
Department Head:
Source Of Energy:
S.No
Division/ Energy
Segment
Process Brief
calendared .And this
3 - ROLL CALENDAR calendared rubber is used
in making Inner Liner and
Gum-Edge
Maste
Battery Limit
Energy Use
List of Equipment
150 MM EXTRUDER FEED

CONVEYOR
150 MM EXTRUDER
Take Away Conveyor
Pneumatic Cylinder

to Calendar
Extruder TCU(10)
120 MM Extruder
120 MM EXTRUDER FEED

CONVEYOR
to Calendar
Take Away Conveyor
Pneumatic Cylinder
Extruder TCU(10)
Calendar
Nip Motor
Calendar TCU
Electrical AC
Motors(3)
Top Take Away Conveyor Electrical AC Motors

Bottom Take Away
Conveyor
Cooling Drums
Sponge Roller Unit
Pneumatic Cylinder
Chaffer Let-off Unit 1&2 Electrical AC Motors
Take Away Conveyor to Wind

Up Unit
Chaffer Passing
Conveyor
Chaffer Application
Conveyor
Sponge Roller Unit
Pneumatic Cylinder
Wind Up Unit-1
Air Blower
Auto-Centering System
Pneumatic Cylinder
Wind Up Unit-2
ELECTRICAL AC
MOTOR
Auto Centering for

Winder-2
Pneumatic Cylinder
MHE Adjustment
Pneumatic Cylinder
TOTAL
Connected
Load
KW
2.2
114.7
2.2
Energy Variables
Existing
Controls
Metering &
% Of Total
Accounting
Energy
System
Wearing Of Belts
Prev Maint
Screw Speed
Temp of Compound
Temp of Extruder's
Barrel,Head & Screw
Compound Leakage
Process Specific
Prev Maint
Wearing Of Belts
Belt loosening
Prev Maint
0.64
Water Circulation
Pipeline Insulation
Leakage
Prev Maint
2.17
Screw Speed
Temp of Compound
Temp of Extruder's
Barrel,Head & Screw
Compound Leakage
Process Specific
Prev Maint
Wearing Of Belts
Prev Maint
0.64
33.15
7.5
77.2
22.31
2.2
Wearing Of Belts
Belt loosening
Prev Maint
0.64
Water Circulation
Pipeline Insulation
Leakage
Prev Maint
2.17
7.5
77.2
1.5
Roll Speed
Gear Box Clearance
Batch Secific
Prev Maint
22.31
Shear Pads
0.43
Water Circulation
Pipeline Insulation
Leakage
Prev Maint
4.77
2.2
Wearing Of Belts
Belt loosening
Prev Maint
0.64
2.2
Wearing Of Belts
Belt loosening
Prev Maint
0.64
7.5
Drum Speed
Chain Loosening
Prev Maint
Sprocket teeth damaging
2.17
16.5
Speed
1.5
Wearing Of Belts
Belt loosening
Prev Maint
0.43
2.2
Wearing Of Belts
Belt loosening
Prev Maint
0.64
1.5
Idle Running
Interlocking
0.43
18
Fan Condition
Idle Running
Prev Maint
Interlocking
5.20
2.2
346
Idle Running
Interlocking
0.64
Relevant Operation Controls


Equipment.
Ref No.LIM/PRN-R/WI/ILC-2
LIM/PRN-R/ILC-2/PROCESS01
Ref No.
3 ROLL 4/63-64
Ref No.
3 ROLL 4/63-64
Ref No.
3 ROLL 4/63-64
Ref No.
3 ROLL 4/63-64
Ref No.
3 ROLL 4/78
Ref No.
3 ROLL 4/78
Ref No.
3 ROLL 4/78
Ref No.
3 ROLL 4/78
Ref No.
3 ROLL 4/65
Ref No.
3 ROLL 4/65
Ref No.
3 ROLL 4/65
Ref No.
3 ROLL 4/65
Ref No.
3 ROLL 4/65
Ref No.
3 ROLL 4/65
Ref No.
3 ROLL 4/69
Ref No.
3 ROLL 4/69
Format No.

Operator
Operator
Operator
Operator
Operator
Operator
Operator
Operator
Operator
Operator
Operator
Operator
Operator
Operator
Operator
Operator
Operator
Operator
Operator
Operator
Logo
LOCATION : _____________
Department Head:
Source Of Energy:
S.No
Division/ Energy
Segment
Process Brief
POWER DISTRIBUTION-
POWER DISTRIBUTION-
ESS-2
ESS-2
POWER FACTOR CORRECTION

& HARMONICS REDUCTION
Power Distribution To Machines

& LT Panels
Battery Limit
Energy Use
List of Equipment
TR14
TR15
TR16
TR18
TR20
Export Feeder From ESS-1 to

All HT Feeders
TRANSFORMERS
Export Feeder From ESS-1 to

All HT Feeders
TRANSFORMERS
TR21
TR22
BNB107-1
BNB107-2
BNB 106
ESS-3 Export Feeder
CAPACITOR BANKS 1 &

2
REACTORS,CAPACITORS & RVT
HARMONIC FILTERS
14/15/21
Cooling Fans,Reactors,Fixed &

Variable Capacitors
CAPACITOR BANKS TO
HARMONIC FILTERS
MDB 14
Duplex Extruder, BNB 107 TSS,

Assembly Line, Conti-1, Conti-2,
ATL Bead Apexing M/C
MDB 15
BNB5 TSS, Stc Calendar, Tyre

Testing M/c(Schench), MLDB
MDB 16
BNB6 PCC1, Duplex Twin Mill, E2Mill

& E3 Mill(Stc), Bead Winding
M/c(Allwell),Work Office, HR
Conference Room,VAC-4, Change
Room,FCW System
MDB 18
New TTM, Midcap Ext(Bias), HVAC-1

& 2, Fisher Cutter, Body Ply
Cutter,Chillers,Chiller Pumps,
Assembly Line Feed Mill
MDB 20
Duplex Single Mill
MDB 21
SRRD Extruder,3Roll
Calendar,BNB7 CR, BNB6 100"
Mill,BNB6 Dump Mill, 9th/10th Row
A/w,
MDB 22
York Chillers, ADMIN, Training

Centre(AKI),New Bead
Winding,Bead Apexing M/c,
Instrument Air Compressors 1 & 2,
Building/Curing/Final
Finish/Stock/Mould Shop/CFT-C Air
Washers
PCC 22.4
Instrument Air Compressors 1 & 2
PCC 22.1
ADMIN, AKI
SLDB - 5
LIGHTING @ BNB 7 GF,FF,SF & ESS2/Street Lighting
MDB 14 to MDB 22, PCC

22.4,PCC 22.1,SLDB-5, PMCC
16.3, ACDB
ACDB
Auxilliary Control Supply For LT

Panels, EnMS, Material
Gate,Emergency Lighting UPS
PMCC 16.3
VAC-4,Change Room,FCW System,

Cooling Tower Fans
List of Equipment
Connected
Load
2.5 MVA
Power Quality
Quality
Winding Temp
Oil
TR14
2.5 MVA
Power Quality
Quality
Winding Temp
Oil
TR15
Energy Variables
Power Quality
Quality
Winding Temp
Oil
2 MVA
Oil
TR18
2 MVA
Power Quality
Quality
Winding Temp
1.25 MVA
Power Quality
Quality
Winding Temp
Oil
TR20
TR16
2 MVA
Power Quality
Quality
Winding Temp
Oil
TR21
2 MVA
Power Quality
Quality
Winding Temp
Oil
TR22
2.5 MVA
Power Quality
Quality
Winding Temp
Oil
BNB107-1
2.5 MVA
Power Quality
Quality
Winding Temp
Oil
BNB107-2
2.5 MVA
Power Quality
Quality
Winding Temp
Oil
BNB 106
ESS-3 Export Feeder
REACTORS,CAPACITORS & RVT
Cooling Fans,Reactors,Fixed &

Variable Capacitors
Load Variation- Switching

of Inductive & Capacitive
Loads
Load Variation- Switching
of Inductive & Capacitive
Loads
Duplex Extruder, BNB 107 TSS,

Assembly Line, Conti-1, Conti-2,
ATL Bead Apexing M/C
Power Quality
BNB5 TSS, Stc Calendar, Tyre

Testing M/c(Schench), MLDB
Power Quality
NB6 PCC1, Duplex Twin Mill, E2Mill

& E3 Mill(Stc), Bead Winding
M/c(Allwell),Work Office, HR
Conference Room,VAC-4, Change
Room,FCW System
Power Quality
ew TTM, Midcap Ext(Bias), HVAC-1

& 2, Fisher Cutter, Body Ply
Cutter,Chillers,Chiller Pumps,
Assembly Line Feed Mill
Power Quality
Duplex Single Mill
Power Quality
SRRD Extruder,3Roll
Calendar,BNB7 CR, BNB6 100"
Mill,BNB6 Dump Mill, 9th/10th Row
A/w,
Power Quality
York Chillers, ADMIN, Training

Centre(AKI),New Bead
Winding,Bead Apexing M/c,
nstrument Air Compressors 1 & 2,
Building/Curing/Final
Finish/Stock/Mould Shop/CFT-C Air
Washers
Power Quality
nstrument Air Compressors 1 & 2
Power Quality
ADMIN, AKI
Power Quality
IGHTING @ BNB 7 GF,FF,SF & ESS2/Street Lighting
Power Quality
Auxilliary Control Supply For LT

Panels, EnMS, Material
Gate,Emergency Lighting UPS
Power Quality
VAC-4,Change Room,FCW System,

Cooling Tower Fans
Power Quality
Energy Planning
Metering &
Accounting
System
% Of Total
Energy
Isolators / Circuit
Breakers
Overcurrent Relays
Differential Relays
Earth Fault Relays /
Fuses Bucholtz Relay
Individual Energy
Meter @ HT Panel
8%
Isolators / Circuit
Breakers
Overcurrent Relays
Differential Relays
Individual Energy
Meter @ HT Panel
10.70%
Existing Controls
EnPIs
(Performance
Indicators)
Isolators / Circuit
Breakers
Overcurrent Relays
Differential Relays
Individual Energy
Meter @ HT Panel
17.70%
Isolators / Circuit
Breakers
Overcurrent Relays
Differential Relays
Individual Energy
Meter @ HT Panel
8.40%
Isolators / Circuit
Breakers
Overcurrent Relays
Differential Relays
Individual Energy
Meter @ HT Panel
Isolators / Circuit
Breakers
Overcurrent Relays
Differential Relays
Individual Energy
Meter @ HT Panel
17.30%
Isolators / Circuit
Breakers
Overcurrent Relays
Differential Relays
Individual Energy
Meter @ HT Panel
14.20%
Isolators / Circuit
Breakers
Overcurrent Relays
Differential Relays
Individual Energy
Meter @ HT Panel
6.90%
Isolators / Circuit
Breakers
Overcurrent Relays
Differential Relays
Individual Energy
Meter @ HT Panel
6.90%
Isolators / Circuit
Breakers
Overcurrent Relays
Differential Relays
Individual Energy
Meter @ HT Panel
7%
Isolators / Circuit
Breakers
Overcurrent Relays
Differential Relays
Earth Fault Relays
Individual Energy
Meter @ HT Panel
5%
Individual Energy
Meter @ HT Panel
Reactive Power
Individual Energy
Manager/ACB/MCCB/Cont
Meter @
actors
MDB14/15/21
O/C Relays,E/F
Relays,ACB
Energy Meter @
MDB-14
O/C Relays,E/F
Relays,ACB
Energy Meter @
MDB-15
O/C Relays,E/F
Relays,ACB
Energy Meter @
MDB-16
O/C Relays,E/F
Relays,ACB
Energy Meter @
MDB-18
O/C Relays,E/F
Relays,ACB
Energy Meter @
MDB-20
O/C Relays,E/F
Relays,ACB
Energy Meter @
MDB-21
O/C Relays,E/F
Relays,ACB
Energy Meter @
MDB-22
ACB/MCCB
ACB/MCCB
MCCB
Energy Meter @
MDB-22
Energy Meter @
MDB-22
Energy Meter @
SLDB-5
MCCB
Energy Meter @
ACDB
ACB/MCCB
Energy Meter @
PMCC 16.3

Relevant Operation
Controls Procedures / Reference/ Performance Calculation
Work Instructions
Equipment.
Format No.


Master Energy Planning Rev

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Master Energy Planning

Day Bin to Mixer

Polymer Charging- Loading

Oil Charging- Oil Tank to Mixer

Oil Volume as per recipe

Refer Flow Diagram With Critical

Time difference between

Gear Box LUBRICATION

DUST SEAL LUBRICATION

Hopper Door to Discharge Door

Hydraulic Power Pack

Mixer Rotor & Gear Box

Cooling System for Motor Electrical AC Motors

Pumps & Heaters

Gear Box Lubrication

Pumps & Heaters

ROLL NIP GAP

TAKE AWAY CONVEYOR

Wearing of Conveyor Belt

Pumps & Heaters

Ref No- BNB 105 2/102-103

Ref No- BNB 105 2/102-103

Ref No- BNB 105 2/102-103

Ref No- BNB 105 2/102-103

Ref No- BNB 105 2/78

RAM & CONTROL

Ref No- BNB 105 2/10- 98R5581001/1025

Name of The Contractor/Service

Ref No- BNB 105 2/81

Ref No- BNB 105 2/81

Ref No- BNB 105 2/81

Ref No- BNB 105 2/81

Ref No- BNB 105 2/81

Ref No- BNB 105 2/81

Ref No- BNB 105 2/81

Mixer TCU To Bottom Roll

Wearing of Conveyor Belt

BATCH OFF UNIT

Take Away Conveyor to

DUST SEAL LUBRICATION

Mixer Rotor & Gear Box Assy

Cooling System for Motor

ROLL NIP GAP ADJUSTMENT

Tank Cleaning after

Energy Meter For

BATCH OFF UNIT

RAM & CONTROL

Mixer Rotor & GearBox

Pumps & Heaters

Dump Mill to Sheeting Mill

Take Away Conveyor to

Master Energy Planning

Time difference between

Mill Idle Running Time

Mill Idle Running Time

Wearing of Conveyor Belt

Wearing of Conveyor Belt Prev Maint

Relevant Operation Controls

Refer Flow Diagram With Critical

Name of The Contractor/Service

Ref NoBNB 106 2/57

Ref NoBNB 106 2/57

Ref NoBNB 106 2/4