DN WIND SYSTEMS INDIA PVT LTD

Document:

WORK INSTRUCTION FOR ROLLING OF PLATES

Responsibility:
Overall: Operating: Engineer (Production & QC) Machine Operator.

Instructions:

1. Process Instruction
1. 2. 3. 4. 5. Lift the plate with correct identification with the help of EOT crane. Load the plate to hydraulic table of machine. Use operating techniques for pre punching and rolling of plate as per Control chart. Start rolling as per instructions as displayed on Control Chart. Make sure the profile is matching to templates provided as per Control Chart only.

2. Process parameters & frequency of inspection.

1. Following parameters to be checked for quality,i. Top & Bottom side circumference. ii. Top & bottom side diameters (ovality). iii. Profile templates at both ends. iv. Root gap. v. Traceability of shell. vi. Visual. 2. Frequency of inspection 100% shells to be check for above mentioned parameters.

3. Specification & Tolerances

1. Dimensions to be maintain as per the corresponding section drawings. 2. Tolerances are as follows,i. Circumference - +6mm & -0mm ii. Diameter Max difference should be less than 1% of required diameter. iii. Profile template Should be within 0 to 3 mm. iv. Root gap to be maintain as per WPS requirements.

4. Points of OHS Concern

1. 2. 3. 4. 5. Assure the hydraulic Pressure is within limits as specified in machine specification. Use tool & tackles of proper capacity for lifting. Use Mask before start of cleaning of plate/shell with air. Use hand gloves while checking with templates and moving shell to next station. Ensure the Electrical supply is appropriate before starting the machine.

5. Points of Environmental Concern

1. Assure every week the hydraulic pipes are leak proof. 2. Collect and locate the removed scale metal to specified position only.

6. Points of Checking
1. 2. 3. 4. 5. 6. 7.
Reviewed by Signature: Reference No. : Issue. No. / Date:

Daily check for hoses and connections are proper Weekly checking of earthing connections for all the earthing pits and tables. Weekly checking for Roller lubricant. Fortnightly checking for hydraulic oil level. Half yearly checking of equipment fire fighting system. Ensure hoses of fire hydrant system are at place. Ensure availability of fire extinguishers.
Approved by Signature: Rev. No. / Date: Page 1 of 3

DNWSIPL/WI/03

01 / 15.01.2013

15.01.2013

DN WIND SYSTEMS INDIA PVT LTD

Document:

WORK INSTRUCTION FOR ROLLING OF PLATES

5. Points for Preventive Maintenance

1. 2. 3. 4. Half yearly tightening of earthing contacts to the earthing pits and tables. Weekly cleaning of switches and sensors. Half yearly cleaning of filters of hydraulic oil. Yearly cleaning of strainer of fire fighting system.

6. Points of Correction Action for deviations

1. 2. 3. 4. Press emergency button of the control unit of machine. In case of emergency, inform security, utility, safety officer & Plant Head. Operators are trained to handle emergency due to fatigue and machine failure. People not involved in fire fighting operation team directly, should quickly move through emergency exit routes & assemble at emergency assembly point.

7. Reaction Plan
1. 2. 3. 4. 5. In case of any non conformity, contact production supervisor In case of major deviation contact QC person. Stop the activity unless approval from QC. Mark according to color code (Hold/Reject) for non conforming objects. Raise internal non conformity (8D) report.

Documents:
No.
1. 2. 3.

Title
Process control chart Rolling plan Rolling Pressure chart

Location
Quality Department Quality Department Rolling Department

Retention
Up to next revision Up to next revision Up to next revision

Records:
No.
1. 2. 3. 4. 5. 6. 7.

Title
Tower dimension report (Register) Rolling book Breakdown Register Preventive Maintenance Register Production Register Accident record Register Internal 8D report

Location
Quality Dept. Production Dept. Maintenance Dept. Machine Operation Machine Shop Office Quality Dept. 3 years 3 years 3 years 3 years 1 Year 1 year 3 years

Retention

Material:
1. SMAW / GMAW welding machine 2. Welding rod / wire 3. Air compressor .

Reviewed by Signature: Reference No. : Issue. No. / Date:

Approved by Signature: Rev. No. / Date: Page 2 of 3

DNWSIPL/WI/03

01 / 15.01.2013

15.01.2013

DN WIND SYSTEMS INDIA PVT LTD

Document:

WORK INSTRUCTION FOR ROLLING OF PLATES

Instruments & Gauges:

1. 2. 3. 4. 5. Measuring tape (5M, 15M, 30M) Scale (6, 12) Right angle. Vernier gauge & thickness meter Rolling template.

Photos:

Pre-punching

Rolling

Inspection
Reviewed by Signature: Reference No. : Issue. No. / Date: Approved by Signature: Rev. No. / Date: Page 3 of 3

DNWSIPL/WI/03

01 / 15.01.2013

15.01.2013