Weekly progress report format for foundry

Please follow for only reference

1. Weekly progress report Name: Sotua rishikumar k Employee no.: 83980 Dept: Maintenance Designation: GET Week: 14-21 AUG 2025

2. Summary of the week Installed and commissioned Fume Extractor VFD (200 kW ID fan motor) Removed old Star-Delta starter and completed safe LOTO-based connections. Monitoring current ratings of fume Extractor VFD at main panel and LT room. Performed Battery Charger and UPS battery inspection (count & capacity) Recorded ABT Meter Readings Completed Holding Furnace H2 WCC connection and Top Block Taflon sheet (4 mm) and champion sheet cutting.

3. Tie rod bottom check nut welding work, Taflon sheet shifting, Hole cutting and fixing. Complete top nut and check nut tightening (spring washer , plane washer and FRP washer) by holding furnace top block arrangement done. Checked soft water outlet flow- identified hose pipe defects and rectified by interchanging inlet(1no.) and outlet(12 no.).

4. Day wise work done DATE: 14 Aug 2025 LINE -2 : Fume Extractor VFD installation work:- Cleaning done in panel. Installed VFD in panel and tight nut-bolts. Connection work pending. LINE -1,2 and Switchyard battery charger and UPS inspection:- In this work note down the how many batteries are used And also noting capacity and weight.

5. SR no. Location Equipment Qty/Capacity Weight per Battery 1. Switchyard Battery Charger 55/2V-150Ah 8.4 KG 2. HT Room Battery Charger 55/2V-150Ah 32.4 KG 3. Sand plant (L1) UPS 20/12V-18Ah 4 KG 4. Sand plant (L2) UPS 20/12V-26Ah 8.5 KG 5. Spectro Lab (L1) UPS 16/12V-18Ah 9 KG 6. Spectro Lab (L2) UPS 16/12V-26Ah 8.5 KG 7. X-Ray Lab -1 UPS 3/12V-42Ah 14 KG 8. X-Ray Lab -2 UPS 30/12V-26Ah 8.5 KG 9. X-Ray Lab -3 UPS 1 UPS 2 30/12V-65Ah 30/12V-42Ah 20. KG 14 KG 10 Store (Vehicle Charging) Battery Charger 120/2V-375Ah 25 KG 11. DG set Battery Charger 2/12V-160Ah 45 Kg

6. SR no. DGVCL Reading ABT meter 1. KWH 1987.878 2. KVAH 2008.474 3. C1 KWH 662.245 4. C2 KWH 674.358 5. C3 KWH 651.280 6. R MD 0.1062600 7. KVArH 237.179 ABT meter reading at 11.00 a.m

7. DATE:- 15 Aug 2025 LINE -2 : Fume Extractor VFD Connection work:- First following lock out tag out (LOTO) procedure at Line 2 LT room for 400 Amp MCCB of main power Fume Extractor. Then ensure with multimeter at fume extractor main panel, no power come. Remove old Star-Deleta connection from main panel power wiring and control wiring both. Then VFD connection done with first change connection in motor terminal box by link and power connection done. Then control connection done for remotely VFD operate by HMI module. After that done ON main power and check rotation of motor by manual slow speed set 800 RPM by VFD setting. Here found anti clock wise speed so change 1 phase in terminal box and again check and okay found. So after that in HMI set 30 Hz frequency and clear all fault in HMI and started in auto. Here fault found F30022 so reset the VDF by control power off and again checked okay found.

8. Specification Set Actual Parking time 8 min 8 min Paring sec 10 sec - Offline cleaning 40 - ID fan speed Hz 30 Hz 30.2 Hz HMI f2 function :- Motor Specification Value Motor Specification Value Rating KW 200 KW Speed 1490 rpm Current Rating 330 Amp Efficieny 96.2 IE3 Frequency 50 ± 5 Weight 750 KG Voltage 415 v D Amb Temperature -20 to 50 c Power factor 0.87 Bearing DE - 6310-C3 NE - 6310-C3

9. DATE:- 17 Aug 2025 LINE -2 : Fume Extractor started and monitoring:- Current ratings monitored at main panel and LT room. Location Value LT room R-44 Amp Y-45 Amp B-44 Amp VFD panel R-44 Amp Y-45 Amp B-44 Amp VFD output Terminal R-131 Amp Y-89 Amp B-133 Amp Additional heater bank wiring work:- R, Y, B and neutral all wiring done with one by any heater coil. After that shifted from old core shop to wedge cutting area by hydra crane.

10. DATE:-18 Aug 2025 Line 1 Holding furnace H2 WCC ( Water Cooling Circuit) connection completed. Top Block taflon sheet(4 mm) and champion sheet measuring and cutting work done. DATE:-19 Aug 2025 Line 1 Holder work followed. Check nut welding work done on bottom side fir tie rod. After that shifted taflon and champion sheet from line 2 melting panel room to holder area. Then use top plate of holding furnace and marked the hole for all 11 nos of tie rod fixing. After that fix sheets above coil and pull one by one top block fixed and 500 mm FRP pipe also fix because from protect from GLD.

11. DATE:-20 Aug 2025 Line 1 Holder work followed. Tightness done by top nut, check nut, Plan washer and spring washer. Here 46 mm spanner used for all tightness done one by one opposite side tie rod. When tightness work done found WCC side holder lifting hydraulic cylinder leakage found in guard side. DATE:-21 Aug 2025 Line 1 Holder work followed. Holder outlet flow of soft water checked. By checked that found hose pipe no. 1(inlet) and no. 12(outlet) defective so interchanging that and again checked Here also change 1 old 1 inch-1/4 hose pipe to new.

12. Outlet Hose no. Measured LPM Required LPM 1. 133 LPM 88 LPM 2. 132 LPM 88 LPM 3. 116 LPM 88 LPM 4. 45 LPM 40 LPM 5. 54 LPM 40 LPM 6. 20 LPM 10 LPM 7. 21 LPM 10 LPM Outlet soft water flow LPM rating for H2 holding furnace.

13. Line 1 A Melting furnace WCC side hydraulic cylinder hose pipe leakage found. So for change that first turn off furnace by Emergency push button from panel. After that hydraulic pump off for A furnace and start the work for changing work for hose. After changing hose pipe check leakage but no leakage found. Line 2 F Melting furnace measure for taflon sheet. Outer diameter 1400 mm Inner diameter 1000 mm

14. Learning and skill gained Gained hands-on in VFD installation, commissioning and current monitoring. Learned safe removal of Star-Delta starter and LOTO procedure. Improved skill in furnace maintenance. Understood importance of UPS battery health monitoring.

15. Conclusion All assigned task were completed. Gained hands-on learning in VFD, furnace maintenance, LOTO safety and monitoring work.

16. Thank you for your continuous support and guidance….