Zawar_Hydrocarbon Training ppt

[Audio] . vedanta HINDUSTAN ZINC Zinc 8 Silver of India transforming for good Precision Hydrocarbon Management Operational SOP & Visual Reference Manual for Zawar Mine Doc No: HZL/ZWHCM/SOP/OOI I Revision: R-2 1 Next Review: 22.05.2026.

[Audio] . The Vedanta Inbound: Fuels and lubricants delivered to quality standard. Periodic sampling tollgate. Hydrocarbon Supply Chain Map Transfer: Transfer point filtration prior to bulk storage. Storage: Best practice storage vessels featuring desiccant filter breathers, clean tanks, and kidney loops. (Note: No dipsticks). Distribution: Clean distribution via tankers to final equipment. Dispensing: Critical compartment fixed filtration at the machine level. Analysis: Scheduled sampling regime and results analysis by site reliability engineers. Replace low-skill tasks with precision tasks aimed at increased equipment reliability..

[Audio] . The Accountability Ecosystem Buyer Commercial Procure exact specifications. Conduct half-yearly vendor site v visits and quarterly on-site audits to verify external practices. 1 HCM Plant Manager HCM Engineers & Plant Manager: Own the process. Dictate right feed to right equipment. Incorporate condition monitoring into work management cycles. Sampler / Analyzer Execute zero-contamination sample collection using lab- certified bottles. Authority to halt unloading if quality parameters deviate. EHS & Store Head Ensure minimum 25m distance from heat sources. Execute monthly 5S audits. Manage licensing and environmental compliance..

[Audio] . Inbound Control: Bulk Unloading Sequence ÄOÄO 120 Time & Action T-Minus 45 Min Vehicle parked on leveled platform for mandatory 45-minute settling time. Ignition off, wheel chocks deployed, tanker grounded. Integrity Check Inspect for tampering on top rod, lock hinges, pipe flan s, and welded bolts. Ve • seals match invoice. Contamination Test Driver opens compartment covers. Plant team tests for water mixing using water• finding paste on the dip rod. Parameter Verification Conduct dip measurement. Extract sample to central lab. Density must measure between 810-845 kg/m2 with maximum 200ppm water. Unloading Execute site-specific transfer (Pump for Balaria/CPP/DG above-ground tanks; Gravity for ZawarmaIa/Baroi below-ground tanks)..

[Audio] . Storage Architecture: Bulk vs. Non-Bulk Bulk Storage (>5000L) Non-Bulk (Drums/Totes) Water Management Scheduled water drain-off procedures required for all above-ground tanks. Quality Baseline Quarterly receipt sampling against IS 1460-2017 standards (e.g., Flash Point Min 350C, Kinematic Viscosity 2-4.5 cSt). Visual Management MSDS, unloading sops, and hazardous chemical licenses prominently displayed. A 0 Environmental Controls Clean, dry location with secondary containment (bunded area sufficient for lull spill). Drainage plug aaa aao— oat Safety Radius Strict minimum 25- meter clearance from any heat source. Inventory Logic Strict First-in-First-Out (FIFO) rotation. Mandatory monthly 5S audits..

[Audio] . Dispensing Protocols & Filtration Mechanics Oil / Fuel Systems Grease Systems Inline Defense Fluid filters equipped with pressure differential gauges to prevent the filtration system from going into bypass. Calibration Centralized distribution systems with strictly calibrated flow meters. Hardware Small containers must feature self-closing spouts or quick-coupler attachments. Dipsticks replaced by 3D sight level glasses. Auto Manual a Flow Dynamics Grease lines kept as low as possible to prevent physical line blockage. Targeting Dispensers clearly marked and hardware- identified for specific grease types to prevent cross-contamination. Application Dedicated selection matrix for auto versus manual grease dispensing systems based on equipment location..

[Audio] . The Contamination Shield & Wear Debris Analysis Transfer point filtration, desiccant breathers, and capped sampling points. Layer 2 (Sampling Rigor): Extraction strictly into lab-certified super-cleaned bottles based on duty condition and run hours. Layer 3 (Wear Debris Analysis - WDA): Optical wear debris and particle • counting to detect hard particles. DCS trending of measurable parameters EEA combined with visual alarm sets to trigger rapid operational intervention. By keeping hard particles out of the system, three-body wear is minimized-transforming maintenance from reactive to predictive..

[Audio] . The Visual Decoding Matrix Shape Key (Operational Zones) Primary Mills (Mill l, 2) & Crushers. Crushers & P&M equipment. specific to Mill G, Mill H, and DTP. Color Key (Fluid Classes) Reds (Gear/Hydraulic): Tellus T68, Gulf Geartek ISO VG 320, Servo system 46. Yellows (Engine/Gear): Shell Rimula 15W40, Servomesh SP 220/320/460. Blacks (Greases): Shell Gadus, Mobilith SHC 220, Servogem 3. Whites/Greys (Coolants/Pumps): Zerex NF RTU, 777-D, Servo system 150. Standardized visual cues prevent the catastrophic misapplication of lubricants at the point of use..

[Audio] . Asset Integration & Rationalization The New Equipment Gate • SEALING INTEGRITY Compatibility: Verify hydraulic/fuel sealing elements against the required lube chart. • UÆECHARTMATCH Hardware Requirements: Mandatory installation of 3D sight glasses, proper capped sampling points, and exploration of auto-lubrication. 230" Rationalization & Collaboration Annual audits to eliminate unnecessary lubricant duplication, lowering purchasing and storage costs without compromising specs. • SPECS MAINTAINED • COST REDUCTION • ECO.FRIE'OLY OPTIONS • STORAGE OPTIMIZATION • 30 SIGHT GLASSESINSTALLED • CAPPEDPOMSREADY • EXPLORED System Integration: Add specific lube parameters (Flash point, Viscosity) and scheduled condition monitoring directly into SAP. Quarterly supplier reviews to source safer environmental alternatives and optimize existing formulations. • FORMULATION OPTIMIZATION • SWPUERCOUA80RATION FLASH POINT: SET SAP CONDITION RCT'VE MONITORING:.

[Audio] . Closing the Loop: Asset Health & Safe Disposal Waste Management Legislatively compliant disposal: Strict segregation of used oils and greases at designated locations. Month-on-month deposit tracking with complete MIS documentation support. SECURE DISPOSAL The Equation of Reliability Clean Precision Wear Inbound + Storage & + Debris Delivery Dispensing Analysis = Minimized Equipment Degradation & Optimized Costs..