PROJECT REPORT ON OPERATIONS MAINTENANCE AND PRACTICE Submitted in partial fulfillment of the requirement for the third semester of the Degree of MASTER OF BUSINESS ADMINISTRATION Of Anna University Chennai during the year 2010 Carried out by R.VIGNESWARI SOWMIYA Register No: 13209631043
Under guidance of Mr.R.RAMAR M.sc, MPhil. ASSISTANT MANAGER-QUALITY ASSURANCE CTEX PETROCHEMICAL LTD MANALI
DEPARTMENT OF MANAGEMENT STUDIES
Page | 1
PANCHETTI THIRUVALLUR DIST CHENNAI – 601 204
DECLARATION
I hereby declare that the Project Report entitled “OPERATIONS MAINTENANCE AND PRACTICE.” is done by me under the the guidance of Miss. SHAILAJA SHAILAJA (Internal) and
Mr.RAMAR (External) at CTEX PETROCHEMICAL LTD is submitted in partial fulfillment of the requirements for the award of the degree in MASTER OF BUSINESS ADMINISTRATION.
2
DATE: PLACE:
SIGNATURE OF THE CANDIDATE
3
ACKNOWLEDGEMENT
My sincere thanks to beloved chairman Sri. M.V. Muthuramalingam , for his premier institution. I would like to express my gratitude to our Director Sri M.V.M. Sasi Kumar, who has also responsible for the molding our things to complete this project.
I take extensive privilege in expressing sense of gratitude and heartfelt thanks to
our Principal Principal Dr. Vemuri Lakshminarayana, M.Tech(IIT, Kanpur), Ph. D.,PGDBA,
and nd kind co-operation, without which PGDIM, PGDOM, MBA., for their whole-hearted a this project would not have been possible.
It is my pleasure to express my sincere gratitude and thanks to my Head of Department Department (COO) Mr. Mr. JERRY JERRY MIAH MIAH my Project Project Guide Guide Miss.shailaja for for their their valuable guidance and support at all stages of the project and without whose constant encouragement, I would have not completed this project.
My heartfelt thanks to Mr.GOMATHI SANKER and MR.R.RAMAR for providing me an opportunity to do my project in CTEX PETROCHEMICAL LTD.
I am also thankful to all the faculty members of the MBA Department for their kind and valuable co-operation during the course of the project. I would also like to thank my parents, friends and well wishers who encouraged me to complete this project successfully.
4
INDEX Chap. no
1
2
Contents
Page no
Acknowledgement List of tables List of chart Introduction a. Indu Indust stry ry prof profil ilee b. b. Comp Compan any y pro profi file le c. Produ roduct ct pro proffile ile d. Desc Descri ript ptio ion n of proce process ss Aim of the project a. Obje Object ctiv ivee of the the stud study y b. b. Scop Scopee of the the stud study y
3 a. b. 4
5 6 7 8
a. b. Findings and observations Suggestions Conclusion Bibliography
LIST OF TABLES
5
Table no 1
Description
Page no
a. b. c. 2. a.
6
INTRODUCTION
7
INTRODUCTION
Maintenance is the function of production management that is concerned with day-today problem of keeping the physical plant in good operating condition. It is an essential activity in the manufacturing of petrochemicals, because it is necessary to ensure the availability of the machines, buildings and services needed by other parts of the organization for the performance of their function at an optimum return on investment in machines, materials and employees. This report reviews the operations and maintenance practice to be ensured in CETEX PETROCHEMICALS LTD .
INDUSTRY PROFILE:
Petrochemicals dominate the global chemicals market with a share of almost 40 percent. The coming years are expected to see the petrochemicals industry undergoing a major metamorphosis, particularly with the Middle East as a major petrochemicals supplier and China emerging as a major processing hub and end-use market. Petrochemicals are the downstream of the oil and gas industry - an industry whose products affect our daily lives. Petrochemicals are a part of our daily lives - the carpeting on which we walk, plastic soda bottles from which we drink, clothing we wear, fertilizers that grow our crops, tires we rely on for transportation, paints we use to brighten our surroundings, pharmaceuticals we need to remain healthy, cosmetics, and many other applications. Petrochemicals get their raw material - known as feedstocks - from the refinery: naphtha, components of natural gas such as butane, and some of the byproducts of oil refining processes, such as ethane and propane. These feedstocks are then cracked to obtain the building blocks of the petrochemical industry: olefins, that is, mainly ethylene, propylene, and 8
the so-called C4 derivatives, including butadiene - and aromatics, mainly benzene, toluene, and the xylenes. These products are then processed to produce a wide variety of consumer and industrial products. Petrochemical Industry in India
The petrochemical industry has been one of the of the fastest growing industries in the Indian economy; it provides the foundation for manufacturing industries such as pharmaceuticals, construction, agriculture, packaging industry, textiles, automotive, etc. The petrochemical industry in India is oligopolistic with four main players dominating the market, namely Reliance Industries Ltd. (RIL) along with Indian Petrochemical Ltd. (IPCL), Gas Authority of India Ltd (GAIL), and Haldia Petrochemicals Ltd. (HPL).
Currently, India has three naphtha- and three gas -based cracker complexes with a combined ethylene annual capacity of over 2.5 MMTA. Besides, there are four aromatic complexes also with a combined Xylenes capacity of 2.9 MMTA. Polymers account for more than 60 percent of total petrochemical production. As shown in the figure below, the industry has been stagnant in terms of capacity addition. Combining the demand for all the key segments in the petrochemical industry, aggregate demand for the entire petrochemical sector in India was around 20 MMTA in 2010
9
COMPANY PROFILE:
Cetex Petrochemicals Ltd was established in 1990 with German technology, located at Chennai (Madras), South India. The plant is located about 20 Kms north of Chennai in the Manali Industrial Belt. Feedstock is drawn by pipeline from the neighboring Chennai Petroleum Corporation ltd. PLANT SIGHT
Cetex has ventured into development of fine chemicals like specialized pharma intermediates and aroma chemical & essential chemicals. In an endeavor to upgrade the lucrative additive business, Cetex aspires to produce Energy chemicals, Lube additive, Water treatment chemicals and Marine chemicals. Through marketing tie-ups with leading majors like Petro-Canada, Cetex stands for high performance speciality products in the Indian market place. Cetex Petrochemicals is the largest manufacturer of Methyl Ethyl Ketone (MEK) and Secondary Butyl Alcohol (SBA) in India. With the consistent quality of its products and
10
services, Cetex commands a formidable market share of more than 60%. In India, Cetex has the distinction of being the only manufacturer of MEK to be ISO 9001-2008, ISO 14001 and OSHAs 18001 certified.
Safety and environment:
Setting and achieving high standards for safety, health and the protection of the environment (SHE) is essential to the performance of Cetex petrochemicals and a key element of our commitment to sustainable development. 1. 2.
Cetex gives top priority to worker safety and equipment management.
The company is well equipped in safety systems and trained man power. The company today has a truly impressive safety record. No accidents have occu rred in the past 11 years. 3.
Cetex has been conferred some of the countries highest awards for following
safety standards set by the industry. Cetex has won the Star Safety Award for 1998 & 1999 from National Safety Council , Tamilnadu and is the winner of All India Award from National Safety Council for three years from 2000 to 2002. Cetex is a zero effluent discharge company and has been certified to be a very environment conscious company. Quality Practice and ISO certification:
The quality management system at cetex is ISO 9000 certified. Product quality at Cetex is at par with International levels and Cetex has no history of product rejection since its inception. The company is well committed to sound environmental practices and is ISO 14001 certified. Cetex is committed to continual improvement and is practicing deep rooted TPM, TQM, and 5S initiatives. 11
In the endeavor to achieve high standards in occupational health and safety, Cetex is OSHAs 18001 certified.
PRODUCT PROFILE: 1. Secondary Butyl Alcohol:
Description:
Secondary Butyl Alcohol or Secondary Butyl Alcohol (SBA) is a water white highly volatile liquid with characteristic odour. Secondary Butanol is non-toxic. Secondary Butanol is used in the manufacture of specialty intermediates, Pharma industry and in the manufacture of paints.
Application:
•
manufacture of Pharma intermediates
•
as solvent in Paints and Lacquer industry
•
as solubilizer for the production of cleaning compounds
•
manufacture of Secondary Butyl Acetate, Nitrocellulose solvents
•
manufacture of Printing Inks and as a solvent in flexographic printing dyes
1. Methyl Ethyl Ketone:
Description:
12
Methyl Ethyl Ketone (MEK) is a water white, highly volatile liquid having Acetonelike odour with no cumulative toxicological properties. Methyl Ethyl Ketone is one of the most versatile solvents, capable of dissolving a wide range of substances. Its excellent solvent properties are used by the surface coating, printing ink, plastic processing, resin industries and lubricating oil de-waxing in the Refineries. Methyl Ethyl Ketone is miscible with most organic solvents and owing to the high reactivity of the carbonyl group, it is used as an intermediate in a number of chemical products, such as Aroma Chemicals. Application:
MEK is widely used in the following applications: • • • • • • • • • • • •
Lubricating oil dewaxing Adhesives Printing Inks Magnetic Audio Video tapes Polyurethane resins Artificial Leather PVC film/Leather cloth industry MEK Oxime manufacture MEK Peroxide manufacture Aroma Chemicals such as Methyl Pentanone Degreasing of metal surfaces, particularly Aircraft parts Epoxy glass laminates for the electronic industry
BY PRODUCTS: SOLVENT – X: Description:
Solvent - X is a pale yellow liquid containing a mixture of Ethyl iso Amyl Ketone, higher ketones and secondary Butanol. Solvent - X has somewhat pleasant smell and is nontoxic. SOLVENT – XX:
13
Description:
Solvent - XX is a clear, colorless and highly volatile liquid with a characteristic odour. Solvent - XX contains predominantly di secondary butyl ether. SOLVENT – XXX: Description:
Solvent - XXX is pale yellow, highly volatile liquid with turpentine like odour. The product is non-toxic. Solvent - XXX is flammable and used as a general purpose solvent and diluent. LPG:
Cetex produces LPG quality Butane as a return stream from its Methyl Ethyl Ketone (MEK) paint. The LPG mainly consists of n-Butane up to 95 % with other C4 hydrocarbons being balance 5%. Cetex's LPG being rich in saturated hydrocarbons, is a clean fuel and finds use in specific furnance applications for Glassm Ceramics and Tile manufacturing. Being rich in Butane, usage on stand - alone basis in large industrial applications requires the use of a vaporizer for good burning particularly in the furnances for Glass and Ceramics. Apart from the above, it can blend well in all proportions with Domestic and Industrial LPG. DESCRIPTION OF PROCESS:
SBA is used almost entirely over (90%) as intermediate for the production of MEK.
One of the most common routes for the production of SBA is the hydration of the n butanes via esterification with sulphuric acid. The first step which takes place mainly in the first reactor is the esterification of butene to Mono-Butyl-Ester which reacts acidic after most of the acid has already reacted. There starts the second main reaction of Mono-Butyl-Ester with n-butane, forming
Di-Butyl-Ester which is neutral, but not stable. The next step is
hydrolysis, in which the secondary butyl alcohol is formed. 14
The SBA reaction requires a feed of sulphuric acid at concentration of 75%. The acid will be diluted in the process to an outlet concentration of 50%. Fresh 98% acid will be blended with spent acid and water to the required feed concentration. The hydrolysis output which is the impure SBA is then neutralised to obtain pure SBA. The impure SBA is neutralised by using the caustic soda which is sodium hydroxide and the outputs are pure SBA and the sulphate.
The pure SBA is used for the manufacturing of MEK. The pure SBA undergoes MEK synthesis process. In the synthesis of raw MEK, hydrogen gas is liberated. The raw MEK undergoes distillation process and finally the pure MEK is obtained and stored. The by product is obtained is heavy ketones.
PRODUCTION:
•
MAIN PRODUCTS :
1. Methyl Ethyl Ketone (MEK), Capacity (7500 MT) 2. Secondary butanol (SBA), Capacity (6000 MT) •
BY PRODUCTS :
1. Butane 2. Sulphuric acid (52%) (Spent acid) 3. Polymer (Sol XXX) 4. Secondary Butyl Ether (SBE) (Sol XX) 5.EAK (Sol X) 6.Hydrogen
15
The production plant is running at his maximum capacity of production. The daily production of the company is 24 MT of SBA. The liberated hydrogen gas is utilised in the boiler as a fuel.
PROCESS CHART:
Sulphuric Acid(98%)
Spent acid disposal
Waste to solar pond Feedacid(75%)
Butene
Spent acid (50-55%)
Esterification
Hydrolysis
Neutralizatio
Pure SBA stora e
Butane recovery system
Butene recovery system
Butane LPG Polymer solvent xxx Pure MEK storage
MEK purification
SBA purification
Butane storage LPG SBE solvent xx
Heavy Ketones
MEK synthesis 16
Raw MEK separation
OBJECTIVE OF THE STUDY
PRIMARY OBJECTIVE
To maximize efficiency and economy in produ ction through optimum use of facilities.
SECONDARY OBJECTIVES
•
To keep the plant facilities in full working conditions with zero or minimum breakdowns.
•
Provide evaluation of all facilities for planned maintenance and replacement wherever required.
•
To keep the internal and external premises of the industrial unit clean, safe and in usable condition.
•
To minimize the loss of productive time because of equipment failure.
•
To minimize the repair time and cost.
•
To minimize the loss due to production stoppages.
•
To efficient use of maintenance personnel and equipment.
•
To improve the quality of products and to improve productivity.
•
To minimize accidents through regular inspection and repair of safety devices . 17
SCOPE OF MAINTENANCE
➢
Maintenance of existing plant and equipments.
➢
Equipment inspection and lubrication.
➢ ➢
New installation of equipments and buildings. Plant protection including fire protection.
18
Planning and scheduling of maintenance: What the maintenance activities are to be carried out? How these activities are to be carried out? Where these activities are to be performed? Why these activities are to be performed? When these activities are to be performed?
Importance and necessity of maintenance: ➢
Equipment breakdown leads to stoppage of production and hence loss of man hours and machine hours.
➢
Many times if the first stage machined is non-operative next ‘n’ number of machine will be idle due to no feeding of material due to operational sequence need.
➢
Some of the breakdowns losses are quantifiable and some are not quantifiable
➢
Due to lack of maintenance product quality will be poor and inconsistent. 19
➢
The losses and inconvenience created.
Totally: ➢
Rescheduling of production plan causing delay in supply.
➢
Rejection, damage to components due to faulty machines.
➢
Increasing sub-contracting and hence more cost.
➢
Loss of production and man hours.
➢
Shortfall is also taken care by overtime and hence increases costs.
Functions of plant maintenance: A) Evaluation/Inspection ➢
Periodic check of plant facilities to examine their working
conditions
to take corrective actions. ➢
To check safety factors for machinery and operators.
➢
Ensure that important spares like belts, bearings, bushes which are frequently
➢
required are as per quality and quantity.
To check if spares purchased for imported and high value machinery are from original source.
➢
Obtain information from senior operators, absorb any unusual sound or trouble from machines. Components and other maintenance items received as spares
to be
checked thoroughly by specialists. A) Engineering and Development: ➢
Maintenance engineers should be innovative and think for changes in arrangements to improve machine’s utility and quality of workmanships.
➢
In mechanical/electrical/instrumental installations maintenance staff should take
it up like a project assignment and take better care of cost
and time factors.
20
➢
If production engineer feel deviations are due to machines the maintenance engineers should involve in trouble shooting to keep machines in efficient condition.
Total maintenance work ➢
Taking care of breakdown maintenance (repair work), planned productive maintenance of machinery and equipments.
➢
Scheduled overhauling of major equipments.
➢
Maintenance of building facilities stores yard compound for safety and better work environment
➢
Attending projects assignments for knowhow on future maintenance needs.
A) Replacement, reconditioning disposal decisions ➢
.
A) Administrative work ➢
Personnel and administrative work of the department
➢
Records, drawing specifications of various departments related work.
➢
Spares list for various machines, import list, budget costs etc, files to be maintained.
➢
Record of machinery insurances to be kept.
A) SAFETY Safety from fire, water, pollution.
Housekeeping, maintenance of open yards and buildings.
21
ORGANIZATIONS CHART OF MAINTENANCE PRACTICE FOR A MEDIUM SIZE COMPANY:
TYPES OF MAINTENANCE 1) CORRECTIVE MAINTENANCE 2) PREVENTIVE MAINTENANCE 3) SCHEDULED MAINTENANCE 4) PREDICTIVE MAINTENANCE
MAINTENANCE POLICY:
➢
Adapt preventive maintenance
➢
Have extra facilities to reduce wear and tear.
➢
Replace parts early to avoid further problems.
➢
Involve operative’s machines care, train them.
➢
Use higher capacity machines to reduce chances of breakdowns.
➢
Buy machines which are easy to change parts and for routine maintenance.
➢
Improve overall capacity of maintenance department in forms of manpower, facilities, and training.
➢
Keep adequate stock of spare parts of all machinery and equipments.
22
➢
Keep standby arrangements for important production machinery. Can also take up alternate product manufacture to release machines for maintenance work.
➢
Good interaction between production, quality control and maintenance department.
BREAKDOWN MAINTENANCE:
The word management language is corrective maintenance or ‘breakdown maintenance’
REASONS FOR BREAKDOWN : ➢ ➢ ➢ ➢
Due to failure to replace worn out parts, bearings, belts etc. Not doing periodic oiling, lubrication of moving parts Poor maintenance of heating or cooling system of process Neglecting small cases like loose nuts, sources, projections of or covers
➢
Not filling up fuel or non supply of fuel due to blockage in pipelines.
➢ ➢
Frequent power failures, erratic voltage, short circuiting. Not attending unusual sound, vibrations of moving parts, overheating of parts etc.
PREVENTIVE MAINTENANCE
This is a method of planned maintenance and avoids the possibilities of breakdown. This is precautionary measure and ensures continuous use of machines after attending the work. This identifies the wear out parts, bent or deviated components, loose joints oiling and lubricating needs bearing wear a nd tear. 23
METHODOLOGY: ➢
Periodic inspection of machinery and equipments to understand discrepancies if any and likely of areas problems.
➢
To take up for corrective action when machineries are still in workable condition.
➢
Inspection and identifications of replaceable parts
is the key to
successful preventive maintenance. ➢
Past data from SQC enables to understand the likely trouble spots and recurrence of problems.
BENEFITS OF PREVENTIVE MAINTENANCE ➢
Reduction of the total down-time and consequent reduction in production loses.
➢
Reduction in the number of major repairs, and consequently reduced maintenance expenses.
➢
Reduction in the number of rejects and n improvements in product quality.
➢
Reduction in the inventory of spare parts.
➢
Reduction in the number of accidents in the plant.
➢
Reduction in the unplanned or crisis management in maintenance.
➢
There are certain costs associated with the preventive maintenance
➢
Scheduled down-time of production.
➢
Replacement parts and supplies.
➢
Instruments e.g.in the case of condition monitoring.
➢
Wages of preventive maintenance technicians and staff.
Each plant should have its own preventive maintenance policies suited to that plant’s needs. the working environment, the type of operations, the type equipment, the age of 24
equipment and plant, and other factors determine the incidents of breakdowns, their severity, and the costs associated with these in the absence or presence of the preventive maintenance programme of a smaller or larger size. In general, plants which are maintained efficiently spend almost three quarters of their time on preventive maintenance, while only one quarter is spent on breakdown maintenance.
OBJECTIVES OF PREVENTIVE MAINTENANCE: ➢
To avoid or minimize possibilities of breakdowns
➢
To ensure availability of all the machines in usable conditions.
➢
To ensure effectiveness and efficiency of all machines.
➢
To ensure safety of employees.
➢
To maintain resale value of the machines.
➢
To reduce unplanned work for maintain staff.
INSPECTION FOR PM: ➢
Initially the past records are to be referred to know what all actions taken last time. this give an idea of important activities, spares, time, and cost needs.
➢
The moving parts are checked again and again to ascertain the wear and tear. Similarly bearings, bearing block, belts and toggles are checked for strength and endurance until next PM.
➢
Based on above observation a check list is made to attend work and to take trial run to verify that the PM work is satisfactory to maintenance and production engineers.
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MECHANICAL-BREAKDOWN MAINTAINANCE
RANGE
TAG NO
EQUIPMEN T NAME
DATE
PROBLEM IDENTIFIE
REMEDY
D
OF DAYS FUNTIO
OF BREAKD OWN
NED BEFORE FAILUR E
K907C
P940
Inducted
Driver
draught fan
STP
side
Bearing
29-12-09
bearing
fixed
9:00-
damaged
OK
16:00
Pump jammed
Shaft,
24-12-9
circulation
bearings,oil,s
11:00-
pump
eal,mech seal
16:00
17 DAYS
2DAYS
renewed OK XR101B
Secondstage reactor
Coil puncture
Coil
lead,
welding work
3-12-09
22DAYS
14-12-09 done
OK
26
P305
Condensable
Pump
water pump
leak
seal
Mech
seal
Renewed
30-11-09 4hrs
OK P305B
P105B
Condensable
Abnormal
Spare pump
30-11-09
water pump
sound
fixed OK
3hs
Newtralizatio
Pump
Stationary
23-11-09
n wash pump
leak
Rotary
25-11-09
seal
face
13DAYS
12DAYS
changed OK S902A
Wood therme
Screw
screw feeder
jammed
feeder
F-208
17-11-09
1NOS&P208
20-11-09
3DAYS
2NOS,Beari ng
changed
shaft renewed OK P904
Spent
acid
Causing leak
Spare pump
4-11-09
fixed OK
5-11-09
Abnormal
Stationary
2-11-09
sound
&Rotary
10-11-09
pump P133B
Spent
acid
pump
26DAYS
8DAYS
face renewed stuffing box changed, taken in line OK P151B
-------------
Pump seal
mech
Rotary changed
face
26-10-09
1DAY
27-10-09 27
&stationary face
fixed,
taken in line OK P940
K901B
STP
Pump jammed
Bearing
10-10-09
Circulation
&seal
11-10-09
pump
changed OK
Instrument Air Poor
Cylinder
24-9-09
Compressors
&piston
1-10-09
performance
12DAYS
1DAY
rings changed calues serviced &fixed K1O1B
Butane
Compressor
Compressors
piston
The
24-9-09
ring following
1-10-09
damaged
4DAYS
spares renewed piston
ring,
value channels taken in line OK P133A
Spent pump
acid
Pump seal leak
mech
The
23-9-09
following
2hrs
17DAYS
spares renewed 28
sleeve mech seal K902B
Wood
Blower
Bearing
thermaze
abnormal
changed,
sound
bearing
18-9-09
nos:2210kc3 P932
Solvent pump
Pump
mech
seal leak
17DAYS
1hrs
The
17-9-09
following
5hrs
9DAYS
spares renewed, mech
seal
changed taken in line OK P934
Remembrance
Pump
The
cleaning pump
abnormal
following
sound
and
mech seal leak
17-9-09
9DAYS
The
12-9-09
17DAYS
following
14-9-09
spares renewed shaft bearing, mech
seal
taken in line OK P912A
98% sulphuric
Pump
acid transfer
seal leak
mech
spares renewed 29
R201
Mek Reactor I
Catalyst to be
Support ring
6-9-09
renewed
after catalyst
17-9-09
filled
top
&bottom down P132B
Acid
feed
pump
Pump
mech
seal leak
The
6-8-09
following
7-8-09
20DAYS
spares renewed sleeve &seal set OK K901A
Instrument Air Poor
Position ring
4-8-09
Compressor
1st,2nd
5-8-09
performance
stage
23DAYS
inlet &discharge value serviced the
of
springs
&seat
plate
changed OK K101B
Butane
Poor
2 ND Stage of
26-7-09
Compressor
performance
value
7hrs
6DAYS
removed &discharge channel &spring channel
30
changed OK
P105A
Neutralization
Pump
mech
wash pump
seal leak
MECH
22-7-09
SEAL
23-7-09
25DAYS
Stationary &rotary ‘O’ring changed taken in line OK P912A
98% Sulphuric
Pump
mech
acid circulation
seal leak
pump
Pump
17-7-09
assembled
18-7-09
with
22DAYS
new
ceramic bellow &silicon carbide face P133B
Spent pump
acid
Pump
mech
seal leak
Pump
10-7-09
assembled
13-7-09
16DAYS
with spares bearing,oil seal P940
Circulation
Pump
Pump
9-7-09
pump
abnormal
assembled
15-7-09
sound seal leak
with
16DAYS
with sparesshaft, bearings, oil 31
seal, seal set
P916B
Furnace
oil
Transfer pump
Pump
Pump
5-7-09
jammed
bearing 4 nos
17-7-09
18DAYS
renewed assembled OK P133A
Spent
acid
pump
pump
Pump
2-7-09
abnormal
bearing
8:30-
sound
&1.250
21:30
&seal
leak
25DAYS
bellow renewed, assembled OK
P154B
SBA
Product
pump
Pump
Pump
24-6-09
abnormal
bearings
8:00-
sound
renewed seal
22:00
&seal
leak
face
9DAYS
lapped
is fixed OK P916A
Furnace
oil
Transfer pump
Pump
seal
Pump
seal
leak &cosing
&casing ‘O’
leak
RING
21-6-09
23DAYS
1-7-09
Renewed taken in line OK P510
C510
Mech
Circulation
leak
seal
Stationary
9-6-09
seal changed 32
pump
taken in line
13-6-09
OK XV106A
Caustic Vessel
Abnormal
Bearing
14-5-09
Aggitator
sound
renewed,620
18-5-09
9DAYS
72&62062& 35*45*7 oil seal
also
renewed P251A
Dryer Column
Seal leak
Bottom pump
Wilo
(mech
seal)pump
14-5-09
10DAYS
2hrs
seal renewed OK P253A
P155A
MEK
Reactor Seal leak
Wilo
pump
Column Reflux
seal renewed
pump
ok
Water
SBA-
Recycle pump
14-5-09 2hrs
Pump
2NOS
9-5-09
abnormal
bearing
30-5-09
sound
changed &seal
19DAYS
0DAYS
spare
renewed OK P303
HOT circulating pump
oil
Abnormal
Coupling
28-4-09
sound
changed,
4-5-09
27DAYS
bearing &oil hauling replaced OK
33
K902A
K101A
Wood
Abnormal
Impellor
25-4-09
thermaze
sound
balanced
5-5-09
secondary
&bearing
draught fan
removed OK
Butane
Poor
Compressors
formance
per 1T
STAGE
value 4 nos
19-4-09
17DAYS
17DAYS
6hrs
serviced &fixed taken in line OK P105B
Caustic
Pump
Neutralization
leak
seal
‘O’ring renewed
pump
8-4-09 in
26DAYS
6hrs
seal taken in line OK
P106
Caustic
Mech
Neutralization
leak
seal
‘O’ring renewed
pump
4-4-09 in
13DAYS
6hrs
seal taken in line OK
P133B
Spent
acid
pump
Mech
seal
leak
Bellow
31-3-09
renewed seal
2-4-09
face
8DAYS
lapped
taken in line OK P925B
Fuel oil pump
Mech leak
seal
Seal
20-3-09
assembled
5hrs
27DAYS
renewed OK P917A
Metro
water
Abnormal
16-3-09
16DAYS
34
pump P132B
Acid
sound feed
pump
Mech
25-3-09 seal
leak
Seal
face
lapped
9-3-09
21DAYS
10-3-09
&fixed K101B
Butane
Poor
H.P
Compressor
performance
suction
SIDE
4-3-09
13DAYS
6hrs
&discharge value serviced OK XR101B
XR101B
Reactor
Mech
Agitator I
leak
Reactor
Mech
Agitator
leak
seal
seal
Spare
seal
20-2-09
fixed OK
7hrs
Spare
19-2-09
seal
RENEWED
24DAYS
23DAYS
20-2-09
OK P133A
Spent
acid
pump
P134A
Ester pump
pump
seal
12-01-09
leak
serviced&fix
13-01-09
&bed
ed
damaged
changed OK
Pump leak
seal Pump
seal
6DAYS
bed
1.250NEW
29-1-09
SEAL
1-02-09
set
21DAYS
fixed OK P132A
Acid Pump
feed
Pump
Pump
8-1-09
abnormal
assembled
9-1-09
sound
with
2DAYS
new
shaft &lapped seal 35
fixed
pump
assembled taken in line OK P132B
Acid
Feed
pump
Pump
seal
Pump
leak
7-1-09
&old
seal
8:30-
changed OK
15:00
20DAYS
CETEX PETROCHAMICALS LTD PREVENTIVE MAINTENANCE SCHEDULE
For no: EN/F/06 MONTH:JAN 2009 TO DEC 2009 DATE
SECTION:MECHANICAL
A SHIFT
B SHIFT
C SHIFT
1
K-902B
P-905A
P-931B
K-903C
P-255B
2
K-101A
P-901A
K-928
K-903D
P-271
3
P-151A
P-902B
P-202A
P-922E
P-103B
4
P-251A
P-907B
P-922A
P-922F
XV-106C
5
XV-106A
P-906B
P-110A
S-903A
P-132A
6
P-925A
P-904
P-133A
S-903B
P-109B
7
P-134A
P-302B
P-156A
S-903C
P-923A
8
P-926
P-251B
K-902A
S-903D
P-153B
9
K-905
P-902A
P-155A
S-903E
P-107A
10
K-901A
P-908B
P-915
C-903
P-201A
11
P-921A
K-904A/B
P-109A
K-902C
P-105B 36
12
K-903A
P-912B
K-907C
K-902D
P-107B
13
P-923B
P-919
XV-107
K-902E
P-254A
14
P-922B
P-913
P-152B
S-902A
P-255A
15
P-920A
P-917B
P-202B
S-902B
P-253B
16
P-252B
P-916B
P-914
C-902
P-132B
17
P-921B
P-906A
P-134B
K-909
P-305B
18
K-906
P-901B
XV-275
P-907D
P-103A
19
XV-106B
P-903
P-922D
P-907F
P-106
20
K-101B
K-201A
P-154A
K-907A
P-110B
21
P-152A
P-301
P-156B
K-907B
P-305A
22
P-907C
P-905B
XR-102
P-940
P-925B
23
K-901B
P-908A
P-924
P-939A
P-133B
24
P-912A
P-911
P-154B
K-908
P-253A
25
XR101A/B
P-273B
P-254B
P-939B
P-274
26
P932
P-922C
P-105A
P-934
P-201B
27
P-910
P-916A
P-920B
P-935
P-151B
28
P-907A
P-918
P-931A
P-941
P-153A
29
P-917A
P-930
P-155B
K-903B
P-109C
P104,P303
P-272
P-201B
P-302A
P-909
IMPORTANCE OF STATISTICS OF FAILURE: How long was the machine component working before it failed? This is the time-tofailure, t.
37
What percentage of instances did it fail at time t. This is the relatively frequency of failure corresponding to time t.
MECHANICAL ANALYSIS
RANGE OF DAYS FUNCTIONED BEFORE FAILURE (0 - 5) (6 - 10) (11 - 15) (16 - 20) (21 - 25) (26 - 30)
NUMBER OF EQUIPMENTS OCCURENCE IN THE RANGE OF LIFE
7 9 5 13 10 4
38
MECHANICAL ANALYSIS
december november october september august july june may april march febuary january
3 6 2 8 2 7 3 4 5 6 2 3
OVERALL ANALYSIS:FOR MECHANICAL
39
M ONTH december november october september august july june may april march febuary january
EQUIPMENT NAME K907C, P940, XR101B,XR101B P305, P305B, P105B, S902A, P904,P133B, P151B, P940
K901B, K1O1B, P133A, K902B, P932, P934, P912A, R201 P132B, K901A K101B, P105A, P912A, P133B, P940, P916B, P133A P154B, P916A, P510 XV106A, P251A, P253A, P155A, P303, K902A, K101A, P105B, P106 P133B, P925B, P917A, P132B, K101B XR101B, XR101B P133A,P134A,P132A,P132B
Name of the Deviation Pump Seal Leak Abnormal Sound Poor Performance Pump Jammed Bearing damaged Piston Ring Damaged Coil Puncture
Frequenc y
Percetag e (%)
30 12 6 4 1 1 1
54.55 21.82 10.91 7.27 1.82 1.82 1.82
BREAKDOWN 3 6 2 5 3 7 4 4 5 5 2 4
Cumalativ e Percentag e 54.55 76.36 87.27 94.55 96.36 98.18 100.00
40
Machine life without breakdown-machanical
Range of life
Frequenc y
Percetag e (%)
13 10 9 7 5 4
27.08 20.83 18.75 14.58 10.42 8.33
16 - 20 Days 20 - 25 Days 6 - 10 Days 0 - 5 Days 11 - 15 Days 26 - 30 Days
Cumalativ e Percentag e 27.08 47.92 66.67 81.25 91.67 100.00
BREAKDOWN MAINTENANCE ELECTRICAL DEPARTMENT
RANGE OF
TAG NO
EQUIPMENT
PROBLEM
NAME
IDENTIFIED
REMEDY
DOWN TIME
DAYS FUNTIONED BEFORE FAILURE
P105B
P105B
Motor tripped
Motor
31-12
continuously
rewinding
4-12
&taken higher
alone
load due to
&fixed
insulation
10
11.3010.30hr
41
failure
P305A
Motor got
Motor
Confeutble
tripped due to
rewinding
23-12
pump
insulation
alone
30-12
failure
&fixed
2
5-12 MK903D
3fd motor
5-12
--------------------
3
16.3019.30hr VVFD by
SFDMK-
SFD
903E
MF 607A
Motor vvfd got
ported
4-12
failure
&stare &
4-12
0
delba Motor
rewinding
Cooling water
insulation(due
done
4-12
pump
to higher load
&replaced
5-1
got failure
in this plane
5
rewinding MP939A
Circulation pump(MEK)
Motor tripped
done
4-12
&replaced
4-01
19
in this plane MXR102
Agitator
D.L.R
got
trouble &cable burnt
Spare
14-9
replaced
14-9
13
Half hr
42
410D
D.G.SET
D.G set RPM
Fuel pump
12-9
failed
solinoid set
12-9
problem afforded
MP101B
MP934
MP691
MP502B
Bwitter rod
Membrane pump
Blower motor
Circulation pump
Frequently tlane failure
13
Half hr
New burner
3-8
rod
1:30
changed
min
Motor end
Motor
abnormal
bearing
sound came
renewed
Motor
Motor
insulation got
rewinding
failed
done
Motor
Motor
13-7
insulation got
rewinding
17-7
failed
done
3
30-7 4 2-8
22-7 12 13-8
17
Motor not run ,tripped MP918
Motor water
continuously
pump
due to feeder side confactor
Spare
11-7
confactor
11:30-
renewed
12;45
13
got Motor not run MP920B
d.m. water
checked feeder
pump
side confactor got burnt
Spare
24-6
confactor renewed
27 2hrs
43
Motor not run
MP109A
Caustic
due to v.f.d
circulation
working o/p
pump
supply got trouble
V.F.D renewed& D.O.L
27-5
starter
1hrs
16
supply given Bearing renewed
MP134A
-------------------
Motor bearing
spare motor
got failed
fixed, motor
15-5
8
send renewed Motor not run MK903A
Blower motor
&trip frequent, intend short at motor inside
MP912A
Acid motor
Spare motor fixed
28-3
and old
13;00-
send to
22:00
14
rewind
Motor bearing
Motor
9-3
noise came
serviced
4hrs
14
Spare Motor not run MK903B
Tmax blower
&cable burnt, contractor jam &coil burnt
motor renewed
7-3
&cable
8-3
21
12-2
12
regulated tested &lineuped
MK903C
FO boiler
Motor bearing
Motor
44
spare blower
jam
renewed &bearing
4hrs
replaced MK906
-------------------
Motor not run
Motor
2-2
&coil burnt
renewed
2hrs
13
&motor coil renewed MP931A ------------------Motor got trip RANGE OF DAYS FUNCTIONED BEFORE FAILURE containing (0 - 5) &bearing jam (6 - 10) (11 - 15) (16 - 20) - 25) MP-154Pump(21 motor Motor got (26 - 30) B struck up & coil burnt
Bearings 21-01 23 NUMBER OF EQUIPMENTS IN THE RANGE OF LIFE both side 2hrs 6 renewed 2 &fixed in 7 place 4 Motor 11-1 2 17 1 bearing 16-01 renewed &coil rewinding
ELECTRICAL ANALYSIS
45
ELECTRICAL ANALYSIS
December November October September August July June May April March Febuary January
6 0 0 2 1 4 1 2 0 3 2 3
MONTH
december november october september august july june may april
NAME OF THE EQUIPMENT
BREAKDOWN
P105B, P305A, MK903D, SFD-MK-903E, MF 607A, MP939A
6
-
-
-
-
MXR-102, 410D
9
MP101B
1
MP934, MP691, MP502B, MP918
4
MP920B
1
MP109A, MP134A
2
-
-
46
march febuary january
MK903A, MP912A, MK903B
3
MK903C, MK906
2
MP931A, MP-154-B
2
Name of the Deviation Motar Insulation Failure Abnormal Sound Bearing Failed Cable & Coil Burnt Motor VVFD Failure DLR trouble Dg Set RPm Failed
Frequenc y
Percetag e (%)
10 3 3 3 2 1 1
43.48 13.04 13.04 13.04 8.70 4.35 4.35
Cumalativ e Percentag e 43.48 56.52 69.57 82.61 91.30 95.65 100.00
47
Range of life 11-15 days 0-5 days 16-20 days 6-10 days 21-15 days 26 - 30 Days
Frequen cy
Perceta ge (%)
Cumalati ve Percenta ge
7
27.08
27.08
6
20.83
47.92
4
18.75
66.67
2
14.58
81.25
2
10.42
91.67
1
8.33
100.00
48
FINDINGS AND SUGGESTIONS: ➢
Diagnosing the fault or failures as early as possible and taking quick decisions regarding the same.
➢
Reducing major break-downs or crisis situations with the help of appropriately organized preventive maintenance programmes.
➢
Designing and Installing the equipment in such a way that failures of the equipment will be low over its lifetime or in other words , increasing what is known as the reliability of the plant ,machinery and equipment in the design staged itself. Also ,The equipment could be so designed that the times for maintenance action are small i.e,the ‘maintainability’ should be high.
➢
Having proper replacement policies of equipment and their component parts in such a way that the total reliability and availability of the system is enhanced at optimal costs.
➢
Having standard times and standard procedures in maintenance as much as possible, so as to gain good control over maintenance operations and also to provide adequate incentives and motivation for maintenance personnel.
➢
Reduction of operations lead times , delivery times through continuous improvements.
➢
No postponements or cancellations of the scheduled production, thus ensuring the supply on time.
➢
Improvements in quality; producing right the first time, self-inspection and certification; all of this leading to unnecessary wastage of time and in actual reduction in operation/process times.
➢
Improved machinery maintenance, improved design of the products and processes, so that the expenditure of time due to breakdown, rejects, reworks is avoided.
Supportive organizational conditions for better maintenance management
49
1).Good Cooperation and coordination between the production and maintenance functions, in general , I essential. ○
Annual planning for maintenance should be done along with the annual production plan.
○
Monthly, weekly, daily maintenance schedules should be drawn, preferably in consultation
with
the
production
people.
These
must
be
properly
communicated to the production people. ○
If there are any changes in the capacity-utilization, process-changes nd method-changes, etc,t he maintenance department should be aware of the same.
In short, there should be much interaction between maintenance and production people at the policy-planning, schedule-making, and all other levels. 2) Maintenance function should not be under production management If a maintenance manager feels that a critical equipment needs quick maintenance attention, in order to avoid a portable breakdown, he should have the full authority to order the shut-down of the equipment. 4) Proper equipment records should be kept giving details such as breakdown –statistics, maintenance carried out, the causes of breakdown, time taken for maintenance, the components and parts of the machinery, the suppliers, dates
on which preventive
maintenance was carried out, the type of preventive action carried out, such information helps in policy-planning, scheduling, and allocation of maintenance resources. 5) Spare –parts inventory should be controlled properly, so that adequate numbers are available for maintenance purposes. 6) To ensure good control, the maintenance work should be standardized as much as possible.
50