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 PANCHETTI THIRUVALLUR DIST CHENNAI – 601 204 Page | 1

DECLARATION I hereby declare that the Project Report entitled “OPERATIONS MAINTENANCE AND PRACTICE.” is done by me under the guidance of Miss. 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.

DATE: PLACE: SIGNATURE OF THE CANDIDATE

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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 Dr. Vemuri Lakshminarayana, M.Tech(IIT, Kanpur), Ph. D.,PGDBA,

PGDIM, PGDOM, MBA., for their whole-hearted and kind co-operation, without which this project would not have been possible.

It is my pleasure to express my sincere gratitude and thanks to my Head of Department (COO) Mr. JERRY MIAH my Project Guide Miss.shailaja for 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.

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INDEX Chap. no Acknowledgement List of tables List of chart 1 Introduction a. Industry profile b. Company profile c. Product profile d. Description of process 2 Aim of the project a. Objective of the study b. Scope of the study 3 a. Contents Page no

b. 4 a. b. 5 6 7 8 Findings and observations Suggestions Conclusion Bibliography

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LIST OF TABLES Table no 1 a. b. c. 2. a. Description Page no

5

INTRODUCTION

6

INTRODUCTION

Maintenance is the function of production management that is concerned with day-to-day 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 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.

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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

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. 8

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 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.

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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.

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 occurred in the past 11 years. 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. In the endeavor to achieve high standards in occupational health and safety, Cetex is OSHAs 18001 certified.

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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

2. Methyl Ethyl Ketone:

Description: 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. 11

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: Description: Solvent - XX is a clear, colorless and highly volatile liquid with a characteristic odour. Solvent - XX contains predominantly di secondary butyl ether. 12

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 nbutanes 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.

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 13

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 byproduct 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

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.

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PROCESS CHART:

Sulphuric Acid(98%)

Spent acid disposal

Waste to solar pond Feedacid(75%) Spent acid (50-55%) SBA purification

Butene

Esterification

Hydrolysis

Neutralization

Butene recovery system

Butane recovery system

Pure SBA storage

Butane LPG

Butane storage LPG

Polymer solvent xxx Pure MEK storage MEK purification Heavy Ketones

SBE solvent xx

MEK synthesis

Raw MEK separation

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OBJECTIVE OF THE STUDY

PRIMARY OBJECTIVE

To maximize efficiency and economy in production 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 .

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SCOPE OF MAINTENANCE
 Maintenance of existing plant and equipments.  Equipment inspection and lubrication.  New installation of equipments and buildings.  Plant protection including fire protection.

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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.  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 to take corrective actions.  To check safety factors for machinery and operators. 18 conditions

 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 checked thoroughly by specialists. B) 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 to be

and time factors.  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. C) Replacement, reconditioning disposal decisions  .

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D) 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. E) SAFETY Safety from fire, water, pollution. Housekeeping, maintenance of open yards and buildings.

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. 20

 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.  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

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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 and tear.

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 successful preventive maintenance.  Past data from SQC enables to understand the likely trouble spots and recurrence of problems. is the key to

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.

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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 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 DATE REMEDY OF BREAKD OWN OF DAYS FUNTIO NED BEFORE FAILUR E K907C Inducted draught fan Driver bearing damaged OK P940 STP circulation pump Pump jammed Shaft, bearings,oil,s eal,mech seal renewed OK XR101B Secondstage reactor Coil puncture Coil welding work OK P305 Condensable water pump P305B Condensable water pump Pump leak Abnormal sound seal Mech seal 30-11-09 4hrs Spare pump fixed OK 3hs 24 30-11-09 13DAYS done 14-12-09 lead, 11:0016:00 3-12-09 22DAYS side Bearing fixed 9:0016:00 24-12-9 2DAYS 29-12-09 17 DAYS

TAG NO

EQUIPMEN T NAME

PROBLEM IDENTIFIE D

Renewed OK

P105B

Newtralization wash pump

Pump leak

seal

Stationary Rotary face

23-11-09 25-11-09 17-11-09 20-11-09

12DAYS

changed OK S902A Wood therme screw feeder Screw feeder jammed F-208 1NOS&P208 2NOS,Bearin g shaft renewed OK P904 Spent pump P133B Spent pump acid Abnormal sound acid Causing leak Spare pump fixed OK changed

3DAYS

4-11-09 5-11-09

26DAYS

Stationary &Rotary face renewed stuffing box changed, taken in line OK

2-11-09 10-11-09

8DAYS

P151B

-------------

Pump seal

mech

Rotary changed

face

26-10-09 27-10-09

1DAY

&stationary face fixed,

taken in line OK P940 STP Circulation pump K901B Instrument Air Compressors Poor performance Pump jammed Bearing &seal changed OK Cylinder &piston 25 11-10-09 24-9-09 1DAY 10-10-09 12DAYS

rings changed calues serviced &fixed K1O1B Butane Compressors Compressor piston damaged ring The following spares renewed piston value channels taken in line OK P133A Spent pump acid Pump seal leak mech The following spares renewed sleeve mech seal K902B Wood thermaze Blower abnormal sound Bearing changed, bearing nos:2210kc3 P932 Solvent pump Pump seal leak mech The following spares renewed, mech changed seal ring,

1-10-09

24-9-09 1-10-09

4DAYS

23-9-09 2hrs

17DAYS

18-9-09

17DAYS

1hrs 17-9-09 5hrs 9DAYS

26

taken in line OK P934 Remembrance cleaning pump Pump abnormal sound mech leak and seal The following spares renewed shaft bearing, mech seal 17-9-09 9DAYS

taken in line OK P912A 98% sulphuric acid transfer Pump seal leak mech The following spares renewed R201 Mek Reactor I Catalyst to be renewed Support ring after catalyst filled &bottom down P132B Acid pump feed Pump seal leak mech The following spares renewed sleeve &seal set OK K901A Instrument Air Compressor Poor performance Position ring 1st,2nd inlet &discharge stage 5-8-09 4-8-09 23DAYS 7-8-09 6-8-09 20DAYS top 17-9-09 6-9-09 14-9-09 12-9-09 17DAYS

27

value serviced the &seat of

springs plate

changed OK K101B Butane Compressor Poor performance 2ND Stage of value removed &discharge channel &spring channel changed OK P105A Neutralization wash pump Pump seal leak mech MECH SEAL Stationary &rotary ‘O’ring changed taken in line OK P912A 98% Sulphuric acid circulation pump Pump seal leak mech Pump assembled with ceramic bellow &silicon carbide face P133B Spent pump acid Pump seal leak mech Pump assembled 13-7-09 28 10-7-09 16DAYS new 18-7-09 17-7-09 22DAYS 23-7-09 22-7-09 25DAYS 7hrs 26-7-09 6DAYS

with sparesbearing,oil seal P940 Circulation pump Pump abnormal sound seal leak with Pump assembled with sparesshaft, bearings, oil seal, seal set P916B Furnace oil Pump jammed Pump bearing 4 nos renewed assembled OK P133A Spent pump acid pump abnormal sound leak &seal Pump bearing &1.250 bellow renewed, assembled OK P154B SBA pump Product Pump abnormal sound leak &seal Pump bearings renewed seal face lapped 8:0022:00 24-6-09 9DAYS 8:3021:30 2-7-09 25DAYS 17-7-09 5-7-09 18DAYS 15-7-09 9-7-09 16DAYS

Transfer pump

is fixed OK P916A Furnace oil Pump seal Pump seal 21-6-09 1-7-09 23DAYS &casing ‘O’ RING Renewed

Transfer pump

leak &cosing leak

29

taken in line OK P510 C510 Circulation pump Mech leak seal Stationary seal changed taken in line OK XV106A Caustic Vessel Aggitator Abnormal sound Bearing renewed,620 72&62062& 35*45*7 oil seal renewed P251A Dryer Column Bottom pump Seal leak Wilo (mech seal)pump seal renewed OK P253A MEK Reactor Column Reflux pump P155A Water SBAPump abnormal sound Seal leak Wilo pump 14-5-09 2hrs 9-5-09 30-5-09 0DAYS 19DAYS 2hrs 14-5-09 10DAYS also 18-5-09 14-5-09 9DAYS 13-6-09 9-6-09

seal renewed ok 2NOS bearing changed &seal spare renewed OK

Recycle pump

P303

HOT circulating pump

oil

Abnormal sound

Coupling changed, bearing &oil hauling replaced OK

28-4-09 4-5-09

27DAYS

30

K902A

Wood thermaze secondary draught fan

Abnormal sound

Impellor balanced &bearing removed OK

25-4-09 5-5-09

17DAYS

K101A

Butane Compressors

Poor formance

per

1T

STAGE

19-4-09 6hrs

17DAYS

value 4 nos serviced &fixed taken in line OK ‘O’ring renewed in 6hrs

P105B

Caustic Neutralization pump

Pump leak

seal

8-4-09

26DAYS

seal taken in line OK ‘O’ring renewed in

P106

Caustic Neutralization pump

Mech leak

seal

4-4-09 6hrs

13DAYS

seal taken in line OK

P133B

Spent pump

acid

Mech leak

seal

Bellow renewed seal face lapped

31-3-09 2-4-09

8DAYS

taken in line OK P925B Fuel oil pump Mech leak seal Seal assembled renewed OK P917A Metro pump P132B Acid pump feed water Abnormal sound 25-3-09 Mech leak seal Seal lapped 31 face 9-3-09 21DAYS 5hrs 16-3-09 16DAYS 20-3-09 27DAYS

&fixed K101B Butane Compressor Poor performance H.P suction &discharge value serviced OK XR101B Reactor Agitator I XR101B Reactor Agitator Mech leak Mech leak seal seal Spare fixed OK seal SIDE

10-3-09 4-3-09 6hrs 13DAYS

20-2-09 7hrs

24DAYS

Spare

seal

19-2-09 20-2-09

23DAYS

RENEWED OK

P133A

Spent pump

acid

pump leak &bed damaged

seal

Pump

seal

12-01-09 13-01-09

6DAYS

serviced&fix ed bed

changed OK seal 1.250NEW SEAL fixed OK set 1-02-09 8-1-09 9-1-09 2DAYS 29-1-09 21DAYS

P134A

Ester pump

Pump leak

P132A

Acid Pump

feed

Pump abnormal sound

Pump assembled with shaft &lapped seal fixed pump new

assembled taken in line OK P132B Acid pump Feed Pump leak 32 seal Pump 7-1-09 20DAYS

&old

seal

8:3015:00

changed OK

CETEX PETROCHAMICALS LTD PREVENTIVE MAINTENANCE SCHEDULE For no: EN/F/06 MONTH:JAN 2009 TO DEC 2009 DATE 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 K-902B K-101A P-151A P-251A XV-106A P-925A P-134A P-926 K-905 K-901A P-921A K-903A P-923B P-922B P-920A P-252B P-921B K-906 XV-106B K-101B A SHIFT P-905A P-901A P-902B P-907B P-906B P-904 P-302B P-251B P-902A P-908B K-904A/B P-912B P-919 P-913 P-917B P-916B P-906A P-901B P-903 K-201A P-931B K-928 P-202A P-922A P-110A P-133A P-156A K-902A P-155A P-915 P-109A K-907C XV-107 P-152B P-202B P-914 P-134B XV-275 P-922D P-154A SECTION:MECHANICAL B SHIFT K-903C K-903D P-922E P-922F S-903A S-903B S-903C S-903D S-903E C-903 K-902C K-902D K-902E S-902A S-902B C-902 K-909 P-907D P-907F K-907A C SHIFT P-255B P-271 P-103B XV-106C P-132A P-109B P-923A P-153B P-107A P-201A P-105B P-107B P-254A P-255A P-253B P-132B P-305B P-103A P-106 P-110B 33

21 22 23 24 25 26 27 28 29

P-152A P-907C K-901B P-912A XR101A/B P932 P-910 P-907A P-917A P104,P303

P-301 P-905B P-908A P-911 P-273B P-922C P-916A P-918 P-930 P-272

P-156B XR-102 P-924 P-154B P-254B P-105A P-920B P-931A P-155B P-201B

K-907B P-940 P-939A K-908 P-939B P-934 P-935 P-941 K-903B P-302A

P-305A P-925B P-133B P-253A P-274 P-201B P-151B P-153A P-109C P-909

IMPORTANCE OF STATISTICS OF FAILURE: How long was the machine component working before it failed? This is the time-tofailure, t. What percentage of instances did it fail at time t. This is the relatively frequency of failure corresponding to time t.

34

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

NUMBER OF EQUIPMENTS OCCURENCE IN THE RANGE OF LIFE
NUMBER OF EQUIPMENTS OCCURENCE IN THE RANGE OF LIFE 13 9 7 5 4 10

(0 - 5)

(6 - 10)

(11 - 15)

(16 - 20)

(21 - 25)

(26 - 30)

35

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

Chart Title
8 7 6 5 4 3 2 2 3 2 3 6

36

OVERALL ANALYSIS:FOR MECHANICAL

MONTH 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

BREAKDOWN 3 6 2 5 3 7 4 4 5 5 2 4

BREAKDOWN
december november 4% 10% 10% 8% 8% 14% 6% 8% 6% 12% 4% 10% october september august july june may april march febuary january

37

BREAKDOWN

K907C, P940, XR101B,XR101B

K901B, K1O1B, P133A, K902B, P932, P934,…

K101B, P105A, P912A, P133B, P940, P916B,…

P154B, P916A, P510

P305, P305B, P105B, S902A, P904,P133B,

P303, K902A, K101A, P105B, P106

P133B, P925B, P917A, P132B, K101B

P132B, K901A

decembernovember october september august

july

june

may

april

march

febuary

january

Name of the Deviation Pump Seal Leak Abnormal Sound Poor Performance Pump Jammed Bearing damaged Piston Ring Damaged Coil Puncture

Frequency 30 12 6 4 1 1 1

Percetage (%) 54.55 21.82 10.91 7.27 1.82 1.82 1.82

Cumalative Percentage 54.55 76.36 87.27 94.55 96.36 98.18 100.00

38

P133A,P134A,P132 A,P132B

XV106A, P251A, P253A, P155A,

P151B, P940

XR101B, XR101B

35

FREQUENCY OF PROBLEMS OCCURED - MECHANICAL

120.00

30

100.00

25 80.00 20 60.00 Frequency 15 40.00 10 Cumulative Percentage (%)

5

20.00

0 Pump Seal Leak Frequency Cumalative Percentage 30 54.55 Abnorm al Sound 12 76.36 Poor Perform ance 6 87.27 Pump Jammed 4 94.55 Bearing damage d 1 96.36

Piston Ring Damage d 1 98.18

0.00 Coil Punctur e 1 100.00

Machine life without breakdown-machanical

Range of life 16 - 20 Days 20 - 25 Days 6 - 10 Days 0 - 5 Days 11 - 15 Days 26 - 30 Days

Frequency 13 10 9 7 5 4

Percetage (%) 27.08 20.83 18.75 14.58 10.42 8.33

Cumalative Percentage 27.08 47.92 66.67 81.25 91.67 100.00

39

Machine Life without Break Down - Mechanical 14 120.00
12 100.00

10 80.00 8

60.00 6

40.00 4

2

20.00

0
Frequency Cumalative Percentage

16 - 20 Days 13 27.08

20 - 25 Days 10 47.92

6 - 10 Days 9 66.67

0 - 5 Days 7 81.25

11 - 15 Days 5 91.67

26 - 30 Days 4 100.00

0.00

BREAKDOWN MAINTENANCE 40

Cumulative Percentage (%)

Frequency

ELECTRICAL DEPARTMENT

RANGE OF EQUIPMENT NAME PROBLEM IDENTIFIED DOWN TIME DAYS FUNTIONED BEFORE FAILURE Motor tripped continuously P105B P105B &taken higher load due to insulation failure Motor got P305A Confeutble pump tripped due to insulation failure Motor rewinding alone &fixed 5-12 5-12 16.3019.30hr SFDMK903E SFD VVFD by Motor vvfd got failure ported &stare & delba Cooling water pump Motor insulation(due to higher load rewinding done &replaced 5-1 4-12 5 4-12 0 4-12 23-12 2 30-12 Motor rewinding alone &fixed 11.3010.30hr 4-12 10 31-12

TAG NO

REMEDY

MK903D

3fd motor

--------------------

3

MF 607A

41

got failure

in this plane

rewinding MP939A Circulation pump(MEK) Motor tripped done &replaced in this plane MXR102 Agitator D.L.R got Spare replaced 14-9 Half hr 410D D.G.SET D.G set RPM failed Fuel pump solinoid set problem afforded New burner rod changed Motor bearing renewed Motor rewinding done Motor rewinding done 17-7 17 13-8 13-7 MP502B Circulation pump Motor insulation got failed 12-9 Half hr 3-8 1:30 min 30-7 4 2-8 22-7 12 3 13 12-9 13 14-9 4-12 19 4-01

trouble &cable burnt

MP101B

Bwitter rod

Frequently tlane failure

MP934

Membrane pump

Motor end abnormal sound came Motor

MP691

Blower motor

insulation got failed

42

Motor not run ,tripped MP918 Motor water pump continuously due to feeder side confactor got Motor not run MP920B d.m. water pump checked feeder side confactor got burnt Motor not run Caustic MP109A circulation pump due to v.f.d working o/p supply got trouble Spare confactor renewed V.F.D renewed& D.O.L starter supply given Bearing renewed MP134A ------------------Motor bearing got failed spare motor fixed, motor send renewed Motor not run MK903A Blower motor &trip frequent, intend short at motor inside Motor bearing noise came Spare motor fixed and old send to rewind Motor serviced 9-3 14 4hrs 28-3 13;0022:00 14 15-5 8 27-5 16 1hrs 2hrs 24-6 27 Spare confactor renewed 11-7 11:3012;45 13

MP912A

Acid motor

43

Spare Motor not run MK903B Tmax blower &cable burnt, contractor jam &coil burnt motor renewed &cable regulated tested &lineuped Motor FO boiler blower Motor bearing jam spare renewed &bearing replaced Motor MK906 ------------------Motor not run &coil burnt renewed &motor coil renewed Bearings Motor got trip MP931A ------------------containing &bearing jam both side renewed &fixed in place Motor MP-154B Motor got Pump motor struck up & coil burnt bearing renewed &coil rewinding 16-01 11-1 17 2hrs 21-01 23 2-2 13 2hrs 4hrs 12-2 12 8-3 21 7-3

MK903C

44

ELECTRICAL ANALYSIS

RANGE OF DAYS FUNCTIONED BEFORE FAILURE (0 - 5) (6 - 10) (11 - 15) (16 - 20) (21 - 25) (26 - 30)

NUMBER OF EQUIPMENTS IN THE RANGE OF LIFE 6 2 7 4 2 1

NUMBER OF EQUIPMENTS IN THE RANGE OF LIFE
NUMBER OF EQUIPMENTS IN THE RANGE OF LIFE 7 6 4 2 2 1

(0 - 5)

(6 - 10)

(11 - 15)

(16 - 20)

(21 - 25)

(26 - 30)

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

Chart Title
6 5 4 3 2 1 0

46

MONTH

NAME OF THE EQUIPMENT P105B, P305A, MK903D, SFD-MK-903E, MF 607A, MP939A MXR-102, 410D

BREAKDOWN 6 9 1 4 1 2 3 2 2

december november october september august july june may april march febuary january

MP101B MP934, MP691, MP502B, MP918 MP920B MP109A, MP134A
-

MK903A, MP912A, MK903B MK903C, MK906 MP931A, MP-154-B

BREAKDOWN

june

july

november

april

may

december

september

august

march

october

BREAKDOWN

febuary

47

january

BREAKDOWN
january 7% december 20%

febuary 7% march 10%

may 7% june 3% july 13% september 30%

august 3%

Name of the Deviation Motar Insulation Failure Abnormal Sound Bearing Failed Cable & Coil Burnt Motor VVFD Failure DLR trouble

Frequency 10 3 3 3 2 1

Percetage (%) 43.48 13.04 13.04 13.04 8.70 4.35

Cumalative Percentage 43.48 56.52 69.57 82.61 91.30 95.65

48

Dg Set RPm Failed

1

4.35

100.00

12

FREQUENCY OF PROBLEMS OCCURED - ELECTRICAL

120.00

10

100.00

8

80.00

6 Frequency

60.00

4

40.00

2

20.00

Motar Abnor Cable & Insulati Bearing mal Coil on Failed Sound Burnt Failure Frequency 10 3 3 3 Cumalative Percentage 43.48 56.52 69.57 82.61

0

0.00 Motor Dg Set DLR VVFD RPm trouble Failure Failed 2 91.30 1 95.65 1 100.00

49

Cumulative Percentage (%)

Range of life 11-15 days 0-5 days 16-20 days 6-10 days 21-15 days 26 - 30 Days

Frequency

Percetage (%) 27.08 20.83 18.75 14.58 10.42 8.33

Cumalative Percentage 27.08 47.92 66.67 81.25 91.67 100.00

7 6 4 2 2 1

120 100 80 60 40 20 0 11-15 days 0-5 days 16-20 days 6-10 days 21-15 26 - 30 days Days Frequency Percetage (%) Cumalative Percentage

50

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

51

1).Good Cooperation and coordination between the production and maintenance functions, in general , I essential. o Annual planning for maintenance should be done along with the annual production plan. o Monthly, weekly, daily maintenance schedules should be drawn, preferably in consultation with the production people. These must be properly

communicated to the production people. o 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.

52

o Preventive work is more easily standardized ,standard procedural manuals for the same may be prepared. o Breakdown maintenance jobs also may be fit into work-standards 7) Good research in materials is a helpful accomplishment to maintenance for eg: Good lubricating oil could save a lot of equipment from premature breakdowns. CLASSIFICATION OF SPARES FOR STOCKING POLICY ANALYSIS 1) MAINTENANCE OR BREAKDOWN SPARES 2) INSURANCE SPARES 3) CAPITAL SPARES 4) ROTABLE SPARES

53

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