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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
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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 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
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.
INDEX Chap. no Contents Acknowledgement List of tables List of chart Introduction a. Industry profile b. Company profile c. Product profile d. Description of process Aim of the project a. Objective of the study b. Scope of the study a. b. 4 5 6 7 8 a. b. Findings and observations Suggestions Conclusion Bibliography Page no
LIST OF TABLES 5
a.Table no 1 a. c. 2. b. Description Page no 6 .
INTRODUCTION 7 .
paints we use to brighten our surroundings.INTRODUCTION Maintenance is the function of production management that is concerned with day-today problem of keeping the physical plant in good operating condition. materials and employees. components of natural gas such as butane. and 8 .an industry whose products affect our daily lives. that is. This report reviews the operations and maintenance practice to be ensured in CETEX PETROCHEMICALS LTD. It is an essential activity in the manufacturing of petrochemicals.the carpeting on which we walk. such as ethane and propane.from the refinery: naphtha. and many other applications. These feedstocks are then cracked to obtain the building blocks of the petrochemical industry: olefins. cosmetics. fertilizers that grow our crops. clothing we wear. Petrochemicals are the downstream of the oil and gas industry . propylene. The coming years are expected to see the petrochemicals industry undergoing a major metamorphosis. buildings and services needed by other parts of the organization for the performance of their function at an optimum return on investment in machines. because it is necessary to ensure the availability of the machines. tires we rely on for transportation. pharmaceuticals we need to remain healthy. particularly with the Middle East as a major petrochemicals supplier and China emerging as a major processing hub and end-use market. plastic soda bottles from which we drink. and some of the byproducts of oil refining processes. Petrochemicals are a part of our daily lives . INDUSTRY PROFILE: Petrochemicals dominate the global chemicals market with a share of almost 40 percent. Petrochemicals get their raw material .known as feedstocks . mainly ethylene.
Petrochemical Industry in India The petrochemical industry has been one of the of the fastest growing industries in the Indian economy.and aromatics. aggregate demand for the entire petrochemical sector in India was around 20 MMTA in 2010 9 .9 MMTA. (RIL) along with Indian Petrochemical Ltd. (IPCL). Gas Authority of India Ltd (GAIL). As shown in the figure below. toluene. Currently. Besides. it provides the foundation for manufacturing industries such as pharmaceuticals.and three gas -based cracker complexes with a combined ethylene annual capacity of over 2. Polymers account for more than 60 percent of total petrochemical production. mainly benzene. construction. etc. Combining the demand for all the key segments in the petrochemical industry. the industry has been stagnant in terms of capacity addition. and the xylenes. namely Reliance Industries Ltd. packaging industry. automotive. there are four aromatic complexes also with a combined Xylenes capacity of 2. These products are then processed to produce a wide variety of consumer and industrial products. and Haldia Petrochemicals Ltd.the so-called C4 derivatives. including butadiene . The petrochemical industry in India is oligopolistic with four main players dominating the market. (HPL). textiles. India has three naphtha. agriculture.5 MMTA.
With the consistent quality of its products and 10 . Feedstock is drawn by pipeline from the neighboring Chennai Petroleum Corporation ltd.COMPANY PROFILE: Cetex Petrochemicals Ltd was established in 1990 with German technology. Cetex stands for high performance speciality products in the Indian market place. Water treatment chemicals and Marine chemicals. PLANT SIGHT Cetex has ventured into development of fine chemicals like specialized pharma intermediates and aroma chemical & essential chemicals. Cetex Petrochemicals is the largest manufacturer of Methyl Ethyl Ketone (MEK) and Secondary Butyl Alcohol (SBA) in India. Cetex aspires to produce Energy chemicals. Through marketing tie-ups with leading majors like Petro-Canada. In an endeavor to upgrade the lucrative additive business. South India. The plant is located about 20 Kms north of Chennai in the Manali Industrial Belt. Lube additive. located at Chennai (Madras).
11 . Cetex gives top priority to worker safety and equipment management. 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 has been conferred some of the countries highest awards for following safety standards set by the industry. ISO 14001 and OSHAs 18001 certified. Cetex commands a formidable market share of more than 60%. 1. Cetex has the distinction of being the only manufacturer of MEK to be ISO 9001-2008. In India. TQM. No accidents have occurred in the past 11 years. Cetex is a zero effluent discharge company and has been certified to be a very environment conscious company. and 5S initiatives. Cetex has won the Star Safety Award for 1998 & 1999 from National Safety Council. Safety and environment: Setting and achieving high standards for safety. 2. Tamilnadu and is the winner of All India Award from National Safety Council for three years from 2000 to 2002. 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. The company today has a truly impressive safety record.services. The company is well equipped in safety systems and trained man power. Cetex is committed to continual improvement and is practicing deep rooted TPM. Quality Practice and ISO certification: The quality management system at cetex is ISO 9000 certified. 3.
PRODUCT PROFILE: 1. Cetex is OSHAs 18001 certified. Methyl Ethyl Ketone: Description: 12 . Nitrocellulose solvents manufacture of Printing Inks and as a solvent in flexographic printing dyes 1. Secondary Butanol is non-toxic. Pharma industry and in the manufacture of paints. Secondary Butanol is used in the manufacture of specialty intermediates. Secondary Butyl Alcohol: Description: Secondary Butyl Alcohol or Secondary Butyl Alcohol (SBA) is a water white highly volatile liquid with characteristic odour. 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.In the endeavor to achieve high standards in occupational health and safety.
higher ketones and secondary Butanol. plastic processing. such as Aroma Chemicals. highly volatile liquid having Acetonelike odour with no cumulative toxicological properties. Its excellent solvent properties are used by the surface coating. printing ink. resin industries and lubricating oil de-waxing in the Refineries. it is used as an intermediate in a number of chemical products. Solvent . SOLVENT – XX: 13 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 . capable of dissolving a wide range of substances. Methyl Ethyl Ketone is miscible with most organic solvents and owing to the high reactivity of the carbonyl group.Methyl Ethyl Ketone (MEK) is a water white. Methyl Ethyl Ketone is one of the most versatile solvents. Application: MEK is widely used in the following applications: • • • • • • • • • • • • BY PRODUCTS: SOLVENT – X: Description: Solvent .X is a pale yellow liquid containing a mixture of Ethyl iso Amyl Ketone.X has somewhat pleasant smell and is nontoxic.
There starts the second main reaction of Mono-Butyl-Ester with n-butane.XX contains predominantly di secondary butyl ether. The next step is hydrolysis. 14 . forming Di-Butyl-Ester which is neutral. Solvent . 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. is a clean fuel and finds use in specific furnance applications for Glassm Ceramics and Tile manufacturing.alone basis in large industrial applications requires the use of a vaporizer for good burning particularly in the furnances for Glass and Ceramics. One of the most common routes for the production of SBA is the hydration of the nbutanes via esterification with sulphuric acid.XX is a clear. 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. usage on stand . but not stable.Description: Solvent . highly volatile liquid with turpentine like odour. The product is non-toxic. colorless and highly volatile liquid with a characteristic odour.XXX is pale yellow. Solvent .XXX is flammable and used as a general purpose solvent and diluent. SOLVENT – XXX: Description: Solvent . Apart from the above. DESCRIPTION OF PROCESS: SBA is used almost entirely over (90%) as intermediate for the production of MEK. LPG: Cetex produces LPG quality Butane as a return stream from its Methyl Ethyl Ketone (MEK) paint. in which the secondary butyl alcohol is formed. Being rich in Butane. it can blend well in all proportions with Domestic and Industrial LPG.
The SBA reaction requires a feed of sulphuric acid at concentration of 75%. The impure SBA is neutralised by using the caustic soda which is sodium hydroxide and the outputs are pure SBA and the sulphate.Hydrogen 15 . PRODUCTION: • MAIN PRODUCTS: 1. hydrogen gas is liberated. The pure SBA undergoes MEK synthesis process. Capacity (6000 MT) • BY PRODUCTS: 1. The acid will be diluted in the process to an outlet concentration of 50%. Capacity (7500 MT) 2.EAK (Sol X) 6. Methyl Ethyl Ketone (MEK). Butane 2. The pure SBA is used for the manufacturing of MEK. In the synthesis of raw MEK. The hydrolysis output which is the impure SBA is then neutralised to obtain pure SBA. Polymer (Sol XXX) 4. Fresh 98% acid will be blended with spent acid and water to the required feed concentration. Sulphuric acid (52%) (Spent acid) 3. The raw MEK undergoes distillation process and finally the pure MEK is obtained and stored. Secondary Butyl Ether (SBE) (Sol XX) 5. The byproduct is obtained is heavy ketones. Secondary butanol (SBA).
The liberated hydrogen gas is utilised in the boiler as a fuel. The daily production of the company is 24 MT of SBA.The production plant is running at his maximum capacity of production. PROCESS CHART: Sulphuric Acid(98%) Spent acid disposal Waste to solar pond Feedacid(75%) Spent acid (50-55%) SBA purification Butene Esterification Hydrolysis Neutralizatio n Butene recovery system Butane recovery system Pure SBA storage Butane LPG Polymer solvent xxx Pure MEK storage MEK purification Heavy Ketones SBE solvent xx Butane storage LPG MEK synthesis 16 .
safe and in usable condition. To minimize accidents through regular inspection and repair of safety devices . Provide evaluation of all facilities for planned maintenance and replacement wherever required. To improve the quality of products and to improve productivity. To minimize the loss due to production stoppages. 17 . To minimize the loss of productive time because of equipment failure.Raw MEK separation OBJECTIVE OF THE STUDY PRIMARY OBJECTIVE To maximize efficiency and economy in production through optimum use of facilities. To minimize the repair time and cost. To efficient use of maintenance personnel and equipment. SECONDARY OBJECTIVES • • • • • • • • • To keep the plant facilities in full working conditions with zero or minimum breakdowns. To keep the internal and external premises of the industrial unit clean.
➢ Plant protection including fire protection. ➢ New installation of equipments and buildings. 18 .SCOPE OF MAINTENANCE ➢ Maintenance of existing plant and equipments. ➢ Equipment inspection and lubrication.
➢ 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 .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.
➢ Obtain information from senior operators. to be conditions 20 . Totally: ➢ Rescheduling of production plan causing delay in supply. Components and other maintenance items received as spares checked thoroughly by specialists. ➢ To check if spares purchased for imported and high value machinery are from original source. ➢ Shortfall is also taken care by overtime and hence increases costs. bushes which are frequently required are as per quality and quantity. ➢ Increasing sub-contracting and hence more cost. ➢ In mechanical/electrical/instrumental installations maintenance staff should take it up like a project assignment and take better care of cost and time factors.➢ The losses and inconvenience created. A) Engineering and Development: ➢ Maintenance engineers should be innovative and think for changes in arrangements to improve machine’s utility and quality of workmanships. absorb any unusual sound or trouble from machines. ➢ Loss of production and man hours. bearings. ➢ Ensure that important spares like belts. ➢ Rejection. ➢ To check safety factors for machinery and operators. damage to components due to faulty machines. Functions of plant maintenance: A) Evaluation/Inspection ➢ Periodic check of plant facilities to examine their working to take corrective actions.
A) Replacement. drawing specifications of various departments related work. maintenance of open yards and buildings. reconditioning disposal decisions ➢ . pollution. ➢ Spares list for various machines. planned productive maintenance of machinery and equipments. 21 . A) SAFETY Safety from fire. budget costs etc.➢ If production engineer feel deviations are due to machines the maintenance engineers should involve in trouble shooting to keep machines in efficient condition. ➢ Record of machinery insurances to be kept. ➢ Maintenance of building facilities stores yard compound for safety and better work environment ➢ Attending projects assignments for knowhow on future maintenance needs. Total maintenance work ➢ Taking care of breakdown maintenance (repair work). files to be maintained. Housekeeping. water. import list. ➢ Scheduled overhauling of major equipments. A) Administrative work ➢ Personnel and administrative work of the department ➢ Records.
➢ Use higher capacity machines to reduce chances of breakdowns. and training. ➢ Improve overall capacity of maintenance department in forms of manpower.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. ➢ Involve operative’s machines care. ➢ Buy machines which are easy to change parts and for routine maintenance. 22 . ➢ Keep adequate stock of spare parts of all machinery and equipments. train them. facilities. ➢ Replace parts early to avoid further problems.
23 .➢ Keep standby arrangements for important production machinery. ➢ Good interaction between production. lubrication of moving parts ➢ Poor maintenance of heating or cooling system of process ➢ Neglecting small cases like loose nuts. bearings. projections of or covers ➢ Not filling up fuel or non supply of fuel due to blockage in pipelines. quality control and maintenance department. PREVENTIVE MAINTENANCE This is a method of planned maintenance and avoids the possibilities of breakdown. bent or deviated components. This is precautionary measure and ensures continuous use of machines after attending the work. loose joints oiling and lubricating needs bearing wear and tear. vibrations of moving parts. ➢ Not doing periodic oiling. Can also take up alternate product manufacture to release machines for maintenance work. overheating of parts etc. This identifies the wear out parts. ➢ Not attending unusual sound. short circuiting. BREAKDOWN MAINTENANCE: The word management language is corrective maintenance or ‘breakdown maintenance’ REASONS FOR BREAKDOWN: ➢ Due to failure to replace worn out parts. sources. erratic voltage. ➢ Frequent power failures. belts etc.
in the case of condition monitoring. BENEFITS OF PREVENTIVE MAINTENANCE ➢ Reduction of the total down-time and consequent reduction in production loses. and consequently reduced maintenance expenses.g. ➢ Instruments e. Each plant should have its own preventive maintenance policies suited to that plant’s needs. the age of 24 is the key to . ➢ Reduction in the unplanned or crisis management in maintenance. ➢ Reduction in the number of accidents in the plant. ➢ Wages of preventive maintenance technicians and staff.METHODOLOGY: ➢ Periodic inspection of machinery and equipments to understand discrepancies if any and likely of areas problems. ➢ Reduction in the number of major repairs. ➢ Reduction in the number of rejects and n improvements in product quality. the type of operations. ➢ Reduction in the inventory of spare parts. the working environment. ➢ Past data from SQC enables to understand the likely trouble spots and recurrence of problems. ➢ Inspection and identifications of replaceable parts successful preventive maintenance. the type equipment. ➢ To take up for corrective action when machineries are still in workable condition. ➢ Replacement parts and supplies. ➢ There are certain costs associated with the preventive maintenance ➢ Scheduled down-time of production.
➢ To ensure effectiveness and efficiency of all machines. plants which are maintained efficiently spend almost three quarters of their time on preventive maintenance. 25 . 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 maintain resale value of the machines. spares. ➢ To ensure safety of employees. belts and toggles are checked for strength and endurance until next PM. this give an idea of important activities. ➢ To reduce unplanned work for maintain staff. In general. and cost needs. and the costs associated with these in the absence or presence of the preventive maintenance programme of a smaller or larger size. time. INSPECTION FOR PM: ➢ Initially the past records are to be referred to know what all actions taken last time. ➢ The moving parts are checked again and again to ascertain the wear and tear. and other factors determine the incidents of breakdowns. their severity. ➢ 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. Similarly bearings. bearing block.equipment and plant.
MECHANICAL-BREAKDOWN MAINTAINANCE RANGE PROBLEM IDENTIFIE D REMEDY DATE OF BREAKD OWN OF DAYS FUNTIO NED BEFORE FAILUR E K907C Inducted draught fan Driver bearing damaged P940 STP circulation pump Pump jammed side Bearing fixed OK Shaft.s eal. 3-12-09 14-12-09 22DAYS 29-12-09 9:0016:00 24-12-9 11:0016:00 2DAYS 17 DAYS TAG NO EQUIPMEN T NAME 26 .mech seal renewed OK XR101B Secondstage reactor Coil puncture Coil welding work OK done lead. bearings.oil.
P305 Condensable water pump Pump leak seal Mech Renewed OK seal 30-11-09 4hrs 30-11-09 3hs 23-11-09 25-11-09 17-11-09 20-11-09 3DAYS 12DAYS 13DAYS P305B Condensable water pump Abnormal sound Pump leak seal Spare pump fixed OK Stationary Rotary face changed OK P105B Newtralizatio n wash pump S902A Wood therme screw feeder Screw feeder jammed F-208 1NOS&P208 2NOS.Beari ng shaft renewed OK changed P904 Spent pump acid Causing leak Spare pump fixed OK 4-11-09 5-11-09 2-11-09 10-11-09 26DAYS P133B Spent pump acid Abnormal sound Stationary &Rotary face renewed stuffing box changed. taken in line OK 8DAYS P151B ------------- Pump seal mech Rotary changed face 26-10-09 27-10-09 1DAY 27 .
taken in line .&stationary face OK P940 STP Circulation pump K901B Instrument Air Compressors Poor performance Pump jammed Bearing &seal changed OK Cylinder &piston 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 28 23-9-09 2hrs 17DAYS ring. 24-9-09 1-10-09 4DAYS 24-9-09 1-10-09 1DAY 10-10-09 11-10-09 12DAYS fixed.
mech changed taken in line OK P934 Remembrance cleaning pump Pump abnormal sound and mech seal leak The following spares renewed shaft bearing.sleeve mech seal K902B Wood thermaze Blower abnormal sound Bearing changed. mech OK P912A 98% sulphuric acid transfer Pump seal leak mech The following spares renewed 29 12-9-09 14-9-09 17DAYS seal taken in line 17-9-09 9DAYS seal 1hrs 17-9-09 5hrs 9DAYS 18-9-09 17DAYS . bearing nos:2210kc3 P932 Solvent pump Pump seal leak mech The following spares renewed.
2nd inlet &discharge value serviced the &seat of plate springs stage 4-8-09 5-8-09 23DAYS changed OK K101B Butane Compressor Poor performance 2ND Stage of value removed &discharge channel &spring channel 30 26-7-09 7hrs 6DAYS .R201 Mek Reactor I Catalyst to be renewed Support ring after catalyst filled &bottom down top 6-9-09 17-9-09 P132B Acid pump feed Pump seal leak mech The following spares renewed sleeve &seal set OK 6-8-09 7-8-09 20DAYS K901A Instrument Air Compressor Poor performance Position ring 1st.
oil seal 10-7-09 13-7-09 16DAYS P940 Circulation pump Pump abnormal sound seal leak with Pump assembled with sparesshaft.changed OK P105A Neutralization wash pump Pump seal leak mech MECH SEAL Stationary &rotary ‘O’ring changed taken in line OK 22-7-09 23-7-09 25DAYS P912A 98% Sulphuric acid circulation pump Pump seal leak mech Pump assembled with ceramic bellow &silicon carbide face new 17-7-09 18-7-09 22DAYS P133B Spent pump acid Pump seal leak mech Pump assembled with sparesbearing. oil 9-7-09 15-7-09 16DAYS 31 . bearings.
250 bellow renewed.seal. seal set P916B Furnace oil Pump jammed Pump bearing 4 nos renewed assembled OK 5-7-09 17-7-09 18DAYS Transfer pump P133A Spent pump acid pump abnormal sound leak &seal Pump bearing &1. assembled OK 2-7-09 8:3021:30 25DAYS P154B SBA pump Product Pump abnormal sound leak &seal Pump bearings renewed seal face lapped is fixed OK 24-6-09 8:0022:00 9DAYS P916A Furnace oil Pump leak seal Pump RING Renewed seal 21-6-09 1-7-09 23DAYS Transfer pump leak &cosing &casing ‘O’ taken in line OK P510 C510 Circulation Mech leak seal Stationary seal changed 32 9-6-09 .
620 72&62062& 35*45*7 oil seal renewed also 14-5-09 18-5-09 9DAYS P251A Dryer Column Bottom pump Seal leak Wilo (mech seal)pump seal renewed OK 14-5-09 2hrs 10DAYS P253A MEK Reactor Column Reflux pump Seal leak Wilo ok pump 14-5-09 2hrs 9-5-09 30-5-09 19DAYS seal renewed P155A Water SBA- Pump abnormal sound 2NOS bearing changed &seal spare renewed OK 0DAYS Recycle pump P303 HOT circulating pump oil Abnormal sound Coupling changed.pump taken in line OK 13-6-09 XV106A Caustic Vessel Aggitator Abnormal sound Bearing renewed. bearing &oil hauling replaced OK 28-4-09 4-5-09 27DAYS 33 .
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 P105B Caustic Neutralization pump Pump leak seal ‘O’ring renewed line OK in seal taken in 8-4-09 6hrs 26DAYS P106 Caustic Neutralization pump Mech leak seal ‘O’ring renewed line OK in seal taken in 4-4-09 6hrs 13DAYS P133B Spent pump acid Mech leak seal Bellow renewed seal face OK lapped taken in line 31-3-09 2-4-09 8DAYS P925B Fuel oil pump Mech leak seal Seal assembled renewed OK 20-3-09 5hrs 16-3-09 27DAYS P917A Metro water Abnormal 16DAYS 34 .
pump P132B Acid pump feed sound Mech leak seal Seal lapped &fixed face 25-3-09 9-3-09 10-3-09 SIDE 4-3-09 6hrs 13DAYS 21DAYS K101B Butane Compressor Poor performance H.250NEW SEAL fixed OK set 29-1-09 1-02-09 8-1-09 9-1-09 21DAYS P132A Acid Pump feed Pump abnormal sound Pump assembled with shaft &lapped seal new 2DAYS 35 .P suction &discharge value serviced OK XR101B Reactor Agitator I XR101B Reactor Agitator Mech leak Mech leak seal seal Spare fixed OK Spare OK P133A Spent pump acid pump leak &bed damaged P134A Ester pump Pump leak seal seal Pump ed seal bed 12-01-09 13-01-09 6DAYS seal seal 20-2-09 7hrs 19-2-09 20-2-09 23DAYS 24DAYS RENEWED serviced&fix changed OK 1.
fixed pump assembled taken in line OK P132B Acid pump Feed Pump leak seal Pump &old seal 7-1-09 8:3015:00 20DAYS 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 K-902B K-101A P-151A P-251A XV-106A P-925A P-134A P-926 K-905 K-901A P-921A 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-931B K-928 P-202A P-922A P-110A P-133A P-156A K-902A P-155A P-915 P-109A 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 C SHIFT P-255B P-271 P-103B XV-106C P-132A P-109B P-923A P-153B P-107A P-201A P-105B 36 .
P303 P-912B P-919 P-913 P-917B P-916B P-906A P-901B P-903 K-201A P-301 P-905B P-908A P-911 P-273B P-922C P-916A P-918 P-930 P-272 K-907C XV-107 P-152B P-202B P-914 P-134B XV-275 P-922D P-154A P-156B XR-102 P-924 P-154B P-254B P-105A P-920B P-931A P-155B P-201B K-902D K-902E S-902A S-902B C-902 K-909 P-907D P-907F K-907A K-907B P-940 P-939A K-908 P-939B P-934 P-935 P-941 K-903B P-302A P-107B P-254A P-255A P-253B P-132B P-305B P-103A P-106 P-110B 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. 37 . t.12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 K-903A P-923B P-922B P-920A P-252B P-921B K-906 XV-106B K-101B P-152A P-907C K-901B P-912A XR101A/B P932 P-910 P-907A P-917A P104.
5) (6 .20) (21 . This is the relatively frequency of failure corresponding to time t.25) (26 .30) NUMBER OF EQUIPMENTS OCCURENCE IN THE RANGE OF LIFE 7 9 5 13 10 4 38 . MECHANICAL ANALYSIS RANGE OF DAYS FUNCTIONED BEFORE FAILURE (0 .What percentage of instances did it fail at time t.15) (16 .10) (11 .
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 .
P253A. P940.55 21.91 7.82 10. P133A. K101B XR101B. P912A. P917A.36 98.P134A.27 1.00 40 . P132B.M ONTH december november october september august july june may april march febuary january EQUIPMENT NAME K907C. P105A. K902B. K101A.55 76. P305B.18 100. P916A. K1O1B.P132B BREAKDOWN 3 6 2 5 3 7 4 4 5 5 2 4 Name of the Deviation Pump Seal Leak Abnormal Sound Poor Performance Pump Jammed Bearing damaged Piston Ring Damaged Coil Puncture Frequenc y 30 12 6 4 1 1 1 Percetag e (%) 54. P912A. P510 XV106A. R201 P132B. K901A K101B. P133B. P925B. P155A. P932. P916B.P133B.55 96. K902A.82 1. P904.27 94. P303. XR101B P133A. P934. S902A. XR101B. P151B.36 87.P132A. P105B. P251A. P940. P105B. P133A P154B. P106 P133B.XR101B P305.82 Cumalativ e Percentag e 54.82 1. P940 K901B.
25 Days 6 .15 Days 26 .33 Cumalativ e Percentag e 27.58 10.5 Days 11 .30 Days BREAKDOWN MAINTENANCE ELECTRICAL DEPARTMENT RANGE OF TAG NO EQUIPMENT NAME PROBLEM IDENTIFIED REMEDY DOWN TIME DAYS FUNTIONED BEFORE FAILURE P105B P105B Motor tripped continuously &taken higher load due to insulation Motor rewinding alone &fixed 31-12 4-12 11.67 100.Machine life without breakdown-machanical Frequenc y 13 10 9 7 5 4 Percetag e (%) 27.10 Days 0 .20 Days 20 .75 14.83 18.67 81.25 91.30hr 10 41 .00 Range of life 16 .08 20.42 8.92 66.3010.08 47.
L.3019.R burnt got Spare replaced trouble &cable .failure Motor got P305A Confeutble pump tripped due to insulation failure Motor rewinding alone &fixed 5-12 23-12 30-12 2 MK903D 3fd motor -------------------- 5-12 16.30hr 3 SFDMK903E SFD VVFD by Motor vvfd got failure ported &stare & delba Motor rewinding done &replaced in this plane rewinding 4-12 4-01 14-9 14-9 Half hr 42 13 4-12 5-1 5 4-12 4-12 0 MF 607A Cooling water pump insulation(due to higher load got failure MP939A Circulation pump(MEK) Motor tripped done &replaced in this plane 19 MXR102 Agitator D.
water pump checked feeder side confactor got burnt Spare confactor renewed 24-6 2hrs 27 43 .410D D.tripped MP918 Motor water pump continuously due to feeder side confactor got Motor not run Spare confactor renewed 11-7 11:3012.45 13 MP920B d.G.m.SET D.G set RPM failed Fuel pump solinoid set problem afforded 12-9 12-9 Half hr 3-8 1:30 min 30-7 2-8 22-7 13-8 13-7 17-7 17 3 13 MP101B Bwitter rod Frequently tlane failure Motor end abnormal sound came Motor New burner rod changed Motor bearing renewed Motor rewinding done Motor rewinding done MP934 Membrane pump 4 MP691 Blower motor insulation got failed 12 MP502B Circulation pump Motor insulation got failed Motor not run .
F. motor send renewed 15-5 8 Motor not run MK903A Blower motor &trip frequent.L starter supply given Bearing renewed 27-5 1hrs 16 MP134A ------------------- Motor bearing got failed spare motor fixed.f. contractor jam &coil burnt motor renewed &cable regulated tested &lineuped 7-3 8-3 21 MK903C FO boiler Motor bearing Motor 12-2 12 44 . intend short at motor inside Motor bearing noise came Spare motor fixed and old send to rewind Motor serviced Spare 9-3 4hrs 14 28-3 13.D renewed& D.0022:00 14 MP912A Acid motor Motor not run MK903B Tmax blower &cable burnt.Motor not run Caustic MP109A circulation pump due to v.d working o/p supply got trouble V.O.
20) MP-154Pump(21 .10) (11 .15) (16 .25) motor Motor got (26 .30) B struck up & coil burnt Bearings 21-01 NUMBER OF EQUIPMENTS 23 THE RANGE IN 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 2-2 2hrs 13 4hrs ELECTRICAL ANALYSIS 45 .5) &bearing jam (6 .spare blower jam renewed &bearing replaced MK906 ------------------Motor not run &coil burnt Motor renewed &motor coil renewed MP931A OF------------------Motor got trip RANGE DAYS FUNCTIONED BEFORE FAILURE containing (0 .
MP918 MP920B MP109A. P305A. MP134A - 46 . SFD-MK-903E. MP502B. MP939A MXR-102. 410D BREAKDOWN 6 9 1 4 1 2 - MP101B MP934.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 P105B. MK903D. MF 607A. MP691.
MP912A.04 13. MK903B MK903C.48 56.35 Cumalativ e Percentag e 43.04 8.70 4.52 69. MP-154-B 3 2 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 10 3 3 3 2 1 1 Percetag e (%) 43.30 95.00 47 . MK906 MP931A.65 100.35 4.march febuary january MK903A.57 82.04 13.61 91.48 13.
Range of life 11-15 days 0-5 days 16-20 days 6-10 days 21-15 days 26 .67 100.33 Cumalati ve Percenta ge 27.58 10.08 47.00 48 .67 81.42 8.08 20.25 91.83 18.75 14.92 66.30 Days Frequen cy 7 6 4 2 2 1 Perceta ge (%) 27.
so as to gain good control over maintenance operations and also to provide adequate incentives and motivation for maintenance personnel.e. ➢ Reducing major break-downs or crisis situations with the help of appropriately organized preventive maintenance programmes. increasing what is known as the reliability of the plant . thus ensuring the supply on time. reworks is avoided. improved design of the products and processes.the ‘maintainability’ should be high. Also . Supportive organizational conditions for better maintenance management 49 . producing right the first time. all of this leading to unnecessary wastage of time and in actual reduction in operation/process times. ➢ Reduction of operations lead times . delivery times through continuous improvements. self-inspection and certification. ➢ Improved machinery maintenance. ➢ 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. ➢ Improvements in quality. ➢ Designing and Installing the equipment in such a way that failures of the equipment will be low over its lifetime or in other words .machinery and equipment in the design staged itself. rejects. ➢ No postponements or cancellations of the scheduled production.The equipment could be so designed that the times for maintenance action are small i. so that the expenditure of time due to breakdown. ➢ Having standard times and standard procedures in maintenance as much as possible.FINDINGS AND SUGGESTIONS: ➢ Diagnosing the fault or failures as early as possible and taking quick decisions regarding the same.
the suppliers. scheduling. ○ Monthly. 4) Proper equipment records should be kept giving details such as breakdown –statistics. there should be much interaction between maintenance and production people at the policy-planning. 5) Spare –parts inventory should be controlled properly. etc. ○ Annual planning for maintenance should be done along with the annual production plan. maintenance carried out. schedule-making. preferably in consultation with the production people. in general . he should have the full authority to order the shut-down of the equipment. ○ If there are any changes in the capacity-utilization. process-changes nd method-changes. 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. I essential. weekly. the type of preventive action carried out. These must be properly communicated to the production people. and all other levels. the maintenance work should be standardized as much as possible. time taken for maintenance.Good Cooperation and coordination between the production and maintenance functions. and allocation of maintenance resources. the causes of breakdown. 50 . 6) To ensure good control.t he maintenance department should be aware of the same. such information helps in policy-planning. daily maintenance schedules should be drawn. so that adequate numbers are available for maintenance purposes.1). the components and parts of the machinery. dates on which preventive maintenance was carried out. In short.
○ Preventive work is more easily standardized .standard procedural manuals for the same may be prepared. CLASSIFICATION OF SPARES FOR STOCKING POLICY ANALYSIS 1) MAINTENANCE OR BREAKDOWN SPARES 2) INSURANCE SPARES 3) CAPITAL SPARES 4) ROTABLE SPARES 51 . ○ 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.
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