MALAYSIAN INSTITUTE OF CHEMICAL AND

BIO-ENGINEERING TECHNOLOGY
(UNIKL MICET)

ASSIGNMENT 1

SUBJECT CODE : CCB 40502

SUBJECT TITTLE : PLANT UTILITIES AND MAINTENANCE

LECTURER’S NAME : Ir. Chong Yuan Foong

DUE DATE : 13/1/2024

NAME ID NUMBER
MUHAMMAD NAFIS BIN MOHD ARIS 55221120092
UniKL CCB 40502 Plant Utilities and Maintenance
MICET October 2023 Assignment 2 Date: 27-12-2023

Your process plant, Section 201, have installed 5 units Durco Mark, 3 unit ProMinent
Metering Pump and 1 unit of KSB Multi-stage High Pressure Pump. All the pumps are in
service for 9 months since plant start-up.
You are maintenance engineer, and assign with a task to prepare specification for
maintenance software. The software feature will improve efficiency of your maintenance
team including inventory level control, work record, work traceability, purchasing and
planning.
Please get ready the software requirement for presentation during maintenance meeting:
Specifically explain the software application for the pumps maintenance planning and
monitoring during shutdown and pumps breakdown.
You should design and explain some document form entry for monitoring purpose.

Submission Date: 13-1-2024

Mark: 10

1
Software Application for Pump Maintenance in Section 201

Specific Features for Shutdown and Breakdown:

1. Shutdown Planning and Monitoring:

a. Pre-shutdown Checklists:

• To guarantee that pump shutdowns are prepared in a complete and

uniform manner, the software allows for creating unique checklists

according to each type of pumps.

• These checklists ensure that maintenance personnel are guided through

essential tasks including flushing fluids, lubricating elements correctly

fastening parts of components and disconnecting power sources in order

to avoid potential problems either during shutdown procedure or restart

one.

b. Real-time Monitoring:

• The software systematically monitors crucial parameters such as

vibrations, temperature and flow during shutdown periods.

• By using this real-time data, one can detect anomalies or possible

problems early thus taking the right corrective action and adjustments

during shutdown without causing damage to pumps which make it a user-

friendly environment.
 c. Post-shutdown Inspection and Report Generation:

• After a shutdown, the software enables thorough checking of each pump’s

status.

• It allows taking pictures, notes and measurements that automatically get

compiled into comprehensive inspection reports.

• These reports point out any maintenance issues or potential problems that

may need to be implemented before the next pump start-up, thereby

ensuring an optimal function and eliminating unexpected downtimes.

2. Breakdown Response and Tracking:

a. Alarm Management:

• The software is well integrated with existing plant alarm systems,

especially those related to pump breakdowns.

• It automatically sends alerts to relevant maintenance personnel via

notifications at the instance of break down thereby ensuring timely

attention and minimizing response time thus making communication fast in

addition to swift action on breakdowns.

b. Fault Diagnosis Assistant:

• To facilitate fast troubleshooting and repairs the software incorporates a

rich information base that comprises of problem-solving guides, corrective

actions for different kinds of pumps as well error codes.

 • This knowledge base serves as a “virtual assistant” to maintenance

personnel, helping them through the diagnostic process and identifying

appropriate repair procedures – leading to more rapid breakdown

resolution and reduced downtime.

c. Work Order Generation and Tracking:

• In order to manage the breakdown efficiently, the software automatically

creates work orders that assign tasks to respective technicians and follows

its progress during each phase of repair.

• It centralizes task monitoring with completion times and accountability

ensuring efficient resource allocation on a necessary basis, as well as

proper workflow management.

d. Spare Parts Management:

• To keep prepared for repairs, the software constantly monitors stock levels

of critical spare parts for pumps.

• When stock levels drop to pre-set thresholds, it automatically reorders for

availability of components during breakdowns. This is a proactive move

that reduces delays in repair processes and enhances overall plant

uptime.
Document Form Entry for Monitoring:

Pump ID and Type:

• By this field, the given pump is unambiguously identified; so it can be tracked

and associated with maintenance records without any possible mistakes.

• It usually consists of a unique pump identification number, as well the make

and model for that specific pump. These details are extremely important in

later references or historical considerations.

Maintenance Activity:

• This classification refers to the type of maintenance that is in progress and

puts data recording into perspective.

• Some of the common types may be regular preventative maintenance i.e

periodical inspections and servicing; corrective measures to rectify defects

identified previously, or even breakdown maintenance involving emergency

repairs after unforeseen failure occurs .Understanding the pattern helps

management plan future activities well “

Date and Time:

• This field documents the precise beginning and end of a maintenance activity

to provide an accurate analysis of how long a certain task takes, establishing

effective scheduling guidelines for activities, as well as monitoring downtime

on equipment.
 • It is a chronological log of maintenance events, which allows for the

identification of trends and root cause analysis.

Measured Parameters:

• This field holds important data points that are collected during maintenance

including vibration levels, temperature readings and flow rates, pressure

measurements.

• These readings provide insights to the health, performance and possible

degradation of pump so that issues can be detected early on for proactive

maintenance planning.

Observations and Notes:

• This field allows space for maintenance personnel to record any significant

observations or findings, deviations from normal behaviour noted during the

process of maintaining something.

• It encourages in-depth documentation of potential concerns, troubleshooting

steps and recommendations for future maintenance actions that contribute to

knowledge transfer and continuous improvement.

Photos and Attachments:

• This functionality allows uploading visual documentation such as images of

the condition of the pump, inspection reports and work order documents.
 • Visual evidence improves comprehension of maintenance work and adds rich

context for future review as well as trouble shooting.

Corrective Actions:

• This field records the particular steps that have been taken to address issues

uncovered during maintenance, which offers accountability and tracks

successful repair work.

• It offers a history of maintenance interventions allowing the evaluation of

repair strategies and identification os recurring problems.

Observations and Notes:

• This field gives space for the maintenance personnel to note down significant

observations, findings or deviations from normal behavior that occur during

any of the procedures involved in a maintenance process.

• It supports the detailed documenting of potential concerns, troubleshooting

steps and recommendations for future maintenance actions fostering

knowledge transfer and continuous improvement.