Preventive maintenance strategy for rotary equipment-

1- Introduction-
Maintenance philosophy adopted for the complex is condition based and supported by
preventive maintenance checks. This philosophy is mainly adopted to minimize the jobs
when machine condition is acceptable and at the same time, to maintain high level of
equipment availability and reliability.
Under preventive maintenance technique, programs are designed so that pre-defined
works/checks are performed on periodic basis. The extent and periodicity is based
either on fixed intervals or on hours of run which would depend upon equipment
category. As the emphasis is more on condition based maintenance, non-invasive
preventive maintenance is followed for most of the equipment. However, for certain
equipment categories and for single line equipment major invasive preventive
maintenance is adapted based on hours of runs or available opportunity (turn
around/slow down etc.) to ensure reliability for the future run. The technique helps to
increase the mean time between failures (MTBF), avert breakdowns, reduce unplanned
maintenance costs and optimize the maintenance of machines based on periodic
maintenance.

2- Scope-
This procedure would cover preventive maintenance programme for all rotary
equipment.
This procedure provides details for
 Logic and frequency
 Task list
 Execution and compliance
 RACI
 Effectiveness review
 Records
3- Preventive maintenance process -
Logic for carrying out preventive Maintenance for various categories of various
equipment’s are defined by Asset integrity team along with frequency and task list.
Rotary equipment having standby, or which could be spared without
shutdown/production losses are covered under minor invasive preventive
maintenance. While major invasive maintenance will be followed for single line
equipment requiring shutdown/ opportunity basis and for certain categories like
reciprocating compressor and gas turbine where maintenance is driven by run hours in
operation. Preventive maintenance task list and frequency will be decided based on
overall maintenance philosophy, experience, history and recommended based
practices of equipment etc. Inputs from RCA /HSEF/RCM/STANDARDS etc. will be
reviewed and incorporated in the program as and when required. The preventive
maintenance effectiveness will be reviewed annually and changes as required will be
effected.
Asset integrity team will create the task list and frequency of each equipment will link
with associated equipment including driver, auxiliaries, instruments etc. Asset integrity
team will also align the frequency of linked equipment with each other. Documentation
necessary for task like equipment service sheet will also be linked with these associated
preventive maintenance task. Following the annual review of the preventive
maintenance schedule, final preventive maintenance schedule will be released for
implementation.
The execution of maintenance jobs is based on the PM orders created, each carried out
as per work management process. After completion of the PM, deviation if any, is
recorded during the job closer.
Preventive maintenance effectiveness review is carried out annually by Asset integrity
team (Rotary) for change in the frequency, updation in the task list based upon the
finding and feedback received by O&M.
4- Minor invasive preventive maintenance of rotary equipment -
The preventive maintenance criteria will be based on equipment types, operating
speed, temperature, and category. Minor invasive preventive maintenance of rotary
equipment will be carried out as per logic & frequency defined in Table-1.
Table 1- Logic for Minor invasive preventive maintenance of rotary equipment.
S. No. Category of Equipment PM frequency
1. Pumps (MPP)

Centrifugal pumps (MPPC)

a) All cold pumps (Excluding sundyne Once in 52 weeks.
pumps).
Once in 52 weeks
b) Hot pumps (Temperature>150 ⁰C) with
online monitoring.
Once in 26 weeks
c) Hot pumps (Temperature>150 ⁰C) without
online monitoring.
Once in 26 weeks
d) Sundyne pumps.

No PM
Dosing pumps- All types (MPPD)

Gear, screw & reciprocating

pumps(MPPG/MPPR/MPPS):
No PM
a) Mono-block.
Once in 52 week
b) Non mono-block except lube oil pumps.

c) Lube oil pumps with steam turbine driver. No PM

(MOP).

d) Lube oil pumps with motor drive. (AOP) Once in 104 weeks
where MOP turbine driven.

e) Lube oil pumps where MOP & AOP are Once in 52 weeks
motor driven.
S. No. Category of Equipment PM frequency
Fans:

ID/FD Fans/Blowers/Blender (MAF/BLD)

a) Equipment with online monitoring system. Once in 52 weeks
b) Equipment without online monitoring system. Once in 26 weeks
2. c) Mono-block. No PM

FIN Fans(MAF) Once in 52 weeks

Cooling tower fans(MEF) including gearbox (MHR) Once in 26 weeks

3. Auxiliary steam Turbines(MGS) Once in 26 weeks

4. Diesel engines(MGA/MGE) Once in 26 weeks

5. Agitator & Mixers(MFA) Once in 52 weeks

6. Soot blowers (MATE/MATO) Once in 52 weeks

7. Sulphur Conveyors (MHC) Once in 26 weeks

8. Coker conveying System 1W,4W,26W,52W

9. Coker bucket cranes 1W,4W,26W,52W

10. Mobile crane crushers 1W,4W,26W,52W

11. HTDS/LTDS/OWS DAF Unit Once in 26 weeks

12. Loading arm 13W,26W,52W

To be decided on case to case
basis based on OEM
13 Miscellaneous process equipment
recommendation & past
experience.
Abbreviations:
MPPC Centrifugal Pumps MCCR Reciprocating compressor
MPPD Diaphragm pumps MCCS Screw compressor
MPPG Gear pumps MEC Engines
MPPR Reciprocating pumps BLD Blenders
MPPS Screw pumps MEF Cooling tower fans
MAF Fans & blowers MFA Agitators & Mixers
MATE Retractable soot blower MGA Generators
MATO Rotary soot blower MGE Engine drivers
MCCC Centrifugal compressor MGG Gas Turbine Generator
MCCL Lube compressor MGS Steam Turbine
MCCO Rotary compressor MGT Gas Turbine
MHR Gear box MHC Conveyors

5- Major invasive preventive maintenance of rotary equipment-

Major invasive preventive maintenance of critical rotary equipment is taken up based
on the condition and the performance of the machine in consideration with the OEM
guidelines. The approach cannot be generalized as different type of machines behave
differently. However, the overhauling philosophy adopted for critical machines is
categorized as below-
 Philosophy for centrifugal compressor and steam turbines.
 Philosophy for Reciprocating compressor.
 Philosophy for Gas turbines.
Centrifugal Compressor and Steam Turbines:
Being in extremely critical services these machines are generally built to the stringent
of standards. Almost all centrifugal compressor and Turbines are built as per API
standards and are designed for uninterrupted run of five years. The requirement of the
overhauling is generally to ensure the mechanical and thermodynamic condition of the
machine.
MCMS (Machine Condition Monitoring Systems) and other diagnostic tools facilitate
monitoring of various parameter continuously, which indicates the health of the
equipment. This gives indication of initiation and development of problem, which if not
attended to, can lead to major breakdown. The parameters monitored for knowing the
machine condition include the vibration, rotor axial position, bearing metal
temperature and speed. All the parameters are trended for comparative checks.
Thermodynamic condition of machine can also be evaluated by performing
calculations. Under performing machine need to be open for check and correction. The
service of the compressor is another important factor which can influence the decision
making. The dirty service generally causes fouling of machines, damage to labyrinths
and seals etc. hence the machines in such services are required to be overhauled more
frequently than the machines in fairly clean services. The construction of the machines,
the sealing system etc. also play an important role in deciding the requirement.
Taking into consideration the above-mentioned factors, the inbuilt design features the
equipment performance and the past experience; the overhauling has been developed.
Ensuring reliable operation of the compressor for the next run between turnaround
assumes significant importance.
Reciprocating Compressors:
The functioning and construction of reciprocating machines develops forces and
motion which are combination of rotary and linear motion. The vibration generated
could be purely due to linear forces or a combined effect of both rotary and linear
motion. The phenomenon is quite complex.
The condition of reciprocating compressor can be monitored quite accurately by
vibration, piston rod drop, bearing metal temperature and valve temperature etc. The
continuous friction generated in many compressor components give rise to problems
related to wear and tear which warrants the replacement of affected components.
For the reason stated above and keeping in view the vendor’s recommendation and
past experience the major invasive preventive maintenance for such machines is linked
to the hours of run.
Gas Turbines:
Compressor parts of this machines are expected to give fairly long run as it operates in
air. The online cleaning technique ensures satisfactory performance level. It’s the
turbine components in combustion chamber and hot gas path which governs the
immediate inspection and the complete overhaul. The life of the components is
determined from the past experience and the other factors like the residual life and the
fuels used for firing. The type of fuel can significantly call for shorter inspection interval
due to corrosive/erosive elements. Hence the major invasive preventive maintenance
of the gas turbine is to be carried out as per vendor guideline with suitable adjustments
required in view of factor like type of fuels and coating etc.
Table 2- Logic for Major invasive preventive maintenance of rotary equipment’s.
Sr.n Factors affecting Recommended
Equipment Category Remarks
o decision Overhauling
A Centrifugal Compressor 1. Mechanical After around The crucial factor
(MCCC/MCCL/MCCO/MCC condition of the 43000 hours of influencing the
S) machine. run based on decision should be;
2. Thermodynami opportunity / a) Ensuring
c performance Turnaround reliable run
of the machine. for the next
3. Single line run length
machines. between
4. Ensuring turnarounds.
reliable run b) Condition of
between the machine.
turnaround. c) Minor
5. Hours of run. defects not
6. Past seen like seal
experience. condition and
bearing etc.
may surface
shortly after
overhaul.
Hence the
internal
inspection
and
replacement
of defective
components
 is advised.
1. Mechanical The crucial factor
condition of the influencing the
machine. decision should be;
2. Thermodynami a) Ensuring
c performance reliable run
of the machine. for the next
3. Single line run length
machines. between
4. Ensuring turnarounds.
After around
reliable run b) Condition of
43000 hours of
between the machine.
B Steam turbines (MGS) run based on
turnaround. Minor defects not
opportunity /
5. Hours of run. seen like seal
Turnaround
6. Past condition and
experience. bearing etc. may
surface shortly after
overhaul. Hence the
internal inspection
and replacement of
defective
components is
advised.
1. Mechanical Overhaul as per
conditions. vendor
2. Equipment recommended
performanc hours of run.
e.
Reciprocating compressor
C 3. Hour of run.
(MCCR)
4. Past
experience.
5. Availability
of stand by
machines.
D Gas Turbine (MGG/MGT) 1. Firing hours. Overhaul as per
2. Mechanical vendor
condition of recommendation
machines. (CI/HGPI/MI)
3. Operational
performanc
e of the
machine.
4. Fuels used
for firing.
 5. Past
experience..

6- Preventive maintenance RACI chart -

Sr.
Activity Description Responsible Accountable Consulted Informed
No
Plant PLANT Head.
Identifying Equipment Categories to be AI Rotary
1. AI Rotary Head Maintenance AI Head,
covered under PM. Engineer
Discipline Head HOD Maint.
Plant PLANT Head.
Defining PM frequency for each AI Rotary
2. AI Rotary Head Maintenance AI Head,
Equipment Category. Engineer
Discipline Head HOD Maint.
Plant PLANT Head.
Listing tasks to be done during PM for AI Rotary
3. AI Rotary Head Maintenance AI Head,
each Equipment Category. Engineer
Discipline Head HOD Maint.
Plant
Creating Task list & frequency for each AI Planning AI Planning AI Rotary
4. Maintenance
equipment to be covered under PM. engineer Head Head
Discipline Head
Checking the task & frequency for Plant AI Respective
AI Planning AI Planning
5. linked/associated equipment including Maintenance Discipline
engineer Head
that of other discipline. Discipline Head Head
Plant
Aligning the frequency of linked AI Planning AI Planning AI Rotary
6. Maintenance
equipment with each other. engineer Head Head
Discipline Head
Sending PM template to operation & Plant
AI Planning AI Planning AI Rotary
7. maintenance, Rotary for annual Maintenance
engineer Head Head
review. Discipline Head
Plant
Plant
Annual review of PM schedule based AI Rotary Maintenance
8. Production Plant Head
on operating experience. Engineer Discipline
Manager
Head
Plant Plant
Annual review of PM schedule based AI Rotary PLANT Head.
9. Maintenance Maintenance
on Maintenance experience. Engineer HOD Maint.
Lead Discipline Head
Plant PLANT Head.
AI Rotary
10. PM effectiveness review. AI Rotary Head Maintenance AI Head,
Engineer
Discipline Head HOD Maint.
Compiling & sending comments to Plant
AI Planning AI Planning PLANT Head.
11. respective asset integrity disciplines for Maintenance
engineer Head HOD Maint.
validation. Discipline Head
Validating comments received from Plant
AI Rotary PLANT Head.
12. O&M and sending final AI Rotary Head Maintenance
Engineer HOD Maint.
recommendation to planning. Discipline Head
13. Releasing PM schedule for AI Planning AI Planning Plant PLANT Head.
implementation. engineer Head Maintenance AI Head,
 Discipline Head HOD Maint.
Plant Plant
14. Filling of equipment service sheet (ESS) Maintenance Maintenance
Engineer Discipline Head

7- Concession deviation-
For any reason, if Preventive Maintenance of any rotary equipment is not carried out
within 4 weeks from the schedule week, a concession/deviation request is raised for
the same by Plant Maintenance Engineer.
No separate Preventive Maintenance Is necessary provided the equipment overhauling
or repair job has been carried out four weeks prior to schedule week of Preventive
Maintenance. Similarly, the PM jobs will be carried out in combination with
repair/overhauling of the planned job of the same equipment if the job is planned
within four weeks from the schedule week of preventive maintenance.
Note (1): Filling of ESS by maintenance is mandatory when preventive maintenance job
is clubbed with any other planned overhaul/breakdown of the equipment.
Note (2): Work order of the preventive maintenance, job of the rotary equipment is
closed with appropriate remarks along with work order of repair/overhauling work
order when both the jobs are clubbed.

8- Records-
Retention
Sr. No Description Responsibility Type
period(Month)
Asset Integrity
1 PM schedule Plant wise Hard Copy 12
Planning Head
2 SAP orders -- Electronic Permanent
 Plant
Filled Equipment service
3 Maintenance Hard Copy 12
sheet (FESS)
Discipline Head
Plant
Concession/Deviation
4 Maintenance Hard Copy 24
requests
Discipline Head
Annual PM Effectiveness Asset Integrity
5 Electronic 24
review Rotary Head