Strategic Maintenance Management

Reliance Infrastructure Generating Stations

 Dahanu TPS - 2x250 MW Thermal power station at Dahanu.

 165 MW combined cycle power station at Kochi, Kerala.

 220 MW combined cycle power plant at Samalkot in Andhra Pradesh.

 48 MW combined cycle power plant at Goa.

 Wind Farm 8 MW Project at Jogimatti in the district of Chitradurga in

Karnataka

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DTPS Geographical Location

 Well connected by Western

Railway & National Highway No. 8.

 On the bank of Arabian Sea

 Surrounded by two natural creeks.

Dahanu
 Nearby Surya River dam (32 kms).

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DTPS Best practices
 Integrated Management System certified for Quality,
Environment & OHS

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DTPS Best practices
 On-line process monitoring & control through Plant Monitoring
System.

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DTPS Best practices
 ERP system for integrated management of Operation, Maintenance,
Logistics, Purchase, Finance, HR etc.

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DTPS Best practices
 Focused Energy Management.

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DTPS Best practices
 Knowledge Management Portal.

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Maintenance Philosophy
 Maintenance at DTPS is perceived as an opportunity to improve reliability
and availability of the equipments and of the unit as a whole.

 Maintenance is used as a tool to maximize generation level and minimize

cost instead of just attending the equipment defects.

 Maintenance is used as a tool to

– Improve Reliability & Availability,

– Maximize generation

– Minimize maintenance cost by Optimizing resource requirement

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Maintenance Management System

Performance Indicators Maintenance Process

Structure

Continual Improvement Maintenance Maintenance

Philosophy Planning &
Administration

Analytical Tools
Monitoring

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Maintenance Philosophy
Maintenance Methodologies

Corrective Preventive Predictive Proactive Maintenance

Maintenance Maintenance Maintenance Maintenance Prevention

• Small • Subject to • Random • ABC • Renovate

Redundant wear-out failures Pattern • Modernize
Items • Consumable • Unpredictable • FMEA • Retire
• Non-Critical • Known wear • Equipment • Replace
• Inconsequential Failure • PM induced Criticality • Design out
Analysis
• Unlikely to fail pattern failure
• Risk
• Coordinated Assessment
Monitoring

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Maintenance Process Structure

Mechanical Maintenance Electrical

Control &
Instrumentation C
U
Maintenance
S
T
O
M
E
R

CUSTOMER Maintenance Planning CUSTOMER

CHP / AHP Civil Maintenance

Maintenance Setup

CUSTOMER

Operation

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Maintenance Management System

Performance Indicators Maintenance Process

Structure

Maintenance
Maintenance Planning &
Continual Improvement
Philosophy Administration

Analytical Tools Monitoring

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Maintenance Administration through ERP

 State-of-the-art ERP system

 Information to plan & optimize maintenance work

 Decision support for equipment–reliability management

 Continuous customization to precisely cater the changing business

requirements

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Maintenance Management System

Performance Maintenance Process

Indicators Structure

Maintenance
Maintenance Planning &
Continual
Philosophy Administration
Improvement

Analytical Monitoring
Tools

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Monitoring Frequency
 Daily
- Maintenance work status
- Maintenance Targets Status
- Critical Equipment Non-Availability Status
- Waste generation
 Weekly
 Preventive Maintenance Compliance
 Defects Pending for Material
 Safety work orders compliance
 Walk through survey findings
 Improvement plan status

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Monitoring Frequency
 Monthly
– Operation Review Team (ORT) meeting is conducted monthly
– Corrective & Preventive actions (CA & PA)
– Shutdown work orders.

 Yearly
– Operation & Maintenance performance
– Objective & target status.
– Divisional Review for QMS, EMS, OHSAS & SA Management

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Maintenance Management System

Performance Maintenance Process

Indicators Structure

Maintenance
Maintenance Planning &
Continual
Philosophy Administration
Improvement

Analytical Monitoring
Tools

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Analytical Tools
Equipment Criticality Analysis

 Identify the equipments, which are having major influence on the

performance of the plant.

 These critical equipments are monitored rigorously to improve the

maintenance as well as operation performance.

– Equipment Criticality Index = Criticality score x Priority

score

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 FMEA

 Root Cause Analysis

 Maintenance Cost Analysis

 Budget utilization analysis

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Maintenance Management System

Performance Maintenance Process

Indicators Structure

Maintenance
Maintenance Planning &
Continual
Philosophy Administration
Improvement

Analytical Monitoring
Tools

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Continual Improvement
New Technologies
 Implementation of SAP System.
 Integrated SCADA for generation, transmission & distribution.
 Fast auto changeover scheme for CW Pump House 6.6 KV switchgear.
(Part of 6 Sigma Project)
 Teflon insulated RTD are used to avoid cable loose connection problem for
temperature measurement due to vibration of equipment in CW Pump
House (Part of 6 Sigma Project)
 Installation of BECK Actuators for Oxygen Control.
 Provision of HEA igniters for reduction in fuel oil consumption.
 VFD for 120 KW Seal air fan motors to reduce power consumption &
improved reliability.
 Upgrading of existing PA System for better Communication.
 Provision of pneumatic shut off gates for improvement in Heat rate.

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Continual Improvement
New Technologies

 Implementation of Software based Calibration Management System .

 PLC System for Air-compressor controls for reliable operation and energy
saving.
 Condenser tube cleaning by bullet shot method to improve condenser
performance.
 Provision of oil level monitoring for fan & mill lube oil systems.
 New PLC for central centrifuge system.
 6.6 KV HT Motor test bench for testing facility.
 Super cleaning of lubricating oil of turbine, generator and HP bypass system.
 Super cleaning of lubricating oil of ID, FD & PA Fan.
 Installation of new Microprocessor based online dew point analyzer for
Hydrogen in generator casing.

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Continual Improvement
New Technologies
 Surface coating of Boiler Tubes by High Velocity Oxy Fuel Process.
 Time synchronization of PMS, DCS of Unit 1&2 & SCADA through GPS
System.
 New HMI System for Plant Management.
 PLC & SCADA System for CW System.
 Fabric expansion joint installation in air & flue gas ducts for reduction in
leakages
 Corrocoating and fiber glass matting of CW pipe to reduce leakages due
to Corrosion.
 Replacement of 220KV Bus CVT by 220KV IPT.
 Installation and commissioning of pull-chord position indicator for coal
conveyors at CHP Control Room.
 To provide digital dynamic display board for displaying online Plant
performance & Environment parameters at various locations.

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Continual Improvement
Technical Audit / Studies

 Renovation and modernization study involving OEM.

 Oceanographic study by Experts.
 Assessment of pre-cooling channels by Experts.
 Area drainage study.
 Civil structure audit for buildings, structures and bridges.
 Audit of compressed air system by OEM.
 Energy conservation study by CII.
 220 KV Transmission network reliability enhancement study by Experts.
 Audit for structure Corrosion by IIT Mumbai.

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Overhaul Planning
 Reduction in shutdown period
 Work Estimation
 Resource Planning
 Accident free overhaul

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Overhaul Project Management

 Progress is tracked through Project management software.

 Reviewed & updated on daily basis.

 Critical path is indicated

 Progress status is published on Intranet

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Maintenance Management System

Performance Maintenance Process

Indicator Structure

Maintenance
Maintenance Planning &
Continual
Philosophy Administration
Improvement

Analytical Monitoring
Tools

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Performance Indicators
Objectives
 Maximize Plant Availability
 Maximize Loading Factor
 Minimize Number of trips
 Minimize Specific oil consumption
 Minimize Aux. Power
 Minimize O&M Cost
 Maintain safe working environment

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Case Study on Condition Monitoring
 Advantages of analysis carried by central department

– Better coordination among different monitoring techniques.

– Limitation of one technique is superseded by another.

– Analysis results of one technique are supported by another.

– Auxiliary is under close observation.

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Case Study 1 – ID Fan Bearing Failure

 Co-ordinated condition monitoring techniques identified a bearing failure of

main boiler auxiliary - ID Fan, using Wear debris analysis, Noise, Vibration
spectrum analysis & Chemical analysis.

 Correct detection of this failure saved the plant from huge losses in terms
of generation, unplanned breakdown time and associated maintenance &
spares costs.

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Fan Details: Radial

 ID fan - 2X50% capacity, driven through hydraulic coupling at 701 RPM.

 Fan drive coupling -: Voith make hydraulic coupling, Oil used IOC make Servo
Torque-10 Bearing : I/P End - 7326 BTY
PUA, O/P End - 7320 BMPUA

Drive motor :

 BHEL make, 1850 KW, 3 ph, 6.6 KV Bearing : NDE NU232,

DE NU 238/6238

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 During the routine monitoring of ID Fan 1B following results were found.
– Vibration - Within limits
– Chemical Analysis of oil - indicated metallic particles
– Noise-Rise of 2 dB, Hissing sound
– Motor current –Normal

 As results were abnormal, oil sample was sent for wear debris analysis to confirm
source of metallic particles.

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 The analysis reported severe sliding wear particles of copper alloy of size
126 microns in large quantities and Copper alloy cutting wear particles of
size 96 microns in marginal quantities

WDA 12th Sept

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 Analysis of another sample taken 4 days later revealed severe sliding wear
particles of copper alloy of size 400 microns in large quantities.

WDA 16th Sept

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Analysis

 It was observed that there was gradual increase in the vibrations of motor
DE bearing.

 On 4th Jan vibrations reached to 10 mm/sec. There was rise in the radial
vibration of motor DE Brg. & slight rise in the trend of hydraulic coupling
axial vibration.

 As motor DE Brg. & Hyd Coupling Brg. has reached critical stage, it was
decided to take the outage of ID fan 1B for replacement of motor &
hydraulic coupling on 5th Jan on an off-peak period.

 Motor DE Brg (6238) found to have fatigue failure.

Inspection of Motor bearing and Hydraulic Coupling show Bearing cage

of Output end bearing (7320 BMPUA) of Hydraulic Coupling found in worn-
out condition.

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Case Study Highlights

 Had we adhered to traditional condition monitoring approach, we could not

have analyzed the deterioration of hydraulic coupling bearing in such an early
stage, since measurement of actual bearing vibrations is not possible as the
bearing is not accessible.
 By adopting different techniques of condition monitoring we arrived at concrete
conclusion on the total health of ID fan 1B.
 Could judiciously delay replacement of Hydraulic Coupling and Bearing.
 Availability of all the resources including hydraulic coupling, motor bearings etc
could be ensured before the actual shutdown of the equipment was taken.
 In-House Condition Monitoring Group Could identify the defect in time this
has increased the confidence level of Maintenance Engineers

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Conclusion
Prevention

Proactive

Predictive

Preventive

Corrective

Focused improvements in O&M practices help to reduce Unplanned

outages of the equipments. Results in improved Reliability, Availability
& Plant loading

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Plant Photographs

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Plant view from the Township

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Turbine Floor

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Coal Mill area

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Switchyard

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Switchyard Control Room

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Flue Gas desulphurization Plant (FGD)

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FGD Control Room

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Solar lights on peripheral roads

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Avenue Plantation

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Thank You