Plant Maintenance & Shutdown Planning

Why So Important ?
Under the current business environment, cost competitiveness and effective maintenance management is key of corporate strategy

The failures of equipments have led to high maintenance and operation costs.

It is very difficult to afford unplanned down time

Shutdown Planning is a mega activity in the continuous running plants so that all activities can be completed within a specified span of time.

Plant Maintenance & Shutdown Planning

How ICT can Help ?
By maintaining Equipment Data Bank with all important details

Keeping History cards ready for reference

Maintaining Logbooks and Equipment Schedules

Shutdown Planning in a most effective manner

Business Intelligence (BI) for Management Analysis and Decision making

Plant Maintenance Management System

Designed to automate the activities of all Sections of Maintenance Department of all IFFCO Units. Includes Equipment Data Bank, Equipment Scheduling, Log Book, Equipment History, MWR, Shutdown, Inspection, Calibration & Testing, Routine Test, Analytical Reports etc. Integration with other running applications like HRMS, Material Management System, Financial Accounting System Data Flows from one Module to another Seamlessly, Just on a Mouse Click. Hierarchical Structure of Equipments has been provided at different levels, Plant, Section, Area, Equipment Category, Sub-Category, Train / Loops etc.

Plant Maintenance Management System

The Static Information like Plant, Section, Area, Equipment Category (e.g. Turbine, Pump, Compressor, Heat Exchanger, Motor etc. , Technical Specifications, Trouble Shooting Parameters are codified in PMMS Masters.

PMMS Masters linked to all Modules of the System to facilitate Quick and Accurate Performance Analysis of the Equipments along with Optimisation of Data Storage.

Access Control and Different kind of Privileges,Rights on each Module, Form and Report is Monitored by One Separate Data Security Module.

EQUIPMENT DATA BANK

SCHEDULING

MWR

LOG BOOK

MASTERS

PMMS ADMN

PLANT MAINTENANCE MANAGEMENT SYSTEM (PMMS)

EQUIPMENT HISTORY

SHUTDOWN

INTEGRATION WITH FAS & HRMS

ANALYTICAL REPORTS

ROUTINE TEST

INSPECTION, CALIBRATION & TESTING

Common Masters
All Static Information like Unit,Plant, Section, Area, Equipment Category, Technical Specifications, Trouble Shooting Parameters are codified in Masters. Common Masters are being referred by each module of PMMS & will be uniform in all units of IFFCO.

Hierarchical Structure of Equipments Plant

Ammonia-1

Section
Mechanical

Area Category

Compressor House, HP Section, LP Section etc Turbine, Pump, Compressor,Controller, Motor etc

Ammonia-2

Electrical

Urea-1

Instrument

Centrifugal, Reciprocating in case of pump etc.

Urea-2

Inspection K-1Train for Complete turbine-compressorgear box etc

Plant Maintenance Management System

Equipment Data Bank Inspection

Equipment Scheduling

Calibration & Testing

MWR

Routine Test

Log Book

Analytical Reports

Equipment History

Integration With Materials

Shutdown

Integration With FAS & HRMS

General PM Schedule

Details
Specifications

Lub Schedule

Drawings

Equipment Data Bank

Spare Parts

Modifications

AMC

Back

Documents

Common Spares

Preventive Maintenance Schedule

Visual Inspection Overhauling Tube Thickness Checking Tray Thickness Checking Etc.

Flushing Top-Up Greasing Sampling Lubrication Schedule Calibrator Calibration Multi Meter Caliberation

Equipment Scheduling

Calibration Schedule

Back

Equipment

Calibration

Switch Calibration Etc.

Stages/Flow of MWR
1. New
By Initiating Cost Centre

2. Approval By Approving Authority 3. Receipt

By Executing Cost Centre After Proper Purging/Isolation

4. Permit Clearance

5. Under Progress/Deferred By Action-by Cost Centre 6. Job Completion Back

After Job Execution

7. Acceptance By Initiating Cost Centre

Personal No, Name, Shift Material Consumption Job Description SIV No Item Code Item Descp. Qty. & Value MWR NO. Plant Name Man Power Details Employee Status

Job Details

Log Book Recording

Eqpt Cat.,Name,Tag Maint. Type Job Status

External Agencies Work Order No. Description Vendor Detail Loadable Value Job Employee Details Job Non-Employee Details Job Executed By

Back

10

11

Job Details

Unit,Plant,Tag No.,Category, Eqpt id, Job details & Constraints etc. Symptoms, Defects& Remedy etc. Item Code ,Description ,Type, Qty, Value etc. Man Power Type, Man Hrs. Over Time Details. Maintenance Type ,Work Order No.,Description, Vendor details, Loadable Value Attached documents detail Summary of Jobs done at a Glance Observations &Loss Details.

Equipment History

Fault Spares Man Power External Agencies Attachments Jobs at a Glance

Insurance Claims

Back

12

Equipment History
It is built to keep Date wise record of all Important Jobs carried out on a Particular Equipment. Integration with Log Book module facilitates to move consolidated data of Job done, Spares consumed, External Agency details, OT etc.directly from multiple Log Books to History, to avoid duplicacy of Job. History card of an equipment consists Detail of Job Done, Engaged Man Power, Spares Consumed, External Agency, Important Data i.e. Protocol Reading etc. Symptom-Cause-Remedy entry is also provided for better analysis of the problem.

13

Shutdown
This Module of PMMS is built to meet all requirements related to Shutdown/Annual turn around.. This Module covers all Shutdown activities 1. Job List Preparation 2. Manpower and Material Planning 3. Other Requirements like Electrical, Crane/Mobile Equipment, Blinds, Scaffolding etc. 4. Marking of Major/Critical Jobs. 5. Monitoring Plant wise daily Shutdown Activities. 6. Maintaining Job History of Equipment 7. Generating Shutdown Report. Provision of job list preparation from any MWR and MWR preparation from shutdown job list is given. Back

14

15

16

Inspection Tests
Dye Penetrant Test Hardness Test Magnetic Particle Test Gauss Measurement Test Radiographic Test Thickness Measurement Test Ultrasonic Examination Vibration Readings Dynamic Balancing Readings Primary Reformer Monitoring -

(a) Tube Master (b) Creep Measurement (c) Delta P Measurement (d) Metallography Measurement (e) Temperature Measurement (f) Visual Inspection

Back

Rubber Line Thickness Measurement Equipment Skin Temperature Measurement Vendor Site Inspection EOT / Mobile Crane Overload Test

17

Electrical - Routine Tests & Check Chart

Measuring Equipment Calibration Motor Checking (a) LT Motor Overhauling (b) HT Motor Monitoring Transformer Checking Cathodic Protection Earthing / Earthing pit Checking Battery & Charger Panel checking Lift Checking Plant Communication Telephone Line Checking

Back

Instrumentation - Calibration
Master Calibration Unit Master Plant Calibrator Master Plant Multi Meter Master

Form and Reports Calibrator Calibration Multi Meter Calibration Equipment Calibration Switch Calibration

18

Analytical Report
Equipment Having recurring jobs Plant wise Equipment vs Defect Equipment wise Failure Analysis Cause wise Failure Analysis ( common defect in many Equipment ) Failure vs Frequency Graph Equipment Expenditure Analysis Section wise Equipment Analysis Equipment Wise MWRs Mean Time to Repair (MTTR) MWR wise Expenditure

19

20

Plant Maintenance & Shutdown Planning

Benefits from ICT
Proper record keeping and documentation Easy handling of Inter departmental jobs Proper Analysis and monitoring of equipment failures and job done Expenditure check on different activities Fast decision making No dependency on single person Best execution planning and optimized utilization of resources Transparency & Knowledge sharing Easy identification of bottlenecks

21