8/3/2019 S K Shukla

1/21

1

Plant Maintenance & Shutdown Planning

Under the current business environment, cost competitivenessand effective maintenance management is key of corporate strategy

The failures of equipments have led to high maintenance and

operation costs.

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

Why So Important ?

It is very difficult to afford unplanned down time

8/3/2019 S K Shukla

2/21

2

Plant Maintenance & Shutdown Planning

By maintaining Equipment Data Bank with all important details

Keeping History cards ready for reference

Shutdown Planning in a most effective manner

How ICT can Help ?

Maintaining Logbooks and Equipment Schedules

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.

8/3/2019 S K Shukla

3/21

3

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.

PLANT

MAINTENANCEMANAGEMENT

SYSTEM

(PMMS)

MASTERS

EQUIPMENT

DATA BANKSCHEDULING MWR LOG BOOK

INTEGRATION

WITH

FAS & HRMS

ANALYTICAL

REPORTS

INSPECTION,

CALIBRATION

& TESTING

ROUTINE

TEST

EQUIPMENT

HISTORY

SHUTDOWNPMMS

ADMN

8/3/2019 S K Shukla

4/21

4

All Static Information like Unit,Plant, Section, Area, Equipment Category,Technical Specifications, Trouble Shooting Parameters are codified in Masters.

Common Masters

Common Masters are being referred by each module of PMMS & will be

uniform in all units of IFFCO.

Ammonia-1

Ammonia-2

Urea-1

Urea-2

Mechanical

Electrical

Instrument

Inspection

Plant

Category

Area

Section

Compressor House,

HP Section, LP Section etc

Turbine, Pump,

Compressor,Controller,

Motor etc

Centrifugal, Reciprocating

in case of pump etc.

K-1Train for

Complete turbine-compressor-

gear box etc

Hierarchical Structure of Equipments

8/3/2019 S K Shukla

5/21

5

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

EquipmentEquipmentData BankData Bank

PM

Schedule

Modifications

Lub

Schedule

Specifications

Drawings

General

Details

Documents

AMC Common

Spares

Spare Parts

Back

8/3/2019 S K Shukla

6/21

6

8/3/2019 S K Shukla

7/21

7

EquipmentEquipment

SchedulingScheduling

Lubrication

ScheduleCalibration

Schedule

Preventive

Maintenance

Schedule

Flushing

Top-Up

Greasing

Sampling

Visual Inspection

OverhaulingTube Thickness Checking

Tray Thickness Checking Etc.

Calibrator Calibration

Multi Meter Caliberation

Equipment Calibration

Switch Calibration Etc.Back

8/3/2019 S K Shukla

8/21

8/3/2019 S K Shukla

9/21

9

8/3/2019 S K Shukla

10/21

10

Log BookLog Book

RecordingRecording

External

Agencies

Job Details

Man Power

Details

Work Order No.

Job Description

SIV No

Item Code

Personal No, Name, Shift

Employee Status

Job Employee Details

Job Non-Employee

Details

Job Executed

By

MaterialConsumption

MWR NO.

Plant Name

Eqpt Cat.,Name,Tag

Maint. Type

Job Status

Description

Vendor Detail

Loadable Value

Item Descp.

Qty. & Value

Back

8/3/2019 S K Shukla

11/21

11

8/3/2019 S K Shukla

12/21

12

EquipmentHistory

Spares

Job Details

Man Power

External Agencies

Jobs at a Glance

Attachments

Insurance Claims

Fault

Unit,Plant,Tag No.,Category, Eqpt id, Job details

& Constraints 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

Summary of Jobs done at a Glance

Attached documents detail

Observations &Loss Details.

Symptoms, Defects& Remedy etc.

Back

8/3/2019 S K Shukla

13/21

13

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.

Equipment History

8/3/2019 S K Shukla

14/21

14

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.

Shutdown

Back

8/3/2019 S K Shukla

15/21

15

8/3/2019 S K Shukla

16/21

16

8/3/2019 S K Shukla

17/21

17

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

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

8/3/2019 S K Shukla

18/21

18

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

8/3/2019 S K Shukla

19/21

19

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

8/3/2019 S K Shukla

20/21

20

8/3/2019 S K Shukla

21/21

Plant Maintenance & Shutdown Planning

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

Benefits from ICT