CMO MRM_May 2024 WITH BREAKDOWN AND IMPROVEMENTDATA.pdf

Details of breakdown & improvement data with details

1. Presented By:–
Central Maintenance OrganizationCentral Maintenance Organization
M I N I N G P O W E R F E R R O-A L L O Y S S T E E L
Synergy in Energy
1
MRM Presentation
May‘2024

2. Employee Development:
No. of internal training:
Plant FY‘23-24 May'2024 FY‘24-25
PWP 43 5 8
SID 44 4 4
IFD 28 5 6
WRM 38 5 10
FAD 11 1 2
Total 164 20 30

3. Vibration Analysis:
CBM Activities for the Month
PlantNo. of Equipments
Condition
Normal Marginal Critical
PWP 38 36 2 -
SID 28 21 7 -
ISP 24 15 9 -
FAD 10 8 2 -
IFD 16 13 3 -
WRM 24 23 1 -
TOTAL 140 116 24 -
Note :As per analysis there is no Critical equipment for the month of May’2024.
Thermographyinspection :
Thermographyinin--house house visited plan
on date 10 to 24 Jun’24.

4. Breakdown more than 03 Hrs
Breakdown
Nature/ Parts Failure
Frequenc
y YTD
Duration in
(Hrs.)
Action taken
PWP MECH
Sporadic / Belt joint failure
of BC –3.
1 10.58Belt laying, positioning, re-jointing & alignment done.
SID MECH
Sporadic / 500 TPD RMHS
Coal ckt. BC –18 Belt
Broken.
1 9
Belt Conveyor both ends taken to position and
Conveyor belt re -jointing work.
FAD E&I
Sporadic / Furnace-D
Capacitor VCB in HT cable
puncher.
1 3
Incomer VCB HT cable meggervalue found B phase
low & found cable puncture. Disconnect capacitor
bank cable and restart the F/C.

5. Capex Status & Maintenance Services :

6. Maintenance Cost :

7. Date
Additional Information
Plant Achievements
PWP E&I PDB and MCC room floor coating work.
B1. Improvement/System Up-gradation :

8. Date
Additional Information
Plant Achievements
SID 100 TPD RMHS Iron Conveyor BC-1A and 3A GantryStrengthening work.
B2. Improvement/System Up-gradation :

9. Date
Additional Information
Plant Achievements
SID
New room of environment lab under ground cable wiring has been
completed & modular switch board installation work done.
B6. Improvement/System Up-gradation :

10. Date
Additional Information
Plant Achievements
SID
Kiln-A & Kiln-B Transfer chute Local feeder has been shifted from field
side to MCC & Feeder modification has been completed.
B7. Improvement/System Up-gradation :

11. Date
Additional Information
Plant Achievements
FAD
Staircase modification for pump installation of Auto transformer heat
exchanger.
B8. Improvement/System Up-gradation :

12. Additional Information
Plant Achievements
IFD MECH Furnace -F Poker machine installation and trial done.
B9. Improvement/System Up-gradation :

13. Additional Information
Plant Achievements
IFD E&IBillet yard crane-2 safety-Projector light installation done.
B10. Improvement/System Up-gradation :

14. Major Shutdown Planned Vs Actual for May’2024
PlantDetail of Shutdown
Planned
Date
Durati
on
Actual Date
Duratio
n
Variation in
Duration
Remark
FAD
Furnace “B”Shutdown
28 May’24
12 Hrs.
18 May’24
16 Hrs.
4 Hrs.
Due to arrest water
leakage of Hood.
Furnace “C”Shutdown
02 May’24
12 Hrs.
02 May’24
10 Hrs.
-2 Hrs. ---
Furnace “D”Shutdown
21 May’24
12 Hrs.
14 May’24
10 Hrs.
-2 Hrs. ---
Furnace “E”Shutdown
14 May’24
12 Hrs.
28 May’24
12 Hrs.
--- ---
SID
Kiln “A”Shutdown
01 to 06 May ’24
6 Days.
Postpone
Kiln “C”Shutdown
16 to 27 May ’24
12 Days.
03 to 14 May ’24
12 Days.
--- ---
IFDGeneral Shutdown
03 May’ 24
8 Hrs.
03 May’ 24
8 Hrs.
--- ---

15. Major Shutdown Planned for Jun’2024 (as per RBP)
Plant Detail of Shutdown Date Duration
FAD
Furnace “A”Shutdown
04 Jun’24
12 Hrs.
Furnace “B”Shutdown
25 Jun’24
72 Hrs.
Furnace “C”Shutdown
18 Jun’24
12 Hrs.
Furnace “D”Shutdown
11 Jun’24
12 Hrs.
SID
Kiln “A”Shutdown
14 to 19 Jun ’24
6 Days.
Kiln “D”Shutdown
01 to 12 Jun ’24
12 Days.
IFD General Shutdown
05 Jun’ 24
8 Hrs.

16. * Execution Index -Completed Notification Vs Raised Notification (All Types)
** Planning Index -Preventive (Auto) Notification (M1) Vs ( M1+M2+M3) Notification.
CMO Planning & Execution Index
INDEX (%)
FY-2024-25
(Average)
FY-2023-24
(Average)
FY-2022-23
(Average)
APR-24 MAY-24
Execution 84.36 82.14 81.01 85.19 83.53
Planning 95.95 95.65 96.39 95.54 96.35
Plant Maintenance Report for the Month
PLANNER
GROUP
TOTAL
NOTIFICA
TION
M1 -PREVENTIVE MAINT.
NOTI.
M2 -BREAKDOWN
MAINT. NOTI.
M3 -GENERAL MAINT.
NOTI.
M5 -MODIFICATION /
REFURBI. NOTI.)
M0 -EXTERNAL
SERVICES NOTI.)
*Execution
Index
**Planning
Index
TOTALOPENCOMP.TOTALOPENCOMP.TOTALOPENCOMP.TOTALOPENCOMP.TOTALOPENCOMP. (In %) (In %)
BEM 338316452715 0 5110114 0 4 2 0 2 86.69 95.18
BMM 21219216176110114 0 4 2 0 2 3 3 0 91.04 92.75
BRE 66 66 1947 0 0 0 0 0 0 0 0 0 0 0 0 71.21100.00
BRM 1291275968 0 0 0 0 0 0 2 0 2 0 0 0 54.26100.00
FEM 319316222942 0 2 0 0 0 0 0 0 1 1 0 92.79 99.37
FMM 264259492105 0 5 0 0 0 0 0 0 0 0 0 81.44 98.11
PEM 2942351081271 0 15422320 0 0 4 4 0 54.42 81.03
PMM 815802827201 0 1 7 1 6 1 0 1 4 4 0 89.33 99.01
SEM 213198101881 0 1 6 0 6 7 3 4 1 1 0 93.43 96.59
SMM 1372133323610971 0 12514114 2 2 9 7 2 81.12 98.09
WEM 429420833374 3 1 3 0 3 0 0 0 2 0 2 79.95 98.36
WMM 44841111400340342 1 1 0 0 0 1 1 0 97.10 91.95
CMO 4899467574039356536211238742051527216 83.53 96.35
Overall Performance
Index (In %)
84.17 95.38 66.07 75.00 22.22 83.5396.35

17. MTTR & MTBF Analysis for the Month
MTBF (Mean Time between Failure) = Total Uptime / Number of Failures
MTTR (Mean Time to Repair) = Total Downtime / Number of Failures
MTBF MTTR
Days Hours
BILP FAP1 PWP1 SIP1 WRM1
0
5
10
15
20
25
30
3.32
1.48
14.98
30.00
0.42
10.33
4.42
30.94 30.86
0.77
Apr-24
May-24
BILPFAP1PWP1 SIP1WRM1
0
4
8
12
16
2.49
1.95
4.64
0.23 0.27
1.14
0.85
13.5 13.32
0.17
Apr-24
May-24

18. Sarda Solutions App Issue Status for the Month
Dashboard

19. 19