Mechanical Presentation.pptx to be checked to understnd

mechanical process and plan has been given to understand the case

1. Understanding Maintenance Practices at BORL Performance Overview Condition Monitoring Practices Few Achievements and Innovations OBJECTIVES

2. A total population of 2021 Rotary & _____ Static equipment is there in BORL including refinery process units as well as in CPP, utilities & BDT. Mechanical maintenance responsibilities: Strive for maximizing the equipment availability Implementation of best maintenance practices & strategies Optimizing the maintenance cost Providing emergency support Mechanical Maintenance –An overview

3. Maintenance planning Field maintenance Central workshop Rotary maintenance Condition monitoring Mechanical Maintenance Structure

4. Centralized maintenance planning SAP supported plant maintenance Equipment performance monitoring Spares management system Maintenance Systems

5. Scheduling of daily jobs Turnarounds planning Spares management Contract management Budget preparation and monitoring MIS generation PLANNING SECTION

6. Execution of routine jobs related to static equipment Resource planning MOC Execution Loss prevention Inspection Recommendation Shutdown and turn around planning Extending support to electrical and instrument Field Maintenance Function

7. 7 SURFACE GRINDER RADIAL DRILLING MACHINE MILLING MACHINE WORKSHOP

8. LLF with preliminary vibration & temperature monitoring PM scheduled as per criticality indexing Predictive Maintenance Based on CM RCFA for atypical and major failures Rotary Maintenance Overview

9. The Rotary equipment are categorized based on their criticality and according to this the maintenance scheduling is fixed. Factors considered for criticality indexing: Safety, Health & Environment/Statutory requirement Process Related Maintenance related Statistical Factor ‐ a) Reliability related b) Condition Monitoring Based on above factors all rotary equipment are categorized as Critical Semi-Critical Non-Critical Equipment Classification and Critical Indexing

10. Equipment's class Preventive maintenance Condition monitoring Lube oil monitoring Critical Quarterly Weekly Monthly Semi-Critical Half Yearly Fortnightly Bi-Monthly Non-Critical Annually Monthly Quarterly PM & CM Scheduling based on Equipment Criticality

11. Availability > 99% PM Compliance > 95% CM Based PdM & Focus area identification Planned Maintenance > 99% KEY PERFORMANCE INDEX

12. SEAL FAILURE IN NUMBERS

13. Seal Failure Trend since Jan-2013

14. In house Mechanical seal cartridge Repair and testing facility Seal face lapping machine Flatness checking by optical flat under monochromatc light Bellow vacuum testing machine Mechanical Seal Reconditioning and Testing Facility

15. Bearings Failure Pattern & RCFA at BORL

16. TOTAL DRIVER – 1450 TOTAL DRIVEN - 1450 Bearing Failure Trend Curve For last 01 Year

17. CONDITION MONITORING PRACTICES

18. Improved Proactive Program at BORL RELIABILITY BASED PROGRAM IMPROVED RELIABLITY

19. Lube Oil Monitoring In-House Patch Test Program and Lube oil conditioning Lube oil patch test BORL CM LAB – OVERVIEW AND ACTIVITIES

20. Progressive Improvement in Lubrication Reliability Since 2014 * Data based on RCFA of failed bearings

21. Mechanical Defects Simulation Kit In-house development Used for imparting Practical training Mechanical defects can be induced in the Kit TRAINING & DEVELOPMENT FACILITIES AT CM LAB

22. MEASURES TAKEN FOR IMPROVING LUBRICATION RELIABILITY Introduction of LMS- Lubrication management system Use of color coded drum stands Use of color coded oil dispensers

23. MEASURES TAKEN FOR IMPROVING LUBRICATION RELIABILITY Use of Desiccant air breathers on drums & equipment to increase the life of lube oil Use of grease dispensing system to avoid wastage and spillage Using online oil condition monitoring bottles for quick checking

24. Awareness campaign to improve lubrication awareness till ground staff Porta-cabin sessions Experts visit Banner displays MEASURES TAKEN FOR IMPROVING LUBRICATION RELIABILITY

25. 25 INNOVATIVE WAY TO REPLACE CCR REACTOR CENTRE PIPE SUPPORT 4 Chain pulley block of equal run placed for lifting the center pipe A gap of 12mm was made by lifting the center pipe for placing the gasket Gasket in four pieces with dove-tail joints was placed from top of reactor 2

26. DE-BOTTLENECKING – NGC CYLINDER HEAD MODIFICATION ORIGINAL COMPRESSION ACHIEVED Modified Cylinder Head without clearance pocket CLEARANCE POCKET BLINDED Rated Capacity achieved, Switched to Single Compressor

27. Improvement Projects Prefab insulation on Coke drum-B Installation of Stepless capacity control system in HCU-MUG Magnetic drive pump for VR service Improvement in job accuracy and reducing MTTR by implementing Laser Alignment. Internal gear pump for Molten Sulfur application in SRU PROSPECTIVE PLANNING

28. 7/19/2017 THANK YOU

29. EQUIPMENT OVERVIEW Equipment Type CDU/VDU DCU HCU MSB OFFSITES SRU HGU CPP CHP RWTP Plant Air /Nitrogen RODM ETP BDT Total Centrifugal pumps 77 52 77 59 37 45 8 31 4 26 - 63 43 52 574 Metering pumps 27 12 9 22 - 10 8 10 - 24 - 41 30 - 193 Gear Pumps - - 22 4 - - - - - - - - - - 26 Vertical/Submersible pumps 8 6 6 10 5 19 9 23 - 21 - - 13 11 131 Screw Pumps 4 3 - 16 5 - - 22 - 6 - - 8 - 64 FD Fan 4 2 2 2 - - 2 6 - - - - - - 18 ID Fan 2 1 1 1 - - 1 3 - - - - - - 9 Fan for AFC 32 42 60 42 - 36 10 12 - 7 - - - - 241 Recip Compressors 3 - 3 8 - - 3 1 - - 3 2 2 - 25 Centrifugal Compressors - 1 1 1 - - - 3 - - 3 - - - 9 Turbines 1 4 8 4 - - - 6 - 1 1 - - - 25 Recip Pumps - - 2 - - - 1 - - - - - - - 3 Screw Compressors - - - 2 - - 2 7 3 - - - - - 14 Soot Blowers 54 32 46 62 - - - 96 - - - - - - 290 Centrifugal blowers - - - 3 - 6 - - - - - 3 - - 12 Mixers/Agitators 7 2 2 1 13 7 4 3 - 20 - 21 24 80 184 Diaphragm pumps - - - - - 7 - - -   - - - - 7 Blower - - - - - - - 49 - 7 - 4 21 - 81 Engine - - - - - - - 1 - 5 - - - - 6 Centrifuge - 1 1 1 - - - 4 -   - - 2 - 9 Gear Box - - 7 - 4 - - 20 16 21 - - - - 68 Crusher - - - - - - - - 3 - - - - - 3 Vibration Screen - - - - - - - - 2 - - - - - 2 Coal Feeder - - - - - - - - 24 - - - - - 24 Wagon Trippler - - - - - - - - 1 - - - - - 1 Stacker Reclaimer - - - - - - - - 1 - - - - 1 Appron feeder - - - - - - - - 1 - - - - - 1 Total 219 158 247 238 64 130 48 297 55 138 7 134 143 143 2021

30. Replacement of checker wall with Blasch Hexwall Replacement of Imported maze sump pump with indigenous vertical pump Replacement of plug type valve unloader with finger type in HCU-MUG-B 14-PA-CF-110A/B Installation of modified mechanical seal 20-EA-00-101A-D, 19-EA-00-101A-D & 19-EA-00-103A/D/E/H, Installation of wireless vibration monitoring system Achievements

31.   CDU DCU MSB HCU HGU SRU OFFSITE Total Centf pump tags 56 36 59 49 9 38 25 w/o stand by 2 2 3 3 2 8 6 WORKING AND STAND BY COMPARISON

32. PM COMPLIANCE & EQUIPMENT AVAILABILITY 2016-17