26.

35 MW CO-GEN PLANT-JDW-II
 Plant Manager.
(Naweed Rashid)
Organogram
Mechanical Manager (O&M)
Maintenance Shahid Sagheer

Team Leader (O&M)

M.Ramzan Adeel

Maintenance Engineer
Boiler Engineer
Shahid Imran (Abdul Qayyum)

Supervisor (F&A)

Welder (01) Mechanical Tech (04)

Fabricator (01)
 UMS Procedure of
Maintenance
Maintenance
Preventive Corrective

Time-Based

Condition Condition-Based
Monitoring Predictive
 YEAR 2017 ACHIEVEMENT

Total hours in a year = 8760 Hrs

Total Synchronized Hours =8250.5 Hrs
Synched hrs (%) =94.2 %
 UMS GOAL TO REDUCE FOHI
(FORCE OUTAGE HOURS INTERNAL)

• The review of equipment at scheduled intervals

before appearing any failure.
• Condition monitoring
• Preventive maintenance in pre-season & post-season
planned shutdown.
• The aim is to ensure 100% availability of the
equipment /zero maintenance hours/no stoppage
/no overhauling.
 Rotating Equipment Compliance
Chart by SKF
2014 2015 2016 2017 2018
Good - 75% 77% 81% 83%

Moderate - 20% 19% 19% 17%

Not - 5% 4% 0% 0%
Acceptable

Example of vibration 2014 2015 2016 2017 2018

reduction
Slat chain Motor (NDE) 18 17 9.5 3.5 1.5
‘mm/sec

Condensate Extraction 22 12 2.8 2.83 1.45

pump (A)
‘mm/sec
USM Spares Management System
• Local Sadiqabad (by Max-Min level)
• Head office (LHR) (by Max-Min level)
• New items (Approved OMS/JDW)
• Import items (Approved by OMS/JDW)
 Major Modification USM
• BCs & carriers structure strengthening to reduce vibration
• Gear coupling replacement with pin-bush type to increase reliability i.e. IDF,
BCs & wet scrapper.
• Bagasse Chutes & slat chain trough replacement by SS to improve operational
reliability & reduction in corrective maintenance.
• D.O analyzer & sample cooler installation to improve operational parameters.
• DA dome replacement to increase mechanical de-aeration.
• ZSS of BCs & Slat chain re-located for operation improvement.
• Installation of NALCO TRASAR to control the water chemistry and chemicals.
• Installation of shed at MCW & ACW pumps to avoid high winding temperature
due to high ambient temperature.
• Interconnecting of service air & instrument air line for operation reliability.
• Installation of expansion bellows at CEP suction line to avoid vibration.
• Installation of filter/moisture drainage arrangement at service air line for
DPAH system # 1 ~ 3 to avoid rusting in vibrators.
Documentation by Maintenance Department
Preventive Maintenance
Sr. No Site Name Document Number Document description Issue Issue date
Status

Mechanical Documents
USM Plant OMS/USM/MM/STG/001 Steam Turbine & Aux. Schedule 1 02-01-2018

USM Plant OMS/USM/MM/STG-AUX-A/002 STG Auxiliary Schedule 1 02-01-2018

USM Plant OMS/USM/MM/STG-AUX-B/002 STG REDUCING GEAR & BARRING GEAR 1 02-01-2018

USM Plant OMS/USM/MM/FAN/003 Boiler Fans 1 02-01-2018

USM Plant OMS/USM/MM/BFP/004 Boiler Feed water Pumps 1 02-01-2018

USM Plant OMS/USM/MM/FAN/005 Boiler Bagasse Feeder 1 02-01-2018

USM Plant OMS/USM/MM/BC/006 Belt Conveyor 1 02-01-2018

USM Plant OMS/USM/MM/SC/007 Slat Chain 1 02-01-2018

USM Plant OMS/USM/MM/WS/008 WET SCRAPPER 1 02-01-2018

USM Plant OMS/USM/MM/IA/009 INSTRUMENT AIR COMPRESSOR 1 02-01-2018

USM Plant OMS/USM/MM/SA/010 SERVICE AIR COMPRESSOR 1 02-01-2018

USM Plant OMS/USM/MM/WTP/011 WATER TREATMENT PLANT 1 02-01-2018

USM Plant OMS/USM/MM/CT/012 COOLING TOWER 1 02-01-2018

USM Plant OMS/USM/MM/AHS-B/013 Dense Phase Ash Handling System 1 02-01-2018

Documentation by Maintenance Department
Preventive Maintenance
USM Plant OMS/OMS/MM/AHS-B/013 Dense Phase Ash Handling System 1 02-01-2018

USM Plant OMS/USM/MM/MCW/014 MCW Pumps 1 02-01-2018

USM Plant OMS/USM/MM/ACW/015 ACW Pumps 1 02-01-2018

USM Plant OMS/USM/MM/DMW/016 DMW Pumps 1 02-01-2018

USM Plant OMS/USM/MM/N-PIT/017 N-PIT Pumps 1 02-01-2018

USM Plant OMS/USM/MM/RW/018 R/W RO Pumps 1 02-01-2018

USM Plant OMS/USM/MM/CTMUP/019 CTMUP Pumps 1 02-01-2018

USM Plant OMS/USM/M/FWP/020 FIRE FIGHTING SYSTEM 1 02-01-2018

USM Plant OMS/USM/MM/SB/021 Boiler Soot blower 1 02-01-2018

USM Plant OMS/USM/MM/MV/022 Mechanical Valves 1 02-01-2018

USM Plant OMS/USM/MM/LOP/023 LUBE OIL PURIFICATION 1 02-01-2018

OMS/USM/MM/LOP/F-023 UNIT
USM Plant OMS/USM/MM/EDG /024 EMERGENCY DIESEL ENGINE 1 02-01-2018

USM Plant OMS/USM/MM/OHC/025 OVER HEAD CRANE 70+5 TON 1 02-01-2018

USM Plant OMS/USM/MM/BTP&DG /026 DIESEL ENGINE SERVICE REPORT 1 02-01-2018

(LOCATION AHMAD PUR LAMMA)
USM Plant OMS/USM/MM/BCR/007 Bagasse carriers 1 02-01-2018

USM Plant OMS/USM/MM/PA/0028 RECIPROCATING AIR COMPRESSOR 1 02-01-2018

USM Plant OMS/USM/MM/DOZER /029 KOMATSU DOZER 1 02-01-2018

USM Plant OMS/USM/MM/MVP/030 Multistage vertical pumps 1 02-01-2018

 Documentation by Maintenance Department
Corrective/Modification Maintenance

• Corrective Maintenance Report

• Plant Modification Report
• KKS Identification System
• Preventive maintenance of equipments
• Pre & post season shutdown reports
• Monthly spare cost report
 ISSUES
• Non-availability of spare parts
• Boiler tube thickness mapping
• ECO-1 issue for upper portion.
• Updated drawings
• Tractors & dozers maintenance
• Unloading pumps for WTP
• Short manuals.
• Critical spares ( strategic/consumables, OEM recommended,
pending head office indents, next pre-season shutdown spares)
• Double drive arrangements
• Additional jobs (Preventive & corrective maintenance of outside
bagasse carrier, bulldozers, tractors, APL pumping station, repair
jobs at co-gen hostel & colony residences )
• Shortage of JDW manpower due to additional jobs at USM