BRIEF ON ROTARY EQUIPMENT

S L MAURYA
CHIEF MAINTENANCE MANAGER
MAINTENANCE OBJECTIVE

OBJECTIVE OF MECHANICAL MAINTENANCE IS TO: -

IMPROVE RELIABILITY OF EQUIPMENT & ENHANCE
PLANT AVAILABILITY AND RUNLENGTH.
 CONTINUOUSLY UPGRADE THE SKILL FOR
INCREASING PLANT RELIABILITY, SAFETY AND
PERFORMANCE.
 OPTIMIZE THE MAINTENANCE COST.
 TO ACHIEVE CUSTOMER DELIGHT THROUGH
QUALITY MAINTENANCE AND FULFILLING THE
EXPECTATIONS & NEED OF THE CUSTOMERS
 MAINTENANCE OBJECTIVE CONTD..

•
 TO COMPLY WITH THE STATUTORY &
REGULATORY REQUIREMENTS RELATED
TO THE EQUIPMENT.
 TO CONTINUALLY IMPROVE THE
MAINTENANCE EFFECTIVENESS FOR
HIGHER PRODUCTIVITY & RELIABILITY
 TO UPGRADE THE SYSTEM, TECHNOLOGY
AND SKILL FOR COMPETITIVE EDGE.
 MAINTENANCE SET UP

• ZONAL/UNIT MAINTENANCE
• CENTRALIZED MAINTENANCE -WORKSHOP/
HEAVY EQUIPMENT
• PLANNING CELL
 MAINTENANCE PHILOSOPHY

• PREVENTIVE MAINTENANCE - TBM

• PREDICTIVE MAINTENANCE - CBM
• CORRECTIVE MAINTENANCE - BM
• SHUT DOWN MAINTENANCE - PM
 MAINTENANCE PHILOSOPHY

PREVENTIVE MAINTENANCE
IT IS BASED ON TIME INTERVAL AS WELL AS
PREDICTIVE MANTENANCE MONITORING
QUARTERLY, HALF YEARLY TO PREVENT
EQUIPMENT BREAK DOWN.
PREDICTIVE MAINTENANCE
IT IS BASED ON CONDITION MONITORING OF ROTARY
EQUIPMENT WEEKLY BASIS TO ASSESS THE HEALTH
OF THE EQUIPMENT.
 MAINTENANCE PHILOSOPHY(CONTD…)

CORRECTIVE MAINTENANCE
IT IS BASED ON ROOT CAUSE ANALYSIS TO
PREVENT REPETIVE FAILURE.
SHUT DOWN MAINTENANCE
IT IS BASED ON THE PLANNED SHUT DOWN SLATE
& UNDERTAKEN FOR THE COMPLETE UNIT.
MAINTENANCE EFFECTIVENESS

• PM EFFECTIVENESS – 98%
• PDM EFFECTIVENESS – 100%
• PLANT AVAILABILITY – 98%
• MAINTENANCE INDEX – 6.18 US$/ EDC
MAINTENANCE ACTIVITIES AT A GLANCE

A) MAINTENANCE JOBS IS PERFORMED THROUGH WORK

REQUEST SYSTEM IN SAP - 100%
B) MATERIAL PROCUREMENT THROUGH SAP –100%
C) CONTRACT ESTIMATE BILLING THROUGH SAP – 100%
D) PREVENTIVE MAINTENANCE SCHEDULING &
MONOTORING THROUGH SAP – 100%
E) SHUT DOWN SCHEDULING & MONITORING THROUGH
PRIMAVERA – 100%
F) CONDITION MONITORING THROUGH SOFTWARE PRO46 –
100%.
CLASSIFICATION OF EQUIPMENT
 ROTARY - 1075 NOS
– PUMPS, COMPRESSORS, TURBINES,
BLOWERS, A F COOLERS, COOLING TOWER
FANS, ID& FD FANS AND MIXERS
 STATIC - 915 NOS
– COLUMNS, REACTORS, VESSELS,
EXCHANGERS, COOLERS, CONDENSERS,
TANKS, FURNACE/HEATERS.
 PIPING - >25000 KM
ROTARY EQUIPMENT

 PUMPS - 825
 CENT. COMPRESSORS - 12
 REC. COMPRESSORS - 30
 TURBINES - 23
 AF COOLERS & CT FANS - 134
 ID & FD FANS - 29
 MIXERS - 66
 SOOT BLOWERS - 22
THANKS