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1.0 ROLE OF M & R IN OPERATIONS

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Presentation on theme: "1.0 ROLE OF M & R IN OPERATIONS"— Presentation transcript:

0 TRAINING MODULE ON INSPECTION, MAINTENANCE & CAPITAL BUDGET

1 1.0 ROLE OF M & R IN OPERATIONS
TERMINAL / DEPOT STRATEGY OPERATIONS STRATEGY MAINTENANCE OBJECTIVE MAINTENANCE STRATEGY

2 1.0 ROLE OF M & R IN OPERATIONS
M&R IS A COMPLEMENTARY FUNCTION TO OPERATIONS MAINTENANCE OBJECTIVES ARE DERIVED FROM OVER ALL TERMINAL STRATEGY AS WELL AS OPERATIONS STRATEGY 2

3 2.0 BROAD M & R OBJECTIVES ENSURE MAXIMUM AVAILABILITY OF PLANT/EQUIPMENT AT OPTIMUM LEVEL OF OPERATIONS STRIVE TO INCREASE THE LIFE SPAN OF PLANT/EQUIPMENT ENSURE SAFETY OF PERSONNEL & EQUIPMENT

4 2.0 BROAD M & R OBJECTIVES IDENTIFY AND IMPLEMENT PROJECTS FOR PROCESS IMPROVEMENTS/COST REDUCTIONS MINIMIZE CONSUMPTION OF RESOURCES (ENERGY, WATER ETC.) OPTIMIZE COST OF MAINTENANCE STORES (INVENTORY CONTROL ON SPARES & CONSUMMABLES) MAINTAIN ACCURATE & UP TO DATE MAINTENACE RECORDS

5 ASPECTS UNDER M&R STRATEGY
3.0 MAINTENANCE STRATEGY ASPECTS UNDER M&R STRATEGY 3.1 HUMAN RESOURCES- WHO WILL DO? IN HOUSE (OWN EMPLOYEES) THRU CONTRACTOR/VENDOR THRU OEM / AUTHORISED SERVICE AGENT (CRITICAL EQPT. VIZ DG SET, FIRE PUMPS ETC.)

6 3.0 MAINTENANCE STRATEGY 3.2 TOOLS, EQUIPMENTS AND CONSUMABLES & SPARES- WHAT WE REQUIRE? TOOLS (SPANNERS,HAND DRILLS Etc.) PPE’S (HELMETS,SAFETY BELT Etc.) INSTRUMENTS (MEGGER,MULTIMETER Etc.) LUBRICANTS ( OILS ADVISED BY OEM) HARDWARE (NUTS, BOLTS, GASKETS Etc.) EQUIPMENT SPARES FITTINGS (BENDS,ELBOWS Etc.)

7 3.0 MAINTENANCE STRATEGY 3.3 PURCHASING
HOW DO WE PROCURE THE MATERIALS? PURCHASE INFORMATION PURCHASE PROCEDURES LIST OF VENDORS INSPECTION PROCEDURES

8 3.0 MAINTENANCE STRATEGY 3.4 STORAGE OF METERIALS –
WHERE & HOW TO KEEP? STORAGE SPACE (ENGINEERING WAREHOUSE) PRESERVATION METHODS (TO ENSURE THAT THE ITEM IS KEPT IN USABLE CONDITION.) INVENTORY CONTROL

9 3.0 MAINTENANCE STRATEGY 3.5 DOCUMENTATION AND TRAINING PROCEDURES
HOW TO CARRY OUT THE JOB? PROCEDURES MANUALS HISTORY CARDS & CHECK LISTS LOG BOOKS

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14 3.0 MAINTENANCE STRATEGY 3.6 MAINTENANCE PLANNING
SEGMENTATION OF INFRASTRUCTURE (PLANT/EQUIPMENT) INTO SUBSYSTEMS TYPE OF MAINTENANCE AND SELECTION FOR INDIVIDUAL SEGMENTS DEVELOPING MAINTENANCE PLAN FOR INDIVIDUAL SUBSYSTEMS DEVELOPING PERIODIC MAINTENANCE SCHEDULES EXECUTION OF JOB DOCUMENTATION

15 3.6.1 SEGMENTATION OF INFRASTRUCTURE
OM & S (OIL MOVEMENT & STORAGE SUBSYSTEM) ELECTRICAL SUPPLY SUB SYSTEM (ESS) FIRE & SAFETY SUB SYSTEM COMMUNICATION SUB SYSTEM COMPANY VEHICLES SUB SYSTEM TERMINAL AUTOMATION SUB SYSTEM BUILDINGS, ROADS & OTHERS SECURITY SUB SYSTEM CUSTOMER CARE EQUIPMENTS

16 OM & S (OIL MOVEMENT & STORAGE SUBSYSTEM)
STORAGE TANK & TANKFARM PIPELINES PUMPS GANTRIES METERING SYSTEMS

17 ELECTRICAL SUPPLY SUB SYSTEM (ESS)
SWITCH YARD TRANSFORMERS CABLES EARTHING SYSTEMS VARIOUS CONTROL PANELS MOTOR CONTROL CENTRE LIGHTING & FLP FITTINGS BATTERIES & UPS CAPACITOR BANKS DG SETS FOLLOW OISD – 137 TOTALLY GET ELECTRI CAL SAFETY AUDIT ONCE IN 3 YEARS

18 FIRE & SAFETY SUB SYSTEM
FIRE ENGINES FOAM SYSTEM HYDRANT LINE & VALVES MOBILE FOAM TENDER FIRE EXTINGUISHERS PPE’S (PERSONAL PROTECTIVE EQUIPMENT) MONITOR, HYDRANTS & SPRINKLERS FOLLOW OISD – 142, 155 & 117 STRICTLY.

19 COMMUNICATION SUB SYSTEM
EPABX WIRELESS/WALKIE-TALKIE LAN/WAN TELEPHONE/FAX

20 COMPANY VEHICLES SUBSYSTEM
TANK TRUCKS OTHER NON-EARNING VEHICLES

21 TERMINAL AUTOMATION SUB SYSTEM
TANKFARM MODULE FIRE PUMP HOUSE AUTOMATION PUMP HOUSE AUTOMATION TANK TRUCK LOADING MODULE

22 BUILDINGS, ROAD & OTHERS
DRIVE WAYS RAILWAY TRACK OFFICE EQUIPMENTS

23 GATES METAL DETECTOR OTHER EQUIPMENTS SECURITY SUB SYSTEM
PERIMETER WALL GATES METAL DETECTOR OTHER EQUIPMENTS

24 CUSTOMER CARE EQUIPMENTS
LABORATORY CALIBRATION TOWER PROVERS

25 3. 6.2 TYPE OF MAINTENANCE BREAK DOWN MAINTENANCE ROUTINE MAINTENANCE
PLANNED MAINTENANCE PREVENTIVE MAINTENANCE PREDICTIVE MAINTENANCE MAJOR MAINTENANCE CAPITAL MAINTENANCE

26 3. 3.6.2.1 BREAKDOWN MAINTENANCE
RECORD HISTORY CARD GENERATED ROOT CAUSE ANALYSIS & DETAILS ENTERED PHYSICAL EQPT COMMISSIONED EQPT. IN SERVICE ABNORMALITY/ BREAK DOWN NOTICED RECTIFIED & PUT BACK

27 BREAKDOWN MAINTENANCE
ADVANTAGES NEEDS VERY LESS TIME, LESS ROUTINE EXPENDITURE DISADVANTAGES MAY CREATE CRISIS SITUATIONS/ ACCIDENTS HUGE EXPENDITURE AT IRREGULAR INTERVALS. HENCE DIFFICULT TO ESTIMATE AND BUDGET MAY REDUCE THE LIFE OF EQPT REQUIRES HIGH LEVEL OF VITAL SPARES. HENCE, HIGH INVENTORY CARRYING COSTS

28 BREAKDOWN MAINTENANCE
SUITABILITY DURABLE EQUIPMENT AND FACILITIES LIKE COMPOUND WALL, DYKEWALLS, ROADS ETC. IN THE ABOVE CASES, ACTION CAN BE TAKEN AFTER PROBLEMS ARE NOTICED. (E.G): POT HOLES IN ROADS, SEEPAGES IN BUILDINGS, PROBLEMS FOR FURNITURE ETC.

29 3.6.2.2 ROUTINE MAINTENANCE PHYSICAL RECORD EQUIPMENT COMMISSIONED
SIMPLE SERVICE AT REGULAR INTERVALS. BREAKDOWNS, IF ANY ARE RECTIFIED RECORD HISTORY CARD GENERATED HISTORY CARD UPDATED ROOT CAUSE ANALYSIS & DETAILS ENTERED

30 ROUTINE MAINTENANCE ADVANTAGES
THE EQUIPMENT/FACILITY GETS INSPECTED AT REGULAR INTERVALS. ABNORMAL CONDITIONS CAN BE IDENTIFIED BEFORE CRISIS. NEEDS LESSER TIME. SERVICE COST CAN BE BUDGETED.

31 BREAKDOWNS CAN NOT BE ELIMINATED
ROUTINE MAINTENANCE DISADVANTAGES BREAKDOWNS CAN NOT BE ELIMINATED INVOLVES HIGH EXPENDITURE AT IRREGULAR INTERVALS AND MINIMAL EXPENDITURE AT ROUTINE INTERVALS SUITABILITY COMPUTERS, WALKIE-TALKIE SETS, PRINTERS, AIR-CONDITIONERS AND OTHER OFFICE EQUIPMENTS LIKE FAX, XEROX, EPABX ETC.

32 3.6.2.3 PLANNED MAINTENANCE RECORD PHYSICAL HISTORY SHEET CREATED.
MAINTENANCE PLAN & PERIODIC SCHEDULE DRAWN INSPECTION CHECK LIST FILLED UP AND HISTORY SHEET UPDATED PHYSICAL EQUIPMENT COMMISSIONED PLANNED MAINTENANCE & INSPECTIONS AT FIXED TIME SCALE.

33 THE EQUIPMENT IS INSPECTED CLOSELY AT REGULAR INTERVALS.
PLANNED MAINTENANCE THE EQUIPMENT IS INSPECTED CLOSELY AT REGULAR INTERVALS. CERTAIN MINOR ACTIVITIES LIKE LUBRICANTS, OIL CHANGE, CLEANING, REPLACEMENT OF GASKETS ETC ARE CARRIED OUT

34 3 PLANNED MAINTENANCE ADVANTAGES
BREAK DOWNS ARE MINIMAL & HENCE BREAKDOWNS COSTS ARE LESS. BETTER LIFE SPAN IN VIEW OF REGULAR INSPECTIONS. BETTER ESTIMATION OF MAINTENANCE COST. BETTER INVENTORY CONTROL OF SPARES, LUBES INVENTORY.

35 PLANNED MAINTENANCE DISADVANTAGES SUITABILITY
NEEDS MORE TIME (MANY ACTIVITIES) REQUIRES MORE RESOURCES REQUIRES SHUTDOWN NEEDS HIGHER LEVEL OF PLANNING SUITABILITY GANTRIES, VALVES, VEHICLES, RAILWAY TRACK, FIRE EXTINGUISHERS, METERS, STRAINERS, STORAGE TANKS

36 3.6.2.4 PREVENTIVE MAINTENANCE
IN THIS TYPE, THE MAINTENANCE SCHEDULES ARE DRAWN AS PER REQUIREMENT BY MANUFACTURER/STANDARDS ADVANTAGES REMOTE POSSIBILITIES OF BREAKDOWNS. BETTER ESTIMATION OF EXPENDITURE. HIGHER RELIABILITY OF EQUIPMENT.

37 PREVENTIVE MAINTENANCE
DISADVANTAGES VERY HIGH REQUIREMENT OF HUMAN RESOURCES. ROUTINE COSTS WILL BE HIGHER FOR MAINTENANCE. REQUIRES MORE DOCUMENTATION.

38 PREVENTIVE MAINTENANCE
SUITABILITY FOR EQUIPMENTS WHICH ARE CRITICAL FROM OPERATIONS AND SAFETY POINT OF VIEW (VIZ. FIRE & SAFETY EQUIPMENT, ELECTRICAL SYSTEM AND OIL MOVEMENT & STORAGE SYSTEMS)

39 PREDICTIVE MAINTENANCE
PREDICTIVE MAINTENANCE IS BASED ON CONDITION MONITORING OF EQUIPMENT AND IT REQUIRES SOPHISTICATED EQUIPMENT FOR MONITORING CONDITION OF EQUIPMENT E.g: MONITORING PUMP PERFORMANCE USING VIBRATION ANALYSIS MONITORING OF BEARING CONDITION USING VIBRATION AND TEMPERATURE. THIS PRACTICE IS EXPLAINED IN OISD-124

40 PREDICTIVE MAINTENANCE
ADVANTAGES SIMILAR TO PREVENTIVE MAINTENANCE DISADVANTAGES IT REQUIRES SOPHISTICATED INSTRUMENT FOR CONDITION OF MONITORING SUITABILITY THIS IS SUITABLE FOR ROTARY EQPT.

41 OVERHAULING & RECONDITIONING
MAJOR MAINTENANCE OVERHAULING & RECONDITIONING OVERHAULING: GIVING A NEW LIFE TO THE OPERATIVE EQUIPMENT RECONDITIONING: BRINGING BACK AN EQUIPMENT TO THE ORIGINAL LEVEL OF OPERATIVE CONDITION OISD STANDARDS HAVE RECOMMENDED FOR OVERHAULING OF CENTIFUGAL PUMPS, POSITIVE DISPLACEMENT PUMPS, COMPRESSORS & DIESEL ENGINES.

42 3.6.2.7 CAPITAL MAINTENANCE ACTIVITIES
REFURBISHING TO PROVIDE TECHNOLOGICAL UPGRADATION REPLACING REPLACING THE EXISTING EQUIPMENT PROVIDING STANDBY PROVIDING ADDITIONAL STAND BY EQUIPMENT THE ABOVE ACTIVITIES ARE THE CAPITAL ACTIVITIES EXECUTED THRU NPCB

43 3.6.3 DEVELOPING MAINTENANCE PLAN
PLAN TO BE DEVELOPED FOR PLANNED MAINTENANCE, PREVENTIVE MAINTENANCE & PREDICTIVE MAINTENANCE. PLAN SHALL BE SPECIFIC FOR A PARTICULAR SUBSYSTEM PLAN SHALL ADDRESS THE REQUIREMENTS OF INDIVIDUAL EQUIPMENTS UNDER THE SUBSYSTEM

44 DEVELOPING MAINTENANCE PLAN
THE PLAN SHALL INCLUDE THE FOLLOWING SUBSYSTEM TYPE OF M&R STANDARDS APPLICABLE INDIVIDUAL EQUIPMENTS WHO WILL DO THE ACTIVITY PURCHASE/PROCUREMENT PLAN REFERENCE TO DOCUMENTATION

45 3.5 DOCUMENTATION ASSET LISTING MAINTENANCE SCHEDULE SPARES LUBE USED
HISTORY CARD PURCHASE M&R ACTIVITIES MIS REPORTS OPER. DETAILS BREAKDOWN ANALYSIS

46 3.6.4 DEVELOPING PERIODIC MAINTENANCE SCHEDULE
SSCHEDULE SHALL BE EQUIPMENT SPECIFIC BE DRAWN FROM THE PLAN HAVE REFERENCE OF TIME SCALE SHOW ACTIVITIES SCHEDULED AND COMPLETED HAVE REFERENCE TO WORK PERMITS HAVE REFERENCE TO HISTORY CARD

47 3.6.5 EXECUTION OF JOB WORK PERMIT TO BE TAKEN AS PER SCHEDULE LIST OF TOOLS & PPE’S TO BE MENTIONED IN THE PERMIT FINAL LIST OF CONSUMABLES USED TO BE MADE AND UPDATED IN HISTORY CARD

48 3.6.6 DOCUMENTATION DOCUMENTATION TO BE DESIGNED IN LINE WITH PLAN
WITH LINKAGES WHEREVER REQD. TO TAKE CARE OF THE REQUIREMENTS OF INDIVIDUAL EQUIPMENTS.

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52 6.0 ROUTINE ACTIVITIES ROUTINE MAINTENANCE OF METERING SYSTEM, STRAINERS ETC. CROSS CHECKING OF METER FACTORS DAILY CHECKING OF TOTALISER PERIODIC HOUSE KEEPING OF SOFTWARE

53 CONTROL ON AMC-OEM EQPTS. Viz. DG SET, FIRE ENGINE etc, NEED TO BE EQUIPMENTS Viz. DG SETS, FIRE ENGINES ETC. NEED TO BE MAINTAINED BY TRAINED PERSONNEL. HENCE, AMCs ARE PLACED ON OEM/ AUTHORISED SERVICE AGENT. COST OF AMC IS HIGHER & HENCE WE NEED TO GET MAXIMUM VALUE FOR MONEY.

54 ROUTINE INSPECTIONS M&R - PIPELINES PITTING/SCALING/LEAKS/PINHOLE
PAINTING & PATCH IF NEEDED LEAKAGE FROM GASKETS INSPECTION OF VALVES/ FITTINGS THERMAL RELIEF SYSTEMS CONTINUITY JUMPERS

55 PERIODIC INSPECTIONS M&R - PIPELINES
ULTRASONIC SURVEY OF THICKNESS (3 YEARS) HYDROTEST (3 YEARS) INSPECTION OF U/G LINES FULL PAINTING (FREQ. TO BE DECIDED) {IF SAND BLASTING IS NOT POSSIBLE, SELECT PRIMER SUITABLY} CLEANING OF STRAINERS (QUARTERLY)

56 M&R - PUMPS IDENTIFY TYPE OF PUMP
REFER OISD 119 FOR FREQUENCY & INSPECTION CHECKLIST.

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64 M&R – STORAGE TANKS EXTERNAL INSPECTION – FREQUENCY TO BE DECIDED BASED ON THE REQUIREMENTS OF LOCATION TYPICAL FREQUENCY FORTNIGHTLY – TANKS WHICH ARE OLD/ CORRODED. MONTHLY – OTHER STORAGE TANKS INSPECTION TO BE DONE AS PER CHECKLIST & CORRECTIVE ACTIONS TO BE TAKEN IMMEDIATELY.

65 TO BE DONE DURING TANK CLEANING JOBS TO BE CARRIED OUT INCLUDE
M&R – STORAGE TANKS INTERNAL INSPECTION TO BE DONE DURING TANK CLEANING JOBS TO BE CARRIED OUT INCLUDE CHECKING THE WELD JOINTS OF BOTTOM PLATE – DP TEST/ VACUUM BOX. THICKNESS MEASUREMENT USING ULTRASONIC INSTRUMENT OF BOTTOM PLATE, SHELL, ROOF ETC. OVERHAULING OF ROOF DRAIN MECHANISM FREQUENCY TO BE DECIDED BASED ON THE REQUIREMENTS OF LOCATION

66 INTERNAL INSPECTION M&R – STORAGE TANKS
REPAIR OF BOTTOM PLATE/ ROOF/ SHELL ETC., IF REQD. AS PER OISD 129 SERVICING/REPLACEMENT OF VALVES, NRVs,ETC. SAFETY PRECAUTIONS, WORK PERMIT SYSTEMS TO BE FOLLOWED DURING TANK CLEANING OPERATIONS.

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69 INSPECT THE FOLLOWING ASPECTS
M&R – GANTRIES INSPECT THE FOLLOWING ASPECTS LEAKAGE, IF ANY ARREST. EASE OF OPERATION & GREASING STRAINER CLEANING AT LEAST ONCE IN A QUARTER IN CASE OF HOSE PIPE HYDROTESTING & CONTINUITY (ONCE IN 6 MONTHS) HOUSEKEEPING OF FLOOR, DRAINS

70 INSPECT THE FOLLOWING ASPECTS
M&R – METERING SYSTEM INSPECT THE FOLLOWING ASPECTS LEAKAGE, IF ANY ARREST. FUNCTIONING OF AIR ELIMINATOR STRAINER CLEANING AT LEAST ONCE IN A QUARTER OTHERS – BREAKDOWN MAINTENANCE SPARES TO BE KEPT PULSE TRANSMITTER, GASKETS, O-RINGS, VANES.BLADES, AIR ELIMINATOR BALL, STRAINER BASKET

71 NPCB PREPARATION OF PROPOSALS
DEPT.WISE LOCATIONS REQUIREMENT TO BE STUDIED AND PROPOSALS TO BE INITIATED. PROPOSALS WITH PROPER JUSTIFICATIONS & COST ESTIMATES TO BE SENT TO RESPECTIVE RO’s / ZONE PROPOSAL CATEGORIES : SAFETY & SECURITY FACILITIES & EQUIPMENT WELFARE OFFICE EQUIPMENT LAB EQUIPMENT ADDITIONAL PRODUCT TANKAGE ENERGY CONSERVATION

72 APPROVAL OF PROPOSALS BOARD APPROVES THE BUDGET FOR THE YEAR
PROPOSALS PUT IN CFD & BOARD MEETINGS BOARD APPROVES THE BUDGET FOR THE YEAR BUDGETED FOR PROGRAM & NON-PROGRAM ITEMS ZONE FORWARDS THE APPROVED PROPOSALS TO LOCATIONS WITH AR NOS. APPROPRIATION REQUEST TO BE SENT TO RO/ ZONE DULY FILLED FOR APPROVAL AS PER LAM AFTER RECEIVING APPROVED AR , EXECUTION PROCESS TO BE INITIATED.

73 EXECUTION OF APPROVED PROJECT
LIST ALL APPROVED NPCB PROJECT LPR PREPARATION PURCHASE PROCEDURE TO BE FOLLOWED AS PER LAM TENDER OPENING / RECAP NEGOTIATION ( IF REQUIRED ) PURCHASE ORDER TO BE PLACED JOB TO BE COMPLETED/ITEMS TO BE RECEIVED PREPARATION OF MRR

74 CLOSE OUT OF NPCB PROJECT
MONTHLY PROGRESS REPORT TO BE MADE FOR EFFECTIVE CONTROL / RECORD AMCA TO BE PREPARED FOR CAPITALISATION OF PROJECT. AMCA TO BE ENTERED IN JDE BY FINANCE PERSON AND SYSTEM GENERATED ASSET NO TO BE RECORDED. AMCA TO BE SENT TO RO/ZONE FOR CLOSURE OF CAPITAL EXPENDITURE FOR PARTICULAR AR NO. ENSURE CWIP IS NIL DELETION ADVICE TO BE SENT TO P&P FINANCE.

75 THANK YOU


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