TRAINING MODULE ON INSPECTION, MAINTENANCE

1
TRAINING MODULE ON INSPECTION, MAINTENANCE
CAPITAL BUDGET
2
1.0 ROLE OF M R IN OPERATIONS
TERMINAL / DEPOT STRATEGY
MAINTENANCE OBJECTIVE
OPERATIONS STRATEGY
MAINTENANCE STRATEGY
3
1.0 ROLE OF M R IN OPERATIONS

• MR IS A COMPLEMENTARY FUNCTION TO OPERATIONS
• MAINTENANCE OBJECTIVES ARE DERIVED FROM OVER ALL
  TERMINAL STRATEGY AS WELL AS OPERATIONS STRATEGY

4
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

5
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

6
3.0 MAINTENANCE STRATEGY

• ASPECTS UNDER MR 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.)

7
3.0 MAINTENANCE STRATEGY

• 3.2 TOOLS, EQUIPMENTS AND CONSUMABLES SPARES-
• WHAT WE REQUIRE?
• TOOLS (SPANNERS,HAND DRILLS Etc.)
• PPES (HELMETS,SAFETY BELT Etc.)
• INSTRUMENTS (MEGGER,MULTIMETER Etc.)
• LUBRICANTS ( OILS ADVISED BY OEM)
• HARDWARE (NUTS, BOLTS, GASKETS Etc.)
• EQUIPMENT SPARES
• FITTINGS (BENDS,ELBOWS Etc.)

8
3.0 MAINTENANCE STRATEGY

• 3.3 PURCHASING
• HOW DO WE PROCURE THE MATERIALS?
• PURCHASE INFORMATION
• PURCHASE PROCEDURES
• LIST OF VENDORS
• INSPECTION PROCEDURES

9
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

10
3.0 MAINTENANCE STRATEGY

• 3.5 DOCUMENTATION AND TRAINING
• HOW TO CARRY OUT THE JOB?
• PROCEDURES
• MANUALS
• HISTORY CARDS CHECK LISTS
• LOG BOOKS

11
(No Transcript)
12
(No Transcript)
13
(No Transcript)
14
(No Transcript)
15
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

16
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

17
OM S (OIL MOVEMENT STORAGE
SUBSYSTEM)

• STORAGE TANK TANKFARM
• PIPELINES
• PUMPS
• GANTRIES
• METERING SYSTEMS

18
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

19
FIRE SAFETY SUB SYSTEM

• FIRE ENGINES
• FOAM SYSTEM
• HYDRANT LINE VALVES
• MOBILE FOAM TENDER
• FIRE EXTINGUISHERS
• PPES (PERSONAL PROTECTIVE EQUIPMENT)
• MONITOR, HYDRANTS SPRINKLERS

• FOLLOW OISD 142, 155 117 STRICTLY.

20
COMMUNICATION SUB SYSTEM

• EPABX
• WIRELESS/WALKIE-TALKIE
• LAN/WAN
• TELEPHONE/FAX

21
COMPANY VEHICLES SUBSYSTEM

• TANK TRUCKS
• OTHER NON-EARNING VEHICLES

22
TERMINAL AUTOMATION SUB SYSTEM

• TANKFARM MODULE
• FIRE PUMP HOUSE AUTOMATION
• PUMP HOUSE AUTOMATION
• TANK TRUCK LOADING MODULE

23
BUILDINGS, ROAD OTHERS

• BUILDINGS
• DRIVE WAYS
• RAILWAY TRACK
• OFFICE EQUIPMENTS

24
SECURITY SUB SYSTEM

• PERIMETER WALL
• GATES
• METAL DETECTOR
• OTHER EQUIPMENTS

25
CUSTOMER CARE EQUIPMENTS

• LABORATORY
• CALIBRATION TOWER
• PROVERS

26
3. 6.2 TYPE OF MAINTENANCE

• BREAK DOWN MAINTENANCE
• ROUTINE MAINTENANCE
• PLANNED MAINTENANCE
• PREVENTIVE MAINTENANCE
• PREDICTIVE MAINTENANCE
• MAJOR MAINTENANCE
• CAPITAL MAINTENANCE

27
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

28
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

29
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.
30
3.6.2.2 ROUTINE MAINTENANCE

• PHYSICAL
• EQUIPMENT COMMISSIONED
• SIMPLE SERVICE AT REGULAR INTERVALS.
• BREAKDOWNS, IF ANY ARE RECTIFIED

• RECORD
• HISTORY CARD GENERATED
• HISTORY CARD UPDATED
• ROOT CAUSE ANALYSIS DETAILS ENTERED

31
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.

32
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.

33
3.6.2.3 PLANNED MAINTENANCE

• RECORD
• 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.

34
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

35
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.

36
PLANNED MAINTENANCE

• DISADVANTAGES
• 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

37
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.

38
PREVENTIVE MAINTENANCE

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

39
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)

40
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

41
PREDICTIVE MAINTENANCE

• ADVANTAGES
• SIMILAR TO PREVENTIVE MAINTENANCE

• DISADVANTAGES
• IT REQUIRES SOPHISTICATED INSTRUMENT FOR
  CONDITION OF MONITORING

• SUITABILITY
• THIS IS SUITABLE FOR ROTARY EQPT.

42
3.6.2.6 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.

43
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

44
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

45
DEVELOPING MAINTENANCE PLAN

• THE PLAN SHALL INCLUDE THE FOLLOWING
• SUBSYSTEM
• TYPE OF MR
• STANDARDS APPLICABLE
• INDIVIDUAL EQUIPMENTS
• WHO WILL DO THE ACTIVITY
• PURCHASE/PROCUREMENT PLAN
• REFERENCE TO DOCUMENTATION

46
3.5 DOCUMENTATION
ASSET LISTING
SPARES LUBE USED
MAINTENANCE SCHEDULE
HISTORY CARD
PURCHASE
MR ACTIVITIES
MIS REPORTS
OPER. DETAILS
BREAKDOWN ANALYSIS
47
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

48
3.6.5 EXECUTION OF JOB

• WORK PERMIT TO BE TAKEN AS PER SCHEDULE
• LIST OF TOOLS PPES TO BE MENTIONED IN THE
  PERMIT
• FINAL LIST OF CONSUMABLES USED TO BE MADE AND
  UPDATED IN HISTORY CARD

49
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.

50
(No Transcript)
51
(No Transcript)
52
(No Transcript)
53
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

54
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.

55
MR - PIPELINES

• ROUTINE INSPECTIONS
• PITTING/SCALING/LEAKS/PINHOLE
• PAINTING PATCH IF NEEDED
• LEAKAGE FROM GASKETS
• INSPECTION OF VALVES/ FITTINGS
• THERMAL RELIEF SYSTEMS
• CONTINUITY JUMPERS

56
MR - PIPELINES

• PERIODIC INSPECTIONS
• 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)

57
MR - PUMPS

• IDENTIFY TYPE OF PUMP
• REFER OISD 119 FOR FREQUENCY INSPECTION
  CHECKLIST.

58
(No Transcript)
59
(No Transcript)
60
(No Transcript)
61
(No Transcript)
62
(No Transcript)
63
(No Transcript)
64
(No Transcript)
65
MR 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.

66
MR 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

67
MR STORAGE TANKS

• INTERNAL INSPECTION
• 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.

68
(No Transcript)
69
(No Transcript)
70
MR 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

71
MR 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

72
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 ROs / ZONE
• PROPOSAL CATEGORIES
• SAFETY SECURITY
• FACILITIES EQUIPMENT
• WELFARE
• OFFICE EQUIPMENT
• LAB EQUIPMENT
• ADDITIONAL PRODUCT TANKAGE
• ENERGY CONSERVATION

73
APPROVAL OF PROPOSALS

• 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.

74
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

75
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 PP FINANCE.

76
THANK YOU