my project report

PROJECT REPORTON

Submitted in partial fulfillment of the requirement for the third semester of the

Degree ofMASTER OF BUSINESS ADMINISTRATION

Of Anna University Chennai during the year 2010

Carried out by

R.VIGNESWARI SOWMIYA

Register No: 13209631043

Under guidance of

Mr.R.RAMAR M.sc, MPhil.

ASSISTANT MANAGER-QUALITY ASSURANCE

CTEX PETROCHEMICAL LTD

MANALI

DEPARTMENT OF MANAGEMENT STUDIES

PANCHETTI

THIRUVALLUR DIST

CHENNAI – 601 204

Page | 1

DECLARATION

I hereby declare that the Project Report entitled “

.” is done by me under the guidance of Miss. SHAILAJA (Internal) and

Mr.RAMAR (External) at CTEX PETROCHEMICAL LTD is submitted in partial fulfillment

of the requirements for the award of the degree in MASTER OF BUSINESS

ADMINISTRATION.

DATE:

PLACE: SIGNATURE OF THE CANDIDATE

2

ACKNOWLEDGEMENT

My sincere thanks to beloved chairman Sri. M.V. Muthuramalingam, for his

premier institution. I would like to express my gratitude to our Director Sri M.V.M. Sasi

Kumar, who has also responsible for the molding our things to complete this project.

I take extensive privilege in expressing sense of gratitude and heartfelt thanks

to our Principal Dr. Vemuri Lakshminarayana, M.Tech(IIT, Kanpur), Ph. D.,PGDBA,

PGDIM, PGDOM, MBA., for their whole-hearted and kind co-operation, without which

this project would not have been possible.

It is my pleasure to express my sincere gratitude and thanks to my Head of

Department (COO) Mr. JERRY MIAH my Project Guide Miss.shailaja for their

valuable guidance and support at all stages of the project and without whose constant

encouragement, I would have not completed this project.

My heartfelt thanks to Mr.GOMATHI SANKER and MR.R.RAMAR for

providing me an opportunity to do my project in CTEX PETROCHEMICAL LTD.

I am also thankful to all the faculty members of the MBA Department for

their kind and valuable co-operation during the course of the project. I would also like

to thank my parents, friends and well wishers who encouraged me to complete this

project successfully.

3

INDEX

Chap. no Contents Page no

Acknowledgement

List of tables

List of chart

1 Introduction

a. Industry profile

b. Company profile

c. Product profile

d. Description of process

2 Aim of the project

a. Objective of the study

b. Scope of the study

3

a.

b.

4

a.

b.

5 Findings and observations

6 Suggestions

7 Conclusion

8 Bibliography

LIST OF TABLES

4

Table no Description Page no

1

a.

b.

c.

2.

a.

5

INTRODUCTION

INTRODUCTION

6

Maintenance is the function of production management that is concerned with day-to-day

problem of keeping the physical plant in good operating condition. It is an essential activity in

the manufacturing of petrochemicals, because it is necessary to ensure the availability of the

machines, buildings and services needed by other parts of the organization for the performance

of their function at an optimum return on investment in machines, materials and employees.

This report reviews the operations and maintenance practice to be ensured in CETEX

PETROCHEMICALS LTD.

INDUSTRY PROFILE:

Petrochemicals dominate the global chemicals market with a share of almost 40 percent.

The coming years are expected to see the petrochemicals industry undergoing a major

metamorphosis, particularly with the Middle East as a major petrochemicals supplier and

China emerging as a major processing hub and end-use market.

Petrochemicals are the downstream of the oil and gas industry - an industry whose

products affect our daily lives. Petrochemicals are a part of our daily lives - the carpeting on

which we walk, plastic soda bottles from which we drink, clothing we wear, fertilizers that

grow our crops, tires we rely on for transportation, paints we use to brighten our surroundings,

pharmaceuticals we need to remain healthy, cosmetics, and many other applications.

Petrochemicals get their raw material - known as feedstocks - from the refinery: naphtha,

components of natural gas such as butane, and some of the byproducts of oil refining

processes, such as ethane and propane. These feedstocks are then cracked to obtain the

building blocks of the petrochemical industry: olefins, that is, mainly ethylene, propylene, and

the so-called C4 derivatives, including butadiene - and aromatics, mainly benzene, toluene, and

the xylenes. These products are then processed to produce a wide variety of consumer and

industrial products.

Petrochemical Industry in India

7

The petrochemical industry has been one of the of the fastest growing industries in the

Indian economy; it provides the foundation for manufacturing industries such as

pharmaceuticals, construction, agriculture, packaging industry, textiles, automotive, etc. The

petrochemical industry in India is oligopolistic with four main players dominating the market,

namely Reliance Industries Ltd. (RIL) along with Indian Petrochemical Ltd. (IPCL), Gas

Authority of India Ltd (GAIL), and Haldia Petrochemicals Ltd. (HPL).

Currently, India has three naphtha- and three gas -based cracker complexes with a

combined ethylene annual capacity of over 2.5 MMTA. Besides, there are four aromatic

complexes also with a combined Xylenes capacity of 2.9 MMTA. Polymers account for more

than 60 percent of total petrochemical production. As shown in the figure below, the industry

has been stagnant in terms of capacity addition. Combining the demand for all the key

segments in the petrochemical industry, aggregate demand for the entire petrochemical sector

in India was around 20 MMTA in 2010

COMPANY PROFILE :

Cetex Petrochemicals Ltd was established in 1990 with German technology, located at

Chennai (Madras), South India. The plant is located about 20 Kms north of Chennai in the

Manali Industrial Belt. Feedstock is drawn by pipeline from the neighboring Chennai

Petroleum Corporation ltd.

PLANT SIGHT

8

Cetex has ventured into development of fine chemicals like specialized pharma

intermediates and aroma chemical & essential chemicals. In an endeavor to upgrade the

lucrative additive business, Cetex aspires to produce Energy chemicals, Lube additive, Water

treatment chemicals and Marine chemicals. Through marketing tie-ups with leading majors

like Petro-Canada, Cetex stands for high performance speciality products in the Indian market

place.

Cetex Petrochemicals is the largest manufacturer of Methyl Ethyl Ketone (MEK) and

Secondary Butyl Alcohol (SBA) in India. With the consistent quality of its products and

services, Cetex commands a formidable market share of more than 60%. In India, Cetex has

the distinction of being the only manufacturer of MEK to be ISO 9001-2008, ISO 14001 and

OSHAs 18001 certified.

Safety and environment:

9

Setting and achieving high standards for safety, health and the protection of the

environment (SHE) is essential to the performance of Cetex petrochemicals and a key element

of our commitment to sustainable development. 

Cetex gives top priority to worker safety and equipment management. The company is

well equipped in safety systems and trained man power. The company today has a truly

impressive safety record. No accidents have occurred in the past 11 years.

Cetex has been conferred some of the countries highest awards for following safety

standards set by the industry.

Cetex has won the Star Safety Award for 1998 & 1999 from National Safety Council,

Tamilnadu and is the winner of All India Award from National Safety Council for three years

from 2000 to 2002.

Cetex is a zero effluent discharge company and has been certified to be a very

environment conscious company.

Quality Practice and ISO certification:

  The quality management system at cetex is ISO 9000 certified. Product quality at Cetex

is at par with International levels and Cetex has no history of product rejection since its

inception. The company is well committed to sound environmental practices and is ISO 14001

certified. Cetex is committed to continual improvement and is practicing deep rooted TPM,

TQM, and 5S initiatives.

In the endeavor to achieve high standards in occupational health and safety, Cetex is

OSHAs 18001 certified.

10

PRODUCT PROFILE:

1. Secondary Butyl Alcohol:  

  Description:

Secondary Butyl Alcohol or Secondary Butyl Alcohol (SBA) is a water white highly

volatile liquid with characteristic odour. Secondary Butanol is non-toxic. Secondary Butanol is

used in the manufacture of specialty intermediates, Pharma industry and in the manufacture of

paints.

Application:

manufacture of Pharma intermediates

as solvent in Paints and Lacquer industry

as solubilizer for the production of cleaning compounds

manufacture of Secondary Butyl Acetate, Nitrocellulose solvents

manufacture of Printing Inks and as a solvent in flexographic printing dyes

2. Methyl Ethyl Ketone:

Description:

Methyl Ethyl Ketone (MEK) is a water white, highly volatile liquid having Acetone-

like odour with no cumulative toxicological properties. Methyl Ethyl Ketone is one of the most

versatile solvents, capable of dissolving a wide range of substances. Its excellent solvent

11

properties are used by the surface coating, printing ink, plastic processing, resin industries and

lubricating oil de-waxing in the Refineries. Methyl Ethyl Ketone is miscible with most organic

solvents and owing to the high reactivity of the carbonyl group, it is used as an intermediate in

a number of chemical products, such as Aroma Chemicals.

Application:      

MEK is widely used in the following applications:  

Lubricating oil dewaxing

Adhesives

Printing Inks

Magnetic Audio Video tapes

Polyurethane resins

Artificial Leather

PVC film/Leather cloth industry

MEK Oxime manufacture

MEK Peroxide manufacture

Aroma Chemicals such as Methyl Pentanone

Degreasing of metal surfaces, particularly Aircraft parts

Epoxy glass laminates for the electronic industry

BY PRODUCTS:

SOLVENT – X:    

Description:

Solvent - X is a pale yellow liquid containing a mixture of Ethyl iso Amyl Ketone,

higher ketones and secondary Butanol. Solvent - X has somewhat pleasant smell and is non-

toxic.

SOLVENT – XX:      

Description:

12

Solvent - XX is a clear, colorless and highly volatile liquid with a characteristic odour.

Solvent - XX contains predominantly di secondary butyl ether.

SOLVENT – XXX:      

Description:

Solvent - XXX is pale yellow, highly volatile liquid with turpentine like odour. The product is non-toxic. Solvent - XXX is flammable and used as a general purpose solvent and diluent.

LPG:

Cetex produces LPG quality Butane as a return stream from its Methyl Ethyl Ketone

(MEK) paint. The LPG mainly consists of n-Butane up to 95 % with other C4 hydrocarbons

being balance 5%.

Cetex's LPG being rich in saturated hydrocarbons, is a clean fuel and finds use in

specific furnance applications for Glassm Ceramics and Tile manufacturing. Being rich in

Butane, usage on stand - alone basis in large industrial applications requires the use of a

vaporizer for good burning particularly in the furnances for Glass and Ceramics.

Apart from the above, it can blend well in all proportions with Domestic and Industrial

LPG.

DESCRIPTION OF PROCESS:

SBA is used almost entirely over (90%) as intermediate for the production of MEK.

One of the most common routes for the production of SBA is the hydration of the n-

butanes via esterification with sulphuric acid. The first step which takes place mainly in the

first reactor is the esterification of butene to Mono-Butyl-Ester which reacts acidic after most

of the acid has already reacted. There starts the second main reaction of Mono-Butyl-Ester

with n-butane, forming Di-Butyl-Ester which is neutral, but not stable. The next step is

hydrolysis, in which the secondary butyl alcohol is formed.

13

The SBA reaction requires a feed of sulphuric acid at concentration of 75%. The acid

will be diluted in the process to an outlet concentration of 50%. Fresh 98% acid will be

blended with spent acid and water to the required feed concentration. The hydrolysis output

which is the impure SBA is then neutralised to obtain pure SBA. The impure SBA is

neutralised by using the caustic soda which is sodium hydroxide and the outputs are pure SBA

and the sulphate.

The pure SBA is used for the manufacturing of MEK. The pure SBA undergoes

MEK synthesis process. In the synthesis of raw MEK, hydrogen gas is liberated. The raw

MEK undergoes distillation process and finally the pure MEK is obtained and stored. The by-

product is obtained is heavy ketones.

PRODUCTION:

MAIN PRODUCTS:

1. Methyl Ethyl Ketone (MEK), Capacity (7500 MT)

2. Secondary butanol (SBA), Capacity (6000 MT)

BY PRODUCTS:

1. Butane

2. Sulphuric acid (52%) (Spent acid)

3. Polymer (Sol XXX)

4. Secondary Butyl Ether (SBE) (Sol XX)

5.EAK (Sol X)

6.Hydrogen

The production plant is running at his maximum capacity of production. The daily

production of the company is 24 MT of SBA. The liberated hydrogen gas is utilised in the

boiler as a fuel.

14

PROCESS CHART:

15

NeutralizationSBA

purificationHydrolysisEsterificationButene

Sulphuric Acid(98%) Spent acid disposal

Feedacid(75%) Spent acid (50-55%)

Waste to solar pond

Pure SBA storageButene recovery

system

Butane recovery system

Butane LPG Butane storage LPG

SBE solvent xxPolymer solvent

xxx

MEK purificationPure MEK storage

Heavy Ketones

Raw MEK separation

MEK synthesis

OBJECTIVE OF THE STUDY

PRIMARY OBJECTIVE

To maximize efficiency and economy in production through optimum use of facilities.

SECONDARY OBJECTIVES

To keep the plant facilities in full working conditions with zero or minimum

breakdowns.

Provide evaluation of all facilities for planned maintenance and replacement wherever

required.

To keep the internal and external premises of the industrial unit clean, safe and in

usable condition.

To minimize the loss of productive time because of equipment failure.

To minimize the repair time and cost.

To minimize the loss due to production stoppages.

To efficient use of maintenance personnel and equipment.

To improve the quality of products and to improve productivity.

To minimize accidents through regular inspection and repair of safety devices

.

16

SCOPE OF MAINTENANCE

Maintenance of existing plant and equipments.

Equipment inspection and lubrication.

New installation of equipments and buildings.

Plant protection including fire protection.

17

Planning and scheduling of maintenance:

What the maintenance activities are to be carried out?

How these activities are to be carried out?

Where these activities are to be performed?

Why these activities are to be performed?

When these activities are to be performed?

Importance and necessity of maintenance:

Equipment breakdown leads to stoppage of production and hence loss of man

hours and machine hours.

Many times if the first stage machined is non-operative next ‘n’ number of

machine will be idle due to no feeding of material due to operational sequence

need.

Some of the breakdowns losses are quantifiable and some are not quantifiable

Due to lack of maintenance product quality will be poor and inconsistent.

The losses and inconvenience created.

Totally:

Rescheduling of production plan causing delay in supply.

Rejection, damage to components due to faulty machines.

Increasing sub-contracting and hence more cost.

Loss of production and man hours.

Shortfall is also taken care by overtime and hence increases costs.

Functions of plant maintenance:

A) Evaluation/Inspection

18

Periodic check of plant facilities to examine their working conditions

to take corrective actions.

To check safety factors for machinery and operators.

Ensure that important spares like belts, bearings, bushes which are

frequently required are as per quality and quantity.

To check if spares purchased for imported and high value machinery are

from original source.

Obtain information from senior operators, absorb any unusual sound or

trouble from machines.

Components and other maintenance items received as spares to be

checked thoroughly by specialists.

B) Engineering and Development:

Maintenance engineers should be innovative and think for changes in

arrangements to improve machine’s utility and quality of workmanships.

In mechanical/electrical/instrumental installations maintenance staff

should take it up like a project assignment and take better care of cost

and time factors.

If production engineer feel deviations are due to machines the

maintenance engineers should involve in trouble shooting to keep

machines in efficient condition.

Total maintenance work

Taking care of breakdown maintenance (repair work),

planned productive maintenance of machinery and

equipments.

Scheduled overhauling of major equipments.

Maintenance of building facilities stores yard compound

for safety and better work environment

Attending projects assignments for knowhow on future

maintenance needs.

C) Replacement, reconditioning disposal decisions

19

.

D) Administrative work

Personnel and administrative work of the department

Records, drawing specifications of various departments related

work.

Spares list for various machines, import list, budget costs etc,

files to be maintained.

Record of machinery insurances to be kept.

E) SAFETY

Safety from fire, water, pollution.

Housekeeping, maintenance of open yards and buildings.

ORGANIZATIONS CHART OF MAINTENANCE PRACTICE FOR A MEDIUM

SIZE COMPANY:

TYPES OF MAINTENANCE

1) CORRECTIVE MAINTENANCE

2) PREVENTIVE MAINTENANCE

3) SCHEDULED MAINTENANCE

4) PREDICTIVE MAINTENANCE

MAINTENANCE POLICY:

Adapt preventive maintenance

20

Have extra facilities to reduce wear and tear.

Replace parts early to avoid further problems.

Involve operative’s machines care, train them.

Use higher capacity machines to reduce chances of breakdowns.

Buy machines which are easy to change parts and for routine

maintenance.

Improve overall capacity of maintenance department in forms of

manpower, facilities, and training.

Keep adequate stock of spare parts of all machinery and equipments.

Keep standby arrangements for important production machinery. Can

also take up alternate product manufacture to release machines for

maintenance work.

Good interaction between production, quality control and maintenance

department.

BREAKDOWN MAINTENANCE:

The word management language is corrective maintenance or ‘breakdown

maintenance’

REASONS FOR BREAKDOWN:

Due to failure to replace worn out parts, bearings, belts etc.

Not doing periodic oiling, lubrication of moving parts

Poor maintenance of heating or cooling system of process

Neglecting small cases like loose nuts, sources, projections

of or covers

Not filling up fuel or non supply of fuel due to blockage in

pipelines.

Frequent power failures, erratic voltage, short circuiting.

Not attending unusual sound, vibrations of moving parts,

overheating of parts etc.

21

PREVENTIVE MAINTENANCE

This is a method of planned maintenance and avoids the possibilities of

breakdown. This is precautionary measure and ensures continuous use of machines after

attending the work. This identifies the wear out parts, bent or deviated components, loose

joints oiling and lubricating needs bearing wear and tear.

METHODOLOGY:

Periodic inspection of machinery and equipments to understand

discrepancies if any and likely of areas problems.

To take up for corrective action when machineries are still in workable

condition.

Inspection and identifications of replaceable parts is the key to

successful preventive maintenance.

Past data from SQC enables to understand the likely trouble spots and

recurrence of problems.

BENEFITS OF PREVENTIVE MAINTENANCE

Reduction of the total down-time and consequent reduction in

production loses.

Reduction in the number of major repairs, and consequently reduced

maintenance expenses.

Reduction in the number of rejects and n improvements in product

quality.

Reduction in the inventory of spare parts.

Reduction in the number of accidents in the plant.

Reduction in the unplanned or crisis management in maintenance.

There are certain costs associated with the preventive maintenance

Scheduled down-time of production.

Replacement parts and supplies.

Instruments e.g.in the case of condition monitoring.

22

Wages of preventive maintenance technicians and staff.

Each plant should have its own preventive maintenance policies suited to that plant’s

needs. the working environment, the type of operations, the type equipment, the age of

equipment and plant, and other factors determine the incidents of breakdowns, their severity,

and the costs associated with these in the absence or presence of the preventive maintenance

programme of a smaller or larger size. In general, plants which are maintained efficiently

spend almost three quarters of their time on preventive maintenance, while only one quarter is

spent on breakdown maintenance.

OBJECTIVES OF PREVENTIVE MAINTENANCE:

To avoid or minimize possibilities of breakdowns

To ensure availability of all the machines in usable conditions.

To ensure effectiveness and efficiency of all machines.

To ensure safety of employees.

To maintain resale value of the machines.

To reduce unplanned work for maintain staff.

INSPECTION FOR PM:

Initially the past records are to be referred to know what all actions taken last time. this

give an idea of important activities, spares, time, and cost needs.

The moving parts are checked again and again to ascertain the wear and tear. Similarly

bearings, bearing block, belts and toggles are checked for strength and endurance until

next PM.

Based on above observation a check list is made to attend work and to take trial run to

verify that the PM work is satisfactory to maintenance and production engineers.

23

MECHANICAL-BREAKDOWN MAINTAINANCE

TAG NOEQUIPMEN

T NAME

PROBLEM

IDENTIFIE

D

REMEDY

DATE

OF

BREAKD

OWN

RANGE

OF DAYS

FUNTIO

NED

BEFORE

FAILUR

E

K907C Inducted

draught fan

Driver side

bearing

damaged

Bearing

fixed

OK

29-12-09

9:00-

16:00

17 DAYS

P940 STP

circulation

pump

Pump jammed Shaft,

bearings,oil,s

eal,mech seal

renewed OK

24-12-9

11:00-

16:00

2DAYS

XR101B Secondstage

reactor

Coil puncture Coil lead,

welding

work done

OK

3-12-09

14-12-09

22DAYS

P305 Condensable

water pump

Pump seal

leak

Mech seal

Renewed OK

30-11-09

4hrs

P305B Condensable Abnormal Spare pump 30-11-09 13DAYS

24

water pump sound fixed OK3hs

P105B Newtralization

wash pump

Pump seal

leak

Stationary

Rotary face

changed OK

23-11-09

25-11-09

12DAYS

S902A Wood therme

screw feeder

Screw feeder

jammed

F-208

1NOS&P208

-

2NOS,Bearin

g changed

shaft

renewed OK

17-11-09

20-11-09

3DAYS

P904 Spent acid

pump

Causing leak Spare pump

fixed OK

4-11-09

5-11-09

26DAYS

P133B Spent acid

pump

Abnormal

sound

Stationary

&Rotary face

renewed

stuffing box

changed,

taken in line

OK

2-11-09

10-11-09

8DAYS

P151B ------------- Pump mech

seal

Rotary face

changed

&stationary

face fixed,

taken in line

OK

26-10-09

27-10-09

1DAY

P940 STP

Circulation

pump

Pump jammed Bearing

&seal

changed OK

10-10-09

11-10-09

12DAYS

25

K901B Instrument Air

Compressors

Poor

performance

Cylinder

&piston

rings

changed

calues

serviced

&fixed

24-9-09

1-10-09

1DAY

K1O1B Butane

Compressors

Compressor

piston ring

damaged

The

following

spares

renewed

piston ring,

value

channels

taken in line

OK

24-9-09

1-10-09

4DAYS

P133A Spent acid

pump

Pump mech

seal leak

The

following

spares

renewed

sleeve mech

seal

23-9-09

2hrs

17DAYS

K902B Wood

thermaze

Blower

abnormal

sound

Bearing

changed,

bearing

nos:2210kc3

18-9-09

1hrs

17DAYS

P932 Solvent pump Pump mech

seal leak

The

following

spares

renewed,

17-9-09

5hrs

9DAYS

26

mech seal

changed

taken in line

OK

P934 Remembrance

cleaning pump

Pump

abnormal

sound and

mech seal

leak

The

following

spares

renewed

shaft

bearing,

mech seal

taken in line

OK

17-9-09 9DAYS

P912A 98% sulphuric

acid transfer

Pump mech

seal leak

The

following

spares

renewed

12-9-09

14-9-09

17DAYS

R201 Mek Reactor I Catalyst to be

renewed

Support ring

after catalyst

filled top

&bottom

down

6-9-09

17-9-09

P132B Acid feed

pump

Pump mech

seal leak

The

following

spares

renewed

sleeve &seal

set OK

6-8-09

7-8-09

20DAYS

K901A Instrument Air

Compressor

Poor

performance

Position ring

1st,2nd stage

inlet

4-8-09

5-8-09

23DAYS

27

&discharge

value

serviced of

the springs

&seat plate

changed OK

K101B Butane

Compressor

Poor

performance

2ND Stage of

value

removed

&discharge

channel

&spring

channel

changed OK

26-7-09

7hrs

6DAYS

P105A Neutralization

wash pump

Pump mech

seal leak

MECH

SEAL

Stationary

&rotary

‘O’ring

changed

taken in line

OK

22-7-09

23-7-09

25DAYS

P912A 98% Sulphuric

acid

circulation

pump

Pump mech

seal leak

Pump

assembled

with new

ceramic

bellow

&silicon

carbide face

17-7-09

18-7-09

22DAYS

P133B Spent acid

pump

Pump mech

seal leak

Pump

assembled

10-7-09 16DAYS

28

with spares-

bearing,oil

seal

13-7-09

P940 Circulation

pump

Pump

abnormal

sound with

seal leak

Pump

assembled

with spares-

shaft,

bearings, oil

seal, seal set

9-7-09

15-7-09

16DAYS

P916B Furnace oil

Transfer pump

Pump

jammed

Pump

bearing 4 nos

renewed

assembled

OK

5-7-09

17-7-09

18DAYS

P133A Spent acid

pump

pump

abnormal

sound &seal

leak

Pump

bearing

&1.250

bellow

renewed,

assembled

OK

2-7-09

8:30-

21:30

25DAYS

P154B SBA Product

pump

Pump

abnormal

sound &seal

leak

Pump

bearings

renewed seal

face lapped

is fixed OK

24-6-09

8:00-

22:00

9DAYS

P916A Furnace oil

Transfer pump

Pump seal

leak &cosing

leak

Pump seal

&casing ‘O’

RING

Renewed

21-6-09

1-7-09

23DAYS

29

taken in line

OK

P510 C510

Circulation

pump

Mech seal

leak

Stationary

seal changed

taken in line

OK

9-6-09

13-6-09

XV106A Caustic Vessel

Aggitator

Abnormal

sound

Bearing

renewed,620

72&62062&

35*45*7 oil

seal also

renewed

14-5-09

18-5-09

9DAYS

P251A Dryer Column

Bottom pump

Seal leak Wilo (mech

seal)pump

seal renewed

OK

14-5-09

2hrs

10DAYS

P253A MEK Reactor

Column

Reflux pump

Seal leak Wilo pump

seal renewed

ok

14-5-09

2hrs

19DAYS

P155A Water SBA-

Recycle pump

Pump

abnormal

sound

2NOS

bearing

changed

&seal spare

renewed OK

9-5-09

30-5-09

0DAYS

P303 HOT oil

circulating

pump

Abnormal

sound

Coupling

changed,

bearing &oil

hauling

replaced OK

28-4-09

4-5-09

27DAYS

K902A Wood

thermaze

Abnormal

sound

Impellor

balanced

25-4-09 17DAYS

30

secondary

draught fan

&bearing

removed OK5-5-09

K101A Butane

Compressors

Poor per

formance

1T STAGE

value 4 nos

serviced

&fixed taken

in line OK

19-4-09

6hrs

17DAYS

P105B Caustic

Neutralization

pump

Pump seal

leak

‘O’ring

renewed in

seal taken in

line OK

8-4-09

6hrs

26DAYS

P106 Caustic

Neutralization

pump

Mech seal

leak

‘O’ring

renewed in

seal taken in

line OK

4-4-09

6hrs

13DAYS

P133B Spent acid

pump

Mech seal

leak

Bellow

renewed seal

face lapped

taken in line

OK

31-3-09

2-4-09

8DAYS

P925B Fuel oil pump Mech seal

leak

Seal

assembled

renewed OK

20-3-09

5hrs

27DAYS

P917A Metro water

pump

Abnormal

sound

16-3-09

25-3-09

16DAYS

P132B Acid feed

pump

Mech seal

leak

Seal face

lapped

&fixed

9-3-09

10-3-09

21DAYS

K101B Butane Poor H.P SIDE 4-3-09 13DAYS

31

Compressor performance suction

&discharge

value

serviced OK

6hrs

XR101B Reactor

Agitator I

Mech seal

leak

Spare seal

fixed OK

20-2-09

7hrs

24DAYS

XR101B Reactor

Agitator

Mech seal

leak

Spare seal

RENEWED

OK

19-2-09

20-2-09

23DAYS

P133A Spent acid

pump

pump seal

leak

&bed

damaged

Pump seal

serviced&fix

ed bed

changed OK

12-01-09

13-01-09

6DAYS

P134A Ester pump Pump seal

leak

1.250NEW

SEAL set

fixed OK

29-1-09

1-02-09

21DAYS

P132A Acid feed

Pump

Pump

abnormal

sound

Pump

assembled

with new

shaft

&lapped seal

fixed pump

assembled

taken in line

OK

8-1-09

9-1-09

2DAYS

P132B Acid Feed

pump

Pump seal

leak

Pump

&old seal

changed OK

7-1-09

8:30-

15:00

20DAYS

32

CETEX PETROCHAMICALS LTD

PREVENTIVE MAINTENANCE SCHEDULE

For no: EN/F/06

MONTH:JAN 2009 TO DEC 2009 SECTION:MECHANICAL

DATE A SHIFT B SHIFT C SHIFT

1 K-902B P-905A P-931B K-903C P-255B

2 K-101A P-901A K-928 K-903D P-271

3 P-151A P-902B P-202A P-922E P-103B

4 P-251A P-907B P-922A P-922F XV-106C

5 XV-106A P-906B P-110A S-903A P-132A

6 P-925A P-904 P-133A S-903B P-109B

7 P-134A P-302B P-156A S-903C P-923A

8 P-926 P-251B K-902A S-903D P-153B

9 K-905 P-902A P-155A S-903E P-107A

10 K-901A P-908B P-915 C-903 P-201A

11 P-921A K-904A/B P-109A K-902C P-105B

12 K-903A P-912B K-907C K-902D P-107B

13 P-923B P-919 XV-107 K-902E P-254A

14 P-922B P-913 P-152B S-902A P-255A

15 P-920A P-917B P-202B S-902B P-253B

16 P-252B P-916B P-914 C-902 P-132B

17 P-921B P-906A P-134B K-909 P-305B

18 K-906 P-901B XV-275 P-907D P-103A

19 XV-106B P-903 P-922D P-907F P-106

20 K-101B K-201A P-154A K-907A P-110B

21 P-152A P-301 P-156B K-907B P-305A

22 P-907C P-905B XR-102 P-940 P-925B

23 K-901B P-908A P-924 P-939A P-133B

33

24 P-912A P-911 P-154B K-908 P-253A

25 XR101A/B P-273B P-254B P-939B P-274

26 P932 P-922C P-105A P-934 P-201B

27 P-910 P-916A P-920B P-935 P-151B

28 P-907A P-918 P-931A P-941 P-153A

29 P-917A P-930 P-155B K-903B P-109C

P104,P303 P-272 P-201B P-302A P-909

IMPORTANCE OF STATISTICS OF FAILURE:

How long was the machine component working before it failed? This is the time-to-

failure, t.

What percentage of instances did it fail at time t. This is the relatively frequency of

failure corresponding to time t.

MECHANICAL ANALYSIS

34

(0 - 5) (6 - 10) (11 - 15) (16 - 20) (21 - 25) (26 - 30)

7

9

5

13

10

4

NUMBER OF EQUIPMENTS OCCURENCE IN THE RANGE OF LIFE

NUMBER OF EQUIPMENTS OCCURENCE IN THE RANGE OF LIFE

MECHANICAL ANALYSIS

december 3november 6

35

RANGE OF DAYS FUNCTIONED BEFORE FAILURE

NUMBER OF EQUIPMENTS OCCURENCE IN THE RANGE OF LIFE

(0 - 5) 7(6 - 10) 9(11 - 15) 5(16 - 20) 13(21 - 25) 10(26 - 30) 4

october 2september 8

august 2july 7june 3may 4april 5

march 6febuary 2january 3

december

november

october

septem

ber

augu

st julyjune

mayap

ril

march

febuary

january

3

6

2

8

2

7

34

56

23

Chart Title

OVERALL ANALYSIS:FOR MECHANICAL

MONTH EQUIPMENT NAME BREAKDOWN

december K907C, P940, XR101B,XR101B 3

36

november P305, P305B, P105B, S902A, P904,P133B, 6october P151B, P940 2

september K901B, K1O1B, P133A, K902B, P932, P934, P912A, R201 5august P132B, K901A 3

july K101B, P105A, P912A, P133B, P940, P916B, P133A 7june P154B, P916A, P510 4may XV106A, P251A, P253A, P155A, 4april P303, K902A, K101A, P105B, P106 5

march P133B, P925B, P917A, P132B, K101B 5febuary XR101B, XR101B 2january P133A,P134A,P132A,P132B 4

6%

12%

4%

10%

6%

14%8%

8%

10%

10%4%

8%

BREAKDOWN

decembernovemberoctoberseptemberaugustjulyjunemayaprilmarchfebuaryjanuary

37

K907

C, P

940,

XR

101B

,XR1

01B

P305

, P30

5B, P

105B

, S90

2A,

P904

,P13

3B,

P151

B, P

940

K901

B, K

1O1B

, P13

3A,

K902

B, P

932,

P93

4, P

912A

, R2

01 P132

B, K

901A

K101

B, P

105A

, P91

2A,

P133

B, P

940,

P91

6B, P

133A

P154

B, P

916A

, P51

0

XV10

6A, P

251A

, P25

3A,

P155

A,

P303

, K90

2A, K

101A

, P1

05B,

P10

6

P133

B, P

925B

, P91

7A,

P132

B, K

101B

XR10

1B, X

R101

B

P133

A,P

134A

,P13

2A,P

132B

de-cem-ber

no-vember

october sep-tember

august july june may april march febuary january

BREAKDOWN

Name of the DeviationFrequenc

yPercetag

e (%)

Cumalative

Percentage

Pump Seal Leak 30 54.55 54.55Abnormal Sound 12 21.82 76.36Poor Performance 6 10.91 87.27Pump Jammed 4 7.27 94.55Bearing damaged 1 1.82 96.36Piston Ring Damaged 1 1.82 98.18Coil Puncture 1 1.82 100.00

38

Pump Seal Leak

Abnormal Sound

Poor Per-formance

Pump Jammed

Bearing damaged

Piston Ring

Damaged

Coil Punc-ture

Pump Seal Leak

Abnormal Sound

Poor Per-formance

Pump Jammed

Bearing damaged

Piston Ring

Damaged

Coil Punc-ture

Frequency

30 12 6 4 1 1 1

Cumalative Percentage

54.5454545454546

76.3636363636363

87.2727272727272

94.5454545454545

96.3636363636363

98.1818181818182

100

2.5

7.5

12.5

17.5

22.5

27.5

32.5

10.00

30.00

50.00

70.00

90.00

110.00

FREQUENCY OF PROBLEMS OCCURED - MECHANICAL

Fre

qu

en

cy

Cu

mu

lati

ve

Pe

rce

nta

ge

(%

)

Machine life without breakdown-machanical

39

Range of life Frequenc

yPercetag

e (%)

Cumalative

Percentage

16 - 20 Days 13 27.08 27.0820 - 25 Days 10 20.83 47.926 - 10 Days 9 18.75 66.670 - 5 Days 7 14.58 81.2511 - 15 Days 5 10.42 91.6726 - 30 Days 4 8.33 100.00

16 - 20 Days 20 - 25 Days 6 - 10 Days 0 - 5 Days 11 - 15 Days 26 - 30 Days 16 - 20 Days 20 - 25 Days 6 - 10 Days 0 - 5 Days 11 - 15 Days 26 - 30 Days

Frequency

13 10 9 7 5 4

Cumalative Percentage

27.0833333333333

47.9166666666666

66.6666666666667

81.25 91.6666666666667

100

1

3

5

7

9

11

13

10.00

30.00

50.00

70.00

90.00

110.00

Machine Life without Break Down - Mechanical

Fre

qu

en

cy

Cu

mu

lati

ve

Pe

rce

nta

ge

(%

)

BREAKDOWN MAINTENANCE

40

ELECTRICAL DEPARTMENT

TAG NOEQUIPMENT

NAME

PROBLEM

IDENTIFIEDREMEDY

DOWN

TIME

RANGE OF

DAYS

FUNTIONED

BEFORE

FAILURE

P105B P105B

Motor tripped

continuously

&taken higher

load due to

insulation

failure

Motor

rewinding

alone

&fixed

31-12

4-12

11.30-

10.30hr

10

P305AConfeutble

pump

Motor got

tripped due to

insulation

failure

Motor

rewinding

alone

&fixed

23-12

30-12

2

MK903D 3fd motor --------------------

5-12

5-12

16.30-

19.30hr

3

SFD-

MK-

903E

SFDMotor vvfd got

failure

VVFD by

ported

&stare &

delba

4-12

4-12

0

41

MF 607ACooling water

pump

Motor

insulation(due

to higher load

got failure

rewinding

done

&replaced

in this plane

4-12

5-1

5

MP939ACirculation

pump(MEK)Motor tripped

rewinding

done

&replaced

in this plane

4-12

4-01

19

MXR-

102

Agitator D.L.R got

trouble &cable

burnt

Spare

replaced

14-9

14-9

Half hr

13

410D D.G.SET D.G set RPM

failed

Fuel pump

solinoid set

problem

afforded

12-9

12-9

Half hr

13

MP101B Bwitter rodFrequently

tlane failure

New burner

rod

changed

3-8

1:30

min

3

MP934Membrane

pump

Motor end

abnormal

sound came

Motor

bearing

renewed

30-7

2-8

4

MP691 Blower motor

Motor

insulation got

failed

Motor

rewinding

done

22-7

13-8

12

MP502B Circulation

pump

Motor

insulation got

failed

Motor

rewinding

done

13-7

17-7

17

42

MP918Motor water

pump

Motor not

run ,tripped

continuously

due to feeder

side confactor

got

Spare

confactor

renewed

11-7

11:30-

12;45

13

MP920Bd.m. water

pump

Motor not run

checked feeder

side confactor

got burnt

Spare

confactor

renewed

24-6

2hrs

27

MP109A

Caustic

circulation

pump

Motor not run

due to v.f.d

working o/p

supply got

trouble

V.F.D

renewed&

D.O.L

starter

supply

given

27-5

1hrs

16

MP134A -------------------Motor bearing

got failed

Bearing

renewed

spare motor

fixed, motor

send

renewed

15-5 8

MK903A Blower motor

Motor not run

&trip frequent,

intend short at

motor inside

Spare

motor fixed

and old

send to

rewind

28-3

13;00-

22:00

14

MP912A Acid motor Motor bearing

noise came

Motor

serviced 9-314

43

4hrs

MK903B Tmax blower

Motor not run

&cable burnt,

contractor jam

&coil burnt

Spare

motor

renewed

&cable

regulated

tested

&lineuped

7-3

8-3 21

MK903CFO boiler

blower

Motor bearing

jam

Motor

spare

renewed

&bearing

replaced

12-2

4hrs

12

MK906 -------------------Motor not run

&coil burnt

Motor

renewed

&motor coil

renewed

2-2

2hrs

13

MP931A -------------------

Motor got trip

containing

&bearing jam

Bearings

both side

renewed

&fixed in

place

21-01

2hrs

23

MP-154-

BPump motor

Motor got

struck up &

coil burnt

Motor

bearing

renewed

&coil

rewinding

11-1

16-01

17

44

RANGE OF DAYS FUNCTIONED BEFORE FAILURE

NUMBER OF EQUIPMENTS IN THE RANGE OF LIFE

(0 - 5) 6(6 - 10) 2(11 - 15) 7(16 - 20) 4(21 - 25) 2(26 - 30) 1

ELECTRICAL ANALYSIS

(0 - 5) (6 - 10) (11 - 15) (16 - 20) (21 - 25) (26 - 30)

6

2

7

4

2

1

NUMBER OF EQUIPMENTS IN THE RANGE OF LIFENUMBER OF EQUIPMENTS IN THE RANGE OF LIFE

45

ELECTRICAL ANALYSIS

December 6November 0October 0September 2August 1July 4June 1May 2April 0March 3Febuary 2January 3

december

november

october

septem

ber

augu

st julyjune

mayap

ril

march

febuary

january

0

1

2

3

4

5

6

Chart Title

46

MONTH NAME OF THE EQUIPMENT BREAKDOWN

december P105B, P305A, MK903D, SFD-MK-903E, MF 607A, MP939A 6

november - -

october - -

september MXR-102, 410D 9

august MP101B 1

july MP934, MP691, MP502B, MP918 4

june MP920B 1

may MP109A, MP134A 2

april - -

march MK903A, MP912A, MK903B 3

febuary MK903C, MK906 2

january MP931A, MP-154-B 2

dece

mbe

r

nove

mbe

r

octo

ber

sept

embe

r

augu

st

july

june

may

apri

l

mar

ch

febu

ary

janu

ary

P105

B, P

305A

, MK9

03D

, SF

D-M

K-90

3E, M

F 60

7A,

MP9

39A

MXR

-102

, 410

D

MP1

01B

MP9

34, M

P691

, MP5

02B,

M

P918

MP9

20B

MP1

09A

, MP1

34A

MK9

03A

, MP9

12A

, MK9

03B

MK9

03C,

MK9

06

MP9

31A

, MP-

154-

B

6 9 1 4 1 2 3 2 2

BREAKDOWN

BREAKDOWN

47

december20%

september30%

august3%

july13%

june3%

may7%

march10%

febuary7% january

7%

BREAKDOWN

Name of the DeviationFrequenc

yPercetag

e (%)

Cumalative

Percentage

Motar Insulation Failure 10 43.48 43.48Abnormal Sound 3 13.04 56.52Bearing Failed 3 13.04 69.57Cable & Coil Burnt 3 13.04 82.61Motor VVFD Failure 2 8.70 91.30

48

DLR trouble 1 4.35 95.65Dg Set RPm Failed 1 4.35 100.00

Motar In-sulation Failure

Abnor-mal

Sound

Bearing Failed

Cable & Coil

Burnt

Motor VVFD

Failure

DLR trouble

Dg Set RPm Failed

Motar In-sulation Failure

Abnor-mal

Sound

Bearing Failed

Cable & Coil

Burnt

Motor VVFD

Failure

DLR trouble

Dg Set RPm Failed

Frequency

10 3 3 3 2 1 1

Cumalative Percentage

43.478260869565

2

56.521739130434

8

69.565217391304

3

82.608695652173

9

91.304347826086

9

95.652173913043

4

100

1

3

5

7

9

11

10.00

30.00

50.00

70.00

90.00

110.00

FREQUENCY OF PROBLEMS OCCURED - ELECTRICAL

Fre

qu

en

cy

Cu

mu

lati

ve

Pe

rce

nta

ge

(%

)

49

Range of life

Frequency

Percetage (%)

Cumalative

Percentage

11-15 days

7 27.08 27.08

0-5 days 6 20.83 47.9216-20 days

4 18.75 66.67

6-10 days

2 14.58 81.25

21-15 days

2 10.42 91.67

26 - 30 Days

1 8.33 100.00

11-15 days

0-5 days

16-20 days

6-10 days

21-15 days

26 - 30 Days

0

20

40

60

80

100

120

FrequencyPercetage (%)Cumalative Percentage

50

FINDINGS AND SUGGESTIONS:

Diagnosing the fault or failures as early as possible and taking quick decisions

regarding the same.

Reducing major break-downs or crisis situations with the help of appropriately

organized preventive maintenance programmes.

Designing and Installing the equipment in such a way that failures of the equipment

will be low over its lifetime or in other words , increasing what is known as the

reliability of the plant ,machinery and equipment in the design staged itself. Also ,The

equipment could be so designed that the times for maintenance action are small i.e,the

‘maintainability’ should be high.

Having proper replacement policies of equipment and their component parts in such a

way that the total reliability and availability of the system is enhanced at optimal costs.

Having standard times and standard procedures in maintenance as much as possible,

so as to gain good control over maintenance operations and also to provide adequate

incentives and motivation for maintenance personnel.

Reduction of operations lead times , delivery times through continuous improvements.

No postponements or cancellations of the scheduled production, thus ensuring the

supply on time.

Improvements in quality; producing right the first time, self-inspection and

certification; all of this leading to unnecessary wastage of time and in actual reduction

in operation/process times.

Improved machinery maintenance, improved design of the products and processes, so

that the expenditure of time due to breakdown, rejects, reworks is avoided.

Supportive organizational conditions for better maintenance management

51

1).Good Cooperation and coordination between the production and maintenance functions, in

general , I essential.

o Annual planning for maintenance should be done along with the annual

production plan.

o Monthly, weekly, daily maintenance schedules should be drawn, preferably in

consultation with the production people. These must be properly

communicated to the production people.

o If there are any changes in the capacity-utilization, process-changes nd

method-changes, etc,t he maintenance department should be aware of the

same.

In short, there should be much interaction between maintenance and production people

at the policy-planning, schedule-making, and all other levels.

2) Maintenance function should not be under production management

If a maintenance manager feels that a critical equipment needs quick maintenance

attention, in order to avoid a portable breakdown, he should have the full authority to order

the shut-down of the equipment.

4) Proper equipment records should be kept giving details such as breakdown –statistics,

maintenance carried out, the causes of breakdown, time taken for maintenance, the

components and parts of the machinery, the suppliers, dates on which preventive

maintenance was carried out, the type of preventive action carried out, such information helps

in policy-planning, scheduling, and allocation of maintenance resources.

5) Spare –parts inventory should be controlled properly, so that adequate numbers are

available for maintenance purposes.

6) To ensure good control, the maintenance work should be standardized as much as possible.

52

o Preventive work is more easily standardized ,standard procedural manuals for

the same may be prepared.

o Breakdown maintenance jobs also may be fit into work-standards

7) Good research in materials is a helpful accomplishment to maintenance for eg: Good

lubricating oil could save a lot of equipment from premature breakdowns.

CLASSIFICATION OF SPARES FOR STOCKING POLICY ANALYSIS

1) MAINTENANCE OR BREAKDOWN SPARES

2) INSURANCE SPARES

3) CAPITAL SPARES

4) ROTABLE SPARES

53