Upload
gregory-mullen
View
215
Download
2
Tags:
Embed Size (px)
Citation preview
1
TRAINING MODULE ON
INSPECTION, MAINTENANCE & CAPITAL BUDGET
2
MAINTENANCE STRATEGY
MAINTENANCE OBJECTIVE
OPERATIONS OPERATIONS STRATEGYSTRATEGY
TERMINAL / DEPOT STRATEGYTERMINAL / DEPOT STRATEGY
1.0 ROLE OF M & R IN OPERATIONS1.0 ROLE OF M & R IN OPERATIONS 1.0 ROLE OF M & R IN OPERATIONS1.0 ROLE OF M & R IN OPERATIONS
3
M&R IS A COMPLEMENTARY FUNCTION TO OPERATIONSM&R IS A COMPLEMENTARY FUNCTION TO OPERATIONS
MAINTENANCE OBJECTIVES ARE DERIVED FROM OVER MAINTENANCE OBJECTIVES ARE DERIVED FROM OVER ALL TERMINAL STRATEGY AS WELL AS OPERATIONS ALL TERMINAL STRATEGY AS WELL AS OPERATIONS STRATEGYSTRATEGY
1.0 ROLE OF M & R IN OPERATIONS1.0 ROLE OF M & R IN OPERATIONS
4
2.0 BROAD M & R OBJECTIVES2.0 BROAD M & R OBJECTIVES
ENSURE MAXIMUM AVAILABILITY OF PLANT/EQUIPMENT ENSURE MAXIMUM AVAILABILITY OF PLANT/EQUIPMENT AT AT OPTIMUM LEVEL OF OPERATIONSOPTIMUM LEVEL OF OPERATIONS
STRIVE STRIVE TO INCREASE THE LIFE SPANTO INCREASE THE LIFE SPAN OF PLANT/EQUIPMENT OF PLANT/EQUIPMENT
ENSURE ENSURE SAFETYSAFETY OF PERSONNEL & EQUIPMENT OF PERSONNEL & EQUIPMENT
5
IDENTIFY AND IMPLEMENT PROJECTS FOR IDENTIFY AND IMPLEMENT PROJECTS FOR PROCESS PROCESS IMPROVEMENTS/COST REDUCTIONSIMPROVEMENTS/COST REDUCTIONS
MINIMIZEMINIMIZE CONSUMPTION OF CONSUMPTION OF RESOURCES RESOURCES (ENERGY, (ENERGY, WATER ETC.)WATER ETC.)
OPTIMIZE COSTOPTIMIZE COST OF MAINTENANCE STORES (INVENTORY OF MAINTENANCE STORES (INVENTORY CONTROL ON SPARES & CONSUMMABLES)CONTROL ON SPARES & CONSUMMABLES)
MAINTAIN ACCURATE & UP TO DATE MAINTAIN ACCURATE & UP TO DATE MAINTENACE MAINTENACE RECORDSRECORDS
2.0 BROAD M & R OBJECTIVES2.0 BROAD M & R OBJECTIVES
6
3.0 MAINTENANCE STRATEGY3.0 MAINTENANCE STRATEGY
ASPECTS UNDER M&R STRATEGYASPECTS UNDER M&R STRATEGY
3.1 HUMAN RESOURCES-3.1 HUMAN RESOURCES-
WHO WILL DO?WHO WILL DO?
IN HOUSE (OWN EMPLOYEES)IN HOUSE (OWN EMPLOYEES)
THRU CONTRACTOR/VENDORTHRU CONTRACTOR/VENDOR
THRU OEM / AUTHORISED SERVICE AGENT (CRITICAL THRU OEM / AUTHORISED SERVICE AGENT (CRITICAL EQPT. VIZ DG SET, FIRE PUMPS ETC.)EQPT. VIZ DG SET, FIRE PUMPS ETC.)
7
3.0 MAINTENANCE STRATEGY3.0 MAINTENANCE STRATEGY
3.2 TOOLS, EQUIPMENTS AND CONSUMABLES & SPARES-3.2 TOOLS, EQUIPMENTS AND CONSUMABLES & SPARES-
WHAT WE REQUIRE?WHAT WE REQUIRE?
TOOLS (SPANNERS,HAND DRILLS Etc.)TOOLS (SPANNERS,HAND DRILLS Etc.)
PPE’S (HELMETS,SAFETY BELT Etc.)PPE’S (HELMETS,SAFETY BELT Etc.)
INSTRUMENTS (MEGGER,MULTIMETER Etc.)INSTRUMENTS (MEGGER,MULTIMETER Etc.)
LUBRICANTS ( OILS ADVISED BY OEM)LUBRICANTS ( OILS ADVISED BY OEM)
HARDWARE (NUTS, BOLTS, GASKETS Etc.)HARDWARE (NUTS, BOLTS, GASKETS Etc.)
EQUIPMENT SPARESEQUIPMENT SPARES
FITTINGS (BENDS,ELBOWS Etc.)FITTINGS (BENDS,ELBOWS Etc.)
8
3.0 MAINTENANCE STRATEGY3.0 MAINTENANCE STRATEGY
3.3 PURCHASING3.3 PURCHASING
HOW DO WE PROCURE THE MATERIALS?HOW DO WE PROCURE THE MATERIALS?
PURCHASE INFORMATIONPURCHASE INFORMATION
PURCHASE PROCEDURESPURCHASE PROCEDURES
LIST OF VENDORSLIST OF VENDORS
INSPECTION PROCEDURESINSPECTION PROCEDURES
9
3.0 MAINTENANCE STRATEGY3.0 MAINTENANCE STRATEGY
3.4 STORAGE OF METERIALS3.4 STORAGE OF METERIALS – –
WHERE & HOW TO KEEP?WHERE & HOW TO KEEP?
STORAGE SPACE (ENGINEERING WAREHOUSE)STORAGE SPACE (ENGINEERING WAREHOUSE)
PRESERVATION METHODS (TO ENSURE THAT THE ITEM IS KEPT PRESERVATION METHODS (TO ENSURE THAT THE ITEM IS KEPT IN USABLE CONDITION.)IN USABLE CONDITION.)
INVENTORY CONTROLINVENTORY CONTROL
10
3.0 MAINTENANCE STRATEGY3.0 MAINTENANCE STRATEGY
3.5 DOCUMENTATION AND TRAINING3.5 DOCUMENTATION AND TRAINING
HOW TO CARRY OUT THE JOB?HOW TO CARRY OUT THE JOB?
PROCEDURESPROCEDURES
MANUALSMANUALS
HISTORY CARDS & CHECK LISTSHISTORY CARDS & CHECK LISTS
LOG BOOKSLOG BOOKS
15
3.0 MAINTENANCE STRATEGY3.0 MAINTENANCE STRATEGY
3.6 MAINTENANCE PLANNING3.6 MAINTENANCE PLANNING
SEGMENTATION OF INFRASTRUCTURE (PLANT/EQUIPMENT) INTO SEGMENTATION OF INFRASTRUCTURE (PLANT/EQUIPMENT) INTO SUBSYSTEMSSUBSYSTEMS
TYPE OF MAINTENANCE AND SELECTION FOR INDIVIDUAL TYPE OF MAINTENANCE AND SELECTION FOR INDIVIDUAL SEGMENTSSEGMENTS
DEVELOPING MAINTENANCE PLAN FOR INDIVIDUAL SUBSYSTEMSDEVELOPING MAINTENANCE PLAN FOR INDIVIDUAL SUBSYSTEMS
DEVELOPING PERIODIC MAINTENANCE SCHEDULESDEVELOPING PERIODIC MAINTENANCE SCHEDULES
EXECUTION OF JOBEXECUTION OF JOB
DOCUMENTATIONDOCUMENTATION
16
3.6.1 SEGMENTATION OF INFRASTRUCTURE
OM & S (OIL MOVEMENT & STORAGE SUBSYSTEM)OM & S (OIL MOVEMENT & STORAGE SUBSYSTEM)
ELECTRICAL SUPPLY SUB SYSTEM (ESS)ELECTRICAL SUPPLY SUB SYSTEM (ESS)
FIRE & SAFETY SUB SYSTEMFIRE & SAFETY SUB SYSTEM
COMMUNICATION SUB SYSTEMCOMMUNICATION SUB SYSTEM
COMPANY VEHICLES SUB SYSTEMCOMPANY VEHICLES SUB SYSTEM
TERMINAL AUTOMATION SUB SYSTEMTERMINAL AUTOMATION SUB SYSTEM
BUILDINGS, ROADS & OTHERSBUILDINGS, ROADS & OTHERS
SECURITY SUB SYSTEMSECURITY SUB SYSTEM
CUSTOMER CARE EQUIPMENTS CUSTOMER CARE EQUIPMENTS
17
OM & S (OIL MOVEMENT & STORAGE SUBSYSTEM)OM & S (OIL MOVEMENT & STORAGE SUBSYSTEM)
STORAGE TANK & TANKFARMSTORAGE TANK & TANKFARM
PIPELINESPIPELINES
PUMPSPUMPS
GANTRIESGANTRIES
METERING SYSTEMSMETERING SYSTEMS
18
ELECTRICAL SUPPLY SUB SYSTEM (ESS)ELECTRICAL SUPPLY SUB SYSTEM (ESS)
SWITCH YARDSWITCH YARD
TRANSFORMERSTRANSFORMERS
CABLESCABLES
EARTHING SYSTEMSEARTHING SYSTEMS
VARIOUS CONTROL PANELSVARIOUS CONTROL PANELS
MOTOR CONTROL CENTREMOTOR CONTROL CENTRE
LIGHTING & FLP FITTINGSLIGHTING & FLP FITTINGS
BATTERIES & UPSBATTERIES & UPS
CAPACITOR BANKSCAPACITOR BANKS
DG SETSDG SETS
•FOLLOW OISD – 137 TOTALLY
•GET ELECTRI CAL SAFETY AUDIT ONCE IN 3 YEARS
19
FIRE & SAFETY SUB SYSTEMFIRE & SAFETY SUB SYSTEM
FIRE ENGINESFIRE ENGINES
FOAM SYSTEMFOAM SYSTEM
HYDRANT LINE & VALVESHYDRANT LINE & VALVES
MOBILE FOAM TENDERMOBILE FOAM TENDER
FIRE EXTINGUISHERSFIRE EXTINGUISHERS
PPE’S (PERSONAL PROTECTIVE EQUIPMENT)PPE’S (PERSONAL PROTECTIVE EQUIPMENT)
MONITOR, HYDRANTS & SPRINKLERSMONITOR, HYDRANTS & SPRINKLERS
•FOLLOW OISD – 142, 155 & 117 STRICTLY.
20
COMMUNICATION SUB SYSTEMCOMMUNICATION SUB SYSTEM
EPABXEPABX
WIRELESS/WALKIE-TALKIEWIRELESS/WALKIE-TALKIE
LAN/WANLAN/WAN
TELEPHONE/FAXTELEPHONE/FAX
21
COMPANY VEHICLES SUBSYSTEMCOMPANY VEHICLES SUBSYSTEM
TANK TRUCKSTANK TRUCKS
OTHER NON-EARNING VEHICLESOTHER NON-EARNING VEHICLES
22
TERMINAL AUTOMATION SUB TERMINAL AUTOMATION SUB SYSTEMSYSTEM
TANKFARM MODULETANKFARM MODULE
FIRE PUMP HOUSE AUTOMATIONFIRE PUMP HOUSE AUTOMATION
PUMP HOUSE AUTOMATIONPUMP HOUSE AUTOMATION
TANK TRUCK LOADING MODULETANK TRUCK LOADING MODULE
23
BUILDINGS, ROAD & OTHERSBUILDINGS, ROAD & OTHERS
BUILDINGS BUILDINGS
DRIVE WAYSDRIVE WAYS
RAILWAY TRACKRAILWAY TRACK
OFFICE EQUIPMENTSOFFICE EQUIPMENTS
24
SECURITY SUB SYSTEMSECURITY SUB SYSTEM
PERIMETER WALLPERIMETER WALL
GATESGATES
METAL DETECTORMETAL DETECTOR
OTHER EQUIPMENTSOTHER EQUIPMENTS
25
CUSTOMER CARE EQUIPMENTSCUSTOMER CARE EQUIPMENTS
LABORATORYLABORATORY
CALIBRATION TOWERCALIBRATION TOWER
PROVERSPROVERS
26
33. 6.2 TYPE OF MAINTENANCE. 6.2 TYPE OF MAINTENANCE
BREAK DOWN MAINTENANCEBREAK DOWN MAINTENANCE
ROUTINE MAINTENANCEROUTINE MAINTENANCE
PLANNED MAINTENANCEPLANNED MAINTENANCE
PREVENTIVE MAINTENANCEPREVENTIVE MAINTENANCE
PREDICTIVE MAINTENANCEPREDICTIVE MAINTENANCE
MAJOR MAINTENANCEMAJOR MAINTENANCE
CAPITAL MAINTENANCECAPITAL MAINTENANCE
27
33. . 3.6.2.1 BREAKDOWN MAINTENANCE3.6.2.1 BREAKDOWN MAINTENANCE
PHYSICALPHYSICAL
EQPT. COMMISSIONED
EQPT. IN SERVICEIN SERVICE
ABNORMALITY/ BREAK DOWN NOTICED
RECTIFIED & PUT BACK
RECORDRECORD
HISTORY CARD GENERATED
ROOT CAUSE ANALYSIS & DETAILS ENTERED
28
BREAKDOWN MAINTENANCEBREAKDOWN MAINTENANCE
ADVANTAGESADVANTAGES
NEEDS VERY LESS TIME,
LESS ROUTINE EXPENDITURE
DISADVANTAGESDISADVANTAGES
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 MAINTENANCEBREAKDOWN MAINTENANCE
SUITABILITYSUITABILITY
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, (E.G): POT HOLES IN ROADS, SEEPAGES IN BUILDINGS, PROBLEMS FOR FURNITURE ETC.PROBLEMS FOR FURNITURE ETC.
30
3.6.2.2 ROUTINE MAINTENANCE3.6.2.2 ROUTINE MAINTENANCE
PHYSICALPHYSICAL
EQUIPMENT COMMISSIONED
SIMPLE SERVICE AT REGULAR INTERVALS.
BREAKDOWNS, IF ANY ARE RECTIFIED
RECORDRECORD
HISTORY CARD GENERATED
HISTORY CARD UPDATED
ROOT CAUSE ANALYSIS & DETAILS ENTERED
31
ROUTINE MAINTENANCEROUTINE MAINTENANCE
ADVANTAGESADVANTAGES
THE EQUIPMENT/FACILITY GETS INSPECTED AT REGULAR THE EQUIPMENT/FACILITY GETS INSPECTED AT REGULAR INTERVALS.INTERVALS.
ABNORMAL CONDITIONS CAN BE IDENTIFIED BEFORE CRISIS.ABNORMAL CONDITIONS CAN BE IDENTIFIED BEFORE CRISIS.
NEEDS LESSER TIME.NEEDS LESSER TIME.
SERVICE COST CAN BE BUDGETEDSERVICE COST CAN BE BUDGETED.
32
ROUTINE MAINTENANCEROUTINE MAINTENANCE
DISADVANTAGESDISADVANTAGES
BREAKDOWNS CAN NOT BE ELIMINATED
INVOLVES HIGH EXPENDITURE AT IRREGULAR INTERVALS AND MINIMAL EXPENDITURE AT ROUTINE INTERVALS
SUITABILITYSUITABILITY
COMPUTERS, WALKIE-TALKIE SETS, PRINTERS, AIR-CONDITIONERS AND OTHER OFFICE EQUIPMENTS LIKE FAX, XEROX, EPABX ETC.
33
3.6.2.3 PLANNED MAINTENANCE3.6.2.3 PLANNED MAINTENANCE
PHYSICALPHYSICAL
EQUIPMENT EQUIPMENT COMMISSIONEDCOMMISSIONED
PLANNED PLANNED MAINTENANCE & MAINTENANCE & INSPECTIONS AT FIXED INSPECTIONS AT FIXED TIME SCALE. TIME SCALE.
RECORDRECORD
HISTORY SHEET HISTORY SHEET CREATED.CREATED.
MAINTENANCE PLAN & MAINTENANCE PLAN & PERIODIC SCHEDULE PERIODIC SCHEDULE DRAWNDRAWN
INSPECTION CHECK LIST INSPECTION CHECK LIST FILLED UP AND HISTORY FILLED UP AND HISTORY SHEET UPDATEDSHEET UPDATED
34
THE EQUIPMENT IS INSPECTED CLOSELY AT REGULAR THE EQUIPMENT IS INSPECTED CLOSELY AT REGULAR INTERVALS.INTERVALS.
CERTAIN MINOR ACTIVITIES LIKE LUBRICANTS, OIL CERTAIN MINOR ACTIVITIES LIKE LUBRICANTS, OIL CHANGE, CLEANING, REPLACEMENT OF GASKETS ETC CHANGE, CLEANING, REPLACEMENT OF GASKETS ETC ARE CARRIED OUTARE CARRIED OUT
PLANNED MAINTENANCEPLANNED MAINTENANCE
35
3 PLANNED MAINTENANCE3 PLANNED MAINTENANCE
ADVANTAGESADVANTAGES
BREAK DOWNS ARE MINIMAL & HENCE BREAKDOWNS BREAK DOWNS ARE MINIMAL & HENCE BREAKDOWNS COSTS ARE LESS.COSTS ARE LESS.
BETTER LIFE SPAN IN VIEW OF REGULAR BETTER LIFE SPAN IN VIEW OF REGULAR INSPECTIONS.INSPECTIONS.
BETTER ESTIMATION OF MAINTENANCE COST. BETTER ESTIMATION OF MAINTENANCE COST.
BETTER INVENTORY CONTROL OF SPARES, LUBES BETTER INVENTORY CONTROL OF SPARES, LUBES INVENTORY.INVENTORY.
36
PLANNED MAINTENANCEPLANNED MAINTENANCE
DISADVANTAGESDISADVANTAGES
NEEDS MORE TIME (MANY ACTIVITIES)
REQUIRES MORE RESOURCES
REQUIRES SHUTDOWN
NEEDS HIGHER LEVEL OF PLANNING
SUITABILITYSUITABILITY
GANTRIES, VALVES, VEHICLES, RAILWAY TRACK, FIRE EXTINGUISHERS, METERS, STRAINERS, STORAGE TANKS
37
3.6.2.4 PREVENTIVE MAINTENANCE 3.6.2.4 PREVENTIVE MAINTENANCE
IN THIS TYPE, THE MAINTENANCE SCHEDULES ARE DRAWN AS PER REQUIREMENT BY MANUFACTURER/STANDARDS
ADVANTAGESADVANTAGES
REMOTE POSSIBILITIES OF BREAKDOWNS.
BETTER ESTIMATION OF EXPENDITURE.
HIGHER RELIABILITY OF EQUIPMENT.
38
PREVENTIVE MAINTENANCEPREVENTIVE MAINTENANCE
DISADVANTAGESDISADVANTAGES
VERY HIGH REQUIREMENT OF HUMAN RESOURCES.VERY HIGH REQUIREMENT OF HUMAN RESOURCES.
ROUTINE COSTS WILL BE HIGHER FOR MAINTENANCE. ROUTINE COSTS WILL BE HIGHER FOR MAINTENANCE.
REQUIRES MORE DOCUMENTATIONREQUIRES MORE DOCUMENTATION.
39
PREVENTIVE MAINTENANCEPREVENTIVE MAINTENANCE
SUITABILITYSUITABILITY
FOR EQUIPMENTS WHICH ARE CRITICAL FROM OPERATIONS FOR EQUIPMENTS WHICH ARE CRITICAL FROM OPERATIONS AND SAFETY POINT OF VIEW (VIZ. FIRE & SAFETY EQUIPMENT, AND SAFETY POINT OF VIEW (VIZ. FIRE & SAFETY EQUIPMENT, ELECTRICAL SYSTEM AND OIL MOVEMENT & STORAGE ELECTRICAL SYSTEM AND OIL MOVEMENT & STORAGE SYSTEMS)SYSTEMS)
40
PREDICTIVE MAINTENANCEPREDICTIVE MAINTENANCE
PREDICTIVE MAINTENANCE IS BASED ON CONDITION PREDICTIVE MAINTENANCE IS BASED ON CONDITION MONITORING OF EQUIPMENT AND IT REQUIRES SOPHISTICATED MONITORING OF EQUIPMENT AND IT REQUIRES SOPHISTICATED EQUIPMENT FOR MONITORING CONDITION OF EQUIPMENTEQUIPMENT FOR MONITORING CONDITION OF EQUIPMENT
E.g: MONITORING PUMP PERFORMANCE USING VIBRATION E.g: MONITORING PUMP PERFORMANCE USING VIBRATION ANALYSISANALYSIS
MONITORING OF BEARING CONDITION USING VIBRATION AND MONITORING OF BEARING CONDITION USING VIBRATION AND TEMPERATURE. THIS PRACTICE IS EXPLAINED IN OISD-124TEMPERATURE. THIS PRACTICE IS EXPLAINED IN OISD-124
41
PREDICTIVE MAINTENANCEPREDICTIVE MAINTENANCE
ADVANTAGESADVANTAGES
SIMILAR TO PREVENTIVE MAINTENANCE
DISADVANTAGESDISADVANTAGES
IT REQUIRES SOPHISTICATED INSTRUMENT FOR CONDITION OF MONITORING
SUITABILITYSUITABILITY
THIS IS SUITABLE FOR ROTARY EQPT.
42
3.6.2.6 MAJOR MAINTENANCE3.6.2.6 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 ACTIVITIES3.6.2.7 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 NPCBNPCB
44
3.6.3 DEVELOPING MAINTENANCE PLAN3.6.3 DEVELOPING MAINTENANCE PLAN
PLAN TO BE DEVELOPED FOR PLANNED PLAN TO BE DEVELOPED FOR PLANNED MAINTENANCE, PREVENTIVE MAINTENANCE & MAINTENANCE, PREVENTIVE MAINTENANCE & PREDICTIVE MAINTENANCE.PREDICTIVE MAINTENANCE.
PLAN SHALL BE SPECIFIC FOR A PARTICULAR PLAN SHALL BE SPECIFIC FOR A PARTICULAR SUBSYSTEMSUBSYSTEM
PLAN SHALL ADDRESS THE REQUIREMENTS OF PLAN SHALL ADDRESS THE REQUIREMENTS OF INDIVIDUAL EQUIPMENTS UNDER THE SUBSYSTEMINDIVIDUAL EQUIPMENTS UNDER THE SUBSYSTEM
45
DEVELOPING MAINTENANCE PLAN
THE PLAN SHALL INCLUDE THE FOLLOWINGTHE PLAN SHALL INCLUDE THE FOLLOWING
SUBSYSTEM SUBSYSTEM
TYPE OF M&RTYPE OF M&R
STANDARDS APPLICABLE STANDARDS APPLICABLE
INDIVIDUAL EQUIPMENTSINDIVIDUAL EQUIPMENTS
WHO WILL DO THE ACTIVITYWHO WILL DO THE ACTIVITY
PURCHASE/PROCUREMENT PLANPURCHASE/PROCUREMENT PLAN
REFERENCE TO DOCUMENTATIONREFERENCE TO DOCUMENTATION
46
HISTORY CARD
ASSET LISTING
SPARESLUBE USED
PURCHASE
OPER.DETAILS
MAINTENANCESCHEDULE
M&R ACTIVITIES
BREAKDOWNANALYSIS
MISREPORTS
3.53.5 DOCUMENTATION DOCUMENTATION
47
3.6.4 DEVELOPING PERIODIC 3.6.4 DEVELOPING PERIODIC MAINTENANCE SCHEDULEMAINTENANCE 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 JOB3.6.5 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
49
3.6.6 DOCUMENTATION3.6.6 DOCUMENTATION
DOCUMENTATION TO BE DESIGNEDDOCUMENTATION TO BE DESIGNED
IN LINE WITH PLAN
WITH LINKAGES WHEREVER REQD.
TO TAKE CARE OF THE REQUIREMENTS OF INDIVIDUAL EQUIPMENTS.
53
6.0 ROUTINE ACTIVITIES6.0 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
M&R - PIPELINESM&R - PIPELINES
ROUTINE INSPECTIONSROUTINE INSPECTIONS PITTING/SCALING/LEAKS/PINHOLEPITTING/SCALING/LEAKS/PINHOLE
PAINTING & PATCH IF NEEDEDPAINTING & PATCH IF NEEDED
LEAKAGE FROM GASKETSLEAKAGE FROM GASKETS
INSPECTION OF VALVES/ FITTINGSINSPECTION OF VALVES/ FITTINGS
THERMAL RELIEF SYSTEMSTHERMAL RELIEF SYSTEMS
CONTINUITY JUMPERSCONTINUITY JUMPERS
56
M&R - PIPELINESM&R - PIPELINES
PERIODIC INSPECTIONSPERIODIC INSPECTIONS ULTRASONIC SURVEY OF THICKNESS (3 YEARS)ULTRASONIC SURVEY OF THICKNESS (3 YEARS)
HYDROTEST (3 YEARS)HYDROTEST (3 YEARS)
INSPECTION OF U/G LINESINSPECTION OF U/G LINES
FULL PAINTING (FREQ. TO BE DECIDED) {IF SAND FULL PAINTING (FREQ. TO BE DECIDED) {IF SAND BLASTING IS NOT POSSIBLE, SELECT PRIMER BLASTING IS NOT POSSIBLE, SELECT PRIMER SUITABLY}SUITABLY}
CLEANING OF STRAINERS (QUARTERLY)CLEANING OF STRAINERS (QUARTERLY)
57
M&R - PUMPSM&R - PUMPS
IDENTIFY TYPE OF PUMPIDENTIFY TYPE OF PUMP
REFER OISD 119 FOR FREQUENCY & INSPECTION REFER OISD 119 FOR FREQUENCY & INSPECTION CHECKLIST.CHECKLIST.
65
M&R – STORAGE TANKS
EXTERNALEXTERNAL 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
M&R – STORAGE TANKS
INTERNAL INSPECTION
TO BE DONE DURING TANK CLEANING
JOBS TO BE CARRIED OUT INCLUDECHECKING 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
M&R – 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.
70
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
71
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
72
NPCBNPCB
PREPARATION OF PROPOSALSPREPARATION OF PROPOSALS
DEPT.WISE LOCATIONS REQUIREMENT TO BE STUDIED AND DEPT.WISE LOCATIONS REQUIREMENT TO BE STUDIED AND PROPOSALS TO BE INITIATED. PROPOSALS TO BE INITIATED. PROPOSALS WITH PROPER JUSTIFICATIONS & COST ESTIMATES TO BE PROPOSALS WITH PROPER JUSTIFICATIONS & COST ESTIMATES TO BE
SENT TO RESPECTIVE RO’s / ZONE SENT TO RESPECTIVE RO’s / ZONE
PROPOSAL CATEGORIES :PROPOSAL CATEGORIES : SAFETY & SECURITY SAFETY & SECURITY
FACILITIES & EQUIPMENT FACILITIES & EQUIPMENT
WELFARE WELFARE
OFFICE EQUIPMENT OFFICE EQUIPMENT
LAB EQUIPMENT LAB EQUIPMENT
ADDITIONAL PRODUCT TANKAGEADDITIONAL PRODUCT TANKAGE
ENERGY CONSERVATIONENERGY CONSERVATION
73
APPROVAL OF PROPOSALSAPPROVAL OF PROPOSALS
PROPOSALS PUT IN CFD & BOARD MEETINGSPROPOSALS PUT IN CFD & BOARD MEETINGS BOARD APPROVES THE BUDGET FOR THE YEARBOARD APPROVES THE BUDGET FOR THE YEAR
BUDGETED FOR PROGRAM & NON-PROGRAM ITEMSBUDGETED FOR PROGRAM & NON-PROGRAM ITEMS
ZONE FORWARDS THE APPROVED PROPOSALS TO ZONE FORWARDS THE APPROVED PROPOSALS TO LOCATIONS WITH AR NOS.LOCATIONS WITH AR NOS.
APPROPRIATION REQUEST TO BE SENT TO RO/ APPROPRIATION REQUEST TO BE SENT TO RO/ ZONE DULY FILLED FOR APPROVAL AS PER LAMZONE DULY FILLED FOR APPROVAL AS PER LAM
AFTER RECEIVING APPROVED AR , EXECUTION AFTER RECEIVING APPROVED AR , EXECUTION PROCESS TO BE INITIATED.PROCESS TO BE INITIATED.
74
EXECUTION OF APPROVED PROJECTEXECUTION OF APPROVED PROJECT
LIST ALL APPROVED NPCB PROJECT LIST ALL APPROVED NPCB PROJECT LPR PREPARATIONLPR PREPARATION
PURCHASE PROCEDURE TO BE FOLLOWED AS PER PURCHASE PROCEDURE TO BE FOLLOWED AS PER LAMLAM
TENDER OPENING / RECAPTENDER OPENING / RECAP
NEGOTIATION ( IF REQUIRED )NEGOTIATION ( IF REQUIRED )
PURCHASE ORDER TO BE PLACEDPURCHASE ORDER TO BE PLACED
JOB TO BE COMPLETED/ITEMS TO BE RECEIVEDJOB TO BE COMPLETED/ITEMS TO BE RECEIVED
PREPARATION OF MRRPREPARATION OF MRR
75
CLOSE OUT OF NPCB PROJECTCLOSE OUT OF NPCB PROJECT
MONTHLY PROGRESS REPORT TO BE MADE FOR MONTHLY PROGRESS REPORT TO BE MADE FOR EFFECTIVE CONTROL / RECORDEFFECTIVE CONTROL / RECORD
AMCA TO BE PREPARED FOR CAPITALISATION OF AMCA TO BE PREPARED FOR CAPITALISATION OF PROJECT.PROJECT.
AMCA TO BE ENTERED IN JDE BY FINANCE PERSON AND AMCA TO BE ENTERED IN JDE BY FINANCE PERSON AND SYSTEM GENERATED ASSET NO TO BE RECORDED.SYSTEM GENERATED ASSET NO TO BE RECORDED.
AMCA TO BE SENT TO RO/ZONE FOR CLOSURE OF AMCA TO BE SENT TO RO/ZONE FOR CLOSURE OF CAPITAL EXPENDITURE FOR PARTICULAR AR NO.CAPITAL EXPENDITURE FOR PARTICULAR AR NO.
ENSURE CWIP IS NILENSURE CWIP IS NIL
DELETION ADVICE TO BE SENT TO P&P FINANCE.DELETION ADVICE TO BE SENT TO P&P FINANCE.
76THANK YOU