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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