PROJECT REPORT

ON
OPERATIONS MAINTENANCE AND PRACTICE
Submitted in partial fulfillment of the requirement for the third semester of the
Degree of
MASTER 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

Page | 1
 PANCHETTI

THIRUVALLUR DIST

CHENNAI – 601 204

DECLARATION

I hereby declare that the Project Report entitled “OPERATIONS MAINTENANCE AND
PRACTICE.” 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.

2
DATE:

PLACE: SIGNATURE OF THE CANDIDATE

3
 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.

4
 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

5
Table no Description Page no
1
a.
b.
c.
2.
a.

6
INTRODUCTION

7
 INTRODUCTION

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

8
 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

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

9
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

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

10
 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:

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.

1.
2. 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.

3. 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.

11
 In the endeavor to achieve high standards in occupational health and safety, Cetex is
OSHAs 18001 certified.

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

1. Methyl Ethyl Ketone:

Description:

12
 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
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:

13
 Description:

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.

14
 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

15
 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.

PROCESS CHART:

Sulphuric Acid(98%) Spent acid disposal

Waste to solar pond

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

Butene SBA
Esterification Hydrolysis Neutralizatio purification
n

Pure SBA
Butane recovery
Butene recovery storage
system
system

Butane LPG Butane storage LPG

Polymer solvent
xxx SBE solvent xx

Pure MEK MEK purification Heavy MEK

storage Ketones synthesis
16
 Raw MEK separation

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
.

17
 SCOPE OF MAINTENANCE

➢ Maintenance of existing plant and equipments.

➢ Equipment inspection and lubrication.
➢ New installation of equipments and buildings.
➢ Plant protection including fire protection.

18
 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.

19
 ➢ 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
➢ 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.
A) 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.

20
 ➢ 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.
A) Replacement, reconditioning disposal decisions
➢ .

A) 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.
A) SAFETY
Safety from fire, water, pollution.
Housekeeping, maintenance of open yards and buildings.

21
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

➢ 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.

22
 ➢ 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.

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.

23
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.
➢ 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

24
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.

25
MECHANICAL-BREAKDOWN MAINTAINANCE

RANGE
OF DAYS
DATE
PROBLEM FUNTIO
EQUIPMEN OF
TAG NO IDENTIFIE REMEDY NED
T NAME BREAKD
D BEFORE
OWN
FAILUR
E
K907C Inducted Driver side Bearing 29-12-09 17 DAYS
draught fan bearing fixed 9:00-
damaged OK 16:00
P940 STP Pump jammed Shaft, 24-12-9 2DAYS
circulation bearings,oil,s 11:00-
pump eal,mech seal 16:00
renewed OK
XR101B Secondstage Coil puncture Coil lead, 3-12-09 22DAYS
reactor welding 14-12-09
work done
OK

26
P305 Condensable Pump seal Mech seal 30-11-09
water pump leak Renewed 4hrs
OK
P305B Condensable Abnormal Spare pump 30-11-09 13DAYS
water pump sound fixed OK 3hs
P105B Newtralizatio Pump seal Stationary 23-11-09 12DAYS
n wash pump leak Rotary face 25-11-09
changed OK
S902A Wood therme Screw feeder F-208 17-11-09 3DAYS
screw feeder jammed 1NOS&P208 20-11-09
-
2NOS,Beari
ng changed
shaft
renewed OK
P904 Spent acid Causing leak Spare pump 4-11-09 26DAYS
pump fixed OK 5-11-09
P133B Spent acid Abnormal Stationary 2-11-09 8DAYS
pump sound &Rotary 10-11-09
face renewed
stuffing box
changed,
taken in line
OK
P151B ------------- Pump mech Rotary face 26-10-09 1DAY
seal changed 27-10-09

27
 &stationary
face fixed,
taken in line
OK
P940 STP Pump jammed Bearing 10-10-09 12DAYS
Circulation &seal 11-10-09
pump changed OK
K901B Instrument Air Poor Cylinder 24-9-09 1DAY
Compressors performance &piston 1-10-09
rings
changed
calues
serviced
&fixed
K1O1B Butane Compressor The 24-9-09 4DAYS
Compressors piston ring following 1-10-09
damaged spares
renewed
piston ring,
value
channels
taken in line
OK
P133A Spent acid Pump mech The 23-9-09 17DAYS
pump seal leak following 2hrs
spares
renewed

28
 sleeve mech
seal
K902B Wood Blower Bearing 18-9-09 17DAYS
thermaze abnormal changed,
sound bearing
1hrs
nos:2210kc3
P932 Solvent pump Pump mech The 17-9-09 9DAYS
seal leak following 5hrs
spares
renewed,
mech seal
changed
taken in line
OK
P934 Remembrance Pump The 17-9-09 9DAYS
cleaning pump abnormal following
sound and spares
mech seal leak renewed
shaft
bearing,
mech seal
taken in line
OK
P912A 98% sulphuric Pump mech The 12-9-09 17DAYS
acid transfer seal leak following 14-9-09
spares
renewed

29
R201 Mek Reactor I Catalyst to be Support ring 6-9-09
renewed after catalyst 17-9-09
filled top
&bottom
down
P132B Acid feed Pump mech The 6-8-09 20DAYS
pump seal leak following 7-8-09
spares
renewed
sleeve &seal
set OK
K901A Instrument Air Poor Position ring 4-8-09 23DAYS
Compressor performance 1st,2nd stage 5-8-09
inlet
&discharge
value
serviced of
the springs
&seat plate
changed OK
K101B Butane Poor 2ND Stage of 26-7-09 6DAYS
Compressor performance value 7hrs
removed
&discharge
channel
&spring
channel

30
 changed OK

P105A Neutralization Pump mech MECH 22-7-09 25DAYS

wash pump seal leak SEAL 23-7-09
Stationary
&rotary
‘O’ring
changed
taken in line
OK
P912A 98% Sulphuric Pump mech Pump 17-7-09 22DAYS
acid circulation seal leak assembled 18-7-09
pump with new
ceramic
bellow
&silicon
carbide face
P133B Spent acid Pump mech Pump 10-7-09 16DAYS
pump seal leak assembled 13-7-09
with spares-
bearing,oil
seal
P940 Circulation Pump Pump 9-7-09 16DAYS
pump abnormal assembled 15-7-09
sound with with spares-
seal leak shaft,
bearings, oil

31
 seal, seal set

P916B Furnace oil Pump Pump 5-7-09 18DAYS

Transfer pump jammed bearing 4 nos 17-7-09
renewed
assembled
OK
P133A Spent acid pump Pump 2-7-09 25DAYS
pump abnormal bearing 8:30-
sound &seal &1.250 21:30
leak bellow
renewed,
assembled
OK
P154B SBA Product Pump Pump 24-6-09 9DAYS
pump abnormal bearings 8:00-
sound &seal renewed seal 22:00
leak face lapped
is fixed OK
P916A Furnace oil Pump seal Pump seal 21-6-09 23DAYS
Transfer pump leak &cosing &casing ‘O’ 1-7-09
leak RING
Renewed
taken in line
OK
P510 C510 Mech seal Stationary 9-6-09
Circulation leak seal changed

32
 pump taken in line 13-6-09
OK

XV106A Caustic Vessel Abnormal Bearing 14-5-09 9DAYS

Aggitator sound renewed,620 18-5-09
72&62062&
35*45*7 oil
seal also
renewed
P251A Dryer Column Seal leak Wilo (mech 14-5-09 10DAYS
Bottom pump seal)pump 2hrs
seal renewed
OK
P253A MEK Reactor Seal leak Wilo pump 14-5-09 19DAYS
Column Reflux seal renewed 2hrs
pump ok
P155A Water SBA- Pump 2NOS 9-5-09 0DAYS
Recycle pump abnormal bearing 30-5-09
sound changed
&seal spare
renewed OK
P303 HOT oil Abnormal Coupling 28-4-09 27DAYS
circulating sound changed, 4-5-09
pump bearing &oil
hauling
replaced OK

33
K902A Wood Abnormal Impellor 25-4-09 17DAYS
thermaze sound balanced 5-5-09
secondary &bearing
draught fan removed OK
K101A Butane Poor per 1T STAGE 19-4-09 17DAYS
Compressors formance value 4 nos 6hrs
serviced

&fixed taken
in line OK
P105B Caustic Pump seal ‘O’ring 8-4-09 26DAYS
Neutralization leak renewed in 6hrs
pump seal taken in
line OK
P106 Caustic Mech seal ‘O’ring 4-4-09 13DAYS
Neutralization leak renewed in 6hrs
pump seal taken in
line OK
P133B Spent acid Mech seal Bellow 31-3-09 8DAYS
pump leak renewed seal 2-4-09
face lapped
taken in line
OK
P925B Fuel oil pump Mech seal Seal 20-3-09 27DAYS
leak assembled 5hrs
renewed OK
P917A Metro water Abnormal 16-3-09 16DAYS

34
 pump sound 25-3-09
P132B Acid feed Mech seal Seal face 9-3-09 21DAYS
pump leak lapped 10-3-09
&fixed
K101B Butane Poor H.P SIDE 4-3-09 13DAYS
Compressor performance suction 6hrs
&discharge
value
serviced OK
XR101B Reactor Mech seal Spare seal 20-2-09 24DAYS
Agitator I leak fixed OK 7hrs
XR101B Reactor Mech seal Spare seal 19-2-09 23DAYS
Agitator leak RENEWED 20-2-09
OK
P133A Spent acid pump seal Pump seal 12-01-09 6DAYS
pump leak serviced&fix 13-01-09
&bed ed bed

damaged changed OK

P134A Ester pump Pump seal 1.250NEW 29-1-09 21DAYS

leak SEAL set 1-02-09
fixed OK
P132A Acid feed Pump Pump 8-1-09 2DAYS
Pump abnormal assembled 9-1-09
sound with new
shaft
&lapped seal

35
 fixed pump
assembled
taken in line
OK
P132B Acid Feed Pump seal Pump 7-1-09 20DAYS
pump leak &old seal 8:30-
changed OK 15:00

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

36
 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
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.

37
What percentage of instances did it fail at time t. This is the relatively frequency of
failure corresponding to time t.

MECHANICAL ANALYSIS

NUMBER OF EQUIPMENTS OCCURENCE IN THE

RANGE OF DAYS FUNCTIONED
RANGE OF LIFE
BEFORE FAILURE
(0 - 5) 7
(6 - 10) 9
(11 - 15) 5
(16 - 20) 13
(21 - 25) 10
(26 - 30) 4

38
MECHANICAL ANALYSIS

december 3
november 6
october 2
september 8
august 2
july 7
june 3
may 4
april 5
march 6
febuary 2
january 3

OVERALL ANALYSIS:FOR MECHANICAL

39
 M
ONTH EQUIPMENT NAME BREAKDOWN
december K907C, P940, XR101B,XR101B 3
november P305, P305B, P105B, S902A, P904,P133B, 6
october P151B, P940 2
K901B, K1O1B, P133A, K902B, P932, P934,
september P912A, R201 5
august P132B, K901A 3
july K101B, P105A, P912A, P133B, P940, P916B, P133A 7
june P154B, P916A, P510 4
may XV106A, P251A, P253A, P155A, 4
april P303, K902A, K101A, P105B, P106 5
march P133B, P925B, P917A, P132B, K101B 5
febuary XR101B, XR101B 2
january P133A,P134A,P132A,P132B 4

Cumalativ
Frequenc Percetag e
Name of the Deviation
y e (%) Percentag
e
Pump Seal Leak 30 54.55 54.55
Abnormal Sound 12 21.82 76.36
Poor Performance 6 10.91 87.27
Pump Jammed 4 7.27 94.55
Bearing damaged 1 1.82 96.36
Piston Ring Damaged 1 1.82 98.18
Coil Puncture 1 1.82 100.00

40
Machine life without breakdown-machanical

Cumalativ
Frequenc Percetag e
Range of life
y e (%) Percentag
e
16 - 20 Days 13 27.08 27.08
20 - 25 Days 10 20.83 47.92
6 - 10 Days 9 18.75 66.67
0 - 5 Days 7 14.58 81.25
11 - 15 Days 5 10.42 91.67
26 - 30 Days 4 8.33 100.00

BREAKDOWN MAINTENANCE

ELECTRICAL DEPARTMENT

RANGE OF
DAYS
EQUIPMENT PROBLEM DOWN
TAG NO REMEDY FUNTIONED
NAME IDENTIFIED TIME
BEFORE
FAILURE

P105B P105B Motor tripped Motor 31-12 10

continuously rewinding 4-12
&taken higher alone
11.30-
load due to &fixed
10.30hr
insulation

41
 failure

Motor got Motor

Confeutble tripped due to rewinding 23-12
P305A 2
pump insulation alone 30-12
failure &fixed
5-12

5-12
MK903D 3fd motor -------------------- 3
16.30-
19.30hr
VVFD by
SFD-
Motor vvfd got ported 4-12
MK- SFD 0
failure &stare & 4-12
903E
delba
Motor rewinding
Cooling water insulation(due done 4-12
MF 607A 5
pump to higher load &replaced 5-1
got failure in this plane
rewinding
Circulation done 4-12
MP939A Motor tripped 19
pump(MEK) &replaced 4-01
in this plane
MXR- Agitator D.L.R got Spare 14-9
102 trouble &cable replaced 14-9 13
burnt
Half hr

42
410D D.G.SET D.G set RPM Fuel pump 12-9
failed solinoid set 12-9 13
problem
Half hr
afforded

New burner 3-8

Frequently
MP101B Bwitter rod rod 1:30 3
tlane failure
changed min

Motor end Motor

Membrane 30-7
MP934 abnormal bearing 4
pump 2-8
sound came renewed
Motor Motor
22-7
MP691 Blower motor insulation got rewinding 12
13-8
failed done

Motor Motor 13-7

Circulation
MP502B insulation got rewinding 17-7 17
pump
failed done

Motor not run

,tripped
Spare 11-7
Motor water continuously
MP918 confactor 11:30- 13
pump due to feeder
renewed 12;45
side confactor
got
Motor not run
Spare
d.m. water checked feeder 24-6
MP920B confactor 27
pump side confactor 2hrs
renewed
got burnt

43
 V.F.D
Motor not run
renewed&
Caustic due to v.f.d
D.O.L 27-5
MP109A circulation working o/p 16
starter 1hrs
pump supply got
supply
trouble
given
Bearing
renewed
Motor bearing spare motor
MP134A ------------------- 15-5 8
got failed fixed, motor
send
renewed
Spare
Motor not run
motor fixed 28-3
&trip frequent,
MK903A Blower motor and old 13;00- 14
intend short at
send to 22:00
motor inside
rewind

Motor bearing Motor 9-3

MP912A Acid motor 14
noise came serviced 4hrs
Spare
motor
Motor not run 7-3
renewed
&cable burnt,
MK903B Tmax blower &cable 8-3 21
contractor jam
regulated
&coil burnt
tested
&lineuped
MK903C FO boiler Motor bearing Motor 12-2 12

44
 spare
renewed
blower jam 4hrs
&bearing
replaced
MK906 ------------------- Motor not run Motor 2-2 13
&coil burnt renewed 2hrs
&motor coil
renewed
MP931A
RANGE OF-------------------
DAYS FUNCTIONED MotorBEFORE
got trip Bearings OF EQUIPMENTS
NUMBER 21-01 23
IN THE RANGE
FAILURE containing both side 2hrsOF LIFE
(0 - 5) &bearing jam renewed 6
(6 - 10) 2
&fixed in
(11 - 15) 7
(16 - 20) place 4
MP-154- Pump(21 - 25)
motor Motor got Motor 11-1 2 17
(26 - 30) 1
B struck up & bearing 16-01
coil burnt renewed
&coil
rewinding

ELECTRICAL ANALYSIS

45
ELECTRICAL ANALYSIS

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

MONTH NAME OF THE EQUIPMENT BREAKDOWN

P105B, P305A, MK903D, SFD-MK-903E, MF
december 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 - -

46
 march MK903A, MP912A, MK903B 3
febuary MK903C, MK906 2
january MP931A, MP-154-B 2

Cumalativ
Frequenc Percetag e
Name of the Deviation
y e (%) Percentag
e
Motar Insulation Failure 10 43.48 43.48
Abnormal Sound 3 13.04 56.52
Bearing Failed 3 13.04 69.57
Cable & Coil Burnt 3 13.04 82.61
Motor VVFD Failure 2 8.70 91.30
DLR trouble 1 4.35 95.65
Dg Set RPm Failed 1 4.35 100.00

47
 Cumalati
Range Frequen Perceta ve
of life cy ge (%) Percenta
ge
11-15
7 27.08 27.08
days
0-5 days 6 20.83 47.92
16-20
4 18.75 66.67
days
6-10
2 14.58 81.25
days
21-15
2 10.42 91.67
days
26 - 30
1 8.33 100.00
Days

48
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

49
1).Good Cooperation and coordination between the production and maintenance functions, in
general , I essential.

○ Annual planning for maintenance should be done along with the annual
production plan.

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

consultation with the production people. These must be properly
communicated to the production people.

○ 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.

50
 ○ Preventive work is more easily standardized ,standard procedural manuals for
the same may be prepared.

○ 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

51