MAINTENANCE PLANNING

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Presentation outline
OVER VIEW OF MAINTENANCE PRACTICES.

MTP & STP FUNCTIONS.

ANURAKSHAN (OLMMS)

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WHAT IS MAINTENANCE
A combination of activities and actions carried out in order to repair, replace, service or modify the components of an industrial asset so as to obtain the desired level of performance for the desired period of time.

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MAINTENANCE MANAGEMENT OBJECTIVE

MAXIMISE PLANT AVAILABILITY

MINIMISE COST THROUGH OPTIMISATION OF RESOURCE UTILISATION

CREATE SAFETY IN WORK, EQUIPMENT AND ENVIRONMENT

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ROLE OF MAINTENANCE MANAGEMENT

TO BALANCE BETWEEN
COST OF MAINTENANCE PLANT AVAILABILITY

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MAINTENANCE MANAGEMENT
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FACTORS INFLUENCING MAINTENANCE

FIANCIAL FACTORS CONTRACT RESOURCE SPARES HOLDING PRODUCTN. FACTORS AVAILABILITY EFFICIENCY SAFETY

EXTERNAL FACTORS LOAD DEMAND ENVIRON.FACTORS EXTERNAL FUNDING 23 May 2012

MAINT.FACTORS PREV. MAINT. CORRECTIVE MAINT.

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MAINT EVOLUTION
OPERATE TO FAILURE APART FROM LUBRICATION-(FIX IT WHEN BROKE) (BEFORE 1950) PREVENTIVE MAINT. (FIX IT BEFORE IT BREAKES) ( BY1950) CONDITION BASED MAINT. (FIX IT WHEN NEEDED) (BY1970) RELIABILITY CENTRED MAINT.(RCM)

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MAINT OBJECTIVES
To support the production demand (qty. & Quality) through ensuring availabilty. Minimise maint cost direct and indirect. Adhering to the statutory safety & environment norms.

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NEED FOR MAINTENANCE

Many of the components are designed for a production cycle life which is less than the plant life cycle.This may be due to technological or economic reasons. External causes prompting immature failure.

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MAINT STRATEGIES
PREVENTIVE MAINTENANCE. -- FIXED TIME BASED -- CONDITION BASED OPERATE TO FAILURE. DESIGN-OUT MAINTENANCE. RCM

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PREVENTIVE MAINTENANCE
Maintenance is carried out

At regular intervals of time (days/running hours etc.) After fixed cumulative output Fixed number of cycles of operation. Aims to reduce the occurence of breakdowns.

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CONDITION BASED MAINT

SUBJECTIVE
- VISUAL (LOOK) - HEARING (LISTEN) - TOUCH/FEEL - INTUITIVE

OBJECTIVE
- ON-LINE

- OFF-LINE

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PdM TECHNOLOGIES
Vibration monitoring and trend analysis. Thermography.( IRT) Wear debris analysis. (Oil analysis). Radiography. Ultrasonography DGA RLA Creep measurement

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OPERATE TO FAILURE (OTF)

No action taken to prevent failure . no action taken to detect onset of failure. Corrective maintenance done upon failure.

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DESIGN-OUT MAINT
Adopted when cost of recurring failure & maint is very high. Aims to address the design or engineering fault. Maintenance free components.

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Maintenance Strategy Road Map

RISK EVALUATION & PRIORITISATION

ANURAKSHAN

REaP

REaP ensures that maximum risk is mitigated for each Rupee spent on outage.

STREAMLINED RELIABILITY CENTERED MAINTENANCE

SRCM

SRCM ensures that only required maintenance is done for achieving reliability.

PREDICTIVE MAINTENANCE (PdM)

CM + PM + PdM+PAM

Equipment condition based maintenance

PROACTIVE MAINTENANCE (PAM)

Root cause based (activity elimination) maintenance

CORRECTIVE MAINTENANCE (CM)

Reactive maintenance (Failure based)

Present Focus

CM + PM

PREVENTIVE MAINTENANCE (PM)

Schedule maintenance (Interval based)
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Source - ATKearny report on DISHA

RELIABILTY CENTRED MAINT

Reliabilty is the ability of an equipment to produce the desired performance level under stated conditions over a stated period. Reliabilty is function oriented. Maint requirement in its operating context.

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WHAT IS RCM

Method of identifying most effective maint. Approach Systematic & logical process of deciding a proper mix of PM, PDM, RTF & proactive maint.

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AIMS OF RCM
Ensure the designed function of the utility with reliability& avilability at least cost RCM Aims at determining a systematic &logical mix of PM,CBM,RTF, Proactive maint. To increase probability of delivering the function of system/equpmt

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RCM QUESTIONAIRE
What is system/equpt function What functional failures are likely to occur What are the likely failure consequences What is to be done reduce failure probability,detect the onset,reduce consequences

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BENEFITS OF RCM
Maint resources are optimised & cost effectiveness. Potential failures are known before they become functional failures. Improvement in operating performance. Longer asset availablity.

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MAINTENANCE PLANNING FUNCTIONS IN NTPC

1. SHORT TERM PLANNING. 2. LONG TERM PLANNING 3. SPARE PARTS MANAGEMENT

4. CONDITION MONITORING

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MAINTENANCE PLANNING

MAINT

F&A

MAINT PLANNING

C&M

OPERATION

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WHAT WE DO ..
SHORT TERM PLANNING (STP)
-- DAILY PLANNING MEETING -- COMITTED WORK PLANNING -- PM SCHEDULING -- UNIT S/D WORK PLANNING -- ANURAKSHAN (OLMMS) -- SPECIAL TASK FORCE ACTIVITY CO-ORINATION. -- INFORMATION (MIS) REPORTS -- HANDLING AUDITS -- O&M LIBRARY & DRAWINGS

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BAR CHARTS
ID 8 9 10 11 12 13 14 15 16 17 18
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Task Name

CW pass-A ARV vent line bend replacement MAL-12 valvespassing problem attending HPH-5B manhole gasket replacement 1CAT-01 oil leakage attending & 1CAT-02 pm jobs FD Fan-1A&1B blade pitch calibration Boiler hydro test Sk y climber/Scaffoldingremoval & Light-upclearance Start up of Unit auxiliaries Boiler Light-up& pa ra meters Build-up Rolling& Unit Synchronisation

Hrs 6h 6h 12h 24h 8h 3h 3h 1h 3h 1h

Mon 13 Jun Tue 14 Jun Start Finish 22 0 2 4 6 8 10 1214 16 182022 0 2 4 6 8 10 12 141618 2022 14/06/05 06:00 AM 12:00 PM 14/06/05 14/06/05 06:00 AM 12:00 PM 14/06/05 13/06/05 12:01 PM 00:02 AM 14/06/05 13/06/05 14:00 PM 14:02 PM 14/06/05 14/06/05 07:00 AM 15:01 PM 14/06/05 14/06/05 21:48 PM 00:49 AM 15/06/05 15/06/05 00:49 AM 03:49 AM 15/06/05 15/06/05 03:49 AM 04:49 AM 15/06/05 15/06/05 04:49 AM 07:49 AM 15/06/05 15/06/05 07:49 AM 08:49 AM 15/06/05

TASK FLOW PROCESS

WORK INPUT (DEFECT REPORTING) WORK DEFINITION WORK MEASUREMENT WORK SCHEDULING WORK PERMIT WORK EXECUTION WORK QUALITY WORK COMPLETION WORK FEEDBACK

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O&M SAFETY SYSTEM

PERMIT TO WORK (PTW ) LIMITED WORK CERTIFICATE (LWC) RESTORATION OF MOTIVE POWER (ROMP) SANCTION FOR TEST (SFT) HOT WORK PERMITS COMPETENT PERSONS AND AUTHORISED PERSONS.

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ANURAKSHAN
version - 8.0

Details of the ORACLE based version

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Salient features of latest version

ANURAKSHAN - 8.0

User friendly Oracle platform Conformance to NTPC Knowledge Team requirement In line with Maintenance Strategy Backend Oracle Database designed for centralised usage Less learning time for end-users Auto email from Application. Graphical trends

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ANURAKSHAN - 8.0
Features - contd...
Access on a need to know basis SMS alert generation can be provided Seasonal PM jobs Days of Week frequency for PM jobs Ability to store & retrieve

Photographs & Scanned Drawings Audio & Video files MS Word / Excel files

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ANURAKSHAN - 8.0
Process Flow Operation
E priority

Job Regn/Updn Process PTW

System Requests PTW

A,B priority E priority (Planned, Requested) PTW to Maintenance

Close PTW

Reports/Query MTP Job Planning Close WOC Manage Master data Reports/Query Job Regn / Upd

PTW from Maintenance

Diagnosis Accept PTW Offer PTW

A,B priority

Job Feedback Reports/Query Job Regn / Upd Maintenance

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ANURAKSHAN - 8.0
Process dependencies
E priority PFW Ready A,B priority Job Planning Diagnosis
Standing WOC

Job Registration

Standing WOC

Execute Work

WOC Feedback

Close WOC Close PFW

Offer PFW for Return

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ANURAKSHAN - 8.0
Work Flow
E priority Diagnose & Assess Job Registration with Isol & prec. Measure Work & Resources, Assess Safety & Isolations, Propose plan dt Print & Sign PFW A,B,C priority Diagnose & Assess Pending jobs Re-Route Shutdowns Opportunity Resources

Organise Res.

Execute Work

Obtain PFW

Committed Work Plan & PFW Request Print Isol slip, Isolate Equip Work Held up, Additional resource organisation Coordinate & Schedule

PFW Ready

Work complete, PFW Return, Trial run

Work Status

Resource organisation

PFW Close Work feedback Corporate IT Dept.PMI Revision 00 Source - KT draft report on MMS Close WOC

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SHORT TERM PLANNING

S.No. 1 FUNCTION OLMMS SYSTEM: -Implementation of PM module strictly. -Implementation of BD module . ACHIEVEMENT Both PM and BD Modules -100 % implemented for Main Plant and CHP; All PTWs are also taken through Anurakshan system

Maximum synchronisation of PM schedule of capital equipment with change over schedule.

100 % done for Milling System of Main plant where changeovers are more ; For all other capital equipment also PM schedule is matched with the changeover schedule

Effective coordination with main plant and CHP.

All problems pertaining to coal quality ,foreign materials etc. Are discussed in daily Planning Meeting are conveyed to CHP through DPM and corrective measures / Feedback taken for rectification ; Depending on the duration of the Force outage , all the pending defects are taken up in the shut-down done 35 100%

Optimum utilisation of opportunity shutdown to liquidate S/D defects.

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SHORT TERM PLANNING

S.No. FUNCTION ACHIEVEMENT

Organising meetings effectively within the scheduled time. Daily Planning Meeting. Daily scheduling Meeting. Daily CHP Planning Meeting. Weekly DM plant and civil Meeting. Other specific Task oriented Meetings.

80% 100% 100% 100% 100%

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LONG TERM PLANNING

S.No. 1 FUNCTION Overhaul contracts award monitoring. ACHIEVEMENT Continuous follow up with Maint., F&A and Contracts for timely award of overhaul contracts. Arranging services of BHEL and other agencies for overhaul works. Continuous monitoring, follow up of overhaul activities and ensuring the completion of overhaul with in schedule. Scheduling the annual outage to get planned outage of 5.7% Overhaul report released on intranet with in month of completion of overhaul. Overhaul cost payback period brought in overhaul report
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Specialist services for overhaul works.

Reducing the planned outage time target value.

Bring out the interactive type overhaul report in Electronic format.

Calculation pay back period of O/H.

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SPARES PART MANAGEMENT

S.No. 1 FUNCTION To monitor R&M cost and inventory of spares. ACHIEVEMENT

To Plan and procure common items like steel and paints. To monitor and review regularly lub oil consumption 10% reduction. To monitor critical overhaul spares for 2000-2001.

To review regularly unit replacement spares.

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7

To monitor and review all ARS items.

Renewal of statutory licences for the HFO/HSD tanks.

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Statutory testing of Tools and Tackles

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S.No. 9

FUNCTION Monitoring the preservation and insurance spares of critical equipments. Preservation and storage of all drawings developed by RSTPS through scanning and digitalisation. Identification and systematic storage of all vendor drawings for easy retrieval. Coordinating with users and FQA for making model QPs for critical developed spares and incorporating the reference in all drawings.

ACHIEVEMENT

10

11

12

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THANK YOU

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