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Plant,
equipment, machinery and building deteriorate due to their
use and exposure to environment conditions. If this process
is allowed to be continued unchecked, these facilities become
unserviceable and brings them to standstill. Industry has
therefore, no choice but to attend to them from time to time,
to repair and recondition them to be able to increase their
life to extent it is economically and physically possible
to do so. It is in this context that maintenance assumes importance
as an engineering plant and equipment is available for productive
use, for the scheduled hours, operating at agreed standard
with minimum waste.
Maintenance
plays a crucial role in the production process in the Refineries
/ Petrochemical plants. A plant may be regarded as successful
when it operates without interruptions, which can however
be achieved only when its facilities are in perfect working
order at all times. The strategic importance of maintenance
increases with increasing sophistication. The overall objective
is to maximize production output at minimum total cost. Effective
maintenance management forms an important approach to reducing
total manufacturing costs and improve productivity of the
production process. Failure to manage maintenance can lead
to high penalty cost due to down time.
All
the process right from planning & scheduling to post TAM
activities are carried out by keeping three points in view
- Quality
Control
- Time
Control
- Cost
Control
- Safety
Quality
Control
- All
material supplies are affected from approved suppliers and
manufactures only.
- All
items procured are inspected /tested.
- Strict
quality control is ensured.
- Stage
wise inspection and certification of jobs by inspectors.
- Jobs
are handled by :
*Experienced & highly skilled
craftsmen.
*Prequalified contractors for individual
jobs based on earlier experience of similar nature.
*Tested & certified contractor
welders.
Time Control
Schedule
is prepared for all major jobs using computerised packages
establishing critical path & duration of turnaround based
on -
- Process
schedule
- Resources
available departmentally.
- Resource
made available through external agencies.
- Involvement
of other agencies.
Cost
Control
- Materials
are procured for turnaround as per inspection recommendations
only.
- Detailed
estimation of contracts are prepared well in advance.
- Proper
reconditioning of high cost equipment is carried out.
- Full
utilisation of company owned & hired resources are ensured.
- Timely
completion is the main essence of turnaround.
Safety
- Proper
work environment can be created only if proper safety measure
steps should be taken into account. Thus safety records
during TAM need to the excellent.
*Briefing about on the job safety
to company and contractor employees.
*Safety training to all contractor
supervisors.
*Monitoring the safety aspects of
job by qualified safety engineers & safety observers.
*Strict compliance of use of safety
gears at work site by all.
- Renewal
of clearance is done on shift basis.
- Certifications
of tools/tackles/lifting devices/ scaffolding material/
welding sets/ cranes are carried out by competent persons.
- Use
of special safety gadgets like protective mask, breathing
equipment wherever necessary.
- Boxing
up of equipment such as vessels, columns etc. Is certified
by inspection, operations, technology & maintenance
department jointly.
Primary Activities
- Maintenance
of existing plant, equipment and buildings.
- Facilities
planning, constituting planning, procurement and installation
of new plant equipment and machinery.
- Maintenance
of utilities - steam, water, compressed air, captive power
plants, LPG storage and filling, air-conditioning etc
- Alterations
or modifications of plant, equipment and buildings.
- Rebuilding
or reconditioning of old plant equipment etc.
Secondary Activities
- Sewage
collection and disposal.
- Pollution
and noise control
- Store
keeping
- Factory
and site cleaning
- Fire
fighting
- Training
of maintenance personnel
Areas of Maintenance
- Mechanical
maintenance
- Electrical
maintenance
- Civil
maintenance
- Electronics
/ Instrumentation maintenance
- Contract
management
Objective of Turn Around Maintenance
- Bring
plant and equipment to their original health.
- Make
plant safe to operate till next outage.
- Improvement
efficiency & throughput of plant by suitable modification.
- Reduce
routine maintenance costs
- Increase
reliability / availability of equipment during operation
- Upgrade
technology by introducing modern equipment & techniques.
Competitive Advantage of TAM
- PII
refineries have vast and rich experience in handling Turn
Around Maintenance
- Main
strength of Turn Around Execution is highly skilled, knowledgeable,
experienced and capable engineers & technician.
- The
present strength of engineers & technician have experience
of handling various turn arounds of crackers, distillation
& other units.
- High
degree of expertise gained over last 40 years of maintaining
various refineries.
- Adoption
of latest maintenance tools & techniques for preventive,
predictive proactive and turn around maintenance.
- Dedicated
team of engineers and technicians.
- PII
has deputed maintenance experts to refineries of various
Middle East and Far East countries such as Nigeria, Kuwait,
Malaysia & UAE.
- The
performance on all these assignments was excellent and left
a mark of their skill and dedication.
- Detailed
data bank on rotary equipment
Analysis of various failures
Modifications to suit process conditions
- Expertise
in welding exotic material - Successfully developing welding
procedures.
- Capabilities
of fabrication on intricate spares & exchangers tube
bundles.
- Mastery
of machining components to high degree of accuracy.
- Expert
knowledge on overhauling to high degree of accuracy.
- Specialised
techniques in repairs to internal cyclones.
- Top
class knowledge on maintaining various electrical equipment
and instrument.
- Capability
of providing and repairing any refractory & civil facilities.
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