0 training module on inspection, maintenance & capital budget

1

TRAINING MODULE ON

INSPECTION, MAINTENANCE & CAPITAL BUDGET

2

MAINTENANCE STRATEGY

MAINTENANCE OBJECTIVE

OPERATIONS OPERATIONS STRATEGYSTRATEGY

TERMINAL / DEPOT STRATEGYTERMINAL / DEPOT STRATEGY

1.0 ROLE OF M & R IN OPERATIONS1.0 ROLE OF M & R IN OPERATIONS 1.0 ROLE OF M & R IN OPERATIONS1.0 ROLE OF M & R IN OPERATIONS

3

M&R IS A COMPLEMENTARY FUNCTION TO OPERATIONSM&R IS A COMPLEMENTARY FUNCTION TO OPERATIONS

MAINTENANCE OBJECTIVES ARE DERIVED FROM OVER MAINTENANCE OBJECTIVES ARE DERIVED FROM OVER ALL TERMINAL STRATEGY AS WELL AS OPERATIONS ALL TERMINAL STRATEGY AS WELL AS OPERATIONS STRATEGYSTRATEGY

1.0 ROLE OF M & R IN OPERATIONS1.0 ROLE OF M & R IN OPERATIONS

4

2.0 BROAD M & R OBJECTIVES2.0 BROAD M & R OBJECTIVES

ENSURE MAXIMUM AVAILABILITY OF PLANT/EQUIPMENT ENSURE MAXIMUM AVAILABILITY OF PLANT/EQUIPMENT AT AT OPTIMUM LEVEL OF OPERATIONSOPTIMUM LEVEL OF OPERATIONS

STRIVE STRIVE TO INCREASE THE LIFE SPANTO INCREASE THE LIFE SPAN OF PLANT/EQUIPMENT OF PLANT/EQUIPMENT

ENSURE ENSURE SAFETYSAFETY OF PERSONNEL & EQUIPMENT OF PERSONNEL & EQUIPMENT

5

IDENTIFY AND IMPLEMENT PROJECTS FOR IDENTIFY AND IMPLEMENT PROJECTS FOR PROCESS PROCESS IMPROVEMENTS/COST REDUCTIONSIMPROVEMENTS/COST REDUCTIONS

MINIMIZEMINIMIZE CONSUMPTION OF CONSUMPTION OF RESOURCES RESOURCES (ENERGY, (ENERGY, WATER ETC.)WATER ETC.)

OPTIMIZE COSTOPTIMIZE COST OF MAINTENANCE STORES (INVENTORY OF MAINTENANCE STORES (INVENTORY CONTROL ON SPARES & CONSUMMABLES)CONTROL ON SPARES & CONSUMMABLES)

MAINTAIN ACCURATE & UP TO DATE MAINTAIN ACCURATE & UP TO DATE MAINTENACE MAINTENACE RECORDSRECORDS

2.0 BROAD M & R OBJECTIVES2.0 BROAD M & R OBJECTIVES

6

3.0 MAINTENANCE STRATEGY3.0 MAINTENANCE STRATEGY

ASPECTS UNDER M&R STRATEGYASPECTS UNDER M&R STRATEGY

3.1 HUMAN RESOURCES-3.1 HUMAN RESOURCES-

WHO WILL DO?WHO WILL DO?

IN HOUSE (OWN EMPLOYEES)IN HOUSE (OWN EMPLOYEES)

THRU CONTRACTOR/VENDORTHRU CONTRACTOR/VENDOR

THRU OEM / AUTHORISED SERVICE AGENT (CRITICAL THRU OEM / AUTHORISED SERVICE AGENT (CRITICAL EQPT. VIZ DG SET, FIRE PUMPS ETC.)EQPT. VIZ DG SET, FIRE PUMPS ETC.)

7


3.2 TOOLS, EQUIPMENTS AND CONSUMABLES & SPARES-3.2 TOOLS, EQUIPMENTS AND CONSUMABLES & SPARES-

WHAT WE REQUIRE?WHAT WE REQUIRE?

TOOLS (SPANNERS,HAND DRILLS Etc.)TOOLS (SPANNERS,HAND DRILLS Etc.)

PPE’S (HELMETS,SAFETY BELT Etc.)PPE’S (HELMETS,SAFETY BELT Etc.)

INSTRUMENTS (MEGGER,MULTIMETER Etc.)INSTRUMENTS (MEGGER,MULTIMETER Etc.)

LUBRICANTS ( OILS ADVISED BY OEM)LUBRICANTS ( OILS ADVISED BY OEM)

HARDWARE (NUTS, BOLTS, GASKETS Etc.)HARDWARE (NUTS, BOLTS, GASKETS Etc.)

EQUIPMENT SPARESEQUIPMENT SPARES

FITTINGS (BENDS,ELBOWS Etc.)FITTINGS (BENDS,ELBOWS Etc.)

8


3.3 PURCHASING3.3 PURCHASING

HOW DO WE PROCURE THE MATERIALS?HOW DO WE PROCURE THE MATERIALS?

PURCHASE INFORMATIONPURCHASE INFORMATION

PURCHASE PROCEDURESPURCHASE PROCEDURES

LIST OF VENDORSLIST OF VENDORS

INSPECTION PROCEDURESINSPECTION PROCEDURES

9


3.4 STORAGE OF METERIALS3.4 STORAGE OF METERIALS – –

WHERE & HOW TO KEEP?WHERE & HOW TO KEEP?

STORAGE SPACE (ENGINEERING WAREHOUSE)STORAGE SPACE (ENGINEERING WAREHOUSE)

PRESERVATION METHODS (TO ENSURE THAT THE ITEM IS KEPT PRESERVATION METHODS (TO ENSURE THAT THE ITEM IS KEPT IN USABLE CONDITION.)IN USABLE CONDITION.)

INVENTORY CONTROLINVENTORY CONTROL

10


3.5 DOCUMENTATION AND TRAINING3.5 DOCUMENTATION AND TRAINING

HOW TO CARRY OUT THE JOB?HOW TO CARRY OUT THE JOB?

PROCEDURESPROCEDURES

MANUALSMANUALS

HISTORY CARDS & CHECK LISTSHISTORY CARDS & CHECK LISTS

LOG BOOKSLOG BOOKS

15


3.6 MAINTENANCE PLANNING3.6 MAINTENANCE PLANNING

SEGMENTATION OF INFRASTRUCTURE (PLANT/EQUIPMENT) INTO SEGMENTATION OF INFRASTRUCTURE (PLANT/EQUIPMENT) INTO SUBSYSTEMSSUBSYSTEMS

TYPE OF MAINTENANCE AND SELECTION FOR INDIVIDUAL TYPE OF MAINTENANCE AND SELECTION FOR INDIVIDUAL SEGMENTSSEGMENTS

DEVELOPING MAINTENANCE PLAN FOR INDIVIDUAL SUBSYSTEMSDEVELOPING MAINTENANCE PLAN FOR INDIVIDUAL SUBSYSTEMS

DEVELOPING PERIODIC MAINTENANCE SCHEDULESDEVELOPING PERIODIC MAINTENANCE SCHEDULES

EXECUTION OF JOBEXECUTION OF JOB

DOCUMENTATIONDOCUMENTATION

16

3.6.1 SEGMENTATION OF INFRASTRUCTURE

OM & S (OIL MOVEMENT & STORAGE SUBSYSTEM)OM & S (OIL MOVEMENT & STORAGE SUBSYSTEM)

ELECTRICAL SUPPLY SUB SYSTEM (ESS)ELECTRICAL SUPPLY SUB SYSTEM (ESS)

FIRE & SAFETY SUB SYSTEMFIRE & SAFETY SUB SYSTEM

COMMUNICATION SUB SYSTEMCOMMUNICATION SUB SYSTEM

COMPANY VEHICLES SUB SYSTEMCOMPANY VEHICLES SUB SYSTEM

TERMINAL AUTOMATION SUB SYSTEMTERMINAL AUTOMATION SUB SYSTEM

BUILDINGS, ROADS & OTHERSBUILDINGS, ROADS & OTHERS

SECURITY SUB SYSTEMSECURITY SUB SYSTEM

CUSTOMER CARE EQUIPMENTS CUSTOMER CARE EQUIPMENTS

17

OM & S (OIL MOVEMENT & STORAGE SUBSYSTEM)OM & S (OIL MOVEMENT & STORAGE SUBSYSTEM)

STORAGE TANK & TANKFARMSTORAGE TANK & TANKFARM

PIPELINESPIPELINES

PUMPSPUMPS

GANTRIESGANTRIES

METERING SYSTEMSMETERING SYSTEMS

18

ELECTRICAL SUPPLY SUB SYSTEM (ESS)ELECTRICAL SUPPLY SUB SYSTEM (ESS)

SWITCH YARDSWITCH YARD

TRANSFORMERSTRANSFORMERS

CABLESCABLES

EARTHING SYSTEMSEARTHING SYSTEMS

VARIOUS CONTROL PANELSVARIOUS CONTROL PANELS

MOTOR CONTROL CENTREMOTOR CONTROL CENTRE

LIGHTING & FLP FITTINGSLIGHTING & FLP FITTINGS

BATTERIES & UPSBATTERIES & UPS

CAPACITOR BANKSCAPACITOR BANKS

DG SETSDG SETS

•FOLLOW OISD – 137 TOTALLY

•GET ELECTRI CAL SAFETY AUDIT ONCE IN 3 YEARS

19

FIRE & SAFETY SUB SYSTEMFIRE & SAFETY SUB SYSTEM

FIRE ENGINESFIRE ENGINES

FOAM SYSTEMFOAM SYSTEM

HYDRANT LINE & VALVESHYDRANT LINE & VALVES

MOBILE FOAM TENDERMOBILE FOAM TENDER

FIRE EXTINGUISHERSFIRE EXTINGUISHERS

PPE’S (PERSONAL PROTECTIVE EQUIPMENT)PPE’S (PERSONAL PROTECTIVE EQUIPMENT)

MONITOR, HYDRANTS & SPRINKLERSMONITOR, HYDRANTS & SPRINKLERS

•FOLLOW OISD – 142, 155 & 117 STRICTLY.

20

COMMUNICATION SUB SYSTEMCOMMUNICATION SUB SYSTEM

EPABXEPABX

WIRELESS/WALKIE-TALKIEWIRELESS/WALKIE-TALKIE

LAN/WANLAN/WAN

TELEPHONE/FAXTELEPHONE/FAX

21

COMPANY VEHICLES SUBSYSTEMCOMPANY VEHICLES SUBSYSTEM

TANK TRUCKSTANK TRUCKS

OTHER NON-EARNING VEHICLESOTHER NON-EARNING VEHICLES

22

TERMINAL AUTOMATION SUB TERMINAL AUTOMATION SUB SYSTEMSYSTEM

TANKFARM MODULETANKFARM MODULE

FIRE PUMP HOUSE AUTOMATIONFIRE PUMP HOUSE AUTOMATION

PUMP HOUSE AUTOMATIONPUMP HOUSE AUTOMATION

TANK TRUCK LOADING MODULETANK TRUCK LOADING MODULE

23

BUILDINGS, ROAD & OTHERSBUILDINGS, ROAD & OTHERS

BUILDINGS BUILDINGS

DRIVE WAYSDRIVE WAYS

RAILWAY TRACKRAILWAY TRACK

OFFICE EQUIPMENTSOFFICE EQUIPMENTS

24

SECURITY SUB SYSTEMSECURITY SUB SYSTEM

PERIMETER WALLPERIMETER WALL

GATESGATES

METAL DETECTORMETAL DETECTOR

OTHER EQUIPMENTSOTHER EQUIPMENTS

25

CUSTOMER CARE EQUIPMENTSCUSTOMER CARE EQUIPMENTS

LABORATORYLABORATORY

CALIBRATION TOWERCALIBRATION TOWER

PROVERSPROVERS

26

33. 6.2 TYPE OF MAINTENANCE. 6.2 TYPE OF MAINTENANCE

BREAK DOWN MAINTENANCEBREAK DOWN MAINTENANCE

ROUTINE MAINTENANCEROUTINE MAINTENANCE

PLANNED MAINTENANCEPLANNED MAINTENANCE

PREVENTIVE MAINTENANCEPREVENTIVE MAINTENANCE

PREDICTIVE MAINTENANCEPREDICTIVE MAINTENANCE

MAJOR MAINTENANCEMAJOR MAINTENANCE

CAPITAL MAINTENANCECAPITAL MAINTENANCE

27

33. . 3.6.2.1 BREAKDOWN MAINTENANCE3.6.2.1 BREAKDOWN MAINTENANCE

PHYSICALPHYSICAL

EQPT. COMMISSIONED

EQPT. IN SERVICEIN SERVICE

ABNORMALITY/ BREAK DOWN NOTICED

RECTIFIED & PUT BACK

RECORDRECORD

HISTORY CARD GENERATED

ROOT CAUSE ANALYSIS & DETAILS ENTERED

28

BREAKDOWN MAINTENANCEBREAKDOWN MAINTENANCE

ADVANTAGESADVANTAGES

NEEDS VERY LESS TIME,

LESS ROUTINE EXPENDITURE

DISADVANTAGESDISADVANTAGES

MAY CREATE CRISIS SITUATIONS/ ACCIDENTS

HUGE EXPENDITURE AT IRREGULAR INTERVALS. HENCE DIFFICULT TO ESTIMATE AND BUDGET

MAY REDUCE THE LIFE OF EQPT

REQUIRES HIGH LEVEL OF VITAL SPARES. HENCE, HIGH INVENTORY CARRYING COSTS

29

BREAKDOWN MAINTENANCEBREAKDOWN MAINTENANCE

SUITABILITYSUITABILITY

DURABLE EQUIPMENT AND FACILITIES LIKE COMPOUND WALL, DYKEWALLS, ROADS ETC.

IN THE ABOVE CASES, ACTION CAN BE TAKEN AFTER PROBLEMS ARE NOTICED.

(E.G): POT HOLES IN ROADS, SEEPAGES IN BUILDINGS, (E.G): POT HOLES IN ROADS, SEEPAGES IN BUILDINGS, PROBLEMS FOR FURNITURE ETC.PROBLEMS FOR FURNITURE ETC.

30

3.6.2.2 ROUTINE MAINTENANCE3.6.2.2 ROUTINE MAINTENANCE

PHYSICALPHYSICAL

EQUIPMENT COMMISSIONED

SIMPLE SERVICE AT REGULAR INTERVALS.

BREAKDOWNS, IF ANY ARE RECTIFIED

RECORDRECORD

HISTORY CARD GENERATED

HISTORY CARD UPDATED

ROOT CAUSE ANALYSIS & DETAILS ENTERED

31



THE EQUIPMENT/FACILITY GETS INSPECTED AT REGULAR THE EQUIPMENT/FACILITY GETS INSPECTED AT REGULAR INTERVALS.INTERVALS.

ABNORMAL CONDITIONS CAN BE IDENTIFIED BEFORE CRISIS.ABNORMAL CONDITIONS CAN BE IDENTIFIED BEFORE CRISIS.

NEEDS LESSER TIME.NEEDS LESSER TIME.

SERVICE COST CAN BE BUDGETEDSERVICE COST CAN BE BUDGETED.

32



BREAKDOWNS CAN NOT BE ELIMINATED

INVOLVES HIGH EXPENDITURE AT IRREGULAR INTERVALS AND MINIMAL EXPENDITURE AT ROUTINE INTERVALS


COMPUTERS, WALKIE-TALKIE SETS, PRINTERS, AIR-CONDITIONERS AND OTHER OFFICE EQUIPMENTS LIKE FAX, XEROX, EPABX ETC.

33

3.6.2.3 PLANNED MAINTENANCE3.6.2.3 PLANNED MAINTENANCE

PHYSICALPHYSICAL

EQUIPMENT EQUIPMENT COMMISSIONEDCOMMISSIONED

PLANNED PLANNED MAINTENANCE & MAINTENANCE & INSPECTIONS AT FIXED INSPECTIONS AT FIXED TIME SCALE. TIME SCALE.

RECORDRECORD

HISTORY SHEET HISTORY SHEET CREATED.CREATED.

MAINTENANCE PLAN & MAINTENANCE PLAN & PERIODIC SCHEDULE PERIODIC SCHEDULE DRAWNDRAWN

INSPECTION CHECK LIST INSPECTION CHECK LIST FILLED UP AND HISTORY FILLED UP AND HISTORY SHEET UPDATEDSHEET UPDATED

34

THE EQUIPMENT IS INSPECTED CLOSELY AT REGULAR THE EQUIPMENT IS INSPECTED CLOSELY AT REGULAR INTERVALS.INTERVALS.

CERTAIN MINOR ACTIVITIES LIKE LUBRICANTS, OIL CERTAIN MINOR ACTIVITIES LIKE LUBRICANTS, OIL CHANGE, CLEANING, REPLACEMENT OF GASKETS ETC CHANGE, CLEANING, REPLACEMENT OF GASKETS ETC ARE CARRIED OUTARE CARRIED OUT


35

3 PLANNED MAINTENANCE3 PLANNED MAINTENANCE


BREAK DOWNS ARE MINIMAL & HENCE BREAKDOWNS BREAK DOWNS ARE MINIMAL & HENCE BREAKDOWNS COSTS ARE LESS.COSTS ARE LESS.

BETTER LIFE SPAN IN VIEW OF REGULAR BETTER LIFE SPAN IN VIEW OF REGULAR INSPECTIONS.INSPECTIONS.

BETTER ESTIMATION OF MAINTENANCE COST. BETTER ESTIMATION OF MAINTENANCE COST.

BETTER INVENTORY CONTROL OF SPARES, LUBES BETTER INVENTORY CONTROL OF SPARES, LUBES INVENTORY.INVENTORY.

36



NEEDS MORE TIME (MANY ACTIVITIES)

REQUIRES MORE RESOURCES

REQUIRES SHUTDOWN

NEEDS HIGHER LEVEL OF PLANNING


GANTRIES, VALVES, VEHICLES, RAILWAY TRACK, FIRE EXTINGUISHERS, METERS, STRAINERS, STORAGE TANKS

37

3.6.2.4 PREVENTIVE MAINTENANCE 3.6.2.4 PREVENTIVE MAINTENANCE

IN THIS TYPE, THE MAINTENANCE SCHEDULES ARE DRAWN AS PER REQUIREMENT BY MANUFACTURER/STANDARDS


REMOTE POSSIBILITIES OF BREAKDOWNS.

BETTER ESTIMATION OF EXPENDITURE.

HIGHER RELIABILITY OF EQUIPMENT.

38



VERY HIGH REQUIREMENT OF HUMAN RESOURCES.VERY HIGH REQUIREMENT OF HUMAN RESOURCES.

ROUTINE COSTS WILL BE HIGHER FOR MAINTENANCE. ROUTINE COSTS WILL BE HIGHER FOR MAINTENANCE.

REQUIRES MORE DOCUMENTATIONREQUIRES MORE DOCUMENTATION.

39



FOR EQUIPMENTS WHICH ARE CRITICAL FROM OPERATIONS FOR EQUIPMENTS WHICH ARE CRITICAL FROM OPERATIONS AND SAFETY POINT OF VIEW (VIZ. FIRE & SAFETY EQUIPMENT, AND SAFETY POINT OF VIEW (VIZ. FIRE & SAFETY EQUIPMENT, ELECTRICAL SYSTEM AND OIL MOVEMENT & STORAGE ELECTRICAL SYSTEM AND OIL MOVEMENT & STORAGE SYSTEMS)SYSTEMS)

40


PREDICTIVE MAINTENANCE IS BASED ON CONDITION PREDICTIVE MAINTENANCE IS BASED ON CONDITION MONITORING OF EQUIPMENT AND IT REQUIRES SOPHISTICATED MONITORING OF EQUIPMENT AND IT REQUIRES SOPHISTICATED EQUIPMENT FOR MONITORING CONDITION OF EQUIPMENTEQUIPMENT FOR MONITORING CONDITION OF EQUIPMENT

E.g: MONITORING PUMP PERFORMANCE USING VIBRATION E.g: MONITORING PUMP PERFORMANCE USING VIBRATION ANALYSISANALYSIS

MONITORING OF BEARING CONDITION USING VIBRATION AND MONITORING OF BEARING CONDITION USING VIBRATION AND TEMPERATURE. THIS PRACTICE IS EXPLAINED IN OISD-124TEMPERATURE. THIS PRACTICE IS EXPLAINED IN OISD-124

41



SIMILAR TO PREVENTIVE MAINTENANCE


IT REQUIRES SOPHISTICATED INSTRUMENT FOR CONDITION OF MONITORING


THIS IS SUITABLE FOR ROTARY EQPT.

42

3.6.2.6 MAJOR MAINTENANCE3.6.2.6 MAJOR MAINTENANCE

OVERHAULING & RECONDITIONING

OVERHAULING:

GIVING A NEW LIFE TO THE OPERATIVE EQUIPMENT

RECONDITIONING:

BRINGING BACK AN EQUIPMENT TO THE ORIGINAL LEVEL OF OPERATIVE CONDITION

OISD STANDARDS HAVE RECOMMENDED FOR OVERHAULING OF CENTIFUGAL PUMPS, POSITIVE DISPLACEMENT PUMPS, COMPRESSORS & DIESEL ENGINES.

43

3.6.2.7 CAPITAL MAINTENANCE ACTIVITIES3.6.2.7 CAPITAL MAINTENANCE ACTIVITIES

REFURBISHING

TO PROVIDE TECHNOLOGICAL UPGRADATION

REPLACING

REPLACING THE EXISTING EQUIPMENT

PROVIDING STANDBY

PROVIDING ADDITIONAL STAND BY EQUIPMENT

THE ABOVE ACTIVITIES ARE THE CAPITAL ACTIVITIES EXECUTED THRU NPCBNPCB

44

3.6.3 DEVELOPING MAINTENANCE PLAN3.6.3 DEVELOPING MAINTENANCE PLAN

PLAN TO BE DEVELOPED FOR PLANNED PLAN TO BE DEVELOPED FOR PLANNED MAINTENANCE, PREVENTIVE MAINTENANCE & MAINTENANCE, PREVENTIVE MAINTENANCE & PREDICTIVE MAINTENANCE.PREDICTIVE MAINTENANCE.

PLAN SHALL BE SPECIFIC FOR A PARTICULAR PLAN SHALL BE SPECIFIC FOR A PARTICULAR SUBSYSTEMSUBSYSTEM

PLAN SHALL ADDRESS THE REQUIREMENTS OF PLAN SHALL ADDRESS THE REQUIREMENTS OF INDIVIDUAL EQUIPMENTS UNDER THE SUBSYSTEMINDIVIDUAL EQUIPMENTS UNDER THE SUBSYSTEM

45

DEVELOPING MAINTENANCE PLAN

THE PLAN SHALL INCLUDE THE FOLLOWINGTHE PLAN SHALL INCLUDE THE FOLLOWING

SUBSYSTEM SUBSYSTEM

TYPE OF M&RTYPE OF M&R

STANDARDS APPLICABLE STANDARDS APPLICABLE

INDIVIDUAL EQUIPMENTSINDIVIDUAL EQUIPMENTS

WHO WILL DO THE ACTIVITYWHO WILL DO THE ACTIVITY

PURCHASE/PROCUREMENT PLANPURCHASE/PROCUREMENT PLAN

REFERENCE TO DOCUMENTATIONREFERENCE TO DOCUMENTATION

46

HISTORY CARD

ASSET LISTING

SPARESLUBE USED

PURCHASE

OPER.DETAILS

MAINTENANCESCHEDULE

M&R ACTIVITIES

BREAKDOWNANALYSIS

MISREPORTS

3.53.5 DOCUMENTATION DOCUMENTATION

47

3.6.4 DEVELOPING PERIODIC 3.6.4 DEVELOPING PERIODIC MAINTENANCE SCHEDULEMAINTENANCE SCHEDULE

SSCHEDULE SHALL

BE EQUIPMENT SPECIFIC

BE DRAWN FROM THE PLAN

HAVE REFERENCE OF TIME SCALE

SHOW ACTIVITIES SCHEDULED AND COMPLETED

HAVE REFERENCE TO WORK PERMITS

HAVE REFERENCE TO HISTORY CARD

48

3.6.5 EXECUTION OF JOB3.6.5 EXECUTION OF JOB

WORK PERMIT TO BE TAKEN AS PER SCHEDULE

LIST OF TOOLS & PPE’S TO BE MENTIONED IN THE PERMIT

FINAL LIST OF CONSUMABLES USED TO BE MADE AND UPDATED IN HISTORY CARD

49

3.6.6 DOCUMENTATION3.6.6 DOCUMENTATION

DOCUMENTATION TO BE DESIGNEDDOCUMENTATION TO BE DESIGNED

IN LINE WITH PLAN

WITH LINKAGES WHEREVER REQD.

TO TAKE CARE OF THE REQUIREMENTS OF INDIVIDUAL EQUIPMENTS.

53

6.0 ROUTINE ACTIVITIES6.0 ROUTINE ACTIVITIES

ROUTINE MAINTENANCE OF METERING SYSTEM, STRAINERS ETC.

CROSS CHECKING OF METER FACTORS

DAILY CHECKING OF TOTALISER

PERIODIC HOUSE KEEPING OF SOFTWARE

54

CONTROL ON AMC-OEM

EQPTS. Viz. DG SET, FIRE ENGINE etc, NEED TO BE

EQUIPMENTS Viz. DG SETS, FIRE ENGINES ETC. NEED TO BE MAINTAINED BY TRAINED PERSONNEL.

HENCE, AMCs ARE PLACED ON OEM/ AUTHORISED SERVICE AGENT.

COST OF AMC IS HIGHER & HENCE WE NEED TO GET MAXIMUM VALUE FOR MONEY.

55

M&R - PIPELINESM&R - PIPELINES

ROUTINE INSPECTIONSROUTINE INSPECTIONS PITTING/SCALING/LEAKS/PINHOLEPITTING/SCALING/LEAKS/PINHOLE

PAINTING & PATCH IF NEEDEDPAINTING & PATCH IF NEEDED

LEAKAGE FROM GASKETSLEAKAGE FROM GASKETS

INSPECTION OF VALVES/ FITTINGSINSPECTION OF VALVES/ FITTINGS

THERMAL RELIEF SYSTEMSTHERMAL RELIEF SYSTEMS

CONTINUITY JUMPERSCONTINUITY JUMPERS

56

M&R - PIPELINESM&R - PIPELINES

PERIODIC INSPECTIONSPERIODIC INSPECTIONS ULTRASONIC SURVEY OF THICKNESS (3 YEARS)ULTRASONIC SURVEY OF THICKNESS (3 YEARS)

HYDROTEST (3 YEARS)HYDROTEST (3 YEARS)

INSPECTION OF U/G LINESINSPECTION OF U/G LINES

FULL PAINTING (FREQ. TO BE DECIDED) {IF SAND FULL PAINTING (FREQ. TO BE DECIDED) {IF SAND BLASTING IS NOT POSSIBLE, SELECT PRIMER BLASTING IS NOT POSSIBLE, SELECT PRIMER SUITABLY}SUITABLY}

CLEANING OF STRAINERS (QUARTERLY)CLEANING OF STRAINERS (QUARTERLY)

57

M&R - PUMPSM&R - PUMPS

IDENTIFY TYPE OF PUMPIDENTIFY TYPE OF PUMP

REFER OISD 119 FOR FREQUENCY & INSPECTION REFER OISD 119 FOR FREQUENCY & INSPECTION CHECKLIST.CHECKLIST.

65

M&R – STORAGE TANKS

EXTERNALEXTERNAL INSPECTION – FREQUENCY TO BE DECIDED BASED ON THE

REQUIREMENTS OF LOCATION

TYPICAL FREQUENCY FORTNIGHTLY – TANKS WHICH ARE OLD/

CORRODED. MONTHLY – OTHER STORAGE TANKS

INSPECTION TO BE DONE AS PER CHECKLIST & CORRECTIVE ACTIONS TO BE TAKEN IMMEDIATELY.

66


INTERNAL INSPECTION

TO BE DONE DURING TANK CLEANING

JOBS TO BE CARRIED OUT INCLUDECHECKING THE WELD JOINTS OF BOTTOM PLATE – DP TEST/ VACUUM BOX.

THICKNESS MEASUREMENT USING ULTRASONIC INSTRUMENT OF BOTTOM PLATE, SHELL, ROOF ETC.

OVERHAULING OF ROOF DRAIN MECHANISM

FREQUENCY TO BE DECIDED BASED ON THE REQUIREMENTS OF LOCATION

67


INTERNAL INSPECTION

REPAIR OF BOTTOM PLATE/ ROOF/ SHELL ETC., IF REQD. AS PER OISD 129

SERVICING/REPLACEMENT OF VALVES, NRVs,ETC.

SAFETY PRECAUTIONS, WORK PERMIT SYSTEMS TO BE FOLLOWED DURING TANK CLEANING OPERATIONS.

70

M&R – GANTRIES

INSPECT THE FOLLOWING ASPECTS

LEAKAGE, IF ANY ARREST.

EASE OF OPERATION & GREASING

STRAINER CLEANING AT LEAST ONCE IN A QUARTER

IN CASE OF HOSE PIPE

HYDROTESTING & CONTINUITY (ONCE IN 6 MONTHS)

HOUSEKEEPING OF FLOOR, DRAINS

71

M&R – METERING SYSTEM

INSPECT THE FOLLOWING ASPECTS

LEAKAGE, IF ANY ARREST.

FUNCTIONING OF AIR ELIMINATOR

STRAINER CLEANING AT LEAST ONCE IN A QUARTER

OTHERS – BREAKDOWN MAINTENANCE

SPARES TO BE KEPT

PULSE TRANSMITTER, GASKETS, O-RINGS, VANES.BLADES, AIR ELIMINATOR BALL, STRAINER BASKET

72

NPCBNPCB

PREPARATION OF PROPOSALSPREPARATION OF PROPOSALS

DEPT.WISE LOCATIONS REQUIREMENT TO BE STUDIED AND DEPT.WISE LOCATIONS REQUIREMENT TO BE STUDIED AND PROPOSALS TO BE INITIATED. PROPOSALS TO BE INITIATED. PROPOSALS WITH PROPER JUSTIFICATIONS & COST ESTIMATES TO BE PROPOSALS WITH PROPER JUSTIFICATIONS & COST ESTIMATES TO BE

SENT TO RESPECTIVE RO’s / ZONE SENT TO RESPECTIVE RO’s / ZONE

PROPOSAL CATEGORIES :PROPOSAL CATEGORIES : SAFETY & SECURITY SAFETY & SECURITY

FACILITIES & EQUIPMENT FACILITIES & EQUIPMENT

WELFARE WELFARE

OFFICE EQUIPMENT OFFICE EQUIPMENT

LAB EQUIPMENT LAB EQUIPMENT

ADDITIONAL PRODUCT TANKAGEADDITIONAL PRODUCT TANKAGE

ENERGY CONSERVATIONENERGY CONSERVATION

73

APPROVAL OF PROPOSALSAPPROVAL OF PROPOSALS

PROPOSALS PUT IN CFD & BOARD MEETINGSPROPOSALS PUT IN CFD & BOARD MEETINGS BOARD APPROVES THE BUDGET FOR THE YEARBOARD APPROVES THE BUDGET FOR THE YEAR

BUDGETED FOR PROGRAM & NON-PROGRAM ITEMSBUDGETED FOR PROGRAM & NON-PROGRAM ITEMS

ZONE FORWARDS THE APPROVED PROPOSALS TO ZONE FORWARDS THE APPROVED PROPOSALS TO LOCATIONS WITH AR NOS.LOCATIONS WITH AR NOS.

APPROPRIATION REQUEST TO BE SENT TO RO/ APPROPRIATION REQUEST TO BE SENT TO RO/ ZONE DULY FILLED FOR APPROVAL AS PER LAMZONE DULY FILLED FOR APPROVAL AS PER LAM

AFTER RECEIVING APPROVED AR , EXECUTION AFTER RECEIVING APPROVED AR , EXECUTION PROCESS TO BE INITIATED.PROCESS TO BE INITIATED.

74

EXECUTION OF APPROVED PROJECTEXECUTION OF APPROVED PROJECT

LIST ALL APPROVED NPCB PROJECT LIST ALL APPROVED NPCB PROJECT LPR PREPARATIONLPR PREPARATION

PURCHASE PROCEDURE TO BE FOLLOWED AS PER PURCHASE PROCEDURE TO BE FOLLOWED AS PER LAMLAM

TENDER OPENING / RECAPTENDER OPENING / RECAP

NEGOTIATION ( IF REQUIRED )NEGOTIATION ( IF REQUIRED )

PURCHASE ORDER TO BE PLACEDPURCHASE ORDER TO BE PLACED

JOB TO BE COMPLETED/ITEMS TO BE RECEIVEDJOB TO BE COMPLETED/ITEMS TO BE RECEIVED

PREPARATION OF MRRPREPARATION OF MRR

75

CLOSE OUT OF NPCB PROJECTCLOSE OUT OF NPCB PROJECT

MONTHLY PROGRESS REPORT TO BE MADE FOR MONTHLY PROGRESS REPORT TO BE MADE FOR EFFECTIVE CONTROL / RECORDEFFECTIVE CONTROL / RECORD

AMCA TO BE PREPARED FOR CAPITALISATION OF AMCA TO BE PREPARED FOR CAPITALISATION OF PROJECT.PROJECT.

AMCA TO BE ENTERED IN JDE BY FINANCE PERSON AND AMCA TO BE ENTERED IN JDE BY FINANCE PERSON AND SYSTEM GENERATED ASSET NO TO BE RECORDED.SYSTEM GENERATED ASSET NO TO BE RECORDED.

AMCA TO BE SENT TO RO/ZONE FOR CLOSURE OF AMCA TO BE SENT TO RO/ZONE FOR CLOSURE OF CAPITAL EXPENDITURE FOR PARTICULAR AR NO.CAPITAL EXPENDITURE FOR PARTICULAR AR NO.

ENSURE CWIP IS NILENSURE CWIP IS NIL

DELETION ADVICE TO BE SENT TO P&P FINANCE.DELETION ADVICE TO BE SENT TO P&P FINANCE.

76THANK YOU

0 training module on inspection, maintenance & capital budget

Documents

maintenance strategy

operations strategy

terminal strategy

subsystems type of maintenance

r objectives slide

mr strategy

safety of personnel

safety belt