Param Sankalp / 04

Param Express

• Data cleansing for next 13 equipment anduploading of cleansed data in SAP.

• Strong push on value initiatives across allsites.

• Finalization of Spares Managementcontract and development in SAP.

• Finalization of ORI tool vendor.

• Finalization & roll out of RCM-KPIdashboard.

• COI Meet is scheduled on 11th July atDharavi Urja .

• Design & configuration of APM tool .

• Starting of Data Analytics project for eachsite under the guidance of IIT –Powaiprofessor in the month of July 2018.

Watch Out ForKey Activities Concluded

• Second Workshop and interaction conductedform 16th to 19th May 2018 at Mumbai , withReliability expert Chris James to review andrefine the FMEA & Maintenance strategy for7 critical equipment's .

• Core maintenance work i.e. Data cleansing ,updating Task list in SAP started for next setof 13 equipment's of Phase B .

• Reliability day successfully conducted on12th April; Site reliability day conducted atCGPL, Trombay, Jojobera & T&D.

• Kick of meeting with GE for RCM ITsolution conducted on 9th May 2018 &Orientation workshop conducted for GEAPM tool; Design configuration is inprogress.

• Conducted ~84 site RCM Immersionsessions (incl. HOD trainings) across allsites covering 1034+ people.

Param Sankalp / 04

Shutdown APC Tracker – a CGPL value initiativeInitiatives focusing on improvement in SHR, SOC, APC, Coal Quality, Ash handling, water

consumption etc. form a major focus area under the Param Sankalp program. The Shutdown

APC tracker is one such initiative, undertaken by CGPL site team. The basic purpose of this

tracker is to notify the operations team on timing the shutdown of various equipment during

unit shutdowns as the unit load decreases over time. APC tracker is launched when the unit

shutdown is initiated and tracks auxiliary power consumption, unit load and time till

desynchronization on a real time basis. Continuously monitored values of various parameters

like MS pressure, MS flow, HRH pressure etc. along with Unit load is used to identify the

optimal number of equipment that need to be operated. The tracker notifies the users at the

precise time for shutdown of equipment like ID fan, PA fan, CWP, BFP, coal mill etc., thereby

reducing power consumption. This tracker is currently being used by CGPL, providing an

annual benefit of INR 1.9 crore. Extension of the tracker to Start-ups as well as adoption at

other sites is currently being explored.

Following the success of Central Reliability Day conducted on 12th April 2018, half-day

Site Reliability Days were conducted at Trombay, Jojobera, CGPL and T&D to

recognize the efforts put in by various employees as part of the Param Sankalp

program. These events started with an inaugural speech by site Chiefs and was

followed by a presentation on progress of the Param Sankalp program and its various

initiatives. Site leadership then felicitated employees with awards under Site RCM

Champion, Best Internal Trainer and RCM Implementation Champion categories.

Various site specific value initiatives were then discussed along with the RCM projects

that were being implemented by individual teams at department level. Leadership has

shown keen interest in these RCM projects and has provided valuable suggestions for

their successful implementation. Site Reliability Days were concluded with a RCM

simulation game dealing with maintenance strategy for an airplane.

Site Reliability Days – celebrating work done so far & planning ahead

Param Sankalp / 04

RCM IT Tool – An introduction

A host of solutions have been initiated across Tata Power to implement RCM ways of

working and the IT tool called Asset Performance Management (APM) from GE is a critical

part of it. The project kicked-off on 9th May and a week long design workshop was

conducted at T&D office, Dharavi to make users aware of the tool’s features. The workshop

was very eventful with attendees mentioning different use cases of the tool. Various

suggestions on tool customizations were given by attendees and were considered by the GE

team. Currently the core team is reviewing all the requirements and tool integration with

internal SAP system will soon be started. The tool is expected to go live in the month of

November and it will be followed by various training sessions.

APM tool will be able to import the equipment criticality classification and the

FMEAs developed by various site teams and perform reliability analysis. Notification history

from SAP will be imported into the tool along with analysis performed in ADoRE to create

health indices and identify bad actors (root causes that cause majority of failures). Key

feature of the tool is to suggest an optimum frequency for PM/CBM activities by

considering the probability of failure, cost of failure and cost of implementing PM/CBM

activity. Additional measurement data from OSI PI will be imported and will be mapped with

respective equipment in APM tool. Custom health indices can be created based on various

measurement data for each individual equipment. Operator rounds can be designed in the

tool to enable easy capture of measurement data. In short APM tool will make use of all the

knowledge gathered during the past 1.5 years and will facilitate reliability improvement by

making use of its unique features.

Reliability Scorecard

Param Sankalp / 04

My CornerConversations with you…

Mr. Kamal Bairwa,

Technical Lead, RCM

Task Force

equipment. Its members are drawn from all sites having cross functional expertise. COI

team can also reach out to external experts on need basis. The teams meet regularly to

resolve the issues referred to them as well as to share the knowledge across the divisions.

The team performance is monitored through a well defined matrix. On a monthly basis,

select teams are invited to share their achievement with chiefs. Moreover, the Tata Power

leadership continuously provides mentoring and guidance to COI functioning.

What are some of the activities taken up by the COI? What are its deliverables?

• Establishing the predominant failure modes along with preventive action items specific

to sites.

• Inter plant equipment performance benchmarking is getting established.

• Resolution of plant problems.

• FMEA review and update based on identification of new failure mode/root cause

• Alignment and uniformity of task lists and measurement points

• Improvement in equipment performance and reliability.

• Implementation of approved new action items across the sites where ever applicable.

• Reduction in overall RPN of equipment

What are the benefits of COI? Can you name some of the outcomes?

The benefits and outcome of COI working has been seen in following areas –

The Corrective maintenance notifications M1(5) and M2 have started going down in last 5

months. It shows that the PM task has been made comprehensive, the repetitive

notifications have gone down. COIs are driving time based maintenance to condition based

maintenance which is the optimum maintenance approach. Ex: BFP COI team has

developed a maintenance methodology based on pump efficiency. The condition

monitoring parameters and techniques are being made uniform. COI was able to solve

complex problems such as U4 vacuum problem in Jojobera by identifying the root cause.

It is also driving the culture of “One Tata Power” way of working. New Maintenance

techniques such as dry out process of Transformer, Boiler tube expander for inspection etc

have also been results of COI interventions.

What needs to be done for the sustenance of COIs?

• System based approach: We are in the process of establishing a system based approach

for issues raised to COI and tracking of the recommendation given by COI.

• Creation of a repository: Work done by COIs shall be stored and be made available to

larger group of O&M teams for knowledge sharing and further idea generation.

• Implementation of recommendations given by COI to the divisions – Effectiveness of

COI functioning will keep improving as their recommendations are implemented. It is

equally important to give feedback on the effectiveness of the solution suggested by

COI.

• Exposure to external expert for complex technical issues

Tata Power established communities of interest to

sustain the RCM way of working and make continuous

improvement. We have COIs for all the critical

Param Sankalp / 04

1. Which of the following is the correct definition

of reliability.

a. Reliability is defined as the probability that a

component or system will perform a required

function for a given period of time.

b. Reliability is defined as the probability that a

component or system will perform a required

function for a given period of time when

used under stated operating conditions.

(Correct)

c. Reliability is defined as the probability that a

component or system will perform under

stated operating conditions.

d. None of the above.

2. Which of the following equipment doesn’t

qualify for Preventive maintenance.

a. Pumps

b. Pulverisers

c. Electronic Components (Correct)

d. Transformers

3. Which of the following curves represents various

phases of equipment life cycle.

a. Bath tub curve (Correct)

b. PF Curve

c. Poisson Distribution

d. Weibull distribution

4. FSN In Spares management Stands for

a. First Moving, Second Moving, Not Moving

spares

b. Fast Moving, Slow moving, Non Moving

Spares (Correct)

c. Foreign Supplied, State Supplies, Nation

Supplied Spares.

d. None of the above

5. Bill of Material (BOM) of an equipment has a

link with calculation logic of Safety stock

a. True (Correct)

b. False

6. ORI Stands For

a. Outage Readiness Index (Correct)

b. Outage rated Index

c. Outage Ranking Index

d. None of the above.

1. Alignment of which of the following is

mandatory for completion of FMEA.

a. Alignment of FMEA with SAP

equipment Codification

b. Alignment of FMEA with Equipment

Bill Of Material(BOM)

c. Alignment of FMEA with SAP

Catalogues

2. a. Data quality is one of the pillars of RCM effectiveness

b. FMEA can be created for failures that have not yet occurred, but can occur in the futurec. Higher reliability always translates to higher availability

3. Which of the following is not true about FMEA?

a. FMEA creation is a one-time activityb. FMEA can be done both for equipment and processes bothc. All failure modes must be captured in FMEA

4. MTBF calculation uses data from which type of notifications ?

a. Preventive Maintenance, b) Corrective Maintenance, c) Breakdown Maintenance

Quiz of the Month –Newsletter Quiz

“Two Truths One Lie”

Send your responses to paramsankalp@tatapower.com

First three correct responses would be awarded.

Answers for quiz of the month

Which are the two truths andone lie in each question?

Param Sankalp / 04

Intuition or experience based negotiation of AMC contracts. May not be optimal

Should cost analysis backed by data provides a realistic estimate of AMC cost for contract negotiations

There has been a reduction in breakdowns because of RCM program!

If you have any questions, please write to us at paramsankalp@tatapower.com