HIMER National Conference 2007

Case Studies on Plant Maintenance

HIMER National Conference-2007, the Sixteenth, was held at GRT Convention Centre,T. Nagar, Chennai on Nov. 28 to 30.

Mr C. Perumal, Manager, HIMER welcomed the gathering of maintenance professionals from around the country.

The Conference was inaugurated by Mr. G. Ravishankar, Head, Business Development, Hofincons.

Around 14 papers were presented by maintenance engineers from various sectors of Indian industries on implementation of modern maintenance practices to improve plant reliability, availability and maintainability
  • Simple, cost-effective, innovative and ingenious solutions for repetitive problems.
  • Application of failure analysis to eliminate problems that reduce profitability
  • Use of predictive maintenance techniques to solve potential disasters
  • Experiences in implementing RCM and Six Sigma practices.
The technical sessions were chaired by Mr B. Thangavel, an eminent professional from the fields of maintenance, inspection and NDT (formerly Maintenance Chief, Nuclear Power Corporation of India Ltd). The papers were discussed and analysed by the participants, with exchange of information and expertise among them.

Presentation of Trophies

The trophies presented during this Conference were as follows.

Organisation Awarded to Paper/s presented
Hindalco Industries Limited, Renukoot 231217, District Sonbhadra (U.P.) Manoj Kumar Patwari, Deputy Manager, Alumina Instrumentation and Rajendra Kumar Agarwal Assistant Manager, Alumina Instrumentation Reliable level measurement in alumina refinery
Hindalco Industries Limited, Renukoot 231217, District Sonbhadra (U.P.) Arvind Kumar and Paresh Kumar Sharma, General Formen, Alumina Instrumentation Resolving frequent failure of control valve in alumina refinery
Reliance Energy Ltd - Dahanu Thermal Power Station, Dahanu 401 608 Prasad Rao, Station Head, Mahesh G Gawade -Manager (Maintenance) and Durgesh G. Kulkarni, Dy Manager (Maintenance) Innovative Maintenance Practices at Dahanu Power Station
Reliance Energy Ltd - Dahanu Thermal Power Station, Dahanu 401 608 Pavanraj S. Shinde and Dinesh R. Mantri, Managers – Control & Instrumentation Reliability improvement through Six Sigma – Reduction of electronic card failures at power station
Bharat Petroleum Corporation Limited, Mumbai 400074 Rajesh C Agarwal, Senior Maintenance Manager (Services) Dry gas seal and measures to improve its reliability
The participants were lavish in their praise of the HIMER Conference as the only forum for practising maintenance engineers of process and engineering plants to share, discuss and enhance their maintenance expertise and for recognizing their contribution to the process industry. Note: A few copies of the printed Conference Proceedings are available for Rs.500/- and the courier charges for the same will be approximately Rs.100/-.
LIST OF PAPERS WITH ABSTRACTS
S# Company Title Name of Author(s)
1 Bharat Petroleum Corporation Limited, Mumbai. Dry gas seal and measures to improve its reliability Rajesh C Agarwal Senior Maintenance Manager (Services)
2 Godavari Fertilisers And Chemicals Limited, Kakinada 533001, Andhra Pradesh Reducing costs through optimum maintenance practices M. Rajesh Manager (Maintenance)
3 Haldia Petrochemicals Limited, East Midnapore, West Bengal 721 602 Diagnostics of High-speed Gearbox of Propylene Feeding Drive in Petrochemical Plant Maidul Islam Naskar Engineer - Mechanical Inspection Sudipta Das Engineer - Mechanical Inspection
4 Hindalco Industries Limited, Renukoot 231217, District Sonbhadra (U.P.) Reliable level measurement in alumina refinery Manoj Kumar Patwari Deputy Manager, Alumina Instrumentation Rajendra Kumar Agarwal Assistant Manager, Alumina Instrumentation
5 Hindalco Industries Limited, Renukoot 231217, District Sonbhadra (U.P.) Resolving frequent failure of control valve in alumina refinery Arvind Kumar General Forman, Alumina Instrumentation Paresh Kumar Sharma General Forman, Alumina Instrumentation
6 Hindustan Petroleum Corporation Ltd – Mumbai Refinery, Mumbai 400074 Improving reliability of plant and machinery through customized maintenance B.G. Raghavendra Senior Engineer Maintenance
7 Indira Gandhi Centre for Atomic Research (IGCAR), Kalpakkam 603102 Experience in operation and maintenance of cooling towers Biswanath Sen Scientific Officer E C. Chandran Head, ACPS A.S.L.K. Rao Head, AC&VSD Y.C. Manjunatha Director
8 Indira Gandhi Centre for Atomic Research, Kalpakkam 603102 Failure analysis of spline shaft in large lathe V. Praveen Kumar Scientific Officer/D, (Central Workshop) S.K. Albert Scientific Officer/G, (Material Technology) R. Veluswamy Superintendent, (Central Workshop) A.S.L.K. Rao Head, (Central Workshop)
9 Indira Gandhi Centre for Atomic Research, Kalpakkam 603102 Commissioning and operating experience of Boiler Feed Pump in SGTF S.P. Pathak Scientific Officer/D V.A. Sureshkumar Scientific Officer/E S. Kishore Scientific Officer/D G. Madhusoodhanan Head, MSS, FRTG I.B. Noushad Head, SGTF (O&M) K.K. Rajan Head, Sodium Facilities Division (Steam Generator Test Facility, Fast Reactor Technology Group)
10 Reliance Energy Ltd - Dahanu Thermal Power Station, Dahanu 401 608 Innovative Maintenance Practices at Dahanu Power Station Prasad Rao Station Head Mahesh G Gawade Manager (Maintenance) Durgesh G. Kulkarni Dy Manager (Maintenance)
11 Reliance Energy Ltd, Dahanu Thermal Power Station, Dahanu 401 608 Reliability improvement through Six Sigma – Reduction of electronic card failures at power station Pavanraj S. Shinde Manager – Control and Instrumentation Dinesh R. Mantri Manager – Control & Instrumentation
12 Reliance Industries Limited, Hazira Role of Purchase and Contracts in Success Shut Down Management L. Santhanam Senior Vice President (P & C)
13 Reliance Industries Limited, Surat, Gujarat Case Studies on Maintenance Cost Optimization, Prevention, Troubleshooting and Reliability N.K. Keshava Prasanna Vice President, Hazira Manufacturing Division
14 Tata Motors Limited, Pantnagar Plant, Uttarakhand Setting of Maintenance Management Process at TATA Motors new Pantnagar Plant N.B. Tilak Assistant General Manager, CMS V.V. Joshi Assistant General Manager, CEPD
Paper 01
Dry gas seal and measures to improve its reliability
Rajesh C Agarwal
Senior Maintenance Manager (Services)
Bharat Petroleum Corporation Limited, Mumbai.
Abstract
Dry gas seals have been applied in process gas centrifugal compressors for over 25 years. Over 80% of centrifugal gas compressors manufactured today is equipped with dry gas seals. This paper provides details of dry gas seals/sealing systems and measures to improve dry gas seal reliability
Paper 02
Reducing costs through optimum maintenance practices
M. Rajesh
Manager (Maintenance)
Godavari Fertilisers And Chemicals Limited, Kakinada 533001, Andhra Pradesh
Abstract
The major challenge is to balance the contradictory situation of maintaining aging equipment to give full production while reducing the cost of maintenance. This is achieved through re-engineering, innovations and skill development of employees. This paper attempts to give the maintenance practices followed at GFCL towards this aim.
Paper 03
Diagnostics of High-speed Gearbox of Propylene Feeding Drive in Petrochemical Plant
Maidul Islam Naskar
Engineer - Mechanical Inspection
Sudipta Das
Engineer - Mechanical Inspection
Haldia Petrochemicals Limited, East Midnapore, West Bengal 721 602
Abstract
Liquid hydrocarbons in petrochemical plants are fed through very high speed straight vane centrifugal pumps, running at speeds of 7000 to 14000 rpm. Such speeds are achieved through step-up gearboxes, which if fail could cause substantial loss. One such gearbox for propylene feed pump of HPL is the subject of this paper and describes a case study with the logical steps in vibration monitoring
Paper 04
Reliable level measurement in alumina refinery
Manoj Kumar Patwari
Deputy Manager
Rajendra Kumar Agarwal
Assistant Manager
Alumina Instrumentation
Hindalco Industries Limited, Renukoot 231217, District Sonbhadra (U.P.)
Abstract
Alumina plant process uses many closed pressurized vessels like digestors and flash tanks. These vessels carry bauxite slurry of around 45% solid. Level measurement is essential for vessel level control. This paper describes the efforts made to reduce maintenance activities during cleaning and replacement of the dip tubes of DP transmitters under difficult process conditions to avoid errors in level measurements. The team had innovatively designed the dip tubes line and the tapping assembly so that it can be easily removed during tank overhauling and fitted back after maintenance.
Paper 05
Resolving frequent failure of control valve in alumina refinery
Arvind Kumar Rajendra Kumar Agarwal
General Formen, Alumina Instrumentation
Hindalco Industries Limited, Renukoot 231217, District Sonbhadra (U.P.)
Abstract
This paper aims to highlight the efforts made to reduce the frequent failures of excess steam line control valve due to jamming in an alumina refinery. Process includes auto cyclic operation of control valves once in a day from DCS through control logic as per defined output set values. Cyclic operation of control valves breaks the slurry scale and avoids jamming of control valves.
Paper 06
Improving reliability of plant and machinery through customized maintenance
B.G. Raghavendra
Senior Engineer Maintenance
Hindustan Petroleum Corporation Ltd – Mumbai Refinery, Mumbai 400074
Abstract
This paper discusses the frequent failure of the mechanical seals of booster pumps handling de-asphalted oil and propane in a lub refinery and how it was solved as a team. The root cause was suspected to be the formation of vapour pressure between mechanical seals as pump suction pressure almost matches with the vapour pressure of propane, resulting in dry run between the seal faces.
Paper 07
Experience in operation and maintenance of cooling towers
Biswanath Sen C. Chandran A.S.L.K. Rao Y.C. Manjunatha
Scientific Officer E Head, ACPS Head, AC&VSD Director
Engineering Services Group
Indira Gandhi Centre for Atomic Research (IGCAR), Kalpakkam 603102
Abstract
This paper highlights operation and maintenance experience of cooling towers at Central Water Chilling Plant of IGCAR. It focuses upon the importance of revamping and up-gradation of cooling tower and management of water quality to improve the performance and save energy. Also, the experience gained in installation of non-chemical water treatment system for control of scale, corrosion and micro organism growth is highlighted.
Paper 08
Failure analysis of spline shaft in large lathe
V. Praveen Kumar Scientific Officer/D S.K. Albert Scientific Officer/G R. Veluswamy Superintendent A.S.L.K. Rao Head
Central Workshop Material Technology Central Workshop
Indira Gandhi Centre for Atomic Research, Kalpakkam 603102
Abstract
This paper discusses the failure analysis conducted to find out the root cause for fracture of a spline shaft in a heavy duty lathe. During machining of a job of large diameter, the tool post had a collision with the rotating chuck and the lathe stopped functioning abruptly. It was observed that the spline shaft inside headstock was broken into two pieces. The cracking had initiated from the circlip groove, however, it is unlikely that the collision alone could have caused such a failure. So a detailed analysis was done to ascertain the exact causes of failure. The normal practice followed to stop the lathe quickly was to reverse the direction of spindle rotation. Detailed stress analysis conducted showed that this could have led to stress levels at the circlip groove that exceeded far above the fatigue limit for the material. Examination of the fracture surfaces revealed partial damage of the surfaces due to their rubbing in operation and cleavage fracture, both inter- and intra-granular, in the remaining part of the surfaces. It is concluded that the frequent reversing of the spindle rotation, notch effect at circlip groove, collision of tool post with the chuck, all together contributed to the failure of the spline shaft.
Paper 09
Commissioning and operating experience of Boiler Feed Pump in SGTF
S.P. Pathak V.A. Sureshkumar S. Kishore G. Madhusoodhanan I.B. Noushad K.K. Rajan
Scientific Officer/D Scientific Officer/E Scientific Officer/D Head, MSS, FRTG Head, SGTF (O&M) Head, Sodium Facilities Division
Steam Generator Test Facility, Fast Reactor Technology Group
Indira Gandhi Centre for Atomic Research, Kalpakkam 603102
Abstract
Steam Generator Test Facility is an experimental facility for testing a model sodium-heated once-through steam generator producing steam at 10.5 m3/h, 172 bar, 493C and is rated for 5.5 MWt. Due to non-availability in the market for such low flow pumps, it utilizes a boiler feed pump whose best efficiency point flow is 63m3/h and the minimum operating flow is 20m3/h. Pump operating flow was chosen as 20 m3/h with automatic recirculation. During commissioning, higher vibration and gradual increase in balancing leak off pressure (BLO) were observed. These were solved. After only 700 hours of cumulative operation of the pump, abnormalities such as high BLO pressure, higher vibration and tripping of pump on motor overload were observed. Rotor erosion was attributed as the cause and the pump was overhauled. This paper discusses the operating experience and modifications carried out to improve the performance of the pump
Paper 10
Innovative Maintenance Practices at Dahanu Power Station
Prasad Rao Station Head Mahesh G Gawade Manager (Maintenance) Durgesh G. Kulkarni Dy Manager (Maintenance)
Reliance Energy Ltd - Dahanu Thermal Power Station, Dahanu 401 608
Abstract
This paper describes the maintenance philosophy and the long term maintenance policies being followed at DTPS, pivotal in achieving lower downtimes, higher availability and PLF and higher fuel efficiency. The paper also discusses the equipment criticality analysis, risk assessment and FMEA that identify critical and risk prone equipments from others and suggest extensive monitoring measures to save the plant from unforeseen failures. The key performance indicators are also discussed, which are the driving and motivating forces towards achieving effective maintenance management.
Paper 11
Reliability improvement through Six Sigma –
Reduction of electronic card failures at power station
Pavanraj S. Shinde Dinesh R. Mantri
Managers, Control and Instrumentation
Reliance Energy Ltd, Dahanu Thermal Power Station, Dahanu 401 608
Abstract
This paper describes the innovative maintenance philosophy and practices regarding various equipment/systems installed at DTPS. There are total 6900 electronic cards in this station. Failure of any card leads to process un-stability, equipment tripping or unit tripping. So this problem is directly linked to generation loss and which in turn related to direct financial loss of DTPS. This paper presents the various innovative ways adopted at DTPS to reduce the card failure rate substantially.
Paper 12
Role of Purchase and Contracts in Successful Shutdown Management
L. Santhanam
Senior Vice President (P & C) –Reliance Industries Limited, Hazira
Abstract
This paper illustrates the role of the purchase and contracts functions in proper planning and execution of shutdown in a process plant. This includes scheduling, deciding on scope and manpower, routine preparations, internal costing, the supply chain elements, vendor data base, selection of suitable vendors, management, awarding of contracts, monitoring, administration, documentation and closing. A detailed discussion of the related issues would be of interest to maintenance professionals.
Paper 13
Case Studies on Maintenance Cost Optimization,
Prevention, Troubleshooting and Reliability
N.K. Keshava Prasanna Vice President, Hazira Manufacturing Division
Reliance Industries Limited, Surat, Gujarat
Abstract
Maintenance cost optimization, maintenance prevention, and the journey towards equipment reliability are discussed in this paper. When there are repetitive failures, a review of the design factors would be worthwhile. Also, planning and prioritization help to reduce maintenance costs. Application of preventive engineering as applied to design review, dimensions, material of construction, processes, and vendors would also contribute to maintenance prevention. Troubleshooting in industry needs not just technical knowledge but also leadership skills. Several case studies are presented by the author to underscore the above points which illustrate how we can proceed to enhance equipment reliability.
Paper 14
Setting of Maintenance Management Process at TATA Motors new Pantnagar Plant
N.B. Tilak
Assistant General Manager, CMS
V.V. Joshi
Assistant General Manager, CEPD
Tata Motors Limited, Pantnagar Plant, Uttarakhand
Abstract
TATA Motors is a large manufacturing unit consisting of various factories across the globe and for manufacturing a range of automobiles from cars, utility vehicles to trucks and earth moving equipment. The construction work at Pantnagar Plant had started from April 2006 and the first ACE vehicle was rolled out in March 2007. Unlike the existing plants, a new strategy of ‘Vendor Park’ is adopted and the complete plant is started as an independent unit from the day-one. To design, build, operate and maintain this new plant with the latest technology machines and equipments, a strategy was formulated with the acquired experience over the past 60 years. A systematized approach of Early Plant Management (from planning to maintenance) not only helps to reduce the costs, but also provides an opportunity for the company to elevate its own level of competency and self-sufficiency.
Feedbacks received from the participants
Experience sharing helped gained knowledge. R.C. Agarwal, BPCL, Mumbai
Good knowledge sharing platform.  Suggestions for problem solving. L. Santhanam, Reliance Industries, Hazira
In present scenario, sharing of technical expertise by different group will definitely help us in day-to-day activities.  This is really a nice conference where we have discussed technical matters freely. S.P. Pathak, IGCAR, Kalpakkam
Problem of various fields and management techniques were discussed in details.  Case studies were very interesting.  The experience will certainly help us in future maintenance practice. Biswanath Sen, IGCAR, Kalpakkam
Definitely the conference  has helped me in enhancing my knowledge on various maintenance management skills which have to be implemented at the conceptual stage itself. V. Praveen Kumar, IGCAR, Kalpakkam
HIMER has provided a platform for industry to share and learn the experience. It is a good indicator of happenings across industry.  
Sharing the knowledge/experience enriches your self.  Good practices can be learnt and practiced. V.V. Joshi, Tata Motors, Uttarakhand
It is an open platform to share our views and exchange the ideas with each other Manoj Patwari, Hindalco, Renukoot
This conference help us to improve strategy to optimize maintenance cost and do some Six Sigma project. Paresh Kumar Sharma
We can implement the modification which are executed successfully in other companies/organization, which we come to know through HIMER seminar. B.G. Raghavendra, HPCL, Mumbai Refinery, Mumbai
Different organization experience on the job.  Different maintenance policies.  Different modes of motivation of technicians and lower staff. S.K. Chaurasia, Tarapur Atomic Power Station, Tarapur
New O & M practices. Innovative methods.  All round efforts. Dinesh R Mantri, Reliance Energy, Dahanu.
It has broadened our vision.  We interacted with various industries and it was a knowledgeable experience. Durgesh G Kulkarni, Relilance Energy, Dahanu
First time I have learnt about a new technique.  Current signature analysis to detect MOV problem.  This technique I want to implement in my plant.  So many ideas from maintenance point of view. Md. Maidul Islam Naskar, Haldia Petrochemicals, Haldia
I am very much excited to listen the different case studies which will help me to conclude any decision in my professional life. Sudipta Das, Haldia Petrochemicals, Haldia
On the third day few of the presentations were good.  Tips taken from these presentations are useful in day-to-day maintenance activities. N.K. Keshava Prasanna, Reliance Industries, Hazira
 
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