TRAINING MODULE ON INSPECTION, MAINTENANCE & CAPITAL BUDGET

1. TRAINING MODULE ON INSPECTION, MAINTENANCE & CAPITAL BUDGET

2. 1.0 ROLE OF M & R IN OPERATIONS TERMINAL / DEPOT STRATEGY MAINTENANCE OBJECTIVE OPERATIONS STRATEGY MAINTENANCE STRATEGY

3. M&R IS A COMPLEMENTARY FUNCTION TO OPERATIONS MAINTENANCE OBJECTIVES ARE DERIVED FROM OVER ALL TERMINAL STRATEGY AS WELL AS OPERATIONS STRATEGY 1.0 ROLE OF M & R IN OPERATIONS

4. 2.0 BROAD M & R OBJECTIVES ENSURE MAXIMUM AVAILABILITY OF PLANT/EQUIPMENT AT OPTIMUM LEVEL OF OPERATIONS STRIVE TO INCREASE THE LIFE SPAN OF PLANT/EQUIPMENT ENSURE SAFETY OF PERSONNEL & EQUIPMENT

5. IDENTIFY AND IMPLEMENT PROJECTS FOR PROCESS IMPROVEMENTS/COST REDUCTIONS MINIMIZE CONSUMPTION OF RESOURCES (ENERGY, WATER ETC.) OPTIMIZE COST OF MAINTENANCE STORES (INVENTORY CONTROL ON SPARES & CONSUMMABLES) MAINTAIN ACCURATE & UP TO DATE MAINTENACE RECORDS 2.0 BROAD M & R OBJECTIVES

6. 3.0 MAINTENANCE STRATEGY ASPECTS UNDER M&R STRATEGY 3.1 HUMAN RESOURCES- WHO WILL DO? IN HOUSE (OWN EMPLOYEES) THRU CONTRACTOR/VENDOR THRU OEM / AUTHORISED SERVICE AGENT (CRITICAL EQPT. VIZ DG SET, FIRE PUMPS ETC.)

7. 3.0 MAINTENANCE STRATEGY 3.2 TOOLS, EQUIPMENTS AND CONSUMABLES & SPARES- WHAT WE REQUIRE? TOOLS (SPANNERS,HAND DRILLS Etc.) PPE’S (HELMETS,SAFETY BELT Etc.) INSTRUMENTS (MEGGER,MULTIMETER Etc.) LUBRICANTS ( OILS ADVISED BY OEM) HARDWARE (NUTS, BOLTS, GASKETS Etc.) EQUIPMENT SPARES FITTINGS (BENDS,ELBOWS Etc.)

8. 3.0 MAINTENANCE STRATEGY 3.3 PURCHASING HOW DO WE PROCURE THE MATERIALS? PURCHASE INFORMATION PURCHASE PROCEDURES LIST OF VENDORS INSPECTION PROCEDURES

9. 3.0 MAINTENANCE STRATEGY 3.4 STORAGE OF METERIALS – WHERE & HOW TO KEEP? STORAGE SPACE (ENGINEERING WAREHOUSE) PRESERVATION METHODS (TO ENSURE THAT THE ITEM IS KEPT IN USABLE CONDITION.) INVENTORY CONTROL

10. 3.0 MAINTENANCE STRATEGY 3.5 DOCUMENTATION AND TRAINING HOW TO CARRY OUT THE JOB? PROCEDURES MANUALS HISTORY CARDS & CHECK LISTS LOG BOOKS

15. 3.0 MAINTENANCE STRATEGY 3.6 MAINTENANCE PLANNING SEGMENTATION OF INFRASTRUCTURE (PLANT/EQUIPMENT) INTO SUBSYSTEMS TYPE OF MAINTENANCE AND SELECTION FOR INDIVIDUAL SEGMENTS DEVELOPING MAINTENANCE PLAN FOR INDIVIDUAL SUBSYSTEMS DEVELOPING PERIODIC MAINTENANCE SCHEDULES EXECUTION OF JOB DOCUMENTATION

16. 3.6.1 SEGMENTATION OF INFRASTRUCTURE OM & S (OIL MOVEMENT & STORAGE SUBSYSTEM) ELECTRICAL SUPPLY SUB SYSTEM (ESS) FIRE & SAFETY SUB SYSTEM COMMUNICATION SUB SYSTEM COMPANY VEHICLES SUB SYSTEM TERMINAL AUTOMATION SUB SYSTEM BUILDINGS, ROADS & OTHERS SECURITY SUB SYSTEM CUSTOMER CARE EQUIPMENTS

17. OM & S (OIL MOVEMENT & STORAGE SUBSYSTEM) STORAGE TANK & TANKFARM PIPELINES PUMPS GANTRIES METERING SYSTEMS

18. ELECTRICAL SUPPLY SUB SYSTEM (ESS) SWITCH YARD TRANSFORMERS CABLES EARTHING SYSTEMS VARIOUS CONTROL PANELS MOTOR CONTROL CENTRE LIGHTING & FLP FITTINGS BATTERIES & UPS CAPACITOR BANKS DG SETS • FOLLOW OISD – 137 TOTALLY • GET ELECTRI CAL SAFETY AUDIT ONCE IN 3 YEARS

19. FIRE & SAFETY SUB SYSTEM FIRE ENGINES FOAM SYSTEM HYDRANT LINE & VALVES MOBILE FOAM TENDER FIRE EXTINGUISHERS PPE’S (PERSONAL PROTECTIVE EQUIPMENT) MONITOR, HYDRANTS & SPRINKLERS • FOLLOW OISD – 142, 155 & 117 STRICTLY.

20. COMMUNICATION SUB SYSTEM EPABX WIRELESS/WALKIE-TALKIE LAN/WAN TELEPHONE/FAX

21. COMPANY VEHICLES SUBSYSTEM TANK TRUCKS OTHER NON-EARNING VEHICLES

22. TERMINAL AUTOMATION SUB SYSTEM TANKFARM MODULE FIRE PUMP HOUSE AUTOMATION PUMP HOUSE AUTOMATION TANK TRUCK LOADING MODULE

23. BUILDINGS, ROAD & OTHERS BUILDINGS DRIVE WAYS RAILWAY TRACK OFFICE EQUIPMENTS

24. SECURITY SUB SYSTEM PERIMETER WALL GATES METAL DETECTOR OTHER EQUIPMENTS

25. CUSTOMER CARE EQUIPMENTS LABORATORY CALIBRATION TOWER PROVERS

26. 3. 6.2 TYPE OF MAINTENANCE BREAK DOWN MAINTENANCE ROUTINE MAINTENANCE PLANNED MAINTENANCE PREVENTIVE MAINTENANCE PREDICTIVE MAINTENANCE MAJOR MAINTENANCE CAPITAL MAINTENANCE

27. 3. 3.6.2.1 BREAKDOWN MAINTENANCE PHYSICAL EQPT. COMMISSIONED EQPT. IN SERVICE ABNORMALITY/ BREAK DOWN NOTICED RECTIFIED & PUT BACK RECORD HISTORY CARD GENERATED ROOT CAUSE ANALYSIS & DETAILS ENTERED

28. BREAKDOWN MAINTENANCE ADVANTAGES NEEDS VERY LESS TIME, LESS ROUTINE EXPENDITURE DISADVANTAGES • 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 MAINTENANCE SUITABILITY 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, PROBLEMS FOR FURNITURE ETC.

30. 3.6.2.2 ROUTINE MAINTENANCE PHYSICAL • EQUIPMENT COMMISSIONED • SIMPLE SERVICE AT REGULAR INTERVALS. • BREAKDOWNS, IF ANY ARE RECTIFIED RECORD • HISTORY CARD GENERATED • HISTORY CARD UPDATED • ROOT CAUSE ANALYSIS & DETAILS ENTERED

31. ROUTINE MAINTENANCE ADVANTAGES THE EQUIPMENT/FACILITY GETS INSPECTED AT REGULAR INTERVALS. ABNORMAL CONDITIONS CAN BE IDENTIFIED BEFORE CRISIS. NEEDS LESSER TIME. SERVICE COST CAN BE BUDGETED.

32. ROUTINE MAINTENANCE DISADVANTAGES BREAKDOWNS CAN NOT BE ELIMINATED INVOLVES HIGH EXPENDITURE AT IRREGULAR INTERVALS AND MINIMAL EXPENDITURE AT ROUTINE INTERVALS SUITABILITY • COMPUTERS, WALKIE-TALKIE SETS, PRINTERS, AIR-CONDITIONERS AND OTHER OFFICE EQUIPMENTS LIKE FAX, XEROX, EPABX ETC.

33. 3.6.2.3 PLANNED MAINTENANCE RECORD • HISTORY SHEET CREATED. • MAINTENANCE PLAN & PERIODIC SCHEDULE DRAWN • INSPECTION CHECK LIST FILLED UP AND HISTORY SHEET UPDATED PHYSICAL • EQUIPMENT COMMISSIONED • PLANNED MAINTENANCE & INSPECTIONS AT FIXED TIME SCALE.

34. THE EQUIPMENT IS INSPECTED CLOSELY AT REGULAR INTERVALS. CERTAIN MINOR ACTIVITIES LIKE LUBRICANTS, OIL CHANGE, CLEANING, REPLACEMENT OF GASKETS ETC ARE CARRIED OUT PLANNED MAINTENANCE

35. 3 PLANNED MAINTENANCE ADVANTAGES BREAK DOWNS ARE MINIMAL & HENCE BREAKDOWNS COSTS ARE LESS. BETTER LIFE SPAN IN VIEW OF REGULAR INSPECTIONS. BETTER ESTIMATION OF MAINTENANCE COST. BETTER INVENTORY CONTROL OF SPARES, LUBES INVENTORY.

36. PLANNED MAINTENANCE DISADVANTAGES NEEDS MORE TIME (MANY ACTIVITIES) REQUIRES MORE RESOURCES REQUIRES SHUTDOWN NEEDS HIGHER LEVEL OF PLANNING SUITABILITY • GANTRIES, VALVES, VEHICLES, RAILWAY TRACK, FIRE EXTINGUISHERS, METERS, STRAINERS, STORAGE TANKS

37. 3.6.2.4 PREVENTIVE MAINTENANCE IN THIS TYPE, THE MAINTENANCE SCHEDULES ARE DRAWN AS PER REQUIREMENT BY MANUFACTURER/STANDARDS ADVANTAGES • REMOTE POSSIBILITIES OF BREAKDOWNS. • BETTER ESTIMATION OF EXPENDITURE. • HIGHER RELIABILITY OF EQUIPMENT.

38. PREVENTIVE MAINTENANCE DISADVANTAGES VERY HIGH REQUIREMENT OF HUMAN RESOURCES. ROUTINE COSTS WILL BE HIGHER FOR MAINTENANCE. REQUIRES MORE DOCUMENTATION.

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

40. PREDICTIVE MAINTENANCE PREDICTIVE MAINTENANCE IS BASED ON CONDITION MONITORING OF EQUIPMENT AND IT REQUIRES SOPHISTICATED EQUIPMENT FOR MONITORING CONDITION OF EQUIPMENT E.g: MONITORING PUMP PERFORMANCE USING VIBRATION ANALYSIS MONITORING OF BEARING CONDITION USING VIBRATION AND TEMPERATURE. THIS PRACTICE IS EXPLAINED IN OISD-124

41. PREDICTIVE MAINTENANCE ADVANTAGES SIMILAR TO PREVENTIVE MAINTENANCE DISADVANTAGES • IT REQUIRES SOPHISTICATED INSTRUMENT FOR CONDITION OF MONITORING SUITABILITY • THIS IS SUITABLE FOR ROTARY EQPT.

42. 3.6.2.6 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 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 NPCB

44. 3.6.3 DEVELOPING MAINTENANCE PLAN PLAN TO BE DEVELOPED FOR PLANNED MAINTENANCE, PREVENTIVE MAINTENANCE & PREDICTIVE MAINTENANCE. PLAN SHALL BE SPECIFIC FOR A PARTICULAR SUBSYSTEM PLAN SHALL ADDRESS THE REQUIREMENTS OF INDIVIDUAL EQUIPMENTS UNDER THE SUBSYSTEM

45. DEVELOPING MAINTENANCE PLAN THE PLAN SHALL INCLUDE THE FOLLOWING SUBSYSTEM TYPE OF M&R STANDARDS APPLICABLE INDIVIDUAL EQUIPMENTS WHO WILL DO THE ACTIVITY PURCHASE/PROCUREMENT PLAN REFERENCE TO DOCUMENTATION

46. 3.5 DOCUMENTATION ASSET LISTING MAINTENANCE SCHEDULE SPARES LUBE USED HISTORY CARD PURCHASE M&R ACTIVITIES MIS REPORTS OPER. DETAILS BREAKDOWN ANALYSIS

47. 3.6.4 DEVELOPING PERIODIC MAINTENANCE 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 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 DOCUMENTATION DOCUMENTATION TO BE DESIGNED IN LINE WITH PLAN WITH LINKAGES WHEREVER REQD. TO TAKE CARE OF THE REQUIREMENTS OF INDIVIDUAL EQUIPMENTS.