The document outlines the maintenance practices and performance overview of rotary and static equipment at BORL, emphasizing the optimization of maintenance costs and enhancement of equipment reliability. It details the structure of mechanical maintenance, condition monitoring practices, and the categorization of equipment based on criticality. Key achievements include improved lubrication reliability, maintenance innovations, and proactive maintenance programs that have significantly reduced seal and bearing failures.

1.  Understanding Maintenance Practices at BORL
 Performance Overview
 Condition Monitoring Practices
 Few Achievements and Innovations
OBJECTIVES

2. A total population of 2021 Rotary & _____ Static equipment is
there in BORL including refinery process units as well as in CPP,
utilities & BDT.
Mechanical maintenance responsibilities:
• Strive for maximizing the equipment availability
• Implementation of best maintenance practices & strategies
• Optimizing the maintenance cost
• Providing emergency support
Mechanical Maintenance –An overview

3. • Maintenance planning
• Field maintenance
• Central workshop
• Rotary maintenance
• Condition monitoring
Mechanical Maintenance Structure

4. • Centralized maintenance planning
• SAP supported plant maintenance
• Equipment performance monitoring
• Spares management system
Maintenance Systems

5. • Scheduling of daily jobs
• Turnarounds planning
• Spares management
• Contract management
• Budget preparation and monitoring
• MIS generation
PLANNING SECTION

6. • Execution of routine jobs related to static equipment
• Resource planning
• MOC Execution
• Loss prevention
• Inspection Recommendation
• Shutdown and turn around planning
• Extending support to electrical and instrument
Field Maintenance Function

7. 7
SURFACE GRINDER
RADIAL DRILLING MACHINE
MILLING MACHINE
WORKSHOP

8.  LLF with preliminary vibration & temperature monitoring
 PM scheduled as per criticality indexing
 Predictive Maintenance Based on CM
 RCFA for atypical and major failures
Rotary Maintenance Overview

9. The Rotary equipment are categorized based on their criticality
and according to this the maintenance scheduling is fixed.
Factors considered for criticality indexing:
• Safety, Health & Environment/Statutory requirement
• Process Related
• Maintenance related
• Statistical Factor ‐ a) Reliability related b) Condition
Monitoring
Based on above factors all rotary equipment are categorized as
• Critical
• Semi-Critical
• Non-Critical
Equipment Classification and Critical
Indexing

10. Equipment's
class
Preventive
maintenance
Condition
monitoring
Lube oil
monitoring
Critical Quarterly Weekly Monthly
Semi-Critical Half Yearly Fortnightly Bi-Monthly
Non-Critical Annually Monthly Quarterly
PM & CM Scheduling based on
Equipment Criticality

11.  Availability > 99%
 PM Compliance > 95%
 CM Based PdM & Focus area identification
 Planned Maintenance > 99%
KEY PERFORMANCE INDEX

12. SEAL FAILURE IN NUMBERS
32
6
15
10
1
6
7
15
4
6
13
1
13
11
13
3
10
4
1
7
8
7
6
5
4
2
11
8
0
5
10
15
20
25
30
35
CDU/VDU MSB HCU DCU HGU SRU OFFSITE
N
O
.
O
F
S
E
L
A
S
UNITS
No. Of Seal Failure
2013-14
2014-15
2015-16
2016-17

13. Seal Failure Trend
since Jan-2013
0
2
4
6
8
10
12
14
16
Jan-13
Feb-13
Mar-13
Apr-13
May-13
Jun-13
July-13
Aug-13
Sep-13
Oct-13
Nov-13
Dec-13
Jan-14
Feb-14
Mar-14
Apr-14
May-14
Jun-14
July-14
Aug-14
Sep-14
Oct-14
Nov-14
Dec-14
Jan-15
Feb-15
Mar-15
May-15
Jun-15
Jul-15
Aug-15
Sep-15
Oct-15
Nov-15
Dec-15
Jan-16
Feb-16
Mar-16
Apr-16
May-16
Jun-16
Jul-16
Aug-16
Sep-16
Oct-16
Dec-16
Jan-17
Feb-17
Mar-17
Apr-17
May-17
Jun-17
Seal Failure Trend

14.  In house Mechanical seal cartridge
Repair and testing facility
 Seal face lapping machine
 Flatness checking by optical flat
under monochromatc light
 Bellow vacuum testing machine
Mechanical Seal Reconditioning and Testing
Facility

15. Bearings Failure Pattern & RCFA at BORL
FATIGUE
16%
Lub Contamination
45%
Rusting
13%
Uneven Loading
14%
Installation Defect
3%
ZZ BRG. FAILURE
2%
MISC. FAILURE
7%
Bearing Failure pattern Based on RCFA data carried
out Since Sep2014

16. TOTAL DRIVER – 1450
TOTAL DRIVEN - 1450
Bearing Failure Trend Curve For last 01 Year
11
9
12
21
16
20
10
8
6
10
8
6
10
9
5
7
8
7
12
4
5
2
3
5
3
4
2
4
5
13
9
8
6
3
4
7
3 3
6
0
5
10
15
20
25
May-16 Jun-16 Jul-16 Aug-16 Sep-16 Oct-16 Nov-16 Dec-16 Jan-17 Feb-17 Mar-17 Apr-17 May-17 Jun-17
No of Bearing Failures
Average Bearing failure Rate
Driven Bearing Failure
Driver Bearing Failure

17. CONDITION MONITORING PRACTICES

18. Improved Proactive Program at BORL
RELIABILITY BASED PROGRAM
Data Collection Fault
Diagnostics
Problem
Identification
Recommend
Action
Suggest
Improvements/
Modifications
* Carry out RCFA
* Failure Pattern
Study
IMPROVED
RELIABLITY

19. Lube Oil Monitoring
In-House Patch Test Program and Lube oil conditioning
Lube oil patch test
BORL CM LAB – OVERVIEW AND ACTIVITIES

20. Progressive Improvement in Lubrication
Reliability Since 2014
* Data based on RCFA of failed bearings
0
10
20
30
40
50
60
70
80
90
100
2014 2015 2016 2017
Overall
Driven
Linear (Overall)
% Bearing failure rate due to lubricant contamination
88 82
59 74
53 53 46 53

21. Mechanical Defects Simulation Kit
 In-house development
 Used for imparting Practical training
 Mechanical defects can be induced in the Kit
TRAINING & DEVELOPMENT FACILITIES AT CM LAB

22. MEASURES TAKEN FOR IMPROVING
LUBRICATION RELIABILITY
Introduction of LMS- Lubrication management system
• Use of color coded
drum stands
• Use of color coded
oil dispensers

23. MEASURES TAKEN FOR IMPROVING LUBRICATION
RELIABILITY
• Use of Desiccant air
breathers on drums &
equipment to increase
the life of lube oil
• Use of grease dispensing
system to avoid wastage
and spillage
• Using online oil condition
monitoring bottles for
quick checking

24. Awareness campaign to improve lubrication awareness till
ground staff
• Porta-cabin
sessions
• Experts visit
• Banner displays
MEASURES TAKEN FOR IMPROVING
LUBRICATION RELIABILITY

25. 25
INNOVATIVE WAY TO REPLACE CCR REACTOR CENTRE
PIPE SUPPORT
4 Chain pulley block of
equal run placed for lifting
the center pipe
A gap of 12mm was made
by lifting the center pipe
for placing the gasket
Gasket in four pieces with
dove-tail joints was placed
from top of reactor 2

26. DE-BOTTLENECKING – NGC CYLINDER HEAD
MODIFICATION
ORIGINAL COMPRESSION ACHIEVED
Modified Cylinder
Head without
clearance pocket
CLEARANCE
POCKET
BLINDED
Rated Capacity achieved,
Switched to Single

27. Improvement Projects
• Prefab insulation on Coke drum-B
• Installation of Stepless capacity control system in HCU-MUG
• Magnetic drive pump for VR service
• Improvement in job accuracy and reducing MTTR by
implementing Laser Alignment.
• Internal gear pump for Molten Sulfur application in SRU
PROSPECTIVE PLANNING

28. 6/18/2024

29. EQUIPMENT OVERVIEW
Equipment Type CDU/VDU DCU HCU MSB OFFSITES SRU HGU CPP CHP RWTP Plant Air /Nitrogen RODM ETP BDT Total
Centrifugal pumps 77 52 77 59 37 45 8 31 4 26 - 63 43 52 574
Metering pumps 27 12 9 22 - 10 8 10 - 24 - 41 30 - 193
Gear Pumps - - 22 4 - - - - - - - - - - 26
Vertical/Submersible pumps 8 6 6 10 5 19 9 23 - 21 - - 13 11 131
Screw Pumps 4 3 - 16 5 - - 22 - 6 - - 8 - 64
FD Fan 4 2 2 2 - - 2 6 - - - - - - 18
ID Fan 2 1 1 1 - - 1 3 - - - - - - 9
Fan for AFC 32 42 60 42 - 36 10 12 - 7 - - - - 241
Recip Compressors 3 - 3 8 - - 3 1 - - 3 2 2 - 25
Centrifugal Compressors - 1 1 1 - - - 3 - - 3 - - - 9
Turbines 1 4 8 4 - - - 6 - 1 1 - - - 25
Recip Pumps - - 2 - - - 1 - - - - - - - 3
Screw Compressors - - - 2 - - 2 7 3 - - - - - 14
Soot Blowers 54 32 46 62 - - - 96 - - - - - - 290
Centrifugal blowers - - - 3 - 6 - - - - - 3 - - 12
Mixers/Agitators 7 2 2 1 13 7 4 3 - 20 - 21 24 80 184
Diaphragm pumps - - - - - 7 - - - - - - - 7
Blower - - - - - - - 49 - 7 - 4 21 - 81
Engine - - - - - - - 1 - 5 - - - - 6
Centrifuge - 1 1 1 - - - 4 - - - 2 - 9
Gear Box - - 7 - 4 - - 20 16 21 - - - - 68
Crusher - - - - - - - - 3 - - - - - 3
Vibration Screen - - - - - - - - 2 - - - - - 2
Coal Feeder - - - - - - - - 24 - - - - - 24
Wagon Trippler - - - - - - - - 1 - - - - - 1
Stacker Reclaimer - - - - - - - - 1 - - - - 1
Appron feeder - - - - - - - - 1 - - - - - 1
Total 219 158 247 238 64 130 48 297 55 138 7 134 143 143 2021

30. • Replacement of checker wall with Blasch Hexwall
• Replacement of Imported maze sump pump with
indigenous vertical pump
• Replacement of plug type valve unloader with finger type in
HCU-MUG-B
• 14-PA-CF-110A/B Installation of modified mechanical seal
• 20-EA-00-101A-D, 19-EA-00-101A-D & 19-EA-00-
103A/D/E/H, Installation of wireless vibration monitoring
system
Achievements

31. CDU DCU MSB HCU HGU SRU OFFSITE
Total Centf pump
tags
56 36 59 49 9 38 25
w/o stand by 2 2 3 3 2 8 6
WORKING AND STAND BY COMPARISON

32. PM COMPLIANCE & EQUIPMENT AVAILABILITY
2016-17
80.0%
85.0%
90.0%
95.0%
100.0%
105.0%
110.0%
Actual PM Compliance
Cumulative PM Compliance
Availability