Param Express. Key Activities Concluded. Watch Out For

Transcription

1 Param Express Key Activities Concluded Second Workshop and interaction conducted form 16 th to 19 th May 2018 at Mumbai, with Reliability expert Chris James to review and refine the FMEA & Maintenance strategy for 7 critical equipment's. Core maintenance work i.e. Data cleansing, updating Task list in SAP started for next set of 13 equipment's of Phase B. Reliability day successfully conducted on 12th April; Site reliability day conducted at CGPL, Trombay, Jojobera & T&D. Kick of meeting with GE for RCM IT solution conducted on 9 th May 2018 & Orientation workshop conducted for GE APM tool; Design configuration is in progress. Conducted ~84 site RCM Immersion sessions (incl. HOD trainings) across all sites covering people. Watch Out For Data cleansing for next 13 equipment and uploading of cleansed data in SAP. Strong push on value initiatives across all sites. Finalization of Spares Management contract and development in SAP. Finalization of ORI tool vendor. Finalization & roll out of RCM-KPI dashboard. COI Meet is scheduled on 11th July at Dharavi Urja. Design & configuration of APM tool. Starting of Data Analytics project for each site under the guidance of IIT Powai professor in the month of July 2018.

2 Shutdown APC Tracker a CGPL value initiative Initiatives 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. Site Reliability Days celebrating work done so far & planning ahead Following the success of Central Reliability Day conducted on 12 th 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.

3 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 9 th 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

4 My Corner Conversations with you Mr. Kamal Bairwa, Tata Power established communities of interest to Technical Lead, RCM sustain the RCM way of working and make continuous Task Force improvement. We have COIs for all the critical 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

5 Answers for quiz of the month 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. Quiz of the Month Newsletter Quiz Two Truths One Lie Which are the two truths and one lie in each question? 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 future c. Higher reliability always translates to higher availability 3. Which of the following is not true about FMEA? a. FMEA creation is a one-time activity b. FMEA can be done both for equipment and processes both c. 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 Send your responses to paramsankalp@tatapower.com First three correct responses would be awarded.

6 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