Notore Chemical Industries Plc GE / P / 02
Rev. No.1
Title :Process For Rotary
General Engineering Rev Date :17.08.16
Inspection
Page : 1 of 7
1.0 OBJECTIVE: To ensure rotating equipment reliability,eliminate breakdown through the application of
modern inspection techniques, to detect equipment problems at an early stage,for accurate failure prediction and
application of sound corrective measures.
2.0 SCOPE:
Start:To carry out ECM schedule checks on rotating equipment.
End:Send reports / recommendation based on machinery acquired data.
3.0 RESPONSIBILITY & AUTORITY: General Engineering Manager is accountable for establishing, managing and continous improvement of this process.
4.0 PROCESS DEFINITION: SIPOC DIAGRAM
Process
Knowledge / Resources / Criteria / Method
Supplier Inputs Skills Technology Critical Activities for Control Output Customer Requirements
Machine CSI -2130 / Calibrate the CSI- Machinery
Critical / non- vibration Dynamix 2500, Data monitoring , 2130 machine health health
critical monitoring Machinery acquisition & analyzer on a yearly assessment
Production equipment. techniques. health analyzer analysis . basis. reports Production Timely response
AMS /
Vibration Emonitor -
Parameters and Machinery Data monitoring & ECM schedule / Abnormality Accurate feed
Production Work permit analysis skills. health manager analysis . review of schedule. report Maintenance back
The CSI 5200
Machinery
Complementary Health Oil
Technology ,like Analyzer (Mini- Machinery
Operation / Lube oil Oil Laboratory) Spectrographic & Calibrate the CSI- health
Technical Maintenance analysis,Infrared and Infrared Thermographic 5200 and Infrared assessment equipment
Services Manual thermography. Thermography analysis Camera. reports Maintenance availability.
Knowledge of
operating
Operation / parameters / Machinery health Condition
Instrument Maintenance equipment Equipment history monitoring Monitoring Accurate feed
Procurement Specifications Manual history. and trending. techniques. Equipment Warehouse back
Knowledge of Report /
operating Recommendation of Regular review of
Equipment Basic rotating parameters / checks carried out set alarm criteria
Condition equipment equipment on rotating specific to each Abnormality Maintenance
Maintenance Assessment principles. history. equipment. equipment. report / Production Timely response
Rotating
equipment
principles,
Condition
Monitoring and
Human Information on Reliability Regular review of Accurate feed
Resources Training Engineering. Dept.Budget Fund allocation Training Calendar Certification Inspection back
GE/ P / 02
Notore Chemical Industries Plc
Rev. No.1
Title :Process For Rotary
Inspection
General Engineering Rev Date :17.08.16
Page :2 of 7
5.0 INTERESTED PARTIES AND THEIR EXPECTATION:
Serial No. INTERESTED PARTIES INTERNAL / EXTERNAL NEEDS / EXPECTATION MONITORING / REVIEW
1 Production Internal Equipment availability / Reliabilty Ref. Process Performer Matrix 6.0
2 Maintenance Internal Analysis Report / Trouble shooting support Ref. Process Performer Matrix 6.0
3 Third Parties External Equipment data / Performance report Ref. Process Performer Matrix 6.0
Notore Chemical Industries Plc GE/ P / 02
Rev. No.1
Title :Process For Rotary
General Engineering Inspection Rev Date :17.08.16
Page :3 of 7
6.0 PROCESS MEASUREMENT MATRIX:
Measurement
Review
Type (Efficiency / Method of Record of
Serial No. Parameter Effectiveness) Unit of Measure Measurement Measurement Frequency Target Responsibility Frequency Forum
1 - Total list of
rotary equipment
covered in
schedule ,
2 -Total number of
equipment schedule
comprises
equipment in Unit meeting
running and idle
mode , as against
the plan,Calculated
on weekly basis.
3 -Data to be
collected from
AMS/Dynamix
Rockwell
Adherence to EMONITOR
ECM schedule software,and Pdm
of rotary Trackers.
1 equipment Efficiency percentage Pdm Tracker Weekly 80 Team Leader Monthly
1 - Reports
generated for all
abnormal
equipment and
communicated to
internal customer
on same day.
2 - Ratio of total Unit meeting
number of report
communicated on
same day to total
number of
abnormal equipmet
Abnormality identied on that
reports day.
communicated 3 - Data to be
to internal collected from ECM
customer within ( abnormality) ECM
2 24 hours Effectiveness percentage report. AbnormalityReport Weekly 100 Team Leader Monthly
1 - Percentage of
faults detected.
Unit meeting
2 - Ration of
Faults detected faults identified on
on the field and field ,communicated
communicated immediately, as
to internal against total faults
customer detected. ECM Log / ECM Engineer
3 immediately. Effectiveness percentage 1 - Equipment Production Log Weekly 100 /Superintendent Monthly
requiring
parameter setting.
2 - Total number of
equipment alarm Plant
review and setting management
done as against meeting
total number of
equipment
requiring review.
Review and
setting of alarm
parameter 3 - AMS
specific to each machinery manager ECM
4 equipment Efficiency percentage , CSI 2130 / Alarm Review Log. Quarterly 100 Superintendent Yearly
GE / P / 02
Notore Chemical Industries Plc
Rev. No.1
General Engineering
Rev Date :17.08.16
TITLE : PROCESS FOR ROTARY INSPECTION
Page : 4 of 7
7.0 PROCESS FLOW CHART:
ACTIVIT
PROCESS FLOW CHART RESPONSIBILITY
Y No.
START
GET INFORMATION ON
ECM ECM
1 SCHEDULE EQUIPMENT SCHEDULE (FIELD) ECM TEAM LEADER/ ENGINEER
LOG BOOK
FOR ECM
REQUEST FOR WORK A
2 F PERMIT ECM ENGINEER
F
A
NO
IS WORK
PERMIT REVISED SCHEDULED
APPROVED
3 ECM ENGINEER / PRODUCTION
YES
1.CSI 2130 / SELECT PARAMETER
2.DYNAMIX 2500 YES SWOT ANALYSIS
MACHINERY HEALTH TO BE MEASURED
ANALYZER 3.RISK SPECIFIC TO EACH
REGISTER
4.SWOT ANALYSIS EQUIPMENT IN THE
4 ANALYZER ECM ENGINEER
SOP FOR CSI SELECT
2130 / DYNAMIX
5 2500 ROCKWELL MEASUREMENT ECM ENGINEER
MACHINERY LOCATION
HEALTH
ANALYZER
WRITE THE
ACQUIRED
TAKE READING MACHINERY
6 CSI AND DATA ON ECM ENGINEER
2130/DYNAM TREND DATA. VIBRATION
BOARD
IX2500 DATA
COLLECTOR
DOWNLOAD THE AMS SUITE
SOP FOR CSI
2130 / DYNAMIX ACQUIRED MACHINERY
7 MACHINERY MANAGER / ECM TEAM LEADER / ENGINEER
2500 DATA
COLLECTOR DATA DYNAMIX 2500
ALLEN
BRADLEY SOFT
WARE
B
GE / P / 02
Rev. No.1
General Engineering
Notore Chemical Industries Plc
Rev Date : 17.08.16
TITLE : PROCESS FOR ROTARY INSPECTION
Page : 7 of 7
8.0 References:
S.NO. REFERENCE TITLE REFERENCE
NO
1 SOP FOR CSI 2130 MCHINERY HEALTH ANALYSER GE / S /35
2 SOP FOR DYNAMIX2500 ROCKWELL DATA COLLECTOR. GE / S/ 36
SOP FOR SUPPORTIVE TECHNOLOGY
3 SOP FOR CSI 5200 -MINI LAB. OIL ANALYSIS GE / S / 37
4 SOP FOR INFRARED THERMOGRAPHY GE / S / 38
5 SOP FOR ALARM LIMITS OF AMMONIA EQUIPMENT GE / S / 41
6 SOP FOR ALARM LIMITS OF UREA SYNTHESIS EQUIPMENT GE / S / 42
7 SOP FOR ALARM LIMIT OF GRANULATION EQUIPMENT GE / S / 43
8 SOP FOR ALARM LIMIT OF UTILITY EQUIPMENT GE / S / 44
9 SOP FOR ALARM LIMIT OF PRODUCT HANDLING EQUIPMENGE / S / 45
10 VIBRATION SEVERITY CHART GE / S / 46
11 CORRECTIVE MAINTENANCE MECH / P / 01
12 RISK REGISTER IAIC/F/P-02/07
13 SWOT ANALYSIS QM-9001-05
9.0 RECORDS:
RETENTION
PERIOD AT
S.NO. RECORD TITLE RECORD NO FILE NAME/ LOCATION MAINTAINED BY LEAST
GENERAL
VIBRATION INSPECTION ENGINEERING
1 VIBRATION SCHEDULE GE / F / P-02 / 01 SCHEDULE OFFICE MANAGER 2YRS
GENERAL
ECM (FIELD ) INSPECTION ENGINEERING
2 ECM(FIELD) LOG BOOK GE / F / P-02 / 02 LOG BOOK OFFICE MANAGER 2YRS
GENERAL
VIBRATION INSPECTION ENGINEERING
3 VIBRATION TRENDING REPORT GE / F / P-02 / 03 TREND REPORT OFFICE MANAGER 2YRS
GENERAL
ABNORMALITY INSPECTION ENGINEERING
4 ABNORMALITY REPORT GE / F / P-02 / 04 REPORT OFFICE MANAGER 2YRS
GENERAL
FOLLOW UP INSPECTION ENGINEERING
5 FOLLOW UP REPORT GE / F / P - 02 / 05 REPORT OFFICE MANAGER 2YRS
GENERAL
MONTHLY INSPECTION ENGINEERING
6 MONTHLY REPORT GE / F / P - 02 / 06 REPORT OFFICE MANAGER 2YRS
GENERAL
INSPECTION ENGINEERING
7 ECM DAILY REPORT GE / F / P -02 / 07 DAILY REPORT OFFICE MANAGER 2YRS
FAULTS
DETECTED & GENERAL
COMMUNICATE INSPECTION ENGINEERING
8 FAULTS DETECTED AND COMMUNICATED GE / F / P -02 / 08 D OFFICE MANAGER 2YRS
GENERAL
ALARM REVIEW INSPECTION ENGINEERING
9 ALARM REVIEW LOG BOOK GE / F / P -02 / 09 LOG BOOK OFFICE MANAGER 5YRS
