maintenance presentation 2015

Brimsdown Maintenance

June 2015

2 HONEYWELL - CONFIDENTIAL File Number

Maintenance Personal

Maintenance Supervisor Rory Hulley

Planner Pipe Fitter Mechanical FitterLawrence Syed David Butler Frank Castiglione

Electrician Instrument TechnicianDavid Brew Richard Chato


Strategy Deployment TTI Chart

January was a bad month due to the breakdown of 30-K-04 - the circulation fan on Zone 2 in the furnace broke down. This fans had not been balanced or serviced for several years. They have now been put on yearly test inspection and balancing PM’s. 30-K-04 is scheduled to be overhauled in the shutdown this year (2015) and 30-K-03 in the shutdown next year (2016).

Maintenance Key Improvement Processes

Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec0

10

20

30

4037

59 6.5 9.5

Monthly Breakdown Downtime Rate 2015

Downtime % Rate

MonthsBre

akdo

wn

Perc

enta

ge

Rat

e

Target Rate 20%


The last few months have been better and this is due to the hard work and dedication of the Maintenance Team, and the cooperation of the Operators.

Maintenance Key Improvement Processes


• 90.04% PM’s have been completed where possible. • 100% ISO PM’s completed on time.

Planned Maintenance


Completed 2015• New heat exchanger for R&S 2

• Silver upgrade – this included pipe work and electrics on the acid dosing; ventilation piping modifications and replacement; waste piping modifications and new air line piping for the breathing apparatus.

Maintenance Improvements 2015


• New platinum hoist on CD96.

• Replacement of the regeneration vent stack on R&S 2

• Assisting Janice Roberts in reducing stores stock by £33K (removal of parts no longer required)



Plans for the remainder of 2015• Shutdown 2015

• New hoist fitted R&S 2 • Honeywell Control System upgrade to PC’s and work stations • New gears for 27-V-02 CD96 number 2 evaporator• Overhaul of 30-K-04

• Other work in progress• Upgrade silver rig pump electrics to include a variable speed drive.• Implement sight glass inspections (SAP completed)• Install and commission the new O2 H2 analyser on R&S 2.



CI’s created

There has been 35 CI’s created by the Maintenance Team; with 27 completed. These range from a cleaning rig for the flame arrestors (7 arresters were due for disposal and replacement in May 2015, saving £10k), to tidyying up and sorting out the maintenance areas.

• Cleaning rig

• Contractor’s stores

Before After

HOS


4 Kaizens events this year

1 Filing/storage area in the maintenance offices (completed)

Before After

2 Silver rig upgrade to include a variable speed drive (not completed). The parts have arrived and are awaiting plant availability to complete.

3 Sight Glass Directive . A site survey has been completed, the equipment entered into SAP, PM’s have been created in SAP and these will be completed when issued.

HOS


4 Permit office electrical cabling (completed)

Before After

5 Safety Kaizens raised at the SSP meeting for safety improvements to the workshop.

1 De greaser (completed)

HOS


2 Air lines in workshop (completed)3 Workshop flooring (completed)

4 Workshop SSP - signs, labeling etc. (completed)

5 Quarantine area in the workshop (due for completion end June)

HOS


Maintenance going forward

• Cross training of maintenance personnel to assist with cover during holidays/time off.

• Training of Operations Supervisor and Lead Operators for front line maintenance to reduce down time, such as calibration of analysers and replacement of buckets on the furnace elevators.

• Continued training of new personnel on site equipment.

• Continue the good work of the Maintenance Team with HOS(SSP) and the site improvements.

• Continue to develop team work within the Maintenance Team.

maintenance presentation 2015

Documents