2. 2 HONEYWELL - CONFIDENTIAL File Number
Maintenance Personal
Maintenance Supervisor
Rory Hulley
Planner Pipe Fitter Mechanical Fitter
Lawrence Syed David Butler Frank Castiglione
Electrician Instrument Technician
David Brew Richard Chato
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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
0
10
20
30
40
37
5
9
6.5
9.5
BreakdownPercentage
Rate
Months
Monthly Breakdown Downtime Rate 2015
Downtime
% Rate
Target
Rate
20%
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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
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• 90.04% PM’s have been completed where possible.
• 100% ISO PM’s completed on time.
Planned Maintenance
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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
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• 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)
Maintenance Improvements 2015
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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.
Maintenance Improvements 2015
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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
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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
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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
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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
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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.
