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Factors Causing Interruption In Equipment Operation
Financial pressures have caused serious reductions in workforce across the board not leaving enough time to handle abnormal plant problems.
Even if there are personnel for abnormal problem solving, they are frequently used for routine operation maintenance work.
Plant personnel may lack adequate skills for the tasks they have to perform.
To achieve uninterrupted plant operation, personnel must have adequate training, problem solving skills and time to handle ALL Problems - Normal And Abnormal. RESCO provides these services.
Engineering Services
Optimization: Maximize (or minimize) a given objective within a set of constraints without violating any constraint.
Establish the Objective of a System in the plant e.g. maximizing efficiency at the operating point or minimizing downtime of a pump. Determine the Set of Constraints in the system such as motor HP limitation, maximizing pump flow, piping resistance to cause frictional losses, varying flow requirement with the time of the day, etc. Then optimize the Objective of the System within the Set of Constraints e.g. determining the equipment setup to maximize operating efficiency within the limits of all the constraints.
It is a known fact that rotating equipment seldom performs at its BEP (best efficiency point). BEP is an ideal design point determined by the manufacturer. Since the operating conditions in the field are different than those at manufacturer's test facilities, equipment seldom operates at the BEP. RESCO optimizes and fine-tunes the equipment to bring the operating point closer to its BEP to improve efficiency and reliability.
Predictive Maintenance: Proper and timely maintenance is crucial to keep the rotating equipment performing efficiently. Proper shaft alignment is a primary factor that keeps rotating equipment in good running condition. Good preventive maintenance programs can prevent unexpected failures and plant shut downs. RESCO develops predictive maintenance programs based upon specific customer needs.
Condition Based Monitoring: Traditional maintenance methods either result in high down time or do not utilize the full useable life of the equipment. Condition Based Monitoring Systems capture the best of all worlds. RESCO designs and implements these systems. Lubrication, vibration, noise and thermal monitoring become an integral part of the total program.
Specific Problem Solving: RESCO investigates, analyzes and solves equipment problems such as seal failures, coupling failures, etc., and system related problems such as cavitation, insufficient NPSH, hydraulic imbalance in parallel operation, etc.
Root Cause Analysis: RESCO performs root cause analysis for recurring problems such as shaft breakage, bearing failures, etc., and determines the true solution.
Technical Training And Personnel Mentoring
What is Training: Training teaches how to perform tasks correctly, efficiently and consistently in a safe manner.The capability to translate theory to practice.
Why is Training Required?:
New personnel need training to learn procedures and practices prevalent in a plant.
Existing personnel need to be retrained as a part of continuous improvement process and to brush off any bad habits they may have acquired.
New technology, process and concepts require training for their effective and efficient implementation.
Performance improvement in personnel can be achieved only by training and continuous learning.
Basics of Training:
Training is a long process of repeated learning.
For maximum benefit, long-term training program must be implemented.
Training must emphasize preserving equipment reliability while maximizing production.
Training must not only provide knowledge but also a means to measure its implementation.
Business Coaching
Business Coaching: Many mid level businesses struggle to translate their vision into execution and achieve the desired results.
Prafulla Pande is a licensee of a powerful set of proprietary tools known as "The CEO Advantage™".These tools are used to coach leadership teams and facilitate better financial results.
Cultural Training: Helping businesses become global by learning how to interactact across different cultures and bridge cultural gaps with their counterparts in other countries.