Revision Date Sep 26, 2013

Document No. MP-AP-02

Issue No. / Date 01 / Sep 26, 2013
Rev No 00 MAINTENANCE Effective Date Sep 26, 2013
Maintenance Department Manual
EPCL Manufacturing Division
PHILOSOPHY AND Prepared by: SSK
PROCESS Unit / Section: WORKSHOP

Department : Maintenance Page No: 1 / 9 Area: All

INITIATED BY :
Maintenance Engineer DATE
(SIDRA KHAN)

REVIEWED BY : Maintenance Unit Manager DATE

(ANEEQ AHMED )

APPROVED BY : Maintenance Manager DATE

(NASIR K.QURESHI)

CHANGE RECORD
S. # Rev. # Date Page # Section Description of Change

DISTRIBUTION
1. MAINTENANCE MANAGER
2. LAN

Prepared by: SSK Reviewed by: ANA Approved by: NKQ

 Revision Date Sep 26, 2013
Document No. MP-AP-02
Issue No. / Date 01 / Sep 26, 2013
Rev No 00 MAINTENANCE Effective Date Sep 26, 2013
Maintenance Department Manual
EPCL Manufacturing Division
PHILOSOPHY AND Prepared by: SSK
PROCESS Unit / Section: WORKSHOP

Department : Maintenance Page No: 2 / 9 Area: All

TABLE OF CONTENTS
1. PURPOSE...................................................................................................................................................................................................... 3
2. INTRODUCTION............................................................................................................................................................................................ 3
2.1 FIELD MAINTENANCE SECTIONS.................................................................................................................................................... 3
2.1.1 STATIONARY EDCVCM............................................................................................................................................................ 3
2.1.2 STATIONARY ROP.................................................................................................................................................................... 3
2.1.3 MACHINERY.............................................................................................................................................................................. 3
2.2 WORKSHOPS..................................................................................................................................................................................... 4
2.3 PLANNING.......................................................................................................................................................................................... 4
3. MAINTENANCE PROCESS FLOW............................................................................................................................................................... 5
4. MAINTENANCE POLICY............................................................................................................................................................................... 6
5. MAINTENANCE PROCESS........................................................................................................................................................................... 6
5.1 SAFETY AND LOSS PREVENTIVE PRACTICES.............................................................................................................................. 7
5.2 QUALITY AND WORK PRACTICES................................................................................................................................................... 7
5.2.1 QUALITY........................................................................................................................................................................... 7
5.2.2 WORK PRACTICES.......................................................................................................................................................... 8
5.3 PREVENTIVE MAINTENANCE.......................................................................................................................................................... 8
5.3.1 WINTER PLAN.................................................................................................................................................................. 8
5.4 CONDITIONING BASED MAINTENANCE.......................................................................................................................................... 8
5.5 RELIABILITY PROGRAM................................................................................................................................................................... 8
5.6 BREAKDOWN (RUN TO FAILURE/REACTIVE/CORRECTIVE MAINTENANCE).............................................................................9
5.7 CRITICAL SPARES REVIEW.............................................................................................................................................................. 9
5.8 OPPORTUNITY BASED / TURNAROUND MAINTENANCE.............................................................................................................. 9
5.9 TRAINING & DEVELOPMENT............................................................................................................................................................ 9
5.10 COMPUTERIZED MAINTENANCE MANAGEMENT SYSTEM (CMMS)............................................................................................ 9
5.11 CONTRACTS MANAGEMENT............................................................................................................................................................ 9
5.11 OTHER MANUALS CHECK................................................................................................................................................................ 9
6. PSRM REFRENCES................................................................................................................................................................................... 10

1. PURPOSE

Prepared by: SSK Reviewed by: ANA Approved by: NKQ

 Revision Date Sep 26, 2013
Document No. MP-AP-02
Issue No. / Date 01 / Sep 26, 2013
Rev No 00 MAINTENANCE Effective Date Sep 26, 2013
Maintenance Department Manual
EPCL Manufacturing Division
PHILOSOPHY AND Prepared by: SSK
PROCESS Unit / Section: WORKSHOP

Department : Maintenance Page No: 3 / 9 Area: All

Purpose of this document is to outline the Philosophy, Processes, and Model & Standards of Maintenance Department. This document
only provides general guidelines and a synopsis of the different processes which are further explained in detail in other procedures
where required.

2. DEPARTMENT ORGANIZATION AND FUNCTIONS

Engro Polymer & Chemical Limited, Karachi manufacturing site comprises of EDCVCM Plant, PVC 1 & 2 Plant and CA plant and its
associated facility all working centrally from 2009 onwards.
Maintenance department is responsible for smooth, safe and reliable running of the plant and it comprises of Field Maintenance Units
(Stationary EDCVCM, Stationary ROP, Machinery,) Planning & Contracts, and Workshops.

2.1 FIELD MAINTENANCE UNITS

These units are centralized having their own craft resources. Stationary EDCVCM, Stationary ROP and Machinery fall in this
category. The primary function of these units is to look after the day to day maintenance with all safety, perform preventive
maintenance & surveillance programs, manage daily schedules of work generated by the Production and other Departments,
attend to failures, monitor inventory of critical spares and ensure integrity for reliable operation.

These units are headed each by a Unit Manager or Section Head / In-charge, who are responsible for stewarding progress of
their units, budget, investment plan items, and other small betterment projects. They have their job descriptions available
with them.
2.1.1 STATIONARY EDCVCM
The function of this unit is to look after the day to day maintenance of EDCVCM Plant’s Stationary Equipments with
all safety, perform preventive maintenance & surveillance programs, manage daily schedules of work generated by
the Production and other Departments, attend to failures, monitor inventory of critical spares and ensure integrity
for reliable operation.

2.1.2 STATIONARY ROP

The function of this unit is to look after the day to day maintenance of ROP (PVCI/II, CA & UTY) Plant’s Stationary
Equipments with all safety, perform preventive maintenance & surveillance programs, manage daily schedules of
work generated by the Production and other Departments, attend to failures, monitor inventory of critical spares
and ensure integrity for reliable operation.

2.1.3 MACHINERY
The function of this unit is to look after the day to day maintenance of ROP and EDCVCM Plant’s Machinery
Equipments with all safety, perform preventive maintenance & surveillance programs, manage daily schedules of
work generated by the Production and other Departments, attend to failures, monitor inventory of critical spares
and ensure integrity for reliable operation.

2.2 WORKSHOPS
Centralized, with fixed manpower locked in, Shops provide service to the entire plant, more so to the Field Maintenance
sections, I&E and Warehouse, which generate most of the workload. Shops carry out the process of mechanical repairs,

Prepared by: SSK Reviewed by: ANA Approved by: NKQ

 Revision Date Sep 26, 2013
Document No. MP-AP-02
Issue No. / Date 01 / Sep 26, 2013
Rev No 00 MAINTENANCE Effective Date Sep 26, 2013
Maintenance Department Manual
EPCL Manufacturing Division
PHILOSOPHY AND Prepared by: SSK
PROCESS Unit / Section: WORKSHOP

Department : Maintenance Page No: 4 / 9 Area: All

reclamation through reverse engineering and fabrication of spares locally. In addition, Shops personnel work as backup
resource to Field maintenance during critical needs.
Shops have sections within, which comprise of Machine Shop, Fabrication Shop, Valve Shop & PSV shop.

2.3 PLANNING & CONTRACTS

Primarily geared to plan for “Unplanned” and “Planned Shutdowns” Contracts Administration, Cost, stewarding of
Maintenance Department as regards achievements, objectives, areas for improvements, investment plans, and expense
budgets.

Secondary role is of coordinating and troubleshooting Computerized Maintenance Management System in Maintenance
Department.

3 MAINTENANCE PROCESS FLOW

Maintenance core responsibility is to ensure safe, smooth & reliable operating plant for its customers, to operate staying within the given
budget & complying to all company systems & procedures with special focus on quality, people development and staying abreast with the
new technological advancements in the related fields.

The main processes of the department contributing to the quality management system are given below:
Prepared by: SSK Reviewed by: ANA Approved by: NKQ
 Revision Date Sep 26, 2013
Document No. MP-AP-02
Issue No. / Date 01 / Sep 26, 2013
Rev No 00 MAINTENANCE Effective Date Sep 26, 2013
Maintenance Department Manual
EPCL Manufacturing Division
PHILOSOPHY AND Prepared by: SSK
PROCESS Unit / Section: WORKSHOP

Department : Maintenance Page No: 5 / 9 Area: All

4 MAINTENANCE POLICY

 Maintenance core responsibility is to ensure safe, smooth & reliable operating plant for its customers, to operate staying within
the given budget & complying to all company systems & procedures with special focus on quality, people development and
staying abreast with the new technological advancements in the related fields.
.
 We will strive for lowering expenses in fixed costs through alternate spares, local fabrication, fewer equipment stops,
optimizing & developing multiple skills, predictive maintenance programs without compromising any quality Controlling

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 Revision Date Sep 26, 2013
Document No. MP-AP-02
Issue No. / Date 01 / Sep 26, 2013
Rev No 00 MAINTENANCE Effective Date Sep 26, 2013
Maintenance Department Manual
EPCL Manufacturing Division
PHILOSOPHY AND Prepared by: SSK
PROCESS Unit / Section: WORKSHOP

Department : Maintenance Page No: 6 / 9 Area: All

Fixed costs though Maintenance is always a challenge. Every year the cost of spares- imported or local go up; every year Dollar
appreciates compared to rupee. We will explore alternate vendors who can provide spares at lower price without compromising
quality and value; we can do reverse engineering and fabricate the spare locally – either in own Shop or outsource locally in
Pakistan. Further alternate materials can be explored;. Whenever the equipment is taken out of service or stops, it is checked
for which spares like gaskets, O rings, etc are replaced. If the stopping of the equipment is somehow prevented through previous
Policy, number of consumables get reduced. Both EPCL and Contractor personnel with multiple skills can reduce the number of
persons on hand which lowers the Salary wages. Application of Predictive Maintenance results in fewer stops and fewer spare
consumption and higher productivity
.
 Planning Section is responsible for administration of contractors, staying within companies systems & procedure and
playing a vital role in developing contractor’s safety awareness, skills and quality assurance. Contractors are part of our
team,. Systems applicable to us should also be applicable to them, e.g. training, R&R within the recognized limits, EPCL
Maintenance team comprises of Contractor and his resources to execute the activities as per a written agreement.

5 MAINTENANCE PROCESSES

The Maintenance Department processes employed are essentially that of “Maintenance & Asset Management”.

The goal is “Increased Asset Reliability”.

In order to achieve the aforesaid and maintain a high service factor & equipment uptime the following processes are employed by the
Maintenance Department:

 SAFETY & LOSS PREVENTION PRACTICES.

 QUALITY AND WORK PRACTICES
 PREVENTIVE MAINTENANCE PROGRAM.
 CONDITIONED BASED MONITORING (PREDICTIVE) PROCESS.
 SURVEILLANCE ROUTINES.
 RELIABILITY PROGRAMS (ROOT CAUSE ANALYSIS).
 BREAKDOWN (REACTIVE/RUN TO FAILURE) MAINTENANCE.
 CRITICAL SPARES REVIEW.
 OPPORTUNITY BASED/SHUT DOWN AND CORRECTIVE MAINTENANCE.
 TRAINING & DEVELOPMENT.
 COMPUTERIZED MAINTENANCE MANAGEMENT SYSTEM (CMMS).

5.1 SAFETY & LOSS PREVENTION PRACTICES

Engro Polymer & Chemicals Limited gives the highest importance to safe operations, safe work practices, and protection of the
environment and the health of its employees in the conduct of its business. It is therefore the company’s policy to have
procedures and system in place to enable its employees to work safely and prevent damage to company assets. Safety is
always given preference over business and profits.
The Maintenance Department operates within set guidelines and procedures laid down to achieve safe operations, and as far as
possible, prevent injury to its employees.
The policies that dictate the Maintenance Department functionality within the aforesaid guidelines are:

 Safety Manual; Environment Manual

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 Revision Date Sep 26, 2013
Document No. MP-AP-02
Issue No. / Date 01 / Sep 26, 2013
Rev No 00 MAINTENANCE Effective Date Sep 26, 2013
Maintenance Department Manual
EPCL Manufacturing Division
PHILOSOPHY AND Prepared by: SSK
PROCESS Unit / Section: WORKSHOP

Department : Maintenance Page No: 7 / 9 Area: All

 Process Safety & Risk Management Manual

 Personnel Safety Management Manual
 Maintenance procedures manual
 Emergency response manual
 HSE Committee
o Sub- HSE Committee for Maintenance
 A Sub-HSE Operations Committee comprising the Technical or Maintenance Manager as chairman
and other relevant interfaces as its members is in place to ensure;
 High quality of Mechanical standards as listed in Section 5 above and procedures
 Review of design and safety of new plant facilities or additions to existing facilities
 Compliance with engineering standards
 Approvals from HSE in case of deviations from EPCL safety practices.
o D-Level Safety Committees
o B-Level Safety Committees

5.2 QUALITY AND WORK PRACTICES

5.2.1 QUALITY
 Implementing a strong Quality Management System.
 Maintain continuous improvement and thrust and train all employees of Maintenance Department on a phased
program basis with focus on required skills.
 Apply statistical techniques to all key productivity, cost, reliability, etc. variables to identify opportunities to improve,
Identify chronic & critical problems and act through PDCA (Plan-Do-Check-Act) cycle for their elimination.
 Stay abreast of technological advancements and utilize networks, where required, to develop plans to continuously
improve / up rate equipment performance and reliability to required levels.
 Promote quality by upgrading personnel skills, tools and work practices while eliminating repetitive maintenance.

5.2.2 WORK PRACTICES

Work practices are defined as the correct way of doing work as per prescribed standard and written procedures.
Apart from the safety procedures described above (section 5.1), the following written work practices are available in
the Maintenance Department:

 Plant specific procedures (Unit wise manuals are / will be available in each area)
 Job Plans (Unit wise Job Plan manuals are available in each area)
 Overall Maintenance Procedure Manual for administrative and common procedures
 International Codes & Standards.

5.2.3 QUALITY ASSURANCE

 Hold Point Concept has been introduced in maintenance. It is a unique method to ensure job quality by introducing
a 3rd Party audit system at every critical juncture of the scope developed.

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 Revision Date Sep 26, 2013
Document No. MP-AP-02
Issue No. / Date 01 / Sep 26, 2013
Rev No 00 MAINTENANCE Effective Date Sep 26, 2013
Maintenance Department Manual
EPCL Manufacturing Division
PHILOSOPHY AND Prepared by: SSK
PROCESS Unit / Section: WORKSHOP

Department : Maintenance Page No: 8 / 9 Area: All

5.3 PREVENTIVE MAINTENANCE

Defined as time based maintenance or periodic checks, inspections, servicing, calibration and adjustment of machines or
equipment based on manufacturer’s instruction or EPCL experience. PM is applied on Equipment Lubrication schedule,
Stationary equipment, Gas Turbines inspections etc.

5.3.1 WINTER PLAN

This type of Preventive Maintenance is done for that equipment which can be isolated and handed over for
Maintenance in winter season without any production loss. The intent is to carryout maintenance / inspection
checks in order to ensure reliable operation during summer.
All PMs are scheduled on maximo and are generated by relevant functions, as per their responsibilities.

5.4 CONDITIONING BASED MAINTENANCE (PREDICTIVE MAINTENANCE)

Condition Based Maintenance is driven by condition monitoring (Surveillance) of the asset due to the fact that a great many
failures do not occur instantaneously, but actually develop over a period of time. If evidence can be found that a failure
process is underway, sometimes, it is possible to take actions to prevent the failure and / or to avoid the consequences. In
other instances the equipment is shutdown in a planned manner for corrective actions.
Condition Monitoring (Surveillance) is the key feature of Condition Based Maintenance. This consists of monitoring of the
equipment without taking it out of service e.g. checking vibrations, temperatures, oil condition, thickness monitoring, thermo-
vision, etc. It also applies on identified Machinery, Pipeline thickness monitoring etc.

5.5 RELIABILITY PROGRAM

To have a system in place that captures reliability related incidences that either cause or have a potential of causing loss or
high recurring maintenance costs. The purpose is that the recommendations and responsibility to prevent recurrence is
documented and formalized and follow up done in a systematic manner. The investigations are aimed at fact finding (Root
Cause Analysis) rather than fault finding. Planning Section stewards this program.
5.6 BREAKDOWN (RUN TO FAILURE/REACTIVE/CORRECTIVE MAINTENANCE)
Work that result from actual/unforeseen breakdown of equipment or system. Such type of work is not desirable and should
be reduced to a minimum by utilizing techniques such as Preventive Maintenance or Condition Based Maintenance already
discussed in previous paragraphs. Equipment Breakdowns considerably reduce plant reliability and affect other planned jobs.

5.7 CRITICAL SPARES REVIEW

It is the responsibility of every Section to develop and maintain a list of critical spares required to keep the unit operational.
Maintaining the inventory levels, ensuring timely replenishment with the help of Warehouse is a prime responsibility.

5.8 OPPORTUNITY BASED / TURNAROUND MAINTENANCE

Maintenance work that is done during a planned total or partial shutdown of plant. During this period the known defects or
deficiencies are rectified, along with scheduled PMs and Inspections.
The roles of Maintenance and Planning Sections are the foremost in this type of activity which primarily involve pre-
turnaround activities, shutting down the plant and taking over equipment for maintenance; maintenance period, handing over
of equipment after maintenance and startup and post turn around review.

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 Revision Date Sep 26, 2013
Document No. MP-AP-02
Issue No. / Date 01 / Sep 26, 2013
Rev No 00 MAINTENANCE Effective Date Sep 26, 2013
Maintenance Department Manual
EPCL Manufacturing Division
PHILOSOPHY AND Prepared by: SSK
PROCESS Unit / Section: WORKSHOP

Department : Maintenance Page No: 9 / 9 Area: All

5.9 TRAINING & DEVELOPMENT

Training & Development of personal is done in a structured manner and through own or hired resources.
Job Qualification programs are planned for technicians to develop into fully qualified multi-skilled technicians to perform
duties required to maintain efficient operation & the opportunity to progress in pay range in line with their acquired skills,
capabilities & experience.
In house training programs consists of technical PEP sessions (Professional enrichment programs) and some skill
development programs which are essentially generated to develop management skills in an individual and are coordinated
by HR Department Karachi.
Other technical & management skill development courses are subscribed to, depending on the need of the individual.

5.10 COMPUTERIZED MAINTENANCE MANAGEMENT SYSTEM (CMMS)

All Maintenance activities are performed through a Computerized Maintenance Management System (Maximo). A
sophisticated system (Maximo), a client server based database system, is in operation since Aug 1999 for this purpose.
CMMS can best be described as a tool to use information to help facilitate maintenance work processes.
CMMS (Maximo) procedures are covered in detail in MP-AP-03 of this manual.

5.11 CONTRACTS MANAGEMENT

All plant related services and contracts are managed to ensure compliance to company’s policy to obtain services at the
most economical costs with timely completion without compromising on safety, quality, reliability and controls. These are
accomplished through transactions with financially sound, pre-qualified reputable firms capable of satisfying our needs and
should be consistent with the efficient management and utilization of inventories where applicable. For Details refer Section
5, “Contract policies and procedures.”

5.12 OTHER MANUALS CHECK

Following are a list of manuals that are not referred to in this manual but reader may need to refer to them for reference to
other company systems. Most of them are available on Intranet
 Safety Manual
 Emergency Response Manual
 Human Recourse Manual
 Gifts & Entertainment Guidelines
 Information Technology Security Manual
 Reporting Guidelines on Irregularities
 Capital Budget Manual
 Purchasing Manual

6 PSRM REFERENCES

PSRM # 3 Operating Procedures and Safe Work Practices procedures

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