Jotun Abu Dhabi-Maintenance
Devree Pipeline Modification
(2019)
Tanuj Rana/Devree piping line modification/ 22-07-19
Teams : Ramesh/Raghunathan/Aji John
Jotun Abu Dhabi-Maintenance Date : April 21st, 2016
Business case Future state / To-be Details set up (next slide)
-To reduce and eliminate composite hose changeover time between tanks 204,214,215,247
and 248 by approximately 65%.
-To improve the changeover efficiency within the budget through pro active changes,ensuring
compliance with HSEQ policy reducing physical and chemical hazards.
-To regulate and improve the 5S standards being followed.
Current situation / As-is Details set up (next slide)
Actions / Road-Map
60% done
40% on-going
Measures / Follow up
Tanuj Rana/Devree piping line modification/ 22-07-19
Jotun Abu Dhabi-Maintenance
Business Case and Objective
- To eliminate composite hose changeover time between tanks
204,214,215,247 and 248 by approximately 65%.
- To improve the changeover efficiency within the budget through pro
active changes,ensuring compliance with HSEQ policy reducing
physical and chemical hazards.
- To reduce change over time from 6 minutes to 2 minutes.
Tanuj Rana/Devree piping line modification/ 22-07-19
Jotun Abu Dhabi-Maintenance
Current Scenario
40
300300 cans
cans minutes/
batch
Batch
Time
size
11 batches Amount Ratio 14
cans/min
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Jotun Abu Dhabi-Maintenance
Transport
FGWH
Process Hose
Changeover/PLC
Flow
Filling,
Crimping
Tanuj Rana/Devree piping line modification/ 22-07-19
Jotun Abu Dhabi-Maintenance
Time Segmentation
Raw material transportation - 10 minutes
16% 14%
8% Changeover time - 6 minutes
Filling in Devree - 45 minutes
Crimping and transfer to FGWH- 15 minutes
62%
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Jotun Abu Dhabi-Maintenance
Material
Machine
Heavy Poor Quality
Composite hose
Paint Leakage Poor packaging
Pump inefficiency
Leaked PM
overflow
Change
over Time
Unskilled
Order Pattern
Improper Planning
Plan Change
Manual changing Lack Of Team Work
Not following WI
Method Does not comply
with HSEQ
Man
Tanuj Rana/Devree piping line modification/ 22-07-19
Jotun Abu Dhabi-Maintenance
P-001
A-001 V-001
ES-001
A-002 P-002
V-002
A-006
SS- 001 SS-002 PV- 001
A-007
LEGENDS
6 way selector
switch
P-003
A-003
OR Gate
V-003
AND Gate
A-004 P-004
V-004 Pilot Valve
P-005
A-005 Emergency
Stop
V-005 5/2 valve
5/3 valve
Designed by:
Jotun Abu Dhabi LLC Tanuj Rana j
Logic Diagram (Devree Pipeline Modification)
Tanuj Rana/Devree piping line modification/ 22-07-19
Jotun Abu Dhabi-Maintenance
P&I Drawing
Tanuj Rana/Devree piping line modification/ 22-07-19
Jotun Abu Dhabi-Maintenance
Desired Action Plan
Sr Action Plan Target Responsible
1 New pipelines to be installed through dummy line and 30/8/2019 Prashanth
through tanks 214,215
2 Analyse the site conditions further and propose the 30/8/2019 Prashanth
need of additional valves and pump
3 Evaluate and discuss cost of the aforementioned with 30/8/2019 Prashanth
Purchase Department and confirm the suppliers and
contractors are competent and reasonable.
4 Train operators to handle the selector switches 30/8/2019 Prashanth
5 Train technicians to handle technical scenarios and 30/8/2019 Prashanth
issues that may arise.
Tanuj Rana/Devree piping line modification/ 22-07-19
Jotun Abu Dhabi-Maintenance
Future Status
Changeover Time
7
0
batch 1 batch 2 batch 3 batch 4 batch 5 batch 6 batch 7 batch 8 batch 9 batch 10 batch 11 batch 12
possible
Column1 Series 2
Tanuj Rana/Devree piping line modification/ 22-07-19
Jotun Abu Dhabi-Maintenance
Conclusion
- Number of batches made in a day on average = 11.
- Current changeover time from one tank to another = 6 minutes.
- Average time taken to prepare a batch = 45 minutes
- Total Time saved in a day = 11 x 4= 44 minutes.
- The time we save through the proposed system will help us prepare an
additional batch everyday with cleaning to spare, furthermore HSEQ and 5S
regulations will be kept in check removing the danger of physical and
chemical hazards!
Tanuj Rana/Devree piping line modification/ 22-07-19
13
Jotun Abu Dhabi-Maintenance
Tanuj Rana/Devree piping line modification/ 22-07-19
