CARBON BLACK PLANT
- Reduced plant downtime by 5% through optimization of PM work and implementation of sound PdM techniques such as vibration monitoring, alignment, IR scanning, NDT, revision of PM work orders urgency and frequency
- Implemented steam turbine and air blower overhaul program running the plant virtually free of breakdowns and acquired extensive hands-on experience on turbine and blower maintenance while working with specialized contractors (Price Turbine, Ainsworth)
- Froze maintenance budget for four years in a row through consistent improvement of planning and scheduling processes, reorganization of maintenance department and revision of outside contractors use
- Planned, organized and coordinated seven annual turnarounds with the last five being finalized within time and budget by introducing a pre-planning stage and better integration of 'in house' labor with outside contracted work
- Initiated facility maintenance program: roofs inspection/repair/replacement; buildings inspection schedule; roads maintenance; yard & storage facilities tidy-up program; waste water ponds dragging plan
- Developed plant wise structural steel inspection plan and finalized repair/replacement program
- Planned, scheduled and directed installation and repairs of heat exchangers and dryers in cooperation with assigned contractors
- Coordinated capital repairs to bag collectors and carbon black reactors through identification of superior bags for collectors, installation of temperature control and steam suppression system on bag filters, procurement and installation of refractory for carcass and tread reactors
- Investigated options, evaluated and acquired refractory materials to be used in lining reactors, dryers and ovens. Assessed refractory installations to conform with design specifications; coordinated 5 major refractory repairs for carcass reactors and 9 months periodical replacement of tread reactor sections followed by reconstruction of each section
- Developed refractory improvement plan and provided technical assistance to upgrade the instrumentation of the carbon black reactors to improve reliability by identifying superior quality refractory, installing temperature control system to protect refractory from temperature excursions