Avadh Rubber Limited

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REGA association with

Avadh Rubber Limited

Avadh Rubber Limited (now Avadh Rail Infra Ltd) is engaged in manufacturing Rubber, Rubber to Metal Bonded, Polyurethane based engineering products used in rolling stocks, track and civil in Indian Railways and also manufacturing critical components of combat vehicles for Ministry of Defense, Government of India. REGA Consultancy was hired in 2018 for Auditing the existing engineering facilities especially Electrical & Utilities, and preparation of technical specifications for procurement of new transformer, PCCs, SDBs and compressors for ramp up of production and future capacity expansion.

Here are a few major benefits of Maxride Rubber Pvt. Ltd. By partnering with REGA Consultancy Services:

Challenges

Challenges

There were many challenges in existing engineering facilities, especially Electrical & Utilities affecting its production efficiency and regular breakdowns. Also, technical specification required for capacity expansion.

  • Challenges in existing electrical system installation, safety, maintenance practices and energy conservation.
  • Correct technical specifications required for increasing production capacity.
  • Erection & commissioning of complete engineering & utility setup for capacity expansion.
  • Regular breakdown for the mixture.
Solution Provided

Findings

The Chief Consultant visited the plant in Haridwar, Uttarakhand for 2 days. A very detailed inspection was done in the for the electrical & utilities in the plant. 2 Service Engineer visited separately for rectifying the issue for the mixture breakdown.

  • Dust seal leakage in Intermix K2, No proper maintenance practices are performed.
  • Motor in the intermix was taking very high current during start up.
  • Multiple small size compressors are used, incorrect sizing of pipelines were found, low capacity of air receiver were installed.
  • Harmonic reactors not available, defective cables used, MMC installation was not proper, existing lighting in main production hall was not working.
  • Intermix control circuit motor not running due to remote NO contact, reason being low lube. Master alarm not reset.
  • 6 Faulty relays found in relay board. Found problem in gland lubrication system & pressure switch contacts.
Challenges

Solution Provided

Corrective action was taken on these while onsite visits and solutions were provided for each challenges. Also, All the possibilities were done by service engineers to resolve the mixture breakdown. Intermix was run after pressure switch safety interlock was bypassed.

  • Leakage was sealed, CLIT routine maintenance and preventive maintenance practices was recommended.
  • Motor starter pane rectified, VFD was installed for power savings.
  • Higher capacity approx. 180 cfm screw compressor with air dryer was installed. Main header of airline size (3 inch) laid down and tapping taken at individual machines.
  • Installation of Air Meter and Energy meter, Calibrated pressure switch fixed for auto unloading.
  • New PCCs with protection relays and energy meter, bus coupler, change over switch and outgoing feeders for installed for distribution boards (MCC).
  • Exiting plant lighting replaced with LED 90/100-Watt.
  • Control circuit remote filled with oil & pressure switch wire reconnected. Faulty relays was replaced.
Solution Provided

Results

Recommendations were provided for the shortcomings in the existing facility to overcome them. Performed Erection & commissioning of complete engineering & utility setup for capacity expansion.

  • Power Consumption reduced to 20%.
  • Production capacity increased to 15% in the existing facility.
  • Mixture Breakdown Reduced to 70%.
  • Proper technical specifications provided for future capacity expansion.
  • Successfully engineering & utility setup for capacity expansion.
Performance

Presenting Performance with Facts

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20 %
Power consumption reduced
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15 %
Production capacity increased
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70 %
Mixture Breakdown Reduced