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Poor RE ?, Does PM relate to designed A/V ?, Breakdown(unplanned) ?
Too much PM – low A/V, high maint costToo low PM – high A/V low maint cost at the first stage due to momentum effect, thenpain latter from significantly low A/V and high LCC
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Maintenace-when ?, what ? How ?
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Best practice maintenanceMaintenance performance
Eliminatethe sourcesof defects
Useequipment-
specific strategies to optimize cost/ benefit
of planned maintenance
Fix it beforeit breaksFix it when
it breaksDon t fix it
Maintenance performance
Eliminatethe sourcesof defects
Useequipment-
specific strategies to optimize cost/ benefit
of planned maintenance
Fix it beforeit breaksFix it when
it breaksDon t fix it
Focus
Keyskills
Risks
• Preempt fai lures by removing root causes/ defects in a cost-effective manner; continue to employ equipment-specific strategies
• Some maintenance investment could have high return in added life
Maintenance Evolution
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Reliability & integrityWhat is reliability ?Operation reliability- the ability of producing(operate) asset to deliver the desire products in the costeffective manner.Equipment reliability- this refers to the ability of the physical asset ( rotating equipment, E&I ) toperform its intended function , without failure. (measurement is MTBF )Process reliability- the ability of the producing asset to operate in a way which does not compromisetechnical integrity or safeguarding functions.Human reliability- the ability of individuals or collective groups to manage the actions on theproduction asset in a competent and effective manner.Equipment maintainability- this address the ease/difficulty in returning equipment to its original state (measurement is MTTR )
What is integrity ?Technical integrity of operating assets exists when under specified operating conditions there is noforseeable risk of its failure that would endanger, people, the environment, or asset value. Which isHSE related i.e. ISO 14000, 18000
RESULTRESULT RESULTRESULT RESULTRESULT+ Preventive + Inspection Plan + Test Frequency/scopeMaintenance plan
RCM/RBI/IPF
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RCM Reliability Centered Maintenance. A process used to determine the maintenance requirements of any physical asset in its operating context. 7 basis questions , RCM
- What are the functions and associated performance standards of the asset in its present operating context ?
- In what ways does it fail to fulfill the function ? - What causes each function failure ? - What happens when each failure occurs ? - In what way does each failure matter ? - What can be done to predict or prevent each failure ? - What should be done if a suitable proactive task cannot be found ?
The outcome from RCM will lead the suitable maintenance technic and timing.
Cost of Non-AvailabilityInspection & testing costs
Inspection & Testing Too Low Inspection & Testing Too Much
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• Review major sparing options (process trains, power)• Challenge uneconomic sparing philosophies• Estimate overall facility effectiveness• Highlight critical elements to availability (focus attention on
procurement, operability, data mgt.)• Establish maintenance strategy and manning levels• KEY for operations and project engineers to agree outcomes based on
analysis• Life Cycle Cost
• PLEASE continue to use in initial operations to confirm performance of all critical equipment
Studies for Design PhaseReliability Engineering
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• Review actual equipment performance with design phase data (failure modes & MTBF for key items)
• Review Maintenance strategy once initial feedback of failure data has been obtained
• Establish areas for technical review where poor performance identified (responsible project engineer)
• Carry out sparing sensitivities as facility production changes • Use to assess risk to production when major maintenance takes
place• KEY for operations staff to understand what is possible
Studies for Operating PhaseReliability Engineering