002 Maintenance M Overview 20 06 06[1]


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002 Maintenance M Overview 20 06 06[1]

  1. 1. وما توفيقي إلا بالله Maintenance Management Overview Dr. Attia Hussien Gomaa Maintenance Engineering Consultant 2008 Engineering service - American University in Cairo (AUC)
  2. 2. Refer to BS3811:2000 Maintenance is the work undertaken in order to keep or restore a facility to an acceptable standard level. Maintenance Acceptable level at certain working condition (HSE, working hours, etc.) Acceptable standard level System level (equipment, unit, plant) Facility Unplanned maintenance (Corrective or run to failure policy for non-critical equipment To restore Planned maintenance (Preventive, Predictive and proactive) policy for critical equipment To keep All activities (information, analysis, repair, etc.) Work undertaken
  3. 3. Total Maintenance cost = Direct cost + Overhead cost + Downtime cost or = PM cost + CM cost + Downtime cost Cost PM Cost Total Maintenance Cost CM Cost Best level Down Time Cost PM level Reliability
  4. 4. Maintenance Management is a powerful systematic methodology to maximize the facility performance and improve the maintenance resource productivity, through optimizing maintenance policies for the critical equipment. Effect on HSE, Process, Standby and Cost Criticality Failure-based, time-based, condition-based, and risk-based Maint. Policy Certain rules and program for long term Policy Resource utilization and efficiency Productivity Materials, manpower, tools, equipment, subcontractors, and cost Resource Utilization + performance + efficiency Effectiveness Applicable and flexible = Organization structure & Team approach Powerful Documented rule-based = Codes & Standards Systematic A total view approach = Good communication (Maintenance, Process, HSE, Inventory, Resource, etc.) Methodology
  5. 5. <ul><li>Main Points: </li></ul><ul><li>Change management </li></ul><ul><li>Leadership & organization structure </li></ul><ul><li>Criticality Analysis </li></ul><ul><li>Maintenance Policies </li></ul><ul><li>Maintenance Program </li></ul><ul><li>Performance Evaluation </li></ul><ul><li>KPI (Key performance indicators) </li></ul>
  6. 6. Criticality Analysis Company Logo HSE Effect Stand By Availability Process Effect Major (B) Without (C) With (D) Minor Minor Major (A) A Fire-fighting system A Steam system A Oil system B Water system C Drain system Criticality Centrifugal Pump (System level)
  7. 7. ???? Maintenance Policies (1) Failure-Based Reactive (ReM): - RTF - CM - BD :: (2) Time-Based Preventive (PM): - Calendar: Weekly Monthly :: - Running: 1000 R.H. 1000 K.M. :: (3) Condition-Based Predictive (PdM): - Oil analysis - Vibration analysis - Temperature analysis - Pressure analysis - Wear analysis - Efficiency analysis :: ( 5) Total-Based Global (GM): - OSM - TPM :: (4) Risk-Based Proactive (PaM): - RCFA - FMEA FMECA - HAZOP - RCM RCM2 - RBI :: Figure (1): Classification of maintenance policies. [Venkatesh 2003, Waeyenberg and Pintelon 2004, and Gomaa et al. 2005]
  8. 8. Comparison of different maintenance policies Maximize the system productivity. Integrated approach . Global Minimize the risk of failures for critical systems. Detection of sources of failures. Proactive Discover hidden failures and improve reliability for critical equipment. Maintenance decision based on equipment condition. Predictive Minimize equipment breakdown. Use-based maintenance program. Preventive Minimize maintenance costs for non-critical equipment. Run to failure (fix-it when broke). Reactive Goals Approach Policy
  9. 9. A comparison among proactive maintenance approaches Improve system HSE and availability. Determination of an optimum inspection plan for critical systems. RBI Preserve system function & improve reliability. Determination of best maintenance requirements for critical systems. RCM Improve HSE effect. Identification of hazards and problems associated with operations. HAZOP Improve equipment availability. Identification of criticality of failures. FMECA Eliminate failures. Identification of root causes of failures. RCFA Goals Approach Policy
  10. 10. Comparison among global maintenance approaches Maximize plant effectiveness and resource productivity. Comprehensive productive-maintenance system. TPM Maximize reliability measures and minimize maintenance cost rates. Optimization approach for the global maintenance system. OSM Goals Approach Policy
  11. 11. Facility equipment are divided into four major categories: <ul><li>Run-to-Failure - Most cost effective to let equipment run unattended until it fails. Used on lowest priority equipment. </li></ul><ul><li>Preventive Maintenance - Perform maintenance tasks on a piece of equipment at regular intervals, whether the equipment needs it or not. </li></ul><ul><li>Predictive Maintenance - Perform maintenance based upon real-time data collected on a piece of equipment. This data shows the ‘health’ of the equipment </li></ul><ul><li>Proactive Maintenance - Determine root causes of failure and implement ‘fixes’ (e.g., redesigning the piece of equipment so that it does not break down as frequently) </li></ul>
  12. 12. Why PM should be done? To prevent equipment failures To detect early failures To discover hidden failures Time-Directed Maintenance (TD) Condition-Directed Maintenance (CD) Failure Finding (FF) Preventive Maintenance:
  13. 13. Predictive Maintenance: Condition based management Visual Inspection Vibration analysis Ultrasonic Pressure analysis Temperature analysis Oil analysis Efficiency analysis Wear analysis
  14. 14. Atypical machine condition-vibration trend
  15. 15. <ul><li>PdM Planning: </li></ul><ul><li>Best Method (vibration analysis, .. etc.) </li></ul><ul><li>Best Frequency (inspection interval) </li></ul><ul><li>Best Locations </li></ul><ul><li>Best Tools </li></ul><ul><li>International Standard (ISO10816, .. etc.) </li></ul><ul><li>Standard Limits </li></ul><ul><li>Severity Chart </li></ul><ul><li>Trouble Shooting Chart </li></ul><ul><li>Reference Creation </li></ul><ul><li>Regular Measurements (monthly, .. etc.) </li></ul><ul><li>Analysis </li></ul><ul><li>Decision Making </li></ul><ul><li>Corrective Actions </li></ul><ul><ul><li>- Good conditions, </li></ul></ul><ul><ul><li>- Routine Maintenance, </li></ul></ul><ul><ul><li>- Repair, or </li></ul></ul><ul><ul><li>- Replace. </li></ul></ul>
  16. 16. PdM Policy: Vibration analysis: 1- Frequency: Every 300 Running Hours 2- Tool: Vibration Equipment: accelerometers, charge amplifier and analyser. Computer program for trend analysis and prediction. 3- International Standard: CDA/MS/NVSH107 4- Method: Record the vibration spectrum, specify the peaks corresponds to the bearing components Record each component peak and frequency. By using the soft ware and the standard limits, determine the trend of each peak. Determine the bearing state(good –need service –need change) 5- Limits: According to CDA/MS/NVSH107 Pre-failure: vibration level≤5.6 m/s Failure: vibration level 5.6≥10 m/s Near catastrophic failure: vibration level >10 m/s 6- Actions: Bearing is Good Call for bearing change Bearing must be changed immediately
  17. 17. Proactive Maintenance: <ul><li>Definition: Determine the root causes of repeated failures and address these rather than just treating the symptom. </li></ul><ul><ul><li>E.g., if seals keep failing on a certain pump, do not just keep rebuilding the pump, figure out why they keep failing. </li></ul></ul><ul><ul><ul><li>Is the type of pump wrong for the application? </li></ul></ul></ul><ul><ul><ul><li>Is the seal material not compatible with the fluid being pumped? </li></ul></ul></ul><ul><ul><ul><li>Is the pump grossly mis-sized for the duty? etc. </li></ul></ul></ul><ul><li>Some root causes of failure: </li></ul><ul><ul><li>Poor Design/Poor Manufacturing, </li></ul></ul><ul><ul><li>Poor shipping, handling, and storage procedures, equipment becomes damaged or begins to degrade before it is installed, </li></ul></ul><ul><ul><li>Poor Installation, </li></ul></ul><ul><ul><li>Poor materials, </li></ul></ul><ul><ul><li>Poor working conditions. </li></ul></ul>
  18. 18. Main failures: Risk: Policy: 5- How to minimize the risk of failures? Main failures: Policy: 4- How to detect the early failures? Main failures: Policy: 3- How to discover the hidden failures? Main failures: PM: 2- How to prevent the failures? <ul><li>System description </li></ul><ul><li>Main parameters </li></ul><ul><li>Main items </li></ul><ul><li>Functional block diagram </li></ul><ul><li>Criticality </li></ul><ul><li>Working conditions </li></ul>1- How to keep or restore the facility at acceptable standard level in certain operating conditions? How? What is the Maintenance?
  19. 19. Computerized Maintenance Management Systems ( CMMS ) CMMS
  20. 20. Most common CMMS: Oil and Gas Companies in Arabic Countries: EMPAC www.plant-maintenance.com EMCMAINT www.emceg.com GMS www.first.com.eg GPS5 www.gps5.com IMPACT-XP www.impactxp.com IMPOWER www.impower.co.uk MAXIMO www.maximo.com MMMS www.kockw.com MP2 www.datastream.net OCEN www.soluziona.com PEMAC www.pemac.org RCM Turbo www.strategic.com SAP-RL INK www.osisoft.com