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Maintenance Management OverviewMaintenance Management Overview

Dr. Attia Hussien GomaaMaintenance Engineering Consultant

2008

Engineering service - American University in Cairo (AUC)

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Refer to BS3811:2000

Maintenance is the work undertaken in order to keep or restore a facility to an acceptable standard level.

Refer to BS3811:2000

Maintenance is the work undertaken in order to keep or restore a facility to an acceptable standard level.

Work undertaken All activities (information, analysis, repair, etc.)

To keep Planned maintenance (Preventive, Predictive and proactive) policy for critical equipment

To restore Unplanned maintenance (Corrective or run to failure policy for non-critical equipment

Facility System level (equipment, unit, plant)

Acceptable standard level

Acceptable level at certain working condition (HSE, working hours, etc.)

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CostCost

PM CostPM CostTotal Maintenance CostTotal Maintenance Cost

CM CostCM Cost

Best levelBest level

Down Time CostDown Time Cost

PM level PM level Reliability Reliability

Total Maintenance cost = Direct cost + Overhead cost + Downtime cost

or= PM cost + CM cost + Downtime cost

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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.

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.

Methodology A total view approach = Good communication(Maintenance, Process, HSE, Inventory, Resource, etc.)

Systematic Documented rule-based = Codes & Standards

Powerful Applicable and flexible =Organization structure & Team approach

Effectiveness Utilization + performance + efficiency

Resource Materials, manpower, tools, equipment, subcontractors, and cost

Productivity Resource utilization and efficiency

Policy Certain rules and program for long term

Maint. Policy Failure-based, time-based, condition-based, and risk-based

Criticality Effect on HSE, Process, Standby and Cost

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Main Points:

- Change management

- Leadership & organization structure

- Criticality Analysis

- Maintenance Policies

- Maintenance Program

- Performance Evaluation

- KPI (Key performance indicators)

Main Points:

- Change management

- Leadership & organization structure

- Criticality Analysis

- Maintenance Policies

- Maintenance Program

- Performance Evaluation

- KPI (Key performance indicators)

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Criticality Analysis

HSE Effect

Stand By Availability

Process Effect

Major(B)

Major (A)

Without(C)

With(D)

Minor

Minor

Centrifugal Pump(System level)

Criticality

Drain system C

Water system B

Oil system A

Steam system A

Fire-fighting system A

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Maintenance Policies(1)

Failure-BasedReactive (ReM):- RTF- CM - BD::

(2)Time-BasedPreventive (PM):- Calendar: Weekly Monthly ::- Running: 1000 R.H. 1000 K.M. ::

(3)Condition-BasedPredictive (PdM):- Oil analysis- Vibration analysis- Temperature analysis- Pressure analysis- Wear analysis- Efficiency analysis ::

(5)Total-BasedGlobal (GM):

- OSM

- TPM ::

(4)Risk-BasedProactive (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]

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Comparison of different maintenance policies

Policy Approach Goals

ReactiveRun to failure (fix-it when broke).

Minimize maintenance costs for non-critical equipment.

PreventiveUse-based maintenance program.

Minimize equipment breakdown.

PredictiveMaintenance decision based on equipment condition.

Discover hidden failures and improve reliability for critical equipment.

ProactiveDetection of sources of failures.

Minimize the risk of failures for critical systems.

Global Integrated approach.Maximize the system productivity.

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A comparison among proactive maintenance approaches

Policy Approach Goals

RCFAIdentification of root causes of failures.

Eliminate failures.

FMECAIdentification of criticality of failures.

Improve equipment availability.

HAZOPIdentification of hazards and problems associated with operations.

Improve HSE effect.

RCMDetermination of best maintenance requirements for critical systems.

Preserve system function & improve reliability.

RBIDetermination of an optimum inspection plan for critical systems.

Improve system HSE and availability.

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Comparison among global maintenance approaches

Policy Approach Goals

OSM

Optimization approach for the global maintenance system.

Maximize reliability measures and minimize maintenance cost rates.

TPMComprehensive productive-maintenance system.

Maximize plant effectiveness and resource productivity.

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Facility equipment are divided into four major categories:

• Run-to-Failure - Most cost effective to let equipment run unattended until it fails. Used on lowest priority equipment.

• Preventive Maintenance - Perform maintenance tasks on a piece of equipment at regular intervals, whether the equipment needs it or not.

• Predictive Maintenance - Perform maintenance based upon real-time data collected on a piece of equipment. This data shows the ‘health’ of the equipment

• 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)

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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:

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Predictive Maintenance:

Condition basedmanagement

VisualInspection

Vibrationanalysis

Ultrasonic

Pressureanalysis

Temperatureanalysis

Oil analysis

Efficiency analysis

Wearanalysis

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Atypical machine condition-vibration trend

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PdM Planning:1. Best Method (vibration analysis, .. etc.)2. Best Frequency (inspection interval)3. Best Locations4. Best Tools5. International Standard (ISO10816, .. etc.)6. Standard Limits7. Severity Chart8. Trouble Shooting Chart9. Reference Creation10. Regular Measurements (monthly, .. etc.)11. Analysis 12. Decision Making13. Corrective Actions

- Good conditions, - Routine Maintenance, - Repair, or - Replace.

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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 componentsRecord 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

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Proactive Maintenance:

• Definition: Determine the root causes of repeated failures and address these rather than just treating the symptom. – E.g., if seals keep failing on a certain pump, do not just keep rebuilding

the pump, figure out why they keep failing. • Is the type of pump wrong for the application? • Is the seal material not compatible with the fluid being pumped? • Is the pump grossly mis-sized for the duty? etc.

• Some root causes of failure:– Poor Design/Poor Manufacturing,– Poor shipping, handling, and storage procedures, equipment becomes

damaged or begins to degrade before it is installed,– Poor Installation,– Poor materials,– Poor working conditions.

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What is the Maintenance? How?

1- How to keep or restore the facility at acceptable standard level in certain operating conditions?

System description Main parameters Main items Functional block diagram Criticality Working conditions

2- How to prevent the failures? Main failures:PM:

3- How to discover the hidden failures? Main failures:Policy:

4- How to detect the early failures? Main failures:Policy:

5- How to minimize the risk of failures? Main failures:Risk:Policy:

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Computerized Maintenance Management Systems (CMMS)

CMMS

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Most common CMMS:

Oil and Gas Companies in Arabic Countries:

EMPAC www.plant-maintenance.comEMCMAINT www.emceg.comGMS www.first.com.egGPS5 www.gps5.comIMPACT-XP www.impactxp.comIMPOWER www.impower.co.ukMAXIMO www.maximo.comMMMS www.kockw.comMP2 www.datastream.netOCEN www.soluziona.comPEMAC www.pemac.orgRCM Turbo www.strategic.comSAP-RLINK www.osisoft.com