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‫وما توفيقي إال باهلل‬

Maintenance Management Overview

Dr. Attia Hussien Gomaa Maintenance Engineering Consultant Engineering service - American University in Cairo (AUC)

2008 MM

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

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Total Maintenance cost = Direct cost + Overhead cost + Downtime cost or Cost = PM cost + CM cost + Downtime cost

Total Maintenance Cost

PM Cost

Down Time Cost

CM Cost Best level PM level MM

Reliability Maintenance Management Overview – Dr. Attia Gomaa

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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. 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)

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Criticality Analysis Centrifugal Pump (System level)

HSE Effect Minor

Major (A)

Process Effect Major (B)

Criticality

Drain system

C

Water system

B

Oil system

A

Steam system

A

Fire-fighting system

A

Minor

Stand By Availability Without (C) MM

With (D) Maintenance Management Overview – Dr. Attia Gomaa

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Maintenance Policies (1)

Failure-Based Reactive (ReM): - RTF - CM - BD (2) :: Time-Based

(5)

(3) Condition-Based Predictive (PdM): - Oil analysis - Vibration analysis Preventive (PM): - Temperature analysis - Calendar: - Pressure analysis Weekly - Wear analysis Monthly - Efficiency analysis :: :: - Running: 1000 R.H. 1000 K.M. ::

Total-Based Global (GM): - OSM

- TPM :: (4) Risk-Based Proactive (PaM): - RCFA - FMEA \ FMECA - HAZOP - RCM \ RCM2 - RBI ::

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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 Reactive Preventive

Predictive

Proactive Global

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Approach

Goals

Run to failure (fix-it when Minimize maintenance costs for non-critical broke). equipment. Use-based maintenance program. Maintenance decision based on equipment condition.

Minimize equipment breakdown.

Detection of sources of failures.

Minimize the risk of failures for critical systems.

Integrated approach.

Maximize the system productivity.

Discover hidden failures and improve reliability for critical equipment.

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A comparison among proactive maintenance approaches

Policy

Approach

Goals

RCFA

Identification of root causes of failures.

Eliminate failures.

FMECA

Identification of criticality of failures.

Improve equipment availability.

HAZOP

Identification of hazards and problems associated with operations.

Improve HSE effect.

RCM

Determination of best maintenance requirements for critical systems.

Preserve system function & improve reliability.

RBI

Determination of an optimum inspection plan for critical systems.

Improve system HSE and availability.

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Comparison among global maintenance approaches

Policy OSM

TPM

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Approach Optimization approach for the global maintenance system. Comprehensive productivemaintenance system.

Goals

Maximize reliability measures and minimize maintenance cost rates. 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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Preventive Maintenance: 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)

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Predictive Maintenance:

Visual Inspection

Efficiency analysis

Wear analysis

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Vibration analysis

Oil analysis

Condition based management

Ultrasonic

Temperature analysis

Pressure analysis

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Atypical machine condition-vibration trend

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PdM Planning: 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.

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Best Method (vibration analysis, .. etc.) Best Frequency (inspection interval) Best Locations Best Tools International Standard (ISO10816, .. etc.) Standard Limits Severity Chart Trouble Shooting Chart Reference Creation Regular Measurements (monthly, .. etc.) Analysis Decision Making Corrective Actions - Good conditions, - Routine Maintenance, - Repair, or - Replace. Maintenance Management Overview – Dr. Attia Gomaa

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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 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 MM

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

2- How to prevent the failures?

How?  System description  Main parameters  Main items  Functional block diagram  Criticality  Working conditions 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 EMCMAINT GMS GPS5 IMPACT-XP IMPOWER MAXIMO MMMS MP2 OCEN PEMAC RCM Turbo SAP-RLINK MM

www.plant-maintenance.com www.emceg.com www.first.com.eg www.gps5.com www.impactxp.com www.impower.co.uk www.maximo.com www.kockw.com www.datastream.net www.soluziona.com www.pemac.org www.strategic.com www.osisoft.com Maintenance Management Overview – Dr. Attia Gomaa

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