002 Maintenance M Overview 20 06 06
Transcript of 002 Maintenance M Overview 20 06 06
MM
توفيقي ومابالله إال
Maintenance 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.
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.
Methodology A total view approach = Good communication(Maintenance, Process, HSE, Inventory, Resource, etc.)
Systematic Documented rule-based = Codes & StandardsPowerful Applicable and flexible =
Organization structure & Team approachEffectiveness 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)
MM 6Maintenance Management Overview – Dr. Attia Gomaa Company Logo
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
Reactive Run to failure (fix-it when broke).
Minimize maintenance costs for non-critical equipment.
Preventive Use-based maintenance program.
Minimize equipment breakdown.
PredictiveMaintenance decision based on equipment condition.
Discover hidden failures and improve reliability for critical equipment.
Proactive Detection 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
RCFA Identification of root causes of failures. Eliminate failures.
FMECA Identification 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
OSMOptimization 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