Maintenance Management Overview

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

2008
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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 To keep To restore Facility All activities (information, analysis, repair, etc.) Planned maintenance (Preventive, Predictive and proactive) policy for critical equipment Unplanned maintenance (Corrective or run to failure policy for non-critical equipment System level (equipment, unit, plant)

Acceptable standard Acceptable level at certain working condition (HSE, level working hours, etc.)
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Maintenance Management Overview Dr. Attia Gomaa

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

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Reliability
Maintenance Management Overview Dr. Attia Gomaa

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 Systematic A total view approach = Good communication (Maintenance, Process, HSE, Inventory, Resource, etc.) Documented rule-based = Codes & Standards

Powerful
Effectiveness Resource

Applicable and flexible = Organization structure & Team approach

Utilization + performance + efficiency Materials, manpower, tools, equipment, subcontractors, and cost

Productivity
Policy Maint. Policy

Resource utilization and efficiency

Certain rules and program for long term Failure-based, time-based, condition-based, and risk-based

Criticality
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Effect on HSE, Process, Standby and Cost

Maintenance Management Overview Dr. Attia Gomaa

Main Points: - Change management

- Leadership & organization structure

- Criticality Analysis - Maintenance Policies

- Maintenance Program
- Performance Evaluation - KPI (Key performance indicators)

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Maintenance Management Overview Dr. Attia Gomaa

Criticality Analysis
HSE Effect Minor

Centrifugal Pump (System level)

Criticality

Major (A)

Drain system
Water system

C
B A A A

Process Effect Major (B)

Oil system Steam system Fire-fighting system

Minor

Stand By Availability Without (C)

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With (D)
Maintenance Management Overview Dr. Attia Gomaa
Company Logo

Maintenance Policies
(1)
(5)

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

(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

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. Detection of sources of failures. Integrated approach.
Minimize equipment breakdown. Discover hidden failures and improve reliability for critical equipment. Minimize the risk of failures for critical systems. Maximize the system productivity. 8

Predictive

Proactive Global

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Maintenance Management Overview Dr. Attia Gomaa

A comparison among proactive maintenance approaches

Policy RCFA FMECA HAZOP RCM

Approach Identification of root causes of failures. Identification of criticality of failures. Identification of hazards and problems associated with operations.

Goals Eliminate failures. Improve equipment availability. Improve HSE effect.

Determination of best maintenance requirements for critical systems.

Determination of an optimum inspection plan for critical systems.

Preserve system function & improve reliability.

Improve system HSE and availability.
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RBI
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Maintenance Management Overview Dr. Attia Gomaa

Comparison among global maintenance approaches

Policy OSM

TPM

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

Time-Directed Maintenance (TD)

To detect early failures

Condition-Directed Maintenance (CD)

To discover hidden failures

Failure Finding (FF)

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Predictive Maintenance:
Vibration analysis

Visual Inspection

Oil analysis

Efficiency analysis

Condition based management

Temperature analysis

Wear analysis

Ultrasonic

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. 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.
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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 level5.6 m/s Failure: vibration level 5.610 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? 1- How to keep or restore the facility at acceptable standard level in certain operating conditions?

How?
System description Main parameters Main items Functional block diagram Criticality Working conditions Main failures: PM: Policy:

2- How to prevent the failures?

3- How to discover the hidden failures? Main failures: 4- How to detect the early failures?
Main failures: Policy: Risk: Policy:

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

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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
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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
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