CHAPTER 1

TURNAROUND Role In Maintenance Management

MAINTENANCE

Act of causing to continue [New Oxford Dictionary]

DEFINITION
TRADITIONAL DEFINITION :
The combination of all technical and associated actions intended to retain an item in, or, restore it to a state in which it can perform its required function.

CURRENT DEFINITION :
All actions that are carried out to safeguard the technical integrity of an asset and to ensure its availability such that maximum cash returns can be realized from the asset thereby enhancing the value of the asset.

ROLE OF MAINTENANCE
Preserve and prolong the working life of plant and equipment. Upkeep and protection of plant, buildings, machinery and other fixed assets. Safeguard investment by minimising deterioration. Keep the assets in efficient working condition. Ensure reliability of plant and equipment. Minimise idle time and loss of production. Maximise efficiency through optimum use of facilities. Generate a safe and healthy, working environment and maintain safety consciousness. Minimise maintenance cost. Improve performance of plant and machinery. Keep abreast of latest maintenance techniques and achieve excellence to meet the new challenges.

NEED FOR MAINTENANCE

To keep assets in top condition. To avoid failures. To minimize hazardous situations. To correct deterioration. To modify plants. To generate safe working conditions. To obtain on grade products. To increase productivity. To reduce wastage of material & parts. To reduce manufacturing cost. To add in high quality & economical operation.

MAINTENANCE
BUSINESS OBJECTIVES INCREASES CASH MARGIN
INCREASES SALES AND REVENUE

INCREASE RESERVES

REDUCES OPERATING COSTS

INCREASES PRODUCTION

COST EFFECTIVE MAINTENANCE

HIGH FACILITY AVAILABILITY

TYPES OF MAINTENANCE
BREAKDOWN MAINTENANCE
This is a PANIC or CRISIS maintenance It is not desired at all in today's environment

TYPES OF MAINTENANCE
BREAKDOWN MAINTENANCE
BATH TUB CURVE
Infantile Deaths Wear-out Stage Abnormal Operations

DISADVANTAGES
Uncertain - Occurrence & Repairs Uncertain Production Costly Repairs Unsafe Situation

TYPES OF MAINTENANCE
PREVENTIVE MAINTENANCE
This is a systematic and planned attention, monitoring and analysis. It is most effective if there is strong age related failure mode. The guiding principle is Prevention is better than cure

OBJECTIVES OF PREVENTIVE MAINTENANCE:

Retard process of deterioration and wear Asses extent of deterioration Action to restore original capacity Improve reliability and maintainability of equipment thus eliminating breakdown

TYPES OF MAINTENANCE
PREVENTIVE MAINTENANCE EXAMPLES
Visual External Inspection
Lubrication Replenishments Strainer Cleaning Painting

Adjusting Belt Tension

Preventive Maintenance Programme

TYPES OF MAINTENANCE
ADVANTAGE OF PREVENTIVE MAINTENANCE Less down time
Fewer repetitive repairs Lower repair cost than breakdown repair cost Superior quality control Increased life of plant and equipment Need of standby equipment reduced Reduction in maintenance cost Leveled workload and workforce Better spares control Enhanced safe working conditions Increase in production

TYPES OF MAINTENANCE
PREDICTIVE MAINTENANCE

By predictive maintenance equipment condition can be known during normal operation through : Online monitoring, measurements, ND testing, etc. Health of equipment can be predicted with certainty and necessary corrective actions generated The result of predictive maintenance can be extrapolated to determine useful residual life Leading to prediction of approximate date of failure

TYPES OF MAINTENANCE
PREDICTIVE MAINTENANCE EXAMPLES
Ultrasonic thickness measurements
On-line vibration measurements Measurement program Testing lubricating oil / hydraulic oil

TYPES OF MAINTENANCE
POPULAR PREDICTIVE MAINTEANCE TECHNOLOGY
TECHNOLOGY Iodic vibration analysis Vibration analysis On-line vibration analysis Oil sample analysis Thermography Motor stator analysis & elect. Surge testing Motor current signature analysis Air borne ultrasonics Pulse-echo ultrasonics Process parameters APPLICATIONS All rotary equipment All rotary equipment Critical rotary equipment Critical & low speed equipment Electrical components, Motor stator and insulation Break down Motor rotor bars, eccentricity Steam traps, vacuum leaks Pipe and vessel thickness Process or mechanical Degradation

TYPES OF MAINTENANCE
PROACTIVE MAINTENANCE
Proactive Maintenance emphasizes on
Root Cause Failure Analysis Precision repairs and installation Training of maintenance and operational personnel Review and correct purchase specification

Proactive maintenance is easily integrated with predictive maintenance and completes the platform needed for Reliability Centered Maintenance program

TYPES OF MAINTENANCE
ADVANTAGES OF PROACTIVE MAINTENANCE
Repetitive problems that shorten component life are identified and designed out This can include standards placed on suppliers for performance acceptability of their products/services, and verification that these are met Assuring that equipment installation is done to precision standards (Balancing, Aligning) leading to extended life Factors limiting component life are identified and eliminated Reliability centered maintenance program

TYPES OF MAINTENANCE

TYPES OF MAINTENANCE

ROOT CAUSE FAILURE ANALYSIS

BREAKDOWN MAINTENANCE

PREVENTIVE MAINTENANCE

PREDICTIVE MAINTENANCE

PROACTIVE MAINTENANCE

RELIABILITY CENTERED MAINTENANCE

TYPES OF MAINTENANCE
The human body parallel to Machine Maintenance
Maintenance strategy Proactive maintenance Technique needed Cost / Barrel / year Monitoring and $ 0.10 correction of failure root causes e.g. contamination Monitoring of $8 vibration and wear Periodic component replacement $ 13 Human body parallel Cholesterol and blood pressure monitoring with diet control Detection of heart disease using ECG or ultrasonics By pass or transplant surgery Heart attack or stroke

Predictive maintenance Preventive maintenance Breakdown maintenance

Large maintenance $ 18 budget

MAINTENANCE ROLE PERFORMANCE

Maintenance areas Rotary maintenance group Inspection function Mechanical workshops Electric shop

Instrument shop
Mobile equipment shop

MAINTENANCE ACTIVITIES
List of work for next week with priorities from each area
Back-logs/operations requirements Preventive maintenance Rotary group recommendations

Planning - estimates workforce needs. Allocates to areas Areas arrange materials and execute work

MAINTENANCE ACTIVITIES
Job orders to shops Material movements History cards Spare parts inventory Central tool store Training needs Maintenance budget Turnaround - advance activities

MAINTENANCE ACTIVITIES

Planned Maintenance

Turnaround Maintenance
Prevents breakdowns and extends operating life Proper estimate of resource requirements Maximise smooth plant runs

MAINTENANCE ACTIVITIES

Turnaround Maintenance
Internal inspection - all static equipment - repairs & renewal
Piping - hammer sounding / utm

Overhaul all vital & essential rotary equipment / relief valves

Overhaul electrical equipment Overhaul instrumentation Safety jobs / modification jobs Data base on condition of equipment

END OF CHAPTER 1