Applied Industrial Plant Maintenance

8/18/2019 Applied Industrial Plant Maintenance

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Applied Industrial Plant Maintenance


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Contents:

1. Introduction

2. Description Of Plant Operation

3. Description of existing maintenance plan

4. List of 22 items wic need maintenance

!. Detailed "tep #$ step maintenance plan

%. Critical pat anal$sis &CP'(

). *ealt and safet$ considerations

+. List te criteria re,uired

-. xamine 3 software Programmes

1/. "creensots of Programmes

11.O#ser0ation 0aluation

12.ustication

13. Conclusion


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Introduction

I am te maintenance super0isor for a mecanical engineering ser0ice

compan$ called Oil 5as urope6. I am responsi#le for te te

organisation of all maintenance witin te compan$6s #usiness.

Currentl$ all maintenance7 ser0ice orders and reports a0e #een recorded

#$ a paper #ased maintenance s$stem.

Our compan$ as grown considera#l$ o0er te last couple of $ears. 8e

manager as appro0ed tat a Computer 9aintenance 9anagement

"$stem &C99"( sould #e purcased and implemented trougout te

compan$ for all te maintenance operations.

I a0e #een set te tas of assessing di;erent software pacages and to

recommend te one most suited for te compan$6s needs.

Description of Plant Operation

9$ compan$ Oil 5as urope6 is a su#sea ser0ice compan$ tat focuses

on pro0iding drilling companies wit in riser safet$ s$stems. 8ese

s$stems allow well operations to #e conducted safel$ during drill stem

testing &D"8(. 8e$ pro0ide te a#ilit$ to rapidl$ sut in te well and

disconnect sould conditions re,uire it. Oil 5as urope6 also pro0ide *

landing strings. lectroe on


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deep water applications and addresses te disconnect pilosop$ from

d$namicall$ positioned mo#ile drilling units.

Description of existing maintenance:

Currentl$ Oil 5as urope6 use a paper #ased maintenance s$stem. O0er

te last couple of $ears Oil 5as urope6 a0e grown rapidl$ meaning a

paper #ased s$stem is no longer suita#le. 8is is incon0enient for te

compan$ #ecause it maes documents ard to nd and means documents

can #e easil$ damaged it also uses up a lot of storage area. ?e are

looing into purcasing a C99" #ecause it will allow ease of tracea#ilit$

regarding maintenance witin te compan$7 reduce storage and also

increase ealt and safet$ #$ remo0ing a possi#le re a>ard of paper

#ased documents.

Items to be maintained:

8o test te C99" programmes I a0e decided to create a maintenance

programme for one of our electrical $draulic control s$stems: =iser

control module &=C9(.

@elow is a list of 22 items tat need to #e maintained witin te =C9.

1. 9andrel

2. Crosso0er

3. Auic Connect Crosso0er

4. DCB

!. "OB

%. "9 Canister

). Lower 9ounting "lee0e

+. pper 9ounting "lee0e

-. Outer Co0er &Lower(

1/. Outer Co0er &pper(


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11. 8op lange

12. 9iddle lange

13. Lower lange

14. P88E Canister

1!. low 9eter

1%. low 9eter Canister

1). @ore 8ransducer

1+. "ear "uttle 'ssem#l$

1-. Cec Bal0e

2/. DCB 9anifold

21. "OB 9anifold

22. "plit =ing

Maintenance Plan:

@elow is a step #$ step maintenance plan for =iser Control 9odule.

Riser Control Module Maintenance Plan

No Description Asset No Service re!uenc"

1 9andrel *@//1 0er$ ! Fears

2 Crosso0er *@//2 0er$ ! Fears

3 Auic Connect Crosso0er *@//3 0er$ ! Fears

4 DCB *@//4 Fearl$! "OB *@//! Fearl$


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% "9 Canister *@//% Fearl$

) Lower 9ounting "lee0e *@//) 0er$ ! Fears

+ pper 9ounting "lee0e *@//+ 0er$ ! Fears

- Outer Co0er &Lower( *@//- 0er$ ! Fears

1/ Outer Co0er &pper( *@/1/ 0er$ ! Fears

11 8op lange *@/11 0er$ ! Fears12 9iddle lange *@/12 0er$ ! Fears

13 Lower lange *@/13 0er$ ! Fears

14 P88E Canister *@/14 Fearl$

1! low 9eter *@/1! Fearl$

1% low 9eter Canister *@/1% Fearl$

1) @ore 8ransducer *@/1) Fearl$

1+ "ear "uttle 'ssem#l$ *@/1+ Fearl$

1- Cec Bal0e *@/1- Fearl$

2/ DCB 9anifold *@/2/ Fearl$

21 "OB 9anifold *@/21 Fearl$22 "plit =ing *@/22 0er$ ! Fears

Critical Pat# Anal"sis:

Critical Pat 'nal$sis is a proGect management tecni,ue used to la$ out all

acti0ities needed to complete a tas7 te time it will tae to complete acti0it$

and te lin or relationsip #etween acti0ities. 8is metod can elp predict

weter a proGect can #e completed on time. CP' can #e used to reorganise te

proGect #efore it as started7 #ut also allows reorganisation during te proGect asit progresses. CP' allows proGects completion to #e ept on trac and ensures

deli0era#les are read$ on time.

CP' can #e done manuall$ or using computer software. 8e proGect manager

maes a list of acti0ities in te order te$ must #e completed wit time

expectations7 te$ ten proceed to create diagrams of te process.

$ealt# % Safet" Considerations:

8ere are a few ealt and safet$ considerations rele0ant to our assets we must

tae into account wen carr$ing out maintenance on components. It is also

important to follow Oil 5as urope6s6 maintenance document for te =C9

wic gi0es assem#l$Hdisassem#l$ procedure details and an$ additional safet$

informationHwarnings.

Lifting Operations and Lifting ,uipment =egulations &LOL=( must #e considered

during maintenance operations as man$ components are a considera#le weigt.

LOL= includes duties of people and companies wo own or a0e control o0er

lifting e,uipment. 8is includes e0er$ #usiness and organisations wose

emplo$ees use lifting e,uipment7 weter owned #$ tem or not. In most cases


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lifting e,uipment is also wor e,uipment so te Pro0ision and se of ?or

,uipment =egulations &P?=( will also appl$.

Personal Protecti0e ,uipment =egulations &PP( will also a0e to #e considered

wen carr$ing out maintenance on =C9. PP co0ers personal safet$ e,uipment

suc as ig 0isi#ilit$ re retardant co0eralls7 safet$ #oots7 safet$ goggles and

safet$ elmets.

Control of "u#stances *a>ardous to *ealt &CO"**( =egulations co0ers all

su#stances tat can #e a>ardous to ealt. In our =C9 we a0e a sealed

cam#er lled *$draulic luid and anoter sealed cam#er lled wit dielectric

uid tese uids would #ot fall under CO"**.

Criteria Re!uired

8ere are a few aspects to #e considered wen identif$ing a suita#le C99"

pacage for Oil 5as urope7 tese include te cost of te programmes7 securit$

of te programmes7 te ease of use and information input witin te programme.

8e #elow #ullet points are te criteria6s witin te programmes I will #e looing

at.

• ase Of se

• Information Input

• Cost

• "ecurit$

&xamine ' soft(are programmes

irst of all I input ! items into eac of te 3 programmes7 C?O=J"7 rontline

9aintenance and xpress 9aintenance to see wic 2 programmes I wanted to

do furter examination on using m$ 22 items a#o0e.

I decided to disregard rontline maintenance at tis point #ecause it ad no login

or user name option meaning te securit$ of te programme could #e low and it

was ,uite diKcult tot use.

Customisation

I now decided to loo into 2 programmes in more dept #$ customising

maintenance information into tem. or te customisation process I decided touse C?O=J" and xpress 9aintenance7 I disregarded ronline maintenance at

tis stage #ecause after ,uicl$ stud$ing te programme it looed 0er$

complicated to use. I input te 22 items stated a#o0e into C?O=J" and xpress

9aintenance to see wic programme I lied #est. I a0e attaced screensots

from eac of te programmes #elow:

C)OR*S igure +: ,, Assets (it#in

C)OR*S


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igure ,: Additional Info tab in Assets

igure ': Detailed Asset + (it#in C)OR*S


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igure -: Detailed Asset , (it#in C)OR*S

&xpress Maintenance

igure .: Detailed Asset + (it#in &xpress Maintenance


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igure /: Detailed Asset , (it#in &xpress Maintenance

igure 0: 1ist of ,, assets (it#in &xpress Maintenance

Observation % &valuation

C)OR*S

C?O=J" seems to #e a secure programme as te log in re,uires user name and

password input. 8e programme is 0er$ eas$ to use and allows $ou to input

assets extremel$ ,uicl$. It allows a great deal of information to #e added a#out

maintenance scedules and oter information a#out te components. 8ere is

e0en an additional information6 ta# were maintenance notes can #e added to

eac aspect. 8ere is noting to dislie a#out tis apart from one pro#lem tat

te software does not allow $ou to delete an asset once it as #een sa0ed. 'part

from tat tis software is simple it loos good #ecause te icons mae it easier

on te e$es. C?O=J" costs approximatel$ M%)/ for an annual mem#ersip.

'dditional pacages are a0aila#le wic co0er te costs of premium support and

allow extra inputs to te programme. 8e programme can #e installed troug

te installation CD meaning no external compan$ as to #e sent out to set it up.

Installation can also #e done remotel$ and site wide #$ te I8 department witin

te compan$. Discounts on cost are a0aila#le if more tan % annual licences are

#eing purcased.

&xpress Maintenance


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xpress 9aintenance does not re,uire a password and user name on log in

meaning it is possi#le not as secure of a programme as it could #e. xpress

9aintenance is ,uite a complicated software to use. It re,uired a few trial and

error6 #efore I managed to correctl$ input m$ assets. 8e information input

allows te most important information to #e added #ut it taes a wile to get

used to te input process. I dislie te loo of tis programme #ecause it6s ,uite#us$ and as a lot of writing. xpress 9aintenance costs M-// for an annual

mem#ersip tis includes installation of te programme #ut re,uires a 3rd part$

0endor to #e sent out.

2usti3cation

I a0e created a ta#le of te criteria of te 3 programmes and scored tem all

out of 1/.

Programme NameSecurit

"&ase of

4seInformation

Input CostC?O=J" - - - -xpress 9aintenance % ) ) %rontline 9aintenance % 2 ! )

'fter careful consideration I a0e decided te #est maintenance programme for

Oil 5as urope is C?O=J". It scored te igest out of te 3 programmes as

seen a#o0e. It is te easiest to use out of te programmes studied7 it is te mostsecure7 all te re,uired information a#out te components can #e added7 and it

loos good. C?O=J" also comes in te ceapest out of te 3 programmes

meaning it will #e cost e;ecti0e for te compan$. 'n annual mem#ersip onl$

costs M%)/ wit te option to upgrade to a premium mem#ersip. 8e fact te

programme can #e installed 0ia CD or remotel$ #$ I8 department means it is a

#onus for ease of Installation Compan$ wide.

Conclusion

In conclusion I feel C?O=J" is o0erall te #est maintenance programme for Oil

5as urope. It is eas$ to use7 cost e;ecti0e as well as allowing group discount forsite purcase6s7 allows a lot of information to #e added regarding maintenance of

component6s7 allows additional information input and it loos good #ut also as

good securit$ wit a user name and password log in.

Documents

Applied Industrial Plant Maintenance