Presentation title: Maintenance Management & Planning Strategies Speaker name: Adel Al-Onaizi Job title: Senior Electrical Engineer Maintenance Company: Kuwait Oil Company

Effective Planning Strategies

Risk Based Approach & Inspection

Maintenance Strategies

Maintenance Management

About Maintenance

AGENDA

Maintenance:- A means to maintain and improve the quality of the elements involved in a production process, continuously and cost-effectively through detecting and controlling the deviation. Maintenance Challenges: To Deliver :

Regulatory Compliance High Plant availability Reliable Equipment Cost Effective & Target Maintenance Statuary/HSE Compliance

Delivery Sustainable Improvement is hard!

Little time available Resources reducing Priories changing

Source of Unreliability

Operations 30 50 %

Assets 30 40 %

Maintenance 10 30 %

Poorly defined & operating procedures & Training

Ineffective cross functional team-working

Lack of measures/targets Inconsistent Operation Lack of training

No adequate strategy Inadequate

monitoring/knowledge of condition

Poor/no rebuild specifications Lack of technical skills/training

Unreliable Plant

Inaccurate initial specification Poor design for maintenance or

operation Change of use/modification Ageing asset

Key steps to successful

Management

1

6

IMPROVEMENT

2

INSPECTION

3

PLANNING 4 SCHEDULING

5

EXECUTION

Implementing Maintenance

Overview of typical Maintenance Implementation Stages

7. Review & measure effectiveness

6. Record results & determine any further maintenance action

5. Plan work, issue work & carry out work

4. Select appropriate maintenance strategy/task

3. Carry out reliability & criticality audit

2. Carry out equipment audit

1.Establish business requirements

IMPLEMENTATION PHASE

Setting up Maintenance Programme can be viewed in four phase, viz.

Initial Set-up

Routine Maintenance

Obtaining useful KPIs

Optimization and Review

Selecting a Maintenance strategy

Selecting an appropriate strategy and choosing one or more techniques became simpler when failure mode are understood. A schematic of the decision process is shown in the figure below:

Overview Detail Comments

What are Maintenance Techniques?

Why do we chose

particular maintenance techniques?

Tasks or procedures designed to establish

serviceability

Match technique to failure mode and criticality

Select appropriate maintenance strategy

Feasibility of application of maintenance

technique

Detect/inspect Repair/restore

Exchange/Re-design

Historic information Failure mode analysis

(FMEA) (FMECA)

On failure Time based (Cyclical)

On condition Design out Opportunity

Simplest technique Safe to implement Physically possible

Confidence in technique Cost effective

Training requirements

Maintenance Decision Diagram

FIXED TIME MAINTENANCE

Y

Is there a reliable

indication/early warning of failure ?

Is the rate of deterioration or time of failure predictable & consistent ?

Is Maintenance likely to be

cost effective ?

Would routine service

extend file to failure ?

Agreed Maintenance

policy

Is the interval between

detection & failure sufficient

to act on ?

Is the suitable condition monitoring routine that

is cost effective & implemented and

operate ?

N

N

N N

Y CONDITION

BASED MONITORING

N

OPERATE TO FAILURE

Is Routine Service cost effective ?

OPERATE TO FAILURE

Y

N

Maintenance Strategy Decision

Planned Maintenance

Preventive Maintenance Scheduled or Fix Time Maintenance (FTM)

- Time interval based

Condition Based or Predicative Maintenance (CBM)- Equipment Condition Based

Routine Asset Care (RAS) - Regular running maintenance e.g. servicing, adjustments,

level checks

Proactive/Predictive or Design Out Maintenance [DOM] - Improvement based

Maintenance Strategy Decision

Unplanned Maintenance Corrective Maintenance or Operate to Failure

- Reactive or Breakdown

Risk Based Approaches

Clear need to anticipate future problems Identify future risk and opportunities Increasing Number of Application: Pressure System Equipment Maintenance Strategies Critical spares Maintenance & Calibration routines Critical trips and alarms Validation

Risk Assessment Matrix

Consequence Insignificant 1

Minor 2

Moderate 3

Major 4

Catastrophic 5 Likelihood

A (Rare) L L L M M B (Unlikely) L L L M H C (Moderate) L L M H E D (Likely) L M M H E E (Almost Certain)

L M H E E

Legend and outcomes: E extreme risk; immediate action required H high risk; senior management attention needed M moderate risk; management responsibility must be specified L low risk; manage by routine procedures

RISK BASED INSPECTION (RBI)

Optimize Operations, Maintenance and Inspection Regime Maximize Run Length of Facilities with Minimum of Risk leading

to improved facility availability

OPERATIONAL RISK

Equipment Production

People

RISK BASED INSPECTION

Target Approach

Criticality Analysis/

Opportunity Assessment

Detailed Assessment

Rapid Assessment

(80/20) Analysis

Generic Assessment

HIGH

MEDIUM

LOW

Decision Process

Task Definition

Document Strategy

RISK BASED INSPECTION Target Approach Screening

RISK BASED INSPECTION Target Approach Critical Analysis

RISK BASED INSPECTION Performance Improvement

RISK BASED INSPECTION Document Maintenance Strategy

PLANNING MANPOWER PRODUCTIVITY

PLANNING MANPOWER PRODUCTIVITY

HOW TO PLAN MAINTENANCE WORK

HOW TO PLAN MAINTENANCE WORK

HOW TO PLAN MAINTENANCE WORK

THANK YOU.

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