Definition

The combination of all technical and administrative

actions, including supervision actions intended to
retain an equipment , or restore it to, a state in which it
can perform a required function or equipment can be
operated to its designed operating capacity with in its
defined parameters.

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 MAINTENANCE STRATEGIES
1. Maintenance strategies
2. No Maintenance strategies
3. Repair & replacement equipment
4. Preventive Scheduled Maintenance (PM)
5. Predictive Maintenance (PdM)
6. Reactive Maintenance
7. Reliability Centered Maintenance(RCB)
8. Risk Based Maintenance(RBM)
9. Total Productive Maintenance(TPM)
10. Value Driven Maintenance(VDM)
11. Evidence Based Asset Maintenance(EBAM)
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Preventative (scheduled) maintenance (PM):It consists of assets being
taken offline, inspected at periodic, predetermined intervals and repaired
if necessary.
Predictive maintenance (PdM):Condition-based approach to asset
management. The advantage of PdM (over PM) is the potential for cost
savings from reduced man-hours spent on maintenance, and more insight
as to the performance and potential issues arising with the machine. ie:
Vibration analysis + visual inspection gives more insight than visual
inspection alone.
Reliability-centered maintenance (RCM):Emerging from the realization
that equipment failure probability is not linear, RCM is an in-depth, highly
involved process that seeks to analyze all the possible failure modes for
each piece of equipment, and customize a maintenance strategy for each
individual machine.
Value driven maintenance: The decision to perform maintenance at any
time is based on cost/benefit analysis. It requires a delicate balancing
between the value that improved reliability can bring and the cost of
maintenance. This is summed up in the four value drivers such as Asset
Utilization, Resource allocation, Cost control,

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Evidence Based Asset Maintenance(EBAM): is the science of
making the right decisions and optimizing asset management
processes with the best available data and with decision criteria
clearly defined. Data-driven decisions provide the most
advantageous methodology for minimizing costs and maximizing
the return on investment from physical assets. Making evidence
based asset management data driven decisions requires access to
maintenance and financial data; therefore, accurately logging
maintenance activities. The four key asset management decision
areas are outlined below:
1. Component replacement.
2. Inspection decision.
3. Capital equipment replacement.
4. Resource requirement.

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Scheduled Maintenance Critical Percentage(SMCP):
shows how late your scheduled maintenance work orders are in relation
to the maintenance schedule. The higher the percentage, the more
attention you should pay to that scheduled maintenance work order. It
takes into consideration the number of days late versus the PM cycle.
scheduled maintenance critical percent is calculated from the following
formula:
(Days late + PM cycle) /PM cycle * 100%.
Why is scheduled maintenance critical percent important? Unplanned
maintenance is generally more expensive than planned maintenance so
by performing your PMs on time or as close to on time as possible can
help avoid any unscheduled breakdowns, repairs and downtime. This
calculation is a simple way to determine which overdue planned
maintenance items should be completed first. scheduled maintenance
critical percent is easy to calculate but critical percent reports should ship
with any good CMMS package.
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 COMPUTERIZED MAINTENANCE MANAGEMENT SYSTEM
A CMMS system is computer software that helps maintenance teams
keep a record of all assets they are responsible for, schedule and
track maintenance tasks, and keep a historical record of work they
perform. We’ve outlined some of the key areas that a CMMS is used
for below:
1. Tracking work orders
2. Scheduling tasks
3. External work requests
4. Recording asset history
5. Managing inventory
6. Audit and certification

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 MAINTENANCE STRATEGIES
 Computerized Maintenance Management System (CMMS) system
is computer software that helps maintenance teams keep a record
of all assets they are responsible for, schedule and track
maintenance tasks, and keep a historical record of work they
perform. We’ve outlined some of the key areas that a CMMS is
used for below:
 Tracking work orders
 Scheduling tasks
 External work requests
 Recording asset history
 Managing inventory
 Audit and certification

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 MAINTENANCE KPI’S

1. Basic Maintenance Metrics.

2. Maintenance Backlog.
3. Mean time to Repair (MTTR).
4. Mean Time Between Failure(MTBF)
5. System Availability.
6. Overall Equipment Effectiveness(OEF).
7. PM Compliance(PMC).
8. Planned Maintenance Percentage(PMP).
9. Scheduled Maintenance Critical Percentage(SMCP).

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 RELIABILITY MAINTENANCE
 Maintenance & reliability are closely related. Reliability starts with
equipment that has been designed for operating conditions &
performance, is necessary that it be operated correctly with in
design limits and according to specified operating parameters.
Correct maintenance is to be carried out to achieve equipment
reliability.
 Importance of bringing the right technology, right equipment
and the right people to build strong systems for improving
Reliability.
 Compliance to Standard Operating Procedure (SOPs) and
Standard Maintenance Procedure (SMP) for improving the
reliability and profitability of the Corporation.

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 RELIABILITY MAINTENANCE
 Reliability is not just mechanical availability but encompasses safety
and energy efficiency also and asset management.

 Introspection is vital to improve our Operations and Maintenance

practices further and as compared to the international benchmarks.

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 RELIABILITY CENTERED MAINTENANCE
 Reliability centered maintenance (RCM) is a corporate-level
maintenance strategy that is implemented to optimize the
maintenance program of a company or facility. The final result of an
RCM program is the implementation of a specific maintenance
strategy on each of the assets of the facility. The maintenance
strategies are optimized so that the productivity of the plant is
maintained using cost-effective maintenance techniques.
There are four principles that are critical for an reliability centered
and maintenance program.
1. The primary objective is to preserve system function
2. Identify failure modes that can affect the system function
3. Prioritize the failure modes
4. Select applicable and effective tasks to control the failure modes

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 RELIABILITY CENTERED MAINTENANCE
EFFECTIVE RELAIBILITY CENTERED MAINTENANCE
 An effective reliability centered maintenance implementation
examines the facility as a series of functional systems, each of which
has inputs and outputs contributing to the success of the facility. It is
the reliability, rather than the functionality, of these systems that are
considered. The SAE JA1011 has a set of minimum criteria before a
maintenance strategy can be called RCM. The seven questions that
need to be asked for each asset are:
 What are the functions and desired performance standards of each
asset?
 How can each asset fail to fulfill its functions?
 What are the failure modes for each functional failure?
 What causes each of the failure modes?
 What are the consequences of each failure?
 What can and/or should be done to predict or prevent each failure?
 What should be done if a suitable proactive task cannot be
determined?

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 MAINTENANCE PLANNING
 Maintenance Planning:
 This is the process in which maintenance work is documented, resources are assigned, work
and safety procedures are identified.
 Maintenance planning identifies and links maintenance needs to maintenance work that
addresses those needs. Planning is required to make the best possible use of human and
financial resources. In Maintenance Planning steps involved are:
 Annual maintenance work plan & long term maintenance plan: should focus on
reasonable expectations and realistic goals. It is used to develop budgets for each
maintenance activity that should be completed during the upcoming year.
» What are the priorities that are required to be addressed?
» Are there enough human and financial resources to deliver the service , if not
ask ?
» When can work be completed?
» Are there program restrictions that need to be considered?
» Are there areas of concern that have been identified during inspections?
» Plan for the Lowest Required Skill Level
 Reasoning
» Why is this task necessary, does it respond to the goals?
» What tasks will be completed over the next 12 months (action plan)?
» Who will be responsible for completing each task?
» When will each task be completed by?
» Where will the human and financial resources come from?

 Approval of plan
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 MAINTENANCE SCHEDULING
 Maintenance Scheduling:
 Planning decides what, how and time estimate for a
job. Scheduling decides when and who will do the job. Planning
of a job should be done before Scheduling a job.
 This is the process in which all resources which are required for work
are scheduled for execution within a specified time frame.
 Schedules and Job Priorities are Important
 Schedule for Every Work Hour Available
 Executing this component requires an understanding of equipment
/asset availability as well as technician, material, and specialty tool
availability.
 Coordination:
 Maintenance Excellence:
 Maintenance KPI are achieved
 Measure Performance with Schedule Compliance
 Overall equipment effectiveness
 No maintenance backlog
 Benchmarking With international standards

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 MAINTENANCE PLANNING & SCHEDULING INCLUDES

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 ADVNATAGE OF PLANNING & SCHEDULING

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 MAINTENANCE COST OPTIMIZATION
 Misdirected maintenance:
Unnecessary work.
Unproductive work
Counterproductive work

 Inefficient maintenance strategies

 Reactive maintenance: Also described as “fix it when it breaks”. This
is the most basic maintenance strategy. Its major drawback is
obvious: the cost to repair (or replace) equipment that is run to
failure is typically much higher than if the problem were detected.

 Preventive maintenance. A preventive strategy assumes equipment

is relatively reliable until, after some period of time, it enters a
.wear-out. zone where failures increase. To postpone this wear-out,
equipment is serviced on a calendar- or run-time basis − whether it
needs it or not. This approach is about 30% less expensive than
reactive.

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 MAINTENANCE COST OPTIMIZATION
 There is an even bigger problem: only about 6% of equipment follows a
time-based “wear-out” pattern. For most other equipment . over 90% −
failures typically result from the cumulative effects of events or
conditions that can occur at any time. That means schedule-based
preventive maintenance can also come too late, after the damage has
begun.
 Optimal control interval determination using minimization the
financial costs
 Benchmarking the opportunity: Improvement in almost every
operation. Industry Benchmarks can help you estimate the
potential in your plant. One frequent benchmark of maintenance
productivity is annual maintenance cost as a percentage of
replacement asset value (RAV) as:
 RAV as 2-3% is excellent
 RAV as 4-7% is typical
 RAV as 20 % is worst
It Is a trend that shows no sign of changing. Plants must therefore increase
the productivity of their existing maintenance
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 MAINTENANCE COST OPTIMIZATION
MAINTENANCE COST OPTIMIZATION CAN BE ACHIEVED THROUGH:
 Predictive maintenance: The third strategy overcomes these
drawbacks by constantly monitoring actual equipment condition
and using the information to predict when a problem is likely to
occur. With that insight, you can schedule maintenance for the
equipment that needs it . and only what needs it − before the
problem affects process or equipment performance. That’s a great
way to improve maintenance productivity, as well as reduce costs
for repairs and unexpected downtime.
 Proactive maintenance. The next strategy is proactive
maintenance, which analyzes why performance is degrading and
then corrects the source of problems. The goal is not just to avoid a
hard failure, but to restore or even improve equipment
performance.

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 HEALTH ASSESSMENT
Why health & remaining life assessment of Equipments is required?
 Increasing cost of new equipment and diminishing resources.
 Extended lead time in plant construction & procurement.
 Stringent environmental, safety and other regulations.
 Increasing awareness for exploring the technological feasibility in
extending component life.
 To avoid environmental / statutory authorities / equipment down
time.

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 HEALTH ASSESSMENT
A pragmatic approach is adopted in handling the cases of
remaining life assessment with :.
 Collection of as much data as possible on the component /
equipment history.
 Brain storming sessions are conducted with the concerned
engineers and technicians using the equipment.
 Other experts who are familiar with the operational details.
 Material & data analysis.
 Arrive a conclusion for further proceeding.
 Re-assessment of equipment health.

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 DESIGN APPROACH
 Components are designed on the basis of yield strength, tensile
strength and fatigue strength with suitable safety factors.
 Under normal operating conditions, deformation and fracture are
not time dependent. As long as the applied stresses do not exceed
the design stresses these components should theoretically last for
indefinite time.
 But in practice various factors cause reduction in life. The Salient
Features Involved are:
• UNDERSTANDING THE ACTUAL DEGRADATION MECHANISM
– High cycle fatigue
– Low cycle fatigue
– Thermal fatigue
– Thermal aging
– Wear
– Corrosion

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 ANALYSIS CRITERIA
 VISUAL EXAMINATION
 NDT involving In-situ Metallography, Ultrasonic Testing,
Magnetic Particle Inspection, DP Test, Ferrite Measurement.
 STRESS ANALYSIS : Stress analysis is carried out to know the
strength of the material.
 NON DESTRUCTIVE TESTING : NDT inspection data provide
good understanding of the component integrity.
 LABORATORY TESTING : Laboratory testing of cut samples
provide valuable information about the material soundness.
 JUDGMENT OF FITNESS OF THE EQUIPMENT : Based on
available data, a judgement about the fitness of the equipment: If
required, repairing of the equipment is suggested, for life extension.
 JUDGMENT OF REMAINING LIFE BASED ON ANALYSIS :
Finally, the estimation for remaining life is carried out.

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 DATA REQUIREMENT FOR LIFE ASSESSMENT
Item Level I Level II Level III
Feature Least detail More detail Most detail

Failure history Plant records Plant records Plant records

Dimensions Design or nominal Measured or nominal Measured

Condition Records or nominal Inspection Detailed

Measured in detail
Temperature and Operational or
Design operational with aid of
pressure measured
instruments

Stresses Design or operational Simple calculation Refined analysis

Material properties Minimum Minimum Actual material

Material samples
No No Yes
required?
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 REMAINING LIFE ASSESSMENT
 After consideration of design factors, safety factors, the extent of
degradation, judgment on the remaining life is made.
 In addition to this, periodic inspection procedures are formulated
and followed to monitor the health of the equipment during the
course of operation.
 RLA is done based on life limiting factors like corrosion, creep and
microstructure degradation with respect to time.
 There are different approaches available to assess the remaining life
based on thermal cycles, creep calculation and fatigues cycles.
 Based on these aspects, the remaining life is ascertained with
integration of rate of degradation v/s available material properties.

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 EQUIPMENT INTEGRITY ASSESSMENT
Equipment Integrity assessment can be done through:
 Reliability Management
 Integrity management plans
 Asset maintenance management
 Material Management:
 Materials failure assessment and its management
 Inspection management of surface and subsurface assets
 Structural integrity management
 Information systems consulting and technical advice
 Corrosion study & inspection
 Pressure relief system failure

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 EQUIPMENT INTEGRITY ASSESSMENT
 Effluent Handling Services Management
 Equipment failure analysis assessment
 Software solutions to ensure your engineering decisions are made
using accurate and complete data
 Pipeline integrity management
 Risk-based inspection (RBI) projects implementation
 Operational process integrity checking
 Process engineering services

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 IS AN APPROACH

BUT

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 WHAT IS THE DIFFERENCE BETWEEN
AN ANALYTICAL OPERATOR/
TECHNICIAN
&
GENERAL OPERATOR

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 IGNORANCE OF INSTALLATION
MANUAL

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 INTENTION OF DOING /
CARRYING OUT

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 TYPES OF FAULT GENERALLY ENCOUNTERED
• ENGINE WILL NOT START
 Difficult starting
 Equipment stops suddenly
 Equipment runs unsteadily or hunts
 Equipment does not shut down properly
 Equipment will not carry load
 Equipment knocks
 Low lubricating oil pressure
 Fuel dilution of lubricating oil
 Excessive use of lube oil
 High lube temperature
 High circulating water temperature
 Unequal or excessive exhaust temperatures
 Smoky exhaust

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 WHAT IS FUNDA
THE CONCEPT

WHICH ? PLACE
WHY ? THE FAILURE OCCURED
WHERE ? FAILURE OCCURRED IN SUB ASSEMBLY
HOW ? IT HAPPENED
WHO ? DID IT /INTENTONAL
WHEN ? EQUIPMENT FAILED
WHAT ANALYZING
WHERE ZEROING

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 ALWAYS ANALYSE,
NEVER ASSUME

ASS---------------------U----------------------ME

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THE MAINTENANCE PROBLEM ANALYSIS…..

• WHY went wrong?

• WHAT went wrong?
• WHEN went wrong?
• HOW went wrong?

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 CAUTION!!
RECOMMENDATION

Recommended that Manual should be read in its

Entirety before performing any operation. Failure to
understand and follow these instructions could result
in serious personal injury and/or damage to
equipment

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 MAJOR CAUSES OF FAILURES
IN ELECTRONIC INSTRUMENTS & TELECOM SYSTEM

TYPES OF FAILURES

NATURAL INVITED

REASONS
DUE TO COMPONENT BREAKDOWN
DUE TO AGING & OBSOLESCENCE
50% DUE TO IMPROPER INSTALLATIO 40% DUE TO LACK
N & COMMISIONING PRACTICES OF PROPER Docments & Training

MAJOR PRECAUTIONS:

1. Loose connection Caution !

2. Improper earthing Warning !
3. Power system Instructions !
4. Excessive vibration Precautions !
5. Buried problems Dangers !
Note !
6. Substandard material Important !
7. Misalignment Protections !
8. Ignorance of Recommendations !
Instructions in manuals Do & don’t !
Never !
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 WORK PERMIT SYSTEM
Importance of work permit system in maintenance
philosophy are designed for safe operation & safety of the
individuals associated in industry. Permits are been issued in
reference to OISD standard 105 :
1. Hot permit.
2. Cold permit
3. Confined space Entry permit.
4. High rise work permit.
5. Electrical isolation permit.
6. Energization permit.
7. Composite permit.

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 WORK PERMIT SYSTEM

References:
a)Work Permit systems in India and Abroad.
b) The Petroleum Rules 2002
c) API-2016, Guidelines and Procedures for entering and cleaning
petroleum storage tanks.
d) API Publication 2009, Safe Welding, Cutting, and other Hot
Work Practices in Refineries,
e) API Standard 2015 - 2001 "Requirements for safe entry and
cleaning of petroleum storage tanks.

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CONCLUSIONS:

 MAINTENANCE TECHNIQUES & SYSTEMS

 MAINTENANCE PLANNING & SCHEDULING

 MAINTENANCE COST OPTIMIZATION

 INTRODUCTION TO HEALTH AND REMAINING LIFE

ASSESSMENT

 EQUIPMENT INTEGRITY AND LIFE EXTENSION

 MAINTENANCE ACTIVITIES ON DCS & PLC

 TROUBLESHOOTING ON MAJOR EQUIPMENT

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•To see something is one thing

•To observe what you see is something different

•To understand what you observe is difficult

•To learn from what you have understood is more difficult

•But to do what you have learnt, that is what really matters

8/28/2017 Sir Winston Churchill

41
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