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Proactive Maintenance
Plant Maintenance and HSE Middle East 6th Annual Meeting
Design
Concept
2000s
Breakdown
Preventive
Reliability-Based
Scheduled
Overhaul
Standby capacity
Skilled
Craftsmen
Trained
Technicians,
Time-based
activity
Scheduled
Overhauls
Regardless of
Actual Need,
Large Crews
Dual Standby
Units
High Spare
Inventory
Built In
Obsolescence
Standby
Predictive Technologies
Failure
Operate to
Manageme Failure,
nt
Frequent
Rebuilds
Reliability
Late 1970s
Highly Overdesigned.
Wearout Types
Failures
Over-Designed
Highly Robust
Slow
A critical piece of
equipment requires
reliability and
availability of all
critical components in
order to continue to be
reliable.
Maintenance
actions can be
seen as the
difference
between the
protected and
unprotected
incident
probabilities
times the event
consequence
The calculation of
Safety Integrity
Levels (SIL) in
calculating the
reduction in risk due to
actions can be used to
show the cost savings
due impact
to maintenance.
The
of predictive and preventive
PRIMARY Maintenance
Focus
Bow-Tie Diagram
Planned
Unplanned
Formulate the
Mix
Unplanned Correct
Breakdown
Maintenance (BK)
Planned Corrective Maintenance
(CM)
Preventive Maintenance (PM):
Calendar Time Based
Running Hours Based
Predictive Maintenance (PdM)
Condition Monitoring
Condition Based Maintenance
9. - What
are the
failure
modes?
MMS
11. Audit
RCM
2. Review
Equipment
History
1.
Equipment
Criticality
3. Carryout FMEA
FMEA
CYCLE
8. Failures
after
implementi
ng RCM
7. Amend
in CMMS
6. Identify
Tasks &
Recourses
4. Select
Maintenance Type
Based on
equipment
Criticality
Assessment
5. Review
and
Update
Equipment
s Job Plans
Moving to Proactive
Maintenance
The Avantis Solution to Asset Performance and Reliability - Reliability Centered Maintenance
Enablements of Avantis, 2006 Invensys Systems, Inc
0.30
0.25
0.20
0.15
0.10
0.05
0.00
DAS
Gas Sites
RAM 0
RAM 1
RAM 2
RAM 3
RAM 4
RAM 5
Gas Average
15
Respondents
88%
58%
28%
Maintenance Process
Standardized, enterprise-wide proactive
maintenance processes such as predictive
maintenance, reliability centered
maintenance, total productive maintenance,
and root cause analysis
Average Performance
Asset uptime and availability = 88.8%
Asset productivity (as a % of capacity) = 84.2%
Service & maintenance cost (as a % of revenue) =
17.2%
18%
62%
91%
27%
67%
91%
3%
21%
39%
12%
48%
77%
7%
21%
66%
39%
54%
79%
19%
36%
62%
3%
13%
14%
11%
29%
58%
29%
54%
77%
3%
22%
50%
Reliability-centered Maintenance
RCM is defined as A process used to
determine what must be done to ensure that
any physical asset continues to do what its
users want it to do in its present operating
context. 2
1.Failure modes and effects analysis (FMEA) is
a structured analysis based on experience
and what if.
2.Decision algorithm determines the
maintenance action plan and its execution.
Maintenance by
F. Stanley
Nolan and Howard F. Heap,
1978
3.Reliability-centered
Age exploration
- The
continuous
analysis,
2
39
40
Conclusi
on
We will not have a safe
plant unless it is a wellmaintained plant
41
Thank you!
Questions?
Email: scooke@adgas.com
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