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Dr. Attia Hussien Gomaa Maintenance Engineering Consultant Engineering service - American University in Cairo (AUC)
2008
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Refer to BS3811:2000
Maintenance is the work undertaken in order to keep or restore a facility to an acceptable standard level.
Work undertaken To keep To restore Facility All activities (information, analysis, repair, etc.) Planned maintenance (Preventive, Predictive and proactive) policy for critical equipment Unplanned maintenance (Corrective or run to failure policy for non-critical equipment System level (equipment, unit, plant)
Acceptable standard Acceptable level at certain working condition (HSE, level working hours, etc.)
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Maintenance Management Overview Dr. Attia Gomaa
Total Maintenance cost = Direct cost + Overhead cost + Downtime cost or Cost = PM cost + CM cost + Downtime cost
PM Cost
Reliability
Maintenance Management Overview Dr. Attia Gomaa
Maintenance Management is a powerful systematic methodology to maximize the facility performance and improve the maintenance resource productivity, through optimizing maintenance policies for the critical equipment.
Methodology Systematic A total view approach = Good communication (Maintenance, Process, HSE, Inventory, Resource, etc.) Documented rule-based = Codes & Standards
Powerful
Effectiveness Resource
Productivity
Policy Maint. Policy
Criticality
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- Maintenance Program
- Performance Evaluation - KPI (Key performance indicators)
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Criticality Analysis
HSE Effect Minor
Criticality
Major (A)
Drain system
Water system
C
B A A A
With (D)
Maintenance Management Overview Dr. Attia Gomaa
Company Logo
Maintenance Policies
(1)
(5)
(3) Condition-Based Predictive (PdM): - Oil analysis - Vibration analysis Preventive (PM): - Temperature analysis - Calendar: - Pressure analysis Weekly - Wear analysis Monthly - Efficiency analysis :: :: - Running: 1000 R.H. 1000 K.M. ::
- TPM
:: (4) Risk-Based Proactive (PaM): - RCFA - FMEA \ FMECA - HAZOP - RCM \ RCM2 - RBI ::
????
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Approach
Goals
Run to failure (fix-it when Minimize maintenance costs for non-critical broke). equipment. Use-based maintenance program. Maintenance decision based on equipment condition. Detection of sources of failures. Integrated approach.
Minimize equipment breakdown. Discover hidden failures and improve reliability for critical equipment. Minimize the risk of failures for critical systems. Maximize the system productivity. 8
Predictive
Proactive Global
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Approach Identification of root causes of failures. Identification of criticality of failures. Identification of hazards and problems associated with operations.
RBI
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Policy OSM
TPM
Approach Optimization approach for the global maintenance system. Comprehensive productivemaintenance system.
Goals
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Preventive Maintenance:
Why PM should be done?
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Predictive Maintenance:
Vibration analysis
Visual Inspection
Oil analysis
Efficiency analysis
Temperature analysis
Wear analysis
Ultrasonic
Pressure analysis
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PdM Planning:
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. Best Method (vibration analysis, .. etc.) Best Frequency (inspection interval) Best Locations Best Tools International Standard (ISO10816, .. etc.) Standard Limits Severity Chart Trouble Shooting Chart Reference Creation Regular Measurements (monthly, .. etc.) Analysis Decision Making Corrective Actions - Good conditions, - Routine Maintenance, - Repair, or - Replace.
Maintenance Management Overview Dr. Attia Gomaa
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4- Method: Record the vibration spectrum, specify the peaks corresponds to the bearing components Record each component peak and frequency. By using the soft ware and the standard limits, determine the trend of each peak. Determine the bearing state(good need service need change) 5- Limits: According to CDA/MS/NVSH107 Pre-failure: vibration level5.6 m/s Failure: vibration level 5.610 m/s Near catastrophic failure: vibration level >10 m/s 6- Actions: Bearing is Good Call for bearing change Bearing must be changed immediately
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Proactive Maintenance:
Definition: Determine the root causes of repeated failures and address these rather than just treating the symptom.
E.g., if seals keep failing on a certain pump, do not just keep rebuilding the pump, figure out why they keep failing. Is the type of pump wrong for the application? Is the seal material not compatible with the fluid being pumped? Is the pump grossly mis-sized for the duty? etc.
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What is the Maintenance? 1- How to keep or restore the facility at acceptable standard level in certain operating conditions?
How?
System description Main parameters Main items Functional block diagram Criticality Working conditions Main failures: PM: Policy:
3- How to discover the hidden failures? Main failures: 4- How to detect the early failures?
Main failures: Policy: Risk: Policy:
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CMMS
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EMPAC EMCMAINT GMS GPS5 IMPACT-XP IMPOWER MAXIMO MMMS MP2 OCEN PEMAC RCM Turbo SAP-RLINK
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www.plant-maintenance.com www.emceg.com www.first.com.eg www.gps5.com www.impactxp.com www.impower.co.uk www.maximo.com www.kockw.com www.datastream.net www.soluziona.com www.pemac.org www.strategic.com www.osisoft.com
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