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Maintenance Management Overview

Dr. Attia Hussien Gomaa
Maintenance Engineering Consultant
2008
Engineering service - American University in Cairo (AUC)
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Maintenance Management Overview Dr. Attia Gomaa
Refer to BS3811:2000

Maintenance is the work undertaken in order to keep
or restore a facility to an acceptable standard level.
Work undertaken All activities (information, analysis, repair, etc.)
To keep Planned maintenance (Preventive, Predictive and
proactive) policy for critical equipment
To restore Unplanned maintenance (Corrective or run to failure
policy for non-critical equipment
Facility System level (equipment, unit, plant)
Acceptable standard
level
Acceptable level at certain working condition (HSE,
working hours, etc.)
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Maintenance Management Overview Dr. Attia Gomaa
Cost
PM Cost
Total Maintenance Cost
CM Cost
Best level
Down Time Cost
PM level

Reliability

Total Maintenance cost
= Direct cost + Overhead cost + Downtime cost
or
= PM cost + CM cost + Downtime cost
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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 A total view approach = Good communication
(Maintenance, Process, HSE, Inventory, Resource, etc.)
Systematic Documented rule-based = Codes & Standards
Powerful Applicable and flexible =
Organization structure & Team approach
Effectiveness Utilization + performance + efficiency
Resource Materials, manpower, tools, equipment, subcontractors, and cost
Productivity Resource utilization and efficiency
Policy Certain rules and program for long term
Maint. Policy Failure-based, time-based, condition-based, and risk-based
Criticality Effect on HSE, Process, Standby and Cost
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Maintenance Management Overview Dr. Attia Gomaa
Main Points:
- Change management
- Leadership & organization structure
- Criticality Analysis
- Maintenance Policies
- Maintenance Program
- Performance Evaluation
- KPI (Key performance indicators)
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Maintenance Management Overview Dr. Attia Gomaa Company Logo
Criticality Analysis
HSE Effect
Stand By
Availability
Process
Effect
Major
(B)
Major
(A)
Without
(C)
With
(D)
Minor
Minor
Centrifugal Pump
(System level)
Criticality
Drain system C
Water system B
Oil system A
Steam system A
Fire-fighting system A
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Maintenance Management Overview Dr. Attia Gomaa
Maintenance Policies
(1)
Failure-Based
Reactive (ReM):
- RTF
- CM
- BD
::
(2)
Time-Based
Preventive (PM):
- Calendar:
Weekly
Monthly
::
- Running:
1000 R.H.
1000 K.M.
::

(3)
Condition-Based
Predictive (PdM):
- Oil analysis
- Vibration analysis
- Temperature analysis
- Pressure analysis
- Wear analysis
- Efficiency analysis
::
(5)
Total-Based
Global (GM):
- OSM
- TPM
::
(4)
Risk-Based
Proactive (PaM):
- RCFA
- FMEA \ FMECA
- HAZOP
- RCM \ RCM2

- RBI ::


Figure (1): Classification of maintenance policies.
[Venkatesh 2003, Waeyenberg and Pintelon 2004, and Gomaa et al. 2005]
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Maintenance Management Overview Dr. Attia Gomaa
Comparison of different maintenance policies
Policy
Approach
Goals
Reactive
Run to failure (fix-it when
broke).
Minimize maintenance
costs for non-critical
equipment.
Preventive
Use-based maintenance
program.
Minimize equipment
breakdown.
Predictive
Maintenance decision
based on equipment
condition.
Discover hidden failures
and improve reliability for
critical equipment.
Proactive
Detection of sources of
failures.
Minimize the risk of
failures for critical systems.
Global
Integrated approach.
Maximize the system
productivity.
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Maintenance Management Overview Dr. Attia Gomaa
A comparison among proactive maintenance approaches
Policy Approach Goals
RCFA
Identification of root causes of
failures.
Eliminate failures.
FMECA
Identification of criticality of
failures.
Improve equipment
availability.
HAZOP
Identification of hazards and
problems associated with
operations.
Improve HSE effect.
RCM
Determination of best
maintenance requirements for
critical systems.
Preserve system
function & improve
reliability.
RBI
Determination of an optimum
inspection plan for critical
systems.
Improve system HSE
and availability.
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Maintenance Management Overview Dr. Attia Gomaa
Comparison among global maintenance approaches

Policy Approach Goals
OSM
Optimization
approach for the
global maintenance
system.
Maximize reliability
measures and minimize
maintenance cost rates.
TPM
Comprehensive
productive-
maintenance system.
Maximize plant
effectiveness and resource
productivity.
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Maintenance Management Overview Dr. Attia Gomaa
Facility equipment are divided into four major categories:
Run-to-Failure - Most cost effective to let equipment run
unattended until it fails. Used on lowest priority equipment.

Preventive Maintenance - Perform maintenance tasks on
a piece of equipment at regular intervals, whether the
equipment needs it or not.

Predictive Maintenance - Perform maintenance based
upon real-time data collected on a piece of equipment. This
data shows the health of the equipment

Proactive Maintenance - Determine root causes of failure
and implement fixes (e.g., redesigning the piece of equipment
so that it does not break down as frequently)
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Maintenance Management Overview Dr. Attia Gomaa

Why PM should be done?

To prevent
equipment failures

To detect
early failures

To discover
hidden failures
Time-Directed
Maintenance (TD)
Condition-Directed
Maintenance (CD)
Failure
Finding (FF)
Preventive Maintenance:
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Maintenance Management Overview Dr. Attia Gomaa
Predictive Maintenance:
Condition based
management
Visual
Inspection
Vibration
analysis
Ultrasonic

Pressure
analysis

Temperature
analysis
Oil
analysis
Efficiency
analysis
Wear
analysis
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Maintenance Management Overview Dr. Attia Gomaa
Atypical machine condition-vibration trend
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Maintenance Management Overview Dr. Attia Gomaa
PdM Planning:
1. Best Method (vibration analysis, .. etc.)
2. Best Frequency (inspection interval)
3. Best Locations
4. Best Tools
5. International Standard (ISO10816, .. etc.)
6. Standard Limits
7. Severity Chart
8. Trouble Shooting Chart
9. Reference Creation
10. Regular Measurements (monthly, .. etc.)
11. Analysis
12. Decision Making
13. Corrective Actions
- Good conditions,
- Routine Maintenance,
- Repair, or
- Replace.
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Maintenance Management Overview Dr. Attia Gomaa
PdM Policy: Vibration analysis:
1- Frequency: Every 300 Running Hours

2- Tool:
Vibration Equipment: accelerometers, charge amplifier and analyser.
Computer program for trend analysis and prediction.

3- International Standard: CDA/MS/NVSH107

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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Maintenance Management Overview Dr. Attia Gomaa
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.

Some root causes of failure:
Poor Design/Poor Manufacturing,
Poor shipping, handling, and storage procedures, equipment becomes
damaged or begins to degrade before it is installed,
Poor Installation,
Poor materials,
Poor working conditions.
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Maintenance Management Overview Dr. Attia Gomaa
What is the Maintenance? How?
1- How to keep or restore the facility at
acceptable standard level in certain
operating conditions?
System description
Main parameters
Main items
Functional block diagram
Criticality
Working conditions
2- How to prevent the failures?
Main failures:
PM:
3- How to discover the hidden failures?
Main failures:
Policy:
4- How to detect the early failures?
Main failures:
Policy:
5- How to minimize the risk of failures?
Main failures:
Risk:
Policy:
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Maintenance Management Overview Dr. Attia Gomaa
Computerized Maintenance Management Systems
(CMMS)
CMMS
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Maintenance Management Overview Dr. Attia Gomaa
Most common CMMS:
Oil and Gas Companies in Arabic Countries:

EMPAC www.plant-maintenance.com
EMCMAINT www.emceg.com
GMS www.first.com.eg
GPS5 www.gps5.com
IMPACT-XP www.impactxp.com
IMPOWER www.impower.co.uk
MAXIMO www.maximo.com
MMMS www.kockw.com
MP2 www.datastream.net
OCEN www.soluziona.com
PEMAC www.pemac.org
RCM Turbo www.strategic.com
SAP-RLINK www.osisoft.com