chapter 01- turnaround - role in maintenance management

8/3/2019 CHAPTER 01- Turnaround - Role in Maintenance Management

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TURNAROUND

Role In Maintenance Management

CHAPTER 1



―Act of causing to continue‖

[New Oxford Dictionary]

MAINTENANCE



DEFINITION

TRADITIONAL DEFINITION :

• ―The combination of all technical and associated actions intended to

retain an item in, or, restore it to a state in which it can perform

its required function‖.

CURRENT DEFINITION :

• ―All actions that are carried out to safeguard the technicalintegrity of an asset and to ensure its availability such that

maximum cash returns can be realized from the asset thereby

enhancing the value of the asset‖.



ROLE OF MAINTENANCE

• Preserve and prolong the working life of plant andequipment.

• Upkeep and protection of plant, buildings, machinery andother fixed assets.

• Safeguard investment by minimising deterioration.

• Keep the assets in efficient working condition.

• Ensure reliability of plant and equipment.• Minimise idle time and loss of production.

• Maximise efficiency through optimum use of facilities.

• Generate a safe and healthy, working environment and

maintain safety consciousness.• Minimise maintenance cost.

• Improve performance of plant and machinery.

• Keep abreast of latest maintenance techniques and

achieve excellence to meet the new challenges.



NEED FOR MAINTENANCE

• To keep assets in top condition.

• To avoid failures.• To minimize hazardous situations.

• To correct deterioration.

• To modify plants.

• To generate safe working conditions.• To obtain on grade products.

• To increase productivity.

• To reduce wastage of material & parts.

• To reduce manufacturing cost.• To add in high quality & economical operation.



INCREASESCASH

MARGIN

BUSINESSOBJECTIVES

INCREASESSALES

AND

REVENUE

INCREASE

RESERVES

REDUCES

OPERATING

COSTS

INCREASES

PRODUCTION

HIGH

FACILITY

AVAILABILITYCOST EFFECTIVE MAINTENANCE

MAINTENANCE



TYPES OF MAINTENANCE

BREAKDOWN MAINTENANCE

• This is a PANIC or CRISIS maintenance

• It is not desired at all in today's environment




BREAKDOWN MAINTENANCE

• BATH TUB CURVE

– Infantile Deaths

– Wear-out Stage

– Abnormal Operations

• DISADVANTAGES

– Uncertain - Occurrence & Repairs

– Uncertain Production

– Costly Repairs

– Unsafe Situation




PREVENTIVE MAINTENANCE

• This is a systematic and planned attention, monitoring and analysis.

• It is most effective if there is strong age related failure mode.

• The guiding principle is ―Prevention is better than cure‖

OBJECTIVES OF PREVENTIVE MAINTENANCE:

• Retard process of deterioration and wear

• Asses extent of deterioration

• Action to restore original capacity

• Improve reliability and maintainability of equipment thus eliminating

breakdown




PREVENTIVE MAINTENANCE EXAMPLES

• Visual External Inspection

• Lubrication Replenishments

• Strainer Cleaning

• Painting

• Adjusting Belt Tension

Preventive Maintenance Programme




ADVANTAGE OF PREVENTIVE MAINTENANCE

• Less down time

• Fewer repetitive repairs

• Lower repair cost than breakdown repair cost

• Superior quality control

• Increased life of plant and equipment

• Need of standby equipment reduced

• Reduction in maintenance cost

• Leveled workload and workforce

• Better spares control• Enhanced safe working conditions

• Increase in production




PREDICTIVE MAINTENANCE

• By predictive maintenance equipment condition can be known

during normal operation through :

– Online monitoring, measurements, ND testing, etc.

– Health of equipment can be predicted with certainty and

necessary corrective actions generated

– The result of predictive maintenance can be extrapolated to

determine useful residual life

– Leading to prediction of approximate date of failure




PREDICTIVE MAINTENANCE EXAMPLES

• Ultrasonic thickness measurements

• On-line vibration measurements

– Measurement program

• Testing lubricating oil / hydraulic oil




TECHNOLOGY

Iodic vibration analysis

• Vibration analysis

• On-line vibration analysis

• Oil sample analysis• Thermography

• Motor stator analysis & elect. -Surge testing

• Motor current signatureanalysis

• Air borne ultrasonics

• Pulse-echo ultrasonics

• Process parameters

APPLICATIONS

All rotary equipment

• All rotary equipment

• Critical rotary equipment

• Critical & low speed equipment• Electrical components, Motor

stator and insulation

• Break down

• Motor rotor bars, eccentricity

• Steam traps, vacuum leaks

• Pipe and vessel thicknessProcess or mechanicalDegradation

POPULAR PREDICTIVE MAINTEANCE TECHNOLOGY




PROACTIVE MAINTENANCE

Proactive Maintenance emphasizes on

– Root Cause Failure Analysis

– Precision repairs and installation

– Training of maintenance and operational personnel

– Review and correct purchase specification

Proactive maintenance is easily integrated with predictivemaintenance and completes the platform needed for

Reliability Centered Maintenance program




ADVANTAGES OF PROACTIVE MAINTENANCE

• Repetitive problems that shorten component life areidentified and designed out

• This can include standards placed on suppliers forperformance acceptability of their products/services, andverification that these are met

• Assuring that equipment installation is done to precisionstandards (Balancing, Aligning) leading to extended life

• Factors limiting component life are identified andeliminated

• Reliability centered maintenance program




BREAKDOWNMAINTENANCE

PREVENTIVEMAINTENANCE

PREDICTIVEMAINTENANCE

PROACTIVEMAINTENANCE

ROOT CAUSEFAILUREANALYSIS

RELIABILITY CENTERED

MAINTENANCE





The human body parallel to Machine Maintenance

Maintenance

strategy Technique needed Cost / Barrel /

year Human body

parallel Proactive

maintenance Monitoring and

correction of

failure root causes

e.g. contamination

$ 0.10 Cholesterol and

blood pressure

monitoring with

diet control Predictive

maintenance Monitoring of

vibration and wear $ 8 Detection of heart

disease using ECG

or ultrasonics Preventivemaintenance Periodic

component

replacement $ 13 By – pass or

transplant surgery Breakdown

maintenance Large maintenance

budget $ 18 Heart attack or

stroke



MAINTENANCE ROLE PERFORMANCE

• Maintenance areas

• Rotary maintenance group

• Inspection function

• Mechanical workshops

• Electric shop

• Instrument shop

• Mobile equipment shop



MAINTENANCE ACTIVITIES

• List of work for next week with priorities from each

area

– Back-logs/operations requirements

– Preventive maintenance

– Rotary group recommendations

• Planning - estimates workforce needs. Allocates to

areas

• Areas arrange materials and execute work

A A C AC S




• Job orders to shops• Material movements

• History cards

• Spare parts inventory

• Central tool store

• Training needs

• Maintenance budget

• Turnaround - advance activities





Planned Maintenance

Turnaround Maintenance

— Prevents breakdowns and extends operating life

— Proper estimate of resource requirements

— Maximise smooth plant runs





Turnaround Maintenance

— Internal inspection - all static equipment - repairs &

renewal

— Piping - hammer sounding / utm— Overhaul all vital & essential rotary equipment /

relief valves

— Overhaul electrical equipment

— Overhaul instrumentation

— Safety jobs / modification jobs

— Data base on condition of equipment

END OF CHAPTER 1



END OF CHAPTER 1

chapter 01- turnaround - role in maintenance management

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