Post on 02-Jun-2018
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*-IncludesHiddenFailureDetectionProgram
HiddenFailures:Thesearedefinedasthosewhosefunctionalfailureisnotknownunlessaskedtoperform.E.g.LiftingofReliefValve,Equipmentprotectivefunctions
ReliabilityBasedMaintenanceBusinessProcess-SteadyStageOperations
Proactive
Maintenance
PredictiveMaintenanceBreakdown
Maintenance
Reactive
Maintenance
Schedulebased
Maintenance
Observation
Maintenance-LLF
FailureAnalysis
ConditionMonitoring/
InspectionProgram
LubricationProgram
CorrectiveRepair
Overhaul
Maintenance
ScheduledJob
Preventive(non-invasive)
Maintenance*
ChangeOver
Program
ReliabilitybasedMaintenanceStrategy
JobNotification
SparePartsManagement
Program
JobExecution
Monitor(KPI's,Metrics)/ReviewofJobs/
Practices/Strategy
Internal/ExternalAuditofJobs/
Practices/Strategy
Equipment/Process
DesignChanges
Contracts/Vendor
ManagementProgram
Documentation
Systems
Knowledge/Skill
DevelopmentProgram
Recommendations
MIS
OperatingWindow
Monitoring
UpdateScope/Practices/Strategy
FMEA/RCM/RBI/
HAZOPstudiesto
reviewschedules/
strategy
A
AA A A FieldChangeOrders
FailureAnalysis
Recommendations
Safety/EnvironmentAuditRecomendations
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JobPlanningandScheduling
IdentifyJob
No
Yes
CreateNotification:
Canberaisedby:
Opn.,Maint.,CES,CTS
Yes
No
Emergencyjob?
No
Urgentjob?
AppendittoMaintenanceBacklogActivities
PMRoutines
Statutory/SeasonalJobs
RoutineJobsBacklog
4Weeks-Advance
IncludeActivitieson
weeklyschedule
JobValidation?
ByMaint./Opn.
RejectJob
4Weeks-Advance
PrepareJobScope
PlanforMaterials+Resources
EstimateJobCost/Duration3Weeks-Advance
PrepareWorkOrders
WOApproval
OrderMaterials
1Week-Advance
ReceiveMaterials,BookResources
FinalizeSchedule
InformMaint.Sup,andOperations
1day-Advance
ApplyforPermit
ConfirmMaterial/
Resources
ReleaseJob?
ExecuteWork
CloseNotification
WorkClosureReport
EquipmentHistorywithcostandduration
Acceptedby
Operations?
ArrangeMaterialsand
ResourcestoreachSite
Yes
No
Yes
Yes
No
10days-Advance
PrepareSchedule
Allresourcesavailable?
Yes
No
AnyAction
items?
CorrectiveRepairKPI's
No
Yes
Analyzedeviations-
CorrectiveAction
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CES:CentralEngineeringServices
FIR:FailureInformationReport
FAR:FailureAnalysisReport
ObservationMaintenance-Look,ListenandFeel(L,L,F)
L,L,FSchedule
PlantOperator
Maintenance
Supervisor
CES-Functional
Engineer
UnitEquipmentList
Surprise
Observation?
FIRRequired?
FARProcess
Yes
Yes
No
No
EveryShift
Weekly
Fortnightly
CorrectiveRepairRecordObservations
KPI's
Analyzedeviations-
CorrectiveAction
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PreventiveMaintenancejobsaredescribedasperiodicmaintenancetasksthatareprimarilynon-invasivew.r.ttheequipment.
PM(PreventiveMaintenance)Jobsshallalsoincludeprotectivefunctionchecksandcalibrationschedules
*ESS:EquipmentServiceSheets
PreventiveMaintenanceJobProcess
PlanJob
ReleaseJob?
PlanResources
PermittoWork
ExecuteWork
Feedback-
Observations
ClosePMOrder
Feedback-
JobFrequency
RevisePM
Frequency/
Schedule
Reschedule
Job
Surprise
Observation?
No
Yes
NotifyCompliance
FIR
Required?
FARProcess
Feedback-
JobScope
ReviseESS
PMOrder
Resources
Available?
Yes
No
Yes
No
No
Yes
EquipmentHistory
EquipmentMasterList
ListSemi-CriticalEquipment.Inst.that
requirecalibration,ProtectiveFunction,
Inst.Alarm+Tripslists
EquipmentType
EquipmentHistory
Operating
i i
DecidePMFrequency
andScope-byCES
ESS
Accept.-Functional
HODs
Input-CMMS
GeneratePMSchedule
IssuePMJobsListing
A
A
CorrectiveRepairPractice
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ChangeoverPractice
StandbyEqupmentList
ChangeoverFrequency(byCES)
Acceptable?
ReviewFequency
(byOperationsandMaint.)
PrepareScheduleconsideringPM
schedule(byCES,Planning)
ImplementSchedule
(byOperations)
Compliance?
NotifyCompliance
(byOperations)
Problemwitheqpt.
takenonline?
UpdateChangeover
Record
Eqpt.cannotbetakenon
lineduetoOpn.reasons?
Stanbyequipment
unavailable?
Yes
No
No
No
Yes
Isashortdurationtrial
possibleinparallel?
Yes
TakeTrial
Bartheequipment.Ensure
freeness.
Ifapplicable,conductstatic
pressuretestwithprocessfluid
Anuallydecoupleandtaketrial
ofdriver
No
Recordobservationsand
takerequiredaction
Yes
Reschedule
Changeover
Opn.toissuejustification
Approvalby-Maint.and
CES-HODs
Reschedule
Changeover
No
Yes
Yes
No
Acceptable?
(byOpn.)
No
Yes
CorrectiveRepairPractice
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*-BMP:BestMaintenancePractices
TheseincludeObservation(LLF),Preventive,Predicitve,Overhaul,ChangeOver,LubricationMaintenancePractices
AlsocoveredinthisflowchartarerecommendationsincludedinFARs.
*SMP:StandardMaintenanceProcedures
CorrectiveMaintenanceJobProcess
PermittoWork
ExecuteWork
Feedback:
RepairScope
IssueReport
Modify/Update
SMP*
Surprise
Observation-
Yes
Corrective
RepairNotification
FIR
Required?
FARProcess
Feedback-
Observations
No
JobScope
ArrangeResources
Reschedule
Job
No
Yes
Resources
Available?
No
Feedback:
BMP
Reviewand
UpdateScope
andFrequencyof
BMPs
Yes
FeedbackfromBMPs*
IssueActionItems
No
EquipmentHistory
SMP
PlanJob
Yes
ReleaseJob?
ScheduleJob
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SingleStreamEquipmentList+
SpecificSemi-CriticalEquipment*
OverhaulMaintenanceJobProcess
*-Specificsemi-criticalequipmentmayincludeequipmentlikereciprocatingcompressors.
Thesemaybeinstalledwithreadystand-by.
Overhaul
Scheduleand
Scope(byCES)
Accept.-Opn./
Maint.HODsReschedule
PlanJob
ArrangeResources
Specialist
Requirement
SparesAdequacy&
Availability
SpecialTooling
SMPs
ExecuteWork
IssueReport
No
Yes
Feedback:
RepairScope
Modify/Update
SMP*
SurpriseObservations
Unattended?
Yes
FIR
Required?
FARProcess
No
Feedback-
Observations
PermittoWork
ReleaseJob?
Reschedule
Job
Resources
Available?No
IssueActionItems
IssueActionItems
No
EquipmentHistory
Yes
YesNo
ScheduleJob
EquipmentHistory
SingleStreamEquipmentList+
SpecificSemi-CriticalEquipment
Cranes+Rigging
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*-BMP:BestMaintenancePractices
TheseincludeObservation(LLF),Preventive,Predicitve,Overhaul,LubricationMaintenancePractices
AlsocoveredarerecommendationsincludedinFARs.
ConditionMonitoringProgram
Eqpt.MonitoringList
Critical Semi-Critical
ConditionMonitoring/Inspection
Parameters&FrequencyCES
CMEquipment/Routes/
Schedule/DataStorage
Accept.-
Maint.HODs
CriticalityCriteria
PublishCMProgram
ImplementCMProgram
Failureccurrence
Detected?
ReviseConditionMonitoring/
InspectionParameters&Frequency
OtherInputs-FAR,BMPs
PublishAnalysisReportJobScope
CorrectiveRepair
No
No Yes
Yes
Program
Compliance?
Reason:
CMProgramScheduleEquip.MonitoringList
CMEquipment
Manpower
YesNo
PublishCompliance
Report
EquipmentMasterList
Feedbackof
Analysis
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LubricationProgram
EquipmentMasterList
CESGuidelines:
Procurement,Storage,
Dispensing,Disposal
Accept.-
Maint.HODs
LubricationMaster
LubeTypesandQuantity
(asperOEM)
PublishLubr.Program
ImplementLubr.Program
No
Yes
Lubrication
FailureEvent?
ReviewLubricant,Schedule,
Dispensing,Condition
Monitoring
CloseLubricationOrder
NoYes
Program
Compliance?
ReviewLub.Program
Schedule
Equip.MonitoringList
Organization
YesNo
PrepareSchedules:
LubricationOilandWearParticleAnalysis
(basedoncriticalityofeqpt.)
OptimizeLubeVarietyand
Quantity
Feedback-
Observations
LubeCondition
Bad/Particles?
FIR
Required?
FARProcess
Yes
Yes
LubeandWear
ParticleAnalysis
Reports-Abnormal?
FIR
Required?
FARProcess
No
No
Yes
EquipmentHistoryPublishCompliance
Report
No
Yes
EquipmentHistory
No
CorrectiveRepair
AnnualProgramEffectiveness
Review-ValidateRequirement,
FrequencyandScope
FARProcess
CorrectiveRepair
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BMP:BestMaintenancePractices
FIR:FailureInformationReport
FAR:FailureAnalysisReport
CES:CentralEngineeringServices
CTS:CentralTechnologyServices
HOD:HeadofDepartment
Repr.:Representative
Opn.:Operations
Maint.:Maintenance
FailureAnalysisReportingProcess
UnhealthySymptom/
FailureOccurence
Unsafecondition
ProductionLoss?
Repititive
/Premature?
RaiseFIR
AttendFailure
ConfirmFIR.
RecommendFAR
(byHOD-InitiatorDept.)
FailureModedecidesFAR
teamleader
Approval?
Maint.HOD
ImplementRecommendations.
Review/UpdateScope&
FequencyofBMP
Comlpetetionof
Recommendations
InformandCloseFAR
TargetDate
Exceeded?
PendingFARList
(withCES)
Yes
No
No
No
Yes
Yes
Yes
Yes
Yes
Yes
Yes
No
No
No
ReviewandResolve
theconstraint
Concurrence-
DisciplineHeads
NoAnalysis+Recommendations
No
EquipmentHistory
EquipmentHistory
ConfirmFAR
requirement?
(byCES-HOD)
RejectFARRequest
Leader:
Functional
Specialist-CES
Maint.Repr.
Opn.Repr.
CTS
Approval?
Opn.HOD
Approval?
CTS.HOD
Approval?
CES.HOD
No
No
Yes
Yes
Yes
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SparePartsManagement
SparePartsClassification
Consumables InsuranceSpares EquipmentSpares(Durables)
Establishstocklevelsbasedonconsumption
(byStores)
Establishstocklevelsbasedonequipmentcriticalityand
behaviour
(byMaint.concurredbyCES)
OrderSpares(byStores)
ReviewConsumption
(atleast3turnsPA)/Non
movingformorethan2
years/Stockouts(not
morethan5%of
consumbles)
(byStores)
ORDER:
SparesspecifictotheUnit-
byMaint.concurredby
CES
Sparescommonbetween
Units-byCESconcurred
byUnitMaint.
Reviewtotalconsumption
(atleast0.5turnsPA)/Non-
Movingformorethan4years
/Stockouts(notmorethan1
%ofdurables)
(byMaint.)
Establishstocklevelsbasedoncriticalityandbehaviour
(byMaint.andconcurredby
CES)
Listofsparesbelow
reorderlevel
(issuedbyStores)Deciderefurbishment/
replenishmentofspares
(byCESconcurredby
.
ReviewUsage
(typical0.1turnsPA)/
Stockouts(none)
(byMaint.)
Listofsparesbelow
minimumlevel/
Stockout
(issuedbyStores)
Refurbish/OrderSpares
(byMaint.)
Reportindicatingstockouts
/requirements
Approval
FollowUp(byStores)
Emergency?
RaisePRImmediately
InspectiononReceipt-
(byIndentInitiator)
Accept?
ClearGRN
Consumables:MonthlyPR
Durables:QuarterlyPR
NoYes
Yes
No
ReleasePO
MonthlyReport
MaterialInventoryList
CESGuidelines
PreservationofSpares
IncludeinStock
NotifyReceipt
StockinBinsafter
preservation
PartNumber,Description,
Quantity,Location,
Qnty-Reservedfor.
ExpectedDeliveryDate
AnnualReviewSparePartsCondition?
AnnualReview
PreservationProcedure
Adequate?
Bad
No
Yes
Good
AvailableStock
AnnualSpares
Requirementbased
onAnnualMaint.
Plan
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ContractsManagement
JobsIdentifiedforOutsourcing
-Classification
JobScopeandFrequencyFixed
(AnnualMaint.Contract)
JobScopeknown-OneTime
(Outage/ProjectJobs)
ScopeandFrequency
Variable
EstimateJob
IdentifyContractors
ObtainBids
PrepareScope+Identify
ResourcesandSkill
Requirements
Technically
Acceptable?
CommerciallyAcceptable?
ReviewEstimate
AwardContract
JobQuality/ScheduleComplianceAcceptable?
ExecuteJob
RejectBid
RejectBid
ContractRecords
Contractor'sFault?
JobCompletionCertificate
CloseOrder
ApprovePayment
DerateContractor
CloseContract
ReviewScope/Resources
CallforRe-bids
No
Yes
No
Yes
Yes
No
No
Yes
PrepareInitialScope+
OptionalScope.Identify
ResourcesandSkill
Requirements
Estimateforfixedscope+
OptionalScope
IdentifyContractors
ObtainBids
Technically
Acceptable?
Commercially
Acceptable?
RejectBid
RejectBid
No
Yes
No
Yes
ReviewEstimate
AwardContract
ExecuteJob
ContractRecords
JobVariation?
Coveredin
OptionalScope?
ExecuteAdditionalScopeObtainquotefrom
Minm.2contractorsfor
additionalscope
Negotiate
AwardVariation
Yes
Yes
No
No
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ShutdownManagementProcess
PlanandSchedule
JobsandActivities
(PlanningDept.)
ApprovalofJobsand
Scheduleby-Opn.,Maint.
HODs
Review
MicroPlanning-24thwkfrom0wk
ArrangeResources
No
Yes
List-CompilationofShutdownJobs-
30thweekfrom0week(wk)
ShutdownJobs
PlantUpgrades
ProjectActivities
ApprovalofSchedule
andBudget-TMC
SpecialistRequirements
SparesRequirements
SpecialToolsandtackles
AdministrationRequirementsPublishListofawaitedresources-
8thweekfrom0wk
No
Yes
PublishIntermediate
Schedule-
4thwkfrom0wk
ScheduleApproved-S/TMC?
Review
PublishFinalSchedule-2ndwkfrom0wk
ResourceMobilization
InitiateJobsExecution
PublishScheduleCompliance-Daily
PublishListofLaggingJobs-Daily
IdentifyResourseConstraints&Mobilize
JobsCompletion
ReviewJobswithPlan
PrepareDocumentation
Planning/SchedulingvsActual
Expenditure-ActualvsBudget
ResourceConstraints
ConsumptionofSpares
ActionItems
ImprovementSuggestions
Within4wks
ReportonBenefitsderivedfrom
Shutdownjobs/Projectsvs
expectedgains.-24weeksaftercompletion
WorkScopes/Manpower/
Supervisors
OrganizationStructure
HeavyLiftingEquipment
PublishandRecordinHistory
PlanandScheduleAdditionalJobs-
4thwk-2ndwkfrom0wk
ReviewResourceAvailability-4thweekfrom0wk
No
Yes
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TUTORIAL
(secondoption)
HiddenFailures:Thesearedefinedasthosewhosefunctionalfailureisnotknownunlessaskedtoperform.E.g.LiftingofReliefValve,Equipmentprotectivefunctions
ProactiveTask:TheseincludethebestpracticesofLLF,Lubrication,PredictiveMaintenance,PreventiveMaintenance,CorrectiveMaintenance,OverhaulMaintenanceandSparesPartsManagement
Itcouldalsoincludeamaintenanceactivitythatisacombinationoftheabovepractices.
PMTask:Thisisascheduledbasedmaintenanceactivity.-InRCMdefinition,thisisalreadyincludedasaPROACTIVEtask.Itistreatedseparatelyforsimplerunderstandinginourorganization.
NoScheduledMaintenance:RuntoFailure
(secondoption)
As Defined by J.Moubray : These are tasks undertaken before a failure occurs, in order to prevent the item from getting into a failed state. They embrace what is traditionally
known as 'predictive' and 'preventive' maintenance.
CLASSICALRELIABILITYCENTEREDMAINTENANCETASKSELECTIONFLOWCHART
FunctionalFailureConsequence
HiddenFailure?
Cananyproactivetaskreducetherisk?
Cananyscheduled
basedfaultfinding
taskreducetherisk?
EstablishPMprogram:
ScopeandFrequency
DefineandImplement
ProactiveTask
Operational
Consequences?
Isthereaproactive
taskwithcostless
thanconsequences?
Isthereascheduled
PMtaskwithcostless
thanconsequences?
NoScheduled
Maintenance
Redesignthe
Process
EstablishPMprogram:
ScopeandFrequency
DefineandImplement
ProactiveTask
UnsafeCondition?
Cananyproactive
taskreducetherisk?
Cananyscheduled
basedPMtask
reducetherisk?
EstablishPMprogram:
ScopeandFrequency
DefineandImplement
ProactiveTask
Non-Operational
Consequences?
Isthereaproactive
taskwithcostlessthanconsequences?
NoScheduled
Maintenance
Redesignthe
Process
DefineandImplement
ProactiveTask
NoScheduled
Maintenance
NoYes
No
NoNo Yes
Cantheprocess
beredesigned?
Changethe
Process
Redesignthe
Process
No Yes
Yes
NoYes
No
No
Cantheprocess
beredesigned?
Changethe
Process
Redesignthe
Process
YesNo
Yes
Yes
Yes No
No
No
Yes
Yes
Yes
Yes
No
No
FunctionalFMEA
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RISKBASEDINSPECTIONSTRATEGY
TUTORIAL
Rev-1
SelectPlantUnit
DefineCorrosionLoops
TeamFormation
C&I,CTS,Opn.-FullTime
FDC,Maint.,HSE-PartTime
Basedon:
Pressure,Temperature,Velocity,pH.MOC
ListLoopComponents
BasedonFailureProbability:
e.g.ColumnTop,Colm.Bottom,HExShell.HEx
Tubes
IdentifyPotentialFailure
Mechanisms&Occurence
Basedon:
Generic-Literature,Experienceatother
locations
Licensor'sRecommendations
PrepareRiskRankingMatrix
DecideInspectionFrequency DecideProcessParametersfor
Monitoring,SetLimits
FixSchedule&Responsibility
MonitordefinedParametersSources:
DCS,IP21,LIMS,Field
DeviationfromOperating
Windowisbeyondsetlimits?
DecideInspectionAreas
General,Localised,
Internal,External
DecideInspectionTypeInvasive,Online
PrepareInspectionChecklist
PrepareInspectionSchedule
CarryOutInspection
Arefindingsconsistentwithpredictedprobabilityof
deterioration?
AnyUnexpected
Failures?
RevisitCorrosionLoop
Definition
No
Yes
Yes
No
Regulations
FARrequired?
FARProcess CorrectiveRepair
No
No
Yes
A
Yes
AdoptionofRiskMitigation
Measures
-ReduceProcessInventory
-ModifyProcess
-EmergencyIsolation
-Eqpt.Redesigning
-Eqpt.Repair/Replacement
-AnyOther