Flow Charts (SWO)

8/11/2019 Flow Charts (SWO)

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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

Flow Charts (SWO)

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