Plant Maintenance Management Set

by Kelly

• ISBN13: 9780750669955
• ISBN10: 0750669950
• Format: Paperback
• Copyright: 2006-08-07
• Publisher: Elsevier Science

Summary

Plant asset management is a holistic approach to managing maintenance. Practical, accessible and business centred, these books provide a complete guide to understanding, planning, organising and managing maintenance. Together they cover the needs of any organisation with assets to maintain and manage. World-renowned expert Tony Kelly identifies real-world business aims and delivers a complete methodology for developing maintenance objectives, formulating a maintenance strategy, and designing and implementing maintenance systems that deliver. With full coverage of key techniques including TPM, RCM and CMMP, this is the complete maintenance management resource. 1. The most comprehensive guide to all aspects of managing and executing maintenance 2. World-renowned author with stand-out ability to cover this huge subject comprehensively and rigorously 3. Fully developed for professionals and students, with both theory and practice and cases form ranging from the process industries to customer services systems

Table of Contents

Preface	xi
Acknowledgments	xiii
Author's biography	xv
Part 1 Introductory chapters	1	(50)
Maintenance and the industrial organization	3	(6)
Introduction	4	(2)
A systems view of maintenance management	6	(3)
Plant acquisition policy and maintenance life-cycle costs	9	(14)
Introduction	10	(1)
Capital asset management	11	(6)
Summary	17	(6)
Formulating maintenance strategy: A business-centered approach	23	(28)
Introduction	24	(1)
Business-centered maintenance	25	(2)
An example of the application of BCM: background	27	(2)
Part A: Audit of the FPP maintenance department	29	(15)
Maintenance objectives	29	(1)
Life plans and preventive schedule	30	(4)
Maintenance organization	34	(4)
Maintenance work planning	38	(3)
Maintenance control system	41	(1)
Maintenance documentation	42	(1)
Audit summary	43	(1)
Part B: An alternative maintenance strategy for continuous operation	44	(1)
Part C: A longer-term view of organizational change	45	(1)
The strategic thought process	45	(6)
Part 2 Maintenance objectives and task selection	51	(110)
The structure of industrial plant	53	(14)
Introduction	54	(1)
Physical asset systems	54	(1)
Modeling industrial plant	55	(5)
The reason for maintenance	60	(1)
Capital replacement policy	61	(1)
Maintenance strategy	62	(5)
Maintenance objectives	67	(18)
Introduction	68	(1)
Maintenance resources and plant output factors	69	(5)
Maintenance resources (men, spares and tools)	69	(1)
Maintenance resources and plant longevity	69	(1)
Maintenance resources and desired plant safety (equipment integrity)	70	(1)
Maintenance resources and product output	70	(4)
A generic statement of a plant maintenance objective	74	(1)
A procedure for formulating maintenance objectives	75	(4)
Maintenance objectives and maintenance performance indices	79	(1)
Maintenance objectives in practice	79	(6)
Preventive maintenance decision-making Part 1: Principles, concepts and techniques	85	(34)
Introduction	86	(2)
Plant items and their failure characteristics	88	(4)
The plan item: a definition	88	(1)
Maintainability diagrams	89	(2)
The items function, failure consequences and failure modes	91	(1)
The preventive maintenance decision problem	92	(3)
The maintenance actions	95	(7)
The alternative actions and their characteristics	95	(1)
The repair vs replace decision	95	(4)
Reconditioning: internal vs contract	99	(2)
In-situ repair techniques and the repair vs replace decision	101	(1)
The timing of the maintenance action: maintenance policy	102	(17)
Fixed-time maintenance	102	(4)
Condition-based maintenance	106	(7)
Operate-to-failure	113	(1)
Opportunity maintenance	113	(1)
Design-out maintenance	114	(1)
Establishing the best maintenance policy	114	(5)
Preventive maintenance decision-making Part 2: Maintenance task selection	119	(20)
Introduction	120	(2)
Examples of maintenance task selection	122	(4)
Example 1: The rubber lining of a chemical reaction vessel	122	(1)
Example 2: The rotary joint of a paper machine	123	(3)
Example 3: The roller element bearings of a paper machine	126	(1)
Assembling the maintenance life plan for a unit	126	(4)
Standby units and the life plan	130	(9)
Maintenance task selection using reliability-centered maintenance	139	(22)
Introduction	140	(1)
The RCM procedure	140	(5)
Application of RCM to a chemical plant	145	(16)
Background	145	(1)
Final reaction stage: the process and equipment	146	(1)
RCM analysis of the final reactor	147	(14)
Part 3 The top-down bottom-up approach	161	(32)
Determining the life plan and schedule: The top-down bottom-up approach	163	(30)
Introduction	164	(4)
The TDBUA	168	(19)
Outline of TDBUA	168	(1)
Step 1: Understanding the structure and characteristics of operation of the plant (the `top-down' stage of the analysis)	168	(5)
Step 2: Establishing a maintenance life plan for each unit of plant (the `bottom-up' analysis)	173	(7)
Step 3: Establishing a preventive maintenance schedule for the plant (putting it all together)	180	(7)
Comments on the TDBUA	187	(2)
Using the TDBUA	189	(4)
Part 4 Controlling plant reliability	193	(12)
Controlling plant reliability	195	(10)
Introduction	196	(1)
Reactive control of plant reliability	196	(2)
Proactive control of plant reliability	198	(1)
Incorporating reliability control systems into the organization	198	(7)
Part 5 Exercises	205	(10)
Exercises on maintenance strategy	207	(8)
Exercise 11.1 An alumina refinery	208	(2)
Exercise 11.2 A gold mine milling process	210	(5)
Part 6 Case studies	215	(52)
Case studies of maintenance strategy	217	(50)
Case study 1 An audit of the maintenance strategy for an agricultural chemical plant	218	(12)
Introduction	218	(1)
An overview of Fertec	219	(2)
Objectives	221	(1)
Maintenance strategy	222	(1)
Plant-operating characteristics	222	(1)
Ammonia plant strategy	222	(6)
Comments and recommendations on strategy	228	(2)
Case study 2 Maintenance strategy review of an aluminum smelter	230	(10)
Introduction	230	(1)
An overview of Smeltall	230	(2)
Carbon plant process flow: overall operation	232	(3)
Green-mix plant-operating characteristics and maintenance strategy	235	(1)
Operating characteristics	235	(1)
Maintenance strategy	235	(1)
Comments and recommendations	236	(1)
Ring furnace maintenance characteristics and strategy	236	(1)
Operating characteristics	236	(2)
Ring furnace maintenance strategy	238	(1)
Comments and recommendations	239	(1)
Summary	240	(1)
Case study 3 A review of the maintenance strategy in a petroleum refinery	240	(3)
Introduction	240	(1)
Plant-operating characteristics	240	(2)
Maintenance strategy	242	(1)
A schedule of outage work for the main process streams	242	(1)
A schedule of maintenance work for the standby equipment (e.g. for pumps)	242	(1)
Online inspection routines	243	(1)
Observations	243	(1)
Case study 4 Maintenance strategy in the coal mining industry	243	(4)
Introduction	243	(1)
An overview of COALCOM	244	(3)
Case study 5 Maintaining an open-cut coal mine	247	(3)
Introduction	247	(1)
Operating characteristics of an open-cut mine	247	(1)
Modeling fleet operation: status diagrams	248	(1)
Summary	249	(1)
Case study 6 Maintenance strategy for a passenger transport fleet	250	(5)
Introduction	250	(1)
Fleet-operating characteristics	250	(1)
Outline of the existing maintenance strategy	250	(2)
Maintenance strategy review	252	(2)
Comments	254	(1)
Case studies Case studies in the electrical power utilities	255	(2)
Introduction	255	(1)
Operating characteristics of an electricity supply system	255	(2)
Case study 7 A gas-fired power station	257	(2)
The station and its operating characteristics	257	(1)
The maintenance strategy in use when the station provided base load	257	(1)
Maintenance strategy review for two-shift operation	257	(2)
Case study 8 An oil-fired power station	259	(3)
The station and its operating characteristics	259	(1)
Production and maintenance objectives	259	(1)
Maintenance strategy before privatization	260	(1)
Steam units	260	(1)
Gas turbine	260	(1)
Maintenance strategy after privatization	261	(1)
Case study 9 A transmission system	262	(2)
Equipment-operating characteristics	262	(1)
Maintenance strategy mapping	263	(1)
Case study 10 A distribution system	264	(3)
Appendix 1 Maintenance terminology	267	(2)
Appendix 2 In-situ repair techniques	269	(6)
Appendix 3 Introductory failure statistics	275	(6)
The statistical parameters of component lifetimes	275	(6)
Probability density functions	276	(1)
The Normal or `wear-out' pdf	277	(1)
The negative exponential, or `random failure' pdf	278	(1)
The hyper-exponential, or `running-in' pdf	278	(2)
The whole-life item failure profile	280	(1)
Index	281	(8)
Preface	xi
Acknowledgments	xiii
Author's biography	xv
Part 1 Introductory chapters	1	(54)
A business-centered approach to maintenance organization	3	(26)
Introduction	4	(1)
Business-centered maintenance	4	(1)
An example of the application of BCM: background	5	(2)
Part A: Audit of the FPP maintenance department	7	(15)
Maintenance objectives	7	(1)
Life plans and preventive schedule	8	(3)
Workload	11	(2)
Maintenance organization	13	(3)
Maintenance work planning	16	(2)
Maintenance control system	18	(1)
Maintenance documentation	19	(2)
Audit summary	21	(1)
Part B: An alternative maintenance strategy for continuous operation	22	(1)
Part C: A longer-term view of organizational change	23	(1)
The strategic thought process	23	(6)
Maintenance organization in outline	29	(10)
Introduction	30	(1)
Modeling the organization	31	(2)
Factors influencing the design of the maintenance organization	33	(6)
The maintenance workload	39	(16)
Introduction	40	(1)
Categorization of the maintenance workload	40	(3)
Mapping the workload	43	(3)
First-line workload	43	(2)
Second-line workload	45	(1)
Third-line workload	46	(1)
Forecasting the maintenance workload	46	(3)
First-line workload	47	(1)
Second-line workload	47	(1)
Third-line workload	48	(1)
Case studies in categorizing and mapping the maintenance workload	49	(6)
Ammonia plant	49	(1)
Chemical plant	49	(1)
Agricultural chemicals	50	(1)
Alumina refining	51	(4)
Part 2 Maintenance organizational concepts, trends and mapping	55	(96)
Maintenance resource structure	57	(32)
Introduction	58	(1)
Mapping the resource structure	58	(4)
Resource characteristics	62	(5)
Manpower	63	(1)
Spare parts	63	(1)
Tools	64	(1)
Information	64	(3)
A decision model for the design or modification of a resource structure	67	(1)
The key decision-making areas of resource structuring	68	(11)
Contract labor	68	(3)
Trade-force composition	71	(3)
Plant specialization	74	(1)
Trade-force location	74	(1)
Non-daywork maintenance cover	75	(2)
Sizing the trade-force	77	(1)
Locations of spares, tools and information	78	(1)
Logistics	79	(1)
A systematic procedure for determining a resource structure	79	(5)
For a new plant	79	(2)
For an existing resource structure	81	(3)
Summary	84	(5)
Maintenance administrative structure	89	(22)
Introduction	90	(1)
Modeling administrative structures	90	(1)
Traditional views on administrative management and some guidelines	91	(6)
Characteristics of maintenance administrative structures	97	(10)
The maintenance--engineering interface	97	(2)
The maintenance--production interface	99	(4)
Responsibility for spare parts management	103	(1)
Vertical polarization	103	(1)
The relationship between the professional engineer and the maintenance supervisor	104	(1)
Major overhaul administration	104	(2)
Summary	106	(1)
The design or modification of the administrative structure	107	(4)
Human factors in maintenance management	111	(16)
Introduction	112	(1)
What are `human factors' in organizations?	112	(1)
The human relations approach to management: a brief review	113	(1)
Maintenance management behavioral characteristics	114	(9)
Individual behavioral characteristics	115	(5)
Group behavioral characteristics	120	(3)
The effect of outsourcing alliances	123	(1)
Auditing maintenance management human factors	124	(3)
Trends in maintenance organization	127	(24)
Introduction	128	(1)
Traditional maintenance organizations	128	(1)
Centralized resource structures	129	(4)
Introduction of flexible working practices	133	(3)
Plant manufacturing units	136	(3)
Slimming the structure ('downsizing')	139	(3)
The movement toward self-empowered plant-oriented teams	142	(3)
Contracting, outsourcing and alliances	145	(2)
Summary	147	(4)
Part 3 Maintenance organization case studies	151	(94)
Case study 1: Moving with the times	153	(16)
Introduction	154	(1)
Background	154	(2)
Audit of the CMG	156	(6)
Setting up the alliance	162	(2)
Observations	164	(5)
Case studies 2 and 3: Cautionary tales of organizational change	169	(16)
Introduction	170	(1)
Case study 2: A bottling plant	170	(5)
Background	170	(1)
The plant maintenance strategy and organization	171	(2)
Organizational change: the way forward	173	(1)
Short-term actions	174	(1)
Case study 3: An aluminum rolling mill	175	(10)
Background	175	(2)
Plant-operating characteristics and objectives	177	(1)
Life plans and preventive schedules	177	(1)
An overview of the organization	178	(3)
Maintenance systems	181	(1)
Observations and recommendations	182	(3)
Case study 4: Reorganization of a colliery	185	(24)
Introduction	186	(1)
Maintenance consultancy at COALCOM -- 1994	186	(15)
Background to COALCOM	186	(1)
Equipment and operating characteristics	187	(2)
Production and maintenance objectives	189	(1)
Life plans and preventive schedule	189	(2)
Maintenance organization	191	(5)
Maintenance systems	196	(1)
Recommendations	196	(5)
Progress visit and consultancy -- 1997	201	(8)
Introduction	201	(1)
Organization	201	(3)
Life plans and preventive schedule	204	(1)
Recommendations -- 1997	204	(5)
Case study 5: The do's and don'ts of maintenance teams	209	(10)
Introduction	210	(1)
Characteristics of teams at Fertec B	210	(3)
Characteristics of teams at Cario	213	(1)
Improving team operation at Fertec B	214	(1)
General comments on maintenance teams	215	(4)
Case study 6: Maintenance audit of an agricultural chemical plant	219	(26)
Introduction	220	(1)
An overview of Fertec A	220	(2)
Objectives	222	(2)
Comments on objectives	222	(2)
Maintenance strategy	224	(8)
Plant-operating characteristics	224	(1)
Ammonia plant maintenance strategy	224	(8)
Maintenance organization	232	(13)
Introduction	232	(1)
The maintenance resource structure	232	(4)
The maintenance administrative structure	236	(9)
Part 4 Total productive maintenance	245	(22)
Total productive maintenance: its uses and limitations	247	(20)
Introduction	248	(1)
What is TPM?	248	(1)
An early case study	249	(4)
Fundamentals of TPM	253	(3)
European applications by non-Japanese companies	256	(5)
Summary	261	(6)
Part 5 Exercises	267	(22)
Course exercises	269	(20)
Exercise E14.1: The changing role of the maintenance supervisor	269	(5)
Background	269	(1)
Part A: The supervisor's role in a traditional organization	270	(1)
Part B: The role of the supervisor after a `downsizing' exercise	270	(2)
Part C: Introduction of self-empowered work teams	272	(2)
Exercise E14.2: Maintenance reorganization in a food processing plant	274	(15)
Background	274	(2)
Company organization and maintenance strategy	276	(4)
The problem	280	(9)
Index	289
Preface	xi
Acknowledgments	xiii
Author's biography	xv
Part 1 Introductory chapters	1	(38)
A business-centered approach to maintenance systems	3	(30)
Introduction	4	(1)
Business-centered maintenance	4	(2)
An example of the application of BCM: background	6	(1)
Part A: Audit of the FPP maintenance department	7	(18)
Maintenance objectives	8	(1)
Life plans and preventive schedule	9	(2)
Workload	11	(1)
Maintenance organization	12	(4)
Maintenance work planning	16	(3)
Maintenance control system	19	(4)
Maintenance documentation	23	(2)
Audit summary	25	(1)
Part B: An alternative maintenance strategy for continuous operation	25	(1)
Part C: A longer-term view of organizational change	26	(1)
The strategic thought process	27	(6)
Introduction to maintenance management systems	33	(6)
The company expressed as a hierarchic systems model	34	(2)
Identifying the maintenance systems	36	(3)
Part 2 Budgeting and control	39	(32)
Maintenance budgeting	41	(12)
Introduction	42	(1)
Maintenance budgeting	42	(3)
The budgeting procedure	45	(8)
Maintenance management control	53	(18)
Introduction	54	(1)
The basics of maintenance management control	55	(1)
Principles of maintenance management control	56	(1)
The control of overall maintenance performance	57	(4)
The control of maintenance effectiveness (the control of plant reliability)	61	(2)
Reactive control of plant reliability	61	(1)
Pro-active control of unit reliability	62	(1)
The control of organizational efficiency	63	(1)
Incorporating systems into the organization	64	(3)
Published methods for measuring maintenance performance	67	(1)
The use of indices of maintenance performance for inter-firm comparisons	67	(1)
Human factors and data collection	67	(4)
Part 3 Work planning and work control	71	(64)
Short-term work planning and control	73	(18)
Introduction	74	(1)
The fundamentals of work planning	74	(1)
Modeling the operation of a short-term work planning system	75	(8)
The shift work planning system	79	(2)
The weekend work planning system	81	(1)
Feedback of maintenance data for control	82	(1)
Comments on work planning and work control	83	(1)
Guidelines for the design of work planning systems	84	(4)
Safety aspects	88	(3)
Management of plant turnarounds -- Part 1: Network analysis	91	(18)
Introduction	92	(1)
Terms, concepts and definitions in network analysis	93	(3)
The network planning procedure	96	(7)
Data collection	97	(1)
Constructing the logic diagram	97	(2)
Establishing the critical path, floats and overhaul time	99	(2)
Deriving a bar chart from the network	101	(1)
Resource histograms	102	(1)
Comments	103	(6)
Management of plant turnarounds -- Part 2: Turnaround methodology	109	(26)
Introduction	110	(1)
Phase 1: Initiating the turnaround	110	(4)
Forming a policy team and appointing a turnaround manager	110	(3)
Key policy decisions for the initiation phase	113	(1)
Selecting a preparation team	114	(1)
Collecting the job lists and other data	114	(1)
Phase 2: Preparing the turnaround	114	(14)
Analyzing and validating the workscope	114	(2)
Freezing the worklist	116	(1)
Preparing task specifications	116	(1)
Identifying pre-shutdown work	116	(4)
Defining contractor work packages and selecting contractors	120	(1)
Creating the work schedule	120	(1)
Techniques for creating a schedule	120	(3)
Optimizing the schedule	123	(1)
Forming the turnaround organization	123	(2)
Defining the site logistics	125	(1)
Formulating a cost estimate	125	(1)
Formulating a safety plan	126	(1)
Formulation of the quality plan	127	(1)
Briefing of all turnaround personnel	127	(1)
Phase 3: Executing the turnaround	128	(2)
The shutdown of the plant	128	(1)
Carrying out the turnaround tasks	129	(1)
Defining and costing the extra work	129	(1)
Defining and costing additional work	129	(1)
Monitoring progress, productivity, safety, quality and expenditure	129	(1)
Starting up the plant	130	(1)
Phase 4: Terminating the turnaround	130	(5)
Part 4 Spare parts management	135	(30)
Spare parts management	137	(28)
Introduction	138	(1)
Outline of the stores operation	139	(3)
Inventory policy	142	(8)
Inventory policy for fast-moving spares	142	(3)
Inventory policies for the control of slow-moving spares	145	(5)
Management of repairable equipment (rotables)	150	(5)
Introduction	150	(1)
The rotable system	150	(3)
Rotable inventory policy: the theory	153	(2)
Rotable inventory policy: in practice	155	(1)
Inventory policy guidelines	155	(1)
Stores documentation	156	(4)
Stores organization	160	(1)
Stores and rotable performance indices	161	(1)
Summary	162	(3)
Part 5 Documentation	165	(34)
Maintenance documentation systems: what they are and how they work	167	(22)
Introduction	168	(1)
A functional model	168	(2)
Plant inventory (Module 1)	170	(2)
Information base (Element 2)	172	(5)
Preventive maintenance schedule (Module 3)	177	(2)
Condition monitoring (Module 4)	179	(1)
Short-term work planning (Module 5)	180	(2)
Long-term work planning (Module 6)	182	(3)
Maintenance control (Module 7)	185	(2)
Summary	187	(2)
Computerized maintenance information systems: their uses and problems	189	(10)
Introduction	190	(1)
Computerized documentation: historical background	190	(3)
The benefits of computerized maintenance information systems	193	(2)
The problems with computerized maintenance information systems	195	(1)
Summary	196	(3)
Part 6 Case study	199	(30)
Case study: Maintenance audit of an agricultural chemical plant	201	(28)
Introduction	202	(1)
An overview of Fertec A	202	(1)
Objectives	203	(3)
Comments on objectives	204	(2)
Maintenance strategy	206	(6)
Plant-operating characteristics	206	(1)
Ammonia plant maintenance strategy	206	(6)
Maintenance organization	212	(5)
Introduction	212	(1)
The maintenance resource structure	212	(3)
The maintenance administrative structure	215	(2)
Work planning systems	217	(8)
Short-term work planning, scheduling and control	217	(6)
The planning of the major shutdowns	223	(2)
Spare parts management	225	(1)
Introduction	225	(1)
Outline of the stores organization and systems	225	(1)
Maintenance control	226	(1)
The control of overall maintenance performance	226	(1)
The control of organizational efficiency	226	(1)
The control of maintenance effectiveness (plant reliability control)	227	(1)
Documentation	227	(2)
Comments and recommendations	228	(1)
Appendix: Weibull analysis	229	(6)
Weibull analysis of item lifetime	229	(3)
Weibull probability paper	232	(1)
A Weibull analysis of a large and complete sample of times-to-failure	232	(3)
Index	235