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Using a Critical Machines Management Program for Optimum Maintenance

Norm Covich Incitec Pivot Limited

Outline
Machines Management and your business Strategic Model for Machines Management

Machines Management and your business
• The cost of not managing your machines.
Strategic Model for Machines Management.

Do you have a Machine Management Strategy? If so .Do you know what it is? .

How critical is the performance of your machines to overall performance of your business? .

You must take into consideration: • Is your plant single stream? • What is the cost of downtime / lost production? • What is the cost of maintenance? – Planned – Unplanned .

Jet Reaction Turbine Gearbox 3 Stage Compressor .

What proportion of your downtime is due to machine problems? Process Electrical Instruments Trips/DCS Piping BE Exchangers Converters Waste Heat Boilers High Voltage Primary Machines Primary Reformer Other Machines .

000 .What lost profit from lost production does this represent? $6.300.

Reaction Turbine Gearbox .

3rd Stage 2nd Stage 1st Stage Compressor .

What proportion of your maintenance costs are attributed to machine problems? Structural Pressure vessels Electrical Instrumentation Primary machines Secondary machines .

600.000 .What does this represent? $9.

Lost Tonnes Unknown .Lost Tonnes by by Root Cause Cause KI Ammonia .no RCA [Root Cause Analysis System] End of Life [Remnant Life Analysis System] External Influence Inadequate Design [Eng Standards / Specifications] No / Inadequate Procedure [Work Instructions / Operating Procedures] Maintenance Strategy [Equipment Life Plans] .

Machines Management and Your Business. Strategic Model for Machines Management. • Critical success factors for machines management. .

Adopt a totally proactive maintenance approach .Strategic intent of Incitec’s machines management program.

Equipment Life Plans . What needs to be done. when and how.Providing systems of work which ensure an appropriate level of proactive maintenance is carried out.

decision making and planning.Installing Systems which provide information to support analysis. Condition Monitoring Systems .

. review system.Review assets to be monitored Conduct failure mode analysis Determine criticality / failure probability / monitoring validity / cost effectiveness Assign C-M method to each asset Integration of C-M techniques Program Management . reporting format. resources and responsibilities.workflow.

Installing Systems which dictate how a maintenance task is to be performed. Work Instructions and ITPs .

abnormal condition management and decommissioning.Installing Systems which dictate how an operating task is to be performed. ie for commissioning. Operating Procedures . normal operation.

Lubrication Management Systems .Ensure ongoing reliable operation through the utilisation of best practice lubrication (filtration) management systems.

Lubrication Management Systems . Full plant audits with 6 monthly reviews. Improved lubrication practices.System to capture and act upon audit data proactively.M. Optimisation of product.Dynamic oil C.

Ensure that no unplanned outages or extension to planned outages occur through component problems. Critical Spares Management .

Critical Spares Management .Control on stores inventory through MRP planner. Savings through Vendor Alliances. Regular stock turnover reports looked at. Dedicated use of SOS software.

Ensure that components are replaced before failing due to an end of life mode. Remnant Life Analysis .

Root Cause Analysis .Ensure that the root cause of equipment failures is established. understood and addressed with the corrective actions reflecting business impact.

Identify Failure / Select Team Leader Collect Data Make Observations Generate Hypotheses Investigate Hypotheses Identify Root Cause and Contributing Factors Nominate Actions and Ownership Report Findings Track Implementation of Actions .

Critical Machine Operation Ongoing operation & maintenance of machine Critical Machine Refurbishment Longer term overhauls & remedial repairs Equipment Life Plan The maintenance plan for the life of this machine detailing timing of routine tasks. Condition Monitoring Information on machine & performance which allows precise planning of future maintenance workscope & timing. Work Instructions / ITP The procedural & quality control document developed to ensure that all repairs & replacement activities are carried correctly & at lowest cost. inspections. Improves machines availability & run-times. Machine protection during upset .Critical Machine Management Model Root Cause Analysis Ascertain & address the root cause not the symptom. Remnant Life Analysis Analyse & establish component life so replacement can be planned before item fails by end of life mode. the first time Critical Spares MGT All necessary spares are available & serviceable when required Lubrication Management Maximises component life. decommissioning & abnormal condition management or critical machines. Corrective actions to reflect the Business Impact Operating Procedures The Standard for commissioning. component replacements. overhauls etc. operating.

Any Questions? .