Planned Equipment Maintenance | PLANT INTEGRITY MANAGEMENT

This area of investigation was directed toward addressing the impact of maintenance practices on the Safaniya Utility Units’ Asset Management Program. Tables 3-4 through 3-8 list the issues addressed in the following areas:
• Planned Equipment Maintenance
• Work Selection/Execution
• Preventive Maintenance
• Corrective Maintenance
• Reliability and Maintenance Improvement

Planned Equipment Maintenance | PLANT INTEGRITY MANAGEMENT

This area of investigation was directed toward addressing the impact of planned maintenance practices on the Safaniya Utility Units’ Asset Management Program. Table 3-4 lists the issues addressed and the resultant findings.

PLANNED EQUIPMENT MAINTENANCE ISSUES

Inquiry Res
Has Safaniya developed individual equipment maintenance plans for major equipment items and generic classes that include predictive (condition monitoring) and preventative (calendar-based) maintenance programs? When were the maintenance plans last updated and what were the bases for updating Maintenance plans are provided in SAP-PM, there was no information available as to the organization that developed the plans, the process used for their development, or the criteria used in their development. However, a test of a good work plan is, is the work getting done in an effective and efficient manner. From our brief review, it appears that the plans are effective and prepared by experienced planners. The planners should be reviewing each completed work request to ensure
Were the equipment maintenance plans developed using a formal process, such as RCM or RBI, which evaluates risk and takes into account degradation mechanism, expected life and operating requirements? that the plan was efficient
What are the predictive and preventive maintenance programs presently in-place? Are maintenance intervals regularly reviewed based on operating history and future operating modes? Condition monitoring (e.g., vibration monitoring, piping inspection, lube oil analysis, etc.) and periodic instrument and electrical checks are accomplished on a regular basis. There was no evidence that the intervals were reviewed and adjusted based on operating and maintenance history.
Are unplanned maintenance outages used to perform upcoming planned maintenance activities? As time and resources permit.
Are work requests for predictive and preventive maintenance automatically generated by the computerized work management system? Yes
Are the operators required to conduct minor maintenance during their process rounds and are they formally trained to perform the maintenance activities? No
Have any equipment failures occurred because a planned maintenance activity could not be carried out in accordance with the plan? What changes were made to ensure that it does not recur? No
 

The key finding from the Planned Equipment Maintenance area is summarized as follows:
• Maintenance plans are provided in SAP-PM but there was no information available as to the organization that developed the plans, the process used for their development, or the criteria used in their development. However, a test of a good work plan is, “is the work getting done in an effective and efficient manner?” From our review, it appears that the plans are effective and prepared by experienced planners. The planners should be reviewing each completed work request to ensure that the plan was efficient. Recommendation: To optimize work plans based on vendor’s recommendations and plant experience processes such as RCM and RBI assessments should be performed to adjust and optimize maintenance resources as well as determine the appropriate frequency for the performance of PM actions.


 

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