∞ Maintenance System Effectiveness Audit

• Hofincons conducts Maintenance System Effectiveness Audit to evaluate the status of maintenance function in an organization and its overall impact on the organization.
• The audit will determine the level of the maintenance management system prevailing in the organization benchmarked against world-class maintenance practices.

Methodology

• Trained and experienced consultants of Hofincons will visit the plant equipped with the audit software, created based on years of experience in asset management.
• The software is designed to bring out the strengths and weaknesses in the maintenance management system and brings out areas for improvement.
• The present status of maintenance will be objectively analysed with professional integrity and quality
• Hofincons will perform a gap analysis to highlight the way things are and the way things should be.
• With poorly organized maintenance operations, this gap tends to increase continuously.

Benefits

• Detailed study of existing maintenance system and maintenance philosophy
• Analysis of the strength and weakness
• Comparison with world class maintenance
• Remedial measures to overcome the weaknesses and move towards world class maintenance.

Software : In-house developed, please contact us for further details.

DETAILED ASSESSMENT REPORT

Plant : Area : Assessment Period From: Average Percentage :

To:

A. Management approach to maintenance(65) B. Maintenance functional assesment (71) C. Maintenance planning and scheduling (64) D. Preventive and predictive maintenance (33) E. Maintenance performance assessment (0) F. Computerised maintenance management system (14) G. Work order system (0) H. Stores support to maintenance (79) I. Operator involvement in maintenance (57) J. Skill development (70) K. Lubrication (78) L. Overall Equipment Effectiveness (OEE) (78) M. Budget planning and costing (64) N. Health safety and Environment (92) O. Supervision effectiveness (100) P. Engineering support to maintenance (50) Q. Tools and tackles (80) R. Maintenance trend (50)

∞ Equipment Hierarchy Build

• For the preventive maintenance routines to be efficient, each asset in an operating plant is to be arranged in hierarchical fashion, with clearly defined parent–child relationship.
• The hierarchy build helps to organize the maintenance function in an efficient way, giving an overall perspective of the requirements.
• Aided by a well-defined Hierarchy build, Maintenance planning & scheduling becomes much more organized, efficient and effective especially in a computerized maintenance management environment.

Methodology

• The basis for the development of hierarchy is the updated P & IDs or PEFS, Functional Block Diagrams, Electrical Single Line Diagrams, Instrument loop schedule and updated master tag list.
• Hierarchy build process starts with the identification of “Systems” and their associated “Apex equipment”. System and Apex equipment are defined as below:

System :	Facility representing a common operating function such as “Fractionation”, “ Gas Compression”
Apex Equipments :	Equipment where primary operations are performed such as “Column”, “Pump”, “ Tanks/Vessels”.

• System or the Apex equipment represents the highest level in the hierarchy, to which the sub-level equipment can be attached.
• Further sub-level equipment will be attached based on logical deduction process.
  

Benefits

• The parent–child relationship of all the equipment of a plant are defined.
• This is the basis for the Maintenance group allocation, which will help in optimized issues of PM work orders.

∞ Functional & Equipment Criticality Analysis (FCA & ECA)

• In any plant, to improve plant availability, the first step is to identify the critical functions and the equipment performing those critical functions.
• Equipment performing critical functions will be given more attention during the operation of the plant to minimize their sudden failure.

Methodology

• From the FBDs, functions performed in the plant will be listed.
• A core team of operation, maintenance will be formed.
• Criticality of each of function and equipment will be analysed based on selected parameters.
• Functions and equipment will be ranked as Extreme, High, Medium and Low.
• Equipment performing critical functions will be selected for equipment criticality analysis.

Benefits

• Maintenance requirement of each asset in the plant will be fixed based on the criticality rating.

Software : In-house developed, please contact us for further details.
References and Standards: NORSOK Standard Z-008: Criticality Analysis for Maintenance Purposes

Functional Criticality		Equipment Criticality

∞ Reliability Centred Maintenance (RCM)

• With modern complex plant equipment, the key to improve equipment availability, product quality and to reduce maintenance costs is to improve the reliability of plant equipment.
• Reliability Centred Maintenance (RCM) is considered around the world as a proven methodology to develop world-class asset management strategies towards this goal.
• RCM is defined as a process used to determine the maintenance requirements of any physical asset in its operating context
• The objectives of RCM are:
• Improve Reliability without compromising the Technical Integrity
• Enhance Availability
• Optimize Maintenance Cost
• Provide Monitoring Plan to Sustain Benefit

Methodology

• Critical equipment will be selected for RCM discussion.
• A core team of operation and maintenance personnel will be formed under the guidance of RCM facilitator.
• This team will list all the failure modes for each type of equipment.
• For each failure mode, suitable preventive or detective task will be identified.
• The frequency of performance of each task will be decided.
• While finalized the tasks, condition monitoring tasks and operator related tasks will be given preference.
• Based on the RCM discussion, maintenance procedures, crew and frequency will be established.
• For certain failure modes, RCM discussion may lead to redesign or minor modification in the design of the equipment.

Benefits

• Required safety and environmental protection levels are met or exceeded
• Equipment availability is maximized
• Cost is minimized (including the cost of maintenance and repair and the cost of lost operations due to scheduled and unscheduled down time).
• Asset life is increased
• RCM creates a documentation trail of decisions made in the development of a maintenance program. This documentation is useful for updating maintenance requirements as additional operating experience is gained

Software : In-house developed, please contact us for further details.

∞ Risk Based Inspection (RBI)

• RBI is a method for using risk as a basis for prioritizing and managing the effort of an inspection program to rationally allocate inspection resources
• In an operating plant or installation, a relatively large percentage of risk is associated with a small percentage of the equipment items
• RBI does not aim at extending inspection intervals, nor does it focus on reducing inspection cost

Methodology

• The RBI method defines the risk of operating equipment as the combination of two separate terms:
• Consequence of failure
• Likelihood of an undetected failure
• The consequence of failure assessment follows these steps
• Definition of scenarios in which leaks progress to undesirable events
• Minor Leak
• Small Hole
• Large Hole
• Rupture
• Estimation of the physical effect of each scenario
• Adverse effect on people, equipment, environment and productivity as a result of the outcome.
• The likelihood of failure assessment takes into consideration such criteria as
• The damage mechanisms applicable to the item analysed
• Internal / External corrosion
• Pitting corrosion
• Hydrogen embrittlement
• Stress Corrosion Cracking
• Creep
• Fatigue
• The inspection history of the item
• The effectiveness of the previous inspection

Definitions

• Risk = Probability of failure X Consequence of failure
• Probability of failure = Likelihood of an event occurring
• Consequence of failure = Severity of an outcome of the event

RBI analysis

• RBI analysis is carried out using any of the following methodologies
• Qualitative: Uses engineering judgments & plant experience as source
• Quantitative: Highly involved calculations using statistical & probability models
• Semi- Quantitative: Uses the best of both qualitative & quantitative approach

Risk Assessment

• Each item is located on a Risk Matrix to have a global representation of the risk.
  
  
• The objective of RBI is to issue an inspection program to reduce the risk to an acceptable level.
  
  
• Quantitative: Highly involved calculations using statistical & probability models
• Semi- Quantitative: Uses the best of both qualitative & quantitative approach

RBI IMPLEMENTATION

• Issues to consider when deciding the most appropriate approach are:
• Right level of experience in units being assessed (especially in the case of specialized corrosive plant)
• What level of influence and ownership is required for the process
• How is RBI to be managed in the future
• Inspection plans to be developed and inspection results fed back into the process
• Quantum of change will be involved to the way integrity/inspection dept. works

Benefits

• RBI is a formal assessment process to deliver:
• Inspection plans and periods for equipment based on level of risk
• Optimised inspection plans based on individual damage mechanisms
• Operational boundaries, which prevent unexpected equipment damage mechanisms / rates
• Risk mitigation measures and other actions to safeguard integrity
• RBI permits the shift of inspection and maintenance resources to provide a higher level of coverage on the high-risk items and an appropriate effort on lower risk equipment

∞ HAZOP Study

• With modern complex plant equipment, the key to improve equipment availability, product quality and to reduce maintenance costs is to improve the reliability of plant equipment.
• Reliability Centred Maintenance (RCM) is considered around the world as a proven methodology to develop world-class asset management strategies towards this goal.
• RCM is defined as a process used to determine the maintenance requirements of any physical asset in its operating context
• The objectives of RCM are:
• Improve Reliability without compromising the Technical Integrity
• Enhance Availability
• Optimize Maintenance Cost
• Provide Monitoring Plan to Sustain Benefit

Methodology

• The technique of Hazard and Operability Studies, or in more common terms HAZOPS, is used for 'identifying potential hazards and operability problems' caused by 'deviations from the design intent' of both new and existing process plants.
• The Hazop Study provides an opportunity to correct these before such changes become too expensive, or 'impossible' to accomplish.

HAZOP STUDY METHODOLOGY

• Hazop study process involves applying in a systematic way all relevant keyword combinations in an effort to uncover potential problems.
• The results are recorded in columnar format under the following headings:
  

  ::: Deviation

  ::: Cause

  ::: Consequence

  ::: Safequards

  ::: Action

HAZOP STUDY METHODOLOGY

These reflect both the process design intent and operational aspects of the plant being studied.

Flow	Temperature
Pressure	Level
Separate (settle, filter, centrifuge)	Composition
React	Mix
Reduce (grind, crush, etc.)	Absorb
Corrode	Erode

Secondary Keywords

• When applied in conjunction with a Primary Keyword, these suggest potential deviations or problems.
• They are typically a standard set as listed below:
  
  

Word	Word
No	The design intent does not occur (e.g. Flow/No), or the operational aspect is not achievable (Isolate/No)
Less	A quantitative decrease in the design intent occurs (e.g. Pressure/Less)
More	A quantitative increase in the design intent occurs (e.g. Temperature/More)
Reverse	The opposite of the design intent occurs (e.g. Flow/Reverse)

The Hazop procedure

• Hazop is very much an iterative process, applying in a structured and systematic way the relevant keyword combinations in order to identify potential problems.
• A team of individuals with expertise in different areas such as engineering, operations, maintenance, safety and chemistry should participate in the discussions.
• The team is guided in a structured brainstorming process, by a leader who provides structure by using a set of guidewords to examine deviations from normal process conditions
• The guidewords are applied to the relevant process parameters e.g. flow, temperature, pressure, and composition in order to identify the causes and consequences of deviations in these parameters from their intended values.
• Finally, the identification of unintended (or unacceptable) consequences results in recommendations for improvement of the process such as:
• Design modifications
• Procedural requirements
• Modifications in written documentation
• Further investigations

∞ Support services for ERP / CMMS implementation

• Proper record of equipment history for future reference
• Increased Equipment Availability, due to better planning
• Increased Equipment Reliability through the identification of repetitive faults
• Better Stock control, giving reduced inventory levels and fewer stockouts
• Better Maintenance cost control
• Improved Safety by providing detailed standard job procedures

Hofincons will assist in:

• Selection of the best ERP/CMMS, depending upon the budget, usage
• Customization of the ERP/CMMS
• Feeding the relevant data in the ERP/CMMS package
• Training the users in data input for future modifications/expansion

Methodology

This audit will be done to:

• Find out the present maintenance Strategy
• Identify the strength and weekness
• Compare the strategy to the world class strategy toidentify the gap
• Define KPIs
• Suggest steps to move to world class maintenance

Master Tag List Preparation

• P & IDs or PEFS
• Electrical Single Line Diagrams
• Instrument Loop schedule

Calculation of Criticality Score

• FCA / ECA will be done to arrive at the criticality ranking.
• Based on the criticality of the equipment, the maintenance requirement of that equipment will be decided.

Data Population

• PM Module
• Technical Objects
• Functional Location
• Equipment
• Measureable Points and Counters
• Object Links and Networking
• Bill of Material
• Equipment BOM
• Assembly BOM (Material BOM )
• Measureable Points and Counters
• Object Links and Networking
• PM Planning
• Maintenance Strategies
• Maintenance Task List
• Maintenance Item
• Maintenance Plan
• Inspection plans to be developed and inspection results fed back into the process
• Quantum of change will be involved to the way integrity/inspection dept. works

• Maximo
• Equipment
• Equipment
• Operating Locations
• Failure Codes
• Condition Monitoring
• Routes
• Inventory
• Asset Catalog setup
• Item Assembly Structure
• Preventive Maintenance
• Plans
• Job Plans
• Safety Plans
• Safety Hazzards
• Safety Precautions
• Lock out/Tag out
  
• Labor
• Labor
• Crafts
• Labor Reporting
• Labor Groups
  
• Resources
• Companies
• Tools
• Service Contracts

Benefits of outsourcing the implementation of / are:

• Enormous data is to be fed into the system, which should be error-free and relevant for proper usage of the ERP/CMMS sytem
• Being first time implementer, most of the organizations are facing difficulties in feeding the relevant and accurate data into the system.
• Moreover, organisation cannot spare adequate skilled personnel for the ERP/CMMS implementation from their regular operation/maintenance teams.
• Hence outsourcing is the best option for better implementation of ERP/CMMS.
• Hofincons is the organization doing implemention of ERP/CMMS for the last 15 years.
• Hofincons is having rich experience in the implementation of SAP, Maximo, Oracle EAM, JD Edwards etc.

Condition Monitoring and Base-Line Vibration Signature

• The modern maintenance concept is to get maximum output from the installed equipment.
• This leads to a change from the time-based maintenance to condition-based maintenance
• Condition-based maintenance is a key technique in the optimization of maintenance requirement of an equipment.
• Available condition monitoring methods are:
• Vibration Monitoring
• Lube Oil Monitoring
• Temperature Monitoring
• Thickness Monitoring
• Performance Monitoring
• Out of these techniques, Vibration Monitoring is the single best tool to identify condition of rotating equipment.

Vibration Monitoring

• The biggest advantage is that all the required data are collected when the equipment is in operation and without opening it.
• Once the exact problems are known, maintenance activity can be planned to suit the plant conditions (depending upon the nature of the problem), necessary spares & crew can be arranged and minimum downtime is required to bring back the equipment nearer to new conditions.

Methodology

• Hofincons Engineers will visit the site with portable instruments and collect vibration data from all the critical equipment, at selected locations.
• After carefully analysing the data collected, a preliminary report will be given at site indicating the corrective actions to be carried out to eliminate the inaccuracies present in the equipment.
• Equipment health condition will be decided as per ISO 10816 standards.
• After eliminating the other inaccuracies, if unbalance is found to be the reason for high vibration in the equipment, then using portable balancing instrument, dynamic balancing will be done at site.
• The detailed report will contain,
• Equipment Sketch
• Vibration Data
• Equipment Trend Chart
• Frequency spectrums
• List of equipment in the Fair and Rough categories
• Recommendation for maintenance for equipment in Fair and Rough
• CM Effectiveness report

Benefits

• Unnecessary stopping and opening of an equipment is avoided.
• Probable defects are known prior to the stoppage.
• Equipment outage can be planned in advance for efficient and effective utilisation of resources.
• Equipment life extension through trend monitoring.
• Time based shutdowns can be avoided.

Safety Integrity Level classification

• SIL (Safety Integrity Level) assessments are used to define the appropriate degree of reliability when using instrumented systems to control and mitigate hazards.
• SIL rating defines the level of safety performance of a Instrumentation Safeguarding Loop/system components.
• SILs are ranked Levels 1-4, with a higher level indicating greater safety performance.
• Typically, higher SILs are achieved with more redundancy, more frequent testing, and diagnostics.
  
  

  Safety Integrity Level	Impact
  1.	Minor property and production protection.
  2.	Major property and production protection. Possible employee injury.
  3.	Employee and community protection.
  4.	Catastrophic community impact.

Safety Integrity Level	Impact
1.	Minor property and production protection.
2.	Major property and production protection. Possible employee injury.
3.	Employee and community protection.
4.	Catastrophic community impact.

Prerequisites for carrying out (SIL)

• Make sure that HAZOP study is carried out for the process
• Make sure that Target Safety level is defined for the process. (Target Safety level is indicated in terms of Frequency of Hazardous Events per year)
• Probability data for the failures should be available (Sources: Manufacturer, Oreda, Safety and Reliability handbook)

Prerequisites for carrying out (SIL)

• Establish the Safety Target Level
• Develop accident scenarios for every initiating event
• Establish the probability of occurrence of initiating event
• Establish the reliability of existing safety system
• Determine if the Safety target level is met, if met, no further evaluation is necessary

Points requiring detailed review during the actual execution of exercise

• Safeguarding Loop / Component performance
• Process interfaces
• Transmitter and sensor robustness and quality control

Selection, installation and maintenance practices

• Ambient Temperature Variation
• High Static Line Pressures
• Drift / Stability
• Redundancy

Benefits

• Detailed study of existing safeguarding system
• Find out adequacy of the existing safeguarding system
• Well defined Target safety levels
• Proposal of additional measures for improvement of the safeguarding system for reduced Risk

Software :

References and Standards: