Maintenance Management Services


The concept of viewing plant maintenance as an expense is rapidly changing to view maintenance as a profit center. Proper maintenance of plant equipment can significantly increase the plant availability and profit of the organization.

Hofincons is one of the market leaders in implementing the best practices in equipment management, improving the equipment performance and enhancing the effectiveness of maintenance management.
 
bullet Maintenance System Effectiveness Audit
bullet Functional & Equipment Criticality Analysis (FCA & ECA)
bullet Reliability Centered Maintenance (RCM)
bullet Risk Based Inspection (RBI)
bullet Reliability, Availability and Maintainability studies (RAM)
bullet Root Cause Failure Analysis (RCFA)
bullet Operability & Maintainability review (O&MR)
bullet Bill of Material development (BOM)

[ Top ]  

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 inspect the facility and conduct series of interview with all the levels of management
  • The effectiveness of the audit supported by the quality and granularity of information gathered during the interview  with customers’ operation, maintenance and support services team
  • Hofincons utilize in-house software, which 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 analyzed with professional integrity and quality
  • Hofincons will perform a gap analysis to highlight the way things are and the way things should be.

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 :   

An electronic software tool, designed to make the job of the auditor easy and to clearly highlight the strengths, weakness and effectiveness of the maintenance functions of an organization.

[ Top ]  

Functional & Equipment Criticality Analysis (FCA & ECA)

  • Criticality assessment helps in ranking the equipment in a plant according to the order of their importance and risk position.
  • This ranking process helps in optimizing the maintenance activities and prioritizing the maintenance needs on the basis of their criticality to business and HSE interests of the company.

Methodology

  • Asset break down structure developed and Function and equipment relationship established
  • A cross functional team analyze failure consequence and likelihood of functions and equipment, considering the effect on production, safety and environment
  • Functions and equipment will be ranked as Extreme, High, Medium and Low.

Benefits

  • Maintenance requirement of each asset in the plant will be fixed based on the criticality rating.
  • Facilitate to assign work order priority in CMMS / EPR environment

Software

A software to define the criticality of each function/equipment in a plant

[ Top ]

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
  • Hofincons having expertise in implementing RCM for Oil & Gas, Petrochemical, Fertilizers industries with most of the commercial Off the Shelf products including Shell Global Solution’s RRM V 2.0,  SOS’s RCM Turbo, Reliasoft RCM+ and Engica Q4 RCM,.

Methodology

  • Critical equipment identified during the course of Criticality analysis is selected for RCM analysis.
  • A cross functional team comprising of operational and maintenance personnel will analyze each equipment utilizing FMEA technique
  • Appropriate maintenance strategy, task, resource requirement determined based on RCM process

Benefits

  • Required safety and environmental protection levels are met or exceeded
  • Equipment availability is maximized
  • Cost is minimized (including the cost of maintenance / 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

[ Top ]

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
  • Structured analysis to identify and focusing on high risk assets and provide appropriate effort to lower risk assets
  • 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 by defining scenarios in which leaks progress to undesirable events,  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 damage mechanisms applicable to the item analyzed,  The inspection history of the item and The effectiveness of the previous inspection
  • Hofincons is conversant with all the three levels of risk analysis as per API 581 such as Qualitative, Quantitative and Semi Quantitative

Benefits

RBI is a formal assessment process to deliver:

  • Inspection plans and periods for equipment based on level of risk
  • Optimized 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

[ Top ]

Reliability, Availability and Maintainability studies (RAM)

  • Availability analysis is to predict the performance of the system over mission time
  • Availability of a system manipulated by reliability and maintainability factors
  • RAM analysis can be performed during FEED and Detailed design phases of engineering projects to analyze system performance with different scenarios validated against targeted availability

Methodology

RAM analysis performed by utilizing commercially available software such as Reliasoft Blocksim 7 with basic data pertaining to Reliability, Availability and Maintainability

Reliability block diagram used to define the system / sub system and their configuration effect are analyzed with different scenarios>

The system/subsystem, which is most influential to the overall availability will be analyzed in great detail to optimize the performance of the overall system

Modification recommendations for achieving availability performance are made based on the availability results achieved in the most economical manner

Benefits

  • Systematic analysis to evaluate capabilities of the systems to perform its intended function
  • Identification of bottle-necks during green field stage helps in re-design and cost benefits
  • Useful to identify critical subsystem and understand their interdependencies
  • Greater visibility on equipment need for improvement
  • Estimation of failure-free operating periods

[ Top ]

Root Cause Failure Analysis (RCFA)

  • Root Cause Failure Analysis (RCFA) is a process of identifying source or origin of the particular failure so that recurrence of the failure can be prevented
  • RCFA is a structured methodology for investigating, categorizing and eliminating the true root cause of particular failure and determine the course of corrective or preventive action

Benefits

  • Avoidance of repeated failures
  • Enhanced maintenance and operation procedures to improve asset life
  • Improved operating efficiency and better plant availability
  • Facilitates to identify training need
  • Reduced maintenance cost

[ Top ]

Operability & Maintainability review (O&MR)

  • Systematic review process of reviewing 3D models of the newly built facility to verify operability & maintainability of the plant
  • Ensures each items of the equipment / piping installed within the facility can be adequately operated and maintained

Methodology

  • Dedicated equipment type checklist and procedures will be developed to verify that the plant designed to maintain and operate adequately.
  • The review process covers following areas,
    • Equipment / piping taken out of service and putting back to service such as Dismantling, removing and reassembling without affecting adjacent facility
    • Sufficient accessibility for Inspection and routine operator checks 
    • Depressurisation, purging, drain, flushing, blowndown, isolation and ventilation performed without affecting adjacent facility
    • Suitability of electrical equipment used in hazardous locations
    • Review of adequate ventilation for electrical items
    • Verification of emergency escape routes, emergency showers and eyewash stations
    • Provision of adequate process sampling and gas testing points
    • Provision for Bulk supplies loading and unloading

Benefits

  • Review and redesign during engineering stage of the project
  • Costly redesign and production loss on the operational stage can be avoided by Identifying shortfalls at the early stage of the project
  • Review process carried out on the staged manner, which will facilitate reengineering will be easy

[ Top ]

Bill of Material development (BOM)

  • Bill of Material is a logical drilldown of equipment to its components & quantities needed for its asset lifecycle
  • Maintenance BOM represented in tree structure with multiple levels of granularity
  • Levels are defined based on maintenance, purchasing and planning perspective

Benefits

  • Facilitates spare pars allocation during maintenance planning and scheduling
  • Where used cross referencing between equipment and spares can be beneficial in optimizing inventory quantities and cost saving decisions

[ Top ]


Back
 
bullet

MATERIALS MANAGEMENT SERVICES 

bullet

DATA MANAGEMENT SERVICES

bullet

DOCUMENT MANAGEMENT SERVICES 

bullet

SUPPORT SERVICES

 
© 2008, Hofincons Infotech & Industrial Services Pvt Ltd.