[ 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 ] |
