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Case Studies in Maintenance and Reliability: A Wealth of Best Practices


ForewordAuthors' BackgroundImpetus for this BookThe Shewhart CycleContentsLocationsGlossary, Acronyms and AbbreviationsAcknowledgementsReferencesThe LocationsLocations in the Middle East and South AsiaFacility: Pharmaceutical PlantFacility: Automobile Parts ManufacturerFacility: Petroleum RefineryFacility: A Large Petroleum RefineryLocations in East AsiaFacility: Liquefied Natural Gas PlantFacility: Large Complex Oil RefineryFacility: New Medium-Sized Complex Oil RefineryFacility: A Medium-Sized Simple Petroleum RefineryFacility: A Regional Oil Company Operating Refineries and Downstream OperationsLocations in EuropeFacility: A Large Petroleum RefineryFacility: Large Oil and Gas Production CompanyFacility: Corporate Technical HeadquartersFacility: A Small Complex Oil RefineryLocation in AustralasiaFacility: Medium-Sized Semi-Complex Petroleum RefineryLocations in Central and South AmericaFacility: Small Petroleum RefineryCreating the VisionBackgroundReview ProcessSelected ProjectsElectricity SupplyAir SupplyWater SupplyDust and Fume PollutionSecurity of Energy Supply to the CanteenResultsFactory Ventilation (HSE)Electricity SupplyAir SupplyWater SupplyDust and Fume PollutionSecurity of Energy Supply to the CanteenLessonsPrinciplesSetting ObjectivesBackground Customer ExpectationsTechnical CriteriaCommercial TermsSelection CriteriaCompetition OutcomeResultsLessonsPrinciplesCbanging ParadigmsBackgroundPrevailing CultureInfrastructureShutdown WorkEconomic ImperativesNew Brooms—To Sweep CleanImprovement ProcessThe Five PrinciplesPrinciple 1—Define a Maintenance PhilosophyPrinciple 2—Maintenance is a Business Process, Not Just a DepartmentPrinciple 3—Contractors are Essential Partners in the EnterprisePrinciple 4—Define the Day-to-Day Maintenance ProcessPrinciple 5—Define the Shutdown Maintenance ProcessResultsLearning PointsImportance and Power of BenchmarkingProviding Leadership and ExpertisePrinciplesApplying Business Best PracticesBackgroundReactionReview ProcessCharacteristics of Refining Industry Top PerformersResults of the ReviewStrategic Decisions on Effecting ChangeManaging the Change ProcessEffective ComputerizationInitiatives to Improve PerformanceLessonsReferenceEvaluate Contractors’ Unit RatesBackgroundEvaluating the SystemReviewing the Existing NormsCorrective ActionsBenchmarking and ResultsValve Gland Packing RenewalLessons LearnedPrinciplesBench markingBackgroundCompany Performance Analysis MethodologyBenchmarking Consultant's MethodologyRecipe for Top PerformanceDriving Improvements in Individual LocationsPartnering ProcessDelivering to the SitesWorkshops and PublicationsPreparing for a Site VisitTeam VisitRoadmap and Follow UpsResultsLessonsPrinciplesStaffiog LevelsOrganizational LevelsNumbers of ManagersSupervision RatiosApproaches to Staffing NumbersGetting our Operator NumbersMaintenance Personnel NumbersStaffing of Instrument GroupStaffing of Electrical GroupLessonsPrinciplesIntegrating Inspaction and Degradation StratagiesBackgroundPrevious Approach to DegradationA New Way ForwardThe Pilot SchemeResults—The Good NewsResults—New ProblemsSpreading the Degradation Management MessageLessonsPrinciplesTechnician Training CballengeBackgroundThe ChallengeTraining FacilitiesTraining StrategyProgress AssessmentResultsLessonsPrinciplesCompetence ProfilesBackground Case Study of a Technician Competence ImbalanceAn Approach to Contractor CompetenceCompetence Profiling—A Bit of TheoryCompetence Grading ScaleCompetence ManagementLessonsPrinciplesOperators and MaintainersBackgroundConcept and Initial TrainingInitial Experience and FindingsRevised SchemeCredits for Competence, Grades, and Salary BandsAssessmentLessonsPrinciplesBuilding a Reliability CultureBackgroundLong-Term IssuesA Driver of BehaviorExecuting the PlanResults: The Moment of TruthRubbing Off the Right WayLessonsPrinciplesMapaging Sur plus StaffBackgroundEmpire BuildingLeadershipIdentifying SurplusesOpportunitiesImplementation ChallengesManaging These ChallengesResultsLessonsPrinciplesReferenceRetraipiog Surplus StaffBackgroundOutline of Barrel Production ProcessQuality ProblemsAn Unfortunate Set of CircumstancesThe ChallengeTank Construction and Repair InformationTraining ProgramResultsLessonsPrinciplesIntegrated PianningBackgroundRevised ModelPlanning StageScheduling StageResultsLessonsPrinciplesCritical Path Planning CapabilityBackgroundCritical Path PlanningTreading on EggshellsTraining CourseResultsLessonsPrinciplesShutdown ManagementBackgroundShutdown AimsPerformance NumbersPractices of Poor PerformersPractices of Top PerformersEffective Work Planning, Organization, and SchedulingResultsLessonsPrinciplesElectrical Maintenance StratagiesBackgroundMaintenance TheoryPreventive Maintenance of Motor StartersPreventive Maintenance of BatteriesModern Maintenance TheoryElectrical Maintenance StrategyElectrical Inspection Strategy—Our ChoicesExcess StaffLessonsPrinciplesMinor Maintenance by OperatorsBackgroundIntroduction to Minor Maintenance by Operators (MMBO)Benefits of MM BOMaintenance Skills Available in Production OperationsCase Study of an MMBO Implementation in EuropeCase Study of an Implementation in AsiaThe Control IssueNew Opportunities to ConsiderLessonsPrinciplesRelocating Machine ToolsIntroductionBackgroundExisting Procedure for Machine RelocationThe ChallengeAnalysisFirst Shop Floor TrialBuilding Extension DelaysSecond Shop Floor TrialResultsLessonsPrinciplesReferencePainting Contract StratagyBackgroundOverall policy directionCommercial IssuesThe StandardLarge Painting WorksIntermediate Work PackagesSmall Work PackagesResultsLessonsPrinciplesReferenceLong Look-Ahead PlanBackground The Day-to-Day Maintenance ProcessUsing the ProcessRush WorkPrioritization of WorkLaunch of the New SystemResultsLessonsPrinciplesWork load Management ...from chaos to orderBackgroundExisting FoundationCorruption of the Priority SystemAnalysisCommunication and TrainingWhen the Rubber Hits the Road—Pilot StudyRoll-Out to Other SectionsResultsLessonsPrinciplesInfrastructure MaintenanceBackgroundInfrastructure ItemsInspection ResultsWhere Do We Start?Developing the Decision MatrixFinding the MoneyResultsLessonsPrinciplesWorkflow ManagementBackgroundThe existing organizationPerformance of the Existing OrganizationSome Management TheoryRedesign of the OrganizationAn IT EnablerResultsSome ProblemsLessonsPrinciplesAdditional ReadingTrip TestipgBackgroundHidden FailuresTechnical Integrity (TI)Testing for Hidden FailuresPilot TrialsThe Case for ChangeResultsLessonsPrinciplesReferencesWork the PlanBackgroundPremise SettingRoles of Team MembersEstablishing Work ScopeHurdle for Additional WorkPlanning, Scheduling, and Resource OptimizationExecutionPost Execution ReviewLessonsPrinciplesKeepipg to ScheduleBackgroundCyclone Replacement ProcedureThe Cards We had been DealtExploring Potential SolutionsScale ModelSafety AspectsResultsLessons LearnedPrinciplesOperators as a Maintenance ResourceBackgroundExecution of Maintenance WorkOperator WorkloadThe ChallengeType of Maintenance Work for OperatorsResultLessonsPrinciplesOverti me ControlBackgroundSystem DesignSome Features of the SystemSome Subtle Features of the DesignResultsLessonsPrinciplesManage ContractorsBackgroundGate Access SystemContractor Management SystemHow Did It Work?Some Specific AspectsSummarized BenefitsLessonsPrinciplesReliability Engineering in New ProjectsBackgroundFunctional RequirementsOriginal ConfigurationDefining the Objective Function for the ModelDesign Basis for Planned ShutdownsAnalysis TechniqueOutputs from the ModelRecommendations Made to Project TeamResultsLessonsPrinciplesReferencesComputipg Reliability DataBackgroundThe OpportunityReliability ParametersPotential Sources of ErrorGas, Smoke, and Fire DetectorsEmergency Shut Down (ESD)and Blow-Down ValvesFire Water PumpsEvident Failures—Weibull ParametersResultsLessonsPrinciplesReferencesTurnaround Perfor m ance Imp rove m entsBackgroundOutline of Shutdown of Crude Distiller and Associated UnitsReview ProcessPotential for Improvements—PlanningPotential for Improvements—ProductivityAnalysis of Previous ContractsReducing Planning Effort and TimeContracts AdministrationManagement PresenceResultsLessonsPrinciplesReducing Shutdown Duration (A practical illustration)BackgroundObservationsSoaker VesselFractionating ColumnResidue PumpsPipeline from Soaker to Fractionating ColumnHeater Outlet Pipes to SoakerImprovement OpportunitiesResultsLessonsPrinciplesA Small Matter of Cleapip gBackgroundThe Cleaning ProblemThe Air-Spider ReplacementAnalysis of Cleaning ActivityQuestionsSolutionResultsLessonsPrinciplesMotor Maintenance RegimesBackgroundMotor Failure DataElectrical FailuresBearing FailuresPerformance of Seven Motors at LocationsSummarized FindingsA Maintenance Strategy for Refinery MotorsLessonsPrinciplesBoiler Feed - Water Pump SealsBackgroundIssues Relating to BFW SealsMeasuring the Seal Face TemperaturesTesting the HypothesisResultsLessonsPrinciplesCooliog Water Pump FailuresBackgroundInternal Inspection ResultsAnalysisTemporary SolutionSolution: Trial Repair of Pump BellSolution: Aeration of WaterCooling Water Pump Failures 313Change ControlLong-Term SolutionLessonsPrinciplesHeater Outlet Flue Gas DampersBackgroundInspection ResultsAnalysisSolutionsChange ControlResultsLessonsPrinciplesLaboratory Oven FailuresBackgroundProblem DescriptionAnalysisSolutionsTrialsResultsLessonsPrinciplesAdditional ReadingPump Reliability BackgroundPump Reliability Improvement FrameworkResultsLessonsPrinciples
 
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