Maintenance plant

The fact that plant maintenance is essential to loss prevention has been emphasized in recent years because  

Overall plant-wide maintenance is an element of fire prevention. It is shared with the business need to maintain the production process, as well as with Process Safety Management and other health, safety, and environmental programs. 

Efficient and regular maintenance ensures a smoothly-running plant and the minimum of interference with production. Maintenance is also an important way of reducing hazards, but can itself be hazardous if not carried out properly. A survey 2 by the UK Health and Safety Executive showed that 30% of all reported incidents in the chemical industry were maintenance-related. In the period 1982-6 there were 502 maintenance accidents, including six fatalities. 

To ensure the safety of the maintenance team, a formal system — normally a permit-to-work system — should be set up and operated 2. (See also case histories Al 94-98, pages 193-194.) 

A permit-to-work system aims to ensure that the risks of a particular job are properly considered. The permit-to-work is a written document which authorizes certain people to carry out specific work at a certain time, and sets out the main precautions needed. 

A formal handbook should be part of the permit procedure. This should make clear whether the cancellation of a permit indicates simply that the job specified on it has been completed, or whether the plant is safe for production to recommence. 

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In plant maintenance, the availability of quantitative and non-invasive screening NDT methods will reduce the time needed for shutdowns and increase the intervals between them. Modem NDT methods will become just as important a tool for Risk Based Inspection approaches and maintenance planning as operational parameters and degradation mechanisms already are. 

Plant location Plant maintenance Plant nutrients Plant patents Plants... 

Maintenance departments provide support to other functions of manufactuting management. Some of the corporate staff activities that are of concern to the plant maintenance organisation are iadustrial relations, finance, material control, services, and manufactuting engineering. 

Equipment-handling faciUties include any device used to convey or temporarily support equipment, or provide access for plant maintenance, eg, portable ladders, davits, A-frames, monorails, forklift vehicles, and cranes. 

Annual plant maintenance and repair costs average about 6% of the fixed capital iavestment, but should be calculated directly from person—hour per shift data or estimates. The annual cost for suppHes can be taken as 15% of the total maintenance and repair cost. 

The former is the responsibihty of the implementation team and is required for the initial implementation and Following any modification to the interlock. The latter is the responsibihty of plant maintenance, with plant management responsible for seeing that it is done on the specified intei val of time. 

Other than the wear problems, actual in-plant maintenance usually involves removal of wood, pieces of blasting wire, and other trash from the ports. When a reagentized feed is used, layers of oily reagents can build up on the spiral surface and sometimes require scrubbing for removal. With feeds containing oily reagents that attack rubber, ra-sion-resistant alloy spiral sections are used. 

I he focus of industrial plant maintenance has always been that the de,sign is correct, and that the operation of the pumps in the. system is as it should be. In this book, you will see that in the majority of occasions, this is not true. Most of us in maintenance spend our valuable time, just changing parts, and in the best of cases, performing preventive maintenance, trying to diminish the time required to change those parts. 

Corporate MOC team Develop management of change system for all sites W. Hiller, Plant Maintenance Supervisor... 

SAIC Data Base Nudear Plant maintenance and repair records by system and component type selected basic event failure rates and unavailability Data mainly for pumps, valves, diesels, batteries, chargers, and heat exchangers 76. 

NUMBER AND TYPE OF RECORDS Plant maintenance and repair records by... 

The main objective of the In-Plant Reliability Data System (IPRDS) was to develop a comprehensive and component-specific data base for PRA and other component reliability-related statistical analysis. Data base personnel visited selected plants and copied all the plant maintenance wor)c requests. They also gathered plant equipment lists and plant drawings and in some cases interviewed plant personnel for Information on component populations and duty cycles. Subsequently, the maintenance records were screened to separate out the cases of corrective maintenance applying to particular components these were reviewed to determine such things as failure modes, severity, and, if possible, failure cause. The data from these reports were encoded into a computerized data base. 

Appendix III of this report provides a detailed description of the reliability data used in event tree and fault tree quantification. Because of its extensive operating experience and the uniqueness of the BRP design, BRP plant-specific data was used whenever possible. Plant-specific data sources included plant maintenance orders, control room log books, surveillance tests, LERs, event reports, deviation reports, plant review committee meeting minutes, and USNRC correspondence. The plant-specific data used spanned the period from 1970 to 1979. Data before 1970 did not include maintenance orders or surveillance tests and therefore were excluded. The plant-specific data collected for BRP is presented in detail in Appendix XIII. Table III-4 summarizes 30 plant-specific component failure rates and Table 11-06 contains plant-specific maintenance unavailabilities for 20 components. These tables are a summary of the BRP component failure and maintenance outages. 

The cost of N2, like that of O2, is particularly dependent on electricity costs, though plant maintenance and transport costs also obtrude. Typical prices in 1992 for No in the USA were about 32 per tonne for bulk liquid (exclusive of transportation and handling charges). Costs for small-scale users of N2 from gas cylinders are proportionately much higher. 

Figure 1.1 Typical organization of a small plant illustrates that plant engineering is one of the essential functions in any plant. Maintenance is normally a subfunction of plant engineering...

Predictive maintenance is not a substitute for the more traditional maintenance management methods. It is, however, a valuable addition to a comprehensive, total plant maintenance program. Where traditional maintenance management programs rely on routine... 

The tube size is often determined by the plant maintenance department standards, as clearly it is an advantage to reduce the number of sizes that have to be held in stores for tube replacement. 

Labour will be needed for construction of the plant and its operation. Skilled construction workers will usually be brought in from outside the site area, but there should be an adequate pool of unskilled labour available locally and labour suitable for training to operate the plant. Skilled tradesmen will be needed for plant maintenance. Local trade union customs and restrictive practices will have to be considered when assessing the availability and suitability of the local labour for recruitment and training. 

Contract maintenance personnel cost more than plant personnel doing the same job. In 1967, it was estimated that the average contract person s services cost 4.71 per hour, while plant maintenance men cost 3.62 per hour.49... 

Plant maintenance Inventory control Staffing, capacity scheduling... 

Plant maintenance/repair costs, 9 533 Plant monoesters, 26 204 Plant nutrient sulfur, 23 589 Plant operation... 

In principle, any catalyst developed in the laboratory can be manufactured in large scale. In practice, however, the necessary investments, which may include development of the production process, and die operating costs of the catalyst production plant including availability and cost of raw materials, plant maintenance, labour etc. may not be justified by the market potential. In the VK69 case, production in the existing plant according to the route in Fig. 8 was preferred but not a strict requirement. 

Plant maintenance organizations are most accustomed to simpler sensors that do not require chemometrics for calibration. Specialized training is required to understand and support more complex chemomet-rics-enhanced analyzers. To some, such specialization can be considered a career dead end . 

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