Prevention program plant maintenance

AAdiy did the preventive maintenance program at the plant not prevent the failure ... 

Maintenance is not merely called upon to repair failed equipment (breakdown maintenance). Over the course of time, maintenance workers have teamed with plant operations personnel to develop preventive maintenance (PM), predictive maintenance (PdM), and condition-based maintenance (CBM) programs, all in an effort to get ahead of problems occurring in plant operations, and to do so as efficiently as possible. 

A. Performance measiires The first step in establishing an effective maintenance basics program is to identify and establish performance measures. Most experienced managers have learned that you get what you measme. Successful pharmaceutical plants develop and implement a series of supportive key performance measures to track and manage improvement of maintenance/reliability. Examples are mean time between failure, maintenance cost per unit of output, percent planned and scheduled maintenance, preventive maintenance tasks completed, expense maintenance cost as a percentage of replacement asset value, etc. These indicators must be available to aU levels of an organization and shoiild be used to maximize individual and group contributions. It would be best if these indicators were part of the reliability-balanced scorecard. 

Preventive maintenance—The plant maintenance program should include preventive measures that recognize the limited life of plant equipment and that service or decommission the equipment before it fails and creates a hazard. 

Effective Preventive Maintenance (PM) programs are essential for ensuring acceptable operational reliability throughout the service life of nuclear power plants. The role of PM are to detect and mitigate component degradation managing of ageing effects. 

Reliability of a plant depends on many parameters, such as the type of fuel, the preventive maintenance programs, the operating mode, the control systems, and the firing temperatures. 

The plant engineer and his maintenance manager will establish whoever carries out the work, basic strategy, programming and procedures. Inspection checklists and record sheets are necessary for systematic location of critical elements/potential defects and setting out frequencies of inspection. Computers and work processors are an obvious aid to effective maintenance management. Inspection-based preventive methods are demonstrably cost effective. 

This type of work is not an exact science. Consequently, other inspection and measurement methods are employed as an aid in identifying corrosion, deposition buildup, structural integrity flaws, and other types of problems. Methods employed generally are various types of NDT, and the protocols are widely used in preventive or predictive PV maintenance programs, especially for boiler plants used in continuous process applications, where a shutdown may be several years hence. Nevertheless, there is a drawback to the use of some types of NDT programs in that lengthy downtimes may be necessary to complete the testing work. Clearly, these can be cost-prohibitive. 

These examples illustrate the importance of careful design, careful monitoring of conditions, and the need for periodic preventive maintenance programs when working with flammable gases and compressors. This is especially important today, because high-pressure process conditions are becoming more common in modern chemical plants. 

Preventive maintenance programs must be organized, managed, and fully supported by management. Good results may not be immediately apparent, but bad results are apparent when plants are not appropriately maintained. 

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. 

All of the effort expended in designing plant-safety systems is of little value unless accompanied by an adequate prooftest program and regular maintenance. These safety systems—consisting of such components as safety-relief valves, tank vents, critical alarms, and protective isolation and shutdown devices—do not operate on a continuous basis. Rather, they are only called into service periodically to warn of, or to prevent, conditions that could lead to plant accidents. [8]... 

C. Preventive/predictive maintenance Cost-effective plants have an equipment criticality ranking scheme and use rehability-centered maintenance (RCM) techniques to determine the equipment that requires preventive maintenance. They use a combination of equipment manufacturers reconunendations, experience, and available PM databases to validate or modify existing PMs and to create new preventive maintenance schedules where necessary then they faithfully execute their PM programs. 

There should be a preventive maintenance program for all important equipment in the plant This will include ... 

It is important to set up preventive maintenance procedures on all equipment in the plant. Equipment is built to operate if proper maintenance is used. Processors should make regular machine checkups and maintenance a habit. A thoroughly implemented machine maintenance program will reduce downtime and operating costs as well as rejects of poor parts. Periodic machine checkups and regular maintenance should become a habit. 

To ensure safest possible operation and to get best overall eeonomie performance of its Nuclear Power Plants, 10 years ago Electricite de Fiance launched a Reliability Centered Maintenance (RCM) project to optimize the preventive maintenance programs. The principles underlying the RCM approach are based on common sense failures must be prevented by preventive maintenance operations in all cases when the repercussions for the installation could be serious or critical in term of safety, availability or maintenance costs. The approach is a 3-phases process ... 

How to optimize Preventive Maintenance Programs with respect to Safety/Plant Performance/Costs/Radiation Exposure ... 

The implementation of optimized Preventive Maintenance Programs drawn up using the RCM methodology is now effective at EDF nuclear plants. The first experience feedback shows some appreciable benefits regarding safety, performance and cost. The impact on the operator culture is proven positive as well. 

A preventive maintenance program can be developed for any industrial function that has a maintenance component. The same principles used in the truck operator example in this chapter can be used for other mobile equipment, machinery, or process maintenance (see Figure A.3). It matters little the type of maintenance. It is more important that the workers, operators, supervisors, and management realize that the care taken in prevention will pay dividends in cost savings, accident costs, less equipment damage, and better overall working conditions and employee attitudes. Care of your physical assets (physical plant, vehicles, machinery, etc.) is critical to the bottom line. The bonus is that you will reduce one of the factors that can contribute to your occupational injury rate. 

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