Spare Parts and Equipment

Operating safety is enhanced by the maintenance of a well organized and adequately stocked inventory of equipment, spare parts, and tools. The proper volume of spares is a function of plant size and complexity and of the availability of parts from equipment vendors. 

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In the construction of new plants and equipment, the employer is responsible that the equipment is suitable for the process application. Checks and inspections are performed to assure that equipment is installed properly, and consistent with design specifications and the manufacturer s instructions. Maintenance materials, instructions, spare parts and equipment will he available... 

The employer shall assure that maintenance materials, spare parts and equipment are suitable for the process application for which they will be used... 

Newly installed equipment is to be checked to assure that it is suitable for the intended process application and that the equipment is installed properly. Spare parts and equipment are to be checked to assure that they also are suitable for the intended processes [l(j), 2(73), 5, 42],... 

It appears from the answers on this point that the supply of spare parts and equipment with the plant is considered a routine matter by the suppliers. They have in several areas also indicated that special spare parts lists would be defined taking into account the local supply situation in a developing country so that plant availability or safety would not be jeopardized by the failure of single items of equipment. A few indications were given that spare part costs were some 2.5% of the price for the complete plant. 

NOTE Maintenance times are arbitrary and deprad on staff availabilify and training, spare parts and equipment availability, and planning. Boroscope techniques can help reduce downtime. 

Plumbing Spare parts and noninstaUed equipment spares... 

The ability to predict machine-train and equipment failures and the specific failure mode provided the means to reduce spare parts inventories by more than 30 per cent. Rather than carry repair parts in inventory, the surveyed plants had sufficient lead-time to order repair or replacement parts as needed. The comparison included the actual cost of spare parts and the inventory carrying costs for each plant. 

Maintenance engineers on the team write similar manuals discussing the repair, cleaning, lubrication, and operation of all the equipment. They will also decide what spare parts and tools must be available for startup, and make certain these are ordered by the purchasing department. 

Although it might be tempting to use the "free space" in switchgear, boiler, compressor, and other equipment rooms for the storage of brooms, paint, drawings and manuals, spare parts, and various other utility and maintenance supplies, it is essential to resist such practices. Suitable broom closets, spare parts storerooms, and utility rooms should be constructed for such storage. 

As provider of Chemical Leasing services PERO Innovative Services was able to include in the project all peripheral devices necessary for the supply, reconditioning, recovery and maintenance of the chemicals. The equipment was engineered based on the principle of cost reduction with regard to chemicals consumption, energy consumption, supply of spare parts and service. The solvent and the stabilisers used were adapted to the specific cleaning needs of Automobiltechnik Blau. 

Assume that the new piece of production equipment is operating without incident for a year or more. The vendor used brand name parts for the piece of equipment but went bankrupt. All of a sudden, a key part on the equipment breaks. For some strange reason, facilities cannot figure out the part number. Unfortunately, there is no documentation because there was no IQ performed, which would normally detail the spare parts and of course part numbers and drawings. 

Equipment maintenance expense This part of cost includes the purchase of spare parts and damageable material, and maintenance fee. 

The cost term includes four types of cost the PM cost and CM cost, which are the costs associated with preventive maintenance and corrective maintenance activities, respectively, the Labor cost (the salary paid to employees) and the inventory cost (the cost associated with storing spare parts of equipments). 

The MTBFs for all equipments are obtained from Center for Chemical Process Safety (1989) and the maintenance time is obtained from Bloch and Geitner (2006) (for pumps, compressors, valves) or estimated if the information is not available (for other equipments). Our example shows the results when the PM time intervals are optimized. Other variables are fixed ten employees, keeping inventory for all spare parts and reasonable numbers for the PM starting time. The maintenance model and the GA are implemented in Fortran running on a 2.8 GHz CPU, 1028 MB RAM PC. The final results for the fraction a (PM time interval = o MTBF) are shown in table 3. 

All equipment shall be maintained in excellent working condition at all times. Sufficient spare parts and tools shall be maintained on the job to provide for immediate (1 hour) repairs of essential operating items. 

The schedule for the overall demilitarization of the nation s stockpile has continued to slip considerably from initial Army projections for a variety of reasons, including permitting delays, budget constraints, and some operational problems. Therefore, the aging of the equipment, the unavailability of spare parts, and the loss of speciahzed expertise are among current concerns since these factors may impede the safe and effective operability of the disposal... 

Equipment maintenance typically is assumed as a given. However the Union Carbide incident at Bhopal, India, where over 2500 people were killed, demonstrates what can happen when there is an insufficient maintenance budget, for both spare parts and for labor. 

Standard POs that include the conditions of sale for medical equipment are usually used to initiate the order. At the time the order is placed, clinical engineering is notified of the order. In addition to current facility conditions, the management must address installation and approval requirements, responsibilities, and timetable payment, assignment, and cancelation software requirements and updates documentation clinical and technical training acceptance testing (hospital facility and vendor) warranty, spare parts, and service and price protection. 

Spare parts and consumables list Equipment fabrication and testing reports Equipment drawings Equipment installation drawings RAM model study report Vendor manuals... 

The operating organization should provide adequate facilities for receiving on the site all materials, spare parts and components for items important to safety. The receiving area should include equipment for safe, convenient handling, and sufficient space with appropriate environmental conditions for proper inspection of items upon receipt. A separate and secure quarantine area should be provided for the temporary retention of stocks not cleared for final storage or issue. 

Equipment validation is no different for ECM manufacturers than for any other device manufacturers. Each piece of equipment must be formally qualified through an installation (IQ) and operational qualification (OQ). The challenge for an ECM manufacturer may be that the equipment is specialized and custom built with none of the required equipment documents being available. The IQ requires written equipment specifications, a user s manual, lubrication requirements, spare parts, and safety features. Additional and perhaps unexpected time and costs are involved in equipment acquisition. 

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