CPD 30301 Plant Maintenance & Inspection

CHAPTER 1 Introduction to Plant Maintenance and Inspection

Intro. to Plant Maintenance & Inspection

Introduction Objectives Scope Advantages Types of Maintenance Personnel The Organization Chart
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Intro. to Plant Maintenance & Inspection

Plant Maintenance
Maintenance defined as that function of production management concerned with the day to day problem of keeping the physical plant in good operating condition Maintenance management concerned with the direction and organisation of resources in order to control (improve) the availability and performance of the industrial plants to some specified level. Plant Maintenance concerned with actions taken by the plant user to maintain an 3 existing system and facilities or to restore it

Intro. to Plant Maintenance & Inspection

Plant Maintenance
Maintainability is concerned with those actions taken by a system and facilities during development so that the system of facilities when installed and operation can be maintained with easily. Maintainability also means design for ease of maintenance. It is the characteristic of system design which determines the ability of system to be retained in or restored to an effective operational condition. It is concerned with the systems down time, include aspects such as: 4 Incorporation of fail safe features

Intro. to Plant Maintenance & Inspection

Reliability defined as the probability of a plant to give satisfactory performance in a particular period of time under specified conditions. The time between failures is called MTBF Availability the percentage of time the machine will be available for operation Availability = Mean Time Between Failures(MTBF) MTBF + Mean Time for Repairs (MTR)

Intro. to Plant Maintenance & Inspection

Introduction Objectives Scope Advantages Types of Maintenance Personnel The Organization Chart
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Intro. to Plant Maintenance & Inspection Objectives

The Production/operational Quality, quantity, safety, environment, cost Equipment/system Reliability, accountability

Intro. to Plant Maintenance & Inspection

Introduction Objectives Scope Advantages Types of Maintenance Personnel The Organization Chart
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Scope of Responsibilities Primary Functions

Maintenance of existing plant equipment Maintenance of existing plant buildings and grounds Equipment inspection and lubrication Utilities generation and distribution Alterations and new installations

Scope of Responsibilities Secondary Functions Plant protection(including fire fighting) Waste disposal Pollution and noise reduction Insurance Administration Storekeeping, accounting etc Senatorial Services/Other services

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Intro. to Plant Maintenance & Inspection

Introduction Objectives Scope Advantages Types of Maintenance Personnel The Organization Chart
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Advantages of Plant Maintenance

Reduction in unscheduled downtime More efficient and reliable Longer equipment life & lower cost of parts Lower equipment maintenance staff Utilization of maintenance staff Optimized the process

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Intro. to Plant Maintenance & Inspection

Introduction Objectives Scope Advantages Types of Maintenance Team Personnel The Organization Chart
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Types of Maintenance Personnel

Planner plan all the maintenance work, scale them with all of the priority (must be experience with execution methods) Executor run all the work instruction given to them with a specific task and time frame Engineer deal with engineering modification to enhance the process or increase the equipment/system reliability.

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Intro. to Plant Maintenance & Inspection

Introduction Objectives Scope Advantages Types of Maintenance Personnel The Organization Chart
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The Organization Chart

Factors need to be considered: Type of operation Continuity of operations Geographical situation Size of plant Scope of the plant maintenance department Work-force level of training and reliability
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Plant Manager
Stock Control & Purchasing

Operation

Quality Control

Safety

Administration

Maintenance Regular Maintenance Mechanical Electrical System Improvement Instrumentation & Control

Plant Manager
Maintenance Manager Maintenance Engineer Routine Maintenance Supervisor Maintenance Control Supervisor Planned Maintenance Supervisor Emergency Maintenance Supervisor

Plant Maintenance
THANK YOU

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PETRONAS, SHELL,BP, SAUDI ARABIA BASIC IND.CORP.(SABIC),QATAR LNG, ALMARAI (SAUDI ARABIA), IDEMITSU, EASTMAN CHEMICALS, BASF PETRONAS, KUWAIT INSTITUTE OF SCIENTIFIC RESEARCH, KHARTOUM REFINERY, LOADSTAR Ltd. (Sri Lanka) etc