Effective Maintenance Management

Providing readers with a clear rationale for doing maintenance, this updated edition and unique guide is written in a language and style that practicing engineers and managers can understand and apply easily. Effective Maintenance Management examines the role of maintenance in minimizing the risks relating to safety or environmental incidents, adverse publicity, and loss of profitability. In addition to discussing risk reduction tools, this book explains their applicability to specific situations so that readers can select the tool that fits their requirements.

In industry, gaps can appear between those involved in and affected by industrial engineering for production, reliability, and plant maintenance. Bridging the gap between designers/maintainers and reliability engineers, this guide is sure to help businesses utilize their assets effectively, safely, and profitably.

Features

• Provides a risk reduction model which links maintenance to specific risks
• Enables readers to establish the critical link between maintenance on one hand and safety, profitability, and asset life on the other
• Examines risks faced during the life cycle of a process plant
• Discusses expensive plant shutdowns, a high cost, high downtime maintenance activity
• Provides an in-depth look at qualitative and quantitative risks
• Includes a table of codes that can be used directly or adapted for use in most maintenance management systems
• Keeps mathematics to a minimum
• Includes chapter previews and summaries, a list of acronyms, and a glossary of terms.

Vee Narayan is a leading authority on maintenance and reliability engineering. He is an experienced maintenance manager with a successful track record in a variety of industries including engineering, petroleum refining, pharmaceutical, liquefied natural gas production and oil & gas exploration and production. He has worked in several countries and cultures, including India, Malaysia, Saudi Arabia, the Netherlands and the United Kingdom.

He led Shell’s Centre of Excellence in Maintenance and Reliability and represented Shell in a Joint Industry Project (OREDAzzz). For eight years, he led the Maintenance Strategy group in Shell’s Exploration & Production Company in Aberdeen.

Vee is a successful trainer over a period of 14 years in specialist areas such as Reliability Centred Maintenance, Root Cause Analysis and other maintenance management subjects. He is a visiting lecturer in the MSc course in Asset Management, Robert Gordon University, Aberdeen, UK, and an Associate Fellow of the MIRCE Akademy, Exeter, UK.

Effective Maintenance Management, Second Edition

From the Back Cover…

… this book has the depth and content to really help maintenance organizations change and improve reliability. This is a book with true content, without having to own numerous other books to provide information one might need.

—Ricky Smith

This new edition of the bestselling and authoritative text (chosen as the basis for a course on risk and reliability strategies offered by ASME) is written at a level and style that practicing engineers and managers alike can readily understand and apply. It describes the crucial role of maintenance in minimizing the risk of safety or environmental incidents, adverse publicity, and loss of profitability. And it explains the applicability of risk-reduction tools to specific situations, thereby enabling you to select the tool that best fits your requirements. Bridging the gap between designers/maintainers and reliability engineers, this book will help your organization utilize its assets more effectively, safely, and profitably.

• New coverage of Risk-Based Inspection and Instrumented Protective Functions
• Accounts of the Longford (1998), Columbia (2003) and Sayano-Shushenskaya (2009) disasters reinforce the evidence for the event escalation theory explained in chapter 9.
• Chapters 12 and 14 are new to this edition.

Preface to the Second Edition

Since publication of the first edition in 2004, risk-based approaches to maintenance and reliability have moved firmly to the forefront of good practices. Two processes, Risk-Based Inspection and Instrumented Protective Functions, have been available for a number of years; they have been further developed and are now established as “must use” techniques. Along with Reliability Centered Maintenance, they provide an integrated suite of readily usable and useful techniques for the maintainer.

Many maintainers find themselves in businesses where the assets are unreliable, profitability is poor, and budgets are under pressure. The financial crisis of 2008 and its aftermath have made matters much worse. In response, we have provided some recipes to address these issues in the form of a new chapter in this edition. New sections in Chapter 10 explain and give clear guidance on the two risk-based processes mentioned above.

In Chapter 8, we have added accounts of the Longford (1998), Columbia (2003) and Sayano-Shushenskaya (2009) disasters. These reinforce the evidence for the event escalation theory explained in Chapter 9.

As is the norm with new editions, we have taken the opportunity to do some housekeeping. Internet website references (URLs) seem volatile and a few of the earlier references are no longer valid. Some books references are also outdated, as new publishers have taken over and ISBNs have changed. These are now corrected.

There is one other significant change – the book summary has been expanded and has now become a new chapter. Apart from the usual corrections and additions, the remainder of the book remains largely faithful to the first edition. I welcome feedback from everyone using this book. Please write to me at the publisher’s email address: info@industrialpress.com.

V. Narayan
Aberdeen, Scotland

Contents

• The Production and Distribution Process
• Process Functions
• Reliability Engineering for the Maintenance Practitioner
• Failure, its Nature and Characteristics
• Life Cycle Aspects of Risks in Process Plants
• Process Plant Shutdowns
• Facets of Risk
• The Escalation of Events
• Maintenance
• Risk Reduction
• Information for Decision Making
• Improving System Effectiveness