MACHINE OVERHAUL DETERMINANTS

2.2 Preparations

To manage the integrity of the asset, the function’s 'key performance indicators' (KPI’s); have to be specified and recorded as a reference point for future measurements.

I started in the early eighties, as a merchant navy engineer in the process industry, with a basic 'Operation & Maintenance Plan', comprising:

• Performing 'Power Readings', executed weekly, before and after an 'online compressor wash' of the gas turbine. For these readings I always walked down to the equipment, to perform readings and an online inspection. This visit was also used 'to chat' with the operator, busy with the 'online compressor wash' procedure. (time spent about 2 hours/unit).

• Making and updating a 'Long Term Maintenance Plan' to monitor the (residual) life time of costly components subject to aging or wear and tear.

• Making a standard network planning for A-B-C inspections. These planning’s, to be executed by two teams, where completed with field workers, assigned to tasks for consistency of the planning.

2.3 Threats

The following barriers could hamper the function of the REE.

• A significant reduction of tacit knowledge in the command line (over the last decades).

• Diminishing tacit knowledge in departments and teams, where rotating equipment has to be repaired, that put an extra burden on the REE-department.

• Highly educated young engineers, who try to analyze hands-on technical problems, caused by the situation as mentioned in the previous paragraph.

• A culture of meetings, computers, and massive data, that blocks the required work of a REE.

2.4 Opportunities

Opportunities, have to be generated in this world. Some idea’s how, could be listed as follows:

• Develop a Maintenance Plan, based on Integrity and their KPI’s. Make this plan in cooperation with the maintenance group.

• Start performance readings on site for standard equipment like pumps, electric motors and for major equipment like compressors and turbines. Follow the slogan: “Machinery love hands-on care”.

• Develop a calculation formula for spares required during overhauls; first for capital equipment and afterwards for standard equipment.

• Develop the skill to build a network-planning; first for standard equipment and afterwards for capital equipment.

2.5 Forces affecting

• Maintenance plan not available nor accepted as leading program.

• Time available for field online inspection tasks (performance).

• Inspection reports not focused on reliability (reliability).

• Event history not recorded explicitly (reliability).

• Remaining lifetime spare parts not managed (lifetime).

• REE time not focused enough on KPI’s.

• REE partly involved in planning and execution of inspections.