SKF Reliability Systems - Library

PM Reviews at Sydney Water
available in the following areas:
• PM’s that can be easily rolled up or eliminated/substituted or reduced/optimised based on current
maintenance policy
• Changes in Maintenance standards for different asset classes, including legislated requirements
• Availability of enough redundancies/standbys • Negligible impact of failures on the process or system
• Decommissioned assets or assets not required to be maintained
• Changed circumstances in the operating process or the addition of new assets
DOCUMENTATION OF RISK REVIEW PROCESS
Figure 3 shows the Asset details and PM details (Headers highlighted in yellow), which is sourced from the
CMMS and documented for the PM Review process, as shown in the table. The revised frequency details are
recorded after the risk assessment is completed, as shown in Figure 4. Once the information is collected from
the CMMS, the spare parts availability can be investigated and recorded in the table shown in Figure 3.
Figure 3 PM Review Documentation – Asset & PM Details
Figure 4 shows the Hazard Identification & Risk Assessment (HIDRA) and Figure 5 shows the PM Review
outcomes for each PM for an asset at the plant or facility. The HIDRA assessment for “Maintenance Safety
Risk” is the risk to personnel while maintenance is being performed on the asset. The HIDRA assessment for
“Process Risk” is the risk to the Process failing if this maintenance activity is eliminated (both Operational &
Environmental), if “run to fail” strategy is adopted for the asset. Figure 6, 7 & 8 shows the HIDRA information,
which is used to determine the Risk Score for the values shown in table Figure 4, based on Consequences of
& Likelihood of the risk occurring.
Once the risk assessment has been
documented for each PM for an asset,
the PM Review team re-assesses the
maintenance methodologies for the
asset. For example an asset with low
risk for “Maintenance Safety” and a low
risk to the operating process (negligible
impact of failure) will be considered by
the PM Review team for a “Run to Failure”
strategy, rather than Time Based PM
maintenance.
An Asset with a low risk for “Maintenance
Safety” and a medium to high risk to the
operating process is then considered
for a combination
of time-based
maintenance & condition
based maintenance
ITEM LOCATION
(Vibration, Oil Analysis,
Thermography etc).
The outcomes of the PM
Review is recorded in the
“Type of Maintenance
Overall”, “Type of
Preventive Maintenance”
and “Remarks” fields as
shown in Figure 5.
38 Vol 23 No 3 AMMJ
Original
Frequency
Revised
Frequency
ITEM LOCATION PM DESCRIPTION
Asset
Craft
FREQ FREQUNIT FREQ FREQUNIT NEXTDATE Criticality
rating
Spare
parts
availability
1 ST0002-06E Dist. Panel Board Service - PM 1 YEARS 1/07/09 0:00 P
2 ST0002ME1594 Fine Screen Inspection - PM 1 YEARS 1/09/08 0:00 M
3 ST0002 Pressure Vessel Inspection - Statutory PM 2 YEARS 1/09/09 0:00 M
4 ST0002MF15717 Transfer Screw Feeder No. 1 Motor - Pow PM 1 YEARS 1/10/08 0:00 P 2
5 ST0002MV15721 Thermoblender Motor 1 - Pow PM 1 YEARS 1/05/09 0:00 P
6 ST0002-15K Lubrication - Biosolids Train A Lime Feed screw Conveyors 1 WEEKS 2 WEEKS 7/07/08 0:00 M
7 ST0002-15L Motors - Poly Dosing System, PM 6 MONTHS 1/08/08 0:00 P 1 Off shelf
Figure 4 – PM Review Documentation – HIDRA Risk Assessments
HIDRA
Maintenance Safety Risk (* 1)
HIDRA
Process Risk (*2)
ITEM LOCATION Consequence Likelihood Score Consequence Likelihood Score
Type of
Maintenance
overall (*3)
CBM / COM
/ PSM / RFM
1 ST0002 -06E Insignificant
Very
Unlikely
6 Severe Unlikely 3
2 ST0002ME1594
3 ST0002
4 ST0002MF15717 Insignificant
Very
Unlikely
6 Minor Unlikely 4
5 ST0002MV15721
6 ST0002 -15K Minor Unlikely 5 Minor Unlikely 5
7 ST0002 -15L Insignificant
Very
Unlikely
6 Minor Unlikely 5
Figure 5 PM Review Documentation – PM Review Outcomes
Type of PREVENTIVE maintenance (*4)
Lub M E I O VIB OIL Ther
mo
1 ST0002-06E CBM Y Y
MCA Other Remarks
Include UPS boards in
thermography
Date
Changed
31/07/08
2 ST0002ME1594 PSM Critical Asset - No Change
3 ST0002 PSM Statutory - No Change
4 ST0002MF15717 RFM
Run to fail. Purchase spare
motor
24/10/08
5 ST0002MV15721 Delete. Included PM 822288 24/10/08
6 ST0002-15K PSM Y Freq changed 31/07/08
7 ST0002-15L RFM
Run to fail. Purchase spare
motors.
20/08/08