Effective Maintenance Program Development/Optimization

Downloaded from Reliabilityweb.com on the web at http://www.reliabilityweb.comcontrol/protective system is controlling/protecting multiple systems, it should be setup asan element at the same level in the hierarchy.Every hierarchy element - whether it is a system, sub-system or an equipment item - has aclearly defined boundary. Boundary definitions are standardized for classes ofsystem/equipment items.The steps involved in developing a plant technical model are as follows (see Figure 3):1. Collect technical information and drawings (PFD’s, P&ID’s, line diagrams,datasheets, O&M manuals, etc.)2. Establish a standard for defining systems’ boundaries. See references 4 and 6 fordetails.3. Develop plant technical hierarchy.4. Define systems’ functions (optional).5. Load hierarchy into the plant maintenance information system (CMMS).5.0 Criticality and Risk AssessmentCriticality and risk assessment is a qualitative analysis of assets failure events and theranking of those events according to their impact on the business goals of the company.The process consists of the following main activities (see Figure 4):1. Establish criticality assessment criteria.2. Define for each assessment criteria the failure consequences and their scores.3. Collect equipment condition assessment records or generic failure frequencies.4. Determine failure frequencies and their ratings.5. Define criticality ranking scores.6. Define criticality ranking rules.7. Select systems and/or equipment for assessment.8. Perform the analysis.9. Rank systems/equipment by criticality.10. Rank systems/equipment by risk.These steps are considered in more detail in the following sections.5.1 Assessment CriteriaThe first step in the analysis is to use the organizational business objectives to define thecriticality assessment criteria. The following are some suggested criticality assessmentcriteria.‣ Health and Safety.‣ Environmental Integrity.‣ Throughput.Page 4