maintenance & reliability inside asset management
TRANSCRIPT
VICTOR D. MANRIQUEZSOLSENCO
PHYSICAL ASSET MANAGEMENTTRACK 6MAINTENANCE & RELIABILITY INSIDE ASSET MANAGEMENT
Victor D. Manriquez, CMRP
• Lima - Peru, 1962
• Mechanical Engineer; Pontificia Universidad Catolica del Peru
• MSc Renewable Energies; Universidad Internacional de Andalucia, Spain
• Diploma in Magisterial Formation, Pontificia Universidad Catolica del Peru
• 30 years of professional experience in mining, oil and energy industry sector.
• Contributor of the magazines “Mantenimiento en Latinoamérica” (24 articles since 2009 “Predictiva 21” (8 articles since 2014), Machinery Lubrication (2014) and Solutions (2013).
• Presenter in Peruvian Congress of Mechanical Engineering and Peruvian Congress of Maintenance Engineering (2012, 2014, 2015)
• Presenter in the 21st SMRP Annual Conference in Indianapolis (2013)
• I teach courses and make workshops related to M & R issues in Peru and Costa Rica since 2009.
Late 80’s
Piper Alpha oil platform.
1988 US National Council on Public Works“Fragile Foundations: A Report on America’s Public Works”.
Asset Management
BSI PAS 55:2008
GFMAM Asset Management Landscape1st edition November 2011
ISO ISO 55000 seriesJanuary 2014
GFMAM Asset Management Landscape2nd edition March 2014
Normative Notable Milestones
ISO 55000 Series
ISO 55000:2014Asset management -- Overview, principles and terminology
ISO 55001:2014Asset management -- Management systems – Requirements
ISO 55002:2014Asset management -- Management systems – Guidelines for the application of ISO 55001.
www.assetinsight.net
www.assetinsight.net
ISO 55001
24 clauses
71 shall statements
9 times “maintenance”
4 maintenance AM system
1 Annex A
4 Bibliography
The Society for Maintenance and Reliability Professionals
(SMRP), USA
European Federation of National Maintenance
Societies (EFNMS), Europe
Asset Management Council (AMC), Australia
Associação Brasileira de Manutenção e Gestão de Ativos (ABRAMAN), Brazil
Gulf Society of Maintenance Professionals (GSMP), Arabian
Gulf Region
Federación Iberoamericana de Mantenimiento (FIM), South
America
GFMAM Members
Institute of Asset Management (IAM), UK
L‘Institut Français D’AssetManagement Industriel et
D’Infrastructures (IFRAMI), France
Plant Engineering and Maintenance Association of
Canada (PEMAC), Canada
The Southern African Asset Management Association
(SAAMA), South Africa
Japan Institute of Plant Maintenance (JIPM), Japan
GFMAM Members
The Asset Management Landscape, 2nd edition March 2014, GFMAM
Asset Management Landscape Subject Groups
N° Landscape Subject Group # subjects
1. Strategy & Planning 5 2. Asset Management Decision-Making 5 3. Lifecycle Delivery 11 4. Asset Information 4 5. Organization & People 5 6. Risk & Review 9 Total 39
Asset Management Landscape Subjects
Asset Management – An Anatomy, Version 3 December 2015, IAM
AMC Conceptual Model for AM
The Asset Management Landscape, 2nd edition March 2014, GFMAM
EFNMS Conceptual Model for AM
The Asset Management Landscape, 2nd edition March 2014, GFMAM
IAM Conceptual Model for AM
Asset Management – An Anatomy, Version 3 December 2015, IAM
Asset life cycle stages
CONCEPT DESIGN PROCUREMENT
INSTALATIONCOMMISSIONINGOPERATION
MAINTENANCE DECOMNMSSIONING FINAL DISPOSAL
Asset life cycle stages
Asset Management – An Anatomy, Version 3 December 2015, IAM
Landscape Subjects – M & RLandscape Subject Group N° Landscape Subject
Asset Management Decision-Making
6 Capital Investment Decision-Making
7 Operations & Maintenance Decision-Making 8 Lifecycle Value Realization
9 Resourcing Strategy
10 Shutdowns & Outage Strategy
Lifecycle Delivery
11 Technical Standards & Legislation 12 Asset Creation & Acquisition
15 Maintenance Delivery
16 Reliability Engineering
17 Asset Operations 18 Resource Management
19 Shutdown & Outage Management
20 Fault & Incident Response
21 Asset Decommissioning and Disposal Asset Information 25 Data & Information Management
Organization & People 26 Procurement & Supply Chain Management
30 Competence Management
Risk & Review
31 Risk Assessment and Management 35 Assets Performance & Health Monitoring
36 Asset Management System Monitoring
38 Asset Costing & Valuation
Landscape Subjects – M & RM & R N° Landscape Subject Landscape Subject
Group
Pre Op 6 Capital Investment Decision-Making AM Decision-Making Pre Op 7 O & M Decision-Making AM Decision-Making Pre Op 8 Lifecycle Value Realization AM Decision-Making Pre Op 11 Technical Standards & Legislation Lifecycle Delivery Pre Op 12 Asset Creation & Acquisition Lifecycle Delivery Pre Op 25 Data & Information Management Asset Information Pre Op 36 AM System Monitoring Risk & Review O & M 15 Maintenance Delivery Lifecycle Delivery O & M 16 Reliability Engineering Lifecycle Delivery O & M 17 Asset Operations Lifecycle Delivery O & M 20 Fault & Incident Response Lifecycle Delivery O & M 35 Assets Performance & Health Monitoring Risk & Review O & M 38 Asset Costing & Valuation Risk & Review STO 10 Shutdowns & Outage Strategy AM Decision-Making STO 19 Shutdown & Outage Management Lifecycle Delivery Post Op 21 Asset Decommissioning & Disposal Lifecycle Delivery People 30 Competence Management Organization & People Resources 9 Resourcing Strategy AM Decision-Making Resources 18 Resource Management Lifecycle Delivery Resources 26 Procurement & SCM Organization & People
M & R – Pre Operations
Stage 1Project
Appraisal
Funding included in CAPEX
Stage 2Project
Selection
Approval
Resources assured
Stage 3FEED
Final PFD available
Preliminary PID available
Identify key functions
Criticality analysis aligned with FMEA
Define critical equipment
Evaluate critical designs
Identify critical redesigns opportunities
Stage 4Execution
Review design recommendations
Final PID and Engineering designs for construction
Update FMEA according to design changes
Evaluate acquired assets
Task selection for critical/non critical
equipment
Develop spare parts strategy
Input strategy in CMMS
Stage 5Operational
KPI Develoment
Reliability analysis in operation
Document learned lessons
Incorporating Reliability Centered Maintenance Principles in Front End Engineering and Design, Mack Morris
M & R – Pre Operations
Stage 1Project Appraisal
Funding included in
CAPEX
Stage 2Project Selection
Approval
Resources assured
Incorporating Reliability Centered Maintenance Principles in Front End Engineering and Design, Mack Morris
M & R – Pre Operations
Stage 3FEED
Final PFD available
Preliminary PID available
Identify key functions
Criticality analysis aligned with FMEA
Define critical equipment
Evaluate critical designs
Identify critical redesigns opportunities
Stage 4ExecutionReview design recommendations
Final PID and Engineering designs for construction
Update FMEA according to design changes
Evaluate acquired assets
Task selection for critical/non critical equipment
Develop spare parts strategy
Input strategy in CMMS
Stage 5Operational
KPI Develoment
Reliability analysis in operation
Document learned lessons
Incorporating Reliability Centered Maintenance Principles in Front End Engineering and Design, Mack Morris
ISO 14224:2016
Petroleum, petrochemical and natural gas industries – Collection and exchange of reliability and maintenance data for equipment
Subject 25 - Information Management
Subject 36 – AM System Monitoring
Metric N°
Metric Name EFNMS
Harmonized Metric
Best value in its class
1.1 Ratio of Replacement Asset Value (RAV) to Craft-Wage Headcount
US$ 8x106 @ 9x106 /
Craft-Wage Headcount
1.4 Stocked MRO Inventory Value as a Percent of Replacement Value (RAV)
E7 < 1,5%
(Q1 0.3% @ 1.5%)
1.5 Total Maintenance Cost As a Percent of Replacement Asset Value
E3 < 3%
(Q1 0.7% @ 3.6%)
Subject 36 – AM System Monitoring
SMRP GUIDELINE 3.0 Determining Leading and Lagging Indicators, SMRP
Subject 36 – AM System Monitoring
Asset Management – An Anatomy, Version 3 December 2015, IAM
Other Subjects
O & M
STO
Post Operation
Organization & People
Resources
Conclusions
Limitations of ISO 55001:2014
Use of GFMAM Landscape
Integration of M & R in Capital Project
Integration of M & R in AM
Monitoring of Performance
QUESTIONS?