Effective
Maintenance
Management
Risk and Reliability Strategies for
Optimizing Performance
Second Edition
V. Narayan
Industrial Press Inc.
New York
Narayan, V. Effective maintenance management
second edtion
risk and reliability strategies for optimizing
performance / V. Narayan.
p. cm
ISBN 978-0-8311-3444-0
1. Plant maintenance—Management. 2.Reliability (Engineering).
3. Risk Management. I. Title.
A full catalog record for this book is available from the Library of Congress
Effective Maintenance Management
Second Edition
Interior Text and Cover Design: Janet Romano
Managing Editor: John Carleo
Copy Editor: Robert Weinstein
Industrial Press Inc.
989 Avenue of the Americas
New York, New York 10018
Copyright © 2012. Printed in the United States of America.
All rights reserved. This book or parts thereof may not be reproduced,
stored in a retrieval system or transmitted in any form without the
permission of the publisher.
10 9 8 7 6 5 4 3 2 1
To the memory of my late parents Venkatraman
and Meenakshi, and my late parents-in-law Saraswathy
and Ramamurthy.
Some years ago, I met the author at an international conference in Exeter. Over lunch, he outlined some of his ideas on risk management and system effectiveness —with a fork and a couple of knives as props. I found his approach refreshing, different, and worth pursuing. These were largely in line with my own views on System Operational Success, so I encouraged him to write this book.
As the author had many years of experience in the maintenance of refineries, gas plants, and offshore platforms, as well as engineering and pharmaceutical plants, I thought that the blend of theory and practice would be useful. The relevance of theory is brought home with a number of illustrative examples from industrial situations, so I feel my point is well made. His approach to maintenance is holistic and as such it could be applied to situations involving financial risk, public health or the maintenance of law and order.
He explains the raison d’être of maintenance; this should help maintenance managers justify their efforts rationally. The discussion on risk perceptions and why they are important may strike a chord with many of us. Knowing what tools to use and where to apply them is important as also how to manage data effectively.
The book will help maintenance managers, planners, and supervisors, as well as students, understand how best to reduce industrial risks. This should help them improve both technical and production integrity, leading to fewer safety, health, and environmental incidents while increasing the quality and production levels and reducing costs.
Dr. Jezdimir Knezevic
MIRCE Akademy
I have had the good fortune to work with talented and experienced people throughout my working life. In writing this book, I have used the knowledge gained from the interaction with the thinking and work of many colleagues, associates and friends. I hope I have done justice to all of them, and that readers, especially maintenance practitioners, apply the knowledge they gain, by improving the effectiveness of maintenance in their Industry.
I met Dr. Jezdemir Knezevic in 1998 by chance at a business party. In the course of a brief discussion, I realized that I had met a teacher who worked in the real world. His practical and yet mathematically sound approach was refreshing, and a friendship began almost immediately. He, in turn, encouraged me to write the first edition of this book. Once I completed the manuscript, he reviewed it critically and made a number of useful suggestions to improve both content and readability.
My colleagues at work have helped shape my thinking. They are too numerous to name, so I will not attempt this task. One in particular, Greg Stockholm, of Shell Chemicals Inc., taught me the Root Cause Analysis process. While problem solving and failure analysis are essential skills for every maintainer, I had not realized till after Greg’s course that there was a structured and logical process available. I have, in turn, trained many others to use Root Cause Analysis and Reliability Centered Maintenance. The feedback and comments made by several hundred students from around the world have helped shape my ideas.
When working on the second edition, I received help from Remo van Namen, who has done a lot of good work on the importance of maintenance work compliance — Figure 12.12 is based on his field observations. Sourav Kumar Chatterjee, an authority on rotating machinery provided insights on vibration analysis, e.g., the information in Table 12-3.1.
Many friends, some in Academia and others in Industry or Consultancy firms have reviewed the first and/or second edition of this book. Their comments and advice have been invaluable. The reviewers include Paddy Kirrane, Jim Wardaugh, Nick Schulkins,Roger Peres, Rob Knotts, Mahen Das, Cor van Alphen, Jane Goodacre, and Dr. Helge Sandtorv. At his initiative, Dr. Sandtorv forwarded a copy to Prof. Marvin Rausand of the Norwegian University of Science and Technology. Dr. Rausand graciously reviewed the first six chapters, and provided detailed comments. My son Sharad, daughter Shweta, father-in-law Ramamurthy and a family friend Rajesh, reviewed it from the lay persons’ point of view. All the reviewers have been very constructive and assisted me greatly in bringing the book to print.
I offer my thanks to Shell U.K Exploration and Production, who allowed me to proceed with this effort while I was working with them.
Keith and Valerie Pottinger converted my sketches and charts into presentable material, corrected my grammar, paginated, and brought this book to its finished form. Notwithstanding many pressures on their time, they have juggled their schedules to help a friend. Sadly, Valerie passed away after the first edition was published, and I miss her cheerful support. My friend Richa Saxena used her graphic arts skills to draft several sample book cover designs.
My publishers, Industrial Press Inc., have been very helpful from the time I first made contact with them. I thank John Carleo, Janet Romano, and Patrick Hansard for their constructive and supportive approach. Working with the copy editor Robert Weinstein has been a delightful experience. He has a great eye for detail and a constructive approach. Throughout the time I was busy with the book, my wife Lata has been patient and considerate, thoughtful and helpful. I am sure I could not have made it without her love and support.
To all of them, I offer my gratitude.