Process Equipment Reliability
- Criticality ranking for every entity in a process line
- A complete review of existing spare parts inventory for all entities in the two top criticality groups, and a running list of all critical spare parts not currently being stocked.
- A complete review of existing documentation and drawings for all entities in the two top criticality groups, and downloading of required and ‘up to date’ documentation and drawings into the company’s maintenance system. Readily available and up to date documentation and drawings in digital form is essential for time efficient troubleshooting by having critical information at everyone’s fingertips, as opposed to multiple time consuming searches for critical information and specifications.
- “Failure modes and Effects Analysis” will be performed on a small number of equipment pieces that are unfamiliar to PRR inc.
- Basic Care instructions for all preventative maintenance and operator checklists will contain all required inspections to ensure process equipment reliability, and lockouts and safe practices while performing the work. Specified tolerance envelopes for size and fits, bolt torques, belt tensions, temperature and vibration limits, wear and corrosion limits, oil and grease type and quantities, operating pressure ranges, etc. will be included in the instructions. Photos, Bolt Torque Tables and Sketches are included where appropriate for clarity of instructions.
- Work flow efficiencies dictate that all spare parts (with stock numbers and locations), tools, equipment and materials be included in each instruction package for equipment precision maintenance and overhauls.
- Basic Care instructions for PM and Operator Routes, while running, will contain critical checks with specified operating parameters and limits, oil types and levels, temperature and vibration limits, etc.
- Standard Job Procedures will be provided for equipment overhauls. These procedures will contain a tool, material and equipment list, spare parts list, machinery weights, a list for any prep work required, and a detailed step-by-step procedure from shut down to start-up.
- Detailed calibration procedures are provided for critical components.
- Detailed Basic Cares will be supplied to ensure all Environmental Regulations and Sampling obligations are met.
- PRRinc can provide a comprehensive set of customized digital inspection forms for critical fits for different sizes and types of bearings, bearing housings, and journals, and other specialized fits that must be checked at various times.
- If requested, customized “Bolting and Fastener Standards”, “Alignment Standards”, “Balancing and Vibration Standards”, “Oil Filtration and Handling Standards” and Internal “Housekeeping and Cleanliness Standards” can be provided.
Process Equipment Reliability dictates that subjective work decisions and actions be eliminated. It is not good enough to say that this is “close enough” when inspecting and adjusting equipment, or leaving the majority of critical fits and tolerances to guess work. And even worst, missing critical checks while performing basic cares on critical equipment can significantly impact process equipment reliability. Trades people must have precise instructions for where and what to look for on a critical piece of equipment during inspections and basic cares.
The process of delivering the required technical documentation to maintenance trades people, and operators, starts with a complete audit of all process line equipment and services. With all equipment entities defined, the criticality ranking for each piece of equipment is calculated using a formula which includes Health and Safety, Environmental, Production Loss, Quality Loss, and Repair Costs ratings in a matrix for probability and impact. This disciplined approach to process equipment reliability rates every piece of equipment from low criticality to the highest criticality. The equipment is sub-divided into four criticality groups. The equipment in the two top ranking groups requires precision maintenance while the equipment in the two lower ranking groups receive their regular maintenance. Criticality Ranking allows the most important pieces of equipment to be worked on first. This is how PRRinc defines process equipment reliability.
PRRinc provides consulting services to those manufacturing facilities wishing to obtain high end operating efficiencies, boost process equipment reliability, and reduce unscheduled downtime of process line equipment due to mechanical and electrical failures. Process equipment reliability is significantly increased through the process of developing or modifying a preventive maintenance program to ensure that detailed instructions reach the hands of trades-people by providing detailed preventative maintenance packages for PM and Operator Routes, Basic Care inspections and services on set frequencies, and Shut BCI’s for equipment based on criticality.
These detailed packages are developed in-house by PRRinc utilizing vendor drawings and manuals, on site process equipment reliability audits, industry standards and best practices. All instruction packages are reviewed by the trades-people who perform the maintenance activities on the equipment to ensure peer review of all work packages.