MAINTENANCE & RELIABILITY INSIDE ASSET MANAGEMENT

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

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


EFNMS Conceptual Model for AM


IAM Conceptual Model for AM


Asset life cycle stages

CONCEPT DESIGN PROCUREMENT

INSTALATIONCOMMISSIONINGOPERATION

MAINTENANCE DECOMNMSSIONING FINAL DISPOSAL

Asset life cycle stages


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


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 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


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%)


SMRP GUIDELINE 3.0 Determining Leading and Lagging Indicators, SMRP

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?

MAINTENANCE & RELIABILITY INSIDE ASSET MANAGEMENT

Leadership & Management

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