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Preventive/Predictive Maintenance Program

Preventive/Predictive Maintenance Program

Preventive/Predictive Maintenance Program

How would I set up a preventive/predictive maintenance program on a 10-year old operated chemical plant? Where do I start to focus? How far do I want to do?  Do you have any articles, plant experiences that you would want to share?  I have 150 pumps total, AINSI and API.  Thank you hula lot.

RE: Preventive/Predictive Maintenance Program

do u take logs in your power plant? If so that would be the easiest form of preventive maintenance. The readings can be  entered in an excel file and monitored. The main parameters will be the bearing temperatures, and vibration analysis results.
Also the changed spares must be logged and a track of the running hours maintained. This can give you an idea of the running hours of mechanical seals and also the wear rings, which can be changed in advance to prevent any break down.
I hope these information help, and I think that monitoring of the parameters can be done in a simple spreadsheet. It requires no sophisticated programs.


RE: Preventive/Predictive Maintenance Program

You can start by digging up all the information the plant has on those pumps, manuals and previous maintenance done on any equipment. Then you have to create a folder on each equipment, just like the doctor has a folder for you, you need a folder for every piece of equipment. But don't get mixed up with Equipment and Components, their two separate things. Most large plants use CMMs, computerized maintenance software. You can keep track of your PM's and your WO's. Aslo don't get these two confused. Preventive Maintenace (PM's) and Work Orders (WO's) are very different, many people make this mistake, including in CMMS programs. You need to create your routine tasks with certain intervals for each equipment that in turn are categorized under a Machine Group and under a specific Engineer Area. These will be your PM's. Then you have to record every maintenance done on the machinery that is not routine. These are your WO's. The heart of any Maintenance department is the Database. Once you gathered enough information and records on your equipment, you will start to notice certain patterns with failures and break downs. This will allow you to prevent these failures ahead of time, thus Predictive Maintenance comes to light.But you need other ingredients for a succesful Maintenance Department. Like for instance an up to date Invetory which also can be comtrolled under CMMS. And most importantly your mechanics, you must have the right people with all the necessary skills. You will notice that most of the breaks downs or failures the occur will  be mostly due to human error. Some bearing that wasn't mounted properly or lubricated on time, etc.. Well I hope this is of some help. Work Safely!   

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