Case Studies in Maintenance and Reliability: A Wealth of Best Practices. V. Narayan

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      Case Studies in

      Maintenance & Reliability

      A Wealth of Best Practices

      Case Studies in

      Maintenance & Reliability

      A Wealth of Best Practices

      V. Narayan

      J.W. Wardhaugh

      M.C. Das

      Foreword by

      The Late Charles J. Latino

      Illustrations by

      Steven van Els

      Industrial Press Inc.

      New York

      Copyright

      Previously published under the title,

      “100 Years in Maintenance and Reliability:

      Practical Lessons From Three Lifetimes”

      Library of Congress Cataloging-in-Publication Data

      Narayan, V.

      100 years in maintenance: practical lessons from three lifetimes / V. Narayan, M.C. Das, J.W. Wardhaugh.

      p. cm.

      ISBN 978-0-8311-3323-8 ( Replacement ISBN 978-0-8311-0221-0

      1. Maintenance. 2. Plant engineering. 3. Facility management. I. Das, M.C. II. Wardhaugh, J.W. III. Title. IV. Title: 100 years of maintenance.

      TS192.N353 2007

      658.2'02--dc22

      2006053263

      Industrial Press, Inc.

      989 Avenue of the Americas

      New York, NY 10018

      Sponsoring Editor: John Carleo

      Interior Text and Cover Design: Janet Romano

      Developmental Editor: Robert Weinstein

      Copyright © 2012 by Industrial Press Inc., New York.

      Printed in the United States of America. All rights reserved.

      This book, or any 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

      Table of Contents

       Cover

       Half Title

       Title Page

       Copyright

       Foreword by Charles J. Latino

       About the Authors

       Part 1: Introduction

1Introduction & Navigation Guide

2The Locations

       Part 2: Leadership

3Creating the Vision

4Setting Objectives

5Changing Paradigms with Leadership and Expertise

6Applying Best Business Practices

7Evaluating Contractors’ Unit Rates

8Benchmarking

       Part 3: People

9Staffing levels

       10Integrating Inspection and Degradation Strategies

       11Technician Training Challenge

       12Competence Profiles

       13Operators & Maintainers

       14Building a Reliability Culture

       15Managing Surplus Staff

       16Retraining Surplus Staff

       Part 4: Plan

       17Integrated Planning

       18Critical Path Planning Capability

       19Shutdown Management

       20Electrical Maintenance Strategies

       21Minor Maintenance by Operators

       22Relocating Machine Tools

       23Painting Contract Strategy

       Part 5: Schedule

       24Long Look-Ahead Plan

       25Workload Management

       26Infrastructure Maintenance

       27Workflow Management

       Part 6: Execute

       28Trip Testing

       29Work the Plan

       30Keeping to Schedule

       31Operators as a Maintenance Resource

       32Overtime Control

       33Managing Contractors

       Part 7: Analyze

       34Reliability Engineering in New Projects

       35Computing Reliability Data

       36Turnaround Performance Improvements

       37Reducing Shutdown Duration

       38A Small Matter of Cleaning

       39Motor Maintenance Regimes

       40Boiler Feed-Water Pump Seals

       41Cooling Water Pump Failures

       42Heater Outlet Flue Gas Dampers

       43Laboratory Oven Failures

       44Pump Reliability

       45Book Summary

       Glossary

       Index

       Foreword

      This book is written by three engineers who have had exceptional experiences in industry, particularly the hydrocarbon process industry. All of them have held positions of authority in the maintenance and reliability of the companies they worked for. A reader will quickly grasp that they were self starters and