Shutdown management is project management of a special kind: managing the repair, replacement or maintenance of critical systems. Manufacturing and process plants, computer systems, airliners, and many other systems must be regularly closed down or taken out of service for planned maintenance operations. This book provides a complete shutdown project planning guide along with a new, detailed model of excellence and step-by-step project guide. In a critical field, this book shows the maintenance manager or project leader how to get the job done correctly.*Covers all aspects of major maintenance project planning, minimizing downtime and improving maintenance schedules *Covers projects ranging from weekend overhauls through to complete plant rebuilds*With detailed checklists and a new step-by-step project guide
With large amounts of revenue at stake, process industries are focusing more on turnaround management as they strive to lengthen the interval between turnarounds. This book outlines a strategy to execute optimized shutdown and turnaround by changing plant operating conditions and inspection techniques. Because shutdown cost for a petroleum refinery is normally 30 percent higher than annual maintenance costs, this book details how to manage the more favorable turnaround option. The author explores different aspects, including philosophy, planning and scheduling, estimation, contractor management, and execution.
Manufacturing and process plants must be regularly closed down for planned maintenance operations. This may entail the complete shutdown and re-start of large-scale serial and batch operations and must be performed in as short a period of time as is cost-effective. This is the process of turnaround, and as the processes are often high value and the maintenance operations intensive, complex and costly, it is vital that it be planned and carried out effectively. Tom Lenahan is an acknowledged expert in this field, who has worked and consulted internationally, and his book will show the maintenance manager or project leader how to get the job done correctly. This will include ensuring that lost production value (including sourcing replacement capacity) is balanced against intensive maintenance costs, as well as numerous other factors that may not be obvious to the first-time shutdown manager. The book draws upon his many years of experience with ICI, and has been written in conjunction with Eutech Engineering Services Ltd. - Foreword by Anthony Kelly, author of Maintenance Strategy and Maintenance Organization and Systems
Turnaround Management for the Oil, Gas, and Process Industries: A Project Management Approach helps readers understand the phases of development in preparation for a turnaround, with each relevant phase easily identified. Specific to the process industry, especially oil and gas, petrochemical and power plants, this reference simplifies the entire lifecycle of a turnaround and provides specific examples of both successful and unsuccessful turnaround projects. By identifying the most significant performance indicators and strategies to ensure that targets are met, this book will help plant managers keep plants safe, efficient and running successfully. - Aligns turnaround project management with ISO guidance and ANSI/PMI standards - Utilizes the best tools for long-term planning, including instructional videos and training material - Helps users gain practical knowledge through both good and bad turnaround management case studies - Presents real-world issues and challenges encountered
Many readers already regard the Maintenance Planning and Scheduling Handbook as the chief authority for establishing effective maintenance planning and scheduling in the real world. The second edition adds new sections and further develops many existing discussions to make the handbook more comprehensive and helpful. In addition to practical observations and tips on such topics as creating a weekly schedule, staging parts and tools, and daily scheduling, this second edition features a greatly expanded CMMS appendix which includes discussion of critical cautions for implementation, patches, major upgrades, testing, training, and interfaces with other company software. Readers will also find a timely appendix devoted to judging the potential benefits and risks of outsourcing plant work. A new appendix provides guidance on the "people side" of maintenance planning and work execution. The second edition also has added a detailed aids and barriers analysis that improves the appendix on setting up a planning group. The new edition also features "cause maps" illustrating problems with a priority systems and schedule compliance. These improvements and more continue to make the Maintenance Planning and Scheduling Handbook a maintenance classic.
The industry-standard resource for maintenance planning and scheduling—thoroughly revised for the latest advances Written by a Certified Maintenance and Reliability Professional (CMRP) with more than three decades of experience, this resource provides proven planning and scheduling strategies that will take any maintenance organization to the next level of performance. The book resolves common industry frustration with planning and reduces the complexity of scheduling in addition to dealing with reactive maintenance. You will find coverage of estimating labor hours, setting the level of plan detail, creating practical weekly and daily schedules, kitting parts, and more, all designed to increase your workforce without hiring. Much of the text applies the timeless management principles of Dr. W. Edwards Deming and Dr. Peter F. Drucker. You will learn how you can do more proactive work when your hands are full of reactive work. Maintenance Planning and Scheduling Handbook, Fourth Edition, features more new case studies showing real world successes, a new chapter on getting better storeroom support, major revisions that describe the best KPIs for planning, major additions to the issue of “selling” planning to gain support, revisions to make work order codes more useful, a new appendix on numerically auditing planning success, and a new appendix devoted entirely to selecting a great maintenance planner. Maintenance Planning and Scheduling Handbook, Fourth Edition covers: •The business case for the benefit of planning •Planning principles •Scheduling principles •Handling reactive maintenance •Planning a work order •Creating a weekly schedule •Daily scheduling and supervision •Parts and planners •The computer CMMS in maintenance •How planning works with PM, PdM, and projects •Controlling planning: the best KPIs KPIs for planning and overall maintenance •Shutdown, turnaround, overhaul, and outage management •Selling, organizing, analyzing, and auditing planning
This second edition of An Introduction to Predictive Maintenance helps plant, process, maintenance and reliability managers and engineers to develop and implement a comprehensive maintenance management program, providing proven strategies for regularly monitoring critical process equipment and systems, predicting machine failures, and scheduling maintenance accordingly. Since the publication of the first edition in 1990, there have been many changes in both technology and methodology, including financial implications, the role of a maintenance organization, predictive maintenance techniques, various analyses, and maintenance of the program itself. This revision includes a complete update of the applicable chapters from the first edition as well as six additional chapters outlining the most recent information available. Having already been implemented and maintained successfully in hundreds of manufacturing and process plants worldwide, the practices detailed in this second edition of An Introduction to Predictive Maintenance will save plants and corporations, as well as U.S. industry as a whole, billions of dollars by minimizing unexpected equipment failures and its resultant high maintenance cost while increasing productivity. - A comprehensive introduction to a system of monitoring critical industrial equipment - Optimize the availability of process machinery and greatly reduce the cost of maintenance - Provides the means to improve product quality, productivity and profitability of manufacturing and production plants
Considering maintenance from a proactive, rather than reactive, perspective, Maintenance Excellence details the strategies, tools, and solutions for maximizing the productivity of physical assets—focusing on profitability potential. The editors address contemporary concerns, key terms, data requirements, critical methodologies, and essential mathematical needs. They present maintenance in a business context, review planning, measurement, feedback, and techniques related to cost, efficiency, and results, and summarize applications of tools and software from statistics and neural networks to cost-optimized models.
Guidelines for Risk Based Process Safety provides guidelines for industries that manufacture, consume, or handle chemicals, by focusing on new ways to design, correct, or improve process safety management practices. This new framework for thinking about process safety builds upon the original process safety management ideas published in the early 1990s, integrates industry lessons learned over the intervening years, utilizes applicable "total quality" principles (i.e., plan, do, check, act), and organizes it in a way that will be useful to all organizations - even those with relatively lower hazard activities - throughout the life-cycle of a company.
