Maintenance Strategy provides safe, effective and cost efficient maintenance management, which is refined and focused with the aim of realizing the best business outcome for Kulevi Oil Terminal.
- Details the key maintenance processes
- Defines the roles, responsibilities and accountabilities of the Kulevi Oil Terminal Maintenance Management and staff
- Defines the continuous improvement processes to ensure the maintenance management system remains a living program
Key elements of Maintenance Strategy:
- ERP - Enterprise Resource Planning program
- Plant Integrity Management
- Knowledge Management
- Equipment Maintenance Plan
- Management of Safety Related and Safety Critical Devices (SRD & SCE)
- Analysis for instrumented shutdown and control systems
- Plant Inspection
- Structural Inspection
- Defect Elimination Program
- Condition Monitoring and Process Data Collection
- Data Analysis
- Operator Performed Maintenance
- Planning and Scheduling
- Spare Parts Management
- Material and Inventory Management
- Quality Assurance and Precision Maintenance Program
- Generic Equipment Maintenance Strategies
- Campaign Maintenance
- Roles, Accountabilities and Deliverables
- Key Performance Indicators (KPI)
Processes that support Maintenance Strategy are:
- Competence management and technical training for all staff
- Contracts for Third Party equipment and services
- Equipment Efficiency Improvement (EEI)
- Management of change
- Integrity and continuous improvement culture
- External and Internal verification processes
The objective of Maintenance Strategy
The objective of maintenance strategy is to minimize maintenance costs without compromising safety, plant integrity, the environment or the desired levels of availability. The Maintenance Management philosophy represents a series of working methods, processes and guidelines designed to meet the overall objective, which can be summarized by the following:
- A structured approach to maintenance optimization shall be adopted based upon the appropriate application of condition-based, planned preventive and corrective maintenance techniques. Fundamental to this approach is the assessment of risk and equipment criticality based on consistent safety, environmental and commercial criteria.
- Clearly defined roles and responsibilities, authorities, and relationships shall be developed for all personnel involved in maintenance activities.
- Key performance indicators shall be established and used to focus attention on critical success factors
- Periodic review and auditing of the maintenance program will be conducted to assure its effectiveness and highlight improvement opportunities.
- Optimize the maintenance activities in line with set targets for plant and equipment availability
- Significant reduction in maintenance costs by the elimination of unnecessary maintenance tasks, when maintenance needs are anticipated and planned in advance
- Terminal efficiency improvement through the elimination of unanticipated breakdowns
- Reduced inventory of spare parts
- Improvement of plant safety, integrity and environmental protection
- Extending the use life of expensive equipment through the detection or elimination of failures
Initial steps in setting the Maintenance Strategy include:
- Equipment identification
- Preliminary criticality review
- Reliability and cost benefit analysis
- Spares support
- Maintenance planning
The Maintenance Strategy follows the founding principles of the condition-based approach that consists of the following working practices:
- All facilities are subject to maintenance, be it classified as predictive, preventive or run to failure. In determining the maintenance category appropriate to the operation of equipment/facilities, emphasis is placed upon equipment criticality, probability and consequence of failure.
- The primary focus is for predictive, non-intrusive condition-based maintenance, including watch keeping, function/performance testing, inspection and other condition monitoring techniques.
- Preventive, intrusive maintenance is conducted to satisfy statutory or self-imposed requirements or where equipment criticality demands preventive (time-based) maintenance is undertaken.
- Equipment that has a known/predictable service-life or critical equipment that has a potential hidden failure mode (e.g. fire & gas detectors) is subject to preventive maintenance. However, the expectation is that such preventative maintenance will be minimized.
- Non-critical plant and equipment that fails in a safe condition will not normally be subjected to predictive or preventive maintenance, being classified as run to failure. However, such equipment may be included in servicing and campaign maintenance programs to minimize breakdowns and preserve the overall condition of the facilities.
The Maintenance Strategy of Kulevi Oil Terminal is the guide for Continuous Review and improvement of maintenance management.