Unifying Plant Maintenance Work Types & Order Priorities For Generation Power Plants

1. Unifying Plant Maintenance Work Types & Order Priorities For Generation Power Plants FHG, SAD, VJG & AMS SAP PM Generation Team

2. Contents • Introduction & Objective • Survey • SMRP- Society for Maintenance & Reliability Professionals • PMO Model from EPRI • Gen-EOA CMMS Classification (GPPD, QPPD & GTPD): Work Types & Priority • Gen-WOA CMMS Classification of Work Types (RPP & SPP) • ARAMCO SAP-Plant Maintenance Classification of Work Types & Priorities • UNITED SAP-Plant Maintenance Classification of Work Types & Priorities • NEBRAS SAP BBR Classification of Work Types (LOG-BBR-WS13) • Other References on Maintenance Work Types, Order Priorities & ISO/IEC Definitions • Recommendations • References • Wrap up (including Q&A, version information)

3. Introduction & Objective • Classifying ‘maintenance work types’ in a logical way is a difficult task. Note: Some use ‘maintenance strategies’ instead of ‘maintenance work types’ • Based on our own experience and survey on industrial practices, this presentation attempts to classify the plant maintenance work types & work priorities for generation power plants • Once reviewed and approved, this can be used to update our maintenance systems (CMMS/SAP)

4. ... continued (SAP- PM Business Drivers) • Reduce costs while improving efficiency, reliability and availability • Standardize,streamline, automate and integrate business processes • Improve safety • Improve resource utilization and efficiency • Improve customer satisfaction • Environmental compliance improvement

5. SMRP Classification-I • SMRP is Society for Maintenance & Reliability Professionals (See References-1 & 2). • For definitions of PM, PdM, etc. see following slides

6. SMRP Classification-II Ref: BP Metric_5.1.1 Actual Cost to Planning Estimate_Stegemiller-Olver_060911_FC.pdf

7. …continued (SMRP) • Preventive Maintenance (PM): An equipment maintenance strategy based on replacing, overhauling or remanufacturing an item at a fixed interval, regardless of its condition at the time. Scheduled restoration tasks and scheduled discard tasks are both examples of preventive maintenance tasks • Failures: The event, or inoperable state, in which an item or asset does not perform its required function

8. …continued (SMRP) • Predictive Maintenance (PdM): An equipment maintenance strategy based on measuring the condition of equipment in order to assess whether it will fail during some future period, and then taking appropriate action to avoid the consequences of that failure. The condition of equipment could be monitored using condition monitoring, statistical process control techniques, by monitoring equipment performance, or through the use of the human senses. The terms condition based maintenance, on-condition maintenance and predictive maintenance can be used interchangeably.

9. …continued (SMRP) • Repairs: Work done to restore the function of an asset after failure or imminent failure • Rework is corrective (repair) work done on previously maintained equipment because of maintenance, operations or material problems that resulted in a premature functional failure of that equipment. The causes of rework may be maintenance, operational or material quality issues. • Corrective Work Identified by PM and PdM’s: Work done to restore the function of an asset before failure that was identified by a PM or PdM task.

10. …continued (SMRP: Analyis) • SMRP classification is simple (only 5 basic work types), straightforward and practical. • Rework sub-type of repairs is an excellent tool for tracking & analysis • Following are not classified explicitly by SMRP: • Turnarounds (or Testing and Inspection, T&I): If turnaround work is based on fixed intervals, it can be classified as PM. If it is based on condition monitoring, it can be classified as PdM! • ‘Safety’ work type: Can be added to Repairs or Proactive Maintenance depending on the specific instance

11. …continued (SMRP: For information only)

12. PMO Model from EPRI: Electric Power Research Institute • The consultants of EPRI solutions (Palo Alto, Calif.), a subsidiary of EPRI, have developed Plant Maintenance Optimization (PMO) and over the years have implemented it at some 158 power plants throughout the United States (Reference-5).

13. …continued (PMO) • PMO model focuses on optimizing four segments (designated by four color schemes in the model): • Maintenance basis consisting of ‘Corrective Maintenance’, ‘Preventive Maintenance’ and ‘Identification of maintenance task’ • Predictive maintenance (condition-directed) • Work management consisting of ‘Work control’ & ‘Work execution’ • Continuous improvement - Learning from experience -consisting of ‘Work closeout’, ‘Continuous Improvement’ & ‘Proactive maintenance’

14. …continued (PMO) • Corrective maintenance (CM) is the most basic of maintenance processes. Tasks are generated as a result of equipment failure. These tasks may be expected(when equipment is purposely "run to failure") or unexpected (when failures are neither desired nor planned). Equipment that is allowed to run to failure typically has been determined to be non-critical and usually includes low-cost items, with spares on hand for immediate replacement. • Preventive maintenance (PM) includes periodic condition monitoring and taking time-based actions to maintain a piece of equipment within design operating conditions to extend its life. PM is normally performed before equipment fails, to reduce that likelihood.

15. …CONTINUED • Predictive maintenance (PdM) is the process of integrating and analyzing equipment condition data from a variety of sources to inform decision-making about the maintenance requirements of major critical equipment. • Continuous improvement (CI) is the organization's process of "learning from experience" gained through high-impact failure events and from performing maintenance work. Continuous improvement consists of Proactive Maintenance (PAM) and Root Cause Analysis (RCA).

16. …continued (PMO) • The Proactive Maintenance (PAM) process makes use of direct feedback from maintenance personnel—through simple means like work order failure cause codes, equipment condition codes, and completion remarks—to improve the effectiveness of the maintenance work the next time it is performed. PAM also calls for making appropriate adjustments to the maintenance strategy, procedures, and/or task frequencies to further eliminate failures or deficiencies in the future. • The Root Cause Analysis (RCA) process is used to determine what happened, why it happened, and what can be done to keep it from happening again on non-routine major equipment events. The resulting problem resolutions must then be approved, prioritized, and implemented, and the event tracked for recurrence. In addition, the appropriate maintenance procedures or practices must be modified to reflect the analysis results

17. …continued (PMO) • Optimizing the maintenance basis is a step-by-step process of incorporating plant knowledge, maintenance history, and industry experience into maintenance recommendations. One method used to optimize the maintenance basis is the well-known Reliability Centered Maintenance (RCM) analysis process.

18. …continued (PMO: Analysis) • PMO Model identifies the following maintenance strategies: • Corrective maintenance (CM) including Run-to-Failure (RTF) • Preventive maintenance (PM) • Predictive maintenance (PdM) • Continuous improvement (CI) consisting of: • Proactive maintenance (PAM) • Root Cause Analysis (RCA) • Reliability Centered Maintenance (RCM)

19. GENERATION-EOA CMMS CLASSIFICATION: • Two of the Generation-EOA Subject Matter Experts for SAP-Plant Maintenance Business Processes surveyed 26 months’ historical data for Generation-EOA power plants for plant maintenance 'work types' and 'work priorities' (Reference-7).  • Survey included three departments: GPPD, QPPD & GTPD • An overview of the survey is given – see next slides

20. …continued (GEN-EOA CMMS)

21. …continued (GEN-EOA CMMS)

22. …continued (GEN-EOA CMMS - Analysis) • GEN-EOA CMMS Survey - Results and Conclusions: • 16 plant maintenance work types are currently used by Generation-EOA power plants & can be classified into 7 groups: • Preventive Maintenance (PM) • Corrective Maintenance (CM) • Testing and Inspection (T&I) • Commissioning - New Equipment • Condition Based Maintenance (CBM) • Special Projects/Modifications • Non-Equipment Related • The PM, CM and T&I work types constitutes nearly 98% of historical work order tasks.

23. …continued (GEN-EOA CMMS - Analysis) • GEN-EOA CMMS Survey - Results and Conclusions (continued): • There is no consistency with regard to the use of sub-types for T&I work type. Hence: • Either streamline the sub-types for T&I • Or delete all the sub-types for T&I work type • No consistency between PM and T&I between two power plants • Retain 'non-equipment related' type. Can call it ‘non-core maintenance’ type(Also see SMRP Survey) • ‘Commissioning - New Equipment’ is wrongly entered by many users because of default selection (first item pull-down list).This was intended to track ‘warranty’ aspects. Can be discontinued by using ‘warranty’ type/sub-type (Also see United Survey)

24. …continued (GEN-EOA CMMS - Analysis) • GEN-EOA CMMS Survey - Results and Conclusions (continued): • Change ‘CBM’ description to ‘PdM’ (See SMRP & PMO Survey) • There is no need for E-type (i.e., very low) work priority.Just four types of work priority (i.e., very high, high, normal & low) are enough • Use ‘Emergency’ in place of ‘Very High’ to highlight the meaning more effectively (See S. ARAMCO Survey)

25. GEN-WOA CMMS Classification RABIGH PP

26. GEN-WOA CMMS Classification SHOIBA PP

27. SAUDI ARAMCO SAP PM ORDER TYPES (Reference-4)

28. SAUDI ARAMCO SAP PM ORDER PRIORITIES (Reference-4):

29. UNITED SAP PM Maintenance Orders Types (Reference-8) • The maintenance order types used: • PM01 – Planned Corrective maintenance • PM02 – Breakdown maintenance (Urgent Unplanned Corrective) • PM03 – Preventative maintenance • PM04 – Refurbishment maintenance • PM05 – Project related maintenance • PM06 – Shutdown related maintenance • PM07-Emergency/Accident related maintenance (for the purpose of insurance claim)

30. UNITED SAP PM ORDER PRIORITIES (Reference-8) :

31. UNITED MAINTENANCE ACTIVITY TYPES (Reference-8) : • The Maintenance Activity Types used: • M01 – Repair • M02 – Replace • M03 – Overhaul • M04 – Rework • M05 – Inspection • M11 – Warranty Work • M12 – Calibration • M13 - ISO

32. SAP BBR CLASSIFICATION: WORK ORDER TYPES • LOG-BBR-WS13 (Reference-6) indicates the following work order types: • PM01 – Corrective maintenance • PM02 – Breakdown maintenance • PM03 – Preventive maintenance • PM04 – Refurbishment maintenance • PM05 – Project related maintenance (engineering and construction) • PM06 – Turnaround maintenance (outages) • PM07 – Change order Note: Above needs to be revised during BBR Reassessment Phase

33. Other References on Maintenance Work Types: • There should be only five to ten major work codes (i.e., work types) falling into the categories of Proactive, Reactive and Other. These should not be confused with problem codes (by John Day, Jr., Manager of Engineering and Maintenance at Alumax of South Carolina) • Not all plant equipment should receive the same attention. Some are more critical than others. Based on their criticality, the equipments can be either intentionally run-to-failure (RTF) or added to one or more maintenance strategies (like PM, PdM, etc). • It is important to consider such factors as consequences of failure (i.e., risk),and probability of failure before determining the criticality of an equipment. Then the ‘criticality’ information shall be documented and entered in the system. If required, the criticality can be further reviewed and revised as part of optimization (CI or RCM).

34. …continued (Other References) • Discussion forum on improving reliability ‘What is Corrective Maintenance’ gives interesting debates on CM, PM, etc(Reference-9). It is too lengthy to be described here, better to visit the link and go through • One proven theory is that the ‘Corrective Work arising out of PM’ to ‘CM’ work order ratio should be about 6 to 1. Note: Proven by John Day, Jr., Manager of Engineering and Maintenance at Alumax of South Carolina, during the period when Alumax of South Carolina was certified as the first “World-Class” maintenance organization • In a lean maintenance environment, follow up corrective work from PM’s should amount to 12% to 20% of the PM total. This is your payback for performing the PM’s. Note: Any extra corrective activity that is not part of the preventive maintenance strategy or procedure, but a result of it must be captured on a separate work order and coded as such. Additionally, it is a proactive activity and the work order should be deemed as such. (Leon Reed Sr. Reliability Engineer, CMRP, Eli Lilly, Indianapolis IN)

35. …continued (Other References) • RTF (Run-to-failure or Run-to-maintenance):Replace the failed non-critical, usually inexpensive equipment i.e., do not refurbish or do not do any PM on such equipment. Equipment is said to be ‘non-critical’, if the failure does not affect safety and/or production (i.e., electricity supply/desalinated water supply to customer) and the spares are available for immediate replacement. Examples: • 10 HP or less and if breakdown does not affect critical or major equipment. The failure also does not jeopardize safety and production reliability (Reference-3) • Units 1-4 traveling water screen motors (2 HP) of Ghazlan power plant • Many classify RTF as a sub-type of CM. It is recommended to classify this separately (work type or sub-type) in system. This is because: • To eliminate preventive maintenance where there is no added value • To move towards reliability centered maintenance (RCM)

36. Other References on Work Priorities: • Characteristics of a world-class work order priority system according to IDCON (Reference-11): • The priority system obviously has a code or number to signify the importance of a work order. But, is there a set of rules that describes what type of work that can be classified as a high, medium and low priority? • Does each work order priority code have a time limit attached to it? For example: Priority 1 will be started immediately, priority 2 within a week, priority 3 within a month etc? • Are the priorities reviewed in a weekly/ daily planning and scheduling meeting JOINTLY by operations and maintenance? (If not, there is little chance to effectively coordinate the production schedule with the maintenance schedule). Work orders should not be over prioritized by strong individuals in the planning and scheduling meetings • Are there high priority work orders older than 3 months in your system? If so, your plant probably has a tendency to over prioritize work orders.

37. …continued (other references: work priorities)

38. Other References on Definitions: ISO 14224:1999(E) & IEC 60050-191:1990 Definitions: • Corrective maintenance: maintenance carried out after fault recognition and intended to put an item into a state in which it can perform a required function • preventive maintenance: maintenance carried out at predetermined intervals or according to prescribed criteria, and intended to reduce the probability of failure or the degradation of the functioning of an item • Item: any part, component, device, subsystem, functional unit, equipment or system that can be individually considered • Failure: termination of the ability of an item to perform a required function • Fault: state of an item characterized by inability to perform a required function, excluding such inability during preventive maintenance or other planned actions, or due to lack of external resources • Maintenance: combination of all technical and administrative actions, including supervisory actions, intended to retain an item in, or restore it to, a state in which it can perform a required function

39. RECOMMENDATIONS: • Based on the survey (SMRP, PMO/EPRI, CMMS, SAP, MAINTENANCE FORUM), it is important to come to an agreement (i.e., unification) with regard to the plant maintenance work types and priorities. Remember that these will be used to record and retrieve history from system (CMMS/SAP) in an orderly manner • Recommendations are given in the next few slides • Once reviewed and approved, this will be: • Used to update our maintenance systems and/or our maintenance policies • Used consistently so that the quality of information in the system can be improved

40. RECOMMENDATION-1, MAINT. WORK ORDER TYPES:

41. …CONTINUED Notes: • Examples: Incident Analysis, Trip Analysis , Continuous Improvement activities like Bad Actors Analysis, Root Cause Analysis (RCA/RCFA), Failure Mode Effects Analysis (FMEA), Plant Maintenance Optimization (PMO). • Example: Feasibility study of employee suggestions, Engineering study, Safety/Environment studies, Safety/Environment audits, etc. • SAP Consultant kept this as a separate type during BBR project.  Hence, we continue to keep this as separate work type for the time being (till we get more info) until BBR Reassessment phase. 

42. RECOMMENDATION-2, PRIORITY Vs RESPONSE TIME:

43. RECOMMENDATION-3, TIME FRAME FOR REWORK • Period to determine whether the failure is ‘pre-mature’ needs to be defined for Rework. Reference-3, Page-25 of 78 indicates 60 days’ period for identifying rework from previous maintenance work. • It is recommended to use 60-days

44. RECOMMENDATION-4, COORDINATING PdM SCHEDULE • Condition monitoring of equipment shall be scheduled when the equipment is running, preferably before it is stopped for changeover (by standby equipment, if applicable). This will avoid unnecessary starts & stops. Also, any abnormalities noticed during condition monitoring can be planned & attended during equipment idle period. • It is recommended to co-ordinate equipment change-over schedule (which is done by operations personnel) and PdM (i.e., condition monitoring) data-collection schedule

45. References • SMRP Best Practice Metrics # 5.11.2 PM & PdM Effectiveness (July 31, 2006) • SMRP Best Practice Metrics # 4.1 Rework (July 10, 2006) and #5.6.2 Proactive Work (Jan 9. 2006) (http://www.smrp.org/body_of_knowledge/best_practices_metrics.htm) • Saudi Aramco Best Practices: Field Reliability Unit Guidelines and Procedures (SABP-G-008, 23 July 2005) • Saudi Aramco General Instruction Manual on Maintenance Work Orders (GI Number 1000.500, 10 January 2005) • Article on ‘Optimizing Power Plant Maintenance’ by Patrick Abbott of EPRI Solutions in POWER magazine (December 2004 issue) • Logistics SAP Plant Maintenance Business Blueprint Reports (LOG-BBR-WS13) • Gen-EOA CMMS Historical Data - survey conducted by Frank H. Gagaring & Suresh A. Dhareshwar (Gen-EOA Subject Matter Experts for SAP Plant Maintenance Business Processes) in Sept 2008 • UNITED Procedure (MWP-PRC-PL-00004-003) • http://maintenanceforums.com/eve/forums/a/tpc/f/209103451/m/2951033833/p/1 • http://www.plant-maintenance.com/terminology.shtml • http://www.idcon.com/reliability-tips-current.htm

46. Wrap Up • Questions & Discussions • Action items • Do you agree? • Thank you • Presentation revision history: • Presented by VJG on 30 Jan 2008 during WS13-2 GBL Unification Meeting (v1) • Revised on 23 March 2008 after obtaining review from experienced operation personnel like TM (v2). Also sent to Gen-EOA/COA/SOA/WOA on 5 April 2008 for review and to close the pending/open item • FHG revised and presented to GEN-EOA Department Coordinators on 28 May 2008 (v4.1) to close the pending/open item in Gen-EOA • VJG revised after getting feedback from Shoiba Power Plant and after the internal project team meeting (v4.2)