A structured way of working is required when setting up a risk based maintenance concept.
This starts at the required documentation and will end at reviewing the maintenance concepts at a regulary basis.
There are assets that are absolutely (mission) critical to the business, especially when they are required to fulfil operations.
The failure of these critical assets is that the risk that must be mitigated, or preferably eliminated.
As with all business practices, managing critical equipment requires a process to ensure that operational risk reduction is actively pursued in addition to all other pertinent business objectives.
Critical equipment often impacts safety, regulatory compliance, cost, or operational throughput. Accordingly, provisions for any critical equipment must be accounted for in order to support the sustainability of the business entity.
According IMO 10.3
The company should establish procedures in its safety management system to identify equipment and technical systems the sudden operational failure of which may result in hazardous situations.
Although it does not specifically mention the term 'Critical equipment' of 'safety critical' the maritime industry uses these wording.
In order to simplify and standardise the method the similar approach can also be used for operational equipment.
The same methodology is also accepted by offshore standards like OCIMF.
Single point of failure
A single point failure is any component failure that could lead to an unacceptable situation.
The risk of these failures exists due to the vessel design, in correct installation, lack of maintenance or mis-operation.
Before an asset manager can start to identify critical equipment, they need to understand and document which single point of failures may occur.
If the risk can not be met by preventive measures, spare materials can be identified to reduce the downtime. The method should be applied to all systems, sub-systems, equipment and maintainable components. It is suggested to use the single line diagrams, system diagrams as a basis.
The overview can be presented using a flow diagram, in the form of a list. In most cases the list will use a similar sequence as the breakdown structure.
Safety Critical Equipment
Safety critical equipment is a piece of equipment or component which, in the event of a (single point) failure may result in a hazardous situation or cause an accident for people or the environment.
Safety Critical Parts
All material items associated with the preventive maintenance and corrective maintenance are candidates for safety critical parts.
Safety critical items are:
Operational Critical Equipment
Operational critical equipment is a piece of equipment or component which, in the event of a (single point) failure may result in a hazardous situation or cause unacceptable downtime.
Operational Critical Parts
All material items associated with the corrective maintenance are candidates for safety critical parts.
Safety critical items are:
Setting up a breakdown structure, is the key element to start a risk based maintenace concept.
Most cmms databases these days, can handle multiple views on the structure.
The breakdown structure is the back-bone of several processes. Therefore it is important to create a proper breakdown structure.
The breakdown structure will be used
1. as a guideline during the newbuild fase
2. as a setup for risk analysis and
3. in the computerised maintenance management system (CMMS)
4. for analysis on breakdowns
Every focus in the lifetime of an asset has its own needs on how to use the breakdown structure.
In several industries standard codings are available. These codes are helpful during the engineering fase, construction fase and shutdown fase.
E.g. During the engineering fase similar equipment is purchased at 1 supplier. Therefore it is prefered combine these equipment in the breakdown structure. In the SFI-code all engines, disregarding the function, are allocated at SFI code 63.
The system structure combines all components serving a specific system. It is therefore possible to create an overview of functions and components in a system.
E.g. In order to assign the correct permits for working on a cooling water system it is helpful to assign which functions will be disrupted.
The overview for locations can be used to regulate the number of persons working in a specific area.
A functional breakdown structure is commonly used to analyse systems.
The functional decomposition is a hierarchy of functions and subfunctions.
E.g. In a cooling water system a filter unit will be added as a subfunctions, since breakdown of the filter will lead to malfunctioning of the cooling water system.
The standard packages speeds up the process, and requires less consultancy compared to standard FMECA sollutions
Inventory of all data requires a lot of preparation. Be sure to request for the correct data, at the start.
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