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PLANT OPERATION & MAINTENANCE
TRACON INDUSTRI
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TRACON CAPABILITY
1. Experienced & Certified Man Power
2. Good Maintenance Strategy Program
3. High Technology Tools & Equipment Support
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TRACON MAN POWER
1. Experienced Man Power
- TRACONs Manpower are Trained, Honesty , Integrity, & Have Good Safety
Behavior.- Have Experienced 2 to 5 Years for Junior Grade, 5 to 10 Years to Middle Grade
, and Over 12 Years for Senior Grade.
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TRACON MAN POWER
TRACON SPECIALIST / ENGINEERING EXPERT
1. Vibration Analyzer
2. Oil Analyzer
3. Thermography Analyzer
4. Ultrasonic Expert
5. Welding Inspector
6. Coating Inspector
7. Vessel Tank Inspector
8. Turbine Specialist
9. Rotating Engineer
10. Static Engineer
11. Process Engineer
12. Intrument Engineer
13. Electrical Engineer
14. etc
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Good Maintenance Strategy Program
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TRACONS MAINTENANCE STRATEGY
CAPABILITY
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1. RELIABILITY-CENTERED MAINTENANCE (RCM) RCM IS A SYSTEMATIC
CONSIDERATION OF SYSTEM FUNCTIONS, THE WAY FUNCTIONS CAN FAIL, & A
PRIORITY-BASED CONSIDERATION OF SAFETY AND ECONOMICS THAT IDENTIFIES
APPLICABLE & EFFECTIVE PM TASKS.
2. RELIABILITY-CENTERED MAINTENANCE (RCM) RELIABILITY-CENTERED
MAINTENANCE (RCM) IS THE PROCESS OF DETERMINING THE MOST EFFECTIVE
MAINTENANCEAPPROACH. RCM WAS FIRST APPLIED ON A LARGE SCALE TO
DEVELOP THE MAINTENANCE PROGRAM OF THE BOEING 747. KNOWN AS MSG-3 IN
THE AEROSPACE INDUSTRY.
3. RELIABILITY-CENTERED MAINTENANCE (RCM) RCM IS A TECHNIQUE FOR
DEVELOPING A PM PROGRAM. IT IS BASED ON THE ASSUMPTION THAT THE
INHERENT RELIABILITY OF THE EQUIPMENT IS A FUNCTION OF THE DESIGN AND
THE BUILD IN QUALITY. AN EFFECTIVE PM PROGRAM WILL ENSURE THAT THE
INHERENT RELIABILITY IS REALISED.
RCM GENERAL OVERVIEW
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OBJECTIVE OF TRACON RCM
Reduce Maintenance Cost
Increase Plant Reliability
Efficiency Energy Consumed
High Plant Productivity
High Level HSE
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HISTORY OF RCM
RCM HISTORY ORIGINATED IN THE AIRLINE INDUSTRY IN THE 1960S. BY THELATE 1950S, THECOST OF MAINTENANCE ACTIVITIES IN THE AIRLINE INDUSTRY
HAD BECOME HIGH ENOUGH TO WARRANT A SPECIALINVESTIGATION INTO THE
EFFECTIVENESS OF THOSE ACTIVITIES. ACCORDINGLY, IN 1960, A TASK FORCE
WAS FORMED.
RELIABILITY CENTERED MAINTENANCE HISTORY CONSISTING OF
REPRESENTATIVES OF BOTH THE AIRLINES AND THE FEDERAL AVAITIONADMINISTRATION (FAA-US) TO INVESTIGATE THE CAPABILITIES OFPREVENTIVE
MAINTENANCE. THE ESTABLISHMENT OF THIS TASK FORCE SUBSEQUENTLY LED
TO THE DEVELOPMENT OF A SERIES OF GUIDELINES FOR AIRLINES AND AIRCRAFT
MANUFACTURERS TO USE, WHEN ESTABLISHING MAINTENANCESCHEDULES FOR
THEIR AIRCRAFT.
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HISTORY OF RCM
Run to
Failure
Preventive
Maintenance
Basic
Inspections
Organized
Preventive Maintenance
Conditioning
Monitoring
Proactive
Maintenance
Reliability
Centered Maintenance
1930 1950 1990 2000 2010
IncreasingReliability
RCM Implemented in general industry
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RCM FLOW PROCESS
Step 1
Select the Most
Critical Equipment
Step 2Identify the
Functions of
the equipment
Step 3Establish
perfomance
Standards
Step 4
Determine Type
of Failures
Step 5
Enumerate
Consequences
Of failures
Step 6Rank the
Consequences
of failures
Step 7
Apply the mosteffective condition
Monitoring
techniques
Step 8
Establish an overallMaintenance plan
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RCM CHART
ReliabilityCentered
Maintenance
Reactive Interval ( PM )Condition Base
MaintenanceProactive
Small Items Non Critical
Inconsequential
Unlikely to Fail
Redundant
Subject to wear-out
Consumable
replacement
Failure pattern
known
Random failurePatterns
Not Subject to
wear
PM Induced failure
RCFA Age Exploration
Failure Modes and
effect Analysis (
FMEA )
Acceptance
Testing
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EQUIPMENTS FAILURE SYMPTOMS
TRACONS EXPERT IN RELIABILITY CENTERED MAINTENANCE
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ADVANTAGE RCM STRATEGY
STRATEGY
DEFINITION
REACTIVE PREVENTIVE PREDICTIVE PROACTIVE
Fix it when itbreaks / Run to
Failure
Conductmaintenance at
regular at
intervals
Maintain basedupon known
condition \/
standards
Redesign toeliminate root
causes of failure
ADVANTAGE
S ( WhenImplemented
correctly )
Cheap Can be planned
for / Scheduled
Spot a potential
failure
Less maintenance
requires
Disadvantage
s ( When
implement
correctly )
High Spare stock
levels.
Emergency
Outages
Unnecessary
replacement of
part. Poor
utilization oflabour
Costly if
implemented
incorrectly
Could be
expensive
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BATHTUNB CURVE
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PREDICTIVE MAINTENANCE TECHNOLOGY
TRACONS EXPERT IN RELIABILITY CENTERED MAINTENANCE
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PREDICTIVE MAINTENANCE TECHNOLOGY
TRIBOLOGY
1. Lubricating Oil Analysis
2. Spectrographic Analysis
3. Wear Particle Analysis
VIBRATION ANALYSIS
1. Rotating2. Static
Other Maintenance / Failure Detection techniques :
Acoustic monitoring
X-ray or Radiography Inspection
Magnetic Particle Inspection
Eddy Current Testing
Ultrasonic testing
Liquid Penetrant
Motor Current Signature Analysis ( MSCA )
Bore scope InspectionTHERMOGRAPHY
1. Infrared Thermometers
2. Line Scanners
3. Infrared Imaging
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