Changing World of Maintenance

1

Way Back

2

Coal Mines Regulation Act, 1912

Coal Mines Regulation Act, 1912 Part 2 - Rule 3 (added in 1937)

Where a mechanical contrivance for ventilation is provided it shall be installed, used and maintained in accordance with the requirements of the inspector

Part 2 - Rule 5 (added in 1948) A competent person shall, once at least every 24 hours examine the state of the external parts of machinery and shall mark with chalk their initials on or near the machinery

Schedule 7 – Part 3 – Clause 40 (Electrical Section) added in 1952 All portable or mobile flameproof apparatus shall be efficiently overhauled and properly re-assembled under approved conditions once every two years, or as more often as may be required

3

A Little Less Far Back

4

Coal Mines Regulation Act, 1982 (Regulations Released in 1984) Section 103

The manager of a mine shall prepare a scheme for the systematic examination or testing of electrical apparatus and mechanical apparatus at the mine.

Coal Mines Regulation Act, 1982

5

Coal Mines Regulation Act, 1982 (Regulations Released in 1984) Mechanical – Underground Mines (Part 67)

Clause 9. The mine mechanical engineer shall be in charge of all persons at the mine who have a duty to supervise or effect: (a) the installation of mechanical apparatus; (b) the examination and testing of mechanical apparatus before it is put into use after installation, re installation or repair; (c) the maintenance of mechanical apparatus in safe working condition when in use and in accordance with the requirements imposed by or under the Act; and (d) the systematic examination or testing of mechanical apparatus in accordance with the scheme in force at the mine under Section 103 of the Act.

Coal Mines Regulation Act, 1982

6

We went off and labelled all assets with a number (DH001, LTU1 etc.) Engineers created a maintenance sheet for each item as best they could Engineers created a large matrix on the wall of their office to track the

maintenance activities (computers were really not available at this time) But where did the maintenance tasks list get developed from ? Local knowledge History or failures Legislation

Coal Mines Regulation Act, 1982

7

Companies begin to have a higher expectation from the maintenance teams including outside the mining industry.

We, in mining, were not the only ones having trouble with managing our maintenance processes … in the outside world incorrect maintenance or poorly performed maintenance led to some catastrophic failures.

Expectations of Maintenance

8

Maintenance Outside of Mining - 1978 Amoco Cadiz

9

Maintenance Outside of Mining - 1984 Bhopal

10

Maintenance Outside of Mining - 1986 Chernobyl

11

Maintenance Outside of Mining - 1988 Piper Alpha

12

Maintenance Outside of Mining - 1989 Exxon Valdez

13

Maintenance Outside of Mining - 1989 Exxon Valdez

14

The Changing World of Maintenance

What does your

organisation expect from

the maintenance

function?

15

The Changing World of Maintenance

Fix it when it breaks

1940 1950 1960 1970 1980 1990 2000 2010 ……..

1st Generation

Higher availability Lower costs Longer asset life

Higher availability, reliability

and throughput Greater cost-effectiveness Greater safety Better product quality No damage to the

environment Longer asset life

2nd Generation

3rd Generation

16

The Traditional View of Equipment Failure

Age

Cond

itiona

l Pr

obab

ility o

f Fail

ure LIFE Most items

wear out at about the same age

A small number of random failures

17

Aircraft Industry

Aircraft system failures were contributing to 60 crashes per 1,000,000 take offs with 40 of these being contributed from equipment failure.

Believed in age related failures

Reduced the maintenance intervals

Resulting in more failures than before

US Government commissioned a study and report by United Airlines

Report was released and was titled “Reliability-centred Maintenance”

18

The Reality of Failure

Pattern A: The “Bathtub Curve” High infant mortality, then a low level of random failure, then a wear-out zone.

Pattern B: The “Traditional View” Random failure then a wear-out zone.

Pattern C: Steady increase in the probability of failure.

Pattern D: A sharp increase in the probability of failure settling down to random failure.

Pattern E: Random Failure No relationship at all between how old it is and how likely it is to fail.

Pattern F: The “Reversed J Curve” High infant mortality then random failure.

A

B

C

D

E

F

19

The Reality of Failure

Patterns D, E and F: Random Failures.

Patterns A, B and C: Age Related Failures

A

B

C

D

E

F

4 %

2 %

5 %

7 %

14 %

68 %

20

11 %

89 %

The Changing View of Equipment Failure

3rd Generation

1940 1950 1960 1970 1980 1990 2000 2010 ……..

2nd Generation 1st Generation

21

Growing Expectations of Maintenance

1940 1950 1960 1970 1980 1990 2000 2010 ……..

Fix it when it broke Individual approach

1st Generation (reactive) Scheduled overhauls Failure prevention Planning and controlled work

Condition monitoring Reliability Design for reliability and

maintainability Risk based strategies HAZOP (Process Industry) Consequence mitigation Participation / flexibility

/ multi skill / teamwork

2nd Generation (preventive)

3rd Generation (proactive)

22

Less Far Back

23

Coal Mines Regulation Act, 1982 (New Regulations Released in 1999) Clause 9

Standards of Mechanical Engineering Practice and Electrical Engineering Practice. A mine manager must in consultation with the mine mechanical engineer, establish standards of mechanical engineering practice for the mine Standards of competency for persons working with relevant equipment Standards for the design, installation, commissioning, operation, maintenance

(including servicing, repairing and overhauling) and decommissioning of relevant equipment at the mine

In the case of a mine, standards for the systematic examination and testing of relevant equipment at the mine for the purposes of a scheme in force under Section 103 of the Act

Coal Mines Regulation Act, 1982

24

Almost Memorable

25

Coal Mine Health and Safety Act 2002 (Regulations Released in 2006) Clause 20

Mechanical Engineering Management Plan. The mechanical engineering management plan for a coal operation must make provision for the following the standards of engineering practice for mechanical plant and installations

throughout their life cycle at the coal operation, including the following

Coal Mines Health and Safety Act, 2002

26

Now

27

Work Health and Safety (Mines) Act 2013 (Regulations Released in 2014) Part 2 – Clause 26

4) must prepare and implement a mechanical engineering control plan for the mine or petroleum site that sets out the means by which the operator will manage those risks

Schedule 10 – Part 2 (Underground Coal Mines) Mechanical Engineering Manager. a) to develop, supervise, monitor and review the mechanical engineering standards and procedures forming part of mining operations at the mine, and b) to supervise the installation, commissioning, maintenance and repair of mechanical plant at the mine.

Work Health and Safety (Mines) Act 2013

28

Future and Now

29

Where to from here?

ISO 55000 is an international standard covering management of physical assets. Initially a Publicly Available Specification (PAS 55) published by the British Standards Institution in 2004 Gives guidance and a 28-point requirements checklist of good practices in

physical asset management ISO 55000 defines requirements for an asset management system, in the

same way as ISO 9001 specifies a quality management system ISO 55000 focuses on helping you develop a proactive lifecycle asset

management system. This supports optimisation of assets and reduces the overall cost of ownership while helping you to meet the necessary performance and safety requirements.

Future and Now - ISO 55000

30

Major events lead to changes in legislation Maintenance developed is now developed using risk based principals Consideration of 6 failure patterns and not only age related failures Consideration of random failures Implementation of a Control Plan to manage risks from Mechanical Plant

through it’s entire life cycle Control Plans generally refer to a Number of Standards of Engineering

Practice Introduction of ISO 55000 which is an international standard covering

management of physical assets

Review

31

All Over

32

Thankyou for listening