Engineering methodology for selecting Condition Based Maintenance
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During the last decade, condition based maintenance and condition monitoring have experienced a growing area of application. Along with the introduction of Integrated Operations (IO) in the Norwegian oil and gas industry, new opportunities in maintenance management emerged and IO became an important driving force for increased use of condition-based maintenance. Although CBM has a wide area of application, it will not be suitable for all equipment types in a process plant. CBM has to be feasible and cost-effective in order to be the preferred maintenance type. The main objective for this master thesis has therefore been to create a methodology for selecting equipment suitable for CBM during the project phase. The methodology is focusing on describing the work process to ensure a qualified and documented specification of equipment/systems suited for CBM, as part of the maintenance engineering. Although condition monitoring instruments can be installed on almost every piece of equipment, this thesis will focus on where CBM actually can create value. Introducing condition based maintenance leads to new challenges within maintenance engineering. Both opportunities and challenges with CBM have been discussed. CBM offers potential benefits such as increased system reliability and availability, more cost-effective and a reduced number of maintenance actions. The potential challenges are technical complexity, organizational changes, responsibilities, competence, requirement for outsourcing and maintenance planning. The success of CBM relies on multiple factors from design of sensors to the end-user’s work process. The use of condition monitoring will require focus with regards to the interaction between human, technology and organisation. In order to establish a methodology, decision criteria for selecting CBM have therefore been reviewed. The primary criteria that have been discussed are that CBM should be feasible, beneficial and cost effective. These criteria create a basis for the methodology. The methodology is designed to provide input to both the maintenance program and the equipment/system design. The timing of performing the specification methodology has therefore been discussed. The analysis should be performed early enough to provide input for detail design and late enough to ensure proper data for performing the methodology. At an early stage of a project traditional methods such as RCM have been regarded as too demanding. A simplified, but still a qualified and documented methodology has therefore been developed. The methodology involves processes like data collection, criticality screening, technical feasibility and cost-benefit evaluation. CBM puts more responsibility on the vendors to deliver support documents such as FMECA and to propose technical solutions for condition monitoring, including a proposal for condition based maintenance program. A short description of the operational implementation of CBM is also presented, but is not emphasized. Here, the challenges of planning maintenance actions will be an important issue. Other implementation issues such as vendor involvement and service agreements have also been briefly described.
Master's thesis in Offshore technology