Optimisation Of Preventive Maintenance In The Process Industry: Alignment With European Standards

Preventive maintenance plays a vital role in ensuring reliable and safe plant operation in the process industry, where continuous production and operational efficiency are critical. Maintenance managers are constantly looking for ways to minimise corrective maintenance and unplanned downtime, which can lead to significant financial losses and safety risks.

Finding the right balance is essential to avoid excessive maintenance that wastes resources and potentially creates new problems. By adapting maintenance practices to European standards, companies can optimise their preventive maintenance strategies to ensure the reliability of their equipment and the quality of their operations.

“Optimising preventive maintenance requires a strategic approach that takes into account equipment specifics, operational requirements, and industry standards to improve equipment reliability and operational efficiency in the process industry.”

Preventive maintenance: Challenges in the process industry

The process industry includes sectors such as chemicals, petrochemicals, pharmaceuticals, and oil and gas – all with complex processes and sophisticated equipment. These industries often operate in harsh conditions, with corrosive materials, extreme temperatures and high pressure. Maintenance requirements vary greatly due to various factors:

• Age of the equipment: Older machines need to be inspected more frequently due to wear and tear.
• Materials processed: Different products stress or corrode equipment to different degrees.
• Environmental influences: Equipment exposed to the elements wears out more quickly and requires more frequent maintenance.

A one-size-fits-all approach to preventive maintenance is inadequate in such a diverse environment. Instead, a tailored programme is required that takes these specific factors into account. This ensures that each piece of equipment receives the appropriate attention without unnecessary intervention, optimising resource allocation and maintaining equipment capacity.

Introduction of completion codes for efficient maintenance management

For effective management of preventive maintenance, maintenance professionals need a robust system for tracking asset status and maintenance activities. Completion codes are a valuable tool in this regard. In MaintMaster's Computerised Maintenance Management System (CMMS), specific completion codes help to monitor and adjust maintenance tasks. These codes include:

• Status OK: The system is working properly and is authorised for further operation.
• Deviation identified: Devices or components deviate from standards or performance expectations and require follow-up measures.
• Deviation identified and corrected: Minor problems are recognised and rectified during maintenance, with actions documented for future reference.
• Status OK (change procedure): The equipment is in good condition, but the maintenance procedures or intervals need to be adjusted.
  
  

By systematically applying these codes, maintenance teams can monitor trends, recognise recurring problems and make informed decisions about maintenance strategies. This structured approach enables a better understanding of the condition of the equipment throughout the plant and facilitates proactive rather than reactive maintenance.

Eliminate deviations by root cause analysis

If deviations are frequently detected during maintenance work, this is a clear signal that the underlying problems need to be addressed. In the process industry, where plant failures can lead to safety risks or environmental damage, identifying the root causes is crucial. Conducting a root cause analysis involves several steps:

1. Identifying the problem: Clearly defining the deviation and its impact on operations.
2. Data collection: Gathering information on equipment history, operating conditions and previous maintenance records.
3. Analysis: Use analysis methods to determine the root cause.
4. Implement the solution: Develop corrective actions that address the root cause, such as material improvements or process adjustments.
5. Verification: Monitoring the system after the corrective actions have been implemented to ensure that the problem has been resolved.

If, for example, a heat exchanger in a chemical plant is frequently fouled (an observed deviation), root cause analysis may reveal that the process fluids are causing unexpected fouling. The solution might be to change the cleaning intervals or add anti-scale agents. Addressing the root cause not only solves the current problem, but also increases the overall reliability of the equipment.

Adaptation of maintenance procedures based on feedback from the field

The feedback from the maintenance technicians is invaluable for refining the preventive maintenance programmes. When a work order is completed with a “Status OK (change procedure)”, it means that the equipment is working properly but the maintenance programme can be improved. Technicians should make specific recommendations on what needs to be adjusted, whether it is the intervals, materials used, techniques or other factors.

Taking this feedback into account can lead to considerable benefits:

• Optimised use of resources: Concentrating efforts on the areas where they are most urgently needed reduces downtime and maintenance costs.
• Improved system performance: Customised processes can extend the service life of systems and improve their reliability.
• Improved safety: Adapting maintenance practices can reduce the risks associated with equipment failure.

For example, if technicians in a pharmaceutical production facility notice that the seals of mixing vessels are wearing out more quickly due to certain solvents, they may recommend switching to seals made from a more durable material. By adapting maintenance procedures to these more durable seals, the plant can avoid future breakdowns and extend the life of the equipment.

It is an advantage if the technician reporting the closure code can describe exactly what needs to be changed. This clarity makes it easier to discuss the necessary measures and implement the adjustments in good time. Open communication between maintenance staff and management facilitates continuous improvement and ensures that preventive maintenance remains effective and relevant.

Utilisation of historical data for proactive maintenance planning

Data-driven decision-making is essential in the process industry. By collating historical data on plant performance, production output and completion codes, maintenance professionals can recognise patterns and trends. With this information, they can:

• Recognise interrelationships: Understand how different products or processes affect equipment performance.
• Anticipate maintenance needs: Forecast periods of increased maintenance needs based on production schedules or seasonal factors.
• Adapt preventive strategies: Proactively change maintenance schedules to address identified trends.

For example, an oil refinery may find that the equipment that processes crude oil with high sulphur content has more corrosion-related anomalies. Knowing this, the maintenance team can schedule more frequent inspections or preventative measures for processing such materials.

Similarly, equipment exposed to harsh weather conditions may require additional protective measures at certain times of the year. By planning accordingly, the plant can prevent weather-related breakdowns.

By compiling the historically produced items in the equipment and assigning them to completion codes, the development of maintenance requirements can be recognised depending on the product. This insight enables more precise maintenance planning and resource allocation. By utilising historical data, maintenance moves from a reactive to a proactive approach, reducing unexpected downtime and improving overall efficiency.

“Incorporating European Standards into maintenance strategies helps companies balance preventive maintenance with operational efficiency and contributes to the overall success and sustainability of the business.”

Alignment with European maintenance standards

European maintenance standards such as EN 13306 on maintenance terminology and EN 31010 on risk management provide a framework for best practice in maintenance management. Compliance with these standards helps to ensure that legal requirements for safety, health and environmental protection are met. In addition, reliability is improved through the introduction of standardised procedures that increase the availability and performance of the equipment.

In the process industry, meeting these standards is not just about complying with regulations, it is also about securing competitive advantage. For example:

• Risk-based maintenance: Prioritising maintenance activities based on the risk associated with equipment failure, with a focus on critical equipment that can cause significant operational disruption or safety risks.
• Life cycle costing: Assessing the total cost of ownership of a system, including maintenance, to make informed decisions about repair, replacement or modernisation.
• Continuous improvement: Regularly reviewing and updating maintenance practices to take account of new technologies, methods or changes in legislation.

Incorporating European Standards into maintenance strategies will help companies to balance preventive maintenance with operational efficiency and contributes to the overall success and sustainability of the business.

Strategic preventive maintenance for operational excellence

Optimising preventive maintenance requires a strategic approach that takes into account equipment specifics, operational requirements and industry standards. By systematically tracking equipment condition and maintenance results using completion codes, performing root cause analysis to address underlying problems and incorporating feedback from the field to adjust procedures, maintenance professionals can improve equipment reliability and operational efficiency.

Using historical data for proactive maintenance planning allows organisations to predict and prepare for maintenance needs, reducing unexpected downtime. Alignment with European maintenance standards ensures that maintenance practices meet industry benchmarks for safety and efficiency, providing a competitive advantage.

Dynamic and data-driven maintenance strategies, that are supported by a robust Maintenance software, are essential in the process industries. Optimising preventive maintenance is not only about routine tasks, but about strategic asset management that promotes productivity, safety and competitiveness.

By using a CMMS to track, analyse and adjust maintenance activities, maintenance professionals play an important role in the success of their organisations. They ensure that assets operate reliably and efficiently, while meeting the highest standards of quality and compliance.