plant production

plant production The condition monitoring services within your plant may be 100% in-house, 100% contracted, or a combination of both. This assignment asks for the details of that service by interviewing both service provider and customer/s. It then asks you to describe the monitoring from a managerial perspective, followed by understanding what work is carried out from a technical point of view. You will then detail the outcomes from the routine condition monitoring testing. Finally you are asked to develop a justification for the service. If you work on a large site with thousands of items of equipment, restrict your answer to one department with no more than say 100 monitored items. (If there are no condition monitoring services at your plant, contact the lecturer for alternative mini project requirements.) Part 1: Scope of Work 15 Marks Interview the manager/superintendent of your condition monitoring program, and if the program is contractor supplied, interview the contractor as well. From the interview you need to determine the full extent of the service from a management perspective (personnel involved, amount of possible equipment included in the program and your estimate of the cost of the program). Interview the customer/owner of the equipment (preferably someone in a supervisory capacity) to determine what they see as the three (3) most significant restrictions to receiving an excellent service. These restrictions maybe within the control of the parties involved and taken from the list shown on the survey sheet attached. If the condition monitoring service is a combination of both in-house and external parties, a separate sheet is needed for each supplier. For each of the restrictions identified, provide recommendations on how best to overcome the problems identified. Your answer should contain specific actions that could be undertaken by either the service supplier and/or client. Part 2: What monitoring work is done 15 Marks From Part 1, you have determined what equipment is being monitored. Interview the condition monitoring technicians and establish what parameters are being collected, for example, vibration, oil, temperature, NDT and process values (e.g. pressure, flow). Detail the exact tests that are carried out on 5 different items of equipment (state what the equipment is), down to the type of vibration reading with frequency ranges, what oil analysis is done and how temperature is monitored, and what process parameters are collected. With the collected information, explain why the data is collected (what fault/problems the technicians are looking for) and then, if you believe there is a short-fall (probably there will be!), recommend additional parameters/readings and actions that are required to cover the short fall. Part 3: Outcomes of condition monitoring work being carried out 10 Marks From the monitoring that is occurring, briefly describe how the information is integrated into a CMMS and/or database then used by maintenance to achieve a corrective outcome. Include a flow diagram detailing the information flow. If some or all of the results from the condition monitoring program do not seem to be used, what changes in management, personnel or systems are required to fully utilise the information being produced. Part 4: Justification for program 10 Marks How does your company justify the ongoing use of the condition monitoring service that they are receiving now, and what additional information would you include to improve the ongoing justification (e.g. maintenance history, return on investment etc.)? Ensure you detail the data (e.g. trend information) that supports your description. If the company appears to have no justification currently available, devise your own ongoing justification for the service and present an example of this justification/s to support your answer. Again ensure you detail the supporting information and/or assumptions. Assessment criteria This is a criterion-based assessment item. Please note that it is highly recommended that you read beyond the course materials to complete assessment items. Your submission will be evaluated by the following criteria: Demonstrate ability to: 1. (40%) demonstration of knowledge and understanding of concepts 2. (30%) clarity of expression, including use of terminology, ease of reading, spelling and grammar, orderly and logical presentation and use of diagrams to illustrate points. 3. (20%) quality of presentation including neatness, appropriate use of figures and tables 4. (5%) evidence of research beyond own experience and course material 5. (5%) use of correct and accurate referencing. Condition Monitoring Survey Sheet (to be filled out for the IN-HOUSE or CONTRACTOR management representative) From the In-house’s perspective ? (Tick if interviewing client) From the Contractor’s perspective ? (Tick if interviewing contractor) (NB: two separate sheets are required if the service is provided by both in-house and contractor) From below pick the 3 most significant restrictions to the condition monitoring service being able to perform an efficient service (the most significant should be 1, 2nd most significant 2 and 3rd most significant 3) Barrier Ranking ¢ Poor quality work carried out by CM technician ¢ Equipment is not monitored at regular intervals ¢ Technician not experienced with equipment they monitor ¢ Shortage of skilled technicians to do the work ¢ Technician not experienced with monitoring equipment ¢ Technician not paying attention to customers’ requirements ¢ Access to site equipment is limited or not available ¢ Reports are too late for corrective action to take place ¢ Poor relationship between clients & CM technicians ¢ Reports have no conclusive results ¢ Reports are too technical and have no value to maintenance staff ¢ Inadequate feedback to CM technician to allow additional research ¢ Maintenance personnel don’t agree/understand CM work sufficiently ¢ Maintenance personnel don’t use the information provided ¢ Service too expensive ¢ There is no way of justifying service ¢ Poor communication or information not being made available as required ¢ Other (specify) Comments

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