EEMUA PUB NO 187-2013 Analyser systems A guide to maintenance management (Edition 2).pdf

1、 Analyser systems A guide to maintenance management PUBLICATION 187 Edition 2 RELEASED BY IHS. NOT FOR RESALE THE ENGINEERING EQUIPMENT AND MATERIALS USERS ASSOCIATION Analyser systems A guide to maintenance management PUBLICATION 187 Edition 2 Copyright 2013 The Engineering Equipment and Materials

2、Users Association. A company limited by guarantee. Registered in England. Company number 477838. ISBN 978 0 85931 187 8 Imprint reference 12-2013 Registered and Trading Address 63 Mark Lane London EC3R 7NQ Telephone: +44 (0)20 7488 0801 Fax: +44 (0)20 7488 3499 E-mail: saleseemua.org Website: www.ee

3、mua.org EEMUA Publication 187 Analyser systems: a guide to maintenance management EEMUA iv ENGINEERING EQUIPMENT AND MATERIALS USERS ASSOCIATION About EEMUA The Engineering Equipment and Materials Users Association is usually known by its initials, EEMUA. EEMUA is governed by a Council of members. T

4、his Council is responsible for the policies, financing, membership, and strategy of the Association. Any organisation that is a substantial user or purchaser of engineering products is eligible to apply to become a member of EEMUA. Membership is subject to the approval of Council. EEMUA Aims EEMUA a

5、ims to improve the safety, environmental and operating performance of industrial facilities in the most cost-effective way, pursuing and promoting leadership in industrial asset management by sharing engineering experiences and expertise, and by the active, enlightened promotion of the distinct inte

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9、ers representatives on EEMUA Technical Committees, Working Groups, and Forums, supported by EEMUA staff. Incorporation, Membership and Other Information For the purposes of conducting its business, EEMUA is incorporated in England and Wales as a company, limited by guarantee, not having share capita

10、l. All usual aspects of company management and business administration are dealt with by the EEMUA executive directors, including policy implementation and leadership of the executive team (the staff). A list of EEMUA publications for sale is given at the end of this Publication. The full list is al

11、so on the Associations website, including details of on-line shopping facilities. To enquire about corporate Membership, write to enquirieseemua.org or call +44 (0)20 7488 0801. EEMUA Publication 187 Analyser systems: a guide to maintenance management EEMUA v ABOUT THIS PUBLICATION Legal Aspects All

12、 rights, title and interest in this Publication belong to EEMUA. All rights are reserved. No part of this Publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means: electronic, mechanical, photocopying, recording or other, without the express prior writt

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14、hose parts of its contents appropriate to the intended application; and that such selection and application is correctly carried out by appropriately qualified and competent persons for whose guidance this Publication has been prepared. EEMUA and the individual members of the Work Group that prepare

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16、amage or loss resulting from the use or reliance on this Publication. Any recommendations contained herein are based on the most authoritative information available at the time of writing and on current good engineering practice, but it is essential for the user to take account of pertinent subseque

17、nt developments and/or legislation. Any person who encounters an inaccuracy or ambiguity when making use of this Publication is asked to notify EEMUA without delay so that the matter may be investigated and appropriate action taken. Consultation and Feedback EEMUA encourages constructive comments on

18、 this Publication from both Members of the Association and others. Comments should be sent on the standard feedback form, a copy of which is provided towards the end of this Publication. An electronic version of the feedback form is available from EEMUA - e-mail your request for a copy to enquiriese

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20、 editions are publicised on the EEMUA website. EEMUA Publication 187 Analyser systems: a guide to maintenance management EEMUA vi EEMUA Publication 187 Analyser systems: a guide to maintenance management EEMUA vii Contents Preface ix 1. Introduction 1 1.1 Purpose of this Publication . 1 1.2 Question

21、s to be addressed . 1 2. Definitions . 5 3. Classifying analysers using a risk based approach 9 3.1 Safety protection 11 3.2 Environmental protection . 11 3.3 Asset protection 13 3.4 Profit maximisation . 13 3.5 Performance target . 14 3.6 Maintenance priority 15 3.7 Support priority 15 4. Maintenan

22、ce strategies . 17 4.1 Introduction . 17 4.2 Reliability Centred Maintenance (RCM) 17 4.2.1 Reactive maintenance 17 4.2.2 Preventative or Planned Maintenance (PM) 18 4.2.3 Condition based strategy 18 4.2.4 Proactive maintenance . 19 4.2.5 Optimising maintenance strategy . 19 4.3 Management systems/o

23、rganisation . 20 4.4 Training/competency . 22 4.4.1 Training needs 22 4.4.2 Selecting trainees 22 4.4.3 Types of training . 23 4.4.4 Vendor training . 23 4.4.5 Classroom training . 23 4.4.6 Technical societies . 23 4.4.7 User training . 24 4.4.8 Retraining . 25 4.5 Optimal resourcing 25 4.5.1 Equiva

24、lent Analyser per Technician (EQAT) calculation method 25 4.5.2 Ideal number of technicians 26 4.5.3 In-house or contracted out maintenance. 27 4.5.4 Off-site technical support requirement 28 4.6 Best practice benchmarking . 28 4.7 Annual analyser Key Performance Indicator (KPI) review . 28 5. Analy

25、ser performance monitoring . 31 5.1 Introduction . 31 5.2 Recording failures - reason/history codes . 31 5.2.1 Typical failure pattern 32 5.3 SPC/proof checking . 34 5.3.1 Analyser control charting 34 5.3.2 Control chart uncertainty limits . 36 5.4 Analyser performance indicators . 37 5.4.1 Key Perf

26、ormance Indicators (KPI) 37 5.4.2 Additional analyser performance indicators . 38 5.4.3 Points to consider in measurement of analyser availability 40 5.4.4 Points to consider in measurement of operator utilisation . 42 5.4.5 Points to consider in measurement of analyser benefit value . 42 5.4.6 Deri

27、ving availability, utilisation and benefit measurement . 43 EEMUA Publication 187 Analyser systems: a guide to maintenance management EEMUA viii 5.4.7 Optimising analyser performance targets 44 5.4.8 Analyser maintenance cost against benefit 48 5.5 Analyser performance reporting 49 Appendix 1. Equiv

28、alent Analyser per Technician (EQAT) . 51 Part 1 Calculated technician number worksheet 51 Part 2 Equivalent analyser inventory worksheet calculation methodology 52 Part 3 Equivalent analyser inventory worksheet . 53 Appendix 2. Example interpretation of control chart readings 59 Appendix 3. Determi

29、nation of control chart limits by measuring standard deviations of differences . 61 Appendix 4. Adopting a maintenance strategy 63 Appendix 5. Example of analyser maintenance cost against benefit 65 Appendix 6. Typical results of analyser performance 69 References and Bibliography . 71 Figures Figur

30、e 1 Interrelationships of subject matter in this Publication . ix Figure 2 Generalized risk graph 9 Figure 3 Failure mode pattern . 19 Figure 4 Organisation of analyser functions 21 Figure 5 Relative maintenance costs . 27 Figure 6 Life cycle diagram . 33 Figure 7 Reliability centred maintenance fai

31、lure patterns . 33 Figure 8 Control charting diagram . 35 Figure 9 Examples of analyser results . 36 Figure 10 Example of control charting with linear interpretation 41 Figure 11 Deriving availability, utilisation and benefit measurement 43 Tables Table 1 Typical application of elements in the risk

32、graph 10 Table 2 Best practice availability targets . 15 EEMUA Publication 187 Analyser systems: a guide to maintenance management EEMUA ix Preface EEMUA 187 is a publication designed to define the best practices in the maintenance of on-line analysers. Analysers are used in industry to measure vari

33、ables which significantly contribute to safety, environmental, asset protection and profit maximisation. Maintenance organisation, prioritising of maintenance effort, maintenance methods, correct resourcing, performance monitoring and reporting all play an important role in successful application of

34、 on-line analysers. The ultimate effectiveness of the contribution of on-line analysers is measured by the ability to perform their functional requirements upon demand. This Publication gives guidance on performance target setting, strategies to improve reliability, methods to measure effective perf

35、ormance, and the organisations, resources and systems that need to be in place to allow this to occur. The various subjects covered in this Publication are discrete items and can appear unrelated in the overall scheme of analyser maintenance procedures and strategies. The following flow path in Figu

36、re 1 ties the Chapters together in a logical sequence of approach. Figure 1 Flow path detailing interrelationships of subject matter in EEMUA Publication 187 This Publication provides a mechanism by which the criticality of an analyser can be determined by means of a risk assessment. The risk assess

37、ment is based on consideration of the consequence of the loss of the analysis to the operation of a EEMUA Publication 187 Analyser systems: a guide to maintenance management EEMUA x process unit, or group of process units, personnel/plant safety and the environment. Determination of a criticality ra

38、ting for the analyser allows target values for reliability to be set for each criticality classification and prioritisation for maintenance and support. Such approaches are covered in Chapter 3. A numbers strategy designed to allow the target reliabilities calculated by the risk assessments to be me

39、t are defined in Chapter 4. Finally, mechanisms for tracking analyser performance and quantifying the performance as meaningful measures are presented in Chapter 5. EEMUA Publication 187 Analyser systems: a guide to maintenance management EEMUA 1 1. Introduction 1.1 Purpose of this Publication This

40、Publication is written with the intention of providing an understanding of analyser maintenance to individuals from a non-engineering background. It is also designed as a reference source to individuals more closely involved with maintenance of analytical instrumentation, and provides guidance on pe

41、rformance target setting, strategies to improve reliability, methods to measure effective performance, and the organisations, resources and systems that need to be in place to allow this to occur. Effective management of on-line analysers is only possible when key criteria have been identified and t

42、ools for measuring these criteria established. On-line analysers are used in industry for the following reasons: Safety and environmental. One category of on-line analyser is those used to control and monitor safety and environmental systems. The key measured parameter for this category of analyser

43、is on-line time. This is essentially simpler to measure than an analysers contribution to profits but as with process analysers applied for profit maximisation, the contribution will be dependent upon ability to perform its functional requirements on demand. Asset protection and profit maximisation.

44、 On-line analysers falling into this category are normally those impacting directly on process control. They may impact directly on protection of assets (e.g. corrosion, catalyst contamination, etc.) or product quality, or may be used to optimise the operation of the process (e.g. energy efficiency)

45、. For this category of analysers, the key measured parameter is either the cost of damage to plant or the direct effect on overall profit of the process unit. Justification as to whether an analyser should be installed on the process may be sought by quantifying the payback time of the analyser, the

46、 pass/fail target typically being 18 months. It should be noted that the contribution of the analyser to reduction in extent of damage to, or the profit of, the process unit is difficult to measure. However, this contribution will be dependent upon the analysers ability to perform its functional req

47、uirements upon demand. This Publication focuses on the cost/benefits associated with traditional analyser maintenance organisations. Due to the complexity of modern analysers, support may be required from laboratory or product quality specialists, e.g. for chemometric models, who may work for other

48、parts of the organisation. Their costs also need to be included in the overall maintenance cost. 1.2 Questions to be addressed When considering on-line analyser systems and their maintenance the following key points list is useful in helping decide where gaps exist in the maintenance strategy. . EEM

49、UA Publication 187 Analyser systems: a guide to maintenance management EEMUA 2 What is the uptime of each critical analyser? Do you measure uptime and maintain records? Do you know the value provided by each analyser and therefore which ones are critical? Do you meet regularly with operations (the customer) to review priorities? What is the value delivered by each analyser in terms of process performance improvement (i.e. improved yield values, improved quality, improved manufacturing cycle time and/or p