1,721,022 research outputs found
Optimizing rotating equipment maintenance management in Nigerian refineries
Get PDFThesis (M.Ing. (Development and Management))--North-West University, Potchefstroom Campus, 2009.Nigeria ranks among notable global exporters of crude oil. However, the refineries positioned for providing finished petroleum products have not met this obligation. Plant reliability is a major crisis amidst rising demands for petroleum products. Rotating equipment availability, a critical constituent of a petrochemical plant, is vital to ensuring refinery reliability. The aim of this research is to: 1. Investigate and identify the causes of rotating equipment failures in Nigerian refineries while also identifying shortcomings in the implementation of current maintenance procedures. 2. Propose a procedure to Manage Rotating Equipment Maintenance Strategy (MREMS) in the Nigerian refineries.
3. Develop a new Internal Job Card system for the rotating equipment maintenance departments of the Nigerian refineries. 4. Propose a model Framework and Approach for Training and People Development (FATPD) amongst other recommendations to optimize rotating equipment maintenance management in the Nigerian refineries. The research evolved around a case study of four (4) petrochemical industries. This was embarked upon to present empirical data on rotating equipment maintenance management practices. Also, survey questionnaires and interviews were adopted to complement data gathering. The research presents five (5) core empirical findings. Firstly, minimal maintenance activity takes place outside scheduled turn around maintenance leading to excessive corrective maintenance actions in Nigerian refineries.
Secondly, job card system in the rotating departments of the Nigerian refineries is not efficient. Thirdly, core skill and competence of bottom level maintenance workforce was
discovered to be inadequate. Fourthly, computer maintenance management system or computer support structures to optimize rotating equipment maintenance in Nigerian refineries have little or zero presence. Lastly, rotating equipment maintenance management practices in Sasol proves rewarding with the integration of condition monitoring into maintenance program.
Computer supports have also been vital to achieving commendable equipment availability. Management commitment, driven by customer focus, ensures that plant
reliability is restored on schedule. A procedure to Manage Rotating Equipment Maintenance Strategy (MREMS) was developed for the Nigerian refineries. This is expected to tackle the issue of low availability of rotating equipment maintenance and also assist maintenance
personnel to review or evolve a more specific equipment maintenance strategy based on reliability-centred maintenance principle of condition-based maintenance. A new Internal Job card is also presented in this dissertation. It would also serve to support the MREMS procedure. The proposed Framework and Approach for Training and People Development (FATDP) have a huge potential to address skills and competency deficiencies, particularly, for bottom level maintenance personnel at the Nigerian refineries. Recommendations on the adoption and implementation of MREMS procedure, Internal Job card and FATDP were also presented in this dissertation.Master
Model-based fault diagnosis framework for effective predictive maintenance
Get PDFThesis (M.Ing. (Development and Management))--North-West University, Potchefstroom Campus, 2011.Predictive maintenance is a proactive maintenance strategy that is aimed at preventing the unexpected failure of equipment through condition monitoring of the health and performance of the equipment. Incessant equipment outage resulting in low availability of production facilities is a major issue in the Nigerian manufacturing environment. Improving equipment availability in Nigeria industry through institution of a full featured predictive maintenance has been suggested by many authors. The key to instituting a full-featured predictive maintenance is condition monitoring. Primarily, this research is focused on how to reduce the prevalent of equipment downtime in the Nigerian manufacturing industry, through the application of Model Based Fault Diagnosis technology as a condition monitoring tool for enhancing predictive maintenance practices in Nigerian manufacturing industry. The following objectives underscore the aim of this research work: * To assess the implementation and performance of predictive maintenance practices in some selected manufacturing companies in Nigeria and verify if there is need for improvement in these practices. * To identify the challenges and barriers to the implementation and performance of full-featured predictive maintenance practice in the Nigerian manufacturing industry. * To develop a framework for enhancing quality of Predictive Maintenance practices in the manufacturing industry in Nigeria through a Model Based Fault Diagnosis and Decision Support System. * To validate that the developed framework meets the Nigerian manufacturing industry needs through the implementation of a prototype in one of the selected manufacturing companies in the case study. The empirical investigation undertaken as part of this research revolves around five (5) of the Nigerian manufacturing companies. Personal interviews were also adopted as means of data collection. The research outcomes reveal the followings: * Top management commitment to the implementation of predictive maintenance strategies in the Nigerian manufacturing industry is inadequate. * Many of the manufacturing companies lack a tool for carrying out continuous condition monitoring in their predictive maintenance program. This is responsible for poor performance of most predictive maintenance programs in Nigerian manufacturing industry. * Inadequate training on the implementation of predictive maintenance principles is adversely affecting the proficiency of personnel in adopting philosophy that underlies practices of predictive maintenance. * The size of equipment part inventory, maintenance work backlog and machine scraps are also enormous in the maintenance yards of the companies.
* Nevertheless, the implementation of predictive maintenance program has a positive impact on the equipment availability of one of the case studies. Management commitment in Chemical and Allied Products (CAP) Plc is outstanding. Application of intelligent condition monitoring system, and personnel training and competence are vital to the success of Predictive Maintenance implementation in CAP Plc. The specific deliverable from this research is a proposed framework (MBFDF) for effective implementation of predictive maintenance strategy through application of model based fault diagnosis technology, which can be adopted to improve performance of predictive maintenance practices in the Nigerian manufacturing industry. The deliverable also includes a soft copy of data in Excel spreadsheet obtained during experimental test of the proposed framework in a small manufacturing company in Nigeria. In this research, a model based fault diagnosis framework (MBFDF) to serve as a condition monitoring and decision support tool for predictive maintenance programs in Nigerian manufacturing industry was developed. Implementation to verify the real-life implementability and effectiveness of the proposed framework was performed in one of the companies used for the case study. A comparison of results with pre-integration predictive maintenance program is presented, showing the implementability and the effectiveness of the proposed MBFDF for condition monitoring in predictive maintenance programs in the Nigerian manufacturing company. Recommendations presented in this dissertation are also vital to the success of implementing predictive maintenance program in Nigerian manufacturing companies.Master
Document management system in owner companies during project execution
No full textThesis (M.Ing. (Development and Management Engineering))--North-West University, Potchefstroom Campus, 2010.Owner companies should consider all elements of Document Management during a project’s life cycle, identify shortcomings and address them successfully to ensure successful completion of projects and ultimately to also ensure legal compliance as stipulated by contractual agreements. Proper governance during the execution of projects involves, amongst others, the establishment of structures and processes, with appropriate checks and balances built into these structures and processes, to enable all stakeholders to be in a position to have access to relevant documentation. Executing projects makes a huge demand on the flow and management of project related documentation through the different phases of these projects. The research, as documented in this dissertation, investigates and evaluates whether Sasol Technology, as the project execution agent for the Sasol Business Units, has efficient governing Document Management processes and procedures in place to support the successful execution of capital projects. Sasol Technology uses a stage gate model, associated with project life cycles, as a systematic approach for the execution of capital projects. Document Management is a new business function that was established in 2008. Not all the functions involved in the life cycle of project execution are fully aligned with the central function managing documentation. There is thus a need for a fully integrated Document Management System, involving all the functions of Sasol which are involved during the different phases of project execution. The literature study analyses existing world best document management and records management practices and procedures and points out that meticulous and strict document and records management practices form the backbone of organisational authentic evidence compliance. The research design method that was chosen to authenticate the research question is an Exploratory Qualitative Approach, combined with a Descriptive Approach. Results are obtained from a combination of three methods. Published and available existing data of how documents are managed in Sasol was gathered and secondary findings are established. Focused and structured interviews were then conducted with experienced team members from the different functions involved in project execution and lastly, e-mail administrated questionnaires were developed and distributed to relevant project team members within Sasol Technology to assess the current system and to determine additional requirements for an enhanced Document Management System, specifically applicable to owner companies in the project execution environment. Whereas the scrutiny of the secondary sources provides a background and the progress made with regard to setting requirements for a standardised Document Management System for the execution of projects in the Sasol Technology and some of the other Sasol Business Units, the primary data findings indicate how the project team members perceive the existing Sasol Technology Document Management System to be. Key findings include, that documentation life cycle management is not fully developed and needs to be addressed in the Sasol Technology project execution environment. Furthermore, integration of the documentation management of the various departments, functions and structures in Sasol will enable better and improved management of project documentation. The specific output of this dissertation is the recommendation of an improved Document Management System to allow the different functions within Sasol Technology and some other Sasol Business Units to have access to an integrated system, included in it all relevant documentation requirements during the life cycle of projects. An added deliverable is a framework of requirements to be included in a document management philosophy, not only for Sasol, but also for other owner companies during project execution.Master
Recommendation on a suitable desalination process for the South African environment
Get PDFThesis (M.Ing. (Development and Management))--North-West University, Potchefstroom Campus, 2010.Supplies of potable water from traditional sources have been increasingly depleted due to increasing world population and per capita water use. In South Africa fresh water is a vital, but scarce resource, distributed unevenly in time (frequent droughts alternate with periods of good rainfall) and space (the eastern half of the country is markedly wetter than the western half). Increasing demand for water, and decreased water quality, make careful water management a priority. Water use in South Africa is dominated by irrigation, which accounts for around 60 per cent of all water used in the country. Domestic and urban use accounts for about 30 per cent, while mining, large industries and power generation account for some 7 per cent. Commercial forestry plantations account for a little less than 4 per cent of total use by reducing runoff into rivers and streams (DWAF).
Desalination of sea water is a promising technology available for the provision of fresh water to the arid regions of South Africa. However, as the technology develops, there is a need for the adequate customization of its technological processes to suite particular geographical regions.
This research work is focused on the determination of an adequate desalination process by the use of a decision tree. The research will explore in qualitative format, the different types of desalination processes available, their pros and cons as well as discuss the factors affecting the selection of desalination processes.Master
A structured approach for the reduction of mean time to repair of blast furnace D, ArcelorMittal, South Africa, Vanderbijlpark
Get PDFThesis (M.Ing. (Development and Management Engineering))--North-West University, Potchefstroom Campus, 2012.Organizations are expected by their shareholders to continually deliver above
industry returns on capital invested and to remain competitive in the industry of choice through productivity, safety and quality. The maintenance function is a key area in which competitiveness through efficiencies and world–class performance can be attained by focusing on the prevention and reduction of long and costly equipment repair times. The question is: how can the mean time to repair of equipment already installed in the plant be reduced? To answer the above question correctly and comprehensively, the research explored mixed methods in finding answers. Quantitative methodology using a survey was used for data collection. Observations and interviews were held with maintenance
personnel to uncover information that couldn’t have been obtained by means of a
survey. The survey was limited to equipment performance measures, human factors,
environmental factors, planning, spare parts, maintainability, procedures and training. To test consistency and accuracy of representation of the total population
under study, a reliability test was done by using Cronbach’s alpha coefficient. To
determine whether there are any differences between groups, an ANOVA test was used. Cohen’s d–value was used to determine practically significant differences between one set of data with another and correlation analysis was used to determine the relationships between the variables. The approach designed and delivered by this research flowed from the existing body
of knowledge, case studies and survey findings. The approach adopts some of the
elements of the failure mode and effects analysis (FMEA) procedure and differs from
other work that has been done by others by taking into account the competency and
experience of maintenance personnel and assigning to them factors which are used
to compute anew MTTR of the equipment. The cost of implementing the recommended corrective actions for realising the new MTTR is determined and evaluated against an improved equipment availability that will be achieved as a result of the recommended corrective actions assuming that the failure rate of the equipment remains constant. This evaluation step imbedded within the approach is valuable for the maintenance function and management for decision making in ensuring that resources at the organization’s disposal are used productively. Validation and test results of the approach showed that the MTTR of equipment installed in the plant can be reduced. The results also indicated that through the use of the designed approach a regular pattern of repair or replacement times can be followed well in advance and that it is practical, user friendly and it also delivers on its objective of offering a structure for analysis and decision making aimed at reducing the MTTR. Included with this dissertation is feedback information that can be included in a maintenance job card feedback section to capture information about factors that can be improved to lower the MTTR as part of a continuous improvement process. Included also is a spare part development and management procedure that can be used by the maintenance function. Recommendations on training of maintenance personnel on the maintainability of equipment, the FMEA procedure and maintenance procedures are highlighted. Information that flowed from this approach will be valuable for continuous plant performance improvement and during the design, installation and operation stages of a blast furnace.Master
Maintenance improvement in the petrochemical industry
Get PDFThesis (M.Ing. (Development and Management Engineering))--North-West University, Potchefstroom Campus, 2011.Technology is the answer to most of our human needs but every technology is often
accompanied by other challenges which often lead to the evolvement of another technology. One of the technologies that have greatly impacted our world is that of energy development out of which the petro–chemical industry is an important one. The petro–chemical industry remains the main energy hub for our world today through ranges of products coming from its ambit but not without its own challenges too. One of which is the issue of breakdown or shut down which always require maintenance. Shutdown, many a times, may be planned (annual, quarterly, condition–based, time–based, preventive and so on) or unplanned (run–to–failure). In any case, maintenance personnel (mechanical, electrical and instrument) must perform their duties to fix it. In the process of fixing the equipment several factors affect the effectiveness
of the personnel. To improve maintenance activities, factors affecting its effectiveness should be addressed. Some of the factors that are already been considered are; Overall Equipment Effectiveness(OEE), Precision maintenance, Maintainability, Computerized Maintenance Management System (CMMS), Work Order management, Equipment, Logistics, Process optimization, Supply chain management, Maintenance strategies, Continuous Improvement Hours and so on. (Taylor, 2000; Siemens.com, 2010). Of those factors, many people hardly think of ergonomics as a factor of reckoning with
maintenance activities. Ergonomics is mostly thought of in relation to operators and office
workers. According to National Institute for Occupational Safety and Health in U.S.A (2009), ergonomic injuries are the most common cause of workplace illness and injury in the United States. Back injuries and cumulative trauma disorders (CTDs) such as carpal tunnel syndrome, tendinitis, bursitis and epicondylitis form the majority of non–fatal occupational injuries and illnesses, costing employers more than 12 billion dollars per year in lost work time, workers compensation payments and medical expenses. Of the cost implication of ergonomics ailment reported above, how much of it is related to maintenance activities? Is there any relationship between maintenance activities andergonomics? In what direction is the relationship? positive or negative? How much is the impact in either direction? If it is negative, how can we mitigate it? Finally, what are the benefits, if any? These are some of the vital questions this dissertation is set to answer in relation to: physical, somatic, medical, overhead cost, production down–time and personnel morale. To achieve the afore–mentioned, several research instruments were employed which include; case studies, questionnaires, physical observations, interviews, literature reviews, internet resources, journals and other sources (industry experts and professionals). Relevant keywords and concepts were thoroughly researched in the literature review which serves as a base for the dissertation. Two hundred technical personnel (maintenance) serve as the population sample and questionnaires were administered to them. Technical personnel with appreciable number of years of experience occupying managerial positions were also interviewed. The outcomes of
all the interviews, observations and questionnaires were analysed and interpreted accordingly to verify how ergonomics impact maintenance. This dissertation based on findings, was able to establish that ergonomics impact the activities of maintenance personnel culminated in proposing an E4M (Ergonomics for Maintenance) assessor. The assessor alongside utilization guidelines and a training matrix will help to effectively mitigate the impact of ergonomics on maintenance activities. There is room for
further development of the tool into a computer based package for real–time assessment and mitigation. The assessor and its instruments cannot work alone without the commitment of stake–holders
in the industry. That is why ecommendations were included for effective application of the tool. The dissertation did not overlook the good works the industry has been doing in the area of creating awareness about repetitive stress injuries among its workforce but only complement
its efforts in areas they might not look into. That is in a bid to improve the effectiveness of its workforce which will directly increase productivity, profit and stakeholders confidence. On the other hand, it will reduce their indirect losses through; production down–time, medical cost and over–head costs. However, the application of the E4M assessor is not limited to the petro–chemical industry only but finds its applicability in other industries like; manufacturing, aviation, automobile and any other field where maintenance activities take place particularly in third world countries.Master
Management model to optimise the use of reverse osmosis brine to backwash ultra–filtration systems at Medupi power station
Get PDFMIng (Development and Management Engineering), North-West University, Potchefstroom Campus, 2014According to the Department of Water Affairs (DWAF, 2004 p.15), South Africa’s water resources are scarce and extremely limited and much of this precious resource is utilised and consumed in our industries. Treatment and re-use of effluent generated is, in some cases,
preferred over use of alternate water resources (Du Plessis, 2008 p.3). The volume of effluent generated in treatment processes like ultra-filtration (UF) and reverse osmosis (RO) units is determined by the feed water quality, with high water loss through effluent generation at poor feed water quality. Current UF and RO applications require an increased UF
production capacity due to the use of UF filtrate for periodic backwashing of the UF membrane units. This results in loss of water and decreases overall recovery. The need therefore exists to increase the overall recovery of product water from the raw water stream by reducing the amount of effluent generated. This would be possible to achieve by using RO brine to backwash the UF unit. The study was conducted to provide a modelling tool, assisting management to optimise the
use of RO brine as backwash water on the UF system at the Medupi power station. The secondary objective of this study was the development of a modelling tool that can be used for other projects, new or existing, as a measure and indication of the usability of RO brine as backwash water on UF systems. By successfully applying this newly developed model, the viability of utilising the RO brine as backwash water for the UF was investigated. This modification would lead to utilizing smaller UF units than previously envisioned, which in turn leads to reducing capital cost with 11.07% and
operating expenditure with 9.98% at the Medupi power station. This also has a positive environmental impact by reducing the amount of raw water used monthly by 10.34% (108 000 m3/month).Master
Mitigating risks associated with Lockout/Tagout (LOTO) of hazardous energy in Nigeria : a tracker approach
Get PDFThesis (MIng (Development and Management Engineering))--North-West University, Potchefstroom Campus, 2013.The main objective of the study was to determine the risk(s) associated with lockout/tagout of hazardous energy and propose a new LOTO procedure which tracks the implementation of LOTO to mitigate against identified risks as a basis for promotion of safety. The study focuses on electrical personnel working in PHCN. Only electrical accident risks are examined, not other types of risk e.g. mechanical, chemical, and nuclear. To gather material for this study, a questionnaire was distributed amongst electrical workers in PHCN and their supervisors were interviewed. Relevant literature and publications were studied as reference. According to electrical personnel experience, electrocution, arc flash, arc blast, burns and lockout and tagout of the wrong electrical circuit are seen as the biggest electrical safety risk with regards to LOTO of hazardous energy. The research reveals new information about electrical accident risks. This information is used to create a procedure for tracking LOTO of hazardous energy. The procedure can be utilized in the mitigation of electrical risks and promotion of electrical safety.Master
Flame treatment of polypropylene plastics within AK Stone Guards
Get PDFThesis (M.Ing. (Development and Management Engineering))--North-West University, Potchefstroom Campus, 2009.Flame treatment of polypropylene is a polarization process which improves the adhesion qualities of the substrate (Kostyk, 2000). Flame treatment is known as a "Pre-Treatment" process and is widely used in industry to promote adhesion before the application of a wide range of processes. Processes such as gluing, painting, lamination and printing are all preceded by a flame treatment process (Eckert, 2004).
The flame treatment process is achieved using a gas burner, normally burning liquid propane gas, which is fired directly onto the surface to be treated (Sabreen, 2005). The flame is passed over the surface at a distance and speed so as to treat the entire surface and not burn the substrate. Chemical changes occur in the substrate however these changes do not penetrate very deep into the substrate (Cain, 2000).
It is important to remember this is a scientific process and the variables speed, distance and temperature of the flame must be controlled with a certain amount of accuracy. The purpose of this research is to determine the ideal conditions which result in the optimum adhesion between the substrate and the proceeding processes. Once the ideal conditions have been determined the research will continue to find the lower limits to gain adequate adhesion thereby tailoring the process for high volume production.Master
A new maintenance strategy for Power Holding Company Nigeria to contest the current power demand problem
Get PDFThesis (M.Ing. (Development and Management Engineering))--North-West University, Potchefstroom Campus, 2009.Power Holding Company of Nigeria (PHCN), responsible for generating, transmitting and distributing electricity in Nigeria is being faced with an apparent huge maintenance problem which seemingly contributes greatly to the power demand problem of the country. This apparent maintenance problem is investigated by surveying its root causes through interviews, questionnaires and data gathered from selected case studies. Questionnaires were used scientifically with a confidence level of 95% and interval of +-5% and +-4.4% to establish a high level of integrity on data gathered. Findings and deliverables are compared to South Africa’s power utility company Eskom for validation of the final deliverable. With the findings of this survey, the research problem was overcome by developing a new maintenance strategy and work authorization system for the company while making some recommendations on the training being given to its maintenance personnel. The New strategy called ‘Utility Availability Centered Maintenance Strategy’ or UACMS is presented in the form of a flow chart/ block diagram with its different
sections fully explained. It mainly combines preventative, predictive and corrective maintenance strategies alongside other modern maintenance techniques. It’s all linked to a computer database support to ensure high effectiveness. Furthermore, the work authorization system called ‘Internal Task Authorization form’ serves to ensure responsibility in task execution within the
company. During the course of this research, an excessive application of corrective
maintenance strategy, lack of root cause analysis and unavailability of computer
based applications were discovered in PHCN.Master
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