Maintenance management review in the safety management system of a major hazard plant

Abstract

The paper presents a case study: the review of the maintenance management system realized in a major hazard plant. The review verified the actual application of the management system and assessed the system implementation as regard the real needs of the plant itself. In fact, only an application closed to the plant requirements can allow law observance, management optimization and economic results as well. In particular, the management system was valued taking into account its design and its implementation. The analysis was carried out in a chemical plant and the study was realized in the following three steps: 1) Conducted a preliminary system review on the basis of an RCM (Reliability Centered Maintenance) model; 2) Conducted a sample data collection effort concerning a Computerized Maintenance Management System (CMMS), using by interviewing personnel and reviewing information contained in safety and management reports; 3)Analyzed data in order to identify data issues within the maintenance management system and to evaluate possible maintenance policies. The study prepared three main findings which will be implemented into the plant system. To date, (1) the plant reliability analyses have been integrated by data obtained both from database and interviews, and according to the upgrading operations carried on the original system during the years; (2) a new equipment and component codification have been proposed in order to identify univocally the components of the plant; and (3) new possible maintenance policies have been identified in order to reduce costs and new possible economic investments have been evaluated