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Asset Management

Asset Management ensures equipment reliability and capability, in order to meet organizational & operational need. Our Maintenance strategy help our customers to enhance their asset performance and overall productivity.

Our Asset Management objective is to :

  • Prevent breakdown or failures of equipment/process
  • Maximize the reliability & useful life of equipment/system as a whole
  • Maximize the performance & Minimize the breakdown frequency of Equipment
  • Keep equipment safe & prevent from any hazards

RISK BASED INSPECTION

Risk Based Inspection help our customers to reduce risks, improve asset safety and reliability. Our RBI service enables you to balance inspection costs and risk by using appropriate inspection and maintenance planning.

Our Approach:

  • Analyze the likelihood and consequences of failure
  • Comply with Industry Standards
  • Develop a cost-effective inspection and maintenance program
  • Ensure mechanical integrity and reliability
  • Prioritize your inspection and maintenance resources those with highest risk

Our risk based inspection services include:

  • Development of a corrosion management plan
  • Determination of the remaining lifetime of your assets
  • Gap analysis
  • Identification of appropriate inspection intervals
  • Specification of risk ranking level
  • Determination of the risk acceptance level
  • Specification of the necessary inspection and maintenance tasks

RAM Studies

Elixir is pleased to offer Reliability, Availability and Maintainability Studies (RAM studies) to companies requiring an assessment of their system as a way of optimising their system’s operational performance.

RAM Studies are used as a way of assessing a production system’s capabilities, both in operation and those still in the design phase. As facilities and plants are being used for longer period of time, a Reliability, Availability and Maintainability Study is able to provide an assessment into the assets life time capabilities and enable businesses to maximise on their return on investment.

A RAM Study can be shown to be broken up into three separate areas:

  • Reliability Services – Predicting the probability in which a system will not experience an unplanned outage;
  • Availability Services – Predicting the probability in which the system is working in a functioning state when required, including both planned and unplanned outages;
  • Maintainability Services – Predicting the probability in which a product / system can be repaired following a failure within a specific time frame.

With the combination of these three services combines into one study, ESC is able to offer a RAM Study that models the predicted production capabilities of a facility.

The benefits of undertaking a RAM Studies include:

  • A reduction in the maintenance and sparing costs, while maintaining and / or increasing production levels;
  • A decrease in the duration of any unplanned and planned outages;
  • Optimisation on capital investment by reducing the cost of production;
  • Optimisation of capital improvement options at the plant and enterprise levels when improve budgets are constrained;
  • Accurate forecasts of equipment lifecycle costs that reflect the equipment age, duty cycle and maintenance effectiveness;
  • Alignment of maintenance resources based on the criticality of equipment to production revenue.

Elixir has a number of Reliability Consultants that have worked on an extensive range of projects across a number of industries. In choosing Elxiir to conduct your RAM Studies, our specialist RAM Studies Consultants are able to:

  • Produce a RAM Study customised based on the needs and requirements of the client;
  • Identify potential critical pieces of equipment;
  • Identify the equipment that has the highest risk of causing operational failures;
  • Identify possible causes of production losses and examine the possible alternatives to overcome them;
  • Produce Reliability Block Diagrams (RBDs) 
  • Produce a RAM Study based on different system configurations;
  • Produce recommendations on how to improve the system availability;
  • Produce a record of the RAM Study in the form of a formal report, detailing an overview of the RAM Study, including any assumptions made as well as the findings as part of the study.

As well as offering RAM Studies, Cost Benefit Analysis (CBA) is done if needed as part of the RAM Study.

RELIABILITY CENTERED MAINTENANCE

Reliability Centered Maintenance (RCM) is an approach towards asset maintenance that determines how to maintain equipment safely and economically. With RCM technique we identify which scheduled maintenance tasks needs be assigned to equipment and at what frequency. It helps us to employ Preventive Maintenance (PM), Predictive Maintenance and Proactive Maintenance techniques in an integrated manner. This increases the probability that a machine or component will function in the required manner with minimum required maintenance. Hence we understand RCM is a key technique to define maintenance strategy that leads to optimal asset performance.

Our approach towards RCM Implementation:

  • Prepare for the Analysis:

We make sure that all members of the analysis team understand and accept the rules and conditions of the analysis like scope of the analysis, gathering and reviewing relevant documentation, etc.

  •  Select the Equipment to Be Analyzed:

Since RCM analysis requires an investment of time and resources, the organization may wish to focus analysis on selected pieces of equipment. Hence we select the equipment to be analyzed based on standard methods like Selection Questions and Criticality Factors.

  • Identify Functions and Potential Functional Failures:

Our objective for maintenance activities are focused toward preserving equipment functionality. Therefore, we first identify the functions that the equipment is intended to perform. Then Equipment functional descriptions are referred to identify potential functional failures. This may include failure to perform a function, poor performance of a function, over-performance of a function, performing an unintended function, etc.

  • Identify and Evaluate the cause Effects of Failure:

This step helps us to prioritize and choose the appropriate maintenance strategy while addressing a potential failure.

  • Identify Causes of Failure:

The cause of failure represents the specific cause of the functional failure and helps us to apply a maintenance strategy to address the potential failure.

  • Select Maintenance Tasks:

Once we have identified the functions that the equipment is intended to perform, the ways that it might fail to perform, the next step is to define the appropriate maintenance strategy for the equipment. Our RCM analysis team’s decision of which strategy to employ for each potential failure is based on judgment/experience, pre-defined logic diagram, cost comparisons and combination of other important factors.

  • Maintenance Plan:

Once the appropriate schedule maintenance tasks have been identified, the final step is to package them into a workable maintenance plan. This involves majorly scheduling of Preventive maintenance plan effectively and efficiently.

Key techniques used for RCM:

  • RCA; FMEA

This helps our customer achieve:

  • Maximized equipment availability, Equipment Reliability, Increased cost effectiveness, Reduced repairing time
ASSET  DATA MANAGEMENT  . 


Exilir has capability to carryout asset data management for various plant assets and completed many asset management projects for various operating companies within GCC covering the following 

  • New Asset Registration
    • Collect Maintainable tag numbers from engineering drawings. 
    • Preparation of Asset Register and Asset Hierarchy tree 
    • Maintenance Craft Procedure for each itmes as per equipment criticality 
    • Uploading asset data into SAP / Oracle data base. 
  • Physical data Verification
    • Existing asset data verification with respective drawings ( PEFS, SLDs )
    • Physical verification of tags at site
    • Resolve data inconsistencies, correct the data and uploading into system
  • Maintenance Management
    • Identify maintenance activities based on equipment manufacturer recommendations
    • Define Maintenance frequency, including step-by-step instructions 
    • Maintenance Task List
    • Preparation of Maintenance Routing 
    • Preparation of Maintenance Plans 
  • Spare Parts Management
    • Obtain BOM details from Vendors (based on catalogue) in standard format templates / spread sheets 
    • Compile data and check parts along with OEM manual 
    • Review spare parts with part list drawings / BOM for each item 
    • Categorize the spare parts

ROOT-CAUSE FAILURE ANALYSIS

When the equipments does not function as per the specifications or undergoes breakdown, it is very important to identify what is the root cause of the problem. We see it as a critical factor since an accurate root cause failure analysis acts as a key input for the Reliability Centered Maintenance (RCM).

Our Approach towards RCA:

  • Collecting an accurate information and data that helps in detail understanding of the problem
  • Identifies the root cause of the stated problem
  • Developing a feasible solution for the identified problem
  • Analyze & monitor the measures taken to address the problem and verify if it is fully addressed
EQUIPMENT CRITICALITY ANALYSIS

An equipment critical analysis (ECA) is used to determine when equipment needs to be inspected or maintained based on priority. ECA as per criticality rating brings in account, preventive and predictive maintenance that allows planning manager to determine which work orders needs immediate attention and which can be rescheduled for a future. ECA also helps to determine the right quantity of spare parts required at right time.

With appropriate analysis of ECA, we ensure availability of critical equipment with minimum downtime.

Our Approach:

We develop a criticality model that defines the degree of criticality of a particular equipment. Our analysis process takes into account downtime, safety, environmental issues, quality, failure, failure history and other factors related to operational processes.

Steps involved while performing ECA are:

  • Review equipment hierarchy
  • Analyze in-depth, the Risks associated with each equipment Failure
  • Develop the Risk Matrix to be used
FAILURE MODES AND EFFECTS ANALYSIS (FMEA)

Our team of experts follow the rigorous process to identify the reason of failure and deliver the most suitable solution for reliable Asset.

Our Approach towards FMEA Service:

  • Identify components/equipment and associated functions
  • Identify Complete failures; Partial failures; Failures over time
  • Identify Incorrect operation; Premature operation
  • Identify Failure to stop functioning at desired time
  • Identify Failure to function at desired time
  • Identify the effects due to identified failure modes
  • Determine the Severity of the failure
  • Identify the root cause of the failure mode
  • Determine the frequency of failure occurrence
  • Identify controls: Identify the suitable mechanism to prevent the cause of the failure mode to either eliminate or to reduce the failure to minimal
  • Determine the effectiveness of the controls identified
  • Determine the actions to be implemented and its target of application
SHUT DOWN / TURN AROUND OPTIMIZATION

Shut down is a scheduled plant maintenance for an extended period of time. We get into the minute details of the processes & equipments which is difficult to look into during standard operation time. With a well managed STO process, we enhance the safety performance, integrity, reliability, Maintenance cost and efficiency of operations.

Our STO Approach:

  • Shutdown Work Identification:
    • Number of failures
    • Root causes of those failures
    • Maintenance costs associated with those failures
    • HSE issues associated with those failures
  • Shutdown Work Planning:

Planning is done to streamline task allocations, determine job procedures, identify labour requirements and to determine the budgets.

  • Shutdown Work Scheduling:

In scheduling we focus on “just in time” delivery of spare parts, Technical labour and Data availability.

  • Shutdown Maintenance Cost Control:

Shut down Maintenance costs are determined by Maintenance Activities. Actual cost thus calculated is compared to budgeted cost and then the work process are planned accordingly.

  • Historical Maintenance Data Analysis:

The historical data provide us with the equipment’s date of purchase, last maintenance scheduled, history of usage, spares quality & other minute details which helps us to do the analysis for critical works to be accomplished.

  • Shutdown Work Execution:

We make sure that Work Execution is done by our Subject Matter Experts and each minute details are monitored continuously during the complete execution phase of a shutdown.

  • Shutdown Work Difficulty Recording:

We keep a record of all the problems faced during Shutdown work execution for the useful planning of the next shut down.

Elixir Engineering

Elixir Engineering is a multi-disciplinary Engineering services company.
With our strong technical team, we have proven to be effective for our Clients.
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