Network Analysis as an effective maintenance planning tool, using Warri Refinery as a case study

ABSTRACT

This

research project “Network Analysis as an effective maintenance planning tool”

created a detailed evaluation of strategies and techniques for planning

maintenance activities in the Nigerian process industry, laying focused

emphasis on operations of Warri Refinery and the effectiveness of CPM Network

analysis. A review of previous works related to maintenance planning was

extensively undertaken and findings revealed the extent in which planning

activities has been carried out in the oil and gas downstream sector. The analysis

of related literatures showed that wrench time and equipment reliability were

not considered by previous researchers. Field studies were then carried out to

ascertain how these maintenance indices have been affected by CPM network

planning. With the use of frequency tables, percentages, standard deviation and

simple regression, data collected were analyzed accordingly. Results deduced

from regression analysis and the simple t-test showed that CPM Network tool is

effective in maintenance forecasting and equipment reliability at 5% level of

significance. These analyses identified with great precision, the need for

stakeholders in the process industry to fully inculcate project management and

network planning tools into maintenance operations. Recommendations on

integrating CPM Network tool and SAP ERP for effective maintenance planning was

proffered. The study was concluded by inferring that innovative use of Network

planning tools for maintenance activities would spur rapid growth and development

of the Nigerian oil and gas downstream sector. Further studies on applying

Network Techniques to aspects of maintenance such as Turnaround Maintenance

(TAM), in Reliability Centered Maintenance (RCM) and Capacity Planning were

suggested.

TABLE

OF CONTENTS

Title

Page - - - - - - - - - i

Certification

- - - - - - - - ii

Dedication

- - - - - - - - - iii

Acknowledgement

- - - - - - - - iv

Abstract

- - - - - - - - - v

Table

of Contents - - - - - - - - vi

List

of Tables - - - - - - - - ix

List

of Figures - - - - - - - x

CHAPTER

ONE - Introduction

1.1

Background of the Study - - - - - - 1

1.2

Statement of Problem - - - - - - 2

1.3

Aim and Objectives of the Study- - - - - - 3

1.4Research

Questions - - - - - 3

1.5 Statement

of Hypothesis - - - - - - 4

1.6 Significance

of Study - - - - - - 4

1.7

Scope and Limitation of Study - - - - - - - 5

CHAPTER

TWO - Literature Review

2.1

Maintenance Planning Defined - - - - - - - 7

2.1.1

Gantt Chart as a Planning Tool- - - - - - - -

2.1.2

GERT Network Technique - - - - - -

2.1.3

Line of Balance - - - - - - - -

2.2

Historical Background of Network Analysis - - - - - - 8

2.2.1

Critical Path Method (CPM) - - 10

2.2.2

Project Evaluation and Review Technique (PERT) - - - - - 12

2.3

Maintenance Planning and Project Management - - - - - - 16

2.4

Maintenance Planning In the Nigerian Oil and Gas Industry- - - - 17

2.4.1

Preventive Maintenance - - - - - 19

2.4.2

Determining Maintenance Crew Size - - - - 21

2.4.3

Scheduling Maintenance Jobs- - - - - 23

2.4.4

Planning Maintenance Material - - - - 25

2.5

Shutdown Maintenance as an Application of Network Analysis - - - - - 27

2.6

Condition-Based Maintenance and Networked Maintenance Planning - - - - 28

2.7

Current Trend in Networked-Based Maintenance Planning: A Critical Review - - - -

- - -30

2.8

Summary of the Literature Review - - - 32

CHAPTER

THREE - Research Methodology

3.1

Design of the Study - - - - 44

3.2 Methods

of Data Analysis - - - - 44

3.3

Source of Data Collection - - - - - - 44

3.3.1

Primary Source - - - - - - - 45

3.3.1.1

Oral Interview - - - - - - -45

3.3.2

Secondary Source - - - - - - - 45

3.4

The Study Area - - - - 46

3.5

Study Population and Sample Size - - - - - 46

 

CHAPTER

FOUR - Presentation and Analysis of Data

4.1

Demography of Respondents/ Discussions of Findings- - - - - - - 48

4.2 Analysis

and Results Using t-test and Simple Regression- - - - - 48

4.3 CPM

Network Analysis using Practical Maintenance Activities- - - - - - 71

4.4

Summary of Results and Discussions……………………….

CHAPTER

FIVE – Recommendations, Summary and Conclusion

5.1

Recommendations - - - - - - - 73

5.2

Summary and Discussions of Findings

5.3Conclusion--

- - - - - - - 73

5.4

Suggestions for Further Research

References

  Appendix