Maintenance Organization and Control for Multi-Plant Corporations 35

ing modes of operation, which lends itself to computerized solu-

tions to determine minimum operating costs. Thus, the centralized
corporate computer can be economically used on a network of
plants whereas each plant on its own basis could not provide a pay-
out for process computer monitoring. This upto-date process mon-
itoring and reporting allows for prompt management attention to
plant problems.
4. Monitoring of machinery and equipment performance. An example
would be the periodic collection of data on all large compression
equipment to determine stage efficiencies and intercooler perfor-
mance since utility costs represent a significant portion of the total
operating costs in most petrochemical or air separation plants.
Where possible, the performance evaluations are translated into
dollars so that business decisions can be made. Figure 2-7 shows a
simplified computer program used for evaluating compressor effi-
ciencies where the results are translated into cost inefficiencies in
dollars/day. Of particular interest, also, is the increased use of field
monitoring methods as a key element in evaluating equipment per-
formance. In many cases, this represents the actual guidelines for
determining frequency of inspections.
5. Monitoring of plant and equipment performance by regular visits of
process and mechanical specialists to the facilities. This provides
the necessary final tie of the centralized group with plant personnel.
6. Establishing safety, technical, and operating procedures to provide
conformity to all plants.
7. The organization of corporate technical and training sessions for
plant personnel based on the management evaluation of need.

Summary

The system of plant maintenance and engineering services outlined has

been successful in achieving exceptionally low maintenance costs for a
nationwide complex of plants.
The initial operating period of the preventive maintenance system had
unusual problems as any new system might, but it has now reached the
point where all plants are near 100 percent compliance. The overall
maintenance system described herein has allowed a steady reduction in
plant personnel with corresponding savings. Actual maintenance costs
have steadily decreased as a percentage of original investment costs with-
out any allowance for labor and material escalation. With these factors
taken into account, the total maintenance cost reductions are indeed sig-
nificant. With the system in existence, the effect on future costs should
continue in a favorable direction.