Effective Maintenance Management, Second Edition

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Effective Maintenance Management, Second Edition

Effective Maintenance Management, Second Edition

Vee Narayan


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Thoroughly updated, the second edition of Effective Maintenance Management provides clear rationale and comprehensive procedures for maintenance in industry. Author Vee Narayan has given us a unique guide, written in clear prose that practicing maintenance engineers, supervisors and managers can easily absorb, digest and apply.

Effective Maintenance Management delivers 12 chapters in 300 pages in this hardcover volume. Narayan examines the role of maintenance as a methodology for  minimizing risk related to safety and environmental concerns in industry. Also examined is adverse publicity from maintenance-preventable accidents, loss of profitability and maintenance-centric tools for risk reduction. The author employs specific situational descriptions to help readers select those tools as they fit the need.


In industry, gaps can appear between industrial engineering for production, reliability and plant maintenance. Effective Maintenance Management works to bridge those gaps via effective management of the maintenance function. The result enables production-oriented businesses to maximize assets while achieving safety and profitability.



  • Provides a risk reduction model which links maintenance to specific risks
  • Enables readers to establish the critical link between maintenance on one hand and safety, profitability, and asset life on the other
  • Examines risks faced during the life cycle of a process plant
  • Discusses expensive plant shutdowns, a high cost, high downtime maintenance activity
  • Provides an in-depth look at qualitative and quantitative risks
  • Includes a table of codes that can be used directly or adapted for use in most maintenance management systems
  • Keeps mathematics to a minimum
  • Includes chapter previews and summaries, a list of acronyms, and a glossary of terms.

Effective Maintenance Management, Second Edition

By Vee Narayan


Vee Naranyan photoVee Narayan is a leading authority on maintenance and reliability engineering. He is an experienced maintenance manager with a successful track record in a variety of industries including engineering, petroleum refining, pharmaceutical, liquefied natural gas production and oil & gas exploration and production. He has worked in several countries and cultures, including India, Malaysia, Saudi Arabia, the Netherlands and the United Kingdom.


He led Shell’s Centre of Excellence in Maintenance and Reliability and represented Shell in a Joint Industry Project (OREDAzzz). For eight years, he led the Maintenance Strategy group in Shell’s Exploration & Production Company in Aberdeen.


Vee is a successful trainer over a period of 14 years in specialist areas such as Reliability Centred Maintenance, Root Cause Analysis and other maintenance management subjects. He is a visiting lecturer in the MSc course in Asset Management, Robert Gordon University, Aberdeen, UK, and an Associate Fellow of the MIRCE Akademy, Exeter, UK. In addition to authoring Effective Maintenance Management – Risk and Reliability Strategies for Optimizing Performance, his second second book for Industrial press is 100 Years of Maintenance and Reliability: Practical Lessons from Three Lifetimes at Process Plants.

Effective Maintenance Management, Second Edition

By Vee Narayan



Dr. Jezdimir Knezevic, MIRCE Akademy

Some years ago, I met the author at an international conference in Exeter. Over lunch, he outlined some of his ideas on risk management and system effectiveness —with a fork and a couple of knives as props. I found his approach refreshing, different, and worth pursuing. These were largely in line with my own views on System Operational Success, so I encouraged him to write this book.


As the author had many years of experience in the maintenance of refineries, gas plants, and offshore platforms, as well as engineering and pharmaceutical plants, I thought that the blend of theory and practice would be useful. The relevance of theory is brought home with a number of illustrative examples from industrial situations, so I feel my point is well made. His approach to maintenance is holistic and as such it could be applied to situations involving financial risk, public health or the maintenance of law and order.


He explains the raison d’être of maintenance; this should help maintenance managers justify their efforts rationally. The discussion on risk perceptions and why they are important may strike a chord with many of us. Knowing what tools to use and where to apply them is important as also how to manage data effectively.


The book will help maintenance managers, planners, and supervisors, as well as students, understand how best to reduce industrial risks. This should help them improve both technical and production integrity, leading to fewer safety, health, and environmental incidents while increasing the quality and production levels and reducing costs.


Chapter 2 Process Functions


The U.S. Air Force initiated a program called Integrated Computer Aided Manufacturing (ICAM) in the 1970s. They developed a simple tool to communicate this program to technical and non-technical staff, named ICAM-DEFinition or IDEF methodology1, 2. With IDEF, we use a graphical representation of a system using activity boxes to show what is expected of the system. Lines leading to and from these boxes show the inputs, outputs, controls, and equipment.


As an illustration, consider a simple pencil. What do we expect from it?


Let us use a few sentences to describe our expectations.

A. To be able to draw lines on plain paper.
B. To be able to renew the writing tip when it gets worn.
C. To be able to hold it in your hand comfortably while writing.
D. To be able to erase its markings with a suitable device (eraser).
E. To be light and portable, and to fit in your shirt pocket.


The item must fulfill these functional requirements or you, the customer, will not be satisfied. If any of the requirements are not met, it has failed. Figure 2.1 illustrates a functional block diagram (FBD) of how we represent the second function in a block diagram.



Figure 2.1 FBD of pencil system.

Effective Maintenance Management, Second Edition

By Vee Narayan


From the Back Cover...


… this book has the depth and content to really help maintenance organizations change and improve reliability. This is a book with true content, without having to own numerous other books to provide information one might need.

- Ricky Smith


This new edition of the bestselling and authoritative text (chosen as the basis for a course on risk and reliability strategies offered by ASME) is written at a level and style that practicing engineers and managers alike can readily understand and apply. It describes the crucial role of maintenance in minimizing the risk of safety or environmental incidents, adverse publicity, and loss of profitability. And it explains the applicability of risk-reduction tools to specific situations, thereby enabling you to select the tool that best fits your requirements. Bridging the gap between designers/maintainers and reliability engineers, this book will help your organization utilize its assets more effectively, safely, and profitably.

  • New coverage of Risk-Based Inspection and Instrumented Protective Functions
  • Accounts of the Longford (1998), Columbia (2003) and Sayano-Shushenskaya (2009) disasters reinforce the evidence for the event escalation theory explained in chapter 9.
  • Chapters 12 and 14 are new to this edition

Preface to the Second Edition

Since publication of the first edition in 2004, risk-based approaches to maintenance and reliability have moved firmly to the forefront of good practices. Two processes, Risk-Based Inspection and Instrumented Protective Functions, have been available for a number of years; they have been further developed and are now established as “must use” techniques. Along with Reliability Centered Maintenance, they provide an integrated suite of readily usable and useful techniques for the maintainer.


Many maintainers find themselves in businesses where the assets are unreliable, profitability is poor, and budgets are under pressure. The financial crisis of 2008 and its aftermath have made matters much worse. In response, we have provided some recipes to address these issues in the form of a new chapter in this edition. New sections in Chapter 10 explain and give clear guidance on the two risk-based processes mentioned above.


In Chapter 8, we have added accounts of the Longford (1998), Columbia (2003) and Sayano-Shushenskaya (2009) disasters. These reinforce the evidence for the event escalation theory explained in Chapter 9.


As is the norm with new editions, we have taken the opportunity to do some housekeeping. Internet website references (URLs) seem volatile and a few of the earlier references are no longer valid. Some books references are also outdated, as new publishers have taken over and ISBNs have changed. These are now corrected.


There is one other significant change – the book summary has been expanded and has now become a new chapter. Apart from the usual corrections and additions, the remainder of the book remains largely faithful to the first edition. I welcome feedback from everyone using this book. Please write to me at the publisher’s email address: info@industrialpress.com


V. Narayan
Aberdeen, Scotland


Effective Maintenance Management, Second Edition

By Vee Narayan


  • The Production and Distribution Process
  • Process Functions
  • Reliability Engineering for the Maintenance Practitioner
  • Failure, its Nature and Characteristics
  • Life Cycle Aspects of Risks in Process Plants
  • Process Plant Shutdowns
  • Facets of Risk
  • The Escalation of Events
  • Maintenance
  • Risk Reduction
  • Information for Decision Making
  • Improving System Effectiveness