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