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As part of our integrated maintenance solutions philosophy we would use a carefully selected combination of the following technologies and services.


  • Reliability Engineering
  • Plant Vulnerability Studies
  • Condition Monitoring Programmes
  • Equipment Criticality Analysis
  • Oil Sampling and Analysis through recognised Tribologists
  • Thermal Imaging Surveys
  • Lazer Alignment
  • Identification of Critical spares and lead times
  • Procurement of Critical spares
  • Sourcing of untimely failed critical machinery
  • Cooler Maintenance and cleaning of coolers
  • Perform Independent 3rd party witnessing of Hydrostatic pressure tests.
  • Plant Maintenance
  • Supply Skilled and semi-skilled labour during shut-downs.
  • Reliability Centred Maintenance

Reliability Centred Maintenance (RCM)

Asset Condition Assessment and Restoration
The principal objective of an Asset Assessment and Restoration programme is to bring equipment economically back to condition, with minimum disruption. During implementation, equipment is assessed and critical differences analysed. A structured process for restoring it to it’s operating optimum condition is then instituted and an action plan for restoration to design condition compiled.

Reliability Centred Maintenance
The fundamental principal of Reliability Centred Maintenance (RCM) is to avoid or mitigate the consequences of failure. RCM is based on determining the balance between corrective and preventative maintenance measures to ensure that the equipment fulfils its intended function in its operating context. This method allows the consequences of each failure mode to be evaluated in its operating state and provides decision logic to decide on the most appropriate maintenance technique.

Total Productive Manufacturing
The main objective of Total Productive Manufacturing (TPM) is to maximise the effectiveness of the facilities that are used within the business by adopting a continuous improvement regime. TPM is an all embracing, results orientated / objectives driven approach for delivering business-wide improvements through the optimisation of complete equipment life cycle management. Its focus creates flexible team working through the involvement of representatives from all departments associated with equipment purchase, installation, maintenance and operation.

Predictive Maintenance Cost Benefits

The true measure of the effectiveness of an integrated predictive maintenance programme can be determined in several ways, examples of this include increased machine availability, increased product quality, reductions in down time and avoidance of costly maintenance overtime. Keyplan Engineering are happy to assist our clients in designing and operating a cost benefit analysis programme, which will truly reflect the impact on the profitability of their plant.

Condition Monitoring Services

Our multi-technology Condition Monitoring Services programmes may include some or all of the following methods, which then enables a comprehensive Maintenance Strategy and Schedule of Planned Preventative Maintenance (PPM) to be implemented:


Thermal imaging has proved to be a critical element of the condition monitoring process. We utilise the latest in thermal imaging technology to provide a highly accurate indicator of emerging problems.
Electrical surveys, are used to identify high resistance joints, overloading and localised heating.
Mechanical surveys help to uncover component deterioration, friction, misalignment and temperature dependant process disorders,
Building surveys show heat loss through inadequate insulation across the building envelope and assist in the location of leaks.

Process Surveys shows heat-transfer co-efficiency losses due to blocked coolers and throttled valves


We can lazer align rotating machinery with latest lazer technology. Potential problems such as angular misalignment, looseness, , misalignment of couplings. Identification of these machine conditions reduces the chances of secondary bearing damage, improves reliability and therefore maintains efficiency and reduce electrical power cost.


In the field of condition monitoring service techniques, we can utilise vibration analysis in a wide variety of rotating machinery applications. Potential problems such as imbalance, looseness, instability of mountings, gearbox and bearing deterioration, misalignment of couplings, and lubrication deficiency can all be easily detected. Early identification of these machine conditions reduces the chances of secondary component damage, improves reliability and therefore maintains efficiency.

Integrated Maintenance Solutions

Keyplan Engineering was recently established to help industry change the way it performs maintenance by introducing innovative approaches to condition monitoring.
The company is using advanced techniques within the ‘Keyplan Reliability check’ recognised as the way forward, in Process plant maintenance to ensure, a range of on-site diagnostic procedures, leading to early detection of wear and tear.
Our specialist engineer with combined 35+ years of Process Plant experience from Mechanical, Process and Electrical to Civil, have a wealth of industrial experience which, when combined with the very latest monitoring technology, provides integrated maintenance solutions to most maintenance problems. These include Plant Vulnerability Studies, Criticality Audits, Risk Based and Reliability Centred Maintenance Assessments, Condition Monitoring and Predictive Maintenance.
Keyplan Engineering is aiming to become one of the premier service organisations in the S.A.
Keyplan Engineering offers innovative integrated maintenance solutions and management programmes guaranteed to improve plant and equipment efficiency, reduce maintenance costs and minimise breakdowns. Increase plant Uptime and minimise plant Downtime.

Equipment Criticality Analysis

Equipment Criticality Analysis & Audit
A Keyplan Engineering Criticality Analysis audit is the optimum method of highlighting potential failures within a production system, identifying the potential hazards associated with these failures and classifying them according to priority. Due to ageing plants and the high cost of upgrading these plants it is important to identify equipment and manage the failure intervals and also have a backup spare strategy.
The process involves: selecting the assets requiring analysis; selecting the categories to be used i.e.. output, safety, repair time etc; putting each asset through the analysis process and reaching an appropriate score.
By using the Reliability Centred Maintenance (RCM) approach, the appropriate maintenance requirements for individual assets can be defined.

The Benefits

  • Reduce the risk of serious failures on high criticality assets
  • Reduced costs by Reduced labour requirement as ‘low criticality’ assets require less attention
  • Reduced usage of parts through unnecessary maintenance
  • Reduced planned maintenance stoppages attributed to unnecessary maintenance
  • High productivity due to ‘critical assets’ improved reliability

Critical Machinery failure Example.. Why Vulnerability Studies are Important?


A local Gas company had a main air compressor failure, lead time to replace this compressor was 10 months, at a cost of 25M which meant the production facility would be down for 10 months, at a production loss of 7 million a day not only this but it would have impacted on their customers they normally supply, also legal cost implications of hospitals not having the oxygen they were contracted to get and peoples lives.


3 smaller Compressors was sourced and procured and the production could commence within 14 days after pipeline modifications and switchgear and transformers was sourced.

Backup storages were big enough to supply the customers during this time of crisis management.

If a Vulnerability study was performed this company would not have faced this crisis it went through and remedial plans would have been in place.

Kruger Park Tours and Kruger Country Retreat

We offer visitors to Kruger National Park and surrounds the opportunity to stay close to the park in the serene Jock of the Bushveld Conservancy near Numbi Gate or inside the park in Skukuza. We then operate adventure activity day trips such as zip-lining over the mountains, elephant interaction, cave exploration and fun filled activities for the kids. Ask one of our representatives for some of the best prices on game drives and safaris in the industry!

Milites Dei Academy – Military Academy Style Training Programs – Adventure Boot Camp – Wilderness Survival Training

Milites Dei Academy specializes in Adventure Boot Camps, Wilderness Survival Training and Military Academy Style Training Programs, from a Special Forces Training perspective.

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