Apac 2015 minimizing integrity failure r02
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Transcript of Apac 2015 minimizing integrity failure r02
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Minimizing the integrity failures of Minimizing the integrity failures of
aging aging plants and plants and equipmentsequipments
Through Through
Reliability Centered Maintenance Reliability Centered Maintenance
ProSafeProSafe APACAPAC
Process Safety Management ConferenceProcess Safety Management Conference
9 March 20159 March 2015
Bhavesh ShuklaBhavesh Shukla
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Introduction to
Minimizing Integrity Failure
through RCM
2015 Bhavesh Shukla
All rights reserved. No part of this publication may be reproduced, distributed, by any
means, without the prior written permission of the publisher.
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Agenda
• Failure Case study
• Types of Maintenance
• Risk Based Maintenance Strategy
• Process Steps
• Exercise
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Reactor agitator failure
Coupling with
Torque Limiting Slip (TLS) Plate
(Clutch)
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Agitator Failure Cost Analysis:
i. Additional cost to Business due to failure =1.3 Million
ii. Cost to prevent failure=$10000
Causal Factor:
i. Aging equipment
ii. Lack of predictive maintenance
iii. torque limiting setting was set too low during gear box replacement which caused pre-mature clutch top limiter replacement which caused pre-mature clutch top limiter slipping which generated heat and caused the high speed coupling to fail
Preventive Action:
i. Temperature monitoring of Gearboxes and motor
ii. Vibration check and analysis program
iii. Lubrication test and analysis program
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Types of Maintenance
•Repair
�Run to failure
•Preventive Maintenance
�Time based�Time based
•Predictive Maintenance�Condition based
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Repair
• Repair – run to failure, is suitable for small
items which are non critical,
inconsequential, unlikely to fail and
redundant.
• For critical equipments and parts is not an • For critical equipments and parts is not an
option.
• When Stakes are high Repair is not an
option
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•Preventive maintenance is time base
Maintenance.
•We change parts or service equipment
before it fail and some time before it need
Preventive Maintenance
before it fail and some time before it need
to be.
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Predictive Maintenance
• Is based on predictive testing, monitoring and
inspection.
• It is suitable for critical equipment which has
� random failure
� not subject to wear
� PM induced failure
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Vibration Monitoring & Analysis
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Condition Based Maintenance
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Reliability Centered Maintenance
• Reliability Centered Maintenance (RCM) is a maintenance strategy that is implemented to optimize the maintenance program of a company or facility using cost-effective maintenance techniques.
• There are four principles that are critical for an RCM • There are four principles that are critical for an RCM program. � The primary objective is to preserve system function
� Identify failure modes that can affect the system function
� Prioritize the failure modes
� Select applicable and effective tasks to control the failure modes
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RCM Process Steps
Operational Risk Number
System Risk Number
Safety Issues, Regulatory Compliance,
Product Quality Issues, Process Throughput,
Operational Cost
In series and will stop the system (24 hr lost)
, Important (8 hr lost) ,Can be Bypassed,
Little effect to system, No effect to system
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Asset Risk Number
Failure Probability Factor
Maintenance Priority Number
Reactive Maintenance Performed…
Daily, Weekly, Monthly, Quarterly, Annually
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System Risk Ranking Process
Area SF RC QF PT OC SRN
PROCESS SYSTEM NAMESafety
FailuresRegulatory Compliance
Quality Failures
Process Throughput
Operational Cost
System Risk Number
Reactor
(1-10) (1-10) (1-10) (1-10) (1-10) 1-10(1-10) (1-10) (1-10) (1-10) (1-10) 1-10
Agitator TLS plate 8 2 10 10 10 8
Cooling control valve 6 8 9 8 5 7.35
Heating Control valve 5 6 6 8 8 6.71
Cooling insulation 3 2 3 4 3 3.07
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Maintenance Priority Ranking ProcessRisk Number ORN FPF
10 24 Hours Lost Daily
8 8 Hours Lost Weekly
6 2 Hours Lost Monthly
4 <1 Hour Lost Quarterly
2 No Lost Annually
System Risk
Operational Risk
Asset Risk
Failure Probability Maintenance
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PROCESS SYSTEM NAMERisk
NumberRisk
NumberRisk
NumberProbability
FactorMaintenance
Priority Number
#1-10 (1-10) # 1-100 (1-10) # 1-1000
Reactor SRN ORN ARN FPF MPN
Agitator TLS Plate 8 10 80 3 240
Cooling control valve 7.35 4 29.40 2 59
Heating Control valve 6.71 3 20.13 5 101
Cooling insulation 3.07 2 6.14 1 6
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Maintenance Strategy
Maintenance Priority Index to determine which
type of maintenance is most effective.
• Repair- run to failure• Repair- run to failure
• Preventive Maintenance
• Predictive Maintenance
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