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Transcript of ISPM Overview
© Reliability Dynamics LLC 2014
Equipment Taxonomy and Failure Reporting
Industry Standard Solution for
Plant Maintenance (ISPM®)
© Reliability Dynamics LLC 2014 Reliability Dynamics
Tony Ciliberti, PE
Principal Engineer, Reliability Dynamics
Twenty-seven years experience as a reliability engineer in petrochemical, oil and gas
Former Principal Consultant/Solution Architect with SAP America’s National
Consulting Practice
SAP Top Talent
SAP Certified Solution Consultant - PLM
Industry standards involvement
United States expert representative on ISO TC 67/SG 4/WG 4 (developing ISO 14224
Version 3)
PERD Project, PERD ERP Subcommittee Chair
BS in Chemical Engineering from Texas A&M University, 1987
© Reliability Dynamics LLC 2014 Reliability Dynamics
Reliability Dynamics LLC
Company Overview
Registered engineering company specializing in equipment reliability and maintenance
solutions for corporate software systems
In business since September 1, 2010
Primary product is the Industry Standard Solution for Plant Maintenance (ISPM®)
US patent pending for equipment taxonomy and failure reporting methodology
Our customers
Pembina Pipeline
Queiroz Galvão Óleo E Gás S.A. (QGOG)
Maersk Drilling
Nexen Inc
Marathon Oil
Fortis Alberta
ExxonMobil
© Reliability Dynamics LLC 2014 Reliability Dynamics
What We Deliver
A toolset for using ERP software that enables high-quality failure data
Engineering methods compliant and consistent with consensus standard engineering
practices
Failure data collection made integral with work management
Standard practices consistent with good engineering practice
Equipment taxonomy
Failure data collection
Failure data aggregation
Failure metrics
Rapid-Deployment Solution (RDS)
No need to reinvent the wheel each time (maintenance is maintenance)
Refinement of the solution through actual practice
Less risk and better results
Enables benchmarking and data exchange
© Reliability Dynamics LLC 2014 Reliability Dynamics
What We Provide
End-to-end methodology for equipment taxonomy and failure reporting
System configuration
Functional location template and categories
Equipment malfunction report and related work processes
Equipment PM condition report
Content
Failure catalogs
Classification structures
Enhancements
Data validations and defaults
Data aggregation
Other supporting functionality
© Reliability Dynamics LLC 2014 Reliability Dynamics
ISPM Solution Overview
Malfunction reports generated for failures found via inspection
Equipment malfunction reports· Standard data collection
processes· Minimum data capture (ISO
14224 Tables 6 and 8)
Classification of individual failure events· Consequence(s) of failure –
qualitative matrix (ISO 14224 Table C.1)
· Lost production amount· Affected equipment/unit(s)· Instrumented safety systems
failure classification (PERD and ISO 14224 Table F.1)
· Other as required by customer (standard class functionality)
Multi-level failure reporting process (MLFRTM)· Work execution at the
component level· Failure reporting at the
equipment level (ISO 14224 Table 6)
Simplified failure metrics (standard SAP reports)
Standard failure coding· (ISO 14224 Annexes A
and B)· Catalog profiles used to
define equipment boundaries and for specificity of codes to equipment classes
Equipment taxonomy· Structurally
synchronized with equipment subdivision (ISO 14224 Annex A)
· Differentiates between functional and physical aspects of equipment (ISO 15926-2, Figs E.9 and E.10)
· Logical and systematic process for representing P&ID tag numbers
· Framework for efficient risk assessment
Use/Location data(ISO 14224 Table 5 and Annex A)· Used to identify how
equipment is used (process conditions)
· Integral parameter in failure metrics
Risk assessment· Similar to and integrated
with malfunction reporting (hypothetical vs. actual failure): same use of codes, operating context, classification, and reporting
Preventive maintenance· Risk data used for strategy
development· Administration at area or
equipment level· Pass/Fail inspection verdict
recorded at equipment or component level
· Inspection verdicts used to optimize interval/scope
LegendEquipment taxonomy
Failure reporting
Future functionality
© Reliability Dynamics LLC 2014 Reliability Dynamics
SAP Landscape with ISPM Appliance
Data Repositories/Other Systems
Corporate ERP System· System of record for equipment master data· Work management system· Initial data collection point for equipment failure data
ERP DATABASE· Work execution· Results recording· Labor and material
bookings
Standard Failure Data
Processes
Equipment Taxonomy
Planned Maintenance and Inspections
Equipment Malfunction
Reports
PM Condition Reports
Equipment failure events
Other target systems, e.g.
Meridium, Ivara, etc.
Failure Data Repository, e.g. OREDA, PERD
Failure consequence accounting
Failure metrics
ISPM Appliance
Data Extracts
Interface
© Reliability Dynamics LLC 2014 Reliability Dynamics
ISPM Benefits
Optimizes bottom-line decision making
Enables corporate-wide failure metrics and benchmarking
Logical and systematic process for representing facilities
One unique ID for each object throughout all systems and records
Separation of functional and physical aspects of equipment minimizes data maintenance requirements
Systematic and validated failure data collection processes
Industry standard compliant
Configurable for participant-specific data
Built-in appliance ensures integration with all corporate aspects
FICO, Materials Management, HR, etc.
No new application support requirements
Improves personnel efficiency
Fleshes-out bad actor equipment for prioritization and preventive strategy development
Shift to quality data collection versus after-the-fact data mining
© Reliability Dynamics LLC 2014 Reliability Dynamics
Taxonomy
Definition: systematic classification of items into hierarchical generic groups based on
common factors
Relevant information is more likely to be found by logical progression from a general focus to
a more specific focus
Information summaries are defined in the context of their unique “parent-child” relationships,
such that the relationships can be interpreted programmatically
Equipment Taxonomy
Technical: systematic organization of equipment into hierarchical groups based on equipment
category, type, subtype, or other attributes
Functional: systematic organization of operating assets of a company into hierarchical groups
based on process function
Master data: representation of equipment taxonomy in an ERP/CMMS
© Reliability Dynamics LLC 2014 Reliability Dynamics
Technical Taxonomy:
Example from ISO 14224, Annex A
Equipment type classification
Equipment subdivision
Generic representation of equipment
Boundary diagram
– Subunits (Major component groups)
– Maintainable items (components)
© Reliability Dynamics LLC 2014 Reliability Dynamics
Functional Taxonomy
Logical representation of
facilities
Asset register: directory of all
locations, plants, areas, etc.
Process equipment (functional):
Labelled with P&ID tag numbers
P&ID tags serve as an “address” to
directly locate equipment
Operating context: gives service
conditions for process equipment
items
Equipment serial numbers: gives
installed and historical serial
number usage for each P&ID tag
© Reliability Dynamics LLC 2014 Reliability Dynamics
Functional Taxonomy
Logical and systematic process for representing P&ID tag numbers
One unique ID for each object throughout all systems and records
All P&ID tag numbers represented in the ERP/CMMS with exact character strings in a
system-validated key field
Smart structure
Integrated with technical taxonomy
Defines equipment-to-component relationships (equipment boundaries) and equipment-
to-equipment relationships in a manner that can be interpreted programmatically
Structurally synchronized with ISO 14224 equipment subdivision
Differentiates between functional and physical aspects of equipment (consistent with ISO
15926-2)
Captures equipment use/location data (operating context)
© Reliability Dynamics LLC 2014 Reliability Dynamics
Functional Location and Equipment Relationship
Functional equipment location Tag P101 is an intangible object that defines process requirements for a
particular pumping service, e.g. pressure, temperature, flow, fluid type (Tag P101 in the example below)
Equipment items (serial numbers 1234 and 2345) define specific materialized objects that execute
process requirements
Field equipment change-outs are captured in SAP via corresponding equipment dismantle/installation
transactions (on 5/8/2001 S/N 1234 was dismantled and S/N 2345 installed)
ISO 15926-2 (Data Model) Industrial automation systems and integration—Integration of life-cycle data for process plants including oil and gas
production facilities, Figures E.9 and E.10.
The duty represented by TAG P101, and Pump 1234 are coincident for the period of the installation, i.e. the state
S1 of Pump 1234 that is installed as TAG P101 is in fact also a state of TAG P101. TAG P101 consists of those
states of the pumps that are installed in this location.
FEL/FCL Equipment
© Reliability Dynamics LLC 2014 Reliability Dynamics
Malfunction reporting
Malfunction Report
An event record in an ERP/CMMS system
Initiated to address equipment critical failures, degraded performance, or incipient conditions
Initiated for the following reasons:
To notify Maintenance of required repairs
To document failure discovered during preventive maintenance and inspections
(regardless of the need for follow-on work)
Two processing stages
Work initiation, “Problem Report”
Work close-out, “Repair Report”
© Reliability Dynamics LLC 2014 Reliability Dynamics
Work Processing with ISPM Appliance
Pro
du
ctio
n
Op
erat
or
Mai
nte
nan
ce L
ead
Te
chM
ain
ten
ance
En
gin
eer
Ap
rova
ls a
nd
P
roce
ssin
g
External Work Processing Flow with the ISPM Appliance for SAP
Re
spo
nsi
bili
tie
s an
d E
xte
rnal
Pro
cess
es
2. Equipment Failure Event
6. Approve Work Request
7. End
Yes
No
10. Execute Work
8. Planning and
Scheduling
14. Classify Malfunction
Report
12. Complete Malfunction
Repair Report
11. Work close-out
5. System validations of required data
4. Create Malfunction Problem Report
3. Work Initiation
15. Quality check of field input
16. End
17. Equipment Failure Metrics
1. Equipment Taxonomy
(prerequisite)
1. Multi-Level Failure Reporting (MLFR) is used to aggregate failure data at the parent equipment level.2. ISPM and MLFR are registered trademarks of Reliability Dynamics LLC.
13. System validations of required data
9. System creates MLFR1,2 statistical
record (if applicable)
Post-repair assessment· Identify primary component failure· Primary comp. failure mechanism· Root cause of primary comp. failure· Corrective action· Failure end date/time· Other· Failure mode inference (PERD only)
1. MLFR data (if relevant)2. Classification of failure event
· Consequence matrix· Production loss· Areas and/or other equipment affected· Other
Initial findings – reason for work· Text description· Failure mode (ISO 14224 only)· Detection method· Failure effect (incipient, degraded,
critical· Condition before malfunction· Other
ISPM Appliance
© Reliability Dynamics LLC 2014 Reliability Dynamics
ISO 14224: Table 6
Failure Data (Required)
ISO Definitions
Normative = prescriptive = how
to comply
Informative = descriptive = help
with conceptual understanding
Normative Terms
“shall” indicates a requirement
“should” indicates a
recommendation
“may” is used to indicate that
something is permitted
“can” is used to indicate that
something is possible
© Reliability Dynamics LLC 2014 Reliability Dynamics
Resource Optimization:
Maintenance Engineer
0%
10%
20%
30%
40%
50%
60%
Data collection Data mining Equipmentoptimization
Administration
Perc
en
t o
f A
vail
ab
le T
ime
Typical Solution
ISPM
© Reliability Dynamics LLC 2014 Reliability Dynamics
PM Condition Reporting
PM Condition Report
An event record in an ERP/CMMS system related to a inspection/preventive maintenance
work order
The work order specifies what needs to be inspected
Used to document inspection results for each item inspected
Inspection verdict: discrete pass/fail judgment
Inspection details, measurements, etc.
Used to optimize preventive maintenance/inspection programs
Inspection interval
Inspection scope
Used in conjunction with follow-on work notifications and malfunction reporting
© Reliability Dynamics LLC 2014 Reliability Dynamics
Failure Metrics
Failure metrics are measurements of equipment reliability and operational
performance
Calculated parameters
MTBF, MTTF, MTTR, MTBR, mean time bypassed, etc.
Dataset queries
User-defined criteria, e.g.
Number of pump failures where production loss exceeds US $100,000
Predominant failure mode for said pump failures
Service conditions for said pumps
Primary failure component for said pumps
Failure mechanism and root cause for said pump primary failure component
Aggregated true cost of failure for all pumps (repair costs + consequences)
© Reliability Dynamics LLC 2014 Reliability Dynamics
ERP Failure Analytics:
Multi-Variable Selection Criteria
Reporting Level (Primary Equipment)
Report Criteria Set 1 Criteria Set 2 Criteria Set 3
1 Pumps in
hydrocarbon
service
Failure mode is
process leak
Production loss >
US $1.0MM
2 Manufacturer
part number,
mechanical seal
Root cause is
improper
installation
Operational loss >
US $50K
3 Steam turbines
in hot standby
service
Failure mode is
external leakage,
process medium
Injuries requiring
medical treatment
Hierarchical Reporting
Report Selection Node Criteria Set 1 Criteria Set 2
1 Facility, Plant,
area, service,
equipment
installation,
equipment
class, or subunit
Pump thrust
bearing failures,
> 50 HP, utilities
service
Detected with
predictive
inspections
SELECTION CRITERIA SET 1
SELECTION CRITERIA SET 1
SELECTION CRITERIA SET 3
SELECTION CRITERIA SET 3
REPORT OUTPUTINTERSECTION OF
CRITERIA SPECIFICATIONS
REPORT OUTPUTINTERSECTION OF
CRITERIA SPECIFICATIONS
SELECTION CRITERIA SET 2
SELECTION CRITERIA SET 2
© Reliability Dynamics LLC 2014 Reliability Dynamics
ERP Failure Analytics Demonstration:
Hierarchical Selection Example
© Reliability Dynamics LLC 2014 Reliability Dynamics
ISPM Appliance for SAP: Solution Delivery
System customization
Enhancements
Consistent with SAP Official ABAP Programming Guidelines
Transferred to Customer system via SAP Transport Management System (STMS)
Configuration transferred via manual settings and STMS
Master data content
Transferred via SAP Legacy System Migration Workbench (LSMW)
Standard ERP quality control processes:
Multi-environment testing and incremental Customer sign-offs
Solution documentation
Solution overview
Business process documents
Configuration and change documentation
Technical specifications
© Reliability Dynamics LLC 2014 Reliability Dynamics
Contact
Tony Ciliberti, PE
Reliability Dynamics LLC
Principal Engineer
Mobile: +1-574-274-3887
Office: +1-713-487-7271
Email: [email protected]
Web: www.rd-eam.com