ISPM_EQ_Taxonomy+ReliabilityData

8/10/2019 ISPM_EQ_Taxonomy+ReliabilityData

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2008 Eventure Events. All rights reserved.

Industry Standards-Based Solutionfor SAP Plant Maintenance (ISPM)Tony Ciliberti, PEReliability Dynamics LLC


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ISPM Overview


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Key Learning Objectives

The importance of industry standard integrationwith corporate information systems

Key objectives for asset management Why a reliability language is imperative for

communicating operational experience Common asset management issues


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Mantra: If you cant analyze1000 things at once, youre

not doing it right


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Plant Maintenance Scope

Most Master Data Most Transactional Data

Risk Management

Designinherently safeand reliableprocesses

Risk Assess-ments

Process andeqpt design data

Equipment capabilities data

Optimize decision-making with accessible high-quality information

Manage risk with preventive maintenance, spare parts, procedures, and other safeguards

Optimize resources

Prioritize activities based on loss potential

Planning and scheduling

As-built

Plant Maintenance


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Key Objectives


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Key Objectives for Enterprise AssetManagement

Maximize production output via increasedequipment availability

Minimize health, safety, and environmentalincidents

Optimize efficiency of resources


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How to Achieve Key Objectives

Make data-driven decisions Optimize decision making with accessible and high-

quality information

Use risk-based prioritization of programs andwork Maximize benefit-to-cost

Optimize work execution with planning andscheduling


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The Importance of Information

We require accurate and accessible informationto make sound decisions about the operation ofour facilities

Better information means better decisions Better decisions mean more reliable and profitable

operation and fewer hazards

The key to better information is high quality data


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Information Challenges

We manage a mountain of information Tens of thousands to millions of equipment items and

related process safety information

Hundreds to thousands of transactions created andprocessed daily

Data-driven decision-making is limited by timeavailable to gather information

Many different people with diverse backgroundscontributing to the data store Data are stored disparately and in a manner that

does not facilitate analyses


11/140 2008 Eventure Events. All rights reserved.

Customer Issues


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My Experience

Many implementations are new wheels Some use of best practices

Implementation partner personnel typically: Have never worked in industry as reliability engineers Have never used EAM solutions they developed in execution oftheir day-to-day engineering responsibilities Are unfamiliar with industry standards

Customer SMEs on new implementations typically: Have never used SAP in execution of their day-to-day engineering

responsibilities Do not fully understand SAP functionality and are unfamiliar with its

nuances (typically gained by application of functionality). Result: disconnects and functionality gaps discovered after go-

live


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My First Corporate Roll- outNotAtypical!

Every location replicated existing facility-specificprocesses in SAP

SAP was not the single source of master data No consistency between locations in technical object

structuring Inconsistent and incomplete practices for failure coding;

personnel reverted to using long text No provisions made for capturing inspection data as

discrete values

Poor work management practices resulting in impropercost allocation

No document management strategy


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Customer Feedback:QatarGas

The problems we had while implementingMeridium w ere that we did not have the properinfrastructu re in SAP that Meridium required in o rderto do the job .

First of all, our asset register in SAP was equipment-based and the functional location levels went down onlyto the Unit Level. Below the Unit Level we had onlyequipment and sub-equipment. The proper setup was tohave functional location hierarchy down to the equipmentlevel. So, instead of having 267 functional locations thatreflected the systems and units in our facility and nearly60000 equipment, we ended up having more that 60000functional locations. All Equipment were dismantled andreinstalled in their new equipment level functionallocations. The asset Tag Numbers, which had beenassociated with equipment, is now associated withfunctional locations

The second problem was that we did not have any failurecodes in the system. So, we needed to establish catalog

profiles, object types and failure codes using catalogs. That third problem was that other reliability elements

were mandatory to have for the reliability analysis. Datalike Malfunction Start/End Date and Time , Duration andfailure modes, etc.. , were all new things that we neededto introduce to our culture and process in order to havethem.

The effectiveness of Meridium rel ies entirely on dataintegri ty and stru cture in SAP. The rel iabil i ty cultu reshou ld be established to g et all the rel iabil i ty datarequired. Establishing the reliability culture in not aneasy job. It required time and effort and one thing aboveall, Management Support


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Some Standard Definitions of Equipment


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Inconsistent Boundary Definitions AffectApplication of Published Failure Data

CPPS reliability datafor motor-drivenpumps

Motor included inequipment boundary Power transmission

(gearbox) included

No mention of controland monitoring


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Inconsistent Boundary Definitions CanCompromise Data Quality

Sample equipmentsubdivision forpumps By definition, does

not include codes

that describe motor Users must be

aware of theboundary, otherwisedata collection maybe compromised


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Inconsistent Boundary Definitions CanCompromise Data Quality

Sample equipmentsubdivision forelectric motors


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Other Data Quality Issues that AffectMetrics

Work executed on blanket orders

Use of stockpiled spare parts instead of bookingmaterials to repair orders

Multiple work orders/notifications for the same repair Timing of work orders/notifications

Inconsistent practices for booking repair time against

work orders Inconsistent treatment/allocation of overhead costs


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Data Access Issues

Data stored in a non-structured manner Scanned Images Free-form text

Disparate data Disparate stand-alone applications Suppliers data repositories

Access databases and Excel spreadsheets


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Data Access Issues

Reasons for disparate data repositories Specialized functionality that will never be part of the

maintenance system, e.g. vibration spectra Configuration of the maintenance system makes it difficult

to input and/or extract discrete inspection data Unwillingness of personnel to turn-over data to the

maintenance system

Issues Repositories are typically available only to the specific site

where they are maintained Merging data is much more difficult


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The Solution

Use standard ..data collection principles andassociated terms and definitions that constitute areliability languagefor communicating operationalexperience

Develop a hierarchical framework (taxonomy) forequipment to make data readily accessible,retrievable, and comparable between similartechnical objects and process applications

Capture data in a manner that facilitates analyses Use discrete values versus scanned images and free text

Cockpit view: give users a single point of entry to allinformation


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Industry Standards


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Some Reasons Why Standardization isImportant for Asset Management

Engineering practice Solutions should follow recognized and generally accepted

good engineering practices (RAGAGEP) Common terms and definitions are imperative to

communicate failure details Standard reliability data allows companies andmanufacturers to learn from others experiences

Solution Ensure capabilities of ERP systems are properly and fully

exploited by SAP customers Ensure that solutions implemented are tried and tested

methods proven by actual practice Streamline and reduce deployment costs


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Examples of Commonly-used IndustryStandards

ISO 14224: Petroleum, petrochemical and naturalgas industries Collection and exchange ofreliability and maintenance data for equipment

ISO 15926-2: Industrial automation systems andintegration -- Integration of life-cycle data for processplants including oil and gas production facilities --Part 2: Data model

Norsok Z-002-DP: Design Principles Coding System API RP 579: Fitness for Service API RP 580: Risk-based Inspection


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Globally Accepted Principles ForStandards Development (ANSI)

Transparency: Essential information regarding standardization activities isaccessible to all interested parties

Openness : Participation is open to all affected interests Impar t ia l i ty : No one interest dominates the process or is favored over

another

Effect iveness and Relevance: Standards are relevant and effectivelyrespond to regulatory and market needs, as well as scientific andtechnological developments

Consensus : Decisions are reached through consensus among thoseaffected

Perform ance Based: Standards are performance based (specifyingessential characteristics rather than detailed designs) where possible

Coherence: The process encourages coherence to avoid overlapping andconflicting standards Due Process : Standards development accords with due process so that all

views are considered and appeals are possible


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Standards versus Software BestPractices

Standards are consensus practices between allmaterially-affected parties

SAP Best Practices are valuable for configuring the

system Business process guidance is very high level and notprescriptive in nature (common customer misperception)

Other Software Best Practices

Individual entitys (partners) practice that typically will varypartner-to-partner Generally no consensus process used in their

development
http://help.sap.com/bp_chem603/BBLibrary/HTML/929_EN_US.htm


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OREDA Example


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OREDA Example


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The OG&P Standards Vision

The intent/purpose of ISO 14224/OREDA is todevelop a reliability language BETWEENcompanies in the oil and gas industry sector, not

just within companies Facilitates merging and analysis of data OREDA (OFFshore REliability DAtabase) is the

platform

Each company independently changing thestandard defeats this intent


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ISPM Equipment ReliabilityData


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Key Learning Objectives

Primary building blocks of a reliability datainfrastructure

The ISO 14224-compliant equipment failure datacollection process in SAP

Use of operating context to classify failure datafor reporting purposes


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We need ..data collection principles andasso c iated term s and d ef in i t ions tha t con s t i tu te a

reliability languagefor communicatingoperational experience.

ISO 14224: 2006


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Compliancy with Industry Standards

ISO 15926, Industrial automation systems and integration Integration of life-cycle data for process plants including oil and gasproduction facilities

Defines relationship between functional and physical objects

ISO 14224, Petroleum and natural gas industries Collection andexchange of reliability and maintenance data for equipment Defines equipment taxonomy and standard processes for collection,

merging, and analysis of reliability data

Norsok Z-002- DP (Norwegian Coding System), Design Principles:Coding System

Defines standard nomenclature for equipment Used to define functional location structural nodes


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ISO 14224 Objectives

Enable the collection, exchange and analysis ofdata based on common viewpoints (reliabilitylanguage)

Exchange RM data on a common format within acompany, between companies, within anindustrial arena or in the public domain

Improve equipment design/reliability via feedbackof data to equipment manufacturers

Improve industrial profitability and safety


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Key Aspects of ISO 14224 Methodology

Taxonomy A systematic classification of items into generic groups based

on factors possibly common to several of the items (location,use, equipment subdivision, etc.)

Provides a master data infrastructure (framework) to: Uniquely assign characteristics as they apply to specific equipment

types and process applications Capture life cycle data associated with equipment; e.g. reason for

removal from service, duration out-of-service, primary componentfailure, condition found, condition left, and components replaced

Store and classify data associated with equipment that makes the datareadily accessible, retrievable, and comparable between similar objects


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Key Aspects of ISO 14224 Methodology

Standard processes for failure data collection

Equipment class boundary definitions Failure and activity codes Time definitions Consequence severity assessment

KPIs and benchmarking


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SAP Master Data

Technical Objects Functional locations Equipment

Catalogs Class and characteristics Measuring points/counters Document information records


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Technical Objects

Purpose/Objectives

Represent an enterprises assets completely,logically, and consistently

Catalog technical objects Logical structure for capturing master data for

industrial assets

Infrastructure for reliability data collection,merging, and analysis Electronic representation (data model) of reality


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Technical Objects Considerations

Should be designed in accordance withapplicable industry and company standards

Design should be systematic and consistent for

uniformity across a broad industrial spectrum Flexible structures to accommodate both simple and

complex facilities

Should be designed for ease of recordkeeping


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Functional Location Objects

Intangible objects that describe process requirements Roll-up points for costs, reliability data, or any other data Structured hierarchically

Functional Area Location (FAL) Grouping location: no equipment installation

Functional Equipment Location (FEL) Equipment installation point Carries P&ID tag number


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Equipment Objects

Tangible objects, most with serial numbers Typically begin as material masters

Material + serial number = equipment

Capabilities must meet or exceed requirements at FELinstallation point FEL-to-primary equipment cardinality should be 1:1

Every equipment item should belong to a standard

equipment class Every equipment class should have failure codes per

industry standard ISO 14224 or equivalent companystandard


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Coincident Individuals


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Functional Location and EquipmentRelationship 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 theexample 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 Pump1234 that is installed as TAG P101 is in fact also a state of TAG P101. TAG P101 consists of those states of the pumps thatare installed in this location.

FEL Equipment


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Equipment Change-outs

FEL is constant in a given service; equipment can move

A change in operating context can skew reliability data when tracked by the equipment object

6/1/2001 9/1/2002

Pump 3456

Mild Service

Harsh Service

TAG P202


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Coincident Individuals

FELEquipment

FEL

Equipment

Capabilities of installed materialized physicalobject (Equipment) must meet or exceedrequirements of functional physical object (FEL)


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Functional LocationHierarchy


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Functional Location HierarchyDesign Guidance

Use a standard process for generating tagnumbers (e.g. NORSOK Z-002-DP)

Use the tagging standard to help define the

hierarchy Differentiate tags at different facilities with a

prefix, e.g. XXYY-[tag no] Country code: XX Installation code: YY

The four-digit code is a logical choice for themaintenance plant ID


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Functional Location HierarchyDesign Guidance

Use a multi-template design Template 1 = enterprise Template 2 = installation grouping levels (FAL)

Template 3 = equipment (FEL) and sub-equipment(SFEL)

Use a dynamic structure with optional nodes toaccommodate different levels of complexity Use functional location categories to identify each

level


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FL Hierarchy Design per NORSOK Z-002-DP Standard


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FL Hierarchy Design per NORSOK Z-002-DP Standard


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Sample Functional Location Structure

FAL Node 2EG2B

EG ALBA ONSHORE 2B

FAL- Node 3EG2B-2029

EG2B MAIN PROCESS SYSTEMS

FAL Node 4: SystemEG2B-23

GAS COMPRESSION AND RE-INJECTION

FAL- Node 3EG2B-4069

EG2B PROCESS SUPPORT AND UTILITY SYSTEMS

FAL Node 4: SystemEG2B-41

HEATING MEDIUM

FAL Node 5EG2B-41-01

MAIN EQUIPMENT


PIPING AND VALVES


MAIN EQUIPMENT

FAL Node 6

EG2B-23-01-1DDRIVER AND POWER TRANSMISSION

FEL Node 9EG2B-23DT001

TURBINE DRIVER, RESIDUE GASCOMPRESSOR

FAL Node 6

EG2B-23-01-1KGAS COMPRESSION, BLOWING AND EXPANSION

FEL Node 9EG2B-23KA001

RESIDUE GAS COMPRESSOR

FAL Node 6

EG2B-41-01-1PPUMPS

FEL Node 9EG2B-41PA001A

HOT OIL CIRCULATION PUMP A


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Functional Location Structural DesignBased on NORSOK Z-002-DP


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Sample Functional location structuraldesign


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FEL Data Roll-up

P101 Pump

Pump S/N 1234

John CraneTandem Seal

FEL

Primary Equipment

Sub-equipment

D a t a f o r p u m p o n l y

i r r e s p e c t i v e o f

i n s t a l l a t i o n p o i n t

D a t a f o r s e a

l o n l y

i r r e s p e c t i v e o f

i n s t a l l a t i o n p o i n t D

a t a f o r e n t i r e s u b

- s t r u c t u r e

( P u m p + S e a l ) f o r f a c i l i t y

l i f e t i m e ( a l l S / N s )

Data = costs, reliabilitydata, etc.


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FEL + Sub-FEL Data Roll-up

P101 Pump

Pump S/N 1234


FEL

Primary Equipment

Sub-equipment

Data for pump S/N 1234only irrespective of

installation point

D a

t a f o r p u m p o v e r

P 1 0 1

l i f e

t i m e

( a l l S / N s

)

P101 Pump Seal

Sub-FELData for all pump seals in stalled in P101

lifetim e (all mechanical seal S/Ns)

Sub-FEL gives additional datadissemination but requires datamaintenance overhead


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Equipment Subdivision andCatalogs

SO 14224/1 926 C h


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ISO 14224/15926 Coherent Taxonomy

A s s e

t r e g

i s t e r

( F u n c

t i o n a

l L o c a

t i o n s

t r u c

t u r e

)

ISO 14224:2006: Petroleum, petrochemical and natural gas industries -- Collection and exchange of reliability and maintenance data for equipment

ISO 14224/15926 I d T


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ISO 14224/15926 Integrated Taxonomy

Maincategory Level Taxonomy hierarchy Definition

1 Industry Type of main industry2 Business category Type of business or processing stream3 Installation category Type of facility4 Plant/Unit category Type of plant/unit5 Section/System Main section/system of the plant

6.1 Equipment ClassClass of similar equipment units. Each equipment classcontains comparable equipment units

U s e

/ l o c a t

i o n

d a

t a a n

d

O p e r a t i n g

C o n

t e x

t

6.2Equipment Unit functionalspecification Equipment unit requirements and operating conditions

6.3 Equipment Unit Asset (S/N) Equipment capabilities

7 Subunit A subsystem necessary for the equipment unit to function

8Component/ Maintainableitem

The group of parts of the equipment unit that arecommonly maintained (repaired/restored) as a whole E q

u i p m e n

t

s u

b d i v i s i o n

9 Part A material spare part or assembly

G T bi E i Cl B d


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Gas Turbine Equipment Class BoundaryDefinition

Establishes consistency indefinition of equipment units Facilitates apples-to-

apples data analysis Includes subunits and

maintainable items

SAP catalog functionalityused for boundary definitions

Catalog profile = boundarydefinition

Catalog group = subunit Catalog code =

maintainableitem/component

Boundary definition

G T bi E i S bdi i i


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Gas Turbine Equipment Subdivision

SAP T h i l Obj C d


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SAP Technical Objects versus Codes

Assign a equipment number (FEL + Equipment) whenhistorical tracking by serial number is required

Any equipment item should be a subset of an equipmentclass

All equipment classes should have code sets for: Failure mode Equipment subdivision (subunits and maintainable

items/components

Need a logical end point for technical objects E.g. a cylinder head would not have an equipment number; it is a

component

Oth C id ti f T h i l


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Other Considerations for TechnicalObjects

Need consistent rules for when to install equipmentcomponents in an FEL as primary equipment or as sub-equipment

Primary equipment: within the equipment boundary, but not anintegral component

If the main unit is removed and the component stays behind, the componentit primary equipment, E.g. Lube oil pump mounted on its ownfoundation/base plate

Sub-equipment: integral component of the main unit If the main unit is removed and the component comes with it, the

component it sub-equipment E.g. Shaft-driven lube oil pump

Rules and guideline should be documented via a technicalobject decision matrix

D i i M t i f T h i l Obj t


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Decision Matrix for Technical Objects


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Technical ObjectClassification

ISO 14224/15926 C h t T


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ISO 14224/15926 Coherent Taxonomy

A s s e

t r e g

i s t e r

( F u n c

t i o n a

l L o c a

t i o n s

t r u c

t u r e

)

ISO 14224:2006: Petroleum, petrochemical and natural gas industries -- Collection and exchange of reliability and maintenance data for equipment

Technical Object Classification and


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Technical Object Classification andCharacteristics

Structure for capturing equipment master data Engineering design specifications/requirements Equipment capabilities

Verification of equipment capabilities versusfunctional requirements

Classification of equipment for data analysispurposes

SAP Class Structure


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SAP Class Structure

Same class ID but separate class types used forcorresponding FELs and equipment

Class level legend:1. Process equipment PE (arbitrary) 2. Corresponds to ISO 14224 equipment categories: DR drilling,

RO rotating, EL electrical, etc.3. Corresponds to ISO 14224 equipment classes, e.g. PU pumps,

EM electric motors, GT gas turbines, etc.

4. Corresponds to ISO 14224 equipment types, e.g. AD aeroderivative gas turbines, IN industrial gas turbines

ISO Class Hierarchy with Characteristics


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ISO Class Hierarchy with Characteristicsfor Gas Turbine FEL Objects


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Data Common to all Equipment Classes


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Data Common to all Equipment Classes(ISO 14224)

Grouping of Characteristics for FEL and


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Grouping of Characteristics for FEL andEquipment Objects

Functional locationcharacteristic grouping

Equipment characterisitcgrouping

Coincident Matching of duty

versus equipment

capabilities Equipmentcapabilities mustsatisfy processfunctionalrequirements

Equipment Attribute Data Capabilities of

physical asset

FEL Use/Location Data

and operating

context Processrequirements (duty)

Division of characteristics between coincident individuals

Value Inheritance from Technical Object


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Value Inheritance from Technical ObjectMaster Record to Characteristic

Values inherit directly fromequipment master tocharacteristic value

Risk rating for Equipment (FEL) via Class


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Risk-rating for Equipment (FEL) via Classand Characteristics Functionality

ISO 14224 matrix accesseddirectly from characteristic viaDIR record (DMS functionality)

Consequence severity (CS) matchedwith likelihood (L) to give risk levels

one or more CSL pairs possible

Materials Classification and Class Search


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Malfunction Reports: SAPCompliance with ISO 14224

Malfunction Report as Subset of the


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Malfunction Report as Subset of theComplete Order Process

1. Equipmentmalfunction

3. GenerateMalfunction

ReportIW24

4. Notificationapproval and

releaseIW28

5. Order releasedfrom notification

IW22/IW28

6. Order planningIW32

7. Assignment ofwork clearancerequirements

2. Use functionallocation

structural displayto selectequipment

IH01

10. Scheduleresources and

work

9. Release orderIW32/IW38

8. Dependencychecks(IW32)

11. Print shoppapers and

attachmentsIW37N

15. Technicalcompletion

IW32

14. Workconfirmations and

CompleteMalfunction

ReportIW41/IW42

13. Ad-hoc partsrequirements

MB1A

12. Execute work

16. SettlementKO88 (Batch)

17. Business CloseOrder (IW32

SAP Notifications and Orders


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SAP Notifications and Orders

Notifications are used to capture history Three step process for malfunction reports (M2

notification) Reporting a problem (simplified version or transaction

variant Post-repair synopsis of findings, actions, and follow-up Consequence assessment and validation of data

Orders are used to capture costs and resources Material posting transactions are invaluable in

tracking component replacements

ISO 14224 Failure Coding and


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ISO 14224 Failure Coding andConsequence Severity Rating

Main category Level Taxonomy hierarchy1 Industry2 Business category3 Installation category4 Plant/Unit category5 Section/System

6.1 Equipment Class

6.2 Equipment Unitfunctional spec.

6.3Equipment Unit Asset(S/N)

7 Subunit

8Component/

Maintainable item 9 Part

U s e

/ l o c a

t i o n

d a

t a

E q u

i p m e n

t

s u b d i v i s i o n

Method ofdetection

Failuremechanism

Classificationof failure data

Consequence/Likelihood

Primarycomponent failure

Consequence/LikelihoodConsequenceseverity rating

Failure mode

Root cause

Corrective

activity

Recommended data for equipment failure


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Recommended data for equipment failurereporting (ISO 14224, Table 6)

Failure Consequence Classification


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Failure Consequence Classification

FEL + Sub-FEL Data Roll-up


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FEL Sub FEL Data Roll up

P101 Pump

Pump S/N 1234


FEL

Primary Equipment

Sub-equipment

Data for pump S/N 1234only irrespective of

installation point

D a

t a f o r p

u m p o v e r

P 1 0 1

l i f e

t i m

e ( a l l S / N s

)

P101 Pump Seal

Sub-FEL

Data for all pump seals in stalled in P101lifetim e (all mechanical seal S/Ns)

Sub-FEL gives additional datadissemination but requires datamaintenance overhead

Multi-level malfunction reporting process


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Multi level malfunction reporting process

Progressive Level of Detail


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Progressive Level of Detail

Malfunction Problem Report


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Malfunction Report

Equipment level assessment

Failure mode (class specific) Equipment-level symptom or observed failure

Method of detection Equipment-level method or activity by which a failure

is discovered Vitally important to distinguish between failures

discovered by either: A planned action (inspection, PM maintenance, audit) By chance (casual observation)



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p

Equipment level assessment

Malfunction start date/time Effect on system

Critical failure Degraded function Incipient failure

Equipment condition at start-up Work priority and administrative data

Malfunction Repair Report


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p p

Component level assessment Primary/Corollary component failure

Consequence severity rating of event

Affected equipment/areas Delta asset value

Failure mechanism Failure root cause

Corrective maintenance activities (equipment andcomponent level)

Follow-on tasks (equipment and component level)


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Malfunction Report Example



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p

Use functional location structuraldisplay to find the FEL for the faileditem. Select

Object Information


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j

Object information pop-upscreen flags user of recent andcurrent work



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p

Breakdown check box promptsuser for malfunction start date

Equipment Boundary Definition via


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q p yDocument Management Service (DMS)

DMS gives quick access to relevantdocuments

Operating Condition at Failure and Effect


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p gon the System

Responsible person (or position defaults fromreference objects

Effect on the system andsystem operating condition atthe time of failure

Custom Help Screens


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p

Methodology-specific customhelp for each field via

Links available to additionaltopics or examples

Malfunction Problem Report: First Tab


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Failure mode: problem/symptom at the equipment level

Coding details available vialong text push button

Malfunction Problem Report: Method of


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Detection

Coding details available via longtext push button

Confirmation of Notification 89029681


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Repair Details for EG2B-23DT001


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Failure required PT replacement Consequence severity: financial impact of

US$8.2 MM

Malfunction Report Selection


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Malfunction Repair Report


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Transaction variant for changemode includes additional tabs and

no action box

Equipment Failure Level of Detail


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Determination

Malfunction Repair Report:f


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Selection of Maintainable Items

The first coding step is selection of the first -out component/maintainable item.Use progressive levels of detail based onconsequence severity and whether it is aprimary or secondary failure component.

Malfunction Repair Report: Selection ofl h l d


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Failure Mechanism/Failure Mode

Identify the failure mechanism (ISO)/failure mode(RCM) for the failed component. One failuremechanism per component.

Malfunction Repair Report: Specificationf A bl /M i l N


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of Assembly/Material No.

Identify material master (MM) number for assembly or part. In many cases this is available in the workorder (components tab). If not, the MM No. can be found via a material inventory search.The material master contains manufacturer and manufacturer part number information, which facilitatesassessments of specific part number failures.

Malfunction Repair Report: Selection ofF il C f M i i bl I


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Failure Causes for Maintainable Items

Specify one or more root cause of failure for each failedcomponent.

Malfunction Repair Report: Item-levelT k


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Tasks

Malfunction Repair Report: RepairA i i i f M i i bl I


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Activities for Maintainable Items

Specify one or more corrective activitiesundertaken to repair each failed component.

Malfunction Repair Report: Close-outI f ti


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Information

Enter malfunction end date

Malfunction Repair Report: NotificationW k


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Workspace

Notification workspace is a shared network locationwhere documents relevant to a particular notification arestored, typically accessed via an action box icon.

Malfunction Repair Report:N i ti t N tifi ti Cl ifi ti


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Navigation to Notification Classification

1. Select component and then click themagnifying glass push button to open theItem Details screen.

2. Click the Class push button

Malfunction Repair Report: Failure EventD t il


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Details

Use characteristic value hierarchies tocapture consequence severity from ISO14224 table C.1

Malfunction Repair Report: Follow-upT sks


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TasksTasks must be confirmed before an ordercan be technically completed (TECO)

Responsibility assignments

Malfunction Repair Report: Follow-upTasks


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Tasks

Tasks can be assignedresponsibility, dates, user statuses,and follow-up actions.

Failure Data Validation by ReliabilityEngineer


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Engineer

Electronicwork request

generated. Work requestrouted to Ops

FM forapproval.

Work orderscheduled.

Plannercreates workorder & plans

the job. Work request

routed toplanner. Approval?

Workperformed by

craftsman.

Work orderdownloadedto Meridium.

Work orderclosed byplanner.

Craftsmaninitiates workorder closureelectronically

Work orderreviewed by

reliabilityengineer.

Updatesrequired?

WorkRequest

Cancelled.

EQUIPMENTHISTORY (Meridium)

yes

no

no

yes

Work RequestFailure Data

(4.1) Verify

Failure Data

Work Closure Failure Data

(4.2)

CraftForemanreport on

closed craftwork orders

Work orderreviewed byarea foreman

Work orderreviewed byOperations

(FM).

re-route w/ comments to appropriate foreman

DOCR WorkOrders

require MOCapproval

Example of Task List/Edit Reporting viaPerson Responsible


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Person ResponsibleSearch criteria set as default togive list of outstanding tasks for

which a given person isresponsible.

Example of Notification List Reportingvia Class: High consequence Failures


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via Class: High-consequence Failures

Searchcriteria


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Schema for ISO 14224

Schema Considerations


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Catalog code group updates Once a code group code has been used, it cannot be

deleted Changing the text description changes the code

meaning and can affect existing data Code group updates involving specific code numbers

therefore must be done with versioning

Schema should allow for updating/versioning

Schema for ISO 14224 Code Sets


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Coding Allows Additional Detail WhileMaintaining Adherence to Standard


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Maintaining Adherence to Standard

Additional details addedfor Code 0900: Pistons


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Tony Ciliberti, PEReliability Dynamics LLC

[email protected]


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Supplementary Slides

Example of Failure Reporting byOperating Context

ISPM Preventive Maintenance and InspectionsAdministration and Reporting Processes


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p g

Transaction MCJC with MultipleSelection


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Selection

Search by Class


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Choose Class Type for Industrial Gas Turbines andInput Characteristic Selection Criteria for Industry


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Input Characteristic Selection Criteria forBusiness Category


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Business Category

Input Characteristic Selection Criteria forInstallation Category


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Installation Category

Input Characteristic Selection Criteria forPlant/Unit Category


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Plant/Unit Category

Input Characteristic Selection Criteria forNormal Operating Mode


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Normal Operating Mode

Complete characteristic selection andExecute the Search


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Execute the Search

Once all selection criteria have beenentered, click the Includesubordinate classes push button

Select Equipment Objects and Populatethe User Help


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the User Help

Objects meeting the selection criteria are given in a list display1. Select the appropriate items and click the push button2. The selected items will populate in the Functional Location Structure selection screen

Execute User Help Selections to PopulateSelection Variant


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Se ect o Va a t

Execute Report


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Total Equipment Downtime for EachRespective Equipment Object


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p q p j

Reliability Metrics for all Equipment Objects atEquipment and Individual Malfunction Report Level


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Specific Notification Details for OneEquipment Object


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q p j


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Tony Ciliberti, PEReliability Dynamics LLC

[email protected]

ISPM_EQ_Taxonomy+ReliabilityData

Documents

Transcript of ISPM_EQ_Taxonomy+ReliabilityData