Reliability and Asset Management Strategy of IOCL by ...
Transcript of Reliability and Asset Management Strategy of IOCL by ...
M&I Dept. - An extended arm of the refineries to improve reliability.
Reliability and Asset Management
Strategy of IOCL
by
Implementation of RBI & RCM
1
M&I Dept. - An extended arm of the refineries to improve reliability.
ASSET MANAGEMENT STRATEGY
• Asset management strategy attained importance
since long.
• Internationally, the first consolidated approach came
up in PAS-55.
• The approach covers all aspects of industry norms
from design, procurement, operation & maintenance.
• Asset integrity has primarily two major factors like
new facilities and upgrading integrity of old facilities.
• This paper will restrict on improving integrity of old
assets by implementation of RBI & RCM.
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M&I Dept. - An extended arm of the refineries to improve reliability.3
Organizational Strategic Plan(Vision, Mission, Risk Management)
Asset Management Policy(Control of Asset Management )
Asset Management Strategy(Long-term Sustainable Strategic Plan)
Asset Management Objectives(Specific & Measurable Outcomes of Assets)
Asset Management Plan(Actions, Responsibilities, Resources & Timeline)
ASSET INTEGRITY
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WHAT IS RELIABILITY
Reliability - How much ?
By reliability we really mean availability of the system.
Of course, not compromising safety and
environmental integrity.
The required level of plant availability is set by overall
business needs.
Availability can be 100% only when reliability is 100%.
Therefore, it is a game of managing the risk for
competitive advantage.
Manage risk & reduce the surprises.
All failures are not equally bad. Manage only those
with higher consequences.
M&I Dept. - An extended arm of the refineries to improve reliability.5
WHAT IS RELIABILITY
In other words, maintenance effectiveness is not
only a measure of the effectiveness of the
maintenance department.
It measures how effectively everyone associated
with the asset is playing their part in doing whatever
is necessary to ensure that asset continues to do
what its user wants it to do.
For reliability, therefore, there must be an
inextricable bond between design, operation and
maintenance.
M&I Dept. - An extended arm of the refineries to improve reliability.6
WHAT IS RELIABILITY
The Bond of Reliability
D O
M
D O
M
D- Design
O - Operation
M - Maintenance
D O
M
Together we can, we will
M&I Dept. - An extended arm of the refineries to improve reliability.7
THE ROUTE TO RELIABILITY
The reliability of an asset can be improved by ensuring
following systems in place:
– to capture & retain the knowledge & wisdom
– Work management processes to exploit the
“Intellectual Capital” (IC).
The Reliability ultimately depends on
Sound design engineering practices
Good operation
Adequate maintenance
There is an inextricable bond between design, operation &
maintenance.
The key to reliability is by implementing RBI & RCM.
M&I Dept. - An extended arm of the refineries to improve reliability.
STRATEGIC INITIATIVES
• To improve the reliability of refineries, M&I has taken up a major initiatives
to implement Risk Based Inspection (RBI) and Reliability Centered
Maintenance (RCM) in all the 8 refineries.
• RBI caters to static equipments & piping and best suited for time
dependent failure modes.
• RCM is best suited for rotary, electrical & instrument items and can handle
random failure modes also.
• To ensure performance improvement both RBI & RCM are being
implemented in the same units, so that each and every equipment/ piping is
addressed to ensure improvement.
• The implementation is in two phases:
First phase is of 16 months to implement in 18 units in presence of
consultant
The second phase is of 24 months where remote support will be
provided by the consultant.
• The 18 units have been selected in such a way that we have a template for
each type of unit, so that multiplying in other units of refineries will be
easier.
M&I Dept. - An extended arm of the refineries to improve reliability.
UNITS UNDER RBI & RCM IMPLEMENTATION IN IOCL
Refinery Pilot Unit Second Unit
GR INDMAX TPS
BR FCCU CRU
JR FCCU LAB
HR CIDW HGU-2
MR AVU DHDT
PR OHCU DCU
PNC - NCU & Swing
DR SDU WHFU
BGR DCU MSQ
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IMPLEMENTATION SCHEDULE OF RBI / RCM IN REFINERIES
10
07.07.14
07.07.14
02.07.14
30.06.14
05.07.14
11.09.14
22.09.14
01.09.14
15.09.14
25.08.14
30.06.14
08.09.14
Dec.14
Dec.14
M&I Dept. - An extended arm of the refineries to improve reliability.
Risk Based Inspection (RBI)
(Best suited for Static Equipment & Piping)
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WHAT IS RBI ? RBI is a method for using Risk as a basis for prioritising
and managing the efforts of an inspection program.
In an operating plant, a relatively large percentage of the
risk is associated with a small percentage of equipment
items.
RBI permits the shift of Inspection & Maintenance
resources to provide a higher level of coverage on the
high risk items and an appropriate effort on lower risk
equipment.
M&I Dept. - An extended arm of the refineries to improve reliability.
PROBABILITY
CONSEQUENCE
RISK
INTERNAL
CORROSION
EXTERNAL
CORROSIONCRACKING
& OTHERS
Release of flammable/
Toxic material Release of
excessive pressure
Environment
damageProduction
loss
RISK ANALYSIS
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RISK ASSESSMENT
RISK MANAGEMENT BY RBI
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THE TRANSITION
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SNAPSHOT – P&ID MARKING AS PER COLOUR CODE
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SNAPSHOT – SYSTEM ID & COLOUR CODE
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SNAPSHOT – CORROSION LOOP IDENTIFICATION
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SNAPSHOT – DATA COLLECTED FOR CORROSION STUDY
Design Press., Design Temp., Operating Press., Operating Temp., Material of Const.,
PWHT, Year in Service, Insulated & Corrosion Circuit from PFD
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CIRCUIT WISE CORROSION RATE FOR CRITICALITY
Circuit Line System Int. corr.
Mech
Int. Corr.
mm/yr
CUI Ext. corr. Ext.
Corr.
Rate
Ext. SCC
05-01-G 14 Feed sys General 0.025 Yes CUI CUI
05-01-H 10 Feed sys General 0.025 Yes CUI CUI
05-01-J 10 Feed sys General 0.025 No General 0.025
05-01-K 10 Feed sys General 0.025 No Oxidation 0.0125 Ext. SCC
05-01-L 6 Feed sys General 0.025 Yes CUI CUI
05-02-A 18 Reactor sys General 0.005 No Oxidation 0.0125
CUI corrosion rates will
be calculated by RBMI
package
Corrosion Rates decided based on:
Literature & Operating Parameters
Corrosion Expert
Validation by old readings
M&I Dept. - An extended arm of the refineries to improve reliability.
RBI EQUIPMENT DATA
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RBI EQUIPMENT HISTORY & NDT DATA
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RBI CORROSION STUDY
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Risk Based Inspection (RBI)
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RBI CRITICALITY ANALYSIS
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Risk with Typical
Inspection Programs
Risk Using RBI Uninspectable Risk
LEVEL OF INSPECTION ACTIVITY
RISK
M&I Dept. - An extended arm of the refineries to improve reliability.
Reliability Centered Maintenance
(RCM)
(Best suited for Rotary, Instrument & light
Electrical items)
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ROLE OF RCM
• RCM provides simple, precise and easily understood
criteria for deciding technical feasibility of PM / PdM task (if
any) in the particular context.
• This means that PM / PdM tasks are only specified for
failures which really need them.
• This in turn leads to substantial reduction in routine work
loads. Less routine work also means that the remaining
tasks are done properly.
• This together with the elimination of counter productive
tasks leads to more effective maintenance.
M&I Dept. - An extended arm of the refineries to improve reliability.29
ROLE OF RCM
• RCM creates awareness in Maintenance professionals
regarding six patterns of failures.
Maintenance professionals, as such, comes to terms with
the reality of randomness after decades in bathtub.
• Maintenance professionals thus realise that the idea of age
related failures simply does not apply to random failures
(Pattern D,E,F).
• An awareness of these facts has led some organisations to
abandon the idea of PM altogether for failures with minor
consequences.
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A
C
D
E
F
B
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RCM - PROCESS OVERVIEW
STEP-1
RCM process determines the functions and associatedperformance standards of the assets in its presentoperating context.
• Output, Thru’put, Quality
• Safety & Environmental Integrity, Quality
STEP-2
RCM process identifies the ways in which the asset canfail to live up to these expectations (failed states).
M&I Dept. - An extended arm of the refineries to improve reliability.32
RCM - PROCESS OVERVIEW
STEP-3
Then follows FMECA (failure modes and effects criticalityanalysis), to identify all the events which are reasonablylikely to cause each failed state.
STEP-4
RCM process seeks to identify a suitable failuremanagement policy for dealing with each failure mode inthe light of its consequences and technical characteristics.
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RCM - PROCESS OVERVIEW
STEP-5
The RCM process provides powerful rules based on RCMdecision logic diagram and decides whether any failuremanagement policy is technically appropriate and worthdoing.
Failure management policy options include:
– predictive maintenance– preventive maintenance– detective maintenance– change the design or configuration of the system– change the way the system is operated– run-to-failure.
M&I Dept. - An extended arm of the refineries to improve reliability.34
RCM PROCESS OVERVIEW
Failure Management - Basics
A great strength of RCM is that it recognises that theconsequences of failures are far more important than theirtechnical characteristics.
In fact, RCM recognizes that the only reason for doing anykind of proactive maintenance is not to avoid failure perse, but to avoid or at least to reduce the consequence offailure.
M&I Dept. - An extended arm of the refineries to improve reliability.35
RCM PROCESS OVERVIEW
Failure Management – Basics
The consequence evaluation process also shifts emphasisaway from the idea that all failures are bad and must beprevented.
In so doing, it focuses attention on the maintenanceactivities which have most effect on the performance ofthe organisation, and diverts energy away from thosewhich have little or no effect.
It also encourages us to think more broadly aboutdifferent ways to manage failure, rather than toconcentrate only on failure prevention.
M&I Dept. - An extended arm of the refineries to improve reliability.
SCREENSHOT – HIERARCHY OF ASSETS
Hierarchy of Assets indicating plant, system &
equipment
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ASSET HIERARCHY
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SCREENING
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RCM SCREENSHOT –RISK NUMBERS & FMEA
Assigning Risk Numbers for equipment
S-PoF (Safety probability of Failure)
S-CoF (Safety Consequence of Failure)
S-Risk (Safety Risk)
E-PoF (Environ probability of Failure)
E-CoF (Environ Consequence of Failure)
E-Risk (Environment Risk)
M&I Dept. - An extended arm of the refineries to improve reliability.
RISK ACCEPTANCE CRITERIA FOR PRODUCTION LOSS
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RISK ACCEPTANCE CRITERIA FOR ENVIRONMENT
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RISK ACCEPTANCE CRITERIA FOR SAFETY
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RISK ACCEPTANCE CRITERIA REPUTATION
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FMEA – Criticality Assessment
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LOGIC TREE FOR CONSEQUENCE ANALYSIS
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LOGIC TREE FOR TASK SELECTION
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CONCLUSION
Result of systematic and scientific asset management
systems by implementation of RBI & RCM will deliver
• Improved reliability of units.
• Improved asset integrity.
• Improvement in Run length.
• Improvement of on-stream factor.
• Improvement in Profitability.
• Reduction in Repair & Maintenance cost.
M&I Dept. - An extended arm of the refineries to improve reliability.
THANK YOU
48
M&I Dept. - An extended arm of the refineries to improve reliability.49
THIRTEEN ELEMENTS OF PAS-55
Element No. Subject
1 HSE and risk management system
2 Quality Management System
3 Asset Production Operations
4 AIMS Leadership
5 Engineering and Project Management
6 Maintenance and Reliability
7 Risk Management
8 Knowledge Management
9 Measurement and Continuous Improvement
10 Human Resources
11 Procurement
12 Information Systems and Documents
13 AIMS organization
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There are basically two approaches:
• Qualitative approach :
In this approach each unit or section of unit is analysed as per
risk based methodology. The high risk units or sections are
taken up for detailed inspection or further detailed quantitative
study.
This will be done to prioritize units for quantitative RBI
implementation.
• Quantitative approach :
In this approach each equipment is analysed as per risk based
methodology and the high risk equipment are identified for
thorough inspection. The inspection methodology is also
derived based on calculations.
WHAT IS RBI ?
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CONSEQUENCE CATEGORY - RBI has categorized failure ofpressure containing equipment into following four undesirableeffects.
– Flammable events
– Toxic events
– Major environment loss
– Business interruption loss.
WHAT IS RBI ?
(QUANTITATIVE APPROACH)
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Consequence Overview
Estimate the release rate or the total mass available for
release
Determine if the fluid is released in a rapid manner or
slowly
Determine if the fluid disperses in atmosphere as a liquid
or gas
Estimate the impacts of any mitigation system
Estimate the consequences.
WHAT IS RBI ?
(QUANTITATIVE APPROACH)
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Likelihood Overview
Frequency ADJUSTED
= Frequency GENERIC * FE * FM
Where
– FE is equipment modification factor
– FM is management system evaluation factor
– Frequency GENERIC is generic failure frequency
WHAT IS RBI ?
(QUANTITATIVE APPROACH)
M&I Dept. - An extended arm of the refineries to improve reliability.54
E D C B A
CONSEQUENCE CATEGORY
LIK
EL
IHO
OD
CA
TE
GO
RY
5
4
3
2
1 12
6
25
3
23
24
4
20
16
11 7
13
17
21 18 15 10
121922
14 9 5
8
M&I Dept. - An extended arm of the refineries to improve reliability.55
Inspection Program Options for Influencing Risk
Change inspection frequencies (when)
Change inspection scope/thoroughness (what)
Change inspection tools/techniques (how)
Change inspection practices (who)
WHAT IS RBI ?
M&I Dept. - An extended arm of the refineries to improve reliability.56
The areas of high risk and low risk may change due tochanged priorities of inspection and testing.
Focus will be made on new high risk areas. This will be acontinuous process.
As the refining margins are reducing all organizations are
making their best effort to find new ways of controlling or
reducing operational risks and associated costs.
WHAT IS RBI ?