Apac 2015 minimizing integrity failure r02
- 1. Minimizing the integrity failures ofMinimizing the integrity failures of agingaging plants andplants and equipmentsequipments ThroughThrough Reliability Centered MaintenanceReliability Centered Maintenance ProSafeProSafe APACAPAC Process Safety Management ConferenceProcess Safety Management Conference 9 March 20159 March 2015 Bhavesh ShuklaBhavesh Shukla 1
- 2. 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. 2
- 3. Agenda • Failure Case study • Types of Maintenance • Risk Based Maintenance Strategy • Process Steps • Exercise 3
- 4. Reactor agitator failure Coupling with Torque Limiting Slip (TLS) Plate (Clutch) 4
- 5. Agitator FailureCost 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 limiterreplacement 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 5
- 6. Types of Maintenance •Repair Run to failure •Preventive Maintenance Time basedTime based •Predictive Maintenance Condition based 6
- 7. 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 7
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- 10. •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. 10
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- 14. 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 14
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- 16. Vibration Monitoring & Analysis 16
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- 19. 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 19
- 20. 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 20 Asset Risk Number Failure Probability Factor Maintenance Priority Number Reactive Maintenance Performed… Daily, Weekly, Monthly, Quarterly, Annually
- 21. System Risk Ranking Process Area SF RC QF PT OC SRN PROCESS SYSTEM NAME Safety Failures Regulatory 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 21
- 22. Maintenance Priority Ranking Process Risk 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 22 PROCESS SYSTEM NAME Risk Number Risk Number Risk Number Probability Factor Maintenance 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
- 23. 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 23