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

1

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

Agenda

• Failure Case study

• Types of Maintenance

• Risk Based Maintenance Strategy

• Process Steps

• Exercise

3

Reactor agitator failure

Coupling with

Torque Limiting Slip (TLS) Plate

(Clutch)

4

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

5

Types of Maintenance

•Repair

�Run to failure

•Preventive Maintenance

�Time based�Time based

•Predictive Maintenance�Condition based

6

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

8

9

•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

11

12

13

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

15

Vibration Monitoring & Analysis

16

17

Condition Based Maintenance

18

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

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

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

21

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

22

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

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

Contact:

bhaveshjayati@hotmail.com

+65 96907710

24