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NSGI Equipment Reliability Short Overview
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NSGI Equipment Reliability Short Overview

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Short overview of Equipment Reliability

Short overview of Equipment Reliability

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NSGI Equipment Reliability Short Overview NSGI Equipment Reliability Short Overview Presentation Transcript

  • Equipment Reliability & Asset ManagementA Short Overview
    William H. Closser, Jr.
    President, NSGI
    Wclosser@thensgi.com
  • Equipment Reliability Process
    Equipment Reliability Process represents the integration and coordination of a broad range of equipment reliability activities into one process for plant personnel to evaluate important station equipment, develop and implement long-term equipment health plans, monitor equipment performance and condition, and make continuing adjustments to preventive maintenance tasks and frequencies based on equipment operating experience.
  • Equipment Reliability
    The ER process includes activities normally associated with such programs as:
    Reliability Centered Maintenance (RCM),
    Preventive Maintenance (periodic, predictive, and planned),
    Surveillance and Testing,
    Life-Cycle Management (LCM),
    Planning, and
    Equipment Performance and Condition Monitoring.
  • Equipment Reliability Process Objectives
    The process is efficient, incorporates human factor considerations, and ensures effective performance during all phases of plant operations.
    A uniform process is used among all plants in an organization.
    Applicable in-house and industry lessons learned are incorporated into the process to improve adequacy and efficiency.
    Changes to the process are timely, responsive to user feedback, and implemented at all affected plants.
  • Equipment Performance Objectives
    Equipment performs reliably through the operating cycle, and standby safety equipment operates properly on demand. Equipment is capable of satisfactory performance under all design conditions.
    Critical equipment is identified based on importance to safety function, and production capability.
    Equipment and system performance criteria are established, performance is monitored, adverse trends are identified, and corrective actions are implemented and verified for effectiveness.
    Failures and failure causes of concern are identified for critical equipment, and measures are established to prevent them.
  • Equipment Performance Objectives
    The need for in-depth analysis of equipment failure is commensurate with the equipment’s importance to plant safety and reliability and the likelihood of recurrence.
    Predictive maintenance technologies are implemented to detect equipment degradation well in advance of potential failure and to optimize equipment performance.
    Equipment aging is managed using preventive maintenance techniques and life-cycle management, including mitigation of environmental stressors (such as temperature, moisture) or operating stressors (such as duty cycles and vibration).
    Documented technical bases exist for preventive maintenance activities and aging management programs.
  • Equipment Performance Objectives
    Equipment performance data and associated trend information are uniformly collected and are readily accessible to support the prompt identification of problems and root causes.
    Equipment unavailability associated with preventive maintenance activities is balanced by the resulting improved equipment reliability and availability from prevented failures.
    Minimal in-service failures of critical equipment occur between scheduled maintenance intervals.
  • R = P x (B +K)
    R: Results (KPI’s, CAP Trends, System Health, etc.)
    P: Processes (ER)
    B: Behaviors (Intolerance, Craft Ownership, etc.)
    K: Knowledge (Personnel Skills & Training)
    Formula for Excellent ER
  • Equipment Reliability Performance 9 Critical Success Factors
    Intolerance of Unanticipated Equipment Failures
    Resolution of Long-Standing or Repetitive Equipment Problems
    Elimination of Design Vulnerabilities
    Focus on Critical Systems
    Proactive Engineering: Focusing on the Long Term
    Craft Ownership and Maintenance Supervision
    Preventive and Predictive Maintenance
    Successful Work Management
    Use of Operating Experience and Benchmarking
  • Example Equipment Reliability Performance Indicators
    forced loss reduction (FLR)
    cross-system component failure/degradation trends from problem reporting data (valves, heat exchangers, breakers, pumps, motors)
    number of overdue preventive maintenance tasks
    number and frequency of significant PM deferrals past the grace period
    number of systems with long-term maintenance plans
    number of non-outage (turn around) temporary modifications open more than three months, and number of outage-related temporary modifications open more than 12 months
    number of systems in accelerated testing
  • Example Equipment Reliability Performance Indicators
    operator workarounds that affect ability to operate equipment
    percentage of PM feedback sheets received, number of PM change requests, and backlog of PM changes waiting for review or implementation
    number of effectiveness reviews of equipment-related root causes and corrective actions (include repeat failures and consistency of engineering effort and quality)
    lost production capability caused by failures of components PM issues
    ratio of corrective maintenance tasks to preventive plus predictive (trend only)
  • Example Equipment Reliability Performance Indicators
    ratio of predictive tasks to preventive tasks (man-hours)
    repetitive equipment failures (more than one failure/cycle)
    frequency of circuit card/power supply failure per 7,000 operating hours or per year
    backlog or trend of corrective maintenance work orders that identify components whose function is failed or substantially degraded
  • ER/Asset Management Best Practices
  • Spare parts program
    Training
    Skills Development & Knowledge Capture
    CBM/
    PdM
    ID spare parts
    CD
    PM
    Scoping & Maint. Basis
    Work Control
    • Prioritize
    • Plan
    • Schedule
    Work Execution
    Work Closeout
    Proactive
    CMU
    R-T-F
    Procedure Mod
    CAP
    -ACA
    -RCA
    Continuous Improvement
    Design Mod
    Long Term Planning
    Simplified Asset Management Process
  • Change Management Plan Outline
    Mission
    Vision
    Stakeholders
    Current & Target Performance Levels
    Threats & Barriers Analysis
    Includes / Excludes Analysis
    Stakeholder Analysis
    Governing Documents
    Communication Plan
    Training Requirements
    Action Plan Detail
    Budget
    Performance Indicators
  • Tools of Change
    Workshops
    Assessments
    Equipment Reliability
    Predictive Maintenance/Condition Based Maintenance – Program & Technologies
    Asset Management
    Maintenance
    Others……
  • Tools of Change
    Library of Guiding Documents:
    Coaching
    Who
    Management
    Technician
    Craft
  • Tools of Change
    Coaching What
    Maintenance Basis Development
    PdM/CBM Process
    Work Management
    Corrective Actions Program
    Life Cycle Management/Equipment Aging
    Materials & Supply Chain Management
    Quality Assurance
    Others ……….
    Industry User Groups
  • 3 Phase Organizational Change Process