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
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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.
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3. Agenda
• Failure Case study
• Types of Maintenance
• Risk Based Maintenance Strategy
• Process Steps
• Exercise
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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
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6. Types of Maintenance
•Repair
Run to failure
•Preventive Maintenance
Time basedTime based
•Predictive Maintenance
Condition based
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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
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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.
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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
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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
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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
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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
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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
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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
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