RAMS for new projects


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RAMS studies for new projects by ARMS Reliability

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RAMS for new projects

  1. 1.
  2. 2. ARMS Reliability commenced business in August 1995.Australia<br />VIC, QLD, WA, NSW, SA<br />North AmericaAustin, Texas<br />South Africa<br />
  3. 3. Empower | Educate | Equip<br />We empower our clients (and their teams) through consulting advice.<br />We educate our clients (and their teams) through relevant and well-delivered training programs.<br />We equip our clients (and their teams) with software and enabling tools.<br />
  4. 4. What Differentiates ARMS from other Service Providers?<br /><ul><li> Engagement of workforce to support cultural change
  5. 5. Delivering Reliability Improvements since 1995
  6. 6. Lead the functional design of Availability Workbench
  7. 7. Lead functional design of SAP Integration
  8. 8. Integration with SAP, Ellipse, Maximo.
  9. 9. Not just a software house, maintenance people understanding maintenance issues
  10. 10. Our team is made up of maintenance and reliability professionals
  11. 11. Real Data Handling
  12. 12. Not just about the tool, implementation and understanding is the key to long term success and sustainability</li></li></ul><li>5<br />Capability<br />17 Engineers, 5 of these have been maintenance/engineering department managers.<br />2 Full Time Trainers.<br />7 Support Staff<br />Some Selected close held subcontract specialists<br />
  13. 13. Companies engage us to<br />build Reliability into their Design on major capital projects<br />Reduce the high cost of unplanned maintenance, eliminate lost revenue caused by unplanned maintenance and escape a reactive maintenance culture. <br />Evaluate existing plant performance and identify bottlenecks and improvement opportunities. <br />Help them quantify whether their current maintenance strategy for new or existing equipment is able to deliver the required business results<br />Eliminate recurring problems<br />Escape a reactive maintenance culture<br />
  14. 14. Our Mining Clients<br />
  15. 15. 8<br />The ARMS Reliability offering<br />
  16. 16. Proactive Asset Management<br />Breakdowns<br />ARMS Specialises in Reliability Processes<br />& Tools That Reduce Reactive Maintenance<br />RCM<br />EAM<br />Work Orders<br />History<br />Optimised<br />Asset Management Strategies<br />Maintenance Plans<br />RCA<br />For Defect Elimination<br />
  17. 17. Services for New Projects<br />Understanding the link between engineering design and the Reliability, Availability, Maintainability and Safety (RAMS) can have a significant impact on the lifecycle cost of a project and determine the difference between a successful project and a financial headache.<br />RAMS Analysis The benefit of doing RAMS analysis early in a major capital project is that critical reliability issues can be addressed before expensive detailed design and procurement, and certainly making changes prior to construction and commissioning saves a lot of valuable time and expense.<br />Maintenance Strategy Development In the design stage of a new project there are many unknowns. By calling on ARMS experience in dealing with similar projects, the development of a maintenance strategy can be streamlined and delivered in a shorter timeframe<br />Capacity & Availability Predictions are crucial in assessing if the planned design will deliver the budgeted throughput and <br />Budget & Resource Forecasting allows you to determine the risk and value impact of various expenditure scenarios and project medium to long term capital and maintenance budgets<br />
  18. 18. Current Reliability Studies<br /><ul><li> BHP Billiton Jansen – RAMS Model to Review Current Design – Pre Feasibility
  19. 19. Peabody Energy – D11 Dozers – Optimize Maintenance Strategy, Compare Repair vs Replace
  20. 20. Collahuasi – Bucyrus 495B1 & 495HR Shovels
  21. 21. Blair Athol Coal – Dragline Maintenance Strategy Review
  22. 22. Blair Athol Coal – Defect Elimination Program
  23. 23. Anglo Gold – Asset Integrity Review
  24. 24. BHP Billiton Iron Ore
  25. 25. Port Expansion - Maintenance Strategy Development
  26. 26. Rapid Growth Project – Maintenance Strategy Development </li></li></ul><li>Other Major Completed Projects<br />A sample of other Reliability projects completed by ARMS using RAMS to predict reliability and capacity:<br /><ul><li> Anaconda Nickel Project (2001)
  27. 27. Zinifex Century Mine (2003)
  28. 28. BMA Blackwater, Coal Prep Plant. (2005)
  29. 29. Argyle Diamonds Crushing Plant (2006)
  30. 30. BHP Olympic Dam Expansion (2007-2008)
  31. 31. BHP Cannington Proposed Expansion Project (2008)
  32. 32. BHP Iron Ore “East Yard: Car Dumper 3 to Shiploader 3” reliability model (2009)</li></li></ul><li>RAMS for New Projects<br />IPA studies have shown that reliability analysis conducted early in project cycle saves 15% of total project costs.<br />
  33. 33. Can you answer the following?<br />• Will the design meet the objectives over the lifetime?• Is there enough redundancy? • Are stockpiles, surge and buffers correctly sized? • Identify bottlenecks. • Will my maintenance strategy deliver what the design expects? • How many resources will be required and when? • How many spares will I need? • How do I develop a maintenance plan for new equipment? • How can I validate the OEM’s recommendations? <br />
  34. 34. RAMS Outputs<br /><ul><li> An early indication of a system’s potential to meet the design availability and reliability requirements.
  35. 35. Enables assessment of lifecycle costs to be carried out.
  36. 36. An early indication of which components or areas contribute to the major portion of capacity loss.
  37. 37. Enables trade offs to be made between reliability, maintainability, redundancy and buffer capacity.
  38. 38. Provides early assessment of Safety and Environmental compliance.
  39. 39. Identifies Critical items
  40. 40. Predicts resource usage</li></li></ul><li>Typical Phases of a Major Capital Project<br />Project Phases Defined by IPA*<br />
  41. 41. RAMS for New Projects<br />
  42. 42. Influence Of A Major Capital Project Lifecycle Cost<br />Low Influence<br />Rapidly Decreasing Influence<br />Major Influence<br />FINAL<br />AUTHORIZATION<br />INFLUENCE<br />EXPENDITURES<br />INFLUENCE<br />EXPENDITURES<br />MECHANICAL<br />FRONT END LOADING<br />COMPLETE<br />COMMERCIAL OPS<br />
  43. 43. Optimal Approach<br />Generic Performance Characteristics<br />RBM (Availability Capacity Modeling)<br />Data Used for Predictions<br />Specific Characteristics<br />RCM (Maintenance Strategy Development)<br />Generic Library RCM Data<br />Project Life<br />
  44. 44. Reliability Tools Applicable<br />Front End Engineering<br />
  45. 45. Isograph Software Suite<br />Design Activity<br />AvSim<br />HAZOP+<br />FaultTree+<br />Reliability Workbench<br />Operate & Maintain(through life support)<br />AvSim<br />LCC<br />FaultTree<br />RCMCost<br />ERP Portals<br />Availability Workbench<br />
  46. 46. Full Integration Reliability Toolkit<br />Seamless Data Flow<br />