Reliability-centered Maintenance is a maintenance philosophy that includes a systematic approach to determining how to maintain equipment safely and economically. RCM is an invaluable business solution for companies
In situations where equipment failure is inevitable, the structured RCM process will ensure a maintenance strategy that will minimise or eliminate the consequences.
The central problem addressed by the RCM process is how to determine which scheduled maintenance tasks, if any, should be assigned to equipment, and how frequently
Reliability Centered Maintenance for minimizing integrity failure by Bhavesh Shukla at APAC 2015 Process Safety Management Conference 9th March 2015 Singapore.
Sample process guide_-_change_managementbalajimuthu10
This document outlines the change management process and procedures for XXXXX Information Technology. It defines change levels from Level 1 to Level 4 based on impact and risk, with Level 1 being minor changes and Level 4 being major changes. It describes the approval, lead time, and documentation requirements for each level. It also outlines the roles and responsibilities in the change management process and the workflows to enter, approve, implement, and close a change request.
The document provides an overview of advanced process control (APC), including its definition, applications, advantages, and limitations. It discusses how APC builds on basic process control techniques by using process models and optimization to enhance plant operation and profitability. Examples are given of APC applications in petrochemical plants and semiconductor manufacturing. The benefits of APC include improved yield, quality, energy efficiency, and responsiveness. However, APC implementations are also complex, time-consuming, and require specialized expertise and resources.
This document discusses state-based control and its benefits over traditional control systems. State-based control recognizes that processes operate in different states, such as running, startup, or shutdown, and the control system should change based on the current process state. This allows the control system to optimize for each state rather than just the running state. Some key benefits of state-based control include improved safety, reduced downtime, increased productivity, knowledge capture from experienced operators, and freeing up operators to manage processes at a higher level.
The document discusses advanced process control (APC) systems and their benefits. APC systems use modeling, multivariable control, and other technologies to automatically optimize control actions and minimize process variation, unlike traditional control systems. Example applications and benefits of APC are provided for dairy manufacturing processes like milk powder production and cheese making. APC can increase throughput, yield, and energy savings while reducing variation. The last section discusses APC solutions for biofuel manufacturing processes like ethanol production.
This document provides a summary of an advanced process control final project. It includes sections on what-if scenario analysis, move suppression tuning, and a literature review of various model predictive control technologies. The what-if scenario analysis examines the effects of changing variables like fuel gas costs and feed rates. The move suppression tuning section details tuning the controller to suppress large manipulated variable moves. The literature review provides overviews of several commercial MPC systems, including descriptions of their capabilities and benefits.
Practical Advanced Process Control for Engineers and TechniciansLiving Online
In today's environment, the processing, refining and petrochemical business is becoming more and more competitive and every plant manager is looking for the best quality products at minimum operating and investment costs. The traditional PID loop is used frequently for much of the process control requirements of a typical plant. However there are many drawbacks in using these, including excessive dead time which can make the PID loop very difficult (or indeed impossible) to apply.
Advanced Process Control (APC) is thus essential today in the modern plant. Small differences in process parameters can have large effects on profitability; get it right and profits continue to grow; get it wrong and there are major losses. Many applications of APC have pay back times well below one year. APC does require a detailed knowledge of the plant to design a working system and continual follow up along the life of the plant to ensure it is working optimally. Considerable attention also needs to be given to the interface to the operators to ensure that they can apply these new technologies effectively as well.
WHO SHOULD ATTEND?
Automation engineers
Chemical engineers
Chemical plant technologists
Electrical engineers
Instrumentation and control engineers
Process control engineers
Process engineers
Senior technicians
System integrators
MORE INFORMATION: http://www.idc-online.com/content/practical-advanced-process-control-engineers-and-technicians-26
Reliability Centered Maintenance for minimizing integrity failure by Bhavesh Shukla at APAC 2015 Process Safety Management Conference 9th March 2015 Singapore.
Sample process guide_-_change_managementbalajimuthu10
This document outlines the change management process and procedures for XXXXX Information Technology. It defines change levels from Level 1 to Level 4 based on impact and risk, with Level 1 being minor changes and Level 4 being major changes. It describes the approval, lead time, and documentation requirements for each level. It also outlines the roles and responsibilities in the change management process and the workflows to enter, approve, implement, and close a change request.
The document provides an overview of advanced process control (APC), including its definition, applications, advantages, and limitations. It discusses how APC builds on basic process control techniques by using process models and optimization to enhance plant operation and profitability. Examples are given of APC applications in petrochemical plants and semiconductor manufacturing. The benefits of APC include improved yield, quality, energy efficiency, and responsiveness. However, APC implementations are also complex, time-consuming, and require specialized expertise and resources.
This document discusses state-based control and its benefits over traditional control systems. State-based control recognizes that processes operate in different states, such as running, startup, or shutdown, and the control system should change based on the current process state. This allows the control system to optimize for each state rather than just the running state. Some key benefits of state-based control include improved safety, reduced downtime, increased productivity, knowledge capture from experienced operators, and freeing up operators to manage processes at a higher level.
The document discusses advanced process control (APC) systems and their benefits. APC systems use modeling, multivariable control, and other technologies to automatically optimize control actions and minimize process variation, unlike traditional control systems. Example applications and benefits of APC are provided for dairy manufacturing processes like milk powder production and cheese making. APC can increase throughput, yield, and energy savings while reducing variation. The last section discusses APC solutions for biofuel manufacturing processes like ethanol production.
This document provides a summary of an advanced process control final project. It includes sections on what-if scenario analysis, move suppression tuning, and a literature review of various model predictive control technologies. The what-if scenario analysis examines the effects of changing variables like fuel gas costs and feed rates. The move suppression tuning section details tuning the controller to suppress large manipulated variable moves. The literature review provides overviews of several commercial MPC systems, including descriptions of their capabilities and benefits.
Practical Advanced Process Control for Engineers and TechniciansLiving Online
In today's environment, the processing, refining and petrochemical business is becoming more and more competitive and every plant manager is looking for the best quality products at minimum operating and investment costs. The traditional PID loop is used frequently for much of the process control requirements of a typical plant. However there are many drawbacks in using these, including excessive dead time which can make the PID loop very difficult (or indeed impossible) to apply.
Advanced Process Control (APC) is thus essential today in the modern plant. Small differences in process parameters can have large effects on profitability; get it right and profits continue to grow; get it wrong and there are major losses. Many applications of APC have pay back times well below one year. APC does require a detailed knowledge of the plant to design a working system and continual follow up along the life of the plant to ensure it is working optimally. Considerable attention also needs to be given to the interface to the operators to ensure that they can apply these new technologies effectively as well.
WHO SHOULD ATTEND?
Automation engineers
Chemical engineers
Chemical plant technologists
Electrical engineers
Instrumentation and control engineers
Process control engineers
Process engineers
Senior technicians
System integrators
MORE INFORMATION: http://www.idc-online.com/content/practical-advanced-process-control-engineers-and-technicians-26
The document discusses process control systems. It defines a process as a sequence of interdependent steps that transforms inputs into outputs. Control refers to regulating all aspects of a process. There are three main types of processes: continuous, batch, and discrete. A process control system uses sensors, controllers and actuators to monitor and regulate variables like pressure, temperature and flow to maintain efficiency and safety. Common applications include manufacturing plants and wastewater treatment. Advanced process control techniques like model predictive control use dynamic models and optimization to control multiple variables simultaneously.
Process control systems involve controlling a physical system using feedback loops. They have controlled variables, input variables, manipulated variables, and set points. Closed loop control is preferred over open loop when external perturbations could affect the system. When choosing a control architecture, consider closed loop control if the task requires continuing action to maintain a state. For example, a cruise control system uses a controller, sensors for speed/acceleration, and manipulates the throttle setting based on a desired speed set point.
Maximizing the return on your control investment meet the experts sessions part2Emerson Exchange
This document discusses when and why advanced control techniques beyond single-loop PID control may be needed. It describes economic incentive, safety/compliance, and equipment protection as key objectives that can require reduced variability. Multi-loop techniques like feedforward, cascade, and override control are introduced to improve control in cases where single PID loops are insufficient. Model predictive control is also presented as an option for addressing difficult dynamics or process interactions. Examples of ammonia plants, spray dryers, and batch reactors are provided.
Advanced control foundation tools and techniquesEmerson Exchange
A new book on advanced control fundamental will be published by ISA in September, 2012. This book addresses all the advanced control products that are included in the DeltaV control system or are planned for a future DeltaV release. In this session two of the authors present and discuss key areas addressed in the book and demonstrate web site that accompanies the book.
Turbine Controls Limited develops standardized gas turbine control systems that provide low cost and faster installation compared to custom systems. The pre-developed systems interface seamlessly with existing plant equipment, improving reliability, functionality, diagnostics, and maintainability. They are designed by engineers using latest techniques to minimize costs and reduce outage times for installation, resulting in quick payback periods. Standard control systems have been developed for GE Frame 3 and 5 engines and Ruston gas turbines from 1MW to 6MW.
Aplication of on line data analytics to a continuous process polybetene unitEmerson Exchange
This Emerson Exchange, 2013 presentation summarizes the 2013 field trail results achieved by applying on-line continuous data analytics to Lubrizol’s continuous polybutene process. Continuous data analytics may be used to provide an on-line prediction of quality parameters, and enable on-line detection of fault conditions. Information is provided on improvements made in the model used for quality parameter prediction, and how the field trail platform was integrated into the process unit. Presenters Qiwei Li, production engineer, Efren Hernandez and Robert Wojewodka, Lubrizol Corp., and Terry Blevins, principal technologist at Emerson, won best in conference in the process optimization track for this presentation.
Eliminating Difficult Start-ups with State Based ControlsISA Interchange
The document discusses challenges with starting up difficult processes and how total automation can help address these challenges. It notes that issues like operator error, aging workforces, variability in operator skills, and process complexity can prolong startups and cause errors. Total automation, where the entire startup process is automated using advanced control strategies, regulatory controls, and state logic, can reduce startup times by half to two-thirds and make the process more reliable and repeatable. It also discusses elements that make processes difficult to control, like small operating envelopes and multitasking requirements, and how automation can help maintain critical process boundaries.
Maximizing the return on your control investment meet the experts sessions pa...Emerson Exchange
The design and commissioning of the controls associated with a continuous or batch process directly impact plant operating efficiency and production quality and throughput. In this session we review techniques that may be used to identify control opportunities to reduce production costs, minimize variations in product quality and to maximize production within the limits set by market demand. Several common application examples from the process industry will be used to illustrate how plant production rate and product quality are directly influenced by process control variation and constraints in plant operation. Starting with an assessment of control loop utilization and automatic control performance, a step by step process is outlined that may be used to identifying and addressing areas where it is possible to justified the time and material costs required to improve control performance. In particular, information will be provided on how to quickly tune single loop control of self-regulating or integrating process and to recognize when variations in control loop performance are not associated with loop tuning. An overview will be provided of tools and techniques that may be used to achieve best control performance over a wide variety of operating conditions. Also, guidance will be provided on when it is possible to justify the cost associated with the installation and commissioning of multi-loop techniques such as feedforward control, ratio and override control. The steps required to commission multi-loop control strategies will be address along with common mistakes to avoid. Also, input will be provided on how to recognize when advanced control techniques such as Fuzzy logic or MPC are needed to achieve the desired control performance. At the end of this session a drawing will be held to give away 10 copies of “Control Loop Foundation – Batch and Continuous Processes”. Many of the ideas discussed in this session are addressed in this book.
Learn how proper control of your MRO processes can streamline your workflow and improve overall product quality. Integrated MRO supply chain management can automate repair and overhaul processes, lowering your maintenance expenditures and overall compliance risk.
Recovery from a process saturation condition benefits of using delta v pid_plusEmerson Exchange
The PIDPlus option of the PID function block in the DeltaV v11.3 allows improved recovery from a process saturation condition. In this workshop the technical basis for the change in the PID are presented. The impact this has on the time required to get to setpoint is examined and the improvement in response for the surge control will be demonstration using a synamic compressor simulation.
In this presentation we address the implementation of a scalar Kalman Filter for use in closed loop control of industrial process that is characterized by one manipulated input and one controlled parameter. A DeltaV linked composite is described that allows Kalman filtering to be used with the PID block in closed loop control. Also, information is provided on a DeltaV module that may be used to get more familiar with the Kalman filter in a test environment. The Kalman Filter composite and test module may be accessed through application exchange at the DeltaV Interactive Portal
The document discusses plans for implementing a preventive maintenance program at a residential life facility. It outlines preparations like gathering equipment data, labeling systems, and preparing equipment. It describes the maintenance management system that will be used to schedule tasks. Implementing preventive maintenance is expected to save significant time on tasks like filter changes. Challenges may include social and technical factors, but the benefits of preventive maintenance in reducing costs and downtime outweigh these challenges.
This document discusses implementing a condition-based maintenance (CBM) program across an entire enterprise using the OSIsoft PI System. It describes CBM as a proactive approach that monitors assets for early signs of degradation to predict and prevent failures. The document outlines how to collect asset data, structure it for analysis and visualization, and create a web portal to monitor asset conditions and receive notifications. Implementing this CBM methodology can help organizations optimize maintenance processes and reduce costs through more efficient asset management.
The DeltaV PIDPlus is based on a modification of the PID reset and rate calculation to account for non-periodic measurement updates. An alternate approach is to use PID with a modified Kalman filter or modified Smith Predictor. Test results are presented that compare the PIDPlus to these alternate approaches.
1) A step test was performed on a simulated gas processing plant to generate data for building a dynamic model predictive controller (DMC).
2) An economic model was generated using the steady state gains from the plant test data to calculate the linear programming (LP) costs associated with changes in economic variables like duty rates.
3) Equal concern errors were calculated for controlled variables (CVs) like sales gas dew point and propane composition based on their relative importance, with a higher weight given to maintaining propane composition given its greater economic impact.
This document defines operator maintenance and its importance. It discusses the different types of start-up for a thermal power plant, including cold, warm, hot, and very hot start-up. It also outlines some of the limitations and terms used in cold start-up procedures, such as turbine pre-warming. Finally, it briefly discusses the different types of maintenance, including preventive, corrective, and shutdown maintenance.
RBI is a risk-based method to determine optimal inspection scope and intervals using data-driven approaches. It improves equipment integrity, safety, and maintenance costs. Keel provides RBI implementation services including onsite data collection, inspection scheduling aligned with plant maintenance, and integrating inspections into the CMMS. Keel also offers additional engineering support services to optimize plant maintenance including reliability analysis, equipment criticality assessment, and project support. The RBI process involves collecting and evaluating data, identifying risks, developing inspection programs, implementing programs into the CMMS, and ongoing review and adjustment.
This document discusses embedding Risk-Based Inspection (RBI) software within IBM Maximo enterprise asset management solutions. RBI helps asset-intensive industries improve safety, uptime, and cost control by predicting failures and focusing resources. Embedding RBI provides predictive models, reliability analysis, and compliance monitoring to maximize asset performance while leveraging existing EAM investments. It can quantify risk, predict failures, focus work, and enable continuous improvement through an integrated approach within the Maximo platform.
This document discusses minimizing integrity failures of aging plants and equipment through reliability centered maintenance. It defines different types of maintenance such as repair, preventive maintenance, and predictive maintenance. The document outlines the process of reliability centered maintenance, including identifying failure modes, prioritizing risks, and selecting maintenance tasks. It provides an example of applying this process to develop a maintenance strategy for different systems based on their risk ranking.
The document provides an overview of reliability centered maintenance (RCM) including:
1. RCM is a process used to determine necessary maintenance to ensure assets perform their intended functions by mitigating failure consequences.
2. An RCM analysis involves a multifunctional team answering seven questions about asset functions, failures, failure causes, effects, importance, and predictive/preventive maintenance techniques.
3. Implementing RCM principles like condition-based maintenance improves reliability by focusing maintenance on asset condition rather than rigid schedules and reducing unnecessary tasks.
The document discusses process control systems. It defines a process as a sequence of interdependent steps that transforms inputs into outputs. Control refers to regulating all aspects of a process. There are three main types of processes: continuous, batch, and discrete. A process control system uses sensors, controllers and actuators to monitor and regulate variables like pressure, temperature and flow to maintain efficiency and safety. Common applications include manufacturing plants and wastewater treatment. Advanced process control techniques like model predictive control use dynamic models and optimization to control multiple variables simultaneously.
Process control systems involve controlling a physical system using feedback loops. They have controlled variables, input variables, manipulated variables, and set points. Closed loop control is preferred over open loop when external perturbations could affect the system. When choosing a control architecture, consider closed loop control if the task requires continuing action to maintain a state. For example, a cruise control system uses a controller, sensors for speed/acceleration, and manipulates the throttle setting based on a desired speed set point.
Maximizing the return on your control investment meet the experts sessions part2Emerson Exchange
This document discusses when and why advanced control techniques beyond single-loop PID control may be needed. It describes economic incentive, safety/compliance, and equipment protection as key objectives that can require reduced variability. Multi-loop techniques like feedforward, cascade, and override control are introduced to improve control in cases where single PID loops are insufficient. Model predictive control is also presented as an option for addressing difficult dynamics or process interactions. Examples of ammonia plants, spray dryers, and batch reactors are provided.
Advanced control foundation tools and techniquesEmerson Exchange
A new book on advanced control fundamental will be published by ISA in September, 2012. This book addresses all the advanced control products that are included in the DeltaV control system or are planned for a future DeltaV release. In this session two of the authors present and discuss key areas addressed in the book and demonstrate web site that accompanies the book.
Turbine Controls Limited develops standardized gas turbine control systems that provide low cost and faster installation compared to custom systems. The pre-developed systems interface seamlessly with existing plant equipment, improving reliability, functionality, diagnostics, and maintainability. They are designed by engineers using latest techniques to minimize costs and reduce outage times for installation, resulting in quick payback periods. Standard control systems have been developed for GE Frame 3 and 5 engines and Ruston gas turbines from 1MW to 6MW.
Aplication of on line data analytics to a continuous process polybetene unitEmerson Exchange
This Emerson Exchange, 2013 presentation summarizes the 2013 field trail results achieved by applying on-line continuous data analytics to Lubrizol’s continuous polybutene process. Continuous data analytics may be used to provide an on-line prediction of quality parameters, and enable on-line detection of fault conditions. Information is provided on improvements made in the model used for quality parameter prediction, and how the field trail platform was integrated into the process unit. Presenters Qiwei Li, production engineer, Efren Hernandez and Robert Wojewodka, Lubrizol Corp., and Terry Blevins, principal technologist at Emerson, won best in conference in the process optimization track for this presentation.
Eliminating Difficult Start-ups with State Based ControlsISA Interchange
The document discusses challenges with starting up difficult processes and how total automation can help address these challenges. It notes that issues like operator error, aging workforces, variability in operator skills, and process complexity can prolong startups and cause errors. Total automation, where the entire startup process is automated using advanced control strategies, regulatory controls, and state logic, can reduce startup times by half to two-thirds and make the process more reliable and repeatable. It also discusses elements that make processes difficult to control, like small operating envelopes and multitasking requirements, and how automation can help maintain critical process boundaries.
Maximizing the return on your control investment meet the experts sessions pa...Emerson Exchange
The design and commissioning of the controls associated with a continuous or batch process directly impact plant operating efficiency and production quality and throughput. In this session we review techniques that may be used to identify control opportunities to reduce production costs, minimize variations in product quality and to maximize production within the limits set by market demand. Several common application examples from the process industry will be used to illustrate how plant production rate and product quality are directly influenced by process control variation and constraints in plant operation. Starting with an assessment of control loop utilization and automatic control performance, a step by step process is outlined that may be used to identifying and addressing areas where it is possible to justified the time and material costs required to improve control performance. In particular, information will be provided on how to quickly tune single loop control of self-regulating or integrating process and to recognize when variations in control loop performance are not associated with loop tuning. An overview will be provided of tools and techniques that may be used to achieve best control performance over a wide variety of operating conditions. Also, guidance will be provided on when it is possible to justify the cost associated with the installation and commissioning of multi-loop techniques such as feedforward control, ratio and override control. The steps required to commission multi-loop control strategies will be address along with common mistakes to avoid. Also, input will be provided on how to recognize when advanced control techniques such as Fuzzy logic or MPC are needed to achieve the desired control performance. At the end of this session a drawing will be held to give away 10 copies of “Control Loop Foundation – Batch and Continuous Processes”. Many of the ideas discussed in this session are addressed in this book.
Learn how proper control of your MRO processes can streamline your workflow and improve overall product quality. Integrated MRO supply chain management can automate repair and overhaul processes, lowering your maintenance expenditures and overall compliance risk.
Recovery from a process saturation condition benefits of using delta v pid_plusEmerson Exchange
The PIDPlus option of the PID function block in the DeltaV v11.3 allows improved recovery from a process saturation condition. In this workshop the technical basis for the change in the PID are presented. The impact this has on the time required to get to setpoint is examined and the improvement in response for the surge control will be demonstration using a synamic compressor simulation.
In this presentation we address the implementation of a scalar Kalman Filter for use in closed loop control of industrial process that is characterized by one manipulated input and one controlled parameter. A DeltaV linked composite is described that allows Kalman filtering to be used with the PID block in closed loop control. Also, information is provided on a DeltaV module that may be used to get more familiar with the Kalman filter in a test environment. The Kalman Filter composite and test module may be accessed through application exchange at the DeltaV Interactive Portal
The document discusses plans for implementing a preventive maintenance program at a residential life facility. It outlines preparations like gathering equipment data, labeling systems, and preparing equipment. It describes the maintenance management system that will be used to schedule tasks. Implementing preventive maintenance is expected to save significant time on tasks like filter changes. Challenges may include social and technical factors, but the benefits of preventive maintenance in reducing costs and downtime outweigh these challenges.
This document discusses implementing a condition-based maintenance (CBM) program across an entire enterprise using the OSIsoft PI System. It describes CBM as a proactive approach that monitors assets for early signs of degradation to predict and prevent failures. The document outlines how to collect asset data, structure it for analysis and visualization, and create a web portal to monitor asset conditions and receive notifications. Implementing this CBM methodology can help organizations optimize maintenance processes and reduce costs through more efficient asset management.
The DeltaV PIDPlus is based on a modification of the PID reset and rate calculation to account for non-periodic measurement updates. An alternate approach is to use PID with a modified Kalman filter or modified Smith Predictor. Test results are presented that compare the PIDPlus to these alternate approaches.
1) A step test was performed on a simulated gas processing plant to generate data for building a dynamic model predictive controller (DMC).
2) An economic model was generated using the steady state gains from the plant test data to calculate the linear programming (LP) costs associated with changes in economic variables like duty rates.
3) Equal concern errors were calculated for controlled variables (CVs) like sales gas dew point and propane composition based on their relative importance, with a higher weight given to maintaining propane composition given its greater economic impact.
This document defines operator maintenance and its importance. It discusses the different types of start-up for a thermal power plant, including cold, warm, hot, and very hot start-up. It also outlines some of the limitations and terms used in cold start-up procedures, such as turbine pre-warming. Finally, it briefly discusses the different types of maintenance, including preventive, corrective, and shutdown maintenance.
RBI is a risk-based method to determine optimal inspection scope and intervals using data-driven approaches. It improves equipment integrity, safety, and maintenance costs. Keel provides RBI implementation services including onsite data collection, inspection scheduling aligned with plant maintenance, and integrating inspections into the CMMS. Keel also offers additional engineering support services to optimize plant maintenance including reliability analysis, equipment criticality assessment, and project support. The RBI process involves collecting and evaluating data, identifying risks, developing inspection programs, implementing programs into the CMMS, and ongoing review and adjustment.
This document discusses embedding Risk-Based Inspection (RBI) software within IBM Maximo enterprise asset management solutions. RBI helps asset-intensive industries improve safety, uptime, and cost control by predicting failures and focusing resources. Embedding RBI provides predictive models, reliability analysis, and compliance monitoring to maximize asset performance while leveraging existing EAM investments. It can quantify risk, predict failures, focus work, and enable continuous improvement through an integrated approach within the Maximo platform.
This document discusses minimizing integrity failures of aging plants and equipment through reliability centered maintenance. It defines different types of maintenance such as repair, preventive maintenance, and predictive maintenance. The document outlines the process of reliability centered maintenance, including identifying failure modes, prioritizing risks, and selecting maintenance tasks. It provides an example of applying this process to develop a maintenance strategy for different systems based on their risk ranking.
The document provides an overview of reliability centered maintenance (RCM) including:
1. RCM is a process used to determine necessary maintenance to ensure assets perform their intended functions by mitigating failure consequences.
2. An RCM analysis involves a multifunctional team answering seven questions about asset functions, failures, failure causes, effects, importance, and predictive/preventive maintenance techniques.
3. Implementing RCM principles like condition-based maintenance improves reliability by focusing maintenance on asset condition rather than rigid schedules and reducing unnecessary tasks.
The document describes a case study applying reliability-centered maintenance (RCM) methodology to develop a maintenance plan for a steam-process plant in Egypt. The plant consists of a fire-tube boiler, feed-water pump, dryers, and process heater. A failure mode and effect analysis was conducted for critical equipment. The boiler and pump were found to be critical. An RCM-based maintenance program was developed that decreased labor costs by 25.8% and downtime costs by 80% compared to the plant's current maintenance.
Cutler-Hammer Maintenance Program LTM 2010p6q4ck9dyn
This document discusses Cutler-Hammer's maintenance program and monitoring services for customers. It outlines predictive, preventative, and reliability-centered maintenance testing and strategies. These include infrared inspection, partial discharge testing, vibration analysis, oil analysis, and remote monitoring. The document also discusses alliance partner expectations, the effects of maintenance quality on failure rates, and long-term maintenance contracts.
Introduction to Reliability Centered MaintenanceDibyendu De
Introduces Reliability Centered Maintenance, strategies employed, formulation of effective maintenance plan, reduction of consequences of failures and failure rate.
Condition Based Asset Management R K GuptaRajuGupta88
The document provides information on condition based maintenance of critical machinery assets. It discusses how predictive maintenance (PdM), proactive reliability maintenance (PRM), and integrated maintenance solutions (IMS) can help reduce maintenance costs and increase reliability. PdM involves collecting machine condition data to detect potential failures, PRM aims to eliminate the root causes of failures through analysis and key performance indicators, and IMS is a comprehensive agreement that includes PRM services and technology upgrades to optimize plant asset efficiency. The document emphasizes that the best companies have high reliability with low maintenance costs by taking a proactive approach to maintenance focused on failure prevention rather than reactive repairs.
The document discusses maintenance management. It defines maintenance as keeping physical plant in good operating condition. The objectives of maintenance include minimizing downtime and costs. Failure can negatively impact operations, reputation, profits and customers. There are different types of maintenance like preventive, predictive, and planned maintenance. Predictive maintenance uses instruments to predict issues. Scheduling maintenance is important for optimizing staff usage. Reliability is measured by mean time between failures. Product reliability depends on component reliabilities. Turning out reliable products requires focus on design, production, testing, maintenance and field operations. Effective maintenance is important for reducing costs and ensuring quality.
Case studies: Predictive maintenance in the petrochemical industryAdvisian
This document summarizes techniques used by Advisian to improve asset reliability and reduce maintenance costs for petrochemical clients. It provides five case studies where Advisian conducted reliability reviews that led to [1] an 88% reduction in instrument maintenance hours, [2] a 56% reduction in gas turbine maintenance costs, [3] improving a work management process that increased job completion from 30% to 70%, [4] reducing shutdown duration by 77% saving 44 production days, and [5] eliminating unplanned downtime and improving gas compressor availability by 75%. The case studies demonstrate Advisian's multi-disciplinary approach to reliability engineering.
The document describes 6 categories and types of maintenance programs for achieving world class maintenance: 1) Routine Maintenance, 2) Corrective Maintenance, 3) Preventive Maintenance, 4) Predictive Maintenance, 5) Reliability Centered Maintenance, and 6) Proactive Maintenance. It then provides details on the objectives and processes involved in each type of maintenance program to ensure critical machine operation, component and part functionality, and zero failures through inspection, monitoring, and repairs. The document emphasizes establishing baselines and metrics like MTBF, MTTR, and MTBA to continuously improve maintenance performance over multiple steps of implementation.
Edwin Van Loon - Exploitation Testing revisedTEST Huddle
This document discusses exploitation testing to test service level agreements (SLAs). It provides an overview of exploitation testing and describes how a pension provider, APG, implemented best practices. APG's IT department involves exploitation services earlier in projects and incorporates formal test approaches like real life testing and state transition testing during exploitation tests. State transition testing is explained through an example that specifies critical system components, potential failures, preventative measures, a state transition diagram, and test cases to test availability defined in the SLA. The document provides information on formally testing IT systems and services against agreed levels defined in SLAs.
The document discusses maintenance management and provides an overview of key concepts. It defines maintenance as work done to keep or restore a facility to an acceptable standard level. It discusses total maintenance costs and different maintenance policies including failure-based, time-based, condition-based, and risk-based approaches. It also compares different global maintenance strategies like total productive maintenance and optimized systems maintenance.
Reliability-centered maintenance (RCM) & Total Productive Maintenance (TPM).pptxSamuel Gher
Two effective theories for maximising equipment care are Reliability-Centered Maintenance (RCM) and Total Productive Maintenance (TPM). Using a data-driven methodology, RCM assigns specific maintenance activities based on the prioritisation of important equipment and the analysis of possible breakdowns. Imagine it like a specialised physician locating and treating particular weak points. TPM, on the other hand, uses employee engagement to promote a continuous improvement culture. Everyone assumes responsibility for maintaining the equipment, from operators doing routine upkeep to quality specialists identifying the underlying causes of defects, much like a well-trained team. Both strive for maximum equipment efficiency, while TPM places more emphasis on cultural change and RCM emphasises accuracy. The best strategy for you will rely on your unique requirements. TPM works best with widespread participation, while RCM excels with vital equipment. In the end, integrating these ideas can result in a really strong
This document discusses approaches for managing risk in innovation projects through reliability engineering. It describes three methods: theoretical using standards and simulations, pragmatic with accelerated testing, and analytical using probability of failure calculations. The theoretical approach involves scoping subsystems and identifying reliability metrics from norms. Calculations include MTBF and FIT rates. Simulations validate designs through FEA, software, and system modeling. Pragmatic testing uses highly accelerated life testing to discover weaknesses early in design phases. The goal is to improve reliability and reduce costs from late-stage changes.
The document discusses different types of maintenance including corrective, preventive, and predictive maintenance. It provides examples of maintenance in various industries like manufacturing, services, and transportation. Preventive maintenance aims to reduce equipment failures and degradation through planned inspection and servicing. Benefits include minimizing downtime, production losses, and maintenance costs. Effective preventive maintenance requires management support, qualified staff, and proper planning and scheduling of maintenance programs.
This document provides an overview of reliability centered maintenance (RCM). It defines key RCM terms and outlines the history and objectives of RCM. The document discusses RCM principles such as being business-oriented and function-focused. It also describes some common RCM tools like FMECA and decision trees. Finally, it outlines the RCM analysis process including steps like defining system functions and analyzing failure modes.
Most companies spend a lot of money training their maintenance personnel to troubleshoot a hydraulic system.
If we focused on preventing system failure then we could spend less time and money on troubleshooting a hydraulic system. We normally except hydraulic system failure rather than deciding not to except hydraulic failure as the norm. Let’s spend the time and money to eliminate hydraulic failure rather than preparing for failure.
This document discusses planned preventive maintenance techniques. It divides maintenance activities into cleaning (C), oiling (O), and tightening (T). It recommends scheduling preventive maintenance tasks on a regular weekly basis. Key aspects of preventive maintenance include using computerized systems to generate and schedule tasks, focusing on operational efficiency, performance, safety, and cost reduction. Total productive maintenance (TPM) aims for zero breakdowns or defects by making all staff responsible for equipment. It utilizes techniques like autonomous maintenance, predictive analysis, and categorizing parts by importance.
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Similar to Apac 2015 minimizing integrity failure r02 (20)
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Available on Amazon
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Presentation slides from XP2024 conference, Bolzano IT. The slides describe a new view to leadership and combines it with anthro-complexity (aka cynefin).
1. Minimizing the integrity failures of
aging plants and equipments
Through
Reliability Centered Maintenance
Bhavesh 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
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 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
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
option.
• When Stakes are high Repair is not an
option
7
10. •Preventive maintenance is time base
Maintenance.
•We change parts or service equipment
before it fail and some time before it need
to be.
Preventive Maintenance
10
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
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
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
20
Operational Risk Number
System Risk Number
Asset Risk Number
Failure Probability Factor
Maintenance Priority 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
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
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
22
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
PROCESS SYSTEM NAME
System
Risk
Number
Operational
Risk
Number
Asset
Risk
Number
Failure
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
• Preventive Maintenance
• Predictive Maintenance
23
I have question for you, Would you get on air plane which is only up and working 80% of time , or even working 99% of time in other word one plane crash out of 100 flight or you would get on that airplane if you knew that the airplane will run no matter what.
And How do the airline do that ? The overall maintenance safety is unbelievable, the same maintenance strategy can be used for our plant equipments.
So question is how you can do that and its not very complicated. With Risked base Maintenance program you can keep your plant up and running without machine breaking down and stopping your production, because most costly and high quality problems come when machine break down and production stopped.
To explain my point lets look at case-study from my own experience.
The agitator for the reactor which was in operation for 29 years failed during critical process step. Because of the failure product in the reactor gelled into hard solid rock.
Torque limiting slip plate failed resulted loss of agitation.
TLS plate is designed to protect motor against mechanical overload. It is set with predetermined torque setting . Over the time due to agitator gearbox bearing deterioration torque level went higher than set value which cause TLS plate to fail or rater it works and decoupled motor from agitator. Motor was still running so there was no alarm of agitation loss. On top of that TLS plate was not identified as critical parts and it took maintenance for more than 4 hours for agitator to mechanically ready, but by then product was too viscous to handle by agitator.
The failure resulted increased business cost of more than one million which includes business continuity expanse of importing product from our other sites air flown , removing gelled material, loss of production and increased number of high risk activities.
Causal factor: unidentified critical part of aging equipment under Maintenance program.
Preventative action implemented including regular vibration monitoring and analysis, Temperature and amp monitoring. Which cost less than $ 10000 and detect condition of equipment for proper maintenance planning.
In the case study there were three type of maintenance involved , some kind of preventive maintenance before failure, repair at the time of agitator breakdown and predictive maintenance as part of corrective action. We will see later why predictive maintenance was selected to prevent agitator failure.
The three type of maintenance has its own advantage and disadvantage and there is no one size fits all solution.
almost one third of all the maintenance costs are wasted as the result of unnecessary or improper maintenance activities which blindly and also indiscriminately involve almost all types of components with no or little consideration to the equipment’s lifetime, outage statistics, and economical value.
Lets look at each of the type maintenance and their Pros and cons then we will see how to select right maintenance type for each equipments.
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 option.
Imagine a person with his wife and baby stranded on deserted road due to poorly maintained car !! He will do anything in this desperate situation for his car to run even if it cause serious accident. Do you think he will do risk assessment?
Preventive maintenance is most widely used and popular maintenance type in most industries, which is time base. We change parts or service equipment before it fail and some time before it need to be.
For example a mechanical seal for a X-chemical is determined to be failing every 24 months, so PM set frequency to replace seal every 20 months.
Advantage- is clear it minimize down time, critical failure and unplanned maintenance.
Disadvantage however is we might be replacing parts much sooner and not utilizing full life of parts. Some time due to change in usage, change in chemical and product it could have working for more than 5 years but we set the frequency was 2 years
Preventive maintenance suitable for equipments which are subject to wear out, consumable and with known failure pattern.
Example : Replacing lube oil, tightening of nut bolt at regular frequency, replacing part and overhauling equipment.
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 (Maintenance has a dark side It sometimes breaks equipment instead of fixing them)
So if time base approach of preventive maintenance require overhaul of equipment then it increases risk of infant mortality, it can be illustrated by bathtub curve.
Advantage: It is most cost effective type of maintenance for critical to process equipment. Replace/ repair what is failing. Reduce infant mortality failure.
Disadvantage: It require detail and many expensive monitoring which may not be cost effective for no-consequential equipment and parts
Example: IR Thermography, Vibration analysis, ultrasound monitoring
Studies conducted by the Japanese Institute of Plant Maintenance and companies like DuPont and Tennessee Eastman Chemical Company have shown that 3 major physical conditions make up some 80% of the variation. These physical conditions are: Looseness, Contamination & Lubrication
The BMW maintenance system Condition Based Service (CBS)* permanently monitors oil levels and the degree of wear and tear of individual components. It also checks the time/km recommendations for service intervals. By analyzing this data the Info Display automatically gives you four weeks notice when and which service is next due.The iDrive Control Display informs you anytime in detail about when a service for a specific component is due so you can plan your service appointments well in advance and avoid any unnecessary maintenance work.
As we saw not one solution fits all for maintenance techniques application, the question is how to determine which maintenance type to chose for particular equipment and its components. And answer is by implementing risk base Maintenance program
Risked base maintenance or reliability centered maintenance is strategy to optimize the maintenance program of a company using cost-effective maintenance techniques.
RCM process has five simple steps. First step of which is to calculate System risk number that include consideration of safety issue, regulatory compliance, product quality, process throughput and operation cost for identified component of process area.
Second step is to determine operation risk number that can be done bas on analyzing that if this part of process fails what will be consequence ? Is it in series and will stop the process for more than 24 hours?, or it is important part and failure will cause 8 hr lost? Or if it fail it can be bypassed without negative consequence or if it fail there will be no effect to overall system . We will rank it 0 to 10 where o when no consequence and 10 means it will cause more than 24 hours loss.
Third step is simple is to determine asset risk ranking by multiplying System risk number with operational risk number.
Forth step is to determine failure probably factor base on reactive maintenance performed. If the system need maintenance daily, weekly, monthly ,quarterly or annually. More. Where annual reactive pose lower risk compare to quarterly .
Fifth step is to calculate maintenance priority number by multiplying Asset risk number with failure probability factor.
It will be very easy to understand with an example
First step of RCM process to determine System risk number.
As we have seen Reactor is my most critical process and we want to identify system component to implement RCM. Let’s analyze, what is the risk of the part failure in terms of safety, regulatory compliance, Product quality, process throughput and operation cost.
We will rank them from 1 to 10 , 1 for less or no negative impact and 10 for high negative impact.
TLS plate of agitator being critical to safety due to loss of agitation can cause uncontrolled exothermic reaction and potential runaway reaction so we rank it 8 on 1 to 10 scale..
Regulatory compliance for the failure is relatively low as it would not lead to release of vapor, permit deviation and so forth so we rank it to 2
Quality failure apparently of high risk and score 10/10 same with process throughput and operational cost.
System risk number is average of five risk numbers and it is 8 so fairly high.
Another example to understand lets look at low risk component.
Cooling water insulation failure will score low in as there is low negative impact for safety failure, regulatory compliance, process throughput and operation cost So Safety risk number for this part of process scored low =3.07
Once System risk number is calculated , Step 2 is to conclude Operational Risk number.
ORN is determine by considering that if the part of process fails what will be consequence ? Is it in series and will stop the process for more than 24 hours?, or it is important part and failure will cause 8 hr lost? Or if it fail it can be bypassed without negative consequence or if it fail there will be no effect to overall system . We will rank it 0 to 10 where o when no consequence and 10 means it will cause more than 24 hours loss.
In Step 3 Asset risk number is simply multiplication of system risk number with operational risk number. So in case of TLS plate ARN is 8 multiply by 9 is equal to 72
Step 4 is to determine failure probability factor which is base on reactive maintenance performed, so TLS plate being part of agitator system and maintenance frequency is six monthly so Falire probably factor for TLS plate is 3
Asset risk number multiplying with failure probability factor will give us maintenance priority number. So TLS plate maintenance priority number is 72 multiply by 3 is equal to 216
Once we have maintenance priority number , we can chose type of maintenance that will be most effective. For our example TLS plate is critical part which need to apply predictive maintenance and best way to identify any developing problem is by monitoring and analyzing vibration of gear box.
On other end when MPN is low, replacing/servicing at regular frequency will not be cost effective as MPN is low and we can choose some kind of predictive maintenance such as visual inspection annually and or Repair when it fail.
This concludes that
Reliability-centered Maintenance is a maintenance philosophy that includes a systematic approach to determining how to maintain equipment safely and economically. RCM is an invaluable business solution for companies
In situations where equipment failure is inevitable, the structured RCM process will ensure a maintenance strategy that will minimize or eliminate the consequences.
The central problem addressed by the RCM process is how to determine which scheduled maintenance tasks, if any, should be assigned to equipment, and how frequently