Reliability Centered Maintenance for minimizing integrity failure by Bhavesh Shukla at APAC 2015 Process Safety Management Conference 9th March 2015 Singapore.
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
This presentation examines the attributes of state based control and the value delivered to manufacturing from the initial design through the operating life of the facility by improving the effectiveness of operators.
Advanced Regulatory Control (ARC) Control Scheme Examples: Handling volatile loads using PID controllers and custom programming within the control system. Includes: Sulfur recovery units, Boilers/Steam distribution, Hydrogen plants, Syngas plants, Air compressors, Acid gas handling, Waste gas incinerators and wastewater treatment.
http://www.aiche.org/ccps/conferences/global-congress-on-process-safety/2015
Is Reliability Centered Maintenance (RCM) right for you?Nancy Regan
This presentation outlines the goals of a Reliability Centered Maintenance (RCM) analysis. It debunks the top misconceptions about RCM. And it poses and answers the top four questions about RCM most people don’t know to ask.
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.
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
This presentation examines the attributes of state based control and the value delivered to manufacturing from the initial design through the operating life of the facility by improving the effectiveness of operators.
Advanced Regulatory Control (ARC) Control Scheme Examples: Handling volatile loads using PID controllers and custom programming within the control system. Includes: Sulfur recovery units, Boilers/Steam distribution, Hydrogen plants, Syngas plants, Air compressors, Acid gas handling, Waste gas incinerators and wastewater treatment.
http://www.aiche.org/ccps/conferences/global-congress-on-process-safety/2015
Is Reliability Centered Maintenance (RCM) right for you?Nancy Regan
This presentation outlines the goals of a Reliability Centered Maintenance (RCM) analysis. It debunks the top misconceptions about RCM. And it poses and answers the top four questions about RCM most people don’t know to ask.
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 presentation outlines the processes and benefits of applying enhanced maintenance planning techniques such as Reliability Centred Maintenance at your place of work. Please go to www.simenergy.co.uk for more information.
Darwin Logerot of ProSys presented an Alarm Rationalization Workshop - Tips, Tricks and Tracks at ISA Automation Week 2012 Contact us at prosys.com or 225-291-9591 x225 if you have any questions.
The Predictive Maintenance solution accelerator is an end-to-end solution for a business scenario that predicts the point at which a failure is likely to occur. Use this solution accelerator proactively to optimize maintenance and to create automatic alerts and actions for remote diagnostics, maintenance requests, and other workflows. The solution combines key Azure IoT services like IoT Hub and Stream analytic.
Condition monitoring (or CM) is the process of monitoring a parameter of condition in machinery (vibration, temperature etc.) and identify a significant change which is indicative of a developing fault.
The use of condition monitoring allows maintenance to be scheduled, or other actions to be taken to prevent failure and avoid its consequences.
Very few organizations pay attention to hydraulic leaks and how they can impact production capacity, asset reliability, and reactivity when a mitigation strategy is in place.
This Tool Box Talk may help you take that next step.
ARLYTIC™ is a big data based multi-connected IoT analytics platform offers unprecedented advantages for machine manufactures as well as the plant managers who are end-users of the machines to avoid machine downtime through analysing the sensors data.
ARLYTIC™ relies on collecting data on the edge to uncover actionable insights, using the right tools and techniques, at the right time, to help a organization achieve its most desired business outcomes.
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.
This presentation outlines the processes and benefits of applying enhanced maintenance planning techniques such as Reliability Centred Maintenance at your place of work. Please go to www.simenergy.co.uk for more information.
Darwin Logerot of ProSys presented an Alarm Rationalization Workshop - Tips, Tricks and Tracks at ISA Automation Week 2012 Contact us at prosys.com or 225-291-9591 x225 if you have any questions.
The Predictive Maintenance solution accelerator is an end-to-end solution for a business scenario that predicts the point at which a failure is likely to occur. Use this solution accelerator proactively to optimize maintenance and to create automatic alerts and actions for remote diagnostics, maintenance requests, and other workflows. The solution combines key Azure IoT services like IoT Hub and Stream analytic.
Condition monitoring (or CM) is the process of monitoring a parameter of condition in machinery (vibration, temperature etc.) and identify a significant change which is indicative of a developing fault.
The use of condition monitoring allows maintenance to be scheduled, or other actions to be taken to prevent failure and avoid its consequences.
Very few organizations pay attention to hydraulic leaks and how they can impact production capacity, asset reliability, and reactivity when a mitigation strategy is in place.
This Tool Box Talk may help you take that next step.
ARLYTIC™ is a big data based multi-connected IoT analytics platform offers unprecedented advantages for machine manufactures as well as the plant managers who are end-users of the machines to avoid machine downtime through analysing the sensors data.
ARLYTIC™ relies on collecting data on the edge to uncover actionable insights, using the right tools and techniques, at the right time, to help a organization achieve its most desired business outcomes.
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.
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
Key Considerations for Scoping Reinstrumentation ProjectsYokogawa1
Reinstrumentation, modernization, or revamp projects can be quite complex. Determining a proper project scope, acquiring the necessary funding, and executing on time and on budget are continuous challenges.
Join us as Ms. Hyonsook Kang, Industry Consultant and retired Project Manager/Engineering Manager for Shell, presents key considerations for scoping reinstrumentation projects, leads a discussion on the best practices and processes for the reinstrumentation project execution.
In this webinar you will learn:
What are the key drivers for reinstrumentation projects?
Do we have the total scope identified? How do we plan for a successful project?
How do we improve operator effectiveness and mitigate the risk of the aging workforce?
What are the different scenarios and best practices for updating, migrating or replacing process controls, safety systems, and instrumentation in plants?
ARC Advisory Group's 2014 European Industry Forum in the Netherlands included this interesting presentation from Willem Hazenberg of Stork on control system migration.
Hybrid optimization of pumped hydro system and solar- Engr. Abdul-Azeez.pdffxintegritypublishin
Advancements in technology unveil a myriad of electrical and electronic breakthroughs geared towards efficiently harnessing limited resources to meet human energy demands. The optimization of hybrid solar PV panels and pumped hydro energy supply systems plays a pivotal role in utilizing natural resources effectively. This initiative not only benefits humanity but also fosters environmental sustainability. The study investigated the design optimization of these hybrid systems, focusing on understanding solar radiation patterns, identifying geographical influences on solar radiation, formulating a mathematical model for system optimization, and determining the optimal configuration of PV panels and pumped hydro storage. Through a comparative analysis approach and eight weeks of data collection, the study addressed key research questions related to solar radiation patterns and optimal system design. The findings highlighted regions with heightened solar radiation levels, showcasing substantial potential for power generation and emphasizing the system's efficiency. Optimizing system design significantly boosted power generation, promoted renewable energy utilization, and enhanced energy storage capacity. The study underscored the benefits of optimizing hybrid solar PV panels and pumped hydro energy supply systems for sustainable energy usage. Optimizing the design of solar PV panels and pumped hydro energy supply systems as examined across diverse climatic conditions in a developing country, not only enhances power generation but also improves the integration of renewable energy sources and boosts energy storage capacities, particularly beneficial for less economically prosperous regions. Additionally, the study provides valuable insights for advancing energy research in economically viable areas. Recommendations included conducting site-specific assessments, utilizing advanced modeling tools, implementing regular maintenance protocols, and enhancing communication among system components.
Hierarchical Digital Twin of a Naval Power SystemKerry Sado
A hierarchical digital twin of a Naval DC power system has been developed and experimentally verified. Similar to other state-of-the-art digital twins, this technology creates a digital replica of the physical system executed in real-time or faster, which can modify hardware controls. However, its advantage stems from distributing computational efforts by utilizing a hierarchical structure composed of lower-level digital twin blocks and a higher-level system digital twin. Each digital twin block is associated with a physical subsystem of the hardware and communicates with a singular system digital twin, which creates a system-level response. By extracting information from each level of the hierarchy, power system controls of the hardware were reconfigured autonomously. This hierarchical digital twin development offers several advantages over other digital twins, particularly in the field of naval power systems. The hierarchical structure allows for greater computational efficiency and scalability while the ability to autonomously reconfigure hardware controls offers increased flexibility and responsiveness. The hierarchical decomposition and models utilized were well aligned with the physical twin, as indicated by the maximum deviations between the developed digital twin hierarchy and the hardware.
About
Indigenized remote control interface card suitable for MAFI system CCR equipment. Compatible for IDM8000 CCR. Backplane mounted serial and TCP/Ethernet communication module for CCR remote access. IDM 8000 CCR remote control on serial and TCP protocol.
• Remote control: Parallel or serial interface.
• Compatible with MAFI CCR system.
• Compatible with IDM8000 CCR.
• Compatible with Backplane mount serial communication.
• Compatible with commercial and Defence aviation CCR system.
• Remote control system for accessing CCR and allied system over serial or TCP.
• Indigenized local Support/presence in India.
• Easy in configuration using DIP switches.
Technical Specifications
Indigenized remote control interface card suitable for MAFI system CCR equipment. Compatible for IDM8000 CCR. Backplane mounted serial and TCP/Ethernet communication module for CCR remote access. IDM 8000 CCR remote control on serial and TCP protocol.
Key Features
Indigenized remote control interface card suitable for MAFI system CCR equipment. Compatible for IDM8000 CCR. Backplane mounted serial and TCP/Ethernet communication module for CCR remote access. IDM 8000 CCR remote control on serial and TCP protocol.
• Remote control: Parallel or serial interface
• Compatible with MAFI CCR system
• Copatiable with IDM8000 CCR
• Compatible with Backplane mount serial communication.
• Compatible with commercial and Defence aviation CCR system.
• Remote control system for accessing CCR and allied system over serial or TCP.
• Indigenized local Support/presence in India.
Application
• Remote control: Parallel or serial interface.
• Compatible with MAFI CCR system.
• Compatible with IDM8000 CCR.
• Compatible with Backplane mount serial communication.
• Compatible with commercial and Defence aviation CCR system.
• Remote control system for accessing CCR and allied system over serial or TCP.
• Indigenized local Support/presence in India.
• Easy in configuration using DIP switches.
Water scarcity is the lack of fresh water resources to meet the standard water demand. There are two type of water scarcity. One is physical. The other is economic water scarcity.
AKS UNIVERSITY Satna Final Year Project By OM Hardaha.pdf
Apac 2015 minimizing integrity failure r02
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
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 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
5
6. Types of Maintenance
•Repair
Run to failure
•Preventive Maintenance
Time basedTime based
•Predictive Maintenance
Condition based
6
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
7
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.
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• 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
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
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
21
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
22
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
23