Industry Standard Solution for Plant Maintenance (ISPM)

March 1, 2018
© Reliability Dynamics LLC 2017 Reliability Dynamics
Industry Standard Solution for
Plant Maintenance (ISPM®)
Use data-driven decision-making for equipment assets to
optimize profitability, safety and compliance
ISPM Overview

March 1, 2018
The Industry Standard Solution for Plant
Maintenance (ISPM®)
Standard application of ISO 14224
methods in enterprise software
 Software vendor certified
 Built-in solution
Proven methodology
 30 years – OREDA/ISO 14224
 13 years – ISPM
Evolutionary product
 Refined through application in industry
(13 years)
 Solicit and incorporate customer feedback

March 1, 2018
ISPM Value Proposition
Use data-driven decision-making for
equipment assets to optimize profitability,
safety and compliance
 Identify and manage risk
 Get visibility of equipment reliability issues and their effect on
profitability and sustainability (corporate bottom line)
 Enable data-driven decision-making for equipment with instant
access to high-quality, trusted data
 Use a logical process to identify, analyze, and resolve equipment
reliability problems

March 1, 2018
Benefits of ISPM Methods
Address prevalent ERP/CMMS deficiencies
Technical hierarchy construction
Standard processes for reliability and maintenance data
Equipment reliability data quality
Ability to manage assets against the bottom line
Improved efficiency
Collect the right data
Analyze data en masse
Eliminate data mining
Use data-driven decision-making
Focus on true priorities

March 1, 2018
The ISPM Bottom-Line Approach
IDENTIFY
Equipment failure events with the greatest consequences
Equipment causing those events (bad-actor equipment)
ANALYZE
High-consequence failure events
Failure patterns of bad-actor equipment causing them
Obtain details necessary to take corrective action
RESOLVE
Bad actor equipment reliability issues
Implement and prioritize corrective measures

March 1, 2018
IDENTIFY Risk (Potential Failure Events)
The Bottom Line

March 1, 2018
IDENTIFY High-Consequence Failure Events
The Bottom Line

March 1, 2018
ANALYZE Failure details
Equipment-Level Analysis

March 1, 2018
ANALYZE Failure details
Component-Level Analysis

March 1, 2018
ANALYZE Manufacturer/Model Performance
Selection Criteria: SRU Claus Tail Gas Service

March 1, 2018
ANALYZE Manufacturer/Model Performance
Reliability Metrics for SRU Claus Tail Gas Service

March 1, 2018
RESOLVE Bad-Actor Equipment Issues
Implement corrective measures for bad actor equipment, e.g.:
Preventive maintenance
Inspections
Procedures
Facilities changes
Prioritize corrective measures based on:
Actual consequences
Future consequence potential

March 1, 2018
ISPM Solution Landscape
High-Quality RM Data Enable Machine Learning Tools
Industrial IoT
Platform and RM
Data Repositories
Corporate ERP System
· System of record for technical tags
· Work management system
· Initial data collection point for equipment failure data
ERP DATABASE
· Work execution
· Results recording
· Labor and material
bookings
Standard
reliability data
processesTechnical
hierarchy
Strategy development
Equipment
malfunction
reports
PM results
recording
Equipment
failure events
GE Predix Platform
· APM, OPM
SAP Leonardo Bridge
· AIN, ASPM, PDMS
IBM Watson
Bentley Assetwise
· OREDA
· CCPS PERD
Equipment
reliability
metrics
IS0 14224 Processes
High-quality
RM data
Engineering and
Construction Phases
Plant information
database, e.g.
Hexagon SPO
· Technical tag list
· Equipment specifications,
attributes, and
interrelationships
Equipment
taxonomy definitions
DataM
apping
InterfaceCapital facilities
specification and
equipment selection
IoT/Big
Data
Analytics
Early fault detection
Risk
assessment
Preventive
maintenance
and inspections
Manage risk, improve production availability, reduce cost, optimize new capital facilities

March 1, 2018
RM Data Quality Management
Quality Assurance
 Technical hierarchy incorporates ISO
14224 equipment taxonomy
 Malfunction reporting incorporates ISO
14224 normative specifications and
notations
 CMMIS validations ensure ISO 14224
data compliance
Quality Control
 Event record reviews
 Results-based feedback/training to field
personnel

March 1, 2018
ISPM Technical Hierarchy Overview
Asset register
Equipment
boundary envelope
Interrelated
equipment

March 1, 2018
Construction of Technical Structure
Compressor Technical Drawings

March 1, 2018
ISO 14224 Boundary Definition

March 1, 2018
ISO 14224 Equipment Subdivision

March 1, 2018
Functional Location / Equipment Relationship
ISO 15926-2, Section E.3.3
Functional equipment location Tag P101 is an intangible object that defines process requirements for a
particular pumping service, e.g. pressure, temperature, flow, fluid type (Tag P101 in the example below)
Equipment items (serial numbers 1234 and 2345) define specific materialized objects that execute process
requirements
Field equipment change-outs are captured in SAP via corresponding equipment dismantle/installation
transactions (on 5/8/2001 S/N 1234 was dismantled and S/N 2345 installed)

March 1, 2018
ISO 14224 Technical Structure
 ERP is system of record for all technical tags
 One unique ID for each tag throughout all
systems, records, and in the field
 Equipment interrelationships defined in system
Use/Location Data
Equipment Subdivison

March 1, 2018
Malfunction Reporting
Data Quality on Inception
Step Details Responsibility
Work Initiation Problem Report (equipment-level
failure notations), system QA checks
Facility personnel
Approvals and
processing
Work approval, planning and
scheduling, create statistical records
Operations
Superintendent
Execution, repair
notes, and close-out
Repair Report (item-level failure
notations), system QA checks
Maintenance Lead
Technician
Failure data quality
control
QA/QC, consequence assessment,
and methods feedback
Reliability Engineer

March 1, 2018
Malfunction Problem Report (Work Initiation)
Equipment-Level Notations

March 1, 2018
Malfunction Repair Report (Work Close-out)
Component-Level Notations

March 1, 2018
Event Consequence
Assessment

March 1, 2018
ISPM PM Condition Reporting
Group administration with per-tag
results
 Pass/Fail inspection verdict per tag
Functional-based preventive
maintenance
 Coincident equipment defaults into call
objects
Automation of follow-on work
 System copies relevant data to new
work notification
 Notification hierarchy used for
traceability between inspection record
and follow-on work
Historical malfunction reports

March 1, 2018
ISPM Risk Assessment Methodology
Functionality incorporates RCM and Process Hazards Analysis (PHA)
PHA is required for many United States processing facilities per OSHA
CFR1910.119
Center for Chemical Process Safety (CCPS) guidelines cover applicable methods,
e.g. HAZOP, What-if, etc.
Scenarios generated identify safeguards by discrete system ID (tag ID, PM
plan number, SJP number, etc.)
This enables “live” monitoring of safeguards, which helps to ensure assumed risk
reduction is actually achieved
Integration of ISO 14224 and RCM content can enable validation of scenarios by
actual operational experience

March 1, 2018
SAP RCM and PHA with ISO 14224 Notations
SAP Notification (Standard)

March 1, 2018
Customer Consequence Matrix

March 1, 2018
Customer Risk Matrices

March 1, 2018
SAP Risk Assessment
SAP Classification (Standard)

March 1, 2018
Risk Reduction Measures
Install remotely operated emergency block valves on distillation
pump suction lines, with automated activation
Install interlocks to shut down associated pumps on EBV activation
Consider changing methanol pump mechanical seals to a dual
configuration with a buffer pot
This recommendation is consistent with guidance by the Center for Chemical
Process Safety (CCPS). Per CCPS guidance, remote isolation of equipment
containing hazardous material is necessary to mitigate a release of
hazardous material when there has been loss of containment. Isolation can
be accomplished with the appropriate location of remotely operated
emergency block valves (EBVs). EBVs should be located…at the inlet of
pumps from vessels with 10,000 pounds of flammable material. All suction
vessels have product inventories during normal operation that exceed this
threshold amount.

March 1, 2018
In-Place Risk Reduction from New
Task/Safeguard Application

March 1, 2018
Tony Ciliberti
Principal Engineer | Reliability Dynamics | Linkedin: tciliberti
tony.ciliberti@rd-eam.com
Thank you

March 1, 2018
Relevant International Standards
ISO 14224:2006
Petroleum, petrochemical and natural gas industries -- Collection and
exchange of reliability and maintenance data for equipment
ISO 15926-2:2003
Industrial automation systems and integration -- Integration of life-cycle data
for process plants including oil and gas production facilities -- Part 2: Data
model

Industry Standard Solution for Plant Maintenance (ISPM)

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