This document discusses performance standards for safety critical equipment on offshore oil and gas drilling units. It defines performance standards as documents that link safety cases to preventative maintenance tasks by establishing acceptance criteria and critical operating parameters. Performance standards help reduce risks by monitoring asset integrity and ensuring safety systems function properly. Regulatory agencies now require performance standards to improve safety. The document provides examples of how performance standards specify maintenance controls and allow equipment performance to be measured and tracked over time.
Definition of Preventive Maintenance, PM Elements, Plant Characteristics In Need of a PM Program, Principle for Selecting Items for PM, PM Measures, PM Models with examples
Condition-Based Maintenance Basics by Carl Byington - PHM Design, LLCCarl Byington
Condition-based maintenance (CBM or CBM+) is a strategy of performing maintenance on a machine or system only when there is objective evidence of need or impending failure. CBM is enabled by the evolution of key technologies, including improvements in - sensors, microprocessors, digital signal processing, simulation modeling, multisensor data fusion, reliability engineering, Internet of Things (IoT) connectivity, data warehousing, cloud computing, machine learning (ML), artificial intelligence (AI), and predictive analytics. CBM involves monitoring the health or performance of a component or system and performing maintenance based on that inferred health and in some cases, predicted remaining useful life (RUL). This predictive maintenance philosophy contrasts with earlier ideologies, such as corrective maintenance — in which action is taken after a component or system fails — and preventive maintenance — which is based on event or time milestones. Each involves a cost tradeoff.
Carl Byington with PHM Design, LLC reviews some of the elements of CBM.
#phmdesign
https://phmdesign.com
Definition of Preventive Maintenance, PM Elements, Plant Characteristics In Need of a PM Program, Principle for Selecting Items for PM, PM Measures, PM Models with examples
Condition-Based Maintenance Basics by Carl Byington - PHM Design, LLCCarl Byington
Condition-based maintenance (CBM or CBM+) is a strategy of performing maintenance on a machine or system only when there is objective evidence of need or impending failure. CBM is enabled by the evolution of key technologies, including improvements in - sensors, microprocessors, digital signal processing, simulation modeling, multisensor data fusion, reliability engineering, Internet of Things (IoT) connectivity, data warehousing, cloud computing, machine learning (ML), artificial intelligence (AI), and predictive analytics. CBM involves monitoring the health or performance of a component or system and performing maintenance based on that inferred health and in some cases, predicted remaining useful life (RUL). This predictive maintenance philosophy contrasts with earlier ideologies, such as corrective maintenance — in which action is taken after a component or system fails — and preventive maintenance — which is based on event or time milestones. Each involves a cost tradeoff.
Carl Byington with PHM Design, LLC reviews some of the elements of CBM.
#phmdesign
https://phmdesign.com
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.
Definition, types of corrective maintenance, steps and cycle;
Measures of corrective maintenance are: Mean Corrective Maintenance Time , Median Active Corrective Maintenance Time, Maximum Active Corrective Maintenance Time.
Then different models : a system that can either be in up (operating) or down (failed) state; a system that can either be operating normally or failed in two mutually exclusive failure modes; a system that can either be operating normally, operating in degradation mode, or failed completely; a two identical-unit redundant (parallel) system. At least one unit must operate normally for system success.
A preprint of an article published in Process Safety Progress: P.M. Haas and G. Hager, "Conduct of Operations: A Control System for Your Most Important Safety Component," Process Safety Progress, Spring 2000, Vol. 19, No. 1, 1999.
For many manufacturers, evaluating and managing the risk of obsolescence is a missing piece of their overall management strategy, an oversight that can have significant implications in terms of business continuity. With a clear obsolescence policy and risk-assessment framework, manufacturing companies can help ensure that their systems and assets remain up and running, supported by a continuous risk-mitigation cycle.
PRINCIPLES AND PRACTICES OF MAINTENANCE PLANNINGlaxtwinsme
Basic Principles of maintenance planning – Objectives and principles of planned maintenance activity– Importance and benefits of sound Maintenance systems – Reliability and machine availability –MTBF, MTTR and MWT – Factors of availability – Maintenance organization – Maintenance economics.
Reliability, availability, maintainability (RAM) study, on reciprocating comp...John Kingsley
What is needed to perform a RAM Study and more details #RAM #Training #iFluids #RAMstudy
.
To know more, on How iFluids can help you operate & maintain Safe and Reliable plant Contact us Today --> info@ifluids.com
For any training enquiries, contact us today --> training@ifluids.com
Application of Lean Tools in the Oil Field Safety ManagementIJERA Editor
Current safety management in oil fields is in low efficiency and data from DOE indicated that the injury rate in the oil and gas field was greater than those for all the other U.S. industries. The paperintroduced lean concepts and tools to the safety management in oil fields. In theresearch, a new safety management methodology has been set up. The study also compared the current safety management and the new safety management which was built up by lean concepts. In addition, several lean tools have been modified to make them fit and work better in oil fields
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.
Definition, types of corrective maintenance, steps and cycle;
Measures of corrective maintenance are: Mean Corrective Maintenance Time , Median Active Corrective Maintenance Time, Maximum Active Corrective Maintenance Time.
Then different models : a system that can either be in up (operating) or down (failed) state; a system that can either be operating normally or failed in two mutually exclusive failure modes; a system that can either be operating normally, operating in degradation mode, or failed completely; a two identical-unit redundant (parallel) system. At least one unit must operate normally for system success.
A preprint of an article published in Process Safety Progress: P.M. Haas and G. Hager, "Conduct of Operations: A Control System for Your Most Important Safety Component," Process Safety Progress, Spring 2000, Vol. 19, No. 1, 1999.
For many manufacturers, evaluating and managing the risk of obsolescence is a missing piece of their overall management strategy, an oversight that can have significant implications in terms of business continuity. With a clear obsolescence policy and risk-assessment framework, manufacturing companies can help ensure that their systems and assets remain up and running, supported by a continuous risk-mitigation cycle.
PRINCIPLES AND PRACTICES OF MAINTENANCE PLANNINGlaxtwinsme
Basic Principles of maintenance planning – Objectives and principles of planned maintenance activity– Importance and benefits of sound Maintenance systems – Reliability and machine availability –MTBF, MTTR and MWT – Factors of availability – Maintenance organization – Maintenance economics.
Reliability, availability, maintainability (RAM) study, on reciprocating comp...John Kingsley
What is needed to perform a RAM Study and more details #RAM #Training #iFluids #RAMstudy
.
To know more, on How iFluids can help you operate & maintain Safe and Reliable plant Contact us Today --> info@ifluids.com
For any training enquiries, contact us today --> training@ifluids.com
Application of Lean Tools in the Oil Field Safety ManagementIJERA Editor
Current safety management in oil fields is in low efficiency and data from DOE indicated that the injury rate in the oil and gas field was greater than those for all the other U.S. industries. The paperintroduced lean concepts and tools to the safety management in oil fields. In theresearch, a new safety management methodology has been set up. The study also compared the current safety management and the new safety management which was built up by lean concepts. In addition, several lean tools have been modified to make them fit and work better in oil fields
Program DevelopmentPeer-ReviewedManagementofCExamp.docxbriancrawford30935
Program Development
Peer-Reviewed
Management
ofC
Examples From Practice
By Fred A, Manuele
M
anagement of change (MOC)
is a commonly used technique.
Its purpose is to:
•Identify the potential consequences
of a change.
•Plan ahead so that counter actions
can be taken before a change occurs and
continuously as the change progresses.
With respect to operational risks, the
process ensures that:
•Hazards are identified and analyzed,
and risks are assessed.
•Appropriate avoidance, elimination
or control decisions are made so that
acceptable risk levels are achieved and
maintained throughout the change pro-
cess.
•New hazards are not knowingly in-
troduced by the change.
•The change does not negatively af-
fect previously resolved hazards.
•The change does not increase the
severity potential of an existing hazard.
This process is applied when a site
modifies technology, equipment, fa-
cilities, work practices and procedures,
design specifications, raw materials, or-
ganizational or staffing situations, and
standards or regulations. An MOC pro-
cess must consider:
•safety of employees making the
changes;
•safety of employees in adjacent work
areas;
•safety of employees who will be en-
gaged in operations after changes are
made;
•environmental aspects;
•public safety;
Fred A. Manuele, P.E., CSP, is president of Hazards Limited,
which he formed after retiring from Marsh & McLennan where he
was a managing director and manager of M&M Protection Consul-
tants. His books include Advanced Safety Management: Focusing on
ZIO and Serious Injury Prevention, On the Practice of Safety, Innova-
•product safety and quality;
•fire protection so as to avoid prop-
erty damage and business interruption.
OSHA's (1992) Process Safety Man-
agement Standard (29 CFR 1910.119)
requires that covered operations have
an MOC process in place. No other
OSHA regulation contains similar re-
quirements, although the agency does
address MOC in an information paper
(OSHA, 1994). Also, this subject is a
requirement to achieve desig-
nation in OSHA's Voluntary
Protection Programs.
Establishing the Need
Three studies establish that
having an MOC system as an
element within an operation's
risk management system
would serve well to reduce
serious injury potential. This
author reviewed more than
1,700 incident investigation
reports, mostly for serious in-
juries, that support the need
for and the benefit of an MOC
system. These reports showed
that a significantly large share
of incidents resulting in seri-
ous injury occurs:
•when unusual and non-
routine work is being per-
formed;
•in nonproduction activities;
•in at-plant modification or
construction operations (e.g.,
replacing an 800-lb motor on a platform
15 ft above the fioor);
IN BRIEF
•Studies and statistics indi-
cate that an effective man-
agement of change (MOC)/
prejoh planning compo-
nent within an operations
risk management system
reduces the potential for
serious injuries.
•Specific guidelines from
pr.
Optimal Maintainability of Hydraulic Excavator Through Fmea/FmecaIJRESJOURNAL
ABSTRACT: The concept of advanced maintenance management technique in the field of heavy earthmoving mining machinery is recently developed in India, and has taken pace with the demand of the same, rising continuously over the years. This paper indulges into considering of hydraulic excavators, which is a large machinery that is designed for excavation and demolitions purposes. It spreads to various sizes and functions. The development of the mining industry has been escalated largely due to the introduction of different types of excavators. These excavators are used to satisfy various mining, industrial and construction needs. The mining excavators are mainly of two types that are used in modern era namely backhoe and dragline, other being suction excavator, long reach/long arm, crawlers and compact excavators, power shovel etc. The data collected and analysis has been done keeping in mind the vicinity of the coal capital of India, where hydraulic excavator is mainly used. It is so, that the same gets prime focus in the paper. The increased penetration of service of the high yield machines in the above-mentioned sectors have made them really important. Halting or stoppages are seen as the bottlenecks, which disturbs the productivity. Seeing the large benefits, and associated productivity and profit loss, the maintenance engineer felt the need to have advanced maintenance of the same. The paper deals with different faults of the excavator, and based on the data acquired, takes on further steps towards carrying out the FMEA analysis which incorporates into it by estimating Severity, Occurrence and Detection of the considered parts respectively, and then Risk Priority Number (RPN) is calculated, ranging from 1 to 1000. The quantitative approach helps in deciding the various maintenance strategies for the different parts and subparts. It is based on the above factors that maintenance plans are initiated, designed and implemented.
The preventive maintenance program is developed using a guided logic approach and is task oriented rather than maintenance process oriented. This eliminates the confusion associated with the various interpretations across different industries of terms such as condition monitoring, on condition, hard time, etc. By using a task oriented concept, it is possible to see the whole maintenance program reflected for a given item. A decision logic tree is used to identify applicable maintenance tasks. Servicing and lubrication are included as part of the logic diagram as this ensures that an important task category is considered each time an item is analyzed.
Maintenance Program Content
The content of the maintenance program itself consists of two groups of tasks.
• A group of preventive maintenance tasks, which include failure-finding tasks, scheduled to be accomplished at specified intervals, or based on condition. The objective of these tasks is to identify and prevent deterioration below inherent safety and reliability levels by one or more of the following means:
o Lubrication/servicing;
o Operational/visual/automated check;
o Inspection/functional test/condition monitoring;
o Restoration;
o Discard.
It is this group of tasks, which is determined by RCM analysis, e. it comprises the RCM based preventive maintenance program.
• A group of non scheduled maintenance tasks which result from:
• Findings from the scheduled tasks accomplished at specified intervals of time or usage;
• Reports of malfunctions or indications of impending failure (including automated detection).
The objective of this second group of tasks is to maintain or restore the equipment to an acceptable condition in which it can perform its required function.
An effective program is one that schedules only those tasks necessary to meet the stated objectives. It does not schedule additional tasks that will increase maintenance costs without a corresponding increase in protection of the inherent level of reliability. Experience has clearly demonstrated that reliability decreases when inappropriate or unnecessary maintenance tasks are performed, due to increased incidence of maintainer-induced faults.
Continued...
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
Reliability-centered maintenance (RCM) & Total Productive Maintenance (TPM).pptx
OTC 2015 LCE Paper
1. OTC-26043-MS
Performance Standards: Bridging the Gap between Safety Cases and
Safety Critical Equipment
T. Schwartz, H. Fix, Life Cycle Engineering
Copyright 2015, Offshore Technology Conference
This paper was prepared for presentation at the Offshore Technology Conference held in Houston, Texas, USA, 4–7 May 2015.
This paper was selected for presentation by an OTC program committee following review of information contained in an abstract submitted by the author(s). Contents of the paper have not been
reviewed by the Offshore Technology Conference and are subject to correction by the author(s). The material does not necessarily reflect any position of the Offshore Technology Conference, its
officers, or members. Electronic reproduction, distribution, or storage of any part of this paper without the written consent of the Offshore Technology Conference is prohibited. Permission to
reproduce in print is restricted to an abstract of not more than 300 words; illustrations may not be copied. The abstract must contain conspicuous acknowledgment of OTC copyright.
Abstract
The pressure to operate safely in risk-sensitive industries such as oil and gas is always present, with many offshore drillers
still struggling to define and practice effective safety-driven maintenance principles on a routine basis, given the dynamic and
inherently dangerous nature of drilling hazards. This has given rise to the concept of establishing a performance-based
approach to safety to directly tie global and regulatory standards to preventive maintenance tasks in the form of performance
standards.
Introduction
What are performance standards and why do we need them? Leading offshore oil and gas drilling contractors are creating
performance standards to reference the systems and controls in place used to mitigate the risk of Major Accident Events
(MAEs), monitor asset performance with Critical Operating Parameters (COPs) and provide a means to continuously assess
regulatory driven maintenance requirements.
Performance standards are created to serve as the “Golden Thread” to link Safety Cases and Preventive Maintenance
procedures for Safety Critical Equipment (SCE) on offshore oil and gas drilling units. Acceptance criteria and operating
parameters are being referenced in the standards to designate which MAE control measures are in place with the goal to
reduce the risk of major accident events to ALARP “as low as reasonably practicable”.
Figure 1 shows an example section of a performance standard listing preventative maintenance control measures reducing the
risk of MAEs connected to that system.
Figure 1: Example MAE Section of a Performance Standard
2. 2 OTC-26043-MS
Every performance standard should be coupled with a comprehensive safety case and adequate maintenance plans providing
clearly defined acceptance standards allowing measuring, monitoring, trending, and appropriate corrective actions as
necessary. Performance standards can also be linked via Computerized Maintenance Management Systems (CMMS) and
Enterprise Resource Planning (ERP) software linking trending data straight to the safety critical equipment.
Regulatory bodies such as the National Offshore Petroleum Safety and Environmental Management Authority (NOPSEMA)
are auditing for offshore oil and gas platform performance standards because they recognize the importance and value they
bring to improving rig safety and environmental protection. Oil and gas drilling contractors need to recognize that
performance standards are quickly becoming the regulatory driven model for offshore drilling units and will be audited more
strictly moving forward.
Safety cases must be accurate and need to include an up to date in-depth description of the facility, risk management
procedures, safety critical system’s functional requirements as well as root-cause failure prevention analysis for each system.
It is imperative for the preventative maintenance job plans to include regulatory driven maintenance requirements, equipment
manufacturer routine maintenance procedures as well as industry standard best practices.
In the oil and gas industry every cost reduction opportunity is crucial and many leading drilling contractors at the head of
preventative maintenance are using the regulatory required Critical Operating Parameters and performance standards to their
advantage. Even though regulatory COPs initially seem burdensome, leading asset management companies are using the
parameters to their advantage to monitor asset performance. By monitoring asset integrity and equipment performance with
the use of rig asset integrity dashboards, drilling companies are not only meeting regulatory requirements but also benefiting
from the financial gains of reduced downtime and equipment costs. Figure 2 is an example of how critical assets can be
monitored not only for health conditions, but also business performance impacts. Typically, these parameters are only being
used in the operation of the rigs, but the opportunity to leverage the data to optimize maintenance and resource planning also
exists.
Figure 2: Graphic of an Asset Integrity Dashboard
Regulatory Considerations
NOPSEMA has given basic guidelines to follow for developing performance standards. The baseline measures in
performance standards for the controls in place used to reduce the risk of MAEs to as low as reasonably practicable (ALARP)
include maintaining control of facility and safety critical equipment Functionality (Ability to function in various
circumstances), Availability (Percentage of time capable of performing its function), Reliability (Probability system will
function correctly), Survivability (Ability to survive potential damaging events), Dependency (Degree of reliance on other
systems), and Compatibility (Compatibility with other control measures). Each of the control measures used in a performance
standard follow the SMART principle to ensure that that they are Specific, Measurable, Appropriate, Realistic and Timely.
3. OTC-26043-MS 3
Figure 3 shows the relationship between Formal Safety Assessments (FSAs) and ongoing operations and risk management.
These are linked through the process of developing performance standards and their continual improvement over time.
Figure 3: Performance Standards and Continuous Improvement (NOPSEMA, 2012)
Concluding Remarks
In summary, performance standards serve a critical role in establishing and sustaining the integrity of the Major Accident
Event control measures by defining and verifying regulatory compliance. Drilling contractors are mitigating the risk of
MAEs by bridging safety cases and preventive maintenance programs through traceability achieved through implementation
of performance standards. Regulatory bodies are requiring the use of performance standards in order to help improve the
visibility of the control measures in place to reduce the risk of MAEs to protect people and the environment.
Each performance standard provides the direct link between a comprehensive safety case and applicable maintenance plans
providing clearly defined acceptance standards thereby allowing measuring, monitoring, trending, and appropriate corrective
actions as necessary. Leveraging the pertinent information captured within a safety case, performance standards are
developed and then implemented within preventive maintenance tasks through a CMMS. Combined with a formalized best
practice review process, the CMMS is utilized to quantitatively analyze the effectiveness of the implementation of the
performance standards.
References:
NOPSEMA Guidance Note N04300-GN0271, Control Measures and Performance Standards, Revision No 4, December 2012