What is needed to perform a RAM Study and more details #RAM #Training #iFluids #RAMstudy
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For any training enquiries, contact us today --> training@ifluids.com
Studying the Advance Maintenance Practice & Computerised MaintenanceIJERA Editor
Many companieѕ think of maintenance aѕ an inevitable ѕource of coѕt. For theѕe companieѕ maintenance
operationѕ have a corrective function and are only executed in emergency conditionѕ. Today, thiѕ form of
intervention iѕ no longer acceptable becauѕe of certain critical elementѕ ѕuch aѕ product quality, plant ѕafety,
and the increaѕe in maintenance department coѕtѕ which can repreѕent from 15 to 70% of total production coѕtѕ.
The managerѕ have to ѕelect the beѕt maintenance policy for each piece of equipment or ѕyѕtem from a ѕet of
poѕѕible alternativeѕ. For example, corrective, preventive, opportuniѕtic, condition-baѕed and predictive
maintenance policieѕ are conѕidered in thiѕ paper.
Applying IPA on Services Quality for Farm Irrigation Engineering - A Case S...theijes
The purpose of development Irrigation Association in Taiwan is to service farmers, improve irrigation and drainage facilities and get the most out of the economy for all members. Therefore, this study takes a case of Kaohsiung Irrigation Association as object, and explores the effect on the service quality to maintain the sustainable development of agriculture. The research takes the service quality scale of Kaohsiung Irrigation Association as the questionnaire and applies importance-performance analysis (IPA) to view the demand on service quality. Through 22 factors and 5 phases to analysis the questionnaire by statistical method including difference analysis, independent T test, one-way analysis of variance and correlation analysis. The result shows that the background parameters and five phases have significant effects such as level of education and position. The analysis of IPA is found that 17 factors in the first quadrant mean that members and users will have confidence and extreme recognition and identity on service quality of water conservancy. The results will explore the important issues of concern on service quality in Kaohsiung Irrigation Association, and could give as a reference to improve the future of construction and provide the ability to play a good role in supervision to strengthen the quality and service efficient in farmers' organizations.
A comparison of a novel robust decentralized control strategy and MPC for ind...ISA Interchange
Abstract: In this work we have developed a novel, robust practical control structure to regulate an industrial methanol distillation column. This proposed control scheme is based on a override control framework and can manage a non-key trace ethanol product impurity specification while maintaining high product recovery. For comparison purposes, an MPC with a discrete process model (based on step tests) was also developed and tested. The results from process disturbance testing shows that, both the MPC and the proposed controller were capable of maintaining both the trace level ethanol specification in the distillate (XD) and high product recovery (β). Closer analysis revealed that the MPC controller has a tighter XD control, while the proposed controller was tighter in β control. The tight XD control allowed the MPC to operate at a higher XD set point (closer to the 10 ppm AA grade methanol standard), allowing for savings in energy usage. Despite the energy savings of the MPC, the proposed control scheme has lower installation and running costs. An economic analysis revealed a multitude of other external economic and plant design factors, that should be considered when making a decision between the two controllers. In general, we found relatively high energy costs favor MPC.
Studying the Advance Maintenance Practice & Computerised MaintenanceIJERA Editor
Many companieѕ think of maintenance aѕ an inevitable ѕource of coѕt. For theѕe companieѕ maintenance
operationѕ have a corrective function and are only executed in emergency conditionѕ. Today, thiѕ form of
intervention iѕ no longer acceptable becauѕe of certain critical elementѕ ѕuch aѕ product quality, plant ѕafety,
and the increaѕe in maintenance department coѕtѕ which can repreѕent from 15 to 70% of total production coѕtѕ.
The managerѕ have to ѕelect the beѕt maintenance policy for each piece of equipment or ѕyѕtem from a ѕet of
poѕѕible alternativeѕ. For example, corrective, preventive, opportuniѕtic, condition-baѕed and predictive
maintenance policieѕ are conѕidered in thiѕ paper.
Applying IPA on Services Quality for Farm Irrigation Engineering - A Case S...theijes
The purpose of development Irrigation Association in Taiwan is to service farmers, improve irrigation and drainage facilities and get the most out of the economy for all members. Therefore, this study takes a case of Kaohsiung Irrigation Association as object, and explores the effect on the service quality to maintain the sustainable development of agriculture. The research takes the service quality scale of Kaohsiung Irrigation Association as the questionnaire and applies importance-performance analysis (IPA) to view the demand on service quality. Through 22 factors and 5 phases to analysis the questionnaire by statistical method including difference analysis, independent T test, one-way analysis of variance and correlation analysis. The result shows that the background parameters and five phases have significant effects such as level of education and position. The analysis of IPA is found that 17 factors in the first quadrant mean that members and users will have confidence and extreme recognition and identity on service quality of water conservancy. The results will explore the important issues of concern on service quality in Kaohsiung Irrigation Association, and could give as a reference to improve the future of construction and provide the ability to play a good role in supervision to strengthen the quality and service efficient in farmers' organizations.
A comparison of a novel robust decentralized control strategy and MPC for ind...ISA Interchange
Abstract: In this work we have developed a novel, robust practical control structure to regulate an industrial methanol distillation column. This proposed control scheme is based on a override control framework and can manage a non-key trace ethanol product impurity specification while maintaining high product recovery. For comparison purposes, an MPC with a discrete process model (based on step tests) was also developed and tested. The results from process disturbance testing shows that, both the MPC and the proposed controller were capable of maintaining both the trace level ethanol specification in the distillate (XD) and high product recovery (β). Closer analysis revealed that the MPC controller has a tighter XD control, while the proposed controller was tighter in β control. The tight XD control allowed the MPC to operate at a higher XD set point (closer to the 10 ppm AA grade methanol standard), allowing for savings in energy usage. Despite the energy savings of the MPC, the proposed control scheme has lower installation and running costs. An economic analysis revealed a multitude of other external economic and plant design factors, that should be considered when making a decision between the two controllers. In general, we found relatively high energy costs favor MPC.
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...
Many manufactured products can have a significant impact on the well-being of consumers. As such, it stands to reason that stringent requirements and standards be set firmly in place for their manufacture.
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...
Many manufactured products can have a significant impact on the well-being of consumers. As such, it stands to reason that stringent requirements and standards be set firmly in place for their manufacture.
Methods for Risk Management of Mining Excavator through FMEA and FMECAtheijes
Management of maintenance systems in the mining industry is an important condition for their operation. If we recognize the need for risk analysis and management of individual maintenance system, it can generate potential overall efficiency and effectiveness. Special importance for the realization of the objectives of the mining industry belongs to redesign, system harmonization between the various technical structure, standardization, technical diagnostics, analysis of different levels of criticality with variant selection and application of optimal solutions. The potential for the destruction of the complex maintenance systems are a reality in the mining industry and their expression in various applications is a realistic one. For different aspects of the analysis it is possible to decrease risk index range from the threshold to the range of high and low threshold of moderate and acceptable risk. Application of FMEA (Failure Mode and Effect Analysis) and FMECA (Failure Modes, Effects and Criticality Analysis) methods are used to manage risk related to the initial phase of defining the prediction of all possible risks, risk factors and RPN budget priorities. Some risks can be grouped according to the type of errors that occur due to their realization. For effective risk analysis and implement measures to reduce their need is and competent team. No matter what the risks involved, FMECA method can reliably estimate the possibility of their implementation with a satisfactory degree of flexibility and compatibility. In this paper an attempt has been made to develop an effective maintenance methodology of excavator such that the maintenance cost is minimized and technical constraints (such as engine, hydraulic and transmission system, break system, electrical and safety system, suspension and track) are efficiently monitored and maintained. These technical constraints depends upon many factors such as a) Geotechnical parameters, b) Geological parameters, c) Mine parameters, d) Production rate, e) Equipment specification and f) Dig ability assessment etc. Based on the above factors maintenance plans are prepared. This paper discusses a risk management strategy system for Optimal Maintenance Program (OMP) of excavators. The OMP includes functional analysis method of FMEA and FMECA. To develop a successful operation system, it is first necessary to create a risk management program. A prudent management program is one that ensures safety and is environmentally and economically responsible.
IMPLEMENTATION OF RELIABILITY CENTERED MAINTENANCE IN AIR COMPRESSOR UNITIAEME Publication
Today’s maintenance programs are suffered from many drawbacks. Some équipements get too little, while some gets too much préventive maintenance than required. Reliability centered
maintenance approach is found to be successful technique for solving such complex management orientated problems regarding the maintenance. Reliability centered maintenance (RCM) is the qualitative technique for developing the optimal preventative maintenance program which ensures
relability of machine opération.
Get yourself trained or Certified for IEC 62443 and other trainings.pdfJohn Kingsley
An informative Online Tech-Talk#3 session to "discover cost-effective ways of enhancing your OT/ICS cybersecurity skills and how to get yourself trained, certified for IEC62443 certification with John Kingsley" held on 8th April 2023 at 6:00 PM IST*
Learn how to achieve this without spending a fortune!
✳ What is the difference between training, certificate and certification
✳ What are the accredited trainings available for IEC 62443
✳ What are the accredited trainings available for OT/ICS cyber security
✳ What are the trainings available for OT/ICS cyber security
✳ Trainings you never knew existed 😮 😱
✳ Maximum value for your money 💲 💰
✳ Shortlisted based on value, cost, coverage, concepts 🎯
✳ Affordable trainings available for OT/ICS cyber security 🛠 🏭
✳ OT trainings PLC, SCADA, Industrial communication protocols 📡
✳ Further Reading on OT/ICS cyber security 📖 📚
All the presentation material for this sessions are available in below links!!
Affordable OT ICS Cybersecurity and other OT Trainings
https://lnkd.in/gfZMfacB
Get yourself trained or Certified for IEC 62443 and other trainings
https://lnkd.in/gnsQkKFs?
So you want to be an OT (ICS)Cybersecurity Engineer
https://lnkd.in/gN4X5FkR
OT Security Professionals TechTalk3 - Discover the Path to OT Security by John Kingsley
Your jumpstart guide on how to get yourself trained, certified for IEC 62443 and OT/ICS Cybersecurity trainings available.
✳ What is the difference between training, certificate and certification
✳ What are the accredited trainings available for IEC 62443
✳ What are the accredited trainings available for OT/ICS cyber security
✳ What are the trainings available for OT/ICS cyber security
✳ Further Reading on OT/ICS cyber security
SANS Institute Abhisam Software Industrial Control System Cyber Security Institute LLC GIAC Certifications International Society of Automation (ISA) exida TÜV Rheinland Group TÜV SÜD Justin Searle CertX Infosec UL Solutions Joel Langill Fedco International Pedro Wirya
#cybersecurity #otcybersecurity #automation #industrialsecurity #networksecurity #security #safety #iec62443 #training #ISA #ISABangalore #ISAsafesec #safesec #Safesecdivision #securityprofessionals #scadahacker #infosec ISA SAFETY AND SECURITY DIVISION ISA BANGALORE OT-ICS/SCADA SECURITY PROFESSIONALS Puneet Tambi Manjunath Hiregange Shiv Kataria Shamikkumar Dave Thilak A Vineet Madan Prabh Nair Infosec Train
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MODIFICATION OF EXISTING FACILITIES FOR 20% ETHANOL BLENDINGJohn Kingsley
MODIFICATION OF EXISTING FACILITIES FOR 20% ETHANOL BLENDING
Government of India (GoI) is proposed to develop infrastructure and storage facilities for 20% Ethanol dosing with MS as Gasoline, in addition to existing 10% Ethanol dosing with MS as Gasoline.
To achieve this there may be modification required in exciting facilities of terminal/depots.
We M/s. iFluids Engineering is leading Design Engineering consultant in India, shall study the existing facilities like storage tanks, unloading & loading piping and Pumps systems. Based on the study we will recommend Economical/Practically possible modifications that required in the facility to maintain 20% Ethanol dosing.
Introduction to oil and gas exploration and processingJohn Kingsley
This is a comprehensive presentation designed to give an overview and to introduce oil & gas operations.
Following are the contents of the presentation :
a) How Oil & Gas were formed ?
b) How are Oil and Gas deposits located ?
c) Economics of Exploration operations.
d) Definition of Oil Reserves.
e) Drilling & Production Process - How are they safely and efficiently extracted for onward processing without creating detrimental environmental impacts ?
f) History of “Off-shore Oil & Gas Exploration”.
g) Different types of “Off-shore Production facilities”.
h) Characteristics of Crude oil.
i) Oil & Gas Industry – Overall Block diagram.
j) Separation of Oil, Gas and Water.
k) Gas treatment and Export.
l) Oil treatment and Export.
m) Water treatment and disposal.
n) Pipeline transportation basics.
Know more about iFluids Engineering --> visit www.iFluids.com
IFLUIDS Engineering with its creativity, innovative and trailblazing techniques has produced proven design & drafting engineering methodologies. Our design & drafting services that provides tangible direction acquired through strategic planning & development, with conceptual and preliminary architectural, civil & structural, mechanical, piping , electrical engineering design, procurement, management consulting and infrastructure planning. Our unique innovation design process provides the framework for our innovation delivery that contributes to the tangible sign of the respect for the environment through our Engineering services to Infrastructure, Petrochemical, Oil & Gas and Energy Sectors.
Our Services
• Plant Engineering
• Architectural
• MEP Solutions
• Civil & Structural
• BIM Solutions
• Mechanical Design
• Design Automation
• Product Design
• Reverse Engineering
• Process Management
Multi-disciplinary Engineering and Drafting design including analysis simulation etc.
IFLUIDS Engineering with its creativity, innovative and trailblazing techniques has produced proven design & drafting engineering methodologies. Our design & drafting services that provides tangible direction acquired through strategic planning & development, with conceptual and preliminary architectural, civil & structural, mechanical, piping , electrical engineering design, procurement, management consulting and infrastructure planning. Our unique innovation design process provides the framework for our innovation delivery that contributes to the tangible sign of the respect for the environment through our Engineering services to Infrastructure, Petrochemical, Oil & Gas and Energy Sectors.
Our Services
• Plant Engineering
• Architectural
• MEP Solutions
• Civil & Structural
• BIM Solutions
• Mechanical Design
• Design Automation
• Product Design
• Reverse Engineering
• Process Management
Engineering Design and consultancy Services including Cybersecurity, Risk MAnagement, Project and Procurement Management Support
Hazop Training - Intermediate Level Course iFluidsJohn Kingsley
The Fundamentals of HAZOP Study
A hazard and operability study (HAZOP) is a structured and systematic examination of a complex planned or existing process or operation in order to identify and evaluate problems that may represent risks to personnel or equipment. In this online training, you will be learning The Fundamentals of HAZOP Study.
What you will learn
HAZOP Study Stands for Hazard and Operability Study. Hazop is the structured brainstorming technique to identify Hazards involved in a chemical process plant. It is an important Industrial Safety tool. HAZOP study is carried out during the design stage of the process plant or during carrying out any modification in the existing plant. Live interactive sessions over the internet, combined with practical examples completed offline and shared via email to us. You will simply require a computer with a reliable internet connection, a headset with a high-quality microphone.
Course Content
What is a HAZOP Study?
Definition of basic terms
Risk matrix/ALARP principle
When to Perform a HAZOP Study
Different stages of Hazop study and relevant Data requirement
HAZOP STUDY - TEAM COMPOSITION
Generally accepted rules of HAZOP
Overall HAZOP Methodology
Layers of protection/Safeguard
Hierarchy of controls (with simple example)
HAZOP Study-Example
https://trainings.ifluids.com/
Introduction to PSM Online Interactive TrainingJohn Kingsley
Process Safety Management (PSM ) refers to a set of interrelated approaches to manage hazards associated with the process industries and is intended to reduce the frequency and severity of incidents resulting from releases of chemicals and other energy sources. These standards are composed of organizational and operational procedures, design guidance, audit programs, and a host of other methods.
A comprehensive PSM program to identify, assess and control facility hazards, including fires, explosions and the release of highly hazardous chemicals is crucial to any industrial organization’s safety plan. With iFluids online PSM training, learners will gain important information about the elements most frequently cited by OSHA, as well as topics like emergency planning and response, mechanical integrity and management of change at a fundamental level.
Course Content
An Overview
Overview and Auditing
Process Safety Information
Process Hazard Analysis
Mechanical Integrity
Management of Change
Employee Participation
Operating Procedures
Training
Contractors
Pre-Startup Safety Review
Hot Work Permits
Incident Investigations
Emergency Planning & Resource
Compliance Audits
Trade Secrets
https://trainings.ifluids.com/
Sil assessment Risk Graph and LOPA Training iFluidsJohn Kingsley
LOPA is the newest methodology for hazard evaluation and risk assessment. On a sliding scale of sophistication and rigor, LOPA lies between the qualitative end of the scale (characterized by methods such as hazard and operability, or HAZOP, analysis and what-if analysis) and the quantitative end (characterized by methods using fault trees and event trees). LOPA helps the analyst make consistent decisions on the adequacy of existing or proposed layers of protection against an accident scenario. The technique is ideally suited for companies striving to meet specific risk targets or to lower risk as low as reasonably practicable (ALARP).
Hazop Fundamentals Online Training iFluidsJohn Kingsley
This course is designed to provide the basics of HAZOP study technique, its outcome and also to perform/review HAZOP report.
Familiarity with HAZOP Terminologies, Methodology, Brief Ideas for taking part /Involve in HAZOP Session. https://trainings.ifluids.com/
John kingsley OT ICS SCADA Cyber security consultantJohn Kingsley
John kingsley OT ICS SCADA Cyber security consultant
SCADA ICS Security Courses
Lack of SCADA ICS security professionals that lead to big gaps between compliance against the respected guidelines with the real situation at site. Critical needs for proper security professional in SCADA ICS
SCADA ICS Security Assurance
Ensuring the SCADA ICS environment to comply with the security requirements in order to maintain the production operations and sustain the business performance
SCADA ICS (OT) Security Services
SCADA ICS Security Services Summary
SCADA ICS Security Asset Management
SCADA ICS Security Risk Management
SCADA ICS Security Assessment
SCADA ICS Standard, Policy & Procedure Management
SCADA ICS Security Implementation
Cyber Security Services
Vulnerability Assessment
Penetration Testing
ISO 27001 Certified Management System Audit
iFluids Lean Six Sigma Case Study oil & gasJohn Kingsley
iFluids Lean Six Sigma Case Study oil & gas
Lean Six Sigma Applications in Oil and Gas Industry: Case Studies
Management Consulting Services
Lean Management Services
Framework to Implement Six Sigma Methodology to Oil and Gas
India Oman Qatar Malaysia Singapore
iFluids Behaviour based safety services and trainingJohn Kingsley
Behaviour-Based Safety: The blame game
An entire department is given bingo cards. The game continues until someone in that department reports a work related injury or illness. At that time, everyone has to turn in his or her markers and the game starts over. Imagine the pressure on the poor worker who slices his or her finger or suffers some type of sprain, not to report an injury, because a co-worker is about to reach BINGO and win the VCR or microwave oven.
Sound familiar? Scenarios such as this are growing in frightening proportions as more and more workplaces are adopting behaviour-based safety programs as part of their health and safety arsenal. UFCW Canada opposes this type of so called Health and Safety program as this type of program also encourages workers to spy on their co-workers for working in an unsafe manner
iFluids Management Consulting & Training Services
Six Sigma
Lean Management
Behavioural Based Safety
Safety Management Gap Analysis
Risk Management Profiling
Accident Investigation
Bottom Tank Inspection by Manual & Mapping Tank Floor Bottom Scanner
Dimensional Control Survey , Storage Tank Inspection
Above Ground Storage Tank Evaluation Program
• Our Above Ground Tank Inspection services include:
• Nondestructive testing services
• Ultrasonic thickness measurement using our DX-20 remote crawler
• MFE 2412 floor scanner
• DX-20 Magnetically- Attached Ultrasonic / Remote Visual Testing Crawler
• Our Tank Inspection Qualifications include:
• API 653 certified inspectors
Mechanical Integrity Program capabilities:
• Thickness Inspections
• Engineering Evaluations
• Corrosion Rate and Remaining Life Determination
• Fitness For Service Evaluations (FFS)
• Turnkey Tank Management Program
Our targeted tank inspections look to find and quantify such damage and deterioration phenomenon as:
• Corrosion Rate
• Remaining Life
• Under Floor Corrosion
• Corrosion Under Insulation (CUI)
• Tide Line and Corrosion Zones
• Settlement and Planar Tilt
Above Ground Storage Tanks within our inspection expertise include:
• SP-001 Tanks
• UL-58
Our inspections are tailored to your process equipment and risk mediation programs such as:
• Mechanical Integrity Program (MIP)
• Process Safety Management (PSM)
• Spill Prevention Control and Countermeasure (SPCC)
• Resource Conservation and Recovery Act (RCRA)
• Chlorine and Chlorine Dioxide Service
• Flammable or Hazardous Chemicals
• Proprietary Process Chemicals
We utilize the following tests in our inspections to gain an understanding of the condition of your equipment.
• Visual Inspections (VT)
• Ultrasonic Thickness Testing (UTT)
• Magnetic Particle Testing (MT)
• Penetrant Testing (PT)
• Radiographic Testing (RT)
• Magnetic Flux Leak Detection (MFL)
• Vacuum Box Testing (VBT)
Peripheral Considerations:
• Secondary Containment Sizing
Our API inspectors have been properly trained and certified and commmonly perform API 653 tank inspections. Many industries call upon iFluids to perform other popular services according to the API 570 and API 510 standards.
Chanigng industrial Control Systems Conference and Networking Session
CICS Introduction
We are in the throes of witnessing an Industrial Revolution, The Industrial Revolution Who Should Attend 4.0! A revolution that will completely change the way we live, work, and relate to one another. In its scale, scope, and complexity, the transformation will be unlike anything humankind has experienced before and with it will change the Industrial Control Systems (ICS).The boundaries delineating the ICS world from the civil world are denigrating, we are now looking at future where residences will be connected the Power Grids, supplying back rather than receiving energy (Renewable Energy – Reverse Metering), Smart Cities which will enable its residents and allow them to interact with the cities control systems and more.In this exciting times, we have created a unique conference where we will hear from the experts from the industry in ICS Domain, on what new is happening? We will endeavor to build a 360° view on the subject and understand the happenings, the challenges, the innovations that is changing the face of Industrial Control systems.
Attendees
SAMIR K PAWASKAR
Cyber Security Expert - GICSP, CRISC, CISM, CISSP, AMBCI, CICA, ISO 27001 LA, CCNP, MCSE
FARIS ABDULLAH AL-KHARUSI
Head of Business Excellence -Real Time Operations & Smart Fields,Petroleum Development Oman
NILANGSHU DEY
Senior Automation Engineer-Qatar Petroleum, Vice President-ISA(International Society Of Automation)
MALIKE BOUAOUD
Director/Lead, ICT and CS Strategy Research & Development QATAR FOUNDATION
KARMA SAMIR SHERIF
Professor -Management Information Systems College of Business and Economics Qatar University
JAVIER DIÉGUEZ BARRIOCANAL
Director – Basque Cybersecurity Centre
SAMUEL LINARES
Partner - iHacklabs
OMAR SHERIN
Director -Cyber Security Advisory - Africa, India & Middle East (AIM)Ernst & Young
SULTAN SALIM HUMAID AL-YAHYAI
Manager Information Technology
MOHAMMED IKRAMI
Senior Security Engineer, Qatar Aluminum Limited
FADI ADLOUNI
Senior Security Systems engineer, Palo Alto Networks.
GOPI KRISHNA DURBHAKA
Technology Evangelist Senior Member, IEEE fellow of ISECE
How to write a plant operating manual
preparation of effective operating manuals
oil and gas pertrochemical process industry pharmaceuticals energy power ca
Case study of dcs upgrade how to reduce stress during executionJohn Kingsley
iFluids Engineering ICS / DCS / SCADA Engineering Design, Procurement, Integration, Testing, Commissioning & Troubleshooting Services
Article Source: This guest blog post was written by Sunny R. Desai, an engineer in the DCS/PLC/SCADA department at Reliance Industries Ltd. A version of this article originally was published at InTech magazine.
Hydrocarbon leak detection in tank farmsJohn Kingsley
On December 10, 2005, Tank 912 at the Buncefield Oil Storage Depot in Hertfordshire, England, was filling with gasoline. According to a report by the European Process Safety Centre, the tank had two forms of level control: a gauge enabling personnel to monitor the filling operation; and an independent high-level switch (IHLS) which was meant to shut down operations automatically if the tank was overfilled.
The first gauge stuck and the IHLS was inoperable, so there was no means to alert the control room staff that the tank was filling to dangerous levels. Eventually, large quantities of gasoline overflowed from the top of the tank. A bund retaining wall around the tank and a system of drains and catchment areas that were supposed to ensure that liquids could not be released to the environment failed. More than 66,000 gallons (250,000 liters) of gasoline escaped from the tank before the explosion occurred.
Risk Assessment, Compliance and Creation of Management Systems as per API 2350: Overfill Protection for Storage Tanks in Petroleum
A visual signal is a luminous source within a coloured transparent enclosure and is used in many applications not least as reinforcement to an audible signal in the event of danger, warning or machine status / system process.
Effectiveness of visual signals
With the possible exception of status indicators, the purpose of the E2S visual signals range is to attract attention as compared with a luminaire or general purpose light which is intended to illuminate a given area and not necessarily attract attention. Therefore the effectiveness or the light intensity of a device as opposed to merely its capacity to illuminate is probably the important consideration. Different light sources may offer significantly different effective light intensity and ability to attract attention, particularly when flashing; however in contrast their ability to illuminate a given area may be fairly poor.
E2S provides information relating to the effectiveness of a visual signal based on actual measurements for each model within the E2S range. The information provided IS NOT based on rule of thumb assumptions and / or calculations alone. We therefore have confidence our measured light output values are meaningful and will better aid product selection.
Introduction to bowtie : A barrier-based approach to riskJohn Kingsley
Bowtie is one of many barrier risk models available to assist the identification and management of risk and it is this particular model we have found (and are still finding) useful.
These pages explain:
what a bowtie can be used for,
how it can help you,
how to go about the methodology and
what to look for within a model.
The bowtie model consists of different elements that build up the risk picture. The risk picture revolves around the hazard (something in, around or part of an organisation or activity which has the potential to cause damage or harm) and the top event (the release or loss of control over a hazard known as the undesired system state).
Consideration is then turned to the threats (a possible direct cause for the top event), consequences (results of the top event directly ending in loss or damage) and the controls (any measure taken which acts against some undesirable force or intention
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.
Overview of the fundamental roles in Hydropower generation and the components involved in wider Electrical Engineering.
This paper presents the design and construction of hydroelectric dams from the hydrologist’s survey of the valley before construction, all aspects and involved disciplines, fluid dynamics, structural engineering, generation and mains frequency regulation to the very transmission of power through the network in the United Kingdom.
Author: Robbie Edward Sayers
Collaborators and co editors: Charlie Sims and Connor Healey.
(C) 2024 Robbie E. Sayers
Final project report on grocery store management system..pdfKamal Acharya
In today’s fast-changing business environment, it’s extremely important to be able to respond to client needs in the most effective and timely manner. If your customers wish to see your business online and have instant access to your products or services.
Online Grocery Store is an e-commerce website, which retails various grocery products. This project allows viewing various products available enables registered users to purchase desired products instantly using Paytm, UPI payment processor (Instant Pay) and also can place order by using Cash on Delivery (Pay Later) option. This project provides an easy access to Administrators and Managers to view orders placed using Pay Later and Instant Pay options.
In order to develop an e-commerce website, a number of Technologies must be studied and understood. These include multi-tiered architecture, server and client-side scripting techniques, implementation technologies, programming language (such as PHP, HTML, CSS, JavaScript) and MySQL relational databases. This is a project with the objective to develop a basic website where a consumer is provided with a shopping cart website and also to know about the technologies used to develop such a website.
This document will discuss each of the underlying technologies to create and implement an e- commerce website.
Welcome to WIPAC Monthly the magazine brought to you by the LinkedIn Group Water Industry Process Automation & Control.
In this month's edition, along with this month's industry news to celebrate the 13 years since the group was created we have articles including
A case study of the used of Advanced Process Control at the Wastewater Treatment works at Lleida in Spain
A look back on an article on smart wastewater networks in order to see how the industry has measured up in the interim around the adoption of Digital Transformation in the Water Industry.
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.
Saudi Arabia stands as a titan in the global energy landscape, renowned for its abundant oil and gas resources. It's the largest exporter of petroleum and holds some of the world's most significant reserves. Let's delve into the top 10 oil and gas projects shaping Saudi Arabia's energy future in 2024.
2. The evaluation of components reliability is a fundamental
aspect for proper maintenance execution; existing reliability
evaluation methods are based on the availability of knowledge
about component states. However, component states are often
uncertain or unknown, especially during the early stages of the
development of new systems. In such cases, it is important to
understand how uncertainties will affect system reliability
assessment. Reliability of systems often depends on their age,
intrinsic factors (dimensioning, quality of components, material,
etc.) and conditions of use (environment, load rate, stress, etc.).
In this context, RAM factors constitute a strategic approach
for integrating reliability, availability and maintainability, by
using methods, tools and engineering techniques (such as Mean
Time to Failure, Equipment down Time and System Availability
values) to identify and quantify equipment and system failures
that prevent the achievement of its objectives.
The majority of industrial systems have a high level of
complexity, nevertheless, in many cases, they can be repaired.
Moreover historical and or benchmarking data, related to sys-
tems failure and repair patterns, are difficult to obtain and often
they are not enough reliable due to various practical constraints.
In such circumstances, it is evident that a good RAM analysis can
play a key role in the design phase and in any modification
required for achieving the optimized performance of such sys-
tems. However, it is difficult to estimate the RAM parameters of
these systems up to a desired degree of accuracy by utilizing
available information and uncertain data [2] (Komal et al., 2010).
Reciprocating Compressor are very sophisticated systems that
go beyond traditional RAM analysis due to specific capabilities
needed for performing a range of working operations that can
ensure the required production efficiency and reliability in the
Oil and Gas industry.
The main aim of this research work was to assess the avail-
ability of reciprocating compressors plant designed, configured,
and eventually compared against End User Site Project that
should be as minimum of 96% during normal production.
Another important goal was the identification and ranking of the
equipment and sub-systems which are major contributors to-
wards unavailability. Ranking is based on the estimated equip-
ment and sub-system contribution towards unavailability. The
final objective was to propose and assess potential cost-effective
optimization options to ensure the achievement of the target
availability, where appropriate, and perform Equipment Criti-
cality Assessment for the systems and equipment assessed as
part of the RAM study.
This work was carried out in collaboration with a company
leader in the production of reciprocating compressors for the Oil
Gas industry that for privacy reasons will be named RC com-
pany. RC company has established as one of its mission a
continuous improvement of its products quality in terms of
availability and reliability in accordance with the standards of
the specific sectors in which the produced systems are applied.
2. Literature review
Among various methods for systems performance modelling
(Root Cause Analysis, RCA; Failure Mode and Effect Analysis,
FMEA; RAM; Quality Control Tools), RAM is an engineering tool
that evaluates the equipment performance at different stages in
design process. It addresses both operation and safety issues and
aims to identify areas with in the system or process where
improvement actions can be initiated. With RAM analysis of the
system key performance metrics such as Mean Time to Failure
(MTTF), Equipment down Time (EDT) and System Availability
values (Asys) can be ascertained. The information obtained from
analysis helps the management in assessment of the RAM needs
of system [3] (Sharma and Kumar, 2008).
In the Oil Gas Industry risk-based maintenance programs to
improve safety, reliability and availability of the plants have been
applied for a log time now.
RAM is one of the risk evaluation models that are applied in
Maintenance and Safety Integrity Management System.
Eti et al. (2006) [4] demonstrated an approach for the inte-
gration of RAMS and risk analysis as a guide in maintenance pol-
icies to reduce the frequency of failures and maintenance costs.
Depending on the information delivered by different indica-
tor decision-making models, managers who are in charge of
maintenance can take measures to review operational manage-
ment, maintenance management and safety management, so
that the indicators mentioned above can better satisfy manage-
ment needs. The decision-making model which is used to
improve equipment reliability, availability and maintainability
are called RAM procedure, and it is also a sustained and close-
loop management system. Dynamic risk rank indicator, predic-
tive maintenance indicator and RAM indicator constitute the
intelligent maintenance indicator decision-making system [5]
(Qingfeng et al., 2011).
RAM is considered to be one of the two most significant areas
for profitability improvement (William, 2001). Moreover, RAM
modelling will contribute to an increased safety and environ-
mental performance, which is an important factor in maintain-
ing the license to operate, by providing real and up-to-date data
concerning the actual state of the plant. Herder at al. (2008) [6]
described the feasibility and prerequisites for implementing
RAM simulation modelling in industrial practice, by means of
developing, implementing and using a RAM simulation model
for the GE Plastics Lexan®
plant in Bergen op Zoom, The
Netherlands.
Lundteigen et al. (2009) [7] in their paper outline a new
approach to reliability, availability, maintainability, and safety
(RAMS) engineering and management. The new approach covers
all phases of the new product development process and is aimed at
producers of complex products like safety instrumented systems
(SIS). The article discusses main RAMS requirements to a SIS and
presents theserequirementsina holistic perspective.The approach
is based on a new life cycle model for product development and
integrates this model into the safety life cycle of IEC 61508.
Saraswat and Yadava (2008) [8] emphasised the role of reli-
ability, availability, maintainability and supportability (RAMS)
aspects for improving performance of engineering systems.
Rajiv and Poja (2012) [9] developed a methodology to permit
the system reliability analysts/managers/engineers/practitioners
to conduct RAM analysis of the system to model, analyse and
predict the behaviour of industrial systems in a more realistic
and consistent manner through a Markovian approach. They
demonstrated that with RAM analysis of the system key perfor-
mance metrics such as Mean Time between Failure (MTBF),
Mean time to Repair Time (MTTR) and System availability values
are ascertained.
3. Reciprocating process compressor in oil and gas industry
The target duty of reciprocating process compressors is the
export of produced gas from a small oil/gas field into a common
manifold system.
The back pressure in the manifold varies depending on the
total gas rate.
The gas is a hydrocarbon mixture of variable molecular
weight, including inert gases such as Nitrogen, and may contain
corrosive/toxic components such as Hydrogen Sulphide.
F. Corvaro et al. / Petroleum 3 (2017) 266e272 267
3. In such system the gas is compressed in a series of discon-
tinuous steps by coaxing a fixed volume of gas into a chamber or
cylinder for compression.
Then the compression of the gas mechanically reduces the
size of this cavity. At the end of the compression cycle the
chamber opens and discharges the high-pressure gas.
Due to the compression process the temperature of the pro-
cess gas increases; for this reason, in some cases separate stages
of compression with intercooling of the gas between them are
applied for limiting the temperature and loads on the
compression cylinder.
It is not rare that only one or two stages of this compression
process are needed. This kind of compressors do not allow an
open gas passage from delivery to suction, even do back flow is
possible by leakage through the clearances between moving
parts.
Reciprocating compressors can achieve high pressure ratios
per stage at low volume flows.
With respect to centrifugal and screw compressors, the
reciprocating ones are used for smaller flow; they also allow a
greater flexibility of duty.
They are built with materials that can stand suitable me-
chanical loads and when in contact with the process gas are also
chemically resistant.
Hydrocarbon compressors API 618 are generally horizontal
and designed with opposed pairs of cylinders, in order to meet
the mechanical balance and gas sealing requirements.
To achieve reasonably practical shaft alignment and permit
thermal expansion, flexible couplings are used between co-axial
shafts.
Horizontal reciprocating compressors require particularly
robust base-frames as the cylinders are supported separately
from the crankcase. This is particularly true offshore with the
baseplate having to provide the necessary stiffness for alignment
and dynamic stability on the offshore installation where the
structure itself is too mobile.
Compressors require suitable piping, Interstage vessels and
coolers with associated control systems. Together with baseplate
and driver this forms the “Compressor System”.
A general scheme of the compressor main elements/compo-
nents is shown in Fig. 1.
The vast majority of compressors are shaft driven by a sepa-
rate electric motor, gas turbine or diesel engine. A drive gearbox
may be required to match the compressor and driver speeds.
Reciprocating compressors are not normally variable speed as
there are a number of ways to modify the output from such
machines including:- reducing cylinder efficiency using clear-
ance pockets, control on suction valve opening, and offloading
cylinders.
The safety of reciprocating compressors handling hazardous
materials is dominated by their piston rod sealing systems. These
require appropriate design, maintenance and operator attention
[10].
3.1. Operating requirements
Reciprocating compressors are generally designed for long
periods of steady operation, up to perhaps 3 years' service
without major overhaul. Valves and seals require service at
perhaps 12/24 or more monthly intervals.
Continuous Duty
Selecting equipment for continuous operation, requires
steady, efficient and reliable operation. Reciprocating compres-
sors cannot run continuously for more than a maximum of about
12/24 months before valve and seal wear becomes unacceptable,
and the motion work may only be able to run for up to 3 years
between major overhauls. Sophisticated monitoring will give the
best information to permit maintenance intervention to be well-
planned and of the shortest possible duration. Chemical addi-
tives may be used to control fouling. Materials are selected for
negligible corrosion in service.
Variable/Intermittent Load Duty
Reciprocating compressors are tolerant of duty changes, but,
being positive displacement ma-chines, recycle control is nor-
mally used to manage flow changes. Some machines are fitted
with unloading systems, these can be complex and may cause
local high temperatures. Reciprocating compressors can be
started up very quickly, provided that detailed checks are carried
out and, above all, no liquid is present in the compressor or
suction system.
Emergency Duty
Reciprocating compressors are not ideal for emergency duty
as they require operator checks and attention during starts. It is
practical to have a set running on full recycle at low power and
perhaps reduced speed, ready to pick up load in a few seconds.
Again, the potential presence of liquid in the suction line would
pose a major hazard.
3.2. Maintenance requirements
Maintenance requirements for reciprocating compressors are
a combination of preventative maintenance of the motion work
and major components and essential predictive maintenance
based on measured performance such as valve temperatures, rod
drop, vibration.
Valves, gas seals, bearings can be accessed by removal of local
covers. Removal/maintenance of seals and bearings requires
lifting equipment to support and position motion work as
required. The pistons and rod are normally removed as an as-
sembly by unscrewing the cross-head nut. Only then can the gas
seal, and the piston rings, be inspected and changed. Recipro-
cating compressors are thus relatively maintenance-intensive,
reducing the availability compared to centrifugal units.
Fig. 1. Components of horizontal reciprocating gas compressor (scheme provided
by RC company).
F. Corvaro et al. / Petroleum 3 (2017) 266e272
268
4. The alignment and levelling of cylinders to crankcase should
be checked periodically, particularly after any cylinders have
been disturbed. Any misalignment or movement will result in
increased fatigue loads on cylinder supports and fasteners.
Movement is often shown up by “panting” of the oil film in
mechanical joints.
Special fasteners permit the tension or stretch of fasteners to
be checked in service. Hydraulically tensioned fasteners are often
fitted to ensure accurate tightening in confined spaces.
The motion works bearings will be white metal, possibly of
shell construction that would simplify maintenance. A high level
of fitting skill is required to work on these machines.
The piston rod and gland arrangements are precisely engi-
neered to avoid gas leakage, assembly and installation of these
components requires some of the highest levels of quality en-
gineering and attention to detail to provide reliable operation.
The control and remote isolation valves will be large and very
heavy, often posing a difficult lifting problem. It is important that
the full operation of these valves be tested before the plant is
returned to service. It may be necessary to carry out in-service
operating tests on valves to ensure their reliability. They also
often have inter-coolers and water cooled cylinder jackets. Hence
liquid may well be condensed inside the compressor. Some
process compressors are of a “lubricated” design, where a
process-compatible lubricating oil is injected in small quantities
into the cylinder. This oil lubricates the piston rings and gas seals.
The oil provides a significant degree of corrosion protection. The
main corrosion potential is if the lubricating oil supply stops,
while condensation continues. This might occur when a set was
stopped, but not isolated and purged with dry gas. Light hydro-
carbon condensate will wash off the oil film, leaving surfaces
exposed to trace corrosive elements in the gas.
The worst corrosion occurs if process deposits (salts, oxides)
are exposed to damp air under poor ventilation conditions. This
may occur if there is a failure that prevents a normal process
clean out. The system is then opened for inspection, and left open
while parts/resources are obtained. This can be avoided by
proper cleaning/venting activities after the inspection, and even
by applying corrosion inhibitors.
The crankcase and cross-head areas should be completely
separate from the process, with clean lubricating oil in a dry gas
(ideally Nitrogen) atmosphere. There should be no potential for
corrosion here, although it is very wise to periodically test the oil
for water, chlorides and light hydrocarbons.
4. Materials and methods
In this work the RAM analysis method has been applied; it is
an assurance activity for safety critical systems in aerospace, nu-
clear power and industries. For the process industries (e.g., oil and
gas, power plants), RAM analysis is rapidly developing and be-
comes a mandatory deliverable for the conceptual design phase.
In this study the RAM analysis has been performed based on
the following documents:
➢ Maintenance Strategy;
➢ Piping and Instrument Diagrams;
➢ Process Flow Diagrams;
➢ Process Operations and Control Philosophy;
➢ Maintenance Policy;
The RAM methodology is presented in detail in the following
scheme (see Fig. 2).
The RAM study was based on failure rate and model data that
are developed and compiled from a number of sources, including
ERM experience and publicly available process equipment failure
rate databases such as OREDA 2009 5th edition SINTEF and
NPRD. When using the generic failure database, a review of the
data set has been performed and some modifications to the data
were applied based on the experience of the application and
operating environment. These modifications and assumptions
have been reviewed and agreed upon with the project team prior
to conducting the RAM model.
For large multi-component equipment such as compressors
and turbines, the failure modes are divided into trip, minor and
critical failures.
Trip failures generally represent an upset of the process and/
or instrument failures and can be rectified during the operating
shift. Minor failures are generally related to equipment failures in
case repair would be needed and performed within a short
period of time.
Critical failures refer to multiple component failures or major
part failure which would require a significant repair time.
This allows a more accurate modelling of the failure-
maintenance cycle.
To assess the time needed to repair non functional equipment
in case of corrective maintenance application, it as to be taken
into account the time required for isolation, depressurization,
on-site mobilization, actual repair time, and restart ramp up
time.
Time spare equipment procurement time, off-site logistics or
administrative processes which are outside the optimization of
the equipment configuration design in the context of RAM study.
Reliability block diagrams were developed for the major
equipment to allow production availability to be quantified. The
analysis was performed using Monte Carlo analysis technique.
Following the assessment of production availability, the
equipment/sub-systems that were found to be the major con-
tributors to unavailability were ranked with respect to the esti-
mated contribution towards unavailability.
Specific Software RAM tools can also be used as Process
Reliability Modelling, Plant Wide Performance Modelling or
simply RAM Modelling. In this case it has been chosen the soft-
ware MAROS for Upstream and Midstream analysis propriety of
DNV.
4.1. Reliability data collection
The goal of RAMS is to create input data for the assessment of
the suitability of a system in a life cycle. That is, to provide data
Fig. 2. Scheme of RAM methodology (scheme provided by RC company).
F. Corvaro et al. / Petroleum 3 (2017) 266e272 269
5. on failure rates of the system, possible failure modes, MDT,
maintenance operations, hazards and their consequences, etc.
This output of RAMS simulations enables the life cycle specialists
to calculate costs and to perform Cost-Benefit Analyses (CBA).
But before the RAMS simulation at system level, input on known
component failure data must be provided. There are then 3
different steps in the application of RAMS, all of which are
interlinked (see Fig. 3).
Step 1: RAMS data compilation (component level)
Failure data compilation stands as the foundation of any
RAMS simulation or process. Whether it is made through testing
or through observed field operation and maintenance feedback,
the study of individual component failure provides data on
failure rate and all other reliability parameters. This data is used
as input for step 2, RAMS simulation.
This is of utmost importance, for as stated above, a great
number of authors state that the use of more complex reliability
models (in step 2) does not necessarily mean there is a better
result, for there is generally a lack of relevant reliability data (step
1). Reliability data has more impact on the RAMS simulation
results than the RAMS simulation models themselves.
Step 2: RAMS simulation (system level)
In this step, the goal is to model the system in terms of
reliability aspects. That is, from values of failure rate, MTBF,
MDT, among others from individual components, be able to
compute values which refer to the same components but while
interacting with each other in a system and a stated environ-
ment. The first methods developed to do so e like the Pre-
liminary Hazard Analysis and the Failure Modes and Effects
Analysis e are of qualitative nature and are mainly intended to
identify failures at system level. Other methods which appeared
later on are of quantitative nature and enabled the reliability
engineers to predict through mathematical formulations
several values for failure rate and related parameters in systems.
These simulation result values are termed design or expected
reliability.
Step 3: Life cycle assessment (system level)
In the life cycle step, the goal is to assess the benefits the
system will bring. In order to do so, costs and incomes must be
Fig. 3. Scheme of RAMS steps and Life Cycle assessment (scheme provided by RC
company).
Fig. 4. Results of subsystems criticality analysis.
Fig. 5. Results of components criticality analysis.
Fig. 6. Global relative loss % for each main subsystem.
Table 1
Results of components criticality analysis.
Description Global rel
loss %
Local rel
loss %
Mean
failure
Abs loss
mean %
MTBF
(years)
Unique
ID
Bare compressor 61,896 61,897 590,9 1306 0,0338 48
Oil unit 36,560 36,561 597,5 0,771 0,0335 50
Nitrogen unit 1,3904 1,3904 25,9 0,029 0,7722 49
Water unit 0,1519 0,1519 947 0,003 0,0211 151
F. Corvaro et al. / Petroleum 3 (2017) 266e272
270
6. assessed. Another part to quantify is costs. RAMS parameters will
play a very big role in determining the costs, since as stated
above, failures will bring costs to the system, i.e. the cost of a
compressor system to be stopped due to a failure, the cost of a
corrective maintenance operation on a compressor system
which forces the impediment the cost of accidents which might
involve serious injuries or death, among others.
So at this step, the idea is to take RAMS simulation results and
create targets for the system studied. The targets will influence
the system's mission profile and the life cycle's CBA, and the
results of the CBA might indicate that the RAMS targets need to
be revised. This is thus an iterative process, for the RAMS targets
influence the CBA and the CBA influences the RAMS targets. It is
then needed to go back to step 2, and rerun the simulations in
order to revise RAMS targets. Finally, the testing and operation
steps in the life cycle will influence step 1, for data can be
collected through the testing and operation phases of the life
cycle. This is a way to achieve reliability growth.
5. Reliability availability results
The data collected and compiled in phase 1 have then been
used to assess the reliability of the reciprocating compressor:
failure rate, MTBF, MDT and other parameters were calculated
and in relation to the interaction of the system under analysis
with other components.
Based on a 10 simulation cycle run with a 20 year life, the
average production efficiency is 97,8% within a standard devia-
tion of ±0.104%. The average volume produced over life is
463,059,000 sm3
starting with 23,149,606 sm3
in 2015 and rising
to 23,196,428 sm3
in 2034.
The average loss over life is 9,980,840 sm3
averaging at
499,042 sm3
per year.
Fig. 4 shows the results of the criticality analysis applied to
compressors subsystems components: the most critical ele-
ments in terms of reliability of the entire system are the guide
and the piston ring; the trust bearings and the gas pressure
packing. The values defined in the analysis for the different types
of valves are almost the same and range around 5% ensuring a
suitable level of reliability.
In Fig. 5 a breakdown of the components criticality for the
selected subsystems is presented; the subsystem that shows the
major vulnerability is given by the electric motor followed by the
guide and piston rings (see Fig. 6).
Table 1 reports, for the analysed subsystems, the mean failure
and the relative mean time between failure.
The average number of outages per year was 11.47 with an
average duration of 12,339 h. The longest outage lasted 59.141 h
and the shortest 0.051 h (see Fig. 7).
There have been analysed 9 main events contributing to the
outages each one identified by an ID.
In Table 2 the number of occurrence of each event contrib-
uting to outages is reported.
Fig. 8 shows a breakdown of the principal events contributing
to the outages.
6. Conclusions
This study was carried out in cooperation with a company
leader in the production of reciprocating compressors with a
mission of continuous quality improvement. They have a
consolidated experience in the application of RCM methodology
since it has a great impact on the preventive maintenance tasks.
The main aim of this research work was the assessment of the
availability of reciprocating compressors plant designed,
configured, and eventually compared against End User Site
Project. The target value to reach for the availability was grater
than 96% during normal production.
Moreover the quality team needed to define and rank the
equipment and sub-systems which are major contributors to-
wards unavailability. Such elements were correctly identified.
Finally potential cost-effective optimization options to ensure to
achieve the target availability were proposed and assessed.
The results of the RCM study applied on reciprocating
compressor API 618, showed that the preventive maintenance
proposed tasks and planning are generated.
The criticality analysis of components allowed to have a time
window for programming effective maintenance activities and
outlined failures and main events contributing to jeopardize the
production process.
The present work recognizes the need for a structured
approach whereby quantitative RAM targets are set at the con-
ceptual design stage and used throughout the plant life cycle to
control and review the RAM performance.
Fig. 7. Frequency of outages.
Table 2
Occurrence of each event contributing to outages.
Contributor Event ID Contribution count Relative contribution %
Critical 10 93 4.0541
Critical 17 562 24.4987
Critical 11 192 8.3697
Critical 13 88 3.8361
Critical 15 257 11.2031
Critical 16 619 26.9834
Critical 14 71 3.095
Critical 12 184 8.0209
Critical 9 200 8.7184
Fig. 8. Principal events contributing to outages.
F. Corvaro et al. / Petroleum 3 (2017) 266e272 271
7. To enhance the credibility of the ideas presented in this work
and the other formulations that are exists in the literature, it is
necessary to work on real case studies.
This would in turn require industry to share some of its
operational data with the academics.
These case studies would demonstrate the usefulness of the
methods and could also be used by process engineers to learn
how to apply RAM principles in process design.
The importance of this study was the possibility to collaborate
with the company and to start a measurement campaign col-
lecting field data that will allow the prosecution of the research
and to increase the reliability and usefulness of results.
Future research will be devoted to on-site measurements and
real data acquisition in working conditions.
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