CCPS Asia regional PSM Meeting Bhavesh Shukla...CCPS Asia regional PSM Meeting Bhavesh Shukla ....

GROWTH INNOVATION SOLUTIONS SUCCESS

1

Reliability Centered Maintenance to Minimize Integrity Failure

CCPS Asia regional PSM Meeting

Bhavesh Shukla

Agenda

•Failure Case study

•Types of Maintenance

•Risk Based Maintenance Strategy

•Process Steps

•Exercise

2

Coupling with

Torque Limiting Slip (TLS) Plate (Clutch)

3

Reactor agitator failure

Cost Analysis:

i. Additional cost to Business due to failure =1.3 Million

ii. Cost to prevent failure=$10000

Causal Factor:

i. Aging equipment

ii. Lack of predictive maintenance

iii. torque limiting setting was set too low during gear box replacement

which caused pre-mature clutch top limiter slipping which

generated heat and caused the high speed coupling to fail

Preventive Action:

i. Temperature monitoring of Gearboxes and motor

ii. Vibration check and analysis program

iii. Lubrication test and analysis program

4

Agitator Failure

Types of Maintenance

5

•Repair

Run to failure

•Preventive Maintenance

Time based

•Predictive Maintenance Condition based

•Repair – run to failure is Suitable only for

Non critical

Inconsequential

Unlikely to fail

Redundant

6

Repair

Repair

• Repair of unexpected break-downs cost more than money

• run to failure, is suitable for small items which are non critical,

inconsequential, unlikely to fail and redundant.

• For critical equipments and parts, it is not an option.

7

Repair

8

Preventive Maintenance

9

•Preventive maintenance is time base

Maintenance. We change parts or service

equipment before it fail and some time

before it need to be.

Preventive Maintenance

10

Preventive Maintenance

11

Preventive Maintenance

12

Predictive Maintenance

13

• Is based on predictive testing, monitoring and inspection.

• It is suitable for critical equipment which has

random failure

not subject to wear

PM induced failure

Predictive Maintenance

14

Predictive Maintenance

15

Predictive Maintenance

16

17

Condition Based Maintenance

Reliability Centered Maintenance

• Reliability Centered Maintenance (RCM) is a maintenance

strategy that is implemented to optimize the maintenance program

of a company or facility using cost-effective maintenance

techniques.

• There are four principles that are critical for an RCM program.

The primary objective is to preserve system function

Identify failure modes that can affect the system function

Prioritize the failure modes

Select applicable and effective tasks to control the failure modes

18

RCM Process Steps

19

Operational Risk Number

System Risk Number

Asset Risk Number

Failure Probability Factor

Maintenance Priority Number

Safety Issues, Regulatory Compliance,

Product Quality Issues, Process Throughput,

Operational Cost

In series and will stop the system (24 hr lost)

, Important (8 hr lost) ,Can be Bypassed,

Little effect to system, No effect to system

Reactive Maintenance Performed…

Daily, Weekly, Monthly, Quarterly, Annually

System Risk Ranking Process

Area SF RC QF PT OC SRN

PROCESS SYSTEM NAME

Safety

Failures

Regulatory

Compliance

Quality

Failures

Process

Throughput

Operational

Cost

System

Risk Number

Reactor

(1-10) (1-10) (1-10) (1-10) (1-10) 1-10

Agitator TLS plate 8 2 10 10 10 8

Cooling control valve 6 8 9 8 5 7.35

Heating Control valve 5 6 6 8 8 6.71

Cooling insulation 3 2 3 4 3 3.07

20

21

Maintenance Priority Ranking Process

Risk Number ORN FPF

10 24 Hours Lost Daily

8 8 Hours Lost Weekly

6 2 Hours Lost Monthly

4 <1 Hour Lost Quarterly

2 No Lost Annually

PROCESS SYSTEM NAME

System

Risk

Number

Operational

Risk

Number

Asset

Risk

Number

Failure

Probability

Factor

Maintenance

Priority Number

#1-10 (1-10) # 1-100 (1-10) # 1-1000

Reactor SRN ORN ARN FPF MPN

Agitator TLS Plate 8 10 80 3 240

Cooling control valve 7.35 4 29.40 2 59

Heating Control valve 6.71 3 20.13 5 101

Cooling insulation 3.07 2 6.14 1 6

Maintenance Strategy

22

Maintenance Priority Index to determine which type of maintenance is

most effective.

• Repair- run to failure

• Preventive Maintenance

• Predictive Maintenance

Contact:

bhaveshjayati@hotmail.com

+65 96907710

23

Q & A