ccps asia regional psm meeting bhavesh shukla...ccps asia regional psm meeting bhavesh shukla ....
TRANSCRIPT
GROWTH INNOVATION SOLUTIONS SUCCESS
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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
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Coupling with
Torque Limiting Slip (TLS) Plate (Clutch)
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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
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Agitator Failure
Types of Maintenance
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•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
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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.
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Repair
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Preventive Maintenance
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•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
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Preventive Maintenance
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Preventive Maintenance
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Predictive Maintenance
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• 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
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Predictive Maintenance
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Predictive Maintenance
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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
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RCM Process Steps
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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
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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
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Maintenance Priority Index to determine which type of maintenance is
most effective.
• Repair- run to failure
• Preventive Maintenance
• Predictive Maintenance
