Application of Risk and Reliability

Methods for Developing Equipment

Maintenance Strategy

Lee Chon Gee/ Alice Feng/Tommy Tang

Det Norske Veritas

Outline of Presentation

¾ Why adopt Risk Based Strategies?

¾ Risk Based Maintenance (RBM) working process
9Screening analysis
9Detailed analysis:
9Risk Based Inspection (RBI)
9Safety Integrity Level Assessment (SIL)
9Reliability Centered Maintenance (RCM)
¾ Living Program
¾ Benefits of RCM –Complex offshore topside process facility
¾ Software Solution
¾ Conclusions

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Why Adopt Risk Based Strategies?

Accidents – Oil & Gas, Process Industry

Introduction of the Risk Based Methodologies
Indicative Volume

Bhopal

Seveso

Piper A

1940 1950 1960 1970 1980 1990 2000 2010 2020

Piper Alpha, North Sea 06.07.1988, 167 killed, compression unit

Flixborough Pasadena Longford
drilling platform, property loss 1.86 billion US $, production loss 8.85 billion US$.
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Latest news Texas City explosion:

March 23, 2005, Fire and Explosion at Texas City Refinery

Houston Chronicle March 24 2005,

Root cause:
The fire began in the plant's isomerization unit, which produces components
used to raise the octane content of gasoline. The cause of the explosion has not Currently
been determined, but both company officials and the FBI have said an
accident, not sabotage by terrorists, is the main focus of the investigation.
unknown
The unit that caught fire had been taken down for maintenance and was being
brought back online when it exploded.
15 people died and over 100 people -- plant workers as well as residents of
nearby
Version
neighborhoods -- suffered injuries in Wednesday's blast.
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 Factors Influencing Operational Risk

People

Operational
Risk

Equipment Production

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Causes for Leaks in HC Plants

About half of the Mechanical

containment losses in a Failure
refinery, petrochemical or 41%
Process Upset
chemical process plant can 8%
be influenced by Sabotage/Arson
maintenance and Natural Hazard 3%
inspection 6%
Unknown
Operational 18%
Error
20%

Design Error
Large property losses in the HC-chemical ind., a 4%
30 year review, 14th edition, M&M Protection
Consultants, 1992

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Challenges Facing Inspection and Maintenance

Maximising
• Plant efficiency / reliability levels
• Product generation/throughput

whilst Minimising
• manning costs
• materials costs
• maintenance work load
• transportation and support
• downtime affecting revenue/operating costs

and Maintaining
• contractual nominations
• HSE requirements

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RIMAP – Risk based Inspection and MAintenance

Procedures
for European industry

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 Risk Based Maintenance (RBM)
Strategy Development
INSP, CMMS, DOC
Input data for screening Input data
DNV, for detailed
Equipment Screening Operator assessment
database Experience
Inspection,
Maintenance High Y Risk Based
history, Risk Level Containment
Risk RBI Maintenance
Failure Strategies
records N
(RBM)
-
Low Risk Y
Protective SIL Output:
Function y Inspection plans
y Equipment function testing
y Preventative maintenance
Minimum y Operator surveillance rounds
maintenance N y First line maintenance tasks
evaluation/ y Condition monitoring
y On-line maintenance
Corrective y Off-line maintenance
Maintenance y Turn around tasks
RCM

RBI: Risk based Inspection CMMS Interface

SIL: Safety Integrity Level Up load to
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RCM: Reliability Centered Maintenance 2005-06-15 CMMS Slide 11

Risk Based Maintenance (RBM)

Strategy Development

Output:
y Inspection plans
y Equipment function testing program
Up-load to y
y
Preventative maintenance routines
Operator surveillance rounds
CMMS y First line maintenance tasks
y Condition monitoring
y On-line maintenance
y Off-line maintenance
y Turn around tasks

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 DNV RBM Methodology – Asset Register

Detailed RBM analysis – Establish RBM Technical Hierarchy

DNV RBM Technical

Company Hierarchy
Site

Plant

Unit

System

Sub-system

Function Equipment

Tag
Failure mode #1 Failure mode #2 Failure mode #3

Failure cause #1 Failure cause #1 Failure cause #1

Root Root Root
cause cause cause
Failure cause #2 Failure cause #2 Failure cause #2
Root Root Root Failure Mode, Failure Causes, Root
cause cause cause
causes
Failure cause #3 Failure cause #3 Failure cause #3
Root Root Root
cause cause cause

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RBM- Risk Based Inspection

What is RBI?
‰ RBI is a method for using risk as a basis to prioritise
and manage the efforts of an inspection program
‰A systematic analysis that establishes the risk levels
associated with the operation of each piece of
equipment and ranks them
‰ An inspection planning methodology which
™Identifies the usually 10 to 20% of your equipment items
which carry 80 to 100% of your risk exposure
™Identifies the type of inspection needed and quantifies
the benefits of it
™lowers your risk exposure and optimises the spending on
inspection

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RBM - Safety Integrity Level Assessment (SIL)
What is SIL?
‰ Safety systems / Electrical, Electronic and Programmable
Electronic Systems (PES)
‰ SIL is the discrete level for specifying the safety integrity
requirements of the safety functions where SIL 4 has the
highest level of safety integrity and SIL 1 has the lowest
‰ Safety functions need to be addressed during design,
maintenance planning and operation & maintenance stages

Programmable
logic unit
Pressure
PLC Transmitter
ESD Blow
PT down

ESD 1 ESD 2

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RBM - Safety Integrity Level Assessment (SIL)

‰ Safety systems, electric, electronic and programmable electronic

systems:
™ Failure rates λ,
™ System reliabilities
™ Probability of failure on demand (PFD)
™ Baysian approach to updating of test intervals
™ Risk cost optimization
‰ Availability requirements - Absolute acceptance requirement for
availability
™ IEC61508/IEC61511
™ Legislative requirements, company requirements, ...
‰ Cost-benefit
™ In some cases it is economically beneficial to test more
frequently than the requirements says.
™ In some cases the consequence is reduced to an economic
consequence only.

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 RBM- Reliability Centred Maintenance
What is RCM?

‰A systematic risk- based approach to create an accurate,

well targeted and optimised maintenance package that
aims at achieving optimum reliability for a facility.

‰ The maintenance strategy and task package developed

is to mitigate the failure causes / root causes identified.

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Type of RCM

ƒ Classical RCM

ƒ Streamlined RCM

ƒ Reverse RCM

ƒ Maintenance Optimization

ƒ Risk Based Maintenance etc.

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 Objectives of RCM

ƒ To gain an in-depth understanding on the

requirements of the facility (in terms of safety,
reliability, operability)

ƒ To identify the different failures that may cause the

above requirements to not be met

ƒ To identify strategies (maintenance, operation,

inspection etc) that will prevent, mitigate these
failures

Version Slide 21

Deliverables

ƒ Maintenance plan / Task List – Task Package

ƒ PM Routines – Detailed Routines

ƒ Task Bundling - Grouping tasks for efficient resource

management

ƒ Sparing identification - Inventory management and

availability

ƒ Turnaround Planning - Task identification and resource

management

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 Deliverables

ƒ Operator Rounds
ƒ Surveillance and condition monitoring by operations

ƒ Surveillance Aids
ƒ Field displayed instructions

ƒ Organizational Development
ƒ Adjusted staffing and resourcing

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Results of a RCM Study

The outcome of the RCM analysis is a recommended

preventive maintenance plan comprising:

„ What to do
„ Skill and tools needed to do it
„ How often to do it
„ An estimate of the required man-hours
„ Job packing to find when to do it

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 Results of a RCM Study

„ Spare parts
„ Awareness of safety and environmental issues on
maintainers level
„ Awareness of main contributors to production
unavailability
„ Documented preventive maintenance program
„ More efficient maintenance program that fits the
organisation (competence and crew)
„ Modifications

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The Project Team

The team must have extensive experience in the

following areas:

„ Process & Safety

„ Reliability
„ Mechanical
„ Electrical & Instrumentation
„ Maintenance
„ Operations

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 Inputs Required
ƒ Asset register
ƒ Safety Cases, Performance Standards
ƒ Drawings / Schematics / Flow diagram
ƒ Maintenance routines, if any
ƒ Maintenance manuals
ƒ Work Procedures, if any
ƒ Operations Procedures, if any
ƒ Known incidents/failure history
ƒ Estimated operational costs
ƒ Hourly costs -maintenance/ contracted personnel
ƒ Requirement against potential spill/pollution to the
environment
ƒ Requirement for operability / down time / availability

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DNV RCM Methodology

Screening Detailed RCM analysis
System / Functional
Equipment System Assignment of
System Screening equipment and failure modes
Boundary Functions
equipment types
Definition

Risk Analysis Failure Modes & Effect

Risk High Risk Analysis (FMEA)

Low Risk Low Risk Risk High Risk

Identification of
Run to Failure failure causes
evaluation

Low Consequence or non- Maintenance Strategy / Task

Implementation critical task selection or Run to
Development of
PM Routines
Package Development / Spare
parts identification
Failure
ERP/CMMS upload
Task optimization
Living Program
CMMS
(Periodic review of new
Implementation
maintenance regime by
(includes planning
RCM team) Data mapping / Job packing /
& scheduling)
load leveling

Version
Task Selection and Optimization
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 DNV RCM Methodology
Step 1: Screening
„ Qualitative analysis
„ Objective is to screen out low risk systems from medium
to high risk systems
„ Screening analysis is performed for each system
(process & utility) at equipment level
„ 2x2 risk matrix is used to perform the analysis
„ PoF is assessed either as Low (<10-5) (category 1) or
High (>10-5)(categories 2,3,4&5)
„ CoF is assessed either as Low (category 1) or High
(categories 2,3,4&5) for safety, environmental, economic
and other impacts
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DNV RCM Methodology

Step 1: Screening

„ All the medium to high risk systems are transferred for

detailed RCM evaluation
„ However, the low risk systems are also included for
detailed RCM evaluation for inclusion in the technical
hierarchy and to identify suitable operator surveillance
tasks or to ‘run to failure’
„ Screening results forms a good basis to have an overall
understanding of the systems

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 DNV RCM Methodology
Step 2: Detailed RCM analysis - Failure Mode and Effects
Analysis (FMEA)
„ The first part under detailed analysis is performing
FMEA
„ This analysis is carried out at failure mode level to
study the effect of failure
„ The question of ‘what if?’ (if failure happens) is applied
and failure effects are analyzed

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DNV RCM Methodology

Step 3: Detailed RCM analysis - Risk Analysis

„ Next step is to find the criticality or in other words to find

the risk of such failure by quantifying failure consequence
„ PoF and CoF of each failure mode is evaluated and risk is
calculated
„ Risk = PoF or failure rate x CoF
„ Either PoF or failure rate is used in the analysis

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DNV RBM Methodology
Four areas of Risk
¾ Risks to people (Safety Risk)
¾ Risks to the environment
¾ Risks to the business interruption (Business Risk)
¾ Risks to capital assets (Follow Costs)

Safety Risk Matrix Business Risk Matrix

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DNV RCM Methodology

FMEA & Risk analysis

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 DNV RCM Methodology
Step 4: Detailed RCM analysis - Maintenance strategy
development

„ After transfer of all medium to high (very high) tags for

Maintenance strategy development
„ Identification of failure causes & root causes against
failure modes
„ Development of suitable maintenance strategy and task
package to mitigate the failure causes
„ Task optimization (dealt separately at later part)

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DNV RCM Methodology

Task Optimization

„ Adjusting maintenance strategies to take advantage of

resource utilization
„ Changing maintenance intervals to coincide with other
activities
„ Grouping or bundling tasks to optimize resources
„ Recognizing other cost-effective timing opportunities

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 DNV RCM Methodology
CMMS Implementation

„ Final maintenance strategy/task package

„ Assessment of tool time (manpower) requirement
„ Data mapping (Maintenance plan & Task list - spread
sheets for CMMS loading)
„ Job packing and load levelling
„ CMMS implementation
„ PM routines developed will be linked to maintenance
task lists

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DNV RCM Methodology

Living Program

„ Concept
- Installation of management and control systems to
ensure continuous feedback and modification of the
maintenance strategy
„ Fosters a culture of continuous improvement and is a primary benefit
of the RCM process
„ Key performance indicators to align with the objectives and
performance requirements
„ Follow-up evaluation within one year
„ Constant feedback from field to optimize the tasks/cost

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 DNV RCM Methodology
Living Program

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DNV RCM Methodology

Root Cause Failure Analysis (RCFA)

Traditional maintenance strategies tend to neglect something important:

important:

ƒ Identification and correction of the underlying problem

ƒ Identification of root causes of failure is essential for any
significant reliability improvement
ƒ Root cause failure analysis (RCFA) is an indispensable
component of proactive maintenance

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 Benefits of RCM

Maximize Revenues

• Higher Reliability, Higher Availability, Increased Production

Optimise Costs

• More Proactive Maintenance, Less Reactive

Maintenance, Deferred Inspections

Sustain Business

• Increased Planning Capability, Higher Budget Predictability,

More Stable Operation

Manage Risk

• Less Exposure to Loss, Lower Incident Rate, Maintain

Compliance
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Software Solution - ORBIT RCM

DNV Best Practice Database:

Refinery DNV ORBIT RCM
Process Plants Failure Mode and
Offshore…….. Cause database
….. DNV ORBIT RCM

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Software Solution - ORBIT+ EAMS
EAM (Engineering Asset Management)

RCM RBI ERP

(Reliability Centred Maintenance) (Risk Based Inspection) Interface

MMS IDS Contract

Management
(Maintenance Management) (Inspection Data Management)
Graphical
Interface
Key
Parts Inspection Measured Inspection
Maintenance Performance
Management Reference Data Program AutoCAD
Indicators
Integration

GIS
AIM (Asset Integrity Management) Link

Asset Document Supplier Data System Access

Organization
Databank Access Information Exchange Security
Control

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ORBIT＋MMS Functional Module

Asset Integrity Mgnt. Work management

Scheduled Program Stores / Inventory Maintenance Repts

Maintenance KPI Data Exchange System Security

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 What is the CMMS doing?
The Central Role of Work Orders

2. Asset Register / Structure Audits:

Budget
Site Centers Budget: " How much do
we spend?
Per PM based on plan " Where do we
Sector discipline, spend it?
per unit CM based on experience " Why do we
and per Overhauls spend it
System site. " Who spends
it?
" What can be
Unit CMMS improved?
Maint. 3. Task Planning
Manuals
Tag/Loop/ Discipline(s)/
Manpower
Spares Equip ID Time/Cost
Work Order Rules:
•Work type shall correspond
Maintenance Manual: Spare parts/
Work Order Inventory to the main purpose of
Work Order cost
" Organisation chart Work Order work and to the analytical
" Standard Job descriptions account on which the job
"
1. Documented Management System

Policy
" Procedure list Equipment Analysis/ is charged
" Blank maintenance forms. History Improvement •The craft leader assuming
Maintenance dossier:
the coordination is the craft
in the main activity
" Description of the equipment. PM based on •All sub task can be charged
" Equipment inventory Execution plan
" Technical data sheets
by diff. unit/craft and
CM based on
" Operating instructions experience resource their own acty.
(CR EXP 2.6.6)
Time Writing Overhauls
Maintenance documentation:

" PM schedules
" Maintenance procedures Note, corrective tasks may be generated, but they should be planned
" Troubleshooting instructions where possible.
" Inspection schedule
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ORBIT+MMS - Maintenance Management System

RBI RCM / SIL

MMS
Technical Scheduled Maintenance
Asset Data
Databank Program Recommendation

Standard
Inspection Work Order Work
Program Management Template

Work Store
Equipment
Assignment Management
Monitoring

Maintenance Maintenance
Cost Work History

Performance Technical
EIS Indicators History
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Conclusions

‰ Experience from conducting RBI and RCM studies for refineries,

petrochemical, chemical, and offshore topsides has demonstrated
significant potential risk reductions and cost benefits of the predictive and
proactive maintenance strategies developed.
‰ The benefits of the integrated RBM process will be exceeding the
benefits achieved for the individual initiatives due to synergy effects such
as: job packing, improvement to data management and workflow.
‰ Improved reliability of the equipment items and hence the system can be
achieved.
‰ Maintenance intervals can be optimized based on the continuous feed
back from the maintenance activities and the failure records and failure
causes identified.

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Conclusions

‰ RCM can save money due to direct maintenance cost reductions by

identification of pieces of equipment that are deemed “non-critical,
run to failure”, eliminating many unnecessary maintenance tasks
‰ Systematic removal of root causes and repetitive problems lead to
reduced production loss associated with un-planned shutdowns,
increasing the bottom line result.
‰ Management of Safety Critical Equipment and protective functions
by SIL assessment improves reliability and yields cost-benefits.
‰ Thus methods need to be consistent and integrated and there must
be a dynamic link to the CMMS’s work management.
‰ To implement RBM by integrating RBI/SIL/RCM, it is required that
the equipment information is available in a central data management
system and that the Risk Based Inspection/Maintenance Strategies,
scheduling and resource information can be up-loaded to the CMMS
for the day to day plant operation.

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