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PSRM Element #8: Mechanical IntegrityMP-AP-03
RELIABILITY ENGINEE
AbS
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Definitions Reliability
The probability of a component/system/process to pits required function, without failure, under stated cofor a specified period of time
Reliability EngineeringThe strategic task of predicting and avoiding failures t
analysis.Quantification of Reliability Issues done, considering:
Why? How? and How often? these failures occur
The cost of failures
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Root Cause Analysis (RCA) A reliability technique used to identify the factors fo Root causes identified and addressed in a systema
manner Investigation aimed at fact finding, not fault finding Time is critical: The earlier the investigations starts
more the chances of minute details being captured
Benefits Increased productivity Improved quality Reduced costs Elimination of accidents and environmental releases
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Reliability Incident Reporting
This system is developed to capture reliability rincidents that either cause, or have a potential causing loss or recurring high maintenance cos
Purpose: Conclusions and responsibility to prerecurrence is documented, and follow up done systematic manner
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What Triggers a Reliability Re Failures related to “Safety Critical” Equipment
Ammonia Leakage from a vessel or machine Loss or potential of production loss
Malfunctioning of Business Critical Machines and/or Stationequipment
Repeated failures resulting in high maintenance
Mechanical Seal failures Repeated failures
Weld failures and frequent leakages
MTBF/ Availability on a decreasing trend Compressor Valve Failures
Motor burn outs
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Qualitative Threshold Protoco Determines what is a Reliability Incident
Uses a Consequence- Frequency matrix to specify severeliability incidents Consequence
C1 Low Hazard Operation (LHO) C2 High Hazard Process (HHP) or no load reduction C3 Business Critical (BC) or 10% load reduction
C4 Safety Critical or 50% load reduction Frequency F1 Once in ≤ 4 years or > 3 years F2 Once in ≤ 3 years F3 Once in ≤ 2 years F4 Once in ≤ 1 year
F4 II I
F3 III I
F2 III I
F1 IV I
C1 C
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Categories of Reliability Incide First Investigation Report (FIR) to be filled by th
engineer The Department Manager appoints a team
The team gives recommendations on the basiscomprehensive RCA
Investigation report to be approved by the DepManager
Does not require a comprehensive RCA
Department Manager may involve other interfadetailed investigation
Investigation report to be approved by Departm
Manager
R I R L
e v e l - I
R I R L
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Categories (Cont’d) No RCA
No detailed investigation unless otherwisenecessary by the UM
The Area UM is responsible for carryinginvestigation
Report and recommendations approved and UM
R I R L
e v e l
-
I I I
R I R L
e v e l -
I V
May be handled by area engineer or superviso
Appropriate actions (corrective maintenance) tmaintenance staff
If deemed necessary, area UM may seek adepartment manager for detail investigation
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Reliability Incident Reporting Prot
Incident Occurs
Area Inchargedecides to make
it a ReliabilityIncident and
assigns a riskscore
Raise
SendsMain
Ma
Planningstewards report
Areas discussRIR in Monthly
BreakoutSessions
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Thank You !
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