Minimizing the integrity failures of Minimizing the integrity failures of aging aging plants and plants and equipments equipments Through Through Reliability Centered Maintenance Reliability Centered Maintenance ProSafe ProSafe APAC APAC Process Safety Management Conference Process Safety Management Conference 9 March 2015 9 March 2015 Bhavesh Shukla Bhavesh Shukla 1
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Minimizing the integrity failures of Minimizing the integrity failures of
aging aging plants and plants and equipmentsequipments
Process Safety Management ConferenceProcess Safety Management Conference
9 March 20159 March 2015
Bhavesh ShuklaBhavesh Shukla
1
Introduction to
Minimizing Integrity Failure
through RCM
2015 Bhavesh Shukla
All rights reserved. No part of this publication may be reproduced, distributed, by any
means, without the prior written permission of the publisher.
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Agenda
• Failure Case study
• Types of Maintenance
• Risk Based Maintenance Strategy
• Process Steps
• Exercise
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Reactor agitator failure
Coupling with
Torque Limiting Slip (TLS) Plate
(Clutch)
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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 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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Types of Maintenance
•Repair
�Run to failure
•Preventive Maintenance
�Time based�Time based
•Predictive Maintenance�Condition based
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Repair
• Repair – run to failure, is suitable for small
items which are non critical,
inconsequential, unlikely to fail and
redundant.
• For critical equipments and parts is not an • For critical equipments and parts is not an
option.
• When Stakes are high Repair is not an
option
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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
Preventive Maintenance
before it fail and some time before it need
to be.
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Predictive Maintenance
• 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
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Vibration Monitoring & Analysis
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Condition Based Maintenance
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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 • 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