RELIABILITY ENGINEERING

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PSRM Element #8: Mechanical Integrity MP-AP-03

Definitions

Reliability

The probability of a component/system/process to perform its required function, without failure, under stated condition for a specified period of time

Reliability Engineering
The strategic task of predicting and avoiding failures through analysis. Quantification of Reliability Issues done, considering: Why? How? and How often? these failures occur The cost of failures

Root Cause Analysis (RCA)

A reliability technique used to identify the factors for failure Root causes identified and addressed in a systematic manner Investigation aimed at fact finding, not fault finding Time is critical: The earlier the investigations starts, the more the chances of minute details being captured Benefits

Increased productivity Improved quality Reduced costs Elimination of accidents and environmental releases

Reliability Incident Reporting (RIR)

This system is developed to capture reliability related incidents that either cause, or have a potential of causing loss or recurring high maintenance costs Purpose: Conclusions and responsibility to prevent recurrence is documented, and follow up done in a systematic manner

What Triggers a Reliability Report?

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 Stationary equipment

Mechanical Seal failures Weld failures and frequent leakages Compressor Valve Failures Motor burn outs

Repeated failures resulting in high maintenance costs

Repeated failures

MTBF/ Availability on a decreasing trend

Qualitative Threshold Protocol

Determines what is a Reliability Incident Uses a Consequence- Frequency matrix to specify severity of reliability incidents Consequence

C1 C2 C3 C4 F1 F2 F3 F4

Low Hazard Operation (LHO) High Hazard Process (HHP) or no load reduction Business Critical (BC) or 10% load reduction Safety Critical or 50% load reduction
F4
F3 F2 F1

Frequency

II

II
II

I
I II II
C3

I
I I I
C4

Once in 4 Once in 3 Once in 2 Once in 1

years or > 3 years years years year

III III IV
C1

III III
C2

Categories of Reliability Incidents

RIR Level - I

First Investigation Report (FIR) to be filled by the area engineer The Department Manager appoints a team The team gives recommendations on the basis of a comprehensive RCA Investigation report to be approved by the Department Manager Does not require a comprehensive RCA Department Manager may involve other interfaces for a detailed investigation Investigation report to be approved by Department Manager

RIR Level - II

Categories (Contd)
RIR Level III

RIR Level IV

No RCA No detailed investigation unless otherwise deemed necessary by the UM The Area UM is responsible for carrying out the investigation Report and recommendations approved and issued by UM May be handled by area engineer or supervisors Appropriate actions (corrective maintenance) taken by the maintenance staff If deemed necessary, area UM may seek advice from department manager for detail investigation

Reliability Incident Reporting Protocol

Incident Occurs
Area Incharge decides to make it a Reliability Incident and assigns a risk score

Raise RIR on MIS

Areas discuss RIR in Monthly Breakout Sessions

Planning stewards report

Sends report to Maintenance Manager

Thank You !