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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

  e  v  e   l  -   I   I

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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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