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How to make your plant safe & reliable?

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by

Hassan Alsada

on 7 October 2015

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Transcript of How to make your plant safe & reliable?

RBI
RCM
RIS
RCA
Reliability Methodologies
"Change for Success"
Reliability Campaign 2014
How to make
your plant
safe & reliable?

What do we mean by Reliability?
Availability
Cost
Safety
Utilizing Asset performance Management
Pro-Active:
CA, RBI, RCM, RIS
Reactive:
RCA
RBI
Loss of containment
RCM
System Focused
RIS
Instruments related to safety
RCA
Identifying the cause
of the failure
CA
Risk identification
What is RBI?
RBI ensure Integrity of Equipment against Loss of Containment based on Risk
Where as:
Risk = PoF X CoF

Inspection
Types
Time
Based
Condition
Based
Risk
Based
RBI Work Flow
Data
Collection &
Analysis

Identify
Deterioration
Mechanisms

Risk
Analysis &
Ranking

Risk
Control
Actions

Develop
Inspection
Plan

Execution
of
Inspection

Repairs
&
Modifications

Data Updating
&
Re-assessment

RBI Benefits
Q&A
Give clear Inspection Strategies based on risk associated with the equipment
Optimization of Inspection Resources and cost saving
Using RBI tool remaining life of equipment is obtained systematically
Improved Equipment Reliability based on clear inspection strategies generated from RBI
Help to improve most of Maintenance KPIs

What's RCM?
Is a process to determine what must be done to ensure that any physical asset continues to fulfill intended functions in its present operating context
Maintenance is a good thing
The more we do, the better
Traditional view:
Maintenance is a necessary evil...like surgery
The less we do, the better
We should do it only when absolutely necessary, or when the benefits clearly outweigh the associated risks and costs
RCM view:
RCM
Failure Types
Evident Failure
Hidden Failure
RCM WORKFLOW
RCM Benefits
Reduce the maintenance cost by providing the proper maintenance strategy.
Increase equipment Availability
Aware the organization about the existing risk.
Q&A
What's RIS?
Risk Matrix
Reliability Instrumented Systems is a methodology for performance management of process instrumentation as well as safety instrumented systems. It accomplishes this through the integration of tools, process and workflows for Calibration Management, Safety Instrumented System Life Cycle Management (SLCM), and Reliability Management tools.
SUSTAINABLE RIS WORK PROCESS

RIS Benefit
The RIS system provides a means of
validating
that safety system are performing as specified in the design specification.
Provides testing standards for Safety Instrumented System and a process to
optimized
the test interval.
The system provides a means to
managing recommendations
for improvements and change.


Q&A
RCA – DEFINITION
Root Cause Analysis is a problem solving methodology. It is a systematic process for identifying the fundamental causes of failures and developing corrective actions to prevent them from reoccurring


Human Cause
Physical Cause
Latent Cause
Q&A
VALIDATE INSTRUMENT DESIGN

Define the Safety Instrumented Function
Functional Safety
Component
Design/Model Safety Instrumented Function and System
Perform SIL Validation

Consolidate Plan to Achieve SIL

Determine & schedule Proof Test ( Function Test ) based on SIL Requirements.
Schedule calibration & inspection to support proof test.
Define & Schedule Maintenance Plan.
Schedule Execution of re-design as required

Execute
Proof tests ( Function or not )
Maintenance.
Recommendations.
Document
Failure Found during testing
SIS trip events
Success or failure of SIF’s

Execute Strategy

Fault-Tree

Thank you!
Full transcript