Reliability Management

Overview
Day 1
 Content
Asset Life Cycle
Engineering Tool
RAM Reliability, Availability &
Maintainability
RCM Reliability Centered Maintenance
RiBM Reliability Risk Based Maintenance
Conclusion
Asset Management Landscape IAM

Asset Life Cycle

 Reliability Tool Project Phases

Design Installation & Operation Maintenance Disposal

Commissioning
RAM Study

Equipment Configuration

Criticality Analysis

RCM

RiBM

Aging Asset Management

Optimized Equipment Critical Standard Maintenance Plans Risk Disposal

Plant Design Hierarchy Asset List Condition Monitoring Plans Prioritization Plan
Standard Operation Procedures
Critical spare parts in inventory
Output

Kaizad P. Sunavala
 RAM Study
Availability

Reliability / Time to Maintainability / Time

Failure / Up Time to Repair / Down Time

Operating Run Down /

Design Maintenance
Redundancy Procedures / Active Repair Man Hour(s) Preparation /
Concept Strategy
Conditions Delay / Ramp Up

Key questions: Key questions:

How to prolong systems life?
What should be done to prevent systems being
failures?
How to identify potential failures of systems?
What are their failure patterns?
How to minimize downtime?
How to perform effective and efficient
maintenance tasks?
How to optimize maintenance cost?
Who should perform maintenance tasks?

Dwi Priyanta
 RAM Study
Simulation
RBD / FTA
Markov
Modeling
Availability

Reliability / Time to Probability Maintainability / Time to

Failure / Up Time Repair / Down Time

Operating Run Down /

Design Maintenance
Redundancy Procedures / Active Repair Man Hour(s) Preparation /
Concept Strategy
Conditions Delay / Ramp Up

Engineering
Parameters

Dwi Priyanta
 Criticality Analysis
Define Define System
Define Risk

Consequences
Systems & Criticality SCR
Model
Asset Ranking System

Define Ops.
Criticality OCR X SCR = ACR
Ranking

Probability =
Establish
Failure AFPF X ACR = MPI
Probability Asset

Sort
Descending

Risk
Prioritized Critical Assets
by MPI
 Can you

RCM
effectively detect NO
NO
symptoms of a gradual
loss of function?

YES

Is an Can you
on-condition task NO repair and restore NO
technically feasible performance and will this
and worth doing? reduce failure rate?

YES YES
Perform the Is a
on-condition task scheduled Can you
at less than restoration (PM) task NO replace the item
the warning interval technically feasible and will this reduce
if most cost effective and worth doing? failure rate?

YES YES

Perform the Is a
scheduled restoration task scheduled
discard (replacement) NO Run-to-failure
at less than the age limit
task technically feasible Action depends
if most cost effective
and worth doing? on consequences

YES

Accomplish the
scheduled replacement task
at intervals less than the age limit if
most cost effective
Example RCM Result
Condition Monitoring Elements
Condition Monitoring Plan
 Condition Monitoring Technology
CSI 9420

CSI 6500 CSI 9830

CSI 2600 CSI 5200

CSI 2140
RiBM
 RiBM
Moving from Time
Based Tasks to Risk
Informed Tasks
Provides
documented basis
for business
decision making
Tasks are deferred
not cancelled
Aging Asset Management
Identify Scope
of Assets

Select Asset
for AAM Study

Select AAM Gather and

Strategy Continuous Analyse Inputs
Improvement
Review

Analyse AAM Identify AAM

Options Options
Fourth Generation:
Optimizing asset RISK,
COST and
PERFORMANCE over
the life cycle
To achieve organization
strategic objective

Fourth Generation:
RAM Study
Criticality Analysis
RCM
Risk Based
Maintenance (RiBM)
Aging Asset
Management

2010 2020
Cost, Performance and Risk
Cost Performance

Risk
 Conclusion
Maintenance expenditure should not regarded as
cost but to buy down risk.
Specific tool/methodology is required to optimize
risk management for each stage of asset life
cycle.
Condition monitoring is very critical in calculating
reliability risk associated with the asset.
Maintenance and asset replacement/
refurbishment plan should be determined by
asset reliability risk.