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Maintenance Engineering applications for achieving Operational Excellence

(in lingua inglese)

L'ingegneria di manutenzione realizza gli obiettivi di produttività e di sicurezza perseguendo l'Eccellenza Operativa.
Saranno presentati approcci e casi concreti volti a comprendere i benefici e le opportunità della scelta di affrontare in maniera sistematica e sistemica gli aspetti connessi all'integrità dell'Asset.

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Atti di convegni o presentazioni contenenti case history
mcT Petrolchimico Milano novembre 2018 workshop

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da Alessio Rampini
mcT Petrolchimico Milano 2018Segui aziendaSegui




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Milano, 29 novembre 2018 Gli atti dei convegni e pi di 10.000 contenuti su www.verticale.net Maintenance Engineering applications for achieving Operational Excellence 1 San Donato Milanese 29th Nov 2018 Stefano Piccoli, MSc. Eng. Something about me 2 Eng. Stefano Piccoli, MSc, Eng. (Italy) ' Engineering Consultant (since 2013) ' Reliability and Maintenance Engineer in Tecnomare spa (2008-2013) ' Nuclear Engineer (2008) Expertise: ' RAM Analysis ' RBD modelling and Monte Carlo Simulations for availability analysis ' FMECA ' RCM ' SIL Verification ' Oil & Gas risk analysis Something about RAMS&E 3 RAMS&E is an engineering company that offers qualified consulting solutions about
Reliability, Availability, Maintainability and Safety (RAMS) of systems and Health,
Safety and Environment (HSE),
by Risk Assessment techniques RAMS&E, by its services, can support the Customer during all the life cycle of the
industrial/technical system
: starting from design and construction for both technical
and authorisation topics, continuing in operation by skills on HSE, Operation&Maintenance and Asset Integrity Management. RAMS&E operates in all industrial sectors with a particular focus on energy, oil &
gas, process engineering, transportation systems and infrastructures.
RAMS&E is registered within Business Incubator of Innovative Company of
Politecnico di Torino (I3P).
It cooperates with national and international research
group and in particular with Politecnico di Torino, the Joint Research Centre of EU '
Ispra site
, the CNR, CESI, Universities of Pisa and Bologna. 4 Operational Excellence 5 Operational Excellence: what is that..' Operational Excellence is the execution of the business strategy more consistently
and reliably than the competition, with lower operational risk, lower operating
costs, and increased revenues. ...but it means basically nothing. Well, it sounds quite desirable... 6 Different ways 7 In today's global market, we simply cannot afford to be inefficient. 8 Operational Excellence: how can we do that..' 9 Asset Integrity Asset Integrity is the ability of the Physical Asset to perform its required Function,
effectively and efficiently, whilst safeguarding People, Environment, Asset and
Company Reputation. Asset Integrity Management is a set of systematic and coordinated activities and
practices through which each Business Unit deals with the integrity of its Asset,
related Systems and Sub-Systems, their associated performance, risks and
expenditure over their life cycles. Key points Asset Integrity includes a variety of tools and techniques focussed on achieving the
best performance from physical assets. The following points can be highlighted. ' It is a planned, programmed and coordinated effort ' Safety is not considered as opposed to production effectiveness but as a
precondition for that ' a safe asset is an asset which runs smoothly, thus
achieving business continuity ' The whole life cycle of the asset should be covered ' i.e. including both the
design phase and the operational one. 10 11 Asset Integrity in practice 12 Does it make sense to carefully design a physical asset while not properly designing the related maintenance activities' 13 The goal of any form of engineering to find a practicable and cost-effective solution to a given problem. Maintenance Engineering's problems are failures. 14 What is a failure' 15 Failure Termination of the ability of an item to perform a required function. Defining failures [BS EN 13306] 16 What is a function' Defining functions 17 Therefore, the function of an item depends on: ' role and position within the system; ' utilization of the system; ' performance level required by the user of the system. The most general way to define a function is: Function = Action + Object + Required performance Pumping water at 10 m3/h and 5 bar differential pressure Consequently, the definition of failure depends on the parameters above, and the
applied maintenance should depend on them as well. 18 Failures are random and generally unpredictable events. Therefore, Maintenance Engineering normally uses risk-based techniques. Risk Based Maintenance R= f (Probability, Damage) Loss of functionality Loss of containment No intervention on demand Risk Based Maintenance (RBM) 19 Safety Instrumented Systems SIL Assessment Pressure equipment RBI Any other equipment RCM Functional Safety (SIL Assessment) Functional Safety is related to the safeguarding of asset integrity, people and
environment through Safety Instrumented Systems (SIS) ' International Standards IEC 61508 (general) and IEC 61511 (process industry) ' Bases on the concept of Safety Integrity Level (SIL) ' Two-steps process: SIL Allocation and SIL Verification 20 Definition of risk-related requirements for safety instrumentation Verification of instrumentation compliance to requirements Risk Based Inspection (RBI) Risk Based Inspection (RBI) is a process aimed at defining an Inspection Plan with
the maximum possible effectiveness in a given asset while keeping the related cost
at a minimum. ' It is another form of Risk Based Maintenance ' It is based on API 580 and API 581 Standards ' It is applicable only to pressure equipment and tanks ' It considers only failures leading to loss of containment ' It involves a continuous, cyclic update process 21 API 581 Figure 4.3 Maintenance activities tailored to real needs Justification and traceability Reliability Centred Maintenance Reliability Centred Maintenance (RCM) is 'a process used to determine what must
be done to ensure that any physical asset continues to do what its users want it to
do' [Moubray, Reliability Centred Maintenance 2nd Ed.]. ' It is a form of Risk Based Maintenance, often based on other RAM Analyses ' It is a structured, traceable process aimed at selecting the best possible
maintenance strategy ' It is based on 'what users want', i.e. on the function of the asset ' It evaluates both technical effectiveness and economical efficiency ' It involves a continuous, cyclic update process 22 R a te o d i g u a sto T e m p o D R a te o d i g u a sto T e m p o E R a te o d i g u a sto T e m p o F 7 % 1 4 % 6 8 % Maintenance activities tailored to real needs Justification and traceability RCM Decisional Chart 23 24 Case Study 1 ' Catalyst production line Background This activity is relevant to a single catalyst production system in a petrochemical
(polymers) plant. ' Client: major chemical company ' The line was initially designed as an experimental facility, now it produces
specialized catalysts for use in all licensed plants in the world ' Very high downtime cost ' Significant constraints in maintenance activities: ' dangerous fluids ' shutdown/startup procedures and delays ' batch operation 25 GOAL: keeping downtime at a minimum while cutting on unnecessary activities. Activity overview 26 DT crit.' Level 1 ' Detailed RCM Pot. crit.' Cost crit.' Level 3 ' Spare parts only H L Yes No L/M Level 2 ' Cost optimization Exp. fail.' Yes H Yes Criticality Analysis [Example] [Example] [Example] Achieved results 27 Suggestion of some new CBM techniques Expected improvement in the MTTF Previous Expected Pompa centrifuga a
trascinamento magnetico 9,38 9,70 3% Bicono 0,75 1,20 60% Pescante mobile 1,50 1,54 3% Agitatore 2,25 2,76 23% Pompa ad anello liquido 2,25 4,81 114% Item type MTTF [y] Improvement Optimized spare parts inventory 28 Case Study 2 ' Commuter train Background This activity has been requested during the design phase of a new commuter train
platform. ' Client: major train manufacturing company ' The Client has to deal with different and conflicting expectations from different
stakeholders: ' Train Operator requiring lower maintenance cost and higher availability ' Subsystem Vendors defining their own maintenance schedule ' Regulating Authorities requiring a justification for every entry in the Maintenance Plan 29 GOAL: reducing Life Cycle Cost and providing a technically sound Maintenance Plan that can be accepted by the Operator and the Authorities. Activity overview 30 1. FMEA (by the Vendors) used as an input: ' functions of components ' effects of failures 2. Application of the RCM decisional chart [example] 3. LCC/ENF simulation [example] 4. Modified Maintenance Plan and assessment of possible saving in maintenance cost [example] Achieved results 31 Significant maintenance cost reduction Previous RCM Gangway 19,22 9,16 -52% SCMT 38,22 29,56 -23% Toilet 5,49 2,07 -62% Wiper 1,07 0,24 -78% Coupler 7,29 3,96 -46% Subsystem Saving Maint. cost ['/1000 km] Development of a structured, in-house process for justifying the Maintenance Plan 32 Conclusions What can we get...' 33 Final word Operational Excellence is a goal that requires all business factors to be world-class.
This includes a high level of Asset Integrity. Does it make sense to optimize business processes if we cannot rely on the
physical assets they use' How can we get high efficiency if our production lines are often down due to
failures' ' In order to achieve a high level of Asset Integrity, properly designed and
optimized maintenance is a must ' Therefore, Maintenance Engineering is one of the keys to Operational
Excellence. 34 Oil & Gas is an asset-intensive business. If you want to be world-class, your assets must perform world-class. 35 Question time 36 Thank you!


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