Using modern reliability tools to improve the availability,

reliability and maintainability of the installations and

extend the lifetime of key electrical equipment

Jean-Charles Guilhem, ABB France

Pekka Koskinen, ABB Finland
Jose Baptista, ABB Brazil
Fernando Vicente, ABB Argentina
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Summary

• Presentation Summary:
• Introduction
• Introduction to reliability engineering
• Reliability Maintenance Process – a continuous flow -
Implementing a Reliability Master Plan in Plants
• Methodology of Reliability Analysis
• Reliability Tools
• Examples (Failure Analysis, Real Cases)
• Benefits of Reliability – back bone of plant performance
• Conclusion

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Introduction

• When the End Users take over their operations they have little
knowledge about the reliability of the equipments, in parallel, the
manufacturers try to design the most reliable products and
systems but have limited information about the real operating
conditions. Anyway the combination of both will lead to the
overall availability and reliability of the installation.

• This tutorial presents how modern reliability tools can now be

used to perform these diagnostics, identify the real root cause
for the failure and help to find the corrective measures in the
installation, or with the equipments, or the combination of both,
to prevent it to happen again.

• Through different examples we shall see how these tools can

also be used by anticipation on existing facilities to arbitrate
decision between the operating performances and costs
performances.

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Introduction

Wall

Reliability at
process
• Determines the
operation • Best practices to
inherent reliability of
prolong the
the equipment or • Maintain the product or
installation
inherent equipment life
reliability and not
degrade the
component life Reliability at
Reliability at
maintenance
design stage
operation

OEM END USER

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Summary

• Presentation Summary:
• Introduction
• Introduction to reliability engineering
• Reliability Maintenance Process – a continuous flow -
Implementing a Reliability Master Plan in Plants
• Methodology of Reliability Analysis
• Reliability Tools
• Examples (Failure Analysis, Real Cases)
• Benefits of Reliability – back bone of plant performance
• Conclusion

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Introduction to Reliability Engineering

• Reliability Engineering is a rapidly evolving discipline whose

purpose is to develop methods and tools to predict, evaluate
and demonstrate RAMS of components, equipment and
systems.
• The reliability of engineering system has become an important
issue during their design because of the increasing
dependence of our lives and schedules on the satisfactory
functioning of these systems.
• In today’s competitive global economy and other factors like
important environmental catastrophic accident (i.e. Japan
Nuclear reactor system) are forcing to manufacturers to produce
highly reliable, safety and easily maintainable engineering
products.

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The Reliability Problem – Missing links
between OEM and Plant Operator / Plant
Maintenance Continuous
• Operations history
• Design criteria Reliability • Enviroment
• Manufacturing anufacturing
datadata • Reliabilityeliability • System expierence
Maintenance Maint • Equipment experience
• Warrantyarrant enance Plan Plan
y time
time • Maintenance history
knowledge kno • Reliabilityeliability Toolsools • Performance history
wledge
• Problem OEM
roblem Plant
withwith otherother operator
applicationapplicati
on
Design Warranty
Screening Feasibility & &
Construction Base Lining

Reliability Reliability design from

design by Installed application / system
OEM
missing link

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What is Reliability?

• Reliability is a broad term that focuses on the ability of a product

to perform its intended function. Mathematically speaking,
assuming that an item is performing its intended function at time
equals zero, reliability can be defined as the probability that an
item will continue to perform its intended function without
failure for a specified period of time under stated
conditions. Please note that the product defined here could be
an electric, electronic, mechanical hardware product, a software
product, a manufacturing process or even a service.

• Definition: “Reliability is the probability that an item will perform

its intended function for a specific interval under stated
conditions” (MIL-STD 721C)

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Reliability terms, definitions and formulas

Some of the important reliability related terms and definitions are:

• Availability (A): The probability that an item is available for use
when required
• Reliability (R): The probability that an item will perform its
assigned mission satisfactorily for the stated time period when
used according to the specific conditions.
• Maintainability: The probability that a failed item will be
restored to its satisfactory operational state.
• MTBF: Mean Time Between Failures describes the expected
time between two consecutive failures for a repairable system.
• MTTR: Mean Time To Repair describes the expected time to
repair an item failed
• OEE: Overall Equipment Effectiveness

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Reliability terms, definitions and formulas

• Availability, in the simple form, is:

Uptime
A= MTBF
Uptime + Downtime A =
MTBF + MTTR

N N
 TBF i  TTR i
i =1 i =1
MTBF = MTTR =
N N

TBF=TTR+TTF

TTR TTF
normal
fail

time
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Reliability terms, definitions and formulas

• Reliability, in the simple form, is described by the
exponential distribution, which describe random
failures:

R (t ) = e − t
Example: A pump switch has failed 3
times in a year. Assuming that life time
(hours) of this electrical component can be

described by the exponential distribution
MTBF =  R ( t ). dt ,what is the MTBF and Failure rate?
0

= 3,42x10 −4 failures/ hour

 3
=
MTBF = e − t
.dt 8760hrs
0
1
MTBF = MTBF =
1
= 2924hours
 −4
3,42x10 f / hour
Failures
 =
mission time Thus, the pump switch expected to
fail every 2924 hours

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Reliability terms, definitions and formulas

• Overall Equipment Effectiveness (OEE) is an

industry standard indicator of how a machine,
production line or a process is performing in terms
of:
• Availability
• Performance (speed, rate)
• Quality

OEE=Availability x Performance x Quality

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Most commonly used distributions

Distribution Application Probability density function

(pdf)
Normal Used for general reliability analysis, 1  t −  2
−  
times-to-failure of simple electronic 1 2  
:mean of the normal times to failure and mechanical components, f (t) = e 
:Standard deviation of the times to failure equipment or systems
2
2
Log-normal Is commonly used for general reliability 1  T '−  ' 
−  
analysis, cycles-to-failure, material 1 2  
f (t ) = e  T ' 
’:mean of the natural logarithms oft he times to strengths and loading variables in
failure probabilistic design. Pieces under wear
T:Standard deviation of the natural logarithms loads, bearing remaining life t T ' 2
of the times to failure assessment
T ' = ln(t )
Exponential Is commonly used for components or f (t ) =  e − t
systems exhibiting a constant failure
rate. Typical applications are: Complex
system non redundancy, complex
system with independent failure rates
Is used to model material strength, t 
Weibull  −1 − 
 t 
:Shape parameter times-to-failure of electronic and f (t ) =   e  
:Scale parameter mechanical components, equipment or
systems
   
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Reliability of systems

• Reliability of a system: A system consists of several

components of which one or more must be working in order for
the system to function. Components may be connected in series
or parallel

•Series arrangement •Parallel arrangement

•Rs=R1*R2; (0,8*0,9)=0,72 •Rs=1-((1-R4)*(1-R3));1-((1-
0,8)*(1-0,9))=0,98

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Maintainability
problem
Typical reliability calculation- Gas train (high MTTR)

Machine A Machine B Machine C Summary

Mission 43800 26280 35040 876

Time(hrs) 0 hrs/year
Reliabilit
Number of y
problem failures/year
failures
1 3 rate)
(high 2
re 1,7
MTBF (hrs) 43800 8760
failu 17520 5153 Hrs/failure

Failure rate 22,8E-06 + 114,2E-06 + 57,1E-06 = 194,1E-06 failures/hrs

Nbr failures at
8760hrs 0,2 + 1 + 0,5 = 1,7 failures/year

MTTR (hrs) 18 24 83 40,6 hrs/failures

Downtime hrs/year
(hrs) 3,6 + 24 + 41,5 = 69,1

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Typical reliability calculation-Gas train

• Availability and Reliability for a year

8760 −69,1 8690
Availability = = = 99,2%
8760 8760
Re liability = e − t = e −1,7 = 18,2%

• What is the reliability for next 5 years?

Re liability(5y) = e −N*time = e −1,7*5 = 0,02%

“This is a typical result for gas, chemical

and petrochemical plant, high availability
and low reliability figures”

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Summary

• Presentation Summary:
• Introduction
• Introduction to reliability engineering
• Reliability Maintenance Process – a continuous flow -
Implementing a Reliability Master Plan in Plants
• Methodology of Reliability Analysis
• Reliability Tools
• Examples (Failure Analysis, Real Cases)
• Benefits of Reliability – back bone of plant performance
• Conclusion

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Reliability Maintenance Process

• The Reliability Maintenance process aims to maximize the life of

equipment and minimize consequence at failures.
• It will set a consistent standard processes and tools for all
activities across the site to assist the organization with the
maintenance plan reviews and the assets life cycle
management.

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Reliability Maintenance Process

Understand Maintenance Perform classification Update existing Upload equipment Establish Life Cycle Plan
Management Strategy analysis maintenance tasks structure
Understand Reliability Optimize Maintenance
Perform criticality analysis
Implementation Review Bill of Materials / Upload and link Plans
Recommendations Current Spares maintenance plans
Specify equipment
Perform Reliability Audit functional requirements Perform reliability
Install Fault Codes
Obtain access Equipment Develop Job Plans modelling
Understand operational including duration
Information Directory
context Load Maintenance Type
Contribute to investment
Access and contribute to
Innovation directory Assign resource planning
Understand failure modes
group/disciplines to
Establish or Review and effects Establish Work-order
execute
priorities Re-engineer / modify
Equipment Structure
Understand failure installation
Map Process and Review behavior Create Job Plan Routes
Present Situation
Perform Life Cycle Costing
Select maintenance type /
frequency
(DO,PM,CBM,
FTR,OTF),ref.page 56

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Maintenance Process

Criticality Maintenance Review Implement Reliability

Strategy Preventive Preventive Objectives
Analysis Definition Maintenance Plans Maintenance Plans Analysis

OEM Manuals Trends

Reliability-Centered Existing PM’s
Maintenance Major Losses

Proactive Mode

Equipment Known Yes Failure Codes Reliable Data

Failures Cause?

No RCA Explanations to
failures

Reactive Mode

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Maintenance Process

Reactive Mode

Proactive Mode

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Reliability Plan implementation on sites

▪1-Prevent / minimise Future Failures –
Proactive maintenance to slow down or prevent any
issues from occurring in the future (Maintenance Concept).
By preventing issues, time and resource will not be required
later on for the analysis of failures and implementation of
solutions.
▪2-Focus on Loss Makers – Identifying where the current
problems are and putting in a solution to address (Plant
Performance Improvement). Loss will always be present on
site, so a method to address is required.

▪3-Improve the Execution Effectiveness – Improvement of

the way we do things so the Reliability implementation is the
most efficient (Work smarter not harder). Implementing the
proactive tasks better will prevent more failures, while
analysing more efficiently will address more issues.
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Reliability Plan implementation on sites

Reliability Phase 1 • 1-Prevent/Minimize future failures

Stabilize (back to • 2-Focus on Loss Makers
basics) • 3-Improve Execution Effectiveness

Reliability Phase 2 • 1-Prevent/Minimize future failures

Improve Equipment • 2-Focus on Loss Makers
Productivity • 3-Improve Execution Effectiveness

Reliability Phase 3 • 1-Prevent/Minimize future failures

Maintenance • 2-Focus on Loss Makers
Excellence • 3-Improve Execution Effectiveness

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Reliability Plan implementation on sites-Phase 1

• Lubrication
• Contamination Control-Establish basic conditions
• Maintenance Precision (balance standards, tolerance, bearing mounting
Prevent/Mini practice, seals handling)
mize Future • Spare part accomodation (humidity, temperature)
Failures

• Capture equipment information-Install Failure Codes

• Capture plant Loss data
• Priorization process
• Implement basic RCA (Root Cause Analysis- 5 whys)
Focus on
Loss Makers • Start to measure reliability KPI (Availabiliy,Reliability,OEE,MTTR)
• Develop Pareto Chart for Top Ten

• Start to implement basic 5S

• Planning and Schedulling implementation
Improve • Improve supervision and work practices
Execution • Develop training plan
Effectiveness

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Reliability Plan implementation on sites-Phase 2

• Develop Equipment Classification
• Create a department for handling and lubrication storage
• Develop oil analysis (motor, compressor and transformer)
Prevent/Mini • Review sampling plan for critical equipment and improve
mize Future Maintenance precision
Failures
• Develop RCM strategy

• Implement and develop RCA phase 2

• Initiate Failure Analysis
• Data gathering formalized
Focus on • RCA reports
Loss Makers • Focused Manufacturing Improvement (FMI) teams implemented
• Start to measure OEE

• Implement and develop 5S phase 2

pro
Improve • Job Analysis
Execution • Engineering skill matrix development
Effectivenes • Audit process implemented for phase 1
s

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Reliability Plan implementation on sites-Phase 3

• Develop and certificate lubrication technicians

• Certificate technicians for critical areas ( i.e electrician to operate
substation)
Prevent/Mini • Apply best practices for contamination control and lubrication
mize Future • Develop deeper Maintenance precision
Failures • Apply RCM for more critical equipment

• Implement and develop RCA phase 3

• Implement and develop formal procedure for Failure Analysis
• Develop and implement Life Cycle Costing
Focus on
Loss Makers • Start to implement Total Productive Maintenance (TPM)

• Implement and develop 5S phase 3

Improve
Execution • Audit process implemented for phase 2
Effectiveness

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Reliability Plan structure

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Understand the Elements of Total Plant

Reliability
HSE and ISO 9001
are part of the
process in all levels

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Reliability Maintenance results in a Gas Plant

• This gas plant has started their operation in 2001.
Corrective maintenance has been decrease since
reliability maintenance implementation

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Reliability Maintenance results in a Gas Plant

Average of emergencies/urgencies work orders per

10.00 month
9.00
8
8.00
7.00
WO Quantity
6.00
5
5.00
4.00
3.00 2.15
2.00
1.00 0.35 0.35 0.25 0.29 0.33 0.3 0.1
0.0
2001 2002 2003 2004 2005 2006 2007 2008 2009 2010

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Summary

• Presentation Summary:
• Introduction
• Introduction to reliability engineering
• Reliability Maintenance Process – a continuous flow -
Implementing a Reliability Master Plan in Plants
• Methodology of Reliability Analysis
• Reliability Tools
• Examples (Failure Analysis, Real Cases)
• Benefits of Reliability – back bone of plant performance
• Conclusion

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Methodology of Reliability Analysis

Gathering data from CMMS system every month

Create Pareto Top Ten equipment Chart

Initiate the Reliability Analysis

Initiate the Root Cause Failure Analysis

Cost analysis development and ROI

Implement the analysis solution and update

maintenance plan
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Methodology of Reliability Analysis

Solution
implementation Pareto development
Data management

Cost Analysis

RCFA
Reliability analysis
ReliaSof t Weibull++ 7 - www. ReliaSof t . com
Re l i a b i l i ty v s Ti m e P l ot
1, 000
Reliabilit y

Dat a 1
Weibull-
2P
RRX SRM M ED FM
F=15/ S=1
Dat a Point s
Reliabilit y Line
0, 800

0, 600
Re l i a b i li ty, R(t)=1-F(t)

0, 400

0, 200

FERNANDO VI CENTE
ABB
16/ 01/ 2011
0, 000 07: 07: 56 p. m .
8000, 000 12000, 000 16000, 000 20000, 000
0, 000 4000, 000
Ti m e, (t)
=  =  = 

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Summary

• Presentation Summary:
• Introduction
• Introduction to reliability engineering
• Reliability Maintenance Process – a continuous flow -
Implementing a Reliability Master Plan in Plants
• Methodology of Reliability Analysis
• Reliability Tools
• Examples (Failure Analysis, Real Cases)
• Benefits of Reliability – back bone of plant performance
• Conclusion

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Reliability Tools
▪ Accelerated Testing ▪ RCM (Reliability Centered ▪ Reliability Testing
Maintenance)
▪ Design Review ▪ Weibayes Estimates
▪ Ishikawa diagram
▪ HALT ▪ QFD
▪ Poisson Distribution
▪ Monte Carlo ▪ TPM
Simulation ▪ Simultaneous Testing
▪ Fault Tree Analysis
▪ Availability ▪ Configuration Control
▪ Reliability Audits
▪ Normal Distribution ▪ Probability Plots
▪ Weibull Analysis
▪ Reliability Growth ▪ Software Reliability
▪ Decision Trees
▪ Bathtub Curves ▪ Maintainability
▪ FMEA (Failure Mode and Effect
▪ Life Cycle Cost ▪ Process Reliability Analysis)
Analysis
▪ Sudden Death Testing ▪ Failure Analysis
▪ OEE
▪ Cost Of Unreliability ▪ FRACAS Report
▪ Reliability Block
Diagram ▪ Failure Forecast

▪ ESS
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Reliability Tools-Monte Carlo Simulation

• Monte Carlo analysis uses statistics to mathematically model a

real-life process and then estimate the likelihood of possible
outcomes
• Monte Carlo analysis is a powerful tool that involves a random
number generation and simulates the behavior of a variable
when data is insufficient to make decisions.

Monte Carlo
Simulation

Deterministic Stochastic
model Model

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Reliability Tools-Monte Carlo Simulation
x

x
2x
1

3
Model
fx
yi
Histogram

nf
u
u

d
e
mulativ nsity ction
400 120.00%
350 100.00%

Probab. Acum.
Frequency
300 80.00%
250 60.00%
200
150 40.00%
100 20.00%
50 0.00%
0

308292,28

582176,08

691729,60

856059,88

965613,40
1020390,16
143962,00
198738,76
253515,52

363069,04
417845,80
472622,56
527399,32

636952,84

746506,36
801283,12

910836,64
Freq
US$
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Reliability Tools-Monte Carlo Simulation

• Example Problem 1: Analyze the Total Downtime Cost of NGL

Recovery Gas Plant

u
s a
d y
1-Model = −  =
T
D
C

1
A
v
a
il
a
b
il
it
y
*
P
r
o
d
u
c
t
C
o
s
t*
P
r
o
d
u
ct
io
n
*
2
4
d
T
o h
n o
s N
d G

u
s a
d y
= − 

N ur
G
L
u n
=
T
D
C

1
A
v
a
il
a
b
il
it
y

*
2
4
h
o
u
r
s
*

d
T
o

L
2-Define Input Distribution Parameters Value
variable Product Cost Triangular Minimum, Most 412;650;812
distribution (usd/ton) probable, Maximum

Production Normal Mean,  (standard 200;25

(ton/h) deviation)
Availability Normal Mean,  (standard 0,9;0,05
deviation)

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Reliability Tools-Monte Carlo Simulation

TDC-Histogram (pdc) TDC-Probability

300 120.00%
250 100.00%

Probab. cum.
Frequency

200 80.00%
150 60.00%
100
40.00%
50
20.00%
0
0.00%

More
4961,60
46572,61
88183,61
129794,61
171405,62
213016,62
254627,62
296238,63
337849,63
379460,63
421071,64
462682,64
504293,64
545904,65
587515,65
629126,65
670737,66
712348,66
753959,66
795570,67
Usd/day

Cumulativ…
Statistics from simulation
Iteration 10000 The probability of TDC ≤
Min. 4619 Usd 400.000 = 80%
Mean 278.970
Max. 874.110
Median 263.973

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Reliability Tools-Monte Carlo Simulation

• Example Problem 2: Analyze the system reliability of
transformer
Mathematical model:
Rs=1-[(1-RTA)*(1-RTB)]
Input Distribution Value

RTA Triangular 0,8;0,9;0,95

RTB Triangular 0,6;0,7;0,8

Question: What is the likelihood

that the system reliability will be
at least 98%?

Answer: 90%

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Reliability Tools-OEE

Theoretical Production Time

Planned Planning
Planned Production Time Down Time Factor (Pf)

Down Equipment Failure Availability

Gross Operating Time Time Setup & Adjustment (A)

Speed Reduced Speed Performance

Net Operating Time Losses Idling (P)
Valuable Quality Process Defects Quality
Operating Time Losses Startup Losses (Q)

Manufacturing OEE
OEE Availability Performance Quality Valuable Operating Time
% = (A) X (P) X (Q) = Planned Production Time

Business OEE
OEE Planning Valuable Operating Time
Total Productivity = X =
% Factor (Pf) Theoretical Production Time

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Reliability Tools-OEE in production line

A B C A B C

OEEA + OEEB + OEEC

OEEtotal= OEEtotal= OEEA x OEEB x OEEC
3

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Reliability Tools-OEE cycle

Line X •Improvement
•teams
•RCA action
Factory 1 : layout
•RCM program

How we
can
improve?”

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Reliability Tools-OEE Exercise

• Planned Operation Time = 24h = 1440 min

• One breakdown caused 180 minutes downtime, no other stops
• Maximum Proven Rate (MPR) = 500 units/hour
• Actual production
– 8700 right first time units (1st class quality)
– 300 defective units (scrap)
• Formulas
• Availability = Planned Operation Time – Unplanned downtime
Planned Operation Time
# Total production
• Performance = Gross operating time x MPR

# Right first time units

• Quality = # Total production

OEE = Availability x Performance x Quality x 100%

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Reliability Tools-OEE Result

• Available production time = 24h = 1440 min

• Unplanned downtime = 3h = 180 min
• MPR = 500 units/hour = 8,333 units/minute
• Actual production
– 8700 pieces first pass units (1 class quality)
– 300 scrapped or repaired units
• Formulas
1440 min – 180 min = 1260 min
– Availability –factor = 1440 min = 0,875
9000 pcs
– Performance factor = 1260 min x 8,333 = 0,857
8700 pcs
– Quality –factor = 9000 pcs = 0,967

– OEE = 0,875 x 0,857 x 0,967 x 100% = 72,5%

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Reliability Tools-Reliability Block Diagram

(RBD)

• A Reliability Block Diagram (RBD) performs the system

reliability and availability analysis on large and complex system
using block diagrams to show network relationship
• The structure of the reliability block diagram defines the logical
interaction of failures within a system that are required to sustain
a system operation
• The RBD system is connected by parallel or series configuration

input 1
1 2 output input output
2
Series configuration
Parallel configuration
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Reliability Tools-Reliability Block Diagram

(RBD)
Generation Generation
plant (R1) Substation (R2)

Transmission Transmission
system (R3) substation (R4)

Subtransmission Distribution
system (R5) substation (R6)

Primary distribution Distribution

syst.(R7) Transformer (R8)

Secondary
distr. Syst.(R9)
R System
= R1 * R2 * R3 * R4 * R5 * R6 * R7 * R8 * R9
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Reliability Tools-Reliability Block Diagram

(RBD) Subsystem
Distribution
Substation

Disconnect Voltage Current Circuit Circuit Power

Switch Transformer Transformer Braker Braker Transf.
(R1) (R2) (R3) (R4) (R5) (R6)

Metal Clad
R
System = R1 * R2 * R3 * R4 * R5 * R6 * R7
Switchgear (R7)

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Reliability Tools-Reliability Block Diagram

(RBD) –Complex System (Power Station)
• This example illustrates SS UPS
Node
1/2

Node ATS Busbar

how to use Reliability 1/2

Block Diagrams (RBDs) Grid and

GenSet
Rectifier
Battery
UPS
Inverter

to analyze the reliability Starting

Block
C60 GC
of a power station
C60 GC
• Reliability of the Power
C60 GC
Station at 10.000hours?
Starting C60 GC
• Availability of the Power Block
C60 GC
Node
6/8

Station 10.000hours? C60 GC

C60 GC

C60 GC

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Reliability Tools-Reliability Block Diagram

(RBD) –Complex System (Power Station)
ReliaSoft BlockSim 7 - www.ReliaSoft.com

A vailability and Reliability vs Time

1.000
1. Power Station
Point Availability Line
Point Reliability Line

0.800

0.600
A(t), R(t)

0.400

0.200

What about Reliability and

Availability at 1 year?
0.000
0.000 2000.000 4000.000 6000.000 8000.000 10000.000

Time, (t)

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Reliability Tools-RCM (Reliability Centered
Maintenance)

MAINTENANCE ...... actions

intended to retain an item in, or
restore it to, a state in which it can
perform its intended functions (BS
4778)

RCM --- A process used to

determine the maintenance
requirements of any physical asset
in its operating context

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Reliability Tools-RCM-Growing Expectations
of Maintenance

The Third Generation

Higher plant availability
and reliability
Greater safety
The Second Generation Better product quality
Higher plant No damage to the
availability environment
The First Generation Longer equipment life Longer equipment life
Fix it when it broke Lower costs Greater cost
effectiveness

1940 1950 1960 1970 1980 1990 2000

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Reliability Tools-RCM-Failure Paterns

The Third Generation 4%

A
Aviation Industry Research
B 2%

C 5%

D 7%

E
The First Generation The Second Generation 14%

F
68%
1940 1950 1960 1970 1980 1990 2000
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Reliability Tools-RCM Process Questions

(FMEA)

1. What are the functions and the associated performance

standards of the asset?
2. In what ways does it fail to fulfill its functions?
3. What causes each functional failure?
4. What happens when each failure occurs?
5. In what way does each failure matter?
6. What can be done to prevent each failure?
7. What should be done if a suitable preventive task cannot be
found?

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Reliability Tools-RCM Maintenance

Strategy Sheet

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Reliability Tools-RCM Typical Results-Gas

Compressor

Maintenance Failure Modes

Strategy Quantity
CBM 127
DO 89
OTF 50
PM 10
TOTAL 276
System Failure Modes
Quantity
Transmission 68
Lubrication 166
Seal Gas
Compressor 12
30

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TOTAL 276
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Reliability Tools-Cost of Unreliability

• The cost of unreliability is a big-picture view of system failure

costs, described in annual terms, for a process plant
• It is the best to begin a reliability assessment with an evaluation
of the overall cost of unreliability. This cost will include both the
direct and indirect costs associated with all reliability issues
• Failures must be concerned from a financial viewpoint and not
simply counting number of failures
• The first category of Cost of Unreliability is direct costs (lost
production, maintenance cost,)
• The second category is indirect cost (the cost of being a reactive
organization, the cost of lost business)

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Reliability Tools-Cost of Unreliability simple

calculation
•For each block: What is the COUR if gross margin is $10.000/hr,
scrap is $ 5.000/incident and maintenance cost is $5.000 per hour of
down time?
Machine A Machine B Machine C Summary

Failure rate 22,8E-06 + 114,2E-06 + 57,1E-06 = 194,1E-06 fail./hrs

MTTR (hrs) 18 24 83 40,6 hrs/failures
Downtime hrs/year
(hrs) 3,6 + 24 + 41,5 = 69,1
Gross margin
lost $36.000 + $240.000 + $415.000 $691.000 $/year
Scrap
disposals $ $1.000 + $5.000 + $2.500 $8.500 $/year

Breakdown
maint $ $18.000 + $120.000 + $207.500 $345.500 $/year

Total $55.000 + $365.000 + $625.000 $1.045.000 $/year

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Reliability Tools-Reliability Audits

• This is one of the most important tool that should be used during
the reliability assessment before to implement the reliability
maintenance system.
• This tool provides a big-picture of the organization regarding to
reliability maintenance status.
• The Reliability Audits assess four key aspect of reliability
maintenance:
1. RELIABILITY PLANNING
2. MAINTENANCE PLAN
3. ROOT CAUSE ANALYSIS (RCA)
4. PRECISION MAINTENANCE

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Reliability Tools-Reliability Audits

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Reliability Tools-Reliability Audits

• A typical Reliabilty Audit Score versus Target

Reliability Audit Reliability
result Planning
100%

80%
60%

40%
20%
Precision Maintenance
0%
Maintenance Plans

Root Cause
Oil&Gas site Target
Analysis

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Reliability Tools-Weibull Analysis

• The Weibull analysis is a powerful tool for life data analysis of all
pieces and process equipment. The practitioner attempts to
make prediction about the life of items based on failure data.
• The Weibull distribution is one of the most widely used lifetime
distribution in reliability engineering. It is a versatile distribution
that can take on the characteristics of other types of
distributions, based on the shape parameter, beta ()
• The Weibull reliability function is given by:

Where:

t  t: mission time (hours)

R t
=e
−  
 
: Shape parameter
: Characteristic life
(hours)

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Reliability Tools-Weibull Analysis (Log-plot)

ReliaSoft Weibull++ 7 - www.ReliaSoft.com
Probability - Weibull
99,000
Probability-Weibull

Part 1\Test 1
Weibull-2P
90,000 RRX SRM MED FM
F=12/S=8
Data Points
Probability Line

63,2%
50,000
U nreliability , F (t)

=2257hs
10,000

Failure
=1,64
5,000

data

FERNANDO VICENTE
ABB
22/04/2011
1,000 03:14:38 p.m.
100,000 1000,000 10000,000
Time, (t)
Part 1\Test 1: = = =

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Reliability Tools-Weibull Analysis (Reliability

plot)
ReliaSoft Weibull++ 7 - www.ReliaSoft.c om
Reliability vs Time Plot
1,000
Reliability

Folio2\Data 1
Weibull-2P
RRX SRM MED FM
F=1000/S=0
Reliability Line

0,800 Folio3\Data 1
Weibull-2P
RRX SRM MED FM
F=1000/S=0
Reliability Line

=2,5
Folio4\Data 1
Weibull-2P
RRX SRM MED FM
0,600 F=1000/S=0
Reliability Line
Reliability , R(t)=1-F (t)

0,400
=0,5
B36,8
0,200 =1

FERNANDO VICENTE
ABB
22/04/2011
04:24:36 p.m.

= 5000hr
0,000
0,000 3000,000 6000,000 9000,000 12000,000 15000,000
Time, (t)
Folio2\Data 1: = = =
Folio3\Data 1: = = =
Folio4\Data 1: = = =

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Reliability Tools-Weibull Analysis (Bath

curve)
• The beta value relation with the Bath tube curve phases

<1
>1
=1

Region  meaning
I <1;Infant mortality (failure rate decrease)

II =1; Random failure (failure rate constant)

III > 1, Wear-out failure (failure rate increase)

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Reliability Tools-Weibull Analysis-(example)

• Problem: Several failure has been detected during

thermography inspection in fuses of main isolator switches
responsible for supply energy to oil well pumps in a big oilfield in
South America.
• A reliability study was required to determine the maintenance
inspection frequency, because the consequence to run-out of
energy in oilfield it had a big impact on business.

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Reliability Tools-Weibull Analysis-(example)

• Failure Data
ReliaSoft Weibull++ 7 - www.ReliaSoft.c om
Age To failure Fuses reliability curve
1,000
(Month) Failure Reliability

Data 1
3 F Weibull-2P
RRX SRM MED FM
F=18/S=0
3 F Data Points
Reliability Line
3,2 F 0,800

=2,6
4 F
4 F
4 F 0,600 =7,2M
Reliability, R(t)=1-F(t)

5 F
5 F
6 F
0,400
6 F
7 F
7 F
8 F 0,200

8 F
9 F FERNANDO VICENTE
ABB
9,2 F 22/04/2011
07:50:05 p.m.
0,000
0,000 4,000 8,000 12,000 16,000 20,000
11 F M onth
15 F = = =

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Reliability Tools-Weibull Analysis-(example)

Replacement analysis:
• Cost for planned replacement (replace the fuse regardless its
condition) = $5000
• Unplanned cost (replace on failure) = $ 100.000 (include
production lost).

C * F (1month ) + C * R (1month )
C = 1 2
1month time
2 ,6
 1 
− 
 7 ,2 
R 1month = e = 0 ,9945
F1month = 1 − 0 ,9945 = 0,0055
($ 100 .000 * 0 ,0055 ) + ($ 5.000 * 0 ,9945 ) 5 .522 $ / month
C = =
1month 1month

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Reliability Tools-Weibull Analysis-(example)

Cost Per Unit Time vs. Replacement Time

16000

13500

11000

8500

6000

4127
3500
1000

0 1 2 3 4 5 6 7 8 9 10 11 12
PM Time (month)

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Reliability Tools-Failure Analysis

What is a FAILURE?
• A good basic definition of failure is the inability of a component,
machine, or process to function properly. However, this
definition is not limited to things that break, causing a complete
shutdown of the system. The concept of failure us much larger
• Can you identify a failure is you see one?

Is this a FAILURE?
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Reliability Tools-Failure Analysis

• Can you recognize a failure?

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Reliability Tools-Failure process

Failure start Failure Potential detection

The function is fulfilled
Functional Failure
Performance

Mínimum level Function is

performance not fulfilled

Windows maintenance Performance

opportunity lost
“PF Interval"
“A Failure is not an EVENT is a
PROCESS”

Time

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Reliability Tools-Failure Analysis

▪ Defects, in which moment can be introduced in a component or

equipment?
Traditional maintenance
Failure origin activities

Project Manufacturing Operation

Material selection Manufacturing error Improper utilization

Dimensioning fault Lack of training Poor Maintenance fault
Lack of knowledge quality process Lack of procedures
Human fault and tools

Life cycle-Reliability maintenance

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Reliability Tools-Failure Analysis (Causes

distribution)
Failure causes in general
3%

18% 30%

23%

26%

Manufacturing Design Maintenance Material selection Operation

Failure causes distribution in Oil&Gas (UK )

70
80
Nr
occurrence 60

40
25
20 18

0 9
2

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Reliability Tools-Failure Analysis (Root

Causes)
•When personnel involve in the RCFA process talk with maintenance
staff regarding to machine failure they say “It was an operation fault”,
if they make the same question for operation people they answer “It
was a maintenance fault”.
•The right answer is that there are no an unique failure cause but
multiple causes
•Unfortunately people involved in failure analysis process incorrectly
use the term “Root Cause” when what they really referring to is a
simple physical cause

Physical

Latent Human

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Reliability Tools-Failure Analysis (Root

Causes)

Imitation
(the easy
way)
Meditation Experience
(the most (The worst
noble was) way)

Human
Learning

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Reliability Tools-Failure Analysis (RCFA

process)

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Summary

• Presentation Summary:
• Introduction
• Introduction to reliability engineering
• Reliability Maintenance Process – a continuous flow -
Implementing a Reliability Master Plan in Plants
• Methodology of Reliability Analysis
• Reliability Tools
• Examples -Real Cases
• Benefits of Reliability – back bone of plant performance
• Conclusion

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Reliability Analysis of NGL gas plant

• Objective Analysis: Perform Reliability Simulation of that

Gas Plant at two different flow capacity, detecting
potential problems and help to take proactive actions for
next four years

Typical NGL
block diagram

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Block Diagram-NGL Gas Plant. Two cases

has been analyzed
Turbo expander
Heat exchanger
Air supply –screw
compressor NGL pumps
Hot-oil pumps [A ] [A ] [A ]
140-P -02A
140-E A -01A 140-EA -01B

140-D E TK-01

Fire heater [A ] [A ] [R:1] [R:2]

140-E A -01C 140-E A-01D
[R:1]
140-P -02B
050-E A -01A 050-K -01A
A eros 140-EA -01 (2/4) Bombas N G L
[A ] 140 (1/2)
[A ] [A ] [A ]
[A ] [R:1]
[A ] [A ]
360-P -01A
Process- Hot oil 300-P -01A 510-P -01A 530-P -01A
TMM 340-K-01A
050-E A -01B 050-K -01B
T rafo
33K v
heater
[A ] [A ] [A ] [R:1]
C ompresor 050-F -01 360-P -01B 360-F -01 N odo 1 300-P -01B 510-P -01B 530-P -01B
010-K -01 [R:1]
[R:1] [A ] [R:1] 050-K -01C
T HM 340-K -01B 050-E A -01C
T rafo
[R:1] [R:1] [R:2]
132K v [R:1]
A RE A 340 360-P -01C 300-P -01C 510-P -01C 530-P -01C
A rea (S uministro de
suministro A rea 300 A rea A rea 530
A ire)(1/2) [R:2] [R:2] A rea 360
E nergia (1/2) (B ombas 510(B ombas (B ombas P s2
050-E A -01D 050-K -01D (Bombas H ot
Booster)2/3 principales)2/3 N G L)1/3
O il)2/3
[A ] [A ] [A ]
A eros de gas de
regeneración 2/4
A rea 050
(compresores)2/4 150-E A -01A 150-EA -01B 150-P -02A
NGL pumps
150-D E TK-01 [A ] [A ] [A ]
210-E A -01A 210-E A-01B 210-EA -01C
Gas compressor Gas compressor [R:1]
150-E A -01C
[R:2]
150-EA -01D
[R:1]
150-P -02B
N odo 2

A eros 150-EA -01 (2/4) B ombas 150 [R:1] [R:2] [R:3]

NGL 210-E A -01D 210-EA -01E 210-EA -01F

A eros de turbina 210

Power Supply-Electric [A ] 210-D G TK-01

transformer [A ] [A ] [A ]
220-E A -01A 220-E A -01B 220-E A -01C

N odo 3
[A ] 220-D G TK-01
[R:1] [R:2] [R:3]
220-E A -01D 220-EA -01E 220-E A-01F

A eros de turbinas 220

[R:1] 230-D G TK-01

A rea 200 (Turbinas de

[A ] [A ] [A ]
gas)2/3
230-E A -01A 230-EA -01B 230-EA -01C

[R:1] [R:2] [R:3]

230-E A -01D 230-EA -01E 230-EA -01F
Gas turbines A eros de turbina 230

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GAS Plant Reliability analysis

• Reliability Curve for two cases

ReliaSoft BlockSim 7 - www.ReliaSoft.com

Point Reliability vs Time

1,000
Reliability

Planta MEGA LLL-60% OF MAXIMUM CAPAC...

Planta MEGA LLL-MAXIMU M CAPACITY CASE

0,800

0,600
Reliability, R(t)

0,400

0,200

FERNANDO VICENTE
ABB
17/01/2011
02:15:01 p.m.
0,000
0,000 3504,000 7008,000 10512,000 14016,000 17520,000

Time, (t)

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Reliability figures by equipment

Case maximum capacity (17520 hs)

t=8 7 6 0 ,0 0 0 0
R=4 6 ,2 7 2 2 E -8

P l a n ta ME GA
L L L -MAXIMUM
CAP ACITY CAS E

R=0 ,0 1 6 9 R=0 ,0 2 1 2 R=0 ,1 5 9 1 R=0 ,1 7 3 4 R=0 ,1 7 5 7 R=0 ,4 9 8 6 R=0 ,7 6 5 9 R=0 ,9 3 3 9 R=0 ,9 3 4 0 R=0 ,9 5 9 9 R=0 ,9 6 5 6 R=0 ,9 6 5 6 R=0 ,9 6 5 6 R=0 ,9 8 4 0 R=0 ,9 9 4 9 R=0 ,9 9 4 9 R=0 ,9 9 4 9 R=0 ,9 9 9 1 R=0 ,9 9 9 6 R=0 ,7 6 6 5 R=0 ,7 2 6 5 R=0 ,3 3 7 5
Imp =2 7 ,3 6 3 6 E -6 Imp =2 1 ,8 6 7 6 E -6 Imp =2 9 ,0 8 9 1 E -7 Imp =2 6 ,6 8 1 1 E -7 Imp =2 6 ,3 3 2 4 E -7 Imp =9 2 ,8 0 8 2 E -8 Imp =6 0 ,4 1 7 8 E -8 Imp =4 9 ,5 4 9 9 E -8 Imp =4 9 ,5 4 4 5 E -8 Imp =4 8 ,2 0 5 2 E -8 Imp =4 7 ,9 2 2 4 E -8 Imp =4 7 ,9 2 2 4 E -8 Imp =4 7 ,9 2 2 4 E -8 Imp =4 7 ,0 2 3 6 E -8 Imp =4 6 ,5 0 7 8 E -8 Imp =4 6 ,5 0 7 8 E -8 Imp =4 6 ,5 0 7 8 E -8 Imp =4 6 ,3 1 5 4 E -8 Imp =4 6 ,2 8 9 0 E -8 Imp =8 7 ,5 4 5 0 E -9 Imp =7 4 ,7 5 5 6 E -9 Imp =3 0 ,8 5 7 0 E -9

Are a 5 3 0 (Bo mb as 2 3 0 -DGTK-0 1 2 1 0 -DGTK-0 1 2 2 0 -DGTK-0 1 ARE A 3 4 0 Bo mb a s NGL 1 40 Bo mb a s 1 5 0 NGL 0 5 0 -F -0 1 3 6 0 -F -0 1 Are a 3 0 0 (Bo mb as Co mp re so r 1 4 0 -DE TK-0 1 1 5 0 -DE TK-0 1 Are a 3 6 0 (Bo mb as Ae ro s d e g a s de Ae ro s 1 4 0 -E A-0 1 Ae ro s 1 5 0 -E A-0 1 Are a su mi n i stro Are a 0 5 0 5 1 0 -P -0 1 C 5 1 0 -P -0 1 A 5 1 0 -P -0 1 B
P s2 NGL )1 /3 (S u mi n i stro de (1 /2 ) Bo o ste r)2 /3 0 1 0 -K-0 1 Ho t Oi l )2 /3 re g e n e ra ci ó n 2/4 (2 /4 ) (2 /4 ) E n e rg i a (1 /2 ) (co mp re so re s)2 /4
Ai re )(1 /2 )

t=8 7 6 0 ,0 0 0 0
Case 60% capacity (17520 hs)
R=0 ,0 0 1 1

P l a n ta ME GA
L L L -6 0 % OF
MAXIMUM
CAP ACITY CAS E

R=0 ,0 3 4 8 R=0 ,1 7 5 7 R=0 ,4 9 8 6 R=0 ,6 1 4 2 R=0 ,7 6 5 9 R=0 ,9 3 3 9 R=0 ,9 3 4 0 R=0 ,9 6 5 6 R=0 ,9 6 5 6 R=0 ,9 6 5 6 R=0 ,9 7 4 1 R=0 ,9 8 4 0 R=0 ,9 8 9 7 R=0 ,9 9 4 9 R=0 ,9 9 8 0 R=0 ,9 9 8 0 R=0 ,9 9 9 1 R=0 ,9 9 9 9
Im p =0 ,0 3 0 4 Im p =0 ,0 0 6 0 Im p =0 ,0 0 2 1 Im p =0 ,0 0 1 7 Im p =0 ,0 0 1 4 Im p =0 ,0 0 1 1 Im p =0 ,0 0 1 1 Im p =0 ,0 0 1 1 Im p =0 ,0 0 1 1 Im p =0 ,0 0 1 1 Im p =0 ,0 0 1 1 Im p =0 ,0 0 1 1 Im p =0 ,0 0 1 1 Im p =0 ,0 0 1 1 Im p =0 ,0 0 1 1 Im p =0 ,0 0 1 1 Im p =0 ,0 0 1 1 Im p =0 ,0 0 1 1

Are a 5 3 0 (Bo m b a s ARE A 3 4 0 Bo m b a s NGL 1 4 0 Are a Tu rb i n a s d e Bo m b a s 1 5 0 NGL 0 5 0 -F -0 1 3 6 0 -F -0 1 Co m p re so r 1 4 0 -DE TK-0 1 1 5 0 -DE TK-0 1 Are a 3 0 0 (Bo m b a s Are a 3 6 0 (Bo m b a s Are a b o m b a s NGL Ae ro s d e g a s d e Ae ro s 1 4 0 -E A-0 1 Ae ro s 1 5 0 -E A-0 1 Are a su m i n i stro Are a 0 5 0
P s2 NGL )1 /3 (S u m i n i stro d e (1 /2 ) Ga s 0 1 0 -K-0 1 Bo o ste r)2 /3 Ho t Oi l )2 /3 5 1 0 (2 /3 ) re g e n e ra ci ó n 2 /4 (2 /4 ) (2 /4 ) E n e rg ia (1 /2 ) (co m p re so re s)2 /4
Ai re )(1 /2 )

t=8760,0000
R=0, 0011

Planta MEGA
LLL-60% OF
MAXIMUM
CAPACITY CASE

R=0, 0348 R=0, 1757 R=0, 4986 R=0, 6142 R=0, 7659
Imp=0, 0304 Imp=0, 0060 Imp=0, 0021 Imp=0, 0017 Imp=0, 0014

Area 530 (Bombas AREA 340 Bombas NGL 140 Area Turbinas de Bombas 150 NGL
Ps2 NGL)1/3 (Suministro de (1/2) Gas
Aire)(1/2)

Slide 82/ June 20th, 2011

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Reliability Analysis of UV/IR sensor of gas

heater
• Problem: Fire heater has been out of service due to
UV/IR sensor (flame detector) failure. Reliability and
Failure analysis has been required due to the
equipment criticality.(Heater out of service = Plant
shutdown)
ReliaSoft BlockSim 7 - www.ReliaSoft.com

1,000
Reliability vs Time Fault tree
Reliability

Diagram1
Reliability Line
UV Sensor
Fails
0,800 • =2,05 and
• =20.759hs OR
0,600
Reliability, R(t)

0,400

0,200

FERNANDO VICENTE
Lamps Lens
ABB
15/01/2011
09:18:20 p.m.
Fails Fails
0,000
0,000 10000,000 20000,000 30000,000 40000,000 50000,000
Time, (t)

Slide 83/ June 20th, 2011

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Failure Analysis-UV/IR Sensor

Currently Design Model that verify New Design: Air

the physical cause intake rotated at
45°
Air intake (to
avoid debris
get into the
sensor

Flame detector

Slide 84/ June 20th, 2011

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Reliability Analysis of Temp. Transmitters
and Pressure Transmitters
• Problem: Several of failure in a randomly way of PT and TT
instruments in gas plant, some of this failures have been
affected production.
ReliaSoft Weibull++ 7 - www.ReliaSoft.com
Reliability v s Time P lot
1,000
Reliability

Data 1
Weibull-2P
RRX SRM MED FM
F=1000/S=0
Reliability Line

0,800

MTBF = 5years
0,600

Datasheet=25y
Reliability, R(t)=1-F(t)

0,400

0,200

FERNANDO VICENTE
ABB
18/01/2011
10:10:27 a.m.
0,000
0,000 20000,000 40000,000 60000,000 80000,000 100000,000
Time, (t)
= =+ =

Slide 85/ June 20th, 2011

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RCM (Reliability Centered Maintenance)Transformer

• From Reliability analysis of gas plant a set of equipment
has been selected to develop and implement new
maintenance strategies.
Power supply
system of gas
plant

Transformer Transference
system system

1-Swtch
1-Transformer 2-Bus bar
2-Regulation 3-Protections
system 4-Transference
automatism
Slide 86/ June 20th, 2011
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RCM (Reliability Centered Maintenance)Transformer

Slide 87/ June 20th, 2011

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Reliability Analysis of Centrifugal pump

• Problem: NGL pumps start to get out of service

more frequently than years before. A reliability
and failure analysis was required.

Slide 88/ June 20th, 2011

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Reliability Analysis of Centrifugal pump

Pump MTTF/ MTTF(hours)  

Pump A 0,9578 4661,134 4866,5 1,13
Pump B 1,1 7164,3 6513 0,84

The question for managers was, could be continued operate in this

way for next two years? What would be the maintenance cost?

Slide 89/ June 20th, 2011

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Reliability Analysis of Centrifugal pump

Operating RSB = e
−1t  1  −1t − − 2t
+ R sw  e e ( )
Pump A   2 − 1 
Parameter NGL Pumps
System
R(17520) 0,1220
Average failure rate 0,000120
Stand-by
Expected Failure in 2 2,1035
Pump B years
MTTF 8329,0194
MTTR 21,0349
Pump´s A (availability) 0,9975
Fault tree
 ( global ) =  Shaft +  Bearing +  Seal +  impeller +  Ca sin g +  Motor

Pump Failure rate

(f/h)
Pump A 0,000281128
Pump B 0,000169465

Slide 90 / June 20th, 2011

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Reliability Analysis of Centrifugal pump

(Cost Analysis)
• Cost of mechanical seal failures = $7.000 (per seal) x 8
(number of mechanical seal failures in both pumps A and
B)= $56.000
• Cost per mechanical seal reparation: MTTR= 10 hr * 2
technician * $21 (cost of labor hour) *8 (number of
mechanical seal failures)= $3.360
• Cost of loss production = 2,1 (number of failures) * 90 NGL
Tons/h * 281 $/Ton * 21hours (10 hours * 2,1 failures)=
$531.090

COUR = Cost Spareparts + Cost labor + Cost lossproduc tion

COUR = $56.000 + $3.360 + $531 .090 = $590 .450

Slide 91/ June 20th, 2011

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Reliability Analysis of Centrifugal pump

Slide 92/ June 20th, 2011

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Failure Analysis of Electric Motor (learning
from catastrophic failures)
• Problem: An electric motor (300KW) of screw compressor has
been taken out of service to perform a major maintenance at
40.000 hours of operation (to perform insulation inspection and
other electrical testing). To take the chance, bearing has been
replaced.
• At almost 4000hours, since last maintenance, the motor has
been catastrophic failed.
• A Failure Analysis was required to know what happened

stator rotor Bearing race

Slide 93/ June 20th, 2011
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Failure Analysis of Electric Motor (Results)

• Electric motor has failed due to the bearing failure

• The bearing has failed because of ball cage has
broken due to fatigue process (fractography
analysis show the fatigue process)

Slide 94/ June 20th, 2011

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Failure Analysis of Electric Motor (the failure
process)
Ductil fracture
Housing

External race

Fatigue
Temperature :1100-1500ºC

shaft

Over heat

Slide 95/ June 20th, 2011

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Failure Analysis of Electric Motor (learning

from errors)

Physical
Roots
Avoid the recurrence
▪ Fatigue

Human Roots

▪ Mounting
and
handling

Organizational Root
▪ Why we have sent the
motor to this
Slide 96/ June 20th, 2011 subcontractor?
 P C I C E u r o p e 2 0 11
Reliability Analysis of screw compressor
RTD
• Problem: Several suddenly stoppages of air
screw compressor have occurred due to RTD
failures. Due to equipment criticality a reliability
analysis has been required
ReliaSoft Weibull++ 7 - www.ReliaSoft.com
Reliability vs Time Plot
1,000
Reliability

Data 1
Weibull-2P
RRX SRM MED FM
F=15/S=1
Data Points
Reliability Line
0,800

MTBF = 3150hs
0,600
Reliability, R(t)=1-F(t)

0,400

0,200

FERNANDO
VICENTE ABB
16/01/2011
0,000 07:07:56 p.m.
0,000 4000,000 8000,000 12000,000 16000,000 20000,000

Time, (t)
= = =

Slide 97/ June 20th, 2011

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Reliability Analysis of screw compressor
RTD (Failure Analysis)
• Symptom: High temperature indication in 1st or
2nd compressor stage (false indication). Stopping
the compressor
• Cause: RTD broke, measuring infinity resistance
• Main cause: High vibration
• Proposal: Reduce vibration on RTD improving
damping and connection design.

Slide 98/ June 20th, 2011

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Reliability Analysis of screw compressor
RTD
ReliaSoft Weibull++ 7 - www.ReliaSoft.com
Reliability v s Time Plot
1,000
Reliability

RTD Reliability Analysis\Data 1

Weibull-2P
RRX SRM MED FM
F=15/S=1
Data Points
Reliability Line
0,800
RTD Improved\Data 1
Weibull-2P
RRX SRM MED FM
F=1000/S=0
Reliability Line

0,600
Graph comparing
reliability design
Reliability, R(t)=1-F(t)
0,400

0,200

FERNANDO VICENTE
ABB
16/01/2011
0,000 07:32:27 p.m.
6,000 12004,800 24003,600 36002,400 48001,200 60000,000
Time, (t)
RTD Improved\Data 1: = = =
RTD Reliability Analysis\Data 1: = = =

Slide 99/ June 20th, 2011

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Summary

• Presentation Summary:
• Introduction
• Introduction to reliability engineering
• Reliability Maintenance Process – a continuous flow -
Implementing a Reliability Master Plan in Plants
• Methodology of Reliability Analysis
• Reliability Tools
• Examples -Real Cases
• Benefits of Reliability – back bone of plant
performance
• Conclusions

Slide 100 / June 20th, 2011

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Benefit of Reliability

• Reputation. The more reliable a •End-User Requirements. Many

product is, the more likely the company end-user in today's market demand
is to have a favorablee reputation. that their suppliers have an effective
• End-User Satisfaction. An unreliable reliability program. These end-users
product will negatively affect customer have learned the benefits of reliability
satisfaction severely. Thus high analysis from experience.
reliability is a mandatory requirement
•Competitive Advantage. Many
for customer satisfaction. companies will publish their predicted
• Warranty Costs. If a product fails to reliability numbers to help gain an
perform its function within the warranty advantage over their competitors who
period, the replacement and repair either do not publish their numbers or
costs will negatively affect profits, as have lower numbers.
well as gain unwanted negative
attention. •Cost Analysis. Manufacturers may
take reliability data and combine it
• Safety. A high reliability figures on the
with other cost information to illustrate
plant means that there are less failures
the cost-effectiveness of their
and then less chances to suffer
products
accidents.

Slide 101 / June 20th, 2011

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Benefit of Reliability

Cost
reduction
by failure Increase Reliability
rate availability
reduction

Slide 102 / June 20th, 2011

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Reliability Motivation for your plant

• What is your annual COUR (Cost of

Unreliability?
• Where is the major losses in your plant?
• What is happening with OEE?
• Do you know what is the failure causes of this
losses?
• What is the alternative for this cost reduction?
• What is the item that require an urgent
engineering intervention?

“Money that results from these questions, is the

motivation to a develop a Reliability Culture in
your organization”

Slide 103 / June 20th, 2011

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Summary

• Presentation Summary:
• Introduction
• Introduction to reliability engineering
• Reliability Maintenance Process – a continuous flow -
Implementing a Reliability Master Plan in Plants
• Methodology of Reliability Analysis
• Reliability Tools
• Examples -Real Cases
• Benefits of Reliability – back bone of plant performance
• Conclusions

Slide 104 / June 20th, 2011

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Conclusions

• In Oil&Gas, chemical and petrochemical industry

is very common to find high availability numbers
but low reliability figures, for this reason most
companies could not advertise the loss money
due to unreliability issues.
• The Cost of Unreliability index is a simple and
practical reliability tool for converting failure data
into cost, helping to managers and the entire the
organization to understand the problem within a
piece of paper.
• The strong competitive environment between
companies to secure business and the current
world financial crisis are forcing organizations to
explore ways to reduce operating cost, through a
reliable process
Slide 105 / June 20th, 2011
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Conclusions

• This tutorial had shown through real cases and

theory examples how important is the Reliability
Engineering applied.
• Those companies that start to implement this kind
of tool in their sites will take several advantages
against their competence.
• A reliability culture is a lifestyle, is not just a thing
that one person is responsible for. Through this
culture an organization can escaping from
reactive mode to proactive mode.
• A Reliability Policy must be necessary for next
years, like safety, quality and environmental policy
years ago.

Slide 106 / June 20th, 2011