predictive maintenance to increase performance of the equipment_ ramzy sa.pdf

8/10/2019 PREDICTIVE MAINTENANCE TO INCREASE PERFORMANCE OF THE EQUIPMENT_ Ramzy SA.pdf

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Ramzy S. Amier KMI KBK inspeksiramzy@radiant utama.com


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Ibarat jantung pada manusia

Harganya mahal

Shutdown adalah biayaProduksi turun = profit turun

Memiliki RESIKO


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Predictive Maintenance techniques

help determine the condition of

inservice equipment in order to predict

when maintenance should be performed. This approach offers cost

savings over routine or Preventive Maintenance , because tasks are performed only when warranted


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1 Eliminate cost downtime

2 Reduce spare parts inventory

3 Optimize machinery performance

4 Reduce need of stand by equipment

5 Reduce maintenance cost

6 Reduce unplanned shutdown

7 Decrease the level of RISK (thru likelihood/ consequences)


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RESIKO/ RISK adalah;suatu kondisi yang timbul karena

ketidakpastian dengan seluruh

konsekuensi tidak menguntungkanyang mungkin terjadi ,

Prof. DR. Ir Soemarno M,S


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B e c o m e

D e c r e a s e

if


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1. Reengineering2. Monitoring/ inspection3. Add protective devices

4. PPE5. Replace the equipment6. Repair/ maintenanceare this, can reduce RISK thruCONCEQUENCES


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May be yes, may be no

Not all Risk can be reduced thru the consequences because; Cost and benefit Typical of industry/ plant

The technology

Mostly the Risk is reduce until

ALARP (As Low As Possibly Applied)by reducing the LIKELIHOOD/ PROBABILITYRISK is NEVER ZERO


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Sumber API


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Sumber API


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20% Caused by Operation error

5% Cause by Design error

70% of ACCIDENTcan be mitigateby Preventive or

Predictive maintenance


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Process MaintenanceContinuous

System

Automated

Loss of productionPredictive

Knowledge

Model

Optimization

Control

Content

Chemical

Discreet

Event

Manual

Cost of repairPreventive

Skill

Practice

Container

Effectiveness

Inspect

Mechanical


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TEAM LEADER Coordinator

EQUIPMENT INSPECTOR MATERIAL/CORROSION SPECIALISTPROCESS SPECIALIST

OPERATION &

MAINTENANCE

MANAGEMENTRISK ASSESSMENT PERSONAL

ENVIRONMENTAL &

SAFETYFINANCIAL/BUSINESS PERSONAL


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1. Forming

4. Performing

3. Norming

2. Storming


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Team meets for the first time

The team tries to go agree goals & objectives

The leader must coach at this time

Leader must try & establish team cohesion


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Team brainstorming their purpose &what tasks needs to be addressed

Team members try to establish theirrole within the group

Team members may also develop personal friendship

Leader still coach at this stage


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Team members start to work fluently

They start to support each other

They agree on team value and rulesand go with consensus

There is improved motivation andthe team also may go on social events


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Effective team and reach this stage they will get the job done

The task is completed

The team can work independently and efficiently

Any disagreements are resolved within the team

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Why the assessment is being done

How the Predictive assessment will be carried out

What knowledge & skill are required for the assessmentWho is on the team

What are their role in Predictive process

Who is responsible & accountable for what action

Which facilities, assets & component will included

What data is to be used in the assessmentWhen the assessment will completed How long the assessment will remain in

effect, when it will be updated


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System definitionA. GOAL & OBJECTIVESB. RISK MEASURESC. LEVEL OF DETAILD. DATA COLLECTION :

HAZARDS INFORMATION (MSDS, HAZOP result etc)DESIGN & OPERATING DATA (Size, procedure etc)WEATHER DATA (Wind speed & direction etc)DETECTION SYSTEM (Gas, Toxic, Flame & Fire detection)FIRE PROTECTION (Flow rate, actuation procedure etc)HISTORICAL DATA (repair, inspection, injury statistic etc)OFFICE DATA (offsite population, land used, topography etc)


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Hazard Identification

HAZARD is Source or situation with a potentialFor harm in term of human injury or ill health,Damage to property, damage to the work place,

Environment or combination of these(OSHAS)

The first step is to prepare a complete list of failure mode that could be

associated with

HAZARD,

and

there

are

many

technique

for

doing

so

such

as:

HAZOP (Hazard Operability)ETA (Even Tree Analysis)What If analysisFTA (Fault Tree Analysis)ChecklistFMEA (Failure Mode & Effect Analysis)


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Probability

The probability assessment is conducted to estimate the probability

of occurrence

for

scenarios

identified

in

the

previous

phase

of

the

risk analysis. The is using historical data or by frequency and putting in categorized such as


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PROBABILITY calculated from FREQUENCY with formula;

Frequency adjusted = Frequency generic x F E x F M

F generic didapat dari referensi seperti UK HSE, DOW index, API dsb

F Evaluation factor adalah management judgment

F Modification adalah bila terjadi modifikasi pada peralatan


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API RBD 581Equip. type Leak Leak 1 Leak 4 Rupture

Cent. Pump 6E 03 5E04 1E04 Piping 8 3E07 3E07 8E08 2E08

Press. Vessel 4E 04 1E04 1E05 6E06

Storage Tank 4E 04 1E04 1E05 2E05

UK HSExecutive DATA

Equipment Items Overall release

frequency/ yearInstrument 5.85E 04

Manual Block Valve, D > 11" 3.95E 04


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SAFETY HEALTH ENVIRONMENT COST

Consequences

No Injury No effect No effect Up to US$ 50K

First Aids Minor effect Slight effect > US$50K US$ 1M 10M

Multiple Fatality Multiple Fatality Massive effect > US$ 10M

1

2

3

4

5


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Risk Ranking

Intolerable

Major

Moderate

Low/Negligible

5

4

3

2

1

1 2 3 4 5


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ALARP regionRisk is taken only If a benefit is desired

Intolerable level

Broadly acceptablelevel

Individual risk 10E03 fatality/y

Individual risk 10E06 fatality/y

Tolerable: if risk reductionIs impracticable or if its cost Is grossly disproportionateTo the improvement gained

Tolerable: if cost of reductionwould exceed the improvement gained


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PLL = Probability Loss Life

V = Value of Life (from all aspect)


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Mechanical aspect:Metallurgical anomaliesWelding processMaterialsCrackingCorrosionMechanical

MITIGATIONASSESSMENT

Environmental aspect:CommunityAsset facilitiesEnvironmental conditionSabotage

CommunityDevelopment

Process/ operation:System deviationChemical inhibitionPressure/ temperatureFlow (over/ less)Operator knowledge

REPAIRMETHODS

ASSET MODIFICATION

Flow parameterTraps/ valvesPipe facilitiesMaterial


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Personal

ProsedurPeralatan


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1 Memiliki kompentensi yang sesuai

2 Profesional (accountable)

3 Memiliki pengetahuan K3

4 Mengerti lingkup kerja

5 Memahami kondisi kerja

6 Berkemampuan membuat laporan

7 Memiliki kemampuan IT


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Sesuai spesifikasi

Memiliki izin operasi (bilaperlu) dan terkalibrasi

Hard/ soft copy (real time)

report

Dilengkapi acessories yang sesuai

Dilengkapi peralatankeselamatan yang sesuai


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predictive maintenance to increase performance of the equipment_ ramzy sa.pdf

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