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Petrofed - Plant Reliability Concerns & Mitigation
18-March-2011
S.Shanmugasundaram, CPCL, Chennai
Topic today
Plant Reliability
Concerns & Mitigation
18-March-2011
Session - Structure
Warm up discussions Business needs Asset Management Reliability Measurement Reliability Improvement Maintenance practices Turnaround Maintenance Q&A Reliability Incident Case study
18-March-2011
Plant reliability
Concerns
Business Safety Environment
18-March-2011
18-March-2011
The value comes from an integrated view of the business

Supply Refining
Asset management Margin Improvement Benchmarking Product portfolio Technology Crude Supply Assessment Project Management Product quality management
Distribution
Markets
Retail
HS&E
Operational Excellence
18-March-2011
18-March-2011
ATU
CPCL
REFINERY 1
Plant VRU 2 Crude Tanks Bombay High Gulf Plant 1 Plant 11
Plant 12
Plant Sulphur 75
Plt 76
Plt 74
Hexane
SULPHUR
Plt 78
Plt 77 Plt 79
HEXANE
NAPHTHA
LPG PETROL ATF
Platformer Plant
3 Plant 4 Plant 5
HDS LUBE HIFI
KEROSENE
LAB FEEDSTOCK DISEL
CPCL
REFINERY 3
DWU FEU Plant
Plt 202
Plt 203
8
NMP PDA
Plant 9 Plant 13
VAC.DIS HDS
Plant 10
LUBE BASED STOCKS INDUSTRIAL FUEL
Plant CDU 201

CRU
Plant 71
Plant 73
Plant 206
Plant 7
ASPHALT
Plant 204
HGU
WAX
VBU
Plant 205
Plant 207
CPCL
Plant 14
CDU
REFINERY 2
Plant 18
ATU
Plant 17
PRU
Plant 15
FCCU
Plant 19
FEED STOCK FOR MEK & POLY BUTENES
SRU
Plant 210
Plant 209
ATU & ARU
PROPYLENE Plant 16
o8 PARAFFIN of 39
WAX
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Sour FG to ATU
LPG to Merox
NSU LSRN HN Kero to Merox
Swt FG LPG
LSRG
CRU 40 m3/hr
MS
Swt FG LPG H2 LSRG OHCU LSRN
Crude
CDU III 430 m3/hr
Diesel VGO
HGU 70000 Nm3/hr
Sour FG to ATU
Kero
249 m3/hr Diesel
VDU EGO VBU 175 m3/hr 140 m3/hr

18-March-2011
Naph. Diesel VGO
UCO to FCCU
Ref II VGO Ref I/II VR
o9 of 39 Refinery
III
S.Shanmugasundaram, CPCL, Chennai VR
COMOX Reactor preheat
Desulphuriser steam
reformer furnace T T, P,T HP steam
hot shift converter
H2
(Start up)
Naphtha feed
Steam superheater S, T T methanator heater waste heat boiler
BFW Preheater
Cl, O2, T,H2O
DMW Preheater
PG Air cooler
T,H2O
CO2 to atmosphere PSA Purge Gas Hydrogen gas
Degassifier
Hot & Cold Condensate seperators Cl,O2,T,H2O process condensate
steam stripped condensate
Reformer Section
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10 10 of 19
FURNACE MAINTENANCE
18-March-2011
contd 11
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12
Plant Reliability
Concerns
Business
Plant availability Operating cost Margin
Safety
Personal Equipment/Property
Environment
Air, Water, Soil & Noise pollution
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13
Business demands from Assets
Safety Environment Efficiency / Yield Availability

Petrofed - Plant Reliability Concerns & Mitigation 18-March-2011
14
Asset Management Concept

Make every effort to keep units operating for a maximum economical period and Use best practice to minimize downtime and limit costs during a turnaround
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15
Business Drivers
Margin Profit Essential Service Economic development Survival Owners choice Strategy / Perspective plan
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16
Refinery KPIs
Energy Loss Routine Maintenance Personnel Productivity Cash Opex Cash Margin Plant availability Inventory Safety
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17
120
LP.
LP.
80 60 40 20 0
GIVEN PERIOD OF TIME
18
C t ude I , I I & I I I - 2 0 0 7 - 2 0 0 8 1600 1400 1200
Cu.M/Hr
1000 800 600 400 200 0
A M M J
CRUDE 2
J A
CRUDE 3
S O N D J
CRUDE 1
F M
CRUDE 1,2&3
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19
Interruptions
FCCU
Year 2004-05 2005-06 2006-07 2007-08
Sl No PLANT
Apr
May 1
Jun
Jul
Aug
Sep
Oct 5 6 13 14
Nov 7 8 9 15 18 19
Dec
Jan
Feb
Mar
2 to 4
10 16
11 12 17 23 24
MONTH FROM HRS
20 21
22
25
TO HRS 5/22/2004 3:30 9/1/2004 0:00 10/1/2004 0:00 10/11/2004 3:00 10/11/2004 16:00 10/18/2004 17:45 11/13/2004 21:00 11/25/2004 19:00 11/26/2004 8:30 4/9/2005 17:00 5/11/2005 4:20
26
NATURE EMERG
27
REASONS SS BREAKER PROBLEM HOURS 11.00 576.00 720.00 243.00 13.00 169.75 9.25 4.25 3.75
DESCRIPTION
1 2 3 4 5 6 7 8 9 10 11
PLANT 16 FCCU PLANT 16 FCCU PLANT 16 FCCU PLANT 16 FCCU PLANT 16 FCCU PLANT 16 FCCU PLANT 16 FCCU PLANT 16 FCCU PLANT 16 FCCU PLANT 16 FCCU PLANT 16 FCCU
MAY '04 5/21/2004 16:30 AUG '04 8/8/2004 0:00 SEP '04 9/1/2004 0:00 OCT'04 OCT'04 OCT'04 10/1/2004 0:00 10/11/2004 3:00 10/11/2004 16:00
PLANNED TA M/C PLANNED TA M/C PLANNED TA M/C & REVAMP PLANNED STARTUP EMERG EMERG EMERG EMERG CAT CARRY OVER PROBLEM FCC FEED PUMP TRIP FCC FEED PUMP TRIP FCC FEED PUMP TRIP
NOV '04 11/13/2004 11:45 NOV '04 11/25/2004 14:45 NOV '04 11/26/2004 4:45 APR '05 4/8/2005 19:00 MAY '05 5/9/2005 12:30
EMERG POWER FAILURE EMERG POWER FAILURE
22.00 39.83
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20
MC Botto m 140 valve
FCCU T'Put 2007-2008
120 100
Cu.M/Hr
80 60 40 20 0
MAB Trip Gascon Cooler leak MC Botto m pump failure
Inspectio n
M o nt h
M M
M
21
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Interruptions
OHCU
Year 2004-05 2005-06 2006-07 2007-08
Sl No PLANT
Apr
May
Jun
Jul
Aug
Sep
Oct
Nov
Dec
Jan
Feb
Mar
1 2 11
4 6 12 18
7 13 14 19
MONTH APR '05 APR '05 APR '05 MAY '05 MAY '05 MAY '05 JUL '05 AUG '05 AUG '05 MAR'06 Apr-06 May-06
9 15 16 17 22
TO HRS 4/7/2005 4:00 4/9/2005 21:00 4/30/2005 9:45 5/1/2005 18:45 5/5/2005 23:30 5/12/2005 15:17 7/22/2005 3:15 8/16/2005 19:00 8/31/2005 21:30 3/30/2006 0:00 4/13/2006 5:00 5/24/2006 6:30 NATURE EMERG EMERG EMERG EMERG EMERG EMERG EMERG EMERG EMERG EMERG EMERG EMERG
10
20
21
23
REASONS
24
HOURS 38.00 47.50 11.50 30.00 49.00 47.50 8.25 41.50 66.00 28.00
DESCRIPTION
FROM HRS 4/5/2005 14:00 4/8/2005 19:00 4/28/2005 10:15 5/1/2005 7:15 5/4/2005 17:30 5/7/2005 19:05 7/20/2005 2:15 8/14/2005 19:30 8/31/2005 13:15 3/28/2006 6:30 4/10/2006 11:00 5/23/2006 2:30
1 2 3 4 5 6 7 8 9 10 11 12
PLANT 207 OHCU PLANT 207 OHCU PLANT 207 OHCU PLANT 207 OHCU PLANT 207 OHCU PLANT 207 OHCU PLANT 207 OHCU PLANT 207 OHCU PLANT 207 OHCU PLANT 207 OHCU PLANT 207 OHCU PLANT 207 OHCU
MAKE UP H2 FAILURE TOTAL POWER FAILURE POWER FAILURE/REFORMER TRIP REFORMER TRIP RGC TRIP RGC TRIP POWER DIP UNIT TRIP REFORMER TRIP REFORMER TRIP
POWER DIP & MAKEUP H2 FAILURE 26.00
POWER FAILURE/REFORMER TRIP 116.20
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22
300 250
OHCU T'put 2007-2008
GT Trip
Cu.M/Hr
200 150 100 50 0
Reforme r Trip
Catalyst change
HGU ID Fan
M o nt h
M M
S O
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23
CRUDE-1
450 400
350
300 250 200 150
100
50 0
2-May
2-Dec 2-Apr 2-Jul 2-Aug 2-Sep 2-Jun 2-Jan 2-Feb 2-Nov 2-Mar
24
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2-Oct
CRUDE-2
600 500 400 300 200 100 0
2-May
2-Dec
2-Apr
2-Jul
2-Aug
2-Sep
2-Jun
2-Jan
2-Feb
2-Nov
2-Mar
25
18-March-2011
2-Oct
FCCU
160 140 120 100
80
60 40 20 0
2-May
2-Jun
2-Jul
2-Aug
2-Sep
2-Dec
2-Feb
2-Apr
2-Jan
2-Nov
2-Mar
26
18-March-2011
2-Oct
CRUDE 3
800 700 600 500 400 300 200 100 0
2-May
2-Dec
2-Apr
2-Jul
2-Aug
2-Sep
2-Jun
2-Jan
2-Feb
2-Nov
2-Mar
27
18-March-2011
2-Oct
OHCU
300 250 200 150 100 50 0
2-May
2-Dec
2-Apr
2-Jul
2-Aug
2-Sep
2-Jun
2-Jan
2-Feb
OHCU
2-Nov
2-Mar
28
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2-Oct
Focus areas
Plant availability
Mechanical Power/Utilities Upstream/Downstream Statutory
Operating cost
Maintenance Cost Chemicals & Catalysts Purchased power & utilities
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NON - AVAILABILITY
The non availability is classified as follows

MECHANICAL REGULATORY OTHERS
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MECHANICAL
Non T/A unit downtimes, including scheduled and unscheduled unit outages for the purposes of unit mechanical repair
Rotary / Static equipment failure Electrical / instruments problems Fire / Accidents due to equipment problems Planned unit shut downs Regulatory S/Ds if the scheduled duration is extended by 25% for maintenance work
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REGULATORY
Process related non T/A down time

Furnace decoking Catalyst regeneration / replacement S/D for inspection by statutory bodies
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OTHERS
Non T/A downtimes caused by factors outside of the unit

Electrical power interruption Hydrogen supply Other upstream / downstream outage Non availability of Feed / Utilities Any other process related downtimes
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Plant Reliability
Concerns
Plant shut downs Breakdowns / low MTBF Poor efficiency Safety hazard Low thruput Poor yield High maintenance cost High inventory
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Plant Reliability
Practices
Online protection alarms/trips Criticality ranking Condition monitoring Preventive maintenance Unit shutdowns / Turn Around AMC / CMC O&Ms Zonal contracts Statutory Inspections IBR / Tanks / Pr. Vessels / Sphere PSVs / Cryogenic storage Modifications / Replacements
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35
Plant Reliability
Organisation
Maintenance
Planning Mechanical Field (Onsite / Offsite / Civil) Mechanical Rotary Electrical Instrumentation Garage / Material Handling Prefabrication / Soot blowers / Machine Shop
Engineering & Inspection

General Engineering Inspection
Process Engineering Operations Projects
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36
Plant Reliability
Job inputs
Maintenance Notification Inspection work list Process schemes Engineering Drawings Operations Work lists Checklists Internal / External audit points Work packages Tag items Hot / Cold PM Work orders Investigation reports OEM Recommendation
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Focus is on reducing..
Integrity and Reliability Reliability & Integrity Management Equipment strategy through RRM methodology Effective maintenance execution Defect Elimination to eliminate bad actors Maintenance Downtime Duration through better predictability Frequency by controlling deterioration Maintenance Effort Routine Maintenance effort and cost Turnaround Maintenance effort by virtue of better overall equipment condition Unplanned
Outages
Duration of Planned Outages
Maint Effort & Cost
All through structured Risk Based Processes, Tools & Organization Need significant shift in the mindset of management & people..
38
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38
TYPES OF MAINTENANCE
ROOT CAUSE FAILURE ANALYSIS
BREAKDOWN MAINTENANCE
PREVENTIVE MAINTENANCE
PREDICTIVE MAINTENANCE
PROACTIVE MAINTENANCE
RELIABILITY CENTERED MAINTENANCE

39
18-March-2011
Present
Future
Minimize reactive maintenance Reduce Time based tasks
Increase condition based tasks
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40
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41
P F Interval
P
100 90 80 70 60 50 40 30 20 10 0 0 5 10 15 20 25 30
35
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42
RISK ASSESSMENT MATRIX (RAM)

ENVIRONMENT CONSEQUENCES REPUTATION SEVERITY A
Never heard of in industry
INCREASING LIKELIHOOD B C D E
Heard of in industry Incident has occurred in our Compan y
PEOPLE
Happens several times per year in our Company
Happens several times per year in a location
ASSET S
0 1 2 3 4 5
no health effect/injury
no damage
no effect
no impact slight impact limited impact considerable impact national impact international impact
slight health effect/injury

minor health effect/injury major health effect/injury PTD* or 1 to 3 fatalities multiple fatalities
slight damage
minor damage localised damage major damage extensive damage
slight effect
minor effect localised effect major effect massive effect
LO W RIS K
MEDIU M RISK
* PTD = Permanent Total Disability

HIGH RISK
43
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43
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44
Reliability
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45
Reliability
Reliability is defined as the ability of an asset to perform consistently at the desired level over a period of time.
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46
ASSET
PLANT & MACHINERY PROCESS PERSON SYSTEMS PROCEDURES
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47
Focus Areas
Reliability and availability of Plant & Machinery Proactive Maintenance Preservation Functions Interface between Process and Machinery Reliability in Systems and Procedures Reliability in Projects
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48
Reliability Issue
AN ISSUE WHICH DETRACT THE ASSETS FROM PERFORMING CONSISTENTLY AT THE DESIRED LEVEL, OVER A PERIOD OF TIME.
ISSUES ARE GLOBAL IN NATURE COMMON TO MORE THAN ONE FUNCTIONS / ASSET TO BE SOLVED AT DIVISION / ORGANISATION LEVEL NEEDS POLICY DECISIONS TO RESOLVE
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49
Reliability Problems
UNSOLVED SPECIFIC ISSUE WHICH AFFECTS THE RELIABILITY AND AVAILABILITY OF A PARTICULAR ASSET.
CAN BE IDENTIFIED AND ANALYSED FOR AN ASSET SOLUTION POSSIBLE WITH THE EXISTING POLICIES HAVE DIRECT IMPACT ON AVAILABILITY AFFECTS THE PROFITABILITY
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50
Reliability Incidents
Failure resulting in S/D Consecutive 3 failures on same mode Failure within 50 % of MTBF Accident Fire Production loss Margin loss
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51
How to improve ?
Measure Identify incidents / Problems Prevent Reduce Effect
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52
KED Total MECHANICAL C hrs. KEDC * month S/D availabili ly hrs. ty Plant 1 Atm 71 672 71.0 Plant 3 12 672 12.0 Plant 4 28 672 28.0 Plant 5 9.6 672 9.6 Plant 7 5 672 5.0 Plant 11 36 672 36.0 Plant 13 5.4 672 5.4 Plant 15 Atm 106 672 106.0 Plant 15 Vac 39 672 39.0 Plant 16 136 672 136.0 Plant 19 3 672 3.0
Plant No
KED Total MECHANICAL C hrs. KEDC * month S/D availabili ly hrs. ty Plant 74 4 672 4.0 Plant 75 5 672 5.0 Plant 76 68 672 68.0 Plant 77 82 672 82.0 Plant 78 31 672 2.13 30.9 FG Recovery 1 672 1.0 CDU 3 85.9 672 85.9 VDU 3 39 672 39.0 Visbreaker 3 13 672 13.0 Reformer 3(CRU) 7 672 7.0 H2 UNIT 3 68 672 68.0 OHCU 300 672 300.0 Nap 3 (NHT) 5 672 5.0 Sulfur 3 (210) 69 672 69.0 1229 1228.8 99.99%
Plant No
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53
MECHANICAL Plant No Plant 1 Vac Plant 8 Plant 9 plant 10 plant 13 Plant 14 DOU Plant 14 HiFi Plant 71 Plant 72 Plant 73 KEDC 29 37 121 62 12 13 4 16 15 76 385
Total hrs. monthly S/D hrs. KEDC * availability
672 672 672 672 672 672 672 672 672 672
29.0 37.0 121.0 62.0 12.0 13.0 4.0 16.0 15.0 76.0 385.00 100.00%
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54
Mechanical Availability REPORT JANUARY 2010 Lube Month Fuel (Act) Fuel (Plan) Lube(Act) (Plan) April 95.50 98.50 100.00 94.00 May 98.83 98.50 98.98 94.00 June 99.76 98.50 99.13 94.00 I Qtr. 98.04 99.37 July 99.66 98.50 96.78 94.00 August 98.73 98.50 97.75 94.00 September 100.00 98.50 93.77 94.00 II Qtr 99.46 96.13 October 99.99 98.50 91.84 94.00 November 98.22 98.50 90.55 94.00 December 99.83 98.50 99.91 94.00 III Qtr 99.36 94.14 January 99.46 98.50 99.55 94.00 February 98.50 94.00 March 98.50 94.00 IV Qtr 99.46 99.55 Cumulative MoU Target 99.01 98.50
18-March-2011
96.84 94.00
55
Prevention
Design reliability Condition monitoring Preventive maintenance Failure Finding
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56
Reduce Effect
Protective Devices Modification Redesign / Replacement Standby / redundancy
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Maintenance
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Changing Maintenance Techniques

Second Generation Schedule overhauls Systems for planning & controlling work Big, slow computers 1960-80
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Third Generation
Condition monitoring
Design for reliability and maintainability Hazard studies
Small, fast computers

FMEA Expert systems Multiskilling and teamwork After 1980
First generation Fix it when it broke Till 1960
59
400 350 300 250
WO
200 150 100 50 0

1
BHS CDU1
2
CDU2
4
DHDS
5
FCCU
6
HYD
Year
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60
Rotary WO Details
100% 90% 80% 70%
% of WOs
60% 50% 40% 30% 20% 10% 0% 0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100%
% of equipment
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61
RELIABILITY TOOLS
FMEA ( Failure Mode Effect Analysis) RCM ( Reliability Centered Maintenance) RCFA ( Root Cause Failure Analysis) LCCA ( Life Cycle Cost Analysis)
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RCFA
Root Cause Failure Analysis
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RCFA - Methodology
Failure defined All hypothesis are developed Elimination of false hypothesis with objective evidence Physical Roots are identified Human Roots (Who has failed) Latent Roots ( Why the human has failed)
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Reliability Incidents Analysis

Record all the reliability Incidents and calculate mechanical availability on monthly basis. Carry out simple failure analysis on the reliability incidents. The failure analysis includes
Event description Effect of the event Chronology Observation Analysis Recommendation
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65
Defect Elimination Management

Defect Elimination Management is an important process to prevent failures fro reoccurring, eliminate bad actors, making the journey from a reactive to a pro-active mode..
Practiced in Shell D/S and U/S facilities
Process
Tools
People
Defect Elimination contains the well known methodology of Root Cause Analysis but does not stop there DEM is a fact based and structured Problem Solving Process DEM includes the process steps that are needed to ensure that the failure does not repeat itself the effective designing out of the root cause Defect Elimination needs to be structured as Information sources are not always fully tapped Contributing/related circumstances are not always obvious and require a through investigation and understanding Root causes can go deeper than manifestations and can be located in equipment defects, organisational problems or have process related deficiencies People tend to jump to conclusions as many are close to problems and have though about possible solutions but usually in isolation without the benefit of a structured and multidisciplinary approach
66
FMEA
Failure Mode Effect Analysis
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FMEA
Failure Mode and Effects analysis is a structured qualitative analysis of a system, subsystem, component or function that highlights potential failure modes, their causes, and the effects of a failure on system operation
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FMEA Methodology
All the possible failure modes for an equipment is identified Risk Priority Number is calculated for each failure mode and equipment as a whole All possible PM tasks for each failure mode is identified with man-hour requirement Failure Mode PM Task matrix is developed PM tasks are selected to cover more than 70 % of risk assessed with optimum man-hour requirement
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FMEA - RPN
Calculation of Risk Priority Number for the purpose of criticality assessment. Factors
Likelihood of Failure
Severity of the failure effects

Cost to repair
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Mode F -1 FM 1 FM 2 FM 3 1 2 1
F-2 7 3 9
F-3 1 4 3
RPN 7 24 27 58
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FEMA RANKING CHART

Sl.No.
Failure Mode LOF
Effect CTR ABCDEFGHI JKL
Ranking
1 2 X SUM (A TO L) = Y 3 4 CRITICALITY RANKING

T=X*Y*Z
CRITICALITY RANKING (N) = sum of Ts

72
PRODUCTIVITY TAG NO SERVICE UNIT LOSS OF SHUTD PRODUCTION OWN REDUNDANCY FACTOR "P" Factor
No.in No. service installed A 1G - 2A/B 1G 4/1G-7B 1G - 5 1G - 6A/B 1G - 7A/B 1G - 8 QUALITY Crude Booster Overhead Product Sour Water 1C-7 Boot to1E1 Water Circulation Stabilizer Feed 1C - 12 Bottom liquid COST Maint. MTBF "C" Factor Cost DELIVERY 5 5 1 1 5 1 B 2 2 1 1 4 1 C 1 1 1 2 1 1 D 2 2 1 2 2 1
RF E = C/D 0.5 0.5 1 1 0.5 1 F=A*B*E 5 5 1 1 10 1
"Q" Factor
SAFETY/ENVIRONMENTAL HAZARD VIOLATION SAFETY / DETECTIO OF "D"owntime ENVIRON N STATUTORY "S" Factor CRITICALITY Factor MENTAL PROBABIL REGULATIO RATING HAZARD ITY N
G 3 3 1 1 3 1
H 3 2 1 1 2 1
I 3 3 1 3 3 1
J=H*I 9 6 1 3 6 1
K 1 1 1 1 1 1
L 1 1 1 1 1 1
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M 1 1 1 1 1 1
N 1 1 1 1 1 1
O=L*M*N 1 1 1 1 1 1
P=F*G*J*K*O 135 90 1 3 180 1
73
5 4 3 2 1
Productivity Loss of Production Above 50 Lacs Rs. 20 to 50 Lacs Rs. 10 Lacs to 20 Lacs 5 < loss < 10 Lacs Loss less than 5 Lacs Unit shutdown Could result in unit shutdown as well as downstream unit shutdown Could result in unit shutdown Could result in throughput reduction No effect on unit operation Redundancy factor Please fill the figures
4 3 2
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3 2 1
Quality Could result product getting out of spec. Could result in contamination No effect on quality
4 3 2 1 1 2 1 2
Safety SAFETY / ENVIRONMENTAL HAZARD Failure results in fatal accident / Major Env. Impact Failure results in minor injury/ Env. Impact Failure results in property loss / Minimal impact No Loss / No environmental impact STATUTORY OBLIGATION No Yes DETECTION PROBABILITY Easily detectable Remote probability
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Cost Maint. Cost 3 Maint. Cost / occasion more than Rs. 5 lacs 2 Maint. Cost / occasion between Rs. 2 & 5 Lacs 1 Maint. Cost / occasion less than Rs. 2 Lacs MTBF 1 IF (MTBF 3 YEARS) 2 IF (MTBF 2-3 YEARS) 3 IF (MTBF 1-2 YEARS) 4 IF (MTBF < 1 YEARS)
1 2 3 4
Delivery IF (0/1 < DOWNTIME IN DAYS/hour < 3/24) IF (3/24 < DOWNTIME IN DAYS/HOURS < 5/40) IF (5/40 < DOWNTIME IN DAYS/HOURS < 10/80) IF (EXCESS OF 10 DAYS/80 HOURS)
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RCM
Reliability Centered Maintenance
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RCM
A process used to determine the maintenance requirements of any physical asset in its operating context
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RCM
A PROCESS TO DETERMINE PREVENTIVE MAINTENANCE TASKS TO BE DONE ON INDIVIDUAL PIECES OF EQUIPMENT IN ORDER TO PRESERVE CRITICAL PLANT FUNCTIONS WHAT SHOULD BE DONE THAN DO EVERYTHING POSSIBLE
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RCM - OBJECTIVES
Preserve System Function Identify Failure Modes that can defeat the functions Prioritize Function need (via the failure modes) Select applicable and effective PM tasks
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Seven basic Q s
1. What are the functions and associated performance standards of the asset in its present operating context ?
In what way does it fail to fulfill its functions ? What causes each functional failure ?
2. 3.
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Seven basic Q s
4. 5. What happens when each failure occurs ? In what way does each failure matter ?
6.
What can be done to predict or prevent each failure ?

What should be done if a suitable proactive task cannot be found ?
7.
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RCM
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Preventive Maintenance Task Categories
Time Directed Condition Directed Failure Finding
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Time Directed
The task action and periodicity are preset The action is known directly provide failure prevention/mitigation benefits Tasks requires some form of intrusion into the equipment
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TD - Examples
Periodic overhauls (Pumps, motors etc) Time specific part replacement like filters replacement
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CONDITION DIRECTED
Identification of a measurable parameter that correlates with failure onset Specification of a value of that parameter when action may be taken before full failure Tasks are non-intrusive in nature with respect to the equipment
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CD - EXAMPLES
Monitoring Diff. Pressure across filters Monitoring flow parameters for deciding strainer cleaning or pump overhauls Monitoring vibration / noise to detect onset of some mechanical damage
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FAILURE FINDING
Periodic surveillance tasks Availability checks Tasks directed to identify failures hidden in nature and fix the before an operational demand
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FF - EXAMPLES
Check standby equipment availability Checking auto cut-in mechanism of a pump Stroke check of a control valve Ensuring tripping logic by simulation
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RUN - TO - FAILURE
No PM task available PM task available but too expensive Equipment failure is low on the priority list for the existing set-up
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PRESENT PM PRACTICE
Determines what can be done for failure prevention than why it should be done Preserve Equipment not Preserve Function
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RCM - Methodology
The refinery is divided into System & Sub-System using P & I Drawings. Functions of each Sub-system is defined All the hardware are listed In / Out interface of the system defined Functional block diagram is developed All possible functional failures are identified and listed Functional failure and Equipment Matrix is drawn. All possible failure Modes and causes for all the functional failures are identified. Failure Mode Effect Analysis is carried out at Local, System and Plant Level.
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RCM Methodology contd..

Logic Tree Analysis is performed on all the possible failure causes and effects. Failure Modes are classified based on the effect ( Safety and Outage) PM tasks which can improve the functional performance of the system are selected. Carry out task comparison Sanity check Consolidation of PM Schedules and RCM recommendations.
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466. .
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Clarity
Turnaround / Planned shutdown: Maintenance activity required to undertake work that cannot be accomplished while plant is in operation Unplanned Shutdown : Usually unscheduled as a result of equipment failure or process upset
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Necessity for a Turnaround

Successful plant turnaround management should lead to better asset leverage and increased organizational profitability
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Objective of a Turnaround
Bring plant and equipment to their optimal health Make plants safe to operate till next outage Enhance plant life Improve efficiency and throughput of plant by suitable modification Reduce routine maintenance costs Increase reliability / availability of equipment during operation Upgrade technology by introducing modern equipment and techniques
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Objective of a Turnaround
To avoid surprises Up-gradation of critical equipment Review on stream factor and remove primary causes of shutdowns Increased productivity / profitability
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Planning Cycle
Planning cycle of next turnaround shall start with review of the just concluded turnaround
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PLANNING CYCLE
Time 0 Year 1 Begin planning Long lead items Budget approval Review TA scope Pre-turnaround jobs Review contractor availability Formulate tendering strategy Review resources Finalise TA organisation Work scope cut off Freeze work scope Procure material Award Contracts Schedule activities Mobilise resources Shutdown unit Start-up unit Review turnaround success
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Year 2
Year 3
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Equipment repaired to capability that meets business needs
Decision based on accurate input of relevant facts & data to work list
Reliable turnaround performance
Zero failures during start-up
Able to produce to max. limits
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Work packaging
Systemisation Standardisation Cut-off date Clarity Self sufficient Spares details Tools requirement Specifications Activity details Inspection requirements Technical data
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Integration
Process performance Operations Inspection Maintenance Statutory Safety Maintenance Reliability Projects Customer
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Achieving Availability
Plant Availability
Sustainable 1st Quartile Performance
Asset Flexibility
Systems Availability Asset Stability
Equipment Reliability
Operational Reliability
Support Processes
Operations Maint.& Implementatio Reliability n & Flawless Processes Start-up
Information Contracting & Management Procurement Tools
Foundation
Business Risk Techniques
Performance Management
Objectives, Targets and KPIs
Integrated Cost Management
Fit for Design for Purpose IT Reliability & Structure LCC
We want the kit to run at maximum margin for optimum costs

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Safety & Environment

Organisation
Oil Industry Safety Directorate Fire & Safety Department Environment Protection & Process Safety Department Occupational Health Services Central Safety Committee Area Safety Committees
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Activities
External safety Audit Internal Safety Audit Safety Surveillance Night visits Monthly Safety talk Safety day / contests Seminars Onsite Emergency Plan / Organisation Offsite Emergency Plan / Organisation Mock drills Safety training Mandatory Tool box safety talk
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Systems / Procedures
Permit System
Cold work Hot work Height work
Safety manuals Penalty for non compliance Bonus for safety performance Fire alarm Mutual Aid
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How do we build Reliability? Each item of equipment performs a function.

A pump moves fluid around a system A heat exchanger exchanges heat between two fluids Pipes and vessels contain the fluids A motor powers rotating or moving equipment.
Maintenance re-establishes or preserves the function Unplanned Reactive or breakdown maintenance More of this has the potential to reduce reliability Proactive or preventative maintenance More of this improves reliability
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Chennai Petroleum Corporation Ltd.

(A Group company of IndianOil)
H2S rich gas leak in Vis-Breaker Unit

due to multiple breakages of small bore pipe fittings in Pulsation Dampeners of Reciprocating Compressor (204K3B)
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The incident
23rd August 2010 Midnight Mild drop in Suction pressure observed Panel Officer alerted Field Operator.
No response from the Field Operator
Shift in-Charge along another operator followed
Field operator found unconscious.

He was rushed to the nearby Hospital. On arrival he was declared dead.
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The operator was found here and the Compressor was found stopped
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Unit Description
CPCL Vis-Breaker Unit VBU (Plant 204) 1 2 3 Year of commissioning Capacity Feed 2004 1.15 MMTPA (140 M3/Hr) VR from Crude Unit. (Unit is capable of processing 20% PDA-Pitch however no pitch intake on the day of incident) ABB Lummus (Shell Soaker Vis-breaking Technology) M/s. Engineers India Limited M/s Kvaerner E&C, Australia M/s. Petrofac International Limited M/s. Dresser Rand 24 & 14 X 10 2HHE-FB2 1st Stage Suc/dis Pr. : 0.49 / 3.4Kscg 2nd Stage Suc/dis Pr. :3.3 / 13.3 Kscg Capacity 3085 NM3/Hr
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4 5 6 7 8
Licensor Consultant Detailed Engineering LSTK Contractor Compressor Make
11
PT-204 VBU PROCESS FLOW

225 Feed
C-1 R-1
9.1 425
Pressure, Kscg Temp, C
E-22
295
F-1
445
Sour water from C-21A/B
G-2
E-28
E-1
Sour water from C-9/C-11
Gas + Naphtha 1.2

E-5 C-7 E-6 E-7 SW to B/L G-7 C-8 G-10 Stabilize r E-12 C-14 VGO C-11 C-10 K-3 M E-8 E-9 C-9
VB Offgas
Soaker Effluent Quench
C-5
Gas oil
Vacuum Flasher
E-13
G5
E-10
Naphtha
G-13 VFCR
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204 K3B FLOW SKETCH

Pressure, Kscg Temp, C
TI-2811 C-41B LIC2804 LIC-2803
PI-2810
50
0.85 40
C-45B
CBD compressor
C-21B
II
12.4 102
C-42B
I
3.8 105
C-44B
0.95
C-8 C-11
LIC-2802
PDT-2808
PDT-2808
E-7
E-8
E-6
E-9
LV-2802
E-33B
FL
VB Gas to B/L C-9

C-11 off gas
From C-7
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Chronological events
1:08:00.000 204 PI2801- fist stage suction volume bottle pressure started dropping down from 0.84 Kg/cm2g. (Safe range 0.57 to 0.67 Kg/cm2g) H2S concentration in this area increased from 0 to the maximum value 50PPM) as per PIN trend. CS tag not indicated. Re-contacting drum C-9 O/L pressure controller, 204PIC-2901 started closing to maintain the set pressure of 12.5 Kg/ cm2g. 204FI2901VB gas to B/L low (447 Nm3/ hr). DCS alarm. A204PI2806 Suction pressure in K3B2 low (2.96 Kg/cm2 g). DCS alarm. %D 204 YL 2801 K3B status indication off.(Motor run contact withdrawn ). Motor stopped. PLC - Sequence of Events data.
1:12:37.000
1:14:00.000
1:17:00.000 1:22:16.550 1:22:56.131
1:23:06.650
204K3B stop alarm. DCS alarm.

Panel in-charge received information from field about a possible gas leak. Mr.Rajendran was found unconscious at plant.
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1:30:00.000
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Observation:
Steam heating for suction bottles and inter stage KOD was kept isolated. (From OVHD) Steam heating to the volume bottles was kept isolated. Take off for suction is taken from bottom of the header for both the compressors Compressor 2nd stage suction volume bottle pressure gauge, boot LT- drain, 2nd stage discharge volume bottle pressure gauge, suction & discharge DP transmitter lead line were found broken and breakages occurred at high stress concentrated areas. Connected nozzles were provided with supports in one plane instead of minimum two and the overhung weight is not kept at minimum as per API 618 Online vibration monitor is not available.
Hooter and Beacon light did not function due to card failure.
Operator did not carry portable gas monitor.
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Typical arrangement of level indicators & pressure gauge connections in 204 K-03A (LI isolation valve oriented 180 deg opposite & not insulated ).
Failure of Drain nipple of Level indicator Pressure gauge connection (both sheared & disconnected) LI vent found bent in second stage suction bottle of compressor 204-K-03B
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Observation
Small bore Instrumentation pipe fittings in 204K3B second stage suction & discharge volume bottle were found broken at 6 locations and lying on the ground/platform.
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Findings:
API-618 (regarding nozzle supports) was not followed. Compressor suction take off was not from top of the header. KOD is not provided for first stage from inception. The responsibility for checking the conformity to the standards for fixing overhung fittings is not clearly visible in LSTK contracts (EIL, Petrofac, Kvaerner and Dresser Rand). Suction volume bottles has inherent design fault to drain liquid completely. Compressor operated at 100% load when the available gas is around 30%. H2S range for the detector is found configured in % instead of ppm. Alarm did not appear in DCS
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Findings:
2nd stage suction volume bottle boot LIC 2804 was showing constant reading of -0.60% for long time. Vibration monitoring systems were not effective and objective. H2S detector measuring unit configured wrongly from commissioning. Involvement of Operations / Safety personnel in detector calibration is missing. The hooter and beacon light system failed..
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Marking of piston hit on end cover was noticed in 204K3B second stage. Clearance between piston and head reduced to nil from 4.5 mm. ( Head of K3A compressor
Piston hitting impression on Head and scales due to water

12
2nd stage suction volume bottle
Suction pipe blocking the water flow to boot
Corrosion due to presence of stagnant water
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Additional Input:
OEM Compressor experienced liquid entry during commissioning stage and the other compressor suffered a major damage after one year of operation. Piston lock nut thread found damaged. API 618 was not followed for providing supports and to keep the weight of overhanging part to minimum. Compressor 2nd stage observed liquid carry over due to which heavy load was experienced by piston rod. (Torque nuts from cross heads opened.)
IOC
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Additional Input:
IIT-Madrs - Fractographic surface analysis of the crack initiation point showed brittle fracture and later stage of failure revealed ductile type of fracture surface. This indicates that failure is progressive with initial propagation of crack by sulphide stress cracking and subsequently failing due to tensile over load when the vibration levels have gone up. This further justifies the phenomena of multiple failures at the same intense. Fracture analysis revealed sulphide stress cracking due to presence of wet H2S. The gas is 12% H2S rich and presence of moisture is confirmed as the scales are visible in suction volume bottle, cylinder chamber and piston head.
13
Lessons learned
Healthiness of Gas detection and alarm systems are to be ensured positively at all time and calibration should be done at least once in a month involving Operating / Safety personal. Carrying of portable gas monitors and hand held radio is must for operating personnel in hazardous area. Pre-Commissioning Safety audit on new facilities should focus on compliance to all standards as per the requirement in Design, Supply, Erection and Commissioning. Operating parameters are to maintained as prescribed in the manual and any change shall be entertained only through MoC. In case of operation of an equipment away from the design conditions is warranted then the with close monitoring. Auto draining and other protection systems are to be checked periodically in compressors handling condensable gas, to avoid liquid entry.
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Lessons learned
Online vibration monitoring and trip should be installed on critical equipments like this. Operating the equipment within design parameters as recommended by the OEM /Licensor Improve awareness and the preparedness which are required for handling hazardous gas leak scenarios. Provide sufficient escape routes with proper lighting and ventilation. Operating personnel should enter into hazardous area with hand held Radio and Gas monitors, especially during abnormal conditions. Operator should be more cautious when entering the hazardous area alone in odd hours.
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POLICY
ENSURE SAFE, HEALTHY, PROFITABLE ENVIRONMENT, BY MAKING THE ASSETS PERFORM CONSISTENTLY AT THE DESIRED LEVEL, THROUGH RELIABILITY ENGINEERING.
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