CRITICALITY ASSESSMENTS:

their importance in the maintenance process

Roy Chenery Marine Consultant
5

consequence
A B C D E

likelihood

4 3 2 1

IMarEST Conference: Condition Based Maintenance London 28-29 September 2010

There is no greater impediment to the advancement of knowledge than the ambiguity of words
Thomas Reid 1710-96

The importance of criticality assessments

IMarEST Conference: Condition Based Maintenance

Agenda

What are criticality assessments and where are they used Criticality assessments compared to critical equipment lists Some examples of where the criticality assessment process could result in improved reliability Questions

The importance of criticality assessments

IMarEST Conference: Condition Based Maintenance

Criticality assessment (with respect to maintenance)

A process for prioritising the criticality of various systems and equipment A risk assessment process, takes account of the likelihood and the consequence of failures, as these vary for similar equipment depending on operating context, design criteria etc Involves the concept of identifying equipment function, functional failure, failure modes, failure effects, control methods Provide visibility of critical areas distinguishes between critical and important Prioritisation:
Human resource Costs Focus, which enables continuous improvement Spares e.g. OEM or approved supplier Scheduling

The importance of criticality assessments

IMarEST Conference: Condition Based Maintenance

The process

Stakeholder teamwork Experience

Criticality process eg FMEA/FMECA/HAZID etc Operations Maintenance HSE Designer / OEM Subject matter expert

Recording of results

The importance of criticality assessments

IMarEST Conference: Condition Based Maintenance

Best practice
The steps to achieving good maintenance management:
Define maintenance strategy Create asset register Prioritise by criticality assessment Identify maintenance task and frequency Carry out maintenance task Record the results maintenance history Assess effectiveness of task Refine task where necessary

Plan Do

Act Check

The importance of criticality assessments

IMarEST Conference: Condition Based Maintenance

Criticality assessment or critical equipment?

The regulatory framework
ISM Code
Purpose To provide an international standard for safe management and operation of ships and for pollution prevention (Preamble 1) Objectives 1.2.2 Safety management objectives of the Company should 1.2.2.2assess all identified risks to its ships, personnel and the environment and establish appropriate safeguards Maintenance of ship and equipment 10.3 The Company should identify equipment and technical systems the sudden operational failure of which may result in hazardous situations

The importance of criticality assessments

IMarEST Conference: Condition Based Maintenance

Criticality assessment or critical equipment?

IACS recommendation 74 A guide to managing maintenance in accordance with the requirements of the ISM Code
Sect. 4 The identification and testing of critical equipment The list of critical equipment and systems will vary according to the type of ship and the operations in which it is engaged.

The importance of criticality assessments

IMarEST Conference: Condition Based Maintenance

Criticality assessment or critical equipment?

The regulatory framework
TMSA Element 4 Critical equipment and systems are defined and identified within the safety management system. Management provides clear instructions on the identification of onboard critical systems, alarms and equipment. Risk-assessment or hazard-identification methods are documented to help the identification of such equipment and systems. Critical equipment and systems are identified in the vessels planned maintenance system. Critical equipment lists are available in an easy-to-understand format. All items listed are identified in the planned maintenance system.

The importance of criticality assessments

IMarEST Conference: Condition Based Maintenance

Criticality assessment or critical equipment?

TMSA
Critical equipment and systems - definition Any vessel-based equipment, operating system or alarm that, were it to fail, would result in the crew or the vessel being placed at risk or that could lead to an accident. Critical equipment or systems should include as a minimum: cargo pump-temperature monitors, pump-room fixed gas-detection systems, fire-detection and fire-fighting systems, crankcase oil-mist detectors, steering gear, emergency generator and main-engine shutdown alarms. No example of reasoning provided

The importance of criticality assessments

IMarEST Conference: Condition Based Maintenance

Risk Assessment in Simple Terms

What can go wrong? How likely is it to go wrong? What happens if it does go wrong? Does it matter? What do we do if it does matter?
Prevent it happening Reduce its frequency Mitigate its consequences

The importance of criticality assessments

IMarEST Conference: Condition Based Maintenance

Reliability Centred Maintenance RCM

Analysis is based on the use of seven questions: What is it supposed to do? In what ways can it fail? What causes it to fail? What happens when it fails? Does it matter if it fails? Can anything be done to prevent the failure? What if the failure cannot be prevented? Function Functional failure Failure mode Failure effect Failure consequence Preventive task Redesign/run-to-fail

The importance of criticality assessments

IMarEST Conference: Condition Based Maintenance

Quick closing valves

The importance of criticality assessments

IMarEST Conference: Condition Based Maintenance

Fire dampers

The importance of criticality assessments

IMarEST Conference: Condition Based Maintenance

Control of design conditions

The importance of criticality assessments

IMarEST Conference: Condition Based Maintenance

Air pipe heads

The importance of criticality assessments

IMarEST Conference: Condition Based Maintenance

Criticality assessments - summary

Distinguishes critical from important Provides a ranking which allows prioritisation of resources etc Process as important as the result Improves knowledge and understanding of risk and maintenance management techniques Satisfies best-practice procedures Enables continuous improvement

The importance of criticality assessments

IMarEST Conference: Condition Based Maintenance

CRITICALITY ASSESSMENTS:
their importance in the maintenance process
Roy Chenery Marine Consultant
5

consequence
A B C D E

likelihood

4 3 2 1

IMarEST Conference: Condition Based Maintenance London 28-29 September 2010