March 1998

Process Industry Practices

Machinery

PIP REEE002
Benchmarking of Reliability Indicators
for Rotating Machinery

PURPOSE AND USE OF PROCESS INDUSTRY PRACTICES

In an effort to minimize the cost of process industry facilities, this Practice has
been prepared from the technical requirements in the existing standards of major
industrial users, contractors, or standards organizations. By harmonizing these
technical requirements into a single set of Practices, administrative, application, and
engineering costs to both the purchaser and the manufacturer should be reduced. While
this Practice is expected to incorporate the majority of requirements of most users,
individual applications may involve requirements that will be appended to and take
precedence over this Practice. Determinations concerning fitness for purpose and
particular matters or application of the Practice to particular project or engineering
situations should not be made solely on information contained in these materials. The
use of trade names from time to time should not be viewed as an expression of
preference but rather recognized as normal usage in the trade. Other brands having the
same specifications are equally correct and may be substituted for those named. All
practices or guidelines are intended to be consistent with applicable laws and
regulations including OSHA requirements. To the extent these practices or guidelines
should conflict with OSHA or other applicable laws or regulations, such laws or
regulations must be followed. Consult an appropriate professional before applying or
acting on any material contained in or suggested by the Practice.

Process Industry Practices (PIP), Construction Industry Institute, The

University of Texas at Austin, 3208 Red River Street, Suite 300, Austin,
Texas 78705. PIP member companies may copy this practice for their
internal use.

Not printed with state funds.

March 1998

Process Industry Practices

Machinery

PIP REEE002
Benchmarking of Reliability Indicators
for Rotating Machinery
Table of Contents
1. Introduction ..................................2
1.1 Purpose ...............................................2
1.2 Scope...................................................2

2. References....................................2
3. Definitions.....................................2
4. Reliability Measurements ............4
4.1 Terminology
Explanation/Conventions/Exceptions
and Notes ............................................4
4.2 Formulae for Reliability
Measurement.......................................7

Process Industry Practices

5. Reporting of Data......................... 8
5.1
5.2
5.3
5.4

Submittal Information...........................8
Sorting of Data.....................................8
Summary .............................................9
Attachments.......................................10
Attachment A
Completed Data
Form - Example 1 ..............................11
Attachment B
Completed Data
Form - Example 2 ..............................12
Attachment C
Example Form for
Data Submittal ...................................13

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PIP REEE002
Benchmarking of Reliability Indicators for Rotating Machinery

1.

March 1998

Introduction
1.1

Purpose
The purpose of this Practice is to standardize reliability terminology and provide the
basis for measurement and data gathering for benchmarking the reliability of rotating
equipment.

1.2

Scope
This Practice covers the definitions of operating performance terminology,
guidelines for standardizing machinery economic performance data, and a suggested
reporting format for this data as a means to benchmark the reliability of rotating
equipment in the process industries.

2.

References
Process Industry Practices (PIP)

PIP REIE686 - Recommended Practices for Machinery Installation and

Installation Design

3.

Definitions
For the purposes of this Practice the following definitions apply:
Active Machinery: Any permanently installed machinery item, such as a pump that is in
active service (available for operation), whether continuous, standby, or intermittent. Active
machinery includes machinery in all types of process services, as well as lubricating oil,
transfer, utility, or effluent services. Active machinery does not include machinery that is
associated with maintenance or office facilities, such as air conditioning or portable
maintenance pumps. Active machinery does not include machinery located in facilities or
units that have been indefinitely shutdown, preserved or abandoned.
Availability: The measure of the percentage of the potential operating time that machinery is
capable of operation, typically expressed as a percentage of an operating calendar year
Average Cost per Repair or Average Repair Cost: The total cost of all repairs divided by the
total number of repairs for a particular machine, type of machine, class (size) of machines, or
similar machines in an operating unit or plant
Economic Performance: Various measures of the costs associated with the operation of
process equipment, typically expressed as a dollar based measures
Equipment Class: Size classification for machinery based on the driver horsepower. Typical
horsepower classes are: 5 HP and less, >5 HP to 50 HP, >50 HP to 200 HP, >200 HP to 1000
HP, and greater than 1000 HP.
Essential Service: A categorization of process machinery based on the operating service and
can include either spared or unspared equipment. Downtime of this machinery results in no

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Process Industry Practices

March 1998

PIP REEE002
Benchmarking of Reliability Indicators for Rotating Machinery

direct production loss or the resulting losses are minor and acceptable, with no resulting
violation of a regulatory agency requirement.
Installed Cost per Horsepower per Machinery Type: The total installed cost of a machinery
train averaged over the nameplate horsepower of the driver, and includes the (new
installation) engineering, procurement (material costs), construction, inspection, start-up and
documentation
Installed Horsepower (HP): The nameplate horsepower rating of the machinery, typically
the driver of the machinery train. Summaries of HP for a unit, plant or service class would
simply be a total of the pertinent machinery driver ratings.
Life Cycle Cost: The total cost of a rotating machinery installation through its lifetime,
including the total cost of purchase, installation, operation, maintenance, and disposal of the
equipment
Machinery Train: The driven equipment, the driver, and auxiliaries such as sealing systems,
integral lubrication components, speed changing gears and couplings. A machinery train does
not include process control system components or switch gear.
Machinery Type: A functional grouping of equipment with similar function and general
characteristics; for example, pumps, turbines, compressors, etc.
Machinery Unit: An individual machinery item, such as a pump, motor, turbine, compressor,
gear box, etc. (The component machines of a machinery train.)
Material Costs: Purchase price for equipment, accessories, and dedicated spare parts; does
not include labor costs.
Material Multiplier: The total installed costs for a machinery train compared to the actual
material costs for the same machinery train
Mean Time Between Repairs (MTBR): The most common measure of operating reliability,
typically stated as the average operating calendar time between required repairs for a
particular piece of machinery, type of machinery, class of machinery, operating unit or plant.
MTBR is not Mean Time Between: (a) Failures, (b) Planned Maintenance, or (c) any other
categorization of shutdowns. MTBR calculations include Repairs due to (a) Failures, (b)
Planned Maintenance, or (c) any other categorization of Repair events. (See Repairs and the
Terminology Explanation section for more details)
Operating Performance: Various measures of the reliability of operation for process
equipment, typically time based measures
Preventive Maintenance: The maintenance activities carried out at predetermined intervals
or according to prescribed criteria and intended to reduce the probability of failure or the
unacceptable degradation of the machinerys function. These maintenance activities are
considered either normal operating tasks (accomplished during normal machinery operation)
or preemptive repairs (work requiring machinery shutdown for safe completion).
Reliability, (Performance): The ability of an item to perform a required function under given
conditions for a given time interval

Process Industry Practices

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PIP REEE002
Benchmarking of Reliability Indicators for Rotating Machinery

March 1998

Reliability Indicators: Those measures of operating and economic performance that quantify
the reliability of rotating machinery (typically presenting the time and cost of rotating
machinery operation in various formats)
Repairs: Work that is done to restore, maintain, or prevent the deterioration of the
machinery performance. Repairs can include maintenance tasks that are categorized as
routine, preventive, predictive, failure correction, or rebuild, that typically require shutdown
of the machinery for their safe accomplishment. (See Section 4.1, Terminology
Explanation)
Repair Cost per Installed Horsepower per year: The annual average repair cost associated
with a particular machine, type of machine, class (size) of machine, or all similar machines in
a particular operating unit/plant, divided by the total nameplate horsepower for that
machinery
Root Cause: The initial causal action, condition, or circumstance for an event, (usually a
term used in failure investigation)
Service Class (Classification): A prioritization of operating machinery based on the
importance of this machinery to the operation, typically using the consequence(s) of a
machinery failure. There are only two service classes: vital (the most critical) and essential.
Vital Service: A categorization of process machinery based on the operating service and
includes unspared or partially spared machinery. Downtime of this machinery results in
production loss and/or violation of a regulatory agency requirement.

4.

Reliability Measurements
The measurement of machinery reliability, both the operating and economic performance,
effectively defines the cost and time of operation. Effective comparability then depends on
the consistent, logical and easily understood groupings of this data.
4.1

Terminology Explanation/Conventions/Exceptions and Notes

4.1.1

Mean Time Between Repair

The average time between repairs for a machinery type was chosen as the
most comparable and easily measured reliability statistic. Therefore, the
longer the average time of operation between repairs, the greater the
reliability of the machinery.
Note: It is intended that data be collected and submitted on broad
categories of machinery types. Data should next be arranged into specific
groupings of those divisions and then in association with the mated
equipment. For example; Pumps, Centrifugal Pumps, Single Stage Pumps,
API / ANSI / Other, Multiple Seals / Single Seals / Sealless, Electric
Motor Driven / Turbine Driven / Other Drivers, Etc.

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PIP REEE002
Benchmarking of Reliability Indicators for Rotating Machinery

March 1998

4.1.2

Repairs
Those tasks, (typically maintenance), that require the shutdown of the
equipment for their safe execution, shall include the following work:

Restore machinery to its normal function or performance

Replace failed, failing, worn or questionable parts

Replace seals, including those that exceed fugitive emission

regulations

Disassemble machinery to remove deposits, debris, or plugging

Disassemble or partially disassemble machinery for inspection

Preventive or predictive maintenance tasks that meet any of the above

criteria or those initiated to correct defects identified by condition
monitoring or surveillance programs

Equipment modifications initiated to improve performance, enhance

component life, ensure that the next unit run is uninterrupted, or to
meet new regulatory requirements (e.g. fugitive emissions, process
safety, hazard mitigation, etc.), unless funded as an engineering design
improvement project (see Non-Repairs, below)

Replacement of all or a portion of a coupling that was damaged by

incorrect assembly, lubrication problems, misalignment, or failed flex
element(s)

Comments: Operator should assure on each occurrence that:

a. The Root Cause of the failure was properly determined.
b. The facet of the rotating machinery that failed was accurately
recorded.
Flawed repairs discovered and corrected before the machinery is returned to
operations control, should not be counted as a second failure (repair), but
rather as a continuation of the first.
Data accumulation for new machinery installations should start with
mechanical sign off/completion (equipment is turned over to
operations/maintenance).
4.1.3

Non-Repairs
Work is not considered a repair if it meets one of the following criteria:

Process Industry Practices

Work does not require machinery shutdown to safely complete

Normal recurring work necessary to ensure nominal run life of the

machinery, such as the on-line accomplishment of oil and filter
changes, topping up oil levels, checking oil mist systems, minor
adjustments and cleanings

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PIP REEE002
Benchmarking of Reliability Indicators for Rotating Machinery


4.1.4

March 1998

Work due to a required change in the machine design, sometimes

referred to as design repairs

Availability
Availability is a quantification of reliability in the time domain, provided
that required repairs are accomplished in an expeditious manner.
Machinery is counted as available for operation when:

It is operating

It is considered to be capable of operation

Machinery is counted as unavailable when:

Maintenance-required machinery downtime is incurred while the

operating unit:
a. Remains running or
b. Is forced to shutdown for the machinery maintenance

Required repairs to spare equipment are deferred for business reasons

(the equipment remains unsuitable for normal operation, thus
unavailable, until repaired)

Time counted as unavailable for a machinery train does not include planned
work performed during shutdowns (or turnarounds) when the shutdown is
for reasons unrelated to the machinery train.
4.1.5

Repair Cost per Installed Horsepower per Year

Repair Cost data is typically grouped into equipment classes based on driver
horsepower, (5 HP and less, >5 HP to 50 HP, >50 HP to 200 HP, >200 HP to
1000 HP, and greater than 1000 HP).
Repair Cost per Installed Horsepower should also be sorted by machinery
type as the data and capability become available.

4.1.6

Installed Cost per Horsepower per Machinery Type

Average installed costs should be reported each year by machinery type,
(i.e., ASME centrifugal pumps, API centrifugal pumps, steam turbines, gas
turbines, centrifugal compressors, etc.).
Recognizing that quality of installation has a significant effect on installed
cost and also a major effect on life cycle costs, the machinery should be
installed in accordance with PIP REIE686 for consistency and
comparability.

4.1.7

Material Multiplier
This material multiplier is typically a whole number multiplier used in
project estimation and for comparing options on machinery types.

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Process Industry Practices

PIP REEE002
Benchmarking of Reliability Indicators for Rotating Machinery

March 1998

These must be appropriately reported by machinery type and class (size) for
reasonable comparability.
4.2

Formulae for Reliability Measurement

4.2.1

Mean Time Between Repairs

(Expressed as a fraction or multiple of a year)
Number of Active Machinery Units

MTBR

Number of Machinery Repairs for the Period

Note:
a. MTBR is typically calculated on an annualized basis for individual
machinery units (drivers separate from driven), by type and in
groupings by class, service, process unit, etc., and is typically done
with each year's data providing discrete annual calculations,
resulting in years between repairs.
b. When data or calculations are for complete trains, or other
variations, the reported data should be marked to properly
distinguish it, and then explained in simple terms.
4.2.2

Availability
Availability (%)

4.2.3

Number of Days Machinery Train Available x 100%

Number of Unit Operating Days for the Year

Average Cost per Repair

Average Cost per Repair

4.2.4

Total Repair Costs

Total Number of Repairs

Annual Repair Cost per Installed HP

Annual Repair Cost

Annual Repair Cost per Installed HP

Nameplate Horsepower

4.2.5

Installed Cost per HP per Machinery Type

Installed Cost per HP Machinery Type

4.2.6

Installed Cost
Nameplate Horsepower

Material Multiplier
Material Multiplier

Total Installed Cost

Actual Material Cost

General Note:
1. The above data and the calculated reliability indicators are to be
tabulated and reported by machinery type to maximize
comparability.

Process Industry Practices

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PIP REEE002
Benchmarking of Reliability Indicators for Rotating Machinery

March 1998

2. See Section 5.2, Sorting of Data, for more information.

5.

Reporting of Data
5.1

Submittal Information
PIP member companies (and others) are encouraged to report their machinery
performance data to the PIP Machinery Function Team through the PIP offices in
Austin, Texas. This performance data will be used to establish machinery
performance benchmarks.
Each calendar years data should be reported by March 1 of the following year.
Blind results (no company identification) of the compiled data will be made
available to all PIP member companies (and others who have submitted data) by June
1. This data will not be generally published outside of PIP member companies.
All Machinery Reliability and Performance data must be reported in a consistent
manner for the most benefit.
Mail or FAX data to:
Process Industry Practices
Construction Industry Institute
3208 Red River Street, Suite 300
Austin, Texas 78705
Fax (512) 473-2968

5.2

Sorting of Data
5.2.1

General
Data should be sorted by service, classification, and machinery type where
possible.
Data should be reported using formats similar to those included as part of the
next section and shown in the attachments.
Note: It is expected that the pump data will be the most readily available,
and should be submitted as soon as practical, (see Section 5.1, Submittal
Information) with other equipment data submitted at a later date, as
available. Submit the data that is currently available.

5.2.2

Format for Data Submittal

See Attachments A and B for examples of completed data submittal
forms.
See Attachment C for an example form for data submittal.
The unit type/plant column on the data submittal form is intended as a
generic identification to improve comparability of data, and the general
identifiers are as follows:
1. refinery

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Process Industry Practices

PIP REEE002
Benchmarking of Reliability Indicators for Rotating Machinery

March 1998

2. chemical plant (commodity)

3. power generation
4. specialty chemical(s)
5. off-site
6. other processes
Specific unit types can be given, if so desired, with a short word description
of an end product, such as: Ammonia, Acid, Acrylate, Urea, Polymer,
Benzene, etc.
Example: A designation of 2-Acid, would be a bulk acid plant (such as
Acetic, Sulfuric, Nitric, etc.). Similarly specific plants can be designated
as: 1-Houston, which would be a refinery located in Houston.
The formulas box on the example form, Attachment A, contains a numerical
representation of the definition for the term in that column (indicating the
math operations to be performed to compute the value for that column). This
is shown as a column number divided by another column number to give the
calculated value for the column in which the formula is placed. Columns 9,
10, and 11 are calculated using the data from other columns, and can be
computed by PIP if the data submitted in columns 4 through 8 is complete.
5.2.3

Statement of Confidentiality
The data submitted will be summarized by the PIP office and shared only
with PIP member companies and others who have submitted their data. The
data will be shared only in a blind format, with arbitrary alpha-numeric
designations substituted for the company/plant identification.
Identification of a specific companys data will be considered only on an
individual and year-by-year basis, with the PIP office receiving each request
in writing, and obtaining approval in writing of each request, from that
companys steering team member (for the identification of the companys
numbers for that year for that individual request only).
Requests for data or identification of data from outside PIP will be limited to
those who have submitted their data.

5.3

Summary
The purpose of collecting and disseminating the machinery performance data is to
advance the most efficient machinery maintenance practices, the most effective
machinery designs, and the most economically sound operating philosophies. The
effective use of this data will reduce the life cycle costs of machinery and thereby
improve the viability of the member company facilities.
Comment: The highest quality data will come from situations where those
responsible for reporting the data will derive benefit from the use of these data.
It is also recognized that this practice will have the most immediate impact by its use
where:

Data is available

Process Industry Practices

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PIP REEE002
Benchmarking of Reliability Indicators for Rotating Machinery

Perceived problems are present

Significant improvement potential exists

Machinery problems have a major impact on process

March 1998

It is expected that the category of process pumps will be the first machinery category
that will fit the above criteria.
5.4

Attachments
See following pages for attachments.
Attachment A
Completed Data Form - Example 1
Attachment B
Completed Data Form - Example 2
Attachment C
Example Form for Data Submittal

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Process Industry Practices

PIP REEE002
Benchmarking of Reliability Indicators for Rotating Machinery

March 1998

Attachment A
Completed Data Form - Example 1

PIP BENCHMARKING DATA

FROM XYZ Chemical

COMPANY

Service

Mach.

Class

Essential

Type
Centrifugal Pump (ASME)

Driver
Type

PERIOD MEASURED

01 / 96

--

12 / 96

10

11

12

# of

Availability

# of

Total

Total

MTBR

$/Repair

$/HP/YR.

Unit Type

Items

(Where
Measured)

Repairs

HP (M)

Repair $ (M)

HP
Class

/ Houston
/ PLANT

Elect. Motor /

620

800

15.25

312

48

67

37.50

52

32

58

13.1

102

32

70

13.1

89

29

50

123

18

46

17

4.9

38

Calculated Values

Plant
2 / Houston

<50 HP

Centrifugal Pump (ASME)

Elect. Motor /
>50 HP <100 HP

Centrifugal Pump (API)

Stm. Turb.
>100 <1000 HP

Steam Turbine

------->200 <1000 HP

Vital

Centrifugal Compressor

Elect. Motor /

12

92%

>1000 HP

Centrifugal Pump (API)

Elect. Motor /

14

>200 <1000 HP

Recip Compressor

Gas Engine /

94%

>1000 HP



DATA ACCUMULATED
Machinery Unit Item
Machinery Train



Formulas:
Column 9 = Col. 4Col. 6
Column 10 =Col. 8Col. 6
Column 11 = Col. 8Col. 7

SPECIAL EXPLANATION:

Submitted by: John Doe, XYZ Chemical_

Process Industry Practices

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PIP REEE002
Benchmarking of Reliability Indicators for Rotating Machinery

March 1998

Attachment B
Completed Data Form - Example 2

PIP BENCHMARKING DATA

FROM JKL Refinery

COMPANY

Service

Mach.

Essential

Driver

HP

PERIOD MEASURED
8

10

11

12

# of

Availability

# of

Total

Total

MTBR

$/Repair

$/HP/YR.

Unit Type

Repairs

HP (M)

Repair $ (M)

14

97%

18

27.0

150.0

Steam Turbine

12

98%

11

30.0

200.0

Gas Turbine

96%

15.0

3.0

Cent. Pumps (API)

Elec. Motor

57

98%

53

12.0

30.0

>200 HP <1000 HP

Steam Turbine

15

95%

22

4.2

31.0

Recip. Comps. >1000 HP

Elect. Mtr

10

93%

23

15.0

45.0

Gas Engine

91%

14

8.0

21.0

2000

3000

36.0

100.0

Class

12 / 96

Items

Type

--

Elect. Motor

Type
Cent. Comp. >1000 HP

01 / 96

(Where Measured)

Class
Vital

/ Channel
/ PLANT

Cent. Pumps (ASME)

Elect. Motor

>50 <200 HP

Steam Turbine

20

39

3.7

27.0

P.D.Pumps <50 HP

Elect. Motor

17

23

.3

19.0

Calculated Values

Plant
1 / Channel

Fans

Other

DATA ACCUMULATED
Machinery Unit Item
Machinery Train






Formulas:
Column 9 = Col. 4Col. 6
Column 10 =Col. 8Col. 6
Column 11 = Col. 8Col. 7

SPECIAL EXPLANATION:
Note that data is reported by train rather than unit of item.

Submitted by: John Dokes, JKL Refining__

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Process Industry Practices

PIP REEE002

March 1998

Benchmarking of Reliability Indicators for Rotating Machinery

Attachment C
Example Form for Data Submittal

PIP BENCHMARKING DATA

FROM
COMPANY

Service

Mach.

Class

DATA ACCUMULATED
Machinery Unit Item
Machinery Train




Type

Driver
Type

PERIOD MEASURED

--

PLANT

10

11

12

# of

Availability

# of

Total

Total

MTBR

$/Repair

$/HP/YR.

Unit Type

Items

(Where Measured)

Repairs

HP (M)

Repair $ (M)

HP
Class

/
/

Calculated Values

Plant

SPECIAL EXPLANATION:

Submitted by: _______________________

Process Industry Practices

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