Asset Reliability Management

YOUR CHALLENGE

Maximizing uptime, reducing unplanned failures and managing compliance are critical priorities for site management. However, these operational goals are often difficult to meet because of a lack of communication and coordination across teams, which leads to inefficient utilization of resources, redundant or ineffective activities, unclear work priorities, unleveraged data, unmaintained systems and ineffective processes. This, too often, leads to extended downtime, high costs, non-compliance and low profitability.

Case Study

Read our case study to discover how PinnacleART’s reliability services helped a client achieve approximately $12 million USD in increased annual profitability.

OUR SOLUTION

PinnacleART offers best-in-class asset reliability management programs that can be implemented in the early design phase of your facility, or as part of an improvement plan to existing assets. Our strategies contain proactive tasks focused on sustaining the desired functionality of your systems and equipment.

During the early design phase of construction, we use Reliability Centered Design (RCD) to build asset management principles into the initial design of the plant. We do this by identifying reliability and maintainability deficiencies and providing risk-justified redesign recommendations, or key equipment specifications, including capital sparing.

For existing facilities, PinnacleART implements Reliability Centered Maintenance (RCM) to assess and quantify opportunities, implement step-change processes and deliver turnkey, sustainable systems within the plant. In addition, we can fully develop and implement the necessary changes in your facility’s CMMS or EAM field data collection and other systems. We ensure a solid process is in place by providing procedures, as well as personnel training. These improvements are designed to span the functional organization, so asset reliability processes are effective and efficient.

Maintenance and Reliability Practices Assessments

PinnacleART’s Maintenance and Reliability (M&R) Practices Assessment tool manages all aspects of M&R assessments and assessment results. The tool is populated with a full suite of M&R program elements that are linked with best practice topics and levels of performance for assessment scoring.

Typical elements that are reviewed include leadership, planning and scheduling, equipment reliability, technology utilization, key performance indicators, CMMS, continuous improvement, knowledge and document management, materials management and project management (shutdown, turnaround, capital projects). Each of these elements can be customized as needed to align with a client’s own internal best practices.

A gap assessment is performed to measure the gaps between actual performance and target performance. Improvement opportunities can then be identified, including action items, responsible individuals, resource requirements, return-on-investment and implementation time.

Maintenance and Repair Procedures

PinnacleART provides detailed repair procedures (i.e. corrective maintenance activities) for critical equipment or complex repairs. These repair procedures are set up like preventative maintenance plans within the CMMS, but are not assigned a frequency. Repairs are pre-planned with steps, access, materials, special tools needs and man-hour estimates. Planning these repair procedures in advance can streamline repairs after failures occur by eliminating the need to search for equipment maintenance manuals to locate details about the equipment or repair required. At the same time, this approach improves work quality by using pre-developed procedures that have been validated by subject matter experts. Based on equipment risk, criticality and work complexity, PinnacleART can provide guidance on which equipment repairs should have a corresponding repair procedure.

Operator Rounds

PinnacleART can define routine operator surveillance duties to be performed by outside operations personnel. These tasks typically include daily surveillance activities (e.g. check for leaks, verify acceptable oil level), documentation of local gauge readings for trending, routine swapping of spare pumps, and other tasks that are not managed by the Computerized Maintenance Management Systems (CMMS). These rounds can be documented on paper round sheets or handheld data collection computers. Some computerized systems can allow for the collection of predictive maintenance task results, such as vibration and infrared temperature readings. These tasks are typically defined during the Reliability Centered Maintenance study, and provide the primary basis for an effective Operator Driven Reliability (ODR) program.

Reliability, Availability, Maintainability (RAM) Simulation

RAM Modeling is a component of PinnacleART’s Reliability Centered Maintenance-based asset management service that is used to simulate all of the probable future performance metrics of a given process design. The output is used to quantify the economics or other performance criteria of equipment-related decisions such as redundancy, spare parts, equipment sizing, maintenance practices and policies, quality of components, etc. For new designs, RAM is a powerful tool for evaluating design decisions affecting such things as:

  • Probability of unplanned events and impacts on life cycle performance
  • Buffer sizing and location
  • Unit/equipment redundancy and sizing
  • Process technology
  • Utility requirements
  • Capital or insurance spares requirements for major equipment

Throughout the life cycle of existing processes and units, RAM can be a vital tool for assisting in decisions such as:

  • Maintenance philosophy, scope and timing
  • Obsolescence and end of useful life (repair or replace/upgrade)
  • Impact of actual failures on risk exposure and priorities of repairs
  • Impact of design or process changes to maintenance, operations and control strategies
  • Spare parts stocking strategy optimization based on actual parts usage and criticality

Reliability Centered Design (RCD) Analysis

PinnacleART recognizes the importance of considering reliability, maintainability and operations and maintenance costs early in the design phase of a greenfield project or facility. Our team employs a Reliability Centered Design (RCD) analysis to build reliability asset management principles into greenfield facilities before construction begins, thus reducing maintenance, repair and staff requirements, without sacrificing the facility’s operational goals.

The RCD process includes a complete review of the design from the perspective of key O&M staff, management and process experts prior to finalizing the design. Design deficiencies that affect system reliability and availability are identified and risk-justified redesign recommendations are provided to the project team for review and possible incorporation into the project design. The RCD process also provides the identification of equipment configuration best practice opportunities and critical/capital spare parts identification. RCD then forms the foundation of a reliability-based asset management program for the facility through expansion into full Reliability Centered Maintenance for the final design.

Reliability Centered Maintenance

Reliability Centered Maintenance (RCM) delivers a set of reliability-based, proactive tasks focused on sustaining the desired functionality of systems and equipment. The PinnacleART approach to RCM enables significant resource savings compared to the original RCM process (MSG-1) and the “classic RCM” process developed for the power and process industries.

Our results, in comparison to those from other approaches, require less investment from the client (i.e. less time for client personnel involvement and less overall cost to complete the analysis), while maintaining appropriate technical rigor. The effectiveness of our results equal, and in many cases exceed, that of other more resource-intensive processes.

The RCM process directly facilitates scheduling and planning tasks so that a clear, concise priority can be assigned to proactive maintenance and corrective tasks. It also identifies cost benefits for allowing low-risk equipment to “run-to-failure” due to the low economic, safety and/ or environmental impact. This process yields a maintenance program with the lowest base (proactive and reactive) cost.

Our RCM process involves key client personnel who have a history with the systems and equipment under analysis. We assist clients in the implementation of their proactive maintenance program by comparing the RCM-recommended tasks with existing proactive maintenance tasks, then making the necessary changes in the client CMMS, EAM and field data collection systems. In addition, PinnacleART™’s experts provide hands-on training to end users to make sure the RCM skill set is embedded in the client’s processes and systems.

During the RCM process, PinnacleART’s team employs our proprietary software, ReliaBuilder© to provide clients with a fully documented plan and a fully sustainable, evergreen program.

Reliability Management Data Development and Cleansing

PinnacleART develops reliability-based asset management programs that are tailored to our clients’ processes, procedures and tools. For these programs to be effective, key plant data needs to be available and up-to-date. PinnacleART works with clients to define the specific process and asset-type data required to be maintained. These requirements are compared to existing data to identify gaps.

PinnacleART then provides skilled data mining and cleansing of this key data, and organizes it into integrated asset management tools and repositories. This effort can include system and equipment walkdowns, Process Flow Diagram (PFD) / Piping and Instrumentation Diagram (P&ID) red-lining, and development of custom drawings and figures necessary for a comprehensive and effective program.

Safety Analysis

PinnacleART conducts Process Hazards Analyses (PHA) on the process design, including HazOp, Layer of Protection Analysis (LOPA) and “What- If” studies. PHAs can identify independent protection layers and assurance tasks needed for risk reduction. The analysis also provides a complete safety case for the project. As required, these analyses are in compliance with PSM, RMP, CalARP and ISO regulations. In addition, PinnacleART can combine RCM and safety analyses to reduce time commitments from project team personnel.

Spare Parts Optimization

PinnacleART’s team of engineers and technicians offer detailed spare parts development and optimization support, such as developing a risk-based spare parts strategy, identifying potential spare parts and Equipment Parts Lists (EPLs), making risk-based recommendations for spare parts to be stocked, associating parts for proactive and corrective maintenance tasks, and incorporating the spare parts information into the CMMS or other material management systems. We work with clients to define a spare parts strategy, which can be based on equipment criticality and/or the risk associated with the availability of individual parts or kits. PinnacleART can review existing inventory to verify item counts and analyze usage history and risks to set appropriate minimum stocking levels and reorder points.

For new projects, PinnacleART collects spare part information from vendor data provided to the project. Our team completes a risk-based demand model based on the dominant failure modes identified during the Reliability Centered Maintenance analysis. The demand model identifies equipment and spare parts that can be justified by economic (quantitative) reasons, or by safety, environmental or other qualitative reasons. This risk-based approach allows the client to make informed decisions concerning adjustments to vendor recommended spare parts.

PinnacleART can also include existing inventory in the analysis to identify parts that are already stocked and prevent possible duplications. In addition to identifying which parts should be stocked, PinnacleART defines a minimum stocking quantity for each part that should be maintained to achieve a risk-driven minimum confidence level that the part will be available when needed by the client.

Standard Operating Procedures (SOP)

PinnacleART can produce standard operating procedures for facility systems and equipment. These procedures include initial and normal start-up, normal and emergency shutdown, equipment isolation and return to service, and emergency management procedures, to name a few. PinnacleART follows client and regulatory formatting requirements as applicable. Results of safety analyses and other processes, which rely on the assurance of operating within safe limits, are employed to provide cautions and warnings within the SOPs and associated training materials.