Dear Colleagues, I am currently employed in the oil and gas industry and our company has established a goal for Product Availability (Processing ability) for its stakeholders. This goal is derived from achieving a Plant operational Reliability of 99.1% and Availability of 94%, taking into account past experiences of failures and inspection interventions. It is crucial that we meet this target. Upon further analysis, this operational target is dependent on the reliability and availability of various sub-units, all the way down to the individual components within those sub-units. The management has set these targets based on demand and supply, but factors such as machine aging, life cycle, repetitive inspection interventions (specifically for gas turbines), and degradation of other components may pose challenges in achieving the target. We aim to establish a benchmark for the expected reliability of the turbines, based on past and present system and component reliability data. This will allow us to determine if the Plant reliability and availability targets are reasonable. I am seeking best practices and benchmarking procedures within the industry for units such as turbines, pumps, and compressors, categorized by power output (1 MW, 5 MW, 10 MW). Your suggestions and insights on this matter are greatly appreciated. Thank you for your time.
In order to achieve optimal results, aiming for 100% availability and reliability should be your target. Your current numbers of 99.1% and 94% seem inadequate to me. To reach these goals, it is crucial to have highly skilled personnel who are trained in top-notch maintenance techniques and procedures. Without this key element, your Predictive Maintenance (PdM) program will not be successful. Starting with a strong lubrication program is essential, then moving on to training and implementing PdM technologies. It is important for your supervisors to understand that without the proper resources, their demands cannot be met. This is just my perspective on the matter.
In the realm of mathematics and practicality, achieving 100% reliability is nearly impossible outside of the initial installation of a new or fully reconditioned item. Over time, all items experience a decline in reliability which can be partially regained through regular maintenance. While availability can come close to 100%, the costs associated with improving it by just a few percentage points can be significant and tend to increase exponentially. Therefore, it is more feasible to set realistic expectations at a slightly lower level. This is why Jap's inquiry is valid and worth considering in terms of economics and practicality.
The oil and gas industry's operational availability exceeds 98%, making it a highly reliable sector.
Achieving 100% plant reliability and availability is achievable with the right equipment redundancy and maintenance practices. Mr. Vee emphasized the importance of having all equipment in top condition to meet reliability targets. In oil and gas processing plants, redundancy is essential for most equipment, although major components like the Main compressor may not have redundancy due to cost and reliability concerns. Despite regular maintenance, achieving 100% reliability has been a challenge, prompting a search for practical average reliability and availability factors based on industry best practices. Seeking guidance on setting up these standards and accessing relevant articles, Mr. Aromatics Thailand requested input from Mr. Vee. It's understood that equipment reliability benchmarks may vary depending on factors like expected lifetimes, operational considerations, and scheduled shutdowns.
When starting a new project, it is crucial to first assess the design specifications to determine the expected reliability and availability of the plant. It is important to note that we should not go beyond the design levels unless we can modify the initial design assumptions. To enhance reliability, a key strategy is to systematically address and eliminate failures. A great starting point is to ensure that all equipment is properly maintained by keeping it clean, dry, and well lubricated, as moisture in oil can lead to unnecessary breakdowns. Additionally, regular checks on the tightness of bolts and the alignment and balancing of rotating machinery are essential steps that can lead to significant improvements. Operational strategies such as duty/standby protocols, smooth loading processes, and consistent operating conditions all play a role in enhancing reliability. By following the vendor's recommended procedures for startup, operation, and shutdown, and refining maintenance programs through techniques like RCM, RBI, and IPF, you can further mitigate risks of failure. Availability is closely tied to the duration and frequency of shutdowns. Effective planning, scheduling, and preparation for maintenance work can help minimize downtime. While it may be frustrating to deal with limitations on installed spare parts, focusing on improving spare availability and logistics support can help reduce overall downtime. Benchmarking can be useful in identifying areas for improvement and best practices. However, the primary focus should be on achieving high system effectiveness, which is a more holistic measure than simple availability. It may take time and effort to reach this level of performance, but the payoff in terms of efficiency and reduced downtime will be significant.
One strategy that has worked well for our company is implementing real-time monitoring of parts and systems. By capturing and analyzing data in real-time, we're able to detect minor changes or faults that could potentially evolve into larger system failures. Monitoring systems like these can help you understand the operational efficiency of your various components on a granular level and identify abnormal patterns that may indicate degradation or impending failure. Along with this, don't forget to consider the impact of environmental factors on your machinery. Undoubtly, Oil and Gas industry units operate in diverse and often harsh conditions which can influence the performance and lifespan of your machines. Utilizing both component-specific data and ambient environmental data can provide a comprehensive overview and help predict potential failures, allowing for proactive maintenance interventions.
You've come to the right place for seeking advice, and it's good to see you're tackling this head-on. One effective method to benchmark reliability is through Reliability-Centered Maintenance (RCM). It's a systematic approach developed in the aviation industry that's been applied to oil and gas as well. Essentially, it involves identifying the functions of your system, potential functional failures, and the necessary maintenance regimes. Another tool that could be used is Overall Equipment Effectiveness (OEE). It's a comprehensive metric that takes into account availability, performance and quality. This is easily applicable to individual components and entire systems. Finally, you mentioned the aging of machines. I strongly recommend regularly auditing and updating your maintenance schedules accordingly. The older equipment gets, the more attention it'll need. I hope that helps and best of luck in achieving your operational targets!
In my experience, it's crucial to partner with experts who specialize in predictive maintenance when dealing with equipment like turbines, pumps, and compressors in a high-demand environment such as yours. Advanced predictive analysis software can provide a data-driven, quantifiable idea of how potential plant malfunctions may affect overall system reliability, helping you achieve the goal of 99.1% reliability and 94% availability. This predictive approach can account for factors such as machine aging, degradation, and life cycle. In terms of benchmarks, you might want to look at published OEE (Overall Equipment Effectiveness) standards for equipment in your category. However, keep in mind that each plant's circumstance is unique and these standards should only serve as a guide. I would also recommend involvement in industry groups, as many share statistics and best practices privately amongst members.
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Answer: - The key performance targets typically include achieving a Plant operational Reliability of 99.1% and Availability of 94%, which are crucial for meeting stakeholders' expectations.
Answer: - Factors such as machine aging, life cycle, repetitive inspection interventions (especially for gas turbines), and degradation of components can impact the reliability and availability of rotating machinery.
Answer: - Benchmarking based on past and present system and component reliability data can help establish benchmarks for the expected reliability of turbines and other units, enabling companies to assess if their reliability and availability targets are reasonable and achievable.
Answer: - Industry best practices and benchmarking procedures can guide companies in setting reliability and availability targets for turbines, pumps, and compressors of varying power outputs like 1 MW, 5 MW, and 10 MW, ensuring alignment with demand and supply considerations.
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