Rethinking Instrumentation. Rethinking ... INSTRUMENTS MAINTENANCE
CHALLANGES. • Number of field ... Stroking control valves and EIVs. ❑ Blow-
down/ ...
WISC 2008
Rethinking Instrumentation Maintenance Fawaz A. AlAl-Sahan Instrument Engineer g Saudi Aramco / Riyadh Refinery
OUTLINE •
Instruments Maintenance Challenges g
•
Effective Routine Maintenance
•
Eff ti P Effective Preventive ti Maintenance M i t
•
Key Performance Indicators
•
Human Errors in Instrumentation
•
Conclusion
OUTLINE •
Instruments Maintenance Challenges g
•
Effective Routine Maintenance
•
Eff ti P Effective Preventive ti Maintenance M i t
•
Key Performance Indicators
•
Human Errors in Instrumentation
•
Conclusion
INSTRUMENTS MAINTENANCE CHALLANGES
• Number of field Instruments is increasing g ¾ Reactive Maintenance ¾ Preventive Maintenance • Human errors
OUTLINE •
Instruments Maintenance Challenges g
•
Effective Reactive Maintenance
•
Eff ti P Effective Preventive ti Maintenance M i t
•
Key Performance Indicators
•
Human Errors in Instrumentation
•
Conclusion
Effective Reactive Maintenance
9 Understanding the unpleasant consequences 9 Part Failure analysis. 9 Manufacturer should be consulted for technical support. pp 9 9 9 9
Manufacturer Website Maintenance / instruction manuals. Manufacturer technical support 24h Hot Line Local vendor support team
Effective Reactive Maintenance
9 In-kind replacement is not always the best option. 9 Adopt innovative (simplicity, reliability) technologies 9 Adopt p universal instruments
9 Tube-Less instruments: 9
Flow : direct Fl di t mounting ti orifice ifi meter, t ultrasonic
9
Pressure : direct mounting mounting, remote sensor, remote seal
9
Level : single-rod GWR
9 Automatic Testing of emergency isolation valves
9 Linkage-free smart positioners
SMAR EMERSON
OUTLINE •
Instruments Maintenance Challenges g
•
Effective Routine Maintenance
•
Eff ti P Effective Preventive ti Maintenance M i t
•
Key Performance Indicators
•
Human Errors in Instrumentation
•
Conclusion
Effective Preventive Maintenance
9 Focus on safety instruments (PZV, ESD, F&G, EIV)
Effective Preventive Maintenance Cont. 9Minor PM (by operation) . E Example: l Stroking control valves and EIVs Blow Blow-down/ down/ draining displacers , pressure & level local gauges
9Utilize condition monitoring systems (AMS, PRM) 9Utilize DCS and smart sensors : Bad PV to alarm Discrepancy Di alarm l b between t DCS and d ESD transmitters
OUTLINE •
Instruments Maintenance Challenges g
•
Effective Routine Maintenance
•
Eff ti P Effective Preventive ti Maintenance M i t
•
Key Performance Indicators
•
Human Errors in Instrumentation
•
Conclusion
Instrumentation KPIs ¾ ESD on bypass ¾ Control C l loops l on Manual M l ¾ Number of modes change ¾ Number of SP (set point) crossing ¾ Number of SP changes ¾ Oscillation ¾ Number of times crossing the thresholds (min & max)
every Day / Shift
Instrumentation KPIs ¾ Bad actors (repeated failures) ¾ Number N b off repairs i with i h no problems bl ¾ Cost per repair ¾ Number of instruments with PM ¾ PM cost / maintenance cost ¾ Instruments maintenance / total plant maintenance ¾ PM compliance (over due, missing critical loops) ¾ Best practices ( Engineering , Maintenance)
every Month M th
OUTLINE •
Instruments Maintenance Challenges g
•
Effective Routine Maintenance
•
Eff ti P Effective Preventive ti Maintenance M i t
•
Key Performance Indicators
•
Human Errors in Instrumentation
•
Conclusion
Human Errors In Instrumentation
Battelle Memorial Institute on 136 refinery incidents found : 47% incidents are due to Human Errors
Human Errors In Instrumentation
Improper Design 85%
Operation & Maintenance 15%
Causes of Human Errors , H&SE (UK) study
Mitigation of Human Errors 9
Designing for human errors-proofing.
9 Knowledge sharing (reliability tips) 9 Effective maintenance procedures. 9 Availability and accessibility of documentation
Mitigation of Human Errors
9
Conduct task analysis on critical tasks
9
Build a learning work culture (errors are lessons / educate on human errors)
9
Class-room training is only one step in the learning process.
CONCLUSION
¾ “Rethinking Instrumentation Maintenance” focus on: u u u u
Design & Selection of instruments Effective reactive & preventive Maintenance Human errors mitigation KPIs.
¾ Designing for reliability and human error-free is the major j step p in improving p g instruments reliability y and mitigating failures.
¾ Adopting p g “Rethinking g Instrumentation Maintenance " approach will result in enhancing instrumentation reliability in the plant.
