‫غ‬ ‫ل‬‫ا‬ ‫ف‬ ‫ن‬ ‫ل‬‫ا‬ ‫م‬ ‫خ‬ ‫ل‬

‫ر ة ر ة د ات ط و از‬ ‫ي‬ ‫ب‬ ‫ع‬‫ل‬‫ا‬ ‫ك‬ ‫ش‬ ‫ل‬‫ا‬

‫الشركة الع برية لخدمات‬
‫النفط والغاز‬
‫‪LEC02 Pillar 3 - Part 01‬‬
Road to CMRP
LEC02 Pillar 3 - Part 01 ‫الشركة الع برية لخدمات‬
‫النفط والغاز‬
LEC02 Pillar 3 - Part 01
RELIABILITY DEFINITIONS
‫الشركة الع برية لخدمات‬
‫النفط والغاز‬
LEC02 Pillar 3 - Part 01
 ‫الشركة الع برية لخدمات‬
‫النفط والغاز‬
‫‪LEC02 Pillar 3 - Part 01‬‬
Reliability
Reliability is the probability that an item/asset
will perform its intended function for a specific
interval under stated conditions without
failure.

The reliability is (BUILT IN) attribute should be

“designed in” when the asset is conceived,
designed, procured, built, installed ,
commissioned , and ready for operation. ‫الشركة الع برية لخدمات‬
‫النفط والغاز‬
LEC02 Pillar 3 - Part 01
Reliability
Usually assets are designed with a certain level of
reliability. This designed-in ( or built-in) reliability
is the result of individual components’ reliability
and how they are configured. This level of
reliability is called inherent reliability.

We can not change or improve reliability of an

asset after it has been installed without replacing
with better and improved components or ‫الشركة الع برية لخدمات‬
‫النفط والغاز‬
redesigning. LEC02 Pillar 3 - Part 01
Reliability
Reliability is “the probability that an item will
perform its intended function for a specific
interval under stated conditions without failure.”
Reliability key words:
Probability: the likelihood of mission success
Function: light, rotate, cut…
Time: hrs, weeks, RPM…
Conditions: Temperature, pressure… ‫الشركة الع برية لخدمات‬
‫النفط والغاز‬
LEC02 Pillar 3 - Part 01
Reliability
The term reliable assets means that :
The equipment and manufacturing
plant and facilities are:
 available
 as and when needed
 and they will perform their intended function
over a predetermined period without failure
or with minimum failures. ‫الشركة الع برية لخدمات‬
‫النفط والغاز‬
LEC02 Pillar 3 - Part 01
‫?‪WHY RELIABILITY‬‬
‫الشركة الع برية لخدمات‬
‫النفط والغاز‬
‫‪LEC02 Pillar 3 - Part 01‬‬
Importance of Reliability
• Reputation — highly reliable assets are
dependable and, if they fail, they can be fixed
quickly.
• Customer satisfaction — reliable assets
produce quality products and support in meeting
customer’s schedule
• Repeat business — resulting from above factors
‫الشركة الع برية لخدمات‬
• Competitive advantage — reduced cost
• Decreased O&M costs ‫النفط والغاز‬
LEC02 Pillar 3 - Part 01
‫?‪RELIABILITY MATHS‬‬
‫)‪(1 + 1 = 2‬‬ ‫الشركة الع برية لخدمات‬
‫النفط والغاز‬
‫‪LEC02 Pillar 3 - Part 01‬‬
 ‫الشركة الع برية لخدمات‬
‫النفط والغاز‬
‫‪LEC02 Pillar 3 - Part 01‬‬
Reliability
Reliability, It is usually expressed as a percentage and
measured by the mean time between failures (MTBF).
−𝒕
𝑹 𝒕 = 𝒆𝑴𝑻𝑩𝑭
MTBF, This is a basic measure of asset reliability. It is
calculated by dividing total operating time of the asset
by the number of failures over some period of time.
𝒕𝒐𝒕𝒂𝒍 𝒐𝒑𝒆𝒓𝒂𝒕𝒊𝒏𝒈 𝒕𝒊𝒎𝒆
𝑴𝑻𝑩𝑭 =
𝒏𝒖𝒎𝒃𝒆𝒓 𝒐𝒇 𝒇𝒂𝒊𝒍𝒖𝒓𝒆𝒔 ‫الشركة الع برية لخدمات‬
‫النفط والغاز‬
LEC02 Pillar 3 - Part 01
Reliability
MTBF is the inverse of failure Rate (FR).
𝟏
𝑭𝑹 = 𝝀 =
𝑴𝑻𝑩𝑭
then;
𝑹 𝒕 = 𝒆−𝒕𝝀

‫الشركة الع برية لخدمات‬

‫النفط والغاز‬
LEC02 Pillar 3 - Part 01
Reliability
Assets Reliability

Reliability expressed by:

REPAIRABLE (MTBF)
Reliability expressed by:
NON REPAIRABLE (MTTF)

‫الشركة الع برية لخدمات‬

‫النفط والغاز‬
LEC02 Pillar 3 - Part 01
Reliability
Example:
Suppose an asset was in operation for 2000 hours (or
for 12 months) and during this period there were 10
failures.
Calculate: MTBF, FR and Reliability if it is required to
operate for 20 hours or for 100hours?

‫الشركة الع برية لخدمات‬

‫النفط والغاز‬
LEC02 Pillar 3 - Part 01
Reliability
Example:
Solution
𝒕𝒐𝒕𝒂𝒍 𝒐𝒑𝒆𝒓𝒂𝒕𝒊𝒏𝒈 𝒕𝒊𝒎𝒆 𝟐𝟎𝟎𝟎𝒉𝒓𝒔
𝑴𝑻𝑩𝑭 = =
𝒏𝒖𝒎𝒃𝒆𝒓 𝒐𝒇 𝒇𝒂𝒊𝒍𝒖𝒓𝒆𝒔 𝟏𝟎
= 𝟐𝟎𝟎 𝒉𝒐𝒖𝒓𝒔/𝑭𝒂𝒊𝒍𝒖𝒓𝒆
Or
𝒕𝒐𝒕𝒂𝒍 𝒐𝒑𝒆𝒓𝒂𝒕𝒊𝒏𝒈 𝒕𝒊𝒎𝒆 𝟏𝟐 𝒎𝒐𝒏𝒕𝒉𝒔
𝑴𝑻𝑩𝑭 = =
𝒏𝒖𝒎𝒃𝒆𝒓 𝒐𝒇 𝒇𝒂𝒊𝒍𝒖𝒓𝒆𝒔 𝟏𝟎
= 𝟏. 𝟐 𝒎𝒐𝒏𝒕𝒉𝒔/𝑭𝒂𝒊𝒍𝒖𝒓𝒆 ‫الشركة الع برية لخدمات‬
‫النفط والغاز‬
LEC02 Pillar 3 - Part 01
Reliability
Example:
Solution
𝟏 𝟏
𝑭𝑹 = 𝝀 = = = 𝟎. 𝟎𝟎𝟓 𝑭𝒂𝒊𝒍𝒖𝒓𝒆𝒔/𝒉𝒓
𝑴𝑻𝑩𝑭 𝟐𝟎
Or
𝟏 𝟏
𝑭𝑹 = 𝝀 = = = 𝟎. 𝟖𝟑 𝑭𝒂𝒊𝒍𝒖𝒓𝒆𝒔/𝒎𝒐𝒏𝒕𝒉
𝑴𝑻𝑩𝑭 𝟐𝟎

‫الشركة الع برية لخدمات‬

‫النفط والغاز‬
LEC02 Pillar 3 - Part 01
Reliability
Example:
Solution
−𝒕 −𝒕
𝑹 𝒕 =𝒆𝑴𝑻𝑩𝑭 =𝒆𝟐𝟎𝟎
Operation for 20 hours:
𝑹 𝒕 = 𝟗𝟎. 𝟒𝟖%
Operation for 100 hours:
𝑹 𝒕 = 𝟔𝟎. 𝟔𝟓%
‫الشركة الع برية لخدمات‬
‫النفط والغاز‬
LEC02 Pillar 3 - Part 01
‫‪MAINTAINABILITY‬‬
‫الشركة الع برية لخدمات‬
‫النفط والغاز‬
‫‪LEC02 Pillar 3 - Part 01‬‬
Maintainability
Maintainability is the measure of an item’s or asset’s
ability to be retained in or restored to a specified
condition.
- Is another design attribute that goes hand in hand
with reliability.
- The objective of maintainability is to ensure
maintenance tasks can be performed easily and
effectively.
‫الشركة الع برية لخدمات‬
Basically, it is ease of maintenance ‫النفط والغاز‬
LEC02 Pillar 3 - Part 01
MAINTAINABILITY MATHS?
(1 + 1 = 2) ‫الشركة الع برية لخدمات‬
‫النفط والغاز‬
LEC02 Pillar 3 - Part 01
Reliability
Mean Time To Repair
(MTTR):
MTTR is the average time
needed to restore an asset
to its full operational
capabilities after a failure.
MTTR is a measure of 𝒕𝒐𝒕𝒂𝒍 𝒎𝒂𝒊𝒏𝒕𝒂𝒊𝒏𝒂𝒏𝒄𝒆 𝒕𝒊𝒎𝒆
asset maintainability. 𝑴𝑻𝑻𝑹 =
𝒏𝒖𝒎𝒃𝒆𝒓 𝒐𝒇 𝒇𝒂𝒊𝒍𝒖𝒓𝒆𝒔
‫الشركة الع برية لخدمات‬
‫النفط والغاز‬
LEC02 Pillar 3 - Part 01
‫‪MTBF VS. MTTR‬‬
‫الشركة الع برية لخدمات‬
‫النفط والغاز‬
‫‪LEC02 Pillar 3 - Part 01‬‬
 ‫الشركة الع برية لخدمات‬
‫النفط والغاز‬
‫‪LEC02 Pillar 3 - Part 01‬‬
RELIABILITY AND MAINTAINABILITY
‫الشركة الع برية لخدمات‬
‫النفط والغاز‬
LEC02 Pillar 3 - Part 01
Reliability and Maintainability

‫الشركة الع برية لخدمات‬

‫النفط والغاز‬
LEC02 Pillar 3 - Part 01
Reliability and Maintainability

‫الشركة الع برية لخدمات‬

‫النفط والغاز‬
LEC02 Pillar 3 - Part 01
Is this good or bad case ?

‫الشركة الع برية لخدمات‬

‫النفط والغاز‬
LEC02 Pillar 3 - Part 01
Is this good or bad case ?

‫الشركة الع برية لخدمات‬

‫النفط والغاز‬
LEC02 Pillar 3 - Part 01
Is this good or bad case ?

‫الشركة الع برية لخدمات‬

‫النفط والغاز‬
LEC02 Pillar 3 - Part 01
‫‪AVAILABILITY‬‬
‫الشركة الع برية لخدمات‬
‫النفط والغاز‬
‫‪LEC02 Pillar 3 - Part 01‬‬
Availability
The probability that an asset is capable of performing its
intended function satisfactorily, when needed, in a stated
environment.

AVAILABILITY is a function of RELIABILITY and MAINTAINABILITY.

𝑈𝑝 𝑡𝑖𝑚𝑒 𝑀𝑇𝐵𝐹
𝐴𝑣𝑎𝑖𝑙𝑎𝑏𝑖𝑙𝑖𝑡𝑦 = =
𝑈𝑝 𝑡𝑖𝑚𝑒+𝐷𝑜𝑤𝑛 𝑡𝑖𝑚𝑒 𝑀𝑇𝐵𝐹+𝑀𝑇𝑇𝑅
also Known as, Inherent Availability (Ai)
‫الشركة الع برية لخدمات‬
‫النفط والغاز‬
LEC02 Pillar 3 - Part 01
Availability
Example:
A plant’s air compressor system operated for 1000 hours last year.
The plant’s CMMS system provided the following data on this
system:
• Operating time = 1000 hours
• Number of failures, random = 10
• Total hours of repair time = 50 hours
Calculate: MTBF, FR , MTTR , RR , Availability and Reliability if we ‫الشركة الع برية لخدمات‬
have to operate this unit for 10, 20, or 100 hours? ‫النفط والغاز‬
LEC02 Pillar 3 - Part 01
Availability
Example:
Solution
𝒕𝒐𝒕𝒂𝒍 𝒐𝒑𝒆𝒓𝒂𝒕𝒊𝒏𝒈 𝒕𝒊𝒎𝒆 𝟏𝟎𝟎𝟎𝒉𝒓𝒔
𝑴𝑻𝑩𝑭 = = = 𝟏𝟎𝟎 𝒉𝒐𝒖𝒓𝒔 / 𝑭𝒂𝒊𝒍𝒖𝒓𝒆
𝒏𝒖𝒎𝒃𝒆𝒓 𝒐𝒇 𝒇𝒂𝒊𝒍𝒖𝒓𝒆𝒔 𝟏𝟎
and
𝟏 𝟏
𝑭𝑹 = 𝝀 = = = 𝟎. 𝟎𝟏 𝑭𝒂𝒊𝒍𝒖𝒓𝒆𝒔 / 𝒉𝒐𝒖𝒓
𝑴𝑻𝑩𝑭 𝟏𝟎𝟎
‫الشركة الع برية لخدمات‬
‫النفط والغاز‬
LEC02 Pillar 3 - Part 01
Availability
Example:
Solution
𝒕𝒐𝒕𝒂𝒍 𝒎𝒂𝒊𝒏𝒕𝒂𝒊𝒏𝒂𝒏𝒄𝒆 𝒕𝒊𝒎𝒆 𝟓𝟎𝒉𝒓𝒔
𝑴𝑻𝑻𝑹 = = = 𝟓 𝒉𝒐𝒖𝒓𝒔 / 𝑭𝒂𝒊𝒍𝒖𝒓𝒆
𝒏𝒖𝒎𝒃𝒆𝒓 𝒐𝒇 𝒇𝒂𝒊𝒍𝒖𝒓𝒆𝒔 𝟏𝟎
and
𝟏 𝟏
𝑹𝑹 = 𝝁 = = = 𝟎. 𝟐 𝒓𝒆𝒑𝒂𝒊𝒓𝒔 / 𝒉𝒐𝒖𝒓
𝑴𝑻𝑻𝑹 𝟓
‫الشركة الع برية لخدمات‬
‫النفط والغاز‬
LEC02 Pillar 3 - Part 01
Availability
Example:
Solution
𝑼𝒑 𝒕𝒊𝒎𝒆 𝟏𝟎𝟎𝟎
𝑨𝒗𝒂𝒊𝒍𝒂𝒃𝒊𝒍𝒊𝒕𝒚 = = = 𝟗𝟓. 𝟐𝟑%
𝑼𝒑 𝒕𝒊𝒎𝒆 + 𝑫𝒐𝒘𝒏 𝒕𝒊𝒎𝒆 𝟏𝟎𝟎𝟎 + 𝟓𝟎

‫الشركة الع برية لخدمات‬

‫النفط والغاز‬
LEC02 Pillar 3 - Part 01
Availability
Example:
Solution
−𝒕 −𝒕
𝑹 𝒕 = 𝒆𝑴𝑻𝑩𝑭 = 𝒆𝟏𝟎𝟎
Operation for 10 hours:
𝑹 𝒕 = 𝟗𝟎. 𝟒𝟖%
Operation for 20 hours:
𝑹 𝒕 = 𝟖𝟏. 𝟖𝟕%
‫الشركة الع برية لخدمات‬
Operation for 100 hours:
𝑹 𝒕 = 𝟑𝟔. 𝟕𝟗% ‫النفط والغاز‬
LEC02 Pillar 3 - Part 01
 ‫الشركة الع برية لخدمات‬
‫النفط والغاز‬
‫‪LEC02 Pillar 3 - Part 01‬‬
Reliability
Equipment Not Meeting Performance Expectations May
Be Analyzed Using A Variety Of Methods:
Main
Methods

Root Cause Weibull Analysis

Analysis (Reliability
(RCA) Analysis). ‫الشركة الع برية لخدمات‬
‫النفط والغاز‬
LEC02 Pillar 3 - Part 01
ROOT CAUSE ANALYSIS
(RCA) ‫الشركة الع برية لخدمات‬
‫النفط والغاز‬
LEC02 Pillar 3 - Part 01
Root Cause Analysis

‫الشركة الع برية لخدمات‬

‫النفط والغاز‬
LEC02 Pillar 3 - Part 01
Root Cause Analysis

‫الشركة الع برية لخدمات‬

‫النفط والغاز‬
LEC02 Pillar 3 - Part 01
Root Cause Analysis

‫الشركة الع برية لخدمات‬

‫النفط والغاز‬
LEC02 Pillar 3 - Part 01
Root Cause Analysis

‫الشركة الع برية لخدمات‬

‫النفط والغاز‬
LEC02 Pillar 3 - Part 01
Root Cause Analysis

‫الشركة الع برية لخدمات‬

‫النفط والغاز‬
LEC02 Pillar 3 - Part 01
Root Cause Analysis

‫الشركة الع برية لخدمات‬

‫النفط والغاز‬
LEC02 Pillar 3 - Part 01
Root Cause Analysis

‫الشركة الع برية لخدمات‬

‫النفط والغاز‬
LEC02 Pillar 3 - Part 01
Root Cause Analysis

‫الشركة الع برية لخدمات‬

‫النفط والغاز‬
LEC02 Pillar 3 - Part 01
Root Cause Analysis

‫الشركة الع برية لخدمات‬

‫النفط والغاز‬
LEC02 Pillar 3 - Part 01
Root Cause Analysis

‫الشركة الع برية لخدمات‬

‫النفط والغاز‬
LEC02 Pillar 3 - Part 01
Root Cause Analysis

‫الشركة الع برية لخدمات‬

‫النفط والغاز‬
LEC02 Pillar 3 - Part 01
Root Cause Analysis
Additional Step:

‫الشركة الع برية لخدمات‬

‫النفط والغاز‬
LEC02 Pillar 3 - Part 01
Root Cause Analysis Brainstorming

Failure Mode and

Effect Analysis

Pareto Analysis (Vital

Few, Trivial Many)

RCA TOOLS
The “5 Whys”

Fishbone (Ishikawa)
Diagram

Flow Charts / Process

Mapping

Tree Diagram
‫الشركة الع برية لخدمات‬
BOWTIE analysis ‫النفط والغاز‬
LEC02 Pillar 3 - Part 01
Root Cause Analysis

‫الشركة الع برية لخدمات‬

‫النفط والغاز‬
LEC02 Pillar 3 - Part 01
Root Cause Analysis

‫الشركة الع برية لخدمات‬

‫النفط والغاز‬
LEC02 Pillar 3 - Part 01
Root Cause Analysis

‫الشركة الع برية لخدمات‬

‫النفط والغاز‬
LEC02 Pillar 3 - Part 01
Root Cause Analysis

‫الشركة الع برية لخدمات‬

‫النفط والغاز‬
LEC02 Pillar 3 - Part 01
Root Cause Analysis

‫الشركة الع برية لخدمات‬

‫النفط والغاز‬
LEC02 Pillar 3 - Part 01
Root Cause Analysis

‫الشركة الع برية لخدمات‬

‫النفط والغاز‬
LEC02 Pillar 3 - Part 01
Root Cause Analysis

‫الشركة الع برية لخدمات‬

‫النفط والغاز‬
LEC02 Pillar 3 - Part 01
Root Cause Analysis

‫الشركة الع برية لخدمات‬

‫النفط والغاز‬
LEC02 Pillar 3 - Part 01
Root Cause Analysis

‫الشركة الع برية لخدمات‬

‫النفط والغاز‬
LEC02 Pillar 3 - Part 01
 ‫الشركة الع برية لخدمات‬
‫النفط والغاز‬
‫‪LEC02 Pillar 3 - Part 01‬‬