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Curso Intro To Reliability Analysis - 0305

This document provides an introduction to reliability analysis and defines key concepts. It discusses the importance of work history data for metrics, reliability analysis, and asset performance management. Work history data includes details of work events, findings, costs and dates. Metrics like MTBF and MTTR require this data. The document emphasizes properly defining failure versus repairs and discusses ISO standards for failure definitions. Consistent definition of terms is important for accurate reliability analysis.

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Alexander Velasquez
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85 views30 pages

Curso Intro To Reliability Analysis - 0305

This document provides an introduction to reliability analysis and defines key concepts. It discusses the importance of work history data for metrics, reliability analysis, and asset performance management. Work history data includes details of work events, findings, costs and dates. Metrics like MTBF and MTTR require this data. The document emphasizes properly defining failure versus repairs and discusses ISO standards for failure definitions. Consistent definition of terms is important for accurate reliability analysis.

Uploaded by

Alexander Velasquez
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPTX, PDF, TXT or read online on Scribd
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Intro to Reliability Analysis

PETROZUATA
MARCH 2005
So let’s start by defining Work History
Data
• The work events that occur to equipment

• The type of work performed

• The conditions found at the time of work


• The technical findings after work is completed

• The date & time associated with the work


• The cost associated with performing the work
Why is this data important?
Metrics and Key Performance Indicators
– Failure Count, MTBF, MTTR, Failure Costs,
Planned/Unplanned Ratio, Reliability,
Availability…

Reliability Analysis
– Component
– System Reliability
MTBF Question?

If you have an MTBF of 333


days, when is the optimal to
do a time based maintenance
task?
MTBF & Failure Prediction
2000

40 30 25 805 600 400

Time to
Failure
Total Runtime = TR

TR / Number of Failures

2000 / 6 = 333 days (MTBF)


Failure Date
MTBF & Failure Prediction
• MTBF is an index of performance
• MTBF is not a prediction tool
Reliability versus Availability
Reliability
• Describes past and current behavior of
equipment
• Projects its future behavior
• Is tied to production and profits
• Optimizes and improves productivity of entire
system
Availability
• Describes past performance, but not time in
service or capacity
• Is represented by a percentage
Reliability versus Availability
An asset that has 4 failures per year
and is only out of service for 4 hours
per failure is considered to be very
available, but is it reliable?
The Facts:
Mission time = 1 year
4 failures/year
4 hours of downtime/failure
16 hours of downtime/year

8760 - 16
= 99.8% available
8760
Available But Not Reliable

-lt
Reliability = e

Natural Logarithmic Base e = 2.718


1 1
Failure Rate l= =
MTBF 91
Mission Time t = 365 (days)
Available But Not Reliable

-lt
Reliability = e e = 2.718
-lt 1 = 1
l=
Reliability = 2.718 MTBF 91
1
-
91
(365) t = 365 (days)
Reliability = 2.718
-4.0109
Reliability = 2.718

Reliability = 1.81%
Pareto Analysis
Example
Metrics Scorecard Analysis
What can these failure dates tell
you?
03/13/1999

02/03/1998 06/19/2000
06/09/2001

10/02/1997
08/13/2002
Dates can tell me that
my asset is wearing
out and typically
wears out after about
314 Days
Dates can tell me the most
appropriate interval to make
a replacement
Dates can tell me the
risk of waiting to
make a component
replacement
System Analysis
APM and Work History Data
• Work History Data:
– Supports the APM Workflow
– Enables Metrics/Scorecards
– Enables Detailed Analysis

• To achieve the desired benefits you


must properly document and manage
the data
What work history data is
important?

If you were recording data about an event,


what would you consider as important
items to collect about the specific event?
Work History Codes
• Where did the events occur?
• What happened?
• Why did it happen?
• What was done?
• When did it happen?
• What was fixed?
• What did it cost?
Defining Work History Data
Many companies attempt to define:

REPAIRS
VS.
FAILURES
What is a repair?
What is a failure?
It’s all in the definition…or is it?
One attempt:

ISO 14224 defines failure as:


“The termination or the degradation of the
ability of an item to perform its required
function.”
Now…what’s its “function”?
Defining Failure:
• Complete failure
• Failure of part of item that causes unavailability
of the item for corrective action
• Failure discovered during inspection, testing, or
preventive maintenance that requires repair
• Failure on safety devices or control/monitoring
devices that necessitates shutdown, or reduction
of the items capability below specified limits

Copied from OREDA 2002, 4th edition (Offshore Reliability Data) Copied from OREDA 2002, 4th
edition (Offshore Reliability Data)
These are not failures, by
definition:
• Unavailability due to preventive or planned
maintenance
• Shutdown of the item due to external
conditions, or where physical failure
condition of the item is revealed. A
shutdown is not to be considered a failure
unless there is some recorded
maintenance activity.
Copied from OREDA 2002, 4th edition (Offshore Reliability Data) Copied from
OREDA 2002, 4th edition (Offshore Reliability Data)
There are…
• Failure modes
• Failure descriptors
• Critical failures
• Incipient failures
• Degraded failure
• And many other failure related terms…
Repair or Failure?
A centrifugal pump is shut down because of
a mechanical seal leak for corrective
maintenance.

Repair?

Failure?
If we adopt the ISO 14224 definition
of failure…
• Need to first define function:
– The function of subject pump is to move liquid
from Point A to Point B at a rate of 100 GPM

– The pump was leaking due to the seal leak and


lost pressure and flow. Flow was reduced to 80
GPM…therefore,

By definition…this is a failure
The point is to be careful how you define
terms…even before you start coding
events or develop key performance
indicators you should define terms,
otherwise…
What is?
• MTBF
• MTBR
• TTR, etc.
Defining Failure…
• Meridium’s Best Practice is the ISO 14224
definition of failure:
– Complete Loss (Termination of Function)
– Partial Loss (Degradation of Function)
– Potential Loss (Latent Functional Loss)

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