KNOWLEDGE SHARING

Reliability & Availability – An

Introduction
M&I Department
Jakarta, 20 September 2023
Context – Production Availability
Applicability of Reliability & Availability

Mission Oriented
System with NO idle
Phase

Mission Oriented
System with Idle Phase

Continuously Operated
System
Why and What is Reliability ?
�Reliability: The ability of an item:
► to perform a required function,
► under given environmental and operational conditions,
and
► for a stated period of time
Why & What is Availability ?
� Availability: The ability of an item to be in a state to perform
a required function under given conditions at a given instant of
time or over a given time interval, assuming that the required
external resources are provided
[IEC 60050-191]

►Note 1: This ability depends on the combined aspects of the

reliability performance, the maintainability performance and
the maintenance support performance.
►Note 2: Required external resources, other than
maintenance resources do not affect the availability
performance of the item.
Terms – MTTF, MTBF, MDT, MUT, MTTR

NOTE MTTR encompasses:

• the time to detect the failure (a); and,
• the time spent before starting the repair (b); and,
• the effective time to repair (c); and,
• the time before the component is put back into operation (d)

The start time for (b) is the end of (a); the start time for (c) is the
end of (b); the start time for (d) is the end of (c).
How to Define Availability ?

The availability of an item at time t

A(t ) = Pr(item is functioning at time t )

The average availability (under certain conditions)

MTTF
Aavg =
MTTF + MTTR

where
MTTF = Mean time to failure
MTTR = Mean time to repair
Reliability Metrics

►Mean time to failure (MTTF)

►Mean time Between Failure (MTBF)
►Number of failures per time unit (failure rate)
►The probability that the item does not fail in a time interval (0, t ]
(survival probability)
►The probability that the item is able to function at time t (availability at
time t )
►Mean downtime (MDT)
►Mean residual life (MRL)
►. . . and many more
Reliability Block Diagrams (RBD) – Reliability Block Modelling
Process
Reliability block diagram (RBD)
Logical, graphical representation of a system showing how the
success states of its sub-items (represented by blocks) and
combinations thereof, affect system success state

Steps to develop RBD:

1. Select a system success/failure definition.
If more than one definition is involved, a separate RBD may
be required for each.
2. Divide the system into blocks to reflect the logical
behaviour so that each block is statistically independent of
the others.
3. Attempt should be made to make the blocks as large as
possible while ensuring that each block contains
(preferably) no redundancy
Reliability Block Diagrams (RBD) – Reliability Block Modelling
Process
Reliability Block Diagrams (RBD) – Structure

Physical Models Reliability Block

Model
Reliability Block Diagrams (RBD) – Series

SERIES SYSTEM MATHEMATICAL EQUATIONS

𝑛
𝑅 𝑠 =∏ 𝑅 𝑖= 𝑅1 𝑥 𝑅2 𝑥 … 𝑥 𝑅𝑛
𝑖=1
𝑛
𝐹 𝑠 =1− 𝑅 𝑠=1 − ∏ 𝑅𝑖
𝑖=1

∞
𝑀𝑇𝑇𝐹 𝑆𝑌𝑆𝑇𝐸𝑀 =∫ [ 𝑅 𝑆𝑌𝑆𝑇𝐸𝑀 ¿ (𝑡 )] 𝑑𝑡 ¿
0

∞
𝑀𝑇𝑇𝐹 𝑆𝑌𝑆𝑇𝐸𝑀 =∫ [ 𝑅 1 ( 𝑡 ) 𝑥 𝑅1 ( 𝑡 ) 𝑥 … 𝑥 𝑅 𝑛 ( 𝑡 ) ] 𝑑𝑡
0
Reliability Block Diagrams (RBD) – Parallel

PARALEL SYSTEM MATHEMATICAL EQUATIONS

=
𝑛
𝑅 𝑃 =1− 𝐹 𝑃 =1− ∏ 𝐹 𝑖
𝑖=1

∞
𝑀𝑇𝑇𝐹 𝑆𝑌𝑆𝑇𝐸𝑀 =∫ [ 𝑅 𝐴 +¿ 𝑅 𝐵 − 𝑅 𝐴 𝑥 𝑅 𝐵 ] 𝑑𝑡 ¿
0
Block Diagram Simplification
 MLN Plant Configuration
MLN PFD
DHU – GLYCOL
CONTACTOR
T-441
GT-400 RBD MLN
DHU-GLYCOL GAS
MOTO-
CONTACTOR
COMPRESSOR INJECTION
T-411
TO WELL SEPARATION DEHYDRATION HP-COMPRESSION MP-COMPRESSION STABILIZATION OIL STORAGE
PRODUCED
WATER
TREATMENT
GT-410
DHU-GLYCOL
PROTECTION
CONTACTOR UTILITY
SYSTEM
T-475
GT-420

RTot = (RSEPX RDHUX RHPCompX RLMPCOMPX RSTABX ROil-storageX RPWTX RPROTX RUTILITY)
Fluid from LP/MP
HP SEPARATION
Well COMPRESSOR-A

DEHYDRATION HP COMPRESSION
LP/MP LP/MP
MP COMPRESSION OIL STORAGE
SEPARATION COMPRESSOR-B DHU – GLYCOL
SEPARATION CONTACTOR GT-400
MP COMPRESSOR
-A OIL STORAGE-A
T-441
LP/MP MOTO-
COMPRESSOR-C DHU-GLYCOL
HP LP/MP COMPRESSOR
CONTACTOR
SEPARATION SEPARATION MP COMPRESSOR
-B OIL STORAGE-B
T-411
GT-410
DHU- GLYCOL
OIL STORAGE-A CONTACTOR
MP COMPRESSOR
-C OIL STORAGE-C
T-475 GT-420
PRODUCED
WATER STABILIZATION OIL STORAGE-B EXPORT LINE
TREATMENT

OIL STORAGE-C
Reliability Data Cycle
OEE – An Overview

Perhitungan Scoring akan mempertimbangkan parameter LPO dalam perhitungan OEE sebagai berikut :
• % OEE (Overall Equipment Effectiveness) = % Upstream Plant Reliability x % Production Performance x % Quality

Dimana:
• % Production Performance = ((Target Produksi – LPO Surface Facilities) / Target Produksi)) x 100% (target produksi
sesuai RKAP)
• % Quality dianggap 100% karena semua produksi dengan kualitas yang ditetapkan diterima konsumen
• Target % OEE mengacu pada asumsi OEE World Class yaitu 85%

Cakupan Upstream Plant Reliability dan OEE ini terdiri dari peralatan Surface Facility (Machinery, Power Distribution
and Transfer, Process dan Equpment Integrity) yang mempengaruhi terjadinya unplanned shutdown dan kehilangan
Produksi.
Terima Kasih