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SABP-G-008
Field Reliability Unit
Guidelines and Procedures
Document Responsibility: Rotating Equipment Division
31 July 2005
Sulaiman Bukhamsin
Salman Mishari
Marwan Khazandar
Hadi Qahtani
Saeed Asiri
Raed Ahmad
Table of Contents
1
2
3
4
5
7
8
9
Introduction.................................................... 2
Definitions...................................................... 2
Organization and Responsibilities................. 4
Maintenance Strategies............. 12
Predictive Programs............................. 14
5.1 Vibration Monitoring Program.... 14
5.2 Lube Oil Condition
Monitoring Program (OCM).............. 18
Proactive Programs..... 20
6.1 Trouble Shooting and
Root Cause Analysis (RCA)............. 20
6.2 Bad Actors and Rework Programs.... 25
6.3 Equipment Trip Reporting.. 26
Reliability Reports............................. 32
History Log and Document Filing......... 40
Appendices
I.
PM Interval Setting............. 43
II. Trip Report.... 45
III. Document Filing .. 47
IV. QA Forms............. 48
V. SAP Procedures...... 51
VI. Vibration Alert Form........ 77
Page 1 of 78
SABP-G-008
Field Reliability Unit
Guidelines and Procedures
Introduction
1.1
Purpose
The purpose of this procedure is to establish guidelines and procedures for
managing field Reliability Programs in a Saudi Aramco Hydrocarbon facility in
accordance to Best In Class Maintenance Practice. Roles and responsibilities
along with a typical unit structure are also defined in order to assure sustaining
these programs to the best quality.
1.2
Scope
This Best Practice gives general guidelines and the minimum requirements for a
unified approach to reliability practices and procedures in Saudi Aramco that
will facilitate transfer of information and comparison on equal basis.
1.3
Disclaimer
This Best Practice is being provided for the general guidance and benefit of
Saudi Aramco operating facilities. The use of the information or material
contained here will not release operating facilities from the responsibility of
safeguarding and controlling their operations within Saudi Aramco established
guidelines such as GIs and engineering standards.
1.4
1.5
References
This Best Practice is based on the latest edition of the references below, unless
otherwise noted.
1.6
1.6.2
SABP-G-008
Field Reliability Unit
Guidelines and Procedures
Definitions
Best-In-Class (BIC): refers to being recognized as a world leader in achieving
sustained superior performance. The Company has defined several strategic imperative
and proposed strategies to achieve BIC one of which is Reliability Maintenance System.
Breakdown Strategy: means that no corrective action is taken on an equipment or
component of equipment until it fails to perform its defined function.
Key Performance Indicators (KPIs): a set of indices designed and installed to gauge
performance of an organization or a program.
Operation, Maintenance, Engineering group (OME): is a team that consist of key
representatives form various divisions. The OME group usually meets regularly to
follow up on pending activities, develop action plans, determine work schedule priority
and status and discuss important issues such as bad actors.
Preventive Maintenance Program (PM): is defined as the servicing of equipment or
a component of equipment at regular intervals regardless of condition. The purpose is
to service equipment before they fail and to bring them back to a healthy condition.
Examples, electrical breaker check, instrument calibration check and verification, etc.
Predictive Maintenance Program (PdM): also known as On condition strategy, is
the servicing of equipment or a component of equipment based on condition rather than
a regular interval. Examples, vibration, lube oil sampling, etc.
Proactive Maintenance Program (PaM): is the organization around full protection of
equipment by proactive activities and through continuous performance measurement.
Reliability Centered Maintenance (RCM): is a systematic process of preserving a
systems function by selecting and applying effective reactive, preventive, or proactive
strategies. The focus is on consequence of system failure rather than the failure it self.
Year-to-Date (YTD): refers to the performance level on a certain KPI or a set of KPIs
since the beginning of the year to the date of reporting.
Mean Time Between Failure (MTBF): The average amount of time in months a piece
of equipment runs between failures.
Bad Actor: Any piece of rotating equipment that fails two or more times within any
12-month period.
Availability: Readiness of any equipment to be placed in service at any given time.
Rework Index: The failure of any piece of equipment within 60 days following a
repair/installation. A new work order must be issued to address every rework.
Page 3 of 78
SABP-G-008
Field Reliability Unit
Guidelines and Procedures
EMP: Equipment monitoring program, e.g., Vibration and lube oil monitoring prog.
MTTR: Mean time to repair.
OCM: Lube oil condition monitoring program.
IDP: Individual development plan.
3
Responsibilities
3.1
Unit Function
A field reliability unit should take custody and care of all reliability programs in
the facility. It is recommended to be part of the Maintenance division for ease of
work flow and interactions with other maintenance areas. However, the unit
must be independent from line maintenance execution areas to provide
independent advice of rotating equipment reliability and workmanship. Some
facilities may prefer the unit to be in engineering division. It is to the facility
management discretion to decide how to structure the reliability unit to best fit
their business needs.
The plant should be divided into areas based on rotating equipment population
and other factors such as how geographically this equipment is located and if
resources and logistics are available. Typically for a large plant within a fenced
area such as a refinery or a gas plant, it is recommended to have 500 rotating
equipment per Area, excluding HVAC and non-critical equipment below 10 HP.
Each area should typically be covered by an area reliability engineer, a vibration
technician, and may have an area senior machinist. Below is an example of a
typical organization chart of a reliability unit:
Reliability Unit
Supervisor
Area 1
Area 2
Reliability
Eng
Reliability
Eng
Vibration
Tech
Vibration
Tech
Senior
Reliability
Eng
Technical
Advisors
Senior
Machinist
Senior
Electrician
Senior
Vibration Tech
PM
Administrator
Senior
PCT
Page 4 of 78
3.2
SABP-G-008
Field Reliability Unit
Guidelines and Procedures
Responsibilities
The unit is responsible for tracking equipment condition and providing support
to achieve best in class reliability targets in a safe and economic mode per Saudi
Aramco best practices and engineering standards.
3.2.1
Administrative duties
Be responsible for the unit operating plan, budget, review cost
sheets and control NDE and variance, coaching & training,
employee evaluations, unit assets (unit diagnostic equipment
and tools), ordering materials, safety of personnel and
equipment under the custody of the unit.
3.2.1.2
Technical duties
Set and approve the non-process alarm and shutdown setpoints on equipment.
Page 5 of 78
SABP-G-008
Field Reliability Unit
Guidelines and Procedures
3.2.2
Establish assets Fault analysis data base ensuring all data, drawings,
and information are complete and all modifications are updated.
3.2.3
SABP-G-008
Field Reliability Unit
Guidelines and Procedures
Perform life cycle cost for bad actors and expensive repairs.
3.2.4
Senior Machinist
A senior machinist will support all areas. He should have more than 10
years experience as a machinist and should have held diverse positions in
the field. He should also have good written and verbal communication
skills. He also must have developed hands on machinist experience as
well as vibration technician knowledge. His duties will include:
Page 7 of 78
SABP-G-008
Field Reliability Unit
Guidelines and Procedures
3.2.6
SABP-G-008
Field Reliability Unit
Guidelines and Procedures
Responsible for the tools in his custody. Report any fault in the
analyzer or software to the Senior Vibration Technician.
Could be responsible for collecting and gathering oil samples for the
area under his custody.
3.2.7
Assist in upgrading the software and configure data bases for both
online and off line monitoring systems.
Finalize sending Lube oil Samples to the lab for analysis. Follow up
with CSD Lubrication Engineer for any concerns. Issue monthly
report to area Operation/maintenance requesting corrective actions
on CSD recommendations.
Be able to upgrade the software and configure data bases for both
online and off line monitoring systems.
PM Administrator
The PM administrator is preferred to be with a competency of planner I
and with PCST or Electrician background. He should have good
statistical capabilities and good knowledge in generating required reports
Page 9 of 78
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Field Reliability Unit
Guidelines and Procedures
3.2.8
Coordinate with the OME to decide when to carry out the PM during
equipment standby or plant T&I.
Generate monthly unit report and statistical reports from the SAP for
all maintenance programs such PM, PdM, Reactive, etc.
Senior Electrician
A senior technical advisor will support all areas. He should have more
than 10 years experience as an electrician and held diverse positions in
the field. He should also have good written and verbal communication
skills. He also must have developed hands on as an electrician. He
should be familiar with electrical Saudi Aramco Standards. He should
also be able to read the electrical and plant drawings. He should also be
able to search the internet web sites as needed.
Page 10 of 78
3.2.9
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Field Reliability Unit
Guidelines and Procedures
SABP-G-008
Field Reliability Unit
Guidelines and Procedures
Maintenance Strategies
Not all equipment should receive the same attention. Some should receive run-tofailure strategies, some preventive maintenance (time based), and some Predictive (oncondition) strategy.
The selection of which strategy to use can be best determined through the conduction of
RCM. RCM, however, can sometimes be very intensive, costly, and time consuming.
In those situations where RCM is seen infeasible, the following basic guidelines can be
used instead.
4.1
Selection Criteria
4.1.1.1
4.1.1.2
4.1.1.3
4.1.1.4
4.1.1.5
4.2
SABP-G-008
Field Reliability Unit
Guidelines and Procedures
4.1.1.6
4.1.1.7
4.2.2
Selection Criteria
4.2.1.1
4.2.1.2
4.2.1.3
Setting of PM intervals
PM intervals should be selected at 2 standard deviations (2) before the
average life of equipment or a component. Such setting is based on 95%
confidence level that replacement will take place before functional
failure. Availability of life data is necessary to determine such setting.
Example is shown in Appendix I.
For new equipment, vendor manuals and Company/Industry
recommendations can be alternatively used.
4.3
Page 13 of 78
SABP-G-008
Field Reliability Unit
Guidelines and Procedures
4.3.2
4.3.3
Predictive Programs
The objectives of the Equipment Monitoring Program are:
1.
2.
3.
4.
Although there are a number of monitoring subprograms, this best practice document
will only cover the two main ones, i.e., vibration monitoring program (VMP) and oil
condition monitoring program (OCM).
SAP should be used to schedule EMP activities and log data for On-line Vibration
Monitoring, Off-line Vibration Monitoring, or Oil Sampling. SAP has a feature that can
trigger a malfunction notification when measurement readings exceeds a particular
threshold value.
5.1
Program Structure
The equipment vibration program should be structured as follows:
1.
2.
SABP-G-008
Field Reliability Unit
Guidelines and Procedures
Monthly portable route survey to collect vibration data on all nonmonitored critical equipment, or non-monitored equipment that are
10 HP or above. This also includes noting and reporting other
problems such as abnormal noise, oil leak, high temperature, dirt,
etc. Although some of these functions are the main responsibility
of Plant Operations (for example, oil leaks, abnormal noise,
housekeeping, etc.), the vibration craftsman will report such
deficiencies as part of his periodic survey.
5.1.1.1
Capable of producing:
A.
B.
C.
D.
E.
F.
G.
H.
I.
J.
K.
L.
5.1.1.2
SABP-G-008
Field Reliability Unit
Guidelines and Procedures
Vibration Measurement
The vibration technician should be able to perform the following tasks at
minimum:
A. Collect accurate and reliable vibration data on rotating equipment,
piping, valves and structures for diagnosis purposes.
B. Perform and manage a monthly vibration monitoring program to
cover off-line equipment. Maintain the software configuration,
archive and analyze the vibration data on a monthly basis.
C. Perform single and double-plane field balancing
D. Measure and record noise pressure levels
E. Check the calibration of non-contact eddy current probes and
vibration pickups
To perform these tasks effectively and safely, the field reliability unit
should use and maintain equipment with at least the following minimum
specifications:
Page 16 of 78
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Field Reliability Unit
Guidelines and Procedures
Vibration pickups
Velometers
Accelerometers (standard and high frequency)
Velocity Pickups
5.1.3
Optical Keyphasor
Page 17 of 78
5.2
SABP-G-008
Field Reliability Unit
Guidelines and Procedures
Sampling Procedure
It is imperative to ensure samples are taken correctly and safely for the
Oil Conditioning Monitoring Program (OCM). The following procedure
should be followed:
1.
Ensure that the sample bottle is perfectly clean and free from any
foreign particles. 250 ml sample bottles must be used (SAP
Material No. 1000158454).
2.
3.
Samples should be taken while the system is hot and under normal
operating load, or immediately after shutdown.
4.
5.
All samples should be taken from the same location, in the same
manner and under the same conditions.
6.
7.
8.
Filling the bottle to 80% will allow enough agitation for the Lab
personnel when analyzing the sample.
9.
10.
Page 18 of 78
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Field Reliability Unit
Guidelines and Procedures
5.2.2
5.2.3
11.
12.
Safety Precautions
5.2.2.1
5.2.2.2
5.2.2.3
5.3
5.2.3.1
5.2.3.2
View trend reports, which provide a quick look at the last five
oil samples taken for a particular piece of equipment
5.2.3.3
5.2.3.4
5.2.3.5
5.2.3.6
5.2.3.7
Corrective Actions
Whenever an oil analysis report requests a corrective action, OCM e-mail
notification feature will be used to inform the plant foreman to take the required
action and enter it in the OCM database. The message will be escalated to the
superintendent if the action was not taken and/or not entered in the OCM
database within a certain period (to be determined by plant personnel).
Page 19 of 78
SABP-G-008
Field Reliability Unit
Guidelines and Procedures
In addition, the plant foreman will also open SAP notification to schedule the
work and carry out the recommendations. Lubrication alerts should be issued as
Equipment Defect Reports (EDRs) using SAP Malfunction Notification (Type
M2). The associated order should have the Maintenance Activity Type of: 01D
Predictive Maintenance.
6
Proactive Programs
6.1
Troubleshooting Responsibilities
Any equipment problem will be investigated first by operations/process
engineering and determined if it is process related or rotating equipment.
If the problem is process related, then it should be handled by operations
engineering. If process engineering determines it is not process related
then it should be directed to the closest discipline. See flow process
below.
Page 20 of 78
SABP-G-008
Field Reliability Unit
Guidelines and Procedures
Notes:
1
Performance problems:
Operation & control
Flow, Head, Speed, ETC.
Performance Test
Reliability problems:
Component failures
Daily maintenance follow ups
PM defects correction
Operation reports
Rot. Equip. Problem
Operation Engineering
Performance
problem
Yes
Operation Engg.
Start Investigation
No
Reliability Unit
start investigation
Yes
Problem solved
No
Problem
Solved
No
Out Side Support
Yes
Modification
Required
Yes
No
No
CSD
Manufacturer
Others
Operation Engg.
Approve Modification
No
Problem solved
Yes
Yes
Issue Report
Issue Report
Page 21 of 78
SABP-G-008
Field Reliability Unit
Guidelines and Procedures
The area reliability engineer should address any request for trouble
shooting rotating equipment problems. For minor problems he can ask
the senior machinist to follow up and report to him the nature of the
problem, findings, and then the engineer can recommend action to be
taken. All failures should be investigated by the area reliability engineer
and then followed up during equipment repair in the field shop. The
senior machinist can follow up on repairs when needed and can also
coordinate with the shops to determine the failure cause. It is the
responsibility of the senior machinist to make sure that all documentation
is properly filed and the cause of the failure is properly documented in
the SAP before it is passed for approval by the reliability engineer.
6.1.2 Failure and RCFA Definition
Acknowledgement: This section was adopted from Maint. BIC focus
team.
Failure can be defined as any change in a machinery component which
causes it to be unable to perform its intended function satisfactorily.
Failure Root Cause Analysis (RCFA) is a structured step by step
technique that focuses on finding the real cause of a problem and dealing
with that, rather than continuing to deal with its symptoms. Root cause
analysis is a procedure for determining and analyzing the causes of
problems in an effort to find out what can be done to solve or prevent
them. It is a process to help reliability engineers understand problem
causes well enough to achieve permanent resolution of those problems.
6.1.3 RCFA Responsibility
It is the responsibility of the area reliability engineer to conduct and
coordinate Root Cause Analysis (RCA) as per criteria listed in 5.1.4. It
is recommended that maintenance personnel (engineers, supervisors, and
crafts) take training sessions and work shop on root cause analysis in
order to have successful and meaningful participation in failure analysis.
6.1.4 Conducting RCFA
It is required to conduct RCFA for equipment as per the following
criteria:
bad actor
Production Loss
Page 22 of 78
6.1.5
SABP-G-008
Field Reliability Unit
Guidelines and Procedures
SABP-G-008
Field Reliability Unit
Guidelines and Procedures
the found tasks. The third step is to eliminate causes for which there
are no supporting facts. The fourth step is to state the final list of the
root causes.
Page 24 of 78
6.2
SABP-G-008
Field Reliability Unit
Guidelines and Procedures
Definition
Rotating Equipments with frequent or costly failures shall be included in
a bad actor program. This equipment can be defined as equipment that
fail two or more times within any twelve months period. Equipment
failing due to human error should be excluded.
6.2.2
6.2.3
6.2.4
6.2.5
Rework Program
The objective of the program is to avoid delays and loss of production
and effort due to repeated equipment repairs. The program is a control
method to assure the quality of the repair is done right from the fist time.
6.2.6
Rework Definition
Any piece of equipment which fails within 60 days from
repair/installation is a rework and should be indicated as rework when
opening a new work order for repair.
Page 25 of 78
6.3
SABP-G-008
Field Reliability Unit
Guidelines and Procedures
6.3.2.2
6.3.2.3
6.3.2.4
6.3.2.5
Page 26 of 78
6.3.3
SABP-G-008
Field Reliability Unit
Guidelines and Procedures
Equipment to be Reported
Only critical equipment shall fall within the scope of this instruction.
6.3.4
6.3.4.2
6.3.4.3
He shall obtain relevant operating data for the last 24 hrs that
might be useful in determining what caused the trip, including
a computer printout of the Sequence Of Events (SOE), Alarm
History, trends of relevant operating conditions immediately
prior to and after the trip, and a copy of the Operator log book
covering the same period. Any operational upsets happened
before the trip period outside his area and might affect the
equipment operations should be mentioned in his input to help
in the trip investigation.
6.3.4.4
6.3.4.5
The Operations Foreman over the area where the trip occurred
is responsible for informing the Operations Superintendent
about the trip immediately.
6.3.4.6
6.3.4.7
SABP-G-008
Field Reliability Unit
Guidelines and Procedures
2)
6.3.4.8
6.3.4.9
SABP-G-008
Field Reliability Unit
Guidelines and Procedures
6.3.4.16 He will complete his part of the trip report and sign it no later
than the 3rd workday after the trip. The Process Engineering
Supervisor will sign the trip report and it should be sent to the
Reliability Unit by the 4th workday following the trip.
6.3.4.17 The reliability engineer is responsible for determining what
caused the trip and how it can be avoided. He should make all
necessary investigation efforts to investigate the root cause of
the trip and recommends remedy solutions.
6.3.4.18 He will be coordinating equipment trip filing and maintaining a
tracking database for all recommendation and action items
taken to prevent the trip from reoccurring.
6.3.4.19 He will assign a document number to the Trip Report form, log
it into the tracking system, and inform the holder of the original
form within one working day after the trip.
6.3.4.20 He will review Trip Reports for completeness and in due time
and report to the Operations Superintendent if there are any
discrepancies or problems.
6.3.4.21 He will analyze data on Trip Reports and correlate information
to develop trends based on historical data.
6.3.4.22 He will report the number of different types of trips within any
period compared to historical averages (YTD & monthly
KPIs). The information will be available for reporting in
monthly Trip Review Meetings, or other meetings concerned
with unit performance.
6.3.4.23 He will fill the last part of the Trip Report, sign it along with
the Reliability Supervisor and send a copy from the Final Trip
Report to the division heads by the 5th workday following the
trip.
Note: Any recommendation affecting equipment design or operating
conditions needs Engineering agreement (approval) before
implementation.
SABP-G-008
Field Reliability Unit
Guidelines and Procedures
Page 30 of 78
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Field Reliability Unit
Guidelines and Procedures
Operations Foreman
Maintenance Foreman
Process Engineer
Inspection unit
Process Unit
Reliability Engineer
Machine shop
PC&CS Unit
Maintenance Superintendent
Operations Superintendent
Engineering Superintendent
No
Approved
Yes
Archive
Page 31 of 78
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Field Reliability Unit
Guidelines and Procedures
Reliability Reports
Acknowledgement: Large part of the report and format is adopted from Ras
Tanura Refinery.
Page 32 of 78
SABP-G-008
Field Reliability Unit
Guidelines and Procedures
XXXXX Department
Monthly Highlights
II.
III.
IV.
V.
Glossary of Terms
Page 33 of 78
SABP-G-008
Field Reliability Unit
Guidelines and Procedures
Monthly Highlights
Page 34 of 78
II
SABP-G-008
Field Reliability Unit
Guidelines and Procedures
90
85
80
75
70
65
60
55
50
Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec
35
30
25
20
15
10
5
0
Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec
Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec
2
1
1
0
0
Jul
Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec
Page 35 of 78
III
SABP-G-008
Field Reliability Unit
Guidelines and Procedures
Area 1
Area 2
Area 3
Area 4
Whole Plant
Centrifugal Pumps
(Target 60)
Centrifugal Comprs
(Target 84)
MTBF
(Months)
Lubricated Recip.
Comprs ( Target 18)
Motors
(Target 180)
Turbines
(Target 60)
Fin-Fans
(Target 36)
Availability
Bad Actors
Availability %
Year TARGET
Bad Actors
Year TARGET
Plant Rework %
Rework
Year TARGET
MSSD Rework %
Year TARGET
Major Equip.
Trips
Total Rotating
Equipment
Repair cost
Monthly Cost
YTD Cost
Year TARGET
Page 36 of 78
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Field Reliability Unit
Guidelines and Procedures
Problem Description
Root Cause
Corrective Action
Date of
Breakdown
Days out of
Service
Cost $ M
Rework Details:
Equipment No.
Date of
Rework
Rework Details
Original
Repair
Org.
Corrective
Repair
Org.
Cost
Trip
Date
Trip
Category
Trip Cost
M$
Cause of Trip
Corrective Actions
Taken
Page 37 of 78
IV
SABP-G-008
Field Reliability Unit
Guidelines and Procedures
Survey
Total Equip
Completed
Alerts
Overdue
Result from
Survey
Drop in
YTD
Pending
Area 1
Area 2
Area 3
Whole Plant
Survey
Total no of
samples
Completed
Alerts
Overdue
This Month
YTD
Pending
Area 1
Area 2
Area 3
Whole Plant
Glossary of Terms
Mean Time Between Failure (MTBF): The average amount of time in months a piece
of equipment runs between failures. Its calculation is based on the total number of
running portion of the equipment population divided by the total number of failures for
the given time interval. MTBF for un-spared equipment is calculated using the entire
population.
MTBF = (No. of running rotating equipment / No. of rotating equipment Techoed/Completed
WOs during last 12 months) X 12
Note: Area reliability engineer should verify that MTBF only covers work orders PM01 with
Notification type M2 associated with a malfunction, or M1 associated with a replacement of
worn part. The dates of break down and return to service should be recorded in the
notification. He also should verify that all failures or age related repairs are accounted for.
Notification type M2 should be used for equipment which failed and the shutdown was
unplanned for. M1 notification should be used where the shut down and repair work was
planned for, in order to replace worn or defective components or equipment which were
detected during Preventive or Predictive Maint inspection.
Page 38 of 78
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Field Reliability Unit
Guidelines and Procedures
Rework Index: Is defined as the failure of any piece of equipment within 60 days
following a repair/installation. A new work order must be issued to address every
rework. The monthly index is calculated as follows:
Monthly Index = (No. of Rot. Equip. month reworks / No. of Rot. Equip. month WOs) X 100
Days out of service: Total number of days equipment removed from service for
maintenance work.
Drop in Alert: Alerts which resulted from a sudden break down. This does not
include alerts which were issued due to a problem found during a scheduled routine
survey.
Overdue: Equipment which where scheduled for survey, however, the survey was not
completed in the due month.
Pending: Equipment which was issued a recommendation but is still waiting
execution.
Page 39 of 78
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Guidelines and Procedures
8.2
8.1.1
Relevant machine condition and symptoms before and during the failure.
Add supporting data such as vibration spectrums, bearing temperature,
process data, etc.
8.1.2
8.1.3
8.1.4
8.1.5
8.1.6
Page 40 of 78
8.3
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Field Reliability Unit
Guidelines and Procedures
Responsibility
History record for maintenance activities can be entered by area maintenance
(Planner, field Area Supervisor), however, the history must be reviewed and
approved by the reliability unit engineer for any equipment failure.
HISTORY PROCESS
Create
Notification
History Flow
Approve
Notification
Complete
Notification
No
Upon Work
Completion
Enter History
inEnsure
the Notification
history
& Change
User Status
entered
to (HISE/HISN)
Craft Frmn.
History
Increase
the
accepted
by
quality
of the
reviewer
entered history
Maint. Engr.
Yes
Complete
Notification
Yes
Proponent
Accepted
work
completion
Opt. Frmn.
No
Proponent Changes User
Status to JINC
Filing
Documentation of equipment database is recommended to be organized
as per the flow chart shown in Appendix IV. It shall be done on
electronic softcopy to ease the search process.
8.4.2 QA Forms
Quality assurance forms are essential to ensure the quality of the task
handled by maintenance craftsman. In addition, it is considered as a
tracking history data for the last job performed in a particular machine in
terms of final alignment readings, clearances,etc. It will also help in
diagnosing equipment malfunction by eliminating suspected causes
when verified against documented check up and repair history.
Documentation should be maintained and filed for all works done
Page 41 of 78
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Field Reliability Unit
Guidelines and Procedures
Appendices
I
II
Trip Report
III
Filing
IV
QA Forms
SAP Procedures
VI
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Guidelines and Procedures
APPENDIX I
PM Interval Setting
Example
Assume that the following 10 life data points (in years) were collected on a piece of equipment:
5.6, 5.4, 5.2, 5.7, 5.2, 5.0, 4.6, 4.3, 4.6, 4.4
The mean or average life () =
(5.6 + 5.4 + 5.2 + 5.7 + 5.2 + 5.0 + 4.6 + 4.3 + 4.6 + 4.4) / 10 = 5 years.
The standard deviation () =
(Xi - )2
SQRT ( ----------------- )
N -1
(Xi - )2
Standard deviation, =
= 2.26
0.5 years
5 years
4 years
2 X 0.5 years
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Guidelines and Procedures
PM Interval Setting
H i s to g r a m o f L if e R an g e
7
6
Frequency
5
4
3
2
1
0
0.0
2 .0
4 .0 4 . 5 5 .0
8 .0
1 0 .0
L ife R a n g e ( y e a r s )
2
Me an life of Equip. ()
St. Deviatio n, ()
(X i )2
-------------N -1
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Guidelines and Procedures
Appendix II
Critical Rotating Equipment Trip Report Form
Date:
Plant:
3/16/2005
Time:
Equipment No.
Equipment Downtime:
Equipment Name:
First Alarm Received:
SUPERVISING OPERATOR
Other Alarms:
Trip Initiated:
Manuallly
ESD (Automatically)
Trip Results:
Personal Injury
Fire
Equipment Damage
Product Loss
Others
None
Primary Cause:
Human Error
Electrical
Mechanical
Instrument
Electrical
Mechanical
Others
Instrument
Login ID
Date:
Review/Comments by Operations Forman:
Date:
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Guidelines and Procedures
Primary Cause:
Human Error
Electrical
Mechanical
Instrument
Others
Login ID:
Date:
Login ID:
Date:
Primary Cause:
Electrical
MAINT.
Human Error
Mechanical
Instrument
Others
PROCESS ENG.
Login ID:
Date:
Action Taken and any recommendations by Process Control Engineer:
Login ID:
Date:
Primary Cause:
Human Error
Electrical
Mechanical
Instrument
Others
Electrical
Mechanical
Instrument
RELIABILITY
Root Cause:
Date:
Maintenance Superintendent:
HEADS
Yes
Engineering Superintendent:
Operation Superintendent:
No
Date:
Login I D:
Date:
Login ID:
Date:
Login ID:
Date:
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Guidelines and Procedures
APPENDIX III
Program
Filing Index
Plant (Area)
Plant A
Programs
Quality
Assurance
forms
Plant B
Equipment
Tag #
Equipment
Tag #
Equipment
Data Sheet
Equipment
Data Sheet
Equipment
Cross Sectional
Drawings
Equipment
Cross Sectional
Drawings
Performance
curves
Performance
Equipment
P&IDs
Equipment
P&IDs
Operating
Parameters
Operating
Parameters
Spare Parts
Spare Parts
Program
Program
Condition
Monitoring
Failure
Analysis
Reports
Bad Actors
Reports
Quality Circle
Folder
Recommendati
on Tracking
Reports
Vibration
Monthly
Reports
OCM
Trip
Reports
curves
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Guidelines and Procedures
APPENDIX IV
QA FORMS
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Guidelines and Procedures
https://livelink.aramco.com.sa/livelink/livelink.exe?func=ll&objId=2004729&objAction=browse&sort=name
Acknowledgement: These Forms were adopted from Mechanical Services Shops Dept.
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Guidelines and Procedures
Horizontal Motor
QA.doc
Electrical Checklist
QA.doc
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Guidelines and Procedures
APPENDIX V
SAP PROCEDURES
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Guidelines and Procedures
This part highlights many useful tools, reference and Links that are available under Corporate Maintenance
System Website
I-
II-
III-
IV-
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I-
SABP-G-008
Field Reliability Unit
Guidelines and Procedures
Allow logical and business oriented interfaces to Plant Maintenance via the Web.
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Guidelines and Procedures
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Guidelines and Procedures
Select PM Assistance for the Notification/Work order and following screen will
appear to show the overall picture of the work order process:
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Guidelines and Procedures
Another source of training is reading the SAP PM User Documentations which contain
the actual Training modules for important transactions used to enter repair History. The
following is a list of important training modules related to notification that are available in
the website. The focus should be on Malfunction report notification (type M2).
1- PM-TRM-IW22-08-Complete Notification
2- PM-TRM-IW22-D-Enter Notification History
3- PM-TRM-MCI5-PMIS-Damage Analysis Report
4- PM-TRM-MCI7-PMIS-Breakdown Analysis Report
How to access these User Training Guides
From the training link under CMSPM Website, select SAP PM User Documents
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Guidelines and Procedures
The above mentioned Users guides are located in three of the listed folders
The PM-TRM-IW22-D-Enter Notification History user training guide is under the PM Notification
Processing History folder.
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Guidelines and Procedures
If one of these folders is selected, the following common screen will appear
Select Modules. The system will list all Users Tanning Guides will appear under the selected
folder.
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Guidelines and Procedures
As an example, the screen blow shows the list under PM Notification Processing History
folder. The users Tanning guide for PM-TRM-IW22-D-Enter Notification History can
be selected from the list.
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Field Reliability Unit
Guidelines and Procedures
Another source of training is accessing the SAP PM e-Learning which contains demo of
important transactions used to enter repair History. The following is a list of these eLearning courses related to notification that are available in the website. The focus should
be on Malfunction report notification type M2.
1- Create Malfunction Request
2- Change Maintenance Request
3- Change Notification using List editing transaction
4- Completed History Approved Notification
5- Enter Notification History
6- Update Notification History
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Guidelines and Procedures
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You have two areas to select: PM NP-01: Notification Processing: Creation &
Approval or PM NP-02: Notification Processing: History
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Guidelines and Procedures
1 - If you select PM NP-01: Notification Processing & Approval. The following screen will appear:
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Guidelines and Procedures
2 And if you select other area PM NP-02: Notification Processing: History, then the following
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Guidelines and Procedures
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Guidelines and Procedures
The Best Practices will be added as new requirements are encountered. At present, the
following Best Practices are present on this page:
1.
The Best Usage of the Order Type and Maintenance Activity Type to identify Proactive and Reactive
Maintenance Work.
2.
3.
4.
5.
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Guidelines and Procedures
Best Practice in the Usage of SAP PM - Attach Electronic Documents to Equipment Record
SABP-G-008
Field Reliability Unit
Guidelines and Procedures
By following this practice, it is possible to organize and store all related items in
one single place.
Attached, is an example of this Best Practice for keeping Electronic attachments
to the Equipment Record some of the items they store with the Equipment
includes:
Technical Specifications
Drawings
Calibration Information
Manufacturer Notes and Recommendations
Other attachments you can store includes, Web Site addresses, Word
Documents, Excel Spreadsheets, etc. - although you can attach any type of
document, the preferred format is Adobe Acrobat due to its compact size.
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Guidelines and Procedures
APPENDIX VI
Reference No.___________
Plant:
Date:
Equip. Description:
Vibration Assessment:
High vibration levels were recorded on the subject equipment. The highest level was
As compared to the following criteria:
Accepted Level:
Alarm Level:
Shutdown Level:
Possible Causes:
The following are possible causes of the recorded high vibration:
_______________________________________________________________________________________
_______________________________________________________________________________________
_______________________________________________________________________________________
Recommendations:
_______________________________________________________________________________________
_______________________________________________________________________________________
_______________________________________________________________________________________
General Note:
It is very important to realize that vibration assessment is by no means a replacement for visual inspection
and proper field troubleshooting. The objective of vibration monitoring is to flag potential problem areas,
hopefully early enough before they become very expensive. Wife a vibration alert is received it is always
recommended as a first step to verify if the equipment is being operated as rated: e.g., correct flow and
head. As a second step, all basic checks and visual inspection should be conducted for a
comprehensive and complete assessment of the equipment condition. However, there should be no
hesitation to request for more sophisticated vibration analysis to further assist in the troubleshooting of
complicated problems.
Data Collected B
Analyzed B
Approved B
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29 June 2005
SABP-G-008
Field Reliability Unit
Guidelines and Procedures
Revision Summary
New Saudi Aramco Best Practice.
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