Building EffecBve Maintenance Systems in Compliance with NORSOK Z008

Transcription

1 Building EffecBve Maintenance Systems in Compliance with NORSOK Z008 John Meiklejohn, Principal Consultant 24 th October 2013

2 Maintenance System Cycle Goals and Requirements Improvements Maintenance Programme Repor:ng and Analysis Maintenance Planning & Scheduling Maintenance Execu:on

3 Contents What is NORSOK? Why should we use NORSOK? Standardising technical hierarchy structures Priori:sing maintenance work based on the consequences of failure Meet performance standards Adhere to safety regula:ons Mi:gate risk Improve overall equipment effec:veness

4 What is NORSOK? Developed by the Norwegian petroleum industry to ensure adequate safety and increased cost effec:veness Ini:a:ve to remove unnecessary ac:vi:es in offshore field therefore reducing costs, lead :mes and adding value Intended to replace individual specifica:ons within oil companies, once approved by the individual company's review strategy these revised standards would then be used

5 Standardising Technical Hierarchy Structures Two basic coding elements proposed: NORSOK Z- DP- 002 Used to iden:fy func:on and its logical loca:on within a system Provides guidelines and full coding for asset iden:fica:on (Tag coding) SFI Group System Provides structure for systems within an installa:on (similar principle to NORSOK Z- DP- 002 system numbering) Requires implementa:on of equipment iden:fica:on (Tag coding) to iden:fy equipment installed in each system

6 Technical hierarchy Technical hierarchy is a cornerstone of maintenance management designed to: Show technical interdependencies of the installa:on Retrieval of tags, equipment and spare parts Retrieval of documents and drawings Retrieval of historical maintenance data in CMMS Planning of opera:ons Cost alloca:on and retrieval Planning and organisa:on of maintenance program Planning of correc:ve work

7 Group Main Equipment Common Coding AWribute Example NORSOK Z- DP- 002 TAG Coding System Number (Annex A of Standard) 86RP001A Telecommunica:ons PABX System A Func:on Sequence (Parallel) Piping and Valves Pipes and Lines Manual Valves Pipe Supports Electrical Related to tagged equipment Not related to tagged equipment Instruments and TelecommunicaBons Cables/JuncBon Boxes Fire and DetecBon System Number (Annex A of Standard) System Number (Annex A of Standard) System Number (Annex A of Standard) System Number (Annex A of Standard) System Number (Annex A of Standard) System Number (Annex A of Standard) System Number (Annex A of Standard) System Number (Annex A of Standard) System Number (Annex A of Standard) 50L001 Pipe for Sea Water System System func:on sequence 50S0021 Specialised loop for Sea Water System System func:on sequence 50V063 Manual Valve 0063 for Sea Water System System Func:on Sequence PB203- G0023 Pipe Guide 0063 for Sea Water System Room B deck pipeline, System Support Func:on Seq. 27PA001A- M01 Motor number 1 for pump 27PA 1A System Func:on and type code sequence (parallel) Kind of item sequence 82EH001A.03AC- X02 Socket Outlet no.2 in circuit of unit posi:on 03AC of switchboard 82EH001A. System func:on code and type sequence (parallel) Circuit number or Withdrawable unit number Kind of item sequence T00001 telecommunica:ons cable. Func:on type Func:on sequence 7DBF8102F- B05 Detector number 5 in loop B in fire zone 8102, flame detector in the fire and gas detec:on system. System func:on and type code Fire Zone loop sequence number Detector Number.

8 NORSOK Z- DP- 002 TAG Guidelines for adopbng into SAP SAP Func:onal Loca:ons are used to structure technical systems in a hierarchical structure: Each Coded Tag represents a fixed LOGICAL posi:on therefore should be represented in SAP as a Func:onal Loca:on Func:onal Loca:on codes in SAP provide hierarchical Logical view of technical structure of installa:on (e.g. Tag 82EH001A.03AC- X02 can be subordinate or installed under tag 82EH001A) Typically func:onal loca:on codes in SAP would be prefixed with a Code represen:ng Rig/Installa:on (e.g. RG01- for technical structures on Rig 01 RG02 for Rig 02 etc.)

9 NORSOK Z- DP- 002 TAG Hierarchy Structuring Example Level 1 Rig Level 2 System Level 3 Major Func:on Level 4 Type Level 5 Tag Template: XXXX- NNXXXXXXXXXXXXXXXXX 1 234

10 NORSOK Z- DP- 002 TAG Hierarchy Structuring Example

11 SFI Coding Structures Consists of a 3 digit decimal classifica:on of a system 10 main groups at highest level Each main group subdivided into 10 groups (2 digits) This is further subdivided into 10 groups Main Group Group Sub Group Digits X X X e.g. Main Group 4 Plalorm Equipment e.g. Group 41 Naviga:on and Searching Equipment e.g. Sub Group 411 Radar Plants

12 SFI Coding Structuring Example

13 Registering NORSOK TAG AWributes Standard SAP system offers limle data valida:on for coding Consider using alterna:ve labelling when manually coding Tags Enter superior Tag when registering Tags within Tags (e.g. Values under main equipment or under Administra:ve Tags e.g. Pipes) Categories can be set up for each TAG coding requirement and used to make amributed mandatory

14 NORSOK TAG AWributes Standard SAP system offers fields suppor:ng inclusion of NORSOK data for generic searches Such as (technical) Object type as a means of registering Func:ons (all NORSOK appendixes in 1 table) Dimensions can be registered SAP classifica:on can u:lise characteris:cs to cater for other NORSOK relevant amributes e.g. RBI, General Maintenance Concept ref Main and Sub func:on details Other fields can be adapted to register amributes such as system Or addi:onal data can be added to standard system (custom development)

15 PrioriBsing maintenance work using risk based maintenance

16 NORSOK Z008 Risk based maintenance and consequence classificabon Used for prepara:on and op:misa:on of maintenance ac:vi:es for systems and equipment including: Offshore topside systems Subsea produc:on systems Oil and gas terminals

17 NORSOK Z008 Key elements of Risk Assessment are: Consequence classifica:on of failure: Consequence/Redundancy/Impact Probability of failure Use of General Maintenance Concepts - GMC (established standard maintenance procedures) Where more in- depth evalua:ons are required the following analysis should be carried out: FMECA Failure Mode, Effect and Cri:cality Analysis RBI Risk Based Inspec:on RCM- Reliability Centred Maintenance

18 Elements of Priority Se^ng (CRI Driven) Assessment Determined based on Impact of Failure Consequence Classifica:on Redundancy Factor Consequence Category Failure Impact (Correc:ve) Priority (Preventa:ve) Priority (Correc:ve)

19 Consequence ClassificaBon (CRI Driven) Consequence category C1 C2 C3 No poten:al for injuries. Poten:al for injuries Poten:al for serious requiring medical personnel injuries. treatment. Consequence safety Equipment classified with outcome of assessment No effect on safety systems. Limited effect on safety systems. Render safety cri:cal systems inoperable. Consequence containment Non- flammable media Non toxic media Flammable media below flashpoint Moderately toxic media Flammable media above flashpoint Highly toxic media Consequence, Environment; resbtubon Bme (***) Natural/normal pressure / temperature media No poten:al for pollu:on (specify limit) < 1 month High pressure/temperature media (>100 bar/80 C) Poten:al for moderate pollu:on. 1 month 1 year Extremely high pressure / temperature media Poten:al for large pollu:on. > 1 year Consequence producbon No produc:on loss Delayed effect on produc:on (no effect in x days) or reduced produc:on Immediate and significant loss of produc:on Consequence Costs No opera:onal or cost consequences Moderate opera:onal or cost consequences Significant opera:onal or cost consequences

20 Redundancy Factor ClassificaBon (CRI Driven) RED A B C Redundancy Degree DefiniBon No redundancy i.e. the en:re system is required to avoid any loss of func:on. One parallel unit can suffer a fault without influencing the func:on. Two or more parallel units can suffer a fault at the same :me without influencing the func:on Tag classified with outcome of assessment

21 OpBons in SAP to Capture Consequence Assessment Func:onal Loca:on Classifica:on Customer Development

22 Risk Assessment (CRI Driven) Redundancy Factor Highest Consequence Colour Coding: HSE ProducBon Cost Category assignment can be directly u:lised to determine priority

23 Consequence Category (CRI Driven) Consequence Category is u:lised to determine risk, priority and :me to repair (in conjunc:on with extent of failure) Failure Consequence Cost Produc:on HSE Highest Consequence Consequence Assessment Outcome C1 C1 C3 C3 Redundancy Factor A Consequence Factor Example shown iden:fies 3 key consequences, Highest Consequence is used in conjunc:on with Redundancy Factor to assign consequence category to Tag

24 Registering Consequence Category in SAP ABC indicator generally adopted to register Consequence Category for Func:onal Loca:on

25 Failure Impact (CRI Driven) Assessment made to determine the probability of failure based on operator knowledge actual case in NORSOK Z008 these are referred to as Failure Impacts and are defined as follows: Failure Impact DefiniBon Note Incipient Imperfec:on in the state or condi:on of an item so that a degraded or cri:cal failure may (or may not) eventually be the expected result if correc:ve ac:ons are not taken. Degraded Cri:cal Failure that does not cease the fundamental func:on(s) but compromises one or several func:ons. Failure of an equipment unit that causes an immediate cessa:on of the ability to perform a required func:on. The failure may be gradual, par:al or both. The func:on may be compromised by any combina:on of reduced, increased or erra:c outputs. An immediate repair can normally be delayed but in :me such failures may develop into cri:cal failure if correc:ve ac:ons are not taken. Includes failures requiring immediate ac:on towards cessa:on of performing the func:on even though actual opera:on may con:nues for a short period of :me. A Cri:cal Failure may result in an unscheduled repair.

26 Registering Failure Impact in SAP SAP Maintenance No:fica:on adapted to accept Failure Impact

27 DeterminaBon of Priority Using CRI Driven Model Consequence category of object Cons Cat DescripBon Failure Impact Priority Cri:cal Low Degraded Low 1 Crit 1, Redundancy A Incipient Low Cri:cal Medium Degraded Low 2 Crit 2, Redundancy A Incipient Low Priority High Medium Low Time to repair 5 days 30 days 180 days 3 Crit 3, Redundancy A 4 Crit 1, Redundancy B 5 Crit 2, Redundancy B 6 Crit 3, Redundancy B 7 Crit 1, Redundancy C 8 Crit 2, Redundancy C 9 Crit 3, Redundancy C Cri:cal Degraded Incipient Cri:cal Degraded Incipient Cri:cal Degraded Incipient Cri:cal Degraded Incipient Cri:cal Degraded Incipient Cri:cal Degraded Incipient Cri:cal Degraded Incipient High Medium Low Low Low Low Medium Low Low Medium Low Low Low Low Low Low Low Low Medium Low Low

28 Failure Impact Priority se^ng example in SAP SAP Maintenance No:fica:on adapted to accept Failure Impact SAP Maintenance No:fica:on enhanced to calculate Priority based on Failure impact and Consequence category Required end date calculated based on no:fica:on crea:on dates & :me to repair set for priority useful for deadline/ mi:ga:on monitoring

29 Meet Performance Standards

30 Performance Standards Describes outline of a barrier as a risk reducing measure and item rela:on to other safety systems in terms of: Func:onality Integrity Survivability When maintaining equipment subject to performance standards it is essen:al for engineers to know what performance standards apply

31 Registering Performance Standards in SAP Example Using Standard SAP Example of Customised Development Custom development enabling Technical Objects on a Maintenance Plan Item to be assigned to individual opera:ons and Performance standards. Link to Documenta:on can be added if required. Func:onality can be provided to allow performance standards results to be recorded Table of values assigned for References

32 IdenBficaBon of Safety CriBcal Elements Key to adhering to safety regula:ons is iden:fica:on of Safety Cri:cal equipment AND work to be carried out on the systems which may impact the ability of the equipment to perform its safety func:ons

33 IdenBficaBon of Safety CriBcal Elements Classifica:on of Func:onal Loca:on Maintenance Ac:vity Type List of value indica:ng the safety barrier / func:on the object forms On Maintenance Plan Item On Correc:ve Work Order

34 Triggers Need for Extended Results Customised development for results recording Result can be entered and compares with tolerances (from Performance Standards)

35 MiBgate Risk

36 MiBgaBng Risk Work Order Deferral Work Order Created Deadline Set Work Order Approaching Deadline Carry out risk assessment Apply for Deferral Approve Deferral Execute Risk Mi:ga:on Measures Reschedule Work Approve Mi:ga:ng Measures

37 Deferral Request - Consequence CategorisaBon Poten:al to record on Tags to reduce assessment :me however may require addi:onal assessment based on impact of failure

38 Deferral Request Risk Category (Probability Based) Standard Coding systems and use of KPI s are cri:cal to the determina:on of Risk Category Could be :me consuming to make the assessment on every occurrence of problem Reduc:on in effort could be achieved by registering assessment on Tag Periodic review and redetermina:on of risk required based on Tag performance

39 Deferral Request Risk Category (Probability Based) Consequent/Probability registered Consequence and Probability can subsequently be used to determine overall risk of deferring preventa:ve maintenance Using the outcome of the risk assessment drives the need for Mi:ga:ng measures to be put in place SAP No:fica:on type used to record /approve request List of No:fica:ons can be reviewed and ac:oned as necessary

40 MiBgaBng Risk Work Order Deadline Monitoring Customised Development Example of Deadline (LAFD Latest Allowable Finish Date - Enhancement Tab of Work Orders) Customised Development Deadline Monitoring Report Dates set when work order is created (Based on Preventa:ve maintenance schedule or Priority)

41 MiBgaBng Risk Work Order Deferral When sesng deadlines (priori:es with response :mes), monitoring is required with a method for recording and approving deferral of work beyond original execu:on dates. Generally most systems will provide a means of monitoring dates, but in standard SAP, most controls require some customised development to fully record measures taken to mi:gate risk of late execu:on of work Customised Development Example of MiBgaBng Risk (Enhancement Tab of Work Orders) Deferral dates (up to 3 permimed) Area to record outcome of risk assessment (per deferral)

42 MiBgaBng Risk Deferral Approval When sesng deadlines (priori:es with response :mes), monitoring is required with a method for recording and approving deferral of work beyond original execu:on dates. Generally most systems will provide a means of monitoring dates, but in standard SAP, most controls require some customised development to fully record measures taken to mi:gate risk of late execu:on of work Customised Development Example of Approving deferral (Enhancement Tab of Work Orders) Date recorded to indicate acceptance of deferral

43 Improve overall equipment effecbveness

44 Improving equipment effecbveness Results Recording and KPI monitoring Analysing FMECA failure mode, effect and cri:cality analysis RBI Risk Based Inspec:on RCM- Reliability Centred Maintenance Implementa:on of Improvements based on analysis of results Improvements Goals and Requirements Standardised Structure, Hierarchy and classifica:on Maintenance Programme General Maintenance Concepts, consequence classifica:on and iden:fica:on of Safety Cri:cal requirements and classifica:on Carrying work in compliance with GMC, Safety and Performance Standards Repor:ng and Analysis Maintenance Execu:on Maintenance Planning and Scheduling Priority & deadline sesng and deferral process Risk assessment and consequence classifica:on

45 Key ReporBng Inputs FMECA On complebon of work register: Failure Mode (Damage to object) Failure Mechanism (Cause of Damage) Remedy Code (Ac:vity performed to rec:fy problem) Tag InformaBon Consequence Category SAP Maintenance NoBficaBon Catalogue codes (specific for type of equipment) Damage Cause Ac:vity FuncBonal LocaBon ABC indicator RBI On complebon of work register: Failure Mode (Damage to object) Failure Mechanism (Cause of Damage) Remedy Code (Ac:vity performed to rec:fy problem) Tag Informa:on Equipment Category SAP Maintenance NoBficaBon Catalogue codes (specific for type of equipment) Damage Cause Ac:vity FuncBonal LocaBon/ Equipment Object Type RCM On reporbng MalfuncBons record: Indica:on of Breakdown start On CompleBon of Work record Time spent on repairing (labour costs) Materials used (Material cost) SAP Maintenance NoBficaBon Breakdown indicator Start of Malfunc:on SAP Maintenance Work order SAP Maintenance Work Order Time Confirma:on Materials issues (Integrated with MM)

46 KPI Measure Key Performance Indicators NORSOK Z008 Potential SAP Source Failure fraction from functional testing of safety critical equipment Measurements recorded out of measurement point Tolerance for Work Orders with SCE related Maintenance Activity type. Preventative man-hours Corrective man-hours Backlog preventative man-hours Work Order Time Confirmations Work Order Time Confirmations List of Incomplete preventative maintenance operations Backlog preventative man-hours SCE critical Overdue corrective man-hours List of Incomplete preventative maintenance operations with Safety Critical Maintenance Activity type List of Incomplete corrective maintenance operations Overdue corrective man-hours SCE critical HSE related equipment failure Cost of single failure events in terms of downtime, repair cost or spare cost Number of repeated failures over a give time period for key components Hidden failures for SCE equipment (recommended NORSOK requirements) detected during test List of Incomplete corrective maintenance operations with Safety Critical Maintenance Activity type Maintenance Notifications (Malfunction reports) raised for equipment with High consequence class for HSE characteristic or classes as Safety Critical element Maintenance Notification with Breakdown indicated work order costs (Labour and Materials) Maintenance Notifications with Breakdown Measurements recorded out of measurement point Tolerance for Work Orders with SCE related Maintenance Activity type, per Performance Standard Reference

47 Thank you for listening For more informa:on visit Absot s stand (No.19) jmeiklejohn@absot.co.uk