Short overview of Equipment Reliability

1. Equipment Reliability & Asset ManagementA Short Overview William H. Closser, Jr. President, NSGI Wclosser@thensgi.com

3. Equipment Reliability Process Equipment Reliability Process represents the integration and coordination of a broad range of equipment reliability activities into one process for plant personnel to evaluate important station equipment, develop and implement long-term equipment health plans, monitor equipment performance and condition, and make continuing adjustments to preventive maintenance tasks and frequencies based on equipment operating experience.

4. Equipment Reliability The ER process includes activities normally associated with such programs as: Reliability Centered Maintenance (RCM), Preventive Maintenance (periodic, predictive, and planned), Surveillance and Testing, Life-Cycle Management (LCM), Planning, and Equipment Performance and Condition Monitoring.

5. Equipment Reliability Process Objectives The process is efficient, incorporates human factor considerations, and ensures effective performance during all phases of plant operations. A uniform process is used among all plants in an organization. Applicable in-house and industry lessons learned are incorporated into the process to improve adequacy and efficiency. Changes to the process are timely, responsive to user feedback, and implemented at all affected plants.

6. Equipment Performance Objectives Equipment performs reliably through the operating cycle, and standby safety equipment operates properly on demand. Equipment is capable of satisfactory performance under all design conditions. Critical equipment is identified based on importance to safety function, and production capability. Equipment and system performance criteria are established, performance is monitored, adverse trends are identified, and corrective actions are implemented and verified for effectiveness. Failures and failure causes of concern are identified for critical equipment, and measures are established to prevent them.

7. Equipment Performance Objectives The need for in-depth analysis of equipment failure is commensurate with the equipment’s importance to plant safety and reliability and the likelihood of recurrence. Predictive maintenance technologies are implemented to detect equipment degradation well in advance of potential failure and to optimize equipment performance. Equipment aging is managed using preventive maintenance techniques and life-cycle management, including mitigation of environmental stressors (such as temperature, moisture) or operating stressors (such as duty cycles and vibration). Documented technical bases exist for preventive maintenance activities and aging management programs.

8. Equipment Performance Objectives Equipment performance data and associated trend information are uniformly collected and are readily accessible to support the prompt identification of problems and root causes. Equipment unavailability associated with preventive maintenance activities is balanced by the resulting improved equipment reliability and availability from prevented failures. Minimal in-service failures of critical equipment occur between scheduled maintenance intervals.

9. R = P x (B +K) R: Results (KPI’s, CAP Trends, System Health, etc.) P: Processes (ER) B: Behaviors (Intolerance, Craft Ownership, etc.) K: Knowledge (Personnel Skills & Training) Formula for Excellent ER

10. Equipment Reliability Performance 9 Critical Success Factors Intolerance of Unanticipated Equipment Failures Resolution of Long-Standing or Repetitive Equipment Problems Elimination of Design Vulnerabilities Focus on Critical Systems Proactive Engineering: Focusing on the Long Term Craft Ownership and Maintenance Supervision Preventive and Predictive Maintenance Successful Work Management Use of Operating Experience and Benchmarking

11. Example Equipment Reliability Performance Indicators forced loss reduction (FLR) cross-system component failure/degradation trends from problem reporting data (valves, heat exchangers, breakers, pumps, motors) number of overdue preventive maintenance tasks number and frequency of significant PM deferrals past the grace period number of systems with long-term maintenance plans number of non-outage (turn around) temporary modifications open more than three months, and number of outage-related temporary modifications open more than 12 months number of systems in accelerated testing

12. Example Equipment Reliability Performance Indicators operator workarounds that affect ability to operate equipment percentage of PM feedback sheets received, number of PM change requests, and backlog of PM changes waiting for review or implementation number of effectiveness reviews of equipment-related root causes and corrective actions (include repeat failures and consistency of engineering effort and quality) lost production capability caused by failures of components PM issues ratio of corrective maintenance tasks to preventive plus predictive (trend only)

13. Example Equipment Reliability Performance Indicators ratio of predictive tasks to preventive tasks (man-hours) repetitive equipment failures (more than one failure/cycle) frequency of circuit card/power supply failure per 7,000 operating hours or per year backlog or trend of corrective maintenance work orders that identify components whose function is failed or substantially degraded

14. ER/Asset Management Best Practices

16. Plan

17. ScheduleWork Execution Work Closeout Proactive CMU R-T-F Procedure Mod CAP -ACA -RCA Continuous Improvement Design Mod Long Term Planning Simplified Asset Management Process

18. Change Management Plan Outline Mission Vision Stakeholders Current & Target Performance Levels Threats & Barriers Analysis Includes / Excludes Analysis Stakeholder Analysis Governing Documents Communication Plan Training Requirements Action Plan Detail Budget Performance Indicators

19. Tools of Change Workshops Assessments Equipment Reliability Predictive Maintenance/Condition Based Maintenance – Program & Technologies Asset Management Maintenance Others……

20. Tools of Change Library of Guiding Documents: Coaching Who Management Technician Craft

21. Tools of Change Coaching What Maintenance Basis Development PdM/CBM Process Work Management Corrective Actions Program Life Cycle Management/Equipment Aging Materials & Supply Chain Management Quality Assurance Others ………. Industry User Groups

22. 3 Phase Organizational Change Process