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RELIABILITY CENTERED MAINTENANCE HPL INITIATIVES

Author: Jaijyoti Dhar, Manager Electrical, Central Services
Introduction
Haldia Petrochemicals Limited, (HPL) started the RCM Initiative in a small way. Around 30 people from various
disciplines including Process personnel underwent a three-day intensive training programme by external faculty on
RCM Process and its benefits.
The RCM Initiative started off by the Company, by first appointing a RCM Team with a Team Leader along with
three other members to take the initiative through and to act as facilitators. The methodology decided to be applied
for RCM Analysis was based on the book Reliability Centered Maintenance by Mr. John Moubray.
Initially as Pilot Projects 10 projects were selected to learn the RCM Process by applying on actual day to day
irritating and persisting problems / issues. This was also to ensure a few success stories, so that RCM can be easily
adopted by the organisation. The RCM Team made presentations at various locations (Plant Control Rooms,
Workplaces, etc..) on the RCM Process and how to select Projects for RCM Analysis. The presentation duration was
around an hour and a half. Personnel from the respective areas including Process and Maintenance Engineers and
Members were present for the presentation. Also present were senior Management persons during each session to
prove the commitment of HPL towards RCM. At the end of each session, Projects were selected and Teams were
formed. The Projects were selected by brainstorming where the field personnel were especially involved, and the
need to solve the persisting problems was felt by all concerned. There were 8 10 persons in a team, which was
multi-disciplinary and consisted of a Team Leader, Facilitator (person who underwent the 3 day Training course),
Process and Maintenance Engineers & Members.
Methodology
As mentioned earlier the RCM Analysis was carried out based on the Methodology mentioned in Mr. John
Moubrays book.
The following formats were prepared and circulated to the various Teams.
Analysis Worksheet
This worksheet details out the Systems, Sub-systems, Functions, Functional Failures, Failure Modes and Failure
Effects.
Decision Worksheet
This worksheet details out the various tasks, which are proposed to be carried out based on the Consequence
Evaluation, Proactive Tasks and Default Action.
System :
Function :
Sub System:
Function Failure Modes Functional Failure Sub-System
Reliability Centred Maintenance
F FF FM H S E O H4 H5 S4
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INITIAL
INTERVAL
CAN BE
DONE BY
RCM DECISION WORKSHEET
SYSTEM
SUB SYSTEM
Page _____ of _____
INFORMATION
REFERENCE
CONSEQUENCE
EVALUATION PROPOSED TASK
DEFAULT
ACTION
H1
S1
O1
N1
H2
S2
O2
N2
H3
S3
O3
N3
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Resource Utilisation
This worksheet details out the resources used for the RCM analysis is terms of manpower, materials, time, etc..
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
R ESO U R C E U T I L I Z A T I O N C H A R T
MAN - HOUR UTILIZATION FOR THEPROJECT
DETAILED ACTIVITY DURATION FOR THEPROJECT
IDENTIFICATION OF SYSTEM & ITS SUB SYSTEMS
Man-Hour Utilization / day for the month of 2002
RCM Team Members Emp #
LISTING OF MAINTENANCE TASKS
IDENTIFICATION OF FUNCTIONS
UTILIZATION OF OTHER RESOURCES
IDENTIFICATION OF FUNCTIONAL FAILURES
LISTING OF FAILURE MODES
LISTING OF FAILURE EFFECTS
ESTABLISHING FAILURE CONSEQUENCES
Will the loss of function caused
by this failure mode on its own
become evi dent to the operating
crew under normal
ci rcumstances?
Is a task to detect whether the
failure is occurring or about to
occur technically feasible and
worth doing?
Does the failure mode
cause a loss of function
or other damage that
could injure or kill
someone?
Yes
No
H S
Is a schedule restoration task to
reduce the failure rate technically
feasible and worth doing?
No
Yes
Schedule
On-Condition Task
H1
H2
No
Yes
Schedule
Restoration Task
Is a schedule discard task to
reduce the failure rate technically
feasible and worth doing?
H3
Is a failure finding task to reduce
the failure rate technicall y feasible
and worth doing?
No
Yes
H4
Could the multiple
failure affect
safety or the
envi ronment?
No
Yes
Schedule Fai lure-
findi ng Task
H5
No
Yes
Re-desi gn is
compulsory
Re-desi gn may be
desi rable
Does the failure mode
cause a loss of function
or other damage that
could breach any
known envi ronmental
standard or regulation?
No
Is a task to detect whether the
failure is occurring or about to
occur technically feasible and
worth doing?
Yes Yes
Is a schedule restoration task to
avoid failures technically feasible
and worth doing?
No
Yes
S1
S2
No
Yes
Is a schedule discard task to
avoid failures technically feasible
and worth doing?
S3
Is a combination of tasks to avoid
failures technically feasible and
worth doing?
No
Yes
Schedule Discard
Task
S4
No
Yes
Re-desi gn is
compulsory
Combination of
tasks
Does the failure mode have a
direct adverse effect on
operational capabil ity (output,
qual ity, customer servi ce or
operating costs i n addition to
the direct cost of repair)?
No
Is a task to detect
whether the failure is
occurring or about to
occur technically feasible
and worth doing?
Is a task to detect
whether the failure is
occurring or about to
occur technically feasible
and worth doing?
No
Yes
E
O
Is a schedule restoration
task to reduce the failure
rate techni cally feasible
and worth doing?
No
Yes
O2
No
Yes
Is a schedule discard task
to reduce the failure rate
technically feasi ble and
worth doing?
O3
No
Yes
O1
Re-desi gn
may be
desi rable
Is a schedule restoration
task to reduce the failure
rate techni cally feasible
and worth doing?
No
Yes
N2
No
Yes
Is a schedule discard task
to reduce the failure rate
technically feasi ble and
worth doing?
N3
No
Yes
No schedule
Maintenance
Re-desi gn
may be
desi rable
N1
RCM DECISION DIAGRAM
Schedule
On-Condition Task
Schedule
On-Condition Task
Schedule
On-Condition Task
Schedule
Restoration Task
Schedule
Restoration Task
Schedule
Restoration Task
Schedule Discard
Task
Schedule Discard
Task
Schedule Discard
Task
No schedule
Maintenance
No schedule
Maintenance
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Modus Operandi
It was decided that the various Teams would meet regularly within their respective Plants at least once a week for
two hours dedicated for the RCM Analysis. The RCM Central Team would provide any help required on RCM
technicalities. However, this method did not work out successfully with all the teams due to the fact that the Team
Members could not get together due to various job schedules and shift operations.
A two-day workshop was then organised by the central RCM Team, wherein all the Teams were to come and
complete their Projects. Any help required were to be provided by the central RCM Team. This methodology proved
to be a success. The Teams were able to dedicate themselves completely for the task and marvellous results could be
obtained at the end of the two-day workshop. Each Team was provided with a PC to enter the data and study results.
We would like to present two case studies on the projects carried out.
Case Study Pre Contacting Pot (PCP) in LLDPE Plant
Brief outline
The PCP is important equipment in LLDPE Plant, and does not have any standby. PCP is used to mix the Catalyst
mud with TEAL, Donor, Propane before feeding it into the Pre-poly reactor. This mixture is very hazardous catches
fire immediately with air.

This is single line equipment and hence, any failure in this, during normal operation, leads to the stoppage of plant
production.
A capital spare of the whole equipment is always kept ready, to minimize the maintenance downtime.
PCP Maintenance before RCM
Major maintenance activities carried out on PCP (8R-101/A-101) along with the problem and impact on production
are as follows:
Date Problem Action Impact on
Production
Apr 15, 02 Agitator speed is very
low.
The problem was with the positioning of the speed
sensor gap. Gap is adjusted and the speed is found to
be OK
Nil
May 06,
02
Bush flushing line
leakage.
Ferrule is opened and found that it is not properly
fitted. So it is fitted properly and tightened.
Yes (2 hours)
Propane
60 Kg/hr
Catalyst
3.5 Kg/hr
TEAL
21 Kg/hr
Donor
2.33 Kg/hr
Refrigerated
Water IN
Refrigerated Water
OUT
To Prepoly Reactor
Pre Contacting
Pot
Operating Conditions
Temperature = 15 Deg C
Pressure = 27 Kg/cm2
TEAL + Catalyst Active Catalyst
PRE-CONTACTING POT AGITATOR
Page 4
Date Problem Action Impact on
Production
May 07,
02
Bush flushing line
leakage.
Ferrule is opened and found that the threads are
damaged. So new ferrule is used; and the line is
boxed up.
Yes (4 hours)
Jun 29, 02 Speed variator oil
leakage.
1) Variator Oil seal is replaced with a new one.
2) Existing bush flushing line was modified to
flexible type to reduce the load on the threads.
Nil (work was done
during planned
shutdown).
Aug 10,
02
Abnormal noise from
the agitator outer
magnet.
Agitator is replaced with the standby one. The outer
magnet is taken out and found that the bearing is
damaged. Bearing is replaced with new one and the
agitator is kept ready.
Yes (2 hours)
Jan 24, 03 Gearbox lube oil
leakage.
Lube oil is replenished from time to time. Gearbox
oil seal is changed during shutdown.
Nil
RCM initiative was taken up for this equipment, as the downtime was 8 hours (nearly 250 MT production loss)
within the first half of financial year 2002-03. RCM analysis was conducted and based on the outcome of the
analysis maintenance philosophy along with maintenance tasks were revised. Condition monitoring, Predictive
maintenance and checklists were prepared and followed to increase the reliability of the equipment.
Part of the Detailed RCM Analysis are given in Exhibit 1. (The complete Analysis is attached).
PCP maintenance after RCM
Maintenance carried out on the PCP after RCM has been implemented.
Date Problem Action Impact on
Production
Apr 08, 03 Nil (Agitator is
replaced with standby
one, so that the old
one can be checked)
Standby agitator assembly is fitted in place of the old
one. The old agitator is dismantled for checking; and
found the inner magnet, thrust pads, bushings to be
in damaged condition. Inner magnet is replaced with
new one with new set of bushing and thrust pads.
The agitator assembly is kept ready as standby.
The maintenance
activity is done
during planned
shutdown as per
the RCM.
Apr 23, 03 High vibration of
Motor bearing.
During condition monitoring (plant level) it is
observed that the bearings are giving high vibration.
Inspection department checked and confirmed that
the bearings are to be replaced at the earliest. Motor
bearings are replaced during a planned shutdown.
Nil.
Apr 25, 03 Abnormal noise from
the stand by variator.
As per RCM the trial run for the stand by variator is
planned during the bearing replacement work. Found
the standby variator to be very noisy in operation.
Old variator is again fitted to the agitator. The
standby variator is opened, properly adjusted, boxed
up and kept ready.
Nil.
May 23,
03
PCP inside
temperature is high.
Found the problem with the 080-TT-1701 indication.
Problem is rectified.
Nil.

Page 5
Maintenance Checklists after RCM
Following parameters are monitored once in every two weeks. If any abnormality is observed, then the necessary
corrective action is taken at the earliest opportunity to improve the reliability of the equipment
Observation
Sl Parameters Date: Date: Date: Date:
1 L/oil condition (Variator) OK/ Not OK OK/ Not OK OK/ Not OK OK/ Not OK
2 L/oil temp. (approx) (Variator)
3 L/oil level (Variator) OK/ Not OK OK/ Not OK OK/ Not OK OK/ Not OK
4 L/oil condition (Gear Box) OK/ Not OK OK/ Not OK OK/ Not OK OK/ Not OK
5 L/oil temp. (Gear Box)
6 L/oil level (Gear Box) OK/ Not OK OK/ Not OK OK/ Not OK OK/ Not OK
7 Motor NDE vibration
8 Motor DE vibration
9 Variator NDE vibration
10 Variator DE vibration
11 Gear Box NDE vibration
12 Gear Box DE vibration
13 Magnedrive NDE vibration
System :
Function :
Function
1.01.01 a Housing Lower Thread Failure
1.01.01 b Top Bearing Cover Thread Failure
1.01.01 c Top Bearing Cover Loosening
1.01.01 d Purge Line Thread Failure
1.01.01 e Purge Line Thread Loosening
1.01.02 a Thread Failure
1.01.02 b Thread Loosening
1.01.03 Seal To prevent leakage 1 Fails to contain the
process fluid from coming
to outside.
1.01.03 a Seal Damage
1.01.07 O-Ring To prevent leakage 1 Fails to contain the
process fluid from coming
to outside.
1.01.07 a O-Ring Damage
1.01.08 Retaining Ring To retain the assembly at
proper position
1 Fails to keep the outer
magnet in position.
1.01.08 a Retaining Ring Slip & Damage
1.02.01 Driven Pulley To transmit motion 1 Belt slippage leading to
improper transmission of
power.
1.02.01 a Friction Surface Damage
1.02.02 a Belt Loose
1.02.02 b Belt Damage
1.02.03 a Friction Surface Damage
1.02.03 b Pulley Key Way Damage
1.02.04 Drive Pulley Key To provide locking
between drive pulley and
motor shaft
1 Drive pulley becomes free
from shaft. Power is not
transmitted.
Key Damage
Reliability Centred Maintenance
Pre-Contacting Pot (PCP)
Mixing of TEAL, Donor, Catalyst, Propylene and propane at 400 +- 10 rpm under controlled reaction at 13 deg. C temperature and 27 kg/cm2 pressure.
(1.02) Belt & Pulley
To transmit motion
To transmit motion
Belt
Drive pulley
Failure Modes Functional Failure Sub-System
(1.01) Magnetic Drive Restricts the process fluid
from coming out and hold
the assembly in position.
To prevent leakage
1.01.04 Cover Bearing To provide support to the
agitator shaft
1.01.01 Housing & Cover
1.01.02 Gland & Collar
1.01.05 Thrust Bearing To provide support to the
agitator shaft and absorb
1.01.06 Housing Bearing To provide support to the
agitator shaft
1. AGITATOR:
1.02.02
1.02.03
1 Fails to contain the
process fluid & hold the
assembly properly
1 Fails to contain the
process fluid from coming
to outside.
1 Fails to take the axial
thrust. This leads to friction
1.01.05 a Bearing Failure
1 Fails to keep the inner
magnet in position &
1.01.04 a Increase in Radial Clearence
Bearing Failure 1.01.06 a Fails to support the shaft 1
Fails to transmit the power
partly or fully.
1
Belt slippage leading to
improper transmission of
power.
1
Page 6
Observation
Sl Parameters Date: Date: Date: Date:
14 Magnedrive DE vibration
Remark
Observed by (Sign. & Name)

Analysis

Analysis done by (Sign. & Name)

Following points are checked once in every 3 months. If any abnormality is observed it is rectified to increase the
reliability of the equipment.
Date of Checking

Sl Checkpoint Observation Remark Observation Remark
1 Tightness of top bearing cover OK/ not OK OK/ not OK
2 Tightness of Magnedirve Gland OK/ not OK OK/ not OK
3 Metal Particles in L/oil (Gear Box) Present/Absent Present/Absent
4 Condition of Lube oil (Gear Box) OK/ not OK OK/ not OK
5 Metal Particles in L/oil (Variator) Present/Absent Present/Absent
6 Condition of Lube oil (Variator) OK/ not OK OK/ not OK
7 Condition of the Belt OK/ not OK OK/ not OK
8 Play of drive pulley OK/ not OK OK/ not OK
9 Drive Pulley surface condition OK/ not OK OK/ not OK
10 Driven pulley surface condition OK/ not OK OK/ not OK
11 Belt tightness OK/ not OK OK/ not OK
12 Bolt tightness of associated lines OK/ not OK OK/ not OK
Final Remarks
Checked by Sign: Name: Sign: Name:
Verified by Sign: Name: Sign: Name:
Outcome of RCM
There has not been any production loss due to failure of PCP after the RCM recommendations are implemented
from April 2003 till date.
Case Study Spent Caustic System in NCU Plant
Brief outline
The Spent Caustic System had major problems with frequent failure of pipelines and associated equipment such as
compressor, mechanical seals, etc..
Spent Caustic from the caustic / water wash tower (2C-330) is washed by cooled gasoline from quench tower and
then stored in the spent caustic storage tank (2T-333). The spent caustic from 2T-333 is pumped to the oxidation
reactor (2V-390). This fluid is split into two streams and fed to the reactor from two nozzles. In the reactor the spent
caustic is mixed with air, which is compressed in the oxidation air compressor (2K-390). In 2V-390, Na
2
S in the
spent caustic is oxidised at elevated pressure and temperature through exothermic reaction. HP stem is introduced
into the reactor to maintain the reaction temperature.
Page 7
The effluent from the top of the reactor is fed into the bottom section of the spent caustic wash tower (2C-390) in a
vapour / liquid mixed phase condition. The liquid from the bottom of the tower is cooled in the circulation cooler
(2E-391) and recycled to the upper part of the tower. Part of the liquid is discharged to the wastewater treatment
plant (OSBL) through the surge pit (2V-395) and CPI separator (2V-397). The vapour contacts with the recycled
liquid on trays of the tower to condense the steam and to eliminate the entrained Na
2
SO4 and NaOH. The remaining
vapour, which is mostly air, is discharged from the top of the tower to the atmosphere.
Sulphuric acid is injected to the tower circulation liquid for neutralisation of 2E-391 outlet. H
2
SO
4
tank (2T-331)
and H
2
SO
4
injection pumps (2P-332A,B) are installed for this purpose.
This project was selected due to high maintenance requirement to keep the system operational. After implementation
of the RCM proposed tasks, the failure rate and breakdown maintenance of equipment and associated pipelines have
drastically reduced.
The details of the study with RCM analysis and pictures of the system are enclosed.


The types of failures occurring in the system were:
Pipe line leakages
Compressor failure.
Caustic pump 2P-390 Mechanical seal leakage.
Page 8
RCM Analysis

Spent Caustic System Plant: NCU
Converting Na2S to Naso4
SL N Sub-System
1.00 SPENT CAUSTIC STORAGE &
TRANSFER
1.01 To receive and store spent caustic from Caustic
Tower bottom @ 4m
3
/hr and temp. of 45C, at
atmospheric pressure, 250ppm Na
2
S, 2-3%
strength.
Sulphide storage and transfer
will not be possible.
1.01.01 Transfer pump 2P-390
failure.
1.02 To pump (6.5 to 7m3/hr) spent caustic from tank
to reactor.
Transfer of spent caustic will not
be possible.
1.02.01 Pump discharge flow control
valve FV_39001 failure.
1.02.02 Pump suction strainer
choking.
1.02.03 Pump sunction/disch. line
puncture.
1.02.04 Motor failure.
1.02.05 Non availability of steady
flow
1.02.06 Level indicator LI 39001
malfunctioning
1.02.07 Sludge deposition at the tank
bottom
1.02.08 FT 39001 malfunctioning
2.00 Oxidation Air compressor(2K-390)/
SPENT CAUSTIC OXIDATION
REACTOR (2V-390)
2.01 To oxidize (by steam & air) dissolved Na
2
S in
spent caustic to Na
2
SO
4
@ 6.5 to 7m
3
/hr.
Operating temp. 200C and pressure 32.5
kg/cm2. Air flow 1500 Nm3/hr.
It will not be possible to convert
sulphides to sulphates.
2.01.01 Air Compressor(2K-390)
failure
2.01.02 Steam Injection Failure
2.01.03 Gasoline carryover from tank
to Reactor
2.01.04 Reactor operational condition
failure
2.01.05 Reactor internals failure
2.01.06 FV 39004 failure (air flow to
2V-390)
2.01.07 Reactor body failure
3.00 SPENT CAUSTIC WASH TOWER 3.01 To wash the oxidized spent caustic with surface
condensate. Pressure atmospheric.
Unable to wash oxidised spent
caustic.
3.01.01 Failure of Surface
Condensate
3.01.02 Overflow from wash tower
top
3.01.03 Wash tower internal failure
4.01 COOLING OF SPENT CAUSTIC
(by 2E-390)
4.01 Cooling from 90C to 35C. (2E-390). . Unable to cool spent caustic. 4.01.01 Heat exchanger tube leakage
4.02 TRANSFER TO WASTE WATER
SYSTEM AFTER
NEUTRALIZATION
4.02 Pumping @ 33.6m3/hr at above conditions. (2P-
391)
Will not be able to pump to
surge pit and neutralisation will
not be possible.
4.02.01 pump mech seal failure
4.03 Neutralize the pump discharge with H2SO4 to
pH 8-9. (2P-332) and sending to surge pit (2V-
395)
Reliability Centred Maintenance
Failure Modes
System :
Function :
Sub System:
Functional Failure Function
Page 9
Decision Worksheet
RCM Outcome
The number of failures in the system has drastically reduced.
F FF FM H S E O H4 H5 S4
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1 1.02 a Y N N N Y Monitor current of motor 33A. 8 H
Monitor FIC > 70% (alarm exists in DCS) Cont.. PE
Gear box oil temp <70 degC. Press : 3 kg/cm2g 24H FM
Isolate pump and flush casing with surface cond S/d FM
b Y N N N Y To check valve opening corresponding to controller output when reqd Inst
c Y N N N Y Check motor current, pump disch. Flow
d Y Y Y ___ Y Thickness monitoring (sampling pt at random) at regular intervals 3 months Insp
Reactor PG & PT calibration for maintaining steady pressure 6 months Inst
e Y N N N Y Vibration monitoring 14 days Insp
Electrical checks 3months Electrical
f Y N Y Y Flow should be tuned to match the minimum frequency Immediately Mech/Process
With 95% valve opening pump performance to be checked 6 months Mech/Inst
g Y N N Y Y Calibration of LT 6 months Inst
h N N Y Tank cleaning Annual S/D Mech/Process
I Y N N Y Y Impulse line flushing 3 months Inst
Zero checking 3 months Inst
2 a Y N N Y N Y Regular monitoring 8 hours Mech
b Y N N Y N Y Control valve maintenance 1 year Inst
c N Y Tank LG cleaning 30 days Inst
Gasoline draining 15 days Process
d Y N N Y N Y PT 39001 calibration 6 months Inst
TI 39001 calibration 6 months Inst
e Y N Y Y Open inspection once in 2 yrs Mech/Insp
f Y N Y Y Calibration, stroke checking 1 year Inst
g Y Y Y Opening and Inspection once in 2 yrs Mech/Insp
3 a Y N Y Y
Health of surface condensate pumps 2P-505 and 2P-305 to be
monitored 3 months Mech/Process
Surface condensate line globe valve operation checking
Before every
start up of
SCOU Process
b Y Y Y LT-39006 calibration checking 6 months Inst
FIC-39006 calibration 6 months Inst
c Y N Y Y Wash tower inlet/outlet chemical analysis 3 months Process
4 a Y Y Y Thickness gauging 3 months Insp
Caustic back up from discharge NRV checking 1 month Mech
Nitrogen purging
Every S/D of
SCOU
system Process
INITIAL
INTERVAL
CAN BE
DONE BY
RCM DECISION WORKSHEET
SYSTEM
SUB SYSTEM
Page _____ of _____
INFORMATION
REFERENCE
CONSEQUENCE
EVALUATION PROPOSED TASK
DEFAULT
ACTION
H1
S1
O1
N1
H2
S2
O2
N2
H3
S3
O3
N3
Page 10
Conclusion
After implementing the recommendations of the Pilot Projects we have found that the number of failures and
production loss due to failures in the maintenance prone equipment have reduced drastically. Both the Process and
Maintenance personnel in HPL are convinced that RCM will help us in achieving reduction in equipment downtime,
better asset care and management and reduce un-necessary maintenance.
Out of all the ten numbers of Pilot Projects taken up all the projects have given us excellent results and HPL is
convinced of the success that can be achieved through RCM.