Maintenance Technology August 2017 - 20

RELIABILITY & MAINTENANCE

equipment that we previously
would have to monitor with
hand-held devices or through
some type of invasive inspection." That's the good news.
The bad news is, despite
the affordability and
widespread availability of
continuous-monitoring
technologies, personnel
still need to know what to
look for amid the data that
constantly streams from them.
Unfortunately, all systems for
analyzing such information are
not created equal. "Depending
on the system you use," Berriman
observed, "you may not be getting a
full and correct picture of equipment and
process conditions in your plant." This is
where his "look to the stars" approach to
data pays off.

Data and reliability
programs

An effective reliability
program consists
of interconnected
building blocks
that include the
following four
steps, aimed
at identifying
impending failures
with enough warning
to allow repair or
replacement. Root
Cause Failure Analysis
(RCFA) determines the
causes of unexpected failures
to improve the program and avoid
similar events.
1. Build a complete master
Not knowing what
equipment list (MEL). The MEL
includes the fixed data for the
to look for amid
next steps in the process and the
information required for planning
Bringing order to chaos
constant streams of
and scheduling work and ordering
Berriman's approach starts with sorting data
plant data delays
parts and materials.
into fixed and variable groups. "This," he
The MEL also contains an
said, "helps us solve the risk-identification
problem resolution.
organized hierarchy of assets that
and -mitigation equation."
users can follow to identify equipFixed data is set when the plant or system
ment. Ideally, the branches should
is built or modified. This includes:
extend down to the "functional location," i.e., the place in
■ plant layout
the process where an asset operates. Associating a particular
■ equipment design
asset with a unique identifier allows it to be tracked as it
■ equipment data
moves from one location to another.
■ material master data (spare/OEM parts)
To complete the MEL, fixed data must be associated with
■ performance parameters
each asset. This includes, among other things:
■ potential failure data.
■ equipment type (pump, motor) classification (centrifugal),
These items become the known variables in the risk-idenlocation, process and operating information, process
tification and -mitigation equation. Variable data, though,
drawings, size, power, material of fabrication, and motorchanges during the operation of a process or asset, including,
frame size
among other things, as a result of raw-material composition,
■ bills of material (BOMs), i.e., spare parts needed to make
process variation, weather, equipment condition, and work
repairs to the equipment.
history.
CMMS systems organize and sort this information in
By selecting the right data points, personnel can populate
various ways and allow the roll-up of metrics, costs, and
the equation and determine their position, which, in this
information to identify performance and trends.
case, means the condition of their site's assets. Doing this
requires building a set of "constellations" to identify and
2. Rank asset criticality. With an accurate MEL, sites can
capture critical asset data.
rank the criticality of their assets. While organizations often
A reliability program is designed to proactively identify
focus on one potential impact, such as production or safety,
and mitigate failures, while eliminating defects. A mainteto completely understand the relative criticality of their
nance program is designed to preserve or restore function
equipment systems, they need to review a number of factors.
to a system. Effective data constellations allow reliability and
Five basic categories are used to determine asset criticality:
maintenance teams to detect and repair problems before they
■ safety
have an impact on performance.
■ environment

20 |

MAINTENANCE TECHNOLOGY

AUGUST 2017



Table of Contents for the Digital Edition of Maintenance Technology August 2017

Editorial
Uptime
On The Floor
Reliable Security, Reliable Operations
Highly Charged Reliability
Drowning in Data? Look to the 'Stars'
Reliable Pumping Supplement
SAP: Tips and Tricks
Steam-Trap Inspections
Saving Tribal Knowledge
Seats for Butterfly Valves
IIoT
ISO 55000
Understand Lube ID Systems
Tomato Processor Boosts Steam Output, Cuts Emissions
Products
Ad Index
Showcase
Final Thought
Maintenance Technology August 2017 - 1
Maintenance Technology August 2017 - Cover1
Maintenance Technology August 2017 - Cover2
Maintenance Technology August 2017 - 1
Maintenance Technology August 2017 - 2
Maintenance Technology August 2017 - 3
Maintenance Technology August 2017 - Editorial
Maintenance Technology August 2017 - 5
Maintenance Technology August 2017 - Uptime
Maintenance Technology August 2017 - 7
Maintenance Technology August 2017 - On The Floor
Maintenance Technology August 2017 - 9
Maintenance Technology August 2017 - Reliable Security, Reliable Operations
Maintenance Technology August 2017 - 11
Maintenance Technology August 2017 - 12
Maintenance Technology August 2017 - 13
Maintenance Technology August 2017 - 14
Maintenance Technology August 2017 - 15
Maintenance Technology August 2017 - Highly Charged Reliability
Maintenance Technology August 2017 - 17
Maintenance Technology August 2017 - 18
Maintenance Technology August 2017 - Drowning in Data? Look to the 'Stars'
Maintenance Technology August 2017 - 20
Maintenance Technology August 2017 - 21
Maintenance Technology August 2017 - 22
Maintenance Technology August 2017 - Reliable Pumping Supplement
Maintenance Technology August 2017 - 24
Maintenance Technology August 2017 - 25
Maintenance Technology August 2017 - 26
Maintenance Technology August 2017 - 27
Maintenance Technology August 2017 - 28
Maintenance Technology August 2017 - 29
Maintenance Technology August 2017 - 30
Maintenance Technology August 2017 - SAP: Tips and Tricks
Maintenance Technology August 2017 - Steam-Trap Inspections
Maintenance Technology August 2017 - Saving Tribal Knowledge
Maintenance Technology August 2017 - Seats for Butterfly Valves
Maintenance Technology August 2017 - IIoT
Maintenance Technology August 2017 - ISO 55000
Maintenance Technology August 2017 - Understand Lube ID Systems
Maintenance Technology August 2017 - 38
Maintenance Technology August 2017 - 39
Maintenance Technology August 2017 - Tomato Processor Boosts Steam Output, Cuts Emissions
Maintenance Technology August 2017 - 41
Maintenance Technology August 2017 - 42
Maintenance Technology August 2017 - Products
Maintenance Technology August 2017 - 44
Maintenance Technology August 2017 - 45
Maintenance Technology August 2017 - Ad Index
Maintenance Technology August 2017 - Showcase
Maintenance Technology August 2017 - Final Thought
Maintenance Technology August 2017 - Cover3
Maintenance Technology August 2017 - Cover4
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