RELIABILITY CENTERED MAINTENANCE OF GAS

COMPRESSOR INSTALLED AT LPG PLANT

 SUPERVISED BY
ENGR. JAVED REHMAN LARIK

GROUP MEMBERS

KARAM ALI 15ME54 (G.L)

AAQIB HUSSAIN 15ME08 (A.G.L)
RASHID ALI 15ME01
ZEESHAN 15ME151
NADEEM ALI 15ME56
CONTENTS

1. Introduction
i. Presentation Outlines
ii. Project Overview
2. Aims & Objectives
3. Reliability Centered Maintenances
i. Why RCM is better?
4. Methodology
5. Failure Modes & Effects Analysis
i. Types Of FMEA
ii. Procedure
iii. Advantages
6. Work done So Far…
i. Software Survey
ii. Field Visit
INTRODUCTION

This presentation covers the following outlines:

 Project overview
 Aims & Objectives
 Reliability centered maintenance
 Methodology
 Failure modes & effects Analysis (FMEA)
 Work done so far
PROJECT OVERVIEW

 This project is about Reliability Centered Maintenance of gas compressor installed at

LPG Plant

 RCM is modern, technologically supported and innovative maintenance strategy. It is

cost effective & reliable than traditional maintenance

 Maintenance of gas compressor in LPG Plants is difficult task. The difficulties often
arise from the lack of reliable maintenance strategies. RCM addresses this problem
effectively
PROJECT OVERVIEW

Some of Common issues of maintenance of Gas compressors are:

1. Vibration issue
2. Air Filter Issue
3. High temperature of lube oil

 In this project these issue will be studied and a frame work for RCM will be developed
 The main focus of project is to conduct FMEA of Gas Compressor using RCM++ (RCM Software)
AIMS & OBJECTIVES

 Identify and Prioritize Failure modes that can affect the compressor function
 To analyze risks in failure of gas compressors
 To make FMEA (Failure modes & effects analysis) of gas compressor using
RCM ++ Software
 Select applicable & effective tasks to control the failure modes
WHAT IS RCM?

 It is a systematic process and methodology for determining the most effective

and efficient maintenance management plan for a specific platform, system or
component [1]

 It is a corporate level maintenance strategy that is implemented to optimize

the maintenance program of a system [2]
WHY RCM IS BETTER

 Slashing the amount of scheduled preventive maintenance

 Eliminating most TBOs ( Time Between Overhauls)
 Reduce MIFs ( Maintenance Induced Failures )
METHODOLOGY

Identify System Identify Identify the Identify the

Function Functional Failures Failure Modes Failure Effects

Determine Identify Failure

Identify Other Consequences
Maintenance Tasks
Logical Actions • Frequency of occurrence
and Intervals
• Severity of the failure mode
FAILURE MODES & EFFECT ANALYSIS (FMEA)

 The FMEA is a tool used to systematically analyze postulated component

failures and identify the resultant effects on system operations. [3]
 The analysis is sometimes characterized as consisting of two sub-analyses,
 Failure modes and effects analysis (FMEA),
 Failure modes and effects criticality analysis (FMECA).
 Successful development of an FMEA requires that the analyst include all
significant failure modes for each contributing element or part in the system.
 FMEAs can be performed at the system, subsystem, assembly, subassembly or
part level
TYPES OF FMEA

The FMEA process is generally applied to the following:[4]

 Design FMEA (DFMEA)
 Process FMEA (PFMEA)
 Machinery and Equipment FMEA (EFMEA)
We do FMEAs typically for three reasons: [5]
 Improving a new design for a product or process
 modifying an existing design or process (assuming there is an FMEA for the
existing design or process)
 using an existing design or process in a new environment, location, or application
(assumes there is an FMEA for the existing design or process).
PROCEDURE OF FMEA

Define the problems

Define the System Choose the type of Subdivide the
of interest for
of Interest FMEA system for analysis
analysis

Evaluate potential
Use the result in Performs quantitive failure modes Identify potential
decision making evaluation capable of producing failure modes
problems
ADVANTAGES OF FMEA

 Increased reliability and asset integrity (right from the start)

 Better safety and environmental integrity
 Improved compliance
 Fewer breakdowns and downtime
 Empowerment through participation
 Risk reduction
[6]
FMEA

 The FMEA process will provide more reliability to an operational process as

entire failure processes have been analyzed in a detailed manner that includes
a list of associated primary and secondary causes that may lead to such
failures. [7]
WORK DONE SO FAR

 Literature review (RCM & FMEA)

 Survey on Software
 Field Visit
SURVEY ON SOFTWARE
 There are different software used for failure analysis, some of them are
 RCM++
 Xfmea
 IRCM
 RBI
 n code
[8]

 RCM++ has most feasible feature of any analysis for our requirements
RCM++

FEATURES

 RCM++ provides a flexible and intuitive interface for defining your system
configuration and recording the functional failure analysis. The software tool includes
configurable equipment selection, failure effect categorization and maintenance task
selection capabilities. [8]

 RCM++ also provides simulation-based calculations that can be used to compare the
costs of potential maintenance strategies and a calculator to estimate the optimum
maintenance interval for preventive repairs/replacements.[9]
FIELD VISIT
 SYSTEM FUNCTION & SPECIFICATIONS
To compress sale gas with following inlet & discharge specifications: [10]

CONDITIONS INLET DISCHARGE

Pressure ( MPa ) 3.57 8.72
TEMPERATURE ( °C) 44 131
Relative Humidity (%) 22~77 -
Molecular weight 17.884 -
Cp/Cv 1.39 1.35
Compressibility 0.95 0.98
Volume (m3/h) 3514 -
Speed (RPM) 7050
FMEA OF COMPRESSOR INSTALLED

Failure mode Effect Cause

Slow Continuous Recurrent Vibration Overheating of Bearings Lubricant oil fed to bearings have got high
temperature due to improper working of lube oil
heat exchanger

Slow Intermittent Recurrent Vibration Potential to cause high vibration and parts Assembled parts of rotor get loose, increasing
damage amplitude of vibrations.

Insufficient intake of air Improper combustion deterioration of air filters

Low overall efficiency
Environmental effects

Gas leakage Reduce discharge pressure The joint of casing has not been tightened firmly
Wastage of gas
( Sudden Continuous irregular ) Risk of Fire
REFERENCES

1. Jeff banks .RCM –an overview of the process

Reserch engineer, The Applied Research Laboratory at The Pennsylvania State University
2. https://www.sciencedirect.com/science/article/pii/s0951832010000591
3. Anthony M. Smith. Reliability Centered Maintenance [book]
4. https://www.researchgate.net/publication/282253338
5. Anthony M.D.(2004). A Statistical Comparison of three root cause analysis tools
Journal of Industrial Technology
6. Niu, G., Yang, B.-S., and Pecht, M., 2010, “Development of an Optimized Condition-Based Maintenance System by Data
Fusion and Reliability-Centered Maintenance
7. George J. Besseris. A methodology for product reliability enhancement via saturated-unreplicated fractional factorial
design
8. http://www.renovetec.com/rcm_software.pdf
9. http://www.savvyaviator.com/rcm_nowlan_heap.pdf
10. Compressor Instruction manual & information provided by maintenance engineer of Plant
Thank You