MOG603

Unit Description and General Aims

This unit provides students sufficient depth of practical understanding of the principles and practical application of reliability and maintenance management in the context of the oil and gas industry. From this broad understanding students develop a framework to apply appropriate reliability and maintenance management techniques to instrument and electrical systems.

This unit takes the student through the process of modelling systems and predicting reliability, availability, maintainability and safety. This unit introduces asset management, asset life-cycle management including asset life progression and optimal life determination principles. Finally the unit brings the various topic areas together in specific application for Electrical and & Instrument systems.

The aim of the unit is to ensure participants gain a wide understanding, are able to place interrelated topics of risk, reliability, safety, integrity and maintenance management in the appropriate context and thus are better placed to communicate effectively with the wide range of disciplines involved in maintenance management through asset life.

Learning Outcomes

On successful completion of this Unit, students are expected to be able to:

1. Analyse and apply asset management, probability theory, failure mode and effects, criticality assessment
2. Compare and contrast failure data from various sources in terms of reliability, accuracy and confidence levels.
3. Model systems in the success or failure domains, derive system failure rates from component failure rates and identify single points of failure or weakness.
4. Relate failure behaviour of equipment to condition, performance and risk to business.
5. Evaluate the relationships between reliability, risk, safety & integrity to arrive at appropriate maintenance plans for Electrical and & Instrument

Student assessment

Prescribed and recommended readings

Required textbook(s)

1. I. Sutton, Process Risk and Reliability Management: Operational Integrity Management, 2010, ISBN: 978-1437778052

OR

2. J. Smith, Reliability, Maintainability and Risk, 2005.

Reference Materials

• Asset Management – Overview, terms and definitions, ISO 55000: 2014
• Asset Management – Management Systems Requirements, ISO 55001: 2014
• Asset Management – Guidelines for the application of ISO 55001, ISO 55002: 2014
• Fault Tree Analysis, Australian standard AS IEC 61025, 2008

• Number of peer-reviewed journals and websites (advised during lectures) [some examples below]:
  • O’Connor, Practical Reliability Engineering, 5th Ed, Wiley, 2012
  • Control Engineering
  • EIT notes

Unit Content

One topic is delivered per contact week, with the exception of part-time 24-week units, where one topic is delivered every two weeks.

Topics 1 and 2

Introduction, Probability theory and systems

1. Definitions of reliability and maintenance management.
2. Who does what, in a typical operating company in the area of reliability and maintenance management.
3. Typical tools, systems and processes and when they are typically applied in practice
4. Probability theory, series and parallel systems, redundancy rules, common cause failure
5. Repairable and non-repairable systems, modelling other factors (human factors, weather)
6. Metrics for measuring safety integrity

Topics 3 and 4

Reliability techniques

1. Reliability Block diagrams
2. Fault Tree Analysis (FTA), Event Tree Analysis (ETA), Monte Carlo, Markov and variance reduction techniques
3. FMEA – Failure Mode and Effects Analysis, FMECA – Failure Mode, Effects and Criticality Analysis, FMEDA – Failure Mode, Effects and Diagnostics Analysis
4. Fault tolerance, diagnostics and diagnostics capability, systematic failures
5. RAM modelling, results and presentation
6. Maintenance strategy selection based on FMECA

Topics 5 and 6

Reliability data and analysis

1. System failure rates, OREDA and limitations
2. Field failure data collection, role of CMMS
3. Data accuracy, databases and confidence limits, managing quality data (range estimation)
4. Statistical methods
5. Cumulative Poisson curves, Chi-square distribution, Weibull, degradation analysis, accelerated life testing, system simulation, reliability prediction models
6. Failure reporting, analysis and corrective action system (FRACAS), action tracking, ranking and reporting

Topics 7 and 8

Introduction to Asset Management and Asset Life-Cycle Management (maintenance management)

1. Asset management and business performance
2. ISO 5500x framework for managing assets
3. Lifecycle phases and definition of asset life, WBS, budgeting maintenance
4. Corrective maintenance analysis, factors and failure behaviour impacting on asset life & cost of maintenance
5. Risk based approaches to focus on the right assets (RCM, RBI, SIL)
6. Asset Integrity, integrity elements and their impact on safety, risk and performance
7. Relationship between Integrity, Risk and Reliability, safety critical elements, performance standards and maintenance prioritisation for SCEs in scheduled and backlog management
8. Establish the integrity lifecycle, examples of integrity delivery and management
9. CMMS management (inc fault codes, narratives, RCA, detailed failure analysis reporting, nominal & revision, OEM support, management of change, data cleansing)

Topics 9,10 and 11

Integrity, ageing assets, Electrical and & Instrument systems maintenance management

1. Operational safety management
2. Integrity measurement
3. Root cause analysis
4. Repair / replace decisions, sustainability
5. Examples of integrity failures / preventive actions
6. Facility shutdown planning and risk based maintenance campaigns
7. Deciding when to repair: during operations or during planned maintenance shutdowns
8. Conclusion: maintenance management for Electrical and & Instrument systems

Topic 12

Project and Revision

In the final weeks students will have an opportunity to review the contents covered so far.  Opportunity will be provided for a review of student work and to clarify any outstanding issues.  Instructors/facilitators may choose to cover a specialized topic if applicable to that cohort.

Professional Development

 Completing this unit will add to students professional development/competencies by:

1. Fostering the personal and professional skills development of students to:
   • Be adaptable and capable 21st century citizens, who can communicate effectively, work collaboratively, think critically and innovatively solve complex problems.
   • Equipping individuals with an increased capacity for lifelong learning and professional development.
   • Planning and organising self and others
   • Instilling leadership qualities and a capacity for ethical and professional contextualization of knowledge
2. Enhancing students’ investigatory and research capabilities through:
   • Solving complex and open-ended engineering problems
   • Accessing, evaluating and analysing information
   • Processes and procedures, cause – effect investigations
3. Developing the engineering application abilities of students through:
   • Assignments
   • Labs / practical / case studies / self-study (where applicable)

Resource Requirements

Software

Web & Video conferencing software

Students will be provided with Blackboard Collaborate (or similar) for video and web conferencing. This will allow them to attend lectures, interact with lecturers and fellow students, and use the Remote Lab facility. Students will be required to download the latest version of Java and .NET in order to use these packages.

Skype

For ease of communicating with peers and lecturers, installation of this package is recommended.

Word, PowerPoint and Excel

It is recommended that students install at least a 2007 version of the Microsoft Office. Older versions will work, but sometimes create issues with file compatibility. If individuals are reluctant to use these, they can also use Open Office (www.openoffice.org).

Virus detection

As students are co-operating with people from throughout the world with a multitude of different PCs, it is recommended that they have good quality up-to-date virus detection software installed. The free version of AVG is sufficient. A thorough automated scan of computers at least once a week is recommended.

Learning Management System

EIT uses a state-of-the-art learning management system (Moodle) for lecturing and interacting with lecturers and fellow students. Students can chat, socialize, and collaborate on projects with similarly motivated and enthusiastic course participants.

Computing resource requirements

Computer

Students’ computers should have an Intel Core Duo CPU and 2 Gigabytes of RAM. Hard disk space available should be at least 2 Gigabytes free. If necessary the built-in hard drive can be augmented with an inexpensive USB drive. No particular special graphics card is required. The operating system should be Windows with Windows 7 Service Pack 1 as a minimum.

Internet

An ADSL Internet connection with a minimum speed of 128 kbps down and 64 kbps up is recommended. 

Good quality headset and low cost web cam

Students will require a good quality stereo headset with analogue or USB connectors.  In addition, a low-cost USB webcam is recommended. Students should budget in the order of $30 for a headset and $20 for a webcam. This will vary from country to country.

Technical Help

For difficulties with other online materials the lecturer should be contacted. Technical material will be accessible 24/7 through the online portal.

Unit Changes Based on Student Feedback