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๐–๐ก๐š๐ญ ๐ซ๐ž๐š๐ฅ๐ฅ๐ฒ ๐๐ซ๐ข๐ฏ๐ž๐ฌ ๐š๐ฌ๐ฌ๐ž๐ญ ๐ข๐ง๐ญ๐ž๐ ๐ซ๐ข๐ญ๐ฒ: ๐ž๐ช๐ฎ๐ข๐ฉ๐ฆ๐ž๐ง๐ญ ๐๐ž๐ฌ๐ข๐ ๐งโ€ฆ ๐จ๐ซ ๐ก๐จ๐ฐ ๐ฐ๐ž ๐จ๐ฉ๐ž๐ซ๐š๐ญ๐ž ๐ข๐ญ?

  • 1.  ๐–๐ก๐š๐ญ ๐ซ๐ž๐š๐ฅ๐ฅ๐ฒ ๐๐ซ๐ข๐ฏ๐ž๐ฌ ๐š๐ฌ๐ฌ๐ž๐ญ ๐ข๐ง๐ญ๐ž๐ ๐ซ๐ข๐ญ๐ฒ: ๐ž๐ช๐ฎ๐ข๐ฉ๐ฆ๐ž๐ง๐ญ ๐๐ž๐ฌ๐ข๐ ๐งโ€ฆ ๐จ๐ซ ๐ก๐จ๐ฐ ๐ฐ๐ž ๐จ๐ฉ๐ž๐ซ๐š๐ญ๐ž ๐ข๐ญ?

    Posted 16 days ago

    When we talk about ๐’‚๐’”๐’”๐’†๐’• ๐’Š๐’๐’•๐’†๐’ˆ๐’“๐’Š๐’•๐’š, we often focus on technical aspects.
    But according to the ๐‘ช๐‘ด๐‘น๐‘ท ๐‘ฉ๐’๐’…๐’š ๐’๐’‡ ๐‘ฒ๐’๐’๐’˜๐’๐’†๐’…๐’ˆ๐’†, asset integrity actually depends on three key pillars:

    โš™๏ธ ๐—œ๐—ป๐—ต๐—ฒ๐—ฟ๐—ฒ๐—ป๐˜ ๐—ฟ๐—ฒ๐—น๐—ถ๐—ฎ๐—ฏ๐—ถ๐—น๐—ถ๐˜๐˜†
    This is the reliability built into the asset through design. It defines the probability of an asset to perform an intended function under certain conditions during a specific period of time.

    ๐Ÿ”ง ๐— ๐—ฎ๐—ถ๐—ป๐˜๐—ฒ๐—ป๐—ฎ๐—ป๐—ฐ๐—ฒ
    This includes all activities aimed at preserving or restoring the asset's condition over time.

    ๐Ÿ› ๏ธ ๐—ข๐—ฝ๐—ฒ๐—ฟ๐—ฎ๐˜๐—ถ๐—ป๐—ด ๐—ฐ๐—ผ๐—ป๐—ฑ๐—ถ๐˜๐—ถ๐—ผ๐—ป๐˜€
    This is how the equipment is actually used in the field - including operating practices, discipline, and human factors.

    While all three pillars are critical, experience across many industries shows that:
    ๐Ÿ‘‰ ๐‘จ ๐’”๐’Š๐’ˆ๐’๐’Š๐’‡๐’Š๐’„๐’‚๐’๐’• ๐’‘๐’๐’“๐’•๐’Š๐’๐’ ๐’๐’‡ ๐’‡๐’‚๐’Š๐’๐’–๐’“๐’†๐’” ๐’Š๐’” ๐’๐’Š๐’๐’Œ๐’†๐’… ๐’•๐’ ๐’‰๐’–๐’Ž๐’‚๐’ ๐’‚๐’๐’… ๐’๐’‘๐’†๐’“๐’‚๐’•๐’Š๐’๐’๐’‚๐’ ๐’‡๐’‚๐’„๐’•๐’๐’“๐’”.
    In other words, even a well-designed and well-maintained asset can fail if it is not operated properly.
    So, the real question becomes:

    ๐‡๐จ๐ฐ ๐œ๐š๐ง ๐ฐ๐ž ๐ข๐ฆ๐ฉ๐ซ๐จ๐ฏ๐ž ๐จ๐ฉ๐ž๐ซ๐š๐ญ๐ข๐ง๐  ๐œ๐จ๐ง๐๐ข๐ญ๐ข๐จ๐ง๐ฌ ๐ญ๐จ ๐ฉ๐ซ๐จ๐ญ๐ž๐œ๐ญ ๐š๐ฌ๐ฌ๐ž๐ญ ๐ข๐ง๐ญ๐ž๐ ๐ซ๐ข๐ญ๐ฒ?
    Here are a few practical levers:
    โ€ข Strengthening operator training and qualification
    โ€ข Improving operating procedures and discipline
    โ€ข Implementing TPM

    As per my experience, the first one is a paramount action to achieve this goal.
    What do you think of it?
    What actions do you think have the biggest impact on improving operating conditions and reducing failures?



    ------------------------------
    Mamadou ANNE
    Maintenance Supervisor
    CMRPยฎ| CJPM (IAPM) | LSSYB (CSSC)
    ------------------------------


  • 2.  RE: ๐–๐ก๐š๐ญ ๐ซ๐ž๐š๐ฅ๐ฅ๐ฒ ๐๐ซ๐ข๐ฏ๐ž๐ฌ ๐š๐ฌ๐ฌ๐ž๐ญ ๐ข๐ง๐ญ๐ž๐ ๐ซ๐ข๐ญ๐ฒ: ๐ž๐ช๐ฎ๐ข๐ฉ๐ฆ๐ž๐ง๐ญ ๐๐ž๐ฌ๐ข๐ ๐งโ€ฆ ๐จ๐ซ ๐ก๐จ๐ฐ ๐ฐ๐ž ๐จ๐ฉ๐ž๐ซ๐š๐ญ๐ž ๐ข๐ญ?

    Posted 16 days ago

    Thanks for the post...this is one that seems to travel around companies constantly.   I would say the foundation that ties all of these items together is a culture of reliability.   Ramesh Gulati does a really nice job explaining culture with real world examples in his book Maintenance and Reliability Best Practices.  This culture ties all parts of the plant together working toward the same goal with the same thought process.   My experience is most manufacturers have a somewhat siloed approach to their teams with operations and maintenance many times at odds with one and other.   A TPM program works to adopt this culture and partnership with the maintenance and operation teams but it requires significant coaching and mentoring to get this cultural change to take place.   It is also very important to have engagement and alignment with senior leadership within the site, division and corporation.  Without it,  all gains will be lost in a matter of time.   As far as your comment on "the first one is a paramount action",  I believe if you attempt to accomplish this like an action item you will fail.   If you take the TPM approach where you understand gaps and use maintenance to coach and improve documentation as a continuous improvement cycle then 1. you are never done and 2. its broken down into bite size pieces which are more easily accepted.   Really good discussion,  I'm interested to hear what other's thoughts on this subject are.



    ------------------------------
    Mark Pospisil
    Program Manager Maintenance Excellence AN Division
    Abbott Laboratories
    Sunbury OH
    ------------------------------



  • 3.  RE: ๐–๐ก๐š๐ญ ๐ซ๐ž๐š๐ฅ๐ฅ๐ฒ ๐๐ซ๐ข๐ฏ๐ž๐ฌ ๐š๐ฌ๐ฌ๐ž๐ญ ๐ข๐ง๐ญ๐ž๐ ๐ซ๐ข๐ญ๐ฒ: ๐ž๐ช๐ฎ๐ข๐ฉ๐ฆ๐ž๐ง๐ญ ๐๐ž๐ฌ๐ข๐ ๐งโ€ฆ ๐จ๐ซ ๐ก๐จ๐ฐ ๐ฐ๐ž ๐จ๐ฉ๐ž๐ซ๐š๐ญ๐ž ๐ข๐ญ?

    Posted 14 days ago

    Thanks for this valuable contribution! 
    I totally agree with you, indeed even if it is fundamental, operators training should be just a part of a whole process sustained by the culture. 



    ------------------------------
    Mamadou ANNE
    Maintenance Supervisor
    ------------------------------



  • 4.  RE: ๐–๐ก๐š๐ญ ๐ซ๐ž๐š๐ฅ๐ฅ๐ฒ ๐๐ซ๐ข๐ฏ๐ž๐ฌ ๐š๐ฌ๐ฌ๐ž๐ญ ๐ข๐ง๐ญ๐ž๐ ๐ซ๐ข๐ญ๐ฒ: ๐ž๐ช๐ฎ๐ข๐ฉ๐ฆ๐ž๐ง๐ญ ๐๐ž๐ฌ๐ข๐ ๐งโ€ฆ ๐จ๐ซ ๐ก๐จ๐ฐ ๐ฐ๐ž ๐จ๐ฉ๐ž๐ซ๐š๐ญ๐ž ๐ข๐ญ?

    Posted 16 days ago

    Can you provide the data you have to support this?

    ๐Ÿ‘‰ ๐‘จ ๐’”๐’Š๐’ˆ๐’๐’Š๐’‡๐’Š๐’„๐’‚๐’๐’• ๐’‘๐’๐’“๐’•๐’Š๐’๐’ ๐’๐’‡ ๐’‡๐’‚๐’Š๐’๐’–๐’“๐’†๐’” ๐’Š๐’” ๐’๐’Š๐’๐’Œ๐’†๐’… ๐’•๐’ ๐’‰๐’–๐’Ž๐’‚๐’ ๐’‚๐’๐’… ๐’๐’‘๐’†๐’“๐’‚๐’•๐’Š๐’๐’๐’‚๐’ ๐’‡๐’‚๐’„๐’•๐’๐’“๐’”.  Thanks for the post.



    ------------------------------
    Christopher Majek
    Reliability Manager
    Citgo Petroleum Corp
    Corpus Christi TX
    ------------------------------



  • 5.  RE: ๐–๐ก๐š๐ญ ๐ซ๐ž๐š๐ฅ๐ฅ๐ฒ ๐๐ซ๐ข๐ฏ๐ž๐ฌ ๐š๐ฌ๐ฌ๐ž๐ญ ๐ข๐ง๐ญ๐ž๐ ๐ซ๐ข๐ญ๐ฒ: ๐ž๐ช๐ฎ๐ข๐ฉ๐ฆ๐ž๐ง๐ญ ๐๐ž๐ฌ๐ข๐ ๐งโ€ฆ ๐จ๐ซ ๐ก๐จ๐ฐ ๐ฐ๐ž ๐จ๐ฉ๐ž๐ซ๐š๐ญ๐ž ๐ข๐ญ?

    Posted 14 days ago

    Here is some reference data: https://theramreview.com/the-human-side-of-failure/
    I also think even the SMRP BOK emphasizes the important of mastering human errors through its pillars (especially the pillar 2). 



    ------------------------------
    Mamadou ANNE
    Maintenance Supervisor
    ------------------------------



  • 6.  RE: ๐–๐ก๐š๐ญ ๐ซ๐ž๐š๐ฅ๐ฅ๐ฒ ๐๐ซ๐ข๐ฏ๐ž๐ฌ ๐š๐ฌ๐ฌ๐ž๐ญ ๐ข๐ง๐ญ๐ž๐ ๐ซ๐ข๐ญ๐ฒ: ๐ž๐ช๐ฎ๐ข๐ฉ๐ฆ๐ž๐ง๐ญ ๐๐ž๐ฌ๐ข๐ ๐งโ€ฆ ๐จ๐ซ ๐ก๐จ๐ฐ ๐ฐ๐ž ๐จ๐ฉ๐ž๐ซ๐š๐ญ๐ž ๐ข๐ญ?

    Posted 15 days ago
    Edited by Dale Nicholson 15 days ago

    Another approach that I have found to be useful is to investigate equipment downtime, involve the operators, and make any necessary repairs or improvements. By doing so, the operators

    • gain a better understanding of how their actions affect the assets,
    • realize someone is paying attention, which tends to improve the way they treat the assets, and
    • realize someone cares about any problems they may deal with every day, which tends to improve their job satisfaction.

    I've had a lot of success with this over the years. In some cases I've been hailed as a hero for implementing changes that eliminate sources of frustration or unnecessary work. In other cases some of the top downtime causes simply went away as the operators addressed them themsleves.



    ------------------------------
    Dale Nicholson, PE, CMRP, CRL
    Reliability Engineering Mgr
    Evonik Corp
    ------------------------------



  • 7.  RE: ๐–๐ก๐š๐ญ ๐ซ๐ž๐š๐ฅ๐ฅ๐ฒ ๐๐ซ๐ข๐ฏ๐ž๐ฌ ๐š๐ฌ๐ฌ๐ž๐ญ ๐ข๐ง๐ญ๐ž๐ ๐ซ๐ข๐ญ๐ฒ: ๐ž๐ช๐ฎ๐ข๐ฉ๐ฆ๐ž๐ง๐ญ ๐๐ž๐ฌ๐ข๐ ๐งโ€ฆ ๐จ๐ซ ๐ก๐จ๐ฐ ๐ฐ๐ž ๐จ๐ฉ๐ž๐ซ๐š๐ญ๐ž ๐ข๐ญ?

    Posted 14 days ago
    Edited by FRANCOIS VIVIAN KINGUE NJANJO 14 days ago

    Hello everyone, Excellent topic Mamadou.

    From a leadership perspective, asset integrity is rarely compromised by design or maintenance alone - it is most often challenged by how operations are managed under pressure.

    When production becomes the dominant driver, we often see a gradual normalization of deviations: operating limits are stretched, procedures become flexible, and discipline weakens. Not by intent, but through accumulated habits.

    This is where integrity is truly at risk.

    Sustainable improvement in operating conditions requires more than training. It demands:

    - Clear definition and strict enforcement of operating envelopes

    - Strong field discipline supported by leadership presence

    - Continuous feedback loops between operations, maintenance, and HSE

    - Alignment of KPIs to ensure production never overrides reliability and safety

    Because ultimately:

    What leadership tolerates becomes the standard.

    And that standard defines the long-term integrity of our assets.

    I'm interested to learn how others are driving this alignment in their organizations.

    ------------------------------
    FRANCOIS VIVIAN KINGUE NJANJO

    Mechanical Engineer | Vibration Analyst | Offshore Maintenance team member|

    Cegelec /Perenco
    ------------------------------



  • 8.  RE: ๐–๐ก๐š๐ญ ๐ซ๐ž๐š๐ฅ๐ฅ๐ฒ ๐๐ซ๐ข๐ฏ๐ž๐ฌ ๐š๐ฌ๐ฌ๐ž๐ญ ๐ข๐ง๐ญ๐ž๐ ๐ซ๐ข๐ญ๐ฒ: ๐ž๐ช๐ฎ๐ข๐ฉ๐ฆ๐ž๐ง๐ญ ๐๐ž๐ฌ๐ข๐ ๐งโ€ฆ ๐จ๐ซ ๐ก๐จ๐ฐ ๐ฐ๐ž ๐จ๐ฉ๐ž๐ซ๐š๐ญ๐ž ๐ข๐ญ?

    Posted 7 days ago

    I will comment in the context of the oil and gas industry, more specifically downhole equipment.

    I agree that the operational factors play a significant role. As mentioned in this thread, the pressure to deliver is the main driver and it comes in different flavors: operating beyond the limits, partially or fully skipping maintenance and not to mention mistakes caused by stress.

    While training and certification can improve operations and maintenance, that may not have a significant impact when equipment is operated outside its intended envelope, which is mostly driven by the business needs.

    Inherent reliability improvement is rarely adopted due to high redesign and deployment costs.

    A reasonable approach would be a risk-based decision making balancing maintenance and operating conditions. Hostile conditions beyond the limits requires heavier and in-depth maintenance. While benign conditions allow skipping part of the standard maintenance schedule.

    That's commonly observed in the offshore versus land operations, and in high risk environments with high temperature, high pressure, H2S and CO2 presence.



    ------------------------------
    Mauricio Arima
    Mechanical Engineer
    SLB
    Clamart, France
    ------------------------------



  • 9.  RE: ๐–๐ก๐š๐ญ ๐ซ๐ž๐š๐ฅ๐ฅ๐ฒ ๐๐ซ๐ข๐ฏ๐ž๐ฌ ๐š๐ฌ๐ฌ๐ž๐ญ ๐ข๐ง๐ญ๐ž๐ ๐ซ๐ข๐ญ๐ฒ: ๐ž๐ช๐ฎ๐ข๐ฉ๐ฆ๐ž๐ง๐ญ ๐๐ž๐ฌ๐ข๐ ๐งโ€ฆ ๐จ๐ซ ๐ก๐จ๐ฐ ๐ฐ๐ž ๐จ๐ฉ๐ž๐ซ๐š๐ญ๐ž ๐ข๐ญ?

    Posted 7 days ago

    Thank you for the valuable discussion.

    From field experience and published reliability data, a significant portion of failures is driven by how equipment is operated, not only how it is maintained.

    • Studies from SMRP and EPRI indicate that around 40โ€“50% of equipment failures are linked to operational practices such as:
      • operating outside design limits
      • frequent start/stop cycles
      • improper warm-up or loading
      • delayed response to alarms

    This aligns with what we see in gas turbines, compressors, and rotating equipment in oil and gas.

    Key point

    Maintenance alone cannot deliver reliability.

    Reliability = Design + Maintenance + Operation discipline

    Why operators must be part of maintenance

    Operators are the first line of defense.

    • They see early symptoms:
      • abnormal vibration
      • temperature drift
      • pressure instability
    • They control:
      • loading rate
      • startup/shutdown sequence
      • adherence to operating envelope

    Without operator involvement:

    • failures are detected late
    • maintenance becomes reactive

    Practical approach

    • Integrate operators into reliability programs:
      • Autonomous Maintenance (basic checks, cleaning, inspection)
      • Daily condition monitoring logs
      • Clear alarm response procedures
    • Link operation with maintenance through:
      • shared KPIs (availability, MTBF)
      • joint RCA sessions

    Critical observation

    If the system allows operation outside limits, the issue is not maintenance.

    It is:

    • weak control philosophy
    • or management pressure overriding discipline

    Conclusion

    Improving reliability requires treating operators as part of the maintenance system, not separate from it.

    Ignoring the operational contribution means ignoring up to half of the problem.



    ------------------------------
    Tarek Abdelgaleel
    I&C Assistant General Manger
    General Petroleum company (Egypt)
    tanta
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