Reliability Availability and

Maintainability (RAM)

Bogor, Mei 2023

1
Content
Introduction
RAM
Reliability Statistic
Reliability Data
Reliability Block Diagram

2
Reliability Availability and
Maintainability (RAM)
Analisis

3
 Performance
Introduction Drop
Start Up Operation

100%
10 years Operation

90% 15 years operation

80%

Improvement
When ??

Life-Cycle
Improvement

Improvement ??
Introduction

RAM increase Availability

and production efficiency

RAM is a methodology used to predict asset

performance for a given configuration in terms of
reliability, maintainability and availability.

RAM analysis by adding capabilities related to

operations tailored to the Oil and Gas industry
which provides as result utilization and production
efficiency

“ Reliability, Availability and Maintainability“

 IntroductionIntroduction
Availability
as ability to keep a functioning state or
Availability ready to operate in the given operational
condition
❖ Uptime
❖ Downtime
Reliability
as ability to perform a specific function
and may be given as design reliability or

RAM
operational reliability
❖ MTTF

Maintainability
as ability to be timely and easily
maintained (including servicing,
inspection and check, repair and/or
Reliability Maintainability modification
❖ MTTR

“ Reliability, Availability and Maintainability“

 Introduction
Profit

High Availability Low Heat Rate

Uptime Downtime Plant Efficiency Process Operator

Quality Ability

Reliability Plant Maintainability

7
Implemented of Asset Integrity Management System (AIMS) using RAM Analysis for Power Plants
 Objective Objective

Provide an estimate of the availability

Identify the major contributors to unreliable equipment

(low MTTF)

Identify the major contributors to high MTTR

equipment

“ Reliability, Availability and Maintainability“

 Risk
Risk is product of likelihood of failure or accident and undesirable
consequences of failure or accident

Risk = Probability of Failure x Consequence of Failure

❑ Damage Mechanism ◼ Personnel / Individual

❑ Material/Environment Degradation & Rate, ◼ Societal
❑ Equipment Failure Mode ◼ Environment
◼ Economic/Asset

Reliability Aspect
Safety Aspect
9
Implemented of Asset Integrity Management System (AIMS) using RAM Analysis for Power Plants
 DEFINITION

Reliability
❑ The probability that an item (or a system) can perform its intended function for
a specified time interval under stated operation conditions.

(MIL-STD-721C,1981) 44

To provide a general definition for the reliability of an item one must address a
minimum of three elements :

1. A probability of an item functioning as intended

2. An operational interval defined in time units or cycles
3. A definition of the item’s operating environment

10
Implemented of Asset Integrity Management System (AIMS) using RAM Analysis for Power Plants
 DEFINITION
Maintainability

The measure of the ability of an item to be restored to a specified condition

when maintenance is performed by personnel having specified skill levels,
using prescribed procedures and resources, at each prescribed level of
maintenance and repair.

MIL-STD-721C (1981)

Maintainability was first considered a subset of reliability. The mid 1960s

saw maintainability established as a separate discipline. Maintainability IS
STILL associated with such discipline as reliability, system safety,
effectiveness engineering, product assurance or other support area.

11
Implemented of Asset Integrity Management System (AIMS) using RAM Analysis for Power Plants
 Formula
Maintainability and Repair Time Prediction

M =1− Exp ( − t / MTTR )

t = Allowable downtime
MTTR = Mean Time to Repair (expected downtime)

 ( i ti )
i =1
MTTR = n

 i
i =1

n = number of subsystems
λ = failure rate of the ith system
t = time to repair the ith unit

12
Implemented of Asset Integrity Management System (AIMS) using RAM Analysis for Power Plants
Reliability theory

Availability Produksi

• Berhubungan dengan jadwal produksi

• Berhubungan dengan jadwal maintenance

Availability equipment

• Kesediaan suatu alat untuk beroperasi

13
 Reliability theory

Jadwal Maintenance

• Dipengaruhi Uptime (Availiability)

• Uptime juga dipengaruhi oleh :
• Kapabilitas mesin
• Target pemasaran
• Kebijakan managemen
• Downtime (maintenance)

14
 Reliability theory

Reliability - Keandalan

• Apa definisi reliability

• Bagaimana menghitung reliability saat komponen dan peralatan
bekerja
• Apa yang menghubungkan reliability dengan Availibility

15
 Reliability theory

Reliability
• Adalah probability suatu komponen, alat atau system untuk
berfungsi pada selama waktu yang ditetapkan pada kondisi yang
ditentukan.

16
Reliability, Availability, Maintainability
Introduction
Reliability, Availability, Maintainability
Introduction
Reliability, Availability, Maintainability
Introduction
Reliability, Availability, Maintainability
Introduction
Reliability, Availability, Maintainability
Introduction
 Introduction
Reliability, Availability, Maintainability
Reliability theory
Reliability theory
Reliability theory
 Kapan dikatakan Gagal

Gagal artinya umur komponen lebih rendah dari pada umur yang
direncanakan

Failure time Jadwal maintenance

 Failure Time

• Setiap komponen memiliki Mean Time to Failure (MTTF)

• MTTF adalah umur rata rata dari suatu komponen.

• Dihitung dengan menggunakan Probability /Weibull.

Filosofi Preventive Maintenance

Jadwal replacement Failure time

• Preventive maintenance : replace before failure ,

Fix time
Filosofi Predictive Maintenance

Jadwal Failure time

replacement

• Predictive maintence: memperpanjang waktu

replacemen dengan memperhatikan kondisi
(condition based). Replace as before failure
Filosofi Predictive Maintenance
31
34
35
36
 PROACTIVE MAINTENANCE
• Berbeda dengan Predictive dan preventive maintenance, Proactive
yang berorientasi UPTIME , maka Proactive maintenance lebih
berorientasai pada RISK REDUCTION
 Filosofi
Proactive Maintenance
• Proactive maintence: waktu replacemen bisa jadi dilakukan lebih
awal umumnya pada reliability 98 %

Jadwal
Failure time
replacement
Reactive maintenance
 Failure Data

Failure 1. Generic : IEEE 493, OREDA DNV,

Data SERH
2. Manufacture Data

3. Historical Failure

45
Failure Data
• Shutdown
Critical • Require
Shutdown

• Derating
• Degradation
Degraded
System
• Alarm

• Internal
Minor
• Component

46
 Introduction
Reliability, Availability, Maintainability

Example Reliability Data Using Weibull Statistic

 Reliability theory

Risk dan Reliability

• Risk adalah suatu potensial resiko yang jika terjadi suatu kegagalan
pada peralatan memiliki dampak kerugian secara financial cukuo
besar

48
 Reliability theory

Risk - consequency
• Safety
• Heath
• Environment
• Production
• Cost
• Property

49
 Reliability theory

Reliability Improvement mean

50
 Reliability
Centered
Maintenance

Bagor, Mei 2023

Content
Introduction
Maintenance Excellence
RAM level Plant to Equipment
RCM

52
 Introduction

Maintenance Excellence is the balance of performance,

risk, and cost to achieve an optimal solution.
(JD. Campbell)

“ Pendataan Asset dan Pengembangan

Maintenance Strategy SAP
FlowPada Surface Facility dan Power Plant PLTP Patuha Unit I “
Diagram
 Introduction

Achieving
Excellence

Optimizing Maintenance
Decision Management

Reliability
Management

Maintenance Excellence Framework

“ Pendataan Asset dan Pengembangan
Maintenance Strategy SAP
FlowPada Surface Facility dan Power Plant PLTP Patuha Unit I “
Diagram
 RAM level Plant

Availability Level 1
1.2

0.8

0.6

0.4

0.2

0
SK-GPRF PG Facility SK-Well SK-TGIM SK-NOG

Availability Plant
The higher unavailable occurred in Sungai Kenawang Gas Production Facility and Pulau Gading Gas Production
Facility. Both Gas Production Facilities have many major equipment become bad actor or contributor unavailable
 RAM Level System

Availability Level 2
1

0.99

0.98
0.97

0.96

0.95

0.94

0.93

0.92

0.91
GTG Power CO2 RMVL Gas Liquid Sales Gas Produced Air De-Ethinizer Mercury Condensate Fuel Gas MOL Sieve NGL Product
System SPRTR Compressor Water Instrument RMVL HNDL/ Dehydration Shipping
STBLZ

Unreliable Equipment
High failure rate is high contributor unreliable equipment will cause degraded performance equipment and
system and effect to availability system
 RAM Level Equipment
Failure Modes GTG
0.00009
0.00008
0.00007
0.00006
0.00005
0.00004
0.00003
0.00002
0.00001
0
Spurious stop Other Abnormal Breakdown Fail to start Faulty output Parameter
Instrument on demand voltage deviation

Failure Rate
Failure rate each failure mode of equipment occurred during operation
 RAM Level Equipment
PF Curve Life (B10) : 3962 hrs
Life (B50) : 10162 hrs
1
Breakdown: 30000 hrs
B10, 3962
0.8

0.6
B50, 10162
0.4

0.2

0
1 10 100 1000 10000 100000

Potential & Functional Curve

P-F curve is base line to predict remaining useful life an equipment. Strategic Maintenance and life cycle
management can be planned before equipment “end life”
 Introduction
Reliability Centered Maintenance (RCM)
Minimize the risk
cost- Maintain based on reliability condition
effective will minimize probability of failure and
maint. risk
❖ PoF = 1-R(t)
❖ Risk = CoF * PoF
Cost-Effective
Maintenance order will be selected and
focus to eliminate the failure mode
before failure occur.
❖ Spent Budget = Cost

RCM Increase Uptime

Uptime is operation time available to
maximize production
❖ Av = Uptime/ (uptime + downtime)
minimize Increase
the risk Uptime
 Introduction
Reliability Centered Maintenance (RCM)

Asset Production Asset

Non
Asset Criticality Critical
Critical

PM PdM Proactive Redesign/ Run to Non Priority

RCM Decision (35%) (25%) (10%)
Modificatn
(<5%)
Failure
(10%)
PM
(15%)
RCM Decision
Introduction
 Langkah RCM

• Definisi batas sistem / peralatan

• Identifikasi fungsi sistem / peralatan
• Identifikasi peralatan fungsional dan jenis peralatan
• Analisis Efek Mode Kegagalan (FMEA) dan Analisis Risiko
• Strategi Pemeliharaan / pengembangan paket Tugas
Boundary/ Batasan
 Failure Mode and Effect Analysis

• Mode Kegagalan – Suatu kejadian unik, yang menyebabkan terjadinya

kegagalan fungsi.
• Fungsi – Apa yang diinginkan oleh pemilik atau pengguna dari suatu asset
fisik tentang apa yang bisa dilakukan oleh asset fisik tersebut.
• Kegagalan Fungsi – Tingkat keadaan pada mana suatu asset fisik atau
sistem tidak mampu untuk melakukan suatu fungsi spesifik sampai suatu
tingkat prestasi yang diinginkan.
• Kegagalan Tersembunyi – Suatu mode kegagalan di mana efek-efeknya
tidak menjadi nyata ke crew operasi pada kondisi normal operasinya
sewaktu mode kegagalan tersebut terjadi dengan sendirinya.
• Efek Kegagalan – Kejadian-kejadian apa saja yang terjadi bila suatu mode
kegagalan terjadi
FMEA
 6 Dampak kegagalan
Failure Effect

Local Effect System Effect Plant Effect

• Failure • Equipment • System fail

impact self failure may may
equipment impact to impact to
system unit plant

Alarm, Trip,
Breakdown Partial Emergency
Shutdown Respon
 6 Dampak kegagalan
Failure Effect

Asset Failure

Index Konsekuensi Produksi/ Severity

Analyze Failure P&ID/ C&A Kegagalan menyebabkab terhentinya produksi dengan

5
durasi lama (shutdown > 8 jam)
Effect Diagram
Kegagalan menyebabkab terhentinya produksi dengan
4
durasi lama (shutdown ≤ 8j am)
No
Keegagalan mengganggu sistem produksi (Alarm,
3
parsial shutdown)

Review Failure
Expert 2 Kegagalan hanya mengganggu kinerja peralatan
Effect

1 Kegagalan tidak mengganggu kinerja peralatan

Yes

Severity
 2.7 Frekuensi mode kegagalan
Occurrences

Dengan nilai PoF = 32.97%. Berdasarkan tingkat PoF pada tabel diatas maka
level PoF status indicator valve yaitu 2 unlikely/ Minor
 6 Detectability
Detectability

Local
Indicator

Inspeksi/
Online
Maintenance,
Monitoring
Test

Failure
 6 Detectability
Detectability
 6 Detectability
Detectability
Nilai Kondisi Deskripsi
1 Very Low Kegagalan dapat dengan mudah dideteksi melalui
sistem kontrol monitoring (Online Monitoring)
2 Low Kegagalan dapat dideteksi melalui sistem monitoring
atau local indicator

3 Medium Kegagalan dapat dideteksi dan hanya dapat diketahui

dengan melakukan inspeksi/ Maintenance/ Regular
Check
4 High Kegagalan tidak dapat dideteksi dan hanya bisa
diketahui dengan menggunakan peralatan khusus dan
analisa lebih lanjut

5 Very High Sangat tidak mungkin untuk mendeteksi kegagalan

Tabel diatas adalah detectability yang mana setiap tingkatan menunjukan

sebuah kegagalan yang dapat didteksi sebelum kegagalan tersebut
berdampak mengganggu kinerja peralatan dan sistem. Semakin rendah nilai
detectability semakin mungkin untuk diketahui kegagalannya
 Risk Priority Number

RPN = Sev* Occ* det; ....................................................................(1)

Sev = Severity or impact of Failure atau Konsekuensi dari kegagalan

Occ = Occurances of Failure atau Kemungkinan dari terjadinya kegagalan
Det = Detectionability atau metode mengethaui mekanisme kegagalan

Risk Priority Number

Kategori Keterangan
(RPN)

Low/ Good 0 – 17 Penanganan peralatan dan tata kelola resiko

sangat memuaskan
Moderate/ Acceptable 18 – 32 Penanganan peralatan dan tata kelola resiko
cukup baik. Perlu diawasi dan sedikit evaluasi
Penanganan peralatan dan tata kelola resiko
High/ Unsatisfactory 33 – 62 perlu diawasi dan dievaluasi agar resiko
terkendali.
Extreme/ Penanganan peralatan dan tata kelola resiko
63 – 125 perlu ditingkatkan ke tingkat aman atau
Unacceptable
diisolasi agar resiko terkendali.
RCM List Asset
(RPN)

High Priority

No
Yes

Review
History/ OREDA
Occurances

No New Interval
MDT < Occ and addtional
task

Yes

Existing Task

Workpack
 Introduction
RCM Water Injection Pump

Water Injection Pump of EOR Facility

 Introduction
Failure Modes of WIP

Failure Mode of Centrifugal Pump

18.00%
16.55%
15.89% 16.06%
16.00%

14.00%

12.00% 11.31%
11.00%

10.00%
8.70%
8.00%
5.85% 6.06%
6.00%
4.35%
4.00%
1.83%
2.00% 1.08% 1.32%

0.00%
Erratic Internal Noise Other High output Parameter Breakdown Low output External Vibration Overheating External
output leakage deviation leakage - leakage -
Utility Process
medium medium
Failure Modes of WIP
Introduction
General Failure Mechanism
Other Electrical
4% 1%
Process
Instrument
17%
23%

Mechanical
55%

Electrical Instrument Mechanical Process Other

 Introduction
Failure Modes of WIP

100.00%

90.00% B10, 1494.05

80.00%

70.00%
Percentage (%)

60.00%

50.00% B50, 9829.09 Reliability

B10
40.00%
B50
30.00%

20.00%

10.00%

0.00%
1 10 100 1000 10000 100000
time (hours)
 Introduction
Failure Modes of WIP

Issue WIP Failure:

• Kerusakan pada Electrical motor lebih cepat dari jadwal life time bearing
• ConMon atau PdM Pompa dangan Analisa vibrasi tidak dapat memprediksi
kerusakan dan memberikan early warning
• Tipe bearing motor existing dengan sleeve bearing
• Tidak Ada spare motor ready line di workshop
• Not redundancy WIP
Recommendation:
• Lakukan RCA untuk kegagalan WIP
• Analisa RCM untuk improve maintenance program
 Introduction
RCM of WIP
 Introduction
RCM of WIP
 Introduction
RCM of WIP
Configuration
Reliability Block
Diagrams

83
RBD Configuration

RBD Configuration
Plant Site RBD Configuration
 Plant Site RBD Configuration
No Item λ system R (t = 1 month ) R( t = 3 months) R( t = 6 months)
1 Separator 4,789E-06 0,9965 0,9897 0,9795
2 Demister 4,789E-06 0,9965 0,9897 0,9795
3 Governor Valve 4,789E-06 0,9965 0,9897 0,9795
4 Main Stop Valve 1,047E-05 0,9924 0,9776 0,9557
5 Turbine 2,341E-05 0,9832 0,9506 0,9038
6 Condenser 0,0001124 0,9222 0,7844 0,6153
7 MCWP 6,03E-09 0,9999 0,9999 0,9999
8 Cooling Tower 2,33E-05 0,9833 0,9509 0,9042
9 Primary Pump 6,932E-09 0,9999 0,9999 0,9999
10 Secondary Pump 2,78E-10 0,9999 0,9999 0,9999
11 Ejector 1 1,925E-05 0,9862 0,9592 0,9202
12 Ejector 2 1,925E-05 0,9862 0,9592 0,9202
13 Inter Condenser 4,789E-06 0,9965 0,9897 0,9795
14 After Condenser 4,789E-06 0,9965 0,9897 0,9795
15 Inter Cooler 1,376E-10 0,9999 0,9999 0,9999
R total = 0,8461 0,6057 0,3669

86
Plant Site RBD Configuration

Grafik
Reliability Reliabilityof Time
As Function

1.2 MCWP &

1 Separator
Demister Separator
Turbine
0.8 Demister
Reliability

Condenser Cooling Tower Turbine

0.6
Condenser
0.4 MCWP
0.2 Cooling Tower

0
0 5 10 15 20
Waktu ( Bulan
Time )
(Months) 8

87
Plant Site RBD Configuration
No Item MTBF ( jam ) MTTR ( jam ) Availability
1 Separator 208824 3 0.9999
2 Demister 208824 2 0.9999
3 Governor Valve 208824 8.1 0.9999
4 Main Stop Valve 95536.5 1.38 0.9999
5 Turbine 42711.1 53 0.9987
6 Condenser 8896.6 5.18 0.9994
7 MCWP 56410.3 19.2 0.9999
8 Cooling Tower 42914.3 131.3 0.9969
9 Primary Pump 34804 4.2 0.9999
10 Secondary Pump 103877 1.5 0.9999
11 Ejector 1 51938.3 1.2 0.9999
12 Ejector 2 51938.3 1.2 0.9999
13 Inter Condenser 208824 1.4 0.9999
14 After Condenser 208824 1.4 0.9999
15 Inter Cooler 208824 3 0.9999
0.983
88
Plant Site RBD Configuration
No Item MTBF ( jam ) MTTR ( jam ) Availability
1 Separator 208824 3 0.9999
2 Demister 208824 2 0.9999
3 Governor Valve 208824 8.1 0.9999
4 Main Stop Valve 95536.5 1.38 0.9999
5 Turbine 42711.1 53 0.9987
6 Condenser 8896.6 5.18 0.9994
7 MCWP 56410.3 19.2 0.9999
8 Cooling Tower 42914.3 131.3 0.9969
9 Primary Pump 34804 4.2 0.9999
10 Secondary Pump 103877 1.5 0.9999
11 Ejector 1 51938.3 1.2 0.9999
12 Ejector 2 51938.3 1.2 0.9999
13 Inter Condenser 208824 1.4 0.9999
14 After Condenser 208824 1.4 0.9999
15 Inter Cooler 208824 3 0.9999
0.983
89
 RAM Analysis Conclusions

1. From RAM analysis it was found that the largest contributor to the plant
shut down is condenser having the highest failure rate. Therefore, to
increase the reliability of the condenser (and thereby the availability of the
plant), proper inspection and maintenance strategy was then planned.

2. It turned out that internal and external corrosion is the primary damage
mechanism in the condenser tubes and structures, therefore more
effective corrosion control should be put in place.

3. It was found that theoretical reliability of the system was 84,61% for 1
month operation compared to actual of 91,74% . The difference was
caused by online restoration program without the need of shutting down
the system.

4. For availability system, the theoretically was 98,3% compared to actual

91,7%, since there are some equipments have longer reparation time (high
MTTR

90
Implemented of Asset Integrity Management System (AIMS) using RAM Analysis for Power Plants
Power System RBD Configuration

“ Reliability, Availability and Maintainability“

Power System RBD Configuration

“ Reliability, Availability and Maintainability“

 Thank You
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