Reliability
Engineering and
RAM Modelling
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Reliability Engineering
Reliability Engineering is a discipline that encompasses a holistic approach to the study of
equipment availability, reliability and maintenance to optimise the economic returns from
plant and equipment.
For major production facilities lost opportunity production • Reliability, Availability and Maintainability (RAM)
costs can be in the order of hundreds of thousands to modeling to identify facility capability.
millions of dollars per day. Hence the availability, reliability • Using RAM models results to specify reliability and
and maintainability of process equipment are of major maintainability targets for equipment subsystems and
importance to these facilities. Improving process equipment optimising redundancy to achieve the performance
availability will result in large economic gains for the facility targets.
operators. • Selecting equipment configurations which are optimal in
terms of Life Cycle Cost.
Advisian engineers apply a systematic approach to
• Failure Modes and Effects Analysis (FMEA) on equipment
reliability, availability and maintainability throughout the
to design out potential failure modes.
design. This approach involves (but is not limited to):
Reliability engineering input during the operations phase
• Setting reliability and availability targets for the facility.
is about identifying the areas of poor or unsatisfactory
• Selecting robust designs / technologies.
performance, analysing and understanding the drivers and
• Eliminating or minimising hazards for maintenance
root causes of poor performance and evaluating proposed
personnel.
solutions.
• Selecting equipment from vendors that offer local
support. Advisian has a range of software and business systems to
• Equipment design reviews addressing issues of apply these techniques. Advisian have applied these tools in
equipment maintainability, layout, access, crainage, etc. diverse industries to achieve improved economic and safety
• Minimising use of equipment that requires specialised performance for our clients.
tools, skills and extensive training.
Reliability Engineering Lifecycle
PREFEASIBILITY/ FEASIBILITY / BASIC DESIGN / DETAILED OPERATIONS
CONCEPT SELECT FEED DESIGN
• Outline reliability • High Level RAM • Detailed RAM study • R&M reviews • KPIs development
and maintainability study of proposed • R&M requirements • FMECA of and analysis
(R&M) requirements concepts/ options for equipment production and • Root Cause
for the plant • Performance selection safety critical Analysis
• Incorporate R&M Estimates • R&M reviews systems • Input in
tasks into the • Understanding • FMECA of • Maintenance maintenance
project schedule CapEx and OpEx production and Strategy strategy review /
and cost drivers safety critical Development optimisation
• High Level systems (RCM/RBM/ RBI) • FMECAs (upgrades)
Operations and • SIL Requirements • SIL Assessment • RAM studies
Maintenance Allocation Studies (for large-scale
Strategy. • Detailed RAM study upgrades/
modifications
Reliability Engineering and RAM Modelling 3
Reliability, Availability &
Maintainability (RAM) Modelling
The purpose of RAM modelling is to assess OPTAGON provides summary and detailed results
and optimise the availability and reliability concerning the availability and shortfall figures for the
total system and each of the subsystems (mean, standard
of production systems to maximise Life Cycle deviations, and confidence intervals), number of times and
Profit. durations operations at various throughout levels, number
RAM modelling is normally done using a Monte Carlo of occasions shortfalls were made up (despite production
simulation tool. It involves modelling the behaviour of the interruptions). Listed below are some of the outputs from
system being studied, subjecting it to a typical set of events modelling.
over its lifetime, and empirically observing how it performs. • Total unavailability and production shortfall
Advisian reliability engineers have experience in a variety of • Number and duration of system breakdowns
RAM simulation packages: MAROS, ACE, OPTAGON, AvSim+, • Distribution of time the system is operating at various
SPARC and others. The preferred RAM simulation package is capacity levels
OPTAGON from DNV-GL. • Criticality ranking by subsystem / component
• Number and duration of different operating states (ie
The functionality within OPTAGON is extensive and enables operating, breakdowns, scheduled maintenance, waiting
complex system behaviour to be incorporated into the for repair, waiting for spares)
system model. OPTAGON is able to model: • Storage tank / stockpile levels and tanks / stockpile tops
• Exponential, Weibull, Normal, Lognormal, and user events
defined distributions of time to failure, repair times, • Confidence levels
logistic delays, and ramped start up delay
• Routine maintenance activities
• Demand profiles that change with time
• Component capacities that change with time
• Changes to plant configuration with time
• Common mode, conditional and linked failures
• Process start up delays
• Dedicated maintenance teams (matching skill to repair
task) for optimising crew size
• Bulk storage including line-pack
• Capital, operating and maintenance costs (with
discounting)
• Environmental impacts
• Multi-stream (product) systems
• Product loading and unloading
4 Reliability Engineering and RAM Modelling
The Applications of RAM Modelling
RAM modelling can be conducted at the design stage of RAM Modelling can also be used to assist in identifying the
a project to maximise the return on the investment in the most cost effective debottle necking options for existing
asset over its life cycle. under-performing assets.
OIL GAS WATER
EXPORT EXPORT DISPOSAL
OIL GAS WATER
PROCESSING PROCESSING PROCESSING
SEPARATION
WELL 1 WELL 2 WELL 3 WELL 4
Reliability Engineering and RAM Modelling 5
Sample of Completed Projects
Client Project / Facility Lifecycle Phase
Oil and gas upstream facilities incl. FLNG
Adma Opco Umm Shaif Gas Injection Facilities (GIF) - RAM study of oil and gas production. FEED, Detailed
Design
Apache Energy Reindeer Wellhead Platform Project - RAM study of offshore facilities FEED
BHP Billiton Pyrenees Project - RAM modelling of the FPSO topsides process equipment and critical Concept, FEED
utilities, critical marine systems and all subsea facilities.
Minerva Development - RAM modelling of the subsea wells, subsea pipelines and Concept
on-shore processing facility (22 design options as part of offshore-onshore concept
selection).
Griffin Venture - RAM modelling of the FPSO topsides facilities. Operations
Chevron Benchamas Field Development Upgrade - several RAM and Life Cycle Cost modelling Operations
studies of existing facilities.
Confidential project - RAM study covering risers and topsides facilities. Concept
Wheatstone Subsea Flowlines and Pipelines (SSFP) project - RAM studies of the umbilical FEED
configurations.
ConocoPhillips Bayu Undan offshore complex - RAM Modelling of the gas platform processing facilities FEED, Detailed
and FSO. Supply chain / tanker offloading operations was also modelled in this study. Design
Bayu Undan offshore complex - RAM Study of the CPP Potable and Demin water system Brownfields
upgrade (covering 2 supply streams and several consumer streams). Upgrade
HESS Equus Project - RAM study covering all subsea facilities, process topsides equipment on Concept, FEED
the semi-submersible and the export line to the 3rd party tie-in.
Occidental Petroleum IS07C Wellhead platform - RAM study of water injection facilities Design
Qatar
Premier Petroleum Yetagun Field Phase 3 RAM Study. FEED
Maanmar Ltd
Shell Sarawak Sarawak Shallow Clastics Project - RAM study of the offshore facilities. FEED
Shell Todd Pohokura Project - RAM study of the offshore facilities as well as detailed RAM study of FEED
chemical injection and corrosion inhibitor packages.
Woodside Energy Blacktip Project - RAM modelling of the offshore facilities. FEED
Limited Chinguetti development - RAM Modelling for tender evaluation of four separate FPSO Concept
options.
Cossack Pioneer Optimisation Project - Availability Study. Operations
Goodwyn A Platform - RAM study of LP train compression and water handling expansion. Operations
Greater Enfield Development - RAM study of new subsea production facilities and low Concept
salinity filtration water injection equipment.
Sunrise Project - availability comparison of the FLNG and onshore LNG options. Concept
Oil and gas downstream facilities incl. onshore LNG
Al-Khafji Joint Operations Hout Onshore Gas Facilities Dehydration Technology Selection - Reliability study of TEG FEED
(KJO) and molecular sieve dehydration technologies.
BG Trinidad & Tobago Carapal Ridge Gas Plant RAM Study. EPCM
BHP Billiton Minerva Gas Plant Long Term Deliverability Project - RAM study of plant upgrade (new Operations
refrigerated chiller and compression facilities for sales gas).
BP Alaska Greater Prudhoe Bay Facilities - RAM Study covered 6 separate gas and oil plants (FS1-3, Operations
GC1-3), NGL facility and central compression plant. The model contained more than
2000 components.
Milne Point Unit RAM Study. Operations
West End Development Project RAM studies. Operations
Centrica RAM study of mid-scale onshore LNG plant. Concept
Exxon Mobil Pt Thomson Project - RAM Study of the Initial Production System. Concept, FEED
PNG LNG Project - Subject Matter Expert support for the combined RAM Study (utilising Detailed Design
the results from separate RAM studies for Upstream and Downstream facilities by others).
JACOS Hangingstone Expansion Project - RAM study of the SAGD (steam assisted gravity drain) Design
oil sands plant.
MEG Energy Christina Lake Project - RAM Study of the Steam-assisted gravity drain (SAGD) oil sands Design
Facility.
6 Reliability Engineering and RAM Modelling
Client Project / Facility Lifecycle Phase
Oil Search Limited Accelerated Gas Project - RAM study conducted for a number of upgrade concepts for Concept
CPF and APF onshore plants and their respective well gathering systems. Historic data
was used to derive failure rates and repair time estimates for existing equipment.
PNG Oil Assets - RAM study of PNG Oil assets was carried out to assess security of supply
of associated gas to the PNG LNG project. Three oil and gas plants (CPF/APF/GPF) and all Operations
onshore wells (70+ from several onshore fields) and gathering system were modelled.
CPF Liquids Storage and Handling System RAM Study was carried out to assess impact
from the condensate export facilities on the performance of the PNG LNG security of LNG
supply.
ROC Oil Cliff Head Development Project - RAM Study. Design
Shell Todd Pohokura Project - RAM Study of the onshore processing plant. Concept, FEED
TXU Energy Australia Iona Gas Plant Expansion Project - RAM Study and FMECA of gas comparession and Design
storage facilities.
Woodside Energy Blacktip Project - RAM modelling of the onshore gas plant. FEED
Limited
Pipelines and Pipeline Facilities
Alcoa Pipeline Optimisation Study. Facilities included a gas supply pipeline (DN700) from Design
Dampier to Wagerup (approximately 1500 km), two inlet and a number of intermediate
compressor stations. Objective of the study was to determine whether the proposed
configuration of the compression facilities will meet the project performance target and,
if not, what additional capital investment required to meet the target.
APA Group Mondarra Gas Storage Facility (MSF) - RAM study. The MSF is used to provide temporary Brownfields
storage for 4.5 PJ of gas from Dampier to Bunbury Natural Gas pipeline (DBNGP) in times Modifications
of low demand and to supply gas to Parmelia pipeline or DBNGP as required. The RAM
study covered the interaction between gas injection, storage and gas withdrawal modes
of operations and equipment used at each of the phases.
National Gas Company of Phoenix Park Valve Station (PPVS) Upgrade - Security of Supply Study. PPVS facilities are Design
Trinidad and Tobago considered critical infrastructure as the station receives treats and distributes main gas
supply for the island. The objective of the study was to carry out an investigation into
parameters that would affect the ability of the facility to deliver on gas supply targets.
SASOL Mozambique to Secunda Pipeline Project - The availability study for a 860 km pipeline Design
and pressure protection station.
SoCal Gas Gas Transmission Compressor Stations Upgrade - SoCal Gas Transmission system Concept (for
plays a vital role in the delivery of natural gas to millions of residential, commercial and Brownfields
industrial customers throughout southern California. A RAM study was carried out to Upgrade)
determine the best compressor configurations for Blythe, Moreno Valley and Ventura
compressor stations. The study examined a number of options that included a mix of
new and existing compressors at each site. Historic records were examined to derive
failure rate and repair time estimates for existing equipment
TransCanada Keystone XL Pipeline Project - RAM study covering three terminals, 187 pumps in 41 FEED
pumping stations. External influences (eg. Power supply by 3rd parties, hurricanes,
tornados) were also examined.
WorleyParsons (internal) Kambalda to Esperance Gas Pipeline - Security of Supply study. Objective of study Design
was to estimate reliability of the pipeline facilities and impact from different logistics
arrangement for pipeline maintenance.
Refineries, Chemical and Mineral Processing Facilities
Agip Kazakhstan North Erkene West Rail Project - RAM Study of the sulphur production, storage and load out Design
Caspian Operating facilities.
Company (AKCO)
BHP Billiton Worsley Alumina Refinery - RAM Study of Digestion Process Operations
Moly Mines Spinifex Ridge Molybdenum Project - RAM modelling of the mineral processing facilities FEED, Detailed
(crushing /screening, grinding, floatation etc). Design
Xtrata ASKAF Iron Ore Project - 5 MTPA Plant RAM Study covering crushing, processing and FEED / Feasibility
offloading facilities
Power Generation and Other Facilities
BHP Billiton Worsley Alumina Refinery - RAM Modelling of the refinery powerhouse and South West Operations
Cogeneration Plant.
Blue Water Power Station RAM study of a coal-fired power station and auxiliary facilities. Design
Western Power Corpora RAM study of the availability / reliability of the water supply to the Collie and Muja power Operations
stations.
Reliability Engineering and RAM Modelling 7
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