A structured approach to improved condition monitoring

Abstract Improved condition monitoring of production equipment enhances process safety and the ability to prepare maintenance, to perform maintenance efficiently, and thus reduce downtime and associated costs. Currently, there is a somewhat limited focus on condition monitoring of static equipment, such as heat exchangers and separators. This is due to organizational barriers, available technology, and budget constraints at management level. The objective of this article is to present a three-step approach that supports the decision-maker in the selection of condition monitoring methods for production equipment. The approach is exemplified by a heat exchanger and the focus is on condition monitoring in the operational phase, including assessment of life cycle costs (LCC).

[1]  B. Blanchard,et al.  Life-cycle cost and economic analysis , 1991 .

[2]  Ulrich Hauptmanns,et al.  Reliability data acquisition and evaluation in process plants , 2011 .

[3]  S. M. Hess,et al.  An evaluation method for application of condition-based maintenance technologies , 2001, Annual Reliability and Maintainability Symposium. 2001 Proceedings. International Symposium on Product Quality and Integrity (Cat. No.01CH37179).

[4]  Ingrid Bouwer Utne,et al.  Challenges due to aging plants , 2011 .

[5]  Adriaan Van Horenbeek,et al.  Life Cycle Benefits of a Condition Based Maintenance Strategy , 2011 .

[6]  Honghong Luo.  The effectiveness of U.S. OSHA process safety management inspection – A preliminary quantitative evaluation , 2010 .

[7]  D. P. Sekulic,et al.  Fundamentals of Heat Exchanger Design , 2003 .

[8]  Dong Yuhua,et al.  Estimation of failure probability of oil and gas transmission pipelines by fuzzy fault tree analysis , 2005 .

[9]  M. Stone,et al.  Pulse echo CHIME as a tool for non-intrusive inspection of pressure equipment , 2005 .

[10]  R. Keith Mobley,et al.  World-Class Maintenance , 2002 .

[11]  Adiel Teixeira de Almeida,et al.  A multi-criteria decision model to determine inspection intervals of condition monitoring based on delay time analysis , 2009, Reliab. Eng. Syst. Saf..

[12]  M. Garetti,et al.  Maintenance cost and benefits evaluation: a key issue for company competitiveness , 2009 .

[13]  Jeffrey K. Liker,et al.  The Toyota way fieldbook : a practical guide for implementing Toyota's 4Ps , 2004 .

[14]  David McMillan,et al.  Quantification of Condition Monitoring Benefit for Offshore Wind Turbines , 2007 .

[15]  R. L. Keeney,et al.  Decisions with Multiple Objectives: Preferences and Value Trade-Offs , 1977, IEEE Transactions on Systems, Man, and Cybernetics.

[16]  J. Moubray.  Reliability-centred maintenance , 1995 .

[17]  Jørn Vatn,et al.  A discussion of the acceptable risk problem , 1998 .

[18]  Mi Sandar Mon,et al.  Heat Exchanger Design , 2008 .

[19]  Junghwan Kim,et al.  Application of TRIZ creativity intensification approach to chemical process safety , 2009 .

[20]  Robin Pitblado,et al.  Global process industry initiatives to reduce major accident hazards , 2011 .

[21]  Lina Bertling,et al.  On the economic benefits of using Condition Monitoring Systems for maintenance management of wind power systems , 2010, 2010 IEEE 11th International Conference on Probabilistic Methods Applied to Power Systems.

[22]  Ralph L. Keeney,et al.  Decisions with multiple objectives: preferences and value tradeoffs , 1976 .

[23]  Ingrid Bouwer Utne,et al.  Life cycle cost (LCC) as a tool for improving sustainability in the Norwegian fishing fleet , 2009 .

[24]  Ray Beebe.  Condition Monitoring of Heat Exchangers , 2000 .

[25]  E. Ziegel,et al.  Root Cause Analysis , 2010, Journal of Clinical Engineering.

[26]  Angela E. Summers.  Continuous improvement and existing safety systems , 2009 .

[27]  Adam S. Markowski,et al.  ExSys-LOPA for the chemical process industry , 2010 .

[28]  Marvin Rausand,et al.  Common cause failures in safety instrumented systems on oil and gas installations: Implementing defense measures through function testing , 2007 .

[29]  Marvin Rausand,et al.  System Reliability Theory: Models, Statistical Methods, and Applications , 2003 .

[30]  A. K. S. Jardine,et al.  Maintenance, Replacement, and Reliability , 2021 .

[31]  Inger Andresen,et al.  A Multi-Criteria Decision-Making Method for Solar Building Design , 2000 .

[32]  Ingrid Bouwer Utne,et al.  Monitoring the mechanical integrity of heat exchangers , 2011 .