Machinery Reliability Indicators

The purpose of machinery reliability indicators is to provide common parameters for measuring the reliability of key types of rotating machinery at all manufacturing locations. The indicators provide locations a means for measuring overall maintenance effectiveness and the success of reliability improvement activities. Sharing data among locations leads to identifying key opportunity areas and best practices for equipment in similar units or services.

Production losses due to Machinery Process Functions (i.e, pump trains, centrifugal compressor trains, reciprocating compressor trains, other) will be tracked using the following parameters:
PROCESS LOSSES – For cause units and all affected units (refineries only).
EQUIVALENT UNIT DOWNTIME – For cause units only (refineries & chemical plants).
Units of Measure: Days

(Chemical Facilities only)

Each production loss will be categorized by:
Production Loss Cause Categories:
1- Caused by Machinery Components.
2- Caused by Machinery Support Systems.
3- Caused by Process/Operational Issues.

1- Centrifugal Compressor.
2- Reciprocating Compressor.
3- Pump
4- Other

1- VITAL – immediate shutdown or major slowdown of unit(s) when train is unavailable.
2- OTHER – normally no effect on unit(s) or recoverable loss when train is unavailable.

MTBR (years) = Number of Active pump train services / Number of repairs to pump trains for calendar year (or 12-month period)

Formula for calculating average maintenance cost:
Average Cent. Pump Train Maintenance Cost = Total Maintenance Cost ($/Year) / Number of Active Pump Train Services ($/Cent. Pump Train)
where,
Total Maintenance Cost = Maintenance cost includes all cost associated with pump trains (pump, driver, couplings, gearboxes and seals) including PM cost.

Author:
Vinoth Kumar