This paper discusses about FMECA software that can be used to identify and to determine risk operating of sub-unit centrifugal compressor and its effect to the whole unit. The FMECA software has been developed using Borland Delphi 7.0 and database desktop facility. Data collection is based on OREDA (Offshore Reliability Data) and actual field data. Several variables in OREDA information, such as maintainable item, failure mode, and failure cause, are used in processes and determination of severity, failure rate, ability detection and hour reparation. The compressor, based on the equipment class subdivision, can be classified into power transmission, compressor unit, control and monitoring, lubrication system, shaft seal system and miscellaneous.

Oleh : Dani Rusirawan, Ricky Hermawan, Ahmad Taufik

Abstract.

This paper discusses about FMECA software that can be used to identify and to determine risk operating of sub-unit centrifugal compressor and its effect to the whole unit. The FMECA software has been developed using Borland Delphi 7.0 and database desktop facility. Data collection is based on OREDA (Offshore Reliability Data) and actual field data. Several variables in OREDA information, such as maintainable item, failure mode, and failure cause, are used in processes and determination of severity, failure rate, ability detection and hour reparation. The compressor, based on the equipment class subdivision, can be classified into power transmission, compressor unit, control and monitoring, lubrication system, shaft seal system and miscellaneous.

Output of the FMECA software is FMECA worksheet for the centrifugal compressor, especially for sub-unit power transmission and compressor unit, which can be used to identify risk priority number (RPN). RPN is an indicator that is very important in the determination of maintenance priority. It is believed that FMECA software can provide significant contribution in order to support engineer’s job and to prevent failure of centrifugal compressor.

Keywords: Centrifugal Compressor, Reliability, FMECA, RPN

1. Introduction

In order to remain competitive, goals of industrial plant facilities must include a high level of machine reliability to reduce downtime, extend equipment life, reduce repair cost, improve equipment efficiency, reduce capital costs, increase productivity and maintain employee’s morale and satisfaction. Maximum equipment and process reliability cannot be achieved or maintained if the plant is continually subjected to breakdowns, treated with inadequate or incorrect repair procedures, or recurring failures.

Although many plant owners have improved the reliability of their operating facilities, lost production and poor equipment one still represent a high annual industrial cost. Even though most failure events are not catastrophic, increased clarity as the cause of failure events is a key of prioritizing and implementing corrective maintenance actions. This will result in sustainable improvements in the reliability, leading to improve profitability and safety.

Rotating equipment such as pumps, fan, blower, compressor, turbines and accessories are a lifeline of process industries. In today’s business environment, centrifugal compressor reliability is more critical than ever. Unscheduled equipment downtime has a negative impact on plant operations; it often results in a temporary halt of both production and processes. In most of centrifugal compressor applications, loss of production results in business interruption, and thus a substantial revenue loss of hundreds of thousands or even millions dollars per day. This revenue loss has a direct impact on the profitability of the plant.

Failure Mode, Effects and Criticality Analysis (FMECA) is performed to evaluate reliability and safety by identifying critical failure modes and their effects on the system. FMECA can also be used to analyze old plants including the processes, with the focus on process function and operation and how failure might occur and affects the whole system. FMECA is a very well methodology within reliability program that designer and operators use for improving regularity of the complex system.

The objective of the research is to develop the FMECA software that can be used to identify and to determine the risk operating of sub-unit centrifugal compressor and its effect to the whole unit using Borland Delphi 7.0 and database desktop facility.

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