40

Application of Criticality Analysis Maintenance Area

By having fully established which equipment is most critical, the prioritization of maintenance

programs and plans could be established in a more efficient way: predictive, preventive, corrective,

detective and even possible redesigns at the level of procedures and minor modifications; It will even

allow you to establish the priority for the programming and execution of work orders.

Scope of Inspection

The criticality study facilitates and centralizes the implementation of an inspection program,

given that the hierarchical list indicates where it is worth carrying out inspections and helps in the

selection criteria of the intervals and type of inspection required for protection and control systems

(pressure , temperature, level, speed, thickness, flow, etc.), as well as for dynamic, static and structural

equipment.

Scope of Materials

The criticality of the systems helps to make more accurate decisions about the level of equipment

and spare parts that should exist in the central warehouse, as well as the requirements for parts, materials

and tools that should be available in the plant warehouses, i.e. , we can reveal the stock of materials and

spare parts for each system and/or equipment, achieving an optimal inventory cost.

Plant Availability Scope

Criticality data allows accurate guidance in project execution, given that it is the best starting

point for carrying out capital investment studies and renovations in the processes, systems or equipment

of a facility, based on the area of greatest total impact. which will be the one with the highest level of

criticality.

At the Staff Level

A good criticality study makes it possible to enhance the training and development of skills in

personnel, given that a plan for technical, artisanal and personal growth training can be designed, based
 41
on the real needs of the facility, taking into account first the most important areas. reviews, which is

where the best initial opportunities for improvement and adding maximum value are concentrated.

Establish Importance Criteria

Security

Atmosphere

Production

Costs (Operations and Maintenance)

Failure frequency

Average time to repair

Evaluation method

Weighted factor model based on risk theory

CRITICALITY = Failure Frequency * Consequence

Consequence = (Operational Impact*Flexibility) + Mtto Costs. + SAH Impact

Weighted Factor Model Based on Risk Theory

Table: FREQUENCY OF FAILURES

Failure frequency:

Parameter greater than 4 failures/year} 4

Average 2 – 4 failures/year 3

Good 1 – 2 failures/year 2

Excellent less than 1 failure/year 1

 42
Table: OPERATIONAL IMPACT
Operational Impact:

Immediate total stop 10

Stopping of the plant complex and has an impact on other complexes 6

Impact on production or quality levels 4

Impact on costs additional operational costs associated with 2

availability

Does not generate any significant effect on operations and 1

production

Table: OPERATIONAL FLEXIBILITY

Operational Flexibility:

There is no production option and there is no spare function 4

There is a shared spare option 2

Spare function available 1

Table: MAINTENANCE COST

Maintenance cost:

Greater than or equal to 20,000 USD 2

Less than 20,000 USD 1

 43
Table: IMPACT ON ENVIRONMENTAL SAFETY AND HYGIENE
Impact on Environmental Safety and Hygiene:

Affects both external and internal human security 8

Affects the environment producing reversible damage 6

Affects facilities causing severe damage 4

Causes minor damage (Accidents and incidents) to own personnel 2

Causes an environmental impact whose effect does not violate 1

environmental standards

Does not cause any type of damage to people, facilities or the 0

environment.

Criticality Matrix

Figure: Criticality Matrix

Current State of the Equipment

Determination of the Technical Condition of the Equipment

This prior review was carried out jointly with the maintenance technicians in charge of the La
Libertad Refinery and technicians in charge of the Parsons Plant. It will be aimed at detecting the degree
of wear of the different parts and mechanisms of each of the equipment, which will allow its technical
condition.
 44
In order to determine if the equipment is in good, fair, poor or very poor condition; We base
ourselves on the criteria in table 3.16, the same ones that we calculate from an assessment and through
the following procedure.

The number of aspects evaluated as good is multiplied by 1; those evaluated as regular, by 0.80;
those evaluated as bad, by 0.60; and those evaluated as very bad, by 0.40.

All these products are added and the result is divided by the number of aspects evaluated.
The previous result is multiplied by 100, and the index is obtained that allows evaluating,
according to the criteria, the technical state of the equipment as a whole.

Table 3.16 CRITERIA TO DETERMINE THE TECHNICAL STATE

WELL (90 – 100) %
REGULAR (75 – 89) %
BAD (50 – 74) %
VERY BAD Less than 50%

To have a greater appreciation of the valued equipment, a photograph was taken trying to reflect

in it the technical state of each of the equipment.

 45
Existing Equipment

Currently the company has 5 pumping machines (equipment) (motor – pump) to carry out the
processes of transforming crude oil into different derivatives such as:

PP2A RESIDUE (CRUDE)

PP8B GASOLINE

PP8A GASOLINE

PP6A LIGHT DIESEL

PP1C RAW
 46
Table 3.9: PP2A
EQUIPMENT
PP2A 300197
ELECTRIC MOTOR
MODE: 5K444CS143P No: NH6O23016
HP: 125 SERVICE FACTOR: 1.15 RPM: 2975
TIME MATING: CONT NEMA DESIGN: FFC
VOLTS: 400 IN CLASS: F
PHASES: 3 FRAME: 444TS
AMPS: 156 TYPE: K
MAX KVAR: 16.8 CODE: H
SDR. c. MAX AMB: 40
ALTERNATIVE RATING: 60
SERVICE FACTOR: 1.0
NEMA NOM EFF: 92.4
DRIVE END BRG: AFBMA 6914Z
DRIVE END BRG: AFBMA 6914Z

BOMB
INGERSOLL – RAND
SIZE: 4X6X12AC SERIAL NO : 098574
RPM: 2975 HP: 125
No
BRG : SKF -6214 / 7313 PY G1
PURCH ITEM NO : 10 – 1506 – 02
 4
Technical Status of the PP8A Equipment at the PARSONS 7
Plant Table 3.25: TECHNICAL STATUS OF THE PP2A EQUIPMENT

e, (
TECHNICAL EVALUATION SHEET

Plant: Parsons

Equipment: MOTOR – PUMP

Brand: Responsible for maintenance:

ENGINE: RELIANCE XT Maintenance technician in charge of the plant
BOMB: INGERSOLL –
RAND

Technical code: PP2A Meaning:

PP: Parsons Plant
2A: Equipment number

Fixed active code: 300197 Meaning:

Manuals: Blueprints: Spare parts:

Yeah Not X Yeah Yes No

Not X
Code: Code:
Meaning: Code: Meaning:
Meaning:

Equipment plate data:

RPM = 2975
HP = 125
V = 400
HZ = 50

Bad Regular Well

Technical status
x
Anchor status x
Housing condition x
Engine Status
x
Coupling status
x
Bomb status
x
Condition of cables and buttons
x
Vibration state Lubrication
x

Conclusion: FAIR
 48

Table 5.9 PP2A CRITICALITY

PP2A 300197 RESIDUE (CRUDE)
Failure frequency: 4

Operational impact: 6

Operational flexibility: 2

Maintenance cost: 1

Impact on safety, environment and hygiene: 2

Consequence = 15
 49

Table 3.2: PP8B EQUIPMENT

PP8B 300207
ELECTRIC MOTOR

RELIANCE XT
FRAME TYPE P DESIGN B IDENTIFICATION NO
324 TS 7MAF21624-G2-YL
HP: 40 VOLTS: 400 Hz: 50 PHASE: 3
RPM: 2950 AMPS: 57.5 SF: 1.15 CODE: G
AMB: 40 0 C DUTY CONT IN CL TEFC:F
55BCO3X30X26
55BCO3X30X26
OPER TEM CODE T3C
BOMB
INGERSOLL – RAND
SIZE: 3X4X10AC SERIAL NO : 098576
GPM: 465 HEAD FT: 283
RPM: 2960 SP. GR. 0.71
HYDRG PSIG: 900 PUMP: 900 CASING
BRG No
: SKF -6214 / 7313 PY G1
PURCH ITEM NO : 1O-1508-02
 5
Technical Status of the PP8A Equipment at the PARSONS 0
Plant Table 3.18: TECHNICAL STATUS OF THE PP8B EQUIPMENT

e, (
TECHNICAL EVALUATION SHEET

Plant: Parsons

Equipment: MOTOR – PUMP

Brand: Responsible for maintenance:
ENGINE: INGERSOLL – Maintenance technician in charge of the plant
RAND
PUMP: RELIANCE XT

Technical code: PP8B Meaning:

PP: Parsons Plant
8B: Equipment number

Fixed active code: 300207 Meaning:

Manuals: Pla you: Spare parts:

Yeah Not X Yeah Not X Yes No

Code: Code: Code:

Meaning: Meaning: Meaning:

Motor plate data: Pump plate data:

RPM = 2950 RPM = 2960

HP = 40 HP = 40
V = 400 GPM= 465
HZ = 50

Regular
Well
Technical status Bad

x x
Anchor status
Housing condition x
x
Engine Status
Coupling status
Bomb status x
Condition of cables and buttons x
Vibration state Lubrication x
x

Conclusion: FAIR
 5
Table 5.2: CRITICALITY PP8B 1
PP8B 300207 GASOLINE
Failure frequency: 4

Operational impact: 4
Operational flexibility: 2

Maintenance cost: 1

Impact on safety, environment and hygiene: 2

Consequence = 11
 5
Table 3.1: PP8A 2
EQUIPMENT
PP8A 300208
ELECTRIC MOTOR

RELIANCE XT
FRAME TYPE P DESIGN B IDENTIFICATION NO 7MAF21624-G1-
324 TS YL
HP: 40 VOLTS: 400 Hz: 50 PHASE: 3
RPM: 2950 AMPS: 57.5 SF: 1.15 CODE: G
AMB: 40 0 C DUTY CONT IN CL TEFC:F
55BCO3X30X26
55BCO3X30X26
OPER TEM CODE T3C
BOMB
INGERSOLL – RAND
SIZE: 3X4X10AC SERIAL NO : 098575
GPM: 465 HEAD FT: 283
RPM: 2960 SP. GR. 0.71
HYDRG PSIG: 900 PUMP: 900 CASING
BRG No
: SKF -6214 / 7313 PY G1
PURCH ITEM NO : 1O-1508-01
 5
Technical Status of the PP8A Equipment at the PARSONS 3
Plant
Table 3.17: TECHNICAL STATUS OF THE EQ

PETROECUFOR

TECHNICAL EVALUATION SHEET

Plant: Parsons
Equipment: MOTOR – PUMP
Brand: Responsible for maintenance:
ENGINE: INGERSOLL–RAND Maintenance technician in charge of the plant
PUMP: RELIANCE XT
Technical code: PP8A Meaning:
PP: Parsons Plant
8A: Equipment number

Fixed active code: 300208 Meaning:

you: Replacem
Manuals: Pla ent yes:
Yeah
Yeah Not X Yes No
x
No
Code: Code: Code either:
Meaning: Meaning: Meaning icated:

Motor plate data: Pump plate data:

RPM = 2950 RPM = 2960

HP = 40 HP = 40
V = 400 GPM= 465
HZ = 50

Technical status Bad Regular Well

Anchor status x
Housing condition x
Engine Status x
x
Coupling status
x
Bomb status
x
Condition of cables and buttons
x
Vibration state Lubrication
x

Conclusion: FAIR
 5
Table 5.1: CRITICALITY PP8A 4
PP8A 300208 GASOLINE
Failure frequency: 3
Operational impact: 4
Operational flexibility: 2

Maintenance cost: 1
Impact on safety, environment and hygiene: 2
Consequence = 11
 5
Table 3.11: PP6A 5
EQUIPMENT
PP6A
ELECTRIC MOTOR
FRAME: 405TS TYPE: P DESIGN: B CODE: O
IDENTIFICATION No: 5MAF21624 – 61 – YL
H.P. : 100 AMP: 126
VOLT:400 SF: 1.15
HZ : 50 TEMP: 40 o C
PHASES: 3 DUTY: CONT
RPM : 2955 ENLL : TEFC
65BC03X30X26
OPER TEMP CODE T3C
BOMB
INGERSOLL – RAND
SIZE: 4X6X12AC SERIAL NO : 098573
RPM: 2955 HP: 100
No
BRG : SKF -6214 / 7313 PY G1
PURCH ITEM NO : 10 – 1506 – 01
 5
Technical Status of PP1C Equipment at the PARSONS 6
Plant
Table 3.27: TECHNICAL STATUS OF THE PP6A EQUIPMENT

e, (
TECHNICAL EVALUATION SHEET

Plant: Parsons

Equipment: MOTOR – PUMP

Brand: Responsible for maintenance:

ENGINE: RELIANCE XT Maintenance technician in charge of the plant
BOMB: INGERSOLL –
RAND

Technical code: PP6A Meaning:

PP: Parsons Plant
6A: Equipment number

Fixed active code: Meaning:

Manuals: Blueprints: Spare parts:

Yeah Not X Yeah Not X Yes No

Code: Code: Code:

Meaning: Meaning: Meaning:

Motor plate data:

RPM = 2955
HP = 100
V = 400
HZ = 50

Technical status Bad Regular Well

Anchor status x
Housing condition x
Engine Status x
Coupling status x
Bomb status x
Condition of cables and buttons x
Vibration status x
Lubrication x

Conclusion: GOOD
 5
Table 5.11: PP6A CRITICALITY 7
PP6A LIGHT DIESEL
Failure frequency: 3

Operational impact: 4

Operational flexibility: 1

Maintenance cost: 1

Impact on safety, environment and hygiene: 2

Consequence = 7
 5
Table 3.15: PP1C 8
EQUIPMENT
PP1C 307491
ELECTRIC MOTOR
SHAFT END BRG: 6316 – JC3 OPP. END BRG: 6316 – JC3
FR:580955 TYPE: ET ENCLE: TE PH: 3.9
o
Max. Amb. 40 C
ID #: H03002816 – 100R – 31
INSULT CLASS: F DUTY: CONT
WT: 5200 NEMA NOM EFFICIENCY: 93.6
AMPS: 47 RPM: 2975
SF: 1.15 SF AMPS: 54 HZ:50 PF: 89.4 VOLT: 3300
GUARANTEED EFFICIENCY: 92.4
BOMB
INGERSOLL – RAND
MODEL: 3640 HP: 300
IB. BRG: 6342 0.B.BRG: 7312BEGAM
S/N: E25OC932 SIZE: 6X8-13
–FT
HEAD : 906.4 RPM: 2983
HYDRO – PRESS: 1200 TEMP or F: 75
Max.Working Press lb/in 2 = 740
 5
Table 3.15: PP1C 9
EQUIPMENT
 6
Technical Status of PP1C Equipment at the PARSONS 0
Plant
Table 3.31: TECHNICAL STATUS OF THE PP1C EQUIPMENT

e, (
TECHNICAL EVALUATION SHEET

Plant: Parsons

Equipment: MOTOR – PUMP

Brand: Responsible for maintenance:

ENGINE: RELIANCE XT Maintenance technician in charge of the plant
BOMB: INGERSOLL –
RAND

Technical code: PP1C Meaning:

PP: Parsons Plant
1C: Team number

Fixed active code: 307491 Meaning:

Manuals: Blueprints: Spare parts:

Yeah Not X Yeah Yes No

Not X
Code: Code:
Meaning: Code: Meaning:
Meaning:

Motor plate data:

RPM = 2975
HP = 300
V = 400
HZ = 50

Well
Bad Regular
Technical status
_X
Anchor status -
_X
Housing condition -
Engine Status _X
x
Coupling status
x
Bomb status
x
Condition of cables and buttons
Vibration state Lubrication
== _X
x

Conclusion: GOOD
 6
Table 5.15: PP1C CRITICALITY 1
PP1C 307491 RAW
Failure frequency: 2

Operational impact: 6

Operational flexibility: 1

Maintenance cost: 2

Impact on safety, environment and hygiene: 1

Consequence = 9
 Table 5.16: HIERARCHY OF THE TEAMS
TEAM HIERARCHY
EQUIPMEN FREQUENCY IMPACT FLEXIBILITY COSTS OF SHA CONSEQUENCE TOTAL HIERARCHY
T
OPERATIONAL MTTO. IMPACT.
PP2A 4 6 2 1 2 15 60 CRITICAL
PP8B 4 4 2 1 2 11 44 CRITICAL
PP8A 3 4 2 1 2 11 33 SEMI CRITICAL
PP6A 3 4 1 1 2 7 21 SEMI CRITICAL
PP1C 2 6 1 2 1 9 18 UNCRITICAL

NOTE: The equipment, due to its importance in the production processes, is considered category “A” for critical equipment, “B” for semi-
critical equipment, and “C” for non-critical equipment.

OF THE TOTAL A SUMMATION IS MADE THAT REsolves 176 WHERE THE AVERAGE VALUE IS 35.
FROM THIS VALUE UPWARDS IT IS CONSIDERED CRITICAL, FROM THE AVERAGE VALUE DOWNWARDS WE CONSIDER THE
FOLLOWING:

FROM 35 I TAKE 50% WHICH IS 17.5 OF THIS VALUE UPWARDS IS CONSIDERED SEMI-CRITICAL, AND OF THIS VALUE
DOWNWARDS IT IS CONSIDERED NON-CRITICAL.