Maintenance & Integrity Management System

Manual Instruction
 Table of Contents

INTRODUCTION ....................................................................................................................... 3
DEFINISIONS ........................................................................................................................... 3
OBJECTIVE .............................................................................................................................. 4
MIMS – BUSINESS PROCESS .................................................................................................. 6
MIMS COMPONENT DESCRIPTION ......................................................................................... 6
CMMS - SAP BUILDING PROCESS ........................................................................................... 7

PM - MM INTEGRATION MODE ............................................................................................... 8

AUTO REVIEW MRP – BUSINESS PROCESS .......................................................................... 9
ON LINED – SCE (SAFETY CRITICAL ELEMENT) .................................................................. 11
SAP - OTHER APPLICATION INTEGRATION.......................................................................... 12
RBI – SOFTWARE IMPLEMENTATION ................................................................................... 13
RCM – SOFTWARE IMPLEMENTATION ................................................................................. 14
AMS SUITE APPLICATION ...................................................................................................... 15
ON-LINED RCA (ROOT CAUSE ANALYSIS) ........................................................................... 16

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INTRODUCTION

Jambi Merang’s Production Facilities has been operating since in 2011 with 20 years design life.
After 2 years operating, in some cases the technical life of equipment is in burn-in phase (early
failure). Adequate maintenance strategy and approach in a standard management system
implementation to stretch equipment life cycle is required for sustainable operation of Jambi
Merang’s production facility
Maintenance & Integrity Management System (MIMS) is an integrated systematic
management approach to maintain the reliability and integrity of an asset over its life cycle.
This integrated system shall provide the best practice concept and methodology of RCM
(Reliability Centered Maintenance), RBI (Risk Based Inspection), AMS Suite Application,
CMMS (Computerized Maintenance Management System) as well as facilitate the alignment
process with material management system to achieve an optimum reliability and integrity of
asset. A comprehensive maintenance & integrity work program is required to anticipate certain
production decline, future maintenance cost and design life concerns.

DEFINITIONS

Reliability is probability of equipments or system will perform their required functions under
specific condition within a certain time period or the duration of probability of failure-free
performance under the stated conditions.

Failure is a condition of inability of any asset to do what its users want it to do or the
probability of an item operating for a given of time without failure.

Functional Failure is defined as the inability of any asset to fulfill a function to a standard
performance which is acceptable to the users.

Failure mode is defined as any event which causes functional failure.

Measurement - mean time to repair (MTTR), mean time between failures (MTBF), Weibull
Analysis, Failure Rate and probability of failure (P-F) interval.

MTTR = Total Repair Time/number of failures

MTBF = Total Operation Time/number of failures

Applicability – Traditionally but not exclusively applied to rotating machineries (compressors,

turbines, valves, pumps, gears) mechanical cross-functional system static or rotating
equipments

Activities involved - condition monitoring, maintenance, vibration analysis, dynamic

monitoring, inspection, root cause analysis and consequence analysis.

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Reliability Centered Maintenance (RCM) Software – as a product or tools of reliability
engineering applied for rotating equipment or mechanical functional system. A systematic risk-
based approach to create an accurate, well targeted and optimised maintenance package that
aims at achieving optimum reliability for a facility.

Code and guidelines: SAE JA – 1011 Evaluation Criteria for Reliability Centered
Maintenance.

AMS Suite Application – as a product or tools of reliability engineering applied for instrument
devices and control system.

Integrity Definition – the availability of materials, equipment and structures to withstand

applied load against the defect from manufacturing, fabrication and construction or damaged
caused by its performance or because the interaction with the environment.

Failure Definition – a condition when a material yielding or its thermo dynamical state is altered
that cannot withstand service load e.g.: stress static or cyclic, high temperature, low
temperature, and environment hostility

Measurement – remaining life, remaining strength, fatigue strength, maximum allowable

operating pressure and specified.

Applicability – static mechanical equipment (piping system, pipeline, heat exchanger, boiler,
pressure vessel, valves, pump casing, compressor casing, storage tank) and structural system.

Activities involved - material selection, welding, commissioning, corrosion protection system,

Inspection (nondestructive testing or destructive testing) and defect assessment

Code and Guidelines – API 580, API 581, DNV G-101, SINTAP, BS-7910, DNV F-101, API
579,R6, R5, ASME B31.G,RSTRENG and Pipeline Defects Assessment manual.

OBJECTIVES

The objectives of Maintenance & Integrity Management System Implementation as follows:

1. High reliability and integrity demands of critical equipment/system are essential to

maintain optimum production availability in safe and sustainability operation up to design
life.
2. Repetitive failures mitigation triggering Loss of Containment (LOC) in Jambi Merang’s
Production Facilities.
3. Early failure detection of critical instrument devices and control system in gas plant
triggering Loss of Production Opportunity (LPO).
4. Onshore equipment failure rate modeling

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MIMS – BUSINESS PROCESS

Established CMMS with adequate Maintenance & Integrity Inspection Work Pack with
integrated interfacing of maintenance software in live mode is essential to achieve high
equipment reliability in oil & gas production facility with sustainable operation.

Fig. 1 – MIMS Business Process

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MIMS COMPONENT DESCRIPTION

Integrated Management System Framework

Maintenance Management System’ is a computerized maintenance management system
which has supported by the System Application Production (SAP / ECC 6.0). The SAP system
is an integrated suite of Order Entry, Scheduling, Manufacturing, Inventory and Financial
software.
In addition, it integrates Enterprise Resources Planning (ERP) system that consists of several
modules, namely Plant Maintenance (PM), Finance (FICO), Human Resources –
Employee Self Services (ESS), and Material Management (MM), which supported by
many functions in the day-to-day operations.

Fig.2 – Integrated Management System Frame Work

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CMMS - SAP BUILDING PROCESS

CMMS are computer-based software programs used to control work activities and resources,
as well as to monitor and report work execution. CMMS are tools for data capture and data
analysis. The major features of CMMS include the processing of maintenance data to give in
useful information on which management decisions are based. This information can be
analyzed or evaluated with respect to previous results such that performance over a period of
time can be assessed. Managers will therefore find it convenient in making use of the available
data to plan for present and future goals. There is also the advantage of printing out this
information in hard copy at any desired period. Other useful information, such as work done in
the maintenance department and its total costs (TC), lists of jobs worked on during a period,
and inventory taking, can be presented in a manner that will greatly ease both the technical and
administrative task of maintenance. Through networking of the systems, information can be
passed efficiently between the maintenance department and the organization’s management.

The CMMS can be used to analyze budgets, downtime, supplies, screening of applicants, etc.
The database programs in CMMS systems contain structured data on workers’ names; job titles;
daily; weekly or yearly schedules; etc. The data processed on CMMS can be stored permanently
or retrieved much faster for future use or modifications. Also, CMMS can be used in
maintenance planning and scheduling, coordinating people, and controlling resources and costs
of maintenance functions. It can also be used in such areas as the analysis of a week’s activity
and budget proposals. In Jambi Merang‘s Production Facilities, CMMS has been established
since Q1 - 2012 with continuous improvement to accommodate MIMS implementation.

CMMS (Computerized Maintenance Management System) – PM Module SAP / ECC 6.0 is core
application to manage maintenance (Mechanical, Instrument, Electrical, DCS, Metering, Safety
Equipment) and asset integrity activities as well as integration with material management
system (MM Module SAP /ECC 6.0), Microsoft Outlook, On-lined SCE (Safety Critical Element),
on-lined MOC (Management of Change) system.

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Fig. 3 – PM SAP Building Business Process

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RBI – SOFTWARE IMPLEMENTATION

RBI (Risk Based Inspection) - Utilizing baseline data to develop risk assessment / analysis
program using PROMIA ( Probabilistic Management Of Integrity Assistant ) software and
facilitate data exchange between core applications and CMMS (SAP-PM);

Fig.4 – Interfacing of RBI – SAP Business Process

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RCM – SOFTWARE IMPLEMENTATION

RCM (Reliability Centered Maintenance) - Building data integration between maintenance

history records in CMMS (SAP-PM) and proven reliability software analysis to identify generic
failure models of critical equipments or parts with below business process;

Fig.5 – Interfacing of RCM – SAP Business Process

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AMS SUITE APPLICATION

AMS Suite Application - Real time monitoring critical instrument equipment to identify health
status, abnormality, performance, early failure detection and if possible online calibration with
minimum interruption to process plant condition.

Fig.5 – Interfacing of AMS Suite Application – SAP Business Process

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ADVANCED PM - MM MODULE INTEGRATION MODE

SAP PM and MM Module Alignment Process

Auto Review MRP (Material Requisition Plan) - Material reservation through Work Order
creation, eliminates manual reservation, as well as foundation to identify failure rates (for
components / parts).

Failure Rate Modeling - using SAP historical data to calculate failure rate for each equipment
parts (BOM – Bill of Material) as an input to exact identification and appropriate MRP setting.
Auto Reminder – Service Contract - using inputs from MM module, generates auto reminder
for due date of blanket contract (service/materials), with set parameter set on 6, 3, 1 months
before end of contract.

Fig.6 – Advanced SAP PM/MM Integration Business Process

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ON LINED – SCE (SAFETY CRITICAL ELEMENT)

Identified Safety Critical Element using previous Bow-Tie Study and SCE Matrix, uploading
SCE register into SAP, as equipment criticality labeling, furthermore to prioritize maintenance
program.

Fig.7 – On lined Safety Critical Equipment in SAP PM Module

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SAP - OTHER APPLICATION INTEGRATION

Integration with MS-Outlook

 PM Module - utilize e-mail based media for communication and alerting for any
maintenance request / MOC activities.
 MM Module - utilize e-mail based media for communication and alerting for PR / PO
approval request, creating user Friendly SAP online approval process, and reduce delay
time for procurement process.

Integration PM - Module with PI System

 On-lined monthly maintenance KPI report, through excel report generator interface
 On-lined monthly SCE WO back log report

Fig.8 – Other Application Integration to SAP PM Module

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ON-LINED RCA (ROOT CAUSE ANALYSIS)

The demands of accurate and real time of investigation process and corrective actions lead JOB
- PTJM to on-line Root Cause Analysis using SAP Solution Manager, the integration of existing
SAP/R3 PM – Module and in line with integrated management system.

Fig.9 – On lined RCA in SAP PM Module

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REFFERENCES

[1] Integrated Management System Concept (5).docx

[2] OREDA - 2009 Version
[3] API 580/581 - RBI (Risk Based Inspection)
[4] SAE JA – 1011 Evaluation Criteria for Reliability Centered Maintenance
[5] NAMUR NE107 – Diagnostic Categories
[6] WP – MIMS (3) (6).xlsx
[7] Field Maintenance Training Matrix
[8] Comprehensive List of Cause (CLC)
[8] BSI: PAS 55-1:2008

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