GoMaximo 2018

Reliability Centered Maintenance

(RCM)
Applied in Maximo

Power Generation Company of Trinidad & Tobago Ltd.,

By Ian Ramsingh
 PowerGen
• Total installed capacity of 1008 MW
• Three Locations -
– PEN 243 MW
– PTLS 765 MW
– POS - Retired

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 Maximo at PowerGen

• Maximo History
– Maximo version 2.1.1 – 1995
– Maximo version 7.5.0.8 & Maximo 7.5.1 Oil & Gas -
– Maximo version 7.6.0.6 & Maximo 7.6.1 Oil & Gas – October 2017
– Maximo Scheduler 7.5.2
– Interface to Financial Application
– Multi site – four (4) sites
 SWOT ANALYSIS - PowerGen
STRENGTHS THREATS
Reliability Culture
Competition
Maximo Asset &
Location History

Experienced, Valued
Employees

Aging Assets Improved Asset

Employees Retiring Reliability & Availability
Knowledge Transfer New Business

WEAKNESS OPPORTUNITIES
Agenda

• Reliability Centered Maintenance (RCM)

• How RCM can be applied in Maximo Oil & Gas
• Benefits
 RCM - Maximo
RCM defined?
Moubray (1991) defined RCM as “a process used to determine what
must be done to ensure that any physical asset continues to
function in order to fulfil its intended function in its present
operating context.”

RCM focuses, not on the system hardware itself rather, on the

system function i.e. function based approach

The overall goal of Reliability Centered Maintenance (RCM) is to

improve the economic posture of a business operation by improving
the cost-effective application of maintenance resources (epri.com)
 Reliability Centered Maintenance (RCM)
Why RCM is Required?
• Operating restrictions that limit maintenance outages
• Change in Operating Mode
• Impact of Asset Failures on Critical Operating Systems
• Utilities - search new ways of optimizing the maintenance management of
their operating assets
– Reliability
– Availability
• Risk & Consequence Identification as a result of Failure
– Financial Impact of Failures
– HSSE Issues
– Safe and Reliable Operating Assets
– Business Continuity
– Political Implications
• Reduction in Reactive Maintenance
• Lessons Learned
 Reliability Centered Maintenance (RCM) - Program

The RCM analysis carefully considers the following questions:

• 1. What does the system or equipment do and what is its
function?
• 2. What functional failures are likely to occur?
• 3. What are the likely consequences of these functional
failures?
• 4. What can be done to reduce the probability of the failure,
identify the onset of failure or reduce the consequences of
the failure?
 Reliability Centered Maintenance (RCM)

A successful RCM project requires two organizational

considerations.
 First, RCM project requires leadership and facilitation by someone
who is well versed in details of the 7-step system analysis
methodology.
 Second, it requires the commitment of a dedicated team of qualified
technicians & supervisors who know the equipment and plant
systems and how they operate together to produce the product

The first step to the successful implementation of the RCM

technique is to ask seven basic questions about the asset that the
methodology is intended to be applied on. (Moubray, 1991):
Seven key steps of the RCM process

F
M
E
C
A
 Reliability Centered Maintenance (RCM)
Elements of RCM
• Identify the criticality of Operating Locations and the System its part off.
• Identify Failure Modes associated with these critical assets at the critical
operating locations
• Determine optimal PM frequencies
• Develop PM tasks that address these Failure Modes
• This analysis is used to determine appropriate maintenance tasks to address
each of the identified failure modes and their consequences.
• A rigorous RCM analysis is based on a detailed Failure Modes and Effects
Critical Analysis (FMECA) and includes probabilities of failure and system
reliability calculations.
Management is all about executing tasks.
Strategic Maintenance is all about deciding what tasks should be executed
based on RCM Program
Lessons Learned being communicated throughout the organization
 Results - Reliability Centered
Maintenance Program

RCM

PM CONDITION BASED REACTIVE - RTF

CONDITION
PdM MONITORING –
REAL TIME
 Reliability Centered Maintenance Elements –
Maximo Oil & Gas
Location (Oil) Item Master
Assets (Oil) Item / Asset
PM / PdM / CDM Program Specifications
Defects (Oil)
Classifications
Tools Job Planning
Procurement
Service Items Scheduling
Problems & Solutions Action Items
Failure History
Lessons Learned
Asset & Location Cost People & Qualifications
Roll up Safety
Permits & Certificates
Incident Investigations
Management Asset & Location Criticality
FMECA
Management of
Change (MoC) Risk Assessment
 Failure Modes - Maximo Oil & Gas
Failure - Means Functional Failure occurs when an item is no
longer capable of performing its intended function.
Failure Mode Defined: Manner in which an item fails
– The part + problem with the part + reason for failure
• Failure Mode and Effects Analysis (FMEA) and Failure Modes
Effects and Criticality Analysis (FMECA) are methodologies
designed to identify potential failure modes for a product or
process.
– To assess the risk & consequences associated with these failure
modes
– To rank the consequences in terms of importance and to identify and
carry out actions to address the consequences
 Critically Ranking of Failure Modes

Loss of Functions ?

Impact HSSE ?
Yes

Impact Critical Operations

Yes
Impact Financial Operations or
Political or Customer relations
Yes
Is the Function Protected by
existing PM Tasks
Yes
Non – Significant Function

At this Stage Elimination of Significant Function

effective maintenance
 Operating Location :FMECA

Summary of Failure
Details
Failure Mode details

Capturing the Failure Modes, the

Function and the Effects

Identifying the Risk &

Operating Procedure Consequences
Policy, PM Program
Maximo Oil & Gas - Location Risk Assessment

Function

Risk & Consequences

Maintenance &
Operating Policies
Maximo Oil & Gas Failure Reporting

Failure Analysis

Safety
Critical
Maximo Oil & Gas – Work Order ( Oil & Gas) > Action Items
Identification of Action Items – such as modify PM tasks to address failure
 Reliability Centered Maintenance (RCM)

Value derived of an RCM Program in Maximo Oil & Gas

 More Effective Job Planning Tasks

 Documented technical basis for identified tasks
 Reduction in PM induced corrective maintenance actions
 Reduction in the costs of PM Tasks
 Improved service reliability or reliability program
 Improved use of man power (resources – right personnel for the right job)
 Reduction in the frequency and severity of catastrophic equipment failures
 Customer Satisfaction
 Return on Investment (ROI)

Corporate
RCM will Focus on GOALS Customer Satisfaction

DATA QUALITY Employee Morale

• Improved Profits > Employee
 Work Management Bonus
 PM/ PdM Program Reliability Program
 Job Planning Key Stake Holder
 Procurement Practices Asset Management Satisfaction
 Inventory Management Strategy
 Incidents (Oil & Gas)
 Investigations ( Oil & Gas)
 MoC (Oil & Gas)

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 RCM in Maximo Oil & Gas

Questions ????

Thank You

References

Mainsaver.com
Epri.com
IBM.com
Reliability web.com
Moubray, 1991
Reliability-Centered Maintenance, F. Stanley Nowlan and Howard F. Heap, 1978, United Airlines.