Reliability Centered Maintenance

Procedures

QHSE-QS-L3-301
Rx xx-xx-2011
Page 1 of 11

25-02-2014

Rev.

RELIABILITY CENTERED MAINTENANCE

PROCEDURES

Date

Original Circulation DIP No. xx

History of Changes

Prepared By : (Head of Reliability

& ConMon )
(Mohammed Al Barwani)

Reviewed By: ( OSM Manager )

Approved By :( GMO )

(Majid Al Zidjali)

(Mansoor Al Abdali)

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Reliability Centered Maintenance

Procedures

QHSE-QS-L3-301
Rx xx-xx-2011
Page 2 of 11

Table of Contents
1. PURPOSE......................................................................................................................... 3
2. SCOPE.............................................................................................................................. 3
3. OBJECTIVES..................................................................................................................... 3
4. DEFINITIONS & ABBREVIATIONS...................................................................................... 3
5. PROCEDURE.................................................................................................................... 4
5.1
5.2
5.3
5.1.1
5.1.2
5.4
5.5
5.6
5.6.1
5.6.2
5.6.3
5.7
5.7.1
5.8

RCM Analysis procedure guidelines............................................................................................................................4

data gathering...............................................................................................................................................................5
ESTABLISH STUDY BOUNDARIES........................................................................................................................5
Establish specific study boundaries..............................................................................................................................5
Form RCM team...........................................................................................................................................................5
PERFORMANCE OBJECTIVES................................................................................................................................6
identify equipment FUNCTIONS................................................................................................................................6
CONDUCT STREAMLINED FAILURE MODES EFFECT CRITICALITY ANALYSIS.......................................6
Identify FMECA for each of the equipment.................................................................................................................6
Conduct RCM Failure Defense task selection for critical (C1, C2, and High Consequences) equipment..................7
Perform RCM failure defense task selection for non-critical equipment & failure modes..........................................8
blue matrix....................................................................................................................................................................8
Task Consolidation and Procedure Development........................................................................................................8
OTHER DATA MAINTENANCE...............................................................................................................................9

6. References....................................................................................................................... 9
APPENDIX 1......................................................................................................................... 10
APPENDIX 2......................................................................................................................... 11

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QHSE-QS-L3-301
Rx xx-xx-2011
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1. PURPOSE
This procedure provides a systematic approach to defining O&M equipment, understanding failure
modes and their effects, and developing Failure Defense Task (predictive, preventive, run-to-failure,
etc.) and first line maintenance program effectively to mitigate the potential for unacceptable failure.
This procedure includes determination of FMEA, application of RCM Analysis appropriate to the
consequences of equipment failure based on the ECA result.

2. SCOPE
This procedure applies to Production equipment under Oman Gas Company (OGC) operational
control. Included in the scope of this procedure is all rotating, instrumentation, electrical and control
systems that are a part of production and processing operations

3. OBJECTIVES
The objective of the RCM is to streamline maintenance by:
o
o
o
o
o
o
o
o
o
o

Identifies actions that minimize Corrective Maintenance.

Emphasizes condition-monitoring tasks.
Eliminates PM tasks determined to be unnecessary or not cost-effective.
Identifies necessary failure-finding tasks.
Extends existing time-directed task intervals through age exploration or frequency optimization.
Addresses design change options.
Identifies where no proactive maintenance is required, or Run-to-Failure (RTF).
Allowing for redundancy where appropriate
Providing the appropriate tools & technology, maintenance duration, and manpower skills.
Optimizing spare parts management system via RCS (Reliability Centered Spares).

4. DEFINITIONS & ABBREVIATIONS

CBM
CMMS
ECA
FCA
FMEA
FMECA
ORD
PM
RAM
RBI
RCM
RCS
RTF
SIL
SRCM

Condition Based Maintenance

Computerized Maintenance Management System
Equipment Criticality Analysis
Failure Characteristic Analysis
Failure Mode Effect Analysis
Failure Mode Effect Criticality Analysis
Operator Routine Duties
Preventive Maintenance
Reliability Availability Maintainability
Risk Based Inspection
Reliability Centered Maintenance
Reliability Centered Spares
Run to Failure
Safety Integrity Level
Streamline Reliability Centered Maintenance

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QHSE-QS-L3-301
Rx xx-xx-2011
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5. PROCEDURE
5.1 RCM ANALYSIS PROCEDURE GUIDELINES
The following diagram (Figure 1) illustrates the overall process of SRCM Analysis, described in
this section and further detailed within Appendix 1 of this document.
The RCM approach deploys a variety of integrated maintenance tools and techniques to increase
the probability that a system or equipment will perform in a required manner over an extended life
cycle with minimum maintenance. This approach is risk-based; SRCM seeks to focus
maintenance development effort on areas that represent the highest risk to the stated goals and
objectives for the asset. This does not mean that no effort is directed towards lower risk areas but
that the focus is on those areas that have the greatest potential to impact business performance.
Within the context of this document, risk is considered to be the product of the consequence of
failure and the likelihood (probability) of failure.

Figure 1: RCM Flowchart Procedures

5.2 DATA GATHERING

This data shall include all manufacturers, vendors and asset register information and tag numbers.
Equipment and components to systems and tag numbers shall be cross-referenced.
COMPANY use RCM software Database for data management and ensure alignment with CMMS
SAP.
The following data that need to perform the RCM:
o
o
o

The Equipment Criticality Assessment result contains detailed information on updating

equipment listings refer to document.
P&ID, PFD, or line diagram.
Gather system general failure, cost information

Information includes:
o
o
o
o
o
o
o

System functions
ECA result
Vendor design, operation and maintenance information
Maintenance history
Component interaction (logic)
Existing PM and surveillance tasks (by equipment no.)
Cost history
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QHSE-QS-L3-301
Rx xx-xx-2011
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5.3 ESTABLISH STUDY BOUNDARIES

5.1.1 ESTABLISH SPECIFIC STUDY BOUNDARIES

Boundaries shall be up to the equipment skid level

Equipment which follows up with SRCM shall be C1, C2, and also which has high
consequence criticality.

5.1.2 FORM RCM TEAM.

Team consists of a facilitator and a multifunctional team.
Primary function of a facilitator is to facilitate the application of the RCM philosophy by
asking question of a multifunctional team chosen for their knowledge of a specific asset or
process ensuring that the group reaches consensus about the answer and recording the
answer.
Multifunctional team usually consists of:
1. Reliability Engineer - Facilitator
2. Operations
3. Maintenance Mechanical
4. Maintenance Instrument
5. Maintenance Electrical
6. Planner
7. SME
The mix of resource types will help obtain concurrence for actions from all groups. They
will be expected to use personal experience to identify potential improvements and
opportunity areas/solutions to include potential design changes (one time improvements)
and improved maintenance/surveillance processes/ techniques and integrity philosophy.
5.4 PERFORMANCE OBJECTIVES
The objectives selected must coordinate with the overall function of the system, and must be
specific and measurable. It may include throughputs, yields, product qualities, or whatever
objective is appropriate for the plant or facility.
5.5 IDENTIFY EQUIPMENT FUNCTIONS
Determine the function for each of equipment Include "safety/environmental" as well as
"production" functions. Define the "key" and the "less important" functions. Typically a third of
items is key or critical items and is addressed with mitigation actions. Another third are non-critical
but are addressed for economic reasons (cost of failure and resource impact). Finally, the last
third of items cannot be cost effectively addressed proactively and typically allowed to run to
failure.
5.6 CONDUCT STREAMLINED FAILURE MODES EFFECT CRITICALITY ANALYSIS
5.6.1 IDENTIFY FMECA FOR EACH OF THE EQUIPMENT
1. What are the functions and associated performance standards of the asset in its
present operating context? (Function and Performance Standard)
2. In what ways does it fail to fulfill its functions? (Functional Failure)
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QHSE-QS-L3-301
Rx xx-xx-2011
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3. What happens when each failure occurs? (Failure Effect)

4. What causes each functional failure? (Failure Mode)
5. In what way does each failure matter? (Failure Consequences)
6. What can be done to predict or prevent each failure? (Task Selection)
7. What should be done if a suitable proactive task cannot be found? (Others Decision)
Diagram below may help to determine question number 5, 6, and 7.

Figure 2: RCM Chart Diagram

COMPANY has dealing with Streamline RCM method to determine RCM objective then
COMPANY will only focus on the critical hazard (failure mode). To determine the critical
failure mode, COMPANY has the method to use 5x5 matrix and the thresholds are already
defined by the COMPANY, see Figure 3 below:
o
o

If the failure effect can be tolerated the failure is not critical. If the failure effect is not
tolerable the failure is critical. Tolerability is based on achieving performance
objectives, safety/environmental standards and effect on function.
The below matrices will normally be used as a guides to determine failure mode rank.

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QHSE-QS-L3-301
Rx xx-xx-2011
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Figure 3: OGC Criticality Matrix

5.6.2 CONDUCT RCM FAILURE DEFENSE TASK SELECTION FOR CRITICAL (C1,
C2, AND HIGH CONSEQUENCES) EQUIPMENT.
For each critical equipment use Failure Defense task selection flow in Failure Defense
Task Philosophy & Management Document which is summarized below:
o
o
o
o

Determine the most applicable and effective Failure Defense task(s) to address the
identified causes
For hidden failures determine appropriate PM detection or failure finding tasks
Selecting the task(s) for evident failures should use the following task and
responsibility hierarchies which promotes driving Operator Routine Duties or First Line
Maintenance as much as reasonably possible
Task hierarchy

First Line Maintenance

Condition Based Monitoring
Preventive Maintenance
o
Invasive preventive restoration task (e.g. disassembly to check bearing
wear and replace as needed)
o
Time-based replacement task (e.g. replacing bearings)
o
Failure Finding Task
o
One time improvement (eliminate failure/failure effect)
Run to Failure

For situations where there is no suitable task, and the consequences (e.g. Safety) are
significant, an engineering/operational change or redesign may be necessary.

5.6.3 PERFORM RCM FAILURE DEFENSE TASK SELECTION FOR NON-CRITICAL

EQUIPMENT & FAILURE MODES
Run to Failure strategy will be applied where it is more cost effective to allow the
component to fail and repair than to spend money and man-hours in maintenance.
This option must pass a run to failure filter Check which requires approval from the Asset
Manager and Operation Support Manager.
Run to Failure Check:

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o
o
o
o
o

QHSE-QS-L3-301
Rx xx-xx-2011
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Confirm that Failure Defense Task cost is higher than cost of running-to-failure if cost
is higher for failure returning to select suitable task step.
Make sure running-to-failure does not introduce significant disruption to production
process.
Ensure running-to-failure will not cause significant secondary damage to equipment. If
failure will cause secondary damage return to select suitable task step.
Confirm there is no regulatory, HSE or certification Failure Defense Task requirement
for equipment. If regulatory, HSE or insurance requirement is found, return to select
suitable task step.
If no any concern issues are found, equipment/component will be allowed to run to
failure.

5.7 TASK CONSOLIDATION AND PROCEDURE DEVELOPMENT

COMPANY shall develop the Failure Defense Task Strategy complete with several things which
mentioned below:
1. Equipment Name
2. Manpower skill and disciplines.
3. Manpower estimation.
4. Duration performing the maintenance task
5. Tools & Technology.
6. Maintenance Task Interval.
7. Spare part need analysis
a. Amount of spare part
b. Stock code
c. Material Cost Estimation
Several things above shall be develop for each of the Failure Defense Task Strategy that already
been defined which lead by the Facilitator during the RCM workshop and all the data result shall
recorded and enter into RCM Database Software and CMMS SAP system.
5.8 OTHER DATA MAINTENANCE
In addition to the use of RCM there are other maintenance development approaches that also
shall be considered. These include:
1. Mandatory Maintenance activities that are mandated by legislation, COMPANY policy or
procedure, or follow directly from COMPANY activities targeted to identify hazards (e.g. hazard
assessments).
2. Generic or Standard Maintenance Policies COMPANY derived maintenance policies
designed to be applied to a standard range of equipment. These may have been developed
previously using RCM or may be the result of previous operating experience with similar
equipment in similar operating environments. This approach may be used as a substitute for
streamlined RCM. An example of where a generic maintenance policy may be considered is
in the inspection and maintenance of certified electrical equipment.
3. Manufacturers Recommendations Manufacturers have detailed technical knowledge
regarding their equipment. RCM result shall take account of manufacturer recommendations
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QHSE-QS-L3-301
Rx xx-xx-2011
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when determining the maintenance strategy for any equipment item. RCM result shall not
make any change to a manufacturers recommended maintenance program that may
adversely affect the equipment warranty.
4. SIS SIL Evaluation RCM result shall undertake a Safety Integrity Level (SIL) evaluation for
each Safety Instrumented System as required by COMPANY specification or regulations. This
will result in the specification of function test intervals being defined for SIS components
including initiators (e.g. pressure transmitters), logic elements (e.g., PLCs) and actuators (e.g.
emergency shutdown valves).

6. References
OGC Reliability & Condition Monitoring Guidelines

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OS-GEN-L2-208

Reliability Centered Maintenance

Procedures

QHSE-QS-L3-301
Rx xx-xx-2011
Page 10 of 11

APPENDIX 1.
RCM KPI Matrix
Table 1: Key Performance Indicator of Reliability Centered Maintenance
Description and / or
Calculation Method or
Metric Name
Intent
Equation
% RCM applied / Total
Percent Critical Equipment
Encourage completion
number of Critical
with RCM Complete
on all critical equipment
Equipment
Percent RCM Tasks
Implemented

Measure effectiveness of
RCM task selection

Number of RCM tasks

implemented / Number
of RCM tasks identified

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QHSE-QS-L3-301
Rx xx-xx-2011
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APPENDIX 2.
Roles and Responsibility Matrix.
A summary of the roles related responsibilities that are required to both implement and manage
Reliability Centered Maintenance process is given the following RCM process RASCI matrix- Table 1.

A
I

Planner

Operator

A
I

Maintenance
Supervisor

Form RCM Team

Data Gathering
RCM Workshop
Facilitation
RCM Result
Upload into SAP

Manager Regional

Activity

ReliabilityHead of

Asset Manager

Execution

OSM

Table 2: RCM RASCI Matrix

A
R

R
C

S
S

C
S

C
S

I
S

R
C

I
I

I
I

I
I

I
R

A
A
A

R = Responsibility owns the problem / project

A = to whom R is Accountable who must sign off (Approve) on work before it is effective
S = can be Supportive can provide resources or can play a supporting role in implementation
C = to be Consulted has information and/or capability necessary to complete the work
I = to be informed must be notified of results, but need not be consulted

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