Purpose : RCM Program Development and Implementation Guidelines , with a thorough understanding of benefits Agenda RCM What it is ? Benefits , Maintenance Types Plant Reliability Asset Management Process and its Importance RCM Reliability Centered Maintenance & Strategies RCM Standards / Documents RCM based Maintenance and Reliability Factors RCM Tools and Soft-Wares Reliability Program ( Based on MSG 3 , Maintenance Steering Group UK ) European Technology Development Ltd www.etd-consulting.com Maintenance Methodologies and Philosophies & Maintenance Program European Technology Development Ltd www.etd-consulting.com Types of Maintenance Methodologies Failure Based or Break down Maintenance FBM Scheduled or Preventive Maintenance PM Predictive Maintenance PDM Proactive Maintenance PAM European Technology Development Ltd www.etd-consulting.com Strategic Maintenance Philosophies Condition Based Maintenance CBM Reliability Centered Maintenance RCM Total Productive Maintenance TPM European Technology Development Ltd www.etd-consulting.com What is RCM Reliability Centered Maintenance (RCM) is a risk-based study process for determining the least cost maintenance and surveillance actions needed to meet operating performance targets. It seeks the optimal mix of condition-based, time- based, and run-to-failure strategies All equipment across which maintenance money is spent (machinery, electrical, instrument, stationary equip, & civil) is subject to RCM study The OBJECTIVE is to be sure were doing the right level of preventive maintenance, at the right frequency, ensuring plant reliability, while also maintaining a competitive cost position European Technology Development Ltd www.etd-consulting.com Maintenance Program Adjustments European Technology Development Ltd www.etd-consulting.com Benefits of RCM RCM benefits can only be achieved when recommended tasks coming from an RCM study are actually transferred into actionable work, whether into PMs , Operations ,or other preventive actions (e.g. recommended plant changes) Benefits include Improved availability Controlled costs Improved safety and environmental protection A comprehensive preventive maintenance database RCM Business Objective MAINTENANCE EFFORT C O S T
NOT ENOUGH EFFORT OPTIMUM TOO MUCH EFFORT TOTAL COST TYPICALLY UNDER MAINTAINED TYPICALLY OVER MAINTAINED fire fighting mode comfort mode RISK BASED
RCM
PREVENTIVE MTCE. COSTS COST OF NON- AVAILABILITY PROD. LOSS +BREAKDOWN European Technology Development Ltd www.etd-consulting.com What is RAMP? Reliability Asset Management Processes Power Plants RAMP is an integrated structure of aligned processes required to successfully yield consistently reliable equipment at the lowest possible cost.
It serves as a tool to assist operating sites understand and implement each of the key processes needed for effective equipment reliability over the equipment life cycle. Cutting Maintenance Cost , Optimizing Inventory . European Technology Development Ltd www.etd-consulting.com Equipment Strategy Analysis Turnaround Strategy Maintenance Strategy Functional/ Criticality Analysis and/or Risk Based Inspection Spare Parts Strategy Training Strategy Operate/Maintain Plan Execute Routine Mtce Turnaround Mtce Work ID Work ID Plan Schedule Execute Document Document Schedule Operate Equipment Performance Data Design & Construct Construct Procure Design
Defect Elimination Other Sites Data Analysis to Determine Stake Prioritize Based On Business Impact Select What to Work on Root Cause Failure Analysis Eliminate System Defect Leverage Learnings Power Plant Equipment Reliability Asset Management Process Optimization Strategies Commission Specific Equipment Plans European Technology Development Ltd www.etd-consulting.com Standards for Power Plants RCM Implementation What standards are behind RCM MIL STD 785B ( Reliability Programs for Systems and Equipment Development ) MIL - STD 1629A ( Procedures for FMECA ) MIL STD 3034 ( RCM Process ) SAE JA 1011 / JA 1012 Evaluation Criteria for (RCM) Processes. OREDA Off-shore reliability data handbook PAS 55 1 Recommendations for Asset Management PAS 55 2 Implementations of Recommendations ISO 55000 ( Asset Management Standard Coming in 2014 ) European Technology Development Ltd www.etd-consulting.com RCM Implementation Step by Step Approach
Identification of Fossil Plant Understanding Systems & Equipment eg. GT , HRSG , Generator , Steam Turbine , etc. Understanding Performance and Function of each system , sub- system and Equipment. Defining Criticality of Each system , equipment with respect to performance and function . Understanding failure modes of each system , equipment & its Consequences with respect to safety , environment , economics and Operation. Reliability Block Diagram Modeling and Weibull Analysis . European Technology Development Ltd www.etd-consulting.com Define Functions & Functional Failures Identify Failure Modes Assess Criticality Develop and Assess Preventive maint Plan Optimize Tasks, Frequency & Cost Recommended tasks Actionable tasks Review based on field feedback RCM Learn & Improve Process Gas Turbine 20 Systems 100 Components 150 Sensors 15000 Parts 1000 Failure Modes 20000 Consequences How many PM Tasks Cover all this ? If all How effective and efficient those tasks are ? RCM Implementation Step by Step Approach
Complete review of PM Preventive Maintenance and reliability program to see whether all function and performance failure modes are mitigated . Changes in PM and reliability programs . Review of Amended PM and Reliability Programs . Based on criticality RBI Risk Based Inspection introduction . Continuous review of Failure Modes with existing and amended PM programs . Effective use of soft-wares for analysis Level of Analysis may be extended into in-house as well as subcontract repair. Integration of same in CMMS or SAP system for monitoring . European Technology Development Ltd www.etd-consulting.com
Spare Parts Strategy Training Strategy How is Criticality Analysis Used in RCM ? The combination of these strategies form the Specific Equipment Plan or SEP High criticality - requires thorough reliability analysis. Medium criticality - Failure Modes and Effects Analysis. Low criticality - generic strategies. Business Impact (Consequence of Failure)
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F a i l u r e 10 20 30 40 50 1 2 3 4 5+ I n c r e a s i n g C r i t i c a l i t y European Technology Development Ltd www.etd-consulting.com RCM Implementation Step by Step Approach Documents Requirements Maintenance Planning Document OEM Specific Equipment Operating Instructional manual OEM Trouble Shooting / Fault Isolation Manuals OEM Overhaul Manuals OEM Work-Scope Planning Guide OEM Complete Repair History Since Commissioning for Systems , Equipment & up-to parts level Last Heavy Maintenance Scope under PM and Corrective Maintenance Overhaul Scope Last Shut Down / Turn Around Scope Performance Data Base . European Technology Development Ltd www.etd-consulting.com RCM Implementation Step by Step Approach Soft-wares and Tools Used
Existing CMMS and SAP System Analysis Soft-wares like Minitab , Statistics , Stat Graphics , Weibull 6++ etc Package Soft-wares Merridium , Isograph etc RCM Tools FRCA Failure Root Cause Analysis FMECA Failure Mode and Its Effect Criticality Analysis RBD Reliability Block Diagram Weibull Analysis ( Reliability Calculations ) RAM Reliability Availability and Maintainability
European Technology Development Ltd www.etd-consulting.com RCM Implementation & ETD Support Conclusions
RCM is a Powerful maintenance Philosophy and as such it its implementation can have a considerable gain in Plant Performance and Functional Reliability Improvement Maintenance Cost Reductions
European Technologies Development have launched proposal with an objective to RCM Awareness and Understanding in Power Plants RCM Study for Fossil Power Plants . RCM program development and Implementation Guidelines Fossil Power Plant Remaining Life Assessment and its integration with RCM for longer life of Asset.
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