Optimization of Maintenance Plan Based on Reliability

Centred Maintenance (RCM) Approach

An Effective Maintenance Strategy to ensure that assets
continue to do what their owners & users require in
their present operating context

DNV GL Energy Advisory

1 DNV GL SAFER, SMARTER, GREENER

Agenda

1. DNV GL Company Introduction

2. Asset Management And Reliability Centred Maintenance

3. Five Steps for RCM Implementation

4. Going Beyond RCM programme

5. DNV GL Value Proposition and Experience

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Agenda

1. DNV GL Company Introduction

2. Asset Management And Reliability Centred Maintenance

3. Five Steps for RCM Implementation

4. Going Beyond RCM programme

5. DNV GL Value Proposition and Experience

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We are a global classification, certification, technical assurance
and advisory company

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DNV GL
150 400 100 14,000
years offices countries employees

DNV GL
Organized to maximise customer value

MARITIME OIL & GAS ENERGY BUSINESS SOFTWARE

ASSURANCE

MARINE CYBERNETICS

RESEARCH & INNOVATION

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DNV GL
 Transition to a safer,
smarter and greener
energy future

Increasing global Integration of Climate change Growing share of Security and

demand for energy markets and extreme renewables ageing assets
energy weather

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 Largest >25 No 1 90
independent technical standards and in high power and high years experience in
advisor on renewable guidelines published as voltage testing with 10 the power industry,
energy and 2,500 a leading certification laboratories incl. our including 30 years in
energy experts body leading lab in Arnhem energy efficiency and
wind energy

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 DNV GL Services on
Service line introduction
Asset Management

We understand the business consequences of a technical decision

and the technical consequences of a business decision

IT supporting tools ISO 55000 based Asset Hearth & Asset

Power Failure
for Asset Asset Management Risk assessment / Management
Investigation and
Management system consulting Asset condition & maintenance
System: CASCADE /
recommendation
/ Gap analysis & lifetime strategy review
AHRM to prevent failure
Road mapping assessment and optimization

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Agenda

1. DNV GL Company Introduction

2. Asset Management And Reliability Centred Maintenance

3. Five Steps for RCM Implementation

4. Going Beyond RCM programme

5. DNV GL Value Proposition and Experience

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Asset Management

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Standards for Asset Management

PAS55
Guideline issued by BSI
PAS 55 is not a standard but a guideline through the IAM
Issued 2004
Revised in 2008

ISO55000 Series
International standard
ISO 55000 standard
based on PAS55
Issued in 15/01/2014

DNV GL

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Asset Management Model

Example:

EVN

EVNNPT,
EVNNPC,
EVNCPC,

EVNNPT,
etc. and/or
PECC, IE,
etc.

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Key elements of Asset Management

RCM Maintenance

1. RCM framework
based on four
types of
maintenance
strategies
2. Condition
monitoring &
Data collection,
PFI, testing &
inspection
3. Health index and
Risk index
assessment Planning
4. Software, IT,
Install & Commissioning
system
integration & O&M
interface Decommissioning

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Maintenance Strategies Evolution
Reliability Centred Maintenance (RCM) - structured process to determine the maintenance strategies

Reactive Maintenance Preventive Maintenance Predictive Maintenance

(RM) (PM) (PdM)

Evolution of Maintenance Strategies

Run to Risk &

Time Condition
Fail (RTF) Criticality
Corrective Based Based Based
Maintenance (TBM) (CBM)
(CM) (RBM)

Repair / replace Maintain at a Maintain & Maintain or

on failure set interval replace based replace assets
For example, on condition with highest risk
replace asset at and greatest
40 year asset importance
life

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RCM History

1960s 1970s

Early Introduction FAA and FAA/Airline produce MSG 1978

Preventive of 747, DC- Commercial Group MSG 1, handbook Department
Mainten- 10, L-1011 Aviation conclusion: Handbook: updated to of Defense
ance led airlines Industry overhauls Mainten- MSG-2, (DOD)
Programs to conclusion formed a had little or ance Airline/ sponsored
based on that current group to no effect Evaluation Manufac- DOD report
concept that preventive study on overall and tures AD-A066579,
periodic mainten- preventive reliability Program Mainten- Reliability
overhauls ance mainten- or safety in Develop- ance Centred
ensured philosophie ance many cases ment. First Program Maintenance
reliability s were applied to Planning by Nowlan
and, unsustaina Boeing 747 Document, and Heap -
therefore, ble applied to Updates MSG-
safety NAVAIR 2 approach
systems, with better
Conditional Probability

As interest increased,
Overhaul interval a variety of other processes
with called
guidance on
Analytical process and
themselves RCM!
of Failure

Maintenance interval
Program determination

Time

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 Advantages & Disadvantages of different maintenance strategies
Reactive Preventive
Advantage
Low cost. Cost effective in many
Less staff. capital-intensive
processes.
Flexibility allows for the
adjustment of
maintenance periodicity.
Increased cost due to Increased component life
unplanned downtime of cycle.
equipment. Energy savings.
Increased labor cost, Reduced equipment or
especially if overtime is process failure.
needed. Estimated 12% to 18%
Cost involved with cost savings over
Disadvantage
repair or replacement reactive maintenance
of equipment. program.
Possible secondary
equipment or process
damage from
Catastrophic failures still
equipment failure.
likely to occur.
Inefficient use of staff
labor intensive.
resources.
Includes performance of
unneeded maintenance.
Potential for incidental
damage to components
in conducting unneeded
maintenance.
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Predictive RCM
Increased component Can be the most
operational efficient maintenance
life/availability. program.
Allows for pre-emptive Lower costs by
corrective actions. eliminating unnecessary
Decrease in equipment maintenance or
or process downtime. overhauls.
Decrease in costs for Minimize frequency of
parts and labor. overhauls.
Better product quality. Reduced probability of
Improved worker and sudden equipment
environmental safety. failures.
Improved worker morale. Able to focus
Energy savings. maintenance activities
Estimated 8% to 12% on critical components.
cost savings over Increased component
preventive maintenance reliability.
program. Incorporates root cause
analysis.
Increased investment in
diagnostic equipment.
Can have significant
Increased investment in
start-up cost, training,
staff training.
equipment, etc.
Savings potential not
Savings potential not
readily seen by
readily seen by
management
management.
Ref: DOE
Agenda

1. DNV GL Company Introduction

2. Asset Management And Reliability Centred Maintenance

3. Five Steps for RCM Implementation

4. Going Beyond RCM programme

5. DNV GL Value Proposition and Experience

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Five Steps of Optimization of RCM

1 Technical Quality Assessment

(TQA) on Current
Maintenance Practice

2 Optimised Reliability-Centred
Maintenance (RCM) Programme
Setting up for Proof of Concept
RCM Implementation

3 Proof of Concept of
Optimized RCM Programme

4 Implementation of
Optimized RCM Programme
by IT supporting tools

5 KPI setting and evaluations

criteria for continuous
improvement

DNV GL
Five Steps of Optimization of RCM : Step 1

1
Technical Quality Assessment (TQA) on
Technical Quality Assessment
(TQA) on Current Current Maintenance Practice on 5 main
Maintenance Practice
topics as
Asset Lifecycle Management

2 Optimised Reliability-Centred
Maintenance (RCM) Programme
Setting up for Proof of Concept
Risk Management and Mitigation
Asset Data Quality & Analysis
RCM Implementation

Maintenance and Operation

3 Proof of Concept of
Optimized RCM Programme
Condition and Performance Assessment

4 Implementation of
Optimized RCM Programme
by IT supporting tools
Output:
TQA report including

5 KPI setting and evaluations

1. Current maintenance practice overview
criteria for continuous
improvement 2. Recommendations

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Five Steps of Optimization of RCM : Step 2

1
Optimised Reliability-Centred Maintenance
Technical Quality Assessment
(TQA) on Current (RCM) Programme setting up for Proof of
Maintenance Practice
Concept
2.1 Asset Classification

2 Optimised Reliability-Centred
Maintenance (RCM) Programme
Setting up for Proof of Concept
Identify asset group for Run to failure/ Time based and
Condition Based maintenance categorization
RCM Implementation

2.2 Diagnostic marker identification for one Asset Group

3 Proof of Concept of
Optimized RCM Programme
Failure Mode, Effects and Criticality Analysis (FMECA) and Asset
Condition Assessment; Methodology and process quality
improvement

4 Implementation of
Optimized RCM Programme
by IT supporting tools
2.3 Predictive Maintenance Plan setting for One Asset
Group
Asset Health and Risk Matrix; Visualization and analysis of

5
assessment result
KPI setting and evaluations
criteria for continuous
improvement

DNV GL
Five Steps of Optimization of RCM : Step 3

1
Proof of Concept of Optimized RCM
Technical Quality Assessment
(TQA) on Current Programme
Maintenance Practice
DNV GL will execute proof of the concept using
Enterprise Maintenance software for the

2 Optimised Reliability-Centred
Maintenance (RCM) Programme
Setting up for Proof of Concept
Customer to understand newly proposed
Maintenance framework based on RCM
RCM Implementation

approach.

3
Covering asset registry, maintenance and
Proof of Concept of
Optimized RCM Programme condition history, threshold settings as well as
maintenance activity order triggering
One selected substation will be put
4 Implementation of
Optimized RCM Programme
by IT supporting tools
Assumptions on inputs for condition analysis
result
DNV GL will use independent software, named
5 KPI setting and evaluations
criteria for continuous
improvement
Cascade

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Five Steps of Optimization of RCM : Step 4

1
RCM implementation with software
Technical Quality Assessment
(TQA) on Current
Maintenance Practice
RCM implementation for one asset group for a
small scale system
RCM implementation for multiple asset groups
2 Optimised Reliability-Centred
Maintenance (RCM) Programme
Setting up for Proof of Concept
for a small scale system
Full RCM implementation for the whole system
RCM Implementation

System integration and interface

3 Proof of Concept of
Optimized RCM Programme

4 Implementation of
Optimized RCM Programme
by IT supporting tools

5 KPI setting and evaluations

criteria for continuous
improvement

Example of Maintenance Management Enterprise software

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Five Steps of Optimization of RCM : Step 5

1
KPI setting and evaluation criteria
Technical Quality Assessment
(TQA) on Current
Maintenance Practice
Reliability (SAIDI, SAIFI, CAIDI), Legal
compliance, Safety and Economy (CAPEX,
OPEX, C/B Analysis)

2 Optimised Reliability-Centred
Maintenance (RCM) Programme
Setting up for Proof of Concept
Asset Life cycle cost calculation
RCM Implementation

3 Proof of Concept of
Optimized RCM Programme

4 Implementation of
Optimized RCM Programme
by IT supporting tools

5 KPI setting and evaluations

criteria for continuous
improvement

Example of Cost visualization of the asset

DNV GL
Agenda

1. DNV GL Company Introduction

2. Asset Management And Reliability Centred Maintenance

3. Five Steps for RCM Implementation

4. Going Beyond RCM programme

5. DNV GL Value Proposition and Experience

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DNV GL Asset Management Approach Beyond RCM implementation

Planning

Install & Commissioning

O&M
Decommissioning

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to serve the overall AM structure and detailed implementation at
all levels

Asset Owner
Strategic
Policy

Strategy

Organisation

Asset Manager
Tactical

Risk
Customer Finance
Management
Design &
Logistics Condition Maintenance
Construction
Service Provider
Operational
Employees Assets ICT Maintenance

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DNV GL approach beyond RCM implementation

Roadmap Continual
Gap analysis Implementation
Development Improvement

Gap analysis vs. Detailed AM AMS implementation Ongoing Support:

PAS55, ISO 55000: roadmap: & support:

Excellence in Asset Management

AM benchmarking,
Current Situations & Challenges

Review goals, policy, Functional Revise policy, risk audit

KPIs, maintenance roadmap framework, strategy, Subject-mater-

ISO 55000 Certification

strategy, processes, & process & work order expert support
Implementation
stakeholders management
roadmap with PFI and Power TIC
Legal obligations & Implementation IT & AM software and
Data analytics
standards plan and integration, cyber
schedule, security Asset health and risk
Current technical &
prioritize actions assessment, and cost
financial situation Health and risk
and cost analysis
methodologies
Awareness sense of estimation & Trainings &
urgency & define financial planning Technical spec & owner
workshops
designed states engineer

DNV GL Approach

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Agenda

1. DNV GL Company Introduction

2. Asset Management And Reliability Centred Maintenance

3. Five Steps for RCM Implementation

4. Going Beyond RCM programme

5. DNV GL Value Proposition and Experience

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Five Steps of Optimization of RCM : DNV GL Value Proposition

Process DNV GL Value proposition

1 Technical Quality Assessment

(TQA) on Current
Maintenance Practice
Incorporating Asset Management with
optimised RCM programme

2,500 exports and independency on

2
Optimised Reliability-Centred
Maintenance (RCM) Programme selecting right tools for condition
Setting up for Proof of Concept
assessment technique
RCM Implementation

Excellence on RCM
By combining data on the condition and

3 Proof of Concept of
Optimized RCM Programme
criticality of all assets, prioritizing
maintenance in the most effective way
Consistently learning from customer

4 Implementation of
Optimized RCM Programme
by IT supporting tools
experience through over 20 years of
Cascade User Conference with customer
sharing platform

5
KPI setting and evaluations
criteria for continuous
Tailoring KPIs based on company
improvement objective and stakeholder expectations

DNV GL
DNV GL Asset Management and Maintenance optimization
consulting experiences

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DNV GL Asset Management and Maintenance optimization
consulting experiences: Case 1

Project name: Consultancy for development of Health Index

(HI) System

Customer name : Singapore Power Group

Year of the completion: 2014

Description: DNV GL delivers asset specific performance

indicators and condition functions, being flexible enabling
customization by the HI users and fully aligned with common IT
and Asset Management systems.

Customer benefits: The HI results enables Singapore Power to

complete a risk based asset management approach, fully aligned
with the latest international asset management standards, like
PAS 55 which Singapore Power has successfully implemented.

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DNV GL Asset Management and Maintenance optimization
consulting experiences: Case 2

Project name: Systematic Optimization for Asset Maintenance

(SOMA)

Customer name : Energisa Group

Year of the completion: 2014

Description: DNV GL to develop and implement an asset

management methodology and framework that would enable the
company to optimize their operations and maintenance (O&M)
costs by improving their assets lifecycles.

Customer benefits: Framework can be used to determine why,

how, what, and when to perform each maintenance activity, as well
to support the decision-making process for buying, keeping, or
renewing electrical assets served as a bridge to base the transition
to the ISO 55000 standard

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DNV GL Asset Management and Maintenance optimization
consulting experiences: Case 3

Project name: SMARTLIFE Consortium on European Asset Management

Customer name :

- Austria (WIEN ENERGIE STROMNETZ),

- Belgium (LABORELEC, EANDIS, SIBELGA, ORES, ELIA)

- France (EDF R&D, ERDF, RTE),

- Italy (ENEL, ERSE, University of Bologna),

- The Netherlands (KEMA, University of Deft, TENNET, ENEXIS),

- Norway (SINTEF, STATNETT, HAFSLUND, EBL),

- Portugal (EDP),

- Spain (IBERDROLA, REE),

- United-Kingdom (EDF ENERGY, NATIONAL GRID, University of Manchester)

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DNV GL Asset Management and Maintenance optimization
consulting experiences: Case 3

Year of the completion: 2011

Description: DNV GL is one of the initiation member aiming to

analyse future asset management needs, propose research and
development plans, and to organize exchange of experiences and
information. Mainly focus on

- identifying critical technologies of equipment and key factors

influencing failure and ageing mechanisms

- deducing methods reflecting the health index of equipment

- identifying best practices and technological innovations

Customer benefits: development of methodology for risk based

asset management and the guidelines for data management practices
and for creation and good implementation of decision support
systems (strategic and operational).

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Thank you!

DNV GL Energy

www.dnvgl.com

SAFER, SMARTER, GREENER

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