Professional Documents
Culture Documents
Contents
1 Scope of Application ......................................... 2
2 Conflicts and Deviations ................................... 5
3 References........................................................ 5
4 Purpose............................................................. 6
5 Definitions ......................................................... 7
6 Acronyms and Abbreviations .......................... 12
7 RAM Study Requirements, Objectives,
Methodology, and Instructions ........................ 13
8 R&M Data Collection and Adjustments ........... 21
9 Assets Information and Configuration ............. 32
10 RAM Study Operational Targets ..................... 32
11 RAM Base-case Model Development
and Adjustment ............................................... 33
12 RAM Base-Case Model................................... 34
13 RAM Study Modeling Phases ......................... 34
14 RAM Improvements Identification
and Prioritization ............................................. 43
15 RAM Improvement, Repair versus
Replace Options Guidelines............................ 46
16 RAM Study Sensitivity Analysis Cases ........... 46
17 RAM Benchmarking Process .......................... 47
18 RAM Study Draft and Final Report .................. 48
Revision Summary .................................................. 51
1 Scope of Application
1.1 This Saudi Aramco Engineering Standard (SAES) provides the mandatory
requirements for the systematic execution of Reliability, Availability, and
Maintainability (RAM) study.
1.4 This SAES can be applied to other facilities not listed in paragraph 1.2 and/or
other assets not listed in paragraph 1.3 following the approval of the Asset
Management Standards Committee Chairman, the CSD of Saudi Aramco,
Dhahran.
1.5 The thresholds of the RAM study application to capital projects are as follows:
1.5.2 To perform the RAM study on Saudi Aramco capital projects above
$5 MM with less than five different or identical and/or redundant assets
shall require the approval of the Chairman, Asset Management Standards
Committee of Saudi Aramco, Dhahran.
1.5.2.4 Others.
1.5.4 For new projects where the PFDs have been extensively developed
during the early phase of FEL 2 phase (i.e., DBSP phase) or extension
projects where existing PFDs are being modified, RAM FEL 2 (DBSP)
shall be replaced by RAM FEL 3 (PP). In this case, RAM FEL 3 (PP)
shall be advanced to start at RAM FEL 2 (DBSP) due date and shall be
completed prior to project FEL Gate-2.
1.5.5 Capital projects with the FPD project Characterization A, B, and C-Type
Projects shall require a RAM study.
1.5.7.1 Fire Protection and Safety assets and installation as these assets
and installations are governed by LPD and Fire Protection
Department mandatory engineering standards, practices and
guidelines.
1.5.7.3 Supporting facilities that are not directly linked to the process
operations including;
1.5.7.3.1 Potable water,
1.5.7.3.2 HVAC,
1.5.7.3.3 Sanitary water,
1.5.7.3.4 Fire water,
1.5.7.3.5 Chemical inhibitors injection.
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Document Responsibility: Asset Management Standards Committee SAES-A-030
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Next Planned Update: 10 June 2024 Reliability, Availability, and Maintainability (RAM) Study Execution
1.6 The RAM study Engineering Standard is applicable, but not mandatory, to the
O&M phase for existing plants and facilities.
1.7 If a facility elects to conduct a RAM O&M, then the RAM study shall comply
with this all this Engineeing Standard and more specifically with subparagraph
10.4 requirments for O&M phase.
2.1 Any conflicts between this document and other applicable Mandatory Saudi
Aramco Engineering Requirements (MSAERs) shall be addressed to the
EK&RD Coordinator.
2.2 Any deviation from the requirements herein shall follow internal company
procedure SAEP-302.
2.3 Direct all requests to deviate from this Engineering Standard in writing to the
company or buyer representative, who shall forward such requests to the
Chairman, Asset Management Standards Committee, the CSD of Saudi Aramco,
Dhahran. The Asset Management Standards Committee Chairman shall follow
internal company procedures, SAEP-302, to process the request.
2.4 The Asset Management Standards Committee Chairman reserves the right to
approve or reject the RAM waiver depending on whether the waiver request
meets the waiver conditions and requirements.
2.5 All RAM study waivers, including approved and rejected, shall be documented
as an Appendix in the RAM study final report.
3 References
3.1 As the RAM study covers all types of assets used in Saudi Aramco operating plants
and facilities, except as modified by this SAES, applicable requirements in the latest
issues of all Saudi Aramco and industry codes, standards, and practices shall be
considered an integral part of this Engineering Standard.
3.2 The RAM studies shall comply with the latest edition of the references listed
below, unless otherwise noted:
4 Purpose
4.1 To ensure that Saudi Aramco has a systematic execution process for the
Reliability, Availability and Maintainability (RAM) study.
4.2 To ensure that roles and responsibilities for RAM study steps and activities in
Saudi Aramco are outlined and auditable.
4.3 To assure that the RAM study data, assumptions, recommendations and
execution are well defined.
4.4 To assure that the RAM study data, assumptions, recommendations and
execution are uniformly documented for the purpose of corporate tracking and
auditing.
4.5 To assure that adequate resources (i.e., work force, person-hours and SMEs) are
provided for the RAM study.
4.6 To assure that process, steps, data, assumptions, logic coding, deliverables, roles
and responsibilities, when utilizing service providers to perform the RAM study,
are clearly defined.
5 Definitions
Asset: Refers to a physical asset of economic value used to generate revenue for the
company. In the RAM study, assets refer to the assets displayed in the Process Flow
Diagrams of the processing plants and facilities.
Asset Key Failure Modes and Damage Mechanisms: Those that lead to the worst
consequences on plant availability due to their high failure frequency (i.e., chronic
problems) and/or extended downtime duration.
Note: Generally, Failure Modes are associated with rotating and electrical assets, while
Damage Mechanisms are associated with static assets. The two terms have been
combined in this Engineering Standard to ensure the coverage of both while performing
a RAM analysis.
𝑀𝑇𝐵𝐹
𝑆𝑡𝑒𝑎𝑑𝑦 𝑆𝑡𝑎𝑡𝑒 𝐴𝑣𝑎𝑖𝑙𝑎𝑏𝑖𝑙𝑖𝑡𝑦 =
𝑀𝑇𝐵𝐹 + 𝑀𝑇𝑇𝑅
Capacity Utilization: The extent or level to which the productive capacity of an asset
or a plant is being used. It is expressed usually as a percentage; it is computed by
dividing the total capacity with the portion being utilized.
Notes:
(1) If a company is running at a 75% capacity utilization rate, it has room (25%) to increase
production, up to a 100% utilization rate of the availability of the plant, without incurring the
expensive costs of building a new plant or facility.
(2) Sometime the capacity utilization may also be computed by dividing the total time where
an asset or a plant is being used to the total available time where the asset is ready for
production.
Failure (of an asset): Termination of the ability of an asset to safely perform any one
of its designed intended functions.
Failure (of a system): Termination of the ability of a system to safely perform any one
of its designed intended functions.
Note: Failure of an asset within a system may occur in such a way that the system retains its
ability to safely perform all its required functions; in this case the system has not failed.
Failure Mode: The physical, chemical or other processes, which lead or have led to
the failure. It is the effect by which the failure is observed.
Note: The term failure mode is generally used for rotating,electrical assets, Emergency
Isolation Valves (EIV)s, and control valves.
Failure Rate: Corresponds to the mean number of failures of an asset per usage unit.
Usually, usage unit is expressed in ‘time’ and exposure time is expressed in ‘years’ and
failure rate is given in ‘failures per year’.
Front End Loading (FEL): A process that divides the project life cycle into stages
and phases with gates, each with defined activities and objective (for further details on
FEL, refer to SAEP-12, SAEP-71, and SAEP-40). For each stage, achievement of the
objectives is evaluated at the gate under a well-documented and systemized
methodology as displayed by FEL stages and gates displayed in Figure 1.
Figure 1 - Overview of Front End Loading (FEL) Stage & Gate Process
Mean Time between Failures (MTBF): The predicted elapsed time between intrinsic
failures of a system during operation. The MTBF can be calculated as the arithmetic
mean (average) time between failures of a system. The MTBF is typically part of a
model that assumes the failed system is immediately repaired (mean time to repair
(MTTR)), as a part of a renewal process. This is in contrast to the mean time to failure
(MTTF), which measures the average time to failures with the modeling assumption
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that the failed system is not repaired (infinite repair time). The MTBF for an asset is
defined as;
∑ 𝐿𝑖𝑓𝑒
𝑀𝑇𝐵𝐹 =
∑ 𝑁𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝐹𝑎𝑖𝑙𝑢𝑟𝑒𝑠
Plant Bottleneck: The phenomenon where the plant performance or capacity is limited
by a single or limited number of pieces of assets. Plant debottlenecking is the process
used to free the plant capacity restriction or limitation.
RAM Service Provider: A company that provides RAM data, modeling, analysis with
consulting and many other RAM related services.
(1) Key failure modes and damage mechanisms shall be defined in conjunction with the
commodity SMEs and designated representative(s) of the operating facility for the project.
(2) Reflecting key failure modes and damage mechanisms in the RAM study makes
substantial contribution to understanding the causes behind the unavailability of the plant
and facility production systems.
MW Megawatts
NDE Net Direct Expenditures
NPV Net Present Value
OE Operational Excellence
OEM Original Equipment Manufacturer
O&M Operate and Maintain
OPEX Operating Expenditures
OIM Operations Instruction Manual
PFD Process Flow Diagram
PM Preventive Maintenance
PMT Project Management Team
PP Project Proposal
P&ID Piping and Instrumentation Diagram
QA/QC Quality Assurance/Quality Control
RAM Reliability, Availability, and Maintainability
R&M Reliability and Maintenance
ROI Return on Investment
SABP Saudi Aramco Best Practices
SAEP Saudi Aramco Engineering Procedures
SAES Saudi Aramco Engineering Standards
SME Subject Matter Expert
SMS Safety Management System
TA Turnaround
TPRM Total Plant Reliability Management
T&I Testing and Inspection
7 RAM Study Requirements, Objectives, Methodology, and Instructions
7.1 General
7.1.3 The current approved RAM study process steps is outlined by Figure 4.
7.1.4 Saudi Aramco type “A” Type Projects (Figure 3), RAM study findings
and reports, for each of the RAM study phases [i.e., RAM FEL 2 (DBSP),
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Note: In Figure 3 ‘M’ refers to Million. To comply with this engineering standard terms and
definitions; then, the defined thresholds for Project Size clusters are as follows:
Small: $4-100MM
Medium: $100-500MM
Large: >$500MM
7.1.5 Saudi Aramco type “B”, “C”, and “C1” Type Projects (Figure 3), RAM
study findings and reports, for each of the RAM study phases [i.e., RAM
FEL 2 (DBSP), RAM FEL 3 (PP) and RAM Execution (Commissioning)],
shall be reviewed by IPT/PMT and Proponent representatives.
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7.1.6 Instrument air is a critical commodity for plant operation and shall have
a targeted availability of 100%.
7.2.3 In line with SAP-12, The RAM study Engineering Standard is applicable
to the FEL 3 (Project Proposal) phase of the projects.
7.2.5 The RAM study Engineering Standard is applicable, but not mandatory,
to the O&M phase for existing plants and facilities. However, if a
facility elects to conduct a RAM O&M; then, the RAM study shall
comply with this all this Engineering Standard and more specifically
with subparagraph 10.4 requirements for O&M phase.
7.2.6 For each RAM study, IPT/PMT (for new projects) and Proponent/FPD
(for existing facilities) representatives shall define the RAM study scope
of work and RAM study boundaries.
7.2.8 The RAM Study kickoff meeting shall be organized by IPT/PMT (for
new projects) and Proponent/FPD (for existing facilities).
7.2.9 The RAM study scope of work shall require full compliance with
SAES-A-030 requirements.
7.2.10 For new projects, the RAM study boundaries shall be defined according
to the project scope of work as defined in DBSP (FEL 2).
7.2.11 For existing facilities, the RAM study boundaries shall be defined by the
proponent and/or FPD representatives for the case of Master Plan
Development.
The RAM service provider(s) shall deliver the five (5) below objectives, i.e.,
7.3.1, 7.3.2, 7.3.3, 7.3.4 and 7.3.5, while conducting a RAM study
7.3.1 Predict and quantify plants and facilities Production Mean Deliverability
in MBCD, MMScfd, MW, KTA or any other applicable production unit.
Note: Production Mean Deliverability is defined as the production average rate
achievable from a given feedstock(s) to produce a given end product(s).
It is given in MBCD, MMScfd, MW, KTA, or in any other production unit.
7.3.2 Predict and quantify plants and facilities Mean Availability in percentage (%).
7.3.3 Predict and quantify plants and facilities Mean Utilization in percentage (%).
7.3.4 Predict and quantify plants and facilities Production Losses due to
internal and external interruptions, e.g., trips, failures, restarts, T&I,
planned maintenance, process upsets, material handling deficiencies,
feedstock shortage, failure to lift end product(s), external failures, etc.
7.3.5 Predict and quantify plants and facilities Reliability Losses due to
internal interruptions, e.g., trips, failures, restarts, process upsets,
unplanned maintenance, etc.
7.4.1 Plants and facilities’ assets shall be built in the RAM model as by logical
process flow function outlined by the facility PFDs.
7.4.2 For new plants and facilities, the IPT/PMT shall avail to the contractor the
latest of the PFD’s versions of plants and facilities with the process
description and operation instruction manual in electronic format.
7.4.3 For existing plants and facilities, the Proponent/FPD shall avail to the
contractor the latest of the PFDs versions of plants and facilities with the
process description and operation instruction manual in electronic format.
7.4.4 Plants and facilities assets’ failure modes and damage mechanisms
impact and consequences in the production system shall be evaluated and
captured in the RAM model during the R&M data collection phase using
the SAES-A-030 Appendix A spreadsheet.
7.4.5 Plants and facilities assets’ failure modes and damage mechanisms shall
be defined and analyzed for each section of the plants as defined by the
plants and facilities’ logical process flow function.
7.4.6 Plants and facilities’ RAM model assets shall be limited to those displayed
in the PFDs.
7.4.7 Plants and facilities’ assets drilldown structure shall not go beyond the
assets displayed in the PFDs.
7.4.8 Plants and facilities’ assets modeling drilldown beyond the PFDs layout
levels (i.e., P&IDs level) shall be first discussed with the CSD Reliability
Group and are subject to the approval of the Chairman of the Asset
Management Standards Committee, and the CSD of Saudi Aramco,
Dhahran, prior to execution.
7.4.9 The RAM model building blocks shall have the same block description
and the same asset ID tags as those marked on the plants and facilities’
PFDs.
7.4.10 The RAM model building blocks composition and description shall
correspond to any of the description below:
tube and shell side, fin fan tubes, fin fan inlet header, and
fin fan outlet header, etc.).
7.4.11 The RAM model shall reflect plant operations, including operational
objectives with operations schemes, scenarios, and constraints.
7.5.1 The RAM model shall reflect the exact function expected from the
process point of view as defined by the process flow function and OIM
of the plant and facilities being studied.
7.5.2 Prior to RAM model execution in the simulation platform, the RAM
Model shall be reviewed, verified, and approved by the following
representatives
7.5.4 When the RAM model review and validation is taking place out of Saudi
Arabia, the involvement of Saudi Aramco Proponent representative(s)
needed for the RAM model review, verification and approval shall be done
via phone or videoconference call to be arranged by the IPT/PMT (for new
projects) or Proponent/FPD (for existing facilities) representatives.
Note: In case this review cannot be done through phone or video conference
call; then, a face to face meeting needs to be held where specified by
IPT/PMT or Proponent/FPD representatives.
7.5.5 The RAM service provider representative(s) shall lead and facilitate the
RAM model review meeting and document the meeting outcome, actions
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and conclusions.
7.5.6 Once the RAM model is dully reviewed, verified and approved by the
designated representatives, listed in paragraph 7.5.2, it shall be shared
with the Proponent and the CSD Reliability Group for documentation
and records.
7.5.8 For new plants and facilities, the IPT/PMT shall coordinate the RAM
model validation process and secure the signature of the RAM model
validation meeting minutes and R&M data validation, in a reasonable
time, after receiving the RAM model or the R&M data from the RAM
service provider.
7.5.9 For existing plants and facilities (i.e., RAM O&M), the Proponent/FPD
shall coordinate the RAM model validation process and secure the
signature of the RAM model validation meeting minutes and R&M data
validation, in a reasonable time, after receiving the official RAM model
or R&M data review and validation request from the RAM service
provider.
7.5.11 The RAM model simulation, results generation, and analysis shall not be
executed without the official validation of the RAM model by the
designated representatives identified in paragraph 7.5.2.
7.6.1 The IPT (for new project) or Proponent for existing plants shall evaluate
the RAM study technical proposal according to the scope of work
requirements.
7.6.1 The IPT (for new project) or Proponent (for existing plants) shall
evaluate the RAM study Service Provider technical qualifications, and
may refer to Saudi Aramco Best-Practice, SABP-A-047, for Technical
and Performance Evaluation Criteria for Reliability, Availability, and
Maintainability (RAM) Service Providers for guidance.
8.1 General
8.1.2 The RAM analysis service providers can download the SAES-A-030
Appendix-A1 spreadsheet from the specified hyperlink.
Note: In case of problems with getting access to the SAES-A-030 Appendix-
A1 spreadsheet, the RAM Service Provider shall contact Saudi Aramco’s
CSD Reliability Group at the beginning of the study to get a soft copy of
the document.
8.1.3 Use of R&M data from the international industry databanks is permissible
in the Saudi Aramco RAM study under the following conditions:
8.1.3.1 The R&M data from the international industry databanks shall
be adjusted, as outlined in paragraph 8.3, to account for Saudi
Aramco’s operating environment, workforce competency,
8.1.3.2 The R&M data from the international industry databanks shall
be adjusted, as outlined in paragraph 8.3, through comparison
with the R&M data extracted from Saudi Aramco’s similar
plants and facilities.
8.1.3.3 The RAM service provider shall visit one to two similar sites of
Saudi Aramco to meet with and interview key field personnel
to collect, using the SAES-A-030 Appendix-A1 spreadsheet,
clean and adjust the R&M data.
Note: Dspite that the existing maintenance information repository
systems (e.g., SAP PM module, PMO, FRACAS, etc.) are
expected to contain assets R&M data,extreme caution should
be exercised while trying to use this data source and we
strongly don’t recommand using it due to the lack of precision.
8.1.4.2 Other companies’ R&M data sources with OEM and/or licenser
data shall be adjusted, as outlined in paragraph 8.3, to account
for Saudi Aramco’s operating environment and workforce
competency, experience and skills.
8.1.4.3 Other companies’ R&M data sources with OEM and/or licenser
data shall be adjusted, as outlined in paragraph 8.3, through
comparison with the R&M data extracted from Saudi Aramco’s
similar plants and facilities.
8.1.4.4 The RAM service provider shall perform the needed site visit(s)
to Saudi Aramco’s similar plants and facilities with Central
Engineering representatives, if and as needed, to meet with and
interview key field personnel and Central Engineering SMEs to
collect, clean and adjust the R&M data.
8.1.6 The R&M data for existing plants and facilities shall be extracted by
performing a field visit to one to two similar plants and facilities and
8.1.7 The R&M data for new plants and facilities shall be extracted from Saudi
Aramco’s existing similar assets’ history if the same or equivalent assets,
technology, and/or license are already available within Saudi Aramco’s
plants and facilities.
8.1.8 The R&M data for new plants and facilities shall use OEM and/or
licenser data if the same or equivalent assets, technology, and/or license
are not available within Saudi Aramco’s plants and facilities and are
being newly introduced to the company.
8.1.9 For Modularization projects (i.e., using modular design), the R&M data
for new plants and facilities shall use designer data to account for
maintainability challenges, hence new repair turnaround durations.
Note: Modular designs use compact design and this might have a major
impact on extending assets MTTR and/or T&I turaround durations.
Special attention shall be given, by the RAM Service Providers, to
miantainability data collection for modular designs.
8.1.10 Prior to the RAM model execution in the simulation platform, the R&M
data shall be submitted for review, verification and approval, using
SAES-A-030-Appendix-A1 ‘R&M Data Validation Sheet’ form, by the
following representatives
8.1.13 After the R&M data review and approval by the representatives
identified in paragraph 8.1.9, the IPT/PMT representative shall share the
approved R&M data with the RAM service provider so they can execute
the model in the simulation platform.
8.2.1 The R&M data shall be collected in a standard format ‘R&M Data
Collection’ Sheet, included in the SAES-A-030-Appendix-A1 spreadsheet.
8.2.2 The RAM service provider shall use Excel sheet ‘R&M Data Collection
Sheet’ in the SAES-A-030-Appendix-A1 spreadsheet to collect and adjust
the R&M data needed for the RAM study as defined in this document.
8.2.3 The RAM service provider shall use ‘R&M Data Collection Sheet’ in the
SAES-A-030-Appendix-A1 spreadsheet and collect the following
information:
8.2.3.1 Plant ID
8.2.3.2 Asset ID
8.2.3.7 Comments
8.2.4 The RAM Service Provider(s) shall perform R&M data collection,
cleansing, adjustment, and validation for the RAM study.
8.2.5 The RAM Service Provider(s) shall visit one to two similar sites of Saudi
Aramco’s to meet with and interview key field personnel (i.e., most
knowledgeable people) to collect, clean and adjust the R&M data.
8.2.6 The RAM Service Provider(s) shall submit an official request to the
IPT/PMT (for new projects) or Proponent/FPD (for existing facilities)
designated representative to identify, one to two, similar Saudi Aramco
plants and facilities to be visited to collect R&M data.
8.2.10 The RAM Service Provider(s) shall visit Saudi Aramco’s designated
plants and facilities, identified in paragraph 8.2.7 to collect and adjust
R&M data.
8.2.11 The RAM Service Provider(s) shall meet with designated plants and
facilities personnel to collect the needed R&M data as identified in the
‘R&M Data Collection Sheet’ in the SAES-A-030-Appendix-A1
spreadsheet for each asset appearing in the plant(s) PFDs. The R&M
data collection meetings with frontline personnel can be done
individually or in groups, depending on the needs.
8.2.12 The RAM Service Provider(s) shall use the ‘R&M Data Collection
Sheet’ in the SAES-A-030-Appendix-A1 spreadsheet and collect
information on unreliability and maintenance events (i.e., operations
interruptions due to planned and unplanned maintenance activities) for
each of the assets as follows:
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(2) CGTs borescope inspection, Midlife Inspection (MLI) and Major Shop
Inspection (MSI) shall be covered under planned maintenance
(i.e., planned, checks, inspections, and planned overhauls).
(3) Pipeline Inline Inspection (ILI) and scraping shall be covered under
planned maintenance (i.e., planned inspections and PM activities).
(4) Pressure Vessels & Heat Exchangers inspection shall be covered under
planned maintenance.
8.2.13 The RAM service provider shall use FIELD 6 of the ‘R&M Data
Collection Sheet’ in the SAES-A-030-Appendix-A1 spreadsheet and
collect one to two key failure mode(s) and damage mechanism(s), as
available, for each of the unreliability events (i.e., unplanned events)
listed in paragraphs 8.2.12.
8.2.14 In case the key failure mode(s) and damage mechanism(s) for each, some
or all of the unreliability events listed in paragraphs 8.2.12 is/are unknown
to the frontline personnel, then it shall be recorded in the ‘R&M Data
8.2.15 The R&M data listed in paragraphs 8.2.3 and 8.2.12 is considered to be
the minimum R&M data to be collected during site visits by the RAM
service provider. The RAM service provider might extend the
information to be collected assuming it has relevance and is deemed
important for the RAM study and can use the ‘R&M Data Collection
Sheet’ in the SAES-A-030-Appendix-A1 spreadsheet “Comments”
sections to capture such information.
8.2.16 For existing plants and facilities, the RAM service provider shall
submit an official request to the Proponent designated representative
for the RAM study to perform a site visit to Saudi Aramco plant to be
modeled to collect the R&M data.
8.2.17 Prior to the RAM model execution in the simulation platform, the RAM
data, identified in paragraphs 8.2.3 and 8.2.12, shall be reviewed, verified
and approved by the representatives identified in paragraph 8.1.10.
8.2.18 Final approved R&M data captured in the ‘R&M Data Collection
Sheet’ in the SAES-A-030-Appendix-A1 spreadsheet, shall be shared
by the RAM Service Provider(s) with the Proponent for record and
documentation and with CSD Reliability Group for R&M data
corporate databank development.
8.2.19 The RAM data adjusted and approved by the Proponent collected from
previous RAM studies can be used in Saudi Aramco’s new RAM studies
as a reference. However, there is still a need to undergo the adjustment
process to make sure that they will represent the plants being modeled
specific environment and workforce skills and competency.
8.3.1.4 In case - from the site visits and frontline personnel interviews -
it has been judged that the asset is not or has not been operating
within its design limits and operating environment as per the
design specifications, in an intermittent or continuous manner;
8.3.1.5 In case - from the site visits and frontline personnel interviews -
it has been judged that the asset has not been maintained in a
timely and adequate manner as per the established PM program
for that asset, then the MTBF(Adjusted) shall be adjusted by
decreasing the MTBF(Reference) by 5% to 10%, as deemed
necessary, as follows:
𝑃𝑀
𝐴𝐹𝑀𝑇𝐵𝐹 = 5 𝑡𝑜 10%
𝑀𝑇𝐵𝐹(𝐴𝑑𝑗𝑢𝑠𝑡𝑒𝑑) = 𝑀𝑇𝐵𝐹(𝑅𝑒𝑓𝑒𝑟𝑒𝑛𝑐𝑒)
8.3.2.3 In case - from the site visits and frontline personnel interviews -
it has been judged that the repair workforce is lacking the skills,
experience and competency needed to timely and properly
carryout the repair on the failed asset, then the MTTR(Adjusted)
shall be adjusted by increasing the MTTR(Reference) by 50% to
100%, as deemed necessary, as follows:
𝑊𝑜𝑟𝑘𝑓𝑜𝑟𝑐𝑒
𝐴𝐹𝑀𝑇𝑇𝑅 = 50 𝑡𝑜 100%
8.3.2.4 In case - from the site visits and frontline personnel interviews -
it has been judged there are problems with spare parts
availability to timely and properly carryout the repair on the
failed asset, then the MTTR(Adjusted) shall be adjusted by
increasing the MTTR(Reference) by 30% to 100%, as deemed
necessary, as follows:
𝑆𝑝𝑎𝑟𝑒 𝑃𝑎𝑟𝑡𝑠
𝐴𝐹𝑀𝑇𝑇𝑅 = 30 𝑡𝑜 100%
8.3.2.5 In case - from the site visits and frontline personnel interviews -
it has been judged that there are problems with repair tools
(e.g., scaffolding, shop tools, maintenance shops, cranes,
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𝑀𝑇𝑇𝑅(𝐴𝑑𝑗𝑢𝑠𝑡𝑒𝑑) = 𝑀𝑇𝑇𝑅(𝑅𝑒𝑓𝑒𝑟𝑒𝑛𝑐𝑒)
8.4.1 All information collected during meetings with plant personnel to collect
R&M data with one to two key failure modes and damage mechanisms,
inspection and consequences shall be documented as an Appendix in the
final report.
8.4.2 All RAM study assumptions so that the final risk quantification and
reduction shall be documented as an integral part of the final report.
8.4.3 The RAM adjusted data and assumptions shall be duly reviewed and
approved by the proponent representatives, using SAES-A-030-
Appendix-A1 as identified in paragraph 8.1.10.
8.4.4 Final adjusted and approved R&M data, captured in the SAES-A-030-
Appendix-A1 spreadsheet, shall be shared by the RAM service provider
with the proponent for record and documentation and with the CSD
Reliability Group for R&M data corporate databank development.
9.1 RAM service provider shall collect and document the following information as
minimum while conducting RAM studies for Saudi Aramco.
9.1.1 Asset Tag ID: this refers to the asset Tag number as displayed in the PFD.
9.1.2 Asset Name: this refers to the asset description as displayed in the PFD.
9.1.3 Asset Category: corresponds to the class category of the asset (e.g., pumps,
compressors, tanks, reactors, Heat Exchangers, Accumulators, Drums,
Pipes, Blowers, Expanders, Steam Turbines, Gas Turbines, Chillers,
Columns, etc.).
9.1.4 Asset Design Capacity: for new assets, this corresponds to the theoretical
maximum output of the asset in a given period under ideal conditions.
Note: For old assets, the design capcity should be validated or replaced by
the Maximum Test Capacity value.
9.1.6 Asset Failure Impact on Production: this reflects the impact of an asset
failure on the production system (need to address all possible
configurations).
9.1.7 Comments: this section shall be reserved for explanations and further
details to de added by RAM service provider as deemed necessary.
10.1 RAM Model simulation shall be executed for next twenty (20) years facility
operations forecast.
10.2 RAM Service Provider shall request IPT/PMT (for new projects) or Proponent/FPD
(for existing facilities) representatives to supply him with the 9.2. Failure to
avail the asset information part of the RAM reports, including draft next twenty
(20) years facility operations forecast.
10.3 RAM model shall be able to factorize and match either a static (i.e., constant
demand) or dynamic (i.e., either increasing, decreasing or variable with time)
facility operational objectives over twenty (20) years forecast.
10.4 If the facility operational objectives are dynamic with time, the RAM model
shall cater for that production dynamic behavior and reflect it in the RAM
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10.5 RAM study Service Provider shall clarify and articulate the facility different
plants production units including the feedstock(s), end product(s) and
intermidiate product(s) as deemed necessary depeonding on the processing
facility.
10.6 RAM study Service Provider shall clarify and articulate the facility production
capacity in Operating days versus Calendar Days and Operating Factor.
10.7 RAM study Service Provider shall work with the IPT/PMT (for new projects) or
Proponent/FPD (for existing facilities) representatives with Process/Operation
Engineers, clarify and define differents units to be considered in the RAM
including input(s), output(s) and result(s) including;
10.7.1 MBOD vs. MBCD and Operating Factor
10.7.2 MWBOD vs. MWBCD and Operating Factor
10.7.3 MMScfd in Operating or Calendar days the Operating Factor
10.8 In case of multiple feeds, of the same product, to the facility, the RAM study
Service Provider shall request the IPT/PMT (for new projects) or
Proponent/FPD (for existing facilities) representatives with Process/Operation
Engineers to calculate the total feedstock quatitiy for each specific product to the
processing facility.
10.9 RAM study shall demonstrate the Capital Efficiency strategy, where production
is delivered with known and acceptable Operational-Risk and no oversizing or
excess capacity is wasted.
10.10 This Capital Efficiency strategy shall be maintained whether the production
profile forecast is static or dynamic.
11.1 During RAM study, as a 1st step, the RAM Service provider shall build the
facility RAM Model and run it using Industry R&M data. This RAM model
shall be called the ‘RAM Industry Model’; see Figure-4 workflow.
11.2 As a 2nd step, the RAM Service provider shall run the facility RAM Model using
Saudi Aramco Site R&M data. This RAM model shall be called the ‘RAM Site
Model’; see Figure-4 workflow.
11.3 The RAM Service Provider shall run a benchmark of both Industry and Saudi
Aramco Site R&M data and shall highlight the differences between both cases
so appropriate actions can be taken to make the necessary R&M data
adjustments as outlined in sub-paragraph 8.3 of this Enginnering Santandard;
see Figure-4 workflow.
11.4 Once R&M data has been adjusted, following the process outlined by
sub-paragraph 8.3, the RAM Service provider shall rerun the facility RAM
Model using adjusted Industry and Saudi Aramco Site R&M data. This RAM
model shall be called the ‘RAM Base-Case Model’; see Figure-4 workflow.
11.5 The RAM Base-Case Model shall be the basis for all the subsequent Sensitivity
Analysis Cases and modifications.
11.6 After running the RAM Base-Case Model, the RAM Service Provider shall
generate the RAM study Draft Report to be subimmited to the IPT/Proponent for
review and comment; see Figure-4 workflow.
11.7 The RAM study Draft Report shall address and contain the following elements
11.7.1 RAM Industry Model inputs, assumptions, constraints and results.
11.7.2 RAM Site Model inputs, assumptions, constraints and results.
11.7.3 The benchmark of both Industry and Saudi Aramco Site R&M data
highlighting the differences between both cases the necessary R&M
data adjustments as outlined in sub-paragraph 8.3 of this Enginnering
Standard.
12.1 RAM Base-Case model shall be issued and cannot be modified after validating
the RAM model and R&M data by different represnetatives, listed in paragraph
7.5.2 and in sub-paragraph 8.1.10.
12.2 The RAM Base-Case model shall the basis of all subsequent sensitivity analysis
cases to be evaluated and analyzed.
12.3 When a sensitivity analysis case recommendations are inplemented, then this
sensitivity analysis case shall become the new RAM Base-Case model.
13.1.1 Shall model, at high-level (i.e., BFDs at DBSP stage), the plants’ and
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13.1.3 Shall generate results with regard to the set business targets of the
operating plants and facilities.
13.1.4 Shall benchmark and rank the operating plants and facilities’ reliability
figures with regard to known industry benchmarks, if and as available
and applicable.
13.1.5 Shall identify the optimal availability needed to deliver the plant
business objectives. The RAM study needs to identify what availability
is needed to deliver the plant business objectives (e.g., 400 MBPD).
If, for example, 95% is the availability needed to deliver the refinery
400 MBPD, then it shall be the recommended availability design target.
However, if a different availability figure, higher or lower than 95%, is
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needed to deliver the 400 MBPD, then the RAM study shall recommend
that availability as the availability design target. The RAM study shall
identify the optimal availability figures to be targeted by design so we
can secure Saudi Aramco’s Capital Efficiency strategy.
13.1.7 For new projects where the PFDs have been extensively developed
during the early phase of FEL 2 phase (i.e., DBSP phase) or extension
projects where existing PFDs are being modified, RAM FEL 2 (DBSP)
shall be replaced by RAM FEL 3 (PP). In this case, RAM FEL 3 (PP)
shall be advanced to kickoff at RAM FEL 2 (DBSP) start date and shall
be completed prior to project FEL Gate 2. RAM FEL 2 shall be
dismissed, and replaced by RAM FEL 3 while keeping RAM FEL 2
execution timeline.
13.2.1 Shall leverage the RAM FEL 2 (DBSP), Section 13.1, model to cover
all plants and facilities’ assets at the PFDs level.
13.2.3 Shall quantify Mean Production Mean Deliverability versus Losses and
provide a Graph (bar chart) and a Table that outlines both over the next
twenty years’ operations forecast.
13.2.5 Shall identify high impact opportunities where design changes and
maintainability improvement opportunities are to be considered,
mitigated, by IPT/Proponent, and included during the detailed design
phase of the project.
13.2.6 RAM FEL 3 (PP) design changes shall first address the failures modes
and damage mechanism, identified in FIELD 6 of the SAES-A-030
Appendix-A1 spreadsheet, that are hindering production through-puts,
which are normally a provider by the simulator under the top 20% bad
actors or performance loss contributors.
13.2.8 Shall identify and rank, in a Table and a Graph, the top 20% Critical
Assets limiting production performance with regard to Production
Mean Deliverability target(s) (i.e., driven by production losses).
13.2.9 Shall identify and rank, in Graph and a Table, the top 20% Critical
Assets limiting production performance with regard to facility Mean
Availability (i.e., driven by availability losses).
13.2.10 Shall identify and rank, in Graph and a Table, the top 20% Critical
Assets limiting production performance with regard to facility Mean
Utilization.
13.2.11 Shall identify and rank, in a Graph and a Table, the top 20% Critical
Assets limiting production performance with regard to Reliability
Losses associated with unreliability events (i.e., driven by assets
failures frequencies).
13.2.12 Based on RAM FEL 3 (PP) results and gaps, RAM Service Provider
can guide and recommend improvement opportunities, for IPT/PMT
(for new projects) or Proponent/FPD (for existing facilities)
representatives, for review and approval to be considered as Sensitivity
Cases for analysis.
13.2.13 Shall be finalized before the 90% project proposal review to allow for
mitigation or identification of key failure mode(s) and damage
mechanism(s) so appropriate design changes and improvement
opportunities shall be incorporated during the Detailed Design phase of
the project.
13.2.14.1 For the known key failure modes and damage mechanisms,
the Failure Analysis Team shall work directly on a mitigation
plan to address them, and the approved solution(s) and
recommendation(s) shall be submitted for implementation
during the Detailed Design phase of the project.
13.2.14.2 For the UNKNOWN key failure modes and damage
mechanisms, the Failure Analysis Team shall use a structured
and thorough failure analysis process on the associated assets
to address those UNKNOWN failure modes and damage
mechanism, and the approved solution(s) and
recommendation(s) shall be submitted for implementation
during the Detailed Design phase of the project.
Notes:
13.2.15 The final failure analysis report, performed by the Failure Analysis
Team, on the top 20% of assets limiting production performance key
failure modes and damage mechanisms shall be shared, by the
proponent RAM study representative, with the CSD Reliability Group
to be included in the R&M data corporate databank development.
13.3.1 Shall be conducted only in the case when there is/are a deviation(s),
from the approved design, due to procurements, construction,
installation and/or commissioning, of plants’ Critical Assets that have
been identified as the top 20% assets limiting production performance
during RAM FEL3 (PP), subparagraphs 13.2.8, 13.2.9, 13.2.10, and
13.2.11.
Note: In the RAM analysis, Critical Assets refer to the assets identified on
the top 20% of the assets limiting the plant production performance
during RAM FEL3 (PP).
13.3.2 If there are no changes with regard to the approved design on plants’
Critical Assets (i.e., the top 20% of assets limiting production
performance identified during RAM FEL3 (PP)), RAM Exec
(Execution, Commissioning) shall not be conducted.
13.3.3 Shall start at 70% of the construction of the execution phase of the
project and shall continue during the commissioning of the operations
phase of the project to update the RAM FEL 3 (PP) with changes and
deviations, on Critical Assets, that have resulted from procuring assets,
constructing plants and/or installing assets in a different manner than
the specified and approved design specifications.
13.3.4 Shall validate the RAM FEL 3 (PP) model for Critical Assets selection,
configuration, procurement, installation, and commissioning with
regard to the approved design specifications and the RAM FEL 3 (PP)
design approved improvement(s) recommendations to close production
performance gaps if any.
13.3.7 The IPT/PMT representative shall avail the list of deviations, on plants’
Critical Assets, listed in paragraph 13.3.5 for the RAM service provider
in order to perform the RAM Exec (execution, commissioning) analysis.
13.3.11 All RAM FEL 3 (PP) deviations categories, listed in paragraph 13.3.10,
from the approved design on Critical Assets shall be listed in a Table
and documented in the RAM Exec report.
13.4.1 The RAM O&M shall not be executed for new projects.
13.4.2 The RAM O&M shall be executed for existing plants and facilities
only, and this section outlines the RAM modeling and analysis
mandatory requirements in case existing plants decide to conduct a
RAM study.
13.4.3 If a facility elects to conduct a RAM O&M, then the RAM study shall
comply with this all this Engineering Standard and more specifically
with subparagraph 13.4 requirements for O&M phase.
13.4.4 The RAM studies’ typical objectives listed under Section 7.4 are all
applicable to the RAM O&M.
13.4.5 The RAM modeling requirements listed under Section 7.5 are all
applicable to the RAM O&M with exception to paragraph 7.5.2.
13.4.6 The R&M data collection and adjustment outlined in Section 8 are all
applicable to the RAM O&M.
13.4.8 During RAM O&M, RAM FEL 3 (PP) IPT/PMT representative shall be
substituted by the Proponent/FPD representative.
13.4.8.1 Proponent representative shall be the lead for the RAM O&M.
13.4.8.2 FPD representative shall be the lead for the RAM O&M
and it shall support Master Plan Development.
13.4.9 Prior executing RAM O&M phase, RAM Service Provider shall execute
the following tasks
14.1 The RAM study improvement shall be limited to the top 20% of assets, limiting
production performance only.
14.2 RAM Service provider(s) shall identify the facility the top 20% of assets,
limiting production performance as outlined in subparagraphs 13.2.8, 13.2.9,
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14.3 RAM Service Provider shall recommend, explain and justify where technical
improvements (i.e. design upgrades, redundancy, maintainability, products
buffering, etc.) should be focused and prioritized based on the production
performance deficiencies and gaps so the facility operational targets can be
attained in effective manner.
14.7 RAM Service Provider(s) shall recommend and guide the IPT/PMT (for new
projects) or Proponent/FPD (for existing facilities) representatives where
design/technical enhancements efforts shall be most effective to enhance the
facility production deficiencies.
14.10.2.1 Shall use redundancy and capital spares in case the first
priority improvements do not close the production
performance gaps. In this case, capital expenditures on
capital spares become justifiable.
14.10.3.2 Shall use and optimize production buffer and storage tanks
to cover for the asset’s downtime due to reliability
limitations until it is restored to service by maintenance.
14.10.3.4 The buffer tank optimization process shall identify for what
product(s) and for how long (capacity) extra buffering tank
storage capacities are needed.
15.1 The RAM study selection between repair vs. replace options, for existing plants’
assets, shall follow the following guidelines
15.1.1 Shall consider repairing the assets if the assets’ production throughput
gap, with regard to the updated nameplate capacity, is less than 25%.
This means that the asset production throughput is more than 75% of the
design updated nameplate capacity.
Note: While considering all the available repair option of the asset, and
when running the RAM simulation, the asset’s production throughput
objective(s) is/are still not met, then we need to consider the asset’s
replacement option to close production gap.
15.1.2 Shall consider replacing the assets if the production throughput gap of
that asset, with regard to the updated nameplate capacity, is exceeding
25%. This means that the asset production throughput is less than 75%
of the design updated nameplate capacity.
16.1 For new projects, RAM study Sensitivity Analysis Cases shall be conducted
during RAM FEL 3 (PP) phase only.
16.2 For existing facilities, RAM study Sensitivity Analysis Cases shall be conducted
during RAM O&M (Operate & Maintain) phase only.
16.3 Conducting RAM study Sensitivity Analysis Cases during RAM FEL 2 (DBSP)
or RAM Exec (Execution, Commissioning) shall be first discussed with the CSD
Reliability Group and are subject to the approval of the Chairman of the Asset
Management Standards Committee, and the CSD of Saudi Aramco, Dhahran.
16.5 RAM Service Provider shall perform the Sensitivity Analysis Cases to reflect
design/technical modifications, introduced by IPT/PMT (for new projects) or
Proponent/FPD (for existing facilities) representatives SMEs, and quantify their
contribution to closing the facility production performance deficiencies.
16.6 The objective of conducting Sensitivity Analysis Cases, by the RAM Service
Provider, is to verify and validate the design/technical recommendations,
identified by the IPT/PMT (for new projects) or Proponent/FPD (for existing
facilities) representatives SMEs, to make sure that they are adding value and
effectively closing production deficiencies.
16.7 For new projects, the RAM Service Provider is expected to modify/run the
RAM FEL 3 (PP) model between four (4) to eight (8) times (i.e., scenarios and
alternative cases analysis) while evaluating the RAM improvements and
recommendations impact on the results (i.e., delivering operational objectives
and verify the effectiveness of the recommendations).
16.8 For existing plants, the RAM service provider is expected to modify/run the
RAM O&M model between four (4) to eight (8) times
(i.e., scenarios and alternative cases analysis) while evaluating the RAM
improvements and recommendations impact on the results
(i.e., delivering operational objectives and verify the effectiveness of the
recommendations).
Note: When conducting the RAM Sensitivity Analysis and evaluating the possible
facility improvement(s) alternatives, the RAM model modifications are, in
general, minor as the RAM Base-Case Model has been already built.
17.2 The RAM study Mean Availability targets shall be based on the plants’ and
facilities’ business needs (i.e., operational plans) and shall not target industry
benchmarks (e.g., Solomon Quartiles or others) through extra capital expenditures.
17.3 The RAM study simulation projected Mean Availability figures shall be compared
to industry benchmark availability figures for information purposes only.
17.4 Industry benchmark of the Mean Availability figures shall not be met through
project CAPEX, but through performance (i.e., TPRM, inspection operation and
maintenance strategies and practices, CMP, SMS and OE practices, etc.).
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18.1 RAM Service Provider(s) shall include the following information in the front
page of the RAM study reports including Draft and Final Reports:
18.2.1 BI Number (for new projects only)
18.2.2 Project Name (for new projects only)
18.2.3 Facility Name
18.2.4 Report Identification
18.2.5 Specify whether it is a Draft Report or a Final Report
18.2.5 Report Revision number
18.2.6 RAM Study FEED Phase [i.e., RAM FEL 2 (DBSP), RAM FEL 3
(PP), RAM O&M (Operate & Maintain), or RAM Exec (Execution,
Commissioning)]
18.2.7 RAM Service Provider Name
18.2.8 Engineer’s Name in charge of executing the RAM study
18.2.9 Senior Engineer’s Name that Reviewed and Approved the RAM study
report
18.2 RAM Service Provider(s) shall structure the RAM Study, Draft, and Final,
reports as follows
18.2.1 1. Executive Summary
18.2.2 2. Acronyms List
18.2.3 3. INTRODUCTION
18.2.4 4. METHODOLOGY
18.2.4.1 4.1. Study Objectives
18.2.4.2 4.2. Scope of Work
18.2.4.3 4.3. Study Input Data
18.2.4.4 4.4. Indenture Level for Study
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18.2.4.5 4.5. RAM Model Cases (i.e., RAM Industry Model, RAM
Site Model, RAM Base-Case Model, and Sensitivity
Analysis Cases)
18.3 RAM Service Provider(s) failure to deliver the RAM study Draft or Final report
18.4.1 RAM Service Provider(s) shall attach to the RAM study Draft and
Final Reports the facility PFDs.
18.4.2 RAM Service Provider(s) shall attach to the RAM study Draft and
Final Reports the facility PFDs.
18.4.3 RAM Service Provider(s) shall attach to the RAM study Draft and
Final Reports R&M Data, in Excel sheet format, from Industry and
Saudi Aramco Site.
18.4.4 RAM Service Provider(s) shall attach to the RAM study Draft and
Final Reports R&M Site Data validation, by the proponent designated
representatives, signoff meeting minutes.
18.4.5 RAM Service Provider(s) shall attach to the RAM study Draft and
Final Reports R&M Site Data validation, by the proponent designated
representatives, signoff meeting minutes.
18.4.6 RAM Service Provider(s) shall include in the RAM study Draft and
Final Reports with the R&M Excel sheet the R&M Site Data
adjustments calculation details.
18.4.7 RAM Service Provider(s) shall include in the RAM study Draft and
Final Reports the facility assets information and configuration.
18.4.8 RAM Service Provider(s) shall include in the RAM study Draft and
Final Reports the RAM study assumptions.
18.4.9 RAM Service Provider(s) shall attach to the RAM Draft and Final
reports the native Excel file including all RAM results and graphs.
18.4.10 RAM Service Provider(s) shall avail the raw data for all the graphs
included in the RAM Draft and Final reports.
18.4.11 RAM Service Provider(s) shall include and explain in the RAM Draft
and Final reports all the what-if scenarios and logic coding used in the
RAM Model.
18.4.12 The RAM study Draft and Final reports findings, assumptions, and
recommendations with the RAM model executable file shall be shared
with IPT/PMT and CSD Reliability Group for record and documentation.
18.5 All submitted information and documents shall be in electronic formats and
shall include
18.5.1 RAM study Draft and Final report in both MS Word format and PDF
format.
18.5.2 The SAES-A-030 Appendix-A1 spreadsheet.
18.5.3 The RAM R&M Industry and Site Data in Excel sheet format.
18.5.4 The RAM R&M Data validation meeting minutes in PDF format.
18.5.5 The RAM model validation meeting minutes in PDF format.
18.5.6 The RAM model Waiver Request Form, if any, in PDF format.
18.5.7 The RAM study approved waivers in PDF format.
18.5.8 All submitted information and documents shall be in electronic formats and
shall not contain any protection password and shall be editable by the end-users.
Revision Summary
08 September 2014 New Saudi Aramco Engineering Standard.
23 April 2015 Minor revision to comply with new CMS and SAEP-12 January 2015 new requirements,
and add further clarifications with additional explanations to enhance the document and
minimize non-needed waivers.
03 March 2016 Major revision to include Value Engineering (VE) study findings and recommendations to
minimize study RAM study costs.
01 April 2017 Minor revision to amend three RAM simulation platforms to be used for RAM studies.
10 June 2019 Major revision to include enhancements and simplifications resulted from May 10, 2018
SAES-A-030 Revision Workshop that involved CSD Reliability Group Engineers and all
RAM Approved Service Providers.