Journal of Mechanical Science and Technology 28 (10) (2014) 3963~3970

www.springerlink.com/content/1738-494x
DOI 10.1007/s12206-014-0907-7

Reliability and risk treatment centered maintenance†

Martin Pexa1,*, Tomáš Hladík1, Zdeněk Aleš1, Václav Legát1, Vít Havlů3, Miroslav Müller2
and Petr Valášek2
1
Department for Quality and Dependability of Machines, Czech University of Life Sciences Prague, Faculty of Engineering,
Kamýcká 129, Prague 6 – Suchdol 165 21, Czech Republic
2
Department of Material Science and Manufacturing Technology, Faculty of Engineering, Czech University of Life Sciences Prague,
Kamýcká 129, Prague 6 – Suchdol 165 21, Czech Republic
3
Unipetrol a.s., Prague, Czech Republic

(Manuscript Received January 14, 2014; Revised May 6, 2014; Accepted August 5, 2014)

----------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------

Abstract

We propose a new methodology for application of well-known tools – RCM, RBI and SIFpro – with the aim to treat risks by means of
suitable maintenance. The basis of the new methodology is the complex application of all three methods at the same time and not sepa-
rately as is typical today. The proposed methodology suggests having just one managing team for reliability and risk treatment centred
maintenance (RRTCM), employing existing RCM, RBI, and SIFpro tools concurrently. This approach allows for significant reduction of
engineering activities’ duration. In the proposed methodology these activities are staged into five phases and structured to eliminate all
duplication resulting from separate application of the three tools. The newly proposed methodology saves 45% to 50% of the engineering
workload and adequate significant financial savings.
Keywords: Maintenance; Risk treatment; Reliability; Management
----------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------

RBI and SIFpro methods will be very briefly described.

1. Introduction
Reliability centered maintenance (RCM) represents a
Nowadays, the complexity of production equipment and structured decision-making support process for application of
numbers of maintained machines are very high. Without a optimum maintenance policies focusing on optimal timing of
proper system of maintenance it is not possible to operate maintenance actions (run to failure, periodical maintenance,
effectively and keep failure-related risks at acceptable levels. maintenance based on conditional monitoring and predictive
Good preventive maintenance leads to lower count of failures, maintenance) [1-11] for any physical asset within its opera-
improves reliability and acts as one of the tools for treatment tional context [1, 12-14].
of risks and undesirable consequences of failures. RCM is mainly used in the process industries and for techno-
Methods like reliability centered maintenance (RCM), risk logically advanced and complex production equipment [15-17].
based inspection (RBI) and safety instrumented function proc- RCM applies functional failure analysis (FFA) [18] and/or
ess (SIFpro) are important tools for reliability improvement failure modes and effects analysis/failure modes and effects
and treatment of risks. For the authors of this paper, these criticality analysis (FMEA/FMECA) [19] for various levels of
well-known methods are taken into account as the tools (with- failures’ criticality. Another RCM procedure aims to differenti-
out any changes) of the proposed new methodology based on ate evident versus hidden failures and failures with operational
their simultaneous and complex application on chosen equip- and economic effects, quality issues and environmental and
ment named reliability and risk treatment centred maintenance safety consequences. The process is finished by assignment of
(RRTCM). May be that some organization uses the methodol- suitable maintenance task, which alleviates or at least does not
ogy very intuitively, but authors have not found till now any worsen the failure criticality. The RCM analysis process typi-
described and estimated the RRTCM methodology in Czech cally comprises three or four steps (Fig. 1) [20, 21].
and world references. Therefore in the introduction, the RCM, Risk based inspection (RBI) represents a strategy for risk-
*
based optimization of inspection and subsequent maintenance
Corresponding author. Tel.: +420 224 383 254
E-mail address: pexa@tf.czu.cz
tasks especially in process industry (mainly in refineries, gas
†
This paper was presented at the ICMR2013, Emeishan, Sichuan, China, July15-18, processing and petrochemical plants) [22]. RBI should be
2013. Recommended by Guest Editor Ming J. Zuo applied for specification of inspection plans for pressure parts
© KSME & Springer 2014
3964 M. Pexa et al. / Journal of Mechanical Science and Technology 28 (10) (2014) 3963~3970
Identification RCM
1A1
of FSI decision PM
1A2 program
...
FSI 1 5B3 PM 1
FSI 2 PM 2 Combining
... ... PM policy
FSI n FMEA PM n
FSI 1,1,...,n - FSI n denoting the code of FSI
1A1,1A2,..., 5B3 - denoting the code of failure mode
PM 1,1,...,n - PM n denoting the code of PM task
Fig. 1. RCM analysis process [20], PM – Preventive maintenance, FSI
– functional significant items.
Fig. 2. Typical risk reduction layers [32].
of all stationary equipment, including vessels and pipelines
[23-26]. During the RBI procedure [27, 28] all pressure
equipment failure modes that affect pressure integrity of
equipment and pipelines are considered. Other failure modes
of pressure equipment, like sedimentations, should be ana-
lyzed and treated within RCM methodology [29].
Safety instrumented function process (SIFpro) is a strat-
egy for optimizing testing intervals plan of control loops [2,
30]. SIFpro covers random safe and unsafe failures of safety
systems, including alarms (Fig. 2), [31, 32]. It deals with ex-
actly defined areas within the field of measuring devices [33-
36]. SIFpro method usually follows a HAZOP analysis [30] or
PHA. These analyses identify where safety instrumented func-
tions (SIF) are required. Where SIF is required, the risk reduc-
tion up to the target safety integrity level (SIL) is defined.
The output of these long-existing methods and tools is an
optimized inspection and maintenance policy. The current
weakness of application of these methods is their subsequent
and separate implementation and realization [29]. However, to
achieve significant savings, these methods must be realized
simultaneously. We propose a new RRTCM methodology and
management system based on integrated application of above
described and verified methods (RCM, RBI and SIFpro).
2. Proposal of new methodology: Reliability risk
treatment centred maintenance (RRTCM)
Each of the methods (RCM, RBI and SIFpro) is concerned
Fig. 3. Example application of individual methods (RCM, RBI and
SIFpro) for atmospheric distillation unit components.
with a specific area of production equipment and its mainte-
nance. Merging these methods into RRTCM allows for har-
monized and structured solution with the following outputs:
- Complex risk evaluation results in suitable structure of
RRTCM organization and simplified relationships with
safety authorities.
- Workload of various professions is reduced (data and in-
formation can be shared for more methods).
- Concurrent application of RCM, RBI and SIFpro brings
synergic effects and allows during the RRTCM’s applica-
tion to decrease time and money consumption.
Integrated methodology RRTCM can be used within
chemical and petrochemical industry, refinery, classical and
atomic power stations, gas transportation and storage. The
RRTCM methodology is suitable and fully or partly applica-
ble to different machines and equipment, such as compressors
with accessories, chemicals and atomic reactors with accesso-
ries, pumps and motors, gas lines with accessories, coolers and
exchangers with control systems.
Application of the new method requires extensive training
of the working team with motivation to implement the pro-
posed method. Note that the RCM, RBI and SIFpro methods
are designed for production equipment (e.g., technological
systems, pipelines, machines, machinery components, measur-
ing devices, etc.) [37]. For instance, in the chemical industry
(Fig. 3), thte RCM method is most widely utilized as it covers
most of the production mechanical equipment. The reason is
that RCM deals mainly with machinery (especially rotating
machines, electrical devices, filters and measuring technology)
 M. Pexa et al. / Journal of Mechanical Science and Technology 28 (10) (2014) 3963~3970 3965

Table 1. Proposal of the RRTCM process.

1. Start up study
2. Major study
3. Collection and analysis of data
Phase 1 4. Implementation seminars
readiness assessment 5. Human resources requirements
6. Vocational knowledge requirements
7. Contract terms
8. Maintenance audit
9. Determination of loss equation
10. Sequence determination of operational systems
11. Setting of analysis boundaries
Phase 2 12. Preparatory action for analysis
preparation for analysis 13. Team establishment
14. Schedule of analysis
15. Device information management
16. Determination of risk matrix
17. RCM analysis procedure
Phase 3
18. RBI analysis procedure
analysis process
19. SIFpro analysis procedure
20. Output structure from new maintenance program
Phase 4 21. New maintenance program
result implementation 22. Implementation plan
23. Harmonization of maintenance activities
24. Updating of system process
Phase 5
25. Changes of analyses
system revision
26. Monitoring of key indicators
Common (merging operations 100%)
Note: Expected intervals of overlaps in this table were obtained during imple-
Partly common (merging operations 1% up to 99%)
mentation of the methodology RRTCM in a petrochemical organization.
Different (merging operations 0%)

[6, 38]. The RBI method embraces all pressure and pipeline
equipment, including those undergoing mandatory mainte-
nance (columns, reactors, exchangers, coolers, pipelines etc.)
[24]. The SIFpro method covers failures of safety systems
including alarms [35]. An organized and integrated approach
aimed at improvement of preventive maintenance should be
the goal of any production company. However, problems with
implementation of these methods may often occur as these
impose a significant organizational change – not even in the
field of maintenance, but also in production and incorporation
of management into the process (technical, managerial and
organizational problems).
Decision-making processes based on risk assessment be-
come more and more important instruments in maintenance
management. RRTCM’s entry analysis is teamwork of a
number of experts from the field of operations, maintenance,
process technology, corrosion and material science, inspection,
health and safety, electro-technology and instrumentation. The
analysis leads to a proposal of harmonized and structures
maintenance process.
The proposed RRTCM system is divided into five phases
(Table 1) further subdivided into individual blocks. Each
phase is understood as a process comprising several consecu-
tive or overlapping activities (blocks). Inputs and outputs of
the phases are data, information, forms, procedures, recom-
mendations etc. that are integral parts of the process. Specific
benefit of the proposal is the visual identification (by colors –
green - 100%, yellow – 1 up to 99% and red – 0% merging
operations).
The first phase is focused mainly on possibilities of im-
plementation of the methods into the company maintenance
process. It deals with collecting data and information by
means of audit and training of staff and management.
The second phase involves the data needed for the analyses
to continue on the approved schedule. The preparation in-
cludes collection and creation of the data as well as coordina-
tion of the team working on these analyses.
The third phase represents the analysis itself. The analysis
follows the defined procedure in order to maintain the com-
plex view of the analyzed production units and keep a stan-
dardized form of outputs.
The fourth phase aims at the implementation of outputs re-
sulting from the analyses into the maintenance information
system. New requirements for maintenance actions’ parame-
ters (time, contents) need to be implemented in a way the
planned shutdowns and turnovers of production equipment are
considered and legislation requirements can be met.
The last, fifth phase, solves the updating process of the im-
plemented system in case of further changes. It targets the
areas where such changes may lead to adjustment of the
analyses. The last phase includes also the assessment of the
whole RRTCM process.
3966 M. Pexa et al. / Journal of Mechanical Science and Technology 28 (10) (2014) 3963~3970

- Reduction of workload (use of collected data in all meth-

ods),
- Specification of maintenance policy with respect to risks,
- Improvement of reliability and availability of equipment,
- Ensuring technical integrity of equipment,
- Meeting requirements of HSE and other legislation,
- Unified database for maintenance, inspection and safety
data,
- Facilitation of continuous improvement feedback process,
- Keeping asset register up to date,
- One source for plans and decisions in the areas of mainte-
nance, inspection and safety requirements,
- Improvement of spare parts processes,
- Gradual development of reliability data database,
- Centralization of maintenance working procedures,
- Involvement of operators into preventive maintenance,
- Environment of RRTCM’s multidisciplinary teams leads
to atmosphere of closer cooperation between departments.
The process of RRTCM application is never totally finished
because the operation of production equipment brings about
changes affecting inputs into the analyses and therefore their
outputs and results. A system for updating input data needs to
be established in order to provide up-to-date data for RRTCM
reflecting the real state of production equipment.
Data for RRTCM (Fig. 5) can be updated periodically based
on defined time intervals or individually based on a specific
issue. Ideally, a complete revision should be done for each
production unit or equipment in an initially specified period of
time (once in a year or two years). However, revisions can be
rescheduled to fit with a schedule of shutdowns.

In addition, periodic data revisions can be extended with

random revisions for certain parts of equipment, where sig-
nificant changes occur (without importance order):
Fig. 4. Incorporation of the RRTCM system into organization structure.
3. Results
Integration of RRTCM system into the organization’s man-
agement structure is presented in Fig. 4 in three levels. The
highest level is the asset management process, the middle
level is the basic connection of RRTCM with maintenance
process, and the last level represents the links to the risk and
reliability management process. The key output of the
RRTCM system is the proposal of preventive maintenance
programs.
Implementation of the updated preventive maintenance
programs in the RRTCM system brings about cost reduction
as well as other advantages:
- Renovation, refurbishment or construction of new equip-
ment (changes in asset register, PLE, safety etc.),
- new findings from inspection and tests,
- new findings of technical condition of equipment during
shutdowns and turnarounds,
- changes of legislation and standards (mandatory mainte-
nance),
- shifts in organization’s business strategy (market changes,
strategy focus, new owner),
- production loss equation (PLE) (major investment pro-
jects, changes of technology etc.),
- company’s criteria of risk tolerance,
- failures and information about development of new deg-
radation modes,
- new results of hazard and operability studies (HAZOP),
process hazard analysis (PHA) or health, safety and envi-
ronment (HSE),
- development and application of new maintenance tech-
niques or devices,
- new results of comparative/benchmarking studies,
- major changes of exchange rates.
 M. Pexa et al. / Journal of Mechanical Science and Technology 28 (10) (2014) 3963~3970
Fig. 5. Diagram of RRTCM system’s updating process.
To achieve the best outcomes and benefits resulting from
RRTCM’s implementation, a clear and firm organization
structure must be defined as well as roles and responsibilities
of individuals. The RRTCM organization structure is pre-
sented in Fig. 6. The structure is divided into four basic parts:
- preventive part,
- management of technical integrity (MOTI) part,
- catalectic failure /reactive part,
- management and control part.
Preventive part shows the position of RRTCM among other
reliability improvement activities (like RCA) and toward de-
fining and monitoring key performance indicators (KPIs).
MOTI focuses on managing technical integrity of equipment
based on RBI studies (production units operation, sharing
information among teams, monitoring of IOW operational
limits. In management and control part, a committee nomi-
nated from organization’s management takes decisions on
future steps and work to be done.
Fig. 6 further shows that besides the management commit-
tee it is good to have a liaison “officer” (central person) ap-
pointed for all issues of reliability/integrity. The liaison officer
then provides support for RRTCM teams during the process of
3967
assessment and definition of maintenance and inspection plans.
Economic benefits of RRTCM implementation can be ex-
pressed as a difference in duration of activities needed for
separate implementation of RCM, RBI and SIFpro methods as
compared with integrated implementation of RRTCM. Rela-
tive durations of separate implementation of the methods on a
specific production unit are presented in Table 2. Time reduc-
tions of the 2nd, 3rd and 4th phase only are considered and
phases 1 and 5 are omitted as these phases relate to the organi-
zation as a whole and the authors had no access to detailed
data about these phases. During application of the RRTCM
methodology there was identified labor consumption in man-
hours for phases 2 till 4 for every process and for further rela-
tive comparison transformed into percentage. In the same way
there were estimated labor consumptions of every process
within phases 2 till 4 for different RCM, RBI and SIFpro
methods as a percentage of the RRTCM`s labor consumption.
In a pessimistic variant of RRTCM implementation, savings
of 44.4% can be achieved. Considering an optimistic alterna-
tive, the saving can amount to 50.5%.
4. Conclusion
When implementing the new RRTCM system, a number of
obstacles can be expected as the implementation intervenes
organization structure, responsibilities and many existing
business processes. Difficulties, which can be encountered by
an implementer of risk and reliability centered maintenance
system, arise from various areas:
- high demands for data inputs,
- quality of analyses,
- maintenance organization,
- bad company culture, low support of top management etc.
The new RRTCM system proposed in this paper integrates
the usually separately applied and previously verified methods
RCM, RBI and SIFpro. For this maintenance solution to be
effective it is absolutely essential to gain the support of com-
pany’s top management. The diagrams in Figs. 4 and 6 dem-
onstrate that the new RRTCM system goes through almost all
levels and organizational units of the company.
Relative time-savings of integrated implementation of the
RCM, RBI and SIFpro methods are presented in Table 2. The
last column in the Table 2 is a labor consumption of newly
designed and proven methodology RRTCM at 100% of man-
hours. Achievable reduction of implementation duration in
case of RRTCM application in phases 2-4 amounts to 44,4%
to 50,5%. Concrete absolute economic benefits of RRTCM
implementation depend on company size and quality of indi-
vidual RRTCM working teams’ work and on concrete abso-
lute labor consumption (in man-hours) of separate and inte-
grated implementation of RRTCM methods (RCM, RBI and
SIFpro) and on unit labor price (in EUR/man-hours).
Organizations disclose specific financial data. However, the
authors ascertained that during one application of RRTCM
3968 M. Pexa et al. / Journal of Mechanical Science and Technology 28 (10) (2014) 3963~3970

Table 2. Comparison of duration (labor consumption%) of separate and integrated implementation of RRTCM methods (RCM, RBI and SIFpro).

Labor consumption (% of man-hours)

RCM RBI SIFPro Total separately
RRTCM
Activities P O P O P O P O
Phase 2
9. 100 100 100 100 100 100 300 300 100
10. 100 100 100 100 100 100 300 300 100
11. 70 90 40 60 20 30 130 180 100
12. 50 70 50 70 70 80 170 220 100
13. 90 100 90 100 90 100 270 300 100
14. 100 100 100 100 100 100 300 300 100
15. 50 70 50 70 30 40 130 180 100
16. 100 100 100 100 100 100 300 300 100
Phase 3
17. 100 100 0 0 0 0 100 100 100
18. 0 0 100 100 0 0 100 100 100
19. 0 0 0 0 100 100 100 100 100
Phase 4
20. 50 60 50 60 20 30 120 150 100
21. 50 60 50 60 20 30 120 150 100
22. 50 70 60 70 30 40 140 180 100
23. 50 70 50 70 20 30 120 170 100
Average 180 202 100
100·(180-100) 100·(202-100)
180 202
Reduction of labor consumption (%)
= =
44,4 50,5

P - pessimistic scenario regarding to RRTCM applied for all methods

O - optimistic scenario regarding to RRTCM partly applied
applied for one method
Note: All estimated data in this table were obtained during implementation of the methodology RRTCM in a petrochemical organization.

RRTCM Coordination and Management Committee

Engineering director, Head of production department, Head of maintenance department,
Management
Chief Reliability Head of technology department, Head of investment department, Reliability engineer, and control
production and risk Head of technical support department part
Support team engineer engineer

- production team
manager Result feedback, improvement KPI monitoring and
- chief maintenance and taken measures evaluation
engineer Reporting and result
- head of inspection feedback
department
- head of
(improvement)
Action (who, when,
maintenance Planning and analysis Recommendation
department how)
- head of
of performance,
investment reliability (KPI) and Preventive
department procedure part
- maintenance
MOTI team Maintenance
scheduler
implementation Inspection and production team
manager realization
- maintenance MOTI
manager Management of MOTI part
technical equipment
integrity
Monitoring and
RRTCM Emergency (correction) reviewing of plan
strategy implementation
optimization Root Cause Failure
Analysis

Result feedback and

Risk Analysis (frequency and reliability improvement
Unreliable equipment search and risks reduction
consequences) of equipment failures

Fig. 6. Proposal of RRTCM structure in an organization.

savings may range from 50.000 to 100.000 EUR. tain) optimal equipment maintenance strategy focused on
The main purpose of RRTCM system and methodology reliability and risk treatment and effective flow of investment
application is, on one hand, shorter time of the RCM, RBI and into physical assets and their maintenance.
SIFpro implementation, and on the other hand, to attach (ob-
 M. Pexa et al. / Journal of Mechanical Science and Technology 28 (10) (2014) 3963~3970 3969

tional techniques, Journal of Mechanical Science and Tech-

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Martin Pexa is a head of Department
for quality and reliability of machines,
Faculty of Engineering, Czech Univer-
sity of Life Sciences Prague. Now he is
an associate professor in Power industry.
His professional profile is oriented to
the quality and reliability of machines,
condition monitoring, bio-fuels and
performance characteristics of engines. He is the author or co-
authored more than 100 scientific articles, conference papers,
research reports, textbooks, teaching materials, etc.
Tomas Hladik is an assistant professor
at Department for quality and reliability
of machines, Faculty of Engineering,
Czech University of Life Sciences Pra-
gue. In 2005 he defended his doctoral
thesis in Quality and dependability of
machinery and equipment. His profes-
sional profile is oriented to the quality
and reliability of machines, maintenance optimization and
logistics. He is the author or co-authored more than 80 scien-
tific articles, conference papers, research reports, textbooks,
teaching materials, etc.
Zdenek Ales is an assistant professor at
Department for quality and reliability of
machines, Faculty of Engineering,
Czech University of Life Sciences Pra-
gue. In 2010 he defended his doctoral
thesis in Quality and dependability of
machinery and equipment. His profes-
sional profile is oriented to the quality
and reliability of machines, maintenance optimization and
condition monitoring. He is the author or co-authored more
than 60 scientific articles, conference papers, research reports,
textbooks, teaching materials, etc.
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