© Reliability Centered Maintenance Recon Monet Procedures Page 1 of 11 spofeptft Hailgall jLéall dy yi OMAN GAS COMPANY S.A.0.C. RELIABILITY CENTERED MAINTENANCE PROCEDURES 25-02-2014 | Original Circulation — DIP No. xx Rev. |* Date History of Changes Prepared By : (Head of Reliability ‘& ConMon ) (Mohammed Al Barwani) (Majic Al Zidjatl) (Mansoor Al Abdali) Reviewed By: ( OSM Manager ) ‘Approved By (GMO ) Users are responsibie for ensuring the use of the correct revision of this document@ Reliability Centered Maintenance Recon ae? Procedures Page 2 of 11 Table of Contents OBJECTIVES... 4, DEFINITIONS & ABBREVIATIONS......ssssssssssssssssssussasseeeessssvssentssssnsssenes 5. PROCEDURE .ssccsssssesssssssssseesensnsssensavsssstensnusnssssesnssssaseenavansssseesseesesss seseeeeesssiei RCM Analysis procedure guidelines data gathering. ESTABLISH STUDY BOUNDARIES. Establish specific study boundaies. Form RCM team. PERFORMANCE OBJECTIVES. identify equipment FUNCTIONS. CONDUCT STREAMLINED FAILURE § Identify FMECA for each of the equipment. (Conduct RCM Failure Defense task selection for critical (C1, C2, and High Consequences) equipment. Perform RCM failure defense task selection for non-critical equipment & failure modes. blue matrix. 5.7.1 Task Consolidation and Procedure Development. SS OTHER DATA MAINTENANCE, 6. References... . APPENDIX Lessesssssssse APPENDIX 2... (© io oe in tn nin DD inininin seesiisisesase LO sesso LL Users are responsibie for ensuring the use of the correct revision of this document© Reliability Centered Maintenance 3ySeeSotr” “ew Procedures Page 3 of 11 . PURPOSE This procedure provides a systematic approach to defining O&M equipment, understanding failure modes and their effects, and developing Failure Defense Task (predictive, preventive, run-to-failure, etc.) and first ine maintenance program effectively to mitigate the potential for unacceptable failure This procedure includes determination of FMEA, application of RCM Analysis appropriate to the consequences of equipment failure based on the ECA result SCOPE This procedure applies to Production equipment under Oman Gas Company (OGC) operational control. Included in the scope of this procedure is all rotating, instrumentation, electrical and control systems that are a part of production and processing operations |. OBJECTIVES The objective of the RCM is to streamline maintenance by: Identifies actions that minimize Corrective Maintenance. > Emphasizes condition-monitoring tasks. Eliminates PM tasks determined to be unnecessary or not cost-effective. © Identifies necessary failure-finding tasks © Extends existing time-directed task intervals through age exploration or frequency optimization. Addresses design change options. Identifies where no proactive maintenance is required, or Run-to-Failure (RTF). Allowing for redundancy where appropriate © Providing the appropriate tools & technology, maintenance duration, and manpower skills, Optimizing spare parts management system via RCS (Reliability Centered Spares), DEFINITIONS & ABBREVIATIONS cBM Condition Based Maintenance cMMS ‘Computerized Maintenance Management System ECA Equipment Criticality Analysis FCA Failure Characteristic Analysis FMEA Failure Mode Effect Analysis FMECA Failure Mode Effect Criticality Analysis ORD ‘Operator Routine Duties PM Preventive Maintenance RAM Reliability Availability Maintainability RBI Risk Based Inspection RCM Reliability Centered Maintenance RCS Reliability Centered Spares RIF Run to Failure SIL Safety Integrity Level SRCM ‘Streamline Reliability Centered Maintenance Users are responsibie for ensuring the use of the correct revision of this document«@ Reliability Centered Maintenance Riecccot ne Procedures Page 4 of 11 5. PROCEDURE 5.1 RCM ANALYSIS PROCEDURE GUIDELINES ‘The following diagram (Figure 1) illustrates the overall process of SRCM Analysis, described in this section and further detailed within Appendix 1 of this document. ‘The RCM approach deploys a variety of integrated maintenance tools and techniques to increase the probability that a system or equipment will perform in a required manner over an extended life cycle with minimum maintenance. This approach is risk-based; SRCM seeks to focus maintenance development effort on areas that represent the highest risk to the stated goals and objectives for the asset. This does not mean that no effort is directed towards lower risk areas but that the focus is on those areas that have the greatest potential to impact business performance. Within the context of this document, ‘risk’ is considered to be the product of the consequence of failure and the likelihood (probability) of failure ROM Workshop souncny ee seen 5.2 DATA GATHERING This data shall include all manufacturers, vendors and asset register information and tag numbers. Equipment and components to systems and tag numbers shall be cross-referenced, COMPANY use RCM software Database for data management and ensure alignment with CMMS SAP. The following data that need to perform the RCM: © The Equipment Criticality Assessment result contains detailed information on updating equipment listings refer to document. © P&ID, PFO, or line diagram. © Gather system general failure, cost information Information includes: © System functions © ECAresult © Vendor design, operation and maintenance information © Maintenance history © Component interaction (logic) © Existing PM and surveillance tasks (by equipment no.) © Cost history Users are responsibie for ensuring the use of the correct revision of this document@ Reliability Centered Maintenance 3ySeeSotr” “ew Procedures Page 5 of 11 5.3 ESTABLISH STUDY BOUNDARIES 5.1.1 ESTABLISH SPECIFIC STUDY BOUNDARIES * Boundaries shall be up to the equipment skid level * Equipment which follows up with SRCM shall be C1, C2, and also which has high consequence criticality. 5.1.2 FORM RCM TEAM. ‘Team consists of a facilitator and a multifunctional team Primary function of a facilitator is to facilitate the application of the RCM philosophy by asking question of a multifunctional team chosen for their knowledge of a specific asset or process ensuring that the group reaches consensus about the answer and recording the answer. Multifunctional team usually consists of: 1. Reliability Engineer - Facilitator Operations Maintenance Mechanical 2 3, 4. Maintenance Instrument 5. Maintenance Electrical 6. Planner 7. SME The mix of resource types will help obtain concurrence for actions from all groups. They will be expected to use personal experience to identify potential improvements and opportunity areas/solutions to include potential design changes (one time improvements) and improved maintenance/surveillance processes/ techniques and integrity philosophy. 5.4 PERFORMANCE OBJECTIVES ‘The objectives selected must coordinate with the overall function of the system, and must be specific and measurable. It may include throughputs, yields, product qualities, or whatever objective is appropriate for the plant or facility. 5.5 IDENTIFY EQUIPMENT FUNCTIONS Determine the function for each of equipment Include "safetylenvironmental” as well as “production” functions. Define the "key" and the "less important" functions, Typically a third of items is key or critical items and is addressed with mitigation actions. Another third are non-critical but are addressed for economic reasons (cost of failure and resource impact). Finally, the last third of items cannot be cost effectively addressed proactively and typically allowed to run to failure. 5.6 CONDUCT STREAMLINED FAILURE MODES EFFECT CRITICALITY ANALYSIS 5.6.1 IDENTIFY FMECA FOR EACH OF THE EQUIPMENT 1. What are the functions and associated performance standards of the asset in its Present operating context? (Function and Performance Standard) 2. In what ways does it fail to fulfil its functions? (Functional Failure) Users are responsibie for ensuring the use of the correct revision of this documentee Reliability Centered Maintenance 9 Riecccot” Procedures Page 6 of 11 Noone ‘What happens when each failure occurs? (Failure Effect) ‘What causes each functional failure? (Failure Mode) In what way does each failure matter? (Failure Consequences) ‘What can be done to predict or prevent each failure? (Task Selection) ‘What should be done if a suitable proactive task cannot be found? (Others Decision) Diagram below may help to determine question number 5, 6, and 7. cage, [el Seremete Teter ee tre Secamemane || orsottareen, || qimseaeteane || Steccteiares na “comer? nosenmtremecey || *etalzestck Figure 2: RCM Chart Diagram COMPANY has dealing with Streamline RCM method to determine RCM objective then COMPANY will only focus on the critical hazard (failure mode). To determine the critical failure mode, COMPANY has the method to use 5x5 matrix and the thresholds are already defined by the COMPANY, see Figure 3 below: If the failure effect can be tolerated the failure is not critical. If the failure effect is not tolerable the failure is critical. Tolerability is based on achieving performance objectives, safety/environmental standards and effect on function. The below matrices will normally be used as a guides to determine failure mode rank. Users are responsibie for ensuring the use of the correct revision of this document© Reliability Centered Maintenance 9 RSeccnn ae? Procedures Page 7 of 11 Potential Seveiy or Time to Falare Actual Severity oF (What Might have gone Worst) consequence Severity Merton tow Medium High Very Hi ee] campanysepcnion | rama | > | Sinope meeanens |e Sao ae | aia gover | i530 Tapa Rava conantonann| Siege | Mer repo amar ete) ss Figure 3: OGC Criticality Matrix 5.6.2 CONDUCT RCM FAILURE DEFENSE TASK SELECTION FOR CRITICAL (C1, C2, AND HIGH CONSEQUENCES) EQUIPMENT. For each critical equipment use Failure Defense task selection flow in Failure Defense Task Philosophy & Management Document which is summarized below: > Determine the most applicable and effective Failure Defense task(s) to address the identified causes © For hidden failures determine appropriate PM detection or failure finding tasks © Selecting the task(s) for evident failures should use the following task and responsibility hierarchies which promotes driving Operator Routine Duties or First Line Maintenance as much as reasonably possible > Task hierarchy «First Line Maintenance * Condition Based Monitoring + Preventive Maintenance ° Invasive preventive restoration task (e.g. disassembly to check bearing wear and replace as needed) ° Time-based replacement task (e.g, replacing bearings) ° Failure Finding Task ‘One time improvement (eliminate failure/failure effect) = Runto Failure For situations where there is no suitable task, and the consequences (e.g. Safety) are significant, an engineering/operational change or redesign may be necessary. 5.6.3 PERFORM RCM FAILURE DEFENSE TASK SELECTION FOR NON-CRITICAL EQUIPMENT & FAILURE MODES Run to Failure strategy will be applied where it is more cost effective to allow the component to fail and repair than to spend money and man-hours in maintenance. This option must pass a run to failure “filter Check” which requires approval from the Asset Manager and Operation Support Manager. Run to Failure Check: Users are responsibie for ensuring the use of the correct revision of this documentQHSE-QS-L3-301 @ Reliability Centered Maintenance ax xxxx-2011 Monet Procedures Page 6 of 11 © Confirm that Failure Defense Task cost is higher than cost of running-to-failure if cost is higher for failure returning to select suitable task step. Make sure running-to-failure does not introduce significant disruption to production process. Ensure running-to-failure will not cause significant secondary damage to equipment. If failure will cause secondary damage retum to select suitable task step. © Confirm there is no regulatory, HSE or certification Failure Defense Task requirement for equipment. If regulatory, HSE or insurance requirement is found, return to select suitable task step. If no any concem issues are found, equipmenticomponent will be allowed to run to failure. 5.7 TASK CONSOLIDATION AND PROCEDURE DEVELOPMENT COMPANY shall develop the Failure Defense Task Strategy complete with several things which mentioned below: 1. Equipment Name Manpower skill and disciplines. Manpower estimation Duration performing the maintenance task Tools & Technology. Maintenance Task Interval. Noon on Spare part need analysis, a. Amount of spare part b. Stock code c. Material Cost Estimation Several things above shall be develop for each of the Failure Defense Task Strategy that already been defined which lead by the Facilitator during the RCM workshop and all the data result shall recorded and enter into RCM Database Software and CMMS SAP system. 5.8 OTHER DATA MAINTENANCE In addition to the use of RCM there are other maintenance development approaches that also shall be considered. These include: 1. ‘Mandatory’ Maintenance — activities that are mandated by legislation, COMPANY policy or procedure, or follow directly from COMPANY activities targeted to identify hazards (e.g. hazard assessments). 2. ‘Generic or Standard Maintenance Policies - COMPANY derived maintenance policies designed to be applied to a standard range of equipment. These may have been developed previously using RCM or may be the result of previous operating experience with similar equipment in similar operating environments. This approach may be used as a substitute for streamlined RCM. An example of where a generic maintenance policy may be considered is in the inspection and maintenance of certified electrical equipment. 3. Manufacturer's Recommendations - Manufacturers have detailed technical knowledge regarding their equipment. RCM result shall take account of manufacturer recommendations Users are responsibie for ensuring the use of the correct revision of this document@ Reliability Centered Maintenance Sex coir “eet Procedures Page 9 of 1 when determining the maintenance strategy for any equipment item. RCM result shall not make any change to a manufacturer's recommended maintenance program that may adversely affect the equipment warranty. 4, SIS SIL Evaluation -RCM result shall undertake a Safety Integrity Level (SIL) evaluation for each Safety instrumented System as required by COMPANY specification or regulations. This vill result in the specification of function test intervals being defined for SIS components including initiators (e.g. pressure transmitters), logic elements (e.g., PLCs) and actuators (e.g. emergency shutdown valves). 6. References OGC Reliability & Condition Monitoring Guidelines OS-GEN-L2-208 Users are responsibie for ensuring the use of the correct revision of this document@ Reliability Centered Maintenance ee APPENDIX 1. RCM KPI Matrix Procedures ‘Table 1: Key Performance Indicator of Reliability Centered Maintenance Metric Name ‘Description and /or Tntent Calculation Method of Equation Percent Critical Equipment Encourage completion RCM applied / Total surnber of Critical with RCM Complete onal eriical equipment | Pero Percent RCM Tasks Measure effectiveness of | Nusiber of RCM tasks Implemented RCM task selection implemented / Number of RCM tasks identified QHSE-QS-L3-301 RX Xx-xx-2011 Page 10 of 11 Users are responsibie for ensuring the use of the correct revision of this document@ Reliability Centered Maintenance Recon see Procedures Page 11 of 11 APPENDIX 2. Roles and Responsibility Matrix. ‘A summary of the roles related responsibilities that are required to both implement and manage Reliability Centered Maintenance process is given the following RCM process ‘RASC’ matrix- Table 1 ‘Table 2: RCM RASCI Matrix Execution . = = z| é 2) 25 BIS Bl) eelsl s z 2 |se|2| 2 = 5 | 25) | & 3 = | & e) 28) = 3 2/2 a|\|o| * i g 2 & Activity 3 3 2 a FormRCMTeam | A | A | R |S | ¢ [Clq Data Gathering TTRiTe,sy] s [s,s RCM Workshop Facilitation hioal Ris) s sit RCM Result aAyaATR Io mya Upload into SAP] 1 | A] Cc] 1 _T1TR 'R= Responsibility — owns the problem / project fo whom “R"is Accountable who must signoff (Approve) om Work beforeit is effective -an be Supportive ~ can provide resources or en play 3 supporting role in implementation (be Consulted —has information andor capability necessars to complete the work T= tobe informed ~ must be notified of results but need not be consulted Users are responsibie for ensuring the use of the correct revision of this document