Benefits of Asset Management and RCM in Power Generation Rev 3

Benefits of Asset Management and RCM
Implementation in Power Generation

Purpose : RCM Program Development and Implementation
Guidelines , with a thorough understanding of benefits
Agenda
RCM What it is ? Benefits , Maintenance Types
Plant Reliability Asset Management Process and its
Importance
RCM Reliability Centered Maintenance & Strategies
RCM Standards / Documents
RCM based Maintenance and Reliability Factors
RCM Tools and Soft-Wares
Reliability Program ( Based on MSG 3 , Maintenance Steering
Group UK )
European Technology Development Ltd
www.etd-consulting.com
Maintenance Methodologies and
Philosophies
&
Maintenance Program
Types of Maintenance Methodologies
Failure Based or Break down
Maintenance FBM
Scheduled or Preventive
Maintenance PM
Predictive Maintenance
PDM
Proactive Maintenance
PAM
Strategic Maintenance Philosophies
Condition Based
Maintenance CBM
Reliability Centered
Maintenance RCM
Total Productive
Maintenance TPM
What is RCM
Reliability Centered Maintenance (RCM) is a risk-based study
process for determining the least cost maintenance and
surveillance actions needed to meet operating performance
targets. It seeks the optimal mix of condition-based, time-
based, and run-to-failure strategies
All equipment across which maintenance money is spent
(machinery, electrical, instrument, stationary equip, & civil) is
subject to RCM study
The OBJECTIVE is to be sure were doing the right level of
preventive maintenance, at the right frequency, ensuring
plant reliability, while also maintaining a competitive cost
position
Maintenance Program Adjustments
Benefits of RCM
RCM benefits can only be achieved when recommended tasks coming
from an RCM study are actually transferred into actionable work,
whether into PMs , Operations ,or other preventive actions (e.g.
recommended plant changes)
Benefits include
Improved availability
Controlled costs
Improved safety and environmental protection
A comprehensive preventive maintenance database
RCM Business Objective
MAINTENANCE EFFORT
C
O
S
T

NOT ENOUGH EFFORT OPTIMUM TOO MUCH EFFORT
TOTAL COST
TYPICALLY
UNDER MAINTAINED
TYPICALLY
OVER MAINTAINED
fire fighting
mode
comfort
mode
RISK
BASED

RCM

PREVENTIVE
MTCE. COSTS
COST OF NON-
AVAILABILITY
PROD. LOSS +BREAKDOWN
What is RAMP?
Reliability Asset Management Processes
Power Plants
RAMP is an integrated structure of aligned processes required
to successfully yield consistently reliable equipment at the
lowest possible cost.

It serves as a tool to assist operating sites understand and
implement each of the key processes needed for effective
equipment reliability over the equipment life cycle. Cutting
Maintenance Cost , Optimizing Inventory .
Equipment
Strategy Analysis
Turnaround Strategy
Maintenance Strategy Functional/
Criticality
Analysis
and/or
Risk Based
Inspection
Spare Parts Strategy
Training Strategy
Operate/Maintain
Plan
Execute
Routine Mtce Turnaround Mtce
Work ID Work ID
Plan
Schedule
Execute
Document Document
Schedule
Operate
Equipment
Performance
Data
Design & Construct
Construct
Procure Design

Defect Elimination
Other
Sites
Data Analysis
to Determine
Stake
Prioritize Based
On Business
Impact
Select
What to
Work on
Root Cause
Failure
Analysis
Eliminate
System
Defect
Leverage
Learnings
Power Plant Equipment Reliability Asset
Management Process
Optimization
Strategies
Commission
Specific
Equipment
Plans
Standards for Power Plants
RCM Implementation
What standards are behind RCM
MIL STD 785B ( Reliability Programs for Systems and
Equipment Development )
MIL - STD 1629A ( Procedures for FMECA )
MIL STD 3034 ( RCM Process )
SAE JA 1011 / JA 1012 Evaluation Criteria for (RCM) Processes.
OREDA Off-shore reliability data handbook
PAS 55 1 Recommendations for Asset Management
PAS 55 2 Implementations of Recommendations
ISO 55000 ( Asset Management Standard Coming in 2014 )
RCM Implementation
Step by Step Approach

Identification of Fossil Plant
Understanding Systems & Equipment eg. GT , HRSG ,
Generator , Steam Turbine , etc.
Understanding Performance and Function of each system , sub-
system and Equipment.
Defining Criticality of Each system , equipment with respect to
performance and function .
Understanding failure modes of each system , equipment & its
Consequences with respect to safety , environment ,
economics and Operation.
Reliability Block Diagram Modeling and Weibull Analysis .
Define Functions &
Functional Failures
Identify
Failure Modes
Assess Criticality
Develop and Assess
Preventive maint Plan
Optimize Tasks,
Frequency & Cost
Recommended tasks Actionable tasks
Review based
on field feedback
RCM Learn & Improve Process
Gas Turbine
20 Systems
100 Components
150 Sensors
15000 Parts
1000 Failure Modes
20000 Consequences
How many PM Tasks Cover all this ? If all How effective
and efficient those tasks are ?
RCM Implementation
Step by Step Approach

Complete review of PM Preventive Maintenance and reliability
program to see whether all function and performance failure
modes are mitigated .
Changes in PM and reliability programs .
Review of Amended PM and Reliability Programs .
Based on criticality RBI Risk Based Inspection introduction .
Continuous review of Failure Modes with existing and
amended PM programs .
Effective use of soft-wares for analysis
Level of Analysis may be extended into in-house as well as
subcontract repair.
Integration of same in CMMS or SAP system for monitoring .

Specific
Equipment
Plans
(SEP)

Equipment
Strategy Analysis
Turnaround Strategy
Maintenance Strategy
Functional/
Criticality
Analysis
and/or
Risk Based
Inspection

Spare Parts Strategy
Training Strategy
How is Criticality Analysis Used in RCM ?
The combination of these
strategies form the
Specific Equipment Plan
or SEP
High criticality - requires thorough reliability analysis.
Medium criticality - Failure Modes and Effects Analysis.
Low criticality - generic strategies.
Business Impact
(Consequence of Failure)

F
r
e
q
u
e
n
c
y

o
f

F
a
i
l
u
r
e
10 20 30 40 50
1
2
3
4
5+
I
n
c
r
e
a
s
i
n
g
C
r
i
t
i
c
a
l
i
t
y
RCM Implementation
Step by Step Approach Documents
Requirements
Maintenance Planning Document OEM
Specific Equipment Operating Instructional manual OEM
Trouble Shooting / Fault Isolation Manuals OEM
Overhaul Manuals OEM
Work-Scope Planning Guide OEM
Complete Repair History Since Commissioning for
Systems , Equipment & up-to parts level
Last Heavy Maintenance Scope under PM and Corrective
Maintenance Overhaul Scope
Last Shut Down / Turn Around Scope
Performance Data Base .
RCM Implementation
Step by Step Approach Soft-wares and Tools Used

Existing CMMS and SAP System
Analysis Soft-wares like
Minitab , Statistics , Stat Graphics , Weibull 6++ etc
Package Soft-wares
Merridium , Isograph etc
RCM Tools
FRCA Failure Root Cause Analysis
FMECA Failure Mode and Its Effect Criticality Analysis
RBD Reliability Block Diagram
Weibull Analysis ( Reliability Calculations )
RAM Reliability Availability and Maintainability

RCM Implementation & ETD Support
Conclusions

RCM is a Powerful maintenance Philosophy and as such it its
implementation can have a considerable gain in
Plant Performance and Functional Reliability Improvement
Maintenance Cost Reductions

European Technologies Development have launched proposal
with an objective to
RCM Awareness and Understanding in Power Plants
RCM Study for Fossil Power Plants .
RCM program development and Implementation Guidelines
Fossil Power Plant Remaining Life Assessment and its
integration with RCM for longer life of Asset.

Thank-you for Sharing Knowledge

Benefits of Asset Management and RCM in Power Generation Rev 3

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Benefits of Asset Management and RCM

Implementation in Power Generation

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