SRCM BACKGROUND

Concentrate maintenance resource where they will

do the most good
Eliminate unnecessary and ineffective maintenance
Devise the simplest and most cost effective means
of maintaining equipment, or testing for
degradation, focusing on predictive or CM activities,
whe applicable
Develop a documented basis for the maintenance
program
Make use of plant maintenance experience when
determining PM task and frequencies
 Logic for SRCM Process
Data collection

Review Indentify Key Important Function

Plant
History
Perform Criticality Analysis
and
conduct
Plant Perform Non-Critical Analysis
Reviews
and
Compare SRCM Results with Existing Maint. Program
interviews

Implement Changes

Establish Living Program

Data Collection
System description
P & ID
Functional Diagrams
Plant Operating and Alarm Response
Procedure
Work Procedures
Vendor Information
Corrective and preventive maintenance
history
Indentify Key Important
Function
Specifying those functions that are
essential to plant operation and safety
Only important functions go through
the Critical Analysis
All components that support the non-
important system functions go through
the Non-Critical Analysis
Perform Criticality Analysis
SRCM process combines FMEA and LTA into one
record
This process allows the analyst to list multiple
failure modes for a specific component and only
identify the dominant plant effects
If the component is determined to be critical, the
analyst identifies the appropriate failure causes and
the applicable PM task
Components that are initially analyzed in the Critical
Analysis but are identified as non-critical will be
evaluated again during the Non-Critical Analysis
 SRCM technique can
significantly reduce the amount
of time required to perform
both FMEA and LTA portions of
analysis
Perform Non-Critical Analysis

Evaluation using economic criteria for

those components that were identified
as functionally non critical in the
critical analysis
Several questions are used to
determine the cost effectiveness of
providing some level of PM vs RTF
Questions Used in the Non-Critical
Evaluation

Is there a high repair/replacement cost if the

component is RTF or is there excessive corrective
maint performed on this component?
Is there a simple cost-effective task that can be
performed to prevent component degradation?
Can failure of this component induce other failure?
Is there an increased personel or environment
hazard if the component is RTF?
Is this component required to perform or in support
of other recommended maintenance activities
Activities during the critical and
non-critical analysis steps

Review of corrective maintenance data

from the plant
Interviews are held with plant
operations and maintenance personnel
to obtain additional information
regarding component performance
and maintenance
Compare SRCM Results with
Existing Maint. Program
COMPARATION BEETWEEN
CLASSICAL RCM AND S-RCM
Classical RCM
Developed for Aviation industry and Power
stations
Inherent Reliability Centred
FMEA tends to focus on all possible failure
modes
Top down approach to the level of components
Time consuming exercise
COMPARATION BEETWEEN
CLASSICAL RCM AND S-RCM
Streamlined - RCM
Developed by Shell
Economic reliability centred
Concentrates on dominant failure modes
Selects PM jobs by considering costs of failure
vs. cost of PM jobs
Top down up to system failures; there after
bottom up
Takes approx. 20% of classical RCM
 DOMINANT FAILURE MODES

SRCM only uses dominant failures in

studies i.e.
only those failures which occur frequently
or are expected to occur.
do not consider failures which could
happen (rarely) during the life time of the
component.
 WHY RCM ?

TOTAL COST OPTIMIZATION

RCM TARGET
S-RCM OVERALL TARGET
 Total Cost Optimisation
TOTAL IMPACT COST
COST

DIRECT MTCE. COSTS

TYPICALLY
fire fighting TARGET TYPICALLY
comfort
UNDER MAINTAINED AREA OVER MAINTAINED
zone for zone
S-RCM
COST OF NON-AVAILABILITY

NOT ENOUGH EFFORT OPTIMUM TOO MUCH EFFORT

MAINTENANCE EFFORT
 What is our target
Reactive Run-to- Condition-based Scheduled
Maintenance
RCA Failure
S-RCM
Maintenance Maintenance

Root Less expensive Very

cause forms of expen
Analysis
maintenance sive
mainte
nance
 SRCM Overall Effect
Reactive Run-to- Condition-based Scheduled
Maintenance Failure Maintenance Maintenance

CURRENT VOLUME AND COST

REDUCED VOLUME AND COST

WORK
Maximise CBM.
VOLUME Challenge TBM.
M/Hrs
Identify BM (where there is no
production HSE or secondary damage
consequences)

COST OF MAINTENANCE
 Where S-RCM fits in.

Risk & Reliability Management

Maintenance Process
 Applying best practice in SRCM can
Bridge gaps

Lubrication

Alignment
Performance

Spare Policy
Seal Design

Time
Risk and Reliability
Management
PRO-ACTIVE ACTIONS
+ PREVENTIVE MAINTENANCE
+ REDESIGN

CONDITION MONITORING
+ INSPECTION
+ TESTING

Balanced
Risk Activity DETERMINE
TASKS
S-RCM

S-RBI
RRM
Cost Effective
IPF Maintenance including breakdown
S-RCM & THE MAINTENANCE PROCESS

Equipment
Data List

Historic Data
SRCM
Initial S-RCM
Analysis RCA
Investigate/Redesign
Recommendations

MMS & Indiv.

PM Tasks
List

Feedback
MTCE Mgt RM Job
System Requests
Improve
Reliability
&
Availability

RM & PM Jobs Plan &

Analysis Schedule
Jobs
Compliance Execute Jobs
Ops & Mtce
S-RCM PROCESS
S-RCM Process

No maintenance case Optimised Case

Identify dominant Identify tasks

modes of failure to prevent or (POC)
reduce consequences

Failure
Consequences
Rate

Criticality Determine impact (PONC/ETBC)

(matrix) on criticality

(PONC/ETBF) Keep the cost

(MEI)
effective tasks
Workshop Preparation

Team Members
Facilitator
Operations Representative - explain how the unit is
operated and used
Mechanical Representative - idea on numbers of failures,
modes of failures, costs and duration of repairs
Instrument Representative - idea on numbers of failures,
modes of failures, costs and duration of repairs
Electrical Representative - idea on numbers of failures,
modes of failures, costs and duration of repairs
Inspection - only required for specific concerns
Chemical/Process Engineers - only required for specific
concerns
 S-RCM WORK SHOP
SYSTEM FUNCTION : RETURN CONDENSATE TO BOILER
SYSTEM FUNCTION FAILURE : NOT ABLE TO RETURN
CONDENSATE TO BOILER

SYSTEM FAILURE CONSEQUENCE PM TASK

FUNCTION EFFECT
DUMP VALVE FAIL HIGH CONDUCTIVITY LOST OF BOILER INSPECT EVERY 3
TO OPEN CAUSING YEAR
BOILER CORROSION
DEAERATOR HIGH CONDUCTIVITY LOST OF BOILER INSPECT EVERY 8
INTERNAL FAIL CAUSING YEAR
BOILER CORROSION
DOSAGE PUMP FAIL HIGH CONDUCTIVITY LOST OF BOILER CHANGE L/O EVERY
CAUSING YEAR
BOILER CORROSION
BEARING PUMP/ PUMP TURBINE LOST OF CHANGE L/O EVERY
TURBINE FAIL STUCK CONDENSATE 2 YEARS & CHECK
VIBRATION EVERY 3
MONTH
TURBINE FAIL TO PUMP STOP LOST OF OST/TRIP/TTV LEAK
DRIVE PUMP CONDENSATE TEST
 S-RCM WORK SHOP
SYSTEM FUNCTION : PROVIDE ELECTRICAL POWER 12 MW
FUNCTION FAILURE : NOT ABLE TO PROVIDE ELECTRICAL
POWER 12 MW

SYSTEM FAILURE CONSEQUENCE PM TASK

FUNCTION EFFECT
FOULING SURFACE CONDENSOR REDUCE POWER CLEAN THE
REDUCE CAPACITY GENERATION CONDENSOR BASED
CAPACITY ON THE
PERFIMANCE
 CONCLUSION
S-RCM IS SIMPLER AND FASTER COMPARE TO THE
RCM
S-RCM DEVELOP PM TO PREVENT FAILURE
S-RCM CAN BE USED TO OPTIMIZE PM
S-RCM CAN OPTIMIZE MAINTENANCE COST
IT REQUIRED MANAGEMENT COMMITMENT
S-RCM REQUIRED THE BEST PEOPLE
S-RCM REQUIRED EVALUATION PERIODICLY
 RECOMMENDATION
USE S-RCM TO OPTIMIZE OUR CURRENT PM
PURCHASE THE S-RCM SOFTWARE INCLUDING TRAINING
DEVELOP TASK FORCE TO EXECUTE THE S-RCM