Benefits of Asset Management and RCM in Power Generation Rev 3

8/10/2019 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

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 itsImportance

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 )

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Maintenance Methodologies andPhilosophies

&Maintenance Program



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Types of Maintenance Methodologies

Failure Based or Break downMaintenance FBM

Scheduled or PreventiveMaintenance PM

Predictive MaintenancePDM

Proactive MaintenancePAM



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Strategic Maintenance Philosophies

Condition BasedMaintenance CBM

Reliability CenteredMaintenance RCM

Total ProductiveMaintenance TPM



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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 performancetargets. It seeks the optimal mix of condition-based, time-

based, and run-to-failurestrategies

All equipment across which maintenance money is spent

(machinery, electrical, instrument, stationary equip, & civil) issubject 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



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Maintenance Program Adjustments



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Benefits of RCM

RCM benefits can only be achieved when recommended tasks coming

from an RCM study are actually transferred into actionable work,

whether intoPMs

, 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


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RCM Business Objective

MAINTENANCE EFFORT

COST

NOT ENOUGH EFFORT OPTIMUM TOO MUCH EFFORT

TOTAL COST

TYPICALLY

UNDER MAINTAINED

TYPICALLYOVER MAINTAINED

fire fighting

mode

comfortmode

RISKBASED

RCM PREVENTIVE

MTCE. COSTS

COST OF NON-

AVAILABILITYPROD. LOSS + BREAKDOWN



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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 .



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Equipment

Strategy Analysis

Turnaround Strategy

Maintenance StrategyFunctional/

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

ProcureDesign

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

OptimizationStrategies

Commission

Specific

Equipment

Plans



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Standards for Power Plants

RCM Implementation

What standards are behind RCM

MIL STD 785B ( Reliability Programs for Systems andEquipment 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 )



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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 .



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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


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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 ?


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RCM Implementation

Step by Step Approach

Complete review of PM Preventive Maintenance and reliabilityprogram 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 .



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Specific

Equipment

Plans

(SEP)

Equipment

Strategy Analysis

Turnaround Strategy

Maintenance StrategyFunctional/

Criticality

Analysisand/or

Risk Based

Inspection

Spare Parts Strategy

Training Strategy

How is Criticality Analysis Used in RCM ?

The combination of these

strategies form theSpecific 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)

Frequency

ofFailure

10 20 30 40 50

1

2

3

4

5+

Incr

easin

gCrit

icalit

y

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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 .



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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



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RCM Implementation & ETD SupportConclusions

RCM is a Powerful maintenance Philosophy and as such it itsimplementation 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.



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Thank-you for Sharing Knowledge

European Technology Development Ltdwww etd-consulting com