Reliability Centered Maintenance (RCM) Applied in Maximo

1. GoMaximo 2018 Reliability Centered Maintenance (RCM)Applied in Maximo Power Generation Company of Trinidad & Tobago Ltd., By Ian Ramsingh

2. PowerGen • Total installed capacity of 1008 MW • Three Locations - • PEN 243 MW • PTLS765 MW • POS - Retired

3. Maximo at PowerGen • Maximo History • Maximo version 2.1.1 – 1995 • Maximo version 7.5.0.8 & Maximo 7.5.1 Oil & Gas - • Maximo version 7.6.0.6 & Maximo 7.6.1 Oil & Gas – October 2017 • Maximo Scheduler 7.5.2 • Interface to Financial Application • Multi site – four (4) sites

4. SWOT ANALYSIS - PowerGen STRENGTHS THREATS Reliability Culture Competition Maximo Asset & Location History Experienced, Valued Employees Aging Assets Improved Asset Reliability & Availability Employees Retiring Knowledge Transfer New Business OPPORTUNITIES WEAKNESS

5. Agenda • Reliability Centered Maintenance (RCM) • How RCM can be applied in Maximo Oil & Gas • Benefits

6. RCM - Maximo RCM defined? Moubray(1991) defined RCM as “a process used to determine what must be done to ensure that any physical asset continues to function in order to fulfil its intended function in its present operating context.” RCM focuses, not on the system hardware itself rather, on the system function i.e. function based approach The overall goal of Reliability Centered Maintenance (RCM) is to improve the economic posture of a business operation by improving the cost-effective application of maintenance resources (epri.com)

7. Reliability Centered Maintenance (RCM) Why RCM is Required? • Operating restrictions that limit maintenance outages • Change in Operating Mode • Impact of Asset Failures on Critical Operating Systems • Utilities - search new ways of optimizing the maintenance management of their operating assets • Reliability • Availability • Risk & Consequence Identification as a result of Failure • Financial Impact of Failures • HSSE Issues • Safe and Reliable Operating Assets • Business Continuity • Political Implications • Reduction in Reactive Maintenance • Lessons Learned

8. Reliability Centered Maintenance (RCM) - Program The RCM analysis carefully considers the following questions: • 1. What does the system or equipment do and what is its function? • 2. What functional failures are likely to occur? • 3. What are the likely consequences of these functional failures? • 4. What can be done to reduce the probability of the failure, identify the onset of failure or reduce the consequences of the failure?

9. Reliability Centered Maintenance (RCM) • A successful RCM project requires two organizational considerations. • First, RCM project requires leadership and facilitation by someone who is well versed in details of the 7-step system analysis methodology. • Second, it requires the commitment of a dedicated team of qualified technicians & supervisors who know the equipment and plant systems and how they operate together to produce the product • The first step to the successful implementation of the RCM technique is to ask seven basic questions about the asset that the methodology is intended to be applied on. (Moubray, 1991):

10. Seven key steps of the RCM process FMECA

11. Reliability Centered Maintenance (RCM) Elements of RCM • Identify the criticality of Operating Locations and the System its part off. • Identify Failure Modes associated with these critical assets at the critical operating locations • Determine optimal PM frequencies • Develop PM tasks that address these Failure Modes • This analysis is used to determine appropriate maintenance tasks to address each of the identified failure modes and their consequences. • A rigorous RCM analysis is based on a detailed Failure Modes and Effects Critical Analysis (FMECA) and includes probabilities of failure and system reliability calculations. Management is all about executing tasks. Strategic Maintenance is all about deciding what tasks should be executed based on RCM Program Lessons Learned being communicated throughout the organization

12. Results - Reliability Centered Maintenance Program RCM PM CONDITION BASED REACTIVE - RTF CONDITION MONITORING – REAL TIME PdM

13. Reliability Centered Maintenance Elements – Maximo Oil & Gas Item Master Location (Oil) Item / Asset Specifications Assets (Oil) PM / PdM / CDM Program Defects (Oil) Classifications Job Planning Tools Procurement Service Items Scheduling Action Items Problems & Solutions Failure History Lessons Learned People & Qualifications Asset & Location Cost Roll up Safety Permits & Certificates Investigations Incident Management Asset & Location Criticality FMECA Management of Change (MoC) Risk Assessment

14. Failure Modes - Maximo Oil & Gas Failure - Means Functional Failure occurs when an item is no longer capable of performing its intended function. Failure Mode Defined: Manner in which an item fails • The part + problem with the part + reason for failure • Failure Mode and Effects Analysis (FMEA) and Failure Modes Effects and Criticality Analysis (FMECA) are methodologies designed to identify potential failure modes for a product or process. • To assess the risk &consequencesassociated with these failure modes • To rank the consequencesin terms of importance and to identify and carry out actions to address the consequences

15. Critically Ranking of Failure Modes Loss of Functions ? Impact HSSE ? Yes Impact Critical Operations Yes Impact Financial Operations or Political or Customer relations Yes Is the Function Protected by existing PM Tasks Yes Non – Significant Function Significant Function At this Stage Elimination of effective maintenance

16. Operating Location :FMECA Summary of Failure Details

17. Failure Mode details Capturing the Failure Modes, the Function and the Effects Identifying the Risk & Consequences Operating Procedure Policy, PM Program

18. Maximo Oil & Gas - Location Risk Assessment Function Risk & Consequences Maintenance & Operating Policies

19. Maximo Oil & Gas Failure Reporting Failure Analysis Safety Critical

20. Maximo Oil & Gas – Work Order ( Oil & Gas) > Action Items Identification of Action Items – such as modify PM tasks to address failure

21. Reliability Centered Maintenance (RCM) Value derived of an RCM Program in Maximo Oil & Gas • More Effective Job Planning Tasks • Documented technical basis for identified tasks • Reduction in PM induced corrective maintenance actions • Reduction in the costs of PM Tasks • Improved service reliability or reliability program • Improved use of man power (resources – right personnel for the right job) • Reduction in the frequency and severity of catastrophic equipment failures • Customer Satisfaction

22. Return on Investment (ROI) RCM will Focus on DATA QUALITY • Improved • Work Management • PM/ PdM Program • Job Planning • Procurement Practices • Inventory Management • Incidents (Oil & Gas) • Investigations ( Oil & Gas) • MoC (Oil & Gas) Corporate GOALS Customer Satisfaction Employee Morale Profits > Employee Bonus Reliability Program Key Stake Holder Satisfaction Asset Management Strategy

23. RCM in Maximo Oil & Gas Thank You References Mainsaver.com Epri.com IBM.com Reliability web.com Moubray, 1991 Reliability-Centered Maintenance, F. Stanley Nowlan and Howard F. Heap, 1978, United Airlines. Questions ????