Reliability Centered Maintenance to Minimize Integrity Failure

Minimizing the integrity failures of ageing plants and equipments

As we know, not one solution fits all for maintenance techniques application, the question is how to determine which maintenance type to chose for particular equipment and its components. And answer is by implementing risk base Maintenance program

Risked base maintenance or reliability centered maintenance is strategy to optimize the maintenance program of a company using cost-effective maintenance techniques.

RCM process has five simple steps.

First step of which is to calculate System risk number that include consideration of safety issue, regulatory compliance, product quality, process throughput and operation cost for identified component of process area.

Second step is to determine operation risk number that can be done bas on analyzing that if this part of process fails what will be consequence? Is it in series and will stop the process for more than 24 hours? or it is important part and failure will cause 8 hr lost? Or if it fails it can be bypassed without negative consequence or if it fail there will be no effect to overall system. We will rank it 0 to 10 where o when no consequence and 10 mean it will cause more than 24 hours loss.

Third step is simple is to determine asset risk ranking by multiplying System risk number with operational risk number.

Forth step is to determine failure probably factor base on reactive maintenance performed. Where annual reactive pose lower risk compare to quarterly.

Fifth step is to calculate maintenance priority number by multiplying Asset risk number with failure probability factor.

In situations where equipment failure is inevitable, the structured RCM process will ensure a maintenance strategy that will minimize or eliminate the consequences.

The central problem addressed by the RCM process is how to determine which scheduled maintenance tasks, if any, should be assigned to equipment, and how frequently