Operations & Maintenance Engineering RCM Handbook: Eni S.p.A. Exploration & Production Division

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Exploration & Production Division 22011.MAN.GEN.RWP 00 1 of 124
Operations & Maintenance Engineering

RCM HANDBOOK
ABSTRACT
This document completes the RCM Guidelines document, setting the Procedures for the application of the
Reliability Centered Maintenance methodology to production facilities (off shore, onshore, pipelines) during the
Concept definition, Execution and Production working phases.
00 Final Issue Fabio Cadelli Vanzini 19 Dec. 03

REV REASON FOR ISSUE PREPARED VERIFIED APPROVED DATE
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Eni S.p.A. Document Class: Doc. N°. Rev. Page
FOREWORD
This document completes the Reliability Centered Maintenance (RCM) Guidelines document [21] and therefore it is
integral part of the Technology Management System (TMS) [4]. It describes the procedures and the corresponding
tasks necessary to implement the activities foreseen in Reliability Centered Maintenance (RCM) programme.
This document presents high-level procedures that shall be adapted and detailed for the plant under development
in accordance with the extension and the depth of the RCM programme. As stated in the RCM Guidelines
document, this depends on the facility complexity, its importance in terms of capital expenditure, the development
phase, and shall be carefully evaluated and scheduled during the project planning.
Typically the following steps should be carried out in order to fulfil a complete RCM programme:
· Functional analysis – definition of the main functions of each equipment and each Facility Functional Unit
(FFU);
· Reliability, Availability, Maintainability and Safety (RAMS) data collection - identification of the equipment failure
modes and their RAMS parameters, such as the failure rate, failure descriptor, failure probability per demand,
active repair time, unavailability, failure causes;
· Facility modelling – functional breakdown of the facility into main functions, (i.e. production, storing, power
generation, distribution, etc) and sub functions (i.e. relieving, controlling, monitoring, containment, etc.)
· Maintainability Analysis – in order to determine the downtime for each equipment and failure mode a set of data
should be collected and analysed, such as fault location time, logistic delay time, active repair time, test time,
etc.;
· Failure Mode – “a qualitative method of reliability analysis which involves the study of the failure modes which
can exist in every sub item of the item and the determination of the effects of each failure mode on other sub
items of the item and the required functions of the item” in terms of safety, environment and production;
· Criticality Analysis – “a quantitative analysis of events or faults and the ranking of these in order of the
seriousness of their consequences” in terms of Criticality vs. Safety, Production, Environment. Severity indexes
have to be set depending on both a Severity Classification and a Risk Matrix setting Acceptability Criteria;
· Maintenance Strategies definition – definition of the best type of maintenance applicable (preventive time/cycle
based, preventive on-condition based, run to failure maintenance) to each item of equipment on the basis of
both the Criticality Ranking (as result of the Criticality Analysis) and other selected parameters, i.e. local Law or
Constraint, asset value, cost/benefit of preventive maintenance, capability to early detect the failure weak
signals;
· Availability Analysis – prediction of the facility performance in terms of Production Availability. This takes into
account both the facility reliability parameters and the maintainability parameters as result of the maintainability
analysis.
In addition, specific requirements as appropriate in order to get RAMS data shall be set for Equipment/Systems
Manufacturers at the bid stage, and the definition of availability and maintainability targets should also be
evaluated.
The procedures address all these activities and guide the involved Work Team step by step.
The RCM programme should be maintained “live” and updated in all phases of the facility life-cycle, in particular
when major facility modifications/revamping will occur, in order to pursue the “continuous improvement” process as
the basis of the facility life cycle cost optimisation.
Beside the best applicable “maintenance form”, the RCM programme establishes the management of spare parts
for both operational and capital/insurance spares, in connection with all the analyses performed during the program
development. The level of analysis detail for spare parts definition greatly differs, depending on the geographical
location of the facility, but as general rules a specific spare parts program shall be planned starting from results of
the RCM programme and, like this, maintained alive and optimised along with the facility life-cycle.
Coordination between all the RCM related analyses, such as HAZOP and Quantitative Risk Analysis (QRA) as well
as all other HSE-QR analysis, must be assured for consistency along with the field development. Particular
attention should be given to ensure that the same RAMS parameters are used for the analyses.
As the RCM Guidelines, this Handbook covers the Concept Definition, Execution and Production working phases of
the facility life cycle. While the definitions of the Concept Definition phase and the Execution phase correspond to
those described in the E&P OPDS Handbook [3], the definition of Production phase not only refers to
Commissioning and Production Start up but it is extended during the running phase of the plant, until the
decommissioning of the plant starts.
TABLE OF CONTENTS
1. INTRODUCTION 14
1.1 General 14
1.2 References 14
1.3 Handbook objective and scope 16
2. RELIABILITY CENTERED MAINTENANCE (RCM) HANDBOOK 17

2.1.1 Handbook structure 18
3. CONCEPT DEFINITION PHASE 19
3.1 RCM methodology procedures for the Concept Definition Phase 19
3.2 Project Basis 20

3.2.1 Scope 20
3.2.2 Procedure 20
3.2.3 Input 21
3.2.4 Output/Deliverables 21
3.2.5 Tools 21
3.2.6 Work team and competences 21
3.3 Risk Acceptance Criteria and Availability Targets 22

3.3.1 Scope 22
3.3.2 Procedure 22
3.3.3 Input 25
3.3.5 Tools 26
3.4 RAMS Data collection 27

3.4.1 Scope 27
3.4.2 Procedure 28
3.4.3 Input 44
3.4.5 Tools 44
3.5 Model preparation 45

3.5.1 Scope 45
3.5.2 Procedure 45
3.5.3 Input 45
3.5.4 Output/deliverables 45
3.5.5 Tools 45
3.6 Maintainability Analysis (MA) 46

3.6.1 Scope 46
3.6.2 Overall Maintainability Analysis procedure 48
3.6.3 Input 54
3.6.5 Tools 54
3.7 Failure Mode and Effect Analysis (FMEA) 55

3.7.1 Scope 55
3.7.2 Procedure 56
3.7.3 Input 58
3.7.5 Tools 59
3.7.6 Work Team and competences 59
3.8 Criticality Analysis 60

3.8.1 Scope 60
3.8.2 Procedure 61
3.8.3 Input 62
3.8.4 Output 63
3.8.5 Tools 63
3.9 Availability Analysis 64

3.9.1 Scope 64
3.9.2 Overall Availability Analysis procedure 64
3.9.3 Input 67
3.9.5 Tools 67
3.9.7 Fault Tree Analysis (FTA) 68
3.10 O&M policies 70

3.10.1 Scope 70
3.10.2 Overall O&M Policy procedure 70
3.11 Expected results 76
3.12 Input to the Execution phase 76

3.12.1 O&M Equipment Requirements Definition 76
3.12.2 Guidelines For O&M Engineering 77
4. EXECUTION PHASE 80
4.1 RCM methodology procedures for the Execution Phase 80

4.1.1 System Breakdown 80
4.1.2 O&M Results from the Concept Definition phase 81
4.2 Contractors/Suppliers data 82

4.2.1 Scope 82
4.2.2 Procedure 82
4.2.3 Input 82
4.2.5 Tools 82
4.3 Maintainability Analysis – revision and integration 83

4.3.1 Scope 83
4.3.2 Procedure 83
4.3.3 Input 83
4.3.5 Tools 83
4.4 Failure Mode and Effects Analysis - revision and integration 84

4.4.1 Scope 84
4.4.2 Procedure 84
4.4.3 Input 84
4.4.5 Tools 85
4.5 Criticality Analysis – revision and integration 86

4.5.1 Scope 86
4.5.2 Procedure 86
4.5.3 Input 87
4.5.5 Tools 87
4.6 O&M Policy revision and integration 88

4.6.1 Scope 88
4.6.2 Procedure 88
4.6.3 Input 91
4.6.5 Tools 91
4.7 Availability Analysis – Plant and systems 92

4.7.1 Scope 92
4.7.2 Procedure 92
4.7.3 Input 93
4.7.5 Tools 93
4.8 O&M Tasks and procedures for overall plant 95

4.8.1 Scope 95
4.8.2 Procedure 95
4.8.3 Input 96
4.8.5 Tools 96
4.9 Overall O&M system 97

4.9.1 Scope 97
4.9.2 Procedure 97
4.9.3 Input 97
4.9.5 Tools 98
4.10 Expected Results 98
4.11 Synthesis of activities and Responsibility Matrix for the Execution Phase 99
5. PRODUCTION PHASE 101
5.1 RCM methodology procedures for the Production Phase 101
5.2 Contractual Maintenance Strategy Assessment 102

5.2.1 Scope 102
5.2.2 Procedure 102
5.2.3 Input 102
5.2.5 Tools 102
5.3 Maintenance data 103

5.3.1 Scope 103
5.3.2 Procedure 103
5.3.3 Input 103

5.3.5 Tools 103
5.4 Operation Data 104

5.4.1 Scope 104
5.4.2 Procedure 104
5.4.3 Input 104
5.4.5 Tools 104
5.5 RAMS Data upgrade 105

5.5.1 Scope 105
5.5.2 Procedure 105
5.5.3 Input 105
5.5.5 Tools 105
5.6 Maintainability Analysis upgrade 106

5.6.1 Scope 106
5.6.2 Procedure 106
5.6.3 Input 106
5.6.5 Tools 106
5.7 Criticality Analysis 107

5.7.1 Scope 107
5.7.2 Procedure 107
5.7.3 Input 108
5.7.5 Tools 109
5.8 Failure Mode and Effects Analysis Upgrade 110

5.8.1 Scope 110
5.8.2 Procedure 110
5.8.3 Input 111
5.8.5 Tool 111
5.9 Availability Analysis – upgrade and comparison 112

5.9.1 Scope 112
5.9.2 Procedure 112
5.9.3 Input 113
5.9.5 Tools 113
5.10 O&M Policy revision 114

5.10.1 Scope 114
5.10.2 Procedure 114
5.10.3 Input 115
5.10.5 Tools 115
5.11 Revision of O&M Tasks and procedures for overall plant 116
5.11.1 Scope 116

5.11.3 Input 116
5.11.5 Tools 116
5.12 Overall O&M system revision 117

5.12.1 Scope 117
5.12.3 Input 117
5.12.5 Tool 118
5.12.7 RCM Activities Conclusion 118
5.13 Expected Results 118
5.14 Synthesis of activities and Responsibility Matrix for the Production phase 118
6. APPENDIX 121
APPENDIX MA1: ACTIVITIES TO TAKE A REFERENCE ITEM OUT OF SERVICE 122
APPENDIX MA2: ACTIVITIES TO BRING A REFERENCE ITEM INTO SERVICE 124

ACRONYMS
AA Availability Analysis
ACMT Active Corrective Maintenance Time
AIChE American Association of Chemical Engineers
AMT Active Maintenance Time
AOT Activities Overlapping Time
APMT Active Preventive Maintenance Time
ART Active Repair Time
BD Blow Down
BIST Time to Bring Into Service a piece of equipment
BOM Bill Of Materials
BOPD Barrel of Oil Per Day
BOPDe Barrel of Oil Per Day of equivalent gas
C Contractors
CA Criticality Analysis
CCF Common Cause Failure
CCR Central Control Room
CM Corrective Maintenance
CMMS Computerised Maintenance Management System
CMT Corrective Maintenance Time
CONCAWE Conservation of Clean Air and Water in Europe
CT Check-out Time
DCS Distributed Control system
E&P Exploration and Production
EIREDA European Industry Reliability Databank
EGIG European Gas Pipeline Incident Data Group
ENF Expected Number of Failures
EP Engineering and Procurement
EPC Engineering, Procurement and Construction
EPF Engineering, Procurement and Fabrication
ESD Emergency Shut Down
ET Operation & Maintenance Engineering Team
FCT Fault Correction Time
FFU Facilities Functional Unit
FEED Front End Engineering Design
FLDT Fault Location/Diagnosis Time
FM Failure Mode
FMEA Failure Mode and Effects Analysis
FPPD Failure Probability Per Demand
FR Failure Rate
FTA Fault Tree Analysis
HAZOP Hazard Operability Analysis
HSE Health, Safety and Environment
LD Logistic Delay
MA Maintainability Analysis
MEL Main Equipment List
MC Maintenance Contractors
MCS Minimal Cut Set
MT Maintenance Time
MTBF Mean Time Between Failure
MTTF Mean Time To Failure
MTTR Mean Time To Repair
NPRD Nonelectronic Part Reliability Data
O&M Operating and Maintenance
OREDA Offshore Reliability Data
OT Operation Team
OTM Operational Time
P&ID Piping & Instrumentation Diagram
PFD Process Flow Diagram
PM Preventive Maintenance
PMT Preventive Maintenance Time

POG Process Operator Guide
RAC Reliability Analysis Centre
RAMS Reliability, Availability, Maintainability and Safety
RBD Reliability Block Diagram
RCM Reliability Centered Maintenance
RI Reference Item
S Suppliers
SD Planned Shut Down
SI System Integrator
SU Start-Up
SoW Scope of Work
TD Technical Delay
TE Top Event
TOST Time to Take Out of Service a piece of equipment
GLOSSARY
Active Corrective That part of the active maintenance time during which actions of corrective
Maintenance Time maintenance are performed on an item, excluding logistic delay.
(ACMT)
Active Maintenance That part of the maintenance time during which a maintenance action is performed on
Time (AMT) an item, either automatically or manually, excluding logistic delay; it considers both
preventive and corrective active times.
Active Preventive That part of the active maintenance time during which actions of preventive
Maintenance Time maintenance are performed on an item, excluding logistic delay.
(APMT)
Active Repair time The average time (hours) required to repair and return the item to a state it is ready to
(ART) resume its function. This excludes the time to detect failure, time to isolate the
equipment from the process before repair, delay and waiting for spare parts or tools,
and any time after the repair has been completed if the item is not put into service
immediately. Time for testing is included in ART.
Availability (A) The ability of an item to be in a state to perform its function under given conditions at a
given instant of time or over a given time interval, assuming that the required external
resources are provided. In other words the probability of functioning of a system or
item at a given time; it also expresses the percentage of hours spent in the good
status versus the system/item expected functioning (sum of the hours spent in good
and failed status). Failed status considers both the no functioning due to failures and
due to preventive maintenance. It is often defined as A(t).
Boundary The interface between an item and its surroundings.
Calendar Time The interval of time between the start and end of data surveillance for a particular
item.
Check-out Time (CT) That part of the active maintenance time during which function check-out before
restart is performed
Company The Company is the party that initiates the project and ultimately pays for its design
and construction. The Company will generally specify the technical requirements.
The Company may also include an agent or consultant authorised to act for, and on
behalf of, the Company.
Contractor The Contractor is the party that carries out all or part of the design, engineering,
procurement, construction/fabrication, commissioning or management of a project, or
operation or maintenance of a facility. The Company may undertake all or part of the
duties of the Contractor.
Corrective Maintenance The maintenance carried out after fault recognition and intended to put an item into a
(CM) state in which it can perform a required function.
Corrective Maintenance That part of the maintenance time during which corrective maintenance is performed
Time (CMT) on an item, including technical delays and logistic delays inherent in corrective
maintenance.
Deliverable The output from an activity and/ or process e.g. document, data, also called product.
Expected Number of The number of times the item is expected to fail over the specified lifetime.
Failures (ENF)
Facility A set of equipment used to perform a useful function for the EP business. Examples
connected with platforms are: production facilities, drilling facilities, accommodation
facilities. The term “Top Side Facilities” includes everything that is mounted on the
platform. For onshore plants, besides “production facilities” the term “utilities” is used
for auxiliary plants, subdivided into on-site and off-site.
Failure Mode (FM) One of the possible states of a faulty item leading to the loss of a specific item
function.
Failure Probability Per The probability of failure for an intermittent system or item, it is expressed in terms of
Demand (FPPD) number of failure versus the number of request of intervention (demands).
Failure Rate (FR) Failure conditional probability of an item, per unit of time; it can be interpreted as the
frequency of failure for the item; it is expressed in failures per hour (1/h). The
reciprocal is the Mean Time To Failures (MTTF).
Fault Correction Time That part of the active maintenance time during which fault correction is performed.
(FCT)
Fault Location/Diagnosis That part of the active maintenance time during which fault location and fault diagnosis
Time (FLDT) are performed.
Hazard and Operability Qualitative methodology that identifies possible deviations from the correct functioning
Analysis (HAZOP) of the process and of the plant services, analysing moreover the consequences of
such anomalies and the actions to be taken to limit them to the smallest possible area.
Logistic Delay (LD) That accumulated time during which a maintenance action cannot be performed due
to the necessity of acquiring maintenance resources, excluding any administrative
delay. Note: logistic delays can be due to, for example, travelling to unattended plants,
pending arrival of spare parts, non standard tools, specialists, test equipment,
information and suitable environmental conditions.
Item The Item is any entity that can be individually identified by a TAG number in
accordance with the Coding Company’s Specifications.
Maintainability The probability that a given active maintenance action, for a item under given
conditions of use can be carried out within a stated time interval, when the
maintenance is performed under stated conditions and using stated procedures and
resources. It expresses the capability of a system or item to be quickly repaired.
Maintenance man-hours The accumulate durations of the individual maintenance times, expressed in hours,
used by all maintenance actions or over a given time interval.
Maintenance Policy Course or general plan of actions for maintenance
Maintenance Strategy Planning and directing of a maintenance policy
Maintenance Time (MT) The time interval during which a maintenance action is performed on an item either
manually or automatically, including technical delay and logistic delay.
Mean Time To Repair The expectation of the time to restoration (the time during which an item is in a down
(MTTR) state due to a failure).
On Condition A set of actions aiming to monitor the system or item performances in order to identify
Maintenance the incipient failures and to intervene with maintenance just before the failure occurs.
Operational Time (OT) The period of time during which a particular item performs its required function(s)
between the start and end of data surveillance.
Population The total number of items of one particular type in service during the period of the
event data surveillance.
Preventive Maintenance The maintenance carried out at predetermined intervals or according to prescribed
(PM) criteria and intended to reduce the probability of failure of the degradation of the
functioning of an item.
Preventive Maintenance That part of the maintenance time during which preventive maintenance is performed
Time (PMT) on an item, including technical delays and logistic delay inherent in preventive
maintenance.
Reference Item (RI) An assembly of Items that performs a specific function in the plant (e.g. main
equipments, control loops, protection loops, skids).
Reliability Probability of functioning of a system or item over a period of time t (Mission Time)
without any interruption. It is represented by R(t).
Supplier The Supplier (Manufacturer/Vendor) is the party that manufactures or supplies
equipment and services to perform the duties specified by the Company or Contractor.
Depending upon the frame agreement, Supplier will refer to the Contractor or directly
to the Company.
System An assembly of Items or Reference Items designed to perform a specific function.
Technical Delay (TD) The accumulated time necessary to perform auxiliary technical actions associated with
the maintenance action itself. TD will include time to take an equipment out of service
and time to bring it back into service.
Unavailability (Q) The complementary term of Availability (Q= 1-A).
SYMBOLS
Key Activity Activity that has to be performed during the Development

process
Non
Compulsory Non-compulsory activity performed only in a sub-set of
Activity projects
Preparation Activity in which the plan of the phase is set up or the

Activity Decision Support Package is prepared before submission
Milestone Milestones underline completion points in the work-flow,

not connected to critical decisions
Decision Critical and mandatory decision point
Non Compulsory Non compulsory decision point, performed only in a sub-

Decision set of projects
Text Input data and information
Text Output data and information
End point
1. INTRODUCTION
1.1 GENERAL
This Handbook expands the content of the Guidelines and presents the detailed procedures to be followed
for the implementation of Reliability Centered Maintenance programme during the design development of
new ENI E&P oil/gas production plants.
The approach is exhaustive, and covers all the tasks, which should be executed in order to apply the
complete RCM methodology to a specific project.
The Handbook refers to the methodology set in the RCM Guidelines and describes the activities presented in
the flow diagrams for the execution of the tasks of the methodology focusing on each phase, i.e. Concept
Definition, Execution and Production. Notwithstanding that, the suggested methodology is flexible enough to
be applied at different levels of details according to the complexity and importance of the project and is able
to consider such factors as local constraints, external constraints, development project risks and criticalities,
financial exposure, economics, CAPEX and OPEX, company and subsidiaries organisation. This flexibility is
highlighted in general terms in the next section and punctually discussed in the activities and tasks
descriptions,
Consequently, the extension and the depth of the RCM programme depend on the facility complexity, its
importance in terms of capital expenditure, the development phase, and shall be carefully evaluated and
scheduled during the project planning.
According to the RCM Guidelines, the Reliability Centered Maintenance (RCM) provides a methodology to
set the maintenance and operation policies and procedures on the basis of the reliability and the criticality (in
terms of safety, production and environment protection) of the equipment belonging to the plant.
In addition the analysis provides good insights for the optimisation of the plant design and organisation in
terms of system architecture, equipment maintainability, logistics.
The application of RCM starts in the Concept Definition design phase, supports the design in the subsequent
phases and “lives” with the plant during operation for a continuous optimisation of the Operation and
Maintenance procedures. The following Figure 1 recalls the system life-cycle covered by RCM approach, that
is longer than that defined in the E&P OPDS Handbook. Indeed, it starts from the Concept Definition phase
and continues during the running phase until the plant decommissioning starts (ref. RCM Guidelines).
The facility decommissioning represents the final milestone for the overall RCM programme, corresponding
to the RCM activities conclusion.
VALUE IDENTIFICATION VALUE REALISATION
End
Start
Gate 1 Concept Concept Gate 3 Hand Production Decommissioning
Evaluation Gate 2 Execution
Selection Definition over and close out
Project Realisation: Commissioning &

Selection of the
Discovery Evaluation- Project Finalisation: Construction, Well Production Start-up.
preferred development RCM activities
Screening basic, FEED, tendering operations, Pre- Project Evaluation and
option(s)
commissioning Close out conclusion
+ running phase till

decommissioning
Figure 1. RCM during the plant lifecycle
This document is managed by the O&M Engineering Team.
1.2 REFERENCES
Ref. Document Number Title
1 SVI.DMS.GL.0001 Guideline for Organizational charts
2 SVI.DMS.GL.0002 Guideline for Job Descriptions
3 SVI.PDS.MA.001.000 OPDS Handbook
4 SVI.TMS.MA.0001.000 TMS Handbook
5 20198.COO.GEN.SDS Rev. 1, Item Numbering and Coding System
March 1996
6 06215.DOC.GEN.SDS Rev. 3, Feb. Plant Functional Units
1996
7 BS 4778:Section 3.2:1991 / IEC Quality Vocabulary Part 3 Availability, reliability and
50(191): 1990 maintainability terms
8 KE00.00.000.AK.O.YP.0002.000 Operation and Maintenance philosophy

1
Rev. A02
9 KE01.00.000.AK.H.RT.0006.000 Risk Tolerability Criteria
1
Rev. P00
10 20550.MAN.MNU.PRG rev.0 07/03 AGIP Standard - Criteri di progettazione Metodologia
e linee guida per l’attribuzione della criticita’ agli item
d’impianto
11 22000.MAN.GEN.SDS Rev.00 Guideline for Maintenance Operating Procedures –
General Maintenance Processes
12 22001.MAN.GEN.RWP Rev.00 Guideline for Maintenance Operating Procedures –
Master Data Management
Preventive Maintenance
Corrective Maintenance
Modifications and Improvement
Extraordinary Maintenance
Maintenance Work Management
Maintenance Reporting
Maintenance Budget Management
Global Maintenance Service Management
21 22010.MAN.GEN.RWP Rev.00 Operations & Maintenance Engineering –Guideline
for RCM Implementation
22 ISO 14224:1999(E) Petroleum and natural gas industries - Collection and
exchange of reliability and maintenance data of
equipment
23 BS EN 13306:2001 Maintenance Terminology
24 OREDA 2002 Offshore Reliability Data – 4th Edition – Det Norske

Veritas – 2002
th
25 OREDA 97 Offshore Reliability Data – 3 Edition – Det Norske
Veritas – 1997
th
26 OREDA 92 Offshore Reliability Data – 2 Edition – Det Norske
Veritas – 1992
27 EGIG Gas Pipeline Incidents – European Gas Pipeline
Incident Data Group
28 CONCAWE Western European cross-country oil pipeline 30-
years performance statistic – February 2002
29 E&P Forum Hydrocarbon Leak and Ignition – Oil Industry
International Exploration & Production Forum
30 AICHE Guidelines Equipment Reliability Data – American
Institute of Process Engineers
31 RAC Reliability Data books – Reliability Analysis Center
32 EIREDA European Industry Reliability Databank 1998
33 IAEA Components Reliability Data for use in Probabilistic
Safety Assessment - International Atomic Energy
Agency Data bank 1988
1
These two references are quoted for example.
1.3 HANDBOOK OBJECTIVE AND SCOPE

This Handbook aims to describe in the form of procedures the methodological approach to support the
Operation and Maintenance Activities for oil and gas production plants set in the RCM Guidelines. In
particular the specific goals aim to:
1. Perform a preliminary Reliability Centered Maintenance analysis during Concept definition phase,
i.e. the selection of the best maintenance policies for main equipment of the plant on the basis of
their criticality; criticality is assessed by Reliability, Availability, Maintainability and Safety (RAMS)
studies.
2. Set the O&M Data and Analyses to be provided by Contractors and Suppliers during the
Execution phase,
3. Design the O&M strategy to be applied during the Execution phase in order to feed the CMMS
and POGs,
4. Organise an RCM overall strategy for the Production phase (i.e. data collection by maintenance
teams, feedback to the O&M Group, continuous monitoring and up date the Maintenance Plan by
the O&M Group).
The study covers all the development stages of the Project: Concept definition, Execution, and Production
[3] and follows the Production phase till the plant decommissioning, as described in the RCM Guidelines.
2. RELIABILITY CENTERED MAINTENANCE (RCM) HANDBOOK
The O&M methodology is based on the Reliability Centered Maintenance structure, aiming to select the
best maintenance policies for the plant items, allowing safe operations, protection of the environment and
the higher system availability compatible with maintenance costs.
This selection is supported by a criticality analysis that determines the items criticality with respect to
safety, production and the environment and ranks them accordingly.
As stated in the RCM Guidelines, the RCM methodology covers the three life cycle phases: Concept
Definition, Execution and Production.
The overall methodology is presented in Figure 2.
Figure 2. Overall structure of RCM methodology versus life-cycle phases

2.1.1 Handbook structure

The Handbook describes phase by phase the procedures to develop each activity foreseen in the phase.
Each activity is detailed according to the following structure:
- Activity denomination. It defines the title of the activity as reported on the RCM flow diagrams.
- Scope. It synthetically describes the scope of the activity and its development.
- Procedure. It describes the steps to be followed to implement the activity.
- Input. It lists the input data necessary to start the activity.
- Output/Deliverables. It lists the main deliverables of the activity in terms of reports, software, etc.
Examples of output data are reported in this section.
- Work team and competences. It points out the work team composition and the required
competences necessary to perform the activity. The work team is principally composed by the
following actors:
1. System Integrator (SI), who represents the Company, is the party that initiates the project
and ultimately pays for its design and construction. He generally specifies the technical
requirements. He is responsible for co-ordination, management and integration of all the
activities related to the project under development.
2. Contractor (C), that is the party that carries out all or part of the design, engineering,
procurement, construction/fabrication, commissioning or management of a project, or
operation or maintenance of a facility. He is responsible for the part of plant included in their
Scope of Work.
3. Supplier (S) (Manufacturer/Vendor), that is the party that manufactures or supplies
equipment and services to perform the duties specified by the Company or Contractor.
Depending upon the frame agreement, he is responsible for the equipment supplied to the
Contractors and/or the System Integrator.
Specific competences are developed within these categories. The principal of them are listed below.
1. O&M Engineering: these competences concern all the disciplines related to the O&M
activities. These skills are the normal background of the Maintenance Engineering
Superintendent and/or his team.
2. Process Engineering: these competences refer to all the disciplines related to the system
design.
3. Reliability, Availability, Maintainability and Safety (RAMS): these competences are specific to
the RAMS disciplines. The Maintenance Engineering Superintendent and/ members of his
team should have knowledge of the matter sufficient to supervise the work performed by
specialists (normally consultants).
4. Logistics: these competences concern all the activities related to logistics features.
5. Maintenance technicians (Company or Contractors): these competences concern all the
maintenance activities that are normally performed on the facilities and are the typical
background of the technicians.
3. CONCEPT DEFINITION PHASE
3.1 RCM METHODOLOGY PROCEDURES FOR THE CONCEPT DEFINITION PHASE

During the Concept definition phase, the O&M Project Team defines:
· the Maintenance Policies for the main assemblies of equipment (Reference Items - RIs)
according to the criticality of the function they perform, in terms of safety, environmental
protection and production;
· the availability of the plant considering both corrective and preventive maintenance time;
· directions for CMMS implementation and guidelines for Process Operator Guides (POG)
development.
The flow chart of the RCM methodology applied to the Concept definition phase is presented in Figure 3.
Preventive maintenance
Corrective maintenance
Risk
Acceptance Maintainability
Criteria analysis
O&M Input to
Project basis Model Criticality O&M
Failure Decision
Policies Execution
PFDs/ PI&D preparation analysis Logics Policies
Analysis Validated Phase
(FMEA)
RAMS data MA
Upgrading
Yes
Preliminary Yes Availability
Target Target
Availability analysis
Analysis
No No
Upgrading
OR
Design
review
CONCEPT DEFINITION PHASE
2
Figure 3. The RCM Methodology flow diagram (Concept Definition phase)
The following sections contain the Procedures detailing the various activities to be executed to apply the
RCM methodology to the Concept Definition phase.
2
Note: the Decision Logics box highlighted in the Flow diagram marks the importance of the application of these logics to the output information
of the Criticality Analysis in order to select the most appropriate maintenance policy for the installation. It is not a real decision point in the
common graph definition.
3.2 PROJECT BASIS
3.2.1 Scope
The Project basis represents a preliminary activity and concerns a collection of the Project information
that is necessary to apply the O&M activities during the Concept Definition phase.
The Company shall provide the scheduling of the Project and the Philosophy (for Safety, Operation &
Maintenance and Logistics) and information concerning the choices already made. The design
engineering team should provide all the relevant information concerning the facilities description, i.e.
Process Flow Diagrams (PFDs), Pipe and Instrumentation Diagrams (PI&D), protection systems
description (ESD, Cause-Effects diagrams) etc.
The O&M Team shall collate this information and keep it updated according to the revisions made by the
design engineering team.
3.2.2 Procedure
The following procedure shall be followed by the O&M Team to accomplish this activity.
1. Collect from the Company the project scheduling, the philosophy for Safety, Operation &
Maintenance and Logistics and the relevant documentation;
2. Collect from the design engineering team all the information concerning the facility description:
· Process Flow Diagrams (PFD)
· Pipe and Instrumentation Diagrams (PI&D)
· Protection System description (ESD, Cause-Effects diagrams, fire fighting, etc)
· …
3. Define a procedure to Archive the information collated in a way to be easy to use for System
Modelling and the following activities, and apply it all the time long the RCM system life,
4. Keep the information updated by utilising the existing system of transfer of data between
Company’s Departments (if existing and appropriate) or defining a dedicated channel for
transfer between the involved Departments.
For example, departments involved could be the design Engineering department, the logistics
department, etc.
5. Draft the Project Basis Report to feed the System Modelling activity
Example of Project Basis Report
The project basis Report shall be complete, consistent, self-standing and easy to read and use. A
example of typical Table of Contents of the report is provided below.
TABLE OF CONTENTS
1. GENERAL
1.1 Introduction
1.2 Scope
1.3 Glossary of special terms, symbols and abbreviations
1.4 Reference
1.4.1 Codes and Standards
1.4.2 Project Documents
2. FIELD DEVELOPMENT SCENARIO
2.1 Overall Development
2.2 General Field Data
2.3 General Design Data
3. PLANT/UNIT/EQUIPMENT FUNCTIONS AND OPERATIONAL PERFORMANCE
3.1 Offshore Facilities
3.2 Onshore Facilities
3.3 Pipelines
4. OPERATIONAL ENVIRONMENT
4.1 Frame of Reference
5. LOGISTIC ASPECTS
5.1 General

5.3 Onshore Facilities
6. OPERATION STRATEGY
6.1 General
6.2 Control systems
6.3 Onshore Plant Control Architecture
6.4 Offshore Plant Control Architecture
6.5 SCADA Philosophy
6.6 Fire & Gas Detection Philosophy
6.7 Overall Electrical Philosophy
6.8 Electrical Control Philosophy
6.9 Pipeline Operations
6.10 Metering and Allocation
6.11 Corrosion Prevention
6.12 Sulphur Management
6.13 Winter Operations
6.14 Documentation
7. MAINTENANCE STRATEGY
7.1 General
7.2 Objectives
7.3 Maintenance Requirements
7.4 Maintenance Management System
7.5 Information Management Systems
7.6 Assurance of Integrity and Availability
7.7 Safety Equipment
7.8 Spares Philosophy
7.9 Health Care Contracts with Individual Vendors
8. MANNING AND TRAINING
8.1 Manning
8.2 Training and Competence
9. ATTACHMENTS
3.2.3 Input
The main input data to this activity are the following:
· Project scheduling and philosophy
· Facility description
· PFD, PI&D,
· ESD description
· Cause-effects diagrams
· Fire fighting description
3.2.4 Output/Deliverables
The main deliverable of the activity is the Project Basis Report.
3.2.5 Tools
No specific tools are required for this activity.
3.2.6 Work team and competences

The System Integrator is in charge of this activity. O&M Engineering and Process Engineering
competences are required for this activity.
3.3 RISK ACCEPTANCE CRITERIA AND AVAILABILITY TARGETS
3.3.1 Scope
The scope of the Risk Acceptance Criteria activity is to set the Criteria that will be used in the Criticality
Analysis to assess the Reference Items failure modes with respect to safety, the environment and the
asset/production.
A Project Risk Matrix set the “acceptance” criteria to be applied in order to screen the critical items,
according to the general policy of the Company.
Qualitative indicators for the failure modes shall be defined.
Availability targets are set according to the general policy of the Company and referred to assess the plant
availability versus its operational performance.
Project Availability Targets have to be settled in compliance with the Availability Contractual
Requirements that must be satisfied by the system: in this perspective, it is important firstly to clearly
understand and interpret the Availability Contractual Requirements, secondly to define the objectives, the
assumptions and the boundary conditions of the successive Availability Analysis in order to exactly
matching the target specifications.
3.3.2 Procedure
The procedure to be followed for the definition of the Risk Acceptance Criteria and the availability
standards is described below.
1. Collect Company’s risk tolerability criteria for the overall project;

2. Select those criteria relevant to the RCM approach and adapt them to the Criticality Analysis
needs;
3. Define Project Risk Matrixes setting acceptance Criteria to be applied in order to screen the
critical items with respect to safety, the environment and the asset/production;
4. With reference to these criteria, define qualitative indicators for the failure modes in terms of:
· frequency of occurrence of the failure mode (not expected/rare/…/frequent),
· effects in terms of safety and environmental protection (negligible/slight/…/major),
· effects in terms of production/asset (negligible/slight/…/major).
5. Collect Company’s availability requirements for the project and defined according to the
general policy of the Company;
6. Define project availability targets for comparison with actual plant availability estimation
Example of Severity and Criticality Matrixes
An example of Severity and Criticality Matrixes with respect to safety, the environment and the
asset/production is given below. These Matrixes have been derived from reference [9].
# Description
0 No effects
1 No effect on work performance but may involve slight injury or health effects (e.g. first
aid case) and employee returns to work the same day
2 Low health effects or slight injury (Lost Time Injury) – Affecting work performance, such
as restriction to activities (Restricted Work Case or Occupational Illness) or a need to
take a few days to fully recover (lost Work Case), e.g. food poisoning.
3 Major injury or health effects (including Permanent Partial Disability and Occupational
Illness) – Affecting work performance in the longer term, such as a prolonged absence
from work. Irreversible health damage without loss of life, e.g. noise induced hearing
loss, chronic back injuries, sensitisation, hand/arm vibration syndrome, repetitive strain
injury.
4 Permanent Total Disability or one to three fatalities – From an accident or occupational
illness. Irreversible health damage with serious disability or death, e.g. corrosive burns,
heat stroke, cancer (small exposed population).
5 Multiple fatalities – From an accident or occupational illness (e.g. chemical
asphyxiation or cancer) large exposed population.
Table 1. Safety Severity Matrix

# Description
0 No effects
1 Slight Damage – No disruption to operation (cost less than 100,000 USD)
2 Minor Damage – Brief disruption (cost less than 1,000,000 USD)
3 Local Damage – Partial shutdown (can be restarted, costs up to 10,000,000 USD)
4 Major Damage – Partial operation loss (2 weeks shutdown, cost up to 100,000,000
USD); Major inquiry for the cost of damage.
5 Extensive damage – Substantial or total loss of operation (costs in excess of
100,000,000 USD); Extensive inquiry for the cost of damage.
Table 2. Asset/Production Severity Matrix
# Description
0 No effects
1 Slight effect – Minor environmental damage. No financial consequences
2 Low effect – Sufficiently large contamination or discharge to damage the environment,
but no lasting effect. Single breach of statutory or prescribed limit, or single complaint.
3 Localised effect – Limited discharges affecting the neighbourhood and damaging the
environment. Repeated breaches of statutory or prescribed limit, or many complaints.
4 Major effect – Severe environmental damage. The company is required to take
extensive measures to restore the damage environment. Extended breaches of
statutory or prescribed limits, or widespread nuisance.
5 Massive effect – Persistent severe environmental damage or severe nuisance
extending over a large area. Loss of commercial, or recreational use or nature
conservancy resulting in major financial consequences for the Company. Ongoing
breaches well above.
Table 3. Environment Severity Matrix

Acceptability criteria for the event criticality are set in the following Risk matrixes.
Consequence Increasing Annual Frequency

0 A B C D E
<10-6 10-6<=IAF<10-4 10-4<=IAF<10-3 10-3<=IAF<10-1 10-1<=IAF<1 >=1
Severity Could occur but Has rarely Has occurred Has occurred in May occur Will occur
People Asset Environment Reputation has not occurred in E&P several times in operating several times a routinely in an
Rating
necessarily industry E&P industry Company year in operating individual plant
been observed Company
in E&P industry
0 Zero Injury Zero Damage Zero Effect Zero Impact 00 0A 0B 0C 0D 0E
1 Slight Injury Slight Damage Slight Effect Slight Impact 10 1A 1B 1C 1D 1E
2 Minor Injury Minor Damage Minor Effect Major Impact 20 2A 2B 2C 2D 2E
Considerable 3A
3 Major Injury Local Damage Local Effect 30 3B 3C 3D 3E
Impact (1)
Single Major National 4B
4 Major Damage Major Effect 40 4A 4C 4D 4E
Fatality Impact (2)
Major
Multiple Extensive Massive
5 International 50 5A 5B 5C 5D 5E
Fatalities Damage Effect
Impact
(1) With respect to the safety of members of the general public onshore, hazards graded as 3A shall be treated as Medium Risk.
(2) With respect to the safety of members of the general public onshore, hazards graded as 4B shall be treated as High Risk.
Criticality Tolerable Risk. No further impact reduction measures are necessary.

3 Monitor performance and manage for continuous improvements.
Criticality Compulsory impact reduction required. Risk is tolerable when appropriate

2 control measures have been identified and implemented.
Intolerable without detailed justification. Does not satisfy initial screening

Criticality criteria. Additional risk reduction measures required. Justifiable if compliance
1 with ALARP principle and individual and societal risk criteria are
demonstrated.
Figure 4. Risk Matrixes setting Acceptability Criteria

Example of Availability Targets
Availability Targets are usually referred to the capability of the system (in terms of percentage of hours
spent in the good status versus the system defined functioning) to ensure, over a defined mission time:
- the 100% of the rated nominal production;
- more than a defined percentage of the rated nominal production;
- a rated production more than 0% of the nominal one;
- a mean rated production more than a fixed threshold.
It is to be remarked that in the definition of the Contractual Requirements and in the related Project
Availability Targets it is fundamental to clearly specify if the interruptions of production due to preventive
maintenance operations have to be considered or not in the evaluation of the System Unavailability.
The following example shows a case of interpretation of Availability Contractual Requirements in order to
define the correct targets to be successively studied by the Availability Analysis. The process of
requirement description, constraints identification and Availability Target definitions are highlighted step by
step.
[,,,]
From the point of view of plant availability the following contractual requirements shall be complied with:
Availability: first contractual requirement

The project design shall be available to produce for 330 operating days per year over the first 24
months of operation from Preliminary Acceptance, producing at 100% of rated capacity.
Requirement description:
This means that the value for availability at 100% of rated capacity shall be at minimum 90.4%; it is
worth noticing that this requirement expresses a very conservative condition with regard to the effective
Complex production since both planned and unplanned shut down days have been included in the total
amount of unavailability days used for the calculation of the reliability.
Contract constraints identification:
According to the contract XXX, the planned shut down of each production train is scheduled every two
years, considering to have the preliminary acceptance on 2005. The first planned shut down is
scheduled on 2006 for one train and on 2007 for the other one. The duration of each planned shut down
is 25 days; no total shut down of the complex is scheduled.
Moreover, 10 days of unplanned shutdown per train per year are foreseen, thus achieving 45 days per
year during which the overall plant production cannot be 100% of rated capacity.
Availability Targets definition:
Therefore in this RAM analysis the average reliability of the plant has to be calculated, to verify that the
minimum figure of 90.4% is achieved at production capacity equivalent to 100% for 330 days/year.
Availability: second contractual requirement

The plant shall also be available to operate 98% of the time over the first 24 months of operation
from Preliminary Acceptance. Project shall be considered unavailable only when both Oil
production units and both Gas production plants are completely shutdown excluding planned
maintenance.
Availability Targets definition:

This means that the Complex is considered available when its production is not zero for at least 98% of
the mission time, excluding turnaround planned shut down.
3.3.3 Input
The main input data of this activity are:
· Company’s Risk Tolerability Criteria
· Availability requirements
The outcome of the activity is represented by:
· Project Risk Matrixes for Risk Acceptability
· Availability Targets
3.3.5 Tools
No specific tools are foreseen.
The System Integrator is in charge of this activity. O&M Engineering competences are required for this
activity. RCM analysts shall be integrated in the O&M team to advise and to support the definition of the
Risk Matrixes and the Availability targets for the project.
3.4 RAMS DATA COLLECTION
3.4.1 Scope
Data collection aim is to provide a reference RAMS Data Bank for the Reference Items composing the
facility under analysis and defined in the system modelling activity. The reference RAMS Data Bank
records data referring to Reference Items templates, that are generic descriptions of the actual Reference
Items belonging to the installation under analysis. For this reason this activity runs in parallel with the
system modelling activity and together they define the level of detail for the study in the Concept definition
phase and exchange information whenever necessary.
In order to identify the Reference Items able to model the whole installation, a Functional analysis shall be
performed and a hierarchical structure defined for the system main functions.
Basically, the Functional Analysis identifies:
• the functions performed by the System;
• which component perform the identified functions;
• which utilities (General Function) are essential for the System;
• which utilities (Auxiliary Function) are dedicated to a specific function;
• the Reference Items i.e. main equipment and control/shutdown loops.
In addition to the main functions that are recorded on the Hierarchical functional diagram, the General
functions that are essential to control and shut down the plant shall also be considered and listed
separately. General functions are the followings:
• Hydraulic power supply;
• Compressed air supply;
• Electric Power Supply;
• Control System;
• Emergency Shut Down (ESD) system and Fire & Gas (F&G) detection system.
RAMS data for the RIs or the elementary Items accomplishing control and shut-down functions shall also
be collated. The Reference Items are therefore represented by main equipment and control/local shut
down loops.
Once the Reference Items of the system are identified, the RIs Template can be built. A Reference Item
template can be represented by main equipment (pumping system, compressor, separator) or by a group
of elementary components whose common function is well identified (e.g., control loops).
The reliability data recorded in the Data Bank address the Reference Item template failure modes. These
failure modes shall be derived neglecting the elementary functions they have to perform in the System.
Going ahead in the RAMS Data Bank construction, once completed the Functional analysis, the collection
of data relevant to the elementary components included in the Reference Item templates shall be
performed. Reliability data should in priority derive from the Company proprietary data banks. In case
these data banks do not contain the specific information required by the RAMS Data Collection Activity,
the main data banks commercially available, such as OREDA, EGIG, CONCAWE, E&P Forum
Datasheets, AICHE, RAC Data Set (MIL and NPRD), EIREDA and IAEA should be referred to [24-33].
Priority Criteria should drive the selection and use of the reference Data Banks.
Generally, the reliability data banks offer the following data for each failure mode:
· Failure Rate (events/million hours): probability per unit of time that the component, good at t, fails
within t+dt;
· Failure Probability Per Demand (events/demand): probability that the component doesn’t
intervene on demand;
· Active Repair Time (hours): time between the manifestation of the failure and its complete
restoration; it involves the time necessary for diagnose the failure, repair it and restart the
component;
· Repair Time (man-hours): workload (expressed by hours per man) necessary to maintenance
operators to perform the reparation of the component.
Some data banks offer parametric relations permitting the correction of the basic parameters by suitable
corrective coefficients, in order to allow the user to better characterise the components also with reference
to the environmental and operational conditions,.
Data collection shall be performed according two main criteria:

1. Data deriving from specific data bank (Company Proprietary Data banks, OREDA, E&P Forum
data sheets, EGIG and CONCAWE) have the first priority;
2. In the case exist different data referred to the same failure mode of a given elementary
component, the most critical datum shall be chosen.
For the items not covered by specific data Banks, reliability data shall be derived from RAC (general
purposes), EIREDA (electric power plants) and IAEA (nuclear power plants).
Once the data for elementary items are collected, the reliability data for the Reference Item template shall
be evaluated. When the RIs template is represented by assemblies of elementary Items, often a
preliminary reliability analysis is required to estimate the reliability parameters, starting from the reliability
data available for elementary items (from commercial Data Banks). This preliminary assessment is
performed by Fault Tree Analysis (FTA) or Reliability Block Diagrams (RBD).
For Reference Item treated as a main component (e.g. separator, compressors etc.) the estimation shall
be directly performed from the data contained in the data banks.
The result of data collection is the collation of reliability data (failure rate and ART) to each RI template
failure mode, quantified by a mean value and its variation range. Uncertainty is due to the process of data
acquisition from the field but also to the fact that a single RI can represent a set of assemblies that are
similar but not identical.
Considering the specific functions of the ESD and F&G systems, i.e. they only intervene in the case a
failure has already occurred (emergency), their availability on demand shall be evaluated separately on
the basis of the Cause and Effect diagram and by multiple failure approach (e.g. FTA and/or RBD) (see
availability analysis description).
The repair times recorded on the data banks only provide an order of magnitude of the outage and do not
take into account the aspects related to spare availability and location, accessibility, weather condition,
etc. This specific consideration will be drawn in the Maintainability Analysis (see next paragraph) in order
to customize the repair times to the specific context.
The RAMS Data Bank shall be updated during the system life cycle, using feedback information from the
Maintainability Analysis upgrade activity, from the RAMS data upgrade during the Execution phase and
on-field data recorded during the Production phase.
After the definition of RIs templates and the construction of the corresponding RAMS data bank, the O&M
Team will be able to model the whole plant and to perform the RAMS analysis foreseen for the Concept
Definition phase, i.e. MA, failure analysis, CA, O&M Policies definition and Availability Analysis.
3.4.2 Procedure
The following procedure shall be followed to implement the RAMS data collection activity.
1. With reference to the Project Base this selection on a hierarchical breakdown of the installation
Basis Report and the System in functional terms (Functional Analysis), whose bottom elements
modelling activity, select the RI are the elementary functions i.e. the Reference Items.
templates to be applied for O&M Basically, the Functional Analysis identifies:
polices · the functions performed by the System;
· which component perform the identified functions;
· which utilities (General Function) are essential for the System;
· which utilities (Auxiliary Function) are dedicated to a specific
function;
· the Reference Items i.e. main equipment and
control/shutdown loops.
In addition, the control and shut down General functions shall also
be considered. General functions are the followings:
· Hydraulic power supply;
· Compressed air supply;
· Electric Power Supply;
· Control System;
· Emergency Shut Down (ESD) system and Fire & Gas (F&G)
detection system.
A Reference Item template can be represented by main
equipment (pumping system, compressor, separator) or by a
group of elementary components whose common function is well
identified (e.g., control loops).
2. List the main Data Banks Use Data Banks to collect data for the main equipment and to
commercially available and feed the reliability analysis performed to assess the failure
relevant to the project. frequency for the other Reference Items templates.
Give first priority to Company proprietary data banks. When these
data banks are not exhaustive, at least consider the Internationally
known Data Banks listed below:
· OREDA,
· E&P Forum Datasheets,
· RAC Data Set (MIL and NPRD),
· AIChE,
· EIREDA,
· EGIG,
· CONCAWE,
· Others.
Whether necessary, complete the list with additional Data Banks.
3. Set priority criteria for the An suggestion of criteria for the application of Company
selection and use of the reference proprietary and the Commercial Data Banks are:
Data Banks. · Data Collection has to cover all the installation: off-shore, on-
shore and pipelines;
· Domain specific Data Banks shall be applied with the highest
level of priority: this means that the first priority is given to the
Company proprietary data banks, then to OREDA (covering
Offshore facilities), E&P Forum (covering Equipment and
Pipes), EGIG and CONCAWE (Onshore Gas and oil
Pipelines) and AIChE (Onshore Pipeline) data banks;
· For the items not covered by domain specific Data Banks,
reliability data shall be derived from RAC (general purposes),
EIREDA (electric power plants) and IAEA (nuclear power
plant)
An example of prioritised Data Bank list is provided in the section
below.
Recommendation: use the same Data Banks, complemented with
data provided by constructors, also during the Execution phase to
detail the O&M analysis working with elementary components.
4. Decide the format of Data A suggestion for Data Collection Sheets and the process to be
Collection Sheets to be used for followed to fill them in is presented in the example of the following
data analysis and recording. section.
5. Group the RIs templates At least consider:

according to their nature and set · RIs templates representing assemblies of elementary Items.
criteria for data selection. The elementary components considered in the data collection
Consider both system main are those identified as constituents of the Reference Items
functions and control and shut and shown at the lower level of the functional analysis of the
down functions. System
· RIs templates representing main components corresponding
to Items of Data Banks
· RI templates representing ESD and F&G detection systems
A suggestion of criteria to be applied to select data relevant to the

component failure mode is the following:
· failure modes able to contribute to at least one of the
Reference Item failure modes
· critical failure modes, i.e. the failure modes able to fully
compromise the capability of the component to perform one of
its functions. When no critical failure modes are available,
degraded failure mode shall be collected.
· the most critical value shall be taken whenever the same
failure mode is recorded by different data bank (conservative
criteria)
6. For the RI templates Relevant RAMS parameters are: Failure rates, Active Repair
corresponding to the elementary Times (ART), Failure Probability Per Demand, Unavailability,
items of the Data Banks, select Expected Number of Failures.
the relevant RAMS parameters The reliability data from the data banks shall be tentatively
from the Data Banks according to averaged.
the criteria set in Step 5.
7. For the RI templates that are If not decided differently, the preliminary reliability analysis shall
assemblies of elementary Items: be performed by Fault Tree Analysis (FTA) or Reliability Block
· select the relevant RAMS Diagrams (RBD).
parameters from the Data Fault Tree Analysis technique (as well as the RBD) analyzes and
Banks for the elementary connects logically all elementary component failures able to cause
items, according to the the Failure Mode of the Reference Item.
criteria set in Step 5. FTA leads to estimate the unavailability (Q) and unreliability
· perform a preliminary (expressed in term of Expected Number of Failure – ENF) that can
reliability analysis to be used to assess the final value for the failure rate and repair
estimate the relevant RAMS time of the specific failure mode relevant to each Reference Item
parameters starting from the template.
reliability data available for The unavailability calculated take into account the Active Repair
the elementary Items Time (ART) composed by the time to correct the failure and time
to test the item under failure.
Expected Number of Failure (ENF) represents the number of
failures occurring over a specify period (1 year). FR and ART can
be considered constant over the component life.
8. RI templates representing ESD Considering the specific functions of the ESD and F&G systems,
and F&G detection systems i.e. they only intervene in the case a failure has already occurred
· select the relevant RAMS (emergency), their availability on demand shall be evaluated
parameters from the Data separately on the basis of the Cause and Effect diagram and by
Banks for the elementary multiple failure approach (e.g. FTA and/or RBD) (see availability
items, according to the analysis description).
criteria set in Step 5.
· Perform an availability
analysis to evaluate the
availability on demand. This
evaluation shall be done in
the Availability Analysis
activity.
9. Use the Data Collection Sheets to Data Collection Sheets shall be applied to extract Failure Modes
record the data all along the for RIs and the related reliability parameters. These data shall be
relevant steps of the procedure. used to structure and feed part of the MA, failure analysis (FMEA)
and CA (see corresponding sections below).
10. Update the RAMS Data Bank Use the feedback from Execution phase RAMS data upgrade and
during the system life cycle on-field recorded data during the running phase.
Note that during the Maintainability Analysis updating activity the
Total Repair Time (and not only the ART) shall be estimated and
the unavailability related to each Reference Item Template
recalculated in order to also consider the fault localisation,
logistical and technical delay times.
Example of Commercial Data Bank prioritizing criteria
The following Table present a list of Data Banks prioritized according to their suitability to off-shore, on-
shore and pipelines applications.
PRIORITY DATA BANK FIELD SPECIFIC COMMENTS

st st
1 OREDA Yes (off shore and partly on This is the 1 priority data bank; it covers mainly off shore
shore) equipment but also several Onshore parts.
2nd EGIG Yes (on shore gas This data bank is specific for on shore gas pipelines.
pipelines)
2nd CONCAWE Yes (on shore oil pipeline) This data bank is specific for on shore oil pipelines.
2rd E&P Forum Yes (off shore, on shore This data bank provides a good overview of data available
and pipelines) from different field specific sources; it could be very useful
to assess the data uncertainty and to cope with items not
treated by the previous banks
3th AIChE No (chemical process) This data bank was born in the chemical process industry
but can be useful to set data for the on shore equipment
not considered by the previous banks.
4th RAC: No (general) This set of banks covers specific items; they can be used to
· Handbook of reliability collect data for the components not covered by the
prediction procedures for previous banks.
mechanical equipment In particular:
· NPRD “Handbook of reliability prediction procedures for
· MIL HDBK 217 mechanical equipment” covers pure mechanical item /
structures and provides models to estimate failure rate
according to the dimensions and loading of them;
NPRD covers all the non electric/electronic equipment of
technical systems
MIL HDBK 217 covers all the electrical/electronic
equipment and provides models to adapt data to the
specific context of application (environment, working
conditions, quality of components)
4th EIReDA No (electrical power This bank addresses all the equipment used in electrical
generation plants) power generation; it could be particularly interesting to
investigate the uncertainty of some data since it compares
values deriving from different data sources.
4th IAEA No (Nuclear power plant) Data collection derives from different commercial and
independency sources (IEEE500, NUREG, UKAEA)
Example of Data Collection Sheets - Contents and use
For each Reference Item template a Data Collection Sheet shall be filled in, reporting:
· Failure Modes,
· Elementary components belonging to the Reference Item templates,
· Reliability data characterising the elementary components,
· The estimated reliability values for the Reference Item Failure Modes,
· The list of main equipment and assemblies that can be represented by the Reference Item
template.
It is suggested to organise RAMS Data in an electronic database easy to interface to RAMS analysis tool.
The typical sheets for Data Collection are shown in the pages below.
RI Template corresponding to an elementary Item
Figure 5 (a/b/c) reports the data collection of a RI Template corresponding to an elementary Item of the
Data Banks.
- Figure 5-a summarises the description of the Reference Item template, in terms of its generic label,
the class of Items it represents, and the components included in the Reference Item template
boundary.
- Figure 5-b represents the Data Collection Sheet that shall be filled in for each component included in
the Reference Item template boundary.
- Figure 5-c records the RAMS data characterising the RI template, obtained by the aggregation of the
detailed failure modes data.
Main equipment,
group of elementary Reference Item code
components or
instrument loop.
Class of Item
represented by the
RI
Components
included in the
Reference Item
boundary
Comments about
Reference Item
boundary
Figure 5-a. Data Collection typical sheet - RI Boundary

Number of
Active Repair components in Operational
Failure Probability Time is the service during Time
Per Demand average time the period of the represents the
The Failure Rate represents the to analyse the total time in
represents the frequency event data
number of failure failure, repair surveillance. It service during
of failure for the per demand. and return the the period of
component; it is represents the
item to a state statistical the event data
expressed in failures per of readiness. surveillance.
sample.
106 hours.
The failure
modes describe
the loss of
required
function(s) that
result from a
failure.
Row identification
number (ID)
Comments
referred to the
failure mode DATA BANK
data. REFERENCE
Note referred to
the ID The Data table
collects all
failure modes
able to
contribute to at
least one RI
Failure mode.
Figure 5-b. Data Collection typical sheet – Elementary item data

The Reference Item failure modes are generally aggregation of detailed failure modes of elementary
items. For example, the column Failure Mode of Figure 5-c presents two failure modes for the RI
considered, i.e. Plugged or Clogged. The External leakage failure mode is the aggregation of the following
detailed failure modes of the item: External leakage, Significant External leakage, Corrosion, Break,
Cracked, Fairly weld.
The RAMS data characterising the Reference Item are obtained the calculation of the aggregated
parameters for each failure mode. In this case, being the RI an elementary item, it is sufficient to apply
algebraic calculation to obtain the aggregated data.
The Expected
Number of
Unavailability
Active Repair Failure
is the
Time is the represents the
probability that
average time number of
The Failure Rate the Reference
to analyse the times the item
represents the Item is
failure, repair is expected to
frequency of unavailable at
and return the fail over the
failure for the RI; any given time.
item to a state specify period
it is expressed in (1 year).
of readiness.
failures per 106
hours.
Row identification
number (ID)
Failure
Note referred to Probability Per
the ID Demand
represents the
number of
failure per
demand.
Figure 5-c. Data Collection typical sheet – Reference Item Data

RI Template corresponding to an assembly of elementary items
Figure 6 (a/b/c) reports the data collection of a RI Template corresponding to an assembly of elementary
Items of the Data Banks.
- Figure 6-a summarises the description of the Reference Item template, in terms of its generic label,
the class of Items it represents, and the components included in the Reference Item template
boundary.
- Figure 6-b represents the Data Collection Sheets that shall be filled in for each component included
in the Reference Item template boundary.
- presents the Fault Tree analysis developed for the RI template to obtain the RAMS data.
- Figure 8 records the RAMS data characterising the RI template, obtained by solving the Fault Trees,
and using for the basic events the components elementary data.
TTº
TICº
TCVº
TYº
Figure 6-a. Data Collection typical sheet - RI Boundary

Figure 6-b. Data Collection typical sheet – Elementary items data (continues)
Figure 6-b. Data Collection typical sheet – Elementary items data
The Reference Item failure modes are generally aggregation of detailed failure modes of elementary items
or generic failure modes of the assembly.
In this case, the RAMS data characterising the Reference Item cannot be obtained by simple algebraic
calculation, because the RI operating mode shall be considered. The aggregated RAMS data for each
failure mode shall be evaluated by mean of Fault Tree analysis and Boolean calculation.
For the Reference Item presented in the example, i.e. Low-Temperature DCS Control, two failure modes
are considered, i.e. fail to regulate and external leakage.
Figure 7 presents the Fault Tree model of these failure modes. The following failure conditions (Top
Events) are analysed.
· TOP1: Loop Temperature DCS Control – Fail to regulate

· TOP2: Loop Temperature DCS Control – External leakage
Figure 7-a. Fault Tree Analysis for Low-Temperature DCS Control (TOP1)
Figure 7-b. Fault Tree Analysis for Low-Temperature DCS Control (TOP2)
The corresponding RAMS data are obtained by solving the Fault Trees.
Figure 8 presents the RAMS data calculated for the sample Reference Item.
Figure 8. Data Collection typical sheet – Reference Item Data

Example of Data Sheets from commercial Reliability Data Banks
OREDA Data Bank
The following tables present the typical data sheets that can be found in the OREDA Data Bank. In the
example the Reference Item is represented by the assembly of the elementary items included in the Item
boundary (see Figure 9 below).
The Failure modes listed on Figure 10 represent all the failure modes of the Reference Item.
Figure 9. Example of table from OREDA Data Bank – Item description

Figure 10. Example of RAMS Data from OREDA Data Bank

AIChE Data Bank
The following figure presents the typical data sheets that can be found in the AIChE Data Bank. In the
example the Reference Item is represented by the assembly of elementary items included in the Item
boundary, i.e. motor, transmission, pump (see Figure 11 below).
The Failure modes listed on the table represent all the failure modes of the Reference Item, classed
according to their state, i.e. catastrophic, degraded, incipient.
Figure 11. Example of table from AIChE Data Bank

EIReDA Data Bank
The following Figure presents the typical data sheets that can be found in the AIChE Data Bank. In the
example the Reference Item is represented by the elementary item “Pump” pictured in Figure 12.
The Data Bank records the operational characteristics of the Item, i.e. operating mode, number of
demands, maintenance policy. The RAMS data can be derived from these information.
Figure 12. Example of table from EIReDA Data Bank

3.4.3 Input
The activity uses as input information the Data Banks, e.g.
· OREDA,
· E&P Forum Datasheets,
· RAC Data Set (MIL and NPRD),
· AIChE,
· EIReDA,
· EGIG,
· CONCAWE,
· Others.
The outcome of the activity is represented by:
· RIs templates
· RAMS Data Sheets collecting at least the following Data for each RI template.
· Failure rates,
· Active Repair Times (ART),
· Failure Probability Per Demand,
· Unavailability,
· Expected Number of Failures
3.4.5 Tools
It is suggested to organise RAMS Data in an electronic database easy to interface to RAMS analysis tool.
The electronic format of RAMS Data Sheets shall be straightforward and user-friendly.

activity. RCM analysts shall be integrated in the O&M team to:
· select Data from the Data Banks;
· perform preliminary reliability analysis to estimate the reliability parameters for RIs represented by
assemblies of elementary Items (FT, RBD analysis, etc.),
· fill in the RAMS Data Sheets.
3.5 MODEL PREPARATION
3.5.1 Scope
The Model Preparation activity aims to define the items to be considered during the RCM process
according to the level of detail adopted for the study and to prepare of the reference model. The model
preparation activity runs in parallel with the RAMS Data Collection activity, exchanging the relevant
hypothesis and information.
The reference model is built following the hierarchical decomposition of the main functions of the plant
(Functional Analysis), whose bottom elements are the elementary functions. The General functions, such
as control and shut down functions are also modelled and added to the hierarchical decomposition. The
decomposition refers to the detail decided for Reference Items templates in accordance with the RAMS
Data Collection activity and the elementary functions correspond to a specific Reference Item (RI).
A Reference Item can represent main equipment (pumping system, compressor, separator) or a group of
elementary components (Items) whose common function is well identified (i.e. a control loop, a protection
loop, a main item, etc).
The identification of RIs should be in accordance with the facilities description set in the Project Basis.
The functional decomposition done in accordance with the RI Templates is not necessarily compliant with
the decomposition in functional units established by the design engineering team. However a matching
between the two decompositions should exist in order to readdress the final result of the RCM analysis on
the specific Items to their TAG.
The functional decomposition is the reference to perform the reliability and criticality assessment; the final
result of the study, i.e. the selection of the best strategies for maintenance, will be set for the RI and then
readdressed on the Items belonging to it (Tags).
3.5.2 Procedure
The procedure steps to be followed to implement the activity are detailed below.
1. Define the plants to be considered in the O&M study and the related boundaries.
2. Describe the plants in terms of main equipment, utilities and control/protection loops;
3. Define the functional model for the whole plant and the related plants;
4. Split each plant into their Reference Items referring to the RI templates set in RAMS Data
Collection Report.
When equipment or assembly are not present in the list of RIs templates, it has to be associated
to the closest RI template, according to a correspondence table univocally defined in the data
collection sheets.
5. Set the relations between the RIs and the Items Tags belonging to them;
6. Draft the list of RIs to be analysed by RCM study and constituting the whole plant.
3.5.3 Input
The input data to this activity are listed below.
· Project Basis Report
· RI templates set in RAMS Data Collection Report
· PFD, P&ID
3.5.4 Output/deliverables
The main deliverables of the activity are:
· Functional breakdown for all the plants
· List of Reference Items
3.5.5 Tools
No specific tools are foreseen.

The System Integrator is in charge of this activity. O&M Engineering and Process Engineering
competences are required for this activity.
3.6 MAINTAINABILITY ANALYSIS (MA)
3.6.1 Scope
The aim of Maintainability Analysis is to estimate the Total Maintenance Time spent to repair and maintain
the Reference Items (RI) as defined in the Model Preparation activity. This estimation is based on
Assumptions and Calculation Criteria that are set before the analysis starts.
The Total Maintenance Time is the combination of the Corrective Maintenance Time (CMT) and the
Preventive Maintenance Time (PMT).
Corrective Maintenance is the maintenance activity carried out after fault detection and intended to put a
RI into a state in which it can perform a required function.
Preventive Maintenance (PM) is the maintenance activity periodically carried out in order to preserve the
proper functioning and prevent the failure occurrence.
The following Table 4 shows the decomposition of the Maintenance Time according to the two main
terms.
MAINTENANCE TIME
ACTIVE MAINTENANCE TIME
PREVENTIVE MAINTENANCE TIME CORRECTIVE MAINTENANCE TIME
LD APMT Active Corrective Maintenance Time LD
ART
TD FLDT FCT CT
Table 4. Maintenance Time decomposition
Except for ART, the maintenance time definitions have been derived from the IEC 60050-91 Standard
(International Electrotechnical Vocabulary – Chapter 191: Dependability and quality of service).
If the use of specific definitions is not explicitly required within the project basis, it is suggested to conform
to this Standard or other recognised International Standards.
At the end of the analysis, each Item is characterised by a maintenance time, which represents the time
required to repair each failure mode and the time required to perform preventive and corrective
maintenance. This estimation is facility-dependant and therefore it shall be performed with specific
reference to the particular environment in which the plant is located.
The outcome of the analysis will be used during RCM process in order to:
· Feed CMT data to FMEA to assess the impact of each failure on asset/production;
· Feed CMT and PMT data to Availability Analysis in order to calculate the availability of the overall
plant taking into account the maintenance policies applied.
· Feed the O&M Policy activity with information concerning the need of spare parts, the skills and
the special tools required to perform each task. This information will support the selection of the
Maintenance Policies, and it will be completed with this iteration to upgrade the Maintainability
Analysis (MA upgrade activity).
3.6.1.1 Assumptions and calculation criteria

In order to evaluate the total Maintenance Time, specific Assumptions and Calculation Criteria shall be
made for the project under development.
Assumptions shall at least concern the following aspects:
· Operational environment;
· Warehouses location and dimension;
· Maintenance personnel location;
· Spare part and special tools location;
· Means of transport.
The following Table 5 traces the correspondence between the maintenance time and the assumptions to
be made with respect to the specific time contributors.
MAINTENANCE TIME
ACTIVE MAINTENANCE TIME
PREVENTIVE MAINTENANCE TIME CORRECTIVE MAINTENANCE TIME
LD APMT Active Corrective Maintenance Time LD
ART
TD FLDT FCT CT
Maintenance Time estimation requires assumptions relevant to the following main aspects:
§ Material § Planned Shut § Safety § In field § ART is based on § Material

location (i.e. down scheduling precautions instrumentation historical reliability data location (i.e.
spare parts, and spare parts,
special tools) § Time estimation operational § Remote Control special tools)
based on procedures System
§ Personnel maintenance taken to put § Personnel
location experience the RI out of § In field location
(Maintenance service and to inspection (Maintenance
technicians, bring it back technicians,
special skills) into service special skills)
Operational environmental conditions
Table 5. Maintenance Time decomposition versus assumptions
In addition to generic assumptions, calculation criteria shall be defined for the following time calculation:
· Fault Location and Diagnosis Time;
· Logistic delay;
· Time to take a Reference Item out of service;
· Time to take a Reference Item into service.
These aspects can be formally studied by the support of the Task Analysis approach.
The Task Analysis is an approach allowing the identification of the main tasks and the related operations
people should perform, the skill required, the time necessary to perform the tasks. It permits to identify
and analyse the interactions of the maintenance technician with both the plant itself and other personnel
of the maintenance team.
Considering the importance of the rapidity of transports on the logistic delay, the following section
introduces a general guide to Assumptions and Calculation Criteria for evaluation about the impact of the
environmental conditions on the transit time by air or by sea. This guide is generic and shall be used as
reference, adapting and integrating it according with the specific information deriving by the specific
project.
Guide to Assumption/Calculation Criteria for transport means
The typical means of transport available for the maintenance activity with the related typical cruise speed
are listed in the table below.
Means V = Cruise speed (knots)

(Typical value to be adapted to the project)
Helicopter 150
Supply Vessel (SV) 10
Ice Breaker Supply Vessel (IBSV) 3
Table 6. Maintenance Time decomposition versus assumptions
For Helicopter the average speed shall be estimated considering the actual service days of the helicopter.
Normally, some flying days are lost, for example during the winter season, and some formula shall be
used to calculate the average speed.
For example, assuming that during the winter season (from November to March) the flying days lost due
to bad weather conditions are:
· 21 during the 2000-2001 winter;
· 20 during the 2001-2002 winter;
· 10 during the 2002-2003 winter.
The average speed can be obtained by the following formula:
365 x3 -(21 +20 +10)

Vaverage =Vno min al =143knots
365 x3
where: Vmean : is the average cruise speed
For transport by sea specific assumptions shall be made to adjust the typical speed value to the actual
environmental condition of the installation.
3.6.2 Overall Maintainability Analysis procedure

The general procedure to develop the Maintainability Analysis foresees two main steps.
1. All RIs shall be considered to be in Corrective Maintenance (CM) regime and only CMT shall be
estimated. The denomination of this activity in the Concept Definition phase RCM flow
diagram is Maintainability Analysis.
2. Once the maintenance policies are allocated, all RIs under Preventive Maintenance (PT) regime
shall be analysed and relevant PMT estimated. . The denomination of this activity in the
Concept Definition phase RCM flow diagram is Maintainability Analysis Upgrading.
Figure 13 details the process within which this procedure shall be developed.
Risk
Criteria analysis
O&M Input to
Project basis Model Criticality O&M Execution
Decision
preparation Failure Policies Policies
PFDs/ PI&D analysis Logics Phase
Analysis Validated
(FMEA)
RAMS data MA
Upgrading
Yes
Target Target
Analysis
No No
Upgrading
OR
Design
review
Maintainability
analysis
Criticality O&M
Decision
Failure Policies
analysis Logics
Analysis
(FMEA)
MA
Upgrading
Figure 13. MA procedure versus RCM approach in Concept definition phase
Each Step of the overall Maintainability Analysis procedure is expanded in the following sections.
3.6.2.1 MA Step1 - Maintainability Analysis Activity Procedure

The first step of the overall Maintainability Analysis procedure corresponds, in practical terms, with the
calculation of the Corrective Maintenance Time (CMT) for each RI defined in the Model Preparation
activity.
Corrective Maintenance is the maintenance activity carried out after fault detection and intended to put a
RI into a state in which it can perform a required function. CMT is the time required to perform a
corrective maintenance action including all times shown in the Figure 14.
CORRECTIVE MAINTENANCE TIME
RI in Time to locate Time to Time to take Time to repair Time to bring RI in

service and diagnose acquire the RI out of and test the RI the RI back service
the failure resources service (ART=FCT+CT) into service
(FLDT) (LD) (TOST) (BIST)
Failure Available for Service
Figure 14. CMT decomposition
The Corrective Maintenance Times listed on the table are defined as below.
Technical delay (TD): the accumulated time due to perform auxiliary technical actions associated with the
maintenance action itself. (i.e. time to take the equipment out of service - TOST - and to bring it back into
service - BIST)
Fault location/diagnosis time (FLDT): that part of the active maintenance time during which fault location
and fault diagnosis is performed.
Active Repair Time (ART): is the total (calendar) time required to repair and return the item to a state
where it is ready to resume its function. This excludes the time to detect the failure (Fault
Location/Diagnosis Time), time to isolate the equipment from the process before repair (Technical Delay),
delay and waiting for spare parts and tools (Logistic delay), and any time after the repair has been
completed if the item is not bring into services immediately. Time for testing is included (Check-out time)
when such testing is an integrated part of the repair activity (definition taken from OREDA 2002). ART
data derive from the “RAMS Data Collection”.
Logistic delay (LD): the accumulated time, during which a maintenance action cannot be performed due to
necessity to acquire maintenance resources, excluding any administrative delay (i.e. the waiting time for
maintenance personnel, spare parts and tools).
In addition to the above, the CMT estimation shall also take into account the following factors:
· Activities Overlapping Time (AOT): several CM activities could be performed at the same time
(i.e. time to get spare part and time to take out of service the equipment).
· Efficiency Factor (EF): the influence of the environmental factor (temperature, wind, snow, etc) on
the outdoor work condition. In absence of other more specific methods defined within the project,
EF shall be estimated by experience.
The CMT shall be calculated following the procedure described below.
CMT Calculation Steps description

Procedure Steps
1. Estimate FLDT Evaluate FLDT considering the time spent to locate where the failure has occurred
and the time to identify the causes.
Estimate FLDT specifying if the failure is detectable by the control system or just
through a field inspection, according to the following steps:
1. Check if the RI under analysis has the operating condition monitored in the
Central Control Room (CCR): if this condition is satisfied, the analyst has to
allocate time required to locate/diagnose the failure by control system.
2. If the information in CCR is unavailable or incomplete, it shall be assumed that
the failure is detected during the routine operational check, which shall be
carried out every X hours (Suggestion for X = 4 hours).
2. Estimate TOST Evaluate TOST starting from the list of activities that are considered essential to
take a RI out of service and giving, for each of them, an estimation of the time spent
to perform it.
Follow the procedure below:
1. Define the type of RI in accordance with the RI groups identified;
2. Check for the actions associated with each RI group;
3. Allocate time for each action required for that RI group taking into account the
instructions provided.
Typical actions that are performed to take a RI out of service are listed in Appendix
MA1. This reference list is generic and shall be adapted to the project under
analysis and whether necessary, integrated with additional actions specific to the
installation.
3. Estimate BIST Evaluate BIST starting from the activities that are considered essential to bring a RI
into service and giving, for each of them, an estimation of the time spent to perform
it.
Follow the procedure below:
1. Define the type of RI in accordance with the RI groups identified;
2. Check for the actions associated with each RI group;
3. Allocate time for each action required for that RI group, taking into account
the instructions provided.
Typical actions that are performed to bring a RI into service are listed in Appendix
MA2. This reference list is generic and shall be adapted to the project under
analysis and whether necessary, integrated with additional actions specific to the
installation.
4. Calculate TD The TD shall be evaluated taking into account the time spent for auxiliary technical
actions associated with the maintenance action itself.
- Evaluate TD as result of the following times:
- Time to Take the RI Out of Service (TOST);
- Time to Bring the RI Into Service (BIST).
5. Estimate ART - Derive ART from the most common database used in the Oil and Gas Industry.
This time includes time to repair and to test the RI.
Usually, ART time is not evaluated.
6. Estimate AOT Give an estimation of the time saved due to maintenance activities overlapping (i.e.
time to get spare part and time to take an Item out service)
7. Calculate ACMT Calculate ACMT according to the following formula:
ACMT = FLDT + TOST + ART + BIST – AOT
8. Estimate LD The LD is function of the time to acquire the maintenance resources (i.e. material
and personnel) necessary to repair a RI.
- Determine LD by the knowledge of the location of the resources and the means of
transport used.
Time to acquire material Time to acquire personnel

Spare parts location Maintenance personnel location
Special tools location Special skills location
>
Logistic Delay
Assumption
Refer to the location of maintenance resources and are based on the draft logistic
plan, on the plant buildings and location, etc.
Calculation criteria
Assume LD to be the longest time between material and personnel recovering.
Experience proves that the LD can be identified with the time to acquire spare parts
as in most of the installations it is greater or, at most, equal to the time required to
recover personnel. In any case, this assumption shall be verified on the basis of the
assumptions made for the specific project.
9. Evaluate EF Apply specific methods defined within the project (if existing) or estimate EF by
experience.
10. Calculate CMT Calculate CMT according to the following formula

CMT= LD + [ACMT x EF]
The typical procedure to calculate the CMT is summarised in the following flowchart.
Estimate Estimate Estimate ART Estimate Estimate AOT

FLDT TOST BIST
Calculate ACMT
= (FLDT+TOST+ART+BIST-AOT)
Estimate LD
Evaluate EF
Calculate CMT
= LD+(ACMTxEF)
Figure 15. CMT calculation procedure
The calculation of the CMT for each RI defined in the Model Definition activity terminates the first step of
the Maintainability Analysis overall procedure.
Example of CMT Work Sheets - Contents and use
The CMT calculation procedure shall be implemented on CMT Work Sheets.

It is suggested to organise Data in an electronic database easy to interface RCM analysis tool.
The typical sheet for CMT calculation is shown in the following table. For each RI, the table shall be filled
in with all the relevant data. The completion of the sheets corresponds to the end of the first step of the
MA overall procedure.
Project:
Sub Project:
Facility Functional Unit FFU:
Main Equipment:
LD
T
RI Logistic Logistic
A
/Item
Description Function Failure Mode EF base 1 base 2
FLDT TOST ART BIST AOT CMT
G
Table 7: Corrective maintenance work sheet
Here below a description for the field is given:

Project: name of the project (i.e. XYZ field development)
Sub Project: name of the part of plant in accordance with the item numbering and coding system (e.g.
Offshore blocks, Onshore, Pipelines, etc.)
Facility Functional Unit (FFU): name of the main function accordance with to item numbering and coding
system (e.g. 200 - Oil Separation, 210 - Crude oil treatment, 300 – Gas separation, etc),
Main Equipment: name of the equipment defined in the O&M Project Basis (e.g. Wellhead production, HP
flare, Oil booster pumps, etc.).
TAG: this field sets the reference to univocally identify the RI (or Item in the Execution phase).
RI/Item: this field contains the name of the RI (or Item in the Execution phase) under investigation.
Description: description of the RI (or Item in the Execution phase) under investigation.
Function: description of the RI (or Item in the Execution phase) function.
Failure Mode: this field sets the Failure Modes for the RI (or Item in the Execution phase) as defined in the
RAMS Data Collection.
EF (Efficiency Factor): coefficient taking into account the environmental influence.
Logistic delay: the time, in hours, necessary to bring spare parts, special tools and maintenance
personnel in place to start the repair; this time is strongly dependent on weather conditions and logistic
appraisals.
FLDT (Fault Location/Diagnosis Time): time, in hours, to locate and diagnose the fault.
Technical delay is split into:
· TOST: Take a RI/Item Out of Service Time
· BIST: Bring a RI/Item back Into Service Time
ART (Active Repair Time): the time, in hours, due to repair or substitute and test the failed RI/Item. This
interval includes Fault correction and Check out times. This data derives directly from the “RAMS Data
Collection”.
AOT (Activities Overlapping Time): time saved due to maintenance activities overlapping (i.e. time to get
spare part and time to take an Item out service)
CMT: the time, in hours, necessary to perform a corrective maintenance action. CMT shall be calculated
through the following formula:
CMT= LD + [(FLDT + TOST + ART + BIST – AOT) x EF]
3.6.2.2 CMT Input sources

During the Concept definition phase the main inputs are:
· The list of RI constituting the plants as defined in the model preparation activity.
· The failure mode associated to each RI with the relevant ART as defined in Data Collection.
3.6.2.3 CMT Output sources

The main output of the MA relevant to the Corrective Maintenance consists of:
· Corrective Maintenance time for all RIs;
· Evaluation of Logistic delay due to personnel and spare parts recovering
3.6.2.4 MA Step2 - Maintainability Analysis Upgrading Activity Procedure

The aim of the Maintainability Analysis upgrading activity is to update the Maintainability Analysis
performed during the first step of the overall MA procedure, by calculating the Preventive Maintenance
Time on the basis of the details provided by the O&M Policies, and by updating the CMT calculation. This
activity corresponds to the second step of the overall procedure.
Preventive Maintenance (PM) is the maintenance activity periodically carried out in order to preserve the
proper functioning and prevent the failure occurrence.
Before estimating this PMT, the RIs requiring a preventive maintenance shall be identified.
This identification is only possible when the Criticality of the each RI is evaluated by the FMEA combined
with CA and the O&M policies are defined. During the definition of the O&M strategy, the necessity,
scheduling and duration of PM tasks for each critical RI is evaluated and details on, e.g. inspection period,
weak signals, spare parts, personnel skill, are available.
Concerning the PMT, it is normally the result of a time due to acquire material and personnel (LD) and a
time spent to perform the action itself (APMT).
These two times are defined according to the following.
Logistic delay (LD): the accumulated time, during which a maintenance action cannot be performed due to
necessity to acquire maintenance resources, excluding any administrative delay (i.e. the waiting time for
maintenance personnel, spare parts and tools).
During the preventive maintenance activity this delay shall not be considered because the task is planned
and any resources recovered in advance.
Active Preventive Maintenance Time (APMT): that part of the active maintenance time during which
actions of preventive maintenance are performed on an item (RI).
The procedure to be followed to implement the MA Upgrading activity is presented in the following table.
MA Upgrading procedure steps Steps description

1. Update the CMT calculation If necessary, implement the procedure for the CMT calculation
(see previous section) updating the input data on the basis of the
strategy set in the O&M Policies.
The Task Analysis approach shall support this step.
2. Calculate LD Regarding to preventive maintenance tasks, LD has normally no
impact on the global MT since the task has been planned in
advance and any resources must be recovered before the action
itself.
If not stated differently, set LD = 0
3. Calculate APMT Plan the preventive maintenance action in accordance with the
criticality of the RI estimated during the FMEA and CA.
Define the periodicity and duration of each PM tasks associated
with the critical RI.
4. Calculate PMT PMT is normally the result of a time due to acquire material and
personnel (LD) and a time spent to perform the action itself
(APMT).
PMT = LD + APMT
The time spent to perform the action can be formally studied by
the support of the Task Analysis approach.
5. Upgrade Total Maintenance Time
The Task Analysis that represents a method to support the Operability Analyses performed during the
system design, is an approach allowing the identification of the main tasks and the related operations
people should perform. It permits to identify and analyse the interactions of the maintenance technician
with both the plant itself and other personnel of the maintenance team. In particular, it describes ‘what’ the
maintenance technician is asked to do to achieve the intervention objectives, the time required to
accomplish the task and it investigates the possible errors arising from the actions.
Two main approaches for task analysis are normally used :
• Hierarchical Task Analysis
• Tabular Task Analysis
These two approaches can be used alone or in combination.
The Hierarchical Task Analysis is a hierarchical approach that describes the task from its top-level goals
down to the level of individual actions. It is usually presented in graphical form and the tasks are
numbered hierarchically.
The Tabular Task Analysis is a columnar tabular approach, which takes each particular task-step or
operation and considers specific aspects. First, maintenance technician functions are listed and broken
down into elemental tasks, and then each task is examined in order to identify any error-likely situation
that may cause difficulties for the operator to complete his tasks.
Example of PMT Work Sheets - Contents and use
The PMT calculation procedure shall be implemented on PMT Work Sheets.

The typical sheet for PMT calculation is shown in the following table. For each RI subject to Preventive
Maintenance, the table shall be filled in with all the relevant data.
Project:
Sub project:
Main Equipment:
T Job
RI Job plan Spare part/ Job plan Task Job plan
A Description plan Tasks Skills UM
/Item description Special tool Frequency Duration Duration
G code
Table 8. Preventive maintenance work sheet

Here below a description for the field is given:

Sub Project: name of the part of plant in accordance with the item numbering and coding system (e.g.
Offshore blocks, Onshore, Pipelines, etc.)
Facility Functional Unit (FFU): name of the main function according with to item numbering and coding
TAG: this field sets the reference to univocally identify the RI (or Item in the Execution phase).
Description: description of the RI (Feed) or Items (Detail) under investigation.
Job Plan code: this field sets the reference code to univocally identify the Job plan.
Job Plan description: description of the Job plan.
Tasks: this field contains a list of activities relevant to the Job Plan. Tasks list will be defined during the
Detail/Construction phase.
Skills: this field contains a list of skill required to perform the Job plan. Skills will be defined during the
Detail/Construction phase.
Spare part/Special tool: this field contains the Spare parts and Special tools required to perform the Job
plan. Spare parts and special tools will be defined during the Execution phase.
Job plan frequency: this field set the Job plan frequency.
UM: this field set the Unit of Measure of the frequency.
Job plan duration: this field contains the estimated time to perform the relevant Job plan
3.6.3 Input
· The list of RIs constituting the plants
· Maintainability Analysis (step 1) output
· O&M Policies
The main output of the MA relevant to Preventive Maintenance consists of:
· Corrective Maintenance Time upgrade
· Preventive Maintenance Time for all RI subject to Preventive Maintenance
3.6.5 Tools
It is suggested to organise Maintainability Analysis Work Sheets in an electronic database easy to
interface to RCM analysis tool. The electronic format of MA Work Sheets shall be as much as possible
user-friendly.

activity. Maintenance technicians shall be interviewed for maintenance times requiring estimation by
experience.
3.7 FAILURE MODE AND EFFECT ANALYSIS (FMEA)
3.7.1 Scope
Failure analysis aims to identify, for each failure mode of Reference Items, the effects on safety,
environment and asset/production. Additional information is provided to point out the control and
protection equipment, able to prevent or mitigate the accident/failure.
The analysis is performed by considering all the relevant working phases. Operation phases include Start
Up (SU), planned Production Phase (PP), Emergency Shut Down (ESD), and Planned Shut Down (SD).
This investigation is normally performed by Failure Mode and Effect Analysis (FMEA), considering all RIs
installed on the Plant., except those belonging to the ESD and Fire and Gas Detection System that should
be analysed through a Fault Tree Analysis or Reliability Block Diagram.
For details on this activity see the Preliminary Availability Analysis description (§ 3.9.2.1).
Failure Mode and Effect Analysis (FMEA) addresses in a systematic way, the effects of each failure in
terms of personnel injuries or loss of life, loss of production, damage to the asset and to the environment.
For each failure mode the detection method and some preventive or mitigation actions are also
envisaged.
The approach is based on a “single failure” criteria, i.e. it assesses each failure considering the others
equipment functioning.
A criticality assessment, for each failure, is performed in semi-quantitative terms allowing a priority
screening of the failures according to their impact on safety, asset, production and environmental
protection.
In order to assess the effects at different level of the system, each Complex/Facility is identified by a list of
Facility Functional Unit (FFU) and each of them is split in terms of Reference Items.
The Complex /Facility representation is provided to the user by a tree representation that allows to identify
the correct hierarchical position of the plant parts.
The equipment hierarchy identified to perform FMEA Analysis shall be modelled in order to split the plant
in three main levels: System (sub-project), Sub System (FFU) and main equipment function (Reference
Items). The function is then related to the Items performing the function itself.
The FMEA addresses the plant at Reference Item level. For this reason, a list of Reference Items shall be
set to guide the analysis.
Reference Items refers to the templates set in the RAMS Data Collection by their Reference Item code.
The relationship between a Reference Item and the related plant Items is not always strict, often a
Reference Item could correspond to several plant Items since the Reference Item boundary set in the
Data Collection contains several equipment, each one identified by its TAG number in P&ID. In this case
the Reference Item to be analysed during FMEA is recognised by the TAG of one of the Items it refers to
and the effects are referred to the loss of the function performed by this set of components.
Example. A Centrifugal Compressor can be considered. It is represented by the Reference Item template
whom code is, for example “KC”, the boundary of the Reference Item template includes all the
compression stages that are identified by different TAG numbers into P&ID. The Reference Item
considered in the FMEA can be tagged as the first compression stage but for the analysis it represents all
the three Items and the failure effects are given considering all the three Items.
The control/ shut down loops pertaining the equipment considered in the FMEA shall be modelled
separately (whenever not included inside the boundary limit of the reference item) and added to the list of
objects (equipment) to be analysed.
The Loops shall be identified uniquely using the Reference Item code and number related to the
instrumentation.
When the components of the loop have different progressive numbers, the code of the RI takes the
progressive number of the transmitter.
Failure Modes for any Reference Items is taken by the Reference Item templates set in the RAMS Data
Collection and associated to the RI TAG. The pair Equipment (or component) and Failure mode is the
case for which the analysis is performed. The effect of a failure mode that occurs for an RI TAG must be
analysed considering the impact on the main equipment function, the functional unit and the overall
system.
3.7.2 Procedure
The procedure to be applied for FMEA analysis is described below.
1. Define the equipment hierarchy The equipment hierarchy identified to perform

necessary to perform the FMEA FMEA Analysis shall be modelled in order to split
Analysis the plant in three main levels: System (sub-
project), Sub System (FFU) and main equipment
function (Reference Items). The function is then
related to the Items performing the function itself.
2. List the Reference Items to be

considered in the FMEA Analysis
3. Model the Control/Shut down loop The control/ shut down loops pertaining the
separately and add them to the list of equipment considered in the FMEA shall be
the RIs to be analysed modelled separately (whenever not included
inside the boundary limit of the reference item)
and added to the list of objects (equipment) to be
analysed.
For each RI:

4. List the potential Failure Modes Failure Modes for any Reference Items is taken
by the Reference Item templates set in the RAMS
Data Collection Document and associated to the
RI TAG. The pair Equipment (or component) and
Failure mode is the case for which the analysis is
performed.
4. Select the operating phase in which Operation phases normally include Start Up (SU),
the failure can occur planned Production Phase (PP), Emergency Shut
Down (ESD), and Planned Shut Down (SD).
5. Assess the effects of the failure at The effect of a failure mode that occurs for an RI
different levels of detail (locally, sub- TAG shall be analysed considering the impact on
project level, …) the main equipment function, the functional unit
and the overall system.
6. Assess the Severity with respect to The classification for severity indexes is provided
Severity Indexes in terms of impact by the Risk Acceptance Criteria activity.
on the Safety, the Environment, asset · For functional equipment the Severity is
and production. evaluated on the basis of the single failure,
assuming that the protection system is well
functioning.
· For protection equipment the severity is
calculated as a combination of the failure of
the protected equipment or system and the
failure of the protection item.
7. Identify and list detection methods
8. Identify and list existing compensation

provisions
9. On the basis of the effects and their

severity assessment, suggest
improvements and recommendations
for design review, maintenance
policies, etc.
Example of equipment hierarchy
Hereinafter an example of equipment hierarchy is provided.
System SYSTEM
(Level 1) (Offshore Block A; Offshore
Block D; Onshore; etc.)
FFU 100 FFU 110 FFU 120 FFU …

(WELLHEAD (INJECTION CHEMICAL PRO……………..
SYSTEM) WELLHEAD INJECTION
B11200PD001A/B
METHANOL DOSING PUMPS
Reference Item
(Level 3)
B11200PD001A B11200PD001B
METHANOL DOSING PUMP METHANOL DOSING PUMP
Items
(Others Level)
B11200PSV213A B11200PSVPSV214A
Pressure Relief Safety Valve Pressure Relief Safety Valve
Example of FMEA Work Sheets - Contents and use
The Failure Mode and Effect Analysis shall be performed by the completion of FMEA Work Sheets.
Commercial Tools already exist on the market and is suggested to select the most appropriate and use
these tools for the analysis.
The typical sheet for FMEA analysis is shown in the following table. For each RI, the table shall be filled in
with all the relevant data.
Project:
Sub Project:
Main Equipment:
Effects Severity
TAG RI/Item Description Function Failure Operating Main FFU Sub Project % Loss of Safety Asset Environment Detection Compensating Improvement/ Document Nr-
Mode Phase Equipment Production Method Provisions Recommendation Rev
Function
Table 9. FMEA work sheet

Sub Project: name of the part of plant in according to item numbering and coding system (e.g. Offshore
blocks, Onshore, Pipelines, etc.)
Facility Functional Unit (FFU): name of the main function accordance with the item numbering and coding
TAG: this field set the reference tag set to univocally identify the RI (or Item in the Execution phase).
Description: description of the item for the RI (or Item in the Execution phase) under investigation.
Function: description of the item function for the RI (or Item in the Execution phase) under investigation.
data RAMS Data Collection Tables.
Operating Phase: the operating phase considered to set the effects of the Failure Mode (Start Up,
Production Phase, Emergency Shut Down - ESD).
Effects: three columns allow to describe the effects of the Failure Mode at different levels of detail (locally,
at FFU level, at Sub Project level). The described effects take into account the mitigation due to
compensating provisions and refers to the Operating Phase set in the previous field.
% Loss of Production: The columns allow estimating the percent loss of production with reference to the
Sub Project (e.g. 33.33 for one train shut down in case of three trains in parallel; 100 for the Sub project
shut down, etc.)
Severity: Three columns allow estimating, by qualitative indexes, the severity of the failure mode, at
system level, in terms of safety, asset and environment protection.
Severity – Safety: the index expressing the severity of Failure Mode in terms of personnel injuries or
death. The classification for severity indexes is given in the Risk Acceptance Criteria activity. Severity has
to be set taking into account the presence and the good functioning of the Detection and Compensations
Provisions described in the related columns.
Severity –Asset: the index expressing the severity of Failure Mode in terms of catastrophic damages to
the assets. The classification for severity indexes is given in the Risk Acceptance Criteria activity. Severity
has to be set taking into account the presence and the good functioning of the Detection and
Compensations Provisions described in the related columns.
Severity – Environment: the index expressing the severity of Failure Mode in terms of environmental
damage. The classification for severity indexes is given in the Risk Acceptance Criteria activity. Severity
has to be set taking into account the presence and the good functioning of the Detection and
Compensations Provisions described in the related columns.
Detection Methods: the alarm signals, indicators, protections, operator checks allowing the failure
detection.
Compensating Provisions: the provisions, already set, to prevent or mitigate the failure mode (e.g.,
protection equipments).
Improvement/Recommendations: the provisions not implemented in the design, recommended to further
prevent or mitigate the failure mode (e.g., protection equipments, operator interventions, sparing
philosophy etc.)
Notes: this filed can be used to clarify the assumptions made during the analysis or to clarify the data
inserted.
3.7.3 Input
The main input data are:
· The list of RI constituting the plants as in System Modelling Activity;
· The failure mode associated to each RI;
· Severity classification from Risk Acceptance Criteria activity.
The analysis has to be compliant with Process philosophy, Shutdown, Blow Down philosophy and Safety
philosophy.
The main output data of the activity are represented by:
· Effects and severities for each failure mode associated to each RI.
· Recommendations to design review and O&M policies
3.7.5 Tools
Commercial tools are available to perform FMEA analysis.
A suggestion is the use of FMEA Modules commercially available in off-the-shelf Software Tools.
3.7.6 Work Team and competences

activity. RCM analysts shall be integrated in the team to animate the FMEA analysis and perform the most
specialised tasks. Maintenance technicians shall also be interviewed for cause-consequences analysis.
Process engineers shall be involved in the analysis to contribute to drafting the final recommendations
and suggestions.
3.8 CRITICALITY ANALYSIS
3.8.1 Scope
Criticality analysis aims to classify the RIs according to the impact of their failure modes on safety,
environmental protection and plant production/asset separately.
The screening is semi-quantitative and is based on the Risk Matrix approach.
The Project Risk Matrix defined at the start of the process is applied in order to screen the critical items
versus the “acceptance” criteria. For the scope of the RCM methodology, these criteria are normally semi-
quantitative, because they address the frequency quantitatively and the consequences qualitatively.
For all the failures studied by FMEA, the quantitative and/or qualitative indicators defined in the Risk
Acceptance Criteria activity are used to assess:
· The frequency of occurrence of the failure mode (quantitative),
· The effects in terms of safety and environmental protection (qualitative),
· The effects in terms of production/asset (qualitative).
The Overall Criticality of each RI is defined as the worst index among the three criticality indexes
respectively versus Safety, Environment and Asset/Production.
3.8.1.1 Criteria
The methodology foresees the evaluation of three different Criticality Indexes:
Criticality index vs. Safety: it represents the impact of the Failure Mode on the personnel or population
safety; it is defined as of the combination of the annual frequency of occurrence class of the Failure Mode
with its Severity in safety terms.
ICS = Annual frequency class x SeveritySafety
Criticality index vs. Asset/ Production: it represents the impact of the Failure Mode on the production and
in terms of asset damage. In the FMEA it is defined as a severity index to consider the asset damage and
a percentage to characterise the loss of production. During CA analysis the percentual loss of production
will be converted in a Severity (SeverityProduction) by considering also the duration of the failure (Corrective
Maintenance Time) and the oil cost. The criticalities are defined as the combinations of the annual
frequency of occurrence with the Severities in terms of business losses.
ICA = Annual frequency class x SeverityAsset

ICP = Annual frequency class x SeverityProduction
The cumulative Severity index vs. Asset/Production will be given by the highest of the two values:
ICA/P = Max(ICA ; ICP )
Criticality index vs. Environment: it represents the impact of the Failure Mode in terms of environmental
damage; it is defined as the combination of the annual frequency of occurrence class for the Failure Mode
with its Severity in environmental terms.
ICE = Annual frequency class x SeverityEnvironment
Severity Indexes has to be set during FMEA, according to the classifications given in Table 1, Table 2 and
Table 3.
Overall Criticality: it represents the overall impact of the Failure Mode considering all types of effects
(safety, asset damage, loss of production and environmental damage). The Overall Criticality Index can
assume three values as defined in the Risk Matrix defined in the Risk Acceptance Criteria activity (Figure
4).
Criticality Intolerable without detailed justification. Does not satisfy initial screening criteria.
1 Additional risk reduction measures required. Justifiable if compliance with ALARP principle
and individual and societal risk criteria are demonstrated.
Criticality Compulsory impact reduction required. Risk is tolerable when appropriate control
2 measures have been identified and implemented.
Criticality Tolerable Risk. No further impact reduction measures are necessary. Monitor
3 performance and manage for continuous improvements.
The Overall Criticality Index shall be estimated as the worst of the three criticality indexes set above:
IOC = Max(ICS ; ICA/P; ICE)
3.8.2 Procedure
The Criticality Analysis consists in the assessment of the Criticality indexes and the application of the Risk
Matrixes to select the Overall Criticality for any RI failure.
The procedure to be applied to implement the activity is described below.
Procedure steps for each RI Steps description

1. Extract from FMEA the Failure Modes
2. Extract from FMEA each RI Failure Mode Severity The Severities versus Safety, Asset damage and
versus Safety, Asset damage and Environment Environment are set during FMEA according to the
Severity Matrices classification
3. Estimate the Severity versus Production Estimate Severity versus Production according the
Severity Matrices classification when the economic
cost of the loss of production is known.
The cost of loss of production CLP (USD) can be
estimated on the basis of the:
- percentual loss of production PLP,
- the time duration of the out of service CMT (h)
deriving from MA,
- the expected production EP (BOPED) ,
- the cost of oil per barrel CO (USD/BOPED),
as follows:
CLP = PLP x CMT x EP x 24 x CO

4. Estimate the annual frequency of occurrence The Annual frequency of occurrence can be
estimated as follows:
- for operational equipment, the Annual
frequency is given by the Failure Rate,
- for protection equipment, the Annual
frequency is given by their Unavailability times
the frequency of demand. The frequency of
demand can be assumed to be 1/10
(demands/year).
5. Calculate the Criticality index vs. Safety ICS = Annual frequency class x SeveritySafety
(See criteria description above)

6. Calculate the Criticality index vs. Asset/Production ICA/P = Max(ICA ; ICP )
where

7. Calculate the Criticality index vs. the Environment ICE = Annual frequency class x SeverityEnvironment

8. Estimate the overall Criticality Estimate the Overall Criticality Index as the worst of
the three criticality indexes set above:
Example of Criticality Analysis Work Sheets - Contents and use
The Criticality Analysis shall be performed by the completion of Criticality Analysis Work Sheets.
The typical sheet for CA analysis is shown in the following table. For each RI, the table shall be filled in
with all the relevant data.
Project:
Sub Project:
Main Equipment:
Failure Severity
TAG RI Description Function Safety Asset / Environment ICS ICA/P ICE Criticality
Mode Production
Table 10. Criticality work sheet

data RAMS Data Collection Tables and FMEA analysis.
Severity: These three columns correspond to the equivalent in the FMEA analysis and record the severity
of the failure mode, at system level, in terms of safety, asset and environment protection, by qualitative
indexes.
Severity – Safety: the index expressing the severity of Failure Mode in terms of personnel injuries or
death.
Severity –Asset: the index expressing the severity of Failure Mode in terms of catastrophic damages to
the assets.
Severity – Environment: the index expressing the severity of Failure Mode in terms of environmental
damage.
Criticality index vs. Safety: it represents the impact of the Failure Mode on the personnel or population
safety.
Criticality index vs. Asset/ Production: it represents the impact of the Failure Mode on the production and
in terms of asset damage.
Criticality index vs. Environment: it represents the impact of the Failure Mode in terms of environmental
damage; it is defined as the combination of the annual frequency of occurrence class for the Failure Mode
with its Severity in environmental terms.
Criticality: it represents the overall impact of the Failure Mode considering all types of effects (safety,
asset damage, loss of production and environmental damage). The Overall Criticality Index is estimated
as the worst of the three criticality indexes set above.
3.8.3 Input
The Criticality Analysis has to be performed for all the Failure Mode analysed in the FMEA.
Input data consists of:
· the RI listed in the FMEA;
· the Corrective Maintenance Time estimated in the Maintainability Analysis,
· the Severity class and percentage of loss of production set in the FMEA tables.
3.8.4 Output
· The output of the Criticality Analysis consists of the lists of items failures each one characterised by
its Overall Criticality, Criticality on Safety, Criticality on Asset/Production and Criticality on
Environment.
3.8.5 Tools
It is suggested to organise CA Work Sheets in an electronic database easy to interface to RCM analysis
tool. The electronic format of CA Work Sheets shall be as much as possible user-friendly.

activity. RCM analysts shall be integrated in the O&M team.
3.9 AVAILABILITY ANALYSIS
3.9.1 Scope
The scope of the Availability Analysis is to predict the performance of the plant in terms of production
availability. The Availability takes into account the fault frequencies of the plant (Reliability) and its ability
to be quickly restored (Maintainability), providing an estimation of the plant productivity.
The Availability of an item is defined as the capability to be in a state to perform its function under given
conditions at a given instant of time or over a given time interval, assuming that the required external
resources are provided. In other words it represents the probability of functioning of a system or item at a
given time. It also expresses the percentage of hours spent in the good status versus the system/item
expected functioning (sum of the hours spent in good and failed status).
Availability estimation is based on the plant design (components, failure modes and frequencies, system
architecture) but also on the Operation and Maintenance Policies foreseen (Maintenance strategies,
Mission Profile, Logistics, etc.). The tuning of the entire maintenance policy will provide the inputs for the
Maintenance Contractors.
The overall plant Availability can be considered as measure of the quality guaranteed by the design and
Operation and Maintenance Planning.
The final aim of the study consists in the determination of the effective Plant Availability and the
determination of the critical weak points leading to possible improvements in the O&M policies.
3.9.2 Overall Availability Analysis procedure

With reference to the RCM Work flow for the Concept Definition phase, the overall procedure for
Availability analysis foresees two main steps:
1. Evaluation of the Preliminary Availability Analysis. It is applied to check the overall plant availability
without any consideration about the maintenance policies applied and evaluates the availability only
taking into account the time lost to repair the RI failed (i.e. Active Repair Time - ART). Furthermore,
a Fault Tree Analysis (FTA) can be performed in order to evaluate the unavailability of the plant due
to the spurious ESD intervention.
2. Evaluation of the final Availability Analysis. It allows assessing the annual downtime of the plant or
the production variations due to corrective (unexpected failures) or preventive maintenance,
according to the failure frequency of components, maintenance data and policies.
Risk
Criteria analysis
O&M Input to
Project basis Model Criticality O&M Execution
Decision
preparation Failure Policies Policies
PFDs/ PI&D analysis Logics Phase
Analysis Validated
(FMEA)
RAMS data MA
Upgrading
Yes
Target Target
Analysis
No No
Upgrading
OR
Design
review
MA
Upgrading

Target Target
Analysis
No No
Upgrading
OR
Design
review
Figure 16. Availability Analysis procedure versus RCM approach in Concept definition phase
The preliminary availability analysis starts supplying useful information concerning the plant availability
and provides feedback to the design team (Design Review) when the target set for the plant is not
satisfied.
The final availability analysis represents a final check to verify the efficacy of the maintenance policies set
for the RIs. It is more detailed than the preliminary analysis, using as input data the results of the MA
upgrading activity, e.g. time spent for material/personnel acquisition (Logistic delay), time for auxiliary
activities (technical delays) and the preventive maintenance.
Availability Analysis highlights the critical items, i.e. the items that more than others, in case of failures,
have a relevant impact on system production. This information can be applied to improve the design
(Design Review) or to revisit the maintenance policies set in the previous stages.
The Availability analysis shall be performed for the Overall plant, considering all the main systems,
auxiliary systems and protection systems. The analysis has to take into account:
· Mission profile for the plant (production, scheduling of operations, etc.),
· Failure frequencies for the equipment,
· Repair times including logistics/technical delay,
· Maintenance policies (corrective, preventive, “on condition”),
· Stock of spare parts,
· Need of specials tools for maintenance,
· Maintenance personnel team and specific skills.
The analysis is normally performed by Reliability Block Diagrams and Monte Carlo simulation.
3.9.2.1 AA Step 1 - Preliminary Availability Analysis procedure

The procedure to be followed to implement the Preliminary Availability analysis is described below.
Steps Description
1. Define the mission profile and environmental Define the plant mission as set of activities the
conditions system has to perform during a stated operative
time to satisfy its performance objectives.
Describe the mission profile in terms of operation
required to the system during the mission.
Describe the environmental conditions that the
system can meet during the accomplishment of its
mission
2. Perform Fault Tree Analysis to evaluate the Spurious ESD events are actions initiated by any
frequency of occurrence of spurious ESD events components belonging to the ESD system without
any process upset or emergency condition has
been really occurred.
The spurious events shall be analysed grouping
ESD causes having the same effects on the plant.
Then, each spurious event shall be analysed in
term of:
· Frequency of occurrence: expected number of
occurrence per year;
· Consequence: percentage of loss of production
due to the spurious event.
These two terms allow to estimate the risk
associated to each spurious event and,
consequently, determine a criticality level.
Examples of systems producing spurious failures
are:
· Fire and Gas detection system (i.e. F&G
detectors);
· Process/Utility sensor (i.e. pressure,
temperature, flow transmitters);
· PLCs units controlling the ESD/Fire & Gas
system.
Spurious failures of items or equipment that don’t
cause a predetermined effect on the plant but,
according to their duty, a sequence of event to be
evaluated case by case shall be considered by the
FMEA.
Due to importance and specificity of this step, it is
not described in this section but fully expanded in §
3.9.7
3. Build the system model for availability Prepare a Reliability Block Diagram (RBD) model by
assessment referring to system model defined in Model
Preparation activity
4. Prepare the input data set for availability Derive input data from:
assessment - Reliability data from RAMS Data Collection
- spurious ESD unavailability by FTA (step 2.)
- Corrective maintenance Times from
Maintainability Analysis activity
5. Assess plant availability Availability assessment using Monte Carlo
simulation
6. Perform Sensitivity / Importance Analysis Perform Sensitivity and importance analysis to
evaluate the criticality of each item on the
availability figure.
For example the importance of each RI with respect to the
unavailability of the plant can be evaluated using the
Fussel-Vesely importance index. This index provides a
measure of the relative importance of each RI among the
others and weights it with respect to the availability of the
system.
7. Compare the results with availability targets Compare the availability figure evaluated by this
approach with the initial targets, in order to verify if
the system accomplishes its functions as required. If
not go to 7.
8. Provide feedback/Recommendations to Design By using the results of the sensitivity and
review importance analysis and FTA for EDS results,
identify possible recommendations to Design
Review, which could contribute to rise the
availability level
3.9.2.2 AA Step 2 - Final Availability Analysis procedure

The procedure to be followed to implement the Final Availability analysis is described below.
Steps Description
1. Upgrade (whether necessary) the mission profile
Define the plant mission as set of activities the
and environmental conditions defined in the system has to perform during a stated operative
Preliminary Availability Analysis time to satisfy its performance objectives.
Describe the mission profile in terms of operation
required to the system during the mission.
Describe the environmental conditions that the
system can meet during the accomplishment of its
mission
2. Upgrade (whether necessary) the system model Prepare a Reliability Block Diagram (RBD) model by
for availability assessment referring to system model defined in Model
Preparation activity
assessment - Reliability data from RAMS Data Collection
- Maintenance Time (corrective + preventive
maintenance time) from the Maintainability
Analysis upgrading activity,
- Role of each equipment versus plant safety
and production, from FMEA sheets,
- Maintenance Policies, by the application for
Decision Logics with reference to O&M Policy
activity,
- Hypothesis on logistic, spares management,
etc from Project Basis and Maintainability
Analysis activities
simulation
5. Upgrade Sensitivity / Importance Analysis Upgrade Sensitivity and importance analysis done
in the preliminary AA by considering the additional
information provided by the more detailed input data
to this activity.
6. Compare the results with availability targets Compare the availability figure evaluated by this
approach with the initial targets, in order to verify if
the system accomplishes its functions as required. If
not go to 7.
7. Provide feedback/Recommendations to O&M By using the results of the sensitivity and
Policies and/or Design review importance analysis, identify possible
recommendations to O&M Policies and/or Design
Review, which could contribute to rise the
availability level.
3.9.3 Input
Preliminary Availability analysis Final Availability analysis

- Plant description and mission profile, from - Plant description and mission profile, from Design
Design Basis, Basis,
- Reliability data from RAMS Data - Reliability data from RAMS Data Collection,
Collection, - Maintenance Time (corrective + preventive
- Maintenance Time (corrective) from the maintenance time) from the Maintainability Analysis,
Maintainability Analysis, - Role of each equipment versus plant safety and
- Role of each equipment versus plant production, from FMEA sheets,
safety and production, from FMEA sheets - Maintenance Policies, by the application for Decision
Logics (see O&M Policy section),
- Hypothesis on logistic, spares management, etc from
Project Basis and Maintainability Analysis activities.
· Availability of the plant. It is normally defined in terms of average production availability: the
effective annual production versus the ideal production that could be obtained in case of absence
of plant shut down due to failures, “On Condition” or Preventive Maintenance.
Ideal Production - Loss of Production due to failures or Maintenanc e (Corrective, On Condition, Preventive )
Availability =
Ideal Production
· Ranking of elementary equipment according to their criticality derived by the Sensitivity and
Importance Analysis, i.e. their contribution to the overall system Unavailability. This result allows
planning the interventions in the O&M plan, leading to an improvement of the effective plant
Availability.
3.9.5 Tools
The current market offers a quite variable choice of software tools for availability analysis able to manage
different maintenance programmes.
Off-the-shelf Software Tools shall be chosen for the Availability Analysis. It is suggested to privilege those
based on Monte Carlo simulation techniques to predict component and system performance. Normally, in
these category of Software Tools the system logic is represented by Reliability Block Diagrams (RBDs);
their blocks may represents components or subsystems. The main parameters they evaluate include
predicted unavailability, number of expected system failures, unreliability and required spare level.

The System Integrator is in charge of this activity. RCM analysts shall perform the analysis. O&M
Engineering competences are required for this activity.
3.9.7 Fault Tree Analysis (FTA)
3.9.7.1 Scope
Within the Availability Analysis activity, Fault Tree Analysis (FTA) technique can be used in order to
evaluate the probability of a spurious ESD initiating event and the related impact on the plant
unavailability. Basically, the spurious ESD initiating event can be caused by the following failures:
· Spurious intervention (failure) of Fire and Gas detection system;
· Spurious intervention (failure) of the process sensors connected to the ESD system;
· Spurious intervention (failure) of the Control Logic Units (relevant to ESD and Fire & Gas system).
The unavailability due to the Spurious ESD initiating event, obtained by FTA, shall be included in the
overall plant availability model (see Preliminary Availability Analysis procedure).
It should be recalled that FTA is also used during RAMS Data Collection in order to define the
Unavailability and Expected Number of Failures for the RIs on the basis of Items data.
3.9.7.2 Procedure
Fault tree Analysis shall be performed according to the Fault Tree Handbook – NUREG 0492, 1981.
A general procedure for the implementation of the FTA is presented below.
1. Define the Top Events to be analysed by FTA (e.g ”Off shore ESD spurious intervention”)
2. Define the reference Mission Time to be applied for the analysis according to the life of the plant
(e.g. 40 years) or, in any case, longer than the wider inspection interval (Preventive Maintenance)
foreseen for the component considered in the tree.
3. Develop a Fault Tree for each Top Event and consider as elementary events the Failure Modes of
the RIs
4. Derive reliability parameters from the RAMS Data Collection
5. Perform the FT calculation and derive the Unavailability and Expected Number of Failures for the
Top Events
6. Perform a Common Cause Failure analysis to highlights dependencies between items failures or
events able to compromise the redundancies. This check can be performed on the Minimal Cut Set
as explained here below.
3.9.7.3 Common Cause Failure (CCF) Analysis

This analysis aims to identify those elementary events able to compromise several items at a time,
leading to the loss of the redundancies foreseen by the system designers.
This check allows putting in evidence all the Minimal Cut Sets dependencies and leads to estimate a more
accurate probability of occurrence of the Top Event (Unavailability or Expected Number of Failures)
avoiding underestimations.
Example of a simple case of CCF Analysis
Consider a fire fighting system powered by two pumps in parallel, each one able to manage the 100% of
the expected flow rate. One of the Minimal Cut Sets will be constituted by the simultaneous failure of the
3
two pumps initially considered as independent in the Fault Tree Analysis :
TOP= P1 * P2
But, if the two pumps are put in the same room, are operated by the same operator, are lubricated by
the same lube system, etc., there are some coupling mechanism able to lead to the loss of both pumps
when a Common Cause Failure intervenes; in this case, common causes consists of the flooding of the
room, an operator error, a failure of the lube system, etc.
In order to consider the criticality of these CCF, the Minimal Cut Set has to be investigated and
modified.
For instance, if the Common Cause Failure is the flooding of the room (F), the Minimal Cut Set has to
change as follows:
TOP= P1 * P2 + F
3
Note that in the formula the symbols “*” and “+” refers to the Boolean operators AND and OR
In Case of more complex situations, the same approach can be applied. A more complex example is
given here below:
TOP = A+ B*C*D + C*D*E
Suppose that G is Common Cause Failure able to compromise the events C and D, the new MCS
expression becomes:
TOP = A+ B*C*D + B*G + C*D*E + G*E
3.9.7.4 Input
Input data consist of:
· System description (PFD and P&ID) and Project Basis;
· Failure rates for elementary components from RAMS Data Collection;
· Repair times from Maintainability Analysis;
· Fire and Gas Cause and Effect Charts (relevant to Onshore, Offshore plants and Pipelines
system)
· ESD Cause and Effect Charts (relevant to Onshore, Offshore plants and Pipelines system)
3.9.7.5 Output/Deliverables
The output of the analysis consists of the Unavailability and Expected Number of Failures for the TOP
event investigated, i.e. the spurious ESD initiating.
3.9.7.6 Tools
The current market offers a quite variable choice of software tools for Fault Tree analysis.
Off the shelf software tools shall be chosen for the Fault Tree Analysis.
3.9.7.7 Work Team and competences

The System Integrator is in charge of this activity. RCM analysts shall perform the analysis. O&M
Engineering competences are required for this activity.
3.10 O&M POLICIES
3.10.1 Scope
The aim of O&M Policy activity is to define the O&M Policies (Corrective, “On Condition”, Preventive
Maintenance) to be applied to any equipment or assembly according to their technical characteristics and
their criticality versus production, safety and environment.
These O&M Policies are then validated at the end of the process, when the design and the O&M policies
are consolidated to guarantee that the plant Availability satisfies the targets set at the beginning of the
analysis.
The activity also contributes to the definition of logistics aspects, defines the O&M Requirements for
Contractors, sets guidelines for Process Operator Guides (POG) implementation and provides directions
for the Computerised Maintenance Management System (CMMS) implementation.
The activity is performed in two stages, starting from the definition of the O&M Policies and then validating
the Policies on the basis of the Availability Analysis outcome.
3.10.2 Overall O&M Policy procedure

With reference to the RCM Work flow for the Concept Definition phase, the overall procedure for O&M
Policies activity foresees two main steps:
1. The definition of O&M Policies concerns the identification of the best maintenance Policy for each
RI. The activity consists of the application of some Decision Logics to any item Failure Mode up to
identify the best maintenance policy. The outcome of this stage is also used to upgrade the
Maintainability Analysis by the implementation of the maintenance polices [see. § MA Upgrading ]
and to perform the final Availability Analysis (see § Final AA).
2. The validation of O&M Policy that concerns the validation of the O&M Policies set in the previous
step, to guarantee that the required level of plant Availability. The completion of this activity will also
give support to the Maintenance Contractors for the selection, volume and store locations of spare
parts.
Risk
Acceptance Maintainability Task analysis
Criteria analysis
O&M Input to
Project basis Model Criticality O&M
Failure Decision
Policies Execution
PFDs/ PI&D preparation analysis Logics Policies Phase
Analysis Validated
(FMEA)
RAMS data MA
Upgrading

Target Target
Analysis
No No
Upgrading
OR
Design
review
O&M Input to
O&M
Policies Execution
Policies Phase
Validated
MA
Upgrading
Availability
analysis Target
Figure 17. O&M Policies procedure versus RCM approach in Concept definition phase
With reference to the first step, Maintainability and Criticality analyses provide the input information
necessary to identify the best maintenance policy for each RI. The choice is based on a Decision Tree
defined once for all in the RCM methodology taking into consideration different aspects, such as:
· Safety/Environment criticality of the item,
· Production/Asset criticality of the item,

· Existence of specific legislation (e.g. for pressure equipment),
· Feasibility of periodic preventive maintenance,
· Feasibility of On condition monitoring (existence of signals, failure evolution),
· Cost related to any strategy.
Then, the policy has to be specified: scheduling for periodic inspections, monitoring approach in case of
on conditioning maintenance, support to logistic decisions, etc.
The specific constraints deriving from Insurance/Warranty will be set in collaboration with Constructors
and Suppliers during the Execution phase.
Then, the second step addresses the validation of these Policies.
Before entering into the detailed description of each step of the overall O&M Policies procedure, the
Section below provides a description of the most common Maintenance Policies.
3.10.2.1 Maintenance Policies

At least the three different maintenance policies described below shall be considered for the selection of
the best O&M Policies for the plant under investigation.
Corrective Maintenance: all the maintenance tasks performed to restore a failure already occurred. This
type of Policy requires an efficient organisation/communication between the maintenance teams, a good
spare parts storage and a high skill of maintenance people in order to locate the failure and restore it very
quickly to reduce the down time of the part of plant involved. The main drawbacks of this approach are:
· Failures occur, this leads to a loss of production and risks for people or environment,
· Maintenance teams continuously works in emergency without any possibility of planning, and with
a higher risk of errors,
· In case some spare parts are not taken in local storages, the logistic time can heavily impact the
downtime of the plant.
Corrective Maintenance is generally applied for Not Critical Failure Modes.
Preventive Maintenance: all the maintenance tasks periodically undertaken in order to prevent the failure
occurrence. This approach requires the selection of the Intervention Interval (Scheduling), i.e. the time
periodicity of the interventions. Typical Preventive tasks are:
· Periodic checks required by laws, assurance or warranty,
· Periodic cleaning of equipment (pipes, filters, etc.),
· Lubrication or greasing of mechanical equipment to reduce wear out and energy consumption,
· General periodic checks of couplings and periodic substitution of parts.
This approach reduces the number of failures, allows a good planning of the interventions, personnel
recruitment and spare supply, reduce the loss of production due to failures.
Often the preventive tasks, in order to prevent the failure, are performed very early and lead to anticipate
component substitution and undesired interruption of the production; the On condition approach (see
below) allows a more complete wear out of the component.
The Preventive Policy is generally applied to Safety/Environment critical Failure Modes, or to those failure
Modes that can impact the production and for which a “on Condition” approach is not possible.
The application of the Preventive Maintenance is practicable when there is a time during the component
life where the failure frequency increases rapidly.
“On Condition” Maintenance: all the maintenance tasks based on the monitoring of the failure evolution,
aiming to intervene just before the failure occurs. The monitoring is performed on some specific signals
named “weak signals” able to predict the incipient failure.
This kind of policy is usually applied to:
· Rotating equipment by the monitoring of vibration,
· Equipment ruptures by x-ray, ultrasonic tests, penetrating liquids, thermography,
· Mechanical degradation by oil or process fluid composition, part consumption,
· Degradation of process components by monitoring of process parameters, endoscophy,
· Electrical devices, by monitoring of voltage, currents, power factor.
The “On Condition” approach can be applied when the monitoring signal is reliable, i.e. it always permits
to identify the failure before it happens; moreover, the incipient failure has to be revealed in time to
intervene with the maintenance before the failure occurs.
Monitoring of “weak signals” can be continuous or periodic; the periodicity has to be set according to the
time evolution of the failure.
This approach is preferred for those Failure Modes characterised by a failure rate that maintain a constant
value with the ageing of the component.
The “On Condition” approach, when applicable, is the best one since it matches the advantages of the
Corrective and Preventive strategies. ”On Condition” Maintenance allows to prevent failures, exhaust the
components, plan the maintenance operations and spare parts supply. A drawback could be the cost of
the implementation of the monitoring activity.
3.10.2.2 O&M Step 1 - O&M Policies selection Procedure

The general procedure to be applied to implement the O&M Policy selection activity is described below.
For each RI:

1. Derive the Failure modes from FMEA activity
2. For each Failure Mode, derive the Criticality from CA activity
3. For each Failure Mode, apply the decision tree addressing the main criteria applied for the policy
selection (see details below)
4. Describe the Maintenance policy for the RI on the basis of the results of the application of the
decision tree to the Failure Modes
5. Update the Maintenance Policies implementing Availability Analysis suggestions/recommendations.
The criteria to be applied for the policy selection are:

1. Overall Criticality 1: in this case the failure must be prevented by Preventive Maintenance or by
“On Condition” Maintenance, if the weak signal used for failure monitoring is fully reliable.
2. Existence of National Laws imposing Preventive periodic Maintenance for Safety/Environment
critical failure modes or components.
3. Overall Criticality 2: in this case a Preventive or “On Condition” approach is recommended.
4. The application of “On Condition” Maintenance must be verified according to the technical
characteristics of the equipment and the evolution of the failure in order to assess:
· Existence of a reliable signal able to perform failure monitoring,
· Feasibility of the monitoring with reference to the evolution speed of the failure,
· Costs for the “On Condition” approach.
5. Shape of the Bath Tube curve for the Failure Mode: an increase of the Failure Rate at the end of
component life addresses mainly to Preventive Maintenance while in case of constant failure rate,
the “On Condition” approach is preferred. The shape of the Bath Tube curve is related to the
equipment type and technology.
6. Mission profile of the plant: the presence in the mission profile of process shut down periods
facilitates the insertion of the preventive tasks without effects on production.
7. Policy applied to manage the spare parts: when the local storage of spare parts is not foreseen,
Preventive or “On Condition” Policy is preferred since they allow spare parts supplying when
necessary, avoiding logistic delays.
For any Failure Mode
Criticality 1? Is there any Law or Is there a moment of the Is there a weak signal able Is this weak signal
Constraint NO component life leading to a to reveal this Failure “Reliable”?
YES (Assurance/Warranty) fast increasing of the Mode?
asking for Preventive failure rate? NO YES
Maintenance?
NO
YES YES NO NO YES
Preventive
Maintenance
Can the failure be “caught”
in time to intervene before
NO
Criticality 2? YES the failure occurs?
YES
NO
NO Is the Cost/Benefit
competitive if compared
with the Preventive
Maintenance costs?
Does a reason exists to
perform Preventive or “On YES
Condition” Strategy for this
Failure Mode? YES “ON Condition”
(Technical and/or Economic) Maintenance
NO
Corrective
Maintenance
Figure 18. Decision Tree for Maintenance Policy selection

Example of O&M Policy Work Sheets - Contents and use
The O&M Policy definition shall be completed by filling in O&M Policy Work Sheets.
The typical sheet for O&M Policy definition is shown in the following table. For each RI, the table shall be
filled in with all the relevant data.
Project:
Sub Project:
Main Equipment:
Failure On RI O&M Policy

TAG RI Description Function Criticality PM CM
Mode Condition description
Table 11. O&M Policies Work Sheet

data RAMS Data Collection Tables and FMEA analysis.
Criticality: it represents the overall impact of the Failure Mode considering all types of effects (safety,
asset damage, loss of production and environmental damage). The Overall Criticality Index is estimated
as the worst of the three criticality indexes versus Safety, the Environment, Asset/Production.
Preventive Maintenance: short description of the activities of Preventive Maintenance foreseen for the RI
under analysis.
Corrective Maintenance: short description of the activities of Corrective Maintenance foreseen for the RI
under analysis.
On Condition Maintenance: short description of the activities of On Condition Maintenance foreseen for
the RI under analysis.
RI O&M Policy description: description of the O&M Policy to be applied to the RI under investigation.
3.10.2.3 Input
The main input data to the activity are:
· Criticality of each Failure Mode versus Safety/Production/Environment,
· Maintainability analysis for each Failure Mode,
· Specific requirements/constraints from National Laws or Regulations
· Policies for spare parts
· Expert judgement.
The outcome is represented by:
· Selection of the Maintenance Policy for all the RI Failure Modes.
· More detailed description of the Policy (inspection period, weak signals supporting the “On
Condition” maintenance, need of spare parts or personnel skill, etc.). This information will be used
to complete the Maintainability Work Sheets prepared during the Maintainability Analysis.
3.10.2.5 Tools
The analysis shall be performed by the support of the Decision Tree. It is suggested to use electronic data
sheets to record the O&M Policy for each RI.
3.10.2.6 Work team and competences

activity. Maintenance technicians shall be interviewed for suggestions based on their experience from the
field.
3.10.2.7 O&M Step 2 - O&M Polices Validation Procedure

The procedure to be followed to validate the O&M Policies is described below.
1. Validate the O&M Policies of those RIs that have been modified to satisfy the Plant Availability
Targets
2. Validate the final O&M Policies identified to satisfy the Plant Availability targets in the most cost
effective way
3. Provide suggestions for the definition of logistic aspects
4. On the basis of the validated policies, define O&M Requirements for Contractors
5. Draft guidelines for POGs implementation
6. Provide directions for CMMS implementation
3.10.2.8 Input
The main input data are represented by:
· RIs ranking according to their Criticality
· System Availability by Availability Analysis
· O&M Policies
The outcome of the activity is the following.
· O&M Policies validated
· Contribution to the definition of logistic aspects
· Definition of O&M Requirements for Contractors
· Guidelines for POGs implementation
· Directions for CMMS implementation
3.10.2.10 Tool
It is suggested to validate the O&M Policies by a process of approval of the O&M Policies Work Sheets
provided by the O&M Policies selection activity. In line with this last activity this data shall be organised in
an electronic database compatible with the commercial software tools.
3.10.2.11 Work team and competences

activity. Maintenance technicians shall be interviewed for suggestions based on their experience from the
field.
3.11 EXPECTED RESULTS

The results that are expected from the application of the RCM methodology during the Concept Definition
phase are summarised here below:
· Identification of the critical Reference Items for the plant;
· Preliminary selection of the best Maintenance Policies for each Item of the plant;
· Evaluation of the Plant/Sub-plant/Equipment Availability;
· Contribution to the definition of the logistic aspects;
· Definition of the requirements to be set for the Contractors and Suppliers;
· Directions for the implementation of the Computerised Maintenance Management System
(CMMS);
· Guidelines for Process Operation Guides (POG) implementation.
These results shall be recorded according to the Company recording practices and transferred to the
Execution phase to be used as input data for the implementation of the RCM Methodology in that Phase.
Considering the importance that the activity of results recording has for the management of the interfaces
between the project phases, the following Chapter describes the main input data and their format for the
transfer to the Execution phase.
3.12 INPUT TO THE EXECUTION PHASE

The input data to the Execution phase shall be organised according to two main topics:
1. O&M Equipment requirements: definition of the O&M requirements concerning Data and Analysis
to be addressed to Contractors and Suppliers that will be involved in the Execution phase. Data
and Analyses required concerns at least the following subject: items data details, Reliability Data,
RAMS Analyses, Maintenance Plan.
2. Guidelines for O&M Engineering: definition of directions for the CMMS implementation and
guidelines for POGs development.
3.12.1 O&M Equipment Requirements Definition
3.12.1.1 Scope
The scope of this activity is the definition of the O&M Data and Analyses to be provided by Contractors
and Suppliers in order to allow the Company to implement a RCM program.
3.12.1.2 Contents
The type or detail of analyses will depend on the relevance and complexity of the project.
In case of full implementation of the RCM program, O&M Equipment Requirements for Contractors shall
address the following O&M Data and Analysis:
· Master Equipment List (MEL);
· Specification Sheet;
· Material Catalogue, Bill Of Materials (BOM’s) and Spare Part Lists;
· Reliability Data Collection (Failure rate and Active Repair Time);
· Maintainability Analysis (MA);
· Failure Mode and Effect Analysis (FMEA);
· Criticality Analysis (CA);
· Availability Analysis (AA);
· Maintenance Plan.
O&M Equipment Requirements for Suppliers shall address the following O&M Data and Analysis:
· Master Equipment List;
· Material Catalogue, Bill Of Materials (BOM’s) and Spare Part Lists;
Depending upon the frame contractor agreement, Suppliers will provide Contractor or Company with
the above data.
3.12.1.3 Input
Detailed input data are defined in the O&M Data and Analyses Requirements for Contractors and
Suppliers document.
Suppliers and Contractors will be provided of the procedures for RCM implementation (Maintainability
Analysis, FMEA, etc.) set in this document.
3.12.1.4 Output
The type or detail of outputs will depend on the relevance and complexity of the project. A full
implementation of the activity will lead to the following results:
· Master Equipment List (MEL);
· Materials catalogue;
· Spare parts lists for Installation and Commissioning;
· First two years (or otherwise required) of operation spare parts list;
· Insurance/Capital spare parts list;
· List of spare parts to be replaced because of their operating life limitations;
· Spare Parts Inter-changeability List;
· Lubrication schedule;
· Bill Of Materials (BOM’s) and Spare Part Lists;
· Reliability Data Collection (Failure rate and Active Repair Time);
· Maintainability Analysis (MA);
· Failure Mode and Effect Analysis (FMEA);
· Criticality Analysis (CA);
· Availability Analysis (AA);
3.12.1.4.1 Work Team and competences

The System integrator is responsible for this activity. The O&M Engineering team is in charge of this task.
3.12.2 Guidelines For O&M Engineering
3.12.2.1 Scope
To define directions and guidelines for the following activities:
· Computerised Maintenance Management System (CMMS) implementation;

· Process Operator Guides (POGs) development.
CMMS directions originate from the need to guarantee coherence between the RCM model and the
CMMS structure. Their aim is to establish the basis for a consistent approach in maintenance definition
and to give a detailed description of the base of maintenance information in order to have maximum
flexibility in maintenance management & data analysis.
POG guidelines aim to establish the basis for the development of POGs. POGs are a set of manuals, very
specific and detailed, Plant-Unit oriented, which are required for safe operation of the individual process
and utility facilities.
Guidelines are intended to be live documents, and therefore they shall be properly updated during the
overall life cycle.
3.12.2.2 Directions for Computerised Maintenance Management System - CMMS
3.12.2.2.1 Contents
This activity shall provide directions to address the following contents.
1. OVERALL DIRECTION FOR CMMS IMPLEMENTATION

· CMMS Boundary limits:
· Compulsory info
· Highly desirable info
· Optional info
· Preventive maintenance procedure

· Condition based maintenance procedure
· Corrective maintenance procedure
· Job plans procedure
· Safety plans/hazard/precaution procedure
· Crafts/tools procedure
· Failure procedure
· Reporting procedure
· Etc.
2. DIRECTIONS FOR COMPANY ASSET DATA COLLECTION AND MANAGEMENT

· Data Collection Company Concept
· Boundary limits definition
· Data collection procedure
· Location codes for plants
· Location codes for plant functional unit/train
· Location codes for equipment (Tag no)
· Location hierarchy
· Equipment hierarchy
· Data collection procedure
· Tagging rules
· Data quality
3. DIRECTIONS FOR PREVENTIVE MAINTENANCE AND JOB PLAN DEFINITION

· Maintenance strategy
· Forms of maintenance
· Maintenance workflow (general)
· Preventive maintenance
· Replacement policy
· Planned maintenance
· Task selection
· Maintenance forecasting
· Maintenance scheduling
· Planning (short/long term planning)
· Maintenance standardization
· Data quality
4. DIRECTIONS FOR MATERIAL DEFINITION AND MANAGEMENT

· Catalogue Company Concept
· Catalogue Attributes
· Stock type definition
· Store - Sub stores
· Stock levels
· Item to be stocked
· ABC analysis
· Economic order quantity
· Reorder level
· Safety stocks
· Spare parts classification
· Data quality
3.12.2.2.2 Input
The inputs are:
· CMMS specification (by Company)
· CMMS Demo (by Company)
3.12.2.2.3 Output
Directions for the CMMS implementation
3.12.2.3 Guidelines for Process Operation Guides
3.12.2.3.1 Contents
This activity shall provide guidelines to address the following contents.
· Description: a comprehensive description of the Facilities Functional Unit (FFU) and individual items
of equipment which make-up the FFU covered in the POG. Simplified P&IDs are provided too.
· Operation: the following aspects are covered, as well as all the safety precaution to be taken:
o Initial start-up (after a planned long-term shutdown)
o Normal Operation
o Planned and Emergency shutdown
o Routine Operational Checks/First Line Maintenance
o Chemical Handling details
· Reference: the following reference data are provided, as appropriate:
o Instrumentation details and set-points
o Valves status list
o Lubrication schedule
o Blinding schedule
o Reference documentation
3.12.2.3.2 Input
The inputs are:
· O&M Project Basis;
· P&IDs;
· Installation, Operation and Maintenance Manuals
· Cause and Effect Diagram
· HAZOP
3.12.2.3.3 Output
Guidelines for POGs
3.12.2.3.4 Work Team and competences

The System integrator is responsible for this activity. The O&M Engineering team is in charge of this task.
4. EXECUTION PHASE
4.1 RCM METHODOLOGY PROCEDURES FOR THE EXECUTION PHASE

The Execution phase is characterised by the preparation of the Detailed Design and Construction of the
plant, therefore the RCM analysis has to be specialised according to the technical details provided by
Contractors and Suppliers and the O&M policies set during the Concept definition phase are detailed into
O&M procedures and tasks.
It follows that during this phase the Contractors and Suppliers become integral part of the RCM process.
In general terms, the data the Contractors are expected to provide, for the part of plant included in their
Scope of Work (SoW), concern the following topics:
· List of all tagged equipment;
· Approved P&ID’s;
· Maintenance proposal;
· Insurance and Critical pare parts list;
· Spare parts holding recommendations. Variety and volume;
· Detailed Maintainability, Failure and Availability analyses.
In order to satisfy the requirements of the Company, the Contractors complement their data with those
provided by their Suppliers.
The System Integrator reviews the information and data provided by the Contractors and Suppliers and
implement them into the overall O&M System.
The System Integrator provides support with the technical Invitation To Tender (ITT) documentation for
Maintenance contracts to be implemented in readiness for the operational phase as and when requested
by the Company.
Ultimately the System Integrator provides an overall O&M system covering:
· Overall O&M plan;
· All data and information collected and produced in readiness for input into the Company CMMS;
· Process Operators Guides.
Company should manage its O&M activities utilising an integrated CMMS during the Production phase.
This facility should also be used by all O&M Contractors to manage the equipment within their respective
SoW.
The flow chart of the RCM methodology applied to the Execution phase is presented in Figure 19.
Operating Manual Operating Manual

Maintenance Plan by Maintenance Plans
Suppliers Revision & Integration
by Contractors
Concept Maintainability
definition analysis
O&M Results
Revision &
Integration Overall O&M
Criticality O&M Availability O&M Tasks
System (O&M
analysis Policies analysis and
Target Plan, POGs
Failure Revision & Revision & Plant & Yes procedures for
Implementation,
Analysis Integration Integration Systems No overall plant
Contractors/ Input CMMS)
(FMEA)
Suppliers Revision &
Data Integration
Upgrading
OR
Maintenance Contracts :
OR
- Technical Docs
- Performance Plant
Design Requirements
review
EXECUTION PHASE
Figure 19. The RCM Methodology flow diagram (Execution phase).
The procedures to be applied for the implementation of the activities foreseen in the RCM methodology
referring to the Execution phase are described in the following sections.
4.1.1 System Breakdown

The analyses made during the Concept Definition phase for the Reference Items are specialised for all
the elementary Items constituting the installation.
In consequence of that, the System breakdown during this phase refers to the Items as defined in the
Company Codification Standards [5].
4.1.2 O&M Results from the Concept Definition phase
All the O&M results from the Concept Definition phase become input data to the Execution phase, in
particular:
· Evaluation of the Plant/Sub-plant/Equipment Availability;
· Contribution to the definition of the logistic aspects;
· Identification of the critical Items for the plant;
· Selection of the best Maintenance Policies for each Item of the plant;
· Definition of the O&M Data and Analysis Requirements for Contractors and Suppliers;
· Directions for CMMS implementation;
· Guidelines for POGs implementation.
4.2 CONTRACTORS/SUPPLIERS DATA
4.2.1 Scope
The scope of Contractors and Suppliers data activity is to receive from Contractors and Suppliers data
and analyses in accordance with “O&M Data and Analysis Requirements for Contractors and Suppliers”
set by the System Integrator.
The Contractors should collect by the Suppliers information such as Main Equipment List (MEL),
Specification sheets, Bill Of Materials (BOM), Insurance and critical spare part list, reliability data, and
validate and integrate them.
The Contractors should provide to the System Integrator, for the part of plant included in their SoW,
information such as: the list of all tagged equipment; the approved P&ID’s maintenance proposal;
Insurance and critical spare parts list, spare parts holding recommendations (Variety and volume);
reliability data, detailed maintainability, failure and Availability analyses.
4.2.2 Procedure
The procedure to be applied for the implementation of the activity is described below.
1. System Integrator submit the O&M Data and Analysis Requirements for Contractors and Suppliers
to Contractors
2. Contractor submit the relevant O&M Data and Analysis Requirements to Suppliers by in accordance
with O&M Data and Analysis Requirements for Contractors and Suppliers set by the System
Integrator
3. Suppliers provide Main Equipment List (MEL), Specification sheets, BOM, Insurance and critical
spare part list, reliability data, to the Contractor
4. Contractors collect and validate data from suppliers and integrate them in their own
5. Contractor submit to the System Integrator, for the part of plant included in their SoW, information
such as: the list of all tagged equipment; the approved P&ID’s maintenance proposal; Insurance and
critical spare parts list, spare parts holding recommendations (Variety and volume); reliability data,
detailed maintainability, failure (FMEA) and Availability analyses
6. System Integrator collect and integrate data from Contractors to prepare:
· MEL;
· Specification sheets;
· BOM;
· Insurance/Critical Spare Parts list;
· RAMS Data for RCM analyses,
for the overall plant
4.2.3 Input
The main input data to this activity are the O&M Data and Analysis Requirements for Contractors and
Suppliers set by the Company.
The outcome of the activity is represented by the following deliverables for the overall plant.
· MEL;
· Specification sheets;
· BOM;
· Insurance/Critical Spare Parts list
· RAMS Data for RCM analyses.
4.2.5 Tools
No specific tools are required for this activity

The System Integrator, together with Contractors and Suppliers, are in charge of this activity. O&M
Engineering competences are required for this activity. RAMS competences, within both the System
Integrator Team and the Contractors/Suppliers Team, are also required to accomplish the activity.
4.3 MAINTAINABILITY ANALYSIS – REVISION AND INTEGRATION
4.3.1 Scope
The aim of the Maintainability Analysis revision and integration activity is to review and integrate the MA
performed during the Concept Definition phase in terms of RIs with the analyses coming from the
Contractors and updated with any possible changes in the Detail design and logistic strategy. The
analysis addresses the system Items as defined in the System breakdown and therefore it has to be
detailed at that level in order to estimate the total maintenance time required to perform Corrective,
Preventive or On-Condition actions on the Items.
The Total Maintenance Time shall be estimated in accordance with the methodology and the procedures
set in the Concept Definition phase (Chapter 3.6).
4.3.2 Procedure
The overall procedure to be implemented to revise and integrate the Maintainability Analysis is presented
below.
1. System Integrator submit the procedures and Requirements to Contractors for Maintainability
Analysis of the part of plant included in their SoW
2. Contractors perform detailed MA for Items supplied, TOST and BIST, according to the
requirements and including information from Suppliers
3. System Integrator collect relevant information concerning changes in Logistic Strategy
4. System Integrator revise and integrate MA done during Concept Definition phase including
detailed MA and ART from Contractors
5. In the frame of the Operability analysis, System Integrator perform Task Analysis to detail the
maintenance tasks, responsibilities, skills, time to perform actions, etc.
6. System Integrator upgrade and fill CMT and PMT Work Sheets in for each Item
Example of CMT and PMT Work Sheets - Contents and use
The CMT and PMT Work sheets set in the Concept Definition phase shall be revised, integrated and
updated with the details of the current analysis and according to CMT and PMT calculation procedures set
in the Concept Definition phase.
The typical sheets for CMT and PMT calculation are shown in the Table 7 and Table 8 (Concept
definition). For each Item, the table shall be filled in with all the relevant data and inputted by the outcome
of the Task Analysis.
It is suggested to collect Data in the same electronic database used during the Concept Definition phase.
4.3.3 Input
The basic information necessary to implement this activity are the following.
· Item list;
· Results from Concept Definition phase;
· RAMS Data;
· Logistic strategy.
The main deliverables of this activity are:
· Corrective Maintenance Time for each item;
· Preventive Maintenance Time for each item.
4.3.5 Tools
It is suggested to organise Maintainability Analysis Work Sheets in an electronic database possibly the
same used during the Concept Definition phase.

The System Integrator, together with Contractors, is in charge of this activity. O&M Engineering
competences are required for this activity. Maintenance technicians shall be interviewed for maintenance
times requiring estimation by experience.
4.4 FAILURE MODE AND EFFECTS ANALYSIS - REVISION AND INTEGRATION
4.4.1 Scope
The scope of Failure Mode and Effect Analysis (FMEA) revision & integration activity is to detail the FMEA
Analysis performed during the Concept Definition phase for the RIs in order to set the information for each
specific Item. Therefore, the activity concerns the extension of the FMEA for RIs to the Items, and its
integration with the analyses provided by the Contractors.
The outcome of the FMEA analysis is the evaluation of evaluates the effects associated to the failure
mode of each Item in term of damages on Safety, Environment and Asset/Production.
4.4.2 Procedure
The procedure to be followed to implement the FMEA Analysis revision and integration activity is
presented below.
1. System Integrator submit the procedures and Requirements to Contractors for FMEA analysis
of the part of plant included in their SoW
2. Contractors require the relevant information from Suppliers, e.g. FMEA analysis at equipment
level, qualitative assessment of failure effects at equipment level, etc.
3. Contractors perform detailed FMEA for Items supplied, including information from Suppliers
4. System Integrator revise and integrate FMEA analysis done during Concept Definition phase
including detailed FMEA analysis from Contractors, according to the following main steps:
For each Item
§ List the potential Failure Modes
§ Select the operating phase in which the failure can occur
§ Assess the effects of the failure at different levels of detail (locally, sub-project level, …)
§ Assess the Severity with respect to Severity Indexes in terms of impact on the Safety, the
Environment, asset and production. The classification for severity indexes is provided by
the Risk Acceptance Criteria activity (§ 3.3).
§ Identify and list detection methods
§ Identify and list existing compensation provisions
§ On the basis of the effects and their severity assessment, suggest improvements and
recommendations for design review, maintenance policies, etc.
5. System Integrator fill in FMEA Work Sheets for Execution Phase
Example of FMEA Work Sheets for Execution Phase - Contents and use
The Failure Mode and Effect Analysis in the Execution Phase shall be performed by the completion of
FMEA Work Sheets.
As in the Concept Definition phase, it is suggested to organise Data in an electronic database easy to
interface RCM analysis tools. Commercial Tools already exist on the market and it is suggested to select
the most appropriate and use these tools for the analysis. If workable, it is recommended to refer to the
same tool used during the Concept Definition phase.
The typical sheet for FMEA analysis is shown in the Table 9 (FMEA Work Sheets Concept). For each
Item, the table shall be filled in with all the relevant data.
4.4.3 Input
The basic input data necessary to perform the FMEA analysis at this stage are the following.
· Item list;
· RAMS Data;
· Severity classification from Risk Acceptability Criteria.
As for the Concept Definition phase, the analysis has to be compliant with Process philosophy, Shutdown,
Blow Down philosophy and Safety philosophy.
The main outcome of the activity is:
· for each item, severity and classification of its failure modes.
The Analysis also provides useful:

· indications and/or recommendations for design review or O&M Policies revision.
4.4.5 Tools
It is suggested the use of FMEA Modules commercially available in off the shelf Software Tools .

The System Integrator, together with Contractors and Suppliers, is in charge of this activity. O&M
Engineering competences are required for this activity. RCM analysts shall be integrated in the team to
animate the FMEA analysis and perform the most specialised tasks. Maintenance technicians shall also
be interviewed for cause-consequences analysis. Process engineers shall be involved in the analysis to
contribute to drafting the final recommendations and suggestions.
4.5 CRITICALITY ANALYSIS – REVISION AND INTEGRATION
4.5.1 Scope
The scope of Criticality Analysis (CA) revision & integration activity is to detail the CA Analysis performed
during the Concept Definition phase for the RIs in order to set the information for each specific Item.
Therefore, the activity concerns the extension of the CA to all the Items, and its integration with the
analyses provided by the Contractors, in order to estimate their criticality according to the impact of their
failure modes on safety, environmental protection and plant production/asset separately.
The screening is semi-quantitative and is based on the Risk Matrix approach described in the Concept
Definition phase.
The outcome of the CA analysis is therefore the criticality of each Item installed on the Plant. The final
criticality of each Item is the worst index among the three criticality indexes respectively versus Safety,
Environment and Asset/Production.
4.5.2 Procedure
The Criticality Analysis consists in the assessment of the Criticality indexes and the application of the Risk
Matrixes to select the Overall Criticality for any RI failure.
The overall procedure to be followed to implement the CA Analysis revision and integration activity is
presented below.
1. System Integrator submit the procedures and Requirements to Contractors for CA analysis of
the part of plant included in their SoW
2. Contractors require the relevant information from Suppliers,
3. Contractors perform detailed CA for Items supplied, including information from Suppliers
4. System Integrator revise and integrate CA analysis done during Concept Definition phase
including detailed CA analysis from Contractors
5. System Integrator fill the CA Work Sheets in with all the relevant data, including Contractors
data
The methodology to be followed to perform the Criticality Analysis is the same as in the Concept Definition
phase, but the level of detail is deeper and moving from RIs to Items.
The procedure to be applied to calculate the criticality of each Item is recalled below. For more details
refer to the CA Analysis activity in the Concept Definition phase.
Procedure steps for each Item Steps description

2. Extract from FMEA each Item Failure Mode The Severities versus Safety, Asset damage and
Severity versus Safety, Asset damage and Environment are set during FMEA according to the
Environment Severity Matrices classification
3. Estimate the Severity versus Production Estimate Severity versus Production according the
Severity Matrices classification when the economic
cost of the loss of production is known.
The cost of loss of production CLP (USD) can be
estimated on the basis of the:
- the time duration of the out of service CMT (h)
deriving from MA,
- the cost of oil per barrel CO (USD/BOPED),
as follows:

4. Estimate the annual frequency of occurrence The Annual frequency of occurrence can be
estimated as follows:
frequency is given by their Unavailability times
the frequency of demand. The frequency of
demand can be assumed to be 1/10
(demands/year).
5. Calculate the Criticality index vs. Safety ICS = Annual frequency class x SeveritySafety
(Impact of the Failure Mode on the personnel or

population safety)
6. Calculate the Criticality index vs. Asset/Production ICA/P = Max(ICA ; ICP )
where
(Impact of the Failure Mode on the production and

in terms of asset damage)
7. Calculate the Criticality index vs. the Environment ICE = Annual frequency class x SeverityEnvironment
(Impact of the Failure Mode in terms of

environmental damage)
8. Estimate the overall Criticality Estimate the Overall Criticality Index as the worst of
the three criticality indexes set above:
The Index can assume three values as defined in

the Risk Matrix set in the Risk Acceptance Criteria
activity (Figure 4)
(Overall impact of the Failure Mode considering all

types of effects, i.e. safety, asset damage, loss of
production and environmental damage)
The Criticality Analysis in the Execution Phase shall be performed by the completion of CA Work Sheets.
As in the Concept Definition phase, it is suggested to organise Data in an electronic database easy to
interface to RCM analysis tools and possibly the same used during the Concept Definition phase.
The typical sheet for CA analysis is shown in the Table 10 (CA Work Sheets Concept). For each Item, the
table shall be filled in with all the relevant data.
4.5.3 Input
The basic input data necessary to perform the CA analysis at this stage are the following.
· List of items;
· Risk Acceptability Criteria from Concept Definition phase;
· CMT from updated MA;
· Severity Class and % of production loss from updated FMEA;
· Updated costs of production loss.
The main outcome of the CA analysis is the ranking of item failures, each one characterised by its Overall
Criticality and Criticality on Safety, Asset/Production and Environment.
4.5.5 Tools
It is suggested to organise Maintainability Analysis Work Sheets in an electronic database possibly the
same used during the Concept Definition phase.

The System Integrator, together with Contractors and Suppliers, is in charge of this activity. O&M
Engineering competences are required for this activity. RCM analysts shall be integrated in the O&M
team.
4.6 O&M POLICY REVISION AND INTEGRATION
4.6.1 Scope
The aim of O&M Policy – Revision and Integration activity is to revise, detail and update the O&M Policies
(Corrective, “On Condition”, Preventive Maintenance) defined in the Concept definition Phase for the RIs
and specialise them for the Items, in order to update them according to the revision of MA and FMEA and
according to the Operation and Maintenance indications set by Constructors. The O&M policies updated
shall therefore consider any equipment or assembly according to their technical characteristics and their
criticality versus production, safety and environment. Maintainability and Criticality analyses provide the
input information necessary to identify the best maintenance policy for each item. Whether changes or
details are requested with respect to the policies set for the corresponding RI, the choice shall be based
on the Decision Tree defined in the Concept definition phase. The activity consists of the application of
some Decision Logics to each item Failure Mode up to identify the best maintenance policy.
Concerning the definition of the most common Maintenance Policies reference should be made to the
description in § 3.10.2.1
4.6.2 Procedure
The general procedure to be applied to implement the O&M Policy Revision & Integration activity is
described below.
For each Item:

1. Check the correspondence with the related RI and derive the O&M policies suggested in the
Concept definition phase from the related O&M Policies Work Sheet
2. Derive the Failure modes from FMEA activity and compare them with the correspondent RI, if
additional ones are identified, set O&M Policies also considering them
3. For each Failure Mode, derive the Criticality from CA activity
4. Derive from the Contractors the information concerning the specific maintenance activities to be
applied to the Item
5. For each Failure Mode, apply the decision tree addressing the main criteria applied for the policy
selection
6. Select the Maintenance policy for the Item on the basis of the results of the application of the
decision tree to the Failure Modes (preventive, on-condition, corrective)
7. Apply the Preventive Maintenance Procedure [13] for preventive and on-condition maintenance
and Corrective Maintenance Procedure (see reference) to detail the Item maintenance policy
8. Update the Maintenance Policies implementing Availability Analysis
suggestions/recommendations.
The criteria to be applied for the policy selection are:

1. Overall Criticality 1: in this case the failure must be prevented by Preventive Maintenance or by “On
Condition” Maintenance, if the weak signal used for failure monitoring is fully reliable.
2. Existence of National Laws imposing Preventive periodic Maintenance for Safety/Environment critical
failure modes or components.
3. Overall Criticality 2: in this case a Preventive or “On Condition” approach is recommended.
The application of “On Condition” Maintenance must be verified according to the technical
characteristics of the equipment and the evolution of the failure in order to assess:
· Existence of a reliable signal able to perform failure monitoring,
· Feasibility of the monitoring with reference to the evolution speed of the failure,
· Costs for the “On Condition” approach.
4. Shape of the Bath Tube curve for the Failure Mode: an increase of the Failure Rate at the end of
component life addresses mainly to Preventive Maintenance while in case of constant failure rate, the
“On Condition” approach is preferred. The shape of the Bath Tube curve is related to the equipment
type and technology.
5. Constraints set by the Constructor/Provider or by the Assurance/Warranty contracts.
6. Mission profile of the plant: the presence in the mission profile of process shut down periods facilitates
the insertion of the preventive tasks without effects on production.
7. Policy applied to manage the spare parts: when the local storage of spare parts is not foreseen,
Preventive or “On Condition” Policy is preferred since they allow spare parts supplying when
necessary, avoiding logistic delays.
For any Failure Mode
Criticality 1? Is there any Law or Is there a moment of the Is there a weak signal able Is this weak signal
Constraint NO component life leading to a to reveal this Failure “Reliable”?
YES (Assurance/Warranty) fast increasing of the Mode?
asking for Preventive failure rate? NO YES
Maintenance?
NO
YES YES NO NO YES
Preventive
Maintenance
Can the failure be “caught”
in time to intervene before
NO
Criticality 2? YES the failure occurs?
YES
NO
NO Is the Cost/Benefit
competitive if compared
with the Preventive
Maintenance costs?
Does a reason exists to
perform Preventive or “On YES
Condition” Strategy for this
Failure Mode? YES “ON Condition”
(Technical and/or Economic) Maintenance
NO
Corrective
Maintenance
Figure 20. Decision Tree for Maintenance Policy selection

The O&M Policy revision and integration shall be completed by upgrading in O&M Policy
Work Sheets.
It is suggested to organise Data in an electronic database easy to interface RCM analysis
tool.
The typical sheet for O&M Policy definition is shown in the following table. For each Item,
the table shall be filled in with all the relevant data.
Project:
Sub Project:
Main Equipment:
Failure On Item O&M Policy

TAG Item Description Function Criticality PM CM
Mode Condition description
Table 12. O&M Policies Work Sheet

Sub Project: name of the part of plant in according to item numbering and coding system
(e.g. Offshore blocks, Onshore, Pipelines, etc.)
Facility Functional Unit (FFU): name of the main function accordance with the item
numbering and coding system (e.g. 200 - Oil Separation, 210 - Crude oil treatment, 300 –
Gas separation, etc),
Main Equipment: name of the equipment defined in the O&M Project Basis (e.g. Wellhead
production, HP flare, Oil booster pumps, etc.).
TAG: this field set the reference tag set to univocally identify the Item
Item: this field contains the name of Item under investigation.
Description: description of the item under investigation.
Function: description of the item function for Item under investigation.
Failure Mode: this field sets the Failure Modes for the Item as defined in the data RAMS
Data Collection Tables and FMEA analysis.
Criticality: it represents the overall impact of the Failure Mode considering all types of
effects (safety, asset damage, loss of production and environmental damage). The Overall
Criticality Index is estimated as the worst of the three criticality indexes versus Safety, the
Environment, Asset/Production.
Preventive Maintenance: description of the activities of Preventive Maintenance foreseen
for the Item under analysis, according to constraints set by the Constructor/Provider, by the
Assurance/Warranty contracts and with reference to mission profiles of plant and units.
Corrective Maintenance: short description of the activities of Corrective Maintenance
foreseen for the Item under analysis, according to constraints set by the
Constructor/Provider, by the Assurance/Warranty contracts and with reference to mission
profiles of plant and units.
On Condition Maintenance: short description of the activities of On Condition Maintenance
foreseen for the Item under analysis, according to constraints set by the
Constructor/Provider, by the Assurance/Warranty contracts and with reference to mission
profiles of plant and units.
RI O&M Policy description: description of the O&M Policy to be applied to the Item under
investigation.
4.6.3 Input
The input data to this activity concern:
· Operation and Maintenance indications set by Constructors.
The main outcome of the activity is represented by detailed Maintenance Policies for all
Item Failure Modes.
4.6.5 Tools
The analysis shall be performed by the support of the Decision Tree. It is suggested to use
electronic data sheets similar to those used in the Concept Definition phase to record the
revised O&M Policy for each Items.

The System Integrator is in charge of this activity and shall collect all the relevant
information provided by Contractors. O&M Engineering competences are required for this
activity. Maintenance technicians shall be interviewed for suggestions based on their
experience from the field.
4.7 AVAILABILITY ANALYSIS – PLANT AND SYSTEMS
4.7.1 Scope
The scope of the Availability Analysis – Plant and System activity is to perform a detailed
Availability Analysis of the system, in order to evaluate the availability in term of average
production availability of the overall Plant.
The activity is executed by the System Integrator implementing the reliability data coming
from Contractors and Suppliers, the revised Maintenance Policies and the availability
analysis performed by the Contractors on the systems supplied. The final availability
analysis takes into account both Corrective and Preventive maintenance actions required
by each Item of the Plant.
The availability targets are set during the Concept Definition phase. During the Execution
phase, they shall be allocated to the Contractors, in order to guarantee that the overall
targets are satisfied.
The AA analysis provides useful information concerning the plant performance versus the
selected O&M Policies and the design. Therefore, the results of the analysis can lead to
preliminary recommendations to improve the O&M policies and/or the design (Design
Review) when the target set for the plant is not satisfied.
4.7.2 Procedure
The overall procedure to be applied to implement the Availability Analysis - Plant& Systems
activity is described below.
1. System Integrator allocate availability targets to Contractors and submit the

procedures and Requirements to Contractors for AA analysis of the part of plant
included in their SoW
3. Contractors perform detailed AA on the System supplied possibly applying RBD
(Reliability Block Diagrams) Analysis, including information from Suppliers
4. System Integrator revise and integrate AA analysis done during Concept
Definition phase including detailed AA analyses provided by Contractors (see
procedure below)
5. System Integrator compare the availability figures evaluated applying the AA
procedure (see below) with the initial targets, in order to verify if the system
accomplishes its functions as required. If not go to 6.
6. By using the results of the sensitivity and importance analysis System Integrator
provide feedback/Recommendations to O&M Policies and/or Design review,
which could contribute to increase the availability level.
The methodology to perform the Availability Analysis applies the same principles as in the
Concept Definition phase, but the level of detail is deeper, moving from RIs to Items.
The procedure the System Integrator shall followed for AA is recalled below. For more
details refer to the Availability Analysis activity – Step 2 in the Concept Definition phase.
Steps Description
4.1 Upgrade (whether necessary) the Define the plant mission as set of activities
mission profile and environmental conditions the system has to perform during a stated
defined in the Concept Definition phase operative time to satisfy its performance
objectives.
Describe the mission profile in terms of
operation required to the system during the
mission.
Describe the environmental conditions that
the system can meet during the
accomplishment of its mission
4.2 Perform Fault Tree Analysis for ESD Due to importance and specificity of this step,
system it is not described in this section but fully
expanded in § 3.9.7
4.3 Upgrade the system model for Prepare a Reliability Block Diagram (RBD)
availability assessment model by including the models provided by
the Contractors
4.4 Prepare the input data set for availability Derive input data from:
assessment - Reliability data from RAMS Data
Collection
- Maintenance Time (corrective +
preventive maintenance time) from the
Maintainability Analysis Revision and
Integration activity,
- Role of each equipment versus plant
safety and production, from FMEA
sheets,
- Maintenance Policies, by the
application for Decision Logics with
reference to O&M Policy activity,
- Information on logistic, spares
management, etc from and
Maintainability Analysis Revision and
Integration activity
4.5 Assess plant availability Availability assessment using Monte Carlo
simulation
4.6 Upgrade Sensitivity / Importance Upgrade Sensitivity and importance analysis
Analysis done in the Concept Definition phase by
considering the additional information
provided by the Design Details and the
Contractors
Go to step 5 of the overall procedure of this
activity.
4.7.3 Input
The basic input data necessary to implement the Availability Analysis – System and Plants
activity are the following.
· Result from Concept Definition phase;
· Item list and mission profile;
· Reliability data from RAMS Data Collection;
· CMT/PMT from MA Revision and Integration;
· Effects of items on safety and production from FMEA Revision and Integration;
· Maintenance policies from O&M Policies Revision and Integration;
· Logistic strategy, spare part management from Project Basis and MA Revision and
Integration.
The main deliverables of this activity are listed below.
· Plant Availability in terms of average production;
· Ranking of items/systems according to their criticality derived by the Sensitivity and
Importance Analysis, i.e. their contribution to the overall system Unavailability. This
result allows planning the interventions in the O&M plan, leading to an
improvement of the effective plant Availability;
· Input to O&M Policy Revision and/or design review.
4.7.5 Tools
The current market offers a quite variable choice of software tools for availability analysis
able to manage different maintenance programmes.
It is suggested to use the same tools selected for the AA during the Concept Definition
phase in order to exploit the modelling efforts done during that phase and to guarantee the
compatibility of the input data and analysis methods.

The System Integrator, together with Contractors, is in charge of this activity. RCM analysts
shall perform the analysis. O&M Engineering competences are required for this activity.
4.8 O&M TASKS AND PROCEDURES FOR OVERALL PLANT
4.8.1 Scope
The scope of the O&M Tasks and Procedures for Overall Plant activity is to define the O&M
Tasks and procedures for the overall plant on the basis of the revision and integration done
in the previous analyses, and the information provided by Contractors and Suppliers. For
this reason, the activity includes the three activities shown in the flow diagram concerning
the Operating Manual and Maintenance Plans provided by Suppliers and Contractors and
the O&M Tasks and Procedures for Overall Plant set by the System Integrator.

Maintenance Plan by Maintenance Plans
by Contractors
Concept Maintainability
definition analysis
O&M Results Revision &
System (O&M
Target Plan, POGs
Failure Revision & Revision & Plant & Yes procedures for
Implementation,
Analysis Integration Integration Systems No overall plant
Contractors/ Input CMMS)
(FMEA)
Suppliers Revision &
Data Integration
Upgrading
OR
OR
Maintenance Contracts :
- Technical Docs
- Performance Plant
Design Requirements
review
EXECUTION PHASE

Maintenance Plan by Maintenance Plan
by Contractors
Maintainability
analysis
Revision &
System (O&M
Target Plan , POGs
Revision & Revision & Plant & Yes procedures
Implementation,
Integration Integration Systems No for overall
Input CMMS)
plant
Figure 21. O&M Tasks and Procedures versus RCM approach in Execution phase
More precisely, the O&M Tasks and procedures for the overall plant are defined taking into
account of the following data:
· Information provided by the Contractors and Suppliers,
· Specific constraints deriving from Insurance/Warranty,
· Final definition of the spare parts management,
· Planning of the human resources for maintenance and the related organization,
· Results from the Availability Analysis.
Data and information provided by Contractors and Suppliers mainly concern operating
manuals and maintenance plans.
The description of the maintenance procedures and the related tasks shall be detailed in
terms of actions to be performed, required skill, manning, tasks duration, required tools, etc.
The Task Analysis approach shall be implemented to support this activity.
4.8.2 Procedure
The overall procedure to be followed to implement the O&M Task and Procedures activity is
presented below.
1. System Integrator submit the procedures and Requirements to Contractors for

operating manuals and maintenance plans of the part of plant included in their
SoW
3. Contractors elaborate the operating manuals and maintenance plans by reviewing
and integrating the operating manuals and maintenance plans provided by the
Suppliers
4. System Integrator collect and review the operating manuals and maintenance
plans provided by the Contractors
5. System Integrator draft O&M Tasks and Procedures by integrating the reviewed
operating manuals and maintenance plans provided by the Contractors, taking into
account the specific constraints deriving from:
- Insurance/Warranty,
- final definition of the spare parts management,
- planning of the human resources for maintenance and the related
organization,
- results from the Availability Analysis, etc
6. System Integrator detail the maintenance procedures and the related tasks in
terms of actions to be performed, required skill, manning, tasks duration, required
tools, etc. The Task Analysis approach shall be implemented to support this
activity.
4.8.3 Input
The required input data to this activity are the following.
· Results from Availability Analysis Plant & System activity;
· Constraints from Insurance/Warranty;
· Spare part management;
· Human resources planning.
· O&M Tasks and Procedures for overall plant;
· Outline of O&M Plan and Process Operator Guides (POGs);
4.8.5 Tools
The Task Analysis shall be performed by the support of graphical tools. For Tabular task
Analysis it is suggested to use electronic data sheets.
It is suggested to use standardised format for Procedures description.

The System Integrator is in charge of this activity and shall collect all the relevant
information provided by Contractors and Suppliers. O&M Engineering competences are
required for this activity. Maintenance technicians, Logistics and Manning experts shall be
interviewed for suggestions based on their experience from the field. Human factor
competencies are an asset.
4.9 OVERALL O&M SYSTEM
4.9.1 Scope
The scope of the Overall O&M System Activity is to finalise a detailed O&M System for the
overall Plant.
The Overall O&M System shall contain at least the following information:
· O&M plan,
· Process Operator Guides (POGs),
· All data ready to be implemented into the Computerised Maintenance Management
System (CMMS). To this aim, all data and information coming from Contractors and
Suppliers are collected and produced in readiness for input into the Company
CMMS.
The Overall O&M system activity also addresses:
· The link between the CMMS Model and the RCM Model,
· The preparation of working procedures for Maintenance Technicians in order to
collect data during maintenance activities useful for the O&M Engineering Team,
devoted to monitor the efficacy of the Maintenance Plan and to update it,
· The preparation of a synthetic representation of the RCM model to handle to the
Operation team to make it aware of the RCM strategy and of the criticalities of each
portion of the plant.
In general, all these tasks should lead to implement a “loop” between the O&M Engineering
Team and the Operation Team in order to realize a “living” Maintenance Plan, that should
be periodically updated on the basis of the feedback from the actual plant performances.
This activity also supports the Company in the preparation of the Invitation To Tender (ITT)
technical documentation for the Maintenance contracts award.
4.9.2 Procedure
The overall procedure to be followed to implement the Overall O&M System activity is
presented below.
1. Starting from the outline of O&M Plan and POG provided by the O&M Tasks and
Procedures Activity, System Integrator (O&M Team) draft O&M Plan and POGs
2. System Integrator (O&M Team) collect all data and information coming from
Contractors and Suppliers for input into the Company CMMS
3. System Integrator (O&M Team) organise and produce in readiness data to be
implemented into the Company Computerised Maintenance Management
System (CMMS).
4. System Integrator (O&M Team) formalise the link between the CMMS Model
and the RCM Model according to the MMS-Master Data Management Procedure
[12].
5. System Integrator (O&M Team) prepare (if not existing) and submit working
procedures for Maintenance Technicians (Company/Contractors) in order to
collect data during maintenance activities useful for the O&M Engineering Team,
devoted to monitor the efficacy of the Maintenance Plan and to update it,
6. System Integrator (O&M Team) prepare a synthetic representation of the RCM
model to handle to the Operation team to make it aware of the RCM strategy
and of the criticalities of each portion of the plant
7. O&M Team support the Company in the preparation of the Invitation To Tender
(ITT) technical documentation for the Maintenance contracts award and in the
definition of the Performance Plant Requirements
8. O&M Team develop procedures to maintain a “living” RCM programme
4.9.3 Input
The main input data to this activity are:
· O&M Tasks and procedures for overall plant;
· Outline of O&M Plan and POGs;
The main deliverables of the O&M System Activity are listed below.
· O&M Plan and POGs;
· Data ready to be implemented in the CMMS;
· Procedures for the “living” RCM programme;
· Support to the preparation of the technical documentation for the Maintenance
contracts award and to the definition of the Performance Plant Requirements.
4.9.5 Tools
No specific Tools are foreseen for this activity. However, it is suggested to record all the
information in an electronic format (compatible with commercial software tools) to be
decided before starting the activity and to be used as support all along the activity
development and life.

The System Integrator is in charge of this activity. O&M Engineering competences are
required all along the implementation of the activity. Maintenance Technicians, Logistics
Experts, can also be involved for their know-how of the field.

The main results expected in the Execution phase are:
· the preparation of an overall O&M Plan;
· a fully development of the POGs;
· data and information to be implemented in the CMMS.
· operational policies set in order to:
- Prepare the link between the CMMS Model and the RCM Model,
- Define the procedures for Maintenance Technicians for data collection
during maintenance activities useful for the O&M Engineering Team,
devoted to monitor the efficacy and to update the Maintenance Plan,
- Provide a synthetic representation of the RCM model to the Operation team
to make it aware of the RCM strategy and of the criticalities of the plant,
- Implement a “loop” between the O&M Engineering Team and the Operation
Team in order to realize a “living” Maintenance Plan whom changes are
driven by the monitoring of the plant performances.
4.11 SYNTHESIS OF ACTIVITIES AND RESPONSIBILITY MATRIX FOR THE EXECUTION

PHASE
In the following Table 13, the activities are described in detail in order to highlight the
related goals and the role of the System Integrator, Contractors and Suppliers.
# STEP GOAL System Integrator Contractors Suppliers

1 Contractors/ To prepare: To collect and validate all To collect and validate all To provide:
Suppliers · MEL data coming from data coming from · MEL
data · Specification Contractors. Suppliers · Specification
Sheet Sheet
· BOM · BOM
· Insurance and · Insurance and
Critical Spare part Critical Spare part
lists lists
Reliability To provide reliability To collect and validate all To collect and validate all To provide failure rate
data data required by the data coming from data coming from and ART of each Item
RAMS analyses. Contractors. Suppliers. supplied.
2 MA To evaluate the Revision and integration of To perform a detailed MA Nil
Corrective MA done during the of the Items supplied.
Maintenance Time of Concept definition phase Times to be evaluated are:
each Item of the plant. based on: · Time to take each
· Possible changes of Item out of service
Logistic Strategy (TOST)
having impact on LD · Time to bring it back
· Detailed MA (TOST into service (BIST)
and BIST) and
reliability data (ART)
coming from
Contractors.
3 FMEA To assess the effects Revision and integration (if To perform a detailed Nil
of each Item failure on any) of FMEA done during FMEA of the Items
Asset, Safety and the Concept definition supplied.
Environment phase based on Detailed
FMEA coming from
Contractors.
4 Criticality To assess the criticality Revision and integration (if To perform a detailed CA Nil
Analysis of each Item versus any) of the CA done of the Items supplied.
Asset, Safety and during the Concept
Environment. definition phase based on
CA coming from
Contractors.
5 O&M Policies To set O&M Policies for Revision and Integration To provide indications Nil
each Item. (if any) according to the about Operation and
revision of MA and FMEA Maintenance of the Items
and according to the supplied.
Operation and
Maintenance indications
set by Contractors
6 Availability To evaluate the Revision of the Availability To perform an AA on the Nil
Analysis availability of the Analysis of the overall System supplied possibly
overall plant. Plant done during the applying RBD (Reliability
Concept definition phase Block Diagrams) Analysis.
based on the Availability
Analysis coming from
Contractors.
7 O&M Tasks To provide O&M Tasks To collect, homogenise To collect, validate and Provide a Maintenance
and and Procedures for the and validate all data integrate Maintenance Plan and an Operating
procedures overall Plant concerning maintenance Plans and Operating manual of the system
plan and operating manual coming from supplied.
manuals coming from Suppliers.
Contractors for the
definition of:
· O&M Plan outline;

· Data to implement the
CMMS
· Process Operator
Guides outline
8 Overall O&M To provide a detailed To elaborate all data Nil Nil
system O&M System for the coming from the previous
overall Plant stage to issue:
· O&M Plan;
· Process Operator
Guides,
and feed the CMMS
9 Maintenance To prepare the Preparation of Nil Nil
Contracts Technical Documentation and
Documentation definition of Performance
Plant Requirements
Table 13. Description of the O&M activities to be implemented during Execution phases.
5. PRODUCTION PHASE
5.1 RCM METHODOLOGY PROCEDURES FOR THE PRODUCTION PHASE

The Production phase is the final addressee of the overall O&M Project. In this phase the
Company should benefit of the maintenance plan developed according to the Reliability
Centered Maintenance approach and capitalise feedback information/ data from operation
to feed the RCM methodology.
As stated in the previous chapters, the maintenance plan is not frozen; it has to “live” with
the plant. For this reason the methodology foresees a continuous upgrade of the O&M
Policies and Plans along the life of the plant, based on the experience made on the plant in
terms of failures, maintenance interventions, effects on the production availability and the
Contractual Maintenance Strategy adopted.
During the Production phase the O&M Engineering Team shall receive data from the
Operations (via DCS) and update the RCM Model and the data Collection in order to refine
the Maintenance Plan set in the Computerised Maintenance Management System (CMMS)
with the goal of increasing the plant Availability; in parallel, the Operation Team shall collect
data from Maintenance interventions to feedback the O&M Engineering Team.
The specific activities and procedures to be implemented during the Production phase are
defined in detail during the Execution phase, precisely by the O&M System activity.
The flow chart of the RCM methodology applied to the Production phase is presented in
Figure 22. The dotted lines concerning the activities “Failure Analysis (FMEA) upgrade” and
“Availability Analysis upgrade” mean that the activities are optional and shall only be
performed in the case the decision is taken as consequence of the occurrence of an
extraordinary event (e.g. project review, repetitive incident, etc).
Project
Review
Contractual
Maintenance
Strategy
Assessment
Maintainability
analysis
Upgrade Overall O&M
Maintenance RAMS Data Criticality O&M Policies Revision of system revision
Data Upgrade analysis Revision O&M Tasks & (O&M Plans, POGs
Revision procedures for implementation,
Failure
overall plant Input CMMS)
Analysis
(FMEA)
Operation Upgrade
Availability
Data analysis
Upgrade and
Comparison
PRODUCTION PHASE
Figure 22. The RCM Methodology flow diagram (Production phase)
The procedures to be applied for the implementation of the activities foreseen by the RCM
methodology during the Production phase are described in the following sections.
5.2 CONTRACTUAL MAINTENANCE STRATEGY ASSESSMENT
5.2.1 Scope
The Maintenance Contractors are instructed to operate according to a Contractual
Maintenance Strategy that is defined at the end of the Execution phase.
The scope of the Contractual Maintenance Strategy Assessment is to revise this strategy
during the Production phase, in order to optimise it on the basis of the Operation and
Maintenance experience during Plant operation.
The outcome of the assessment contributes to the revision of the O&M Policies.
5.2.2 Procedure
The general procedure concerning the implementation of the Contractual Maintenance
Strategy Assessment Activity is presented hereafter.
1. O&M Engineering submit the guidelines and/or procedures to Maintenance

Contractors for the assessment of the Contractual Maintenance Strategy of the
part of plant they are responsible for
2. Maintenance Contractors provide the O&M Engineering Team lessons learnt and
data from the implementation of the strategies, according to the O&M
Engineering Team Guidelines/Procedures
3. O&M Engineering Team elaborate alternative maintenance strategies for O&M
Contractors to submit to the O&M Policy revision
5.2.3 Input
The input data to this activity come from the Execution Phase and concern:
· O&M Policies;
· Contractual Maintenance Strategy for Maintenance Contractors.
The main deliverable of this activity is represented by suggestions for improvement of O&M
Policies.
5.2.5 Tools
No specific tools are foreseen for this activity.

The O&M Engineering Team is in charge of this activity. The Maintenance Contractors shall
provide the information required to assess the Contractual Maintenance Strategy.
5.3 MAINTENANCE DATA
5.3.1 Scope
The scope of the Maintenance Data activity is to collect data concerning maintenance
interventions and to use them to update the RAMS data defined in the Execution phase.
Data are collected from the Maintenance Technicians according to the procedures set at
the end of the Execution phase and supplied to the O&M Engineering Team, devoted to
monitor the efficacy of the Maintenance Plan and to update it.
5.3.2 Procedure
The overall procedure to be followed to implement the Maintenance Data collection activity
is presented below.
1. O&M Engineering submit the guidelines and/or procedures to Maintenance

Contractors/Technicians for Maintenance Data collection according to the MMS-
Work Management Procedure [17].
2. Maintenance Contractors/Technicians provide the O&M Engineering Team with
data collected and recorded according to the format decided for the facility
according to the MMS- Global Maintenance Service Procedure [20].
3. O&M Engineering Team store the information for RAMS Data Upgrade according
to the MMS-Maintenance Reporting Procedure [18].
5.3.3 Input
The input data to this activity come from the Execution Phase and concern:
· RAMS Data;
· Procedures for data collection.
The main deliverable of this activity is represented by actual operational maintenance data
to upgrade RAMS data from Concept Definition and Execution Phase.
5.3.5 Tools
information in an electronic format easy to interface with the Company Reliability data bank.
The format shall be decided by the O&M Engineering team and used by the Maintenance
Contractors all along the production phase.

The O&M Engineering Team is in charge of this activity. The Maintenance Contractors shall
provide the information required according to the procedures for data collection.
5.4 OPERATION DATA
5.4.1 Scope
The scope of the Operation Data collection activity is to collect data related to plant
operation. The operation team uses the synthetic representation of the RCM model setting
the RCM strategy and the criticalities of each portion of the plant, to monitor the actual
performance of the plant and to supply data to the O&M Engineering Team for RAMS Data
upgrade and the comparison between the actual availability level and the prediction.
5.4.2 Procedure
The overall procedure to be followed to implement the Maintenance Data collection activity
is presented below.
1. O&M Engineering submit the synthetic representation of the RCM model setting
the RCM strategy and the criticalities of each portion of the plant and procedures
for Operation data collection to Operation Team for Operation Data collection
2. Operation Team provide the O&M Engineering Team with data collected and
recorded according to the format decided for the facility
3. O&M Engineering Team store the Operation data for RAMS Data Upgrade
4. O&M Engineering Team use the data for comparison between the actual
availability level and the prediction (see also Availability Analysis Upgrade and
Comparison Activity)
5.4.3 Input
The input data to this activity come from the Execution Phase and concern the synthetic
representation of the RCM model and the related procedures for data collection.
The main deliverable of this activity is represented by actual operation data to upgrade
RAMS data from Concept Definition and Execution Phase and (optional) to compare with
the calculated availability.
5.4.5 Tools
information in an electronic format easy to be interfaced with the Company Reliability data
bank. The format shall be decided by the O&M Engineering team and used by the
Operation Team all along the production phase.

The O&M Engineering Team is in charge of this activity. The Operation Team shall provide
the information required according to the procedures for data collection.
5.5 RAMS DATA UPGRADE
5.5.1 Scope
The scope of RAMS Data upgrade activity is to update the RAMS Data required by RCM
analyses with maintenance data from the field and operation feedback and to feed the
Company Reliability Data Bank.
The O&M Engineering Team updates the RAMS data used for the RCM analysis during the
Execution phase on the basis of the information provided by the Maintenance
Contractors/Technicians, Operation Team and whether executed, by the feedback of
project review. These data are then used for the revision and periodic upgrade of the
Maintainability Analysis for the specific installation. In the case the decision of updating all
the RCM analyses is taken due to extraordinary events, such as poor plant availability, the
updated RAMS data are also used for re-performing the FMEA and the Availability analysis.
5.5.2 Procedure
The overall procedure to be followed to implement the RAMS Data upgrade activity is
presented below.
1. O&M Engineering Team updates the RAMS data used for the RCM analysis
during the Execution phase on the basis of the information provided by the
Maintenance Contractors/Technicians, Operation Team and whether executed, by
the feedback of project review
2. O&M Engineering Team select the relevant data to feed the Company Reliability
Data Bank and record them
5.5.3 Input
· RAMS Data from Execution Phase;
· Maintenance Data;
· Operation Data;
· Feedback from project review (if any).
The main deliverable of this activity is represented by the upgraded RAMS Data collection
for RCM analyses and the Company Reliability Data Bank.
5.5.5 Tools
No specific Tools are foreseen for this activity. The data shall be recorded according to the
RAMS Data collection format and the Company Reliability Data Bank format.

The O&M Engineering Team is in charge of this activity.
5.6 MAINTAINABILITY ANALYSIS UPGRADE
5.6.1 Scope
The scope of the Maintainability Analysis upgrade is to review the MA performed during the
Execution phase on the basis of the updated RAMS data and any possible changes in the
logistic strategy and/or in the installation (Project review).
5.6.2 Procedure
The overall procedure to be implemented to periodically revise and update the
Maintainability Analysis is presented below.
1. O&M Engineering Team refer to the RAMS Data update

2. O&M Engineering Team collect relevant information concerning changes in
Logistic Strategy (if any)
3. O&M Engineering Team revise and integrate MA done during Execution phase
on the bases of the updated information (data from steps 1 and 2)
4. O&M Engineering Team upgrade and fill CMT and PMT Work Sheets in for each
Item
Example of CMT and PMT Work Sheets - Contents and use
The CMT and PMT Work sheets set in the Execution phase shall be revised and updated
with the new set of RAMS Data and according to CMT and PMT calculation procedures set
in the Concept Definition phase.
The typical sheets for CMT and PMT calculation are shown in the Table 7 and Table 8
(Concept definition). For each Item, the table shall be filled in with all the relevant data.
It is suggested to record Data in the same electronic database used during the Concept
Definition phase.
5.6.3 Input
The input data to this activity concern updated set of RAMS Data.
The main deliverables of this activity is the updated Preventive and Corrective Maintenance
Time of the Items of the installation.
5.6.5 Tools
It is suggested to organise Maintainability Analysis Work Sheets in an electronic database
possibly the same used during the Execution phase.

5.7 CRITICALITY ANALYSIS
5.7.1 Scope
CA evaluates the “living” criticality of each Item installed on the Plant. The O&M
Engineering Team reviews the CA performed during the Execution phase on the basis of
the updated MA and extraordinarily, FMEA analysis. The critical items detected during the
updated analysis are notified for the revision of the O&M Plan. In the case of a total update
of the RCM analyses, a potential Project Review can be suggested. In the case a project
review is decided, the RAMS data should be updated to include the proposed modifications
and the RCM flow repeated.
5.7.2 Procedure
The Criticality Analysis consists in the assessment of the Criticality indexes and the
application of the Risk Matrixes to select the Overall Criticality for any RI failure.
The overall procedure to be followed to implement the CA Analysis revision and integration
activity is presented below.
1. O&M Engineering Team refer to the Maintainability Analysis upgrade and FMEA
analysis upgrade (if applicable)
2. O&M Engineering Team revise and upgrade CA analysis done during Execution
phase or last upgrade in the Production phase on the bases of Maintainability
Analysis upgrade and FMEA analysis upgrade (if applicable)
3. O&M Engineering Team fill the CA Work Sheets in with all the relevant data
The methodology to be followed to perform the Criticality Analysis is the same as in the
Execution phase.
The procedure to be applied to calculate the criticality of each Item is recalled below. For
more details refer to the CA Analysis activity in the Concept Definition and Execution
phases.
Procedure steps for each Item Steps description

2. Extract from FMEA each Item Failure The Severities versus Safety, Asset damage
Mode Severity versus Safety, Asset damage and Environment are set during FMEA
and Environment according to the Severity Matrices
classification
3. Estimate the Severity versus Production Estimate Severity versus Production
according the Severity Matrices classification
when the economic cost of the loss of
production is known.
The cost of loss of production CLP (USD) can
be estimated on the basis of the:
- the time duration of the out of service
CMT (h) deriving from MA,
- the cost of oil per barrel CO
(USD/BOPED),
as follows:

4. Estimate the annual frequency of The Annual frequency of occurrence can be

occurrence estimated as follows:
frequency is given by their
Unavailability times the frequency of
demand. The frequency of demand can
be assumed to be 1/10
(demands/year).
5. Calculate the Criticality index vs. Safety ICS = Annual frequency class x
SeveritySafety
(Impact of the Failure Mode on the

personnel or population safety)
6. Calculate the Criticality index vs. ICA/P = Max(ICA ; ICP )
Asset/Production where
ICP = Annual frequency class x
SeverityProduction
(Impact of the Failure Mode on the

production and in terms of asset damage)
7. Calculate the Criticality index vs. the ICE = Annual frequency class x
Environment SeverityEnvironment
(Impact of the Failure Mode in terms of

8. Estimate the overall Criticality Estimate the Overall Criticality Index as the
worst of the three criticality indexes set
above:
The Index can assume three values as

defined in the Risk Matrix set in the Risk
Acceptance Criteria activity (Figure 4)
(Overall impact of the Failure Mode

considering all types of effects, i.e. safety,
asset damage, loss of production and
The Criticality Analysis in the Execution Phase shall be performed by the completion of CA
Work Sheets.
It is suggested to organise Data in an electronic database easy to interface to RCM
analysis tools and possibly the same used during the Execution phase.
The typical sheet for Criticality Analysis is shown in the Table 10 (CA Work Sheets
Concept). For each Item, the table shall be filled in with all the relevant data.
5.7.3 Input
The basic input data necessary to perform the CA analysis at this stage are the following.
· List of items
· CA from Execution phase or last upgraded CA analysis
· Upgraded MA
· Upgraded FMEA (whether applicable)
· Risk Acceptability Criteria (from Concept Definition and Execution phase).
The main deliverables of the CA analysis revision activity are:
· Revised Criticality Analysis;
· Actual Criticality of each item versus Production/Asset, safety and Environment;
· Suggestions for O&M policies revision.
5.7.5 Tools
It is suggested to organise Maintainability Analysis Work Sheets in an electronic database
possibly the same used during the Concept Definition phase.
5.8 FAILURE MODE AND EFFECTS ANALYSIS UPGRADE
5.8.1 Scope
Scope of the Failure Mode and Criticality Analysis upgrade activity is to upgrade the FMEA
done during the Execution phase or the last upgrade of the Production phase on the basis
of the updated RAMS data and any possible changes in the installation (Project review).
FMEA Analysis (as well as Availability Analysis) is optional and shall only be implemented
in the case an extraordinary event occurs (e.g. Project review) and the decision is therefore
taken to review the overall or part of the analysis (last issue). Figure 23 highlights the
optional part of the RCM methodology applied to the Production phase.
Project
Review
Contractual
Maintenance
Strategy
Assessment
Maintainability
analysis
Upgrade Overall O&M
Maintenance RAMS Data Criticality O&M Policies Revision of system revision
Data Upgrade analysis Revision O&M Tasks & (O&M Plans, POGs
Revision procedures for implementation,
Failure overall plant Input CMMS)
Analysis
(FMEA)
Operation Upgrade
Availability
Data analysis
Upgrade and
Comparison
PRODUCTION PHASE
Criticality
analysis
Failure Revision
Analysis
(FMEA)
Upgrade
Availability
analysis
Upgrade and
Comparison
Figure 23. Optional RCM Activities during Production phase
5.8.2 Procedure
The procedure to be followed to implement the FMEA upgrade activity is presented below.
1. O&M Engineering Team refer to the RAMS Data update

2. O&M Engineering Team revise and integrate FMEA analysis done during
Execution phase or the last update during the Production phase on the bases of
RAMS Data upgrade and feedback from project review, according to the following
main steps:
For each Item
§ List the potential Failure Modes
§ Select the operating phase in which the failure can occur
§ Assess the effects of the failure at different levels of detail (locally, sub-project
level, …)
§ Assess the Severity with respect to Severity Indexes in terms of impact on the
Safety, the Environment, asset and production. The classification for severity
indexes is provided by the Risk Acceptance Criteria activity (§ 3.3).
§ Identify and list detection methods
§ Identify and list existing compensation provisions
§ On the basis of the effects and their severity assessment, suggest
improvements and recommendations for design review, maintenance policies,
etc.
3. O&M Engineering Team fill in FMEA Work Sheets for Production Phase
Example of FMEA Work Sheets for Production Phase - Contents and use
The Failure Mode and Effect Analysis in the Production Phase shall be performed by the
completion of FMEA Work Sheets.
As in the previous phases, it is suggested to organise Data in an electronic database easy
to interface RCM analysis tools. Commercial Tools already exist on the market and it is
suggested to select the most appropriate and use these tools for the analysis. If workable, it
is recommended to refer to the same tool used during the Execution phase.
The typical sheet for FMEA analysis is shown in the Table 9 (FMEA Work Sheets Concept).
For each Item, the table shall be filled in with all the relevant data.
5.8.3 Input
The basic input data necessary to perform the FMEA analysis at this stage are the
following.
· Item list;
· Updated set of RAMS Data and feedback from project review;
· Severity classification from Risk Acceptability Criteria.
The main outcome of the activity is the updated FMEA Analysis (severity and classification
of failure modes for each item).
The Analysis also provides useful indications and/or recommendations for design review or
O&M Policies revision.
5.8.5 Tool
It is suggested the use of off the shelf Software Tools forFMEA analysis.

O&M Engineering Team is in charge of this activity. RCM analysts shall be integrated in the
team to animate the FMEA analysis and perform the most specialised tasks. Maintenance
technicians shall also be interviewed for cause-consequences analysis. Process engineers
shall be involved in the analysis to contribute to drafting the final recommendations and
suggestions.
5.9 AVAILABILITY ANALYSIS – UPGRADE AND COMPARISON
5.9.1 Scope
The scope of the Availability Analysis upgrade and comparison activity is to evaluate the
plant availability implementing the Operation data provided by the Operation Team and to
compare it with the measured plant availability.
The activity is optional and it is executed by the O&M Engineering Team only in the case an
extraordinary event occurs (e.g. unexpected repetitive incident) and the decision is taken to
review the analysis.
In this special case, the availability estimated in this activity is compared to the availability
measured during the plant operation and on the basis of this comparison the O&M
Engineering Team provides suggestion to the revision of the O&M Policies or ask for a
project review. The availability analysis is then repeated to assess the
changes/improvements suggested during the project review.
The Availability Analysis, normally performed to evaluate the availability in term of average
production availability of the overall Plant, could also be limited in its scope within this
activity to address parts of the plant that are estimated more critical.
The methodology to perform the Availability Analysis applies the same principles as in the
Concept Definition and Execution phase, but the results of the analysis are used with
different objectives and not used to compare availability but with the actual measured plant
availability.
5.9.2 Procedure
The overall procedure the O&M Engineering Team shall apply to implement the Availability
Analysis – Upgrade and Comparison activity is described below. This procedure can be
applied to evaluate the Availability analysis of the overall plant as well as selected parts of
the plant.
Steps Description
1. Upgrade (whether necessary) the mission Define the plant mission as set of activities
profile and environmental conditions defined the system has to perform during a stated
in the Execution phase operative time to satisfy its performance
objectives.
Describe the mission profile in terms of
operation required to the system during the
mission.
Describe the environmental conditions that
the system can meet during the
accomplishment of its mission
2. Upgrade the system model for availability Prepare a Reliability Block Diagram (RBD)
assessment model by including all changes made during
the plant production interval covered by the
analysis
assessment - Reliability data from RAMS Data
upgrade
- Maintenance Time (corrective +
preventive maintenance time) from the
Maintainability Analysis upgrade
activity,
- Role of each equipment versus plant
safety and production, from FMEA
sheets,
- Maintenance Policies
- Information on logistic, spares
management, etc from and
Maintainability Analysis Upgrade

simulation
5. Upgrade Sensitivity / Importance Analysis Upgrade Sensitivity and importance analysis
done in the Execution phase or last updated
analysis by considering the additional
information provided by plant operation
6. Compare the availability figures and Comparison between availability figures
identify deviations evaluated applying the AA procedure and the
actual measured figures and identification of
deviations
7. Analyse deviations Analysis of deviations to identify the causes
in order to provide suggestions/
recommendations for project review.
8. Upgrade the availability model Update or modify the initial availability model
whether limitations in modelling are identified
and go to 2. Otherwise go to 10.
9. Provide feedback/Recommendations to Use of the results of the sensitivity and
O&M Policies revision and/or Project review importance analysis and the deviations’
analysis to provide
feedback/Recommendations to O&M Policies
and/or Project review
10. Repeat the AA procedure to assess Assessment of the efficacy of the
modifications suggested during the project modifications suggested during the project
review review to increase plant availability
5.9.3 Input
The basic input data necessary to implement the Availability Analysis – Upgrade and
Comparison activity are the following.
· AA from the Execution Phase;
· Operation Data;
· Item list and mission profile;
· Reliability data from RAMS Data Upgrade;
· CMT/PMT from MA upgrade;
· Effects of items on safety and production from FMEA upgrade;
· Maintenance policies from O&M Policies (Execution phase or last update in
Production phase);
· Logistic strategy.
· Plant Availability in terms of average production or selected parts of plant
availability;
· Ranking of items/systems according to their criticality derived by the Sensitivity and
Importance Analysis, i.e. their contribution to the overall system Unavailability.
· Comparison between calculated and actual availability, assessment of deviations
and suggestions/recommendations for O&M Policies revision and project review;
5.9.5 Tools
The current market offers a quite variable choice of software tools for availability analysis
able to manage different maintenance programmes.
It is suggested to use the same tools selected for the AA during the Execution phase in
order to exploit the modelling efforts done during that phase and to guarantee the
compatibility of the input data and analysis methods.

O&M Engineering Team is in charge of this activity. RCM analysts shall perform the
analysis.
5.10 O&M POLICY REVISION
5.10.1 Scope
The aim of O&M Policy Revision activity is to revise and update the O&M Policies
(Corrective, “On Condition”, Preventive Maintenance) defined in the Execution phase or in
the last update done during the Production phase, according to the MA and CA upgrade
and possible suggestions from Availability Analysis upgrade activity.
As already said in the Execution phase, the O&M policies shall consider any equipment or
assembly according to their technical characteristics and their criticality versus production,
safety and environment. Maintainability and Criticality analyses provide the input
information necessary to identify the best maintenance policy for each item. Whether
changes or details are requested with respect to the policies set previously, the choice shall
be based on the Decision Tree defined in the Concept definition phase. The activity
consists of the application of some Decision Logics to each item Failure Mode up to identify
the best maintenance policy.
Concerning the definition of the most common Maintenance Policies reference should be
made to the description in § 3.10.2.1.
5.10.2 Procedure
The general procedure to be applied to implement the O&M Policy Revision activity is
described below.
For each Item whose O&M Policy shall be upgraded:

1. Derive the Failure modes from FMEA activity (last issue)
2. For each Failure Mode, derive the Criticality from CA revision activity
3. For each Failure Mode, apply the decision tree addressing the main criteria
applied for the policy selection also considering the recommendations provided
by:
- Contractual Maintenance Strategy Assessment
- Availability Analysis (when applicable)
4. Describe the Maintenance policy for the Item on the basis of the results of the
application of the decision tree to the Failure Modes
5. Upgrade the relevant O&M Policy Work Sheet
The criteria to be applied for the policy selection are recalled hereafter:
1. Overall Criticality 1: in this case the failure must be prevented by Preventive
Maintenance or by “On Condition” Maintenance, if the weak signal used for failure
monitoring is fully reliable.
2. Existence of National Laws imposing Preventive periodic Maintenance for
Safety/Environment critical failure modes or components.
3. Overall Criticality 2: in this case a Preventive or “On Condition” approach is
recommended.
The application of “On Condition” Maintenance must be verified according to the
technical characteristics of the equipment and the evolution of the failure in order to
assess:
- Existence of a reliable signal able to perform failure monitoring,
- Feasibility of the monitoring with reference to the evolution speed of the failure,
- Costs for the “On Condition” approach.
4. Shape of the Bath Tube curve for the Failure Mode: an increase of the Failure Rate at
the end of component life addresses mainly to Preventive Maintenance while in case
of constant failure rate, the “On Condition” approach is preferred. The shape of the
Bath Tube curve is related to the equipment type and technology.
5. Constraints set by the Constructor/Provider or by the Assurance/Warranty contracts.
6. Mission profile of the plant: the presence in the mission profile of process shut down
periods facilitates the insertion of the preventive tasks without effects on production.
7. Policy applied to manage the spare parts: when the local storage of spare parts is not
foreseen, Preventive or “On Condition” Policy is preferred since they allow spare parts
supplying when necessary, avoiding logistic delays.
The O&M Policy revision shall be completed by upgrading in O&M Policy Work Sheets
prepared in the Execution phase or during the last update of the Production phase.
It is suggested to organise Data in an electronic database easy to interface RCM analysis
tool.
The typical sheet for O&M Policy definition is shown in Table 12. For each Item, the table
shall be filled in with all the relevant data.
5.10.3 Input
· Suggestions/ recommendations from Contractual Maintenance Strategy
assessment.
The main outcome of the activity is represented by detailed Maintenance Policies for
relevant Items.
5.10.5 Tools
The analysis shall be performed by the support of the Decision Tree. It is suggested to use
electronic data sheets similar to those used in the Execution phase to record the revised
O&M Policy for the concerned Items.

The O&M Engineering Team is in charge of this activity. Maintenance technicians shall be
interviewed for suggestions based on their experience from the field.
5.11 REVISION OF O&M TASKS AND PROCEDURES FOR OVERALL PLANT
5.11.1 Scope
The scope of the O&M Tasks and Procedures for overall plant revision is to revise the O&M
Tasks and Procedures for the overall plant taking into account the revision of the O&M
Policies based on the results of the previous activity.
5.11.2 Procedure
The overall procedure to be followed to implement the O&M Task and Procedures activity is
presented below.
1. O&M Engineering Team update O&M Tasks and Procedures for overall plant on the
basis of the O&M Policies revision, taking into account the specific constraints
deriving from:
- Insurance/Warranty,
- spare parts management,
- planning of the human resources for maintenance and the related organization,
- results from the Availability Analysis (whether applicable)
5.11.3 Input
The required input data to this activity are the following
· O&M Tasks and Procedures revision from Execution Phase;
· Results from CA and, whether available, from AA;
· Updated O&M policies;
· Actual Constraints from Insurance/Warranty.
· Revised O&M Tasks and Procedures for overall plant;
· Input to O&M Plan and Process Operator Guides (POGs) revision;
· Updated Data to implement the Computerised Maintenance Management System
(CMMS).
5.11.5 Tools
No specific Tools are foreseen for this activity.

The O&M Engineering Team is in charge of this activity. Maintenance technicians, Logistics
and Manning experts shall be interviewed for suggestions based on their experience from
the field.
5.12 OVERALL O&M SYSTEM REVISION
5.12.1 Scope
The scope of the overall O&M System Revision activity is to review overall O&M System in
force and whether necessary to update:
- the O&M plan,
- the Process Operator Guides (POGs) and
- the data to be implemented into the CMMS.
All data and information coming from Maintenance Contractors are collected and produced
in readiness for input into the Company CMMS.
The Overall O&M system activity also concerns the update of the following files:
· working procedures for Maintenance Technicians in order to collect data during
maintenance activities,
· synthetic representation of the RCM model used by the Operation team to make it
aware of the RCM strategy and of the criticalities of each portion of the plant.
· link between the CMMS Model and the RCM Model
In general, all these tasks belong to a “loop” between the O&M Engineering Team and the
Operation Team aiming to maintain alive the Maintenance Plan.
5.12.2 Procedure
The overall procedure to be followed to implement the Overall O&M System revision activity
is presented below.
1. Starting from the updated outline of O&M Plan and POG provided by the O&M
Tasks and Procedures for overall plant Activity, O&M Engineering Team update
O&M Plan and POGs
2. O&M Engineering Team collect all data and information coming from
Maintenance Contractors and Operation Team for input into the Company
CMMS
3. O&M Engineering Team organise and produce in readiness data to update the
Company Computerised Maintenance Management System (CMMS).
4. O&M Engineering Team update the link between the CMMS Model and the
RCM Model
5. O&M Engineering Team update working procedures for Maintenance
Technicians in order to collect data during maintenance activities,
6. O&M Engineering Team update the synthetic representation of the RCM model
used by the Operation team
7. Whether necessary, O&M Engineering Team update procedures to maintain a
“living” RCM programme
5.12.3 Input
The main input data to this activity are:
· Updated O&M Tasks and Procedures for overall plant;
· O&M Plan and POG in force;
· CMMS.
The main deliverables of the O&M System Activity are listed below.
· Upgraded O&M Plan and POG;
· Upgraded data to be implemented in the CMMS;
· Upgraded procedures for the “living” RCM programme.
5.12.5 Tool
information in the electronic format decided and used in the Execution phase as support
tool all along the activity development and life.
The O&M Engineering Team is in charge of this activity, supported by Maintenance
Contractors and Operation Team.
5.12.7 RCM Activities Conclusion
The facility decommissioning represents the final milestone for the overall RCM
programme, corresponding to the RCM activities conclusion. The closure of the activity
shall be accompanied by the delivery of a final set of documents, including features such as
consolidation of the final approaches, O&M policies, tasks and procedures, data banks,
maintenance management system, etc, capitalization of the experience gained during the
execution of the programme including lessons learnt, feedback from Contractors and
Suppliers, etc.

A close communication between the O&M Engineering Team and the Operation Team is
maintained in order to guarantee a “living” Maintenance Plan whom changes are driven by
the monitoring of the plant performances.
The main results expected in the Production phase are:
· the continuous revision and optimisation of the overall O&M Plan;
· the periodic revision of the POGs;
· the continuous update of data and information to be implemented in the CMMS.
5.14 SYNTHESIS OF ACTIVITIES AND RESPONSIBILITY MATRIX FOR THE PRODUCTION

PHASE
In the following Table 14, the activities are described in detail in order to highlight the
related goals and the role of the O&M Engineering Team, Maintenance Contractors,
Operations Team.
# STEP GOAL O&M Engineering M Contractors Operation Team

Team
1 Contractual To feed the O&M To elaborate To provide to the Nil
Maintenance Policies for alternative O&M Engineering
Strategy revision maintenance Team lessons learnt
strategies for O&M and data from the
Contractors to implementation of
submit to the O&M the strategies
Policy revision
2 Maintenance To provide To collect To collect Nil

Data maintenance maintenance data maintenance data
data to upgrade coming from the according to the
the RAMS data O&M Contractors procedure for data
used in the and Maintenance collection set in the
Execution phase Technicians Execution phase
3 Operation To provide To collect all data Nil To collect operation
data reliability data coming from the data according to
required by the Operation Team the procedure for
RAMS analyses. data collection set in
the Execution phase
4 RAMS Data To update RAMS To update and Nil Nil

upgrade data required by validate RAMS
RCM analyses data coming from
on the bases of the O&M
the operation Contractors, the
feedback Operation team,
the Maintenance
technicians
5 MA upgrade To update the Revision of the MA Nil Nil
Preventive and done during the
Corrective Execution phase
Maintenance or last update
Time of each based on
Item of the plant. operation feedback
6 Failure To assess the Extraordinary Nil Nil
Analysis actual effects of revision of FMEA
(FMEA) each Item failure done during the
upgrade on Asset, Safety Execution phase
and Environment or last update
based on
operation RAMS
data
7 CA revision To assess the Revision of the CA Nil Nil
actual criticality done during the
of each Item Execution phase
versus Asset, or last update
Safety and based on MA and
Environment. FMEA upgrade
8 AA upgrade To evaluate the Extraordinary Nil Nil
(optional) actual availability revision of the
of the overall Availability
plant. Analysis of the
overall Plant done
during the
Execution phase
or last update
based on the
Operation data
coming from the
Operation team
9 Revision of To revise the To revise the O&M Nil Nil
O&M Tasks O&M Tasks and Tasks and
and Procedures for Procedures for the
procedures the overall Plant overall Plant based
on operation data
and RCM analyses
update (partial or
total)
10 Revision of To revise the To update the: Nil Nil
Overall O&M O&M System for · O&M Plan;
system the overall Plant · Process
Operator
Guides,
· CMMS
11 RCM To close the To deliver the final Nil Nil
Activities RCM Activities set of documents
Conclusion (final approaches,
O&M policies,
tasks and
procedures, data
banks,
maintenance
management
system, etc,).
To capitalise the
experience
Table 14. Description of the O&M activities made during the Production phase.
6. APPENDIX
APPENDIX MA1: ACTIVITIES TO TAKE A REFERENCE ITEM OUT OF SERVICE
Isolation (Process and Electrical)

Process isolation is the functional interruption between a RI and all the circuits connected
with it. It consists in identifying all the lines to and from the RI and in closing the closest
valves in each one of the connected lines. General methods of isolation are:
· Block Valve;
· Single Block Valve and Bleed;
· Double Block Valves and Bleed;
· Spectacle Blind or Spade;
· Removable Spool Pieces or Sprung Pipe providing physical disconnection;
· A combination of the above.
Electrical isolation is the mechanical break-off in a power conductor way. It is achieved by

the following general tasks (where applicable):
· Open and extract incomer circuit breaker at the relevant switchboard;
· Turn operation selector switch to “Excluded” at the RI local control panel or MCC;
· Open and padlock in “off” position upstream circuit breaker;
· Open and padlock incomer isolators;
· Put the cable, conductor way or bus-bar voltage at ground potential with earthing
knife switch.
Depressurisation
Depressurisation is the gradual reduction of pressure inside a RI. The fluid pressure can be
released to atmosphere or to a safe location in case of non-poisoning, non-flammable
products (e.g. air, nitrogen), to flare in case of poisons or flammable products (e.g. H2S,
HC).
Draining
Draining is the removal of all the liquid remained in a RI after the shutdown. The liquid
contained HC is conveyed to Closed Drain System.
Purging
Purging is the removal of poisoning and/or flammable gas from a RI and/or circuit. The gas
can be removed by low-pressure steam, water or nitrogen. In the offshore facilities, supply
of steam is not foreseen. Water can be used in small vessels, KO drums or for the piping
usually carrying liquid hydrocarbons. Nitrogen is the most common purging mean and the
following procedures can be followed:
1. by displacement;
2. by subsequent pressurisations and depressurisations.
The purging by displacement is used for piping headers and for circuits consisting in few
branch lines and small vessels. Nitrogen is introduced by one connection at one end of the
circuit and conveyed to flare header from the other end. Pressure in the circuits is
maintained slightly higher than flare value.
The purging by subsequent pressurisations and depressurisations is used for high capacity
circuits provided with several branches lines and big vessel. The nitrogen is introduced by
one or preferably two connections located on one end of the circuit and discharged after
pressurisation on the opposite end. Pressurisations and depressurisations are carried out
until H2S and HC content in the circuit drops below the value approved by the HSE safety
certificate. Nitrogen is an asphyxiating gas at high concentrations. The appropriate safety
precautions must be observed when venting nitrogen to atmosphere or entering a RI where
nitrogen may be present in high concentration.
Washing
Washing is the removal, by means of water, of fluid HC and liquid chemical compounds,
spread as very thin layer on the inner surface of piping and equipment and accumulated
together with foreign material at the bottom of any RI. Washing is usually carried out by
water introduced by means of temporary connections at the top of the RI and drained from
the bottom to the close drain system.
Blinding
Blinding is the installation of blanks, spectacles or blind flanges between the flanges of all
the piping connected to a RI. The scope of the blinding is to isolate the RI in order to
prevent any trace of fluid enters from the connected piping. Only piping open to atmosphere
is not blinded. Such typical blinding is required when the RI has to be:
· removed;
· opened;
· internally inspected;
· subject to internal works.
A detailed list of blinds shall be prepared for the project.
Check against the respective isolation certificate in accordance with HSE hazards isolation
and control procedure before disconnecting a flange shall be performed.
Atmosphere inside the RI shall be tested for H2S, N2, O2, HC vapour content before
entering.
Ventilation
Ventilation is the natural internal circulation of air through a RI when the man-ways are
open. The scope of the operation is to remove any trace of poisons vapours and bad
smells. The man-ways can be opened only after that the test of inside atmosphere gives
positive results.
MECHANICAL
RI CODE DESCRIPTION N/A DEPRESS. DRAINING PURGING WASHING BLINDING VENT.
ISOLATION
Table MA1.1. Example of recording table for RI versus take-out of service activities
APPENDIX MA2: ACTIVITIES TO BRING A REFERENCE ITEM INTO SERVICE
Reinstalling (RIs and circuits)

Reinstall means to place the RI undergone the maintenance in the previous position and
correctly fixed.
Reinstall the circuit implies:
· To restore its previous mechanical completion as per P&ID’s and Construction
drawing;
· Remove all the blinds;
· Reconnect all the flanges using new gasket and ring joints and dynamometric tools
if required.
· Check that each pair of flanges is provided with all the bolts and nuts;
· Ascertain that plugs and blank flanges are installed as per mechanical drawing and
all the valves in the instrument taps are open.
Leak test
Test for leaks is to ascertain that the reinstalled circuit is free from leaks at the normal
operating condition. The test is carried out by using air, nitrogen added up with helium or
process water, as follows:
1. air at 1 barg: the scope test is to prove that all drain and vent valves are closed and
all flanges are connected. The test is carried out in all circuits independently of the
process fluid.
2. air up to 7 barg: the scope of the test is to find out leaks in all the circuits with
opening pressure £ 7 barg;
· For the following systems: sea water, service water, fresh water, closed drain
and firefighting water air is vented to atmosphere and replaced with process
water up to the operating pressure value. During the pressure increasing, the
leak test is carried out.
· For the following systems: inert gas, fuel gas, liquid/gaseous HC, hydraulic oil,
diesel fuel, air is vented to atmosphere and replaced with nitrogen containing
helium up to the operating pressure value as per following procedure.
Pressure is increased by steps of 20-50 barg depending on system pressure
and leaks are checked for each step. Leaking flanges are marked up on the
blind list with the relevant pressure valve. Pressure test is continued in case of
small leaks, the pressure is reduced below 50 barg and the flanges are
tightened. The value of 50 barg max is fixed in order to prevent the bolts yield
point. If the leak cannot be stopped, the circuit is depressurised and flanges,
gasket, ring joints carefully checked for integrity and cleanliness. Gaskets and
ring joints are in any case replaced. The test is continued till the operating
pressure value is reached.
Nitrogen removing
After a positive leak test Nitrogen is vented to atmosphere up to 0,2 barg.
Commissioning of the circuit and of the repaired RI and re-check for leaks
It is common practice to slowly increase flow, temperature and pressure during the
commissioning. Check for leaks is performed in all the reconnected flanges.
NITROGEN
RI CODE DESCRIPTION N/A REINSTALLING LEAK TEST COMMISSION
REMOVING
Table MA2.1. Example of recording table for RI versus bring to service activities

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Eni S.p.A. Document Class: Doc. N°. Rev.

Exploration & Production Division 22011.MAN.GEN.RWP 00 1 of 124

Operations & Maintenance Engineering

00 Final Issue Fabio Cadelli Vanzini 19 Dec. 03

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1.3 Handbook objective and scope 16

2. RELIABILITY CENTERED MAINTENANCE (RCM) HANDBOOK 17

3. CONCEPT DEFINITION PHASE 19

3.1 RCM methodology procedures for the Concept Definition Phase 19

3.2 Project Basis 20

3.3 Risk Acceptance Criteria and Availability Targets 22

3.4 RAMS Data collection 27

3.5 Model preparation 45

3.6 Maintainability Analysis (MA) 46

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3.7 Failure Mode and Effect Analysis (FMEA) 55

3.8 Criticality Analysis 60

3.9 Availability Analysis 64

3.10 O&M policies 70

3.11 Expected results 76

3.12 Input to the Execution phase 76

4.1 RCM methodology procedures for the Execution Phase 80

4.2 Contractors/Suppliers data 82

4.3 Maintainability Analysis – revision and integration 83

4.4 Failure Mode and Effects Analysis - revision and integration 84

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4.5 Criticality Analysis – revision and integration 86

4.6 O&M Policy revision and integration 88

4.7 Availability Analysis – Plant and systems 92

4.8 O&M Tasks and procedures for overall plant 95

4.9 Overall O&M system 97

4.10 Expected Results 98

5. PRODUCTION PHASE 101

5.1 RCM methodology procedures for the Production Phase 101

5.2 Contractual Maintenance Strategy Assessment 102

5.3 Maintenance data 103

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5.3.3 Input 103

5.4 Operation Data 104

5.5 RAMS Data upgrade 105

5.6 Maintainability Analysis upgrade 106

5.7 Criticality Analysis 107

5.8 Failure Mode and Effects Analysis Upgrade 110

5.9 Availability Analysis – upgrade and comparison 112

5.10 O&M Policy revision 114

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5.11.2 Procedure 116

5.12 Overall O&M system revision 117

5.13 Expected Results 118

APPENDIX MA1: ACTIVITIES TO TAKE A REFERENCE ITEM OUT OF SERVICE 122

APPENDIX MA2: ACTIVITIES TO BRING A REFERENCE ITEM INTO SERVICE 124

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PMT Preventive Maintenance Time

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