RCM, FMECA, RCM, FMECA

RCM Reliability Centered Maintenance-FMECA Failure mode effects & criticality analysis

GazNeft Morgan establishes maintenance and inspection plans through RCM & FMECA; RCM is an engineering framework that enables the definition of a complete maintenance regimen. It regards maintenance as the means to maintain the functions a user may require of machinery in a defined operating context. As a discipline it enables machinery stakeholders to monitor, assess, predict and generally understand the working of their physical assets. This is embodied in the initial part of the RCM process which is to identify the operating context of the machinery, and write a Failure Mode Effects and Criticality Analysis (FMECA). The second part of the analysis is to apply the "RCM logic", which helps determine the appropriate maintenance tasks for the identified failure modes in the FMECA. Once the logic is complete for all elements in the FMECA, the resulting list of maintenance is "packaged", so that the periodicities of the tasks are rationalized to be called up in work packages; it is important not to destroy the applicability of maintenance in this phase. Lastly, RCM is kept live throughout the "in-service" life of machinery, where the effectiveness of the maintenance is kept under constant review and adjusted in light of the experience gained. RCM can be used to create a cost-effective maintenance strategy to address dominant causes of equipment failure. It is a systematic approach to defining a routine maintenance program composed of cost-effective tasks that preserve important functions. The important functions (of a piece of equipment) to preserve with routine maintenance are identified, their dominant failure modes and causes determined and the consequences of failure ascertained. Levels of criticality are assigned to the consequences of failure. Some functions are not critical and are left to "run to failure" while other functions must be preserved at all cost. Maintenance tasks are selected that address the dominant failure causes. This process directly addresses maintenance preventable failures. Failures caused by unlikely events, non-predictable acts of nature, etc. will usually receive no action provided their risk (combination of severity and frequency) is trivial (or at least tolerable). When the risk of such failures is very high, RCM encourages (and sometimes mandates) the user to consider changing something which will reduce the risk to a tolerable level. The result is a maintenance program that focuses scarce economic resources on those items that would cause the most disruption if they were to fail. RCM emphasizes the use of Predictive Maintenance (PdM) techniques in addition to traditional preventive measures.

RAM Reliability Availability Maintainability

GazNeftMorgan RAM modeling assesses a production systems capabilities, whether it be operation or still in design phase. The results from RAM modelling will identify possible causes of production losses and can examine possible system alternatives.

RAM modelling can simulate the configuration, operation, failure, repair and maintenance of equipment. The inputs to RAM modelling will include the physical components and maintenance schedules in a system and the outputs can determine how productive the system can be over the plant life. RAM studies will generate sufficient data to base decisions for possible systems changes that may increase system efficiency and hence project profits.

The key benefits of RAM modeling includes:

  • Detecting failures in the early part of design;
  • Optimizing maintenance schedules;
  • Adequately allocating the spares inventory;
  • Increasing the effectiveness of logistics; and
  • Identifying equipment priorities on failure.

Our reliability engineers will liaise with the client to identify their needs and develop the basis for the RAM model.

Once the basis is agreed a model of the system is created. Analysis of the model generates results and recommendations for improvement of the design or of the operating results. Communication during all stages with the client and the reliability engineers is continuous and ensures maximum results.

Once the basis is agreed a model of the system is created. Analysis of the model generates results and recommendations for improvement of the design or of the operating results. Communication during all stages with the client and the reliability engineers is continuous and ensures maximum results.

RCA Root Cause Analysis

GazNeftMorgan performs Root Cause Analysis (RCA) as a structured process that uncovers the physical, human, process that uncovers the physical, human, and latent causes of any undesirable and latent causes of any undesirable event in the workplace. Benefits: Indispensable component of proactive and reliability centered maintenance, uses advanced investigative techniques, Apply correctives, Eliminates early life failures, Extends equipment lifetime, Minimizes maintenance. A Root Cause Analysis (STEP, FMEA, FAILURE TREE ) will disclose:

Why the incident, failure or breakdown occurred

How future failures can be eliminated by:

  • changes to procedures
  • changes to operation
  • training of staff
  • design modifications
  • verification that new or rebuilt equipment is free of defects which may shorten life
  • repair and reinstallation is performed to acceptance standards
  • identification of any factors adversely affecting service life and implementation of mitigating actions.