Operation & Maintenance Engineering Guideline For RCM Implementation

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OPERATION & MAINTENANCE

ENGINEERING
Guideline for RCM Implementation
ABSTRACT
This document sets the overall methodology for the application of the Reliability Centered
Maintenance approach to production facilities (off shore, onshore, pipelines) during the Concept
definition, Execution and Production and Close out working phases.
00 Final Issue Fabio Cadelli Vanzini 19 Dec. 03

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FOREWORD
This document is integral part of the Technology Management System (TMS) and describes the
Reliability Centered Maintenance (RCM) programme.
The RCM program is “A systematic approach for identifying effective and efficient Preventive
Maintenance (PM) tasks for equipment and items in accordance with a specific set of procedures and
for establishing intervals between maintenance tasks”.
The Technology Management System (TMS) is a documental system that collects and formalises
recommended Techniques, Best Practices and Tools relevant to technology issues of the
Development process, as defined in the Opportunity and Project Development System (OPDS).
The main objective is to provide a comprehensive and structured set of knowledge addressed to the
effective management of technology projects issues in compliance with OPDS needs.
TMS guidelines cover the overall development process and define the reference best practice in the
EP Division. They include:
1. the description of main technological tasks to be conducted for the OPDS activities;
2. the relationships among different tasks, also when belonging to different OPDS activities;
3. the description of how to perform tasks in order to produce the required output/deliverables;
4. the definition of inputs and human resources needed to perform the tasks.
The current document covers the third bullet above, describing the procedure and the corresponding
tasks necessary to implement the RCM programme and to produce the required deliverables.
Similarly to the OPDS, TMS is applicable to different project sizes and embeds the necessary
flexibility to consider the factors such as, local constraints, external constraints, development project
complexity, development project risks and criticalities, financial exposure, economics, CAPEX and
OPEX, company and subsidiaries organisation.
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.
Typically, the following steps should be carried out in order to fulfil a complete RCM programme:
· Functionality 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 and Effect Analysis (FMEA) – “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 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 will be
used for the analyses.
These Guidelines provide the overall workflow of the RCM methodology for the Concept Definition,
Execution and Production working phases. 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 also covers the
running phase of the installation until its decommissioning starts.
The detailed description and procedures for the RCM methodology implementation are given in the
RCM handbook [21].
TABLE OF CONTENTS
1. INTRODUCTION 11
1.1 General 11
1.2 References 11
1.3 Guideline objective and scope 14
2. OVERALL O&M STRATEGY VERSUS THE PLANT LIFE CYCLE 15
3. RELIABILITY CENTERED MAINTENANCE (RCM) 17
3.1 Introduction 17
3.2 Overall structure of the methodology 17
4. CONCEPT DEFINITION PHASE 20
4.1 Overall approach to the O&M activities 20
4.2 RCM Methodology for Concept Definition Phase 20

4.2.1 Project Basis 21
4.2.2 Model preparation 21
4.2.3 Risk Acceptance Criteria and Availability Targets 21
4.2.4 RAMS Data collection 21
4.2.5 Maintainability Analysis (MA) 22
4.2.6 Failure Analysis (FMEA) 22
4.2.7 Criticality Analysis 23
4.2.8 Preliminary Availability Analysis 23
4.2.9 O&M policies selection 23
4.2.10 Availability analysis 24
4.2.11 O&M Polices Validated 24
4.2.12 Input to the Execution phase 24
4.3 Expected results 24
5. EXECUTION PHASE 25
5.2 RCM Methodology for Execution phase 25

5.2.2 Contractors/Suppliers data 26
5.2.3 Maintainability Analysis 26
5.2.4 Failure Analysis (FMEA) 26
5.2.6 O&M Policies Revision and Integration 26
5.2.7 Availability Analysis 27
5.2.8 O&M Tasks and procedures for overall plant 27
5.2.9 Overall O&M system 27
5.3 Expected Results 27

5.4 Synthesis of activities and Responsibility Matrix for the Execution Phase 28
6. PRODUCTION PHASE 30
6.2 RCM Methodology for Production phase 30

6.2.1 Contractual Maintenance Strategy 30
6.2.2 Maintenance data 31
6.2.3 Operation Data 31
6.2.4 RAMS Data upgrade 31
6.2.5 Maintainability Analysis 31
6.2.6 Failure Mode and Effects Analysis 31
6.2.8 Availability Analysis 31
6.2.9 Revision of O&M Tasks and procedures for overall plant 31
6.2.10 Overall O&M system revision 32
6.2.11 RCM Activities Conclusion 32
6.3 Expected Results 32
6.4 Synthesis of activities and Responsibility Matrix for the PRODUCTION PHASE 32
7. RCM PROGRAMME VERSUS PROJECT IMPORTANCE 34
8. SUGGESTIONS FOR RCM PROGRAMME IMPLEMENTATION 36
8.1 Suggestions 36
9. APPENDIX - RCM ACTIVITIES SYNTHESIS 37

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
Time (AMT) performed on 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
(ART) is ready to 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 The maintenance carried out after recognition and intended to put an item
Maintenance (CM) into a state in which it can perform a required function.
Corrective That part of the maintenance time during which corrective maintenance is
Maintenance Time performed on an item, including technical delays and logistic delays
(CMT) 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
Demand (FPPD) terms of 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
(FCT) performed.
Fault That part of the active maintenance time during which fault location and
Location/Diagnosis fault diagnosis are performed.
Time (FLDT)
Hazard and Operability Qualitative methodology that identifies possible deviations from the correct
Analysis (HAZOP) functioning 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- The accumulate durations of the individual maintenance times, expressed
hours 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 The time interval during which a maintenance action is performed on an
(MT) 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
(MTTR) in a down state due to a failure).
On Condition A set of actions aiming to monitor the system or item performances in order
Maintenance to identify 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 The maintenance carried out at predetermined intervals or according to
Maintenance (PM) prescribed criteria and intended to reduce the probability of failure of the
degradation of the functioning of an item.
Preventive That part of the maintenance time during which preventive maintenance is
Maintenance Time performed on an item, including technical delays and logistic delay inherent
(PMT) 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 o 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
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 should start in the Concept Definition design phase, support the
design in the subsequent phases and “live” with the plant during operation for a continuous
optimisation of the Operation and Maintenance procedures. For this reason the Guidelines
cover a period longer than that defined in the E&P OPDS Handbook. They concern the three
working phases Concept Definition, Execution and Production. While the definitions of the
Concept Definition phase and the Execution phase correspond to those addressed in the
OPDS Handbook, the definition of Production phase not only refers to Commissioning and
Production Start up (as in the OPDS Handbook) but is extended to cover the plant running
phase until its decommissioning starts.
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 sets the Guideline to be followed for the implementation of Reliability Centered
Maintenance programme during the development of 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.
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.
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.
The procedures to be applied for the execution of the tasks of the methodology are set in detail
in the RCM Handbook [21].
This document is managed by the O&M team, all changes and contribution to this document
will be shared and validated by the O&M 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,
50(191): 1990 reliability and 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
Procedures – Preventive Maintenance
Procedures – Corrective Maintenance
Procedures – Modifications and
Improvement
Procedures – Extraordinary Maintenance
Procedures – Maintenance Work
Management
Procedures – Maintenance Reporting
Procedures – Maintenance Budget
Management
Procedures – Global Maintenance Service
Management
21 22011.MAN.GEN.RWP Rev.00 Operations & Maintenance Engineering –
RCM Handbook
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 –
th
26 OREDA 92 Offshore Reliability Data – 2 Edition –
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 &
1
These two references are quoted for example.
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
1.3 GUIDELINE OBJECTIVE AND SCOPE

These Guidelines aim to define the methodological approach to support the Operation and
Maintenance Activities for oil and gas production plants. In particular the specific goals aim to:
1. Perform a preliminary Reliability Centered Maintenance 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 Computerised Maintenance Management System (CMMS) and Process
Operator Guides (POGs),
4. Organise an RCM overall strategy for the Production phase (i.e. data collection by
maintenance teams, feedback to the O&M Team, monitoring and up date the
Maintenance Plan by the O&M Team).
The study covers all the development stages of the Project: Concept definition, Execution, and
Production [3] and follows the Production phase during the facility running until the plant
decommissioning starts, when and RCM activities close.
2. OVERALL O&M STRATEGY VERSUS THE PLANT LIFE CYCLE
The activity is oriented to perform a set of tasks during the Concept definition, Execution,
Production working phases whose main final goal consists in the preparation of the
Maintenance Plan and to organise a O&M Engineering Team able to monitor and update
the Maintenance Plan during Operation.
The preparation of the Maintenance Plan is based on the Reliability Centered Maintenance
(RCM) approach that foresees a criticality analysis of the items constituting the plant, to
address the selection of the best maintenance Policies.
The Reliability Centered Maintenance tasks are based on a functional breakdown (RCM
Model), defined in the O&M Data Collection activity, that emphasises the role of each item
to fulfil the system functions and used as reference for items’ criticality screening (Figure 2).
Maintenance Planning Work Orders
RCM CMMS In-field

MODEL MODEL maintenance
interventions
Maintenance FeedBack Info from Maintenance
Figure 2. Long term O&M Strategy
One of the first goals of the O&M activity is the definition of this RCM Model, according to
the functional representation of the plant; the Maintenance Policies are set, during the
Concept Definition (Figure 3), for the main equipment (Reference Items - RIs), applying a
Failure Mode and Effect Analysis and the related Criticality assessment.
In the mean time the overall methodology to O&M Activities is being defined.
The definition of the O&M Methodology and the selection of the best Maintenance Policies
for the main items (RIs) become part of the requirements to be set for the Contractors.
Input from Concept definition design
RCM
MODEL
Requirements Maintenance Policies for

for Contractors/Suppliers Reference Items
Figure 3. O&M Activity during Concept definition phase
During the Execution phase (Figure 4), the RCM model shall be detailed by the integration
of the information and data provided by the Contractors and Suppliers, up to define the
Maintenance Tasks that have to be set in the CMMS under implementation.
In the mean time, some additional activities shall be performed in order to:
· prepare the link between the CMMS Model and the RCM Model,
· define the procedure for Maintenance Technicians (Company and/or Contractors)
in order to collect data during maintenance activities useful for the O&M
Engineering Team, devoted to monitor the effectiveness of the Maintenance Plan

and to update it,
· provide a synthetic representation of the RCM model to the Operations Team to
make it aware of the RCM strategy and of the criticalities of each portion of the
plant,
· implement a “loop” between the O&M Engineering Team and the Operations Team
in order to realise a “living” Maintenance Plan whom changes are driven by the
monitoring of the plant performances and maintenance feedback.
Data from :
·Concept Definition
(O&M)
·Contractors
·Execution design
RCM
CMMS MODEL
MODEL
· Maintenance Planning
· Support to redesign Maintenance Reports
OPERATIONS Synthetic Functional

TEAM Model for Operators
Figure 4. O&M Activity during the Execution Phase
During the Production phase (Figure 5), the O&M Engineering Team will receive data
concerning the actual plant availability from Operations (via DCS) and failure data from
Maintenance Technicians in order to refine the Maintenance plan to increase plant
Availability; in parallel, the Operation Team collects data related to Maintenance
interventions to feedback the O&M Engineering Team.
Maintenance FeedBack Work Orders
RCM CMMS In-field

MODEL MODEL maintenance
interventions
Maintenance Planning Info from Maintenance
OPERATIONS
Update of the
TEAM
Synthetic Functional
Model for Operators
Figure 5. O&M Activity during Production phase

3. RELIABILITY CENTERED MAINTENANCE (RCM)
3.1 INTRODUCTION
The O&M methodology is based on the Reliability Centered Maintenance structure, aiming
to select the best maintenance policies for the plant items, by the support of a criticality
analysis. The criticality analysis addresses the plant items individually and assesses their
criticality vs. safety, production and environment.
The general philosophy of RCM is described here below.
Maintenance aims to preserve the proper functioning of the plant and its production and
asset in safe conditions with protection of the environment. The priority to be set for the two
aims, i.e. safety/environment and production/asset is different, in the terms that while safety
and environmental protection are prevalent and have to be guaranteed in any case
production has to be preserved in order to maintain the profitability of the plant.
Maintenance policies are therefore driven by the two constraints below:

1. Maintenance has to avoid any failure or degradation able to compromise the safety of
people or the environment, whichever is the cost of this preventive Policies,
2. Maintenance has to prevent any failure able to compromise the production and asset,
when the maintenance cost is compatible with the production benefits.
These considerations point out the need of a method able to assess the impact of each
failure on safety, environmental protection and production, separately.
For the failures impacting on safety or affecting the environment, preventive measures must
be applied.
As regards the failures that are not relevant for safety/environment, a distinction has to be
performed in order to reduce the maintenance costs: failures with strong influence on
production has to be prevented by Periodic or “On Condition” based interventions, the other
ones can be managed by a Corrective strategy if less expensive.
The choice between the periodic or “on condition” strategies is determined according to the
specific characteristics of the item, its failure modes, the technical feasibility of failure
monitoring and other considerations.
The final goal of the study is the selection of the best maintenance policy allowing safe
operations, protection of the environment and the higher system availability compatible with
maintenance costs.
During the methodology definition, particular attention shall be paid to the problem of
updating, since the analysis should be applied at different levels of detail following the
evolution of the design and should be maintained during the plant operation. Therefore, the
methodology as well as the supporting software tools have to be sufficiently flexible to
guarantee the possibility of updating the analyses and related results.
3.2 OVERALL STRUCTURE OF THE METHODOLOGY

As stated in the previous chapters, the RCM methodology covers the three life cycle
phases: Concept Definition, Execution and Production.
The overall methodology is presented in Figure 6.
Figure 6. Overall structure of RCM methodology versus life-cycle phases
The execution of a Reliability Centered Maintenance programme requires the set up of a

Work Team Work team and owning all the necessary competences to make the
programme a success. The work team is principally composed by the following actors:
- 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. The O&M
Engineering Team belongs to this category.
- 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. The Maintenance Contractor belongs to this category.
- 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. The Maintenance Supplier belongs to
this category.
Specific competences are developed within these categories. The principal of them are
listed below.
- 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.
- Process Engineering: these competences refer to all the disciplines related to the
system design.
- 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).
- Logistics: these competences concern all the activities related to logistics features.
- 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.
Being the teams involved and activities to be executed in each phase different, for the sake
of clarity the workflow and the corresponding description are presented phase by phase.
4. CONCEPT DEFINITION PHASE
4.1 OVERALL APPROACH TO THE O&M ACTIVITIES

During the Concept definition phase, the O&M Engineering 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.
To achieve these results, the RCM approach is applied according to the following stages:
1. Identification of the Reference Items

2. Definition of Risk Acceptance Criteria
3. Reliability Data collection including RI Preliminary Reliability Analysis
4. Maintainability Analysis
5. Failure analysis
6. Criticality analysis
7. Preliminary Availability Analysis
8. Selection of O&M policies and validation
9. Availability analysis
10. Input data to Execution Phase
The flow chart of the RCM methodology applied to the Concept definition phase is
presented in Figure 7. The overall approach is synthesised by graphs in the Appendix.
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 7. The RCM Methodology flow diagram (Concept Definition phase)
4.2 RCM METHODOLOGY FOR CONCEPT DEFINITION PHASE

The various activities to be executed to apply the RCM methodology to the Concept
Definition phase are described in the following sections.
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.
4.2.1 Project Basis

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 will 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.
4.2.2 Model preparation

The first step of the methodology consists in the definition of the level of detail to be
adopted for the study and the preparation of the reference model. This level is based on a
hierarchical breakdown of the plant in functional terms, whose bottom elements are the
elementary functions. These elementary functions are defined according to RAMS data
collection and correspond to a specific Reference Item (RI).
A RI can represent main equipment (pumping system, compressor, separator) or a group of
elementary components (Items) whose common function is well identified (e.g. control
loops).
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 RCM on the specific Items to their TAG.
The identification of RIs should be in accordance with the facilities description set in the
Project Basis.
4.2.3 Risk Acceptance Criteria and Availability Targets

The definition of Risk Acceptance Criteria is a parallel task whose aim is to set the Criteria
that will be used in the Criticality Analysis to assess the RIs 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 are defined 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).
Availability targets are set according to the general policy of the Company and referred to
assess the plant availability versus its operational performance.
4.2.4 RAMS Data collection

Data collection aim is to provide a reference reliability data bank for the RIs identified in the
model preparation.
Since the RIs could represent assemblies of elementary Items, often a preliminary reliability
analysis is required to estimate the reliability parameters for RIs, starting from the reliability
data available for Items (from Company Proprietary and/or Commercial Data Banks). This
preliminary assessment is performed by Fault Tree Analysis (FTA) or Reliability Block
Diagrams (RBD).
Data for Items 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 reliability Data Banks commercially available, e.g. OREDA,
EGIG, CONCAWE, E&P Forum Datasheets, RAC Data Set (MIL and NPRD), AIChE,
EIREDA, IAEA, etc. should be referred to [24-33].
Priority Criteria should drive the selection and use of the reference Data Banks (e.g. first
priority for proprietary data banks, then for offshore specific data bank such as OREDA,
EGIG, CONCAWE, E&P Forum data sheets).
The result of data collection is the collation of reliability data (failure rate and ART) to each
RI, 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.
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 repair times to the
specific context.
4.2.5 Maintainability Analysis (MA)

The aim of the Maintainability Analysis is to evaluate the total down time (Maintenance
Time), due to preventive and corrective actions associated with each RI on the plant. Total
down time is then used to estimate more carefully the availability of the System and the
availability of a single RI.
In this view, MA completes the repair time derived from the data banks estimating, for each
RI, the following contributions:
· Logistic delay (i.e. the waiting time for maintenance personnel, spare parts and
tools)
· Technical delay (i.e. time necessary to take the equipment out of service and time
to bring it back into service)
· Fault location/diagnosis time;
· Preventive maintenance time
In order to estimate the terms listed above, the following aspects should be investigated:
· Specifying the personnel skill required to perform the maintenance task,
· Highlighting the need of spare parts,
· Highlighting the need of special tools to perform the repair,
· Highlighting design or management improvements leading to a reduction of the
total downtime,
· Checking the feasibility of any maintenance policy (corrective/preventive/on
condition).
These aspects can be formally studied by the Task Analysis approach that represents a method to
support the operability analyses performed during the system design. 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.
The complete MA process foresees two main steps:
1. In the first one, Maintainability Analysis only estimates the time due to corrective
actions, i.e. technical delay, fault location/diagnosis and logistic delay. As regards
to the logistic delay, some preliminary indications are given because the final
location of the head quarters and warehouses is normally not yet decided in the
Concept Definition phase.
2. Then, once the maintenance policies are allocated on the bases of the information
deriving from the Criticality Analysis and data on Preventive Maintenance, all RIs
under Preventive Maintenance (PM) regime shall be analysed and relevant PMT is
estimated. This activity is presented in the flowchart (Figure 7) under the title MA
Upgrading.
4.2.6 Failure Analysis (FMEA)

When the RIs have been identified and the related failure modes have been characterised
by their reliability parameters, the failure analysis can start.
Failure analysis aims to identify, for each failure mode of RIs, 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).
Normally, this investigation is 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 FTA. For details on this activity
see the Preliminary Availability Analysis description (§ 4.2.8)
4.2.7 Criticality Analysis

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.
4.2.8 Preliminary Availability Analysis

The preliminary availability analysis 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).
This 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 analysis is normally performed by Reliability Block Diagrams and Monte Carlo
simulation.
Furthermore, a Fault Tree Analysis (FTA) can be performed in order to evaluate the
unavailability of the plant due to the spurious ESD intervention.
Generally, the following Items are considered in the analysis:
· Fire, gas detectors;
· Process sensors connected to the ESD system;
· ESD control logic units.
FTA also determines the criticality ranking of each Item belonging to the ESD activation
system.
4.2.9 O&M policies selection

Maintainability and Criticality analyses provide the input information necessary to identify
the best maintenance policy for each RI. Decision logics should be applied to use this
information in the most appropriate way for the specific installation. The choice is based on
a Decision Tree defined once for all in the RCM methodology taking into consideration
different aspects:
· 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.
The output of this final investigation is the selection of the most appropriate maintenance
policy for all the RIs.
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.
The outcome of this stage is also used to upgrade the Maintainability Analysis by the
implementation of the maintenance polices (step 2 in § 4.2.5) and to perform a more
detailed availability analysis (see § 4.2.10).
4.2.10 Availability analysis

The effectiveness of the maintenance policies set for the RIs can be checked evaluating the
overall plant availability through a more detailed analysis, also considering the time spent
for material/personnel acquisition (Logistic delay), time for auxiliary activities (technical
delays) and the preventive maintenance applied to.
The final Availability analysis 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.
Plant availability represents a measure of the maintenance effectiveness. In addition it
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 analysis is normally performed by an advanced Reliability Block Diagram approach
using Monte Carlo simulation.
4.2.11 O&M Polices Validated

The O&M Policies are 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 target set at
the beginning of the analysis.
4.2.12 Input to the Execution phase
4.2.12.1 O&M Equipment requirements

The conclusion of the study consists in the 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 are relevant to:
· Item data details: MEL, Specification sheet, BOM, Insurance and Critical Spare part
lists;
· Reliability Data;
· RAMS analyses: MA, FMEA, CA, AA;
· Maintenance Plan.
4.2.12.2 Directions for O&M Engineering

A follow-up of this phase consists in the definition of the directions for the CMMS
implementation and guidelines for POGs development.
Concerning CMMS implementation, these directions originate from the need to guarantee
coherence between the RCM model and the CMMS structure.
4.3 EXPECTED RESULTS
The results expected from the application of the RCM methodology during the Concept
Definition phase are listed here below:
· Evaluation of the Plant/Sub-plant/Equipment Availability;
· Contribution to the definition of the logistic aspects;
· Identification of the critical Reference Items for the plant;
· Preliminary selection of the best Maintenance Policies for each Item of the plant;
· Definition of the requirements to be set for the Contractors and Suppliers;
· Direction for the implementation of the CMMS;
· Guidelines for POGs implementation.
5. EXECUTION PHASE

During the Execution phase, the O&M policies set during the Concept definition phase are
detailed into O&M procedures and tasks integrating data and information provided by
Contractors and Suppliers.
The Contractors should provide, for the part of plant included in their Scope of Work (SoW),
the following information:
· List of all tagged equipment;
· Approved P&ID’s
· Maintenance proposal;
· Insurance and Critical spare parts list,
· Spare parts holding recommendations. Variety and volume;
· Detailed Maintainability, FMEA and Availability analyses.
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 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 8. The overall approach is synthesised by graphs in the Appendix.
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 8. The RCM Methodology flow diagram (Execution phase).
5.2 RCM METHODOLOGY FOR EXECUTION PHASE

The various activities to be carried out for the application of the RCM methodology to the
Execution phase are described in the following sections.
This design 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 up to set the Maintenance and
Operation Procedures. 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].
5.2.1.1 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.
5.2.2 Contractors/Suppliers data

Contractors and Suppliers shall provide 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, 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, FMEA and
Availability analyses.
5.2.3 Maintainability Analysis

Maintainability Analysis estimates the maintenance time required to perform Corrective and
Preventive actions on all Items identified. The system integrator reviews and integrates 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 has to be detailed in order to set the information for each
specific Item and the Task Analysis shall support the activity in the frame of the Operability
Analysis.
5.2.4 Failure Analysis (FMEA)

Failure Analysis, normally developed according to the Failure Mode and Effect Analysis
(FMEA) method, evaluates the effects associated to the failure mode of each Item in term
of damages on Safety, Environment and Asset/Production. The system integrator reviews
and integrates the FMEA, performed during the Concept Definition phase for the RIs, with
the analyses coming from Contractors. The analysis has to be detailed in order to set the
information for each specific Item.

Criticality Analysis evaluates the criticality of each Item installed on the Plant. The System
Integrator reviews, details and integrates the CA, performed during the Concept Definition
phase, with the analyses coming from Contractors.
The final criticality of each Item is the worst index among the three criticality indexes
respectively versus Safety, Environment and Asset/Production.
5.2.6 O&M Policies Revision and Integration

A revision of the O&M Policies set during Concept Definition has to be performed in order
to update them according to the revision of MA and FMEA and according to the Operation
and Maintenance indications set by Constructors.
5.2.7 Availability Analysis

Availability Analysis is performed 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.
This 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.
5.2.8 O&M Tasks and procedures for overall plant

This activity is the combination of the three activities shown in the flow-diagram concerning
the O&M Tasks and procedures for overall plant, the Operating Manual and Maintenance
Plans provided by Suppliers, and the Operating Manual and Maintenance Plans provided
by Contractors.
Data and information provided by Contractors and Suppliers mainly concern operating
manuals and maintenance plans.
The Contractors elaborate the operating manuals and maintenance plans by reviewing and
integrating the operating manuals and maintenance plans provided by the Suppliers.
The System Integrator defines the O&M Tasks and procedures for the overall plant taking
into account 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.
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.
5.2.9 Overall O&M system

The System Integrator elaborates the Overall O&M system including:
· O&M plan,
· Process Operator Guides (POGs),
· All data ready to be implemented into the 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 a working procedure for Maintenance Technician in order to
collect data during maintenance activities useful for the O&M Engineering Team,
devoted to monitor the effectiveness 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 operation.
This activity also supports the Company in the preparation of the technical documentation
for the Maintenance contracts award.

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.
In addition, some operational policies are set in order to:

· Prepare the link between the CMMS Model and the RCM Model,
· Define the procedure for Maintenance Technician (Company and Contractors) in
order to collect data during maintenance activities useful for the O&M Engineering
Team, devoted to monitor the effectiveness of the Maintenance Plan and to update
it,
· 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 each portion of the
plant,
· Implement a “loop” between the O&M Engineering Team and the Operation Team
in order to realize a “living” Maintenance Plan that is periodically updated on the
basis of the feedback from the actual plant operation.
5.4 SYNTHESIS OF ACTIVITIES AND RESPONSIBILITY MATRIX FOR THE EXECUTION

PHASE
In the following Table 1, 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 Failure To assess the effects Revision and integration (if To perform a detailed Nil
Analysis of each Item failure on any) of FMEA done during FMEA of the Items
(FMEA) 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 1. Description of the O&M activities to be made during Execution phases.

6. 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 will receive data from the
Operations (via DCS) and continuously updates the RCM Model and the data Collection in
order to refine the Maintenance Plan set in the CMMS with the goal of increasing the plant
Availability; in parallel, the Operation Team will catch 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.
The flow chart of the RCM methodology applied to the Production phase is presented in
Figure 9. The dotted lines concerning the activities “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.
The overall approach is synthesised by graphs in the Appendix.
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 9. The RCM Methodology flow diagram (Production phase)
6.2 RCM METHODOLOGY FOR PRODUCTION PHASE

The various activities to be executed to apply the RCM methodology during the Production
phase are described in the following sections.
6.2.1 Contractual Maintenance Strategy

The Maintenance Contractors are instructed to operate according to a Contractual
Maintenance Strategy that is defined at the end of the Execution phase. This strategy is re-
assessed during the Production phase, in order to optimise it on the basis of the Operation
and Maintenance working experience.
6.2.2 Maintenance data

Data are collected from the Maintenance Technicians according to the procedure set at the
end of the Execution phase and supplied to the O&M Engineering Team, devoted to
monitor the effectiveness of the Maintenance Plan and to update it, The maintenance data
are used to update the RAMS data defined in the Execution phase.
6.2.3 Operation Data

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 the comparison among
the actual availability level and the prediction.
6.2.4 RAMS Data upgrade

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 Technicians
and possible project review. These data will feed a Company Reliability Data Bank and are
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.
6.2.5 Maintainability Analysis

The O&M Engineering Team reviews 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).
6.2.6 Failure Mode and Effects Analysis

In the case an extraordinary event occurs and the decision is taken to review the FMEA
performed during the Execution phase, the O&M Engineering Team performs it on the
basis of the updated RAMS data and any possible changes in the installation (Project
review).

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.
6.2.8 Availability Analysis

Availability Analysis is performed in order to evaluate the availability in term of average
production availability of the overall Plant. The activity is executed by the O&M Engineering
Team implementing the Operating data provided by the Operation Team in the case an
extraordinary event occurs 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.
6.2.9 Revision of O&M Tasks and procedures for overall plant

The O&M Engineering Team revises the O&M Tasks and procedures for the overall plan
taking into account the revision of the O&M Policies based on the results of the previous
assessment.
6.2.10 Overall O&M system revision

The O&M Engineering Team revises Overall O&M system and whether necessary the team
updates the O&M plan, the Process Operator Guides (POGs) and the data to be
implemented into the CMMS.
All data and information coming from O&M Contractors are collected and produced in
readiness for input into the Company CMMS.
6.2.11 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 and Close out 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.
6.4 SYNTHESIS OF ACTIVITIES AND RESPONSIBILITY MATRIX FOR THE PRODUCTION

PHASE
In the following Table 2, 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 2. Description of the O&M activities to be made during the

Production phase.
7. RCM PROGRAMME VERSUS PROJECT IMPORTANCE
The RCM methodology described in these guidelines for the Project Definition, Execution
and Production phases is exhaustive, and covers all the tasks which should be executed for
its application to a specific project.
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.
The OPDS Handbook provides the necessary built-in flexibility by recognising different
projects classes and identifying a specific roadmap for each of them, starting from the
consideration that, “within the EP division, development projects are different in terms of
complexity, difficulty, Capex, etc…”,
Projects are ranked in three classes:
· Strategic projects (high exposure)

· Significant projects (moderate exposure)
· Routine project (low exposure)
The higher a project is rated, the more it is subject to monitoring by management and also
more guidance will be provided to handle difficult situations.
Project Class is established at the start of OPDS considering the recommendations of the
Development Project Kick-off Team.
The classification is based primarily on the quantitative criteria full project life Capex (ENI’s
share) representing a synthetic metric to evaluate the degree of exposure that the
Company is facing in committing resources to develop the specific opportunity.
Project Classes
(defined at the beginning of the project)
Strategic projects
n More than 50 MUSD full life capex ENI’s equity
Evaluation Gate 1 Concept
Gate 2
Concept Gate 3 Execution Hand Production n More than 200 MUSD full life capex 100%
Selection Definition over and close out
n Critical Technologies (Deepwater,...)
Significant Projects
Concept Concept Hand Production n From25 MUSD up to 50 MUSD full life capex
Evaluation Gate 2 Gate 3 Execution
Selection Definition over and close out ENI’s equity
Routine Projects
Concept Concept Hand Production n From5 MUSD up to 25 MUSD full life capex
Evaluation Gate 2 Execution
Selection Definition over and close out ENI’s equity
Out of OPDS applicability n Below 5 MUSD full life capex ENI’s equity
(only investment proposal)
Figure 10. Project Classes
Project classification recognises also the relevance of further criteria of qualitative nature
such as critical technologies. In this case the enhanced complexity embedded in the
project, regardless the level of investment, makes necessary to apply the highest level of
control and assurance foreseen for the strategic projects class.
More precisely, all the Projects with the following characteristics/ or applying the following
technologies should be considered strategic project regardless the level of investment:
- Sub sea-deepwater
- Heavy oil
- Gas to liquid
- Floating Production System
- Sub sea processing
- High pressure-high temperature
On the other side, all the projects that do not apply new technologies and/or that are similar
to existing facilities can be considered routines projects regardless the level of investment.
The RCM methodology should therefore be able to answer to the different needs that each
class of projects presents and is flexible enough to be properly adapted to the project
classes defined above (Figure 10). Therefore, the extension and the depth of the RCM
programme shall be carefully evaluated and scheduled during the project planning in
accordance with this classification. The RCM programme should normally be implemented
for the overall plant. However, it can also be applied to selected portions of plant, when the
O&M procedures and tasks are already consolidated for the rest of the installation.
Table 3 provides the list of activities to be performed in each phase where the RCM
methodology should be applied versus their importance with respect to the project classes.
Activities Strategic Significant Routine
· Project Basis PFDs/P&ID

· Risk Acceptance Criteria
· RAMS Data
· Model preparation
· Maintainability analysis
Concept
· Failure analysis (FMEA)

· Criticality analysis
· Preliminary Availability Analysis
· O&M Policies (selection and validation)
· MA Upgrading
· Availability Analysis
· O&M Policies Validated
· Contractor/Suppliers Data
· Maintainability analysis revision & integration
· Failure analysis (FMEA) revision & integration
Execution
· Criticality analysis revision & integration

· O&M policies revision & integration
· Availability analysis Plant & Systems
· O&M Tasks and procedures for overall plant
· Overall O&M System
· Contractual Maintenance Strategy Assessment

· Maintenance Data
· Operation Data
·
Production
RAMS Data Upgrade

· Maintainability analysis Upgrade
· Failure Analysis (FMEA) Upgrade
· Criticality analysis revision
· Availability analysis Upgrade and Comparison
· Revision of O&M Tasks & Procedures for overall plant
· Overall O&M System revision
Importance: Very high High Medium Low
Table 3. RCM activities and project classes

8. SUGGESTIONS FOR RCM PROGRAMME IMPLEMENTATION
The suggestions provided hereafter provide valuable support to the implementation of the
RCM programme.
8.1 SUGGESTIONS
Maintain a collaborative link between the Process Engineering Department and the
O&M Department to maintain the Plant Description always updated according to the
last revision
Guaranty a synergy between the Logistics Function and the O&M Department to
maintain the logistics organisation updated
Apply the RCM analysis to the whole facility when it presents a new concept, new
technologies, harsh environmental conditions, etc. and/or the project is strategic. When
the facility is standard, address the RCM analysis only to the parts that are new and/or
submitted to particular conditions (environment, operating profile, etc.)
Establish an efficient system to exchange information among the members of the O&M
engineering Team, and between the Team and the Contractors/Suppliers
Whether necessary, train the Maintenance Engineering Superintendent and/or some
members of his staff to RAMS methodologies principles and the management of their
application
Refer to RAMS experts when developing specific analysis, such as FMEA, FTA, CA
Establish a robust data recording system and use it during the three phases of the
RCM programme development
Require the Contractors/Suppliers to be compliant with the established data recording
system
Address clear requirements to Contractors/Suppliers for RCM analysis of the part of
plant they are responsible for, by providing guidelines, procedures, etc.
Use electronic Data Sheets compatible with the most common software tools to record
the results of FMEA, MA, CA
Apply Reliability Block Diagrams and Monte Carlo simulation for Availability Analysis of
the plants and Fault Tree Analysis for Emergency Shut Down systems by using
dedicated commercial software tools.
Whenever available, refer primarily to the Company proprietary data banks and then to
International Data Banks for data collection, setting priorities for their use
Require the Contractors/Suppliers to use the same RCM approach of the Company
Clearly define the boundary of the system within which each Contractor should perform
the analysis and the level of detail required
Pay attention to the interfaces between the parts of plants developed by different
Contractors and, whether necessary, develop ad-hoc analysis for the interfaces
Develop the O&M Tasks and Procedures for the overall plant as result of the
Maintainability and Availability analysis and using the information provided by the
Contractors/Suppliers. Optimise the tasks description and timing for the Maintenance
technicians by applying the Task Analysis approach
Set up the Preventive Maintenance interventions by harmonising the Maintenance
Policies selected for each Item (maintenance intervals, tasks duration, etc.)
Assure the coherence between the RCM approach and the Maintenance Management
System of the Company
Maintain the RCM programme alive and update it during the running phase with the
information which are recorded on-field
Verify that during the running phase the maintenance reports are complete and drafted
according to the requirements and guidelines set at the end of the Execution phase
Establish a method to check the quality of the information collected during the running
phase
During the running phase, check the validity of the hypothesis done during the design
phases and record the deviations to update the RCM model for the plant and as lesson
learnt for future installations
Capitalise the information gained by the application of the RCM methodology to the
facility under monitoring and use it to improve the methodology for further application.
Select the relevant data to feed the Knowledge Management System of the Company
9. APPENDIX - RCM ACTIVITIES SYNTHESIS

Exploration & Production Division 22010.MAN.GEN.SDS 00 A - 1 of 20
SYMBOLS
Key Activity Activity that has to be performed during the

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

Preparation
Activity the 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

Decision sub-set of projects
Text Input data and information
Text Output data and information
End point
Concept definition phase
Risk
Criteria analysis
O&M Input to
Failure Decision
Policies Execution
(FMEA)
RAMS data MA
Upgrading
Yes
Target Target
Analysis
No No
Upgrading
OR
Design
review

Risk
Criteria analysis
O&M Input to
Failure Decision
Policies Execution
(FMEA)
RAMS data MA
Upgrading
Yes
Target Target
Analysis
No No
Upgrading
OR
Design
review
Activity Denomination
Risk Acceptability Criteria
Availability targets
Activity Description
Setting of Acceptability Criteria for
Inputs Safety, Production and Environment by Output/Deliverables
Risk Matrix
Company’s Risk Setting Availability targets for production Risk Matrix for Risk
Tolerability Criteria and Acceptability
Availability requirements Availability Targets
SI
Project Basis
Collection of the information and data
Inputs that will be applied to implement RCM Output/Deliverables
during Concept Definition
- Project Scheduling Project basis Report,
- Project Phylosophies collecting all the
- System description information
- PFDs, P&IDs characterizing the Project
- ESD description
- Cause-Effect diagram
- Fire Fighting
description
SI
SI System Integrator C Contractors S Suppliers

Risk
Criteria analysis
O&M Input to
Failure Decision
Policies Execution
(FMEA)
RAMS data MA
Upgrading
Yes
Target Target
Analysis
No No
Upgrading
OR
Design
review
RAMS Data
Selection from ENI E&P standards of RIs
Inputs templates aiming to the definition of the Output/Deliverables
level of detail to be applied for O&P
Data banks policies RIs Templates data
- OREDA setting:
- E&P Forum datasheets Data collection (failure modes and - Failure rates
- RAC Dataset reliability parameters) for RIs Templates - Active repair times
- etc - Unavailability
- Failure probability per
demand
SI
- Expected number of
failures
Model Preparation
- Definition of the plants to be
Inputs considered in O&M study and related Output/Deliverables
boundaries
- Project Basis Report - Decomposition of each plant in its RIs - Functional breakdown
- RI templates set in with reference to the RI templates set for all plants
RAM data collection in RAMS Data Collection - List of RIs
- PFD, P&ID - Definition of relationships between RIs
and Item TAGs
SI

Risk
Criteria analysis
O&M Input to
Failure Decision
Policies Execution
(FMEA)
RAMS data MA
Upgrading
Yes
Target Target
Analysis
No No
Upgrading
OR
Design
review
Maintainability analysis
Determination of the total maintenance
Inputs time relevant to each RI: combination of Output/Deliverables
Corrective Maintenance Time and
- List of Ris Preventive Maintenance time - CMT/PMT for all RI
- RIs failure modes
- Active Repair Time For CM:
from RAMS Data - Evaluation of logistic
delay due to personnel
and spare parts
recovery
SI
Failure Analysis (FMEA)
Analysis of RIs Failure Modes:
Inputs - effects on people, asset & production, Output/Deliverables
environment
- List of RIs - definition of detection methods and For each RI:
- RIs failure modes preventive or mitigation actions - effects and severity for
- Severity classification each failure mode
from Risk Acceptability
criteria
SI

Risk
Criteria analysis
O&M Input to
Failure Decision
Policies Execution
(FMEA)
RAMS data MA
Upgrading
Yes
Target Target
Analysis
No No
Upgrading
OR
Design
review
Preliminary Availability
Analysis
Inputs Evaluation of the plant unavailability by
- Project Basis Report RBD and MC simulation, without taking Output/Deliverables
(PFD and P&ID) into account logistic delays and
preventive maintenance. - Plant Unavailability
- RIs failure rates from
The unavailability due to spurious ESD - Unavailability due to
RAMS data
initiating events is estimated by Fault spurious ESD
- Repair Time from MA
Tree Analysis intervention
- Fire and Gas Cause
- Ranking of RIs
and Effect Charts
according to their
- ESD Cause and Effect
criticality versus
Charts
production availability
- HAZOP results
SI
Criticality Analysis
Inputs Evaluation of the importance (Criticality)
- Risk Acceptability of each failure mode considered in the Output/Deliverables
Criteria FMEA versus Safety, Asset & Production
- List of RIs and the Environment by the use of Ranking of RIs failures
- Corrective Criticality Indexes and Acceptance each one characterized
Maintenance Time Criteria by its Overall Criticality
from MA and Criticality on Safety,
- Severity Class and % Failure Modes ranking according to their Asset/production and the
of production loss impact on the plant, estimated in terms Environment
from FMEA of risk
- Costs of production
loss SI

Risk
Criteria analysis
O&M Input to
Failure Decision
Policies Execution
(FMEA)
RAMS data MA
Upgrading
Yes
Target Target
Analysis
No No
Upgrading
OR
Design
review
O&M Policies
Inputs
Selection of best Maintenance Policy for
- Criticality of each each RIs failure mode considered in the Output/Deliverables
failure mode versus FMEA by the use of Decision Trees
Safety, Production and - Maintenance Policy for
the Environment all RIs Failure Modes
- MA for each Failure - Further details of the
Mode Policy (e.g. inspection
Specific Requirements/ period, weak signals,
Constraints from spare parts, personnel
National Authorities skill) to upgrade the
- Policies for Spare Parts Maintainability Analysis
- Expert judgment SI
MA Upgrading
Maintainability Analysis upgrade with the
Inputs details provided by the O&M Policies and Output/Deliverables
the Task Analysis, i.e. inspection period,
- Maintainability Analysis Weak signals, need for spare parts and - MA revision
- O&M Policies personnel specific skill, etc. - Total Maintenance
Time upgrade
SI

Risk
Criteria analysis
O&M Input to
Failure Decision
Policies Execution
(FMEA)
RAMS data MA
Upgrading
Yes
Target Target
Analysis
No No
Upgrading
OR
Design
review
Availability Analysis
Inputs Activity Description

- Availability target Availability Analysis of the overall
- Project basis plant by RBD and MC simulation Output/Deliverables
- RIs failure frequencies
- Maintenance Time from - Plant Availability in
MA terms of average
- Effects of RIs on safety ad production
production from FMEA - Ranking of elementary
- Maintenance policies from equipment according to
O&M Policies their criticality
- Hypothesis on logistic, - Suggestion for O&M
spare management, from Policies upgrade and/or
project basis and MA SI design review
O&M Policies validated
Output/Deliverables
Validation of the O&M policies on the
basis of the information provided by the - Definition of O&M
Inputs
Availability Analysis and the RIs Policies
- System Availability by Criticality - Contribution to the
Availability Analysis definition of logistic
- RIs ranking according aspects
to their criticality - Definition of O&M
- O&M Policies Requirements for
Constructors
- Guidelines for POGs
implementation
SI - Directions for CMMS
implementation

Execution phase

by Contractors
definition analysis
O&M Results
Revision &
System (O&M
Target Plan, POGs
Implementation,
(FMEA)
Data Integration
Upgrading
OR
OR
- Technical Docs
- Performance Plant
Design Requirements
review
EXECUTION PHASE

by Contractors
definition analysis
O&M Results
Revision &
System (O&M
Target Plan, POGs
Implementation,
(FMEA)
Data Integration
Upgrading
OR
OR
- Technical Docs
- Performance Plant
Design Requirements
review
EXECUTION PHASE
Contractors/Suppliers data
- S to provide MEL, Specification sheets,
Inputs BOM, Insurance/Critical Spare parts Output/Deliverables
list, failure rates and ART for Items
O&M Data and Analysis - C to collect and validate data from For the overall plant:
requirements for Suppliers - MEL,
Contractors and - SI to collect and integrate data from - Specification sheets,
Suppliers set by SI Contractors to prepare MEL, - BOM,
Specification sheets, BOM, - Insurance/critical
Insurance/Critical Spare parts list for Spare parts list
the overall plant - RAMS data for RCM
- analyses
SI C S
Maintainability Analysis
Revision & Integration
- C to perform detailed MA for Items
Inputs supplied, TOST, BIST; Output/Deliverables
- SI to revise and integrate MA done
- Item list during Concept definition phase - Corrective
- Results from Concept considering detailed MA and ART from Maintenance Time for
Definition phase Contractors, changes in Logistic each Item
- RAMS Data Strategy, Task Analysis results, etc. - Preventive
- Logistic strategy Maintenance Time for
each Item
SI C


by Contractors
definition analysis
O&M Results
Revision &
System (O&M
Target Plan, POGs
Implementation,
(FMEA)
Data Integration
Upgrading
OR
OR
- Technical Docs
- Performance Plant
Design Requirements
review
EXECUTION PHASE
- C to perform a detailed FMEA of the
Inputs Items supplied; Output/Deliverables
- SI to revise and integrate FMEA done
- Item List during Concept definition phase based For each Item, severity
- Results from Concept on detailed FMEA from Contractors and classification of each
definition phase failure mode
- RAMS data
- Severity classification
from Risk
Acceptability Criteria
SI C
Criticality Analysis Revision
& Integration
Inputs - C to perform detailed CA for the Items
- Risk Acceptability supplied; Output/Deliverables
Criteria - SI to revise and integrate the CA done
- List of Items during the Concept definition phase Ranking of Item failures
- Results from Concept based on CA from Contractors each one characterized
definition phase by its Overall Criticality
- CMT from updated MA and Criticality on Safety,
- Severity Class and % Asset/Production and the
of production loss Environment
from updated FMEA
- Updated costs of
production loss SI C


by Contractors
definition analysis
O&M Results
Revision &
System (O&M
Target Plan, POGs
Implementation,
(FMEA)
Data Integration
Upgrading
OR
OR
- Technical Docs
- Performance Plant
Design Requirements
review
EXECUTION PHASE
O&M Policies
Inputs
- Revise and update the selection of best
- Criticality of each Maintenance Policies for each Item Output/Deliverables
failure mode versus failure mode considered in the FMEA
Safety, Production and - Refer to Contractors indications for the - Detailed Maintenance
the Environment Policies selection Policy for all Item
- MA for each Item - Whether necessary, make use of Failure Modes
Failure Mode Decision Trees optimized on AA
- Specific Requirements/ feedback.
Constraints from
National Authorities
- Policies for Spare Parts
- Suppliers’ indications SI C
- AA feedback


by Contractors
definition analysis
O&M Results
Revision &
System (O&M
Target Plan, POGs
Implementation,
(FMEA)
Data Integration
Upgrading
OR
OR
- Technical Docs
- Performance Plant
Design Requirements
review
EXECUTION PHASE
Availability Analysis for
Plant & Systems
Inputs Activity Description

- Results from Concept - C to perform AA of the Systems
definition phase supplied by RBD Output/Deliverables
- Item list and mission profile - SI to revise the Availability Analysis
- Items failure frequencies of the overall plant done during the -Plant Availability in
- CMT/PMT from MA Concept definition phase based on terms of average
- Effects of Items on safety AA provided by Contractors production
and production from FMEA - Ranking of Items/
- Maintenance policies from Systems according to
O&M Policies their criticality
- Logistic strategy, spare part - Input to O&M Policy
management, from project Revision and/or design
basis and MA
SI C review
O&M Tasks and procedures
for overall plant
- S to provide Maintenance Plans and
Operating Manuals
Inputs - C to collect, validate and integrate Output/Deliverables
- Constraints from Maintenance Plans and Operating - O&M Tasks and
Insurance/Warranty Manuals from S procedures for overall
- Spare part management - SI to collect, harmonize and validate plant
- Human resources data concerning Maintenance Plans and - Outline of O&M Plan and
planning Operating Manuals from C with the POG
support of the Task Analysis approach - Data to implement the
- SI outline the O&M Plan and POG, CMMS
provide input to CMMS implementation
SI C S


by Contractors
definition analysis
O&M Results
Revision &
System (O&M
Target Plan, POGs
Implementation,
(FMEA)
Data Integration
Upgrading
OR
OR
- Technical Docs
- Performance Plant
Design Requirements
review
EXECUTION PHASE
Overall O&M system
Elaboration of all data to issue the O&M
Inputs Plan and Process Operator Guides, and Output/Deliverables
to implement the CMMS
- O&M Tasks and - O&M Plan
procedures for overall Preparation of the procedures to be - POG
plant applied during the Production and Close - Data ready to be
- Outline of O&M Plan and Out phase in order to implement a implemented in the
POG “living” RCM Program. CMMS
- Data to implement the - Procedures for the
CMMS “living” RCM Program
SI

Production phase
Project
Review
Contractual
Maintenance
Strategy
Assessment
Maintainability
analysis
Upgrade Overall O&M
Failure
Analysis
(FMEA)
Operation Upgrade
Availability
Data analysis
Upgrade and
Comparison
PRODUCTION PHASE
Project
Review
Contractual
Maintenance
Strategy
Assessment
Maintainability
analysis
Upgrade Overall O&M
Failure
Analysis
(FMEA)
Operation Upgrade
Availability
Data analysis
Upgrade and
Comparison
PRODUCTION PHASE
Contractual Maintenance
Strategy assessment
- MC to the O&M ET lessons learnt and
Inputs data from strategies implementation Output/Deliverables
- O&M ET to elaborate alternative
From Execution Phase: maintenance strategies for MC to - Suggestion for
- O&M Policies submit to the O&M policy revision improvement of O&M
- Contractual Policies
Maintenance Strategy
for MC
ET MC
Maintenance data
- MC and MT to collect maintenance
Inputs data according to the procedure set in Output/Deliverables
the Execution phase
From Execution phase: - To gather maintenance data from MC - Actual operational
- RAMS Data and MT and to upgrade the RAMS data maintenance data to
- Procedures for data used in the Execution phase upgrade RAMS data
collection from Execution phase
ET MC
ET O&M Engineering Team MC Maintenance Contractors OT Operation Team

Project
Review
Contractual
Maintenance
Strategy
Assessment
Maintainability
analysis
Upgrade Overall O&M
Failure
Analysis
(FMEA)
Operation Upgrade
Availability
Data analysis
Upgrade and
Comparison
PRODUCTION PHASE
Operation data
- OT to collect operation data according
Inputs to the procedure set in the Execution Output/Deliverables
phase
From Execution phase: - ET collect operation data from OT to Estimation of the actual
- Procedures for data upgrade the reliability and availability plant availability
collection data used in the Execution phase
ET MC OT
RAMS data upgrade
O&M ET to upgrade RAMS data required
Inputs by RCM analyses on the bases of Output/Deliverables
feedback from MC and OT
- RAMS data from Upgraded RAMS data
Execution phase Feed of the Company Reliability Data collection
- Maintenance data Base
ET

Project
Review
Contractual
Maintenance
Strategy
Assessment
Maintainability
analysis
Upgrade Overall O&M
Failure
Analysis
(FMEA)
Operation Upgrade
Availability
Data analysis
Upgrade and
Comparison
PRODUCTION PHASE
Maintainability Analysis
O&M ET to revise and update the MA
Inputs developed during the execution phase on Output/Deliverables
the basis of operation feedback
Updated set of RAMS Updated Preventive and
data Corrective Maintenance
Time of the Items of the
installation
ET
Upgrade (optional)
O&M ET to revise and update the FMEA
Inputs analysis developed during the execution Output/Deliverables
phase on the basis of the updated set of
Updated set of RAMS RAMS data and operation feedback Updated FMEA analysis
data This activity should only be performed
when the decision is taken as
consequence of extraordinary events
ET

Project
Review
Contractual
Maintenance
Strategy
Assessment
Maintainability
analysis
Upgrade Overall O&M
Failure
Analysis
(FMEA)
Operation Upgrade
Availability
Data analysis
Upgrade and
Comparison
PRODUCTION PHASE
Criticality Analysis revision
O&M ET to revise and update the
Inputs Criticality Analysis developed during the Output/Deliverables
execution phase on the basis of the
- Upgraded MA updated MA and FMEA - Revised Criticality
- Upgraded FMEA Analysis
- Risk Acceptability - Actual Criticality of
Criteria each Item versus
Production/Asset,
Safety and
Environment
- Suggestions for O&M
ET
policies revision
Availability Analysis
Plant & Systems (optional)
- O&M ET to re-evaluate the plant
Inputs availability implementing the operation Output/Deliverables
data provided by the OT.
- AA from the Execution - Comparison of actual availability and - Actual availability of
phase measured availability to provide the overall plant
- Operation data suggestion for O&M Policies revision - Suggestion for O&M
policies revision and/or
This activity should only be performed project review
when the decision is taken as
consequence of extraordinary events
ET

Project
Review
Contractual
Maintenance
Strategy
Assessment
Maintainability
analysis
Upgrade Overall O&M
Failure
Analysis
(FMEA)
Operation Upgrade
Availability
Data analysis
Upgrade and
Comparison
PRODUCTION PHASE
O&M Tasks and procedures
revision (overall plant)
- O&M ET to revise O&M tasks and
Inputs procedures set in the Execution phase Output/Deliverables
on the bases of operating data and
- O&M Tasks and RCM analyses update - Revised O&M Tasks and
procedures revision - To provide input to O&M Plan and POG procedures for overall
from Execution phase update, and data to CMMS update plant
- Results from CA and - Input to O&M Plan and
whether available from POG revision
AA - Updated Data to
- Updated O&M policies implement the CMMS
- Actual Constraints from
Insurance/Warranty ET
Overall O&M system revision
(O&M Plan, POG, CMMS)
O&M ET to elaborate all data to revise
Inputs and update the O&M Plan and Process Output/Deliverables
Operator Guides, and to upgrade input
- Updated O&M Tasks data to the CMMS - Upgraded O&M Plan and
and procedures for POG
overall plant - Upgraded feed to CMMS
- O&M Plan and POG in
force
- Data to update the
CMMS
ET MC OT

Operation & Maintenance Engineering Guideline For RCM Implementation

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

Exploration & Production Division 22010.MAN.GEN.SDS 00 1 of 37

OPERATION & MAINTENANCE

00 Final Issue Fabio Cadelli Vanzini 19 Dec. 03

Exploration & Production Division 22010.MAN.GEN.SDS 00 2 of 37

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· Availability Analysis – prediction of the facility performance in terms of Production Availability.

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1.3 Guideline objective and scope 14

2. OVERALL O&M STRATEGY VERSUS THE PLANT LIFE CYCLE 15

3. RELIABILITY CENTERED MAINTENANCE (RCM) 17

3.2 Overall structure of the methodology 17

4. CONCEPT DEFINITION PHASE 20

4.1 Overall approach to the O&M activities 20

4.2 RCM Methodology for Concept Definition Phase 20

4.3 Expected results 24

5.1 Overall approach to the O&M activities 25

5.2 RCM Methodology for Execution phase 25

5.3 Expected Results 27

Exploration & Production Division 22010.MAN.GEN.SDS 00 5 of 37

6.1 Overall approach to the O&M activities 30

6.2 RCM Methodology for Production phase 30

6.3 Expected Results 32

7. RCM PROGRAMME VERSUS PROJECT IMPORTANCE 34

8. SUGGESTIONS FOR RCM PROGRAMME IMPLEMENTATION 36

9. APPENDIX - RCM ACTIVITIES SYNTHESIS 37

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PMT Preventive Maintenance Time

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Key Activity Activity that has to be performed during the Development

Preparation Activity in which the plan of the phase is set up o the

Milestone Milestones underline completion points in the work-flow,

Decision Critical and mandatory decision point

Non Compulsory Non compulsory decision point, performed only in a sub-

Text Input data and information

Text Output data and information

Exploration & Production Division 22010.MAN.GEN.SDS 00 11 of 37

VALUE IDENTIFICATION VALUE REALISATION

Project Realisation: Commissioning &

+ running phase till

Figure 1. RCM during the plant lifecycle

Ref. Document Number Title

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5 20198.COO.GEN.SDS Rev. 1, Item Numbering and Coding System

8 KE00.00.000.AK.O.YP.0002.000 Operation and Maintenance philosophy

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1.3 GUIDELINE OBJECTIVE AND SCOPE

1. Perform a preliminary Reliability Centered Maintenance during Concept definition

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2. OVERALL O&M STRATEGY VERSUS THE PLANT LIFE CYCLE

Maintenance Planning Work Orders

RCM CMMS In-field

Maintenance FeedBack Info from Maintenance

Figure 2. Long term O&M Strategy