Marine Engineering

ME14 1329
Maintenance Management
Gilang Rahadian (04211740000020)

Work Book 5:

5
Major Maintenance Business Process
Part 2
Course
Instructor:
Dwi
Priyanta
Department of Marine Engineering – ITS

EDUCATE – ENHANCE – EMPOWER

Rev. Oct. 2015
ME14 1329 Maintenance Management
 W Maintenance Business Process Part 2
orkbook 5 : Major

CONTENTS

1. Introduction.................................................................................................3
2. Maintenance Management Process and Equipment Criticality Overview...4
3. Methodology for Risk-Based Maintenance Management...........................5
4. Maintenance Management Process: A Global View....................................6
4.1. Maintenance Planning.........................................................................7
4.2. Spare Parts...........................................................................................7
4.3. Personnel and Resources.....................................................................7
5. Consequence Classification / Criticality Analysis.........................................8
6. Establishing Maintenance Program.............................................................9
7. Reference..................................................................................................10

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© Dwi Priyanta Page 2 of 10

EDUCATE – ENHANCE – EMPOWER Rev. May 2015
 ME14 1329 Workbook 5 :
Maintenance Management Major Maintenance Business Process Part 2

1. Introduction

 Read Norsok Z-008 (Edition 3, June 2011) Risk based maintenance and
consequence classification carefully.


1. Determine the purpose of NORSOK Z-008.

2. Explain the possible application of Norsok Z-008 in the asset

life cycle.

3. Study and find the anatomy / organization of Norsok Z-008. (Hint

: Read Foreword part of the Norsok Z-008).

Answer :

1. To provide requirements and guidelines for:

 Establishment of technical hierarchy
 Consequence classification of equipment
 How to use consequence classification in maintenance
management
 How to use risk analysis to establish and update PM programmes
 How to take decision related to maintenance

2. a. Design phase : Establish initial maintenance programme as an

input to manning requirements & system configuration selection
of spare parts.
b. Preparation for operation.
c. Operational phase : Updating and optimisation of existing
maintenance programmes.

3. As a prepared & published with support by the Norwegian Oil

Industry Association (OLF) The Federation of Norwegian Industry,
Norwegian shipowner association and The Petroleum Safety
Authority Norway (PSA)
© Dwi Priyanta Page 3 of 10
EDUCATE – ENHANCE – EMPOWER Rev. May 2015
 2. Maintenance Management Process and Equipment
Criticality Overview

4. Study Figure 1, Figure 2 and Figure 3 in the standard. Find the
relations among those figures.


Answer :
Figure 1 : Maintenance Management Process
Figure 2 : Consequence Classification Process
Figure 3 : Establishing maintenance programme for new plant

The relations among those figures are figure 2 explain how to classified
the equipment based on its function. After we classified the
equipment, we must determine what kind of maintenance that
needed for each classification.
 3. Methodology for Risk-Based Maintenance
Management

 Study carefully section 4 of Norsok Z-008 Edition 3, June 2011.

5. Determine the key elements of methodology for risk
based maintenance.
 6. Explain briefly why safety functions is important to be
maintained in risk based maintenance and how to establish
safety function requirements?
7. Static process equipment is also one of important asset which
is covered in risk-based maintenance. Explained briefly how to
manage this equipment from point of view risk-based
maintenance.
8. How to set up risk decision criteria in risk-based
maintenance methodology?

Answer :

5. a. Consequence classification of functional failure.

b. Use of GMCS in combination with classical RCM methods.
c. In case no GMCS are applicable of the purpose of the study
required more in-depth evaluation an RCM/RBI analysis should
be carried out.
d. The application of the consequence’s classification &
additional list factors for decision making related to
corrective maintenance and handling at spare parts.

6. Safety function is important to be maintained in risk based

maintenance because it will determine the safety system
and their performance. The development of failure rate
and system unavailability should be used as the basis for
charging of test chain of test interval and other mitigating
actions to ensure compliance with function requirement.
7. In order to establish an inspection programme for this
equipment, it is necessary to perform detailed evaluations
similar to an FMECA, usually named RBI.

The process requires knowledge of:

a. Damage mechanism which depends on material
properties, internal fluid compositions and the external
operational environment — determining the probability
of failure,
b. Consequence of leak failure with respect to personnel,
environment damages and financial losses

The combination of the above represents the risk of failure

which should be mitigated.

8. The following principles should apply:

a. the risk matrix should as far as possible be the same for all
operation for a company in order to aid common companywide
optimization and devote resources accordingly as well as
having a common language for communicating risk;
b. Further, the same criteria should be used for all equipment and
systems (also those excluded from this standard). This is in
particular important for topside maintenance and inspection
planning which are handling basically the same hardware;
c. The consequence of loss of functionality (both loss of MF and
sub functions) should take into account the standby redundancy
(see 3.1.33) and reduce the impact accordingly.

Annex C gives example of criteria which can be used for

classification, development of preventive work tasks and for
prioritization of work orders, as well as for optimization of
spares.
 4. Maintenance Management Process: A Global
View

 Redraw Figure 1 of Norsok Z-008. Study carefully Section 5, and pay

attention to Figure 1. The figure depicts Level 0 / major maintenance
 bsiness process.

9. Make notes and summary of following blocks which are listed

 in Figure 1.
 Goals and requirements
 Maintenance Program
 Planning
 Maintenance Execution
 Reporting
 Analysis and Improvements
 Organization
 Materials
 Documentations
 Maintenance and Verification
 Risk Level
 Production Assurance

Since each block represents major process, is it possible to develop

sub-process, activities and tasks in each major process?

Answer :

 Goals and requirements : Goals should be established that commit the

organization
 Maintenance program : Should include maintenance interval & written
procedure
 Planning : Is a structural set of task that include the activities,
procedure, resource
 Maintenance Execution : Preparations, work permit, carrying out work
and reporting
 Reporting: Collection and quality assurance of maintenance data
 Analysis and Improvements: Carry out analysis of historical maintenance
data unwanted maintenance
 Organization: People, their training, competence, jobdesc, and work
process
 Materials: Consumable, spare parts, tools required to carry out
maintenance
 Documentations: All documentation required to carry out and manage
maintenance
 Maintenance and Verification: A key to good maintenance is a well
organized management team.
4.1. Maintenance Planning
10. Pay more attention on planning and read section 9 of Norsok Z-
008 (edition 3, June 2011). One of the biggest problems in
maintenance planning and scheduling is how to manage many
planned maintenance activities effectively. Prioritizing work
order is one of the best way in order we can manage
maintenance activities effectively. Explain briefly what are key
activities in maintenance planning and also how to prioritize
maintenance activities.
 Key activities : detailed planning, order material, personnel and
tools for the activities
 How to priorize:
- Assigning the consequence of failure to the case
- Assigning the failure impact
- For failure impact “degraided of incipient failure”, a time
to failure shall be assigned and used in the setting of
priority for the repair.
- The risk associated with the consequence and probabilities
shall be defined
- Compensating operational actions used to temporarily
maintain the function can be described as redudancy
 - Compensating measures shall be in place when failure on
the safety critical function.

4.2. Spare Parts

11. Read section 11 of Norsok Z-008 (edition 3, June 2011). Spare
parts availability will contribute to shortened the downtime
of asset. Briefly explained how to do spare parts assessment.

12. Redraw work flow for evaluation of spare parts (Figure 6).

13. Explain detail content in each box of work flow for evaluation of
spare parts (the category of spare parts; location and holding;
reorder level and order quantity).

Answer:
11. The spare part assessment shall be based on results from the
consequence classification. The demand rate and which spare
parts are needed for corrective maintenance is more challenging
to be estimated.
12. Workflow for Evaluation of Spare Parts
13. Spare parts can be categorized as follows:
a. Capital Spare parts:
 Vital to the function of the plant, but unlikely to suffer a
fault during the lifetime of the equipment.
 Delivered with unacceptably long lead time from the
supplier and usually very expensive
 Often these spare parts are characterized by a
substantially lower cost if they are included with the initial
order of the system package.
b. Operational Spare Parts
Spare parts required to maintain the operational and
safety capabilities of the equipment during its normal
operational lifetime.
 c. Consumables
Item or material that is not item specific and intended for
use only once (non-repairable).

4.3. Personnel and Resources

14. Read section 12 of Norsok Z-008 (edition 3, June 2011). Personnel

and resources will also contribute to shortened the downtime of
asset. Briefly explained type of personnel should be involved in
maintenance activities.

Answer :
The type of personnel should be involved, are:
a. Maintenance personnel with specific experience from
different type of systems/equipment. Typically this will
involve mechanical, instrument, electrical and corrosion
inception qualification on senior level.
b. Maintenance planners and maintenance supervisors.
c. Operation and process personnel with process experience
handling the production impact of a failure.
d. Personnel with specific experience related to risk assessment
and maintenance analysis.
e. Maintenance engineers.
 5. Consequence Classification / Criticality Analysis

 15. Read and Study carefully section 7 of Norsok Z-008 (edition 3, June
2011) and redraw Figure 2. This Figure shows the flow on how to
 classify the equipment before its maintenance program
established.

16. Read and Study carefully section 6 and Appendix D of Norsok Z-

008 Edition 3, June 2011. Read and Study carefully section 5 and
Annex A of Norsok Z-CR-008 Rev. 1 May 1996.
Hint: Read also Appendix D of Norsok Z-008 Edition 3, June
2011; section 5 and Annex A of Norsok Z-CR-008 Rev. 1 May
1996.

17. Read and Study carefully section 7 of Norsok Z-008 (edition 3, June
2011), briefly explained what activities should be done in each
block listed in Figure 2.

Answer:
15.
17. The Steps :
1. Technical Hierarchy  Established the technical hierarchy used
to identify systems and equipment.
2. Identify MF’s  Each plant system should be divided into a
number of MF’s covering the entire system.
3. Identify Sub Functions  MF’s are split into sub functions by
standardized for typical process equipment.
4. Assign MF Redundancy  This step shall be specified.
5. Assign MF Consequences  The entire MF failure
consequences is no longer be able to perform its required
functions.
6. Assign Sub Function Redundancy  The number of parallel
units and capacity per unit shall be stipulated.
7. Assign Sub Function Consequences  Sub function is assessed
with respect to HSE, production and cost.
8. Input from other analyses  Structures/pipelines and risers.
9. Equipment mapping to function  The equipment carrying out
the sub functions shall be assigned to the respective sub
functions.
 6. Establishing Maintenance Program

 Read Section 8 of Norsok Z-008, pay attention and redraw Figure 3.

The figure depicts how to establish / to set up maintenance program.
 18.Make notes and explain relevant activities in each block drawn
in Figure 3.
 19.Pay much attention on generic maintenance concept (GMC).
Explain what is GMC.
20.What do we have to do if there is no such GMC?

Answer :

18. A. Group and Classification

Input to the process is the technical hierarchy and a functional
grouping and functional classification of the plant in question.

B. Safety functions
For safety functions with given availability requirements, there
exists models for how to estimate testing time, see OLF 070 or IEC
61508.

C. Generic Concepts
The next step is to assess if the equipment has common definitions.

D. Adjustment of GMCs
In the actual case, the generic concepts should be evaluated in view
of the plant's production value (deferred production) and its repair
capacity (manufacturing, spare parts and equipment) to manage the
most common defects.

E. Risk analysis/ Assignment of Maintenance Activities

In the event that there is not a GMC applicable and further
 thorough evaluations are required for the purpose of the study, an
IEC 60300-3-11 and DNV RP-G-101 analysis should be conducted in
accordance with the RCM / RBI / SIL criteria.

F. Developing Generic Maintenance Concepts

The above RCM/RBI/SIL analysis can be transformed to a GMC for
later use on similar equipment. Additional experience related to
use of the concepts should be included.

G. Low Consequence Items

A scheduled corrective maintenance strategy may be selected (run
to failure), for equipment identified with a low result of failure.

H. Establish Maintenance Programme

All maintenance activities will, eventually, be organized and
prepared to take account of plant production plans, resource
requirements, turnaround times, etc.

19. A GMC is a set of maintenance actions, strategies and maintenance

details, which demonstrates a cost efficient maintenance method
for a defined generic group of equipment functioning under similar
frame and operating conditions. The use of the GMC should ensure
that all defined HSE, production, cost and other operating
requirements are met.

20. An FMECA/RCM/RBI analysis should be carried out to study in more

depth evaluation.
7. Reference

1. Various Consultancy Documents Performed by Author

2. Norsok Z-008 (Edition 3, June 2011) Risk based maintenance

and consequence classification

3. Norsok Z-008 (Rev. 2, Nov. 2001) Criticality analysis for

maintenance purposes

4. Norsok Z-CR-008 (Rev.1, May 1996) Common

Requirements Criticality Classification