RCM Process for Client Understanding

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Velosi Background and Experience
Velosi Certification Services is an International Company engaged in Asset Integrity Management
(AIM) Reliability Centered Maintenance, Risk Base Inspection, Health, Safety and Environment
(HSE), FEED, Detail Engineering, Design Review, As-Building, Quality Assurance, Quality Control,
Third Party Inspection, NDT and Certification services over 35 years of experience. With over 8000
employees and a worldwide network of offices we provide Third Party Inspection and Certification
Services for Oil and Gas Industry, Fertilizer, General Engineering Industry and Power Sector. The
services provided by the company include certification, engineering and inspection services for
contractors, project management companies, government and other public sector. Velosi is pre-
qualified with most of the major Oil and Gas companies in the Middle East, Europe, Far East,
American Continent, India and Pakistan.
Process industry and manufacturers are expected to maintain a high standard of quality control and
quality assurance throughout their operations in order to ensure proper plant operations, reliability
and maintenance excellence. High on the list of concerns is always the need to balance revenue and
operating costs with safety and quality standards; that is why it is important to evaluate and monitor
company assets on periodic basis
Velosi Asset Integrity Management Services are centered on helping Oil & Gas sector, Petrochemical and
manufacturing sector to extend their asset life cycles, employ an effective risk management system and
optimize production safety by improving asset integrity. Through our wide range of services, we can work
with clients to create a comprehensive plan suitable to their individual specific need.
Our professionals are highly skilled in the area of new build or conversion projects relating to floating,
production, storage and offloading (FPSO) units, Mobile Offshore Production units (MOPU), jack-
ups, semi-submersibles, drill ships, offshore fixed platforms, pipe laying or derrick barges and other
offshore support vessels.
Velosi’s capabilities include Inspection, Certification of offshore and onshore Drilling Rigs,
Platforms, Barges and other offshore equipment.
The Rig Inspection Services Division has the expertise in Drilling Rigs – both Onshore and Offshore
marine and derricks. The Rig Inspection Services inspect and certify to the requirements of API, IDAC
and SOLAS and a more detailed profile is available herewith pertaining to this services.
Presently Velosi has more than 8000 engineers, Specialists and Inspectors in various disciplines
having worldwide presence with 70 offices in 40 countries.
The Company provides Quality System Consultancy and Certification Services – ISO 9001, ISO
14001, ISO 29001, OHSAS 18001 and Contractors Safety Checklist for Safety, Health &
Environment Consultancy Services.

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 The Company provides Authorized Inspection (AI) Services in the areas of ASME Boiler and
Pressure Vessel Code, and any other Boiler and Pressure Vessel Codes under agreement with Seneca
Insurance Company an ASME accredited AIA.
The company is accredited by UKAS to inspect and issue certificate of conformity to pressure
equipment and is a “NOTIFIED BODY” under EC Directive 97/23/EC.
The Company provides Inspection and Certification Services for all types of Cranes, Hoists, Rigging,
Lifting Equipment and Scaffolding. Offers custom built Training Courses for personnel in all aspects
of operation and maintenance of cranes, rigging and scaffolding, forklift operation, self-elevating
platform operation, and other similar areas associated with Plant and Construction Equipment and
Industrial Safety. The Company is a “Member of the Association” of Lifting Equipment Engineers
Association of United Kingdom. Recently our Company has been recommended for accreditation by
UKAS for lifting equipment inspection & certification.

Resources and Capabilities of the Company

The services provided by Applus+ Velosi include, but are not limited to the following:

Engineering Consultancy, Detail Engineering and FEED study, Design Review and Certification
HSECES identification and management Systems.
AIMS (Asset integrity management Systems) compliance and bench marking audits/assessments
Integrity assessment of plants and pipelines.
Risk based Inspection (RBI) services in accordance with API 580 and API 581
Reliability Cantered Maintenance Services (RCM).
Fitness for service studies in accordance with API 579. As-Building via conventional methods as
well as Laser Scanning, Design/Drafting services for existing facilities.
Third Party Inspections, Certification & IVB Services.
Third Party Inspection and Expediting Services.
Boiler & Pressure Vessel Certification (ASME, BS, DIN and EN Standards).
Safety Integrity Level Assessment (SIL) in accordance with IEC 60508 and 60511.
Corrosion studies and preparation of corrosion loops.
Evaluation & Condition Monitoring of CP System.
External Corrosion Direct Assessment (ECDA).
Development of inspection data management system.
Safety and Environmental Engineering; HAZOP, QRAs, HSEIA, Hazards Identification and
Safety studies.
Specialized NDT inspections.
Review & Assessment of CP system.
Lifting Equipment Inspection and Certification.
Materials and Welding Technology.
Accreditation for Marking of Products.
Access Engineering (Riser & Topside Inspection/Repairs thro’ Abseiling technique).
Provision of Qualified Engineering Personnel on Contract.
API Certified Inspectors for Tubes, Casing & Crossover Pipes.
Indian Boiler “Inspection Authority” & “Competent Authority” approved by Central Boiler Board
of India.

Velosi’s Software

VAIL-PLANT (Risk Based Inspection & Data Management System)

VAIL-RCM (Reliability Centered Maintenance Tool)
VAIL-PIPELINE (Pipeline Integrity Management System)
VAIL-SIL (Safety Integrity Level)
VAIL-HAZOP (Process Hazards Analysis Tool)
VAIL-IMC (Integrity Management Console)
Development of software based on specific client needs

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VELOSI APPROACH TO CARRY OUT THE RCM
Kick off Meeting
Kick of meeting will be held after the project award. Velosi RCM team and TNB REMACO project
team will attend the meeting. The meeting is tentatively scheduled for one (1) day. The following
items will be discussed and finalized
Project Objective
Project plan with Key dates and Milestones
Project resource schedule and organization chart
Project Quality Assurance Plan
A presentation will be delivered by Velosi on the project execution procedure
Data collection
For Data collection part, Velosi will send a list of the required data earlier than the kick-off meeting
date. This is to ensure that time will be better managed by verifying the data that has already been
collected by TNB REMACO.
Velosi project team shall identify the data requirement for FMECA based RCM analysis.
Following data is required as a minimum:
Equipment Lists
Engineering data and drawings (P&ID, PFD, SLD’s, vendor drawings etc.)
Project Process Descriptions
Equipment data sheets
Spare Parts Interchangeability Record (SPIR) sheets for availability of spare parts in FMEA
study
Equipment Tagging Procedure
OEM Manuals
Plant Operation and Maintenance Manuals
Guidelines and Standards
Preparation of Asset Register
Preparation of Asset Register is the first step in conducting FMECA based RCM analysis. Following
are the steps to develop the Asset Register;
Identification and evaluation of data required for the preparation of Asset Register
Identification of tags from collected documents like P&IDs, single line diagram & equipment
list.
Identification of system and system boundary description, location, parent tag, discipline, etc.
from P&IDs & equipment list
Identification of make, model and serial no. etc. from the OEM manuals and data sheets
Populate the Engineering data in Asset Register for each tag
Submission of Asset Register for review and comments.
Incorporation of comments and final submission.
Identification & Evaluation of Collected Data
For the preparation of Asset Register, Velosi will identify and evaluate the data from the collected
documents, which will be necessary for completion of Asset Register.
Following data will be required as a minimum.
Engineering drawings
Data sheets & OEM manuals
Operation & maintenance register/manuals and routines, project dossier, vendor
documents Cost centre, equipment category, make, model & system codes etc

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 Development of Equipment Hierarchy
Velosi team will develop the Asset Register from equipment lists, P&IDs, PFDs and single line
diagram.
Velosi team will also identify system, system boundary, and parent tag and discipline to develop
equipment hierarchy.
Population of Equipment data in Asset Register
Velosi team shall identify and populate asset data in the Asset Register as per basic data requirement
for items subject to maintenance which would cover following as a minimum:
Tag number
Equipment description
Equipment Hierarchy
Engineering Parameters
Manufacture, Model, Serial No
Object type & its description
Document Number (P&ID, SLD, PFD & equipment data sheet)
System code & description
Operating description / Parameters
Submission for Review and Comments
After completing the above steps, Velosi shall review the Asset Register and submit it to the TNB
REMACO for review and comments.
FMECA Based RCM Analysis
FMECA based RCM Analysis will be carried out for all TNB REMACO assets. Main activities shall
include the following:
Preparation of data base for FMECA based RCM analysis
Identification of failure modes
Conduct FMECA analysis
o Identification of Failure Modes
o Assigning of Cause, Effects and Maintainable items
o Assigning of Equipment Criticality
Review, verification and validation of RCM analysis results
Maintenance Strategy decision, Recommendations
Preparation and presentation of RCM Report
Approach for FMECA based RCM Analysis
FMECA based RCM analysis to determine all functions (Primary & Secondary Functions),
Functional Failures (Total or Partials), Failure Modes, Failure Effects, Failure Characteristic (age or
not age related failures), Failure Classification (Hidden or evident), Influencing Factors (root causes),
Failure Criticality (Safety, Environment, Production and Non production).
The FMECA Process will be supported by VELOSI and other published Generic Failure Data Bases
which will be modified to be applicable for TNB REMACO.

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Task Resources/
Description of Approach and Method Deliverables
No. Location
1 Task 1:Kick-Off Meeting & Data Collection
1.1 Sub Task 1.1: Letter of award & project commencement
The project commencement date will be as per date of N/A
letter of award of contract.

Sub Task 1.2: Kick off meeting

1.2 Kick off meeting will be held at TNB office/site; Velosi Project Project plan
RCM team and TNB project team will attend the Manager, with Key
meeting. The meeting is tentatively scheduled for one (1) Project dates and
day. The following items will be discussed and finalized. coordinator & Milestones.
Project objective QA, RCM Project
Project plan with key dates and Milestones consultants. resource
Project resource schedule and organization chart schedule and
Project Quality Assurance Plan organization
A presentation will be delivered by Velosi on the project chart.
execution procedure. Project
Sub Task 1.4: Data Collection & review Quality
Assurance
For data collection part, Velosi will send a list of the Plan.
required data earlier than the kick-off meeting date upon
confirmation of the order. This is to ensure that time on Report on data
site will be better managed by verifying the data that has collection
1.3 already been collated by TNB. This list will be enclosed status.
in the report on ‘data collection & follow up procedure’.
During the visit to field for the walk through survey the
data will be collected.

2 Task 2:
RCM Project Review of
Preparation of data base for RCM study Manager, TNB Asset
2.1 Velosi will prepare the data base for RCM as per the Project Criticality
fields which are necessary for the completion of RCM coordinator, Assessment.
Study. RCM
Asset register developed in first phase would be the base consultant,
asset register for the preparation of data base for FMECA RCM
Engineer,
RCM study.
Electrical
Below tasks explain the complete procedure of Engineer,
preparation and completion of RCM study. Rotary
Equipment
Engineer.
3 Task 3: FMECA based RCM analysis

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Task Resources/
Description of Approach and Method Deliverables
No. Location
3.1 Sub Task 3.1: Process discussion and study preparation
Group Session no.1 - Conduct Process Project
a discussion with TNB Engineers(functional Manager,
review, boundary definition, Technical Project
hierarchy) coordinator,
RCM
Velosi will conduct the process discussion with TNB consultant,
engineers at TNB Site, this is required for a RCM Risk Matrices
comprehensive understanding of the facility. The system Engineer, and
& equipment boundaries, functional statements and the Electrical Acceptance
verification of technical hierarchy in the asset register Engineer, Criteria
shall be completed during these sessions. The asset Rotary Document
register and functional boundary diagrams given will be Equipment
used for this purpose. Engineer.
The benefit of this discussion is that it enables the RCM
team to complete the RCM analysis (especially the
FMECA process that follows) with minimal subsequent
input from TNB personnel. From our experience we
have concluded that a highly successful process
discussion will lead to a very accurate analysis that is
completed in the shortest possible timeframe.
Preparation of FMECA based RCM
b
methodology document
RCM methodology document will be submitted to TNB
during this stage of the project. This document will
contain the following.
- Velosi’s streamlined RCM methodology
- Compliance of RCM approach to standards
- Benefits of VELOSI’s RCM methodology
- Task selection decision logics
- Establishing asset management system using
Velosi’s RBM (Risk Based Maintenance)
concept
- Establishment of Asset Integrity Management
Strategy CBM Technique.
- Business process flow charts showing interface
between RCM & existing performance and
reliability key processes

c
Review/Development of Risk Matrices &
Acceptance Criteria
Velosi will study the HSE policy, Risk acceptance
criteria and decision parameters of TNB and hold
discussions with relevant discipline people at TNB Site.
Velosi will develop four risk matrices (first-safety,
second-environmental, third-business interruption and
the fourth-optional matrix to include either follow cost or

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Task Resources/
Description of Approach and Method Deliverables
No. Location
capital asset or reputation etc.) that will be used for the
FMECA, risk analysis and asset criticality analysis. If
such matrices have already been developed, accuracy &
suitability of such matrices will be reviewed. Data
gathering part of this activity will be done during the
process interview.
d
Verification of technical hierarchy of TNB
This is the hierarchy which will show the functional
interdependency of the studied equipment in the plant
and is crucial for an accurate analysis. The groundwork
for this has already been put in place during the Process
Interview and the sub task here will complete the
definition and prepare it for upload into VAIL-RCM
software. The boundary diagrams given by TNB will be
referred. TNB CMMS team should give their inputs on
this and about the number of levels configured in
CMMS.
RCM process and quality of data will be compliance to
international standards SAEJA1011/1012, ISO14224,
IEC60812, MIL-STD-2173.
RCM Software set up & data import
e SAP Certified, Maximo Integral VAIL-RCM software
will be loaded at TNB personnel laptops with the
information required to conduct Asset Criticality
Analysis and RCM analysis. RCM software is a valuable
aid to the RCM consultant that will enable to conduct the
analysis from data loading stage to task package
completion stage.

3.2 Task-3.2 Methodology for Failure Mode Effects and

Criticality Analysis (FMECA)
RCM Project
a Manager,
FMECA and Risk Analysis (VELOSI)
Project
The Failure Modes Effects and Criticality Analysis coordinator,
(FMECA) & Risk Analysis are proposed to be conducted RCM
in two phases. The first phase is conducted in the consultant,
VELOSI Abu Dhabi and utilizes the knowledge gained RCM
during the process interview as below. Engineer,
- To determine all applicable failure modes and their Electrical
characteristics (age related/non age related, Engineer,
revealed/non revealed) for various tag types. Rotary
- To evaluate the failure effects of each failure mode Equipment
of different tag types; to differentiate whether the Engineer.
effect is local, system or at plant level; to evaluate
the consequence of each failure mode.
- The failure effect descriptions shall include all the
information needed to support the evaluation of the

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 Velosi Proposal No. VAIL-18-292

Task Resources/
Description of Approach and Method Deliverables
No. Location
consequences of the failure, such as: In what ways it
poses a threat to safety or the environment, In what
ways it affects production or operations, like
shutdown, reduced throughput, etc and what
physical damage is caused by the failure
- Having evaluated the failure effects, the next step is
to assign a POF (Probability of failure) and the
consequence (Consequence of failure) categories
using the risk matrices developed. For POF
evaluation, site specific failure rates and failure
modes will be gathered from TNB personnel.
VELOSI would also refer to OREDA database and
other generic databases such as PDS, EsREDA, T-
Book, ZEDB, Non-electronic parts reliability data,
Process equipment reliability data etc. VELOSI also
has experts who can assist to analyze and develop
data. Using generic numbers is seldom accurate and
hence it will be done only where necessary after
discussions with TNB.

Group Session no.2 FMECA & risk analysis group

sessions (with TNB)
The RCM team will then meets TNB team at TNB Site
and discuss/verify the results of the initial analysis. The
b
intention of the discussion/study is:
- To evaluate all applicable failure modes developed
by VELOSI
- To determine / review the effects of the failures of
each equipment.
- To risk rank the equipment using the Risk Matrices
developed.
- To achieve teams’ consensus on the risk ranking of
an asset.
- To get expert opinions on the equipment failures
and effects from design engineers if available,
operators etc.

Post FMECA review and data management

(VELOSI)
After the group sessions, the database will be finalized
with all the necessary corrections / inputs received TNB
c personnel.
4 Task 4: Final reporting & presentation RCM Project
4.1 Sub Task 4.1: Preparation Manager, Final
RCM
reporting and
This sub task covers the preparation for the final consultant,
Presentation
presentation. RCM
to TNB
Sub Task 4.2: Presentation Engineer

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 Velosi Proposal No. VAIL-18-292

Task Resources/
Description of Approach and Method Deliverables
No. Location
4.2 Delivering the final presentation of the RCM study
results, findings, recommendations, single point failure
identification, launching a living program etc. to TNB
RCM team and management. RCM Project
Manager,
Sub Task 4.3: Submission of final reports.
RCM
4.3 This activity is revising all the draft reports submitted by consultant,
VELOSI incorporating comments if any from TNB and RCM
submission of final reports. Engineer
One cycle of review process is considered, which covers RCM Project
first draft submission by VELOSI, review & release of Manager,
comments if any from TNB and incorporation of RCM
comments & submission of final reports by VELOSI consultant,
both in soft and hard forms. RCM
Engineer
5 Task5: Project close out activities RCM Project
Manager,
5.1 Sub Task 5.1: Project Close out Activities Project Close
RCM
The activities contained here will be to: consultant, out Report
Generate a “Road Map” for analysis of low risk RCM
Engineer,
equipment.
Electrical
Compile a list of all reported or otherwise Engineer
identified issues
The problems faced and their resolution
6 Task 6: Follow up support RCM Project Follow up
Follow up support will be provided to TNB after the Manager , support report
CMMS 1
RCM study (during defects liability period).
Consultant
7.1 Sub Task 7.1 Support during implementation & RCM Project
execution of RCM tasks Manager
- It is proposed to hold discussions with TNB to (Velosi, TNB
find out any issues that may require )
clarification towards successful
implementation of RCM strategies. This
support will be after the completion of CMMS
upload by TNB and during actual
implementation / execution of RCM results.

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DELIVERABLES
FMECA based RCM analysis Report
Implementation of VAIL Plant-EIRMS Module

BENEFITS OF RCM STUDY ANALYSIS

RCM is a formal method to determine the maintenance requirements of an asset in its operating
context. It stresses a proactive approach to maintenance while attempting to match best maintenance
practice to mitigate a potential failure relative to the importance of preventing that failure.
If performed properly, RCM will;
Reduce overall maintenance cost
Improve realized reliability/availability
Provide a documentation trail for maintenance program changes
Provide details for continuous improvement of the maintenance program and equipment
performance
Ensures that;
The right maintenance is performed
At the right time
By the right people
In the right way
With the right training and tools
Benefits;
Improved Operating performance (Output, Product Quality and Customer Service)
Greater Maintenance and Cost Effectiveness Longer Useful Life of Expensive
Items
A Comprehensive Database
Team Work for Maintenance activities
Accurate Forecasting and Scheduling of Maintenance Budgets

Codes and Standards for RCM.

Reference Documents

Document Reference Document Title

RCM Standards

SAE JA1011/1012 Evaluation Criteria for RCM Processes

British Standard Analysis techniques for system reliability – Procedure for failure mode
BS EN 60812: 2006
and effects analysis ( FMEA )

International Standard Analysis Techniques for System Reliability – Procedure for

CEI IEC 60812
Failure Mode Effects and Criticality Analysis ( FMECA)

CEI IEC 60300-3-11 International Standard Part 3-11 Application Guide – Reliability Centered Maintenance

OREDA 2009 Reliability Data Handbook

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Data collection

Petroleum, Petrochemical and Natural Gas Industries-Collection and Exchange of

ISO 14224
Reliability and Maintenance Data for

Reference standards

API 610 Centrifugal Pumps for Petroleum, Petrochemical and Natural Gas industries

Lubrication, Shaft-Sealing, and Control-Oil Systems and Auxiliaries for Petroleum,

API 614
Chemical and Gas Industry Services

API 617 Centrifugal Compressors

API 618 Reciprocating Compressors

API 674 Positive Displacement / Reciprocating Pumps

BS 4778-3.2:1991 British Standard Quality Vocabulary – Section 3.2: Glossary of International Terms

API RP 750 Management of Process Hazards

Rotary-Type Positive-Displacement Compressors for Petroleum, Petrochemical, and

API 619
Natural Gas Industries

API RP 579 Fitness For Service, First Edition January 2000

API 673 Centrifugal Fans for Petroleum, Chemical and Gas Industry Services

API 661 Air Cooled Heat Exchangers for General Refinery Services

API 682 Pumps—Shaft Sealing Systems for Centrifugal and Rotary Pumps

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VELOSI PROJECT TEAM

VELOSI TnB Remaco

Project Director
Ijaz ul Karim Rao Project Manager

Project Manager
Muhammad Azhar Operation Manager-Lahore,Pak
Hafiz Akhtar

Software & Admin Support Principal Internal Verifier

Arshad Ali / Jafar Hussain Mr. Tony William

Velosi Project Team Members

1. Ms. Mubeena Khatoon (Manager Engineering Services)

2. Mr. Omer Ishaq (Project Coordinator/LEEA level-I, II, IV & V Certified)
3. Mr. Atif Shuja (Design Instrumentation Engineer)
4. Mr. Muhammad Farooq Ijaz (Lead Process Safety Engineer)
5. Mr. Sami Ullah (Sr. HSE Engineer)
6. Mr. Faisal Ghaffar (Sr. RCM Engineer)
7. Mr. Hassan Rasheed (Lead Integrity & Reliability Engineer)
8. Mr. Abdul Rahman (Sr. E & I Engineer)
9. Mr. Syed Munawwer Alam (Sr. RCM Engineer-Mechanical)
10. Mr. Manoj Kumar (Sr. RCM Engineer-Electrical)
11. Mr. Sarmad Mushtaq (Sr. Mechanical Engineer)
12. Mr. Moeid Iqbal (Sr. Reliability Engineer)
13. Mr. Ibrar Hussain (Sr. Electrical Engineer)
14. Mr. Idrees Ahmad (Electrical Engineer)
15. Mr. Ghulam Murtaza (Sr. Mechanical Engineer (Rotary)
16. Mr. Muhammad Idrees (Inspection Engineer / Industrial Engineering)
17. Mr. Muhammad Younis (Sr. Process Engineer)
18. Mr. Muhammad Adeel (Associate Engineer)
19. Mr. Arshad Ali (Sr. Software Engineer)
20. Mr. Azhar Iqbal (Sr. Software Engineer)
21. Mr. Badar Ibrahim Khan (Software Engineer)
22. Mr. Muhammad Faiz ul Qadir (Software Engineer)

VELOSI Worldwide resources

PROJECT MANAGEMENT AND QA

Throughout the study, VELOSI will keep Client informed of the study progress and any major issues
arising. It is expected that there will be constant communication to ensure efficient use of time. Project
co-ordination is the responsibility of the project manager.
The study will be performed in accordance with VELOSI’s Quality Assurance Procedures. The
company has implemented a quality assurance (QA) system which is based on the requirements of
the international standard for quality assurance (ISO 9001-2015).

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