PT PERTAMINA

(PERSERO)
DIREKTORAT PENGOLAHAN

MATERI MAINTENANCE STRATEGY

DEVELOPMENT (with simple RCM
approach

Jakarta
November 2013

CONFIDENTIAL AND PROPRIETARY

Any use of this material without specific permission of Pertamina is strictly prohibited

Activity Deliverable

1. Equipment Performance Need

2.Equipment Maintenance Strategy

3.
4.
5.
6.

Equipment Major PM Task and BOM

Equipment Condition Monitoring Task List
Equipment MSL (Insurance Item)
OEM/OPM Criteria as additional

MAINTENANCE MANAGEMENT

DevelopmentDefine
Define
Maintenance
Strategy

Maintenance
Task
(package
based on
maintenance
strategy)

Material
Management

Define Sudden
failure that likely
happened to the
Equipment

Define Equipment Performance

Need (Readiness Criteria)

Define Equipment Sensitifity to

Process Including Risk to
Bussines

Implementation

Define Maintenance
Task

Define Equpment Criticality

Define Failure Mode of the

equipment (sudden or gradual)

Define Which are

Sudden or

Definee Parts
Damage for each
failure

Breakdown Allowable?

Define Failure Dectection

Methode

Define Condition Monitoring

Should Performe

Define Running Hour based

Preventive Maintenance

Define BOM for

Each Task

Define Long Lead

Time Material

Define Insurance
Parts

Job
Proposed &
Detail
Planning

Planned OH
Monitoring

Execution &
Evaluation

Maintenance timing
based on Time or
Running Hour

Planned OH
Dashboard
Monitoring

Executor Selection

Maintenance timing
Based on
Performance

Performance

OEM Supervision
Scope Development
standard OH plus
Condition based
(finding last
inspection)

Detail Planning

Material

Major Parts

PM Efectivenes
(finding vs.
Frequency)

Equipment Performance Need

Defining equipment reliability criteria, based on operation, mechanical
and safety aspect :
1. Ex. Compressor : Flow, Pressure, Valve temperature, Vibration,
Leakage, Safety device ie. Anti surge Etc.
2. Turbine : Speed, Steam Consumption, Vibration etc

Maintenance Strategy
1. Defining what are maintenance activity should be performed to
the equipment to fulfill its reliability criteria, Consist of PM, PDM
or event breakdown/run to failure.
2. Defining Maintenance strategy by utilizing RCM Logic

Equipment Major PM Task and BOM

1. Review of exsisting equipment PM Task refer to equipment
maintenance strategy.
2. Create PM task if no PM task yet

Equipment Condition Monitoring Task List

Activity Creating condition monitoring task list refer to maintenance
strategy

MSL Insurance Item

Activity defining what are spare part should be ready in stock to
restore equipment function if the equipment experience most likely
incident during its operation and meet below criteria :

1. Part are likely broken because of the incident

2. Part are long lead delivery time.
3. Part are cinsumable to restore the equipment function.

OEM, OPM, Non OEM Part

1. Ref Pedoman No.

PERTAMINA MS
Equipment Sensitifity to Process, risk to bussines ?
Equpment Criticality Analysis
Equipment Performance Need
Menentukan sedetail apakah physical node yang
akan dievaluasi
Menentukan Functional Failure, Failure Mode &
Effect serta mekanisme terjadinya (sudden or
gradual). Pada setiap physical node yang telah
ditentukan.
Menentukan maintenance strategy peralatan,
penentuan maintenance strategy

The 7 steps of RCM

An RCM process identifies the following items in sequence:
1) Functions the desired capability of the system,how well it is to
perform, and under what circumstances
2) Functional failures the failed state of the system (when the
system falls outside the desired performance parameters)
3) Failure modes the specific condition causing a functional failure
4) Failure effects the description of what happens when each
failure mode occurs
5) Failure consequences the description of how the loss of
function matters
6) Maintenance tasks and intervals the description of the
applicable and effective tasks, if any, performed to predict, prevent,
or find failures
7) Other logical actions including but not limited to run-to-failure,
engineering redesigns, and changes/additions to operating
procedures or technical manuals

MAINTENANCE STRATEGY

Maintenance Strategy development Activity

Define Equipment Sensitifity to Process Including

Risk to Bussines
Define Equpment Criticality
Define Equipment Performance Need (Readiness
Criteria)
Define Physical node
Define Functional Failure, Failure Mode & Effect of
the equipment (sudden or gradual)
Breakdown Allowable?
Define Potential Failure Dectection Methode
(Symptomp, Detection)
Define Condition Monitoring Should Performe
Define Running Hour based Preventive Maintenance

Define Equipment Performance Need

Performance Margin

Design Capability
Actual Capability (deteriorated)

Performance masih baik

meskipun telah mengalami
detrioration

Operation Need

Performance need harus di set up dengan jelas sehingga definisi

functional failure menjadi jelas dan mencakup seluruh parameter
operasi yang utama.

Functional Failure

Define how detail the funtional system is?

Functional

location/Equipment/Assy part

Define Function
Define Failure

Functional
System

Function

Funtional Failure

Tag No

Performace Need

Below margin and or out side of

operating window

211-C-1

To transfer gas from X To Y @ A bar

press & B Nm3/h at minimun speed
C rpm and D degC

No Flow
Low Flow
High gas temperature
High Noise or Vibration

Functional Effect & Failure MOde

FM = Events which lead to functional failure

FE = Further functional consequence of failure and include other systems failure

Work Sheet

RCM LOGIC TO DETERMINE MAINTENANCE TASK

Worksheet

Worksheet

Maintenance Strategy Matrix (the Result)