Reliability Centered Maintenance

  • • ‘’It is an approach that helps to create a safe and economical maintenance program which focuses on equipment and instrumental error’s safety and operational consequences.’’

Reliability Centered Maintenance – RCM

Reliability Centered Maintenance – RCM: It is a method that finds appropriate error management principles for any asset.

According to BS EN 13306; maintenance is a combination of all technical, administrative, and managerial actions to maintain the object throughout its life or to bring it into the state of action. Maintenance activities include many activities such as inspection, testing, measurement, fault detection, repair and part replacement. Preventive, corrective, immediate and scheduled maintenance are observed in the industry.

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Our goal is to provide maintenance optimization by minimizing incidental / corrective maintenance. The maintenance work that is carried out at the facilities brings with it many hazards, a systematic maintenance management that will be applied will eliminate the potential hazards by a maintenance procedure that includes all maintenance work and maintenance instructions including what to do during maintenance.

Maintenance management will reduce the shutdown period by providing minimum inventory control of the materials used during maintenance. On the other hand, it is possible to provide maintenance management audits in the internal audits performed for the management systems and the training plans to increase the qualifications of the maintenance personnel.

Equipment maintenance periods are determined by “Health and Safety Condition in the Use of Work Equipment Regulations“ in Turkey. However, even if the requirements of this regulation are fully implemented, equipment integrity losses cannot be avoided without classification according to the degree of danger. In this context, the API RP 581 – Risk Based Inspection Control study by American Petroleum Institute “will be carried out and the overall risks of the facilities will be managed by focusing on the inspection efficiency of high-risk equipment.

It is known that the unit risks in most enterprises are caused by a low percentage of the equipment in the plant. The control and inspections of these equipment with a low percentage of the facility and with a high level of risk will be prevented from potential hazards.

A Few Symptoms That Need Optimization in Maintenance Strategy

  • Increase in unscheduled maintenance and repairs
  • Devotion to producer’s information in maintenance strategy
  • Ignoring hidden failures in control strategies
  • Deviations in goals determined in maintenance management
  • Failure to obtain the desired yield from the CMMS used.

Tools Used in Reliability and Maintenance Management Studies

  • M&OP – Maintenance & Operability
  • Safety Integrity Level (SIL – BS EN 61508-5)
  • Reliability Centered Maintenance (RCM – BS EN 60300-3-11)
  • Risk Based Inspection technology (RBI – API RP 580/581)
  • Fitness for Service (FFS – API 579-1/ASME FFS-1)

ProSCon Reliability Projects

• The company carries out trainings with international certified experts in all stages of the project
• Establishment of a multi-disciplinary working team in your organization
• Performs criticality analysis specific to your process.
• Together with the project team, it examines the root causes and effects of failure.
• Based on failure consequence analysis, creation of preventive maintenance, control and corrective maintenance tasks with the help of the project team.
• Providing CMMS consultancy support in order to use your own data.