05 December 2007 Revision 5 RCM2 Case Study Project Plan Cooling Fan System (topic link) link)

Content Introduction Why this study Output Team Planning System boundaries Functional Block diagram & Major Equipment Key information Let’s get started

Introduction From within the Maintenance Forum the initiative was born to conduct a “Virtual RCM” study to learn and share knowledge in an interactive way. A Case & Operating Context is defined for the Company Ollie’s Olefins based on business impact/criticality. There are a lot of methods which are called RCM In this study the RCM2 methodology of John Moubray will be applied

Goal and output Make a maintenance plan which preserve the functions of the chosen Cooling Fan System throughout the technologically useful live by selecting and applying the most cost effective technique for managing failures and their consequences Output: -Maintenance schema -Operator Care Instruction -Modifications (can also be operational procedure)

Team Team Forum Alias Rogier de Mulder Rogier Steve Turner Youssef X Abbaoui? Johnny W Campbell Johnny W. Campbell Bruno S Santos bsbsantos Steven van Els savanels Trevor SullivanTrevors Mike W Ward Mike66

Planning The project kick-off is in week 41 after publishing project plan on forum Minimum 1 session a week depending on input A live chat or telecom can be organised to discuss different views if necessary Estimated time needed is 11 sessions, completion date end 2007 (new estimated is febr. 2008) Participant are assumed to have basic RCM knowledge starting the study Session Content Kick off – Setup project and team1 session (WK 42) Functions and performance standards1 sessions Functional Failures & Failure Modes2 sessions Failure Effects2 sessions Failure Consequences 2 sessions The RCM Task Selection Process3 sessions Spare2 sessions Finalizing report by facilitator 1 week

System Selection (Boundary)

Funct. Block diagram & Major Equipement

Key information Plant located on island near to sea Operation 24h/7 days a week /365 day’s a year It can sell all product it can make 30 equal systems in production unit System supplies ambient air to refrigeration system Performance indicator: If fan < 200 RPM audible alarm sounds in control room Revenue loss of $5000 per hour if one system down for > 30 min System cost a lot of maintenance hours due to breakdown disturbing the process (how much cost / failure history?)

Let’s get started -Who is willing to be part of the team? -let share addresses within the team, mail me your address please? -When the team is complete I will setup a platform to share / add remark or something to be able to give your input when it suits your agenda -We are in different time zone's I think, so live discussion can be a problem, Can we make an overview of possibilities when to discuss /chat live? -To share learning's everyone get’s read rights on chosen platform and only team member write rights All information needed for study will documented and posted -Final Result per session will be post on maintenanceforum to share learning -English is not everyone’s native language so can give misunderstanding, treat everyone with respect, lets focus on the big picture and not argue about minor language details.

Step 1 functions -Step 1 – Describing Functions We have enough information to start with defining the function A function statement should consist of a verb, an object and a desired standard of performance If we miss relevant information it will be an action point for someone to retrieve of we make a decision as a group We can use the template supplied by Rolly12 Other steps will be added during the study

Step 1 functions Primary functions: What's the main reason the asset exist? Secondary functions: Asset is expected to fulfill one ore more functions in addition to their primary function To help none of these functions is overlooked they are diveided in 7 categories (ESCAPES): - Environmental integrity - Safety/structural integrity - Control/containment/comfort - Appearance - Protection - Economy/Efficiency - Superfluous functions One of the most mistakes in the RCM process is carrying out the analysis on too low level in the equipment hierarchy.

Step 2 Functional Failures Step 2 – Describing Functional Failures A functional failure is defined as the inability of any asset to fulfil a function to a standard of performance which is acceptable to the user Functional Failures can be placed under the following headings: partial and total failure Upper and lower limits Gauges and indicators The operating context

Step 2 Functional Failures Who shoulls set the standard?

Step 3 Failure Modes A failure mode is any event which causes a functional failure A failure mode description should at the very least consist of a noun and a verb i.e. Bearing seizes A list of reasonably likely failure modes should include: failures which have occurred before failure modes which are already the subject of proactive maintenance routines any other failure mode which have not yet occurred but which are considered to be real possibilities

Step 3 Failure Modes How much detail? failure modes should be defined in enough detail for it to be possible to select a suitable failure management policy

Step 4 Failure Effect failure effect describes what happens when a failure mode occurs The level of describing the failure effect depends whether it includes all information needed to support the evaluation of the consequences of the failure (decision diagram). The effect of the failure should be described as if nothing was being done to prevent it.

Step 4 Failure Effect The following should be recorded: What evidence (if any) that the failure has occurred In what ways (if any) it poses a threat to safety or environment In what (if any) it affects production or operations What physical damage (if any) is caused by the failure What must be done to repair the failure