A method for defining the maintenance strategy

in a coherent, systematic and logical manner. It is

a structured methodology for determining the
maintenance requirements of any physical asset
in its operation context
Primary objective of RCM is to preserve system
function
The RCM process consists of looking at the way
equipment fails, assessing the consequences of
each failure (for production, safety, etc), and
choosing the correct maintenance action to
ensure that the desired overall level of plant
performance (i.e. availability, reliability) is met
 Asset registering and validation
Criticallity ranking
FMEA dan Task Development
Job Bundling and Levelling
Check list development
CMMS template development
CMMS data upload
 Maintenance Run to Failure
Criticality PM
FMEA Task
Ranking PdM
Selection Proactive

Continuous
Improvement Planning

Feedback and
Execution Scheduling
Measurement
 Registering asset based on company and
regulation standard
Would be the backbone for strategic
maintenance development
Validation would be needed for ensuring that
equipment is in place and on operation
 RCM WORK
NO LOCATION TAG NEW DESCRIPTION SYSTEM NAME Object Type Description
STATU CENTRE

1 RCM CENTRAL GAS PLANT IDOPS 3KKAQ001 RECEIVER,PIG OF LTR Onshore - In field Flowline or Pipeline PIG, TRAP
2 RCM CENTRAL GAS PLANT IDINS 3KPT0005 TRANSMITTER,PRESSURE OF 3KKAQ001 Onshore - In field Flowline or Pipeline TRANSMITTER
3 RCM CENTRAL GAS PLANT IDINS 3KESDV0002 VALVE,ESD OF 3KKAQ0001 Onshore - In field Flowline or Pipeline CONTROL VALVE
4 RCM CENTRAL GAS PLANT IDINS 3KZSC0002 SWITCH,POSITION CLOSED OF 3KKAQ001 Onshore - In field Flowline or Pipeline INSTRUMENT SWITCH
5 RCM CENTRAL GAS PLANT IDINS 3KZSO0002 SWITCH,POSITION OPEN OF 3KKAQ001 Onshore - In field Flowline or Pipeline INSTRUMENT SWITCH
6 RCM CENTRAL GAS PLANT IDINS 3KSOV0002 VALVE,SOLENOID OF 3KKAQ001 Onshore - In field Flowline or Pipeline SOLENOID VALVE
7 RCM CENTRAL GAS PLANT IDINS 3KPT0006 TRANSMITTER,PRESSURE OF 3KKAQ001 Onshore - In field Flowline or Pipeline TRANSMITTER
8 RCM CENTRAL GAS PLANT IDINS 3KPDT0011 TRANSMITTER,PRESS.DIFF. OF 3KKAQ001 Onshore - In field Flowline or Pipeline TRANSMITTER
9 RCM CENTRAL GAS PLANT IDINS 3KPSV0009 VALVE,PRESS.SAFETY OF 3KKAQ001 Onshore - In field Flowline or Pipeline RELIEF VALVE
10 RCM CENTRAL GAS PLANT IDOPS SP409 BLOCK,ANCHOR OF SYSTEM_3K Onshore - In field Flowline or Pipeline STRUCTURE,CONC/STEEL
11 RCM CENTRAL GAS PLANT IDOPS SP710 COUPON,CORROSION OF 3KKAQ001 Onshore - In field Flowline or Pipeline PROBE, CORROSION
12 RCM CENTRAL GAS PLANT IDOPS SP111 TEE,BARRED OF 3KKAQ001 Onshore - In field Flowline or Pipeline PIPING, PROCESS
13 RCM CENTRAL GAS PLANT IDSTA 12"-BA-CD-3-2-053 VALVE,BALL FROM RAWA STATION Onshore - In field Flowline or Pipeline VALVE, BALL
14 RCM CENTRAL GAS PLANT IDSTA 12"-BA-CD-3-2-056 VALVE,BALL OF 3KKAQ001 Onshore - In field Flowline or Pipeline VALVE, BALL
15 RCM CENTRAL GAS PLANT IDSTA 12"-BA-CD-3-2-058 VALVE,BALL OF 3KKAQ001 Onshore - In field Flowline or Pipeline VALVE, BALL
16 RCM CENTRAL GAS PLANT IDSTA 4"-GL-CD-3-1-111 VALVE,GLOBE OF 3KKAQ001 Onshore - In field Flowline or Pipeline VALVE, GLOBE
17 RCM CENTRAL GAS PLANT IDSTA 4"-BA-CD-3-1-144 VALVE,BALL OF 3KKAQ001 Onshore - In field Flowline or Pipeline VALVE, BALL
18 RCM CENTRAL GAS PLANT IDSTA 8"-BA-CD-3-1-146 VALVE,BALL OF 3KKAQ001 Onshore - In field Flowline or Pipeline VALVE, BALL
19 RCM CENTRAL GAS PLANT IDSTA 6"-GL-CD-3-1-148 VALVE,GLOBE OF 3KKAQ001 Onshore - In field Flowline or Pipeline VALVE, GLOBE
20 RCM CENTRAL GAS PLANT IDSTA 6"-BA-CD-3-1-149 VALVE,BALL OF 3KKAQ001 Onshore - In field Flowline or Pipeline VALVE, BALL
21 RCM CENTRAL GAS PLANT IDSTA 8"-CK-CD-3-3-110 VALVE,CHECK TO SEPAR.GLT SLUG CATCHER Onshore - In field Flowline or Pipeline VALVE, CHECK
22 RCM CENTRAL GAS PLANT IDSTA 8"-BA-CD-3-1-292 VALVE,BALL GAS FROM LTR PIG RECEIVER Separation and Stabilization VALVE, BALL
23 RCM CENTRAL GAS PLANT IDSTA 8"-BA-CD-3-1-982 VALVE,BALL GAS FROM LTR PIG RECEIVER Separation and Stabilization VALVE, BALL
24 RCM RAWA STATION IDOPS 3KKAQ103 RECEIVER,PIG LETANG-RAWA Onshore - In field Flowline or Pipeline PIG, TRAP

25 RCM RAWA STATION IDOPS 3KKAQ102 RECEIVER,PIG TENGAH Onshore - In field Flowline or Pipeline PIG, TRAP

Asset Register LTRO - RCM.xls

 Frequent
(occurs regularly in a
5 5 10 15 20 25
year)
>1
Probable
(occurs at least once
4 4 8 12 16 20
in a lifetime)
10-02 - 100
Likelihood

Rare
(not likely to occur in
3 3 6 9 12 15
a lifetime)
10-04 - 10-02
Remote
(credible but not
2 2 4 6 8 10
expected to occur)
10-06 - 10-04
Improbable
(possible but
1 1 2 3 4 5
unrealistic)
<10-06
1 2 3 4 5
Severity Level
Negligible Minor Significant Major Catasthropic
Permanent Disability,
Medical Treatment Minor Injury (one or Fatality(s)/Public
Safety MTC/FAC or less Multiple
RWC more LWC's) Hospitalization
Hospitalization
Consequence

Environment < $10M $10M - $100M $100M - $1MM $1MM - $10MM > $10MM

Business Interruption
(include impact of lead time)
< $10M $10M - $100M $100M - $1MM $1MM - $10MM > $10MM

Capital Asset < $10M $10M - $100M $100M - $1MM $1MM - $10MM > $10MM
 We define possible failure mode based on the
equipment.
Every failure mode has failure defend task or
maintenance task.
Every maintenance task has detail
information, such as : person in charge,
interval time and work man hours.
 NEW DESCRIPTION MAT WORK CTR INTERVAL INTERVAL
UNIT

VALVE,PRESS.SAFETY OF 3KKAQ001 Function Test 1Y PSV INSPECTION PM IDINS 1 Year

VALVE,PRESS.SAFETY OF 3KKAQ001 First Line Maintenance General Visual Inspection (car seal & leakage) IDOPS 1 Month

VALVE,PRESS.SAFETY OF 3KKAQ001 Predictive Maintenance Visual Inspection and Fugitive Survey IDIE 2 Year

VALVE,PRESS.SAFETY OF 3KKAQ001 Certification Program MIGAS certification for PSV IDQA 3 Year

COUPON,CORROSION OF 3KKAQ001 Predictive Maintetnance Corrosion Monitoring Program IDIE 6 Month

TEE,BARRED OF 3KKAQ001 Predictive Maintenance Visual Inspection and Fugitive Survey IDQA 2 Year
TEE,BARRED OF 3KKAQ001 Inspection Program NDT Inspection IDIE 5 Year
TEE,BARRED OF 3KKAQ001 Predictive Maintenance Global Corrosion monitoring IDIE_C 3 Year
VALVE,BALL GAS FROM LTR PIG RECEIVER Predictive Maintenance Global Corrosion monitoring IDIE_C 3 Year
VALVE,BALL GAS FROM LTR PIG RECEIVER First line maintenance House keeping & Visual Inspection IDOPS 1 Year
VALVE,BALL GAS FROM LTR PIG RECEIVER Preventive Maintenance Greasing program IDSTA 6 month
VALVE,BALL GAS FROM LTR PIG RECEIVER Predictive Maintenance Acoustic Leak Detection IDCMO 6 month
VALVE,BALL GAS FROM LTR PIG RECEIVER Predictive Maintenance Global Corrosion monitoring IDIE_C 3 Year
VALVE,BALL GAS FROM LTR PIG RECEIVER First line maintenance House keeping & Visual Inspection IDOPS 1 Year
VALVE,BALL GAS FROM LTR PIG RECEIVER Preventive Maintenance Greasing program IDSTA 6 month
VALVE,BALL GAS FROM LTR PIG RECEIVER Predictive Maintenance Acoustic Leak Detection IDCMO 6 month
VALVE,PRESS.SAFETY OF 3KKAQ103 Function Test 1Y PSV INSPECTION PM IDINS 1 Year

Task Workshop All (1).xlsx

 Job bundling will unify the same tasks, tasks
in same location or tasks for equipments that
are attached to main equipment.

Examples of job bundling :

All vibration analysis will be done together in one
campaign
All valves and wellheads in one area
Instruments that are attached on the main
equipment
 Levelling will distribute maintenance
workload.
Maintenance workload will be mathced with
available resources.
We will know whether maintenance resources
is sufficient or not.
Schedulling will benefit the most from
levelling
 Hours

500

0
1000
1500
2000
2500
3000
01-Jun-13

01-Jul-13

01-Aug-13

01-Sep-13

01-Oct-13

01-Nov-13

01-Dec-13

01-Jan-14

01-Feb-14

01-Mar-14

01-Apr-14

01-May-14

01-Jun-14

01-Jul-14

01-Aug-14

01-Sep-14
Total Manhours per Month

01-Oct-14

01-Nov-14

01-Dec-14

01-Jan-15

01-Feb-15

01-Mar-15

01-Apr-15

01-May-15

01-Jun-15

01-Jul-15
 16,000
Comparison of Yearly Requirement & Capacity
14,000

12,000

10,000
Hours

8,000

6,000

4,000

2,000

0
IDOPS IDROT IDSTA IDINS IDELE IDCMO
YEARLY REQ AVERAGE 14,556.99 629.08 924.92 2,163.69 1,053.23 320.98
YEARLY CAPACITY 12,600 10,080 - 2,520 5,040 2,520
 Check list consists of points to be done
during maintenance task.
Check list development based on manual
books, experiences and standards.
NO DESCRIPTION

1 AftercoolerCondensationDrain
2 Belts - Inspect/Adjust/Replace
3 Carburetor Air/ Fuel Ratio -Check/Adjust if applicable
4 Crankshaft Vibration Damper Inspect
5 Engine Crankcase Breather - Clean
6 Engine Oil - Change (for engine jack pump engine oil change is done every month)
8 Engine Oil Filter - Change
9 Exhaust Piping - Inspect
10 Gas Pressure Regulator Condensation - Drain
11 Hoses and Clamps - Inspect/Replace
12 Ignition System Spark Plugs - Check/Adjust/Replace if applicable
13 Ignition System Timing - Check/Adjust
14 Inlet Air System Inspect, change air filter
15 RadiatorClean
16 Valve Stem Projection - Measure/Record
17 Engine Speed/Timing Sensor - Clean/Inspect
18 Engine Valve Lash - Inspect/Adjust
19 Check lube oil seal
20 Replace bushing coupling if necessary
 Based on CMMS data template
Asset register
Task based asset
Will be executed based on company
need
Review periodically
NO YEAR CUSTOMER PROJECT PROJECT DETAIL
1 2014 PT Skefindo Primatama - RCM Engineer Supply for Star Risk ranking development
Conoco Phillips Indonesia - Star Energy Project FMEA workshop
Energy Maintenance task development
Standar check list development
Executed in 12 areas, 3000 equipments
2 2013 PT Reliapro - PT Chevron SLS Reliabilit Centered Equipments validation on fields
Pasific Indonesia Maintenance Study Risk rangking development
Development Services, PT FMEA and maintenance task development
Chevron Pasific Indonesia Standard SOP and SRP development
Economic analysis on applied maintenance
Reliability modelling on plants
Data template development for MAXIMO
uploading
Executed in 9 areas, 1700 equipments
3 2013 PT. Pakarti Tirto Agung - Development of RCM Plan Risk rangking development
PT. Conoco Phillips Indonesia FMEA dan maintenance task development
Standar check list development
Job bundling and levelling for maintenance plan
Executed in 4 areas, 1600 equipments

4 2013 PT. Bonne Indo Teknik - Facility, Integrity, Equipments validation on fields
PT. Transportasi Gas Indonesia Management System GAP analysis
Development Risk rangking development
FMEA dan maintenance task development
Reliability modelling on plants
Database template and format development for
maintenance activities
In-house CMMS development consultation
Executed in 9 areas, 1120 equipments
5 2012 PT. PLN (PERSERO) SEKTOR
PEMBANGKITAN BENGKULU
6 2011 PT. Bukaka Teknik Utama -
PT. Chevron Pasific Indonesia
7 2010 PT. PLN (PERSERO) Sektor
Pembangkitan Tarahan,
Lampung Sumatera Indonesia
Development of Asset Risk rangking development
Management Programme and FMEA dan maintenance task development
Training workshop
Spareparts criticallity ranking
Planning and development blue matrix for
maintenance plan
Executed in 2 areas PLTA, 1400 equipments
Base Line Program for Equipments validation on fields
Equipment at Pasir Ridge, Vibration analysis
Preparation for RCM Used oil analysis
Implementation Transformator oil analysis
Thermography analysis
MCSA analysis
Baseline data development as reference point for
maintenance data trending
Executed in power plant area
FMEA Development for PLTU Equipment validation on fields
Tarahan Risk rangking development
FMEA and maintenance task development
Database template and format development for
maintenance activities
In-house CMMS database development
Executed in 1 area, 2 unit PLTU, 5600 equipments
 PT Skefindo Primatama - Conoco Phillips
Indonesia
PT Reliapro - PT Chevron Pasific Indonesia
PT. Pakarti Tirto Agung - Conoco Phillips
Indonesia
PT. Bonne Indo Teknik - PT. Transportasi Gas
Indonesia
PT. PLN (Persero) Sektor Pembangkitan Bengkulu
PT. Bukaka Teknik Utama - PT. Chevron Pasific
Indonesia
PT. PLN (Persero) Sektor Pembangkitan Tarahan,
Lampung Sumatera Indonesia
Thank You