2- Instrument and Control System
Instrument and Control System will be grouped into four (4) groups as follow:
- Emergency Shutdown (ESD) System
- Process Control System (PCS)
- Pressure Safety Valve (PSV) and Fire & Gas System (F&G)
- Local Gauge (LG)
Smart Type instrument and Asset Management System (HART system) are applied to ESD and PCS control loops. If any problem occurrs, Breakdown Maintenance should be carried out to the relevant loop.
The maintenance for the DCS hardware and software installed in Company Plant will be fixed based on a SUPPLIER’’s recommendations.
Reliability Centered Maintenance (RCM)
For equipment having a high criticality (Vital and/or Critical) RCM study will be carried out. The RCM method (for Rotating Equipment and Electric Equipment classified as Vital and Critical) is split in:
- Functional analysis
- Reliability data collection
- Failure Mode and Effect Analysis (FMEA)
Risk Based Inspection (RBI)
For equipment having a high criticality (Vital and/or Critical) RBI study will be carried out. RBI (for Static Equipment, Piping) for:
- Inspection Interval
- Type of inspection
- Risk evaluation
CMIMS Data Preparation
PMCOilPro will prepare the following information for CMIMS data loading:
- Master Equipment List
- Attribute Data of Equipment
- Spare Parts list preparation
- Topo-functional break-down for tagged Items
- Maintenance & Inspection Plans for major & minor overhaul (Preventive Maintenance: PM). The Plans include:
- Lubrication schedule
- Standard maintenance job task
- Maintenance interval and duration
- Labor
- Discipline
- Specific Tools
Inspection Engineering
This activity is to review local national legislation for inspection and develop an inspection strategy.
EPC365 will perform the following engineering work for inspection:
- Asset register
- Develop Inspection strategy
- Written Scheme of Examination
- Baseline survey
Deliverables
- Inspection Asset register and technical data to upload into CMIMS.
- Inspection strategy and inspection plan to upload into CMIMS.
- Written Scheme of Examination
- Baseline inspection dossiers
- Pigging philosophy
Lifting Equipment
PMC OilPro will execute following activities for Lifting Equipment
- List of fixed lifting equipment
- Technical data collection of each fixed equipment
- Maintenance plan for each fixed lifting equipment in accordance with local legislation.
Integrity engineering
EPC365 will hold a SCE review workshop to identify the SCE and setting up their performance standards in accordance. The meeting will be organized by the Engineering Manager with support of the Lead HSE Engineer, and Company representatives, PMC oilpro’s relevant discipline representatives and Project Engineers.
Deliverables:
- Performance standards (Maintenance, inspection and operational tasks)
- Operational Integrity Assurance Scheme (OIAS) dossier
- Location tags list of SCEs
- SCE task list and standard text
Spare parts and specific tool review and optimization
Spare parts and specific tool review and optimization will be performed as follow:
- Prepare the complete supply chain process to be performed before Start-up the Spare Parts store in the Company.
- Determine the main equipment (or main tag)
- Optimize Operational Spare Parts(SPIR)
- Implement Spare Parts data into CMIMS Material Master(MM) module
- Identify all concerned equipment requiring Specific Tools included in the Purchase Order.
Deliverables
- Procedure of the supply chain process
- Spare Parts Supply Chain follow-up (on weekly basis)
- Spare parts dossier
- All MM templates for implementation into the Company information system
- Specific Tools List
CMIMS Set-Up
EPC365 will provide CMIMS set-up plan which includes Uninterruptable Power Supplied Server/Software purchase support, Data Import support, Training of system operation and Acceptance Test Planning support after Effective Date.
Maintenance and Inspection manuals preparation
EPC365 will submit all Vendor’s Installation, Operation and Maintenance manuals to Company.
User Manual Activities – First Level of Maintenance
This activity includes:
(1) Develop the First Level Maintenance activities which concern the daily / weekly actions on the facilities such as:
- General visual checks
- Checking and topping up of lubricants
- Safety systems healthiness visual checking (checking of F&G alarms…) and anomaly reporting
- Housekeeping, plan general cleanliness
- Cathodic protection reading / checking
(2) Develop the Spading Book
EPC365 will prepare the following documents
- First Level Maintenance activities document
- Spading Book
Maintenance Contract with SUPPLIER
EPC365 will prepare the following maintenance Contract Scope of work with SUPPLIER's as example:
- Long term maintenance agreement for Gas Turbine and Compressor
- Long term maintenance agreement for ICSS
Long term maintenance agreement for Gas Turbine and Compressor
The following service will be provided by SUPPLIER.
1- Maintenance Management Support Services
- Assist to prepare the Annual Operating Schedule
- Assist to mobilize specialists
- Assist to develop emergency response in case of the Plant accidents.
- Assist to develop its HSE standards in compliance with the local regulation.
- Provide trainings for new employee
- Provide periodical HSE audit to secure safe Plant operations.
- Assist to develop the Management of Change.
2- Technical Advisory Services
- Assist to develop and update the specific operation and maintenance procedures, engineering documents (e.g. drawings) and the master data populated into CMIMS.
- Provide technical suggestions to fulfill required remedial actions for the Plant.
- Assist to schedule and manage the maintenance activities.
- Assist to develop and update the maintenance program in order to secure the integrity of the Plant.
3- Spare Parts Supply
- Provide spare parts as requested
Long term maintenance agreement for ICSS
1- Maintenance Contract covers the followings system :
- Distributed Control Systems (DCS)
- Safety Instrumented Shutdown Systems (SIS)
- Supervisory Control and Data Acquisition Systems (SCADA)
- Instrumentation (transmitters, analytical sensors, smart protocols)
The following service will be provided by SUPPLIERs:
1- Telephone Support
When a customer needs immediate assistance during normal business hours, the Call Center is available for a telephone support.
2- Systems Maintenance and Consultation Planning
o determine how you are utilizing technology to impact overall plant performance and insure continuous improvement.
3- Preventive Maintenance
Periodic inspections for the purpose of detecting, correcting and preventing potential failures before they become actual or major failures will be provided.
4- Foundation Fieldbus reliability and performance services: Consulting, engineering services will be provided.
5-Spare parts supply
As per request, spare parts will be supplied in a timely manner.
6- Training:
Classroom training for managers, engineers, operators, and maintenance staff will be provided.
Deliverable Handover to Company
Contractor will hand over all developed documents with other engineering documents and all data to be registered in CMIMS will be submitted by CD or DVD so that Compay can enter them in CMIMS.
Request form
Maintenance and Inspection review
This activity is to ensure the that optimum Maintainability and Accessibility of the Plant In this purpose, the PMC OilPro will perform 3D model review.
Deliverables:Maintainability and Inspectability study report
Maintenance Plan preparation
MIE for CMIMS data preparation will be carried out according the following scheme:
The results of Reliability Availability Maintainability (RAM) Study, Safety Critical Element (SEC) and Written Scheme of Examination (WSE) will be taken into the consideration during the Maintenance and Inspection Engineering.
Criticality AnalysisThe Criticality Analysis will be performed for criticality ranking and selection of maintenance strategy of each Item as follows:
1- The criticality Analysis of Rotary Equipment, Static Equipment and Electrical Equipment will be carried out in consideration of HSE Parameters and productivity parameters as follows:
HSE Parameter is Failure Effect based on Equipment Service Condition.
Productivity Parameter is Effect for plant operation.
Each parameter is classified 4 levels (Vital, Critical, Middle and Low) Type your paragraph here.
2- Regarding the Instrument and Control System, the Equipment listed in Safety Critical Element (SCE) will be classified as Vital.
Definition of Maintenance & Inspection Type
The type of Maintenance and Inspection will be defined for Vital & Critical Equipment as follows:
1- For Rotary Equipment. Static Equipment, Electric Equipment
Maintenance and Inspection Engineering!
EPC365 provides all services related to management and coordination of Maintenance and Inspection Engineering (MIE)
- Various studies subject to MIE Work
- Maintainability & Inspectability review through 3D model review
- Data preparation for loading to CMIMS
Data collection and compilation
- EPC365 prepares the Master Equipment List according to methodology for the project
- Draw up a complete list of all tagged equipment to be registered in Computerized Maintenance & Inspection Management System (CMIMS).
- All data related to MIE Work will be managed by EPC365’s Engineering Data Management system.
- EPC365 will issue a Master Document Register (MDR), in Excel Format in EPC365, listing all the deliverables as requested in the Maintenance and Inspection Engineering.
- Data collection methodology
- Master Equipment List
- Operating Spare Parts list
- SUPPLIERs and MANUFACTUREs list
- Master Document Register (MDR)