Title Page no.

Total

Criticality analysis for maintenance purposes 1 10

Criticality analysis for maintenance purposes

Process correspondence:
Anskaffelse, Boring/WS, HMS - risikostyring, Prosjekt, Vedlikehold
NORSOK Standard Reference:
Z-008 Rev 02, Nov 2001

Document / Revision No. Owner Approved

5047 / 01 Technical-Director-EkoJ 28.06.02

Filnavn: 5047CriticalityAnalysis.fm_exp Utskriftsdato: 03.09.04

 Title Page no. Total

Criticality analysis for maintenance purposes 2 10

ADDITIONAL REQUIREMENTS TO NORSOK STANDARD

NORSOK standard cross reference list:
Z-008 Criticality Analysis for Maintenance Purposes, Rev. 02,Nov. 2001

For information please contact the following:

N. Tønnessen - email: [email protected] Tlf. (+47) 52 02 21 47

Document / Revision No. Owner Approved

Filnavn: 5047CriticalityAnalysis.fm_exp Utskriftsdato: 03.09.04

 Title Page no. Total

Introduction 3 10

1 Introduction
1.1 Purpose and Scope
These additional technical requirements are developed by Phillips Petroleum Company Norway.
These additional technical requirements cover requirements additional to the NORSOK Stand-
ards as listed under Normative References.
The purpose of the document is to define a process for developing a maintenance program for
projects and modifications complying with both PPCoN requirements and NPD regulations.
Operating experience has given PPCoN knowledge about what level of maintenance that is
needed to maintain safe work environment and production availability. For some equipment
groups PPCoN and manufacturers have developed maintenance concepts that have proven to
be successful in ways of safety, availability and maintenance cost. Detailed maintenance anal-
yses for these groups are not required.
For other equipments groups, typically equipment with a large population attending different
functions, there is a potential for optimising maintenance effect and resources by using reliability
and risk based analysis techniques.
This document will give instructions to focus analysis efforts on systems and equipement groups
that have a potential for optimising maintenance programs and minimise efforts on systems and
equipment groups that allready have been analysed or given a experience based maintenance
concept.

1.2 Responsibility
The Maintenance Manager is responsible for this document and for ensuring that it is updated
or revoked when required by organisational or operational conditions.

1.3 Approval
The Manager Operations & Development shall approve the document

1.4 Distribution/revision
This document is distributed via Portal for steering documentation on PhilNet Norway.

1.5 Filing/retrieving
The record copy (RC) is filed by the Section for Information Logistics.

1.6 Registration
This manual as well as the directives is registered with an individual document number in the
company's document administration system, which is managed by the Section for Information
Logistics.

Document / Revision No. Owner Approved

5047 / 01 Technical-Director-EkoJ 28.06.02

Filnavn: 5047CriticalityAnalysis.fm_exp Utskriftsdato: 03.09.04

 Title Page no. Total

Introduction 4 10

1.7 Handling of non-conformances

Deviations shall be handled in accordance with guideline 4929, "Prosedyre for avviksbehan-
dling". All approved/rejected deviations shall be sent to the Technical Document Centre for reg-
istering and filing.

1.8 Normative References

NORSOK Standards:
Z-008 Criticality Analysis for Maintenance purposes, rev 2, November 2001.
PPCoN References:
Document 5048N “Krav til sentrale sikkerhetsfunksjoner”
Document nr 4920, “Prosedyre for Avviksbehandling”.
Document nr 4942 ”Retningslinje for etablering av forebyggende vedlikeholdsprogram”
Guide for the application of failure modes, effects & criticality analysis to PPCoN projects revi-
sion 3.
Guide for the application of reliability centred maintenance to PPCoN projects, revision 2.
EkoPLM user guide, issue 4.
SAP kokebok “Taskliste”
SAP kokebok “Klassifisering av tasklister”
SAP kokebok “Maintenance item”
SAP kokebok “Vedlikeholdskonsept”
Other References:
N/A

Document / Revision No. Owner Approved

5047 / 01 Technical-Director-EkoJ 28.06.02

Filnavn: 5047CriticalityAnalysis.fm_exp Utskriftsdato: 03.09.04

 Title Page no. Total

Analysis requirements 5 10

2 Analysis requirements
2.1 Workflow

Document / Revision No. Owner Approved

5047 / 01 Technical-Director-EkoJ 28.06.02

Filnavn: 5047CriticalityAnalysis.fm_exp Utskriftsdato: 03.09.04

 Title Page no. Total

Analysis requirements 6 10

The workflow of the analysis is split in four main parts; identification of safety functions, identifi-
cation of ESD valves, the criticality analysis and maintenance program analysis/development.
All systems (and all equipment connected) defined in this chapter shall be included in the criti-
cality analysis.

2.2 Safety functions

Safety functions, as defined in document 5048N “Krav til sentrale sikkerhetsfunksjoner”, shall be
identified for all equipment included and/or influenced by the project/modification. Identified
safety functions shall have an assigned function test programme as defined in document
number 5048N “Krav til sentrale sikkerhetsfunksjoner”.

2.3 Safety critical ESD valves

PPCoN has identified all safety critical ESD valves on all platforms with a corresponding test pro-
grame and test procedures. New installation, modification or project changing the premises of
the identification must be addressed, evaluated and corrected for.
For further details, please contact technical responsible person for valves in PPCoN.

2.4 EkoPLM or NORSOK Z-008 analysis?

EkoPLM is a PPCoN developed analysing tool, based on failure modes, effects and criticality
analysis (FMECA) and reliability centered maintenance (RCM) analysis methodology.
For existing platforms without an EkoPLM analysis and systems not analysed by the EkoPLM
tool, analysis shall be done according to NORSOK Z-008.
For existing platforms with an EkoPLM analysis, systems analysed by the EkoPLM tool shall be
updated when a modification or project influence on plattform performance.
For new platforms the EkoPLM analysing tool or equivalent tool subject to PPCoN acceptenace
and approval shall be used. Systems not analysed (ref 2.6) shall be covered by a simplified anal-
ysis. A simplified analysis include chapter 2.2, 2.3 and assigning a maintenance program as de-
scribed in chapter 3.1.2 Development of maintenance program for equipment categories not
analysed på side 9.
In situations where NORSOK Z-008 requires a RCM analysis, the RCM tool of EkoPLM or equiv-
alent tool subject to PPCoN acceptenace and approval, shall be used to document the analysis.

2.5 Decision criteria

2.5.1 EkoPLM analysis

Appendix II ”Probability Category and Consequence Code Definitions” in ”Guide for the applica-
tion of failure modes, effects & criticality analysis” shall be revised by the project to ensure con-
sistent use of decision criteria on the platform, reflecting the criticality of the platform.

2.5.2 NORSOK Z-008 analysis

Table 1 and 2 in chapter 5.2.3 of NORSOK standard Z-008 shall be revised by the project to
ensure consistent use of decision criteria on the platform, reflecting the criticality of the platform.

Document / Revision No. Owner Approved

5047 / 01 Technical-Director-EkoJ 28.06.02

Filnavn: 5047CriticalityAnalysis.fm_exp Utskriftsdato: 03.09.04

 Title Page no. Total

Analysis requirements 7 10

2.6 Systems to be analysed

The systems to be criticality analysed shall include the following system groups:
SYSTEM GROUP 0 - WELLHEADS AND FLOWLINES
SYSTEM GROUP 1 - OIL/NGL PROCESS
SYSTEM GROUP 2 - GAS PROCESS
SYSTEM GROUP 3 - WATER INJECTION RESERVOIR STIMULATION
SYSTEM GROUP 4 - OIL AND GAS EXPORT
SYSTEM GROUP 5 - PROCESS UTILITY
SYSTEM GROUP 6 - PROCESS UTILITY AND FACILITY SUPPORT
SYSTEM GROUP 9 - DRILLING
Systems of the systemgroups
SYSTEM GROUP 7 - SAFETY AND LOSS PREVENTION
SYSTEM GROUP 8 - FACILITY SYSTEMS
shall be not be analysed. A Maintenance programme is to be assigned as described in section
3.1.2 Development of maintenance program for equipment categories not analysed på side 9.

Document / Revision No. Owner Approved

5047 / 01 Technical-Director-EkoJ 28.06.02

Filnavn: 5047CriticalityAnalysis.fm_exp Utskriftsdato: 03.09.04

 Title Page no. Total

Maintenance programme 8 10

3 Maintenance programme
After the criticality analysis NORSOK/EkoPLM define a workprosess leading up to a mainte-
nance program. The kind of analysis required depends on the criticality of the equipment and
the availability of allready defined maintenance concepts. In this chapter specific requirements
for developing a maintenance program is given.

3.1 Equipment categories and development of maintenance pro-

gramme

3.1.1 Equipment categories not to be analysed

The following equipment categories shall not be analysed (in the RCM part of EkoPLM) to define
a preventive maintenance programme, without consulting PPCoN representative prior to the
analysis.
1 Air-condition, Refrigeration Equipment
16 Compressors, Vacuum Pumps (main equipment in system group 0, 1, 2, 3, or 4)
19 Lifting and Material Handling Equipment
30 Electrical Motors (main equipment in system group 0, 1, 2, 3, or 4)
31 Power Generating/Transforming Equipment
32 Combustion Engines
41 Heat exchangers (main equipment in system group 0, 1, 2, 3 or 4)
60 Piping, incl. Risers
61 Piping Specialities
63 Gearbox, Power Transmission Equipment (main equipment in system group 0, 1, 2, 3, 4 or 9)
64 Offshore Platform Structures
67 Pumps (main equipment in system group 0, 1, 2, 3, 4 or 9)
80 Communication Equipment
84 Turbines
91 Automatic/Actuator-Operated Valves (defined as safety critical)
93 Safety relief valves
95 Pressure Vessels, Storage Tanks
The following categories shall not be included in an EkoPLM analysis. They shall be defined as
equipment with consequence class 3 (LOW) in NORSOK Z-008;
10 Buildings and Equipment Containers
13 Computer Equipment
15 Household Equipment
20 Containers, Baskets
21 Lifts and Conveyor Equipment
26 Cables
49 Laboratory-, Hospital Equipment

Document / Revision No. Owner Approved

5047 / 01 Technical-Director-EkoJ 28.06.02

Filnavn: 5047CriticalityAnalysis.fm_exp Utskriftsdato: 03.09.04

 Title Page no. Total

Maintenance programme 9 10

77 Shop Equipment

3.1.2 Development of maintenance program for equipment categories not ana-

lysed
Either NORSOK Z-008 or EkoPLM cover the development of an inspection program for piping,
structure, pressure vessels, heat exchangers and atmospheric tanks. Reference is made to doc-
ument TCD2 4314 to NORSOK Z-001 for further details concerning responsibilities for develop-
ing inspection programs.
PPCoN has developed a set of maintenance concepts based on maintenance and operating ex-
perience. The maintenance concepts are available in SAP as Task Lists, and to find the selec-
tion of valid maintenance concepts, reports in SAP or an Intranet (PhilNet) report is available.
The concepts define maintenance tasks, maintenance task frequency, generic work descriptions
and discipline man-hours.
After identifying the selection of valid maintenance concepts, a recommendation of the most ap-
propriate concept should be made based on the details of each concept, operating conditions
and manufacturer recommendations.
The final recommendation from the project, including the requirements defined in document nr
4942 ”Retningslinje for etablering av forebyggende vedlikeholdsprogram”, shall be presented to
the Phillips Petroleum Company Norway’s Equipment responsible/PM responsible person for fi-
nal approval.

3.1.3 Development of maintenance program based on analysis results

The development of a maintenance programme based on analysis results shall be according to
the chosen methodology (either EkoPLM or NORSOK Z-008).

3.2 Documentation of end product

A Word document shall be linked to the platform functional location (for example BD/EKOJ) de-
scribing the safety functions, critical ESD valves, decision criteria’s and systems included in the
analysis.
Database files containing the analysis for each system shall be linked to the platform functional
location.
On every functional location (tag level) the assigned consequence classes (high, medium, low)
for each consequence shall be documented in the classification field of the functional location.
The following five fields shall be documented.
Example (classification on tag level);

Safety class: High

Production class: Medium

Environment class: Medium

Cost class: Low

Scheduled maintenance Yes

For EkoPLM analysis results, the highest consequences class for the functional location (tag)
identified shall be used, and consequence class 1 and 2 shall be documented in the classifica-
tion field as ”high”.

Document / Revision No. Owner Approved

5047 / 01 Technical-Director-EkoJ 28.06.02

Filnavn: 5047CriticalityAnalysis.fm_exp Utskriftsdato: 03.09.04

 Title Page no. Total

Maintenance programme 10 10

The maintenance program shall be documented in SAP according the requirements described
in document nr 4942 ”Retningslinje for etablering av forebyggende vedlikeholdsprogram”.

Document / Revision No. Owner Approved

5047 / 01 Technical-Director-EkoJ 28.06.02

Filnavn: 5047CriticalityAnalysis.fm_exp Utskriftsdato: 03.09.04