Risk-Based Reliability-Centered Maintenance (RCM3) for Rotating Equipment in a Mature Onshore Streamflood Gathering Station: A Case Study of Duri Field, Indonesia

Abstract

Surface facilities in mature steamflood oilfields depend on a comparatively small population of rotating machines whose failure interrupts custody transfer, constrains produced-water treatment, and erodes the economics of aging assets. This paper reports a complete application of Risk-Based Reliability-Centered Maintenance (RCM3) to the rotating equipment of Central Gathering Station Duri Area-1 (CGS-1), a heavy-oil gathering station in the Duri steamflood, Indonesia, where maintenance has historically followed fixed calendar intervals. Equipment criticality analysis over the full rotating-equipment inventory classified 42 units as critical; Pareto screening of OREDA-referenced failure frequencies reduced this population to 30 units for detailed analysis. Weibull fitting of site work-order records for the highest-criticality unit, a high-pressure crude shipping pump, yielded a shape parameter of 1.18 and a characteristic life of 9,910 h, corresponding to 82.2% reliability at the existing 2,500-h preventive interval — well short of the 95% expectation for export-critical machines. Failure-mode Pareto analysis showed five mechanisms accounting for 82.6% of OREDA-referenced failures, dominated by instrumentation faults and external leakage. The RCM3 Information and Decision Worksheets converted 26 failure modes into a program of 13 on-condition, 8 restoration, and 5 failure-finding tasks, reducing assessed risk from predominantly intolerable to tolerable levels. Ten-year costing projects a stable USD 6,552–7,049 annual expenditure for the case-study pump and roughly USD 183,000 per year across all 30 critical units; sensitivity analysis identifies outsourced support services, not labor rates, as the governing cost driver (±6% versus ±0.5% for ±20% input variation). The study supplies a documented, replicable template for shifting mature onshore facilities from time-based to risk-based maintenance.