Maintenance and Reliability Engineering

Benchmark Consulting Engineering L.L.C provides specialists and tools for Maintenance and reliability engineering services focuses on ensuring the continuous operational performance and longevity of assets, equipment, and systems within various industries at any complexity level for oil & gas, chemical, petrochemical, and energy. This discipline combines engineering principles, data analysis, and management strategies to optimize maintenance practices and enhance overall reliability. Benchmark Consulting Engineering L.L.C provide specialized services for Maintenance and Reliability Engineering that involve conducting the following:

Asset Registration

The Asset Register (Location Hierarchy) represent a hierarchal systematic and taxonomic classification of business units, processes, systems and equipment into generic groups based on various factors such as geographical location, functionality, process, usage etc. reflecting parent child relationship in a structural format utilizing ISO-14224, ISO-55001 and Client’s specific guidelines. Asset Boundary Mark-up drawings are delivered to outline the boundaries of individual assets or groups of assets within a system to ensure consistency and accuracy in the collection of reliability and maintenance data. Read More

CMMS/EAM/ERP Data Preparation (Maximo/SAP)

Data preparation is a key aspect of CMMS projects, which has major impact on the usage and usefulness of the system for years or decades afterwards.

Data preparation covers the establishment of the plant functional locations and equipment structures, with all related information such as Functional locations, criticality, specifications, documentation, as well as spare parts, warranty periods, contracts, preventive maintenance instructions, etc.

Benchmark Consulting Engineering L.L.C working approach consists of working with our clients and their EPC companies, ideally at the very early stage of the project to ensure that technical data is captured in the predefined format (templates) ahead of commissioning phase. We are responsible for the quality of the data captured, entire data preparation process is managed by our multidisciplinary experts, who have rich experience and intimate knowledge on both plant maintenance operations and SAP PM and other leading CMMS.

The below are typical (not limited to) data objects that we can support to prepare:

  • Functional Location Templates
  • Asset/Equipment templates
  • Classes and Characteristics Templates
  • Catalogue Profile Templates
  • Measurement Point Templates
  • Bill of Materials Templates (BOM)
  • Task Lists/Job Plan, Maintenance Plan templates
  • Data Loading and CMMS implementation
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HSECES Safety Critical Elements

Health Safety and Environmental Critical Equipment Systems (HSECES) covers equipment and systems of which failure could cause or contribute to an accident with severe or catastrophic consequences, or of which its purpose is to prevent or limit the effect of such accidents.

Benchmark Consulting Engineering L.L.C approach for HSECES identification and accomplishment is as follows:

  • Identification of the potential Major Accident Hazards (MAH)
  • Identification of safety barriers (such as to prevent / mitigate / control / emergency response) having potential to cause MAH
  • Consideration of Bow Ties and client specific COMAH reports to identify the potential HSECES equipment for each MAH scenario.
  • Preparation of the HSECES Register and assignment of HSECES barriers and categories utilizing HSE Matrix and International Guidelines
  • Preparation of generic and specific minimum assurance tasks (MAT) with threshold values
  • Preparation of generic and specific performance standards (PS) with assurance values
  • Packaging and translation of identified HSECES and their relevant MATs into planned works at desired intervals in CMMS.
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Criticality Assessments (Maintenance/Business)

In the dynamic and complex landscape of the oil & gas, chemical, petrochemical, and energy industries understanding the criticality of assets is supreme for maintaining operational excellence. Benchmark Consulting Engineering L.L.C Criticality Assessment services offer a specialized approach to evaluate and prioritize assets, ensuring that resources are strategically allocated to safeguard essential functions and optimize overall performance.

Our structured process helps to improve asset availability and reliability, identify maintenance strategy, ensure plant safety, and equipment uptime.

We ensure involvement and inputs from a broad range of our multidisciplinary specialists having rich oil and gas industrial experience to manage high standards of outcomes during the criticality assessment workshops.

  • Criticality assessment is executed to prioritize assets utilizing 5/5 or 6/6 risk matrix depending upon client’s requirements. We utilize multiple factors to perform criticality assessments depending upon our client’s requirements such as HSE, Operations, Maintenance, business etc.
  • We perform criticality assessments in a structured and systematic way to assess the risk asset failures pose to a business. The method is used to rank the criticality of assets relative to each other. This supports the implementation of targeted plant maintenance strategies proportional to the failure’s impact. 
  • Maintenance or business criticality report is submitted to the clients along with the detailed calculations
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Maintenance Procedure / Maintenance Work Instructions:

Benchmark Consulting Engineering L.L.C Maintenance Work Instructions service for oil & gas, chemical, petrochemical, and energy industries offers a specialized solution to guide Client’s and End User team through the critical process of maintaining assets with accuracy and adherence to industry-specific standards.

A standard maintenance procedure or work instruction is a detailed list of steps that describes how to perform a maintenance task and is also a documented standard to which the job or task should be performed. These procedures are essential for ensuring equipment's efficient and safe operation and extending its lifespan.

We believe that one of the best ways to ensure proper maintenance execution is to have well-written procedures for collecting the data and hence we engage specific subject matter expertise who are professionally trained and have hands-on experience in their area of expertise to deliver maintenance procedures to our worthy clients.

Benefit from our step-by-step procedures for maintenance tasks, enabling Client’s and End User team to follow a systematic approach to execute maintenance works. These instructions mitigate the risk of errors, fostering a consistent and compliant maintenance workflow.

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Maintenance Manuals

Maintenance Manuals are designed to provide Client’s and End Users with accurately crafted, industry-specific manuals that serve as essential guides for the maintenance of assets, ensuring adherence to standards and optimizing operational reliability

The key benefits of Maintenance Manuals is as following:

  • Precision in Maintenance Procedures: Achieve operational precision with detailed and industry-specific maintenance procedures outlined in our manuals.
  • Enhanced Safety Culture: Foster a culture of safety with integrated safety protocols and emergency response plans, ensuring the well-being of Client’s and End User personnel and assets
  • Regulatory Compliance Assurance: Stay compliant with industry regulations by following the documented procedures and guidelines provided in our manuals
  • Operational Efficiency and Reliability: Optimize operations by implementing predictive maintenance strategies, reducing downtime, and extending the lifespan of critical assets.
  • Customization for Varied Assets: Adapt manuals to the specific needs of each asset, promoting efficient and targeted maintenance practices.
  • Cost-Effective and In-House Maintenance: Empower Client’s and End User team to conduct routine maintenance in-house, potentially reducing costs associated with outsourcing and ensuring a more streamlined approach to asset management.
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Reliability Studies

Benchmark Consulting Engineering L.L.C offers a comprehensive and systematic approach to assess, analyze, and enhance the reliability of systems, processes, and assets. Backed by a team of experienced experts, we explore deep into the particulars of Client’s operations to ensure optimal performance, minimize downtime, and maximize the longevity of critical components.

Benchmark Consulting Engineering L.L.C commitment to excellence ensures that your systems and assets operate reliably, contributing to a safer, more efficient, and cost-effective operational environment.

The below are typical (not limited to) services that we can support to our esteemed clients:

  • Reliability, Availability and Maintainability (RAM) Analysis

    RAM Analysis is commonly used to forecast facility performance and establish a foundation for achieving optimal Production Availability, which is a key performance metric indicating the proportion of time the system operates at full capacity.

    RAM Study serves as a crucial tool in maximizing value from a capital project and establishing Reliability considerations as a structured discipline to achieve cost - effective solutions over the Asset Life Cycle.

    Benchmark Consulting Engineering L.L.C provides RAM study during Engineering and Operate Phase for New Projects, as well as, existing facilities modifications/expansions.

    The key benefits of RAM Studies is as following:

    • Determine "bottlenecks" where redesign may increase throughput and profits.
    • Computing the optimal reserve or buffer.
    • Demonstrating the capability of the design to fulfil availability and reliability criteria
    • Assessing the impact on availability of increases in production demand,
  • Reliability-Centered Maintenance (RCM) Analysis

    RCM Analysis is a method employed to identify the necessary actions required to ensure that a physical asset continues to perform its intended functions within its current Operating Context. RCM Analysis address the following Questions:

    • What are the Asset functions?
    • What are the possible failures?
    • What is the causes of the failure?
    • What is impact of the failure?
    • What are the preventive actions for the failure?
    • What if the failure cannot be prevented?
    • Implementing RCM principles, Benchmark Consulting Engineering L.L.C develop optimized maintenance strategies based on the criticality and impact of assets on operations. This ensures that maintenance efforts are efficiently directed, maximizing asset performance and minimizing the downtime utilizing the industry’s best practices – BS EN IEC 60812, SAE JA1011, SAE JA 1012, ISO-14224, and OREDA.

  • FMECA (Failure Mode Effect and Criticality Analysis)

    FMECA Analysis is a systematic approach that is utilized to identify and assess failure probabilities. Employing FMECA methodologies based on the Asset criticality, Benchmark Consulting Engineering L.L.C analyse potential failure modes and their effects on operations. This proactive approach allows to implement preventive measures, reducing the likelihood of failures and associated risks.

    FMECA Methodology adopts the following approach:

    • Data Gathering and segregation
    • Define the Equipment Information, Class Boundary and Functional Requirements
    • Define Failure Modes as per ISO 14224
    • Define Failure Causes
    • Identify Probability (as per Industrial Database)
    • Define Failure Impact
    • Evaluate Current Existing Control
    • Evaluate Current RISK (Consequences x Probability)
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    Spare Part and Material Management

    In critical industries, operational continuity is essential and effective Spare Part and Material Management is a cornerstone for success.

    Spare Parts list and Interchangeability Record commonly known as SPIR/ SPIL/ RSPL is a comprehensive List includes the information about the Spare Parts recommended by original equipment manufacturers (OEM) that owner operator should purchase. The interchangeability aspect outlines which spare parts can be used interchangeably across different equipment or versions of equipment.

    Benchmark Consulting Engineering L.L.C design SPIR templates as per specific requirements for clients considering the industrial best practices.

    The below are typical (not limited to) services that we can support to our esteemed clients:

    • Inventory Optimization
    • Strategic Procurement Planning
    • Lifecycle Management
    • Demand Forecasting
    • Vendor Relationship Management
    • Performing identification of critical spares based on Operating philosophy of industrial plant to ensure business continuity
    • Performing identification of operational spares required for maintenance to trigger accurate maintenance cost in CMMS
    • Digitalization and Technology Integration
    • Risk Mitigation Strategies
    • Data Analytics for Decision-Making
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    EAM/CMMS/ERP Training Services

    In today’s rapidly evolving business landscape, effective training on Enterprise Asset Management (EAM), Computerized Maintenance Management System (CMMS), and Enterprise Resource Planning (ERP) systems is essential for organizations seeking to maximize the potential of these powerful tools.

    Benchmark Consulting Engineering L.L.C comprehensive training services are designed to empower Client’s teams with the knowledge and skills needed to proficiently use and leverage these systems, ensuring operational efficiency, streamlined processes, and data-driven decision-making.

    We are dedicated to providing a customized learning experience that aligns with Client’s organization's goals and objectives.

    The below are typical (not limited to) EAM/CMMS/ERP trainings that Benchmark Consulting Engineering L.L.C can deliver to esteemed clients:

    • System Familiarization
    • Module-Specific Training
    • Customized Training Plans
    • Role-Based Training
    • Hands-On Practical Exercises
    • Data Input and Reporting
    • Integration Training
    • Continuous Learning Resources
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    Master Data Cleansing and Modifications

    In the era of Computerized Maintenance Management Systems (CMMS) or Enterprise Resource Planning (ERP) platforms, the accuracy and cleanliness of master data are fundamental to effective asset and maintenance management.

    Our Master Data Cleansing and Modification services are personalised to optimize Client’s CMMS/ERP system, ensuring that data is accurate, up-to-date, and aligned with operational needs.

    The below are typical (not limited to) cleansing activities that Benchmark Consulting Engineering L.L.C can deliver to esteemed clients:

    • Data Auditing and Assessment
    • Identification of Inconsistencies and Duplicates
    • Standardization and Data Normalization
    • Data Enrichment and Completeness
    • Modification of Master data
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