An Integrated Reliability-Based Maintenance Framework for Centrifugal Pumps in Upstream Oil Production: Combining FMEA, Weibull Analysis, RCM, and Economic Evaluation
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Centrifugal pump failures impose substantial economic and operational penalties in upstream oil production, yet the established reliability methodologies — Failure Modes and Effects Analysis (FMEA), Weibull probabilistic modelling, and Reliability-Centered Maintenance (RCM) are predominantly applied in isolation, limiting their collective diagnostic and prescriptive value. This study proposes an integrated five-stage reliability-based maintenance framework that establishes explicit quantitative linkages among these methods, extended to Life Cycle Cost (LCC) and Net Present Value (NPV) evaluation. Three novel integration mechanisms are introduced: Weibull-derived failure frequencies recalibrate the FMEA Occurrence rating to eliminate subjective bias; the Weibull shape parameter β directly determines the RCM maintenance strategy type and the B10 life defines the maintenance interval; and the expected number of failures E[N(t)] from the Weibull renewal function is embedded in the LCC failure cost term, establishing a quantitative probabilistic–economic coupling. Applied to API 610-compliant centrifugal pumps in upstream oil production facilities in Oman, the framework provides a replicable, data-driven methodology for reducing unplanned downtime, optimizing maintenance expenditure, and supporting evidence-based asset management decisions.
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