搜索
HowtoMaintainEquipmentforCompaniestoGetMaximalProfitDongLiang,Ph.DRCGroupCo.,Ltd.,NorwayNovember10-12,1999Jinan,ChinaInternationalWorkshoponPlantEngineering‘99Jinan22019/10/3PresentationOutline•OverviewoftheNorwegianOilIndustry•Growingdemandsformaintenance•RiskBasedMaintenance•SystemizationofMaintenancePrograms•ContinuousImprovementofMaintenancePrograms•Concludingremarks32019/10/3Oil&GasProduction•Norwayistheworld’s2ndlargestoilexportcountry•Annualoilproductionabout150milliontonandnaturalgasabout30billionM3•Over80offshoredrillingandproductionplatformsinoperation42019/10/3Operation•Firstwellwasdrilledin1966•Currently9operatorsand18partnerlicenseecompanies•Statoilisthenationaloilcompanyandisinvolvedineveryproductionoperation52019/10/3Challenges•Highproductioncostsduetoharshoffshoreenvironment–Highexplorationcosts–Highinvestment–Highsafety/environmentrequirements–Highoperation/logisticscosts–Highlaborcost•Turbulentoilprice•Seriouscompetition62019/10/3GrowingDemandsforMaintenance•Incompliancewithstatutorylaws,regulations,andrequirements•Highequipmentreliability:health,safety,andenvironment•Highequipmentavailability-productivity•Highproductquality•Reductionofmaintenancecosts72019/10/3MaintenanceTechnologyDevelopment•Changeofmaintenancestrategy•RiskBasedMaintenance•Systemizationofmaintenanceprograms•Continuousimprovementofmaintenanceprograms82019/10/3195019601970198019902000BreakdownFixedIntervalPMRCMCBMTPMDevelopmentofMaintenanceStrategyRBM92019/10/3RiskBasedMaintenance•Concept:Maintenancestrategyandeffortdependonequipment/componentrisks•Why?•RiskAssessment–Risk=Consequence*Probability–Consequences:•Healthandsafety•Environment•Deferredproduction/service•Materialdamages102019/10/3AnImportantConcept-MaintenanceRelatedCosts•Directcosts:–Routineservices(CBS)–Predictive&Preventivetasks(CPM)–Correctivetasks(CCM)•Indirectcosts:–Management–Administration–Supports•Failureconsequencecosts(CRISKEX):–Health,Environment,andSafety(HES)–Production/services–Materialsdamage–Damagetoreputation112019/10/3RelationshipbetweenMaintenanceCosts1000%LevelofPreventiveMaintenanceBasicservicelikelube,cleaning,etc.CRISKEXCost$CMINCCMCPMCBS-Costofbasicservices;CPM-Costofpreventivemaintenance;CCM-Costofcorrectivemaintenance;CRISKEX-Costs/lossesduetounplannedevents;CTOT=CBS+CPM+CCM+CRISKEX;CMIN-MinimalCTOTCTOTCBS122019/10/3Risk-MaintenanceStrategy132019/10/3RiskDistribution1,0%20,0%38,0%41,0%IIIIIIIVMSI-MaintenanceSignificantItems142019/10/3RiskBasedInspection-RBI•EquipmentTypes:Static–Piping–Vessels–Structures–……•NDT(Non-DestructiveTesting)inspection–(MPI)MagneticParticleInspection–Ultrasonictesting–Radiography–Eddycurrenttesting•Achievements–Optimalinspectionmethods–Optimalinspectionintervals–Increasedreliabilityandavailability–Reducedinspectioncosts152019/10/3RiskBasedTest-RBT•EquipmentTypes:ProtectiveInstruments–Alarms–Trips•Hiddenfailure:Failureondemands•Maintenancemethods–FunctionalTests•Achievements–OptimalTestintervals–Increasedreliabilityandavailability–Reducedtestcosts162019/10/3RiskBasedMaintenance-RBM•EquipmentTypes:–Rotatingequipment–Processinstruments–Electricalmotors,powergeneration,...–……•Evident(detectable)failures:–Highvibration–Wornout–Leakage–…...•Analysismethods:–RCM(ReliabilitycenteredMaintenance)–Riskanalysis–Cost-benefitanalysis•Achievements–Potentialriskandranking-maintenancesignificantlevels–Performanceofpresentmaintenanceprograms–Optimizedmaintenanceprogram172019/10/3MaintenanceProcessMaintenanceobjectiveEstablishmentofMaintenanceProgramMaintenanceProgramplanning/schedulingMaintenanceexecutionResultreportingandrecordingAnalysis182019/10/3SystemizingMaintenanceProgram•Standardizationofmaintenanceprograms-MaintenanceConcepts(seenextpage)•Output–Maintenanceprograms–Requiredresources•Benefits–75%reductionofmaintenanceplanningtime–25%reductionofmaintenanceefforts–Asystematic,welldocumented,andauditableprocess192019/10/3RequirementAnalysis•Requirements–Contractualregulation–Statutoryregulation:Actsorlaws–Consensusregulation:withprovisionslike“inaccordancewithrecognizedstandardsofgoodproductionpractice”•Linkto:–Plant/System/equipment–Operation•Cranelifting•Usinghightemperaturelikewelding,fire,•……202019/10/3ContinuousImprovement•Reportingandrecordingmaintenancehistory–Failurefindings–Maintenanceworks•Analysisofhistorydata–Failures,reasons,andcosts–Performanceofpresentmaintenanceprograms–Update/improvementofmaintenanceprograms•Benefits–Asystematic,welldocumented,andauditableprocess–Optimizedmaintenancecosts–Increasedreliability,availabilityandproductquality212019/10/3ResultsofRiskAssessmentImprovedProgramExistingProgramWithoutMaintenance$0$10000$20000$30000$40000$50000$60000222019/10/3Cost-BenefitRatio10,157,474,231,662,951,110,950,03DrivesystemWireropesMotorsFestoonsystemTrolleysystemShieveAntiswaysystemGear232019/10/3ConcludingRemarks•Growingdemandsformaintenance–Incompliancewithstatutoryrequirements–Highreliability–Highavailability-productivity–Reductionofmaintenancecost•Solutions:–RiskBasedMaintenance–Systemizingmaint