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HowtoMaintainEquipmentforCompaniestoGetMaximalProfitDongLiang,Ph.DRCGroupCo.,Ltd.,NorwayNovember10-12,1999Jinan,ChinaInternationalWorkshoponPlantEngineering‘99Jinan23-Oct-19PresentationOutline•OverviewoftheNorwegianOilIndustry•Growingdemandsformaintenance•RiskBasedMaintenance•SystemizationofMaintenancePrograms•ContinuousImprovementofMaintenancePrograms•Concludingremarks33-Oct-19Oil&GasProduction•Norwayistheworld’s2ndlargestoilexportcountry•Annualoilproductionabout150milliontonandnaturalgasabout30billionM3•Over80offshoredrillingandproductionplatformsinoperation43-Oct-19NorwegianContinentalShell53-Oct-19Operation•Firstwellwasdrilledin1966•Currently9operatorsand18partnerlicenseecompanies•Statoilisthenationaloilcompanyandisinvolvedineveryproductionoperation63-Oct-19Challenges•Highproductioncostsduetoharshoffshoreenvironment–Highexplorationcosts–Highinvestment–Highsafety/environmentrequirements–Highoperation/logisticscosts–Highlaborcost•Turbulentoilprice•Seriouscompetition73-Oct-19GrowingDemandsforMaintenance•Incompliancewithstatutorylaws,regulations,andrequirements•Highequipmentreliability:health,safety,andenvironment•Highequipmentavailability-productivity•Highproductquality•Reductionofmaintenancecosts83-Oct-19MaintenanceTechnologyDevelopment•Changeofmaintenancestrategy•RiskBasedMaintenance•Systemizationofmaintenanceprograms•Continuousimprovementofmaintenanceprograms93-Oct-19195019601970198019902000BreakdownFixedIntervalPMRCMCBMTPMDevelopmentofMaintenanceStrategyRBM103-Oct-19RiskBasedMaintenance•Concept:Maintenancestrategyandeffortdependonequipment/componentrisks•Why?•RiskAssessment–Risk=Consequence*Probability–Consequences:•Healthandsafety•Environment•Deferredproduction/service•Materialdamages113-Oct-19AnImportantConcept-MaintenanceRelatedCosts•Directcosts:–Routineservices(CBS)–Predictive&Preventivetasks(CPM)–Correctivetasks(CCM)•Indirectcosts:–Management–Administration–Supports•Failureconsequencecosts(CRISKEX):–Health,Environment,andSafety(HES)–Production/services–Materialsdamage–Damagetoreputation123-Oct-19RelationshipbetweenMaintenanceCosts1000%LevelofPreventiveMaintenanceBasicservicelikelube,cleaning,etc.CRISKEXCost$CMINCCMCPMCBS-Costofbasicservices;CPM-Costofpreventivemaintenance;CCM-Costofcorrectivemaintenance;CRISKEX-Costs/lossesduetounplannedevents;CTOT=CBS+CPM+CCM+CRISKEX;CMIN-MinimalCTOTCTOTCBS133-Oct-19Risk-MaintenanceStrategy143-Oct-19RiskDistribution1,0%20,0%38,0%41,0%IIIIIIIVMSI-MaintenanceSignificantItems153-Oct-19RiskBasedInspection-RBI•EquipmentTypes:Static–Piping–Vessels–Structures–……•NDT(Non-DestructiveTesting)inspection–(MPI)MagneticParticleInspection–Ultrasonictesting–Radiography–Eddycurrenttesting•Achievements–Optimalinspectionmethods–Optimalinspectionintervals–Increasedreliabilityandavailability–Reducedinspectioncosts163-Oct-19RiskBasedTest-RBT•EquipmentTypes:ProtectiveInstruments–Alarms–Trips•Hiddenfailure:Failureondemands•Maintenancemethods–FunctionalTests•Achievements–OptimalTestintervals–Increasedreliabilityandavailability–Reducedtestcosts173-Oct-19RiskBasedMaintenance-RBM•EquipmentTypes:–Rotatingequipment–Processinstruments–Electricalmotors,powergeneration,...–……•Evident(detectable)failures:–Highvibration–Wornout–Leakage–…...•Analysismethods:–RCM(ReliabilitycenteredMaintenance)–Riskanalysis–Cost-benefitanalysis•Achievements–Potentialriskandranking-maintenancesignificantlevels–Performanceofpresentmaintenanceprograms–Optimizedmaintenanceprogram183-Oct-19MaintenanceProcessMaintenanceobjectiveEstablishmentofMaintenanceProgramMaintenanceProgramplanning/schedulingMaintenanceexecutionResultreportingandrecordingAnalysis193-Oct-19SystemizingMaintenanceProgram•Standardizationofmaintenanceprograms-MaintenanceConcepts(seenextpage)•Output–Maintenanceprograms–Requiredresources•Benefits–75%reductionofmaintenanceplanningtime–25%reductionofmaintenanceefforts–Asystematic,welldocumented,andauditableprocess203-Oct-19RequirementAnalysis•Requirements–Contractualregulation–Statutoryregulation:Actsorlaws–Consensusregulation:withprovisionslike“inaccordancewithrecognizedstandardsofgoodproductionpractice”•Linkto:–Plant/System/equipment–Operation•Cranelifting•Usinghightemperaturelikewelding,fire,•……213-Oct-19223-Oct-19233-Oct-19ContinuousImprovement•Reportingandrecordingmaintenancehistory–Failurefindings–Maintenanceworks•Analysisofhistorydata–Failures,reasons,andcosts–Performanceofpresentmaintenanceprograms–Update/improvementofmaintenanceprograms•Benefits–Asystematic,welldocumented,andauditableprocess–Optimizedmaintenancecosts–Increasedreliability,availabilityandproductquality243-Oct-19253-Oct-19263-Oct-19273-Oct-19283-Oct-19ResultsofRiskAssessmentImprovedProgramExistingProgramWithoutMaintenance$0$10000$20000$30000$40000$50000$60000293-Oct-19Cost-BenefitRatio10,157,474,231,662,951,110,950,03DrivesystemWireropesMotorsFestoonsystemTrolleysystemShieveAntiswaysystemGear303-Oct-19ConcludingRemarks•Growingdemandsformaintenance–Incompliancewithstatutoryrequirements–Highreliability–Highavailability-productivity–Re