HowtoMaintainEquipmentforpaniestoGetMaximalProfitDongLiang,Ph.DRCGroupCo.,Ltd.,Norway

November10-12,1999

Jinan,ChinaInternationalWorkshoponPlantEngineering‘99JinanPresentationOutlineOverviewoftheNorwegianOilIndustryGrowingdemandsformaintenanceRiskBasedMaintenanceSystemizationofMaintenanceProgramsContinuousImprovementofMaintenanceProgramsConcludingremarksOil&GasProductionNorwayistheworld’s2ndlargestoilexportcountryAnnualoilproductionabout150milliontonandnaturalgasabout30billionM3Over80offshoredrillingandproductionplatformsinoperationNorwegianContinentalShellOperationFirstwellwasdrilledin1966Currently9operatorsand18partnerlicenseepaniesStatoilisthenationaloilpanyandisinvolvedineveryproductionoperationChallengesHighproductioncostsduetoharshoffshoreenvironmentHighexplorationcostsHighinvestmentHighsafety/environmentrequirementsHighoperation/logisticscostsHighlaborcostTurbulentoilpriceSeriouspetitionGrowingDemandsforMaintenanceInpliancewithstatutorys,regulations,andrequirementsHighequipmentreliability:health,safety,andenvironmentHighequipmentavailability->productivityHighproductqualityReductionofmaintenancecostsMaintenanceTechnologyDevelopmentChangeofmaintenancestrategyRiskBasedMaintenanceSystemizationofmaintenanceprogramsContinuousimprovementofmaintenanceprograms195019601970198019902000BreakdownFixedIntervalPMRCMCBMTPMDevelopmentofMaintenanceStrategyRBMRiskBasedMaintenanceConcept:Maintenancestrategyandeffortdependonequipment/ponentrisksWhy?RiskAssessmentRisk=Consequence*ProbabilityConsequences:HealthandsafetyEnvironmentDeferredproduction/serviceMaterialdamagesAnImportantConcept

-MaintenanceRelatedCostsDirectcosts:Routineservices(CBS)Predictive&Preventivetasks(CPM)Correctivetasks(CCM)Indirectcosts:ManagementAdministrationSupportsFailureconsequencecosts(CRISKEX):Health,Environment,andSafety(HES)Production/servicesMaterialsdamageDamagetoreputationRelationshipbetweenMaintenanceCosts1000%LevelofPreventiveMaintenanceBasicservicelikelube,cleaning,etc.CRISKEXCost$

CMINCCMCPMCBS-Costofbasicservices; CPM-Costofpreventivemaintenance; CCM-Costofcorrectivemaintenance;CRISKEX-Costs/lossesduetounplannedevents;CTOT=CBS+CPM+CCM+CRISKEX;CMIN-MinimalCTOTCTOTCBSRisk-MaintenanceStrategyRiskDistributionMSI-MaintenanceSignificantItemsRiskBasedInspection-RBIEquipmentTypes:StaticPipingVesselsStructures……NDT(Non-DestructiveTesting)inspection(MPI)MagneticParticleInspectionUltrasonictestingRadiographyEddycurrenttestingAchievementsOptimalinspectionmethodsOptimalinspectionintervalsIncreasedreliabilityandavailabilityReducedinspectioncostsRiskBasedTest-RBTEquipmentTypes:ProtectiveInstrumentsAlarmsTripsHiddenfailure:FailureondemandsMaintenancemethodsFunctionalTestsAchievementsOptimalTestintervalsIncreasedreliabilityandavailabilityReducedtestcostsRiskBasedMaintenance-RBMEquipmentTypes:RotatingequipmentProcessinstrumentsElectricalmotors,powergeneration,...……Evident(detectable)failures:HighvibrationWornoutLeakage…...Analysismethods:RCM(ReliabilitycenteredMaintenance)RiskanalysisCost-benefitanalysisAchievementsPotentialriskandranking->maintenancesignificantlevelsPerformanceofpresentmaintenanceprogramsOptimizedmaintenanceprogramMaintenanceProcessMaintenance

objectiveEstablishmentof

MaintenanceProgramMaintenanceProgram

planning/schedulingMaintenance

executionResultreporting

andrecordingAnalysisSystemizingMaintenanceProgramStandardizationofmaintenanceprograms-MaintenanceConcepts(seenextpage)OutputMaintenanceprogramsRequiredresourcesBenefits75%reductionofmaintenanceplanningtime25%reductionofmaintenanceeffortsAsystematic,welldocumented,andauditableprocessRequirementAnalysisRequirementsContractualregulationStatutoryregulation:ActsorsConsensusregulation:withprovisionslike“inaccordancewithrecognizedstandardsofgoodproductionpractice”Linkto:Plant/System/equipmentOperationCraneliftingUsinghightemperaturelikewelding,fire,……ContinuousImprovementReportingandrecordingmaintenancehistoryFailurefindingsMaintenanceworks

AnalysisofhistorydataFailures,reasons,andcostsPerformanceofpresentmaintenanceprogramsUpdate/improvementofmaintenanceprogramsBenefitsAsystematic,welldocumented,andauditableprocessOptimizedmaintenancecostsIncreasedreliability,availabilityandproductqualityResultsofRiskAssessmentDrivesystemWireropesMotorsFestoonsystemTrolleysystemShieveAntiswaysystemGearImprovedProgramExistingProgramWithoutMaintenance$0$10000$20000$30000$40000$50000$60000Cost-BenefitRatio10,157,474,231,662,951,110,950,03DrivesystemWireropesMotorsFestoonsystemTrolleysystemShieveAntiswaysystemGearConcludi