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HowtoMaintainEquipmentforCompaniestoGetMaximalProfitDongLiang,Ph.DRCGroupCo.,Ltd.,Norway

November10-12,1999

Jinan,ChinaInternationalWorkshoponPlantEngineering‘99JinanPresentationOutlineOverviewoftheNorwegianOilIndustryGrowingdemandsformaintenanceRiskBasedMaintenanceSystemizationofMaintenanceProgramsContinuousImprovementofMaintenanceProgramsConcludingremarks04-May-252Oil&GasProductionNorwayistheworld’s2ndlargestoilexportcountryAnnualoilproductionabout150milliontonandnaturalgasabout30billionM3Over80offshoredrillingandproductionplatformsinoperation04-May-253NorwegianContinentalShell04-May-254OperationFirstwellwasdrilledin1966Currently9operatorsand18partnerlicenseecompaniesStatoilisthenationaloilcompanyandisinvolvedineveryproductionoperation04-May-255ChallengesHighproductioncostsduetoharshoffshoreenvironmentHighexplorationcostsHighinvestmentHighsafety/environmentrequirementsHighoperation/logisticscostsHighlaborcostTurbulentoilpriceSeriouscompetition04-May-256GrowingDemandsforMaintenanceIncompliancewithstatutorylaws,regulations,andrequirementsHighequipmentreliability:health,safety,andenvironmentHighequipmentavailability->productivityHighproductqualityReductionofmaintenancecosts04-May-257MaintenanceTechnologyDevelopmentChangeofmaintenancestrategyRiskBasedMaintenanceSystemizationofmaintenanceprogramsContinuousimprovementofmaintenanceprograms04-May-258195019601970198019902000BreakdownFixedIntervalPMRCMCBMTPMDevelopmentofMaintenanceStrategyRBM04-May-259RiskBasedMaintenanceConcept:Maintenancestrategyandeffortdependonequipment/componentrisksWhy?RiskAssessmentRisk=Consequence*ProbabilityConsequences:HealthandsafetyEnvironmentDeferredproduction/serviceMaterialdamages04-May-2510AnImportantConcept

-MaintenanceRelatedCostsDirectcosts:Routineservices(CBS)Predictive&Preventivetasks(CPM)Correctivetasks(CCM)Indirectcosts:ManagementAdministrationSupportsFailureconsequencecosts(CRISKEX):Health,Environment,andSafety(HES)Production/servicesMaterialsdamageDamagetoreputation04-May-2511RelationshipbetweenMaintenanceCosts1000%LevelofPreventiveMaintenanceBasicservicelikelube,cleaning,etc.CRISKEXCost$

CMINCCMCPMCBS-Costofbasicservices; CPM-Costofpreventivemaintenance; CCM-Costofcorrectivemaintenance;CRISKEX-Costs/lossesduetounplannedevents;CTOT=CBS+CPM+CCM+CRISKEX;CMIN-MinimalCTOTCTOTCBS04-May-2512Risk-MaintenanceStrategy04-May-2513RiskDistributionMSI-MaintenanceSignificantItems04-May-2514RiskBasedInspection-RBIEquipmentTypes:StaticPipingVesselsStructures……NDT(Non-DestructiveTesting)inspection(MPI)MagneticParticleInspectionUltrasonictestingRadiographyEddycurrenttestingAchievementsOptimalinspectionmethodsOptimalinspectionintervalsIncreasedreliabilityandavailabilityReducedinspectioncosts04-May-2515RiskBasedTest-RBTEquipmentTypes:ProtectiveInstrumentsAlarmsTripsHiddenfailure:FailureondemandsMaintenancemethodsFunctionalTestsAchievementsOptimalTestintervalsIncreasedreliabilityandavailabilityReducedtestcosts04-May-2516RiskBasedMaintenance-RBMEquipmentTypes:RotatingequipmentProcessinstrumentsElectricalmotors,powergeneration,...……Evident(detectable)failures:HighvibrationWornoutLeakage…...Analysismethods:RCM(ReliabilitycenteredMaintenance)RiskanalysisCost-benefitanalysisAchievementsPotentialriskandranking->maintenancesignificantlevelsPerformanceofpresentmaintenanceprogramsOptimizedmaintenanceprogram04-May-2517MaintenanceProcessMaintenance

objectiveEstablishmentof

MaintenanceProgramMaintenanceProgram

planning/schedulingMaintenance

executionResultreporting

andrecordingAnalysis04-May-2518SystemizingMaintenanceProgramStandardizationofmaintenanceprograms-MaintenanceConcepts(seenextpage)OutputMaintenanceprogramsRequiredresourcesBenefits75%reductionofmaintenanceplanningtime25%reductionofmaintenanceeffortsAsystematic,welldocumented,andauditableprocess04-May-2519RequirementAnalysisRequirementsContractualregulationStatutoryregulation:ActsorlawsConsensusregulation:withprovisionslike“inaccordancewithrecognizedstandardsofgoodproductionpractice”Linkto:Plant/System/equipmentOperationCraneliftingUsinghightemperaturelikewelding,fire,……04-May-252004-May-252104-May-2522ContinuousImprovementReportingandrecordingmaintenancehistoryFailurefindingsMaintenanceworks

AnalysisofhistorydataFailures,reasons,andcostsPerformanceofpresentmaintenanceprogramsUpdate/improvementofmaintenanceprogramsBenefitsAsystematic,welldocumented,andauditableprocessOptimizedmaintenancecostsIncreasedreliability,availabilityandproductquality04-May-252304-May-252404-May-252504-May-252604-May-2527ResultsofRiskAssessmentDrivesystemWireropesMotorsFestoonsystemTrolleysystemShieveAntiswaysystemGearImprovedProgramExistingProgramWithoutMaintenance$0$10000$20000$30000$40000$50000$6000004-May-2528Cost-BenefitRatio10,157,474,231,662,951,110,950,03DrivesystemWireropesMotorsFestoonsystemTrolleysystemShieveAntiswaysystemGear04-May-2529Concl

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