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Click to edit Master title style,Click to edit Master text styles,Second level,Third level,Fourth level,Fifth level,*,*,How to Maintain Equipment for Companies to Get Maximal Profit,Dong Liang,Ph.D,RC Group Co.,Ltd.,Norway,November 10-12,1999Jinan,China,International Workshop on Plant Engineering 99 Jinan,Presentation Outline,Overview of the Norwegian Oil Industry,Growing demands for maintenance,Risk Based Maintenance,Systemization of Maintenance Programs,Continuous Improvement of Maintenance Programs,Concluding remarks,10/2/2024,2,Oil&Gas Production,Norway is the worlds 2nd largest oil export country,Annual oil production about 150 million ton and natural gas about 30 billion M3,Over 80 offshore drilling and production platforms in operation,10/2/2024,3,Norwegian Continental Shell,10/2/2024,4,Operation,First well was drilled in 1966,Currently 9 operators and 18 partner licensee companies,Statoil is the national oil company and is involved in every production operation,10/2/2024,5,Challenges,High production costs due to harsh offshore environment,High exploration costs,High investment,High safety/environment requirements,High operation/logistics costs,High labor cost,Turbulent oil price,Serious competition,10/2/2024,6,Growing Demands for Maintenance,In compliance with statutory laws,regulations,and requirements,High equipment reliability:health,safety,and environment,High equipment availability-productivity,High product quality,Reduction of maintenance costs,10/2/2024,7,Maintenance Technology Development,Change of maintenance strategy,Risk Based Maintenance,Systemization of maintenance programs,Continuous improvement of maintenance programs,10/2/2024,8,1950,1960,1970,1980,1990,2000,Breakdown,Fixed Interval PM,RCM,CBM,TPM,Development of Maintenance Strategy,RBM,10/2/2024,9,Risk Based Maintenance,Concept:,Maintenance strategy and effort depend on equipment/component risks,Why?,Risk Assessment,Risk=Consequence*Probability,Consequences:,Health and safety,Environment,Deferred production/service,Material damages,10/2/2024,10,An Important Concept-,Maintenance Related Costs,Direct costs:,Routine services(C,BS,),Predictive&Preventive tasks(C,PM,),Corrective tasks(C,CM,),Indirect costs:,Management,Administration,Supports,Failure consequence costs,(C,RISKEX,):,Health,Environment,and Safety(HES),Production/services,Materials damage,Damage to reputation,10/2/2024,11,Relationship between Maintenance Costs,100,0,%Level of Preventive Maintenance,Basic service like lube,cleaning,etc.,C,RISKEX,Cost$,C,MIN,C,CM,C,PM,C,BS,-Cost of basic services;C,PM,-Cost of preventive maintenance;C,CM,-Cost of corrective maintenance;,C,RISKEX,-Costs/losses due to unplanned events;C,TOT,=C,BS,+C,PM,+C,CM,+C,RISKEX;,C,MIN,-Minimal C,TOT,C,TOT,C,BS,10/2/2024,12,Risk-Maintenance Strategy,10/2/2024,13,Risk Distribution,MSI-Maintenance Significant Items,10/2/2024,14,Risk Based Inspection-RBI,Equipment Types:Static,Piping,Vessels,Structures,NDT(Non-Destructive Testing)inspection,(MPI)Magnetic Particle Inspection,Ultrasonic testing,Radiography,Eddy current testing,Achievements,Optimal inspection methods,Optimal inspection intervals,Increased reliability and availability,Reduced inspection costs,10/2/2024,15,Risk Based Test-RBT,Equipment Types:Protective Instruments,Alarms,Trips,Hidden failure:Failure on demands,Maintenance methods,Functional Tests,Achievements,Optimal Test intervals,Increased reliability and availability,Reduced test costs,10/2/2024,16,Risk Based Maintenance-RBM,Equipment Types:,Rotating equipment,Process instruments,Electrical motors,power generation,.,Evident(detectable)failures:,High vibration,Worn out,Leakage,.,Analysis methods:,RCM(Reliability centered Maintenance),Risk analysis,Cost-benefit analysis,Achievements,Potential risk and ranking-maintenance significant levels,Performance of present maintenance programs,Optimized maintenance program,10/2/2024,17,Maintenance Process,Maintenanceobjective,Establishment of Maintenance Program,Maintenance Programplanning/scheduling,Maintenanceexecution,Result reportingand recording,Analysis,10/2/2024,18,Systemizing Maintenance Program,Standardization of maintenance programs-Maintenance Concepts(see next page),Output,Maintenance programs,Required resources,Benefits,75%reduction of maintenance planning time,25%reduction of maintenance efforts,A systematic,well documented,and auditable process,10/2/2024,19,Requirement Analysis,Requirements,Contractual regulation,Statutory regulation:Acts or laws,Consensus regulation:with provisions like“in accordance with recognized standards of good production practice”,Link to:,Plant/System/equipment,Operation,Crane lifting,Using high temperature like welding,fire,10/2/2024,20,10/2/2024,21,10/2/2024,22,Continuous Improvement,Reporting and recording maintenance history,Failure findings,Maintenance works,Analysis of history data,Failures,reasons,and costs,Performance of present maintenance programs,Update/improvement of maintenance programs,Benefits,A systema
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