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HowtoMaintainEquipmentforCompaniestoGetMaximalProfitDongLiang,Ph.DRCGroupCo.,Ltd.,Norway

November10-12,1999

Jinan,ChinaInternationalWorkshoponPlantEngineering‘99JinanPresentationOutlineOverviewoftheNorwegianOilIndustryGrowingdemandsformaintenanceRiskBasedMaintenanceSystemizationofMaintenanceProgramsContinuousImprovementofMaintenanceProgramsConcludingremarks7/4/20242Oil&GasProductionNorwayistheworld’s2ndlargestoilexportcountryAnnualoilproductionabout150milliontonandnaturalgasabout30billionM3Over80offshoredrillingandproductionplatformsinoperation7/4/20243NorwegianContinentalShell7/4/20244OperationFirstwellwasdrilledin1966Currently9operatorsand18partnerlicenseecompaniesStatoilisthenationaloilcompanyandisinvolvedineveryproductionoperation7/4/20245ChallengesHighproductioncostsduetoharshoffshoreenvironmentHighexplorationcostsHighinvestmentHighsafety/environmentrequirementsHighoperation/logisticscostsHighlaborcostTurbulentoilpriceSeriouscompetition7/4/20246GrowingDemandsforMaintenanceIncompliancewithstatutorylaws,regulations,andrequirementsHighequipmentreliability:health,safety,andenvironmentHighequipmentavailability->productivityHighproductqualityReductionofmaintenancecosts7/4/20247MaintenanceTechnologyDevelopmentChangeofmaintenancestrategyRiskBasedMaintenanceSystemizationofmaintenanceprogramsContinuousimprovementofmaintenanceprograms7/4/20248195019601970198019902000BreakdownFixedIntervalPMRCMCBMTPMDevelopmentofMaintenanceStrategyRBM7/4/20249RiskBasedMaintenanceConcept:Maintenancestrategyandeffortdependonequipment/componentrisksWhy?RiskAssessmentRisk=Consequence*ProbabilityConsequences:HealthandsafetyEnvironmentDeferredproduction/serviceMaterialdamages7/4/202410AnImportantConcept

-MaintenanceRelatedCostsDirectcosts:Routineservices(CBS)Predictive&Preventivetasks(CPM)Correctivetasks(CCM)Indirectcosts:ManagementAdministrationSupportsFailureconsequencecosts(CRISKEX):Health,Environment,andSafety(HES)Production/servicesMaterialsdamageDamagetoreputation7/4/202411RelationshipbetweenMaintenanceCosts1000%LevelofPreventiveMaintenanceBasicservicelikelube,cleaning,etc.CRISKEXCost$

CMINCCMCPMCBS-Costofbasicservices; CPM-Costofpreventivemaintenance; CCM-Costofcorrectivemaintenance;CRISKEX-Costs/lossesduetounplannedevents;CTOT=CBS+CPM+CCM+CRISKEX;CMIN-MinimalCTOTCTOTCBS7/4/202412Risk-MaintenanceStrategy7/4/202413RiskDistributionMSI-MaintenanceSignificantItems7/4/202414RiskBasedInspection-RBIEquipmentTypes:StaticPipingVesselsStructures……NDT(Non-DestructiveTesting)inspection(MPI)MagneticParticleInspectionUltrasonictestingRadiographyEddycurrenttestingAchievementsOptimalinspectionmethodsOptimalinspectionintervalsIncreasedreliabilityandavailabilityReducedinspectioncosts7/4/202415RiskBasedTest-RBTEquipmentTypes:ProtectiveInstrumentsAlarmsTripsHiddenfailure:FailureondemandsMaintenancemethodsFunctionalTestsAchievementsOptimalTestintervalsIncreasedreliabilityandavailabilityReducedtestcosts7/4/202416RiskBasedMaintenance-RBMEquipmentTypes:RotatingequipmentProcessinstrumentsElectricalmotors,powergeneration,...……Evident(detectable)failures:HighvibrationWornoutLeakage…...Analysismethods:RCM(ReliabilitycenteredMaintenance)RiskanalysisCost-benefitanalysisAchievementsPotentialriskandranking->maintenancesignificantlevelsPerformanceofpresentmaintenanceprogramsOptimizedmaintenanceprogram7/4/202417MaintenanceProcessMaintenance

objectiveEstablishmentof

MaintenanceProgramMaintenanceProgram

planning/schedulingMaintenance

executionResultreporting

andrecordingAnalysis7/4/202418SystemizingMaintenanceProgramStandardizationofmaintenanceprograms-MaintenanceConcepts(seenextpage)OutputMaintenanceprogramsRequiredresourcesBenefits75%reductionofmaintenanceplanningtime25%reductionofmaintenanceeffortsAsystematic,welldocumented,andauditableprocess7/4/202419RequirementAnalysisRequirementsContractualregulationStatutoryregulation:ActsorlawsConsensusregulation:withprovisionslike“inaccordancewithrecognizedstandardsofgoodproductionpractice”Linkto:Plant/System/equipmentOperationCraneliftingUsinghightemperaturelikewelding,fire,……7/4/2024207/4/2024217/4/202422ContinuousImprovementReportingandrecordingmaintenancehistoryFailurefindingsMaintenanceworks

AnalysisofhistorydataFailures,reasons,andcostsPerformanceofpresentmaintenanceprogramsUpdate/improvementofmaintenanceprogramsBenefitsAsystematic,welldocumented,andauditableprocessOptimizedmaintenancecostsIncreasedreliability,availabilityandproductquality7/4/2024237/4/2024247/4/2024257/4/2024267/4/202427ResultsofRiskAssessmentDrivesystemWireropesMotorsFestoonsystemTrolleysystemShieveAntiswaysystemGearImprovedProgramExistingProgramWithoutMaintenance$0$10000$20000$30000$40000$50000$600007/4/202428Cost-BenefitRatio10,157,474,231,662,951,110,950,03DrivesystemWireropesMotorsFestoonsystemTrolleysystemShieveAntiswaysystemGear7/4/202429Concl

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