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,2021/3/29,2,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,2021/3/29,3,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,2021/3/29,4,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,2021/3/29,5,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,2021/3/29,6,Maintenance Technology Development,Change of maintenance strategy Risk Based Maintenance Systemization of maintenance programs Continuous improvement of maintenance programs,2021/3/29,7,1950,1960,1970,1980,1990,2000,Breakdown,Fixed Interval PM,RCM,CBM,TPM,Development of Maintenance Strategy,RBM,2021/3/29,8,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,2021/3/29,9,An Important Concept- Maintenance Related Costs,Direct costs: Routine services (CBS) Predictive & Preventive tasks (CPM) Corrective tasks (CCM) Indirect costs: Management Administration Supports Failure consequence costs (CRISKEX): Health, Environment, and Safety (HES) Production / services Materials damage Damage to reputation,2021/3/29,10,Relationship between Maintenance Costs,2021/3/29,11,Risk - Maintenance Strategy,2021/3/29,12,Risk Distribution,MSI - Maintenance Significant Items,2021/3/29,13,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,2021/3/29,14,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,2021/3/29,15,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,2021/3/29,16,Maintenance Process,2021/3/29,17,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,2021/3/29,18,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,2021/3/29,19,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 systematic, well documented, and auditable process Optimized maintenance costs Increased reliability, availability and product quality,2021/3/29,20,Results of Risk Assessment,0,10 000,20 000,30 000,40 000,50 000,60 000,2021/3/29,21,Cost-Benefit Ratio,2021/3/29,22,Concluding Remarks,Growing demands for maintenance In compliance with statutory requirements High reliability High availability - productivity Reduction of maintenance cost Solutions: Risk Based Maintenance Systemizing maintenance programs Continuous improvement of maintenance programs,2021/3/29,23,9、静夜四无邻，荒居旧业贫。21.3.2921.3.29Monday, Ma