如何维护公司的设备能得到最大的赢利

HowtoMaintainEquipmentforCompaniestoGetMaximalProfitDongLiang,Ph.DRCGroupCo.,Ltd.,Norway

November10-12,1999

Jinan,ChinaInternationalWorkshoponPlantEngineering‘99Jinan第一页，共二十四页。PresentationOutlineOverviewoftheNorwegianOilIndustryGrowingdemandsformaintenanceRiskBasedMaintenanceSystemizationofMaintenanceProgramsContinuousImprovementofMaintenanceProgramsConcludingremarks第二页，共二十四页。2023/4/242Oil&GasProductionNorwayistheworld’s2ndlargestoilexportcountryAnnualoilproductionabout150milliontonandnaturalgasabout30billionM3Over80offshoredrillingandproductionplatformsinoperation第三页，共二十四页。2023/4/243OperationFirstwellwasdrilledin1966Currently9operatorsand18partnerlicenseecompaniesStatoilisthenationaloilcompanyandisinvolvedineveryproductionoperation第四页，共二十四页。2023/4/244ChallengesHighproductioncostsduetoharshoffshoreenvironmentHighexplorationcostsHighinvestmentHighsafety/environmentrequirementsHighoperation/logisticscostsHighlaborcostTurbulentoilpriceSeriouscompetition第五页，共二十四页。2023/4/245GrowingDemandsforMaintenanceIncompliancewithstatutorylaws,regulations,andrequirementsHighequipmentreliability:health,safety,andenvironmentHighequipmentavailability->productivityHighproductqualityReductionofmaintenancecosts第六页，共二十四页。2023/4/246MaintenanceTechnologyDevelopmentChangeofmaintenancestrategyRiskBasedMaintenanceSystemizationofmaintenanceprogramsContinuousimprovementofmaintenanceprograms第七页，共二十四页。2023/4/247195019601970198019902000BreakdownFixedIntervalPMRCMCBMTPMDevelopmentofMaintenanceStrategyRBM第八页，共二十四页。2023/4/248RiskBasedMaintenanceConcept:Maintenancestrategyandeffortdependonequipment/componentrisksWhy?RiskAssessmentRisk=Consequence*ProbabilityConsequences:HealthandsafetyEnvironmentDeferredproduction/serviceMaterialdamages第九页，共二十四页。2023/4/249AnImportantConcept

-MaintenanceRelatedCostsDirectcosts:Routineservices(CBS)Predictive&Preventivetasks(CPM)Correctivetasks(CCM)Indirectcosts:ManagementAdministrationSupportsFailureconsequencecosts(CRISKEX):Health,Environment,andSafety(HES)Production/servicesMaterialsdamageDamagetoreputation第十页，共二十四页。2023/4/2410RelationshipbetweenMaintenanceCosts1000%LevelofPreventiveMaintenanceBasicservicelikelube,cleaning,etc.CRISKEXCost$CMINCCMCPMCBS-Costofbasicservices; CPM-Costofpreventivemaintenance; CCM-Costofcorrectivemaintenance;CRISKEX-Costs/lossesduetounplannedevents;CTOT=CBS+CPM+CCM+CRISKEX;CMIN-MinimalCTOTCTOTCBS第十一页，共二十四页。2023/4/2411Risk-MaintenanceStrategy第十二页，共二十四页。2023/4/2412RiskDistributionMSI-MaintenanceSignificantItems第十三页，共二十四页。2023/4/2413RiskBasedInspection-RBIEquipmentTypes:StaticPipingVesselsStructures……NDT(Non-DestructiveTesting)inspection(MPI)MagneticParticleInspectionUltrasonictestingRadiographyEddycurrenttestingAchievementsOptimalinspectionmethodsOptimalinspectionintervalsIncreasedreliabilityandavailabilityReducedinspectioncosts第十四页，共二十四页。2023/4/2414RiskBasedTest-RBTEquipmentTypes:ProtectiveInstrumentsAlarmsTripsHiddenfailure:FailureondemandsMaintenancemethodsFunctionalTestsAchievementsOptimalTestintervalsIncreasedreliabilityandavailabilityReducedtestcosts第十五页，共二十四页。2023/4/2415RiskBasedMaintenance-RBMEquipmentTypes:RotatingequipmentProcessinstrumentsElectricalmotors,powergeneration,...……Evident(detectable)failures:HighvibrationWornoutLeakage…...Analysismethods:RCM(ReliabilitycenteredMaintenance)RiskanalysisCost-benefitanalysisAchievementsPotentialriskandranking->maintenancesignificantlevelsPerformanceofpresentmaintenanceprogramsOptimizedmaintenanceprogram第十六页，共二十四页。2023/4/2416MaintenanceProcessMaintenance

objectiveEstablishmentof

MaintenanceProgramMaintenanceProgram

planning/schedulingMaintenance

executionResultreporting

andrecordingAnalysis第十七页，共二十四页。2023/4/2417SystemizingMaintenanceProgramStandardizationofmaintenanceprograms-MaintenanceConcepts(seenextpage)OutputMaintenanceprogramsRequiredresourcesBenefits75%reductionofmaintenanceplanningtime25%reductionofmaintenanceeffortsAsystematic,welldocumented,andauditableprocess第十八页，共二十四页。2023/4/2418RequirementAnalysisRequirementsContractualregulationStatutoryregulation:ActsorlawsConsensusregulation:withprovisionslike“inaccordancewithrecognizedstandardsofgoodproductionpractice”Linkto:Plant/System/equipmentOperationCraneliftingUsinghightemperaturelikewelding,fire,……第十九页，共二十四页。2023/4/2419ContinuousImprovementReportingandrecordingmaintenancehistoryFailurefindingsMaintenanceworks

AnalysisofhistorydataFailures,reasons,andcostsPerformanceofpresentmaintenanceprogramsUpdate/improvementofmaintenanceprogramsBenefitsAsystematic,welldocumented,andauditableprocessOptimizedmaintenancecostsIncreasedreliability,availabilityandproductquality第二十页，共二十四页。2023/4/2420ResultsofRiskAssessmentDrivesystemWireropesMotorsFestoonsystemTrolleysystemShieveAntiswaysystemGearImprovedProgramExistingProgramWithoutMaintenance$0$10000$20000$30000$40000$50000$60000第二十一页，共二十四页。2023/4/2421Cost-BenefitRatio10,157,474,231,662,951,110,950,03DrivesystemWireropesMotorsFestoonsystemTrolleysystemShieveAntiswaysystemGear第二十二页，共二十