搞好设备管理使企业效益最大化

HowtoMaintainEquipmentforCompaniestoGetMaximalProfitDongLiang,Ph.DRCGroupCo.,Ltd.,Norway

November10-12,1999

Jinan,ChinaInternationalWorkshoponPlantEngineering‘99JinanPresentationOutlineOverviewoftheNorwegianOilIndustryGrowingdemandsformaintenanceRiskBasedMaintenanceSystemizationofMaintenanceProgramsContinuousImprovementofMaintenanceProgramsConcludingremarks11-Nov-232Oil&GasProductionNorwayistheworld’s2ndlargestoilexportcountryAnnualoilproductionabout150milliontonandnaturalgasabout30billionM3Over80offshoredrillingandproductionplatformsinoperation11-Nov-233NorwegianContinentalShell11-Nov-234OperationFirstwellwasdrilledin1966Currently9operatorsand18partnerlicenseecompaniesStatoilisthenationaloilcompanyandisinvolvedineveryproductionoperation11-Nov-235ChallengesHighproductioncostsduetoharshoffshoreenvironmentHighexplorationcostsHighinvestmentHighsafety/environmentrequirementsHighoperation/logisticscostsHighlaborcostTurbulentoilpriceSeriouscompetition11-Nov-236GrowingDemandsforMaintenanceIncompliancewithstatutorylaws,regulations,andrequirementsHighequipmentreliability:health,safety,andenvironmentHighequipmentavailability->productivityHighproductqualityReductionofmaintenancecosts11-Nov-237MaintenanceTechnologyDevelopmentChangeofmaintenancestrategyRiskBasedMaintenanceSystemizationofmaintenanceprogramsContinuousimprovementofmaintenanceprograms11-Nov-238195019601970198019902000BreakdownFixedIntervalPMRCMCBMTPMDevelopmentofMaintenanceStrategyRBM11-Nov-239RiskBasedMaintenanceConcept:Maintenancestrategyandeffortdependonequipment/componentrisksWhy?RiskAssessmentRisk=Consequence*ProbabilityConsequences:HealthandsafetyEnvironmentDeferredproduction/serviceMaterialdamages11-Nov-2310AnImportantConcept

-MaintenanceRelatedCostsDirectcosts:Routineservices(CBS)Predictive&Preventivetasks(CPM)Correctivetasks(CCM)Indirectcosts:ManagementAdministrationSupportsFailureconsequencecosts(CRISKEX):Health,Environment,andSafety(HES)Production/servicesMaterialsdamageDamagetoreputation11-Nov-2311RelationshipbetweenMaintenanceCosts1000%LevelofPreventiveMaintenanceBasicservicelikelube,cleaning,etc.CRISKEXCost$

CMINCCMCPMCBS-Costofbasicservices; CPM-Costofpreventivemaintenance; CCM-Costofcorrectivemaintenance;CRISKEX-Costs/lossesduetounplannedevents;CTOT=CBS+CPM+CCM+CRISKEX;CMIN-MinimalCTOTCTOTCBS11-Nov-2312Risk-MaintenanceStrategy11-Nov-2313RiskDistributionMSI-MaintenanceSignificantItems11-Nov-2314RiskBasedInspection-RBIEquipmentTypes:StaticPipingVesselsStructures……NDT(Non-DestructiveTesting)inspection(MPI)MagneticParticleInspectionUltrasonictestingRadiographyEddycurrenttestingAchievementsOptimalinspectionmethodsOptimalinspectionintervalsIncreasedreliabilityandavailabilityReducedinspectioncosts11-Nov-2315RiskBasedTest-RBTEquipmentTypes:ProtectiveInstrumentsAlarmsTripsHiddenfailure:FailureondemandsMaintenancemethodsFunctionalTestsAchievementsOptimalTestintervalsIncreasedreliabilityandavailabilityReducedtestcosts11-Nov-2316RiskBasedMaintenance-RBMEquipmentTypes:RotatingequipmentProcessinstrumentsElectricalmotors,powergeneration,...……Evident(detectable)failures:HighvibrationWornoutLeakage…...Analysismethods:RCM(ReliabilitycenteredMaintenance)RiskanalysisCost-benefitanalysisAchievementsPotentialriskandranking->maintenancesignificantlevelsPerformanceofpresentmaintenanceprogramsOptimizedmaintenanceprogram11-Nov-2317MaintenanceProcessMaintenance

objectiveEstablishmentof

MaintenanceProgramMaintenanceProgram

planning/schedulingMaintenance

executionResultreporting

andrecordingAnalysis11-Nov-2318SystemizingMaintenanceProgramStandardizationofmaintenanceprograms-MaintenanceConcepts(seenextpage)OutputMaintenanceprogramsRequiredresourcesBenefits75%reductionofmaintenanceplanningtime25%reductionofmaintenanceeffortsAsystematic,welldocumented,andauditableprocess11-Nov-2319RequirementAnalysisRequirementsContractualregulationStatutoryregulation:ActsorlawsConsensusregulation:withprovisionslike“inaccordancewithrecognizedstandardsofgoodproductionpractice”Linkto:Plant/System/equipmentOperationCraneliftingUsinghightemperaturelikewelding,fire,……11-Nov-232011-Nov-232111-Nov-2322ContinuousImprovementReportingandrecordingmaintenancehistoryFailurefindingsMaintenanceworks

AnalysisofhistorydataFailures,reasons,andcostsPerformanceofpresentmaintenanceprogramsUpdate/improvementofmaintenanceprogramsBenefitsAsystematic,welldocumented,andauditableprocessOptimizedmaintenancecostsIncreasedreliability,availabilityandproductquality11-Nov-232311-Nov-232411-Nov-232511-Nov-232611-Nov-2327ResultsofRiskAssessmentDrivesystemWireropesMotorsFestoonsystemTrolleysystemShieveAntiswaysystemGearImprovedProgramExistingProgramWithoutMaintenance$0$10000$20000$30000$40000$50000$6000011-Nov-2328Cost-BenefitRatio10,157,474,231,662,951,110,950,03DrivesystemWireropesMotorsFestoonsystemTrolleysystemShieveAntiswaysystemGear11-Nov-2329Concl