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1、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,搞好设备管理使企业效益最大化,2,2021/5/2,Presentation Outline,Overview of the Norwegian Oil Industry Growing demands for
2、maintenance Risk Based Maintenance Systemization of Maintenance Programs Continuous Improvement of Maintenance Programs Concluding remarks,搞好设备管理使企业效益最大化,3,2021/5/2,Oil & Gas Production,Norway is the worlds 2nd largest oil export country Annual oil production about 150 million ton and natural gas ab
3、out 30 billion M3 Over 80 offshore drilling and production platforms in operation,搞好设备管理使企业效益最大化,4,2021/5/2,Norwegian Continental Shell,搞好设备管理使企业效益最大化,5,2021/5/2,Operation,First well was drilled in 1966 Currently 9 operators and 18 partner licensee companies Statoil is the national oil company and i
4、s involved in every production operation,搞好设备管理使企业效益最大化,6,2021/5/2,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
5、,搞好设备管理使企业效益最大化,7,2021/5/2,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,搞好设备管理使企业效益最大化,8,2021
6、/5/2,Maintenance Technology Development,Change of maintenance strategy Risk Based Maintenance Systemization of maintenance programs Continuous improvement of maintenance programs,搞好设备管理使企业效益最大化,9,2021/5/2,1950,1960,1970,1980,1990,2000,Breakdown,Fixed Interval PM,RCM,CBM,TPM,Development of Maintenanc
7、e Strategy,RBM,搞好设备管理使企业效益最大化,10,2021/5/2,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,搞好设备管理使企业效
8、益最大化,11,2021/5/2,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 /
9、services Materials damage Damage to reputation,搞好设备管理使企业效益最大化,12,2021/5/2,Relationship between Maintenance Costs,搞好设备管理使企业效益最大化,13,2021/5/2,Risk - Maintenance Strategy,搞好设备管理使企业效益最大化,14,2021/5/2,Risk Distribution,搞好设备管理使企业效益最大化,15,2021/5/2,Risk Based Inspection - RBI,Equipment Types: Static Piping V
10、essels 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,搞好设备管理使企业效益最大化,16,202
11、1/5/2,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,搞好设备管理使企业效益最大化,17,2021/5/2,Risk Based Maintenance - R
12、BM,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 -
13、maintenance significant levels Performance of present maintenance programs Optimized maintenance program,搞好设备管理使企业效益最大化,18,2021/5/2,Maintenance Process,搞好设备管理使企业效益最大化,19,2021/5/2,Systemizing Maintenance Program,Standardization of maintenance programs - Maintenance Concepts (see next page) Output Mai
14、ntenance programs Required resources Benefits 75% reduction of maintenance planning time 25% reduction of maintenance efforts A systematic, well documented, and auditable process,搞好设备管理使企业效益最大化,20,2021/5/2,Requirement Analysis,Requirements Contractual regulation Statutory regulation: Acts or laws Co
15、nsensus 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, ,搞好设备管理使企业效益最大化,21,2021/5/2,搞好设备管理使企业效益最大化,22,2021/5/2,搞好设备管理使企业效益最大化,23,2021/5/2,Cont
16、inuous 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,搞好设备管理使企业效益最大化,24,2021/5/2,搞好设备管理使企业效益最大化,25,2021/5/2,搞好设备管理使企业效益最大化,26,2021/5/2,搞好设备管理使企业效益最大化,27,2021/5/2,搞好设备管
