如何维护公司的设备能得到最大的赢利

1、How to Maintain Equipment for Companies to Get Maximal ProfitDong Liang, Ph.DRC Group Co., Ltd., Norway November 10 - 12, 1999Jinan, ChinaInternational Workshop on Plant Engineering 99 JinanPresentation Outline Overview of the Norwegian Oil IndustryGrowing demands for maintenanceRisk Based Maintenan

2、ceSystemization of Maintenance ProgramsContinuous Improvement of Maintenance ProgramsConcluding remarks.Oil & Gas ProductionNorway is the worlds 2nd largest oil export countryAnnual oil production about 150 million ton and natural gas about 30 billion M3Over 80 offshore drilling and production platf

3、orms in operation.OperationFirst well was drilled in 1966Currently 9 operators and 18 partner licensee companiesStatoil is the national oil company and is involved in every production operation.ChallengesHigh production costs due to harsh offshore environmentHigh exploration costsHigh investmentHigh

4、 safety / environment requirements High operation / logistics costsHigh labor costTurbulent oil priceSerious competition.Growing Demands for MaintenanceIn compliance with statutory laws, regulations, and requirementsHigh equipment reliability: health, safety, and environment High equipment availabil

5、ity - productivityHigh product qualityReduction of maintenance costs.Maintenance Technology DevelopmentChange of maintenance strategyRisk Based MaintenanceSystemization of maintenance programsContinuous improvement of maintenance programs.195019601970198019902000BreakdownFixed Interval PMRCMCBMTPMDe

6、velopment of Maintenance StrategyRBM.Risk Based MaintenanceConcept: Maintenance strategy and effort depend on equipment / component risksWhy ? Risk AssessmentRisk = Consequence * ProbabilityConsequences:Health and safetyEnvironmentDeferred production / serviceMaterial damages.An Important Concept- M

7、aintenance Related CostsDirect costs:Routine services (CBS)Predictive & Preventive tasks (CPM)Corrective tasks (CCM)Indirect costs:ManagementAdministrationSupportsFailure consequence costs (CRISKEX):Health, Environment, and Safety (HES)Production / servicesMaterials damageDamage to reputation.Relati

8、onship between Maintenance Costs1000% Level of Preventive MaintenanceBasic service like lube, cleaning, etc.CRISKEXCost $CMINCCMCPMCBS - Cost of basic services; CPM - Cost of preventive maintenance; CCM - Cost of corrective maintenance;CRISKEX - Costs / losses due to unplanned events; CTOT = CBS + C

9、PM + CCM + CRISKEX; CMIN - Minimal CTOTCTOTCBS.Risk - Maintenance Strategy.Risk DistributionMSI - Maintenance Significant Items.Risk Based Inspection - RBIEquipment Types: StaticPipingVesselsStructuresNDT (Non-Destructive Testing) inspection(MPI) Magnetic Particle Inspection Ultrasonic testingRadiog

10、raphyEddy current testingAchievementsOptimal inspection methodsOptimal inspection intervalsIncreased reliability and availabilityReduced inspection costs.Risk Based Test - RBTEquipment Types: Protective InstrumentsAlarms TripsHidden failure: Failure on demandsMaintenance methodsFunctional TestsAchie

11、vementsOptimal Test intervalsIncreased reliability and availabilityReduced test costs.Risk Based Maintenance - RBMEquipment Types:Rotating equipment Process instrumentsElectrical motors, power generation, .Evident (detectable) failures:High vibrationWorn outLeakage.Analysis methods:RCM (Reliability

12、centered Maintenance)Risk analysisCost - benefit analysisAchievementsPotential risk and ranking - maintenance significant levelsPerformance of present maintenance programsOptimized maintenance program.Maintenance ProcessMaintenanceobjectiveEstablishment of Maintenance ProgramMaintenance Programplann

13、ing / schedulingMaintenanceexecutionResult reportingand recordingAnalysis.Systemizing Maintenance ProgramStandardization of maintenance programs - Maintenance Concepts (see next page)OutputMaintenance programsRequired resourcesBenefits75% reduction of maintenance planning time25% reduction of mainte

14、nance effortsA systematic, well documented, and auditable process.Requirement Analysis RequirementsContractual regulationStatutory regulation: Acts or lawsConsensus regulation: with provisions like “in accordance with recognized standards of good production practiceLink to:Plant / System / equipment

15、OperationCrane liftingUsing high temperature like welding, fire,.Continuous ImprovementReporting and recording maintenance historyFailure findingsMaintenance works Analysis of history dataFailures, reasons, and costsPerformance of present maintenance programsUpdate / improvement of maintenance progr

16、amsBenefitsA systematic, well documented, and auditable processOptimized maintenance costsIncreased reliability, availability and product quality.Results of Risk AssessmentDrive systemWire ropesMotorsFestoon systemTrolley systemShieveAnti sway systemGearImproved ProgramExisting ProgramWithout Maintenance$0$10 000$20 000$30 000$40 000$50 000$60 000.Cost-Benefit Ratio10,157,474,231,662,951,110,950,03Drive systemWire ropesMotorsFestoonsystemTrolleysystemShieveAnti swaysystemGear.Concluding Remar