Successful "Risk & Reliability Management” at Petroleum Development Oman

Introduction

Petroleum Development Oman (PDO), an oil and gas exploration and production company with numerous oil-producing facilities at Oman, is in the business of finding and producing crude oil and gas, and transporting it to where it is needed. Hofincons has just completed executing a Risk and Reliability Management (RRM) Project at PDO covering 28 oil-producing stations and gas plants. The work essentially consists of reviewing the existing maintenance strategy of PDO and providing recommendations for updating the maintenance strategy.

Methodology

PDO provided Hofincons the results of Functional Criticality Analysis which prioritizes functions of the respective facilities as Most Critical, Critical and Less Critical based on the function’s criticality score with reference to production, environment and safety. Most Critical functions were selected for carrying out the Reliability Centered Maintenance (RCM) analysis.

Data collection

RCM analysis covered the rotating equipment, electrical and process control instrumentation associated with the critical functions. A software was used for carrying out RCM analysis. For each equipment tag covered in the analysis, failure history was retrieved from EPMARS (Exploration Production Maintenance and Administrative Reporting System). For each failure mechanism, the actual MTBF (Mean Time Between Failures) was calculated. The relevant information such as the functions, the associated equipment tags, failure mechanisms and other related aspects were entered into the RCM software. A training program on Hofincons approach was conducted at PDO’s Corporate Office with a cross-functional field team with the requisite experience. Hand-outs on RCM were prepared and distributed.

RCM analysis

Hofincons compiled and displayed the list of critical functions and functional failures and then validated the failure mechanisms with the field team. Inputs were obtained from all the members regarding stand-by configurations (equipment criticality). RCM decision diagram was followed to arrive at the type of task. The introduction of the technology was discussed for the latest condition monitoring techniques. The best possible proactive task to improve equipment availability and reliability was selected.

The field team's input for estimating MTTR for individual failures was obtained. Based on MTBF and discussions with the members, the task was selected and arrived at the appropriate frequency for each task. The operating conditions were assessed by visiting the various sites along with the RCM field team.

Based on the RCM analysis, various tasks were recommended at suitable frequencies to prevent specific failure modes. The existing Maintenance Craft Procedures (MCP) were reviewed in the light of these recommendations and revised or rewritten as required. Hofincons identified the areas of potential improvement in maintenance routine/tasks. The RCM analysis identified specific tasks for operators, condition monitoring and craft technicians. Separate MCPs and checklists have been written for each service-interval for these disciplines. Based on the frequency of MCPs, Maintenance Job Plans were updated indicating revised checklist frequency, crew required and job duration.

Cost Benefit Analysis & Monitoring Plan

A Cost Benefit Analysis was prepared on implementation of RCM recommendations and the cost savings per equipment were determined. Short term and Long term monitoring plans based on key performance indicators were established to monitor the gains achieved through RCM implementation. A final report was presented to PDO which included RCM analysis report, Maintenance Craft Procedures, Maintenance Job Plan, Cost Benefit Analysis and Monitoring plan.

It is estimated that PDO will save around 1.8 million US dollars every year as a result of this.

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