[精选]如何维护公司的设备能得到最大的赢利(1)24777.pptx

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1、How to Maintain Equipment for How to Maintain Equipment for Companies to Get Maximal ProfitCompanies 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 Indus

2、tryGrowing demands for maintenanceRisk Based MaintenanceSystemization of Maintenance ProgramsContinuous Improvement of Maintenance ProgramsConcluding remarks2023/5/202Oil&Gas ProductionNorway is the worlds 2nd largest oil export countryAnnual oil production about 150 million ton and natural gas abou

3、t 30 billion M3Over 80 offshore drilling and production platforms in operation2023/5/203OperationFirst well was drilled in 1966Currently 9 operators and 18 partner licensee companiesStatoil is the national oil company and is involved in every production operation2023/5/204ChallengesHigh production c

4、osts due to harsh offshore environmentHigh exploration costsHigh investmentHigh safety/environment requirements High operation/logistics costsHigh labor costTurbulent oil priceSerious competition2023/5/205Growing Demands for MaintenanceIn compliance with statutory laws,regulations,and requirementsHi

5、gh equipment reliability:health,safety,and environment High equipment availability-productivityHigh product qualityReduction of maintenance costs2023/5/206Maintenance Technology DevelopmentChange of maintenance strategyRisk Based MaintenanceSystemization of maintenance programsContinuous improvement

6、 of maintenance programs2023/5/207195019501960196019701970198019801990199020002000BreakdownFixed Interval PMRCMCBMTPMDevelopment of Maintenance StrategyRBM2023/5/208Risk Based MaintenanceConcept:Maintenance strategy and effort depend on equipment/component risksWhy?Risk AssessmentRisk=Consequence*Pr

7、obabilityConsequences:Health and safetyEnvironmentDeferred production/serviceMaterial damages2023/5/209An Important Concept-Maintenance Related CostsDirect costs:Routine services(CBS)Predictive&Preventive tasks(CPM)Corrective tasks(CCM)Indirect costs:ManagementAdministrationSupportsFailure consequen

8、ce costs(CRISKEX):Health,Environment,and Safety(HES)Production/servicesMaterials damageDamage to reputation2023/5/2010Relationship between Maintenance Costs1000%Level of Preventive MaintenanceBasic service like lube,cleaning,etc.CRISKEXCost$CMINCCMCPMCBS-Cost of basic services;CPM-Cost of preventive

9、 maintenance;CCM-Cost of corrective maintenance;CRISKEX-Costs/losses due to unplanned events;CTOT=CBS+CPM+CCM+CRISKEX;CMIN-Minimal CTOTCTOTCBS2023/5/2011Risk-Maintenance Strategy2023/5/2012Risk DistributionMSI-Maintenance Significant Items2023/5/2013Risk Based Inspection-RBIEquipment Types:StaticPip

10、ingVesselsStructuresNDT(Non-Destructive Testing)inspection(MPI)Magnetic Particle Inspection Ultrasonic testingRadiographyEddy current testingAchievementsOptimal inspection methodsOptimal inspection intervalsIncreased reliability and availabilityReduced inspection costs2023/5/2014Risk Based Test-RBTE

11、quipment Types:Protective InstrumentsAlarms TripsHidden failure:Failure on demandsMaintenance methodsFunctional TestsAchievementsOptimal Test intervalsIncreased reliability and availabilityReduced test costs2023/5/2015Risk Based Maintenance-RBMEquipment Types:Rotating equipment Process instrumentsEl

12、ectrical motors,power generation,.Evident(detectable)failures:High vibrationWorn outLeakage.Analysis methods:RCM(Reliability centered Maintenance)Risk analysisCost-benefit analysisAchievementsPotential risk and ranking-maintenance significant levelsPerformance of present maintenance programsOptimize

13、d maintenance program2023/5/2016Maintenance ProcessMaintenanceobjective2023/5/2017Systemizing Maintenance ProgramStandardization of maintenance programs-Maintenance Concepts(see next page)OutputMaintenance programsRequired resourcesBenefits75%reduction of maintenance planning time25%reduction of mai

14、ntenance effortsA systematic,well documented,and auditable process2023/5/2018Requirement Analysis RequirementsContractual regulationStatutory regulation:Acts or lawsConsensus regulation:with provisions like“in accordance with recognized standards of good production practice”Link to:Plant/System/equi

15、pmentOperationCrane liftingUsing high temperature like welding,fire,2023/5/2019Continuous ImprovementReporting and recording maintenance historyFailure findingsMaintenance works Analysis of history dataFailures,reasons,and costsPerformance of present maintenance programsUpdate/improvement of mainten

16、ance programsBenefitsA systematic,well documented,and auditable processOptimized maintenance costsIncreased reliability,availability and product quality2023/5/2020Results of Risk AssessmentDrive systemWire ropesMotorsFestoon systemTrolley systemShieveAnti sway systemGearImproved ProgramExisting Prog

17、ramWithout Maintenance$0$10 000$20 000$30 000$40 000$50 000$60 0002023/5/2021Cost-Benefit Ratio10,157,474,231,662,951,110,950,03Drive system Wire ropesMotorsFestoonsystemTrolleysystemShieveAnti swaysystemGear2023/5/2022Concluding RemarksGrowing demands for maintenanceIn compliance with statutory req

18、uirementsHigh reliabilityHigh availability-productivityReduction of maintenance costSolutions:Risk Based MaintenanceSystemizing maintenance programsContinuous improvement of maintenance programs 2023/5/20239、静夜四无邻，荒居旧业贫。5月-235月-23Saturday,May 20,202310、雨中黄叶树，灯下白头人。20:19:1020:19:1020:195/20/2023 8:19

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