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Customized assistance for the management of the entire maintenance process

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  1. Maintenance Management System for Customer Support Customized assistance for the management of the entire maintenance process AN 9/04/2011

  2. Contents • Executive Summary • Our Mission Statement • Main Objective • Main Services & Solutions offered • Typical Project Organization • Main Competences • Applicable International Standards • Competitive Advantages • Engineering Tools • Details of Inspection and NDT tools • Final Considerations AN 9/04/2011

  3. Executive Summary • Why maintenance is to be considered strictly related to production? • In the production systems, besides their maintenance costs, it is priority to consider the cost of deferred production due to the maintenance activities; • It is easily understood, that to predispose strategies to reduce the losses of production of the productive systems means to optimize the production process itself; • The main objective is to find the right balance between maintenance activities and lower production losses; • For this purpose “Design to cost” procedures shall be closely linked with RAM analysis. AN 9/04/2011

  4. Executive Summary • Actual systems scheduled maintenance state-of-the-art • The production systems are normally shut down for planned inspections, during which are foreseen technical controls in accordance with legislative and regulatory bodies’ requirements related to: • Internal inspection of all pressure vessels; • Metrology regulatory procedures; • Instrumentation, Fire & Gas certification; • SIL test interval; • Manufacturer constraints (i.e. to comply with possible warranties); • Etc ... AN 9/04/2011

  5. Executive Summary • Conclusion and what actions to be taken ? • It is necessary reverse the trend by increasing the capacity of a plant to operate for a long period without major scheduled maintenance actions; • Drastically reduce these maintenance operations means limiting the downtime of system, say “institutional”; • Decrease the system down time (unavailability) means to reduce production losses and indirectly to optimize the production; • Accordingly in oil & gas industries, it is a feature of Life Cycle Cost (LCC) analysis to take the cost of deferred production into consideration as an important cost category. AN 9/04/2011

  6. Our Mission • General Statements • To work in close partnership with customers to tailorise after-sale support and to ensure that maintenance assistance is to the purpose: ‘to increase the availability of system while lowering the maintenance costs’; • To customize the maintenance service, studying the most effective after-sale support for a long product life-cycle means maximisation of customers revenues; • To put the customer in the position to manage and control the maintenance activities; • The key word is: • Maintenance Engineering: • Its integration into the project with the scope of coordinating the activities and resources to optimize the maintenance support system. AN 9/04/2011

  7. Our Mission • What We Promise to the Customer AN 9/04/2011

  8. Our Mission • How do we get the promises • During project execution, we report to the Customer the production efficiency, expressed as a percentage of the predicted production vs design capacity by means of avaliability analysis; • The availability analysis allows assessing the annual downtime of the plant in terms of loss of production due to both corrective and preventive maintenance actions, according to the failure frequency of components, maintenance data and policies; • For a plant recently examinated a production efficiency is estimated to be 80.1%; • The 80.1% represents the average of this graph over time. AN 9/04/2011

  9. Our Mission • Customer Gain • In light of our long experience in the O&M field, the increasing the availabilty is possible through reducing the plant down time due to scheduled shutdowns, by means a qualified maintenance support organization to perform the following activities: • Reliable day-to-day operations and routine maintenance; • Reducing cost of equipment service and repair; • Utilization of local and remote monitoring and diagnostics; • Site training, documentation and procedure development; • Certified engineering and technical support; • Reducing cost of Inventory management. • A further down time reducing can be achieved by providing spare for critical items (for example: flare K.O. drums both onshore and offshore); • To study and to implement design modifications and improvements. In conclusion, the Customer can have a “powerful” support tool consists of human resources, methodologies and technologies to increase BOPD AN 9/04/2011

  10. Main Objectives • Our goal is to collaborate with customers to optimize maintenance costs in terms of efficiency and operational availability of systems. The scope of collaboration is tailored to the needs of the customer; • To facilitate the optimization of maintenance services, the supportability requirements are identified (spares, manual, skill of personnels, etc) during early stage of the design of the plant and equipment; • Services offered range from traditional maintenance and post-warranty service contracts to the full service maintenance support through which it is ensured the required level of operational availability & safety of plant. AN 9/04/2011

  11. Main Services & Solutions Offered • A full range of support solutions to customers from project engineering to fiel support; • Resources and department dedicated to after-sale support activities; • Introducing Reliability, Availability and Maintainability (RAM) concepts, during the design phase. Project Engineering Mechanical/Piping Electrical Instrument/Automation Maintenance Engineering RAMS Safety CMMS Field Support Pre/Commissioning Start Up Operation & Maintenance Manuals Training Maintenance Execution AN 9/04/2011

  12. O&M Typical Project Organization AN 9/04/2011

  13. Main Competences • Maintenance Engineering Activities • To provide decision support methodologies to assess the most critical areas of the plant in order to take action to reduce maintenance costs and keep checking the level of risk of accidents of the plant within certain safety limits. Acronyms: RCM (reliability centered maintenance) FMEA (failure mode effect analsysis) AN 9/04/2011

  14. Main Competences • Operations & Maintenance Activities • During O&M activities the CMMS provides a support to manage and control all activities related to maintenance of the plant to optimize the maintenance costs and to check the overall availability level of the plant. AN 9/04/2011

  15. Applicable International Standards • Moreover local laws and site regulations can be applied where needed, in accordance with customer specifications: • NUREG • ASME • ASTM • SAE • IEC • BS • API • …… AN 9/04/2011

  16. Main Competitive Advantages Integrated Approach • Our strength is to provide integrated services activities during the plant life cycle, from engineering to maintenance execution. AN 9/04/2011

  17. Other Competitive Advantages • Full range of Operation & Maintenance services: from engineering to field service, • Integration between specialized activities; • Flexible and modular services, according to project requirements and customer needs; • Turn-key services for large and complex O&M Engineering projects; • Competitive prices thanks to expertise and many previous experiences. AN 9/04/2011

  18. Engineering Tools • Commercial tools for RAM Engineering (BlockSim, Relex, Isograph, etc.) ; • Internally developed tools for supporting RCM projects; • Internally structured DBs related to O&M activities; • Web-based tools to collect equipment maintenance and failure history; • Implementation of tools for machine predictive maintenance programme (vibration analysis, thermographic analysis, acoustic and ultrasonic); • Customized CMMS implementation; • Commercial toos for Inspection & NDT monitoring. AN 9/04/2011

  19. Details of Inspection and NDT tools • Key features • Elettra Energia utilizes “Inspection Manager software” for NDT management and corrosion monitoring, to optimize the cost of inspection activities by means the following key features: • Active P&I :abiltiy to directly search P&ID and locate the exact position of any item with a direct connection to IM; • 3D Plant Representation: 3D Graphic capabilities; not a mandatory but an invaluable tool to obtain information and also for maintenance purposes; • Data Structure:respect for Real Data structure by following the logical hierarchy of the customer’s plant and making it available in the Inspection Manager browser; • Inspection Management:real position of Inspection points with the ability to check values and survey history using graphic tools; • DataBase Implementation:fast data loading and easy data retrieval, thanks to the 3D tools. AN 9/04/2011

  20. Inspection and NDT tools • Example of main features (process start-up) Equipment: piping and equipment P&I Data Base • All items shown in the plant P&I can be retrieved; • Data extracting tool (ALEF) divides items into categories (Vessels, Pipes, PSV, Instruments, etc…); • Items are loaded into the Inspection Data Base and linked biuniquely to P&I data; • All other item data (design data, certification, inspections, expiry dates…) can be entered by field operators (inspectors, maintenance personnel etc..) at a later stage. Data extracting tool Piping Item 1 Item 2 Item 3 Item 4 Item n Inspection Manager (IM) data acquisition is based on the process of data retrieval from the P&I: AN 9/04/2011

  21. Inspection and NDT tools • Example of main features (sketch and equipment editors) This tool has been developed to enable users to identify the position of inspection areas easily and precisely. The required position can be found simply by printing the 3D model showing the inspection point of interest. A 3D model is the fastest way to load equipment and pipe construction data. Inspection Manager offers tools to draw both sketches and equipment, providing a 3D model in a very short time. AN 9/04/2011

  22. Inspection and NDT tools • Example of main features (plant 3D rendering) This tool provides an immediate understanding of the plant as a whole as well as rapid access to technical information attached to each tag (material, dimensions, diameters, thickness, insulation, specifications etc.). AN 9/04/2011

  23. Inspection and NDT tools • Example of main features (inspection history) Data from inspections carried out over time can be entered for each item listed in the IM database (pipe, equipment, machine, PSV, instrument etc.). Each item’s inspection history and all related documentation are readily available. Various kinds of inspection activities are supported, such as: • - Ultrasound Thickness Gauge • - Weight loss corrosion coupon • - Ultrasound defect searching • - Visual inspections • - Customised inspections can be easily implemented Inspection data can be viewed quickly and easily. For example, it is possible to check the equipment or a sketch status directly from its 3D model.

  24. Final Considerations • Main objectives to be reached AN 9/04/2011

  25. O&M Department AN 9/04/2011