Stephen Renshaw - Assetivity - Developing preventive maintenance programs for new compressor stations – A CSG case study

PO Box 10856 BRISBANE QLD 4000

Ph: +61 7 3606 1603 Email: [email protected]

Web: www.assetivity.com.au

Introduction

This presentation is based on the Preventative Maintenance Program development for Gas Compressor Hub Stations for a major CSG development

Focus on Maintenance Strategy Development

Process Safety/Integrity/Critical Function development by parallel group

Used a database software solution for data analysis, storage, and reporting.

Used both existing in-house and customised processes for developing the maintenance strategy and identifying spares requirements.

Overview

Takeaways:

Understand the need to focus on critical assets when developing a preventative maintenance program for a gas compression station.

Understand the factors to consider in developing the right approach to maintenance strategy development.

Treat the development of the maintenance program as a Project.

Overview of a Gas Compression Hub

Gas SeparatorsNodal

CompressionHub

CompressionDehydration Metering

Water StorageWater

Treatment

Flare

Plant and Instrument Air

Nitrogen Generation

Emergency Power

Main Power Generation

Electrical Reticulation and

Sub-Staions

Civil Infrastructure- Buildings

- Roads- Lighting

-Fencing and Security

Gas Wells

Fire protection

Accommodation Camps

Potable Water Plant

Environmental Systems- Brine storage

- Oily Water- Vegetation

Management

Product

Scale of the project

Development of the strategy for a CSG Hub Station

>10000 Systems/Assets (Hierarchy Lines)

>20000 Maintenance Task lines

>600 Work Instructions

Around 4500 Assets and 6000 maintenance lines are directly attached to the Gas Compressors.

In summary, in a large CSG compression station only 45% of assets will be related to the actual gas compressors.

Where is the Maintenance Cost?

Up to 88% of your maintenance cost are related to compression equipment.

What will Drive Reliability?

Where the maintenance cost is?

Or

Where the critical assets are?

Critical assets that will drive the reliability of the plant.

Documentation Management – A significant issue

Asset information

P&IDs

Data Sheets

OEM Data

Maintenance Strategy Information

Maintenance Service Agreements/OEM Manuals

Strategy Analysis (FMEA /RCM/PMO sheets)

Australian and Company Standards and Procedures

Maintenance Plans and procedures

Work instructions

Critical Function Tests

Need processes to obtain this from your EPC during the construction phase.

Developing the Maintenance Plan

Maintenance Plan

Budget

Reliability

OEM/Service Agreement

Requirements

Resources

Regulatory and

Compliance

Process Safety

Stra

tegi

c G

oal

sEx

tern

al D

rive

rs

Maintenance Plan Development and Execution

Computerised Maintenance Management SystemDevelop Asset List

and Hierarchy

Regulatory Compliance

An

alysis Pro

cess

Maintenance Tasks

Critical & Insurance

Spares

PM, CM & Overhaul Spares

Contractual Obligations

OEM Recomendations

Existing Plans(Other Sites)

Protective Functions

Failure Modes Analysis

Criticality Ranking

Maintenance Plans

(Grouped Tasks)

Work Planning and Scheduling

Inventory

Job Pack- Work Order

- Work Instruction- Parts

Why The Analysis Process is Important

Obtaining the Right Outcome

My Focus

Which Approach Should You Use?

Gut Feel When you are feeling gutsy

Use Manufacturer’s Recommendations When you need something really quickly, or when warranty depends on

it Cut and Paste PMs from “identical” equipment

When you need something quickly, and accuracy is less important Using “template” tactics from other, similar equipment

When you need something quickly, and accuracy is less important Statistical Techniques/Weibull Analysis

When you have large quantities of reliable data Reliability Centred Maintenance

For new equipment, when few other options are possible PM Optimisation/Reverse RCM

For existing equipment, where accuracy is important Full zero based RCM

Incr

easi

ng

up

fro

nt

cost

Incr

easi

ng

risk

Strategy Development Spreadsheet vs. Database Solutions

Spreadsheets Database

Advantages: - Minimal training required - Common software - Ability to customise inputs, process and

reports

Advantages: - Single source of truth - Multiple users in one database - Revision control - Strict input rules - Rapid rollout to similar plant

Disadvantages: - Difficult to manage and control - Subject to errors and information loss - Lack of revision and version control - Require discipline in naming and filing.

Disadvantages: - Expense - Higher training requirements - Proprietary database, difficult to

customise - Difficult to create custom reports.

Better for smaller jobs with few systems and assets

Better for larger jobs involving multiple people and large numbers of systems and assets.

Creating Task Lists and Work Instructions – Another Significant Effort

Task Database

Task Grouping and Sequencing

Task List

Task List

Task List

Task List

Work Instruction

Work Instruction

20000 Task Lines

>500 Task Lists

A number of detailed

Work Instructions

Developing the Implementation Plan

Scope

Planning

Definition

Verification

Change Control

Time

Schedule

Cost

Resources

Materials

Follow robust project management principles managing:

Quality

Planning

Assurance

Control

Human Resources

Internal / External

Communication

Risk Management

Procurement Management

Ref: Project Management Institute, A Guide to The Project Management Body of Knowledge

Interface to With Other Stakeholders

Maintenance plan development cannot occur in isolation. Planning needs to involve other key stakeholders

EPC Consultants and Contractors

Operations and Development

Maintenance

Process Safety

Process Integrity

Risk Management

Contractual Services

Suppliers

Case Study Points

Project delivery schedule

Don’t get to optimistic about availability of data.

Identify EPC contract deliverables early.

Commissioning deadline

The ready for service date may be different to the commissioning date, maintenance may be required prior to commissioning depending on contract.

Some maintenance may not be required until long after commissioning – Can plan development be deferred?

Resources

Do you have the internal skills and resource availability?

Are the skills required for a short or long term?

Reporting – The Asset Management Plan

Results of the analysis must be consolidated at the end:

What is the expected reliability?

What is the budgeted maintenance cost?

What labour resources (internal and contract) are required?

What inventory is required?

What other actions are required?

The final report provides a reference point from which:

Performance of the preventative maintenance program can be monitored.

Ongoing improvement activities can be developed.

Communicates key information to key stakeholders.

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In Conclusion…

Need to focus on critical assets

In Gas compression hubs the compressors will be 90% of the maintenance costs, but represent 80% of assets

Reliability is determined by the critical assets, no matter how small.

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In Conclusion…

Designing your maintenance plan development process:

Must be tailored to your business needs and nature of your assets.

Must focus on identifying the correct tasks that will efficiently deliver your business needs.

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In Conclusion…

Managing the project

Ensure that someone is specifically responsible for delivering the PM program as a project

Must be based on sound project management principles.

Develop an Asset Management Plan on completion as a reference point to monitor performance of the Preventative Maintenance program.

23

Thank you. Any Questions?

For more information, please contact me. Steve Renshaw Senior Consultant Assetivity Pty Ltd PO Box 10856 Brisbane Qld 4000 AUSTRALIA [email protected] http://www.assetivity.com.au Phone: +61 7 3606 1603 Mobile: +61 438 345 054

Copyright Assetivity Pty Ltd 2014