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www.theonltd.com
Brian Mercer
Sustaining Production
Operations During
Downturns
www.theonltd.com
Scope
• Context
• Asset Integrity Focus
• Early stages
• Through Life Improvements
• Current Activities
•...
www.theonltd.com
Context - UKCS
www.theonltd.com
• UKCS is in decline
• OPEX has grown by 50% since 2005
• Unit operating costs in £/bbl have risen 350%
•...
www.theonltd.com
• Focus on maintaining safe production
• Improved performance at lower cost
• CAPEX slashed but OPEX rema...
www.theonltd.com
• Essential for license to operate
• Not just inspection and corrosion management
• Covers all aspects of...
www.theonltd.com
Early Stages
• Asset integrity begins at the early project stages.
• Process safety addressed through eff...
www.theonltd.com
Through Life Improvements
• Real data to drive real improvements
• Set realistic targets and continually ...
www.theonltd.com
Current Activities
• Safety Critical Equipment categorisation and
consolidation
• Too easy to say equipme...
www.theonltd.com
Current Activities
• Preventative Maintenance Optimisation
• Using RCM techniques with real data
• Primar...
www.theonltd.com
Current Activities
• Development and implementation of Risk Based Ex
Maintenance
• Analyse maintenance re...
www.theonltd.com
• Strategic planning
• Proper use of condition monitoring systems
• Tie in with performance monitoring sy...
www.theonltd.com
Benefits
Benefits:
• Improved Safety and Asset Integrity
• Less people in harm’s way
• World class safety...
www.theonltd.com
Questions?
www.theonltd.com
Contact Us
Steve Rowbottom - Managing Director
steve.rowbottom@theonltd.com
Zulfiqar Hussain - Business D...
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Sustaining Production Operations During Downturns

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  1. 1. www.theonltd.com Brian Mercer Sustaining Production Operations During Downturns
  2. 2. www.theonltd.com Scope • Context • Asset Integrity Focus • Early stages • Through Life Improvements • Current Activities • Other Potentials • Benefits • Questions
  3. 3. www.theonltd.com Context - UKCS
  4. 4. www.theonltd.com • UKCS is in decline • OPEX has grown by 50% since 2005 • Unit operating costs in £/bbl have risen 350% • Prior to price slump: • Project deferrals • Rate / material reductions • Personnel reductions • Short-term initiatives • Price slump exacerbated problem and accelerated initiatives Context
  5. 5. www.theonltd.com • Focus on maintaining safe production • Improved performance at lower cost • CAPEX slashed but OPEX remains high • But the good times will return – won’t they? Context
  6. 6. www.theonltd.com • Essential for license to operate • Not just inspection and corrosion management • Covers all aspects of maintenance and reliability • Evolves over the life of an asset: • Starts in the design stage • Only stops when decommissioning completed • Opportunities to improve throughout lifecycle • It is not a cost – it is an investment • Get it right – reliability / safety increase – costs reduce. • Inefficiency = increased risk Asset Integrity Focus
  7. 7. www.theonltd.com Early Stages • Asset integrity begins at the early project stages. • Process safety addressed through effective design and safety studies – e.g. HAZID, HAZOP, LOPA etc • Reliability and maintainability can be designed in – not just an afterthought. • Often overlooked • Someone else’s concern • Leads to sub-optimal performance • Requires more human intervention – increased risk • Increases life cycle costs
  8. 8. www.theonltd.com Through Life Improvements • Real data to drive real improvements • Set realistic targets and continually monitor performance • Quick to identify hot spots / bad actors • Feeds reliability improvement plans • Drives maintenance optimisation • Improves safety • Optimise through risk based approaches
  9. 9. www.theonltd.com Current Activities • Safety Critical Equipment categorisation and consolidation • Too easy to say equipment is safety critical • Enables proper safety critical maintenance planning • Results have shown 65% reduction in Safety Critical Equipment count. • Will greatly enhance Safety Critical maintenance performance • Better compliance demonstration to regulatory authorities
  10. 10. www.theonltd.com Current Activities • Preventative Maintenance Optimisation • Using RCM techniques with real data • Primary focus on sustaining safety performance • Driving out waste and inefficiency • Reduced frequency for many planned maintenance routines • Revised maintenance strategies • Substantial cost reductions
  11. 11. www.theonltd.com Current Activities • Development and implementation of Risk Based Ex Maintenance • Analyse maintenance records to determine histories, including PM frequencies, gaps, bad actors, standard record keeping • Implement early opportunities for inspection reduction • Develop prioritised inspection requirements – highest risk • Grouping by zone / geography, equipment type and exposure risk. • Develop sampling strategies • Indicative 60%+ savings
  12. 12. www.theonltd.com • Strategic planning • Proper use of condition monitoring systems • Tie in with performance monitoring systems • Fit for purpose design and off-the-shelf procurement • Technology progress (and boldness) • Multi-skilling Other Potentials
  13. 13. www.theonltd.com Benefits Benefits: • Improved Safety and Asset Integrity • Less people in harm’s way • World class safety critical maintenance • Reduced risk of ignition of hydrocarbon releases. • Enhanced regulatory compliancy demonstration • Reduced vendor requirements • Improvements to offshore logistics and bed space • Cost savings • Reputation • Sustainable future
  14. 14. www.theonltd.com Questions?
  15. 15. www.theonltd.com Contact Us Steve Rowbottom - Managing Director steve.rowbottom@theonltd.com Zulfiqar Hussain - Business Director zulfiqar.hussain@theonltd.com Brian Mercer - Director, Project Management brian.mercer@theonltd.com Ian Wallis - Director, Safety, Risk & Reliability ian.wallis@theonltd.com Aberdeen Office: London Office: 30 Abercrombie Court Trinity Square Prospect Road 23 – 59 Staines Road Westhill Hounslow Aberdeenshire TW3 3HL AB32 6FE Tel +44 (0)1224 907444 Email: info@theonltd.com

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