Highlighting Advisian's experience across the industry

1. advisian.com
Predictive Maintenance in the Petrochem Industry
Introduction to Reliability Engineering and True Predictive Maintenance

2. Case Studies from our
experience across the industry

3. Structured instrument criticality reclassification led to an
88% reduction in maintenance manhours required
Advisian 3
The challenge
• Instrument planned maintenance costs were too high
• ISO 9000 accreditation had made the planned maintenance program very expensive
• Any changes would need to satisfy the UK offshore regulators prior to any
implementation
What we did
• A thorough examination of the instrumentation with a view to their:
— Criticality
— Dominant failure modes
— Target availability
• Developed a completely new program with the asset team
• Managed the process with the HSE offshore safety branch to ensure regulatory
compliance and acceptance
• Implemented the changes offshore
Benefits
• Reduced the instrumentation planned maintenance
program from 15,000 man-hours a year to just
1,800 man-hours a year
• Reduction in POB
• A marked reduction in the number of spurious trips
Element 1: asset register criticality ranking

4. Most maintenance programs are built from OEM
manuals – now they too are discovering their flaws
Advisian 4
The challenge
• Their business model for industrial turbine packages has been redefined by the move
to long-term service agreements (LTSAs) where they now pay for the cost of
maintenance.
What we did
• The client asked Advisian to assist in reviewing and redefining the work programs to
ensure that each task was sensible, defensible and occurred at the appropriate interval.
• The analysis also examined possibilities to make design changes to facilitate better
maintenance.
• In all, the engagement delivered a valuable reduction in the maintenance programme,
coupled with a new approach to control and protection philosophy, allowing the client
to de-tune overly sensitive instrumentation to provide the enduser with alarms as
opposed to trips.
Element 2: Equipment maintenance strategies
Benefits
• 56% reduction in maintenance labour costs for
8,000 running hour interventions
• Availability improvements of at least 1.5 days per
year per gas turbine from planned maintenance
alone
• A reduction in control and instrumentation engineer
resource requirement of around 60%

5. Sometimes a “compliance culture” hides true
levels of risk
Advisian 5
The challenge
• Following the Buncefield disaster, operators rushed to implement large PM
programs
• Our client felt their system was clogged up by tasks of little or no value
• An RCM revealed the opportunity to remove 88% of tasks on part of the site
• Six months after the RCM nothing had changed
What we did
• Revealed to the client how the link between work orders issued, planning,
executing and reporting had broken down
• Built a new process for planning, reporting and measuring achievement
• Implemented the new system at the largest of their seven sites
Benefits
• Plan attainment grew from less than 30% to more than 70% within six weeks
• Corporate risk profile lowered due to the audit trail now existing between jobs
issued and jobs done
Element 3: Work management

6. Shutdown programmes have often grown from a
historical perspective with little scrutiny or challenge
Advisian 6
The challenge
• This client operates a vast onshore oilfield via a network of gathering centers
• Each gathering centre had a planned shutdown programme that sacrificed 44
days of production in every four year cycle
What we did
• We led an RCM review of the equipment which was the rate determining step
behind each shutdown intervention
• We examined how some simple design changes would have an impact on
shutdown duration
• Revealed that the initial program emerged from equipment manuals written in
the 1960s and that subsequent technological improvements had not been
taken
into account
• Built a program to change the shutdown content planning
Benefits
• 44 days per four years reduced to just 10 days
per four years – an improvement of 77%
• Planned flaring reduced by 65%
• Project awarded Chairman’s Prize for HSE
Element 4: Shutdown management

7. Reliability problems are rarely just maintenance
problems and require a multi-disciplinary approach
Advisian 7
The Challenge
• This client had a 3 x 50% fleet of gas export booster compressors whose reliability
was unacceptably low.
• The machines were “identical,” yet their performance appeared markedly different.
• Previous attempts to improve performance had not worked.
What we did
• We led an RCM review with a user group drawn from operations, maintenance and
process engineering functions.
• Conducted a detailed analysis of the production, maintenance and condition
monitoring data coupled with interviews in the field.
• Revealed commissioning errors, start-up procedure problems, inappropriate
maintenance and incorrect system knowledge.
• Built a programme to tackle performance.
Element 5: Reliability improvement process
Benefits
• Trips reduced by 75%
• Unscheduled downtime eliminated
• Fleet availability now exceeding delivery
target
• Awarded “Project of the year” by gas director

8. For more information
Advisian 8
Alex Buehler
Director of Operations, USA
E: alex.buehler@advisian.com
P: + 1 770 235 1744
Tony Geraghty
SVP, Reliability Engineering, EMEA
E: anthony.geraghty@advisian.com
P: + 44 (0) 771 734 6660