Case studies

Completed an RCM study for the plant equipment. These maintenance plans resulted in an efficient condition-based maintenance program.

• The negotiated annual maintenance expenditure (contract) was reduced to US 400M$ compared to an initial contractor proposal of 2,400M$, as a result of the level of work definition.
• Resultant maintenance costs are $0.004/mcf compared to $0.04 to $0.05/mcf for other company facilities. A full 90% less. 

• This work definition also allowed a major reduction in “typical” maintenance staffing plans

• Maintained leadership endorsement of continuous improvement process
• Established PM job plans with application of RCM
• Eliminated recurring failures with RCFA
• Effective use of CMMS for planning and scheduling

• Increased compressor reliability from 95.5 to 98+%
• Increased production 2-4 MMSCFD through better compressor reliability

Notable portions of a R&M strategy were implemented, including RCM, condition-based maintenance, RCFA, and a maintenance alliance with a local supplier focused on reliability management and cost efficiency. A follow up maintenance assessment in 2001 confirmed significant improvement.

• Facility Efficiency over 98.5%
• Maintenance Cost Reduction of 50%
• Reliability Analysis (RCM) to: a) reduce maintenance work b) replace instrument calibrations with function tests and c) minimize maintenance work on non-critical equipment

Implementation of an ‘industry leading’ Reliability & Maintenance Strategy which included measurement, analysis and evaluation of the efficiency and effectiveness.

• Improvements in 6 of 8 Maintenance Assessment Areas
• Performance over 1 year after strategy implementation
• Operations Efficiency = 99.95%
• Production Critical Equipment Reliability = 99.48%
• Production Critical Equipment Availability = 99.45%
• SCE work orders overdue = 0
• Planned vs. Unplanned Work = 98.2%
• Overdue PMs = 2.2%
• Facility Availability above 98.8% for six continuous years