Casos prĂĄcticos

Equipment Performance Monitoring Empowers Operational Reliability

Industria

PetrĂłleo y gas

Soluciones

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VisiĂłn general

In the dynamic landscape of industrial operations, ensuring equipment reliability is fundamental to sustaining productivity and profitability.

However, achieving and maintaining reliability can pose significant challenges due to the complexities of processes and the inherent risk of equipment failures.

In 2023, recognizing these operational challenges, our Maintenance and Reliability Solutions engineers, embedded within the client’s operational team, began implementing equipment performance monitoring techniques to proactively enhance reliability. This proactive approach aimed not only to mitigate operational risks but also enhance equipment performance across their client’s UK offshore facilities.

DesafĂ­o

The monitoring techniques were required to mitigate client concerns related to:

Unplanned Downtime

Frequent equipment failures and breakdowns resulting in revenue losses and operational inefficiencies.

Inconsistent Equipment Performance

Suboptimal operating points for rotating and static equipment affecting overall plant performance.

Limited Visibility

The absence of real-time insights into equipment health and performance hindering timely decision-making and optimal preventive maintenance intervention efforts.

Nuestra soluciĂłn

The team identified the production-critical equipment process values that required analysis to give valuable, forward-looking insights. The resulting analysis provided visibility of opportunities to enhance equipment performance and allowed identification of suitable corrective actions for emerging issues.

In addition to existing conventional condition monitoring (such as bearing temperature and vibration levels) our reliability engineers trended already available process values against manufacturer/system performance parameters, to understand equipment operating points and infer equipment condition. Analysis not only looked at the ‘steady-state’ process values, but also short-duration, transient occurrences that may indicate equipment or control system performance issues. The plant data history provides data in relation to:

  • Flow rate
  • Pressure/differential pressure
  • Temperature/differential temperature
  • Level
  • RPM
  • Current
  • Voltage
  • Power

These values were used to monitor the production-critical equipment for a range of failure types across the varied equipment population, some of which would be unnoticed by the control room operator. Example types of failure include:

  • Mechanical wear/erosion
  • Blockage
  • Leakage
  • Cavitation
  • Flow constriction
  • Reduced heat transfer
  • Position deviation
  • Actuation time deviation
  • Deviation from performance curves
  • Calibration drift
Our Results

The implementation of equipment performance monitoring by the Oceaneering team has yielded significant improvements by better understanding plant operation, empowering the client with the data needed to positively influence production availability.

Performance Assurance

Provide confidence that plant is operating optimally, without hidden problems.

Cost Savings

The transition from reactive to proactive maintenance strategies generates significant cost benefits by increasing availability whilst reducing projected OPEX over a facility’s lifespan.

Enhanced Performance

Proactive monitoring enables the operator to fine-tune equipment set points, resulting in improved efficiency, reduced energy consumption, and enhanced product quality.

Downtime Reduction

Early identification and resolution of potential issues minimizes unplanned downtime and mitigates associated revenue losses.

Ya sea a travĂ©s de un proyecto Ășnico o integrados en un equipo de operaciones, los servicios de fiabilidad operativa de Oceaneering pueden adaptarse para satisfacer las necesidades de la organizaciĂłn, ofreciendo soluciones innovadoras para mejorar la eficiencia operativa y la fiabilidad en una amplia gama de tipos de plantas.

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