Reciprocating Compressors form part of a Condensate Recovery Unit (CRU) in an oil production site. CRU downtime is a major contributor to flaring. The Compressor maintenance programme was based on the Manufacturer's Recommendations and entailed a regular "minor" planned shutdown for strip down and inspections. This resulted in flaring:
A major Gas Turbine Manufacturer's business model for industrial turbine packages has been changed by the move to Service Agreements. This means the OEM now pays for the cost of maintenance.
- It was possible to de-tune some overly sensitive instrumentation to provide the end-user with alarms as opposed to trips.
- Calibrations and loop test intervals on many instruments were able to be extended
- 56% reduction in maintenance labour costs for annual 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%
The client was facing government pressure to meet contractual obligations on gas supply for domestic use. RCM was used to develop a maintenance strategy for the critical items of process equipment to ensure obligations were met
By implementing these changes, the client was able to almost eliminate unscheduled compressor downtime (94% reduction)
A sintered carbon pump used to circulate aluminium at the bottom of the furnace used in an Aluminium Recycling plant. The pump was suffering from a low MTBF resulting in reduced output and high maintenance costs
All the major causes of failure were related to design, training, competence and procedures (ie none of the major solutions were cyclic maintenance recommendations). These included:
- Pumps damaged by operators during cleaning
- No assembly instructions for pumps
- No procedure for baking components (to eliminate moisture in the components) prior to assembly
- No oven temperature indicator
- No oven timer
- Brittle pump components damaged in transit
- Brittle pump components damaged in stores
Dealing with these issues resulted in Pump MTBF increasing by a factor of seven, with a similar reduction in corrective maintenance costs.