Offshore AIM Solution Reduces FPSO Maintenance Backlog by 40%
Learn how an optimized integrity management plan improved critical maintenance activities for an offshore operating company.
Due to the demanding offshore environment and the complexity and volume of equipment onboard its FPSO fleet, an operating company frequently battled overloaded maintenance backlogs. The client needed to confirm that the equipment onboard the FPSOs operated at the highest levels of efficiency while downtime was minimized and the operations were completed in a safe, compliant and responsible manner.
ABS Group developed and implemented a holistic approach to asset integrity management (AIM), integrating the FPSO systems with processes and best practices to provide maximum asset reliability at the most cost efficient and effective levels.
- Downtime and loss of operational efficiency
- Maintaining high safety and compliance standards
- Prioritization of critical vs. non-critical work orders
Identify and assess criticality of all equipment onboard the FPSO
Review the client's existing maintenance program and identify opportunities for increased efficiency
Develop and implement an overarching AIM program specific to the client's equipment, operating needs and applications
Evaluate the computerized maintenance management system (CMMS) and prepare client for a future CMMS upgrade
Improve ongoing maintenance efficiency and reduce work order backlog
Conduct Equipment Audit and Ranking
To gain a detailed understanding of the mechanical components onboard the client's FPSO, we assisted the owners in identifying each piece of equipment and developing a Master Asset List. After carefully evaluating each system and subsystem, we developed a comprehensive Asset Criticality Ranking (ACR) to identify specific maintenance approaches for each asset based on operational and safety criteria.
Identify Maintenance Approach and Management Process
Using a Risk Based Inspection (RBI) approach, we defined the extent and frequency of maintenance needed for each piece of equipment. The specific needs, usage metrics and exposure of each asset drove these recommendations. We blended this RBI approach with a preventative maintenance program to form a complete mechanical integrity plan.
Additionally, we conducted a review and cleanup of the client's computerized maintenance management system (CMMS) data. To manage ongoing scheduling and maintenance frequency, we input new maintenance schemes and updated process flows in the CMMS.
As an extension of our reliability engineering program, we provide reliability analytics for the client and conduct structured root cause failure analysis in case of a critical event.
By identifying the specific maintenance needs of the equipment and eliminating unnecessary or overscheduled maintenance, we created a 40% reduction in the work order backlog. This helps maintenance personnel to prioritize and complete critical maintenance projects more quickly, without interference from standard scheduled maintenance tasks.
Additionally, our engineering team reviewed and made improvements to more than 20% of the client's critical system maintenance plans. These improvements promote the strategic allocation of time and resources towards key pieces of equipment and minimize unnecessary maintenance on less critical or lower value assets.
As a result of our efficient condition-based and predictive approach, future maintenance will incorporate less intrusive inspection techniques, avoiding destructive activity or excessive downtime.