Contents:
1. Introduction
2. Description Of Plant Operation
3. Description of existing maintenance plan
4. List of 22 items which need maintenance
5. Detailed Step by step maintenance plan
6. Critical path analysis (CPA)
7. Health and safety considerations
8. List the criteria re
Introduction
I am the maintenance supervisor for a mechanical engineering service company called ‘Oil & Gas Europe’. I am responsible for the the organisation of all maintenance within the company’s business.
Currently all maintenance, service orders and reports have been recorded by a paper based maintenance system.
Our company has grown considerably over the last couple of years. The manager has approved that a Computer Maintenance Management System (CMMS) should be purchased and implemented throughout the company for all the maintenance operations.
I have been set the task of assessing different software packages and to recommend the one most suited for the company’s needs.
Description of Plant Operation
My company ‘Oil & Gas Europe’ is a subsea service company that focuses on providing drilling companies with in riser safety systems. These systems allow well operations to be conducted safely during drill stem testing (DST). They provide the ability to rapidly shut in the well and disconnect should conditions require it. ‘Oil & Gas Europe’ also provide EH landing strings. Electro-hydraulic control improves response times, enables ‘Real Time’ data feedback, reduces the physical umbilical size on deep water applications and addresses the disconnect philosophy from dynamically positioned mobile drilling units.
Description of existing maintenance:
Currently ‘Oil & Gas Europe’ use a paper based maintenance system. Over the last couple of years ‘Oil & Gas Europe’ have grown rapidly meaning a paper based system is no longer suitable. This is inconvenient for the company because it makes documents hard to find and means documents can be easily damaged it also uses up a lot of storage area. We are looking into purchasing a CMMS because it will allow ease of traceability regarding maintenance within the company, reduce storage and also increase health and safety by removing a possible fire hazard of paper based documents.
Items to be maintained:
To test the CMMS programmes I have decided to create a maintenance programme for one of our electrical hydraulic control systems: Riser control module (RCM).
Below is a list of 22 items that need to be maintained within the RCM.
1. Mandrel
2. Crossover
3. Quick Connect Crossover
4. DCV
5. SOV
6. SEM Canister
7. Lower Mounting Sleeve
8. Upper Mounting Sleeve
9. Outer Cover (Lower)
10. Outer Cover (Upper)
11. Top Flange
12. Middle Flange
13. Lower Flange
14. PTTX Canister
15. Flow Meter
16. Flow Meter Canister
17. Bore Transducer
18. Shear Shuttle Assembly
19. Check Valve
20. DCV Manifold
21. SOV Manifold
22. Split Ring
Maintenance Plan:
Below is a step by step maintenance plan for Riser Control Module.
Riser Control Module Maintenance Plan
No
Description
Asset No
Service Frequency
Additional Info
1
Mandrel
HB001
Every 5 Years
LPI & Strip/Recoat
2
Crossover
HB002
Every 5 Years
MPI & Strip/Recoat
3
Quick Connect Crossover
HB003
Every 5 Years
MPI & Strip/Recoat
4
DCV
HB004
Yearly
Verification Test Required
5
SOV
HB005
Yearly
Verification Test Required
6
SEM Canister
HB006
Yearly
3rd Party to carry out Maintenance
7
Lower Mounting Sleeve
HB007
Every 5 Years
Visual Inspection, Strip/Recoat
8
Upper Mounting Sleeve
HB008
Every 5 Years
Visual Inspection, Strip/Recoat
9
Outer Cover (Lower)
HB009
Every 5 Years
Visual Inspection, Strip/Recoat
10
Outer Cover (Upper)
HB010
Every 5 Years
Visual Inspection, Strip/Recoat
11
Top Flange
HB011
Every 5 Years
MPI & Strip/Recoat
12
Middle Flange
HB012
Every 5 Years
MPI & Strip/Recoat
13
Lower Flange
HB013
Every 5 Years
MPI & Strip/Recoat
14
PTTX Canister
HB014
Yearly
Verification Test Required/Seals replaced
15
Flow Meter
HB015
Yearly
Verification Test Required
16
Flow Meter Canister
HB016
Yearly
Verification Test Required
17
Bore Transducer
HB017
Yearly
Strip Assembly, Rebuild, Verification Test
18
Shear Shuttle Assembly
HB018
Yearly
Strip Assemby, replace shear stem
19
Check Valve
HB019
Yearly
Replace Component
20
DCV Manifold
HB020
Yearly
Verification Test Required
21
SOV Manifold
HB021
Yearly
Verification Test Required
22
Split Ring
HB022
Every 5 Years
Replace Component
Critical Path Analysis:
Critical Path Analysis is a project management technique used to lay out all activities needed to complete a task, the time it will take to complete activity and the link or relationship between activities. This method can help predict whether a project can be completed on time. CPA can be used to reorganise the project before it has started, but also allows reorganisation during the project as it progresses. CPA allows projects completion to be kept on track and ensures deliverables are ready on time.
CPA can be done manually or using computer software. The project manager makes a list of activities in the order they must be completed with time expectations, they then proceed to create diagrams of the process.
Health & Safety Considerations:
There are a few health and safety considerations relevant to our assets we must take into account when carrying out maintenance on components. It is also important to follow ‘Oil & Gas Europe’s’ maintenance document for the RCM which gives assembly/disassembly procedure details and any additional safety information/warnings.
Lifting Operations and Lifting Equipment Regulations (LOLER) must be considered during maintenance operations as many components are a considerable weight. LOLER includes duties of people and companies who own or have control over lifting equipment. This includes every business and organisations whose employees use lifting equipment, whether owned by them or not. In most cases lifting equipment is also work equipment so the Provision and Use of Work Equipment Regulations (PUWER) will also apply.
Personal Protective Equipment Regulations (PPE) will also have to be considered when carrying out maintenance on RCM. PPE covers personal safety equipment such as high visibility fire retardant coveralls, safety boots, safety goggles and safety helmets.
Control of Substances Hazardous to Health (COSHH) Regulations covers all substances that can be hazardous to health. In our RCM we have a sealed chamber filled Hydraulic Fluid and another sealed chamber filled with dielectric fluid these fluids would both fall under COSHH.
CWORKS
Express Maintenance