Case study: Maintenance burden and costs reduced using RTAMO™

PetroSA case study header

Client: DUE TO COMMERCIAL INTERESTS THE CLIENT HAS REQUESTED TO REMAIN ANONYMOUS
Location: North Sea
Asset type: Low voltage motors

Client Background
An integrated global energy company who have interests in 49 fields.

Business challenge for the customer 
To ensure cost efficiency in the current economic climate, our client was scrutinising aspects of their maintenance regime to ensure that effort is optimised on equipment that does not have an immediate production or safety benefit. 

This also including consideration of reducing preventative maintenance on items with low failure rates or those which can run-to-failure (RTF) with minimal adverse consequences.

It was recognised that the OPEX was too high and the persons on board (POB) capacity insufficient to liquidate current maintenance burdens.

How Lloyd’s Register helped 
We applied RTAMO™, our software enabled maintenance optimisation solution, to deliver a study that would provide the client with optimised maintenance frequencies on their Low Voltage (LV) Motor population. The ultimate aim was the reduction in maintenance burden which would allow for a reduction in OPEX costs.

The study, which took three weeks, included 970 items. The analysis was broken down in to distinct areas to allow for new frequencies to be assigned to planned maintenance (PM) on LV Motors:

1. Interrogation of the data to determine failure rates for each of the facilities
2. Subject the data to RTAMO cost analysis
3. Assign the PMs an agreed severity
4. Optimise maintenance activities

The fully auditable study will allow for formal update of the necessary client strategies/ documents pertinent to LV Motors as well as the update of their work management system (WMS).

Analysis outcome

  • 93 Planned Maintenance Routines (PMR) recommended for their frequency to increase
  • 9 PMRs have no change
  • 761 PMRs recommended for their frequency to decrease
RTAMO case study image 1
 

Results

  • With the implementation of the analysis and agreed commercial and time assumption, an estimated financial saving of 65% can be made on annual maintenance on LV Motors (determined by the previous maintenance outlay versus the proposed strategy).
  • An estimated reduction of 7127 annualised man hours can be achieved.
  • Recommendations were made in relation to greasing regime importance and for the strategy to be applied consistently to the population of LV Motors 
  • If the optimisation study had not occurred there would be a continued miss-use of time and therefore cost in doing maintenance activities where it is not required.
RTAMO case study image 2
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 

Benefits 

  • Unnecessary planned maintenance tasks eliminated
  • Maintenance intervals extended where justifiable
  • Reduced maintenance burden 
  • Reduced OPEX costs
  • Improved production critical reliability and availability

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