You are on page 1of 10

Applied Industrial Plant Maintenance

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 companys 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 companys 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
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18

Description
Mandrel
Crossover
Quick Connect Crossover
DCV
SOV
SEM Canister
Lower Mounting Sleeve
Upper Mounting Sleeve
Outer Cover (Lower)
Outer Cover (Upper)
Top Flange
Middle Flange
Lower Flange
PTTX Canister
Flow Meter
Flow Meter Canister
Bore Transducer
Shear Shuttle Assembly

Asset No
HB001
HB002
HB003
HB004
HB005
HB006
HB007
HB008
HB009
HB010
HB011
HB012
HB013
HB014
HB015
HB016
HB017
HB018

Service Frequency
Every 5 Years
Every 5 Years
Every 5 Years
Yearly
Yearly
Yearly
Every 5 Years
Every 5 Years
Every 5 Years
Every 5 Years
Every 5 Years
Every 5 Years
Every 5 Years
Yearly
Yearly
Yearly
Yearly
Yearly

19
20
21
22

Check Valve
DCV Manifold
SOV Manifold
Split Ring

HB019
HB020
HB021
HB022

Yearly
Yearly
Yearly
Every 5 Years

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 Europes 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.
Criteria Required

There are a few aspects to be considered when identifying a suitable CMMS


package for Oil & Gas Europe, these include the cost of the programmes, security
of the programmes, the ease of use and information input within the programme.
The below table rates 3 CMMS programmes out of 10 for security, cost, ease of
use & information input.
Programme Name
CWORKS
Express Maintenance
Frontline Maintenance

Securit
y
9
6
6

Ease of
Use

Information
Input
9
7
2

Cost
9
7
5

9
6
7

Programme Examination
CWORKS scored best overall. The programme scored a high security rating as
the log in requires user name and password input. The programme is very easy
to use and allows you to input assets extremely quickly. It allows a great deal of
information to be added about maintenance schedules and other information
about the components. CWORKS costs approximately 670 for an annual
membership. Additional packages are available which cover the costs of
premium support and allow extra inputs to the programme.
Express Maintenance I felt was the second best out of the 3 software
programmes tested. The security didnt score as high because there was no
password and user name required. The programme was relatively easy to use
after having studied it for a while. The information input is vast so it scored
highly in that aspect. Express Maintenance costs more than CWORKS at 900 for
an annual membership.
Frontline maintenance was the third programme tested. The programme again
had no login or user name option meaning the security scored lower than
CWORKS. After using this programme for a while I decided to disregard it
because it was much more difficult to use compared to CWORKS and Express
Maintenance. Frontline maintenance costs approximately 850 for an annual
membership.
Customisation
I now decided to look into 2 programmes in more depth by customising
maintenance information into them. I input the 22 items stated above into
CWORKS and Express Maintenance to see which programme I liked best.
CWORKS definitely came out on top for being the most user friendly and easiest
to use. I have attached screenshots from each of the programmes below:
CWORKS

Express Maintenance

Observations
During customisation of the maintenance programmes I found that CWORKS is a
lot quicker to input assets into. I think this is due to its ease of use. The system is
very user friendly and it allows a great deal of information to be added. There is
even an additional information tab where maintenance notes can be added to
each aspect. There is nothing to dislike about this software it is simple, it looks
good because the icons make it easier on the eyes.
Express Maintenance is more complicated software to use. It required a few trial
and error before I managed to correctly input my assets. The information input is
not as vast as CWORKS but it still allows the most important information to be
added. I dislike the look of this programme because its quite busy and has a lot
of writing.
Evaluation
After careful consideration I have decided the best maintenance programme for
Oil & Gas Europe is CWORKS. It is the easiest to use out of the programmes
studied, it is the most secure, all the required information about the components
can be added, and it looks good. CWORKS also comes in the cheapest out of the
3 programmes meaning it will be cost effective for the company. An annual
membership only costs 670 with the option to upgrade to a premium
membership. The programme can be installed through the installation CD
meaning no external company has to be sent out to set it up, again saving
money. Installation can also be done remotely and site wide by the IT
department within the company. Discounts on cost are available if more than 6
annual licences are being purchased.
In conclusion I feel CWORKS is overall the best maintenance programme for Oil &
Gas Europe. It is easy to use, cost effective as well as allowing group discount for
site purchases, allows a lot of information to be added regarding maintenance of
components, allows additional information input and it looks good but also has
good security with a user name and password log in.

You might also like