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 required
9. Examine 3 software Programmes
10.

Screenshots of Programmes

11.Observation & Evaluation

12.Justification

13.

Conclusion

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

Description
Mandrel
Crossover
Quick Connect Crossover
DCV
SOV

Asset No
HB001
HB002
HB003
HB004
HB005

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

6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22

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
Check Valve
DCV Manifold
SOV Manifold
Split Ring

HB006
HB007
HB008
HB009
HB010
HB011
HB012
HB013
HB014
HB015
HB016
HB017
HB018
HB019
HB020
HB021
HB022

Yearly
Every 5
Every 5
Every 5
Every 5
Every 5
Every 5
Every 5
Yearly
Yearly
Yearly
Yearly
Yearly
Yearly
Yearly
Yearly
Every 5

Years
Years
Years
Years
Years
Years
Years

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 bullet points are the criterias within the programmes I will be looking
at.

Ease Of Use

Information Input

Cost

Security

Examine 3 software programmes

First of all I input 5 items into each of the 3 programmes, CWORKS, Frontline
Maintenance and Express Maintenance to see which 2 programmes I wanted to
do further examination on using my 22 items above.
I decided to disregard Frontline maintenance at this point because it had no login
or user name option meaning the security of the programme could be low and it
was quite difficult tot use.
Customisation
I now decided to look into 2 programmes in more depth by customising
maintenance information into them. For the customisation process I decided to
use CWORKS and Express Maintenance, I disregarded Fronline maintenance at
this stage because after quickly studying the programme it looked very
complicated to use. I input the 22 items stated above into CWORKS and Express
Maintenance to see which programme I liked best. I have attached screenshots
from each of the programmes below:
CWORKS
CWORKS

Figure 1: 22 Assets within

Figure 2: Additional Info tab in Assets

Figure 3: Detailed Asset 1 within CWORKS

Figure 4: Detailed Asset 2 within CWORKS

Express Maintenance

Figure 5: Detailed Asset 1 within Express Maintenance

Figure 6: Detailed Asset 2 within Express Maintenance

Figure 7: List of 22 assets within Express Maintenance

Observation & Evaluation

CWORKS
CWORKS seems to be a secure programme 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. There is
even an additional information tab where maintenance notes can be added to
each aspect. There is nothing to dislike about this apart from one problem that
the software does not allow you to delete an asset once it has been saved. Apart
from that this software is simple; it looks good because the icons make it easier
on the eyes. 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. The programme can be installed through
the installation CD meaning no external company has to be sent out to set it up.
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.
Express Maintenance

Express Maintenance does not require a password and user name on log in
meaning it is possible not as secure of a programme as it could be. Express
Maintenance is quite a complicated software to use. It required a few trial and
error before I managed to correctly input my assets. The information input
allows the most important information to be added but it takes a while to get
used to the input process. I dislike the look of this programme because its quite
busy and has a lot of writing. Express Maintenance costs 900 for an annual
membership this includes installation of the programme but requires a 3 rd party
vendor to be sent out.

Justification
I have created a table of the criteria of the 3 programmes and scored them all
out of 10.
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

After careful consideration I have decided the best maintenance programme for
Oil & Gas Europe is CWORKS. It scored the highest out of the 3 programmes as
seen above. 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 fact the
programme can be installed via CD or remotely by IT department means it is a
bonus for ease of Installation Company wide.
Conclusion
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.