Maintenance Optimization of Oilfield Production Assets using Maintenance Audit Method applied in the Manufacturing Industry
Authors: Joledo Akorede , Falode Olugbenga , Sinha Jyoti , Wheelhouse Paul 
Published: August 2020

Analysis and investigation of the applicability of Maintenance Assessment/Audit methodology used in a Manufacturing firm was done based on previous maintenance experience on an Oilfield Production Asset (Floating, Production, Storage and Offloading Asset – FPSO). The Audit/Assessement Methodology used in PepsiCo International was reported in details and future work to be carried out in in respect of its practical application in Oilfield Production Assets was stated in future work.

Comparison and Anlysis were based on (1) Machines and Equipment (2) Processs and (3) Maintenace System/Organisation existing in both industeris (Manufaturing and Oilfield Production Assets). Overall it was found that both industries have very similar characteristics and feautures in areas (1) and (3), with a few similarities shared in (2). It was therefore inferred that the Maintenance Audit Methology adopted in the assessment of PepsiCo International (a manufacturing firm) can equally be adopted in the Maintenance Audit of an Oilfield Production Assets.

The maintenance Assessment of PepsiCo looked at the existing PeMM (PepsiCo Maintenance Methodology) put in place by the organisation across its companies in UK with particular reference to PepsiCo, Skelmersdale and found out its strength in virtually all the areas identified as key components of the benchmarking standards used for assessment. However, the assessment found a few hotspots as used by PespiCo on some of the elements of Maintenance Best Practice used as a benchmark. The CMMS systems do not meet the standard of the trend of development in the current work place.

An improvement data base management system is suggested which will integrate all maintenance organisation elements and thus help in making maintenance decisions based on integrated simulation that allows different factors of maintenance organisation to be considered. The Maintenance Audit activities is geared towards to a reduction in planned downtime, Replace MP2 system, further improve temporary repairs standards and housekeeping, include capital replacement measure in PeMM and complete early equipment management initiative and listen to the voice of the internal customer in PeMM.

Furthermore, some areas of quick improvement were also identified which include, Close-out procedure for all projects to review activities & effectiveness, Eliminate all current temporary repairs, Ensure 100% of jobs are captured in MP2, Utility technician attends hand over meeting where possible and utilities are added to the handover sheet, Record "As Found" and "As Left" condition when carrying out PM activities, Closer laison between the planner and duty Floor Line Manager (FLM) in advance of a shutdown day and Use of anti-slip safety boots in fryer area of the plant.

Improvement programme reduced the downtime by 8 days, ensure fewer inspections, reduce waste, increase the life span of equipment, reduce and asset utilization, reduce cost in finance administration, users friendly system which enhances productivity, integration with others systems to reduce un-planned downtime, minimise product risk, improved budget planning, facilitate life cycle planning, improve operability and maintainability, streamlined commissioning, support lean manufacturing, enhance team work, deliver requirement & ownership, provide stakeholders feedback and PeMM assessment by customers.