Optimization of Maintenance Strategies in an Oil and Gas Production Facility to Minimize Maintenance Cost

Article Sidebar

Main Article Content

Awara, Biokpomabo Festus
Ebieto Celestine
Udeh Ngozi
Omorogiuwa Eseosa

Abstract: In this study, maintenance strategies in an oil and gas production facility were optimized to minimize maintenance costs. The centrifugal pump system in Port Harcourt Refinery was selected for this study because it significantly impacts on the productivity of the refining plant. The pump system’s failure mode effects and criticality analysis (FMECA) were examined, and an optimized maintenance task was developed for the system. The exponential reliability method was employed to analyse the pump’s failure data to determine the pump systems' failure rate and reliability while reliability centred maintenance (RCM) and linear programming (LP) model were employed to optimize the pump’s maintenance strategies and the pump’s maintenance labour force respectively.  Broad-based results of the optimized maintenance strategies consisted of on-condition-directed (CD) maintenance, preventive maintenance (PreM), and Proactive maintenance (ProM) strategies to be carried out monthly. The optimized maintenance labour force result revealed that approximately three engineers and two technicians should be employed for the pump’s maintenance task with a minimum of N2, 585, 700 as cost of salaries for the labour force monthly as against the current maintenance labour force requiring fourteen engineers and thirteen technicians monthly. The results showed that the labour cost decreased from N180,000,000 per year to N31,028,400 per year (approximately 82.76% reduction) using the proposed optimized maintenance task compared to the current maintenance plan. Conclusion and recommendation were made that the maintenance optimization technique presented in this work should be adopted by the oil and gas processing and production companies in order to minimize maintenance cost.

Optimization of Maintenance Strategies in an Oil and Gas Production Facility to Minimize Maintenance Cost. (2024). International Journal of Latest Technology in Engineering Management & Applied Science, 13(10), 32-41. https://doi.org/10.51583/IJLTEMAS.2024.131005

Downloads

Downloads

Download data is not yet available.

References

Afefy, I. H. (2010). Reliability-Centered Maintenance Methodology and Application: A Case Study’. Journal of Engineering, 2(12), pp. 863–873. DOI: https://doi.org/10.4236/engineering.2010.211109

Ahasan, U. (2015). An Application of Reliability-Centered Maintenance (RCM) in Lead Oxide Production System - A Case Study. Proceedings from BUET Int’l Conference, Bangladesh, 4(3), 36-57.

Al-Najjar, B. (2007). The lack of maintenance and not maintenance which cost: A model to describe and quantify the impact of vibration-based maintenance on company’s business. Int. J. Production Economics. 107, 260 – 273 DOI: https://doi.org/10.1016/j.ijpe.2006.09.005

Alsyouf (2007). The role of maintenance in improving companies’ productivity and profitability’ . International Journal of Operations & Production Management, 3(7), pp. 501-512. DOI: https://doi.org/10.1016/j.ijpe.2004.06.057

Bhangu, N. S., Singh, R., & Pahuja, G. L. (2011). Reliability Centered Maintenance in a Thermal Power Plant: A Case Study, International Journal of Productivity and Quality Management, 7 (2), in press. DOI: https://doi.org/10.1504/IJPQM.2011.038686

Brah, S. A. & Chong, W. K. (2004). Relationship between total productive maintenance and performance. International Journal of Production Research, 42(12), 2383-2401. DOI: https://doi.org/10.1080/00207540410001661418

Deeptesh, S. & Amit, S. (2015). ‘Study of Centrifugal Pump Using Failure Mode Effect and Critical Analysis Based on Fuzzy Cost Estimation’. International Journal of Science and Research, 4(7), pp. 75-82

Ethevenin, T. J. E. (2010). ‘Maintenance performance measurement in Oil & Gas Industry’, Retrieved from http://scholarbank.nus.edu.sg/handle/10635/22139

Goodfellow, W. J. (2000). ‘Applying Reliability Centered Maintenance (RCM) to Overhead Electric Utility Distribution Systems’. Proceedings of IEEE Conference, Wellington, 23(19), pp.565-566. DOI: https://doi.org/10.1109/PESS.2000.867647

Igor, B. (2004). Reliability Theory and Practice. Courier Dover Publication, Minneola, New York.

Ilogamhc, I. &Emmanuel, F. (2014). Reliability Analysis of Crude Oil Pumps: A Case Study, M.Eng Thesis, Department of Mechanical Engineering, University of Port Harcourt, Choba, Rivers state.

Itthipol, I. N., Rungreunganun, V., & Talabgaew, S. (2017). Reliability Analysis for Refinery Plants. KMUTNB Int’l .J Appl. Sci. Technol, 10(1), 61–70.

Khathutshelo, M. & Brian, T. S. (2018). The impact of plant maintenance on quality productivity in Gauteng breweries. International Journal of Operations & Production Management, 1(7), 1224-1232.

Misikir, T. (2004). Productivity Improvement in Ethiopian leather industry though efficient maintenance management. Department of Mechanical Engineering, Addis Ababa.

Murtjhy., D. N. P., Atcen., A., & Eclleston, J. A. (2002). Strategic maintenance management. Journal of quality in Maintenance Engineering, 8, (4) 287-305. DOI: https://doi.org/10.1108/13552510210448504

Port Harcourt Refining Company (PHRC) Limited (2021). ‘Port Harcourt Refining Company Limited: Establishment and Products’. Retreived from http://www.nnpcgroup.com/Port-Harcourt-Refining-Company-Limited-Directory / 17th December 2021.

Samuel, O., Felix, I., Oluseyi, A., Enesi, S., Abraham, A., Obafemi, O., & Stephen, A. A. (2018). A Reliability-Centered Maintenance Study for an Individual Section-Forming Machine. Int’l Journal of Mechanical Engineering and Technology, 5(1), 26-32.

Zhu, H., Pei, J., Wang, S.,& Huang, X. (2019). Reliability Analysis of Centrifugal Pump Based on Small Scale Sample Data. International Journal of Performability Engineering, 9(4), 423-432.

Zineb, A., Latifa, E., Jamal, F., Abdeslam, L., &Haj, E. M. (2017). Improving Efficiency of a Production Line by using Overall Equipment Effectiveness: A Case Study. International Journal of Production Research, 4(2), 33-40.

Article Details

How to Cite

Optimization of Maintenance Strategies in an Oil and Gas Production Facility to Minimize Maintenance Cost. (2024). International Journal of Latest Technology in Engineering Management & Applied Science, 13(10), 32-41. https://doi.org/10.51583/IJLTEMAS.2024.131005

Similar Articles

You may also start an advanced similarity search for this article.