SOLUTIONS

The oil & gas company selected ARMS Reliability’s OnePM®-powered ASM approach to identify the unit’s current maintenance gaps, develop optimized maintenance strategies for almost 48,000 assets, and standardize strategies across similar equipment.

The client chose ARMS Reliability based upon its technical expertise and proven experience optimizing maintenance strategies on projects in the oil & gas and petrochemical industries. Using the OnePM® solution for maintenance-task development has been demonstrated to be 3-4x more efficient than traditional approaches, and ensures operating context is considered in failure-mode mitigation.

Over a six-month period, the ARMS team used OnePM® to review and develop strategies for the unit’s almost 48,000 maintainable assets. Since all facilitations had to be performed remotely, the client-ARMS time-zone difference of 2.5 hours meant collaborative efforts had to be especially deliberate and well-organized. ARMS provided the client team with access to OnePM® so that they could watch the whole maintenance-build process in real time, and monitor strategy quality as each was completed.

Stage 1: Asset Strategy Preparation

Finding and Filling Maintenance Data Gaps

ARMS Reliability critically reviewed the client’s asset list and work-order history to identify gaps – such as incorrect grouping assignments, missing criticality values, naming inconsistencies, availability of OEM manuals, Bills of Materials, incorrectly assigned work orders, and blank fields – which might present challenges to delivering a successful outcome for the project. While ARMS’ ASM process is flexible towards data deficiencies, better-quality data typically produces a higher-quality solution. So, the ARMS team and the client team worked together to fill data gaps as much as possible, using practiced knowledge of industry best practices as necessary.

Stage 2: Asset Information Analysis

Developing Maintenance Strategy Recommendations

Based upon the updated asset information, ARMS Reliability leveraged its own asset-strategy library of Failure Mode and Effects Analysis (FMEA) templates to develop failure modes and mitigating tasks for each equipment sub-class. Using OnePM®, the ARMS team deployed the sub-class strategies to specific assets and, based on operational context, made necessary adjustments to the effects of failure, maintenance tasks, and sparing strategy, in order to maximize cost and risk effectiveness.

Using OnePM® access to view live progress, the client team reviewed ARMS recommendations and offered their own site-specific operational context. Facilitated workshops provided a platform to work through the ultimate changes to the process.

The ARMS team performed a detailed cost-benefit analysis on specified assets, to identify cost-effective and risk-mitigating maintenance tasks. For each failure mode, the cost, safety, environment, and other risk categories were forecast over a desired lifecycle, to determine the best maintenance strategy.

Once the optimized tactics and maintenance strategy were selected, ARMS performed a system forecast to define appropriate budget and resource predictions for the plan.

Stage 3: Equipment Strategy Approval

Consolidating Data and Recommendations for Optimal Strategy Data Sheets

Throughout this process, ARMS Reliability used OnePM® to merge grouped asset data with approved maintenance recommendations, simplifying the work required in this stage as custom views are made available to review and facilitate the consolidated strategy data sheets.

Before generating the strategy data sheets, OnePM® conducted an automated Quality Assurance (QA) check using defined rules developed throughout the project – including checks for blank fields and data inconsistencies that might compromise the quality of the strategy data sheets. Once the QA check was cleared and the data was approved, OnePM®’s report generator exported it all into the client’s strategy data sheets.

This superior method ensures generation of strategy data sheets is rapid, accurate, and responsive if further changes are required, negating the need to completely rework documents.