One Stop Maintenance Initiatives Presentation

Mbah Tono Maramis Godjali Masturi Yavino Udin - Fitriansyah

Maintenance - NBU Department

Outline
IPM Section

Welding Section
Mechanic Section

Safety Section
Power Section 5S Implementation at PTM Deck

IPM 2013 Strategic Initiatives

Prioritize IPM WO of equipment related to platform shutdown and environment, to achieve target of two cycle in a year.
Manifold header system Auto-con Panel Air System Fire & Gas Protection System Slop System Water treatment

Promote predictive maintenance by performing periodic or continuous (online) equipment condition monitoring
Thermal Imager to detect heat as indicative of failing electrical equipment Vibration Monitoring to monitor vibration as failing indicative on rotating equipment

Welding Flow Line Leaking Prevention

4 most possible root causes of flow line leaking: Fluid Contents Corrosive materials (sand content) and erosive materials (high CO2 content) could cause erosion and corrosive problem Fluid Velocity/Pressure & Temperature High fluid rate and high fluid temperature could cause more severe affect due to erosion and corrosion Piping Material & Coating Quality Poor material and coating quality which incompatible with fluid nature could accelerate erosion and corrosion process Welding Quality Welding defect could cause hydrogen embrittlement and residual stresses which effect on material strength reduction and crack initiation Production / CnC Side
Fluid Contents Fluid Velocity & Temperature
interrelated

Maintenance / Welding Side

Piping Material & Coating Quality Welding Quality

Flow Line Leaking Prevention Recommendation

1. Need further study to improve material grade selection that could solve on corrosion and erosion problem # proposed to be upgraded to 13% chrome materials or well tubing materials (3% chrome) with better corrosion and erosion resistant (market available) which could be implemented for pilot project at INTB platform (most often leaking platform) 2. Need further study for high abrasion and corrosion resistant coating application by considering coating surface preparation, coating adhesive & high operating temperature 3. Provide tool to control piping material and coating quality # proposed to provide XRF (X-Ray Fluorescence Instrument) that have function to provide qualitative and quantitative material component analysis and to ensure the validity of material certificate 4. Provide detail SOP welding, which consists of surface preparation, electrode selection, joint design, the amount of power input & welding methods 5. Provide welding quality control check lists to ensure that welding quality meets the required standards, which consists of welding defects visual inspection (cracks, undercutting, porosity, incomplete penetration, etc.) and NDT inspection (hydro test, dye penetrant test, MPI, etc.) 6. Welding supervisor shall get welding inspector certificates as field welding inspector
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Mechanical WIDP/WIDA Air Compressor Improvement (Lesson Learned from low-low air instrument WIDA incident)
Existing System:
WIDP/WIDA : 2 Units Screw Air Compressor (GA-45FF) 2 Units Reciprocating Air Compressor (T30-3000) 1 Unit Emergency Air Compressor (manual switch) Interconnection WIDA-WIDP (open)

Action Plan Purchase 1 unit screw air compressor for WIDP (procurement process) Install 2 unit redundant air compressors for WIDA independently (MPP 2014) based on air consumption requirement Other Improvements Routine condition monitoring on air compressor performance (built-up/rest time, pressure switch & alarm function test) Install double alarm with different pressure low setting (to avoid worse condition, if one alarm is failed)

Disadvantages: Heavy duty for one unit air compressor to support air requirements for WIDA-WIDP in one time (20m build-up time and 2m rest time) Very risky to integrate air system for WIDA & WIDP (if WIDA/WIDP air system is failed will influence another directly) Very difficult to trace if any air line leaking problem

Proposed (Separate WIDP/WIDA Air System):

WIDP: 3 Units Screw Air Compressor (GA-45FF) 1 Unit Emergency Air Compressor (manual switch) Interconnection WIDA-WIDP (normally closed) WIDA: 2 Independent Units Reciprocating Air Compressor (T30/3000) or Higher
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Mechanical Air Line Replacement Project Evaluation

2013 Target vs Achievement
WIDB 75% WIDC & WIDD/DC 0%

Project period: 96 days / Target: 180 days So slow progress.

Evaluation Results:
Late to follow up PJA findings more than 1 month due to lack of communication Incompetent third party management in air line replacement project Lack of experiences in project management Poor material management Lack of knowledge and commitment from third party with contract terms Lack of number personnel & inacceptable working schedule Lack of tool provision & lack of material quality Limited Power section resource to assist third party in preparing jumper line to tie-in

Proposed solution:
Need to evaluate the implementation of VQHSE-MS Need to apply standardization for bid evaluation & implementation of approved vendor list Ask procurement to speed-up the implementation of contract performance monitoring system Need to evaluate the personnel requirement of section (case: Power/Welding vs Refurbishment) Proposed 2014 air line replacement projects Internal project with additional SO from experienced man powers
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Safety Installation of Roof Protection for Ansul Big Units

Old Type

New Type (with canopy)

Advantage of New Type Improve reliability of fire protection system by protecting the unit from extreme weather and falling object (heavy rain & bird droppings)

Safety Fire Water Sprinkle Line Replacement

Old Corroded One New Fresh One

Whats New Benefit?

To remedy plugged, leaking and corroded problem on fire water sprinkle line Material usage effectiveness reduce material of water sprinkler line (pipe, elbow and bushing) Cost effectiveness compared to external project done by third party: - Actual cost for 1 vessel: US$ 10,000 - Third partys cost for 1 vessel: US$ 60,000 - Saving estimation: US$ 50,000 / vessel Achievement & Plan 2013 WIDP V-102, V-202 & V-100 100% WIDP V-200, V-230 & V-340 In Progress

Power Air Compressor Control Panel Upgrading

Old Air Compressor Control Panel at WIDP New Control Panel WIDP

Cost-Benefit Analysis
Cost: +/- US$ 12,000 Benefit: - Simplicity is the ultimate sophistication (Steve Jobs) - Uniformity with control panel in other NBU platforms - Ease of maintenance & troubleshooting Next Plan >>> INDA & INT-AC (Target: 2013)
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5S at PTM Deck - Terminology

Sort (Ringkas) : Throw away unnecessary and unrelated items in workplace Set in Order (Rapi) : Arrange items in the proper place for quick retrieval and storage Shine (Resik) : Keep the workplace clean, neat and tidy Standardize (Rawat) : Standardize the way of maintaining order and

cleanliness

Sustain (Rajin) : 5S is a habit and is continually improved

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Sort Set in Order Program Plan

Sort
Usage of red tag & green tag for sorting purpose Daily temporary material in/out checking & reporting (PIC: material man) 5S joint inspection (weekly)

Set in Order
Re-layout and repositioning Usage of rack/box for better arrangement Repainting border line (six monthly) Repainting area marking (six monthly) 5S joint inspection (weekly)

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Shine Standardize Sustain Program

Shine
General routine cleaning & waste segregation by barge crew (daily) 5S joint inspection (weekly) Repainting deck area (yearly)

Standardize
SOP for daily routine cleaning SOP and checklist for 5S inspection SOP for temporary material in/out checking SOP for material disposal and arrangement Marking standards 5S criteria guideline 5S audit form

Sustain
5S training & socialization 5S review/feedback meeting (weekly) 5S poster campaign 5S audit (six monthly) 5S progress control board 5S award

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SORT Use of Tag Card

Material name: Location: Reason: PIC:

Red Tag Material must be removed from PTM deck ASAP (collected in red tag zone firstly)

Material name: PTM Deck Location: PIC:

Green Tag Material is stored in PTM deck

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SET IN ORDER PTM Layout Plan

Deck Utilization Plan

Deck Painting Plan

5S PTM Deck Implementation in Picture

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th4nkS 4LL..!!!

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