Reliability Improvement and Maintenance Cost Reduction on Reciprocating Compressor

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Reliability Improvement and Maintenance Cost Reduction on Reciprocating Compressor

Situation

Reciprocating Compressors form part of a Condensate Recovery Unit (CRU) in an oil production site. CRU downtime is a major contributor to flaring. The Compressor maintenance programme was based on the Manufacturer’s Recommendations and entailed a regular “minor” planned shutdown for strip down and inspections.

This resulted in flaring:

  • during the inspections; and
  • as a result of failures caused by the inspections (they were highly invasive and carried out in the field under time pressure).

What We Did

Carried out an RCM study on the CRU focussing particularly on the failure modes addressed by the existing maintenance programme. This study recommended a change to a programme of (non-invasive) condition-based tasks.

Results

  • Eliminated 10 days per year of planned shut down, resulting in a reduction in flaring of more than 100,000 barrels per year of condensate across the fleet.

This project won a Chairman’s Award for HSE Improvement.