A/S Norske Shell E&P Ormen Lange

Title

Tittel

02V 2.11.2018 VOIDED Maintenance

Manager

Rev 11.01.2006 First issue K.A. Larsen K.A. Larsen H. Anthonsen

M

Rev. Date Reason for Issue Author Org. Unit Verified Approved

Doc. No 37-00-NS-X02-00034 Owner Maintenance Manager/Bjørn

Kongshaug

Discipline Discipline Doc. Type

Process ProcessEP-72 Level Level4.1

Area Code System Code

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Tag No.
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Maintenance Strategy for Mechanical Stationary Equipment

Contents
1. Purpose and Scope____________________________________________________________5
Purpose___________________________________________________________________________5
Strategy purpose____________________________________________________________________5
Audience__________________________________________________________________________5
Scope_____________________________________________________________________________6
2. Definitions and Abbreviations___________________________________________________7
Abbreviations______________________________________________________________________7
Definitions_________________________________________________________________________7
3. The Overall Strategy__________________________________________________________9
Goals_____________________________________________________________________________9
PM criteria________________________________________________________________________9
FLM______________________________________________________________________________9
FLM activities______________________________________________________________________9
Maintenance Analysis_______________________________________________________________9
Simplified RCM analysis____________________________________________________________10
Condition monitoring_______________________________________________________________10
Non critical equipment______________________________________________________________10
SIL______________________________________________________________________________10
4. Guidelines for Mechanical Stationary Equipment__________________________________11
Piping system_____________________________________________________________________11
Valves____________________________________________________________________________11
Slug catchers______________________________________________________________________12
Heat exchangers___________________________________________________________________12
Coolers and dryers_________________________________________________________________12
Filters____________________________________________________________________________12
Furnaces_________________________________________________________________________13
Vessels and tanks__________________________________________________________________13
Coalescers, hydro cyclones and columns_______________________________________________13
Loading arms_____________________________________________________________________13
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Pig launcher / receivers_____________________________________________________________13

Equipment subject to periodic control_________________________________________________14
5. References_________________________________________________________________15
References________________________________________________________________________15
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1. Purpose and Scope

Purpose The purpose of this document is to establish a maintenance strategy for

stationary mechanical equipment and provide guidelines for selecting
maintenance strategies for individual equipment and items.

The strategy is in line with the overall Ormen Lange Operation and
Maintenance Strategy and Regulations.

Strategy Equipment maintenance strategy in this context means analysing techniques

purpose to be applied, and the selected maintenance strategy for each category and
size of equipment

Audience The document shall be used by anyone involved in maintenance and

modification of stationary mechanical equipment on Ormen Lange, including
contractors

Continued on next page

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1. Purpose and Scope, Continued

Scope This strategy covers all stationary equipment on Ormen Lange. A separate
Maintenance Strategy will cover the offshore facilities.

Stationary equipment typically comprise of:

 Piping systems
 Valves
 Slug catchers
 Pig launcher / receivers
 Heat exchangers and reboilers
 Coolers
 Filters and strainers
 Furnaces, stacks and heat recovery units
 Vessels
 Coalescers
 Hydro cyclones
 Tanks.
 Columns
 Loading arms
 Valve Interlocking devices
 Flares
 Mooring devices.
 Oil separators, etc.
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2. Definitions and Abbreviations

Abbreviations The following abbreviations are used in this document..

Part Function
RCA Root Cause Analyses.
RCM Reliability Cantered Maintenance
RBI Risk Based Inspection
LCC Life Cycle Cost
SIL Safety Integrity Level

Definitions The following table define basic maintenance concepts:

Concept Definition
Condition Periodic or continuous monitoring of an item of an
Monitoring equipment or an equipment to provide knowledge both of its
CM current state, and of its changes with time, with the view to
minimising the execution of unnecessary maintenance, and
to reduce random breakdowns.
Performance Periodic or continuous monitoring of an item of an
Monitoring equipment or an equipment to provide knowledge both of its
PeM current state regarding production performance, and of its
changes with time, with the view of planning overhaul or
replacement before the equipment fail, and thereby reduce
random breakdowns
Condition Any planned examination and restoring of equipment or part
Based of the equipment, based on continuous or periodic
Maintenance monitoring and evaluation of equipment technical condition
CBM and performance degradation, or by monitoring technical
condition through first line maintenance.
Break Down Examination and restoring of an equipment or part of
Maintenance equipment to an acceptable performance standard, after the
BDM equipment has failed.

Continued on next page

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2. Definitions and Abbreviations, Continued

(continued)Error! No text of specified style in document.

Concept Definition
Preventive Any planned examination and restoring of equipment or part
Maintenance of the equipment at predetermined intervals intend to reduce
PM the probability of equipment failure or performance
degradation.
PM is normally applied for safety barriers
SIL testing A planned examination and testing of physical barriers,
including ESV valves etc.
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3. The Overall Strategy

Goals The strategic maintenance goals are:

 To safeguard Technical Integrity
 97% Production availability (inherent)
 Maximum 21 days production SD for maintenance every 4th year
 40 – 70% Condition based maintenance (man-hours)
 85% of maintenance pre-planned (Total Reliability)

PM criteria Criteria for PM routine:

 Technical integrity threaten – safety critical item
 Loss of function resulting in potential production loss
 Repair cost followed by equipment breakdown
 Safety barrier

FLM The overall maintenance Strategy for Ormen Lange is specifying extensive
use of FLM. Condition and performance monitoring of some equipment shall
be included in the FLM program.

Hand-held PC will be used for FLM Management.

Reference
See also the RCM decision logic.

FLM activities Typical activities to be included in the FLM program:

 Visual inspection and checking of equipment
 Checking of readings
 Condition of small electrical motors etc.

Maintenance Production critical equipment is as a general rule subject to RCM analysis,

Analysis provided that preventive maintenance interventions can prevent consequences
from equipment failure.

Continued on next page

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3. The Overall Strategy, Continued

Simplified Piping systems containing HC gases, condensate and heating medium shall be
RCM analysis subject to a simplified RCM analysis. Only one functional failure shall be
applied for loss of containment. Criticality shall be predefined.

Condition Condition monitoring and performance monitoring shall be applied for

monitoring equipment like heat exchangers, suitable shutdown valves etc.

Non critical Equipment not critical to safety or production is as a general rule operated to
equipment break down maintenance.

SIL Valves and equipment categorised as SIL components and SIL loops shall be
included in the SIL reliability analysing and calculation program.

SIL testing may be performed and recorded automatically during planned or

during unplanned shutdowns. Failure rates shall be calculated continuously
and used for evaluation of SIL test intervals.

Reference
See also the separate SIL strategy and instrumentation strategy for details.
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4. Guidelines for Mechanical Stationary Equipment

Piping system Guidelines for piping system:

 RCM shall be applied for containment of HC gas and heating medium.
 Periodic inspection in accordance with inspection programme.
 Online condition monitoring of erosion/corrosion by installed;
- Monitoring probes and chaotic protection
- Movements by wave frequency and
- Torque data collectors.

Note: See also the Inspection Strategy

Valves Guidelines for valves:

 Preventive maintenance shall be applied for critical valves as a general rule.
This includes;
- Periodic inspection,
- Testing, re-certification, and
- Control of condition and functionality.
 For selected critical valves online condition monitoring shall be applied,
e.g.
- Online registration of torque,
- Travel time and
- Lack detection.
 The instrument discipline holds the responsibility for the;
- Actuator unit,
- Control function,
- Steering loops, and
- Functional testing of these and the valve.
 The mechanical stationary discipline holds the responsible for the valve
integrity and relevant testing to verify this.

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4. Guidelines for Mechanical Stationary Equipment, Continued

Slug catchers Guidelines for valves:

 External and internal cleaning and periodic inspection, in accordance with
the inspection programme.
 Online condition monitoring of erosion/corrosion in connected pipelines by;
- Installed monitoring probes,
- Movements by wave frequency and
- Torque data collectors.

Heat Guidelines for heat exchangers:

exchangers  RCM shall be applied for heat exchangers as a general rule.
 External and internal periodic inspection, in accordance with the inspection
programme.
 Online performance monitoring of operational efficiency for production
critical equipment.
 Online condition monitoring/ corrosion by installed monitoring probes,
movements by wave frequency and torque data collectors.

Coolers and Guidelines for coolers and dryers:

dryers  External and internal periodic inspection, in accordance with the inspection
programme.
 Online performance and condition monitoring of operational efficiency for
production critical equipment.

Filters Guidelines for filters:

 External and internal periodic inspection, in accordance with the inspection
programme.
 RCM to be applied for critical filters.
 Online monitoring of diff. pressure above filters.
 First line maintenance to be applied for monitoring diff. pressure. Break
down maintenance applied for changing/cleaning filters.

Continued on next page

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4. Guidelines for Mechanical Stationary Equipment, Continued

Furnaces Guidelines for furnaces:

 External and internal periodic inspection, in accordance with the inspection
programme.
 Online condition monitoring of operational efficiency.

Vessels and Guidelines for vessels and tanks:

tanks  External and internal periodic inspection, in accordance with the inspection
programme.
 RCM to be applied for production critical vessels.
 Leakage detection in tank bottom

Coalescers, Guidelines for coalescers, hydro cyclones and columns:

hydro cyclones  External and internal periodic inspection, in accordance with the inspection
and columns programme.
 RCM to be applied for production critical coalescers.
 Online condition monitoring of operational efficiency.

Loading arms Guidelines for loading arms:

 Preventive maintenance to be applied.
 Extended use of first line maintenance.
 Periodic inspection in accordance with the inspection programme and
maintenance plan.

Pig launcher / Guidelines for pig launchers / receivers:

receivers  Detailed RCM analysis to be carried out for pig launcher/receiver.
 Preventive maintenance to be applied.

Continued on next page

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4. Guidelines for Mechanical Stationary Equipment, Continued

Equipment The following equipment shall be subject to periodic control in accordance

subject to with maintenance plan:
periodic control  Valve Interlocking Devices
 Oil extraction units
 Flares

Tittel
5. References
References The following references apply for this strategy.
Document number
37-00-NS-X02-00008
37-00-NS-X02-00010
37-00-NS-X02-00032
37-00-NS-X03-00005
37-00-NS-X18-00008
37-00-NH-B45-5186498
37-00-NS-X02-00036
37-00-NS-X02-00037
37-00-NH-B45-5186498
37-00-NS-X02-00035
37-00-NS-X02-00003
37-00-NS-M02-00001
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Document name
Overall Maintenance Strategy
RCM Strategy
Condition Monitoring and Performance Monitoring
– Operation Phase
Plan - Maintenance Resources and competence
Lasteplan for SAP Blueprint
Monitoring Specification
Maintenance Strategy Civil Equipment
Maintenance Strategy for SIL Classified Equipment
SIL & SU Compliance Report
Maintenance Strategy for Electrical Equipment
Equipment Maintenance Strategy for
Instrumentation
Maintenance Strategy for Rotating Machanical
Equipment