Overview of the Project
In 2020, ARMS Reliability embarked on a project to optimize the maintenance build of a Floating Production Storage and Offloading (FPSO) vessel operating in Mexico. This was a critical initiative for the client responsible for the FPSO's engineering, procurement, construction, mobilization, installation, operation, and maintenance.
The ARMS team utilized their proprietary Asset Strategy Management platform, OnePM®, along with the world’s largest component strategy library, to develop a comprehensive plan for the FPSO’s maintenance strategy. The project was carried out in three phases, each designed to optimize different aspects of the maintenance lifecycle.
Phase 1: Planning for Success
The first phase involved the development of the foundational maintenance plan for the FPSO. The ARMS team created the Reliability and Integrity Guide along with Supporting Asset Class Documents.
The Reliability and Integrity Guide served as a roadmap to ensure the FPSO’s availability goals were met without compromising safety or environmental performance. It provided a structured approach for executing and continually improving the asset management program across the region.
The Supporting Asset Class Documents provided more granular insights into specific asset classes, detailing criticality, exceptions, and maintenance governance for each.
Phase 2: Building for Efficiency
In this phase, ARMS Reliability implemented the Maintenance Philosophy Guide using OnePM®. This guide integrated client data, OEM manuals, and ARMS’ own expertise to evaluate over 50,000 assets through a criticality assessment.
The Criticality Assessment ranked assets on a scale from 1 to 5 based on their importance, allowing for tailored maintenance strategies to be deployed. These strategies were developed using Failure Mode and Effects Analysis (FMEA) Templates, which grouped similar assets together and applied specific OEM recommendations.
OnePM® streamlined the strategy deployment process, ensuring that each asset received a personalized maintenance approach based on criticality and operational needs.
Phase 3: Readying for Efficacy
The final phase focused on preparing the FPSO for operational efficiency. OnePM® was used to populate the CMMS load sheets, create Primary Maintenance Instructions (PMIs), and develop forecasts for labor, spares, and maintenance requirements over the FPSO's 20-year lifecycle.
By leveraging OnePM®, ARMS was able to automate the traditionally lengthy process of generating load sheets and PMI documents, saving valuable time and resources. The system provided a detailed forecast of maintenance needs, labor, and spares, ensuring optimized budgeting and a clear understanding of long-term operational costs.
Key Benefits and Insights
Superior Performance
By centralizing maintenance data within OnePM®, ARMS enabled the client to achieve superior performance. The digital strategy created a streamlined process that eliminated inefficiencies, resulting in greater productivity at lower costs.
Exceptional Efficiency
OnePM® significantly reduced the project timeline. What would have typically taken three years was completed in just nine months. This efficiency was further enhanced as future FPSO projects will begin with approximately 40% of the maintenance work already completed.
Managed Risk
OnePM® provided the client with critical risk visibility, enabling informed decision-making across safety, environmental, and cost considerations. The system’s risk justification tools allowed the client to manage and mitigate risks at both the asset and system level.
Conclusion
The integration of ARMS Reliability’s expertise and OnePM® software into the FPSO capital project ensured that maintenance strategies were optimized for both efficiency and effectiveness. The three-phase approach, from planning and building to readiness, demonstrated how digital solutions can revolutionize asset management in the oil and gas industry.
By standardizing maintenance practices and automating key processes, ARMS helped the client achieve superior performance, reduce costs, and ensure long-term operational success.