2015 - ADCO, ASAB Full Field Development, UAE
Summary
The ASAB Full Field Development project aimed to enhance production capacity from the ASAB oil field, one of Abu Dhabi's key onshore oil assets. The expansion involved the installation of new processing units, water injection facilities, and gas handling systems to improve production efficiency while ensuring long-term asset integrity.
Challanges
Reliability and availability optimization for aging infrastructure while integrating new production units into the existing plant framework. High failure rates in critical rotating equipment: Compressors, pumps, and turbines required an in-depth reliability analysis to ensure sustained operations under extreme desert conditions.Balancing preventive and corrective maintenance costs: The client needed an optimized maintenance strategy that would minimize costs without sacrificing reliability. Operational efficiency and downtime reduction: ADCO sought to increase plant availability and production efficiency while ensuring that equipment failures did not lead to costly shutdowns. Managing equipment criticality and spare parts logistics: The large-scale nature of the project required an advanced spare parts optimization strategy to avoid unnecessary stockpiling while ensuring quick availability of critical components.
Solution
Conducted a RAM analysis to assess the impact of different failure scenarios on production availability, identifying key bottlenecks and critical equipment requiring redundancy.
Led FMECA workshops to systematically analyze potential failure modes, their impact on production, and the most effective mitigation strategies.
Developed Root Cause Analysis (RCA) methodologies, applying 5-Whys and Fishbone (Ishikawa) analysis, ensuring that repetitive failures were eliminated rather than temporarily fixed.
Designed and implemented Condition-Based Maintenance (CBM) and Predictive Maintenance (PdM) strategies using vibration analysis, thermal imaging, and oil analysis to reduce unplanned downtime.
Applied Reliability-Centered Maintenance (RCM) techniques, categorizing assets based on their function and failure consequences to prioritize maintenance efforts where they had the most impact.
Provided a detailed Spare Parts Optimization (SPO) study, ensuring that lead times, inventory costs, and supplier reliability were factored into the procurement strategy.
Utilized Risk-Based Inspection (RBI) methodologies to optimize inspection intervals, reducing excessive maintenance efforts while maintaining compliance with API 580/581 standards.
Performed a Life Cycle Cost (LCC) analysis, demonstrating the long-term financial benefits of an optimized reliability strategy versus traditional preventive maintenance approaches.
