One of Australia's leading energy companies produces natural gas from wells drilled into coal seams, and then turns it into liquefied natural gas (LNG) for export. The plant had a conservative maintenance setup, generating too many and often unnecessary work orders to maintain the equipment. Consequently, the workload and the costs were too high. MaxGrip optimized the maintenance of the LNG plant with our Asset Improvement Program including mapping the current situation through our proven AIM-methodology and first deployment for quick fixes.
Case study – highlights
Approach
Stage one: Fixing the basics. The project started with a review of the asset register, the safety-critical elements (SCEs), and a first benchmark and optimization of the preventive maintenance (PM) routines.
Stage two: Fully optimizing the maintenance build in the CMMS system, completing the workload levelling process, and aligning all tasks with updated maintenance strategies and performance standards.
Results
The first stage alone resulted in savings of US$ 600,000 year on year on man hours only. Stage two, the actual PM optimization project, has also yielded very good results. By reducing the number and frequency of PM tasks, clustering and enriching them, the company was estimated to save over US$ 1.75 million year on year.
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