Gå til hovedinnhold

RNNP: Significant variations in maintenance

This year’s edition of Trends in risk level in the Norwegian petroleum activity (RNNP) for the first time provides an overview of maintenance status on the facilities on the shelf and at the land facilities. The reported numbers show there are large differences in relation to the degree of labelling and classification of systems and equipment, the backlog in preventive maintenance and outstanding corrective maintenance. This also includes safety-critical systems and equipment.


Maintenance is one of the most important preconditions for prudent operations. To maintain prudent technical conditions, equipment and systems must be maintained correctly and in a timely manner.

Good maintenance management has a positive effect on safety level and regularity. Deficient maintenance, however, can be a direct cause of serious incidents.

About the underlying data
The PSA notes that there is some uncertainty associated with the underlying maintenance data. The numbers are presented as the companies have reported them.

The fact that this is the first time this type of data is collected in connection with RNNP could also impact the quality.

Regulatory requirements and reported data
The regulations require all equipment on a facility to be labelled (“tagged”) and classified as regards the consequences of potential malfunctions on health, safety and the environment. The classification shall determine the maintenance. The regulations also require that use of facilities/land facilities shall take maintenance status into consideration, e.g. with a view toward risk contributors.

The operators were asked to provide data for the decision basis for maintenance management:

  • *Total equipment labelled (“tagged”)
  • *Number of “tags” classified
  • *Number of “tags” classified as HSE-critical
  • Most recent classification

and for the status of performed maintenance:

  • Number of hours of preventive maintenance (PM)
  • Number of hours of corrective maintenance (CM)
  • Number of hours of modifications and projects
  • Number of hours of planned shutdown
  • *PM backlog, total number of hours
  • *PM backlog, number of hours HSE-critical
  • *CM outstanding, total number of hours
  • *CM outstanding, number of hours HSE-critical

*The RNNP report is focused on the reporting categories marked with an asterisk.

Data has been collected from a total of 71 production facilities, 27 mobile facilities and eight land facilities.

In all, this provides an important picture of the condition of maintenance and maintenance management on the Norwegian shelf.

The PSA will follow up the findings from the collected data. We also expect the companies to actively use this information to improve their maintenance management.
 

Production facilities

Labelling and classification

[chart text: * Total number of “tagged” equipment, * Number of classified “tags” * Number of “tags” classified as HSE-critical]
Overview of labelled and classified equipment – production facilities

The RNNP numbers show that most production facilities have labelled systems and equipment, but a total of 18 out of 70 have not classified them. The numbers show that a quarter of the equipment on the facilities has not been risk-assessed as regards maintenance.

As regards classification, it is difficult to form a picture of risk as decision basis for maintenance purposes, the extent of the need for maintenance, and the required resources.

Backlog

[chart text: • PM backlog, total number of hours, • PM backlog, number of hours HSE-critical]
Overview of backlog of preventive maintenance (PM) – production facilities

The figure shows the backlog of preventive maintenance, which is to say planned maintenance not yet performed. This also includes the maintenance of HSE-critical systems and equipment.
 

Outstanding

[chart text: • CM outstanding, total number of hours, • CM outstanding, number of hours HSE-critical]
Overview of outstanding corrective maintenance (CM) – production facilities

The figure shows a large degree of outstanding corrective maintenance. For some facilities, the amount of outstanding maintenance is abnormally high.

Despite the fact that little of this equipment is classified as HSE-critical, the level of outstanding maintenance is very high. Some facilities have up to 50,000 hours of outstanding corrective maintenance.

Maintenance backlog and outstanding maintenance introduce risk contributions. Therefore, it is important to strictly monitor the backlog and the risk it represents. The risk shall be identified to ensure that the decision basis for considering measures is optimal.
 

Mobile facilities

Labelling and classification

[chart text: • Total number of “tagged” equipment, • Number of classified “tags”, • Number of “tags” classified as HSE-critical]
Overview of labelled and classified equipment – mobile facilities

Most mobile facilities report low numbers for both labelling and classification of systems and equipment. Some have hardly labelled or classified anything at all.

16 of 27 facilities have less than 10,000 “tags”. Seven have less than 5000. One facility is at zero.

The numbers can also indicate that only the newest mobile facilities have labelled equipment pursuant to regulatory requirements.

The situation is no better in relation to the degree of classification. Without satisfactory classification, it is difficult to form a picture of risk as a decision basis for maintenance purposes, the extent of the need for maintenance, and how much resources this requires.

The numbers also show that most mobile facilities fare poorer than the production facilities as regards labelling and classification. Considering that systems and equipment are to be labelled and classified as regards the health, safety and environmental consequences of potential malfunctions, this is serious.
 

Backlog

[chart text: • PM backlog, total number of hours, • PM backlog, number of hours HSE-critical]
Overview of backlogs of preventive maintenance (PM) – mobile facilities

There is a backlog of preventive maintenance on some of the facilities. The backlog also includes HSE-critical systems and equipment.

The backlog should also be viewed in connection with the degree of labelling and classification. Mobile facilities mostly have low numbers for labelling and classification of equipment.
 

Outstanding

[chart text:• CM outstanding, total number of hours, • CM outstanding, number of hours HSE-critical]
Overview of outstanding corrective maintenance (CM) – mobile facilities

For some mobile facilities, the level of outstanding maintenance is high.

Maintenance backlog and outstanding maintenance introduce contributors to risk. Therefore, it is important to strictly monitor the backlog and the risk it represents. The risk shall be identified to ensure that the decision basis for considering measures is optimal.

 

Land facilities
One of the land facilities did not have data available.
 

Labelling and classification


[chart text:• Total number of “tagged” equipment, • Number of classified “tags”, • Number of “tags” classified as HSE-critical]
Overview of labelled and classified equipment – land facilities

The figure shows that most facilities have labelled systems and equipment, but that one of the facilities has only classified the HSE-critical equipment (did not report data for total classification). In such cases of classification, it is difficult to form a picture of risk as a decision basis for maintenance purposes, the extent of the need for maintenance, and the resources required.

 

Backlog

[chart text: • PM backlog, total number of hours, • PM backlog, number of hours HSE-critical]
Overview of backlogs of preventive maintenance (PM) – land facilities

For some facilities, the figure shows a large backlog for preventive maintenance. In other words, there is a large amount of planned maintenance which has not been performed, including for HSE-critical systems and equipment.

Facility 3 did not report any data.

Outstanding

[chart text: • CM outstanding, total number of hours, • CM outstanding, number of hours HSE-critical]
Overview of outstanding corrective maintenance

The figure shows a large degree of outstanding maintenance for some facilities. For some facilities, the level of outstanding maintenance is abnormally high.

Maintenance backlogs and outstanding maintenance introduce contributors to risk. Therefore, it is important to strictly monitor the backlog and the risk it represents. The risk shall be identified to ensure that the decision basis for considering measures is optimal.
 

 

Contact information
Semsudin Leto, supervision coordinator
E-mail: semsudin.leto@ptil.no