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Modeling an Oil Drilling Rig Total Productive Maintenance System Using Causal Loop Diagram Simulation
Mohamed Hassan*
ABSTRACT
This paper presents a model for total productive maintenance for an electrical maintenance system in a drilling rig. Literature and technological advances are introduced for applying maintenance strategies including total productive maintenance. This work introduces an overview on one of the modeling techniques called causal loop diagram in conjunction with applying the total productive maintenance system dynamics for improving the availability of the oil drilling equipment. The use of a new maintenance strategy to improve a maintenance system may prove unfeasible and costly after the period of time needed for implementation. Therefore, applying a modeling technique including model verification and validation may reduce the time and cost needed to prove the feasibility of such maintenance systems. In the current work, the model has been developed using the causal loop diagrams (CLD) simulation technique and has showed that applying TPM improves the electrical maintenance system through improved equipment availability and reduced downtime. Therefore appropriate steps were taken to implement such TPM system through a deployment plan knowing in advance that the system is feasible. Managerial and engineering personnel,
as well as maintenance engineers were involved in the system implementation. Keywords: TPM, CLD, Electrical maintenance system, Drilling rig, Modeling
I. INTRODUCTION
Due to the world-wide competition in the oil industry activities, the work quality isnt the only effective factor that affects the performance of the facility. But also fast and safe missions are necessary to be able to compete and lead, especially in drilling rigs. Therefore its not optional to improve the performance of the work systems, but it became a must. The utilization of the resources is the main factor that affects both the performance and profit of a company, this means decreasing the downtime hours and keeping operation running without any failures. The facility in this research was a Drilling Super Rig in the Middle East area focusing on the performance improvement of the electrical maintenance system. The problem was always the existence of the unplanned maintenance activities dealing with shutdowns. This problem faces all facilities especially that work seven days a week and twenty four hours a day like this facility. The production mangers always give priority to operation instead of periodic
*The University of Akron Research Foundation, 411 Wolf Ledges PKWY, Akron, OH, 44311, USA
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maintenance, as they consider the maintenance time is a downtime. Therefore a practical way or a solution is necessary to achieve both continuous operation and effective maintenance simultaneously utilizing the available resources. Achieving zero or minimum shutdowns was a dream long time ago, but now by using new methodologies the facilities could improve the availability of its resources together with improving the performance. Obviously, the maintenance teams are seeking to achieve minimum breakdowns and high equipment efficiency. Total Productive Maintenance (TPM) is considered one of the effective methodologies that can be used for this objective (Ana, R., 2008). TPM integrates the efforts of all parties that can work to improve the facility equipment availability especially within the maintenance department (Kamran, S. and Seyed, A., 2009). The problem that many facilities face is the unplanned maintenance due to the unplanned shutdowns. The problem even has a bigger scale when the facility has to work without stoppage for seven days a week and twenty four hours a day to be profitable like the facility under study. This paper discusses improving the electrical maintenance system performance through modeling a TPM system, then once the model is verified, implementing its scheme and measuring its effectiveness in comparison with the model output (Marcelo, R. and Kazuo, H., 2006). The case study is the electrical maintenance system in a drilling rig.
simulation methods has shown that the most suitable model for a manufacturing process of a low series production is a conceptual model presented by an activity cycle diagram (Jerry, B., 1999). Because the activity cycle diagram can be used to present the desirable level of detail of the observed complex system, it also enables the presentation of interrelations between all the basic elements of the manufacturing process in a comprehensible manner. But in our case, which is not considered too complicated, where the objective is to present the problem in an easy, simple and clear way to be understood by the managers, then the Causal Loop Diagrams simulation technique would be the choice (James, R., 2001).
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loops, assume that the main variable in the loop starts to increase, and after tracing the effect of a change around the loop and at the end of the loop, if the variable begins to decrease, then it is called a balancing loop. But, if the variable is still increasing at the end of the loop, then it is called a reinforcing loop. On addition the above loops may be closed or open loops. For comparison, the closed loop is better as it
gives feedback to the system under modeling that can be used as a correction factor for the system output. Figure 2 shows the following types of loops.
Figure 2. Model of the electrical maintenance system using causal loop diagrams
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if the simulation model proved that, such a system may be feasible, and then this would be considered a justification for the top management when requesting the deployment of the system (Eric, D., 2007). Figures 3, the left two columns show the model simulation runs to calculate the overall unplanned maintenance cost, the outsourcing cost, the overtime cost, and the shutdown cost. The peaks show only when there is an unplanned maintenance activity, while on the normal operation time no peaks are present. This show the high cost of the unplanned maintenance that need to be eliminated. Figure 3, the right two columns show the team skills, which show only during the maintenance times, the equipment utilization which was always under 1.0, the shutdown hours due to the unplanned maintenance, which sometimes exceeded 20 hours or almost a whole day, the overtime hours which was always existing and the working hours was constant as the maintenance team was always on duty.
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means that the shutdown cost is the most significant cost that needs to be decreased. The model showed weekly overtime jobs, which was the actual practice. This may indicate either high rate of equipment failures or repeating jobs due to lack of experience of the team performing the jobs. The equipment availability was always less that 95% which indicates high repair times. The outsourcing was needed four times which indicates low level of experience of the maintenance staff that resulted in these outsourcing cases.
Step 2: Create TPM teams. Step 3: Study of the current conditions using techniques such as the 5 why to diagnose the problems root causes. Step 4: Specify TPM objectives. Step 5: Prepare a deployment plan to clarify the resources, training and maintenance management systems needed. Step 6: Measure and compare results. Step 7: Continuous review to achieve continuous improvement (Mel, A., et. al, 1999). The study of the shutdowns illustrated the following root causes for the most problems: 1. Lack of operators training 2. Not applying a proactive maintenance system such as the predictive maintenance. But on the contrary, always following a fire-fighting maintenance system as in case of the unplanned maintenance (John, K. and Horst, M., 2004). 3. Unavailability of spare parts. Table 1 Deployment plan for employees training
Mission
Specifying trainees levels
Resources
Team meeting for brainstorming and evaluation sheets.
Start
October 2009
Finish
Responsible
Preparing Training training department program and resources material for every level Implementing Projector, training for computer and every level training room Evaluating training program Course evaluation sheet
November March 2009 2010 Course start One month after course end
Sr. Elec.
Supervisor
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Table 1 shows an example of a deployment plan for an effective employees training system. The training needs are evaluated, training materials to be developed, training to be conducted the training evaluation is to be done after one month from the training course end. Table 2 Deployment plan for predictive maintenance system
Mission Resources Start October 2009 Finish May 2010 Responsible Sr. Elec. Predictive Cash maintenance tools purchase System implementation System evaluation
determining the needs for certain measurements, the necessary tools are purchased. The system then is put in place with periodic evaluations to determine its effectiveness in lowering the breakdown time and cost.
Maintenance October teams and 2009 tracking tools. Periodic evaluation sheets and team analysis Every month
Table 2 shows an example of a deployment plan for implementing a predictive maintenance system. After
Figure 5. Number of breakdowns before and after applying the TPM system Figures 6, shows the model runs after applying the TPM system. The left two columns show the model simulation runs to calculate the overall unplanned maintenance cost, the outsourcing cost, the overtime
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cost, and the shutdown cost. The peaks show improvement compared with Figure 3. The unplanned maintenance averaged about 2.5 jobs per year, the overall cost dropped to an average of $7,500. The
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equipment availability was one, which means the equipment was always available as the shutdowns in most cases were planned. The model prediction to the number of shutdowns averaged three times compared to an actual number of four.
V. CONCLUSIONS
The culture of I operate; you fix should change to All of us in the same boat by involving operators in the maintenance and providing managers support, which had been achieved during the study. It was shown that employees training, predicative maintenance implementation and having a shutdown items list should be among the most important tools to
be employed in order to improve the maintenance system. Simulation saves cost and time to predict the actual implementation model outputs. Also it has flexibility in tracking the effect of changing any variable through the model runs. The designed model can be applied in any rig to measure the effect of key variables on the performance of any maintenance system. Time and money was saved which lead to improve the electrical maintenance system through applying a TPM system even in harsh environment that works 24 hours a day 7 days a week that cannot afford shutting down the operation system.
to be able to study the system in more details and for more outcomes. The effect of the model input variables; training, predictive maintenance and use of shutdown list on the
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TPM system performance can be studied more to rank the most effective variables on the TPM maintenance system effectiveness.
[7] Faiz, R. B. and Eran, A. (2009). Decision making for predictive maintenance in asset information management. Interdisciplinary Journal of Information, Knowledge and Management, Volume 4. [8] James, R. (2001). Simplified translation of CLDs into SFDs, 19th International Conference of the System Dynamics Society, Washington, USA. [9] Jerry, B. (1999). Introduction to simulation. Winter Simulation Conference, Maryland, USA. [10] John, K. and Horst, M. (2004). A novel approach to predictive maintenance. [Online] Available: www.stle.org/assets/document/ Deutsch_award_winner.pdf, (September 30, 2010). [11] John, S. (2002). Model verification and validation. Winter Simulation Conference, Maryland, USA. [12] Kamran, S. and Seyed, A. (2009). Analyzing the effects of implementation of Total Productive Maintenance (TPM) in the manufacturing companies: a system dynamics approach. World Journal of Modeling and Simulation, Volume 5 (2), pp. 120-129. [13] Macro, C., Alessandro, P. and Bianca, R. (2004). Accelerated TPM by simulation. Advanced Simulation Technologies Conference. The Society for Modelling and Simulation International, Virginia, USA. [14] Marcelo, R. and Kazuo, H. (2006). Analysis of the fall of TPM in companies. Journal of Materials Processing Technology, Volume 179, pp. 276-279. [15] Mel, A., Paul, C., Hank, C. and Bernard, J. (1999). Simulation as a tool for continuous process improvement. Winter Simulation Conference, Maryland, USA.
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VII. REFERENCES
[1] Ana, R. (2008). Total productive maintenance overview, Technologies in Machine Building. [Online] Available: www.tcm.ugal.ro/Anale/ 2008/L20_AUDJG_2008_AR.pdf, (September 30, 2010). [2] Anu, M. (1997). Introduction to modeling and simulation. Winter Simulation Conference, Maryland, USA. [3] Averill, M. (2009). How to build valid and credible simulation models. Winter Simulation Conference, Maryland, USA. [4] Cathal, H. and John, R. (2006). Process modeling support for the conceptual modeling phase of a simulation project. Winter Simulation Conference, Maryland, USA. [5] Dean, S. (1997). Verification & validation in military simulations. Winter Simulation Conference, Maryland, USA. [6] Eric, D. (2007). Successfully deploying total productive maintenance. Material Handling and Logistics Conference, HK Systems, Utah, USA.
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[16] Michael, T. (2005). A project management causal loop diagram. ARCOM Conference, Association of Researchers in Construction Management, London, UK. [17] Muhamad, Z. and Pang, C. W. (2001). Application of total productive maintenance (TPM) concept in palm oil mill factory. Journal Mekanikal, Volume 12, pp. 59-73. [18] Ravikumar, M. and Bhaskar, A. (2008). Improving equipment effectiveness through TPM. Medwell Journals, International Business Management, volume 2 (3), pp. 91-96.
[19] Saaty, T. (2001). The analytic network process: decision making with dependence and feedback. RWS Publications. [20] Tihomir, O., Vesna, D. and Mario, J. (2008). Choosing the most appropriate simulation method for business process modeling using AHP method. [Online] Available: www.foi.hr/ CMS_home/znan_strucni_rad/konferencije/.../ T06_02.pdf. (September 30, 2010). [21] Vensim, PLE (1999). Personal learning edition users guide. Ventana Systems, Inc., Version 4. [Online] Available: www.vensim.com/ venple.html. (November 2, 2012).
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