A Case Study in Achieving Process Improvements and Cost Reduction at Critical Remote Facilities
One of the largest national oil companies in South America was looking for way to reduce its costs and prioritize process improvements for its upstream and downstream supply chains. With remote floating production storage and offloading production units and compression stations responsible for supplying gas to users, managing cost is a constant concern. When equipment fails in a remote offshore location, replacing critical parts or entire systems adds enormous cost to the operations. The customer needed a solution to provide early notification of impending equipment failure before lost production occurred.
The GP Strategies Solution
In 2010, GP Strategies began working with the customer on their Floating Production Storage and Offloading (FPSO) production unit and critical gas compression station that is responsible for compressing 30% of the Brazilian off-shore gas to additional users. It was critical that this gas processing facility ensured continuous, uninterrupted operation. Unscheduled downtime translated into higher costs and workforce inefficiencies. In an effort to help manage costs and improve maintenance planning, the customer installed the EtaPRO™ Predictor™ condition monitoring software, EtaPRO™ Predictor™ Fault detection, diagnosis & prognosis for rotating machines allowing them to know which maintenance to prioritize and how machinery reliability can be improved to guarantee uninterrupted production. Upon initial success at the facility, the customer partnered with GP Strategies to support additional improvements to their downstream value chain, or thermal electric power plants.
GP Strategies was able to help the company achieve performance improvements through a combination of critical monitoring of key production assets and expert knowledge transfer. Early identification of potential equipment failure allowed the customer to schedule planned maintenance activities, saving significant cost and avoiding lost production time. In addition, increased efficiency resulting from process improvements helped them achieve emissions reduction.