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Case Study

Roll out of a risk-based maintenance strategy returns considerable benefits for FPSO fleet

Vysus Group helps a global FPSO owner/operator apply a risk-based maintenance strategy across its fleet, to realise significant benefits in terms of reduced maintenance hours and costs.




Floating Production Storage and Offloading (FPSO) units


For the initial four FPSO units the results were a net reduction in maintenance time for the equipment under review of 7,200 hours per year with an associated recurring OPEX reduction of £1.1M (30%).

Client challenge

Our Client, a global FPSO fleet owner/operator, was facing challenges with the volume of maintenance across the portfolio of vessels. Like many organisations operating numerous, separate facilities there was little in the way of understanding of how the many thousands of annual hours of maintenance tasks had been derived through the years, nor the value of those tasks in relation to maintaining equipment function. Also, in common with many organisations, there had been little in the way of undertaking to define, rationalise and drive a consistent approach to maintenance across the fleet, with each FPSO being managed as separate entities from different offices. As such, the Client was looking to set an appropriate level of maintenance activity within a fleet-wide strategy and to implement in phases – the first phase being an initial four FPSO units covering operations in UK and Brazil.

How we helped

The project required a targeted approach, aiming for the best possible return on investment and clear-cut gains. After an initial review of the asset’s Maintenance Management System and analysis of the distribution of maintenance and inspection hours, a scope of work was agreed for the candidate vessels covering non-safety-critical jobs. The opening basis covered more than 23,000 annualised PM hours across the agreed equipment types:

  • LV Motors
  • Fans
  • Pumps
  • Instrumentation
  • Valves
  • Lighting and Small Power
  • Power Distribution

The scope of work was delivered by a small set of our highly experienced, multi-disciplinary reliability and maintenance consultants. Strategies for each equipment type were developed centred on comprehensive Failure Mode and Effects Analysis (FMEA). Maintenance tasks were developed to mitigate functional failure and, where appropriate, to detect the onset of failure through condition monitoring.

Task intervals were analysed taking into account equipment criticality (from preceding Vysus Group project work). Combined, the output is a risk-based maintenance programme for the equipment under study. Although this project was delivered for the upstream offshore oil and gas industry, the same methodology and software is equally applicable in other high-risk, capital-intensive process industries – such as refining, petrochemical, renewables and manufacturing – enabling asset owners and operators to tailor their maintenance strategy and PM plans to suit their specific risk and commercial context.

Powerful results

The project resulted in the identification and implementation of changes that brought about a net reduction of 7,200 hours per year. This translated to a recurring, year-on-year 30% reduction in OPEX of £1.1M.

The value derived from the first four FPSOs provided sufficient substantiation of the project concept that led to the award of further streams of work for the Fleet.

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