Page 251 - TPM A Route to World-Class Performance

Case studies 225

Peter Hanson, Hydrocyclone Team Co-ordinator, comments: ’Prior to the
project, Maintenance Technicians had no idea of the Operations side and vice
versa. It was a real success in terms of the training aspect and brainstorming
equipment issues.’

Separators
Again, two sigruficant results from the two vessels involved in the pilot
project, with OEE up from 30 per cent to 88 per cent on VO1 and up 60 per
cent on V02.

Unplanned shutdowns reduced by 55 per cent
Perhaps the result with the biggest impact generated by the project is that
concerning the reduction of unplanned shutdowns. In 1996, unplanned
shutdowns were running at an average of 5.4 per month. The target for 1997
was set at four per month - a 31 per cent reduction year on year. The reality
was that unplanned shutdowns averaged just 2.6 per month - a reduction of
55 per cent. This figure greatly affects the rate of oil production and is the
main reason why Delta has had a dramatic increase in its oil production in
1997.
Broken down, the figures for the second half of 1997 look even more
impressive. During the first half of the year, unplanned shutdowns were
running just below the target, at 3.8 per month. However, from July to December
there were only nine unplanned shutdowns - 1.5 per month. really is an
impressive statistic. All on Delta onshore and offshore can be proud of tlus
achievement. However, it does need to be sustained and, although there
were only a total of 31 unplanned shutdowns in 1997, if we consider external
events that caused FD to shut down, there are still considerable improvements
to be had in striving towards a goal of zero unplanned events.
This is one of the main themes of continuous improvement and, just to
prove it can be done, Delta achieved zero unplanned events in August,
September and November 1997.
Looking smcdy at some of the CI project areas, the MOL pumps achieved
a remarkable improvement in unplanned shutdowns, down from thxty-seven
in 1996 to nineteen in 1997. Again, the second half of the year accounted for
only four of these unplanned events. The other sigruiicant improvement was
in the area of Natural Gas Lift (NGL) unplanned shutdowns - these were
reduced by 75 per cent in 1997.

ECS rates as low as 5 mdkg
One of the Forties Delta’s key environmental targets is to develop and deliver
options to reduce environmental emissions. The legal h t of oil in water
discharged to sea is 40 mg/kg. However, Forties Delta set an environmental
target of 23 mg/kg at the beginning of the year.
Through the work of the separator and hydrocyclone teams, Effluent Control