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Oil and gas industries are among the sensitive and complex industries that require efficient and practical maintenance and repairs due to high volume of production, high added value, technical and safety risks, the need to comply with international standards and high competition. Maintenance and repairs in the oil and gas industry can lead to improved performance, reduced costs, increased equipment life, reduced breakdowns, increased reliability, increased productivity, reduced waste, environmental protection, and improved employee safety. To achieve these goals, the use of maintenance and repair software is a necessary solution. Maintenance and repair software can help managers and operators of maintenance and repair activities in the oil and gas industry to be able to:
Plan, schedule, monitor, control, and report maintenance and repair activities accurately, quickly, and consistently.
To store and manage data, information, knowledge related to maintenance and repairs in a documented, orderly, searchable, analyzable manner.
Update, improve and coordinate methods, standards, technologies, tools and interpersonal relationships in the field of maintenance and repairs.
Measure, evaluate, compare and optimize performance, costs, breakdowns, customer satisfaction, profitability and other indicators.
What are the important challenges of the oil and gas industry?
Oil and gas industries are among the world’s strategic, profitable and high-risk industries, which play a vital role in the production of energy, fuel, petrochemicals and other valuable products for countries and societies. These industries face many challenges, some of which can be mentioned:
High competition between companies, countries and regions for access to markets, resources, technologies and profitability in the oil and gas industries.
Fluctuations in oil and gas prices in global markets and its impact on production, demand, investment, income and costs of oil and gas industries.
Compliance with international standards in the field of quality, safety, health, environment and professional ethics in oil and gas industries.
Responding to the needs, expectations and satisfaction of customers, shareholders, employees, suppliers, governments and other stakeholders in the oil and gas industry.
Prevention of technical, operator, human, natural and cyber risks.
To prevent equipment failure, production stoppage, human accident, environmental pollution and damage to the reputation of companies in the oil and gas industry.
Increasing efficiency in oil and gas industries
To face these challenges and maintain competitiveness and efficiency in the oil and gas industries, it is necessary to carry out maintenance and repair activities in a professional, up-to-date, practical and efficient manner. Maintenance and repairs in the oil and gas industries include the set of necessary measures to maintain, restore, improve and update the equipment, systems and processes used in the oil and gas industries. Maintenance and repairs in the oil and gas industry have many purposes and benefits, some of which can be mentioned:
Improving the performance of equipment, systems and processes in oil and gas industries in terms of efficiency, accuracy, reliability, quality, speed and coordination.
Reducing maintenance and repair costs in oil and gas industries by preventing sudden breakdowns, reducing production downtime, reducing energy and material consumption, reducing the need to replace parts and equipment, and reducing inspection and test costs.
Increasing the lifespan of equipment, systems, and processes in the oil and gas industry by maintaining optimal performance conditions, preventing erosion and corrosion, fixing defects, rebuilding parts and equipment, and updating technologies.
Reducing breakdowns of equipment, systems and processes in oil and gas industries by predicting performance behavior, identifying causes of breakdowns, fixing breakdowns on site or in the workshop, preventing recurrence of breakdowns and quick response to breakdowns.
Increasing confidence in equipment, systems and processes in the oil and gas industry by proving functionality, proving compliance with standards, proving compliance with security conditions and protecting products.
Increasing productivity in the oil and gas industries by increasing the production level, increasing the income level, increasing the profitability level, increasing the customer satisfaction level and increasing the employee satisfaction level.
Reducing waste in the oil and gas industry by reducing excessive consumption of resources, reducing product losses, reducing industrial waste, reducing product contamination and reducing time waste.
Protecting the environment in oil and gas industries by reducing gas production
Monitoring maintenance and repair activities in oil and gas companies
Managers in oil and gas industries monitor maintenance and repair activities using condition monitoring systems and software. Condition monitoring is a set of actions that are performed by checking the condition of machines and equipment and checking its changes over time based on parameters such as vibrations, sound, performance, lubrication, temperature, pressure and flow.
The purpose of condition monitoring is to detect breakdowns and defects in the early stages and prevent sudden and costly equipment shutdowns.
Condition monitoring in the oil and gas industry can help improve reliability, reduce repair costs, prevent equipment breakdowns, control production processes, and protect the environment. Some methods of monitoring the situation in the oil and gas industry are:
Analysis of oil and abrasive particles: In this method, the oil and particles in the oil are the parameters that are monitored. This method can be considered similar to a blood test, which doctors use to find out the health status of a person.
Vibration monitoring: In this method, machine vibrations are measured and based on that, the state of the device is measured, and if there is a fault, the fault can be detected. This method is mostly used for rotating machines.
Sound monitoring: examination of a rotating equipment in terms of sound or sound pressure, which is done by a sensitive microphone
Thermography: One of the condition monitoring methods based on temperature monitoring of rotating equipment
Using CMMS status monitoring systems and software, managers can:
Collect, store, transmit, process and analyze data related to equipment status.
Identify, categorize and rank errors, defects, dangerous signs and undesirable trends.
Take appropriate decisions to eliminate or reduce errors and defects.
Planning, scheduling, cost estimation and prioritization of maintenance and repair activities.
Monitor, evaluate and improve equipment performance and maintenance activities.
Avoid sudden and expensive stops.
Determine the right time to perform maintenance and repair activities based on the actual condition of the equipment.
Increase the useful life of equipment and reduce maintenance and repair costs.
Continuously monitor, evaluate and improve equipment performance.
It provides access to equipment status information for users anywhere in the world.
Why is equipment maintenance and safety essential?
Preventive maintenance of the equipment is the key to increase the life of the equipment and ultimately save your time and money. While the common perception may be that preventive and proactive maintenance is unnecessary, the reality is that without it, users often end up with more expensive repairs.
1- Increasing productivity
When equipment is running efficiently, projects are completed on time or ahead of schedule. When maintenance suffers, efficiency suffers. When efficiency decreases, so does your profit and bottom line. Modern maintenance solutions allow operations managers to digitize essential equipment details, find duplicate work orders and review asset history.
2- Injury prevention
Maintenance ensures that all business equipment assets are operating in accordance with the manufacturer’s instructions. As underperforming parts are upgraded, assets operate at a constant level of productivity throughout the year. This reduces the frequency of capital expenditures required to purchase new equipment.
3- Increase safety
The more assets are checked, the less likely dangerous problems such as marine fires will occur. Businesses that follow preventive maintenance programs reduce the risk of unexpected breakdowns, health risks and injuries, and liabilities.
4- Reducing costs
While it may seem counterintuitive to spend the time and money to inspect or repair equipment, the reality is that larger, more complex repairs come with larger price tags. Equipment use to the point of failure can be 10-fold. Cost more than periodic maintenance. Sometimes, these repairs can be done quickly by in-house employees. Other times, organizations must wait for outsourced professionals to do the work.
The role of technology in the future of the oil and gas industry
Technology is one of the effective factors in the development and growth of oil and gas industries. Technology can help increase efficiency, reduce costs, improve quality, improve safety and protect the environment. Some of the roles of technology in the future of the oil and gas industry are:
• Use of artificial intelligence and machine vision: these technologies can help monitor the condition, detect defects, guarantee quality, predict failures, determine the right time for repair, monitor compliance with security standards, etc. They can also use advanced algorithms, patterns find relationships and unusual events in the data and suggest improvement solutions
• Use of robots and unmanned systems: these technologies can help to perform dangerous, difficult, difficult and time-consuming activities in remote places, deep sea, adverse weather areas, etc. They can also help with data collection, equipment inspection, process monitoring, etc.
• Using the Internet of Things and smart sensors: these technologies can help connect everything together using wireless and cloud networks. They can also collect large and diverse data from different sources such as monitoring systems, control systems, Accounting systems, buying and selling systems, etc. help. These data can be used to analyze and optimize processes, respond to law violations, respond to contract violations, respond to market needs, etc.
• Use of blockchain and cryptocurrencies: these technologies can help create transparency, security, efficiency and reduce costs in transactions, contracts, transportation, distribution, etc.
They can also help solve problems related to sanctions, exchange rate changes, oil and gas price changes, etc.
Reactive net upgrade to a successful and modern maintenance program
A successful modern maintenance and repair program in the oil and gas industry must focus on three main factors: data, software and systems integrity. Together, these three factors can help improve efficiency, reduce costs, increase reliability, and protect the environment. In the following, we will explain each of these factors:
• Data: Data is the primary source of information for making decisions about the condition, performance, and maintenance needs of equipment. Data can be collected from various sources such as sensors, condition monitoring, laboratories, repair reports, failure history, etc. Data must be accurate, complete, up-to-date and accessible. Data should be organized and standardized so that they can be used for analysis and forecasting.
• System integration: This factor means that the maintenance and repair system is integrated with other systems that are involved in the production and business processes of the organization. For example, the maintenance and repair system should be coordinated with the accounting, purchasing, sales, quality, HSE (health, safety and environment) system, warehousing, etc. This integration makes the information to be transmitted comprehensively and uniformly at the level of the organization and better decisions are made to improve the performance of equipment and processes.
• Software: The software provides the necessary framework and tools to collect, store, process, display and share data. The software must be able to synchronize with other systems in the organization. The software must be usable, changeable and expandable. The software should have advanced capabilities such as artificial intelligence, machine learning, regression, neural network, etc. to analyze data and find patterns, relationships and unusual events in them and be applicable on most devices.
Sanat Novin data exploration maintenance and repair software, by examining the problems and needs assessment of the oil and gas industries in Iran, has made it possible to take a big step in the implementation of this system in the oil and gas industry in order to improve the level of this industry. It requires planning, coordination, training, evaluation and continuous improvement. To implement this system, you must go through the following steps:
• Determining maintenance and repair goals and strategies: At this stage, expectations, needs, benefits and challenges related to the implementation of this system should be identified and defined. Performance indicators, quality criteria, standards and measurement methods should also be specified.
• Selection of suitable equipment and activities: In this stage, sensitive, effective, economic and monitorable equipment and activities should be selected based on the methods of risk analysis, failure analysis, cost-benefit analysis, etc.
Collecting and processing the desired data: in this stage, the necessary data for monitoring the condition, diagnosing the cause of failure, predicting the time of failure, determining the appropriate time for repair, etc., must be collected from various sources such as sensors, condition monitoring, laboratories, Collected repair reports, breakdown history, etc. Then the data should be stored, refined, synchronized, extracted, analyzed using appropriate software.
• Implementation of maintenance activities and preventive repairs: at this stage, we must carry out maintenance activities and preventive repairs that are determined based on the collected data in a regular and precise manner. At this stage, standard checklists, technical instructions, suitable tools and experienced experts should be used. Also, the results of the activities should be recorded and reported.
• Evaluation and continuous improvement of the maintenance and repairs system: In this stage, the performance of the system should be measured and compared using the indicators determined in the first stage. Strengths, weaknesses, opportunities and threats should also be identified and improvement solutions should be suggested. At this stage, user feedback, statistics and information, cause and effect analysis, creative problem solving, etc. should be used.
The importance of maintenance and repairs in oil and gas drilling industries?
Preventive maintenance and repairs or PM is one of the important methods to increase the life and productivity of oil and gas drilling rigs. PM includes actions that are regularly planned and performed on drilling rigs to reduce breakdowns and unwanted stoppages.
PM makes drilling machines work in the best possible conditions, for example: the implementation of maintenance and repairs in drilling increases the rate of penetration (ROP). ROP is one of the important criteria for measuring drilling performance, which shows how fast a well can be drilled. ROP is influenced by many controllable and uncontrollable variables. Controllable variables include weight on tool (WOB), revolutions per minute (RPM), flow rate (FR) and differential pressure (DP). By optimizing and controlling these variables, ROP can be maximized and drilling time and cost can be reduced.
Maintenance and repair software or CMMS, which is used to manage and plan the activities of maintenance and repair of equipment and physical assets of organizations, can help in this field. For example:
• Registering and maintaining information related to drilling equipment, birth certificates, records, spare parts, documents and certificates.
Planning and scheduling preventive, predictive and corrective maintenance activities related to drilling
Monitoring and control of drilling equipment performance, maintenance and repair indicators, costs, consumption of spare parts, downtime and repair
Provide comprehensive reports and data analysis to improve maintenance and repair processes, increase productivity, reduce costs and increase reliability.
Integrated communication with other organization systems and facilitating accounting, warehouse, purchasing, production, personnel and monitoring
By conducting detailed studies and analyzing maintenance and repair processes in the oil and gas drilling industry, through the design and implementation of its maintenance and repair software, Kavash Sanat Company has been able to provide appropriate capabilities and facilities to meet the needs and challenges of provide this area. Using advanced technologies and optimization methods, this software can effectively and efficiently manage, plan, monitor and control maintenance and repair activities. The main purpose of this software is to increase productivity, reduce costs, increase reliability and reduce risks in oil and gas drilling industries.