Heavy Oil CVC station Fin Fan Cooler (FFC) units experienced an unacceptably high failure rate in 2004 and 2005. In 2005 there were 180 cases of V-Belt cut off and the cost of poor quality performance was $117,747 / year. This presentation will discuss 178 FFC units that have a similar design and their performance during 2004 and 2005. The presentation will show the success of several reliability tools in identifying and reducing the most frequently occurring failures for Fin Fan Coolers at Chevron’s Duri Heavy Oil Field. Tools used and steps involved in the Reliability Improvement Process include: 1) Analysis of Computer Maintenance Management System (JDE) data, 2) Use of Pareto chart to identify most frequent failure modes, 3) Field assessment of the issues, 4) RCA and FMEA process, 5) Development of short- and long-term solutions (Weibull analysis), 6) Pilot application and preliminary results, and 7) Path forward for further improvement. The specific solution shown will be the application of spring loaded V-Belt tensioners and updated SWP of V-Belt Replacement to extend V-Belt life. The MTBF has increased from a typical 13 - 17 months to 70 months. Maintenance cost savings are estimated at $62,817/year.

 

Rahadian Bayu PT. Chevron Pacific Indonesia Riau, Indonesia