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INTEGRATED MAINTENANCE

MANAGEMENT
Divisi Manajemen Proyek dan Pemeliharaan Fasilitas
Dr.-Ing. Mohamad Fauzan Amir
Indonesia PSC Exploration and
Exploitation

More than 300 Production Sharing Contract companies (PSC Companies) whilst 25 % of them are in
production

Courtesy of Divisi Eksplorasi


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Indonesia Upstream Asset Production Facilities
> 12000 >12000

Coverage > 1300


>3400
>500

Turbo Rotating Pipeline Vessel dan Platform


Machinery Equipment Tanki

Challenge : Aging Facilities


< 30th, > 30th,
55.31% 44.69%

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Sistem Informasi Pemeliharaan Fasilitas Operasi (SIPFO)

Gangguan Produksi

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SIPFO Dashboard

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Unplanned Shutdown Monitoring

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Equipment Asset Monitoring

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Indonesia Oil and Condensate Production
YTD 30 June 2017

PRIVATE AND CONFIDENTIAL 8


Indonesia Natural Gas Production
YTD 30 June 2017

* Produksi Gas Net : (Gas Konsumen+as LPG) + (Own use+Fuel) + as Kondensat + Flare + Losses + Shrinkage (exclude Gas Lift dan Injeksi)

PRIVATE AND CONFIDENTIAL 9 9


Availability & Reliability

Reliability, Availability, & Maintainability


Plant Capacity = 100% (RAM) study to anticipate the possible
production loss opportunity
EMCL Availability = 96.05%
ENI Availability = 96.73%
Reliability =
100% Potential - % Unplanned Downtime
95 % Availability =
100% Potential (% Planned Downtime +
% Unplanned Downtime)
The production target has considered the
5% planned production loss opportunity
Planned Downtime % Planned >
% Unplanned
Unplanned Downtime

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Efforts to Reduce Production Disruption

Regulation Implementation of PTK. 041 (Pemeliharaan Fasprod Migas)

Assessment Planned & Reduction of


Maintenance Spare part & Back
/Review Predictive Production
Forum Cluster Up Strategy
Maintenance Maintenance Disruption

Inventory parts
optimal
Assessment Backup strategy Shifting
conducted to for critical unplanned
Problem solving improve equipment maintenance
sharing, maintance Reutilization of to planned or
Sosialisasi management idle assets predictive
WA group (KKKS Review critical transfer tool or maintenance
equipment spareparts Schedule
maintenance)
between PSC compliance
companies
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Forum and Maintenance Cluster

National Production Facilities


Maintenance & Project Forum
(FP3FP)

Maintenance
Cluster North Maintenance Maintenance Maintenance
Sumatera Cluster Java, Bali Cluster Cluster Sulawesi,
Maintenance & Nusa Tenggara Kalimantan Papua & Maluku
Cluster South
Sumatera
67 PSC Companies (Produksi)

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Maintenance Assessment

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Oil Production Vs. Unplanned Shutdown
(2010 -2017*)
1,000,000

800,000

600,000
BOPD

400,000

200,000

-
2010 2011 2012 2013 2014 2015 2016 2017*
Unplanned LPO 22,890 21,280 16,603 10,494 11,581 10,011 7,097 3,401
Realisasi Produksi 944,899 902,053 859,674 824,192 788,777 782,915 831,175 808,797
% LPO thdp Prod 2.4% 2.4% 1.9% 1.3% 1.5% 1.3% 0.9% 0.4%

*) YTD per 30 Juni 2017


Hanya controllable LPO (eksternal, fasprod, offtaker & sumur), tidak termasuk gangguan karena alam

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Gas Production Vs. Unplanned Shutdown
(2010 2017*)

10,000.0

8,000.0

6,000.0

4,000.0
MMSCFD

2,000.0

-
2010 2011 2012 2013 2014 2015 2016 2017*
Unplanned LPO 149.7 277.9 372.7 180.0 272.0 194.0 59.0 32.1
Realisasi Produksi 8,857.0 8415 8149 8130 8218 8079 7939 7512
% LPO thdp Prod 1.4% 1.9% 3.3% 1.1% 1.6% 1.1% 0.6% 0.4%

*) YTD per 30 June 2017


Hany controllable LPO (eksternal, fasprod, offtaker & sumur), tidak termasuk gangguan karena alam

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LPO Unplanned Oil(2010 2017*)
25,000

20,000

15,000
BOPD

10,000

5,000

-
2010 2011 2012 2013 2014 2015 2016 2017*
Eksternal 561 1,750 801 1,057 1,031 608 554 2
Offtaker 4,156 1,313 495 270 2,081 1,091 337 132.5
Sumur 4,130 2,567 3,990 1,034 1,238 552 762 351
Fasilitas 14,043 15,650 11,317 8,133 7,231 7,760 5,443 2,915
Unplanned LPO 22,890 21,280 16,603 10,494 11,581 10,011 7,097 3,401
Realisasi Prod 944,899 902,053 859,674 824,192 788,777 782,915 831,175 808,797
% LPO thdp Prod 2.4% 2.4% 1.9% 1.3% 1.5% 1.3% 0.9% 0.4%

*) YTD per 30 June 2017


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LPO Unplanned Gas (2010 2017*)
400.0

350.0

300.0

250.0

200.0
MMSCFD

150.0

100.0

50.0

-
2010 2011 2012 2013 2014 2015 2016 2017*
Perpanjangan
5.5 38.7 22.3 0 0 0 0 0
Shutdown
Fasilitas 124.40 162.70 266.00 92.00 135.00 90.00 45.00 24.80
Proyek Baru 6.3 43.7 0 0 0 0 0 0
Sumur - 9.4 5.1 1 2 2 0 1.42
Offtaker 13.5 23.4 79.3 87 135 102 14 5.89
Unplanned LPO 149.7 277.9 372.7 180.0 272.0 194.0 59.0 32.1
Realisasi Prod 8,857.0 8415 8149 8130 8218 8079 7939 7512
% LPO thdp Prod 1.4% 1.9% 3.3% 1.1% 1.6% 1.1% 0.6% 0.4%
*) YTD per 30 June 2017

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Planned Shutdown Optimization
Rencana vs Realisasi
LPO Planned SD Minyak (bopd)
0
BBLSThousands

6657
5
10 4569
15
20 2088
25 Planned LPO Minyak
30 Aktual Planned LPO Minyak
Rencana LPO Minyak Realisasi LPO Minyak Gain

Rencana vs Realisasi
1-Jan-16 1-Feb-16 1-Mar-16 1-Apr-16 1-May-16 1-Jun-16 1-Jul-16 1-Aug-16 1-Sep-16 1-Oct-16 1-Nov-16 1-Dec-16 LPO Planned SD Gas (mmscfd)
0 138
113
200
400
MMSCF

600
800 25
1000
Planned LPO Gas Aktual Planned LPO Gas
1200 Rencana LPO Gas Realisasi LPO Gas Gain

1400

Source: Planned maintenance LPO 2016

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THANK YOU
Pengelolaan Pemeliharaan KKKS

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Distribusi Gangguan Produksi (2016)

Surface Pump, Surface Pump


23.0, 0.% 0.3, 1%

Storage Tank,
Storage Tank
31.1 , 1% Instrument, Instrument
0.2, 1%
689.5, 13% Process Facility 7.7
Process Facility,
10.7 17%
1299.3, 24%
24%

Kelistrikan
Pipa, 586.4, Kelistrikan, 10.4
11% 1980.8, 23%
36% Pipa
9.5
21%
Kompresor, Kompresor
832.4, 15% 6.0
13%

(a) Unplanned LPO Minyak per katagori (BOPD,%) (b) Unplanned LPO Gas per katagori (MMSCFD, %)

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Why Unplanned?
Monitoring tidak mungkin dilakukan,
Pemeliharaan preventive & predictive
tidak mendeteksi indikasi failure
Intervensi korektif tidak dilakukan
Wheather, 3rd party,

Barriers dan Controls yang ada


tidak mampu mendeteksi,
mencegah, dan mengurangi
Design failure event, sehingga terjadi
Containment eskalasi failure

Control
Detection

Preventive Maint.
Predictive Maint.

Monitoring
Corrective Action

Spare Mitigation
Note: Swiss cheese model by Redundancy Emergency Response
James Reason published in 2000
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Tantangan : Fasilitas Tua
Overall LPO (BOEPD) Planned Vs. Unplanned >
<
30th, 30th,
55.3 44.6
LPO Shutdown Terencana (Planned Shutdown) dan Gangguan Produksi (Unplanned
Shutdown)
120,000 109,403
Pemeliharaan terencana yang baik dapat
100,000 91,665 berpotensi menurunkan kejadian gangguan
produksi (unplanned shutdown)
80,000
66,601
63,346 61,955
BOEPD

60,000 53,154
50,023
45,098

40,000

20,000

-
2010 2011 2012 2013 2014 2015 2016 2017*
Unplanned 45,687 51,742 63,289 26,122 31,656 24,304 17,332 11,665
Planned 45,978 11,604 46,114 40,479 30,299 28,850 27,767 38,358
Total LPO (Planned + Unplanned) 91,665 63,346 109,403 66,601 61,955 53,154 45,098 50,023

*) YTD per 30 Juni 2017, banyak planned SD di semester 1

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