Petronas’ Journey in Developing Risk Based Maintenance Approach for its Offshore Pedestal Cranes

Abstract Over the last three years, PETRONAS has spent approximately USD 36 million on the maintenance of a total of 107 pedestal cranes. This has emerged as the main contributor for the overall static equipment maintenance costs. In the pursuit of operational efficiency and cost optimization, PETRONAS is pioneering a shift from traditional time-based maintenance to a Risk-Based Maintenance (RBM) approach. The RBM methodology aims to enhance safety and reliability while optimizing overall expenditures. The proposed methodology systematically divides the pedestal crane into key systems/components, subjecting each to a comprehensive risk assessment. Risk is calculated as the product of Probability of Failure (POF) and Consequences of Failure (COF) for individual component. PETRONAS has crafted a methodology for determining POF and COF, considering factors such as historical failure data, remaining design life, compliance with maintenance programs, crane category as per API 2C, usage of the crane, location of the crane and prior derating instances. A customized scoring system, harmonized with PETRONAS ‘s risk matrix, quantifies the POF and COF for each component, offering a refined evaluation of risk specific to the crane's configuration and operational context. This approach guides the formulation of a maintenance program, with higher-risk components receiving more focused and frequent action plan. The integration of continuous evaluation into the maintenance process is crucial. Thus, post each maintenance cycle, risk assessments are dynamically re-evaluated, determining subsequent inspection schedules. This adaptive approach ensures that maintenance efforts align with the evolving risk profile of the crane, enhancing responsiveness to changing operational conditions over the years. Incorporating a systematic and data-driven RBM methodology for offshore pedestal cranes, this initiative epitomizes PETRONAS's commitment to innovation and efficiency. By shifting from a time-based to a risk-based, PETRONAS anticipates substantial reductions in overall maintenance costs, improved operational efficiency and heightened safety in offshore lifting operations.