Maintenance

Work management & reliability execution

Preventive, corrective, predictive, condition-based, emergency and shutdown work against the asset hierarchy.

MTBF

412hrs

MTTR

6.4hrs

PM Compliance

88%

Schedule Adherence

76%

Backlog

1,240hrs

Emergency Work

11%

Maintenance workflow

Standard execution chain

Issue›Inspection›Work Request›Planning›Approval›Work Order›Material Reservation›Execution›Verification›Close

CRITICAL Maintenance AgentAI-3391

Bearing degradation predicted on Compressor C-201

C-201 · CPF Train 02

Confidence

87%

ImpactUnplanned shutdown risk ≈ $920K · 36 hrs deferment

Probable causes

Vibration 1x/2x harmonics rising over 21 days
Lube oil particle count above alarm
Load cycling above design envelope

Recommended actions

Schedule inspection within 7 days
Reserve bearing BR-550
Verify lubrication system
Combine task with planned shutdown window

Data analysed

180 days of vibration history
43 maintenance records
16 comparable compressors
Current operating conditions

Governance: human approval required for safety-critical execution

Asset hierarchy

Site → Plant → Area → System → Equipment → Component

SiteZenith Central Complex
PlantCentral Processing Facility
AreaArea B — Compression
SystemTrain 02 Compression System
EquipmentC-201 Gas Export Compressor
ComponentThrust bearing assembly
ComponentLube oil skid
ComponentDry gas seal

Maintenance cost

Labor, spare parts and contractor ($K)

Maintenance strategies & schedules

Calendar, runtime, meter, condition and calibration triggers

Plan	Asset	Strategy	Trigger	Next due	Compliance	Status
PM-101	C-201	Condition-based	Vibration > 6.5 mm/s	in 8 days	92%	Watch
PM-118	C-204	Runtime	Every 4,000 run hours	in 21 days	96%	On plan
PM-134	P-402	Calendar	Every 90 days	in 84 days	74%	At risk
PM-140	ESP-W143	Meter reading	Every 2,500 motor cycles	in 12 days	81%	Watch
CAL-22	PT-3301	Calibration	Annual — pressure transmitter	in 34 days	100%	On plan

Work order materials

WO-24118 · reserved from warehouse against C-201

SKU	Item	Required	Reserved	Issued	State
SP-BR-550	Thrust bearing BR-550	2	1	0	Shortage — PR-5521 raised
SP-SEAL-402	Mechanical seal kit	4	4	2	Partially issued
SP-FLT-19	Oil filter element	1	1	1	Consumed

Failure codes & root cause

Repeat failures and corrective actions

Code	Failure mode	Asset	Occurrences	RCA
FC-BRG-01	Bearing wearRevise lubrication interval	C-201	6	Open
FC-SEA-03	Mechanical seal leakAPI plan 11 → plan 32	P-402	3	Complete
FC-ELE-07	Motor current instabilityVSD tuning + sand check	ESP-W143	4	In progress
FC-COR-02	Internal corrosionInhibitor dosage increase	PL-07	2	Complete

Technicians, crafts & contractors

Skills, shift and current load

Resource	Craft	Shift	Skills	Load	WOs
M. Saleh	Rotating Equipment	Day A	Vibration Cat II, Alignment	86%	5
R. Adel	Mechanical	Day A	Seals, Pumps	62%	3
S. Nabil	Instrumentation	Night B	Calibration, DCS loops	71%	4
K. Osman	Electrical	Day B	HV switchgear, VSD	48%	2
Contractor — MechServ	Turnaround	Rotational	Scaffolding, Welding	93%	11

Work orders

Open and recently closed

WO	Asset	Title	Type	Priority	Craft	Due	Cost	Status
WO-24118	C-201	Bearing inspection & vibration survey	Predictive	P1	Rotating Equipment	Aug 19	$18,400	In Progress
WO-24102	ESP-W143	ESP telemetry diagnostic and well test	Corrective	P1	Production	Aug 18	$9,200	Approved
WO-24087	P-402	Mechanical seal replacement	Corrective	P2	Mechanical	Aug 21	$6,400	Waiting Material
WO-24070	C-204	Lube oil sampling & analysis	Condition-based	P3	Reliability	Aug 24	$1,200	Planned
WO-24041	PL-07	Cathodic protection survey	Preventive	P2	Integrity	Aug 27	$15,600	Planned
WO-23998	S-101	PSV recertification	Preventive	P3	Static Equipment	Aug 12	$3,100	Completed
WO-23961	T-305	Roof drain inspection	Preventive	P3	Static Equipment	Aug 09	$800	Completed

Turnaround & shutdown

CPF Train 02 — September window

Total jobs

412

Critical jobs

Completed

Delayed

Duration

21days

Budget

$18.4M

Committed $12.1M

Maintenance data upload

Work orders — cost, downtime and craft hours

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Expected columns: wo_id, asset, type, craft, date, labor_hours, parts_cost, labor_cost, downtime_hours

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