For an offshore operator on the Norwegian Continental Shelf, frac pumps were inspected and HP iron pressure-tested after every stimulation, adding 10 hours per zone. Wear and failure data, validated by Monte Carlo simulation, confirmed the wear was non-critical. A defined threshold allowed pumps to run through Zone 3 before inspection, shifting from conservative intervention to controlled run-to-limit. A predictive model now forecasts valve life based on sand type, pressure, rate and fluid viscosity.
Redesigned and documented a critical production line for a FMCG manufacturer in the East Midlands. OEE improvement sustained across a 12-month baseline period.
Developed and implemented a planned maintenance strategy across 6 water treatment facilities. Annual savings confirmed in year-one audit against baseline costs.
Hydraulic pumps and gearbox on an HPU showed accelerated wear flagged by vibration analysis. Weibull life modelling confirmed wear was system-driven, not ageing. A 2018 overhaul had set all pumps to identical pressure settings, creating vibrational resonance. Introducing a pressure differential resolved it. A design deficiency was also identified: no isolation check valves between pumps and the common discharge manifold.
Full engineering review of GMP cleanroom systems, resolving 23 identified compliance risks. Zero compliance failures recorded across two subsequent regulatory inspections.
Overhauled the maintenance strategy for a fleet of 8 offshore support vessels. Maintenance cost reduction achieved within 24 months through RCM and spare parts rationalisation.
