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Offshore stimulation equipment, frac pump operations
01 Oil & Gas / Offshore

Aker BP STMF, data-driven reliability optimisation

USD 2.5M

Frac pumps were inspected and HP iron pressure-tested after every offshore 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.

  • +5 operational days per 28-day campaign
  • USD 500k saved per day
  • USD 2.5M campaign savings

Related: Reliability engineering Oil & Gas

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Hydraulic power unit with pumps and gearbox
04 Industrial / Reliability Retainer

HPU reliability retainer, hydraulic pump & gearbox investigation

Root cause

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.

Related: Reliability engineering Retainer packages

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Pharmaceutical cleanroom
05 Pharmaceutical

Cleanroom engineering review

Zero

Full engineering review of GMP cleanroom systems, resolving 23 identified compliance risks. Zero compliance failures recorded across two subsequent regulatory inspections.

Related: Asset management Pharmaceutical

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Offshore support vessel
06 Marine

Vessel maintenance overhaul

40%

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.

Related: Maintenance engineering Marine

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