Bonga FPSO – The Key Levers in Ensuring Reliable Performance of Critical Rotating Equipment

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Abstract This paper is a critical review of the application of the apposite brownfield total equipment care (TEC) principles and concepts largely contributory to the higher rotating equipment reliability and availability figures in the Bonga Deepwater operation. The approach defines how the performance of an ageing fleet of rotating machinery susceptible to myriads of production challenges including changing production fluids chemistry, reservoir pressure decline, equipment obsolescence and reliability reduction of ancillary equipment, supply chain disruptions effect of COVID – 19 and its aftermath and others has been unlocked in a cost-effective manner to support the bottom-line business aspirations and achieve 1 billion barrels milestone. This paper is one of a series of Bonga themed papers proposed for OTC 2024. The Bonga field journey to One Billion Barrels started with the launch of the Bonga Business Improvement Plan (BBIP) in 2016 with keen focus on improving on four (4) critical systems per year through End-to-End system reliability improvement, Asset register update, Reliability centered maintenance, Critical Sparing reviews, Surveillance refresh and Preventive Maintenance Optimization. Key strategies deployed are: Embedding Proactive Technical Monitoring (PTM) to aid in early identification and mitigation of threats prior to becoming big issues, by leveraging on technology tools such as Exception Based Surveillance (EBS), SmartConnect, Plant Information, Solar InSight, and System-1 amongst others, Deepening Failure Investigations by deploying Causal Reasoning methodology across business (including HSSE type events) to understand root causes and systemic issues, and driving Maintenance Efficiency, capacity & capability building through strong collaboration with major rotating equipment manufacturers during planning and execution of major overhauls, utilizing onsite workshop and corporate workshop onshore for major maintenance activities not limited to valve overhauls, electric motor repairs, and pumps, and improved execution strategies resulting in optimized maintenance costs. With our Proactive Threat Management approach, daily surveillance, strong collaboration with equipment OEMs during planning of major equipment overhauls, improved execution strategies and execution efficiencies, Bonga FPSO have been able to achieve significant improvement in plant availability of >95%, reliability >96%, and significant reduction in greenhouse gases (GHG) emissions through reduction of flares and fuel emissions, which has overall contributed to the 1 billion barrels export milestone achieved. This paper presents the benefit of digitalization, robust Asset Management processes and competence development as key enablers to improved plant and equipment Reliability, Availability & Utilization in any production facility.