Active Work Orders
8
1 emergency
Estimated Total Cost
$3.77M
Across all planned work
Total Duration
638h
27 days
Avg Risk Score
62
Out of 100
Production at Risk
$4.9M
If deferred 30 days
Work Orders
HRDH3-K-0001A
predictive
Replace NDE Dry Gas Seal Assembly (John Crane 28AT)
emergency
94
Primary seal leak rate 28.5 Nm³/h exceeding 20 Nm³/h OEM limit. Secondary containment holding but degradation at 3.8%/month. Replace complete cartridge. Concurrent: inspect intermediate labyrinth, replace buffer gas filters, verify seal gas panel calibration per API 692.
Production impact if offline: $1,600,000/day · Criticality: A · Current availability: 94.8%
HRDH3-K-0001A
predictive
1st Stage Impeller In-Situ Balancing (Ø650mm)
high
72
1× amplitude 5.8 mm/s indicates ~18g residual imbalance per API 617. In-situ trim balance during seal replacement window. If unsuccessful, extract barrel cartridge for shop balance at MAN Jubail service center.
Production impact if offline: $1,600,000/day · Criticality: A · Current availability: 94.8%
HRDH3-E-0101
predictive
Tube Bundle Hydroblast + Gasket Replacement
high
78
Fouling at 84% TEMA limit (0.00042 vs 0.0005 m²·K/W). Pull bundle, hydroblast 15,000 psi per ASME PCC-2 Art. 4.1. Replace SS/graphite spiral wound gaskets. ECT 100% of 1,240 SA-179 tubes — plug defects >40% wall loss per API 510.
Production impact if offline: $420,000/day · Criticality: B · Current availability: 96.5%
HRDH3-GT-0001A
condition based
Journal Bearing #2 Borescope + Ferrographic Oil Analysis
high
68
Vibration 4.2 mm/s approaching ISO 10816-3 Gr1 alarm (4.5). Orbit plots show subsynchronous whirl. Borescope tilting-pad via access port. Lube oil ferrography + particle count per ISO 4406. If Babbitt damage confirmed, plan bearing replacement in upcoming HSI window.
Production impact if offline: $1,850,000/day · Criticality: A · Current availability: 97.2%
HRDH3-GT-0001A
preventive
GE LM2500+G4 Hot Section Inspection (25,000hr)
medium
42
HSI at 50,000 hrs (current: 42,850 — 7,150 remaining). Per GE TIL-2023-142: combustion liners, transition pieces, crossfire tubes inspect/replace. HPT Stg 1&2 nozzles borescope+FPI. HPT Stg 1 blades tip measurement, cooling holes, coating. Mark VIe update to v06.03. LTSA rate: $225-275/op hour.
Production impact if offline: $1,850,000/day · Criticality: A · Current availability: 97.2%
HRDH3-P-0101A
condition based
Mechanical Seal Replacement (John Crane 4600, API 53B)
medium
52
Barrier fluid consumption (synthetic ISO VG 32) up 40% over 30 days indicating face wear. Replace seal cartridge. Verify barrier fluid pressurization, refill accumulator. Concurrent: reverse indicator alignment check — vibration suggests 0.002" offset.
Production impact if offline: $1,200,000/day · Criticality: A · Current availability: 98.4%
HRDH3-ESP-W012
predictive
ESP Performance Review — Well 12 (Baker Hughes 400)
medium
58
Motor temp 165°C trending to 175°C trip. Intake GVF rising 12→22% over 90 days. (1) Adjust VSD frequency for optimal pump curve. (2) Evaluate Baker Hughes MVGAS gas separator upgrade. (3) If degradation continues, plan workover with rig mobilization ($450K-650K including rig time).
Production impact if offline: $680,000/day · Criticality: A · Current availability: 93.2%
HRDH3-K-0003
preventive
Ariel JGK/4 Valve Replacement — 3rd Stage (Ø5.375in)
low
35
Suction/discharge valves showing 12% Cv degradation. Replace 4 plate-type valve assemblies with non-metallic sealing elements. Concurrent: inspect piston rings, rider rings, packing on all stages per Ariel SB-2024-08. Check VVCP clearance pockets.
Production impact if offline: $520,000/day · Criticality: B · Current availability: 96.5%
AI Maintenance Optimization Summary
Predictive scheduling vs reactive maintenance
Cost Reduction
38%
vs reactive maintenance
Unplanned Downtime
-72%
Year-over-year reduction
Failure Prediction
94.2%
Model accuracy (F1 score)
Annual Savings
$18.6M
Estimated for GOSP-IV