Analysis of reliability based on preventive maintenance of failures in the VSH-2 mechanical pumping unit for oil extraction

The safety and reliability of assets in the Oil and Gas sector are considered essential to maximize availability and minimize downtime in production and operations. Due to the aging of assets (mechanical elements), the industry is reviewing the maintenance planning of critical equipment through Reliability Centered Maintenance (RCM). This research project focuses on Tibú, which is the area of the largest oil exploitation in northeastern Colombia, in production to date from 113 active wells, with 41 variable speed hydraulic unit 2 (VSH-2), and the rest corresponds to other types of equipment. The extraction of crude oil using artificial equipment, such as the VSH-2, is a primary factor in the oil sector. When the reservoirs lose pressure and do not flow naturally is necessary to aid the reservoir to stimulate the extraction of crude oil from the well. The main problem under study is establishing the redesign of the VSH-2 units mechanical element by identifying the frequency of failure and the costs generated through corrective and preventive maintenance. As part of the methodology, the Failure Mode, and Effect Analysis (FMEA) method was used, and the data collected in the maintenance histories were based on data using the SAP software, considering, in turn, the experience of the maintenance group of the Tibú field. The main results showed that the redesign of the VSH-2 mechanical element significantly increased the reliability of the mechanical crude extraction system by changing the hose system to 316 stainless steel pipes. Furthermore, based on reliability data, the results showed that the redesign of the system was possibly increased by 90% with 92,000 h of work in the frequency of the failures presented by the system about the Manifold hose to the nitrogen accumulator due to the auxiliary medium external leak failure mode, which was 11,900 h. Finally, with this redesign, maintenance standards and theories (plans and routes) were considered, which allowed for increasing both the reliability of the mechanical oil extraction system and the financial resources of the oil extraction field related to stops due to maintenance.