How Operators Drive Reliability at Irving Oil
Transcript of How Operators Drive Reliability at Irving Oil
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How Operators Drive Reliability at Irving OilHow Operators Drive Reliability at Irving Oil
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PresenterPresenter
Mark Porter
Operator Driven Reliability
Project Manager
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Irving Oil Refinery, Saint John, NB, Canada
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Irving Oil ODR ProgramIrving Oil ODR Program
“At Irving Oil, we believe Operations can have a bigger impact on asset reliability than our maintenance department”
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ODR Pilot History at Irving OilODR Pilot History at Irving Oil
� ODR project development phase,
2009-2010
� Focused pilot, Sept 2010 until today
� Pilot area 160K bpd Crude Unit, 105K bpd Fluid
Catalytic Cracking Unit
� 70 Operations personnel, supporting maintenance
and engineering staff
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ODR Program Overview
Operator Rounds
Minor Maintenance
Operator Task List
Asset Operating Procedures
Operator Driven
Reliability(ODR)
HousekeepingEffective
Communications
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ODR Program ObjectivesODR Program Objectives
– Increase asset reliability
– Increase data transparency
– Increase effectiveness of Operations work processes
– Standardize Operator work – Standardize Operator work processes in all areas
– Reduce Refinery Operating costs by $0.05/bbl crude feed rate
– All support Irving Oil Refinery Safety culture in all areas and across all shifts
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ODR BehavioursODR Behaviours
� Operator “ownership” of production equipment
– Who has primary responsibility your car’s reliability?
– operator/owner• mechanic
� Operator direct involvement in � Operator direct involvement in equipment “basic care”
– Equipment cleanliness
– Early detection of potential failures
– Equipment minor maintenance
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� Asset Operating Procedures– Irving Oil and Innovatia partnership
– Drive reliability through consistent, optimal methods of asset operation
– Alignment to the 4 “causes” of reliability
ODR AOP’s
Asset Operating Procedures
InstalledRight
DesignedRight
OperatedRight
MaintainedRight
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Asset Operating Procedures (Technology)Asset Operating Procedures (Technology)
� 4 Types of AOP’s:
� Normal Startup
� Normal Shutdown
� Prepare for Maintenance
� Return from Maintenance� Return from Maintenance
� 2750 Rotating Assets x 4 AOP’s
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Asset Operating ProceduresAsset Operating Procedures
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� API Seal Plan 32 and Gold Wrist Watches
Asset Operating Procedures
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– Equipment Care & Condition Monitoring (ECCM)
• Based on Basic Equipment Maintenance Plans (BEMP)
• Meridium Software was the best fit for Irving Oil
– Housekeeping Surveys
– Alignment to the 4 “causes” of reliability
ODR Operator Rounds
– Alignment to the 4 “causes” of reliability
Asset Operating Procedures
OperatorRounds
InstalledRight
DesignedRight
OperatedRight
MaintainedRight
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Operator Rounds (Technology)Operator Rounds (Technology)
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Cleanto
Inspectto
Detectto
Correctto
+ Mean Time
Between
ODR Work Process
to Inspect
to Detect
to Correct
to Prevent
Between
Failures
Housekeeping Operator Rounds Operations/Maintenance
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• Qualitative Benefits
Improved business decisions based on automated data collection and analysisReduced maintenance costs with improved safety as a result of operations assuming a portion of the maintenance activity, and performing repairs before they run to failure
Increased safety and reduced exposure to fines/litigation by adhering to PSM standards
Improved consistency of work processes based on clarity around roles,
Irving Oil ODR Program
Improved consistency of work processes based on clarity around roles, responsibilities, expectations, and accountability for all Operators across the Refinery
Improved forecasting and control of maintenance costs (MTBF)Increased clarity around priorities, issues, and risks, based on improved communications and documentation to support shift changes
Increased Operations ownership of equipment through Operator RoundsBlending of Reliability Engineering knowledge/principles and Operations activities
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� Quantitative Benefits– Survey Compliance
• 95.3%
– Exception Reports
– ~400 proactive work orders issued for Pilot Area
– $200K (12 months, in one of 7 areas)
Irving Oil ODR Program
– $200K (12 months, in one of 7 areas) saved resulting from Operations minor maintenance activities
– Operator awareness of reliability gaps
– Improving communications between the field and the office
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“At Irving Oil, we believe
Operations can have a bigger
impact on asset reliability than
Irving Oil ODR Program
impact on asset reliability than
our maintenance department”
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Questions & Answers