IBM Maximo and EXP Enterprise to Reliability at Oman · Using IBM Maximo and Ivara EXP Enterprise...
Transcript of IBM Maximo and EXP Enterprise to Reliability at Oman · Using IBM Maximo and Ivara EXP Enterprise...
Using IBM Maximo and Using IBM Maximo and Ivara EXP Enterprise to Ivara EXP Enterprise to Improve Asset Reliability Improve Asset Reliability p yp y& Performance at Oman & Performance at Oman Refining & PetrochemicalRefining & PetrochemicalRefining & PetrochemicalRefining & Petrochemical
Denis Marshment, Director, Asset Dynamics Asia‐ Project Manager in Oman
TopicsTopics
• Introducing Mina Al-Fahal Refinery (MAF)• Background to Project RCM at MAFg j• Implementation strategy• Examples of MAF implementation approach• Examples of MAF implementation approach• Next steps• Critical success factors
Mina al Mina al FahalFahal RefineryRefinery
• Part of Oman Refineries &Part of Oman Refineries & Petrochemicals Company (ORPC)
• Oman’s first refinery, commissioned in 1982
• Revamped in 1997 with total capacity of 107,000 bpd
• Employing:– 140 Operations– 60 Maintenance & Reliability
• Simple process producing:– Mogas– Mogas– Kerosene– Diesel– Light Residue (For further g (
processing)– LPG & Fuel Gas
Project ScopeProject Scope
• Diagnostic Report• Asset Prioritization.• Reliability Centered Maintenance (RCM2) Analysis
• Crude Unit• Platformer Unit
• Implementation of RCM
Challenges with this strategyChallenges with this strategy
• Deploying RCM across a large asset base• Working with limited resource availability• Converting RCM analysis into actual work• Implementing the new work practices in the field• Implementing the new work practices in the field• Tracking the benefits & monitoring performance• Sustaining the programmeSustaining the programme
RCM OutputsRCM Outputs
Condition & State
Condition & State
Human Senses85%
Human Senses85%
Descriptive80%
Descriptive80%
Failure Finding33%
Failure Finding33%M
Inspection92%
Inspection92%
Maintena
NumericNumericPredictive
25%Predictive
25%
ance Pro
Time BasedTime Based
Predictive Tech
Predictive Tech
Preventive 5%Preventive 5%
gram
Run to Failure33%
Run to Failure33%
We need effective tools for data collection & analysis
Redesign 4%Redesign 4%
data collection & analysis
IvaraIvara EXP EXP Execute
WorkIdentify the
Right Work at Ri ht Ti
Predict Asset Health
Maximo
Right TimeProcess Control Tools
Asset Management
Maximo
Asset Prioritization
Inspections
Work Order Management
Planning &Scheduling
Condition-based management
Rules-based diagnostic
RCMSc edu g
MRO Materials
Procurement
Tasks and Jobs
engine
Indicator-based job triggers
Performance Predictive Tools
Personnel &Trades
analysis and tracking
Applied RCM
RCM PROJECT ACTIVITIESRCM PROJECT ACTIVITIES
• Commenced in July 2009• Asset Prioritization Analysis – all system ranked- August
2009.• RCM Analysis – 26 analysis completed – Dec 2009RCM Analysis 26 analysis completed Dec 2009
o Crude unit.o Platformer Unit.
• RCM Analysis Implemented into Ivara EXP– Jan 2010o 26 analysiso 7,000+ action planso 50,000+ indicators
Work Order IntegrationWork Order Integration
RCM
MaximoIvara EXP
Asset Reliability Program
O C diti-On Condition-Failure Finding-Schd Restoration-Corrective-Redesign-Run to Failure
Alarm Management
Work Orders
Work Orders
Condition Indicators
Check Sheets
Run to Failure
Status Updates
Maximo IntegrationMaximo Integration
RCMMaximoIvara EXP
Asset Reliability Program
-On Condition
RCMStatus Updates
Work Orders
-Failure Finding-Scheduled Restoration-Corrective-Redesign-Run to Failure
Alarm Management
Work Orders
Condition Indicators
Check Sheets
PMStandard
TasksStandard
Jobs Triggering Rule
Job Plan
SKF Aptitude IntegrationSKF Aptitude Integration
Vibration Reading
AptitudeVibration OPC Manager
OPC ServerVibration Monitoring Solution
OPC Manager (OPC Client)
Using standard jobs to trigger pump Using standard jobs to trigger pump changechange oversoverschange change oversovers
Standard Task (Job Plan)(Job Plan)
Standard Job / TriggerStandard Job / Trigger(PM)
Asset information Asset information –– now now digitized and easily retrievabledigitized and easily retrievabledigitized and easily retrievabledigitized and easily retrievable
Calculating calibration span error for Calculating calibration span error for intervalinterval OptimisationOptimisationinterval interval OptimisationOptimisation
Custom data cards and attachments Custom data cards and attachments replace paper recordsreplace paper records
Drawings & other documents Drawings & other documents linked to the RCM processlinked to the RCM processlinked to the RCM processlinked to the RCM process
Next stepsNext steps
C ti ith ll t t th f th l t• Continue with rollout to other areas of the plant• Increase usage by maintenance groups
I kill f li bili• Improve core skills of reliability support team• Continue to monitor compliance• Identify & quantify potential benefits
Critical success factorsCritical success factors
Top level management support & leadership• Top level management support & leadership• Motivated client team / flexible consulting team• Internal marketing campaignInternal marketing campaign• Emphasis on development of RCM templates• Fully leverage Ivara EXP capabilitiesy g p• Establish internal core team to support maintenance groups • Establish KPI’s to monitor compliance & performance