Transcript EQUATE PETROCHEMICAL COMPANY Why do RCM?

EQUATE PETROCHEMICAL COMPANY
EQUATE RCM Project
Implementation
By Khalid Al-Anzi
EQUATE PETROCHEMICAL COMPANY
EQUATE Profile
An ISO 9001:2000 & ISO 14001 $2B company established in 1996.
Owned By:
Petrochemical Industries Company, Kuwait
The Dow Chemical Company, USA.
Boubyan Petrochemical Company, Kuwait
Products:
Ethylene, Ethylene Glycol, Poly Ethylene, Poly Propylene.
Vision of The Company
Obligated to Adding Value to our Customers .
Value of the company
Ensure our culture is a model for Standards and Best Practices.
EQAUTE Future
EQUATE is expanding to add another $4B in capital assets.
EQUATE PETROCHEMICAL COMPANY
EQUATE Reliability Initiatives & Growth
2006 EQUATE Major Turn Around
RCM Project Implementation Completed
Reliability Section Fully established
2005
Operator Driven Reliability Program
initiated
Fire Fighting
Event Driven
2004
RCM project Started
Optimization of Work Processes
2003 Reliability Engineering initiated
2002-4 Full RBI program established
2000-02 Full PPM program established
1999 EQUATE 1st TA
1997 EQUATE Started
1994-6 EQUATE
Construction
Fire Prevention
Reliability Driven
EQUATE PETROCHEMICAL COMPANY
Why do RCM?
Optimize Preventive Predictive Maintenance activities.
Understand the risks associated with our Equipment/System Failures
and how to manage them.
Change EQUATE PPM Program approach from an Event Driven to a
Reliability Driven.
Ensure that EQUATE Assets are performing at the levels demanded by
our customers.
Change the culture to promote “Data” approach vs. “I feel” approach.
EQUATE PETROCHEMICAL COMPANY
RCM Project Objectives
PPM Evaluation and optimization through:
Implementation of RCM for all operating EQUATE Plant facilities by end of
2006.
Update all PPM plans in EQUATE CMMS System with the RCM frequencies and
tasks by Year end of 2006.
Extract Operator Driven Reliability (ODR) tasks from RCM analysis by end of
2006.
Ensure continuous improvement process to sustain RCM after implementation.
EQUATE PETROCHEMICAL COMPANY
RCM Project Stages
Project initiated and sponsored by EQUATE Management in January 2004 and started in March
2004.
The implementation team Consisted from Maintenance (Core) ,Operation and Reliability members .
RCM Implementation Phases were:
Data Collection & Criticality Analysis.
Data Analysis.
Frequency Optimization & Task Grouping.
CMMS Update and implementation.
Sustain RCM.
Use of Strategic RCM Turbo and Strategic Resources as support during the project.
EQUATE PETROCHEMICAL COMPANY
RCM Analysis Results
Discipline
ELECTRICAL
Number Of
Failure Modes
Equipment
Strategy
Number of Failure
CBM
1598
FTM
1689
OTF
1987
1329
291
INSTRUMENT &
ANALYZER
MECHANICAL
CBM
3751
1339
Failure Modes Total
FTM
5945
OTF
12246
CBM
2731
FTM
1898
OTF
2019
30404
EQUATE PETROCHEMICAL COMPANY
RCM Project Expectations
Types of Equipment
Total
Equipment
Analyzed
Average Yearly
Man-Hours
Before RCM
Expected
Average
Man-Hours
After RCM
Delta %
Mechanical
1339
9009
7905
-12%
Electrical
1329
6904
4031
-42%
Instrument
2711
10576
7208
-32%
Analyzers
1040
16691
10973
-34%
Total
6419
43180
30117
-30%
EQUATE PETROCHEMICAL COMPANY
ODR-RCM expected Results
Task
Total
Number of Rotating Equipment Analyzed
614
Total hours for Vibration & Lubrication
Checks before RCM
3663
Vibrations & Lube Checks Hours
Transferred to ODR after RCM
2462
Total Hours Expected after
RCM
1221
ODR RCM Driven Tasks
•Vibration Readings.
•Lube level checks and Sampling.
•Look Feel Listen Tasks.
EQUATE PETROCHEMICAL COMPANY
Realized Results in 3Monthes
Types of
Equipment
3M Average
Man-Hours
Expected Hrs
After RCM
Actual Hours
Electrical
413
81
58
Instrument
1277
187
169
Analyzers
1453
1032
1080
Total
3142
1300
1307
58% Realized
EQUATE PETROCHEMICAL COMPANY
Lessons Learnt
•
•
•
DATA, DATA, DATA
– Document history in Failure Mode Format not activity Based format.
– Educate your maintenance organization on the importance of DATA documentation and
mining.
– Establish standard format on data gathering, documentation and storage into your
CMMS.
– Let your CMMS work for you.
Reliability Analysis
– Distinguish between real failure modes and symptoms.
– Root Cause Successes as well as Failures.
– Probability, Probability Growth Charting and Reliability Modeling will let the DATA talk.
– Listen to the data.
Sustain Performance
– Integrate your PPM Tools into your work processes to ensure alignment and performance.
– Set challenging goals and targets, then Reward achievements.
– Measure, Analyze, Improve, control then do it all over again.
EQUATE PETROCHEMICAL COMPANY
Thank You