Reliability Program Approval Presentation_
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Transcript of Reliability Program Approval Presentation_
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Reliability Centered Maintenance in CPPL
RCMRCM
ReactiveReactive Time-BasedTime-Based Condition-BasedCondition-Based ProactiveProactive
•Small items•Non-critical•Inconsequential•Unlikely to fail•Redundant
•RCFA identified•Age exploration•FMEA identified•Acceptance testing
•Failure pattern known•Subject to wear out•Consumable replacement
Time Based Failures Cover 8% to 23% of failures.
•Random failure pattern•Not subject to wear•PM will not prevent these failures!
Condition Based Failures Cover 77% to 92% of failures
5% of work
35% of work
50% of work
10% of workGoals:
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What is Reliability?
Good Design
Quality Construction
Excellence in Operations
Excellence in Maintenance
Inspections and Analysis
Reliability is the sum of these 5 elements. Therefore, we all own reliability!
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Reliability Centered Maintenance in CPPL
RCMRCM
Condition-BasedCondition-Based
50% of work
Starting place for this decision moment:• Critical rotating equipment and engines• Gear boxes• Lubrication• Related motors
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RCM Technologies Provided Vibration Data Collection
• Pipelines (460+ Most Critical Assets)
• Terminals (20 – 40 Most Critical Assets)
Oil Sample Collection• Monthly (Engines)
• Quarterly (Gearboxes and Large Oil Systems)
Repair and Installation Standards and Specifications • Must go out in 2012 to all facilities.
Other Technologies• Ultrasonic
• Electrical Testing
• IR Thermography
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Analysis and Reporting Details Vibration Analysis & Oil Analysis, Reporting w/recommendations
Website Dashboard Available for all Assets • Quickly Monitor & Review Asset Status
• High Level
• Technical Detailed Reports
• Vibration Analogs -> SCADA-> PI-> Reliability Team
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Mobile Diagnostic System
EASY INSTALLATION
RAPID CONFIGURATION
CLEAR DIAGNOSTICS
NEAR REAL-TIME ONLINE ACTIONABLE DIAGNOSTICS
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Network and Communications Flexibility
Communications with SAP/CMMS SCADA / PI 2010Reliability Team
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RCM – Phased Approach
Outsourced Data Collection, Analysis &
Recommendations
Eng. Services Review and
Work Request
Rotating Equip. Leads
Plan & Perform Work
Phase I
Outsourced & Auto Data Collection
Eng. Services Analysis, Recommendations & Request (add RE in year
three)
Planners & Schedulers (will have to
identify resources –team working this)
Rotating Equip Leads Perform
Work
Phase II
Auto Data Collection & Lubricants
Program
Planners & Schedulers
Rotating Equip Leads Assess
Data & Perform Work
Phase III
Eng Services Analysis, System Maintenance
and Program Evolution
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Reliability Centered Maintenance in CPPL
$0.0$0.5$1.0$1.5$2.0$2.5$3.0$3.5$4.0
Millions
Inst
rum
enta
tion
Pipes
Rotatin
g Equip
Unknown
Tanks
Light
ing
Elect
rical
Safety
Buildin
gs
Facili
ties
Boilers
Mis
c
Mar
ine
Maint $/YR
A portion is electric motors for rotating equipment
A portion is critical rotating equipment and engines
Numbers have some amount of uncertainty
App. $3.2MM/yr
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Economic Drivers
Rotating Equipment et al$3.2MM/YR
Electrical Motors$1.2MM/YR
Actual Yearly Breakdown Maintenance Costs
• 60% of the spend is Pipelines• 40% of the spend is Terminals
• East GC Terminals has already put in place a contract program to stabilize their spend or it would be higher
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Goals and Assumptions Goal: Reduce spend by 65% over a five year period and sustain
• Fully expect a $2 MM/year reduction in spend when mature
AssumptionsP10 case: 20% reduction in cost per year
P50 case: 30% reduction in cost per year
P90 case: 35% reduction in cost per year
13% Discount rate used
Program Costs• Contractor Costs: $1.2MM +/- 20%
• Additional Reliability Eng. in year 3
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Impact to Operations CFR pricing came in at 1.25MM versus .5MM
Great Idea Poor Business Case
Discussion with Todd Tullio• Condition Based Monitoring Technicians - Does not meet 4 part qualifications for O/Q
qualification.
• Pipeline and Hazardous Materials Safety Administration – Subpart G –Qualification of Pipeline Personnel 195.501 (a) (b) 1,2,3,and 4.
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NPV & Tangible Benefits
Free-up resources for
more value added
condition driven
maintenance(↓$)
Optimized PdM
Technologies &
Frequency(↓$)
Reduce Non- Value Added
time driven maintenance(↓$)
SAP/CMMS Structure: Optimum Data, PM Optimization 40%, Awareness Training, Source & Failure Codes ID
Criticality
Assessm
ents Improved
Improved Operator Safety
Operator Safety
One size does n
ot fit all
due to criticality
ratings (↓$)
Maintenance & Reliability Manual – Unity, Governance & Accountability w/RACI allocations to each job function.
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East Gulf Coast Terminals Division 2010 experienced a Equipment Breakdown Cost of $1MM – $1.2MM in one
year.
Implemented Vibration Program in Early 2011.
Experienced no unscheduled breakdowns after vibration program was implemented.
Able to perform acceptance testing.
Repaired old equipment to expected standards (w/o new replacement) to insure optimum operation.
End Results – Alvin Brass and Olvice Greenwood are very happy with the success of their new vibration program.
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Cost DistributionPipeline and Terminal Divisions
Pipeline Division (June 2012 –Dec. 2012 $180,000 = TOTAL
PIPELINE BUSINESS
$36,000 = EACH PIPELINE
DIVISION
Terminals Division (June 2012-Dec. 2012) $120,000 TOTAL
TERMINAL BUSINESS
$24,000 = EACH
TERMINAL DIVISION
Pipeline Division 2013 $360,000/YR. $72,000 YR./DIV.
Terminals Division 2013 $240,000/YR. $28,800/DIV.
Note: The pricing could change by +/- 20% as we are currently going through final negotiations with CBM service provider.