Equipment Reliability Strategy FMRIMS@STRATEGY

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Equipment Reliability Strategy FMRIMS@FacStrategy

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Presentation Agenda Background FMRIMS Equipment Degradation Template

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Private & Confidential 3 FMRIMS@FacStrategy can identify issues that cause operational problems which can result in significant business loss. FMRIMS@FacStrategy can establish the key elements of effective maintenance, reliability and integrity activities Best Practice, Procedures, Instructions, Standards and Competence

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Reliability Mindset Skilled Workforce Effective Leadership Design It Right Operate It Right Fix It Right Stable Unit Reliable Equipment Flawless Operation Equipment Reliability Strategy Foundation of Operational Excellence PROACTIVELY DEFINE CAPABILITY and NEEDS of the process and equipment based upon criticality ANALYZE LOSSES to drive continuous improvement OPERATE WITHIN CAPABILITY of process and equipment EFFICIENTLY and EFFECTIVELY PROVIDE NEEDS of equipment and process

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5 Benchmarking Analyzes ability to meet its strategic goals and objectives as compared to pacesetters. Defines performance and best practices gap. Prioritizes critical capability gaps across the improvement program Provides analytical foundation for resource allocation Maximizes organization investments to optimize its capabilities Provides linkage between strategic direction, practicability and organization capability Benchmarking Availability / Reliability / Cost Improvement Program Decision Gap Closure Evaluation Assessment of Practice at Pacesetters? Gap Definition Assessment where others are? MC

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8 Expected Reliability Performance with Best Practices Implemented Equipment MTBF, yr Centrifugal pump (ANSI) 4.0 API Pumps, except slurry pumps 7.6 Centrifugal compressors (clean services) 8.2 Centrifugal compressors (fouling services) 5.6 Screw compressors, liquid injected 6.2 Screw compressors, dry type, clean gas 4.0 Axial compressors 8.0 Reciprocating compressors, labyrinth-piston type 7.8

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Presentation Agenda Background FMRIMS Equipment Degradation Template

Equipment Strategy: 

Equipment Strategy Structured approach to define minimum maintenance needed to achieve unit performance requirements Teams Accomplish Objective Through: Cross-functional Team of Skilled Members Assess equipment’s functional requirements Identify equipment and component failure modes and degradation mechanisms Assess risks for continued operation of the equipment assuming continued degradation Cost-effective mitigation of unacceptable risks

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Equipment Degradation Template at your fingertip = FMRIMS@FacStrategy ?

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Equipment Degradation Template (or EDT): What it is: An Equipment Degradation Template or EDT is a document included providing information related to equipment degradation mechanisms (EDT’s), their probability and tasks to be applied for mitigation. There are EDT's for fixed equipment, machinery and some other equipment types. There also process EDT's, e.g. for fouling and catalyst deactivation. How it is used: EDT's are used in the development of Equipment Strategies for equipment and systems. Systematic use of EDT’s enhances the quality and consistency of equipment strategies and is the basis for an efficient process. In work selection, EDT's are used to assess the probability of failure as used in the unmitigated Risk. They are also used to assess the effectiveness of proposed tasks in mitigating the probability of failure.

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There’s a good analogy of EDT’s with the medical profession Medical Doctors have a library of possible diseases and use symptoms, past history, test / assessment to diagnose the cause. Engineers also use list of possible disease (EDT’s) that equipment can suffer and use past history, symptoms, operating conditions, etc to diagnose possible cause and develop remedial / improvement actions. It’s easier, less expensive, and healthier (safer) to prevent diseases than it is to cure them We would all rather know and practice the necessary lifestyles that will prevent us from having lung cancer or heart disease than it is to cure either after we contract them Same is true with EDT’s for equipment Preventing vibration, fatigue, cracks, leaks, ruptures, high corrosion rates, and metallurgical degradation is usually easier, much less expensive, and safer than coping with the aftermath of equipment failures.

Equipment Degradation Templates: 

Equipment Degradation Templates Concise guidance for equipment and components Degradation mechanisms Failure modes Probability of occurrence Mitigation Strategies to reduce risks (typically mitigate probabilities) Sources: Third party equipment and materials specialists Industry experience Equipment Degradation Template

-- Review of Equipment Degradation Template --: 

Coverage: Centrifugal Pumps, Centrifugal Compressors, Reciprocating Compressors, Steam Turbines, Gas Turbines, Fans, El. Motors, Expanders, Diesel Engines, High Speed Gears -- Review of Equipment Degradation Template --

-- Review of Equipment Degradation Template --: 

Coverage: Material Templates, Instrumentation Templates, Electrical Templates, Fixed Equipment, Facilities Templates, Other Templates, -- Review of Equipment Degradation Template --

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17 Conceptual Design / Process Design Detailed Engineering Procurement Construction / Installation Operation Maintenance Commissioning / Start-up Facility Maintenance Risk and Reliability Management Decommissioning Technical Standards Project Manager Manual Project Engineering Manual Design Engineering Manual Design Procedure / Controls Mechanical Engineering Manual Suppliers List Purchasing Procedure Standard Contracts Manual Standard Suppliers Manual Field Engineer Manuals Installation Standards Non Process Quality Control Manual Inspections Manual Startup Manual Turn Over Procedure Testing Procedures Manual Commissioning Manual Operating Manual Troubleshooting Manual Procedures Job Task Analysis Training Spare Parts Repairs Planning Reporting / Failure Codes Engineering Specialists Subject Matter Experts Manuals Asset Improvements Process Manual Defect Elimination Manual Project Development Manual Process Selection Economics Project Economics Cost Estimating Manual Equipment Design Practices FMRIMS BEST PRACTICES FMRIMS Leadership Objectives Organization Process Plan Assessment Review 1 8 7 5 4 3 2 11 9 10 6

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