3 rd rd Plant Maintenance in Middle East Plant Maintenance in Middle East January 10 - 13, 2010 – Abu Dhabi, UAE January 10 - 13, 2010 – Abu Dhabi, UAE Qadeer Ahmed Qadeer Ahmed Senior Reliability Engineer Senior Reliability Engineer Asset Management to improve Plant Reliability DELIVERING ENERGY TO THE WORLD
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33rdrd Plant Maintenance in Middle East Plant Maintenance in Middle EastJanuary 10 - 13, 2010 – Abu Dhabi, UAEJanuary 10 - 13, 2010 – Abu Dhabi, UAE
– KPIs Monitoring the performance– Process and Equipment Reliability– Retrieving the data from MMS to analyze– Queries MMS data for reports– Condition Assessment
DELIVERING LNG TO THE WORLD
Why Asset Management?• Focused approach to Improve Maintenance & Reliability
– Repair base to Reliability base
• Ensure High Availability– Proactive availability modeling rather knowing by incident
• Contribution to Company's Vision– Customer Satisfaction, Efficient and Reliable Operations– Financial Performance
• Provide Better Control and Sustainability– Proactively involve in monitoring and efficiently managing assets.
• Teamwork & Organization Learning– Develop strong relationship among cross-functional teams
DELIVERING LNG TO THE WORLD
Asset Management at Qatargas
DELIVERING LNG TO THE WORLD
AM Philosophy at QG:
• Asset Centric Approach using Meridium• Philosophy at Qatargas:
– Root Cause & Failure Analysis: Critical Failures, Bad Actor Elimination
– Condition Assessment: Calibration, Inspection and Thickness Management
DELIVERING LNG TO THE WORLD
Criticality Assessment, Growth Analysis
Efficiency & Utilization Loses
Nameplat eLine
N ameplateOutput
Cut back Loss es
Process Reliab ility = 94%
Demonstrated Output (Eta) @CDF = 63.2% or R=36.8%
Product ion: Et a =1 03 63 T/ D , Be ta= 2 0
Los ses
Demons trated Weibull Production L ine
Efficiency & Utilization Loses
Nameplat eLine
N ameplateOutput
Cut back Loss es
Process Reliab ility = 94%
Demonstrated Output (Eta) @CDF = 63.2% or R=36.8%
Product ion: Et a =1 03 63 T/ D , Be ta= 2 0
Los ses
Efficiency & Utilization Loses
Nameplat eLine
N ameplateOutput
Cut back Loss es
Process Reliab ility = 94%
Demonstrated Output (Eta) @CDF = 63.2% or R=36.8%
Product ion: Et a =1 03 63 T/ D , Be ta= 2 0
Los ses
Demons trated Weibull Production L ine
Production Weibull
Reliability – Growth Analysis
DELIVERING LNG TO THE WORLD
Meridium – RCM, RCA, Record Manager
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Challenges, Critical Success Factors & Results
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Challenges / Critical Success Factors:
• Committed Leadership– Continuous Support and Commitment
• Adequate & Dedicated resources to Implement, Control and Sustain
• Organizational Culture – Proactive rather Reactive
• Ensure Good Quality Data– Required good quality data to produce good results
• Cross-functional teamwork• Employee Training & Workshops
DELIVERING LNG TO THE WORLD
Results
• Safety• Onshore
– Six years LTA free• Offshore
– Seven years LTA free
• Reliability – Reduced Critical Trips– Significant drop in Loss Production Events– Improved Plant Availability and Reliability
• Others Provides up-to-date database with maintenance & equipment information Proactive rather reactive approach Integration/Interface among different systems SAP/Meridium etc.
DELIVERING LNG TO THE WORLD
Finally, Asset Management is Cross-functional Activity