GRS 1 Global Reliability System Refining Congress - Argentina Refining Congress - Argentina D.E. Fitzgerald.

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GRS

Global Reliability SystemGlobal Reliability System

Global Reliability SystemGlobal Reliability System Refining Congress - ArgentinaRefining Congress - Argentina

D.E. Fitzgerald

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GRSEXXONMOBIL GLOBAL RELIABILITY SYSTEMEXXONMOBIL GLOBAL RELIABILITY SYSTEM

AgendaAgenda

• System OverviewSystem Overview

• Q&AQ&A

–Review ExxonMobil’s Global Reliability System in Review ExxonMobil’s Global Reliability System in sufficient detail to provide an understanding of how sufficient detail to provide an understanding of how the system achievesthe system achieves

•Improved facility reliability Improved facility reliability

•Improved maintenance effectivenessImproved maintenance effectiveness

ObjectivesObjectives

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GRSGRS - BACKGROUND

GRS supersedes and replaces earlier ExxonMobil GRS supersedes and replaces earlier ExxonMobil systems which date from the mid 90’ssystems which date from the mid 90’s

GRS is a Global Common System, a common framework for Reliability Improvement • Facilitates Identification and Accelerated Application of Global

Best Practices

The System has requirements, supported by practices; benefits are obtained from the Practices, the “how to’s”

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GRSGlobal Refinery Maintenance CostsGlobal Refinery Maintenance Costs 1996 - 20021996 - 2002

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GRS

Reliability & Maintenance ResultsReliability & Maintenance Results

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GRSReliability DefinitionReliability Definition

ReliabilityReliability is the probability that assets will is the probability that assets will produce theproduce the required product, required product, at theat the target rate target rate

without interruption for awithout interruption for a predetermined time, predetermined time, within within applicable quality applicable quality specifications, when specifications, when

the assets are operated within a specified design the assets are operated within a specified design andand operating envelope. operating envelope.

Meet run plan targets

Run till next scheduled shutdown

100%Right First Time

Keep within “Process Operating Window”.

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GRS

Table of Contents

IntroductionElement 1 Management Leadership,

Commitment & Accountability Element 2 Risk Assessment & Management Element 3 Facilities Design& ConstructionElement 4 Process & Facilities Information

and DocumentationElement 5 Personnel and Training Element 6 Operations and Maintenance

6A Site Plans and Objectives6B Operating Envelope6C Equipment Strategy6D Work Selection6E Routine Work Planning, Scheduling

and Execution6F Turnaround/Shutdown Work

Planning, Scheduling, and Execution6G Loss Monitoring and Response6H Operator Care6I Abnormal & Non-Routine

Operations6J Performance Improvement

Element 7 Management of ChangeElement 8 Third Party ServicesElement 9 Incident Investigation & AnalysisElement 10 Community Awareness and

Emergency ResponseElement 11 Global Reliability System

Assessment and ImprovementAppendix 1 Glossary

PurposeExpected ResultsRequirementsKey MeasurementsLinkagesInputs & Outputs

Global Reliability System

ELEMENT

GRS – Intranet Web-based Manual GRS – Intranet Web-based Manual ContentsContents

WhitePapers

Practices

ProcessSummaries

Detailed

Examples

Overview

(Optional)

Practices Practices and and

ExamplesExamples

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GRS

ImproveImprove11

GRS Assessmentand Improvement

6J

PerformanceImprovement

OIMS andSupportingElements 10

Community Awareness

7

Managementof Change

4

Process & FacilitiesInfo & Documentation

3

Facilities Designand Construction

5

Personneland Training

8

Third PartyServices

ProactiveLeadership, Plans,Objectives and Strategies

ProactiveLeadership, Plans,Objectives and Strategies

1

ManagementLeadership

6A

Site Plans & Objectives

2

Risk Assessmentand Management

6C

Equipment Strategy

6B

Operating Envelope

6D

Work Selection

EffectivePlanning, Scheduling and Execution

EffectivePlanning, Scheduling and Execution

6H

Operator Care

6I

Abnormal andNon-Routine Operations

6G

Loss Monitoringand Response

6F

TA/Shutdown Planning,

Scheduling & Execution

6E

Routine Work Planning,

Scheduling & Execution

DenotesOut of Program Work

ReactiveReactive9

Incident Investigationand Analysis

System Simplified FlowSystem Simplified Flow

Plan Execute

Analyze

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GRS

• Complete 100% of Annual Plan • All work planned and scheduled• Job Packs developed and used• Correct spare parts and

tools available • Repairs completed right

first time and on schedule • Repairs documented

Design it Right

Stable UnitReliable Equipment

Operate it Right

Fix it Right

• Equipment design supports high reliability

• Operate within defined envelopes

• Structured rounds to monitor & care for equipment

• Planned response to unit upset or non-routine operation

• Monitor losses daily against set targets, identify cause, take corrective action

• Changes managed

SKILLED WORKFORCE EFFECTIVE LEADERSHIPSKILLED WORKFORCE EFFECTIVE LEADERSHIP

• Training and procedures provided to Operations and Maintenance

• Equipment maintenance needs and operating envelopes defined

RELIABILITY MINDSETRELIABILITY MINDSET

GRS OVERVIEWGRS OVERVIEW

PROACTIVELY DEFINE PROACTIVELY DEFINE CAPABILITYCAPABILITY and and NEEDSNEEDS of the of the process and equipment based process and equipment based

upon criticalityupon criticality

OPERATE WITHIN CAPABILITYOPERATE WITHIN CAPABILITYof process and equipmentof process and equipment

EFFICIENTLY and EFFICIENTLY and EFFECTIVELYEFFECTIVELY

PROVIDE NEEDSPROVIDE NEEDS of of equipment and equipment and

processprocess

ANALYZE LOSSESANALYZE LOSSES to drive continuous to drive continuous

improvementimprovement

GRS drives the following key concepts . . .GRS drives the following key concepts . . .

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GRSGRS OVERVIEWGRS OVERVIEW

In order to achieve this RELIABILITY,

DEFINE the CAPABILITY of the process and equipment Operating Envelopes (6B) Equipment Strategies (6C)

Ensure that we OPERATE WITHIN THAT CAPABILITY Operator Care (6H) Abnormal and Non-Routine Operation (6I)

To be COMPETITIVE,

OPTIMIZE support effort consistent with the potential loss and probability of that loss Work Selection (6D) Annual Planning (6A)Planning, Scheduling and Execution (6E/F)

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GRS

Expected Results:Expected Results:

Sustainable reliability, availability and manufacturingSustainable reliability, availability and manufacturing(maintenance and operations) cost performance that is consistent with (maintenance and operations) cost performance that is consistent with Business objectivesBusiness objectives

An organization that understands and is working to achieve theAn organization that understands and is working to achieve thesite's reliability, availability, and manufacturing cost objectivessite's reliability, availability, and manufacturing cost objectives

Leadership and commitment that is demonstrated throughLeadership and commitment that is demonstrated throughmanagement behavior and visible actionsmanagement behavior and visible actions

ELEMENT 1 - LEADERSHIPELEMENT 1 - LEADERSHIP

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GRS

6C Equipment 6C Equipment StrategiesStrategies

6B Operating6B OperatingEnvelopesEnvelopes

6H Operator Care6H Operator Care 6I Abnormal & Non-6I Abnormal & Non-routine Operationsroutine Operations

6A Site Plans and 6A Site Plans and ObjectivesObjectives

6D Work Selection6D Work Selection

6E Routine Work P/S/E6E Routine Work P/S/E6F Turnaround P/S/E6F Turnaround P/S/E

Critical Critical EquipmentEquipment

PM scope & PM scope & frequencyfrequency

Monitoring Monitoring tasks based tasks based on criticality on criticality

Effective/efficient field Effective/efficient field rounds & console monitoringrounds & console monitoring

Effective, Effective, efficientefficient

unit maintenanceunit maintenance

Effective response to Effective response to minimize lossminimize loss

Critical Critical Operating Operating ScenariosScenarios

Key Linkages (6C)Key Linkages (6C)

Operating Envelopes for Operating Envelopes for Process Critical ParametersProcess Critical Parameters

1 Year 1 Year PlanPlan

Breakdown / Breakdown / Discretionary Discretionary

WorkWork

Latest Acceptable CompletionLatest Acceptable Completion

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GRS

• Equipment Strategy practices defined for each equipment type:Equipment Strategy practices defined for each equipment type: - fixed equipment - machinery - electrical- fixed equipment - machinery - electrical

- instruments - analyzers -infrastructure- instruments - analyzers -infrastructure

• Strategy defines the interventions necessary to protect the Strategy defines the interventions necessary to protect the reliability of the equipmentreliability of the equipment

• predictive and preventive maintenancepredictive and preventive maintenance

• operator monitoring tasksoperator monitoring tasks

• design improvements design improvements

• job packs and spare parts job packs and spare parts

• Strategies are living documents - continuously improved and Strategies are living documents - continuously improved and updated with updated with

• changes in operating context changes in operating context

• learnings from repairs and failureslearnings from repairs and failures

Element 6C - Key RequirementsElement 6C - Key Requirements


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GRS

Strategies developed using RCM principlesStrategies developed using RCM principles

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Potential FailuresPotential Failures

Point Where Failure

Starts

P

Point Where Failure is Detectable(depends on inspection technique)

Point Where it has Failed(depends on operatingcontext)

F

Time

Cond

ition

P-F Interval

Time from Detection to Failure

Monitoring Interval = 1/2 of P-F Interval

Element 6C - Key RequirementElement 6C - Key Requirement


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RCM ReviewRCM ReviewFailure PatternsFailure Patterns

A

B

C

D

E

F

Infant Random Wearoutor External

The right tasks at the right time:

Replace Reciprocating CompressorRider Bands - Replace Annually

Reciprocating Compressor RodPacking. Replace every 2 years

Pump Shaft Fatigue Failure - NoScheduled Maintenance

Compressor Bearing - monitoring only

Resistor - No Scheduled Maintenance

Instrumentation - failure finding

Will Time Based Will Time Based PM Task bePM Task be

effectiveeffective Will ConditionWill ConditionMonitoring Task beMonitoring Task be

effectiveeffective

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GRS















Key Linkages (6B)Key Linkages (6B)




WorkWork

Latest Acceptable Completion Latest Acceptable Completion Date based SDD’sDate based SDD’s

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GRS

““Integrated Operating Envelope” Integrated Operating Envelope”

If an operating parameter has multiple limits, the “IntegratedIf an operating parameter has multiple limits, the “IntegratedOperating Envelope” is the result of the most restrictive of these limits Operating Envelope” is the result of the most restrictive of these limits

Tier ITier ILimitsLimits

Tier 3Tier 3LimitsLimits

Many Optimisationand lower impactReliability related

Envelopes

Tier 2Tier 2LimitsLimits

IntegratedIntegratedOperatingOperatingEnvelopeEnvelope

Highimpact Reliability

Envelopes

PredominantlySHE and

higher impact Reliability related

Envelopes

OPERATING ENVELOPESOPERATING ENVELOPES

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GRS

Minimum Tasks PerformedMinimum Tasks PerformedWhich Parts are Operator Care?Which Parts are Operator Care?

Visual Equipment Checks

Check Equip Temp, Pressure, Amps, etc.....

Check Lubrication, Look for Leaks

Check Vibration

Clean Equipment

Grease/Oil Equipment

Change Oil

Tighten Belts

Replace Filters

Repair Leaks

Change Safety Valves

Improve Equipment Access

Control Process

Check Process Conditions

Make Rounds

Housekeeping

Check Critical Devices

Troubleshoot Instrument/ Electrical Problems

Equipment PM Tasks

Clean Exchanger

Remove Field Equipment for Shop Work

Replace Corroded Pipe

Replace Leaking Valve

Dismantle/ Repair/ Reassemble/ Reinstall Failed Equipment

Equipment PM/Pd Data Analysis

Optimize PM/Pd Tasks and Frequency

Equipment Failure Analysis

Bad Actor Identification and Corrective Action

Identify/ Eliminate Unjustified or Idle Equipment

Change to New Type Pump Seal

Revise Piping or Exchanger

Select and Install New Bearing

New Design to Meet SHE Requirements

Design Change to Meet Changed Process Requirements

Capacity Creep

Operate Monitor Basic Service Special Service Repair Diagnose Modify Redesign

OperationsOperationsGGAAPP

MaintenanceMaintenanceGGAAPP

EngineeringEngineeringGGAAPP

Traditional StateTraditional State

OPERATE IT RIGHTOPERATE IT RIGHT

Operator CareOperator Care

Expectations with GRSExpectations with GRS

MaintenanceMaintenance

MAINTAIN IT RIGHTMAINTAIN IT RIGHT

EngineeringEngineering

RE-DESIGN IT RIGHTRE-DESIGN IT RIGHT

GRS OVERVIEW WORKSHOPGRS OVERVIEW WORKSHOP

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GRS















Key Linkages (start & end 6D, 6E & 6F)Key Linkages (start & end 6D, 6E & 6F)




WorkWork

Latest Acceptable Completion Latest Acceptable Completion Date based SDD’sDate based SDD’s

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GRS

6E/6F6E/6FPS&EPS&E

WORK SELECTION - Work FlowWORK SELECTION - Work Flow

TAProgram

AnnualProgram

Breakdown(Functional

Failure)Discretionary

REJECT (Not met criteria)(Not met criteria)

Plan & Schedule(based on resource + material availability)

NonCRIT

Standard Repair Timeframe by

Equipment Class

VCRIT

Break-in to Schedule

In-Program (future) Out-of-Program

All WorkAll WorkScreener

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GRS

Benefit to CostBenefit to Cost

• A target benefit-to-cost ratio is defined by Site Management as theA target benefit-to-cost ratio is defined by Site Management as the

hurdle for task screening.hurdle for task screening.

• Basis is short term, both for benefit and cost.Basis is short term, both for benefit and cost.

All items that clear the All items that clear the hurdle are selectedhurdle are selected

ACCEPTEDACCEPTED

All items that do not clear All items that do not clear the hurdle are rejected.the hurdle are rejected.

REJECTEDREJECTED

WORK SELECTION – Discretionary ItemsWORK SELECTION – Discretionary Items

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GRS

Multi-MonthMulti-MonthMaintenanceMaintenanceOutlookOutlook

(3 month)(3 month)

Critical few jobsCritical few jobs affecting many peopleaffecting many people significant impact on productionsignificant impact on production

Updated monthlyUpdated monthly Consistent with process three month outlookConsistent with process three month outlook

Detailed activity planDetailed activity plan Library of these kept on fileLibrary of these kept on file Job preparation activitiesJob preparation activities Must be value added (criteriaMust be value added (criteria

defined)defined) Small jobs don't need Job PackSmall jobs don't need Job Pack

PlanningPlanningJobJobPackPack

Short-termShort-termMaintenanceMaintenanceScheduleSchedule(4 week)(4 week)

Updated weeklyUpdated weekly Weeks 2-4 may have unresolved issues (evolving)Weeks 2-4 may have unresolved issues (evolving) Week 1 has no unresolved issues, showsWeek 1 has no unresolved issues, shows

when jobs will be donewhen jobs will be done who will do the jobswho will do the jobs and what resources they needand what resources they need represents the 5 daily schedules for Week 1represents the 5 daily schedules for Week 1

Consistent with Process 4-Week ScheduleConsistent with Process 4-Week Schedule

Element 6E - Routine Work PS&EElement 6E - Routine Work PS&E


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GRS

Repairs

PM’s

ImproveWork

Contingency

PM’s

ImproveWork

Repairs

Week 1Week 1 Week 2Week 2 Week 3Week 3 Week 4Week 4

60% of annualwork ($$) is

predefined andrisk screened

in an approvedAnnual Program

25% for scheduled Breakdown Mtceto repair failures

ZeroProgramSlippage

Only schedulewhen ready to

execute(inc matls)

10% requesteddiscretionary workscreened/approved

“out-of-program”with higher hurdle

Res

ou

rce

Req

uir

emen

tR

eso

urc

e R

equ

irem

ent

5% for Break-insCrit Equip/Events

with job packs and spares

Repairs

PM’s

ImproveWork

PM’s

ImproveWork

Repairs

Repairs

PM’s

ImproveWork

PM’s

ImproveWork

Repairs

Repairs

PM’s

ImproveWork

Contingency

95%Complianceto schedule

Contingency Contingency

Operations justify move to weeks 2/3/4and define if any planned work slips

Usually Week 4+ (ex small repairs) to allow good

planning and scheduling

Element 6E - Improved StateElement 6E - Improved State


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GRS

Site Site long range plans developedlong range plans developed to identify timing for SD/TA’s and to identify timing for SD/TA’s and long term milestoneslong term milestones

Provide Provide Steering CommitteeSteering Committee and and organizational structureorganizational structure to manage to manage TATA

Establish the Establish the TA strategies, objectives, basis, and key constraintsTA strategies, objectives, basis, and key constraints

Utilize a Utilize a milestone planmilestone plan based on SD/TA complexitybased on SD/TA complexity covering all covering all major activitiesmajor activities

IntegrateIntegrate Maintenance, Operations, Inspection & Projects plans & Maintenance, Operations, Inspection & Projects plans & schedulesschedules including pre and post work activities including pre and post work activities

Identification of critical and near-critical path workIdentification of critical and near-critical path work; includes ; includes risk risk assessing potential discoverablesassessing potential discoverables and impact on SD/TA objectives and impact on SD/TA objectives

Schedule key reviewsSchedule key reviews throughout Planning & Scheduling, Execution throughout Planning & Scheduling, Execution and Closeout to steward progress, cost & performanceand Closeout to steward progress, cost & performance

Element 6F - Turnaround PS&EElement 6F - Turnaround PS&E


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GRS

New facilities achieve reliability, availability and costs consistent with New facilities achieve reliability, availability and costs consistent with the business objectivesthe business objectives

Site design and equipment selection incorporates Reliability Best Site design and equipment selection incorporates Reliability Best Practices. Reliability Reviews conducted by knowledgeable site Practices. Reliability Reviews conducted by knowledgeable site representatives and technical specialistsrepresentatives and technical specialists

Facilities meet the requirements of the Global Reliability System prior Facilities meet the requirements of the Global Reliability System prior to commissioning and startup to commissioning and startup

Operating EnvelopesOperating Envelopes Equipment StrategiesEquipment Strategies Operator Care TasksOperator Care Tasks

Element 3 - Facilities Design & ConstructionElement 3 - Facilities Design & Construction

Expected Results:Expected Results:


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GRS




Design it Right


Operate it Right

Fix it Right






• Changes managed






PROACTIVELY DEFINE PROACTIVELY DEFINE CAPABILITY CAPABILITY andand NEEDS NEEDS of the of the

process and equipmentprocess and equipment

OPERATE WITHINOPERATE WITHIN process and process and equipment equipment CAPABILITYCAPABILITY

ProvideProvide equipment equipment and process and process needs needs EFFICIENTLY and EFFICIENTLY and

EFFECTIVELYEFFECTIVELY



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GRS

Element 6G/9 linkage to 6J/6AElement 6G/9 linkage to 6J/6A

Plan1 ~~~~~2 ~~~~~3 ~~~~~4 ~~~~~

6A

0

20

40

60

80

0 500 1000 1500 2000 2500 3000

Total Cost Per Installed Pump (TCPI) (US $)

MT

BR

(m

on

ths

)

0

20

40

60

80

0 500 1000 1500 2000 2500 3000

Total Cost Per Installed Pump (TCPI) (US $)

MT

BR

(m

on

ths

)

Estimated Opportunity by Equipment Class

0

10

20

30

40

An

aly

zer

He

at

Ex.

Pu

mp

s

Atm

. T

an

ks

Inst

rum

en

ts

PR

V

M$/

yr

6J - Analyze Operations & MaintenanceActivities

6E - Equipment Data6E - Equipment Data6F - Equipment Data6F - Equipment Data6G - Loss Data6G - Loss Data6H - Observations 6H - Observations

9 - Incident Investigation 9 - Incident Data9 - Incident Data

IncidentIncident

External BenchmarkExternal Benchmark $ $

Information for: Information for: Equipment Strategies 6CEquipment Strategies 6COperating Envelope 6BOperating Envelope 6B


NewNewTechnologyTechnology

andand

Network

Best

Practices

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GRS

• Each Reliability Plan should include the same specific topics Each Reliability Plan should include the same specific topics – Section A - Management SummarySection A - Management Summary– Section B - Basic Assumptions and Alignment with Refining Section B - Basic Assumptions and Alignment with Refining

Business PlanBusiness Plan– Section C - Current Performance and OutlookSection C - Current Performance and Outlook– Section D - Base Reliability & Maintenance ActivitiesSection D - Base Reliability & Maintenance Activities– Section E - System Assessments and Gap Closure PlansSection E - System Assessments and Gap Closure Plans– Section F - Focused Reliability Improvement ActivitiesSection F - Focused Reliability Improvement Activities– Section G - TurnaroundsSection G - Turnarounds– Section H - Resource PlanningSection H - Resource Planning

• Site management should determine level of detail required for each Site management should determine level of detail required for each topictopic


6J/6A - Performance Improv. /Site Plans and Objectives 6J/6A - Performance Improv. /Site Plans and Objectives

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GRS

EventEvent

Near Miss orGreater Potential?

(Actual x Potential x Barriers)

Loss >50K$?

Link RCFAFactors to

GRS Elements

Actionsfor tracking

and follow-up

HLVI’sfor sharing

per GMOP 9.1

EnterEnterintointo

DatabaseDatabase

ToolTool

CategorizePer RCFA STD

(+ GRS 9 considerations)

High

Medium

Low

CFWTCFWT(Causal Factor(Causal Factor

Why Tree)Why Tree)

5 - WHY5 - WHY Site only

Element 9 - Incident Investigation & AnalysisElement 9 - Incident Investigation & Analysis


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GRS




Design it Right


Operate it Right

Fix it Right






• Changes managed






PROACTIVELY DEFINE PROACTIVELY DEFINE CAPABILITYCAPABILITY and and NEEDSNEEDS of the of the process and equipment based process and equipment based

upon criticalityupon criticality

OPERATE WITHIN CAPABILITYOPERATE WITHIN CAPABILITYof process and equipmentof process and equipment

EFFICIENTLY and EFFICIENTLY and EFFECTIVELYEFFECTIVELY

PROVIDE NEEDSPROVIDE NEEDS of of equipment and equipment and

processprocess



GRS drives the following key concepts . . .GRS drives the following key concepts . . .

GRS 1 Global Reliability System Refining Congress - Argentina Refining Congress - Argentina D.E. Fitzgerald.

Documents

grs background grs

grs assessment

reliability improvement

continuous improvement

training element

high reliability

sustainable reliability

documentation element