Reliability Through Correlation and Colaboration

Reliability Through Correlation & Collaboration

between Maintenance, Operations, and Reliability Improvement Technologies

Chad Broussard, CMRP (Reliability Supervisor) &

Alan King (Rotating Equipment Subject Matter Expert)

Phillips 66

Speaker Bio• Phillips 66

• Reliability Supervisor: Manages Reliability Group (Rotating Equipment, Electrical, Instrumentation, Arc Flash (Engineers & Subject Matter Experts) and Drafting Group.

• Senior Staff Engineer, Reliability : Supported Reliability Team and Rotating Equipment Network with implementation of maintenance and reliability programs.

• Being able help a workforce to change a reactive environment to a proactive culture which enables them to operate reliable assets.

• Family, Friends, Fishing, Golf and Bible Study

Formation

1. In Spring of 2011 we got together to discuss the past, current and future desired state of Reliability. As we discussed we analyzed and discovered several opportunities needing attention.

2. From this analysis, we formed a reliability team consisting of division rotating equipment leads and subject matter experts to analyze data from our Enterprise Asset Management system.

3. We completed a high-level gap analysis and implemented a condition monitoring program utilizing vibration analysis to build the foundation for what we consider to be a world-class maintenance and reliability program.

4. This was consistent with our corporate focus on safety and operating excellence.

GAP Analysis and Benchmarking

Purpose:• Implement best practices and standards for rotating equipment, non-rotating, electrical,

instrumentation, and facility drawings with an emphasis on reliability driven programs in each discipline.

Figure 1: To achieve maximum effectiveness in our business goals, we measure against four key facets.

The 40 elements become key performance indicators (KPI) to measure for continuous improvement.

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Reliability Group

Oil and Gas Industry AverageSpider Diagram

The spider chart and rank deviation chart compare Phillips 66 to industry benchmarks and guide specific recommendations for improvement and associated economic implications.

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Foundation, Strategy and Path Forward

Reliability Centered Maintenance (RCM) Framework

The RCM Framework incorporated with the Plan, Do, Access, and Adjust continuous improvement cycle.

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Development of CBM Program

Focus on Rotating Equipment 3 phases of maturity in our condition monitoring program.

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Phase II – Mobility

The mobile suitcases are mainly used for any “bad actors” at remote pump stations across deserts, plains and mountains.

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Final Phase

“Boots on the Ground to Cellular and Satellite” Vibration software with data obtained through mobile vibration suitcases, the cloud server, and cellular technology.

Equipment Operating Parameters

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SCADA and Processbook

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Analytical Software

Analyst Software to help keep us abreast of vibration anomalies.

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Measurement Enables

The scale does not lie!

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Evaluating the Results

• Pump Station 1: Spectral data on an electric motor showed looseness and imbalance in rotor assembly, and misalignment across the coupling. The rotor cage had actually shifted in the core and the rotor was loose on the shaft. Because CBM - Vibration Analysis detected the problem, the repair cost was only $21,000 instead of the typical $120,000.

• Pump Station 2: Spectral data and temperatures indicated a problem with the outboard bearing. Operators shut down the pump, repaired flat spots in bearings and polished the shaft at the site. Temperatures dropped 15 degrees and the vibration returned to normal, yielding a repair savings of $60,000.

• Lubrication Program: In performing our analysis, the team found cases of “wrong oil for the application” issues. The discovery and resulting decisions resulted in a one-time savings of more than $100,000.

Small “catches” can add up quickly!

JPEG image

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Return on Investment

KPI’s / Metric’s / Rotating Equipment & Lubrication

2010 2011 2012 2013$0

$1,000,000

$2,000,000

$3,000,000

$4,000,000

$5,000,000

$6,000,000 $5.4MM

$4.0MM

$4.5MM

$2.5MM

Maintenance Cost Reduction

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Operational Deflection Shape

Vibration, Experience, Support and Technology

Compressed (zipped) Folder

#1 Mainline (Before/Analysis Phase) #1 Mainline (After Modifications)

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Temporary Skid mounted Engine w/Positive Displacement Pump

High vibration / Metal Fatigue / Leak Prevention

Manually Operator / Correlated RPM’s

10 in./sec.

5.5 in./sec.

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Utilizing PDM Tools and Cloud Technology

The analysis phase of the ODS modeling used to identify how and where the pipe was moving along with the severity.

Compressed (zipped) Folder

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Mobile Vibration Testing across PipelinesThe picture below shows the completed modifications with the buried piping and a discharge dampener (orange) installed on the end of the piping.

Accelerometers w/ yellow cables mounted

This shows one of the five mobile vibration suitcases in a durable case to protect the vibration instrumentation.

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Baseline Readings

Baseline readings are very essential to ensure new installations or existing repairs meet our maintenance and reliability specifications.

Asset Reliability – Yield Significant Savings – Avoid Costly Repairs – Increased Capacity

Foundation and Path Forward

Strong foundations are so critical to the success and sustainability of our Reliability Programs

Microsoft Excel 97-2003 Worksheet

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Thank you for your Time!

Please have a Great Day