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A RELIABLE PLANT IS A SAFE PLANT

Hosny Elsayed Ma’aden Mine & Refinery Reliability Manager

2nd Annua l K ingdom P roce s s Sa f e t y 2016

09 t h – 10 t h May , i n A l Khobar

THE ROAD TO ASSET RELIABILITY EXCELLENCE APPROACH

SAFETY & ASSET MANAGEMENT GOALS

SAFETY & RELIABILITY INTEGRATION.

RISK BASED MAINTENANCE.

RELIABILITY EXCELLENCE APPROACH.

RELIABILITY OBJECTIVE & ROAD MAP.

OUR TODAY AGENDA

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SAFETY POLICY STATEMENT

All Injuries are Preventable

No Task is so urgent that it cannot be done Safely

Management Must Provide a Safe Work Place.

We are each responsible for Preventing Injuries

Everyone is empowered to Stop Unsafe Event.

All Committed to Safety

ASSET RELIABILITY MANAGEMENT GOAL

Continuous Improvement of the

Asset Reliability to deliver Safely

predictable performance Uptime at

the Lowest Sustainable Cost.

Safely Plant Uptime

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ASSET RELIABILITY MANAGEMENT It is Holistic Approach of consistent and structured strategies

designed to Improve asset Reliability, Availability & Integrity with cost

effective Index.

Identifying and embracing the best practices in Asset Management

enables an organization to avoid failures, reactive work practices and

other “barriers to success.”

Achieve world-class performance at any manufacturing facility.

Valuable resources can be applied to value-added activities.

UPTIME / OEE / ASSET UTILIZATION MODEL

Ass

et U

tiliza

tion

(AU)

Uptim

e /

OEE

Pr

oduc

tion

Utili

zatio

n

Qua

lity

Util

izatio

n

Pote

ntia

l Rat

e Ut

iliza

tion

Ac

tua

lA

vail

ab

ilit

y

Su

sta

ina

ble

Pe

ak

Ra

te

N o D e m a n d / M a r k e t L o s s e s

Changeover / Transition Losses

Q U A L I T Y L O S S E S

P R O C E S S R A T E L O S S E S

U N S C H E D U L E D D O W N T I M E

Scheduled Down time S C H E D U L E D D O W N T I M E

OEE = UPTIME X RATE X QUALITY

AU = AVAILABILITY X RATE X QUALITY

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RELIABILITY (OEE/AU) IMPACT ON SAFETY

Source: Ron Moore, Making Common Sense Common Practice.

PLANT THAT RUN RELIABLY HAVE FEWER INJURIES

SAFETY & REL IAB I L I TY INTEGRAT ION

A RELIABLE PLANT IS :

1. A SAFE PLANT,

2. A COST-EFFECTIVE PLANT,

3. FRIENDLY ENVIRONMENT PLANT."

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AN UNRELIABLE PLANT IS :

1. UNSAFE PLANT,

2. COSTLY,

3. UNFRIENDLY ENVIRONMENT PLANT."

SAFETY & REL IAB I L I TY INTEGRAT ION

PROCESS SAFETY EVENT (PSE)PROCESS SAFETY is a disciplined framework for managing

the integrity of hazardous operating systems and processes byapplying good Design principles, Engineering, and Operating &Maintenance practices.

PROCESS SAFETY EVENT (PSE) is an unplanned oruncontrolled LOPC of any material including non-toxic and non-flammable materials (e.g steam, hot condensate, nitrogen,compressed CO2 or compressed air) from a process, or anundesired event or condition that, under slightly differentcircumstances, could have resulted in a LOPC of a material.

Based on severity and consequence of event it is classified as. Tire 1 , Tire 2 , Tire 3 or Tire 4

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THE PROCESS SAFETY PYRAMID

MajorAccident

(Tire 1)

Loss Of Containment Potential for many

Injuries, Plant Damage (Tire 2)

Process Safety Breach : Loss of layer of Protection, MI Integrity, or shutdown System,

exceeding critical limits – ( Tire 3) Minor Process Errors : Exceeding Safe

Operating Limits , Ignoring Process Alarms , Missed Critical Inspection , Faulty Designs

(Tire 4)

Every Major Accident Result in Fatalities and major plant damage. It is also implies hundreds of Process Safety Errors

POOR Operational

Discipline Results in

Major Accidents

Source: Andrew Hopkins, "Failure to Learn: The BP Texas City Refinery Disaster,"

… Y o u D o n ’ t I m p r o v e W h a t Y o u D o n ’ t M e a s u r e …

DEFECT (FAILURE MODES ) EFFECT RELIABILITY

1 Major Inc

10 Losses 6,500 Repair /

Corrective Work Orders

20,000 defects (Failure Modes)

Every Major Inc. ( Large Production Loss , Lost Time Accident , etc) implies thousands of defect

Corrective,Emergency,& Unplanned Activities

Likelihood of Unsafe Acts& conditions

… R i s k : t h e p o s s i b i l i t y ( P r o b a b i l i t y ) t h a t s o m e t h i n g b a d o r u n p l e a s a n t w i l l h a p p e n …

- Personal safety events are driven by highfrequency, low consequence activities, while

- Process safety is driven by low frequency, highconsequence activities.

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RELIABILITY OPTIMIZATION PYRAMIDS

RCFA

Volumetric Downtime Tracking

Bad Actors , Defect Elimination Program

RCFA Insight Analysis

Asset Management Strategy (AMS) - Continuous Improvement

Reliability Walk down – Observation –Proactive Findings

Design It Right Operate It Right Maintain It Right

Most modern companies recognize the benefits of improved plant reliability and the elements needed to achieve it. These include -Strategies & spare-parts optimization-Risk-based Maintenance

Design &

Build Integrity

Create BarriersASSET

RELIABILITY 

Sustain  Integrity

Maintain Barriers

Operating Within The Limits

Working Within Barriers

CI  of  Defect Elimination

All Injuries are PreventableAll Failure are PreventableNo Task is so urgent that it cannot be done Safely

No Task is so urgent that it cannot be done ReliableManagement Must Provide a safe Work Place.

Management Must Provide a Reliable Work Place.We are each responsible for preventing InjuriesWe are each responsible for preventing FailuresEveryone is empowered to Stop Unsafe Behavior.

Everyone is empowered to Stop Unreliable Behavior

INTEGRATING RELIABILITY & SAFETY POLICY

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INTEGRATING RELIABILITY & SAFETY GOALS

To Achieve ZERO INCIDENTS / INJURIES , you must believe

in ZERO FAILURE / UNPLANNED DOWNTIME

* * * * * FAILURES INDUCE GREATER RISK OF INJURY * * * * *

How To Achieve it

RELIABILITY EXCELLENCE (Rex) approach is mandatory with

Specific Standards for Operation & Maintenance (SOP, EMS)

“ Success comes from knowing what you don’t know, more than coming from what you do know.“ Ray Dalio

Eng. Hosny Elsayed

ROAD TO RELIABILITY EXCELLENCE

ROAD TO RELIABILITY EXCELLENCE

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ASSET RELIABIL ITY & INTEGRITY

Asset RELIABIL ITY is the ability (probability) of an Asset or system performing (without failure) its intended (required) function under given (stated) conditions For a stated period of time.

Asset INTEGRITY is the ability of an asset to perform its required function effectively & efficiently whilest ProtectingEnvironment, Health & Safety (EHS) –

Plant Availability ( Maintenance) Mission

To preserve the functions of Plantphysical assets throughout their life cycleto the satisfaction of their Stakeholderowners, users & the society as a whole

• Safe Work Place • Safe Work force• Safe working Asset EHS

Business Risk Mitigation / Control

… I t i s i m p o s s i b l e t o g o s o m e w h e r e i f y o u d o n ’ t k n o w w h e r e y o u a l r e a d y a r e …

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Plant Availability ( Maintenance) Mission

To Deliver : Regulatory Compliance High Plant Availability Reliable equipment Statutory / HSE compliance Cost-effective & Targeted maintenance

Plant Availability ( Maintenance) Mission

Delivering Sustainable improvements is hard ! Little time available Resources reducing Priorities changing

Area With Highest ROI

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Run to Failure Preventive Maintenance

Predictive Maintenance

Proactive Maintenance

Reliability Centered

MaintenanceRisk Based

Maintenance

Maintenance Reliability Strategy History

Fixing when fails

Fixed time or

performance based

Periodic Monitoring &

Diagnosis

RCFA based failure finding

Defect Elimination

Continuous Improvement

based , cost effective

way

Integrity, Reliability, Availability

and Cost based

Combination of RCM , RBI,

& SIS Maintenance Optimization To

Increased Asset Reliability

MAINTENANCE RELIABILITY EVOLUTION

MAINTENANCE DOMAIN MODES

Reactive maintenance :Preventive maintenance :Predictive maintenance : Proactive maintenance : RCM Maintenance :

Risk Based Maintenance :

Failure basedTime/performance basedCondition basedRoot Cause based

CI & Criticality based

Integrity, Reliability, Availability and Cost base

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MAINTENANCE LIFE CYCLE COSTS

Specification Design Manufacturing Installation Commissioning Operation Replacement

Performance

Reliability

Maintainability

Support System

• The Opportunity For Maintenance Cost Reductions is HighestAt The Design Stage, & It Will Very Low After Commissioning

Process

Design

Reliability

Quality Control

FAT

Design Fault

Maintainability

Design Fault

Performance

testing

Design Fault

Poor Maintenance

Mal-Operation

Wear Out

Obsolescence

Disposal

Reliability Starts from Design, RFQs & Contracts should Include : High Efficiency Asset Performance Guarantees – Uptime Maintenance Guarantees – PM Frequency (max 30 min/month)

Reliability

The POTENTIAL - FAILURE Curve

OldDefinitionof Failure

Large Business Consequences!

$$$$$$$

F

Functionally FailedEquipment not performing

intended function

New definition of failure

Vibration Oil AnalysisUltrasound Thermography

Can Smell it

Can See it

P

Reactive Domain:Too Little, Too Late

Planning & InterventionWindow

P r o a c t i v e D o m a i n : D e f e c t E l i m i n a t i o n

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P-F Curve & Swiss Chess Model

Proactive Mode

$$ Material

$$ Labor

Reactive Mode

M&R Cost reduced by 20% Labor reduced by 24%

Material reduced by 16%

• Hazards (Failures) are contained by multiple protective barriers

• Barriers may have weaknesses or holes’

Sch. & PM Compliance

• When holes align, the hazard (Failures) passes through the barriers resulting in the potential for adverse consequences.

• Barriers may be physical engineered containment or behavioral controls dependent on people

ASSET RELIABIL ITY EXCELLENCE

Technical IntegrityManagement of

Hardware risk barriers

Process SafetyManagement of Major risk

Asset IntegrityThe ability of an asset to perform its required

function effectively and efficiently while safeguarding life and the environment

Asset Reliability PerformanceThe ability of an asset to perform its required function while making an optimum contribution to the business

Reliability Excellence

Occupational SafetyIncidents that primarily affect an individual on

each occurrence

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RISK BASED MAINTENANCE STRATEGY

A RBM’s Strategy prioritize maintenance resources toward assetsthat carry the M O S T R i s k if they were to fail. It is amethodology for determining the most economical use ofmaintenance resources, so the maintenance effort across afacility is optimized to minimize any risk of a failure RBM strategy is based on two main phases:

1. Risk assessment

2. Maintenance planning based on the risk (RBWS)

… F a i l u r e i s s i m p l y t h e o p p o r t u n i t y t o b e g i n a g a i n , t h i s t i m e m o r e i n t e l l i g e n t l y …

WHY ADOPTING RISK BASED STRATEGIES

True reliability is achieved when the mostSAFELY & COSTLY effective methodsare applied to the Plant Assets.

Maximizing the maintenance effort withthe minimum total cost to the business.

Area With Highest ROI

… T h e o n l y r e a l m i s t a k e i s t h e o n e f r o m w h i c h w e l e a r n n o t h i n g …

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ASSET RELIABILITY EXCELLENCE.

Eng. Hosny Elsayed

Asset Reliability is the ability of the asset to perform the function for which it was designed for

Asset Integrity is the ability of an asset to perform its required Function effectively and efficiently whilst protecting health, safety and the environment

Asset Availability is the availability of reliable asset at design integrity to process

i

ASSET RELIABILITY, INTEGRITY, AVAILABILITY & MAINTAINABILITY (RIAM)

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THE RELIABILITY FOCUS

Production

Reliability

MaintenanceProcurement

Materials Management

• Standardized procedures• Waste and loss elimination• Quick changeovers• Stable, consistent processes• Operator care

• Risk management• Asset management• Loss and waste elimination• Performance management

• Asset care• Life cycle asset management• Loss and waste elimination• Useful life extension

• Dock-to-dock materials management• MRO materials management• Materials handling and JIT• Inventory management

Management• Coordinated planning•Operations management•Master production schedule• Performance management

•Lowest total cost of ownership•Remove costs from the supply chain

MATERIALSMANAGEMENT

ASSET CARESCHEDULINGWORK

MANAGEMENT

PROCESSES

FACILITIESEQUIPMENT

WORKMEASUREMENT

WORKPLANNING

TRAININGORGANIZATION

STRUCTURESUPERVISIONEAMS

OPTIMIZATION

MANAGEMENTREPORTING

BUDGETINGCOST CONTROL

CONFIGURATIONMANAGEMENT

EQUIPMENT HISTORY

AUDITSRELIABILITY

ENGINEERING

SUSTAINABILITY

OPERATORCARE

PROCUREMENTEQUIPMENT

PROCESS DESIGN

MANAGEMENT COMMITMENTPLANT PARTNERSHIPS

PRINCIPLES

ORGANIZATIONALBEHAVIOR

MASTERPLAN

OBJECTIVESGOALS

GOVERNINGPRINCIPLES

STATUSASSESSMENT

CULTURE

PERFORMANCEMANAGEMENT

LOSSELIMINATION

THE 29 ELEMENTS OF Reliability Excellence - Rex.THE 29 ELEMENTS OF Reliability Excellence - Rex.

REX – THE RELIABILITY EXCELLENCE MODEL

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ASSET MAINTENANCE & RELIABILITY

P •Work Planning

S •Work Scheduling

E •Work Execution

H •Work HistoryD2D Maintenance

Work History

Analysis / Assessment

Strategy Development

Reliability

“ B y f a i l i n g t o p r e p a r e , y o u a r e p r e p a r i n g t o f a i l . ”

Eng. Hosny Elsayed

RELIABILITY OBJECTIVE &

ROADMAP

RELIABILITY OBJECTIVE &

ROADMAP

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PLANT / ASSET RELIABILITY

Reliable Equipment

Reliable Process

Reliable Team

Asset Re l iab i l i ty Should

In tegrat ing Equipment ,

P rocess & Team Rel iab i l i ty

RELIABILITY ENGINEER ROLE Successful Plant / Asset reliabilityprogram Should defining theexpectations of the ReliabilityEngineering role.

Reliability Engineer

Role Profile

Reliability Reporting

Reliability Plans

New Asset

Spec. & Design

Criticality Analysis

Perform FMEA /

RCMAsset

Management

Strategy

PdM & PM

plans

Root Cause Failure

Analysis

Statistical Data

Analysis

Monitor Key

metrics

Coaching Plant

Personnel

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REL IABIL I TY ROADMAPThe journey to a proactive Asset ManagementPerformance (AMP) model involves peoplefrom all levels of the organization.

It is critical that the Reliability Roadmap beaccepted and supported by all stakeholders.

EHS INCIDENTSWASTE

COST

PLANNED DOWNTIME

UNPLANNED DOWNTIME

R E L I A B I L I T Y R O A D M A P G O A L

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R E L I A B I L I T Y R O A D M A P G O A L

AVAILABILITY / Uptime

CAPACITY QUALITY

EMPLOYEE RETENTION

BUSINESS SUSTAINABILITY

Reliability Road Map

Re

lia

bil

ity

Cu

ltu

re •Leadership

Find The Champion Form Steering Committee•Vision & Strategy Develop the strategy Benchmark and set Target •People Human error Change Management Communication •Training & Buy-in Senior Management Program Management CM & precision Skills

Re

lia

bil

ity

Str

ate

gy

•Assets Register Build Master Asset List Unit , System & sub sys. Function

•Criticality Asset Criticality Rating •Failure Modes Practical FMEA Assess Risk Develop Strategy•Reliability Study MTBF - MTTR - Weibull Bad Actors - Block diagram

Ma

inte

na

nc

e S

tra

teg

y •Reactive Maintenance Low Value , no downtime, no impact on EHS•Preventive Maintenance Time/performance based•Predictive Maintenance Condition based•Proactive Maintenance Root Cause based•RCM Maintenance CI & Criticality based •Risk Based Maintenance Failure age related? Action to prevent Failure ?

Ma

inte

na

nc

e L

ife

Cy

cle • Design /

Procurement Maintainable and Reliable

• Spares Management Organized / Optimized / Clean SPIR /

•Planning & scheduling RBWS – Prioritized – Organize

• Precision Skills Aligned / Balanced / tight

• Precision Operation Operate Within Envelope -SOP

• Maintain Function Lubricate , Adjust , Preserve

Reliability Culture Reliability Strategy Maintenance Strategy Maintenance Life Cycle (MLC)

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THANKSTHANKS

2nd Annua l K ingdom P roce s s Sa f e t y 2016

09 t h – 10 t h May , i n A l Khobar

Hosny Elsayed Ma’aden Mine & Refinery Reliability Manager