Asset
Management
RELIABILITY SCENARIO
.
Reliability and Maintenance Strategy
Industrial effectiveness pillar
Principles Elements
Production Losses
Operations Execution
Management
.
Reliability and
Maintenance Strategy
Process Control and
Optimization
Industrial
HES Quality
Effectiveness Maintenance Planning &
Production Scheduling
Execution
Planned Turnaround Cost Management
Performance Management
MRO Management
Continuous Improvement & Good Practice
Sharing
Reliability and Maintenance Strategy
Industrial effectiveness pillar
The objective of this element is to establish guidelines for responding to challenges of reliability and maintenance processes by:
• Using CMMS – Computerized Maintenance Management System – to register and manage equipment data; (SAP-Maximo)
• Analyzing and classifying equipment based on their criticality;
• Developing an overall asset management strategy and related programs,
• Developing long-term maintenance strategies to manage the execution of maintenance work;
Definition • Cultivating the preference toward programmatic maintenance rather than reactive maintenance and;
• Leveraging data to continually improve and optimize the asset management and maintenance strategies.
This is key to Industrial effectiveness as it will result in having a safe and reliable process, higher equipment integrity, reliability
and availability, higher production stability, higher productivity, improved quality and optimized life cycle costs.
Equipment Registration & Data Management Asset Management Strategy Maintenance Resource Strategy
Criticality Analysis PM/PdM Programs Leveraging Reliability Data
Reliability Strategy - KPIs
IEG Losses Maintenance Cost Index
Indicators
Fixed Cost Maintenance Efficiency
Index
Reliability Strategy – KPIs – IEG Losses
2018 Production KPI 2018 Equipment Reliability KPI
337.376
46
46.258
34
28.396
98.823 110.737
73.858 8
53.958 86
1 10.354
53 3
20 4.25 3.258
2 11
Cracker HDPE:U51 HDPE:U52 LDPE Total Cracker HDPE:U51 HDPE:U52 LDPE Total
IEG Losses(Ktons) No. of Shutdown No. of Equipment Shutdown IEG Losses(Ktons)
Reliability Strategy – KPIs – IEG Losses by Equipment
Ethylene IEG Losses by Equipment Failure HDPE: U52 IEG Losses by Equipment Failure
3
3.25
4.25 4.25
1.31 1
1 1 1.21
1 1 0.73
Propylene Compresor (Opn) Total Reactor 52-LT-500160 Válvula rotatoria 52- Total
No. of Equipment Shutdown IEG Losses(Ktons) deltanque 52-D-5001 RF-4001
No. of Equipment Shutdown IEG Losses(Ktons)
HDPE:U51 IEG Losses by Equipment Failure
10.35
8
4 4.76
1.85
2.88
0.86
1 2
1
Reactor Rotary Valve Ethylene Main Extrusor Total
(degasser) Compressor
No. of Equipment Shutdown IEG Losses(Ktons)
Reliability Strategy – KPIs – IEG Losses by Equipment
LDPE IEG Losses by Equipment Failure
35
28.4
23.17
18
4
3
2
1.41 1 1 0.93 1 1 1 1 1 1
0.34 0.21 0.41 0.75 0.04 0.07
0.03 0.06 0.98
No. of Equipment Shutdown IEG Losses(Ktons)
Reliability Strategy – KPIs – Asset Cost
Maintenance Cost Index Total Cost of Ownership+
(%ERV)
(%ERV)
0.8 0.8 0.7 0.7 0.7 0.7 0.7 0.7 0.7 0.7 0.7 0.7
0.6
0.6 0.52
0.46 0.6
0.4
0.35
0.4 0.29
0.63 0.18
0.23 0.6 0.4
0.5 0.52 0.63 0.63
0.2 0.11 0.42 0.52 0.55
0.06 0.3 0.44
0.03 0.1 0.18 0.24 0.2 0.31
0 0.18 0.24
0.04 0.1
0
2017 Jan Feb Mar Apr May Jun Jul Aug Sep
Maintenance Cost Index PA (yearly) Total Cost Ownership+ PA (yearly)
MCI Trend TCO+ Trend
1.50% 2.00%
1.00% 1.50%
0.50% 1.00%
0.00% 0.50%
Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec 0.00%
Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec
Site HDPE LDPE Ethylene Utilities
Site HDPE LDPE Ethylene Utilities
Reliability Strategy – KPIs – Asset Cost
Maintenance Efficiency Index Regulations and Law
(%ERV)
3 Mechanical Integrity KPIs
% Basic Equip Review
2.5 SIS and Barriers % Criticality Assessed
1.8 1.8 1.8 1.8 1.8 1.8 1.8 1.8 1.8
2 % Equip in PM Programs
1.5 PM compliance
2.5 % Corrective vs PM/PdM
1 MTBF
0.5 0.87 1.08
1.19 % Condition-based WOs
0.07 0.14 0.28 0.44 0.59
0
2017 Jan Feb Mar Apr May Jun Jul Aug
Maintenance Eff Index PA (yearly)
MEI Trend
6.00%
4.00%
2.00%
0.00%
Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec
Site HDPE LDPE Ethylene Utilities
Reliability Strategy – Baseline
Revisit what we have in place today: Reference
what is working? BUSINESS DIRECTIVE
DE 6010-00012-EN – GLOBAL – INDUSTRIAL EFFECTIVENESS PILLAR
What is not?
What should we do differently? GLOBAL STANDARD
ANX 6010-00020-EN – Global Standard – Mechanical Integrity
ANX-Industrial Effectiveness-Reliability and Maintenance Strategy
ANX-Industrial Effectiveness-Operations Execution
Field Routine and ODR
ANX-Industrial Effectiveness-Maintenance Planning and Execution
ANX-Industrial Effectiveness-Planned Turnaround
GAP Analysis of Reliability Process over 2018 by Intelius
2017 International Study of Plant Reliability and Maintenance (RAM)
Effectiveness
¡Gracias!
By Omar Caballero
