Delivering Value. chemical strategy. through instrument reliability. presentation

Transcription

1 Delivering Value a dow chemical strategy through instrument reliability. presentation 1

2 Introduction 85% Reduction in Reactor Trips, Millions of $$ in EBIT savings 2

3 Dow Deer Park Operations world s largest participant in the acrylic monomers marketplace adhesives, coatings, inks, textiles, polymers and superabsorbent 700-acres located on the Houston Ship Channel & 67 process units 3

4 The Case for Change Our Opportunity 67 Process Units 2011 Instrument / CV Equipment Failures Primary Goal Identify the Biggest Bang for our Buck Rest of Plant (62 units) 5 Reactors 48% of Total $Millions 8% of the Production Units Account for 48% of the Downtime These 5 reactors have similar process technology (Leverage!!) 4

5 The Case for Change Our Opportunity Rest of Plant (62 units) 48% of Total 5 Reactors 16% of Total 9% of Total Validation that We re on the Right Track 5

6 Understanding the Client s Needs Kaizen Event What are your needs? We need reliability strategies and also immediate improvements! Reliability Team Leaders Lack of Maintenance Funding Health of Instruments Overdue Interlock Tests More Thorough Interlock Tests Valve Trips are Increasing Lots of Wiring Trips Run to Failure Dow MET Gaps Don t know where the Opportunities are Accepting Abnormal Conditions Not identifying the Root Causes Challenging Process Cond. For Technologies Quality Workmanship from Techs QA on New Installations SAP Equipment Data is Poor High Workload Spec Sheets Not Accurate No Reliability Infrastructure Need More Work History Lack of Continuous Training Technologist Very Involved in Day to Day Not Focused on Deviation Alarms Culture of Repair vs. Improve Bottlenecks in Management Systems Types of Challenges Old / EOL Instruments PPM Strategies Repeat Failures People or Process 6

7 Instrument Reliability Model Our Approach Trip Investigations Create the Infrastructure Capital Projects FEL Special Projects Instrument Status Top Opp. List Assessments EMS / Diagnostics 7

8 The Operating Discipline The Control Plan 1. Strategy Document 2. Work Process 3. Procedure Documentation Updates PMs in Place 4. Investigation Report 5. Execution FEL Capital Projects Maintenance Requests Supplier Failure Analysis 8

9 The Operating Discipline Control Valve EMS CONTROL VALVE DOWNTIME What can we do to reduce trips? 9

10 The Operating Discipline Control Valve EMS CONTROL VALVE DOWNTIME 1) Criticality Rankings 2) PPM schedules 3) Spare Parts 4) Procedures 5) Validate Design Conditions : Focus on Equipment Maintenance Strategy 10

11 The Operating Discipline Control Valve EMS CONTROL VALVE DOWNTIME : Begin leveraging EMS and using CBM 11

12 The Operating Discipline Control Valve EMS CONTROL VALVE DOWNTIME Only train that had not received PPMs since start of program : Continued success except for 1 out of 5 trains 12

13 The Operating Discipline Control Valve EMS CONTROL VALVE DOWNTIME : Sustained Success!! 13

14 The Operating Discipline Control Valve EMS Challenge: Valve had travel deviation alarms on the asset management system. The valve would oscillate whenever the input was above 40%. Solution: Found that the nut that holds the actuator to the base was very loose. Erratic response on governor valve Due to loose bracket. Triggered profile, as captured on AMS. Valve position would get erratic when input got above 40%. After adjustments. 14 Avoided a Reactor Trip!!

15 The Operating Discipline Control Valve EMS Challenge: The team was challenged to find alternative ways to save money regarding valve repair scopes. Solution: We performed diagnostic scans on all the critical CV. Went removed 15 valves (nearly 36%) from the scope. Grand total of $120,000 in cost avoidance! Was on the list for maintenance after scan just changed out travel sensor! 15

16 The Operating Discipline Assessments 10,000 Assessments 2,400 Concerns 400 Work Orders 16

17 The Operating Discipline Condition Monitoring Identify critical/redundant instruments. Set alarm limits with operations and process automation. Investigate, Solve Problems and Leverage. Steam damage to transmitter Loose wiring connection Wet leg on impulse line 17

18 The Operating Discipline Top Opportunity Two technologies on the top opportunity list that were also repeat failures. These technologies accounted for multi-million dollars of production losses. dp Level: MTBF 0.3 to 4 Years TOx Temperatures: MTBF 0.23 to 3 Years 18

19 Results Achieved Instrument Reliability Program Reactor Trips caused by IEA Equipment Trip Reduction of 85% 19 Millions of $$ in EBIT Savings!!

20 Summary Keys to Success Voice of the Customer Razor Sharp Focus Deliver Results Kaizen Event Operating Discipline Data Based Decisions We need quick wins and sustainable, leverageable solutions There will always be more good ideas than we have capacity to execute How can you win the game if you don t know the score Lead, Lag Measures 20

21 Instrument Reliability Team Shadrach Stephens I & E Maintenance Group Leader B.S. Electrical Engineering 11 years experience across multiple industries 6 years experience within Dow Chemical Recent Accomplishments Recipient of the 2013 HART Plant of the Year Control Engineering and Plant Engineering Magazine s 2014 Engineering Leaders Under 40 Award Team Contributors: Christopher Garcia I & E Technology Leader David Taylor Engineering Instrument Lead Alan Hoes & Don Clark Sr. Instrument Technologist Teddy Wyly & Johnny Garcia I & E Reliability Technician 21