reliability engineering services-+asset+performance... · rca root cause analysis identify true...
TRANSCRIPT
Soluciones de Ingeniería y Mantenimiento, S.L.
Reliability engineering services
SiM introduction – General October 2017
Madrid
About SiM
SiM is a Spain-based Asset Management and Reliability Engineeringconsultancy company established in 2009 providing support to clients in theOil, Gas, Petrochemical (OGP) and Energy businesses.
SiM provides business-oriented solutions for clients in the OGP and Energyindustries during the visualization, engineering and O&M phases of the assets.
Who we are
SiM introduction – General October 2017
Who we are – E&MS Group
Madrid, Spain
Villahermosa, México
Maturín, Venezuela
E&M Solutions
Bogotá, ColombiaE&M Solutions
Lima, Perú
SiM is part of the E&MS Group with offices in America and Spain
SiM introduction – General October 2017
Our people
Rotating equipment
Static equipment
Corrosion & metallurgy
Reliability
Electrical engineering
Instrumentation & Control
Process engineering
Maintenance
SiM specialists background as final users in the oil, gas andpetrochemical industry with + 20 years of experience, helpsmeet clients’ expectations on the operation of their assets
SiM introduction – General October 2017
Decommissioning Implementation
Operation & Maintenance
Engineering
Physical Assets
Management
• With a holistic approach consistent with client’s business strategies.
• Applying integrated processes to improve productivity while reducing the life cycle costs of assets at acceptable levels of risk.
SiM offers integrated solutions
Our philosophy
SiM introduction – General October 2017
UPDATING / DECOMMISSIONING
OPERATION &MAINTENANCE
DEVELOPMENTDEFINITIONVISUALIZATION
• FEL 1 Feasibility / opportunity evaluation
• FEL 2 Conceptual project
• FEL 3 Engineering design
• FASE 4 Implementation
ASSETS PROJECT PHASE
Products and services – Assets lifecycle phases
SiM assists clients in mitigating risks during project phases
Design for production efficiency assuranceand lowest life-cycle costs of the assets
SiM introduction – General October 2017
UPDATING / DECOMMISSIONING
OPERATION &MAINTENANCE
DEVELOPMENTDEFINITIONVISUALIZATION
• Asset management
• Operational integrity
• Operational reliability
• Operational efficiency
• Conversion to new scenarios
ASSETS OPERATIONS PHASE
Products and services – Assets lifecycle phases
SiM helps clients optimize the operation of their assets
Keep safety, maintenance and operationstandards and key performance indicators
SiM introduction – General October 2017
SiM helps meeting objectives through performance improvement
The need for asset performance optimization
Operating
Performance
Business Objectives
Authority Requirements
SiM introduction – General October 2017
Acronym Product Main objective
ECA Equipment Criticality Analysis Assess equipment importance
FMEA / FMECA Failure Mode Effects / and Criticality AnalysisAssess equipment potential ways of failure / and their operational impact
MHA Maintainability and Mechanical Handling AssessmentAvoid maintenance-related safety issues, simplify operations and reduce downtime
RAM Reliability, Availability and Maintainability StudyAssess asset inherent ability to meet specified productivity targets
RBI Risk Based Inspection StudyDefine cost-effective inspection strategies and tasks for fixed equipment and piping
S-RCM / RCM (Streamlined) Reliability Centered Maintenance StudyDefine cost-effective CBM and PM maintenance tasks for equipment
RBS Reliability Based SparesDefine optimum spare parts inventories based on RCM studies
LCCA Life Cycle Cost AnalysisMinimize net present value of asset CAPEX/OPEX meeting productivity targets
PM/CBM/CM Development of Maintenance Plans & ProceduresDefine cost-effective maintenance plans supporting asset productivity targets
RCA Root Cause AnalysisIdentify true source of problems to avoid recurrence
Common reliability and maintenance (R&M) products
SiM introduction – General October 2017
SiM can help define an approach for developing R&M studies
CONSULTANT SCOPE OF WORK
Implementation of mitigation measures
(as required)
FMECAMaintenance
PlansS-RCM
CMMSTemplates
Upload to CMMS
RAM
Client’s Inputs
RCS
Incorporation of maintenance plans in the RAM model
Incorporation of RAM outcomes in maintenance plans
Optimize scope of work of R&M studies based on items failure impact
Approaches in developing R&M studies
AssetRegister
List items for R&M studies according to a defined taxonomic classification
SiM introduction – General October 2017
List items for R&M studies according to a defined taxonomic classification
CONSULTANT SCOPE OF WORK
MHA
MHA outcomes implementation
ECA
RBI
Maintenance Plans
S-RCMCMMS
Templates
CMMS PopulationMHA outcomes implementation
Internals not in RBI
Approaches in developing R&M studies
SiM can help define an approach for developing R&M studies
AssetRegister
Client’sInputs
Optimize scope of work of R&M studies based on items failure impact
References
SiM introduction – General October 2017
Some references
• Technical-economical assessments.
• Risk analyses.
• LCCA pre-selection of turbo-compressors and power generation.
• Operability assurance studies.
• ITB packages development.
Feasibility Studies Gas Transportation System, Algeria-Italy (2011-13)
UPDATING / DECOMMISSIONING
OPERATION &MAINTENANCE
DEVELOPMENTDEFINITIONVISUALIZATION
SiM introduction – General October 2017
UPDATING / DECOMMISSIONING
OPERATION &MAINTENANCE
DEVELOPMENTDEFINITIONVISUALIZATION
Some references
• Pre-selection of equipment/options.
• Definition of optimum gas turbine drivers ambient temperature rating.
• RAM simulation of options.
• Life Cycle Costs analysis of options.
• PMC services during FEED.
Power Generation/Export Gas Compressors Selection, Bolivia (2010)
SiM introduction – General October 2017
UPDATING / DECOMMISSIONING
OPERATION &MAINTENANCE
DEVELOPMENTDEFINITIONVISUALIZATION
Some references
• Contract options qualitative and quantitative assessment.
• Definition/development of contract type
• Development of Instructions to Bidders.
• Bid evaluation method development and support.
• Definition of operability assurance studies during the development phase.
Development of Gas Compression ServicePerú (2015-2016)
SiM introduction – General October 2017
UPDATING / DECOMMISSIONING
OPERATION &MAINTENANCE
DEVELOPMENTDEFINITIONVISUALIZATION
Some references
• Development of operability assurance studies during the EPC Phase
• Defined MHA and RCM scope of work by equipment importance through ECA.
• Assisted EPC Contractor in meeting Owner maintainability requirements.
• Developed an S-RCM study
ECA/MHA/S-RCM Studies Gas Processing Plant (EPC Phase), Saudi Arabia (2016-2017)
SiM introduction – General October 2017
UPDATING / DECOMMISSIONING
OPERATION &MAINTENANCE
DEVELOPMENTDEFINITIONVISUALIZATION
Some references
• Development of a methodology for assessing hazardous services.
• Hazards assessments under owner’s HSE Codes, EU CLP Directive, Waste Framework Directive and U.S. EPA RCRA criteria.
• Definition of project requirements for equipment in hazardous services.
Hazardous Service Definition Oil & Gas Waste Plant (EPC Phase), Abu Dhabi (2017)
SiM introduction – General October 2017
UPDATING / DECOMMISSIONING
OPERATION &MAINTENANCE
DEVELOPMENTDEFINITIONVISUALIZATION
Some references
• Process modeling and simulation.
• Production efficiency definition vs production profiles.
• Critical sub-systems and equipment identification.
• Sensitivities for optimizing turnarounds, start-up ramp, equipment configurations
RAM Analysis of an LPG Extraction Plant (FEED Phase), Algeria (2015)
SiM introduction – General October 2017
Some references
• Detail engineering of instrumentation, controls and electrical interfaces.
• Procurement technical support and expediting.
• Shop QA/QC and FAT development.
• Support to construction, commissioning and start-up.
Detail Engineering Hydrogen Purification Unit, Spain (2013-14)
UPDATING / DECOMMISSIONING
OPERATION &MAINTENANCE
DEVELOPMENTDEFINITIONVISUALIZATION
SiM introduction – General October 2017
UPDATING / DECOMMISSIONING
OPERATION &MAINTENANCE
DEVELOPMENTDEFINITIONVISUALIZATION
Some references
• Diagnosis of a Maintenance Organization supporting +400k BOPD.
• Gap analysis following the guidelines of PAS 55 (later ISO 55000)
• Development of a 2-year actions plan to close the gaps.
• Follow-up to implementation of the actions plan.
Gap Analysis of the O&M Organization in an Oil & Gas Field, Venezuela (2013)
SiM introduction – General October 2017
Some references
UPDATING / DECOMMISSIONING
OPERATION &MAINTENANCE
DEVELOPMENTDEFINITIONVISUALIZATION
• FMECA of critical compression packages.
• S-RCM of critical compression packages.
• Mitigation actions to support the maintenance plans of the existing packages.
• RCM training and workshops at end user’s facilities.
RCM Studies of Critical Packages In Refineries, Spain (2015)
SiM introduction – General October 2017
Some references
• Vibration analysis of 2 x 17 MW steam turbine driven generators in a direct type solar power plant.
• Initial start-up operation after commissioning.
• Thermal transient behavior diagnosed.
Steam Turbogenerator Vibration Analysis, Spain (2012)
UPDATING / DECOMMISSIONING
OPERATION &MAINTENANCE
DEVELOPMENTDEFINITIONVISUALIZATION
SiM introduction – General October 2017
Some references
• Failure Investigation on a Hydrodynamic, Variable Speed, Planetary Gear Drive for a Coker Gas Compressor.
• Support to the end user in addressing technical issues to the OEM.
• Involvement in further actions associated with avoiding recurrence of the failure.
Machinery Failure InvestigationOil Refinery, Spain (2013)
UPDATING / DECOMMISSIONING
OPERATION &MAINTENANCE
DEVELOPMENTDEFINITIONVISUALIZATION
SiM introduction – General October 2017
Some references
• Diagnosed the application of an RCA methodology in a Refinery under a Corporate Reliability Project.
• Identified aspects potentially affecting the effectivity of RCA.
• Offered recommendations aimed at closing identified gaps and improving applied methods.
RCA Methodology ApplicationAssessment, Spain (2015)
UPDATING / DECOMMISSIONING
OPERATION &MAINTENANCE
DEVELOPMENTDEFINITIONVISUALIZATION
SiM introduction – General October 2017
Some references
UPDATING / DECOMMISSIONING
OPERATION &MAINTENANCE
DEVELOPMENTDEFINITIONVISUALIZATION
• Integrity assessments aiming at identifying potential SSC phenomena.
• Identification of SSC failure potential based on NACE MR-0175.
• Recommended mitigation measures for preventing the occurrence of failures with large consequences.
Gas Metering Station Proactive Assessment, Mexico (2012)
SiM introduction – General October 2017
UPDATING / DECOMMISSIONING
OPERATION &MAINTENANCE
DEVELOPMENTDEFINITIONVISUALIZATION
Some references
• Due diligence / technical audit.
• O&M historical records analysis / reliability functions definition.
• Assessment of design vs. current/future operating conditions.
• RAM modelling and simulation / LCCA of options.
• Compressor performance assessment.
Offshore Platforms Topside Assessments, Trinidad & Tobago (2014)