Material and Contract Services LLC

Transcription

1 REFINERY MAINTENANCE SYSTEM CAPABILITIES Material and Contract Services, LLC has the knowledge, resources and experience to reduce maintenance cost, improve employee productivity and equipment operating time. Our capabilities include installing computer maintenance systems, loading the system data base and establishing manual processes and procedures to improve the planning, scheduling and execution of maintenance work. Every Refinery owner wants to increase production whilst reducing expenditure and the frequency of equipment down due to maintenance problems.. Within oil refineries, maintenance is about avoiding emergency critical path situations. It is about identifying problems before they become cause for concern and getting the large, difficult tasks finished so that shutdowns can be shortened. Often these problems are cleaning and inspection related. Maintenance is a pretty wide concept and normally consists of two types of maintenance: proactive and reactive, Proactive maintenance is a maintenance strategy for stabilizing the reliability of a refinery. MACS maintenance programs central theme involves directing corrective actions aimed at root causes of failure, not active failure symptoms, faults, or machine wear. Reactive maintenance is a form of maintenance in which equipment and facilities are repaired only in response to a breakdown or a fault. Because of the potential for loss of production, reactive maintenance is at odds with just in time production. People call it fire fighting maintenance and it occurs only when there is breakdown. MACS maintenance systems move a refineries programs to proactive maintenance to avoid loss of money.. Refinery maintenance presents challenges in various areas and one of those targets is the quick, efficient cleaning of heat exchangers and other plant assets. Often regarded as a traditional procedure, MACS EQUPMENT MAINTENANCE programs encourage a more inventive approach to achieve successful descaling whether for performance or for integrity inspection. Oil Refinery program elements utilize risks, rather than time, as the basis for prioritizing and scheduling stationary equipment maintenance and inspections. When scheduling plant equipment maintenance work, we plan work we schedule the work so the maintenance and inspection scopes are completed at the most optimal intervals and using the most appropriate methods. This can be determined individually for each of the refineries' equipment components.

2 A results oriented maintenance management system is much easier to implement early in the process. A common mistake is assuming that a good computer system will take care of the problem. It is essential that a manual system be coordinated with the computer system to ensure that the whole process does not become paper bound, producing paper and data that are not used to produce practical results. If your challenge is mandatory maintenance, scheduled maintenance, or unanticipated repairs, Maintenance Planning should ensure all maintenance is performed in the most efficient way by integrating the maintenance tasks into the overall plan. You can performing maintenance ahead of schedule to leverage a piece of equipments idle time, i.e. schedule maintenance work with the equipment is scheduled to be off line. The Maintenance project starts with a review and assessment of the maintenance programs, systems and resources. This phase of the project starts with a review of manual and computer systems, a job walk of the maintenance work areas, discussions with maintenance managers and shift supervisors, a review of the planning and scheduling of maintenance work and work backlog and the daily work schedule. Items such as equipment status reports, backlog control and workers safety are included. A Maintenance System report is prepared. The report included: Overview Highlights of the maintenance review Summary Highlights of the strengths, shortcomings, outline of recommendations and savings Recommendations detailed list of steps required to implement improvements and assignment of responsibilities Plan and Schedule a timeline with tasks, steps and action required to execute the work Including assigning the tasks to individuals responsible for the improvements Milestones Management Check Points list of major action items to be completed and targets and budget dollars to complete the tasks Conclusion Discussions on overall performance levels and goals to improve the long term Performance of the maintenance programs, including worker training and safety. Projects on cost savings and equipment uptime. The main elements of our maintenance programs include: Productivity Evaluation

3 An estimate of current productivity and what can be expected with a fully trained maintenance staff how many maintenance personnel are required to provide the equipment maintenance program? Equipment Availability and Reliability An assessment of production equipment operating times vs production requirements. How down time impacts production. Equipment Register A list of pant equipment including the equipment name, model, date of installation and location within the plant. The equipment register lists the planned inspection dates, major maintenance dates and resources to perform the work. Our equipment monitoring includes process activities such as corrosion monitoring, inspections and maintenance. The equipment monitoring programs reduced operating costs while ensuring regulatory and insurance compliance. Safety An evaluation of safety programs and recommendations. MACS policies and procedures are structured to the work environment and to the skills and knowledge of the maintenance crews. Safety is of utmost importance in developing the work procedures. Training The working level and supervisory levels must be trained not only in maintenance technical matters but also in methods of getting the work done efficiently, safely and correctly (quality). There is always the danger of spending a lot of time and money on training that does not produce results. A practical approach is needed and again the most benefit will usually be from making sure all involved know what is expected of them and what they have to do to get results. While there is often some need to train fitters in specific skills, it can usually be of a lesser priority Work Request Production personnel prepare a work request when they identify tasks/repairs that are required on a piece of equipment.

4 Work Order Prepare work orders for routine maintenance, eliminating any manual input. Classify work orders by the type of work performed. Once completed, the inventory, history, and budget files are updated automatically. The work order can be used for : a. Repetitive Tasks b. Planned and Breakdown maintenance work Preventive Maintenance Maximize your resources, reduce downtime and increase efficiency.. Our easy to use, intuitive system helps you identify potential breakdowns and prevent equipment failure impacting your production and profits. A work orders is prepared when preventive maintenance is due and it documents your activities making it easier to analyze trends and spot recurrent problems. Planning and Scheduling Monitor planned maintenance work by monitoring equipment operating conditions via odometer, hours, days, calendar dates, days of the week, tire depth, or fuel and oil consumption Effective Planning and Scheduling of Maintenance work: a. Reduce maintenance costs b. Efficiently utilize scarce maintenance resources c. Automatically schedule resources for maintenance without affecting transportation plans and delivery schedules d. More effective decision making with full visibility of resource availability and planning constraints e. Single, integrated system for all employee scheduling needs for optimum short, mediumand long term workforce efficiency d. Improves operational efficiency and smooth handling of disturbances e. Improving resource utilization and customer service f. Better alignment of long term employee capacity with business demand Repair Histories

5 Produce complete repair histories for each plant area or piece of equipment, including parts and labor. Most refineries do not possess accurate historical data on previous cleaning or inspection activities including data on pressures, volumes used, technology applied or any other significant Information elements. Without this data, the key to improving performance the next time around is missing. Refinery personnel refer to pressure jetting or chemical flushing and very little else. MACS equipment history programs provide a clear and precise information gathering strategymaintenance personnel understanding the details of the problem information such as limitations of access, deposit characteristics all of which help contractors to apply the best technology in the most efficient manner. This information reduces the chance of bottlenecking by preparing and understanding a cleaning problem before it occurs, planning for the best cleaning technology which benefits plant performance and increases energy savings. Maintenance Backlog The maintenance backlog tracks incomplete maintenance work and it is used to schedule work when new work is scheduled. The backlog is also used to determine the number of labor hours of incomplete work by crew type. Tool Tracking It's simple to find out which employees have what tools assigned to them with this optional feature. The date and time of assignment and return information is also tracked. Asset Depreciation Allows you to track the depreciation on your assets using the Straight Line Depreciation method. Warranty Tracking Track the warranty information on all of your equipment, tools and vehicles. Know when your assets are still covered under warranty, length of term and more.