LET US BE THE GAUGE EXPERTS. So You Don t Have To Be

Transcription

1 LET US BE THE GAUGE EXPERTS So You Don t Have To Be SM

2 FAST Instrument Audit: Reducing Costs and Improving Reliability, Safety Audits of more than 150,000 mechanical pressure and temperature installations revealed that processing plants could realize a first-year savings of $51,171 1,2 and an ongoing annual savings of $21,073 3 by consolidating, standardizing and improving their gauge configurations. Total cost of ownership savings were determined by: Reducing inventory costs and complexity. By standardizing on full scale ranges and options, plants could reduce unique gauge configurations by as much as 75%, which translates to a reduction in carried inventory of approximately 30%. 4 Improving the reliability of gauges. On average, 40% of gauge installations had failed or were near failure; correcting misapplications and ensuring compatibility with operating conditions reduces the failure rate. 4 Lowering maintenance costs. By reducing the frequency of gauge replacement, time spent on gauge maintenance drops by 25%. 4 Included in the first year savings are $30,098 1 of engineering resources, which are provided at no charge. These resources include: An audit of gauge installations and existing inventory by certified instrumentation engineers. Data analysis and recommendations to improve the reliability of instrumentation. Implementation support to help transition to the new population. To learn more about the FAST program, please contact us at or fast@wika.com. (1) First year savings only. Includes engineering resources for physical audit, storeroom review, data compilation, and ERP and MOC support, which are provided at no charge (2) Based on average audit of 1,000 installations, requiring two instrumentation engineers for one week (3) Ongoing annual savings. Inventory savings based on industry averages for overhead, inventory management, shrinkage, obsolescence, inventory tax, and cost of capital (4) Based on results from more than 250 WIKA instrument audits 1 Call FAST or visit

3 FAST = A True Zero Cost Solution $51,171 Savings $0 Cost $3,240 Inventory Reduce complexity and standardize RESULT Reduce carried inventory and misapplication $12,500 Reliability for process conditions RESULT Reduce frequency of gauge failures $5,333 Maintenance Reduce time spent replacing gauges RESULT More time to trouble shoot, engage in PdM efforts! $30,098 Engineering Resources (Instrument Audit, Data Analysis, Recommendations, Implementation Support) Instrument Audit Data Analysis Support Field inspection of all gauge installations Review of existing inventory Certified Instrumentation Engineers (TWIC, OSHA, reciprocal, etc. Maximize field coverage Minimize complexity of configurations Eliminate redundant, obsolete or wasted inventory ERP Import Sheets MOC Documents Easy Order Guide Physical Gauge Tagging New Gauge Population & Culture $21,073 Ongoing Annual Savings Call FAST or visit 2

4 FAST INSTRUMENT AUDIT temperature and accessories. maintenance program. 5 Ways Gauges Help Troubleshoot Critical Equipment and Reduce Costly Repairs Problem: Poor Pump Performance Is the Pump Damaged? Process Off-Spec? Problem: Mechanical Seal Failure Is the Seal Receiving Adequate Cooling? Lubrication? 1 DISCHARGE PRESSURE 4 PRIMARY FLUSH PRESSURE Is pressure reading at design? NO 2 SUCTION PRESSURE Is suction pressure reading at design? psig higher than suction pressure? NO 5 SECONDARY FLUSH PRESSURE 30 psig higher than primary flush pressure? NO YES NO 3 SUPPLY PRESSURE Strainer clogged, or other upstream process issues. Efficiency is reduced from internal wear to pump. Pressure not adequate to maintain cool, clean seal chamber - grit & heat accelerate wear. Barrier contamination & accelerated seal face wear possible from low set pressure. 3 Call FAST or visit

5 PROCESS: Discuss symptoms you are experiencing and determine your expectations Build a comprehensive record of gauge installations, and identify and rate problematic conditions recommendations to address failed installations, and standardize and consolidate the population Support implementation of improved gauge population documentation DELIVERABLES: a recommended plan of action for transitioning to Procedural and engineering controls, such as stainless steel tags, to improve replacement time and accuracy BENEFITS: A comprehensive, sustainable gauge maintenance year after year Reduction in misapplication of gauges and carried inventory Reduction in maintenance time spent replacing gauges Improved safety by ensuring you have the proper gauge for each application Call FAST or visit 4

6 FAST TURNAROUND INSTRUMENT PLANNING standardize the pressure and temperature measurement instruments you need...before your turnaround actually begins. We can then help you avoid delays by sending you the right gauges for your applications just before your turnaround begins. PROCESS: standardize Recommend types and number of gauges needed; Provide status reports, document change orders and maintain communication on your needs 5 Call FAST or visit

7 Turnarounds can be incredibly stressful and dangerous 40% of incidents occur during the take-off and landing periods of a start-up and shutdown, although we operate in the mode less than 5% of the time.* * Sherman J. Glass Jr., President of Exxon Mobil as quoted in Plant Reliability and Maintenance, Oil & Gas IQ., Oct 13, 2010 DELIVERABLES: data sheet for each installation to ensure proper documentation of gauges BENEFITS: Provide longer unit life Reduce maintenance costs Increase safety and reliability technology Call FAST or visit 6

8 FAST INSTRUMENT FAILURE ANALYSIS Sometimes it seems that one particular gauge needs replacing a lot more often than others, and failure and systematically remove these causes. Analysis to resolve any safety and reliability issues. More than 30% of plants lack defined ownership of their gauges 40% of instruments in a typical processing plant have failed or are about to fail. * * More than 300 WIKA Instrument Audits. WIKA internal data. 7 Call FAST or visit

9 PROCESS: conduct a thorough root cause analysis, to other problems in the process DELIVERABLES: Provide root cause analysis report you to determine next steps BENEFITS: Improve safety and reliability Reduce gauge replacement and frequent costs for reordering gauges Reduce maintenance costs Call FAST or visit 8

10 FAST INSTRUMENT SAFETY TRAINING Experienced personnel are retiring and not being replaced $10 billion per year is lost in U.S. process plants from abnormal situations caused by human error.* * Abnormal Situations Management Consortium 9 Call FAST or visit

11 PROCESS: You recognize the need for education and presentation to your needs identify and correct problems, and use gauges to troubleshoot larger issues DELIVERABLES: to eliminate the problem from recurring BENEFITS: Apply continuous improvement to operations and processes Reduce maintenance costs and Avoid operational disruptions and Improve employee productivity Increase safety and reliability Call FAST or visit 10

12 WIKA s FAST Program SM With WIKA s FAST Program, you won t have to worry about gauges. Our FAST engineers audit your gauge population to improve uptime, lower costs and keep you safer. The FAST program is a value-added, total care solution providing engineering resources for the same price you would normally pay for just gauges. Full Suite of Services Instrument Audit Instrument Planning Analysis Instrument Safety WIKA s Instrument Audit provides expert analysis and solutions from our FAST engineers, who help you put the right gauge in place for your application to improve reliability and lower costs. Our team performs an Instrument Audit, standardizes the instruments you need, and sends the products when you really need them... before your turnaround begins so you can avoid delays. Send us your failed gauge, and our engineers will conduct a root cause analysis. By understanding the mode of failure our FAST engineers can recommend a solution to prevent further safety issues. Our FAST engineers train your team on proper gauge installation/maintenance and the signs of instrument failure to look for when completing a scheduled evaluation of your instrumentation. Visit call FAST (3278) or fast@wika.com to learn more. B /14 Copyright 2014 WIKA Instrument LP All Rights Reserved