Let Us Be The Gauge Experts So You Don t Have To FAST Audit
Can you relate to these plant situations? Present State of Gauge Population No analysis has been performed in a long time... if ever. Knowledge Gap I inherited a mixed bag. The plant was constructed before I was born. Lack of Ownership Operations replaces gauges. Maintenance stores them. That is the extent of our procedures. Like and Kind Replacement Our P&IDs have gauge locations marked but no specifications are indicated. Lack of Resources I don t have time to identify, analyze, correct and document the 1000+ gauges in our plant. Safety Concerns Putting off work definitely affects the safety of the refinery.
What if your plant s status could be transformed to Best Practice? WIKA s Full Audit Service Team (FAST) is a group of instrumentation engineers formed to help you establish a gauge management system that maximizes reliability, and minimizes inventory and unique models. FAST engineers provide the visibility you need to optimize your gauge maintenance and supply program. More than 40% of all oil and gas professionals will retire in the next 10 years * All compromised gauge installations corrected Best models specified for all application types Consolidated gauge model list Full plant coverage Only the models you need Sustainable supply & management model * Source: Cambridge Energy Research Associates
FAST Audit An on-site FAST Audit is the first step in constructing a world-class instrumentation program. During an audit, FAST engineers visually inspect your population of mechanical pressure and temperature indicators, documenting failures as well as opportunities for improving reliability. FAST engineers then analyze the data to supply you with best practice recommendations for individual installations and your plant as a whole. With this data in hand, FAST engineers will then be able to assess your plant s needs and streamline your gauge management process. 30% More than of plants lack defined ownership of their gauges *
Facts & Credentials Approximately 125 gauges recorded per day (per engineer) Data recorded with intrinsically safe ipad (Class I, Div II) FAST engineers possess a TWIC card and are current with OSHA Basic Plus certification More than 250 plant audits conducted by FAST Audit scope can be tailored to your plant s needs Unit and tag number included for each recorded gauge to assist with maintenance Gauge types included in audit scope Mechanical pressure gauges Mechanical temperature gauges (bi-metal thermometers) Level gauges (by request) 40% of instruments in a typical processing plant have failed or are about to fail * * Based on results from more than 250 WIKA instrument audits
Audit Analysis & Deliverables The FAST Audit service includes a comprehensive analysis of the information collected on-site. The results of this analysis along with known plant specifications provide the groundwork for a customized gauge management solution a solution designed to maximize reliability and safety while minimizing complexity and costs. Process Discuss symptoms you are experiencing & determine your expectations Build a comprehensive record of gauge installations & identify & rate problematic conditions Deliverables Final report on current gauge installations, including a recommended plan of action for transitioning to new population Easy Order Guide to help installers navigate to appropriate new configurations Application Guide, which provides recommendations for specific installations & categorizes them by process Benefits A comprehensive, sustainable gauge maintenance program with ongoing support that provides savings year after year Reduction in misapplication of gauges & carried inventory Decrease in gauge spend with correct configurations & fewer failures Reduction in maintenance time spent replacing gauges Improved safety by ensuring you have the proper gauge for each application Analyze data & provide engineering based recommendations to address failed installations & standardize & consolidate the population Procedural & engineering controls, such as stainless steel tags, to improve replacement time & accuracy Support implementation of improved gauge population with ERP data import & assistance with MOC documentation $10 billion Per year is lost in U.S. process plants from abnormal situations caused by human error * * Based on results from more than 250 WIKA instrument audits
Additional FAST Services In addition to the on-site audit, the FAST program includes other services to help you implement best-practice standards for instrumentation management. FAST Instrument Failure Analysis Sometimes it seems that one particular gauge needs replacing a lot more often than others, and you don t know why. In order to avoid equipment failures, you must understand the root causes of failure and systematically remove these causes. If you are experiencing repeated gauge failures, then you should schedule an Instrument Failure Analysis to resolve any safety and reliability issues. For a full understanding of your problematic installation, you can have the gauge sent to WIKA where our engineers will diagnose the cause of failure and provide you with a complete test report including recommendations. FAST Instrument Safety Training The Abnormal Situation Management Consortium found that one of the most common causes of procedural operations failures in process plants was failure to detect abnormal conditions. Our FAST engineers can train your team to look for signs of failure and understand their causes. FAST Turnaround Instrument Planning In today s competitive environment, plants are being run harder and longer. Scheduled plant shutdowns or turnarounds help companies address equipment issues before they cause costly unplanned downtime. Our FAST engineers can help streamline and improve the rapid success of your plant turnarounds with Turnaround Instrument Planning. Our team will perform a full instrument audit and 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.
WIKA s FAST Program With WIKA s FAST Program, you won t have to worry about gauges. Let our FAST engineers provide you with a thorough review of your gauge population to improve uptime, lower cost & keep you safer. Their total care audit solution provides you with the engineer resources and expertise you need to take your instrument management to best practice status. WIKA Instrument, LP 1000 Wiegand Blvd., Lawrenceville, GA 30043 Tel. (855) 651-FAST (3278) fast@wika.com www.wika-fast.com B054-1000 5/17 WIKA is a registered trademark of WIKA Alexander Wiegand SE & Co. KG., used under license by WIKA Instrument, LP. Copyright 2017 WIKA Instrument, LP. All Rights Reserved.