The document discusses issues with maintenance and asset management practices in industry. It questions whether company boards understand the risks associated with poor maintenance. It also asks if insurers are supporting mediocrity in maintenance practices through their underwriting. The presenter has decades of experience consulting on asset management and believes current practices in industry are poor and not supporting reliability.
Condition-Based Maintenance: 10 Steps Towards Continuous ImprovementOSIsoft, LLC
The move from calendar-based maintenance to predictive maintenance is an ongoing process. But where should you begin? These ten easy steps can provide some guidance for getting started.
Does it annoy you that in spite of regularly performing Preventive Maintenance (PM) on your equipment it continues to breakdown? Some may call this insanity – Continuing to do the same thing over and over, expecting a different result. So what do you do? Maybe take a close look at your current PM Program.
There are known best practices which will not only enhance your PM program but also increase equipment reliability. Remember most work comes from PM and PdM and then it must be planned correctly, scheduled with production, executed to schedule and to specifications. If this occurs you will be seeing the results. "less breakdowns"
Check out this article and post your comments please.
Why do people not understand the P-F Curve? At a recent maintenance function, I asked 70 maintenance and reliability professionals how many of them had heard of the P-F Curve and only about 10% stated they had. From that 10%, only 1% felt like they truly understood it. This was shocking to me. I assumed everyone had heard about the P-F Curve and its intent.
The intent of the P-F Curve is to illustrate how equipment fails and how early detection of a failure provides time to plan and schedule the replacement or restoration of a failing part without interruption to production or operations.
Once you understand the P-F or PF Curve you will have a better awareness of how equipment fails.
Most companies don’t measure mean time between failures (MTBF), even though it’s the most basic measurement that quantifies reliability. MTBF is the average time an asset functions before it fails. So, why don’t they measure MTBF? Let’s define reliability first before we go any further.
Reliability: The ability of an item to perform a required function under stated conditions for a stated period of time
So why don’t we measure Mean Time Between Failure. This articles discusses this issue.
How good is your organization at identifying failures? Sure you see failures when they occur, but can you identify when recurring failures are creating serious equipment reliability.
Condition-Based Maintenance: 10 Steps Towards Continuous ImprovementOSIsoft, LLC
The move from calendar-based maintenance to predictive maintenance is an ongoing process. But where should you begin? These ten easy steps can provide some guidance for getting started.
Does it annoy you that in spite of regularly performing Preventive Maintenance (PM) on your equipment it continues to breakdown? Some may call this insanity – Continuing to do the same thing over and over, expecting a different result. So what do you do? Maybe take a close look at your current PM Program.
There are known best practices which will not only enhance your PM program but also increase equipment reliability. Remember most work comes from PM and PdM and then it must be planned correctly, scheduled with production, executed to schedule and to specifications. If this occurs you will be seeing the results. "less breakdowns"
Check out this article and post your comments please.
Why do people not understand the P-F Curve? At a recent maintenance function, I asked 70 maintenance and reliability professionals how many of them had heard of the P-F Curve and only about 10% stated they had. From that 10%, only 1% felt like they truly understood it. This was shocking to me. I assumed everyone had heard about the P-F Curve and its intent.
The intent of the P-F Curve is to illustrate how equipment fails and how early detection of a failure provides time to plan and schedule the replacement or restoration of a failing part without interruption to production or operations.
Once you understand the P-F or PF Curve you will have a better awareness of how equipment fails.
Most companies don’t measure mean time between failures (MTBF), even though it’s the most basic measurement that quantifies reliability. MTBF is the average time an asset functions before it fails. So, why don’t they measure MTBF? Let’s define reliability first before we go any further.
Reliability: The ability of an item to perform a required function under stated conditions for a stated period of time
So why don’t we measure Mean Time Between Failure. This articles discusses this issue.
How good is your organization at identifying failures? Sure you see failures when they occur, but can you identify when recurring failures are creating serious equipment reliability.
Reliability Centered Maintenance (RCM) is a proven, logical, sensible approach that helps companies improve reliability. Yet most companies are not getting the return they expected. They see RCM as too much trouble for too little reward. So that’s why we decided to publish this new report. Find out why RCM doesn't work, what needs to change and how to put RCM to work at your company so it doesn't become another Resource Consuming Monster.
We know RCM works however I wanted to share with you the 5 Biggest Mistakes people make using Reliability Centered Maintenance. Love to hear your comments or tell us what you have seen work and not work.
“My maintenance staff is highly trained and do not like using procedures.” If the statement is valid, and the cost of asset failure is not important to our operation, then your staff must have an unlimited and infallible memory – congratulations!
Did you know that the most complex equipment ever built was a nuclear submarine and that the first nuclear submarines experienced failures due to lack of effective procedures, thus ending in catastrophic failure?
If safety is number one in your organization, then repeatable, effective work procedures should be as well.
Advanced Maintenance And Reliability (Maintenance and Reliability Best Pract...Ricky Smith CMRP, CMRT
Maintenance and reliability has taken great strides toward managing asset reliability by applying known best practices in maintenance and reliability finding that they can optimize reliability and reduce total cost and reduce risk by applying known best practices. However, if not most organizations are still trapped in the old way of thinking.
As Albert Einstein once said: "the significant problems we face cannot be solved with the same level of thinking we were at when we created them".
If you are thinking your operators are not important in helping with the management of asset reliability, think again. You cannot achieve an optimal state of asset reliability with the operators. This is a Great article on this topic.
10 Things an Operations Supervisor can do Today to Improve ReliabilityRicky Smith CMRP, CMRT
Continuing the series that started with maintenance technicians and supervisors, if you are new to the position of Operations Supervisor, what are some of the things you can begin working on immediately to improve reliability within the area you work?
Risk Management - Business Continuity Planning and ManagementCody Shive
This presentation outlines the basics behind Business Continuity planning and management. Targeted to CEO's, CFO's and CIO's, this presentation emphasizes the processes and the need to make BCP/M part of the Enterprise's fabric.
Building Operational Excellence in Petroleum Refining Training CourseKarl Kolmetz
There are many aspects of building operational excellence. Partial list may include;
1. Health, Safety and the Environment
2. Reliability – Continuity of Operations
3. Quality
4. Cost
5. People Development
Reliability Centered Maintenance (RCM) is a proven, logical, sensible approach that helps companies improve reliability. Yet most companies are not getting the return they expected. They see RCM as too much trouble for too little reward. So that’s why we decided to publish this new report. Find out why RCM doesn't work, what needs to change and how to put RCM to work at your company so it doesn't become another Resource Consuming Monster.
We know RCM works however I wanted to share with you the 5 Biggest Mistakes people make using Reliability Centered Maintenance. Love to hear your comments or tell us what you have seen work and not work.
“My maintenance staff is highly trained and do not like using procedures.” If the statement is valid, and the cost of asset failure is not important to our operation, then your staff must have an unlimited and infallible memory – congratulations!
Did you know that the most complex equipment ever built was a nuclear submarine and that the first nuclear submarines experienced failures due to lack of effective procedures, thus ending in catastrophic failure?
If safety is number one in your organization, then repeatable, effective work procedures should be as well.
Advanced Maintenance And Reliability (Maintenance and Reliability Best Pract...Ricky Smith CMRP, CMRT
Maintenance and reliability has taken great strides toward managing asset reliability by applying known best practices in maintenance and reliability finding that they can optimize reliability and reduce total cost and reduce risk by applying known best practices. However, if not most organizations are still trapped in the old way of thinking.
As Albert Einstein once said: "the significant problems we face cannot be solved with the same level of thinking we were at when we created them".
If you are thinking your operators are not important in helping with the management of asset reliability, think again. You cannot achieve an optimal state of asset reliability with the operators. This is a Great article on this topic.
10 Things an Operations Supervisor can do Today to Improve ReliabilityRicky Smith CMRP, CMRT
Continuing the series that started with maintenance technicians and supervisors, if you are new to the position of Operations Supervisor, what are some of the things you can begin working on immediately to improve reliability within the area you work?
Risk Management - Business Continuity Planning and ManagementCody Shive
This presentation outlines the basics behind Business Continuity planning and management. Targeted to CEO's, CFO's and CIO's, this presentation emphasizes the processes and the need to make BCP/M part of the Enterprise's fabric.
Building Operational Excellence in Petroleum Refining Training CourseKarl Kolmetz
There are many aspects of building operational excellence. Partial list may include;
1. Health, Safety and the Environment
2. Reliability – Continuity of Operations
3. Quality
4. Cost
5. People Development
Optimizing Petroleum Refining FCC Unit Operations TrainingKarl Kolmetz
The success of every company depends of each employee's understanding of
the key business components. Employee training and development will unlock
the companies' profitability and reliability. When people, processes and
technology work together as a team developing practical solutions, companies
can maximize profitability and assets in a sustainable manner. Training and
development is an investment in future success - give yourself and your
employees the keys to success
Optimizing Petroleum Refining Unit Operations Training CourseKarl Kolmetz
Many aspects of petroleum refining operations management can be improved
including, product recoveries, purities and energy utilization, and safety. This
cannot be achieved without first an understanding of basic fundamental
principles of design and operation. These principles need to be understood in
advance of operating and trouble shooting a process unit operation for the
manager or problem solving to be effective.
This seminar focuses on the core building blocks of the petroleum refining
process systems, equipment and economics. This program will emphasize the
refining process unit operation fundamentals, safe utilization of these
fundamentals by operations, engineering, maintenance and support personnel.
Dear students get fully solved assignments by professionals
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The challenges facing in pharmaceutical maintenanceMANUEL PACINI
Maintenance strategies for the pharmaceutical industry.
Maintenance and service-related items are often the second-largest budget element in a laboratory after salaries and benefits
Reliability Centered Maintenance (RCM) is a proven, logical, sensible approach that helps companies improve reliability. Yet most companies are not getting the return they expected. They see RCM as too much trouble for too little reward.
So that’s why we decided to publish this new report. Find out why RCM doesn’t work, what needs to change and how to put RCM to work at your company so it doesn’t become another Resource Consuming Monster.
Nowlan and Howard Heap published “Reliability Centered Maintenance”, the ground-breaking study that changed maintenance forever. Yet myth, mystery and confusion about RCM still abound.
So let’s begin with the basic truths. To paraphrase RCM practitioner, Doug Plucknette, of GPAllied, RCM is a structured process developed to ensure the designed safety and reliability capabilities of a process or piece of equipment. The beauty of understanding the RCM process is it can be applied to virtually any physical asset in any plant around the world.
RCM’s roots go back to the early 1960’s, when the commercial airline companies were considering buying the new jumbo jet, the Boeing 747. At the time, the airlines religiously practiced time-based preventive maintenance. Why? Because the conventional wisdom was that equipment wears out over time. So that meant taking planes out of service for maintenance every 1,000, 5,000 or 10,000 hours.
But the problem with the 747’s was the amount of maintenance specified by federal regulators was three times more than the maintenance required for Boeing 707’s. That meant more time in maintenance, more time out of service, and a huge disruption to operations.
Clearly, the airlines’ traditional approach to maintenance would not be economically feasible for the new jumbo jets.
So the airlines had two choices: Either buy a larger fleet of planes or develop a more economical approach to maintenance.
That’s why United Airlines led a task force to re-evaluate the concept of preventive maintenance and determine the most economic strategy, without compromising safety. The result was the process that we now know as RCM, which was successfully employed on the 747 and all subsequent jet aircraft.
SOLVED SMU MBA ASSIGNMENTS AVAILABLE....Naveen Kumar
Remaining Answers are available in Paid Assignments……..
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Proactive Maintenance: EMAL’s Strategic Solution for Cost Competitivenessalcircle.com
The recession which started in 2008 has affected all industry sectors, aluminium being no exception. The LME has since then dropped from a high of nearly $ 3200 per ton at its peak and is now hovering around $ 1800 in the face of lower global demand. That is nearly a fall of 43 %. Only a few aluminium producers have been able to sustain this shock. It has led many companies to scale back their production, some others to shutdown while for many it translates to cutting cost to remain competitive. The economic and political realities have forced managers to reduce cost.
Dear students get fully solved assignments
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Operations Excellence in the Management of Ageing AssetsAdvisian
Advisian's Tony Geraghty discusses Operations Excellence in the Management of Ageing Assets at the 2016 Abu Dhabi International Petroleum Exhibition & Conference
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Send your semester & Specialization name to our mail id :
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Pushing the limits of ePRTC: 100ns holdover for 100 daysAdtran
At WSTS 2024, Alon Stern explored the topic of parametric holdover and explained how recent research findings can be implemented in real-world PNT networks to achieve 100 nanoseconds of accuracy for up to 100 days.
GDG Cloud Southlake #33: Boule & Rebala: Effective AppSec in SDLC using Deplo...James Anderson
Effective Application Security in Software Delivery lifecycle using Deployment Firewall and DBOM
The modern software delivery process (or the CI/CD process) includes many tools, distributed teams, open-source code, and cloud platforms. Constant focus on speed to release software to market, along with the traditional slow and manual security checks has caused gaps in continuous security as an important piece in the software supply chain. Today organizations feel more susceptible to external and internal cyber threats due to the vast attack surface in their applications supply chain and the lack of end-to-end governance and risk management.
The software team must secure its software delivery process to avoid vulnerability and security breaches. This needs to be achieved with existing tool chains and without extensive rework of the delivery processes. This talk will present strategies and techniques for providing visibility into the true risk of the existing vulnerabilities, preventing the introduction of security issues in the software, resolving vulnerabilities in production environments quickly, and capturing the deployment bill of materials (DBOM).
Speakers:
Bob Boule
Robert Boule is a technology enthusiast with PASSION for technology and making things work along with a knack for helping others understand how things work. He comes with around 20 years of solution engineering experience in application security, software continuous delivery, and SaaS platforms. He is known for his dynamic presentations in CI/CD and application security integrated in software delivery lifecycle.
Gopinath Rebala
Gopinath Rebala is the CTO of OpsMx, where he has overall responsibility for the machine learning and data processing architectures for Secure Software Delivery. Gopi also has a strong connection with our customers, leading design and architecture for strategic implementations. Gopi is a frequent speaker and well-known leader in continuous delivery and integrating security into software delivery.
Elevating Tactical DDD Patterns Through Object CalisthenicsDorra BARTAGUIZ
After immersing yourself in the blue book and its red counterpart, attending DDD-focused conferences, and applying tactical patterns, you're left with a crucial question: How do I ensure my design is effective? Tactical patterns within Domain-Driven Design (DDD) serve as guiding principles for creating clear and manageable domain models. However, achieving success with these patterns requires additional guidance. Interestingly, we've observed that a set of constraints initially designed for training purposes remarkably aligns with effective pattern implementation, offering a more ‘mechanical’ approach. Let's explore together how Object Calisthenics can elevate the design of your tactical DDD patterns, offering concrete help for those venturing into DDD for the first time!
Observability Concepts EVERY Developer Should Know -- DeveloperWeek Europe.pdfPaige Cruz
Monitoring and observability aren’t traditionally found in software curriculums and many of us cobble this knowledge together from whatever vendor or ecosystem we were first introduced to and whatever is a part of your current company’s observability stack.
While the dev and ops silo continues to crumble….many organizations still relegate monitoring & observability as the purview of ops, infra and SRE teams. This is a mistake - achieving a highly observable system requires collaboration up and down the stack.
I, a former op, would like to extend an invitation to all application developers to join the observability party will share these foundational concepts to build on:
Alt. GDG Cloud Southlake #33: Boule & Rebala: Effective AppSec in SDLC using ...James Anderson
Effective Application Security in Software Delivery lifecycle using Deployment Firewall and DBOM
The modern software delivery process (or the CI/CD process) includes many tools, distributed teams, open-source code, and cloud platforms. Constant focus on speed to release software to market, along with the traditional slow and manual security checks has caused gaps in continuous security as an important piece in the software supply chain. Today organizations feel more susceptible to external and internal cyber threats due to the vast attack surface in their applications supply chain and the lack of end-to-end governance and risk management.
The software team must secure its software delivery process to avoid vulnerability and security breaches. This needs to be achieved with existing tool chains and without extensive rework of the delivery processes. This talk will present strategies and techniques for providing visibility into the true risk of the existing vulnerabilities, preventing the introduction of security issues in the software, resolving vulnerabilities in production environments quickly, and capturing the deployment bill of materials (DBOM).
Speakers:
Bob Boule
Robert Boule is a technology enthusiast with PASSION for technology and making things work along with a knack for helping others understand how things work. He comes with around 20 years of solution engineering experience in application security, software continuous delivery, and SaaS platforms. He is known for his dynamic presentations in CI/CD and application security integrated in software delivery lifecycle.
Gopinath Rebala
Gopinath Rebala is the CTO of OpsMx, where he has overall responsibility for the machine learning and data processing architectures for Secure Software Delivery. Gopi also has a strong connection with our customers, leading design and architecture for strategic implementations. Gopi is a frequent speaker and well-known leader in continuous delivery and integrating security into software delivery.
Dev Dives: Train smarter, not harder – active learning and UiPath LLMs for do...UiPathCommunity
💥 Speed, accuracy, and scaling – discover the superpowers of GenAI in action with UiPath Document Understanding and Communications Mining™:
See how to accelerate model training and optimize model performance with active learning
Learn about the latest enhancements to out-of-the-box document processing – with little to no training required
Get an exclusive demo of the new family of UiPath LLMs – GenAI models specialized for processing different types of documents and messages
This is a hands-on session specifically designed for automation developers and AI enthusiasts seeking to enhance their knowledge in leveraging the latest intelligent document processing capabilities offered by UiPath.
Speakers:
👨🏫 Andras Palfi, Senior Product Manager, UiPath
👩🏫 Lenka Dulovicova, Product Program Manager, UiPath
Why You Should Replace Windows 11 with Nitrux Linux 3.5.0 for enhanced perfor...SOFTTECHHUB
The choice of an operating system plays a pivotal role in shaping our computing experience. For decades, Microsoft's Windows has dominated the market, offering a familiar and widely adopted platform for personal and professional use. However, as technological advancements continue to push the boundaries of innovation, alternative operating systems have emerged, challenging the status quo and offering users a fresh perspective on computing.
One such alternative that has garnered significant attention and acclaim is Nitrux Linux 3.5.0, a sleek, powerful, and user-friendly Linux distribution that promises to redefine the way we interact with our devices. With its focus on performance, security, and customization, Nitrux Linux presents a compelling case for those seeking to break free from the constraints of proprietary software and embrace the freedom and flexibility of open-source computing.
GraphRAG is All You need? LLM & Knowledge GraphGuy Korland
Guy Korland, CEO and Co-founder of FalkorDB, will review two articles on the integration of language models with knowledge graphs.
1. Unifying Large Language Models and Knowledge Graphs: A Roadmap.
https://arxiv.org/abs/2306.08302
2. Microsoft Research's GraphRAG paper and a review paper on various uses of knowledge graphs:
https://www.microsoft.com/en-us/research/blog/graphrag-unlocking-llm-discovery-on-narrative-private-data/
LF Energy Webinar: Electrical Grid Modelling and Simulation Through PowSyBl -...DanBrown980551
Do you want to learn how to model and simulate an electrical network from scratch in under an hour?
Then welcome to this PowSyBl workshop, hosted by Rte, the French Transmission System Operator (TSO)!
During the webinar, you will discover the PowSyBl ecosystem as well as handle and study an electrical network through an interactive Python notebook.
PowSyBl is an open source project hosted by LF Energy, which offers a comprehensive set of features for electrical grid modelling and simulation. Among other advanced features, PowSyBl provides:
- A fully editable and extendable library for grid component modelling;
- Visualization tools to display your network;
- Grid simulation tools, such as power flows, security analyses (with or without remedial actions) and sensitivity analyses;
The framework is mostly written in Java, with a Python binding so that Python developers can access PowSyBl functionalities as well.
What you will learn during the webinar:
- For beginners: discover PowSyBl's functionalities through a quick general presentation and the notebook, without needing any expert coding skills;
- For advanced developers: master the skills to efficiently apply PowSyBl functionalities to your real-world scenarios.
State of ICS and IoT Cyber Threat Landscape Report 2024 previewPrayukth K V
The IoT and OT threat landscape report has been prepared by the Threat Research Team at Sectrio using data from Sectrio, cyber threat intelligence farming facilities spread across over 85 cities around the world. In addition, Sectrio also runs AI-based advanced threat and payload engagement facilities that serve as sinks to attract and engage sophisticated threat actors, and newer malware including new variants and latent threats that are at an earlier stage of development.
The latest edition of the OT/ICS and IoT security Threat Landscape Report 2024 also covers:
State of global ICS asset and network exposure
Sectoral targets and attacks as well as the cost of ransom
Global APT activity, AI usage, actor and tactic profiles, and implications
Rise in volumes of AI-powered cyberattacks
Major cyber events in 2024
Malware and malicious payload trends
Cyberattack types and targets
Vulnerability exploit attempts on CVEs
Attacks on counties – USA
Expansion of bot farms – how, where, and why
In-depth analysis of the cyber threat landscape across North America, South America, Europe, APAC, and the Middle East
Why are attacks on smart factories rising?
Cyber risk predictions
Axis of attacks – Europe
Systemic attacks in the Middle East
Download the full report from here:
https://sectrio.com/resources/ot-threat-landscape-reports/sectrio-releases-ot-ics-and-iot-security-threat-landscape-report-2024/
Securing your Kubernetes cluster_ a step-by-step guide to success !KatiaHIMEUR1
Today, after several years of existence, an extremely active community and an ultra-dynamic ecosystem, Kubernetes has established itself as the de facto standard in container orchestration. Thanks to a wide range of managed services, it has never been so easy to set up a ready-to-use Kubernetes cluster.
However, this ease of use means that the subject of security in Kubernetes is often left for later, or even neglected. This exposes companies to significant risks.
In this talk, I'll show you step-by-step how to secure your Kubernetes cluster for greater peace of mind and reliability.
SAP Sapphire 2024 - ASUG301 building better apps with SAP Fiori.pdfPeter Spielvogel
Building better applications for business users with SAP Fiori.
• What is SAP Fiori and why it matters to you
• How a better user experience drives measurable business benefits
• How to get started with SAP Fiori today
• How SAP Fiori elements accelerates application development
• How SAP Build Code includes SAP Fiori tools and other generative artificial intelligence capabilities
• How SAP Fiori paves the way for using AI in SAP apps
Le nuove frontiere dell'AI nell'RPA con UiPath Autopilot™UiPathCommunity
In questo evento online gratuito, organizzato dalla Community Italiana di UiPath, potrai esplorare le nuove funzionalità di Autopilot, il tool che integra l'Intelligenza Artificiale nei processi di sviluppo e utilizzo delle Automazioni.
📕 Vedremo insieme alcuni esempi dell'utilizzo di Autopilot in diversi tool della Suite UiPath:
Autopilot per Studio Web
Autopilot per Studio
Autopilot per Apps
Clipboard AI
GenAI applicata alla Document Understanding
👨🏫👨💻 Speakers:
Stefano Negro, UiPath MVPx3, RPA Tech Lead @ BSP Consultant
Flavio Martinelli, UiPath MVP 2023, Technical Account Manager @UiPath
Andrei Tasca, RPA Solutions Team Lead @NTT Data
zkStudyClub - Reef: Fast Succinct Non-Interactive Zero-Knowledge Regex ProofsAlex Pruden
This paper presents Reef, a system for generating publicly verifiable succinct non-interactive zero-knowledge proofs that a committed document matches or does not match a regular expression. We describe applications such as proving the strength of passwords, the provenance of email despite redactions, the validity of oblivious DNS queries, and the existence of mutations in DNA. Reef supports the Perl Compatible Regular Expression syntax, including wildcards, alternation, ranges, capture groups, Kleene star, negations, and lookarounds. Reef introduces a new type of automata, Skipping Alternating Finite Automata (SAFA), that skips irrelevant parts of a document when producing proofs without undermining soundness, and instantiates SAFA with a lookup argument. Our experimental evaluation confirms that Reef can generate proofs for documents with 32M characters; the proofs are small and cheap to verify (under a second).
Paper: https://eprint.iacr.org/2023/1886
Leading Change strategies and insights for effective change management pdf 1.pdf
Perspectiveson Asset Management
1. Perspectives on Maintenance and Asset Management in industry Do Company Boards understand the risks? Do insurers compensate the Company Boards for taking risks? Are current underwriting practices supporting mediocrity? Is there a better way?
2. About me – Steve Turner In 1977Joined RAAF at 17... Bachelor of Engineering (Aero) RMIT Worked in maintenance and reliability with the RAAF including an exchange officer post with the UK Ministry of Defence on a reliability think tank post. Left RAAF in1989 3 Years with GMH purchasing department running production improvement programs with its suppliers Graduated with MBA from Monash in 1993 (part time studies) 3 years with Price Waterhouse (now PWC) as a senior consultant
3. About me – Steve Turner Started OMCS International in 1996 Grown to be a highly respected consulting business in the area of asset management. Works in all sectors where physical assets generate the revenue. Most of our business is in Oil and Gas, Chemicals and Mining. Have been working with the power industry in Europe – focus on Nuclear Power stations.
4. The agenda Lessons learnt The ESSO Longford Disaster The BP Texas Disaster The sad response by industry Maintenance strategy explained What we typically find wrong Summary Discussion
6. The Longford Disaster On 25 September 1998, at the Longford Gas Plant in Victoria, Australia, a gas absorber burst, releasing a large cloud of hydrocarbon vapours. Seconds later, it exploded. Two staff were killed and 4 million people were deprived of gas for about two weeks
9. Some of the findings – Royal commission and Hopkins What would normally be considered abnormal was normalized - Hopkins Vital shut down and control mechanisms had not been working for 10 days– Other indicators were not seen as critical Engineering staff had been cut or moved to the city This led to lack of control of decision making on site The plant personnel were driven by production targets It was common practice to run the operation in the “red zone”.
10. John Boshier - Chief Executive OfficerInstitution of Engineers, Australia It has been 3 years since the Esso Longford gas plant exploded in September 1998. This passage of time has allowed Australia’s major hazard facilities to review the disaster and implement changes to ensure that such a tragedy does not re-occur. Unfortunately, according to the author of this report, the industry and the engineering profession have not learnt as much as they might have from the tragedy. Far more could be done to apply the lessons from Longford at facilities around Australia.
11. Reference to the report http://www.engineersaustralia.org.au/shadomx/apps/fms/fmsdownload.cfm?file_uuid=199C7EF9-9642-91DD-6B9D-9E1CAEB72F31&siteName=ieaust
13. BP Texas City Refinery Explosion March 2005 John Mogford BP - Senior Group Vice President, Safety & Operations Paper delivered at Center for Chemical Process Safety, 2nd Global Congress on Process Safety, Orlando, Florida 24 April 2006
14. Reference to the Report www.bp.com/genericarticle.do?categoryId=98&contentId=7017238
15. BP Texas City Refinery Explosion It’s not an easy story to tell. BP doesn’t come out of it well. And it’s a complicated tale involving many factors that go well beyond the process of operating a refinery safely – BP’s empowerment ethos, the behaviour of individuals in leadership and the clarity of our standards to name a few. ....
16. BP Texas City Refinery Explosion This was a preventable incident, as I will explain. It should be seen as a process failure, a cultural failure and a management failure. Our investigations have revealed significant deficiencies in the work and safety culture at Texas City. The question, of course, is why these deficiencies developed – and why weren’t they sufficiently identified and addressed before the explosion.
17. What I have learnt recently We have been in touch with BP Texas City and have had long phone conversations. I am told, they have spent $18 M USD in the last few years on consultants writing maintenance procedures and maintenance programs. They seem to have gone overboard since they simply don’t have the staff to complete the work. The real problem is they seem to have swung the pendulum too far the other way.
19. My impressions of asset management in hazardous facilities... The process of asset management in hazardous plants is appalling in almost every case. This low level is considered satisfactory. The leaders of business do not understand the implications. There is a fundamental lack of knowledge about the subject: The aviation industry figured it out in the seventies but few organisations outside of aviation are anywhere close to where they should be.
20. What I observe The problems found by the Longford Royal Commissions are endemic in industry and there is not much motivation to change. The concepts of maintenance analysis are not difficult to apply yet most organisations are in complete disarray. Maintenance engineers have not had much impact: In the past, they have not articulated their needs well, and have not been good at getting improvements happening. Many are still in that situation.
21. What I suspect I suspect Company Boards don’t want to listen because they: See maintenance as an uncontrollable drain on cash which, in the past, no one has been able to manage properly, Feel that improvements in the area of reliability and maintenance may provide high returns, but prefer to take shorter term cost reduction strategies. Base decisions on bad experiences; they don’t have confidence in reliability improvement programs.
26. A deep water drilling company maintenance program before and after
27. The problem The fundamentals of asset integrity and reliability relate directly to the preventive and predictive maintenance programs deployed by asset managers. In over a decade of providing review programs in all industries, the common thread is that almost all companies have gaps in their programs while at the same time the over-service in others. The result is that few companies have control over the condition of their assets.
28. 28 How organisations get into trouble - the vicious cycle of reactive maintenanceTM.
29. The Birth of industrial Plant.. a Common Scenario Maintenance not involved in the design. Poor maintainability. Lack of condition monitoring considerations: Inspection facilities. Sample points. Gauges and alarms. Inadequate maintenance facilities. Design not functionally capable. etc FMECA is not seen by maintenance.
30. The Birth of industrial Plant.. cont The project runs over budget and the design capability is reduced. There is little margin between what the plant can achieve and what is expected of it. The maintenance tradesmen arrive too late for adequate training and preparation. Commissioning is done in a rush and often not fully completed.
31. After Commissioning …. The project is handed over without a maintenance program The tradesmen write one… Little input from operations No consistent method No audit trail of rationale Generally risk averse - over-servicing Page 6
32. The Infancy days… Failures happen and useless tasks are added. Operations has no buy in for the maintenance plan and there is a reluctance to cooperate. Not all the PM Program is achieved and this becomes the culture of the organisation. Temporary repairs creep in and get out of control Consultants arrive and cut heads
33. The Vicious Circle of Reactive MaintenanceTM Backlog grows PM is missed Standards Drop More preventable failures Morale Declines Resources taken by Breakdowns Head / Budget Reduction Temporary Repairs More repeat work
35. Almost all assets fail in some way at some time The mechanisms of failure are referred to as failure modes. Maintenance personnel are interested in to characteristics regarding failure modes: The pattern: Wear out Random Infant Mortality Rate of deterioration Sudden Gradual
36. Age Studies (Nowlan and Heap) show that intrusive maintenance needs to be avoided.. C: Gradual 5% D: Almost Random 7% A: Bath Tub 4% E: Random 14% B: Wear Out 2% Conditional Probability of Failure F: Infant Mortality 68% Age or Life Source: United Airlines 1978
37. Step 6…. RCM Task Selection Sequence Hidden Evident Operational Loss Hazard Repair Only Condition Monitoring Condition Monitoring Condition Monitoring Condition Monitoring Scheduled Restoration Scheduled Restoration Scheduled Restoration Scheduled Restoration Scheduled Discard Scheduled Discard Scheduled Discard Scheduled Discard Failure Finding Modification Modification or No PM Modification or No PM
38. The frequency of On-Condition tasks must be less than the P-F Interval. Resistance to Failure P-F Interval (months) Potential Failure Functional Failure Check at 1 monthly intervals Age Option 1..Monitor Condition (Condition Monitoring)
39. Option 2…Fixed time replacement Safe Life The frequency of fixed time replacement must be before safe of economic life.
40. Maintenance Options for Evident Failure Modes… Age Related Failure Pattern Fixed Time Replacement only Random Gradual Sudden Rate of Deterioration
41. Maintenance Options for Evident Failure Modes… Condition Based Replacement only Age Related Failure Pattern Random Gradual Sudden Rate of Deterioration
42. Maintenance Options for Evident Failure Modes… Age Related Failure Pattern Fixed Time Replacement or Condition Based Replacement Random Gradual Sudden Rate of Deterioration
43. Maintenance Options for Evident Failure Modes… Failure will always be a breakdown Age Related Failure Pattern Random Gradual Sudden Rate of Deterioration
44. Maintenance Options for Evident Failure Modes… Age Related Failure Pattern Random Gradual Sudden Rate of Deterioration
45. Start measuring plant metrics Expected Failure Inherent Capability Loss Planned Maintenance Maintenance Capability Loss Unexpected Failure Inherent Performance Level Available Time TotalTime
47. Perspectives on Maintenance and Asset Management in industry Do Company Boards understand the risks? Do insurers compensate the Company Boards for taking risks? Are current underwriting practices supporting mediocrity? Is there a better way?