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33rdrd Plant Maintenance in Middle East Plant Maintenance in Middle EastJanuary 10 - 13, 2010 – Abu Dhabi, UAEJanuary 10 - 13, 2010 – Abu Dhabi, UAE
Qadeer AhmedQadeer Ahmed
Senior Reliability EngineerSenior Reliability Engineer
Asset Management to improve Plant Reliability
DELIVERING ENERGY TO THE WORLD
DELIVERING LNG TO THE WORLD
– Introduction• Qatargas Operating Company Limited
– What is Asset & Asset Management?• Maintenance Management?• Performance Management?
– Asset Management at Qatargas• MMS, PMS, CMS
– Results / Critical Success Factors• LPE, Critical Trips, Safety
– Q&A
Agenda
DELIVERING LNG TO THE WORLD
Introduction - Qatargas
DELIVERING LNG TO THE WORLD
• Qatargas is pioneer in Qatar’s LNG production and will be the largest producer of LNG in the world
• Qatargas existing LNG capacity is approx 25.6 MTPA of LNG.
• Qatargas is going through phenomenal expansion and capacity will be 42 MTPA of LNG by 2011
• Qatargas Expansion Projects – 4 new Mega Trains (7.8 MTPA) : TR4&5 in production – Largest LNG Trains– Laffan Refinery (150K BPD): Naphta, Kerosene, Gasoil – Common Sulfur Project (12K TPD) – Granulated Sulfur– Q-Max & Q- Flex LNG Ships (Q-Flex:210,000 m3 and Q-Max:266,000 m3)
• High Availability & Reliability is a pre-requisite to meet demand– Asset Management is Important for Maintenance and Reliability
Introduction:
DELIVERING LNG TO THE WORLD
Introduction: Geographic Location
32”
North Field (80 KM)
Qatargas
DELIVERING LNG TO THE WORLD
A Glimpse - Qatargas Offshore:
LNG TRAIN 5
QATARGAS NFB COMPLEX
LNG TRAIN 4
PU
WH4 - 64 m(12 Slots)
QatargasRas Laffan Industrial City
PL434”
(91 km)
Power/Comm5-6 Power/Comm
5-4
QATARGAS NFB COMPLEX
WH6 - 56 m(15 Slots)
WH5 - 46 m(15 Slots)
PL5-616”
(800 m)
PL5-416”
(300 m)
Power/CommMain
FOC to
Shore
PL638”
(81 km)
DELIVERING LNG TO THE WORLD
A Glimpse - Qatargas Onshore:
LNG Tanks
CSP
Liquids Loading Berths
QG2 TR4 & 5QG3TR6 & QG4TR7
Laffan Refinery
QG1
Liquid Storage
LNG Loading Berths
(10 – 42 MTPA)
~150,000 BPD
12,000 TPD
DELIVERING LNG TO THE WORLD
Integrated Product Flow Offshore
QG2 (TR4/5) QG3 (TR6) QG4 (TR7)
Storage Condensate/NGL/LNG Common Sulfur Project
Refinery Berths
QG1(TR1/2/3)
(42 MTPA)
12,000 TPD
150,000 BPD
DELIVERING LNG TO THE WORLD
What is Asset Management?
• Asset:– Fixed/Capital Assets are Equipments & Plants
• Asset Management:– It is a life cycle management of assets to ensure availability,
reliability and utilization of the assets to safely meet the business objectives at optimized cost.
– Important aspects of Asset Management• Maintenance Management• Performance Management
DELIVERING LNG TO THE WORLD
Maintenance Management
• SAP is used for Maintenance Management
– Asset Register – Functional Locations Hierarchy– Maintenance Notification/Work Orders– Maintenance Plans– Maintenance Execution etc..
• Condition Monitoring – System1
DELIVERING LNG TO THE WORLD
Performance Management
• Meridium – Asset Performance Management
– KPIs Monitoring the performance– Process and Equipment Reliability– Retrieving the data from MMS to analyze– Queries MMS data for reports– Condition Assessment
DELIVERING LNG TO THE WORLD
Why Asset Management?• Focused approach to Improve Maintenance & Reliability
– Repair base to Reliability base
• Ensure High Availability– Proactive availability modeling rather knowing by incident
• Contribution to Company's Vision– Customer Satisfaction, Efficient and Reliable Operations– Financial Performance
• Provide Better Control and Sustainability– Proactively involve in monitoring and efficiently managing assets.
• Teamwork & Organization Learning– Develop strong relationship among cross-functional teams
DELIVERING LNG TO THE WORLD
Asset Management at Qatargas
DELIVERING LNG TO THE WORLD
AM Philosophy at QG:
• Asset Centric Approach using Meridium• Philosophy at Qatargas:
– Maintenance Management – SAP• Condition Monitoring: System1 & Machinery Manager
– Performance Management - Meridium• Key is Maintenance and Performance
DELIVERING LNG TO THE WORLD
Asset Centric Approach
Scorecard, KPIs
Risk Base Inspection
ReliabilityAnalytics
RCM / FMEA
RCFA
Asset
Meridium Domain SAP Domain
Interface
DELIVERING LNG TO THE WORLD
Maintenance Management
– Asset Register (Estimated 300K-400K Tags)– Functional Locations Hierarchy– Maintenance Notification/Work Orders– Spare Usage – Maintenance Plans– Maintenance Execution etc..
DELIVERING LNG TO THE WORLD
Asset Register Hierarchy in SAP:
DELIVERING LNG TO THE WORLD
Condition Monitoring System:
• CMS (Condition Monitoring System)– Primarily focused on:
• Vibration Monitoring– Online Monitoring – BN System 1– Offline Monitoring – Machinery Manager
• Lube Oil Management– Condition base– Interval base
DELIVERING LNG TO THE WORLD
Performance Management at QG:• Performance Management System using Meridium:
– Reliability Analytics: Reliability Growth, Production Weibull, etc..
– Criticality Assessment: Based on Risk Matrix
– Reliability Center Maintenance: Maintenance Strategies for System
– Failure Mode & Effect Analysis: Maintenance Strategies for Critical Equipments
– Root Cause & Failure Analysis: Critical Failures, Bad Actor Elimination
– Condition Assessment: Calibration, Inspection and Thickness Management
DELIVERING LNG TO THE WORLD
Criticality Assessment, Growth Analysis
Efficiency & Utilization Loses
Nameplat eLine
N ameplateOutput
Cut back Loss es
Process Reliab ility = 94%
Demonstrated Output (Eta) @CDF = 63.2% or R=36.8%
Product ion: Et a =1 03 63 T/ D , Be ta= 2 0
Los ses
Demons trated Weibull Production L ine
Efficiency & Utilization Loses
Nameplat eLine
N ameplateOutput
Cut back Loss es
Process Reliab ility = 94%
Demonstrated Output (Eta) @CDF = 63.2% or R=36.8%
Product ion: Et a =1 03 63 T/ D , Be ta= 2 0
Los ses
Efficiency & Utilization Loses
Nameplat eLine
N ameplateOutput
Cut back Loss es
Process Reliab ility = 94%
Demonstrated Output (Eta) @CDF = 63.2% or R=36.8%
Product ion: Et a =1 03 63 T/ D , Be ta= 2 0
Los ses
Demons trated Weibull Production L ine
Production Weibull
Reliability – Growth Analysis
DELIVERING LNG TO THE WORLD
Meridium – RCM, RCA, Record Manager
DELIVERING LNG TO THE WORLD
Challenges, Critical Success Factors & Results
DELIVERING LNG TO THE WORLD
Challenges / Critical Success Factors:
• Committed Leadership– Continuous Support and Commitment
• Adequate & Dedicated resources to Implement, Control and Sustain
• Organizational Culture – Proactive rather Reactive
• Ensure Good Quality Data– Required good quality data to produce good results
• Cross-functional teamwork• Employee Training & Workshops
DELIVERING LNG TO THE WORLD
Results
• Safety• Onshore
– Six years LTA free• Offshore
– Seven years LTA free
• Reliability – Reduced Critical Trips– Significant drop in Loss Production Events– Improved Plant Availability and Reliability
• Others Provides up-to-date database with maintenance & equipment information Proactive rather reactive approach Integration/Interface among different systems SAP/Meridium etc.
DELIVERING LNG TO THE WORLD
Finally, Asset Management is Cross-functional Activity
Operations
Process control, LPEsMonitoring
KPIs
ReliabilityRCFA
Asset Register
Mtce Strategies
Maintenance
