2012 ARS, Asia Pacific: Jakarta Session 13 Begins at 9:40 AM, Thursday, October 18th
Reliability Leading-Lagging Indicator in PT.Badak NGL Rony Arsanto
PRESENTATION SLIDES The following presentation was delivered at the:
International Applied Reliability Symposium, Asia Pacific October 16 - 18, 2012: Jakarta, Indonesia http://www.ARSymposium.org/asia/2012/
The International Applied Reliability Symposium (ARS) is intended to be a forum for reliability and maintainability practitioners within industry and government to discuss their success stories and lessons learned regarding the application of reliability techniques to meet real world challenges. Each year, the ARS issues an open "Call for Presentations" at http://www.ARSymposium.org/asia/presenters/index.htm and the presentations delivered at the Symposium are selected on the basis of the presentation proposals received. Although the ARS may edit the presentation materials as needed to make them ready to print, the content of the presentation is solely the responsibility of the author. Publication of these presentation materials in the ARS Proceedings does not imply that the information and methods described in the presentation have been verified or endorsed by the ARS and/or its organizers.
The publication of these materials in the ARS presentation format is Copyright © 2012 by the ARS, All Rights Reserved.
Agenda Applied Reliability Symposium, Asia Pacific 2012
Introduction Reliability Leading Lagging Indicator Leading Indicator Lagging Indicator Summary Questions
Rony Arsanto, PT Badak NGL
5 min 10 min 15 min 10 min 5 min 10 min
Session 13
Slide Number: 2
Applied Reliability Symposium, Asia Pacific 2012
Vocabulary
Introduction
AMoR : Aware for More Reliable AEO : Asset Efficiency Optimization CNA : Client Need Analysis ECR : Equipment Criticality Rating MCR : Material Criticality Rating MPTA : Maintenance Planning & Turn Around OEE : Overall Equipment Effectiveness RCA : Root Cause Analysis RLLI : Reliability Leading Lagging Indicator RM : Reliability & Maintenance PCR : Procedure Criticality Rating PDS : Potential Dead Stock PRF : Plant Reliability Factor SCAT : Systematic Cause Analytic Technique Rony Arsanto, PT Badak NGL
Session 13
Slide Number: 3
PT. Badak at a glance SHAREHOLDERS
*)
55%
PT.Badak NGL at a glance
20% 15%
LNG & LPG Plant Facilities GAS PRODUCERS
Award and Certification LNG Plant Benchmarking Company Clients
Rony Arsanto, PT Badak NGL
Session 13
Slide Number: 4
Applied Reliability Symposium, Asia Pacific 2012
Applied Reliability Symposium, Asia Pacific 2012
10%
BONTANG SAMARINDA BALIKPAPAN
*) 1974: PERTAMINA 55%, JILCO 15%, HUFCO 30% 1990: PERTAMINA 55%, VICO 20%, JILCO 15%, TOTAL 10%
Rony Arsanto, PT Badak NGL
Session 13
Slide Number: 5
Facilities
MPTA
Process Trains
8
LNG
22.5
LNG Tanks
6
LPG
1.02
LPG Tanks
5
Boilers
21
DOCK 3
DOCK 2
Applied Reliability Symposium, Asia Pacific 2012
LPG TANKS
5
DOCK 1
Power Generators
15
Sea Cooling Water Pumps
22
Loading Docks
3
Accredited since 2009 ISO 9001:2008 ISO 17025:2005
6
4
3 1
Certified since 2001
Unit
2
UTI-1
A
UTI-2
H
B C
G D
F E
1977
1983
1989
1993
1997
1999
Tr. A/B
Tr. C/D
LPG Tr. E
Tr. F
Tr. G
Tr. H
6 Rony Arsanto, PT Badak NGL
Session 13
Slide Number: 6
Applied Reliability Symposium, Asia Pacific 2012
Production Capacity
.
PROPER GOLD Received 2011
Certified since 2000 .
ISO 14001:2004
ISRS-8
SMK3
Level 8
Emas
Certified since 2010
Received 2012
50,000,000 Safe Man Hours (8 Dec 2006 - 18 Sep 2012) Rony Arsanto, PT Badak NGL
Session 13
Slide Number: 7
Benchmarked by Phillip Townsend Associates Inc. (PTAI) Among 9 worldwide LNG Plants in 2009
Rony Arsanto, PT Badak NGL
Session 13
Slide Number: 8
Applied Reliability Symposium, Asia Pacific 2012
Applied Reliability Symposium, Asia Pacific 2012
The 1st rank in Safety, Health
The 2nd rank in Reliability Aspect The 1st (lowest) in Operating Cost The 1st (lowest) in Maintenance Cost The 2nd lowest in Personnel Cost
Rony Arsanto, PT Badak NGL
Session 13
Slide Number: 9
Reliability Leading Lagging Indicator Background, Definition, Objective & Scope RLLI “Traffic Light”, Matrix & Strategy
Lagging Indicator The 3 Year RLLI Journey Additional Leading Indicator Additional Lagging Indicator
Rony Arsanto, PT Badak NGL
Session 13
Slide Number: 10
Applied Reliability Symposium, Asia Pacific 2012
Applied Reliability Symposium, Asia Pacific 2012
Leading Indicator
Rony Arsanto, PT Badak NGL
Session 13
Slide Number: 11
as of July 16, 2012 100% 99.86%
In PTB mostly people tends to define “reliability” with Plant Reliability Factor Mostlywhich maint.craft overlook w/Reliability the importance of Equipment Reliability is not Equipment or Production Reliability In fact it supposed to be availability. However term of PRF is used in PTAI for benchmarking among LNG Plant People paradigm “reliability performance” historically always meet the target
Rony Arsanto, PT Badak NGL
Session 13
Slide Number: 12
99.02%
98%
99.35%
99.29% 98.65%
99.07% 99.25%
98.17%
99.25%
99.13%
98.13% 97.19%
96% Applied Reliability Symposium, Asia Pacific 2012
Applied Reliability Symposium, Asia Pacific 2012
Potential Lack of Communication & misinterpretation of Reliability
96.94%
“Reliability”Trend Group 95.5% (PTAI Benchmarking 2009)
94%
PRUR PRF
92%
90% 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012
Note : PRF related to availability not reliability Rony Arsanto, PT Badak NGL
Session 13
Slide Number: 13
PRUR (Plant Related Unscheduled Reduced) Scheduled Down Time
(Max.Sustainable Rate)
Unscheduled Down Time & Plant Trip
Applied Reliability Symposium, Asia Pacific 2012
Maximum Sustainable Rate
Standby/Idle
22.5 MTPA
PRUR (Plant Related Unscheduled Reduced) = Trip + Unschedule Down Time + Reduced Rate or Slowdown Plant Reliability Factor ( PRF ) = 1 - PRUR / MSR Plant Availability Factor ( PAF ) = 1 - (PRUR+Sch.Downtime) / MSR Note : PRF is not Equipment Reliability Rony Arsanto, PT Badak NGL
Session 13
Slide Number: 14
Applied Reliability Symposium, Asia Pacific 2012
Reduced rate /slowdown
PRUR
Rony Arsanto, PT Badak NGL
Session 13
Slide Number: 15
Reliability Leading/Lagging Indicator
efforts and drivers to lead and maintain reliability condition
Lagging
results and indicators of reliability performance
Indicators of Plant Reliability with traffic light approach Condition Monitor the efforts and actions to maintain the Plant Reliability Analyse the result – causes of the recent Plant Reliability Condition As Open Discussion to formulize the composite KPI consist of leading & lagging indicator Out of the box and communicate with “simple language” and educate the paradigm of reliability
Rony Arsanto, PT Badak NGL
Session 13
Slide Number: 16
Leading Indicators
Leading
Applied Reliability Symposium, Asia Pacific 2012
Applied Reliability Symposium, Asia Pacific 2012
In PTB it is a “simple language” to engage people in Reliability program 78.9%
80.0%
Strategy
Simple initially, more complex subsequently Colour Zone
Update
DANGER
daily
ALERT
weekly monthly
MANAGEABLE
Rony Arsanto, PT Badak NGL
Lagging Indicators
“ see the light check the matrix do the strategy update the indicator” Session 13
Slide Number: 17
Target
Achieved
Bad Actor Elimination
25
10 x per year
5x
Score (%) 12.5
WO-1 Completion
15
90-100 %
100 %
15
PM Overdue*
15
Max. 1 %
0%
15
MCR-1 replenishment
15
90-100%
97,6%
11.4
Reliability Work Program
10
Max.5 % delay
+0.87 %
10
Reliability Reward
10
12 per year
100 % YTD
10
Reliability Campaign
10
6 x per year
3x
5 78.9
* Pay Out Criteria : achieved or not , other prorated Rony Arsanto, PT Badak NGL
Purpose
Year
Applied Reliability Symposium, Asia Pacific 2012
Achieve KPI : PRF Train Trip
Improve Maintenance, Reliability, Inventory, Asset Management and Reliability Culture
Leading & Lagging
Session 13
Potential Cost Saving ($)
Slide Number: 18
$ 76k / trip
Top 20 Bad Actor Elimination Operator Driven Reliability Trip Avoidance & Reliability Reward
760k
$ 76k / trip
2013
Historical Data Improvement Reliability Dashboard Aware for More Reliable Reliability Engineering Introduction Alarm Management System
500k
Maint.,Rel. and Inventory Cost Optimization
2014
Top 30 Bad Actor Elimination Proactive Maintenance Improvement
760k
$76k /trip
Life Data Analysis Repairable System Analysis RAM Analysis RCM Mentality
500k
Maint.,Rel. and Inventory Cost Optimization
2012
Weight
Target
Achieved
PRF
35
98.6 % -98.8 %
99.87 %
Score (%) 35
Train Trip
25
8x -10 x
4
25
MCR-1 Service Level*
20
Min. 99 %
96.23 %
0
WO-1 issuance *
20
Max. 2 % from PM & PdM
1.8 %
20 80%
* Pay Out Criteria : achieved or not , other prorated
Rony Arsanto, PT Badak NGL
Session 13
Slide Number: 19
Rony Arsanto, PT Badak NGL
Session 13
Slide Number: 21
Remark
760k
Top 10 Bad Actor Elimination PM & PdM Completion WO1 Completion
Indicator
Applied Reliability Symposium, Asia Pacific 2012
Weight (%)
Reliability Benchmarking &Campaign Reliability Website RCM Update
Rony Arsanto, PT Badak NGL
Session 13
Slide Number: 20
Applied Reliability Symposium, Asia Pacific 2012
Applied Reliability Symposium, Asia Pacific 2012
Indicator
Refer to ISA-18 2 2009 Alarm Management is the set of practices and processes that ensures an effective system. For managing an existing system by implementing alarm management lifecycle
Currently alarm come up more than maximum manageable that potentially lead to experience trip due to lack of situational awareness caused by alarm flooding
Rony Arsanto, PT Badak NGL
Session 13
Slide Number: 22
Applied Reliability Symposium, Asia Pacific 2012
Applied Reliability Symposium, Asia Pacific 2012
Analysis of annunciated alarm rates is a good indicator of the overall health of the alarm system based on alarm average rates below
Rony Arsanto, PT Badak NGL
Session 13
Slide Number: 23
Indicator
Just like “STOP card” for reliability concern
AMoR (Aware for More Reliable) Technician Competency Assessment
Put AMoR on PT.Badak NGL intranet
Rony Arsanto, PT Badak NGL
Session 13
Slide Number: 24
PCR-1(Procedure Criticality Rating 1) Assessment Applied Reliability Symposium, Asia Pacific 2012
Applied Reliability Symposium, Asia Pacific 2012
Represent reliability awareness from both permanent and contractor to remedy constraint where originally permanent employee only can report reliability concern by issuing WO
Inactive Stock LI/Total Stock LI PM & PdM Completion RCM Update RAM Analysis
Rony Arsanto, PT Badak NGL
Session 13
Slide Number: 25
RM Benchmarking Target*
Reactive Work
< 20 %
WO PM / Total WO
< 20 %
WO PdM / Total WO
> 40 %
Applied Reliability Symposium, Asia Pacific 2012
Overtime/Total Hours Worked
5%
MCR-1 On Hand Zero
99 %
Rony Arsanto, PT Badak NGL
Back to Journey Back to Lag Indicator
Related to ECR-1 Plant Safety & Reliability Performance
Aimed to represent the PM & PdM quality
Divided by total downtime to identifiy percentage of breakdown
Rony Arsanto, PT Badak NGL
Session 13
Slide Number: 49
Summary
Where to Get More Information
Reliability Leading & Lagging Indicator is a “simple language” to engage people in reliability program Reliability Reward as one of Leading Indicator is successfully avoid 7 potential trip, however need to more encourage people to provide consistent failure data The Reliability Leading and Lagging Indicator (RLLI) is living data and shall be dynamically improved inline with the RLLI Journey and historical data The RLLI educates people that Reliability is not a “low hanging fruit” as shown on PRF achievement, actually PRF is availability not equipment reliability
Challenge: how to determine the formula of weighing & targeting for composite KPI where it depends on living data i.e historical data, judgment and adjustment. Rony Arsanto, PT Badak NGL
Session 13
Slide Number: 50
Applied Reliability Symposium, Asia Pacific 2012
Applied Reliability Symposium, Asia Pacific 2012
Rony Arsanto
MNL/SHEQ-MS/18 Quality & Operational Control MNL/SHEQ-MS/13 Incident Analysis & Investigation PT.Badak NGL Maintenance Manual PT. Badak NGL Reliability Procedure SKF Reliability System CNA Benchmarking Developing Performance Indicators for Managing Maintenance – Terry Wireman Rules of Thumb for Maintenance and Reliability Engineer – Ricky Smith & R.Keith Mobley Process Risk & Reliability Management – Ian S.Sutton The Certified Reliability Engineer Handbook – Donald W.Benbow and Hugh W. Broome Handbook of Reliability Engineering & Management – W.Grant Ireson, Clyde F.C and Richard Y. Moss RCM Implementation Made Simple – Neil B.Bloom Physical Asset Management Handbook – Kyoumars Bahrami Key Performance Indicator : Developing, Implementing & using Winning KPI Rony Arsanto, PT Badak NGL
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Slide Number: 51
Questions
Reliability Engineer PT.Badak NGL Bontang, East Kalimantan
[email protected],id
Rony Arsanto, PT Badak NGL
Thank you for your attention.
Session 13
Slide Number: 52
Applied Reliability Symposium, Asia Pacific 2012
Applied Reliability Symposium, Asia Pacific 2012
Do you have any questions?
Rony Arsanto, PT Badak NGL
Session 13
Slide Number: 53
Reliability Reward Criteria – rev.0 22.5 MTPA
Capacity increased from 3.3 MTPA in 1977 to 22.5 MTPA in 1999. Provision facility for further expansion. Continual improvement from previous expansion experiences. 13.5
•
19.4
19.1
•
16.2
•
11.8
•
9.2
• 4.6
Applied Reliability Symposium, Asia Pacific 2012
•
3.3
•
Found Gas Reserv e
Train A/B Modification Train A/B Operation
Train A/B/C/D Debottlenecking
Train C/D Expansion
LPG Plant Expansion
Train E Expansion
Train E/F Debottlenecking
Train F Expansion
Train G Expansion
•
Train H Expansion
•
‘81
‘77
‘83
‘88
‘89
‘91
‘93
‘97
‘98
‘99
Well-planned expansions, good project executions, and excellent operational records reflects PT Badak NGL human resources high competency .
Applied Reliability Symposium, Asia Pacific 2012
1
2
Rony Arsanto, PT Badak NGL
Development Era
3
4
Session 13
5
6
Slide Number: 56
Applied Reliability Symposium, Asia Pacific 2012
•
1972
Eligible for both PTB and Contractor, no exclusivity Demonstrate either proactive maintenance, corrective maintenance or Bad Actor Management Prioritize for ECR-1 (Top Equipment Critical Rating) Showing Reliability Culture Improvement Report for repetitive lesson learnt in the future Key in the failure data consistently Suggested by Reliability Engineer Approved by Reliability Manager for non trip avoidance Acknowledged by Maintenance Senior Manager for trip avoidance Evidence for auditable purpose
Rony Arsanto, PT Badak NGL
Session 13
Slide Number: 55
Rony Arsanto, PT Badak NGL
Session 13
Slide Number: 57
Session 13
Slide Number: 58
PT.Badak NGL PRF & Train Trip as of July 16, 2012 No
Jun - Aug
1.
PRF (%)
2.
Trains Trip/Unscheduled SD (times)
9 Feb: Train A Low Pressure Hydaulic Piston due to ferrule tube leak
Applied Reliability Symposium, Asia Pacific 2012
MONTH
DESCRIPTION
100
99.86
4
0
4
99.93
Max. 8 x
99.95
99.96
99.82
99.84
99.86
4 Monthly
Monthly
YTD
3
3
Cum. 2012
1
1 1
1
1
0
0
Feb
Mar
Apr
0 0
Jan
Acceptable limit
99
2
2
0
100
Min. 98.8 %
13 June: Train B Danger Vibration 4YI-57B (G4KT-3) spurious spike
15 May: Train H ESD/EDP Spurious Activated during lightning strike
100 4
KPI Acceptable Limit
99.84
2 May: Train G Flash fire incident from vent at 5E-1
4
YTD
Jul
1
0
May
Rony Arsanto, PT Badak NGL
Jun
Jul
98
100
99.85
99.99
100
99.26
99.99
100
Jan
Feb
Mar
Apr
May
Jun
Jul
Session 13
Slide Number: 60
Applied Reliability Symposium, Asia Pacific 2012
Applied Reliability Symposium, Asia Pacific 2012
Rony Arsanto, PT Badak NGL
Rony Arsanto, PT Badak NGL
Session 13
Slide Number: 59