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

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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