Case Study: Company Pe through Reli Integrity of P Case Study

Case Study: Improving
Company Performance
through Reliability and
Integrity of Plants MarcusEvans Conference Prague, Czech Republic, 17 th & 18 th September 09 www.ceskarafinerska.cz Tomas Palma, Production Unit Manager FCC Unit and Oil Movements Kralupy ČESKÁ RAFINÉRSKÁ, a.s. tomas.palma@crc.cz, www.ceskarafinerska.cz tomas.palma@crc.cz, www.ceskarafinerska.cz
www.ceskarafinerska.cz ČESKÁ RAFINÉRSKÁ, a.s. Location Litvinov Established: Full operations started: Privatised: Transformed to processing mode: 28.3.1995 1.1.1996 25.3.1996 1.8.2003 Refineries Litvinov, capacity 5,1 Mt Kralupy, capacity 3,3 Mt Operation mode: Processing refinery
ČESKÁ RAFINÉRSKÁ, a.s. – Major Crude Oil Processor in the Czech Republic Major Crude Oil Processor in the Czech Republic www.ceskarafinerska.cz CRC Shareholders 51,23 % 32,44 % 16,33 %
ČESKÁ RAFINÉRSKÁ, a.s. – Major Crude Oil Processor in the Czech Republic Major Crude Oil Processor in the Czech Republic www.ceskarafinerska.cz ČESKÁ RAFINÉRSKÁ, a.s. – Major Crude Oil Processor in the Czech Republic Major Crude Oil Processor in the Czech Republic
www.ceskarafinerska.cz Performance Improvement Project Project timing Initiated in December 2004 Implementation of first recommendations in June 2006 Still on­going, both development and implementation phases going, both development and implementation phases Project scope was to introduce Asset Management via Revised business processes (focus to maintenance and procurement) Improved utilisation of company ERP system Updated master data (asset, material and service registers, PEFS, BoM) Adopted risk based approach in defining work scope Step change in company behaviour change in company behaviour
ČESKÁ RAFINÉRSKÁ, a.s. – Major Crude Oil Processor in the Czech Republic Major Crude Oil Processor in the Czech Republic www.ceskarafinerska.cz Maintenance Costs Development 110 100 ­ 10% 90 ­ 18%
% 80 ­ 27% 70 60 50 2005 2006 2007 2008 2009 Trend Year B­D Maintenance Requests Work Force Routine Maintenance Costs ČESKÁ RAFINÉRSKÁ, a.s. – Major Crude Oil Processor in the Czech Republic Major Crude Oil Processor in the Czech Republic www.ceskarafinerska.cz Process Units Availability Development 160 + 56% 150 140 + 28% 130 % 120 110 + 2,3%
100 90 80 2005 2006 2007 2008 2009 Trend Year Pressure Envelope Integrity Equipment Reliability Units Availability ČESKÁ RAFINÉRSKÁ, a.s. – Major Crude Oil Processor in the Czech Republic Major Crude Oil Processor in the Czech Republic www.ceskarafinerska.cz Asset Management, Basics for Implementation Asset Management strategy must be developed from company targets Assets are not just process equipment but also people, knowledge, data …
ČESKÁ RAFINÉRSKÁ, a.s. – Major Crude Oil Processor in the Czech Republic Major Crude Oil Processor in the Czech Republic www.ceskarafinerska.cz Asset Management, Basics for Implementation Opinion Alignment Knowledge of company targets, identification of priorities, what/who to be centre of attention, support by organisational structure, … Standardization Assets classification (equipment, human resources, data, knowledge, etc.), set­up of business processes and links between them, … up of business processes and links between them, … Systematic Data Collection Definition of performance indicators and how to obtain them, selection of suitable detail levels, sufficient personnel availability, … Application of Feedback Reporting based on received information analysis, risk based priorisation of measures, evaluation of implemented measures, … priorisation of measures, evaluation of implemented measures, …
ČESKÁ RAFINÉRSKÁ, a.s. – Major Crude Oil Processor in the Czech Republic Major Crude Oil Processor in the Czech Republic www.ceskarafinerska.cz Revised Business Processes How was done Several workshops with key stakeholders organised Duplicities and delay times identified and where possible eliminated Processes described and configured in company ERP system What is new Efforts focused on work preparation and planning Integrated scheduling for routine as well as shutdown activities One work package covered by one responsible person Purchasing of materials and services only via procurement process Purchasing of materials and services only via procurement process
ČESKÁ RAFINÉRSKÁ, a.s. – Major Crude Oil Processor in the Czech Republic Major Crude Oil Processor in the Czech Republic www.ceskarafinerska.cz Improved Utilisation of Company ERP System How was done Project team established providing processes analysis and re Project team established providing processes analysis and re­definition ERP system configuration done together with external advisor Massive campaign provided to increase knowledge of ERP system ded to increase knowledge of ERP system What is new Detailed work plans, schedules and activity reports in ERP Preventive maintenance automatically generated Other SW tools interfaced with ERP (Visions, INtools, Primavera, …) ERP became centre of truth, side „hand ERP became centre of truth, side „hand­made“ reports eliminated
ERP literacy significantly improved ČESKÁ RAFINÉRSKÁ, a.s. – Major Crude Oil Processor in the Czech Republic Major Crude Oil Processor in the Czech Republic www.ceskarafinerska.cz Updated Master Data How was done Only key process data and document types selected for update Data classification criteria established prior any work started Big volumes updated by 3rd parties What is new Increase of records in ERP (e.g. 3 x more items for Asset Register) Processes and responsibilities for further data management established Performance indicators set up to show utilisation of detailed records Faster updates after investment projects and plant changes Faster updates after investment projects and plant changes
ČESKÁ RAFINÉRSKÁ, a.s. – Major Crude Oil Processor in the Czech Republic Major Crude Oil Processor in the Czech Republic www.ceskarafinerska.cz Risk Based Approach in Defining Work Scope How was done Several risk matrices developed (break Several risk matrices developed (break­down, preventive, shutdown, …) RRM applied to review preventive maintenance strategies RBI results embedded to inspection programs What is new Priority of every work challenged against unified risk matrix Modification in Czech legislation achieved CRC establishing ourselves statutory inspection intervals „Equipment family“ method adopted to reduce inspection scope of work „Equipment family“ method adopted to reduce inspection scope of work
ČESKÁ RAFINÉRSKÁ, a.s. – Major Crude Oil Processor in the Czech Republic Major Crude Oil Processor in the Czech Republic www.ceskarafinerska.cz Step Change in Company Behaviour How was done Production equipment placed into centre of attention Company organisation modified accordingly Substantial training and educational program started What is new Production Asset Teams committed to increase assets performance Much better cooperation between maintenance and operations Gradual reduction of dependency on contractors, more responsibility now covered by internal CRC supervisors Asset Management general awareness increased Asset Management general awareness increased
ČESKÁ RAFINÉRSKÁ, a.s. – Major Crude Oil Processor in the Czech Republic Major Crude Oil Processor in the Czech Republic www.ceskarafinerska.cz Main Challenges during Implementation Too many changes at the same time Other important activities ongoing in parallel (e.g. major shutdowns) Limited availability of in­house Limited availability of in human resources Quality of local contractors Stable management support Stable management support
ČESKÁ RAFINÉRSKÁ, a.s. – Major Crude Oil Processor in the Czech Republic Major Crude Oil Processor in the Czech Republic www.ceskarafinerska.cz Future Focus Direction CRC‘s concentration so far was on equipment, processes and data Currently, most of defects show significant areas for improvement in human reliability
ČESKÁ RAFINÉRSKÁ, a.s. – Major Crude Oil Processor in the Czech Republic Major Crude Oil Processor in the Czech Republic Thank you for your
attention
Questions / Comments Comments
Tomas Palma, Production Unit Manager FCC Unit and Oil Movements Kralupy ČESKÁ RAFINÉRSKÁ, a.s. tomas.palma@crc.cz, www.ceskarafinerska.cz tomas.palma@crc.cz, www.ceskarafinerska.cz
www.ceskarafinerska.cz