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Tiwest Joint Venture
Tiwest Pigment Plant Kwinana Using Downtime & Uptime Metrics to drive plant improvement Tiwest Joint Venture Presentation • Tiwest • Why we needed the system to collect Downtime & Uptime data • What is the system • How do we use for improvement Lessons learnt Tiwest Joint Venture Tiwest Joint Venture Tiwest Sites Location Map Tiwest Joint Venture Tiwest Joint Venture • Mine at Cooljarloo (Heavy mineral concentrates) • Heavy Minerals Separation and Synthetic Rutile plant at Chandala • TiO2 Pigment Plant at Kwinana Uses technology licensed by Kerr McGee to make ultra white TiO2 pigment. 97,000 tonnes pa. 260 employees Used in coatings, plastics, high gloss paints, ceramics, paper, cosmetics, sunscreen, smarties ………………. The Kwinana Pigment Plant Tiwest Joint Venture Maintenance status - 2002 Tiwest Joint Venture • Lack of planning and detailed measurement • Four building blocks to establish – – – – Planning & Scheduling Maintenance KPIs Plant performance measurement Robust improvement cycle Tiwest Joint Venture What is the system? What is this system ? Tiwest Joint Venture Downtime – Automatically record all instances of plant downtime and allow for Operator entry of plant information Uptime – Automatically record all instances of plant production rate reduction below a specified threshhold and allow for Operator entry of plant information Emmission Alarms – Automatically capture all small scale fugitive emissions and allow for Operator entry of plant information Other Plant Tiwest Joint Venture A A Services B B C C D Chlorination Oxidation Finishing Tiwest Joint Venture Tiwest Joint Venture Tiwest Joint Venture Lessons: Lessons: Guidelines around coding Categories Operator training Create the need ! Start with the bottleneck Predict how you want to analyse the data Design the database Downtime first, others after Be prepared to change Prototype on a spreadsheet Make easy for manual input Tiwest Joint Venture Rate hurdle Average rate for 4 hr period Manual entries Tiwest Joint Venture Lessons: Update rate target Plan for how you want to report data Manual data needs vetting Ensure can extract to Excel Tiwest Joint Venture Manually entered System Architecture DCS SCADA Rosemount Wonderware Lessons: Affect from virus attack No licences but no backup Technology flexible and cheap Tiwest Joint Venture Data Historian INSQL SQL Server Microsoft Control room PC Engineers PC Managers PC Tiwest Joint Venture How do we use it for improvement Improvement process Weekly – KPI review – Action plan progress review. – Future action plan commitment Monthly – – – – – Weekly review Are we getting the results? Are we targeting the right things ? Readjust priorities Improvement targets for month Tiwest Joint Venture 1 Month Pareto – Lost Tonnes Lessons: Convert Downtime and Uptime to tonnes lost Make sure don’t react to short term one of issues Tiwest Joint Venture 3 Month Pareto – Lost Tonnes Lessons: Show operators & trades the data Use Excel for graphing to prototype Tiwest Joint Venture Lost Tonnes Monthly Comparison Tiwest Joint Venture 1 2 3 4 5 1000 0 6 7 8 9 10 So ut as h o f h / T Ca ra l co ns n N Ya E Sa o rd n d Ra f U Sa Se c k 300 n d p L Bo e ile So Se ve rs ut p L l 3 h ev SW o Li f G el 3 m 3 N 0 e Sc 1 B W ru l ... H bb 2S er O E U 4 C as t 4 D 00 ool 20 N e 1C W rs C Do C hlo or G ontr rin 55 o a 2 l R to r R ac Sna oom k O ke S 2 U ff C ou 40 ol th D 0 S l ect 20 o i o 1A uth n C Do hl or or in at or Month 5000 4000 3000 2000 Chlorine Alarms by Month 29 27 25 23 21 19 17 15 13 11 C Chlorine Alarms by Area 9 7 5 3 1 on tro l Se la s C ok e Bo un dr y A1 Sn ak e A4 00 Pi pe ra ck hl or in at io n 1600 1400 1200 1000 800 600 400 200 0 N ec ov er om y pr es sio n C C R Gas Alarms Tiwest Joint Venture Chlorine Alarms by date 500 400 300 200 100 0 Chlorine Alarms by Tag 800 700 600 500 400 300 200 100 0 Summary – Lost Tonnes – For Discussion Tiwest Joint Venture Lost Tonnes Event Current Trends / Comments What Do We Think Is Working? Further Ideas / Actions? • Scheduled Maintenance • Dec03 saw improved consistency in frequency and duration • Shut co-ordinator (75%) • Shut planning / scheduling / execution • Shut co-ordinator (other 25%) • Tighten durations / CP • Strategy for reducing frequency at higher line rates • Full Sand Separator • 85% drop from OctNov03 to Dec03 • N2 purge system • Dump valve timing • Increased dump leg size •? • Chlorinator Recycle Header Pressure • 75% drop from OctNov03 to Dec03 – mainly during Chlorinator rebricks in OctNov03 • Ceramic venturi crossover • Install cerramic venturi crossover on other lines • Clean out header on plant shut • Chlorinator PM routines and quality of work • U200 Problems (chlor offline) • 90% drop from OctNov03 to Dec03 – mainly during Chlorinator rebricks in OctNov03 • Alignment of D Chlor shuts with Line Shuts • Align all Chlor shuts with Line Shuts • Chlorinator PM routines and quality of work • TIC/HIC Blockages • Highest loss in Dec03 – a result of DCS failure on Boxing Day • G222 Repack • No issue in Dec03 – need to be 100% sure that further ideas will fully address problems • B309B Oxidiser Water Leak • One off event at end of Oct 03 – need to be 100% sure that problem fully addressed • Data Not Recorded • Data entry improving each month • Increased focus on data entry • K Jarvie work on Reporting System • DCS Failure / Lost control file • One off electrical hit on Boxing Day (second highest loss in Dec03) • N/A • N Bell action plan • Sand Blast • Gradually increasing through Dec03. Sympton of oxidiser / shotgun issues • N/A • TOP PRIORITY – Production Team • Clean out / replace pipework on plant shut • “Excess XOver Temp Strategy” idea from MT? • Online repacking • Install harder packing ring and collar • Replace during Puri upgrade • Actions from original root cause investigation? Drilldown – Paretos – High Level Summary Loss P/M? Comment Current Initiatives Whom Scheduled Maintenance Maint/ Prodn A Line Ceramic oxi installation (27%) Additional Line Shuts (14%) Scheduled Line Shuts incl. overruns (59%) Lock in Shut Co-ordinator role Execute Line shuts to agreed schedule Close loop on Shut performance (esp. startup issues) to eliminate overruns Review Dec performance and capture ideas to reduce duration Two major events plus multiple events on A and B Lines Agree and approve idea form for improving N2 purge monitoring and control Workshop to determine frequency of scheduled and event based cleaning of sand separators Implement idea for increasing K+ to 1000 ppm on B line for Grade 834 Implement idea for optimising dump leg valve timing Sand Separator Levels Prodn Tiwest Joint Venture When Pot. Redn. T Young A Temp. T Young 8 Jan In prog 15 Jan 60% A Temp, 15 Jan J Cullen 5 Dec D Anderton 12 Dec N Kon-Yu 8 Dec G Theunissen 12 Dec 50% G222 Repack Maint Four events in Oct/Nov Agree direction following purification review Agree go / no go decision on improved pump Commission N2 regulation G Hewson T Munro K Matthias 12 Dec 12 Dec 20 Jan 50%? Chlor Recycle Header Pressure (during re-bricks) Prodn Low rates due to A/B/D Chlor rebircks. Wet air caused blocked tuyeres See separate action for Chlor Recycle Header Pressure (excl. re-bricks) N/A N/A 100% G301 Gearbox / Coupling Maint Majority of problems on G301B Short term corrective actions completed Capture further actions in idea 3011 Execute action plan K Matthias J Smith K Matthias Done 10 Dec 31 Jan 75% Tube Bundle Failure Maint/ Prodn Single event Confirm all resulting actions completed / locked in L Hughes 12 Dec 100% Plant Shut – E210A Reboiler valves Maint Single event 5 Dec 12 Dec 19 Dec 100% A Templeman Submit AFE for replacement valves Approve AFE Confirm estimated installation date J Smith T Martin J Smith Lost Tonnes Charts Comments Tiwest Joint Venture Tracking Down… • • • • Line (Scheduled) Maintenance – due to high focus on shut execution and benefit of regular, scheduled shuts Recycle Header Pressure / Standby U200 – record chlorinator OSE, rebricks back in Nov03 Sand Separator Level – larger dump legs installed, cleaning regime, increased reliability of dump valves G222 Packing Failure – online repacking procedure Tracking Up… • • • Node Failures / TIC/HIC blockages / Crossover Temps – mainly due to one event on Dec 26th Shotgun Changeout / Sand Blast – TOP PRIORITY Fouled vapourisers – ongoing issue and D213 solids carryover Next Steps… • • • Progress ideas to Cash Flowing status Review existing ideas for “Tracking Up” areas to ascertain what’s working / not working Generate new ideas to address “Tracking Up” areas Tiwest Joint Venture Further extensions to the system Shift supervisor handover Morning meeting data Tiwest Joint Venture Shift supervisor handover Morning meeting data Tiwest Joint Venture Control Room Operator Log Every 4 hours the most important points are logged Tiwest Joint Venture Parameter outside limit Tiwest Joint Venture Control Room Operator Shift Log for shift supervisor Conclusion Tiwest Joint Venture • A formal plant improvement process requires recording of plant information. It is a building block of good maintenance. • Tiwest has delivered significant improvement using targeted improvement strategies Tiwest Joint Venture Thankyou Implementation & Lessons learnt • • • • • • • • • • • • • • • • • • • Prototyped on spreadsheet Started on Downtime Never right the first time/ technology can make quick changes Predict how you want to analyse the data Construct database to reflect Make easy for manual input Rules around coding Operator training Need a need form line personnel Show analysis to personnel Ensure can extract to EXCEL No licences/ no backup Start on bottleneck Update rate target Technology is flexible and cheap Allow for expansion Plan for what you want to get out of it Manual data input needs vetting Design for Operator entry and reporting output Tiwest Joint Venture
