A Reliable Plant is a Safe Plant - Hosny

11‐May‐16
1
A RELIABLE PLANT
IS A SAFE PLANT
Hosny Elsayed
Ma’aden Mine & Refinery Reliability Manager
2 n d A n n u a l K i n g d o m P r o c e s s S a f e t y 2 0 1 6
0 9 t h – 1 0 t h M a y , i n A l K h o b a r
THE ROAD TO ASSET RELIABILITY EXCELLENCE APPROACH
SAFETY & ASSET MANAGEMENT GOALS
SAFETY & RELIABILITY INTEGRATION.
RISK BASED MAINTENANCE.
RELIABILITY EXCELLENCE APPROACH.
RELIABILITY OBJECTIVE & ROAD MAP.
OUR TODAY AGENDA

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SAFETY POLICY STATEMENT
All Injuries are Preventable
No Task is so urgent that it cannot be done Safely
Management Must Provide a Safe Work Place.
We are each responsible for Preventing Injuries
Everyone is empowered to Stop Unsafe Event.
All Committed to Safety
ASSET RELIABILITY MANAGEMENT GOAL
Continuous Improvement of the
Asset Reliability to deliver Safely
predictable performance Uptime at
the Lowest Sustainable Cost.
Safely Plant Uptime

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ASSET RELIABILITY MANAGEMENT
It is Holistic Approach of consistent and structured strategies
designed to Improve asset Reliability, Availability & Integrity with cost
effective Index.
Identifying and embracing the best practices in Asset Management
enables an organization to avoid failures, reactive work practices and
other “barriers to success.”
Achieve world-class performance at any manufacturing facility.
Valuable resources can be applied to value-added activities.
UPTIME / OEE / ASSET UTILIZATION MODEL
AssetUtilization
(AU)
Uptime/OEE
ProductionUtilization
QualityUtilization
PotentialRateUtilization
ActualAvailability
SustainablePeakRate
N o D e m a n d / M a r k e t L o s s e s
Changeover / Transition Losses
Q U A L I T Y L O S S E S
P R O C E S S R A T E L O S S E S
U N S C H E D U L E D D O W N T I M E
Scheduled Down timeS C H E D U L E D D O W N T I M E
OEE = UPTIME X RATE X QUALITY
AU = AVAILABILITY X RATE X QUALITY

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RELIABILITY (OEE/AU) IMPACT ON SAFETY
Source: Ron Moore, Making Common Sense Common Practice.
PLANT THAT RUN RELIABLY HAVE FEWER INJURIES
SAFETY & RELIABILITY INTEGRATION
A RELIABLE PLANT IS :
1. A SAFE PLANT,
2. A COST-EFFECTIVE PLANT,
3. FRIENDLY ENVIRONMENT PLANT."

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AN UNRELIABLE PLANT IS :
1. UNSAFE PLANT,
2. COSTLY,
3. UNFRIENDLY ENVIRONMENT PLANT."
SAFETY & RELIABILITY INTEGRATION
PROCESS SAFETY EVENT (PSE)
PROCESS SAFETY is a disciplined framework for managing
the integrity of hazardous operating systems and processes by
applying good Design principles, Engineering, and Operating &
Maintenance practices.
PROCESS SAFETY EVENT (PSE) is an unplanned or
uncontrolled LOPC of any material including non-toxic and non-
flammable materials (e.g steam, hot condensate, nitrogen,
compressed CO2 or compressed air) from a process, or an
undesired event or condition that, under slightly different
circumstances, could have resulted in a LOPC of a material.
Based on severity and consequence of event it is classified as
. Tire 1 , Tire 2 , Tire 3 or Tire 4

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THE PROCESS SAFETY PYRAMID
Major
Accident
(Tire 1)
Loss Of Containment
Potential for many
Injuries, Plant Damage
(Tire 2)
Process Safety Breach :
Loss of layer of Protection, MI
Integrity, or shutdown System,
exceeding critical limits – ( Tire 3)
Minor Process Errors : Exceeding Safe
Operating Limits , Ignoring Process Alarms ,
Missed Critical Inspection , Faulty Designs
(Tire 4)
Every Major Accident Result in
Fatalities and major plant damage.
It is also implies hundreds of
Process Safety Errors
POOR
Operational
Discipline
Results in
Major
Accidents
Source: Andrew Hopkins, "Failure to Learn: The BP Texas City Refinery Disaster,"
… Y o u D o n ’ t I m p r o v e W h a t Y o u D o n ’ t M e a s u r e …
DEFECT (FAILURE MODES ) EFFECT RELIABILITY
1
Major Inc
10 Losses
6,500 Repair /
Corrective Work Orders
20,000 defects
(Failure Modes)
Every Major Inc. ( Large
Production Loss , Lost Time
Accident , etc) implies
thousands of defect
Corrective,
Emergency,
& Unplanned
Activities
Likelihood of Unsafe Acts
& conditions
… R i s k : t h e p o s s i b i l i t y ( P r o b a b i l i t y ) t h a t s o m e t h i n g b a d o r u n p l e a s a n t w i l l h a p p e n …
- Personal safety events are driven by high
frequency, low consequence activities, while
- Process safety is driven by low frequency, high
consequence activities.

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RELIABILITY OPTIMIZATION PYRAMIDS
RCFA
Volumetric
Downtime
Tracking
Bad Actors , Defect
Elimination Program
RCFA Insight Analysis
Asset Management Strategy (AMS)
- Continuous Improvement
Reliability Walk down – Observation –
Proactive Findings
Design It Right Operate It Right Maintain It Right
Most modern companies recognize the benefits of
improved plant reliability and the elements needed to
achieve it. These include
-Strategies & spare-parts optimization
-Risk-based Maintenance
Design &
Build Integrity
Create Barriers
ASSET
RELIABILITY
Sustain Integrity
Maintain Barriers
Operating Within
The Limits
Working Within
Barriers
CI of Defect
Elimination
All Injuries are Preventable
All Failure are Preventable
No Task is so urgent that it cannot be done Safely
No Task is so urgent that it cannot be done Reliable
Management Must Provide a safe Work Place.
Management Must Provide a Reliable Work Place.
We are each responsible for preventing Injuries
We are each responsible for preventing Failures
Everyone is empowered to Stop Unsafe Behavior.
Everyone is empowered to Stop Unreliable Behavior
INTEGRATING RELIABILITY & SAFETY POLICY

11‐May‐16
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INTEGRATING RELIABILITY & SAFETY GOALS
To Achieve ZERO INCIDENTS / INJURIES , you must believe
in ZERO FAILURE / UNPLANNED DOWNTIME
* * * * * FAILURES INDUCE GREATER RISK OF INJURY * * * * *
How To Achieve it
RELIABILITY EXCELLENCE (Rex) approach is mandatory with
Specific Standards for Operation & Maintenance (SOP, EMS)
“ Success comes from knowing what you don’t know, more than coming from what you do know.“ Ray Dalio
Eng. Hosny Elsayed
ROAD TO
RELIABILITY
EXCELLENCE
ROAD TO
RELIABILITY
EXCELLENCE

11‐May‐16
9
A S S E T R E L I A B I L I T Y & I N T E G R I T Y
Asset R E L I A B I L I T Y is the ability
(probability) of an Asset or system
performing (without failure) its intended
(required) function under given (stated)
conditions For a stated period of time.
Asset I N T E G R I T Y is the ability of an
asset to perform its required function
effectively & efficiently whilest Protecting
Environment, Health & Safety (EHS) –
Plant Availability ( Maintenance) Mission
To preserve the functions of Plant
physical assets throughout their life cycle
to the satisfaction of their Stakeholder
owners, users & the society as a whole
•Safe Work Place
•Safe Work force
•Safe working Asset
EHS
Business Risk Mitigation / Control
… I t i s i m p o s s i b l e t o g o s o m e w h e r e i f y o u d o n ’ t k n o w w h e r e y o u a l r e a d y a r e …

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To Deliver :
 Regulatory Compliance
 High Plant Availability
 Reliable equipment
 Statutory / HSE compliance
 Cost-effective & Targeted maintenance
Delivering Sustainable improvements is hard !
 Little time available
 Resources reducing
 Priorities changing
Area With Highest ROI

11‐May‐16
11
Run to Failure
Preventive
Maintenance
Predictive
Maintenance
Proactive
Maintenance
Reliability
Centered
Maintenance
Risk Based
Maintenance
Maintenance Reliability Strategy History
Fixing when
fails
Fixed time
or
performance
based
Periodic
Monitoring &
Diagnosis
RCFA based
failure finding
Defect
Elimination
Continuous
Improvement
based ,
cost effective
way
Integrity,
Reliability,
Availability
and
Cost based
Combination
of RCM , RBI,
& SIS
Maintenance Optimization To
Increased Asset Reliability
MAINTENANCE RELIABILITY EVOLUTION
MAINTENANCE DOMAIN MODES
Reactive maintenance :
Preventive maintenance :
Predictive maintenance :
Proactive maintenance :
RCM Maintenance :
Risk Based Maintenance :
Failure based
Time/performance based
Condition based
Root Cause based
CI & Criticality based
Integrity, Reliability,
Availability and Cost base

11‐May‐16
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MAINTENANCE LIFE CYCLE COSTS
Specification Design Manufacturing Installation Commissioning Operation Replacement
Performance
Reliability
Maintainability
Support System
• The Opportunity For Maintenance Cost Reductions is Highest
At The Design Stage, & It Will Very Low After Commissioning
Process
Design
Reliability
Quality Control
FAT
Design Fault
Maintainability
Design Fault
Performance
testing
Design Fault
Poor Maintenance
Mal-Operation
Wear Out
Obsolescence
Disposal
Reliability Starts from Design, RFQs & Contracts should Include :
 High Efficiency Asset
 Performance Guarantees – Uptime
 Maintenance Guarantees – PM Frequency (max 30 min/month)
Reliability
The POTENTIAL - FAILURE Curve
Old
Definition
of Failure
Large Business
Consequences!
$$$$$$$
F
Functionally Failed
Equipment not performing
intended function
New definition
of failure
Vibration
Oil AnalysisUltrasound Thermography
Can Smell it
Can See it
P
Reactive Domain:
Too Little, Too Late
Planning & Intervention
Window
P r o a c t i v e D o m a i n :
D e f e c t E l i m i n a t i o n

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P-F Curve & Swiss Chess Model
Proactive Mode
$$ Material
$$ Labor
Reactive Mode
M&R Cost reduced by 20%
Labor reduced by 24%
Material reduced by 16%
• Hazards (Failures) are
contained by multiple
protective barriers
• Barriers may have
weaknesses or holes’
Sch. & PM Compliance
• When holes align, the
hazard (Failures) passes
through the barriers
resulting in the potential for
adverse consequences.
• Barriers may be physical
engineered containment
or behavioral controls
dependent on people
A S S E T R E L I A B I L I T Y E X C E L L E N C E
Technical Integrity
Management of
Hardware risk barriers
Process Safety
Management of Major risk
Asset Integrity
The ability of an asset to perform its required
function effectively and efficiently while
safeguarding life and the environment
Asset Reliability Performance
The ability of an asset to perform its required function
while making an optimum contribution to the business
Reliability Excellence
Occupational Safety
Incidents that primarily
affect an individual on
each occurrence

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RISK BASED MAINTENANCE STRATEGY
A RBM’s Strategy prioritize maintenance resources toward assets
that carry the M O S T R i s k if they were to fail. It is a
methodology for determining the most economical use of
maintenance resources, so the maintenance effort across a
facility is optimized to minimize any risk of a failure
 RBM strategy is based on two main phases:
1. Risk assessment
2. Maintenance planning based on the risk (RBWS)
… F a i l u r e i s s i m p l y t h e o p p o r t u n i t y t o b e g i n a g a i n , t h i s t i m e m o r e i n t e l l i g e n t l y …
WHY ADOPTING RISK BASED STRATEGIES
 True reliability is achieved when the most
SAFELY & COSTLY effective methods
are applied to the Plant Assets.
 Maximizing the maintenance effort with
the minimum total cost to the business.
Area With Highest ROI
… T h e o n l y r e a l m i s t a k e i s t h e o n e f r o m w h i c h w e l e a r n n o t h i n g …

11‐May‐16
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ASSET
RELIABILITY
EXCELLENCE.
Eng. Hosny Elsayed
Asset Reliability is the ability of the asset
to perform the function for which it was
designed for
Asset Integrity is the ability of an asset to
perform its required Function effectively and
efficiently whilst protecting health, safety and
the environment
Asset Availability is the availability of
reliable asset at design integrity to process
i
ASSET RELIABILITY, INTEGRITY,
AVAILABILITY & MAINTAINABILITY (RIAM)

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THE RELIABILITY FOCUS
Production
Reliability
Maintenance
Procurement
Materials
Management
• Standardized procedures
• Waste and loss elimination
• Quick changeovers
• Stable, consistent processes
• Operator care
• Risk management
• Asset management
• Loss and waste elimination
• Performance management
• Asset care
• Life cycle asset management
• Loss and waste elimination
• Useful life extension
• Dock-to-dock materials management
• MRO materials management
• Materials handling and JIT
• Inventory management
Management
• Coordinated planning
•Operations management
•Master production schedule
• Performance management
•Lowest total cost of ownership
•Remove costs from the supply chain
MATERIALS
MANAGEMENT
ASSET CARESCHEDULING
WORK
MANAGEMENT
PROCESSES
FACILITIES
EQUIPMENT
WORK
MEASUREMENT
WORK
PLANNING
TRAINING
ORGANIZATION
STRUCTURE
SUPERVISIONEAMS
OPTIMIZATION
MANAGEMENT
REPORTING
BUDGETING
COST CONTROL
CONFIGURATION
MANAGEMENT
EQUIPMENT
HISTORY
AUDITS
RELIABILITY
ENGINEERING
SUSTAINABILITY
OPERATOR
CARE
PROCUREMENT
EQUIPMENT
PROCESS DESIGN
MANAGEMENT COMMITMENTPLANT PARTNERSHIPS
PRINCIPLES
ORGANIZATIONAL
BEHAVIOR
MASTER
PLAN
OBJECTIVES
GOALS
GOVERNING
PRINCIPLES
STATUS
ASSESSMENT
CULTURE
PERFORMANCE
MANAGEMENT
LOSS
ELIMINATION
THE 29 ELEMENTS OF Reliability Excellence - Rex.THE 29 ELEMENTS OF Reliability Excellence - Rex.
REX – THE RELIABILITY EXCELLENCE MODEL

11‐May‐16
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ASSET MAINTENANCE & RELIABILITY
P •Work Planning
S •Work Scheduling
E •Work Execution
H •Work History
D2D Maintenance
Work History
Analysis / Assessment
Strategy
Development
Reliability
“ B y f a i l i n g t o p r e p a r e , y o u a r e p r e p a r i n g t o f a i l . ”
Eng. Hosny Elsayed
RELIABILITY
OBJECTIVE &
ROADMAP
RELIABILITY
OBJECTIVE &
ROADMAP

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PLANT / ASSET RELIABILITY
Reliable
Equipment
Reliable
Process
Reliable
Team
Asset Reliability Should
Integrating Equipment ,
Process & Team Reliability
RELIABILITY ENGINEER ROLE
Successful Plant / Asset reliability
program Should defining the
expectations of the Reliability
Engineering role.
Reliability
Engineer
Role
Profile
Reliability
Reporting
Reliability
Plans
New
Asset
Spec. &
Design
Criticality
Analysis
Perform
FMEA /
RCM
Asset
Manage
ment
Strategy
PdM &
PM
plans
Root
Cause
Failure
Analysis
Statistical
Data
Analysis
Monitor
Key
metrics
Coaching
Plant
Personnel

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RELIABILITY ROADMAP
The journey to a proactive Asset Management
Performance (AMP) model involves people
from all levels of the organization.
It is critical that the Reliability Roadmap be
accepted and supported by all stakeholders.
EHS INCIDENTS
WASTE
COST
PLANNED DOWNTIME
UNPLANNED DOWNTIME
RELIABILITY ROADMAP GOAL

11‐May‐16
20
RELIABILITY ROADMAP GOAL
AVAILABILITY / Uptime
CAPACITY
QUALITY
EMPLOYEE RETENTION
BUSINESS SUSTAINABILITY
Reliability Road Map
ReliabilityCulture
•Leadership
Find The Champion
Form Steering Committee
•Vision & Strategy
Develop the strategy
Benchmark and set Target
•People
Human error
Change Management
Communication
•Training & Buy-in
Senior Management
Program Management
CM & precision Skills
ReliabilityStrategy
•Assets Register
Build Master Asset List
Unit , System & sub sys.
Function
•Criticality
Asset Criticality Rating
•Failure Modes
Practical FMEA
Assess Risk
Develop Strategy
•Reliability Study
MTBF - MTTR - Weibull
Bad Actors - Block
diagram
MaintenanceStrategy
•Reactive Maintenance
Low Value , no downtime, no
impact on EHS
•Preventive Maintenance
Time/performance based
•Predictive Maintenance
Condition based
•Proactive Maintenance
Root Cause based
•RCM Maintenance
CI & Criticality based
•Risk Based Maintenance
Failure age related?
Action to prevent Failure ?
MaintenanceLifeCycle
• Design /
Procurement
Maintainable and Reliable
• Spares Management
Organized / Optimized /
Clean SPIR /
•Planning & scheduling
RBWS – Prioritized – Organize
• Precision Skills
Aligned / Balanced / tight
• Precision Operation
Operate Within Envelope -
SOP
• Maintain Function
Lubricate , Adjust , Preserve
Reliability Culture Reliability Strategy Maintenance Strategy
Maintenance Life Cycle
(MLC)

11‐May‐16
21
THANKSTHANKS
2 n d A n n u a l K i n g d o m P r o c e s s S a f e t y 2 0 1 6
0 9 t h – 1 0 t h M a y , i n A l K h o b a r
Hosny Elsayed
Ma’aden Mine & Refinery Reliability Manager

A Reliable Plant is a Safe Plant - Hosny

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