STORK

A FLUOR COMPANY
24 Feb. 2017.
ASSET MANAGEMENT MENU

INTEGRITY ASSESSMENT

We continually improve the performance of your facility, avoiding

unplanned downtime and reducing planned downtime as much as
possible.

We do that by:

Assessing your facility along three lines of sight:

Compliance with respect to:
as-is built in comparison to design

(A- Design compliance)

as-is condition in comparison to requirements (B Condition compliance)

as-is use in comparison to current (legislative) requirements

(C Management of Change requirements)

Assessment by using standards:

Read more
Standard condition classification on 1-6 scale (6: unacceptable).
3/9/17 3
MAINTENANCE as integrated part of
ASSET MANAGEMENT

Requirement is: manage your asset in alignment with the strategy

of the organization
Key issues:

Have a clear and risk based decision strategy (ISO 31.000)

Manage your asset from on a long term, sustainable perspective

Include requirements from share- and stakeholders in the asset

strategy as part of compliance management (ISO 19.600)

A standard guideline such as ISO 55.001 will help to define your

road map.
In this session, well focus on the long term investment strategy.
Focus: type of investment planning (*) which is required in a long
term asset management framework

3/9/17 (*) with related forecast methodology

4
 Click on the pictogram below
to insert an image

MAINTENANCE
INSPECTION MANAGEMENT.
You need to know the status of your plant; what can it do?
Asset management therefore includes inspection management.
Inspection management contains a logic, documented, traceable
methodology in order to determine the optimal combination of
inspection frequencies and inspection tasks.
The aim is to ensure that inspection is focused onto the high risk
areas, while inspection in low risk areas is reduced or eliminated.
By means of this process, a significant reduction in costs for
inspection and maintenance is obtained whilst at the same time
the level of control on the asset is optimized.

Risk Based
Integrity
Methodologies.
Integrity
Integrity
management
management

3/9/17
 Click on the pictogram below
to insert an image

PREVENTIVE MAINTENANCE
ITS ALL ABOUT LEARNING & FORESEEING.....

IN
IN THE
THE PAST
PAST LIES
LIES THE
THE PRESENT
PRESENT
IN
IN THE
THE PRESENT
PRESENT WHAT
WHAT WILL
WILL BE.
BE.

3/9/17 6
 Click on the pictogram below
to insert an image

PREVENTIVE MAINTENANCE & INVESTMENTS

FORESEEING WITH HORIZON AT..... IDEALLY YOU HAVE A
HOTKEY THAT REVEALS
THE FUTURE....
(SO THATS WHAT WE AIM
FOR)

2030

3/9/17 7
 Click on the pictogram below
to insert an image

KEY FACTORS FOR AM DEVELOPMENT.

ITS ALL ABOUT LEARNING & FORESEEING.....
Requirements with respect to developments:
10,3%: Production reliability
9,2%: Condition Based Maintenance
8,4%: Production Asset Lifetime Extension
8,3%: Predictive Maintenance

Common aspects:

Analytics of behavior:
Predicting is step 1;
Transparency in predicting step 2;
Validated prediction step 3.

WCM Disclaimer: all results shown are preliminary. No rights can be claimed from those results
Its about recognizing the physics &
modelling the characteristics &
3/9/17 8
assessing the specifics
 Click on the pictogram below
to insert an image

WHICH ISSUES DOES LTARP ADDRESS?

MAPPING WITH REQUIREMENTS: LTARP is the acronym for:
LONG
Required development as TERM
..
per questionnaire: Score Criterion:
x Part of investment
ASSET
Optimisation of spare parts 7,3%
REPLACEMENT
Predictive maintenance 8,3% X Prediction meth.
Condition based maintenance 9,2% X Requirement 4 ,,
PROGRAM
Production reliability 10,3% X Performance req.
Production asset lifetime 8,4% X Investment req.
extension
Overall coverage: 43,4%

3/9/17 9
 All disciplines make the
HOW IS THE LTARP PREDICTION OBTAINED? same journey / decision
FLOWLINE OF PREDICTION PROCESS: line

Data
Data acquisition
acquisition Model
Model Design
Design
..

Selection of
Defining Key Predictor Variables
Parameters for Data
Multiple Regression
Collection
Modelling
Remedial
Data Collection Measures
Satisfactory
results.
No

Data Preparation Yes

Unsatisfactory
Model
validation

Satisfactory
Deterioration
Deterioration
curves Model
Model Selection
Selection
curves
3/9/17 10
 Sample with human stats:
LTARP: ALIGNMENT WITH RCM? Hospitalization & End Of Life
WHERE DO APPROACHES DIFFER? # of hospitalizations and survival %

Differences:
Decision aspect LTARP RCM Criterion: 100% -
Obsolescence Product lifecycle per
X -
supplier.
Economic criterion Integrated costs summary.
X x
for replacement
Durability New perspectives
X -
assessment integrated.
All equipment in Investment Failure costs
- (I) X (F)
asset tree

Similarities:
Decision aspect LTARP RCM Criterion:
Risk assessment X X POF * COF. ; However:
Type of failure & Satisfactory risk reduction.
X X
mitigating measure
Failure of equipment LTARP: only EOL perspective.
X X
components

High level: Failure versus End Of Life failure

3/9/17 11
 Click on the pictogram below
to insert an image

LTARP: WORK PROCESS DESCRIPTION.

END OF LIFE FAILURE; SAMPLES.

Required parts for repair no longer available.

Costs of repair are extensive (> 50% of new)

Construction / process does not comply with current

requirements (QHSE)

Note: this type of assessment is NOT part of std. RCM

(equipment is considered state of the art).

3/9/17 12
MAINTENANCE
LTARP & RCM; SAMPLE:

Lets take a pump:

RCM: Critical? On bearings? CBM (Vibration measures).

LTARP: What is EOL scenario? Failure of the pump casing

due to deterioration(wear) over time? What is its
current condition and what is the failure criterion? What
is the condition curve with time? EOL specification.

Note: Bearing condition is not EOL relevant since it is

supposed to result in standard repair.

3/9/17 13
 Click on the pictogram below
to insert an image

Level 33
OPERATIONAL ASSET MANAGEMENT

Level
Level 11

Level 22
Level

Level
LINES OF SIGHT

Assessment along lines of sight:

Economical.
Economical. Integrated,
Integrated, modular
modular Deterioration.
Technical aging Long
Long Term
Term
Asset Management
Asset Management
Maintainability (obsolescence) Functional.
Functional. Planning Compliance.
Planning && Control
Control
Functional aging (efficiency)

Investment
Costs (overall costs level)

Investment
planning
planning

elongation
elongation
Life
Life Cycle

Lifetime
(Deterioration) (Obsolescence) (Ownership costs) (Compliance)

Lifetime
costs
costs
Aging Function Economy Compliance

Cycle
Condition: 4 2 3 NA
Water pumps type Remnant life: 5 Yr. 3 Yr. 4 Yr. NA
Function.
centrifugal 3 Yr.

Condition: 3 4 NA 2
Cooling units type Remnant life: 10 Yr. 3 Yr. NA 10 Yr.
Function.
local (airco) 3 Yr.

Condition: 3 2 NA NA
Aging
Heating type hot air. Remnant life: 12 Yr. > 15 Yr. (Nvt) NA NA 12 Yr.

3/9/17 14
 Click on the pictogram below
to insert an image

OPERATIONAL ASSET MANAGEMENT

LINES OF SIGHT.
The overall method for condition assessment and End Of
Life condition assessment:
6 points classification.
Class: Implies: Assessment criterion:
1 Very good No or ample reduction of performance.
2 Good Meets with all requirements
3 Average Clear proof of reduction in performance.
4 Bad Planned action foreseen.
5 Very bad Immediate action required.
6 Unacceptable Unacceptable; Out of control.

Traffic lightplus assessment model.

Aligns with familiar inspection codes.
Multi- disciplinary (E,I,W,R,S,C)
3/9/17 15
 Click on the pictogram below
to insert an image

OPERATIONAL ASSET MANAGEMENT

TYPICAL RESULTS.

Long
Longterm
termmaintenance
maintenanceinvestments.
investments.

Lifetime reduction due to

clustering
(limited impact on availability)
Lifetime elongation measure
(obsolescence mngmnt &
protective measures)

3/9/17 16
 Click on the pictogram below
to insert an image

AM OPERATIONAL: LTARP
MAPPING ON MAINTENANCE PROCESS:
Preselection based on customer-specific criteria:
Scope of ones own asset management (which
installations)
Level of control (can be fixed due to insurance Y/N)
Level of predictability (analogous choice TDM or CBM).
Cost level (will a dive into costs pay out).
Note: costs criterion as per depreciation LTARP
item.
Note:
Process-critical items, when selected:
The more critical, the sooner replacement (risk
management).
Item-specific assessment criterion (when required).
Discipline generic assessment.
3/9/17 17
 Click on the pictogram below
to insert an image

OPERATIONAL ASSET MANAGEMENT:

HOW TO GROUP THE ASSETS?

Criteria for group definition:

By pre-selection (limit scope):

Frozen maintenance scope (insurance items)

Maintenance-demand is frozen (discussion is not useful;

Use Dependent Maintenance)

Beyond costs limit as per costs/merits

In scope:

Technically comparable

Equally behaving (comparable prediction).

3/9/17 18
 Click on the pictogram below
to insert an image

OPERATIONAL ASSET MANAGEMENT

LTARP CHARACTERISTICS GROUPING:
Characteristics:
Behavior
Behavior specified
specified
Scope is typically 40% of total asset tree. by
by Equipment
Equipment
Equipment
Equipment
Record
Record Record
Record
cards.
cards.
Of those, on 2nd thought 50%> forecast time zone. Equipment
Equipment Record
Record
card.
card.
-- System
System or
or
card.
card.
-- Transformer
With that per typical (ERC) 20 equipms (so
-- Transformer
-- Typical
Typical
Typical
Typical of
of
or
or
number x 0,05). Specific
-- --Pump
Specific
Pump
Number one of a kind ERCs 1% of asset scope.
Selection
Selection
Asset
Asset tree
tree
-- Transformers
Transformers
-- Pumps
Pumps
-- Lines
Lines End
End Of
Of Life
Life specification.
specification.
-- Valves
Valves for
for Equipment
Equipment based
based on
on
-- CMMS
CMMS item
item specific
specific criteria
criteria
-- E-distribution
E-distribution Applying or
or
a r a ct e ri stics for
for group
group on
on the
the basis
basis
ch
of
of group
group criteria
criteria
3/9/17 19
 Click on the pictogram below
to insert an image

OPERATIONAL ASSET MANAGEMENT

LINES OF SIGHT
Focus is on:
Identifying the Assets that require replacement from a
variety of perspectives.
Generate overview of investments with time.

LTARP
LCC
LTE
On the basis of that overview:
Define control measures such as Life Time Extension (LTE)
o Buy additional lifetime (spare parts)
o Modification of use (reduction of deterioration)
Clustering (downtime reduction & advantage of scale)
Modification - in design or of use.
3/9/17 20
 Click on the pictogram below
to insert an image

TYPICAL QUESTIONS: Q&A Timeslot:

DOES LTARP REQUIRE RISK ASSESSMENT? Providing additional
A: In general: No. However:.. insight in the approach.
Q: How is risk processed in LTARP? (does that imply that
every asset has a unique ERC?)
(RCM)
Asset Critical? If:
If: Use
Use in-between
in-between control
control points
points yields
yields
significant
significant probability
probability of
of failure
failure resulting
resulting
Y Y N from
from ongoing
ongoing degradation:
degradation:
Reject
Reject based
based on
on calculation.
calculation.
PM RTF IfIf not:
(TDM/CBM) & Spares RTF not: standard criterion from functional
standard criterion from functional
requirement.
requirement.

LTARP
Selection
Selection
part
Min.
Min.Acc.
Acc.level.
level.
Calculated.
Calculated.
Equipment
Record
Specific reject
criterion?
Listed
Listed acc.
acc. criteria.
criteria. Card
Y

Default
Default value.
value.
3/9/17
21
 Click on the pictogram below
to insert an image

COMPLIANCE & INTEGRITY. Q&A Timeslot:

HOW DO THESE MERGE? Providing some details on
the approach.
Q: Are integrity and compliance to be managed in the same
way?

A: This depends on the interpretation that one uses.

Our vision on this subject is as follows:

Both refer to meeting set requirements.

Integrity refers in our setting to technical integrity.

This focusses onto technical requirements for the physical
asset. Examples: wall thickness, crack toughness, yield
strength.

Compliance refers in our setting to technical compliance.

This refers to the controls that ensure by means of processes
that the organization is aligned with the set requirements.
So in our technical perspective the answer is: Yes
3/9/17 22
 Click on the pictogram below
to insert an image

OPERATIONAL ASSET MANAGEMENT: Q&A Timeslot:

WHICH LINES OF SIGHT? Providing some details on
the approach.
Q: How to assess the level of conforming with
requirements?
By means of the three main lines of sight.
Sight: Relates to: Example: .. To what level does the..
A Design ..as-built situation meet the design requirements?
B Maintain ..the installation meet the minimal requirements for use?
C Manage ..actual function meet current requirements for that purpose?

The compliance ABC ( an A-B-C-case).

Sight: Relates to: Example:
A Design The color code of the material does not comply with the design requirements.
B Maintain The material has been attacked resulting in a probability of failure.
C Manage The actual process conditions deviate from the conditions as per design.

3/9/17 23
OPERATIONAL ASSET MANAGEMENT Q&A
LINES OF SIGHT& OVERVIEW IN FOREST. Timeslot:
Q: How do I keep overview over the amount of deviations Providing
that I have to manage? more
A: In multiple ways: details 5
Overview of requirements with related control measures
(compliance register) in terms of A/B/C. 6
Assessment of deviations by classification with respect
to requirements, with wrap-up to asset level.
Number of findings: Condition 2
class:
Line of sight Remark:
1 2 3 4 5 6 *: Assessment of the change
(assessment):
A: Design
B: Maintenance
1 2 1
1 4 3


management concerns the
comparison of the [current 1
type of use] with respect to
C: Management See * [use as specified in the design]
(eg production line that is
taken out of operation without
1 1 being formally known as such).

3/9/17 24

Unacceptabl
 MENU

THANK YOU
FOR YOUR
ATTENTION