Our plants (GS, SS and AWT) use a large number of electric motors as their equipment drivers. All equipment drivers must be kept on running condition all the time to ensure plant’s high productivity. These drivers have their electrical power supplied from the Switchgear, MCC, & Switch-rack, and thus the equipments condition is deemed critical to the reliability of the whole plant.
Unavailability of process driver in our plants shall disconnect a chain of process and creates a downtime and inevitable losses. Therefore, there is always production losses associated with Switchgear, MCC, Switch-rack problems. The biggest impact to production will trigger the schedule of improvement action.
The research has been developed based on statistic of failure as per given bar chart for GS, SS and AWT:
Development of the outcomes
A method of recording and analyzing all significant cost metrics associated with equipment downtime in a plant (GS, SS and AWT) and providing a way to assign time and/or monetary value to previously considered “non-tangible” cost of downtime.
True Downtime Cost of Switchgear, MCC, & Switchrack include:
- Lost of potential production cost without generated steam and delivered water & oil excluding the possibility of bottleneck.
- Energy surge cost during start-up (energizing phase),
- Man-hour (regular and overtime), in this calculation we’ll not include this man-hour cost.
- Repair cost.
1. SS – Cost of Unreliability
2. GS – Cost of Unreliability
3. AWT – Cost of Unreliability
Minimum Acceptable requirements
Project Execution Plan has been developed based on the biggest impact on the production. They are in sequence:
Analyze and compare the alternatives
As the biggest impact is on SS and GS, the below table is a comparison the cost of unreliability:
Develop preferred alternative
This Failure Mode and Effect Analysis (FMEA) is a powerful tools to react with the electrical improvement opportunities as part of maintenance program:
Monitor and Evaluation (Post Mortem)
- During period January ’10 – December ’10, we had 478-failures and 4933-hour downtime on electrical motor protection (MCP) & power supply system (switchgear + MCC) in GS and SS with the Total Cost (True Downtime Cost) 1,368,154 US$.
- Method to extract raw data from Database to document losses to production and equipment repair cost still not using yet standardized method for GS and SS. Increased DB utilization:
- To provide meaningful management reports that will enhance control of maintenance of MCC (% reliability, % availability, MTTF, etc.).
- To ensure that maintenance is performed efficiently through organized planning and coordinated use of material, manpower, and time is a necessity.
- Industrial Accident / LTI – zero.
- Unplanned Shut Down – zero
The following action items are a must for achieving the Success Metrics above:
- Good team work & coordination – meet on regular basis, good cross functional participation and good team commitment.
- Follow the project management practices.
- Follow HES procedures and approved standards & codes.
- Utilize Best Practices.
- Involve the right resources.
- Peters, Max S & Timmerhaus, Klaus D. (1991), Plant Design and Economics for Chemical Engineers 4th Edition, Singapore: McGraw-Hill, Inc.
- Sullivan, William G., Wicks, Elin M. & Koelling, C. Patrick (1942), Engineering Economy 15th Edition, Singapore: Prentice Hall, Inc.