cost optimization
TRANSCRIPT
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1.220 Million $ Cost Optimization in ADGAS plant Maintenance By applying creative ideas (kaizen)
• Done by:
• Ahmed Al Ali
• SIE (Process)
• 30.01.2016 1
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New back up air line Removal of redundant VRU panel Replace corroded SOV boxes at plant 19 Replace pump well pressure control valves limit
switches Replace Sulphur shore slop tank RTD junction
boxes Replacement of SOV at LNG jetty entrance Sulphur loading line skin temperature Sulphur loading arm control panel LNG tank D-103 deluge valve cable fault How much we have saved?
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As UAE government has announced 2015 as innovation year and inline with ADGAS innovation strategy (kaizen) we have implemented creative ideas.
During day to day maintenance activities we came across many break downs and repeated problems.
These repeated problems consumes a lot of man hours and materials.
To rectify these problems we have implemented many innovative solutions that resulted in plant reliability and cost optimization by using internal resources.
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Disadvantages of not having back up air header line:
Un availability of Instrument & plant air during compressor shutdown in utility plant.
Consume more energy while using portable air compressor.
Delay the ship loading due un availability of air during utility compressor trip.
Maintenance of loading pumps lifting jobs and all control valves will be delayed.
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Before
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After
New Air
header
line
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Advantages of new back up air header line:
Continuous availability of instrument air and plant air during air compressors shutdown in utility plant.
Saving Energy, so no need for portable air compressor during shortage of plant & instrument air
Increase the reliability of STOREX instruments while ship loading
Avoid ship delaying time ( Two times plant 28 air compressor failed, Operations used the instrument air backup line and resumed the Sulphur ship loading ).
Easy loading pump lifting maintenance.
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Description cost
Manpower (10
person)
50,000 $
Engineering 20,000 $
Scaffolding 10,000 $
Safety standby 5,000 $
Materials 60,000 $
Ship delay charge 40,000 $ per year
Total 185,000 $
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• Disadvantages of Old panel:
The VRU compressor was tripping due to
panel purge which was not required as
almost all loops were transferred from local
panel to control room during SCSU project.
Space occupied by the panel un-necessary.
Consuming energy for the panel which was
not in use.
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Before
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After
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Advantages of Removal of the panel:
VRU compressor is more reliable and not
tripping.
Enough space is available now for major
shutdown maintenance of compressor.
Energy saving by isolating the power
which was used by redundant panel.
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Description Cost
Manpower 40,000 $
Mobilization 10,000 $
Materials 20,000 $
Accommodation &
food
10,000 $
Production loss per
year
20,000 $
Total 100,000 $
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• Disadvantages of old SOV boxes:
1- Pilot flare Auto Ignition system some
times fail to operate due to corroded & old
tubing's.
2- Difficult to remove SOV’s for
maintenance.
3- Difficult to replace the faulty SOV’s.
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Before
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After
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Advantages of new modification:
1- Easy maintenance.
2- Long life working condition of the
solenoid valves.
3- Pilot flare Auto Ignition system is
reliable.
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Description cost
Manpower 40,000 $
Mobilization 10,000 $
Materials 20,000 $
Accommodation &
food
10,000 $
Total 80,000 $
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Disadvantages of Old mechanical lever operated limit switches:
Un availability of valves feedback indication due to mechanical lever getting stuck.
Frequent failure of mechanical levers due to corrosive atmosphere.
Consume more materials for the maintenance.
Consume more man hours for repair and replace the limit switches.
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Old mechanical
lever operated
limit switches
Before
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New magnetic
operated limit
switches
After
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Advantages of new magnetic limit switches:
Maintenance free due to no mechanical moving parts (lever).
Saving Man hours. Increase the reliability of the pump pressure
control valves. Saving cost of Materials. More efficient system for Operations to
confirm the valves position.
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Description cost
Manpower (6
person) for 60 days
80,000 $
Engineering 20,000 $
Safety standby 5,000 $
Materials 70,000 $
Total 175,000 $
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Disadvantages of Old RTD JB’s:
Getting corroded and damaging frequently since it was metal JB’s affected by corrosive atmosphere.
Located inside confined space which is always required safety standby for maintenance.
Maintenance team exposure to toxic gases. Required scaffolding whenever routine or
break down jobs there.
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Before
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After
New FRP
junction
boxes outside
confined space
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Advantages of new RTD junction boxes:
No toxic gases exposure for maintenance team
Easy maintenance because we have shifted the JB’s outside the slop tank pit.
Scaffolding not required. Safety standby not required. New JB’s not getting corroded very fast,
since we have used FRP material.
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Description cost
Manpower per
year
20,000 $
Scaffolding 10,000 $
Safety standby 5,000 $
Total 35,000 $
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Disadvantages:
1- Difficult to maintain the SOV’s.
2- Isolation valves were seized and difficult
to operate for replacement of faulty SOV’s.
3- Delay the ship loading during SOV
failure.
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Before
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After
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Advantages of new isolation valve and Mounting plate:
1- Easy maintenance. 2- Made the LNG & LPG loading Process more reliable. 3- Avoid unwanted ESD. 4- New SOV by pass valves provided for immediate resuming of loading / circulation in case of SOV failure.
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Disadvantages of Sulphur loading line without skin temperature indication: Line getting frequently chocked which
was causing delay Sulphur ship loading. Difficult to trace out the Sulphur blockage
in the loading line. Consuming more manpower and time. More energy consumption to remove the
chock from the line.
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Before
Sulphur
Loading line
without Temp.
points
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New Temp.
Control
Panel
New Temp.
Element with
SS conduit
New Temp.
Element
JB
After
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Advantages of new skin temperature ( 36 points) in Sulphur loading line: Sulphur loading line not getting frequently chock
as Operations having now facility to monitor the temperature and take action immediately.
Easy to identify the location of the blockage in the loading line.
Saving manpower and time. Saving energy. Saving the cost of the cables for new system by
using excess cables from old projects which were lying in the salvage yard.
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Description cost
Manpower 20 technicians X
30 days = 55,000 $
Mobilization 20,000 $
Materials 115,000 $
Accommodation &
food
10,000 $
Total 200,000 $
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Description:
An incident had taken place when
Sulphur ship hit jetty #5 during berthing.
This incident caused the damage of the
control panel.
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Disadvantages of giving contract to
replace the control panel:
High cost to bring the vendor.
Long time to finish all the formalities to
bring the vendor on site which will delay
the ship loading.
Consuming more manpower and
materials.
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Before
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Before
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After
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Advantages of Replacement of control panel with new using internal resources: Saving the cost of the vendor and labour. Save the time by fabricating new panel with
internal wiring and fixing on site. Saving manpower and time. Save the cost of material by using available
materials in our stock and some from non movable items.
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Description cost
Manpower 50, 000 $
Mobilization 20,000 $
Panel 100,000 $
Accommodation &
food
10,000 $
Total 180,000 $
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Disadvantages:
Non availability of deluge valve during
fire emergency.
To rectify this fault it was required to
replace 250 meter underground control
cable which can be done through outside
contractor which means high cost for
material and manpower.
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Before
D-103 Deluge valve faulty cable
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After
New Junction
box installed
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Advantages of new modification: Continuous availability of Deluge valves. Rectified Long standing cable fault. Deluge valve ( fire water system ) put back
on service which was not operate able for long period.
Saved the cost of replacing 250 meter multi core underground control cable.
Saved the cost of CIVIL work ( Opening / closing trenches, excavation, remove and relaying cable ).
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Description cost
Manpower (15
person)
40,000 $
Engineering 10,000 $
Scaffolding 20,000 $
Safety standby 10,000 $
Materials 100,000 $
Civil works 100,000 $
Total 280,000 $
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Description Cost
New back up air line
185,000 $
Removal of redundant VRU panel 100,000 $
Replace corroded SOV boxes at
plant 19
80,000 $
Replace pump well pressure
control valves limit switches
175,000 $
Replace Sulphur shore slop tank
RTD junction boxes
35,000 $
Sulphur loading line skin
temperature
200,000 $
Sulphur loading arm control panel 180,000 $
LNG tank D-103 deluge valve
cable fault
280,000 $
Total 1,220,000 $
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Thank you