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July 2017
Reliability Consulting
 
In This Issue
News Brief: Emerson Teams with Dupont Sustainable Solutions to Deliver Operational Certainty
Reliability Tip
Upcoming Events
  Featured White Paper – Operational Readiness for New Assets – Bridging the Gap Between Construction and Operations

It traditionally has been the case that significant leakage of anticipated project value occurs during the turn-over/commissioning and ramp-up periods of the new asset lifecycle. Case studies have measured this leakage to be as much as 30% of the value that was anticipated during the early stages of the total lifecycle. The early stages consume the first three to five years and include the engineering, design, construction, commissioning and ramp-up phases. The ramp-up phase is usually the first year after commissioning—often a painful period of unstable operations, with significant lost revenue and profit opportunities due to unexpected and extended downtime.

Of equal and often greater significance, the actual operations and maintenance costs (O&M) of the assets during the longest portion of the total asset lifecycle—the operate/maintain stage (often 30 years or more)—typically are 1% to 2% higher (conservatively speaking) than the expected total lifecycle costs assumed in the initial business case—and this does not include the operability value destroyed because of poor design choices, unprepared operators and maintainers, antiquated maintenance strategies and a lack of necessary documentation. Choices made during the early design and construction phases set in place the long-term operating performance, as well as the long-term operations and maintenance costs for the more than 30-year life of the asset. Poor choices can doom the organization into incurring unnecessary lifecycle costs, reaching into the hundreds of millions of dollars for some large projects.

This whitepaper will explore the factors that determine the level of lifecycle costs, as well as the emerging operational readiness best practices that can dramatically reduce risk and improve ramp-up, operational performance and long-term O&M costs with relatively modest investment up front.

To read the white paper, click here.

 
 
 
 
News Brief: Emerson Teams with Dupont Sustainable Solutions to Deliver Operational Certainty

May 30, 2017 — DuPont Sustainable Solutions announced that Saline Water Conversion Corporation (SWCC) selected their team, including Emerson’s Reliability Consulting, to boost operational performance across their fleet. The release highlights the strategic nature of SWCC’s drive to top quartile performance.

Emerson’s expertise in automation and reliability will play a key role in connecting technical and technological improvements to the realization of business value through improved asset availability and lower maintenance costs.

For more information on these services:
http://www.emerson.com/en-us/automation/services-consulting
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Reliability Tip:

How Often Should You Revisit Your Asset Criticality?

There is no hard and fast rule on when a review is necessary. If the ranking was performed a few years ago it may be time to revisit the process. This is especially true when changes to processes and equipment have been made.

A good criticality ranking process takes several perspectives into account when considering the potential impact of a failure. In addition to the obvious production perspective, other factors that may be considered include:

  • Safety
  • Environmental
  • Time to repair
  • Parts availability and lead times
  • Technical support availability
  • Customer impact
  • Quality
  • Redundancy of equipment

If an equipment modification or replacement has been made that could alter the original ranking in any of these areas, it is time to revisit the criticality of the asset. For example, if a new compressor was installed with a different manufacturer than the original, spare parts would have changed so we would need to consider lead times. Are parts readily available for the new compressor? Is technical support available? Is a trained technician available? These things could impact our ranking.

Other areas that could cause a change in the criticality values are safety and environmental regulations. If new regulations have been issued or existing ones significantly modified (such as the NFPA 70E Arc Flash risk assessment criteria), it may be time to review the ranking.

By keeping the Asset Criticality Ranking current, it will allow Managers to make decisions on how to care for the plant’s most important equipment.

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UPCOMING EVENTS
CRL Workshop
July 25, 2017
Minneapolis, MN

Additional information here.

Maximo World
August 1-3, 2017
Orlando, FL

Additional information here.

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Your Local Connection

Learn more about local reliability community activities and local access to Emerson’s expertise and accelerators. Click here to connect.

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