EQUATE PETROCHEMICAL COMPANY EQUATE RCM Project Implementation By Khalid Al-Anzi

EQUATE PETROCHEMICAL COMPANY EQUATE Profile  An ISO 9001:2000 & ISO $2B company established in  Owned By:  Petrochemical Industries Company, Kuwait  The Dow Chemical Company, USA.  Boubyan Petrochemical Company, Kuwait  Products:  Ethylene, Ethylene Glycol, Poly Ethylene, Poly Propylene.  Vision of The Company  Obligated to Adding Value to our Customers.  Value of the company  Ensure our culture is a model for Standards and Best Practices.  EQAUTE Future  EQUATE is expanding to add another $4B in capital assets.

EQUATE PETROCHEMICAL COMPANY EQUATE Reliability Initiatives & Growth 1997 EQUATE Started 1999 EQUATE 1 st TA Full PPM program established Full RBI program established 2003 Reliability Engineering initiated 2004 RCM project Started Optimization of Work Processes 2005 Operator Driven Reliability Program initiated 2006 EQUATE Major Turn Around RCM Project Implementation Completed Reliability Section Fully established EQUATE Construction Fire Prevention Reliability Driven Fire Fighting Event Driven

EQUATE PETROCHEMICAL COMPANY Why do RCM?  Optimize Preventive Predictive Maintenance activities.  Understand the risks associated with our Equipment/System Failures and how to manage them.  Change EQUATE PPM Program approach from an Event Driven to a Reliability Driven.  Ensure that EQUATE Assets are performing at the levels demanded by our customers.  Change the culture to promote “Data” approach vs. “I feel” approach.

EQUATE PETROCHEMICAL COMPANY RCM Project Objectives PPM Evaluation and optimization through:  Implementation of RCM for all operating EQUATE Plant facilities by end of  Update all PPM plans in EQUATE CMMS System with the RCM frequencies and tasks by Year end of  Extract Operator Driven Reliability (ODR) tasks from RCM analysis by end of  Ensure continuous improvement process to sustain RCM after implementation.

EQUATE PETROCHEMICAL COMPANY RCM Project Stages  Project initiated and sponsored by EQUATE Management in January 2004 and started in March  The implementation team Consisted from Maintenance (Core),Operation and Reliability members.  RCM Implementation Phases were:  Data Collection & Criticality Analysis.  Data Analysis.  Frequency Optimization & Task Grouping.  CMMS Update and implementation.  Sustain RCM.  Use of Strategic RCM Turbo and Strategic Resources as support during the project.

EQUATE PETROCHEMICAL COMPANY RCM Analysis Results Discipline Number OfFailure Modes Number of Failure EquipmentStrategy ELECTRICAL1329 CBM 1598 FTM 1689 OTF 1987 INSTRUMENT & ANALYZER 3751 CBM 291 FTM 5945 OTF MECHANICAL1339 CBM 2731 FTM 1898 OTF 2019 Failure Modes Total 30404

EQUATE PETROCHEMICAL COMPANY RCM Project Expectations Types of Equipment Total Equipment Analyzed Average Yearly Man-Hours Before RCM Expected Average Man-Hours After RCMDelta % Mechanical % Electrical % Instrument % Analyzers % Total %

EQUATE PETROCHEMICAL COMPANY ODR-RCM expected Results TaskTotal Number of Rotating Equipment Analyzed614 Total hours for Vibration & Lubrication Checks before RCM 3663 Vibrations & Lube Checks Hours Transferred to ODR after RCM 2462 Total Hours Expected after RCM 1221 ODR RCM Driven Tasks Vibration Readings. Lube level checks and Sampling. Look Feel Listen Tasks.

EQUATE PETROCHEMICAL COMPANY Types of Equipment 3M Average Man-Hours Expected Hrs After RCM Actual Hours Electrical Instrument Analyzers Total Realized Results in 3Monthes 58% Realized

EQUATE PETROCHEMICAL COMPANY DATA, DATA, DATA –Document history in Failure Mode Format not activity Based format. –Educate your maintenance organization on the importance of DATA documentation and mining. –Establish standard format on data gathering, documentation and storage into your CMMS. –Let your CMMS work for you. Reliability Analysis –Distinguish between real failure modes and symptoms. –Root Cause Successes as well as Failures. –Probability, Probability Growth Charting and Reliability Modeling will let the DATA talk. –Listen to the data. Sustain Performance –Integrate your PPM Tools into your work processes to ensure alignment and performance. –Set challenging goals and targets, then Reward achievements. –Measure, Analyze, Improve, control then do it all over again. Lessons Learnt

EQUATE PETROCHEMICAL COMPANY Thank You