On June 28, on the site of the Moscow oil refinery "Gazprom neft", a case conference was held under the title "Practice in application of reliability management methods in Russia". About 100 representatives of the biggest industrial companies took part in the event: Gazpromneft, SIBUR, Severstal, Rosneft, EuroChem, MMK, OMK, etc.
Reliability and risk management was the key topic that today sparks genuine interest of companies who are looking toward production optimization and expense reduction. Though it is quite a fresh topic for the Russian market, a number of companies could share their success stories and findings.
Igor Sergeev, head of reliability team at the technical supervision department of Ryazan Oil Company of OJSC Rosneft, spoke about 4 years of experience in application of reliability management methods and tools. In his report Igor focused on what composes a successful project: processes, people and technologies. Working in these three directions at the same time helps implement reliability methods seamlessly and correctly. Particular attention was paid to integration of equipment walk-down routines with the Meridium platform and development of an integrated system for equipment state indication including integration with the System1 GE for steady-state vibration diagnostics. Among the key results Igor named establishment of a reliability management subdivision, implementation of a single inspection scheme and development of a common equipment state database.
Denis Akhmadeev, production performance manager at SIBUR Holding, told about current progress in implementation of reliability methods and tools at Tomskneftekhim, SIBUR's affiliate. Top priority project objectives were improvement of equipment reliability and safety along with cost reduction. For pilot deployment the RCM, RBI, FMEA, RCA and other methods were chosen. Today, the company has significantly reduced the costs for maintenance of LD polyethylene machines by 34% on the average. For current equipment state monitoring the RCM method is used.
Andrey Zolotov, senior manager at the repair directorate of Severstal Russian Steel division, demonstrated outcomes of enhancement of the maintenance and repair system based on reliability methods: in under two years the number and duration of unplanned downtimes was significantly reduced. The complex project was notable for deep integration of the SAP MRO and Meridium platforms. This allowed to significantly reduce labor intensity during MRO planning. There is no doubt, along with technical improvements, Severstal pays special attention to personnel management and training. "The key to success in reliability projects is people, people, and people again," Andrey comments.
Igor Vostrikov, the chief engineer at the oil refinery directorate of Gazprom-neft, told about a large-scale program on increasing availability of processing facilities. There are three focus areas: increasing plant service life, reducing unplanned downtimes and reducing planned downtime duration. The program for prolonging overhaul periods includes deployment of advanced reliability management systems, replacement of aging equipment and deployment of modern monitoring systems.
The second session was dedicated to practical tools. Meridium representatives, Anton Melnik and Romel Soares, presented new capabilities and the development vector of Meridium software. They pointed out that cooperation with Russian companies helps Meridium fit the product to a specific market and customer's needs, and such conferences provide a great opportunity to receive feedback.
Andrey Kondratyev, GE Digital, told about integrated GE solutions which complement Meridium software and add to business effect from their use.
The last report was presented by Dmitry Skvortsov, development director at Prostoev.NET. In his report, he spoke of the skills necessary for reliability experts, personnel training and corporate organizational structure.
Following the report, a round-table discussion was held and the participants could interrogate speakers and discuss relevant topics face to face. The conference guests note that such events are important and useful for experience sharing and face-to-face communication among professionals.
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Gazpromneft was the organizational sponsor of the event. Media sponsor: Prostoev.NET.