Why Doesn’t a Great Maintenance Process Equal Great Results?

Becht made an interesting observation on maintenance processes after consulting in several facilities — Some of the best results come from organizations with poor maintenance work processes and some organizations with a great work process have poor results. Why is this? The reason is that maintenance results or maintenance value is dependent on more than […]

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Integration Of Integrity Operating Windows Into Process Safety Management

Integrity Operating Windows (IOWs) are an important component of a world class mechanical integrity program. IOWs are not a new concept, as they have been around in different forms for many years. However, due to some recent high-profile industry indictments and with the publication of the first edition of API RP 584 Integrity Operating Windows […]

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Equipment Health is an Investment NOT an Expense

Equipment health is integral in an operating facility to obtain the highest performance; not just for a unit but across the whole plant. Equipment and system reliability is perhaps the most critical element of profitability. History shows that differences in operating expenses between best-in-class refineries and poor performers can be as much as $20-30MM/year  it’s […]

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Fundamentals of Operational Reliability

Introduction Operational reliability is a priority for any process unit facility.  A definition of Reliability is: “The ability of an apparatus, machine, or system to consistently perform its intended or required function or mission, on demand and without degradation or failure.” Reliability is something that owners and operators consider a priority, but achieving stable reliable […]

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Five Reasons Why Your Training Program Will Fail

Good training is something that we know is necessary. In light of Industry’s aging demographics and retiring experience, we need good training to carry us successfully into the future. As technology evolves more quickly and changes almost daily, we need good training to help us to wring the last dollar out of our constant upgrades […]

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Due Diligence – Making Rapid, Accurate Judgements

or  “Kidnapped By My Own Business Team” A number of years ago I worked closely with an Operating Company Business Team and Mergers and Acquisitions group performing due diligence assessments. I often led these assessments and my input on reliability, maintenance, mechanical integrity and inspection was incorporated into a multi discipline team of legal, environmental, […]

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Treat Reliability Like …

This blog outlines ways to think about reliability to help drive a culture of continuous improvement.  It is the fourth in a series of Blogs on improving plant reliability performance through changes in culture, programs, equipment design, maintenance and operation. The principles we applied in implementing successful reliability programs in a number of operating plants […]

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Reliability Program Implementation and High Altitude Climbing – What They Have in Common

This is the third in a series of Blogs on improving plant reliability performance through changes in culture, programs, equipment design, maintenance and operation.   [Click link to review  Making Bad Actor Elimination Programs Work; or the second blog, Reliability Beliefs – Driving Organizational Accountability]    This blog compares experiences in successful high-altitude expedition climbing and the effort to […]

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Are Your Heaters Affecting Your Reliability?

From a process standpoint, your Fired Equipment items are not only some of the most critical but some of the most risky items in day-to-day operations. Add in the presence of open flames and failures can be dramatic.  In today’s refining climate, fired equipment is required to run 4, 5, 6 or even 7 years […]

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Reliability Beliefs – Driving Organizational Accountability

This is the second in a series of Blogs on improving plant reliability performance through improvement in culture, programs and equipment design, maintenance and operation.  This Blog focuses on Reliability Beliefs – a key element in organizational accountability for everyone to do the right thing every time.  Read the first blog in the series – […]

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