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TR-20-09 Inspection and Reliability Evaluation(Kenji-Saito)
TR-20-09 Inspection and Reliability Evaluation(Kenji-Saito)
&
TR-20-09
(Inspection and Reliability Evaluation)
Self-introduction
Introduction of Company and Refinery
1. Inspection and Maintenance of Static Equipment
1.1 Maintenance Activities in Japanese Refineries
1.2 Typical Problems of Static Equipment
1.3 Effective Inspection Method for Static Equipment
1.4 Risk Based Optimization of Maintenance
2. TPM activity
3. Brief information of Toa’s Flexi-coker
Introduction of Company and Refinery
HSSE
PEOPLE
GRM COST
MAX. MIN.
Refinery Location/ capacity
CD Capacity Japan Total 4,834,924 BPSD (28 Refs)
Showa Shell Group 515,000 BPSD ( 3 Refs) (as of Mar. 2009)
Crude processing Share (2007)
Total intake 3,986kBD
SSSKK
Others 12.3%
Japan
10.3%
Energy Idemitsu : 140,000
Nippon
Cosmo Teiseki : 4,724
Oil
12.1% 25.3% Nippon : 145,000
J-Energy : 205,200
Nippon : 250,000
Idemitsu Nippon : 127,000 Kashima : 270,000
13.8% Exxon Idemitsu : 120,000
Mobil Fuji Sodegaura : 192,000 BPSD
16.7% Idemitsu : 220,000
Kyokuto : 175,000
Seibu : 120,000 BPSD
Cosmo : 240,000
Yamaguchi
TonenGeneral : 335,000
Nippon : 340,000
Kyuseki : 160,000
Toa Keihin : 185,000 BPSD
Taiyo : 120,000
Idemitsu : 160,000
Cosmo : 140,000 Cosmo : 175,000
Showa Yokkaichi : 210,000 BPSD
TonenGeneral : 170,000
TonenGeneral : 156,000
Nansei : 100,000
Nippon : 115,000 Cosmo : 80,000
Showa Shell Manufacturing Operational Excellence
Royal Dutch SAUDI Public
Shell Group ARAMCO Shareholders
TOA OIL is a member of the Showa Shell Group, whose primary business is oil refining. The TOA
OIL Group comprises four companies: TOA OIL Co., Ltd., its consolidated subsidiaries (GENEX Co.,
Ltd. and TOA TECS Co., Ltd.), and an affiliate (OHGISHIMA OIL TERMINAL Co., Ltd.). The
Group's primary businesses are oil operations and electric power operations (independent power
production).
Oil Operations and Electric Power Operations
TOA OIL engages in contract refining on the basis of a crude oil contract refining agreement with
Showa Shell Sekiyu K.K. Specifically, TOA OIL receives crude oil and feedstock from Showa Shell
Sekiyu, processes them into various oil products, and delivers the finished products to Showa Shell
Sekiyu. Showa Shell Sekiyu sells the finished products to consumers, and TOA OIL receives
processing charges (for refining costs).
We also supply fuel and other resources for GENEX Co., Ltd., which is in IPP business.
Organization of TOA OIL CO.,LTD
Chairman President
Executive
Director
Director
4 29 6 8 1 434
Audit Keihin Refinery
Corporate
Ethic Personnel
Planning Finance HSSE
Compliance Admin.
Oct.1 , 2009
TOA OIL CO, Ltd. has Keihin Refinery
LPG
PP SPLITTER PROPYLENE
NAPHTHA HYDROTREATER NAPHTHA ISOSIEVE
(4,150)
(17,000) (6,000) MO-GAS
SOLVENT
CRUDE PLATFORMER MO-GAS
(8,500)
DISTIL-
Crude KERO-HDS / LGO HDS KERO/DGO
LATION
(15,000/20,000)
(65,000) FCC
VACUUM DISTILLATION VGO HDS
(58,000) (46,000) (42,000) MO-GAS
5 10 59 53 178 127
Environment Manufacturing
Engineering Mizue Ogimachi
H.R Cultivation & Safety Control
& Division Factory Factory
Division Division
Enhancement
Business Efficiency Purchasing/Contracting Technology Ope. Sec-1 Ope. Sec-4
Oct.1 , 2009
1. Inspection and Maintenance of Static Equipment
Contents
Makers/Manufactures/ Fabricators
・Tower/Vessel/Heat exchanger/Piping
Pump/Turbine/Mortar
・Steel Makers/others
Engineering company
Institutes
Contractors
Maintenance Management Tools
Extensive knowledge
System/Products/Equipments Effective RCM
Reliability MTTR
(Mean Time To Repair)
Maintainability Failure Rate
(Number/Time)
Components
Reliability Centered Maintenance (RCM)
What is “ RBI ” ?
RBI must systematically evaluate both the probability of
failure and the associated consequence of failure.
Key elements
■ Assessment of Failure Probability for Equipment (Leakage)
■ Consequence Assessment (Fire; Toxic; Environment; Economical) for
Equipment.
■ Risk Assessment
How to implement
■ RBI is focused on maintaining the mechanical integrity of process
equipment items and minimizing the risk of loss of containment due to
deterioration such as pin-hole, crack ,and rupture.
Instrument and Control / Electrical/ Structural/ Machinery components are not covered
We can get
What is TPM
Total Productive Maintenance (TPM) was introduced to Japan in 1971.
The goal of the TPM program is to markedly increase production while at the
same time, increasing employee morale and job satisfaction.
Why TPM ?
TPM was introduced to achieve the following objectives.
•Avoid wastage in a quickly changing economic environment.
•Producing goods without reducing product quality. Loss
•Reduce cost. Elimination
•Produce a low batch quantity at the earliest possible time.
•Goods sent to the customers must be non defective.
Main Losses of Unit Operation
Loss by Planned Maintenance
Loss by Re-processing
Activity Missions of TPM
1. Individual Improvement for a Greater Equipment Efficiency
Model equipment is selected and improved to its ultimate efficiency by eliminating interference (e.g. unplanned Shut down);
5. Creation of Initial Control System for New Products and New Equipment
Products easy to manufacture and equipment easy to operate are investigated by receiving all feed back information
2009 Mizue Factory T/A Maintenance Safty Activities Daily Schdule Original 2009,02,04
3 Me e tin g Everyday 7:45~8:00 Accident Prevention Committee Ope1 Before LCG Holder TOA Involve:4/7~5/5
*Stre tc h in g Exe rc ise Ope2 No-219 Road TOA Involve:4/8~5/2
*Sho rt No tic e Fo r Safty Ope3 Before Control Room TOA Involve:4/9~4/30
* 〃 Sa fty Commitee Genex Before Temporary Huose TOA & Genex Involve
*Safty Spee c h Plant Owner / Contractor : 4/7~5/2
4 To ol B ox Me etin g( KY K) Everyday 8:00~ Each contractor and/or Group
5 En te rin g Edu c atio n (Wo rke r) ・8:40~ Safty Foreman Quality Control Building 3F 教育依頼者多数の場合には
・13:15~ 9:20~の1回を追加
6 Risk An alysis Me e ting everyday 9:15~10:20 Engineering/operation/HSSE/Technical FCC Area Temporaly House 2F Period: 4/6~5/2
8 TOA Safty Che c k Patro l Everday HSSE/Engineering/Operation Ope1 Safty Patrol & Record the result 4/7~5/5
13:15-14:00 Ope2 ,input them to PC 4/8~5/2
Ope3 4/9~4/30
Genex 4/7~5/2
9 To a Re gu lar Me e tin g Everyday TOA HSSE/Engineering/Operation/ Ope1 Meeting Room of Accident.P.C
15:00-15:20 Technical/Others Ope2 Temporary House near Ope2
And Contractor/Accident Prevention Ope3 Temporary House near Ope3
Committee Genex Temporary Hpuse near Genex
Corporate adviser
Chairman Toa Oil Keihin Refinery
Chiyodakosho(Main contractor) Refinery Manader
Mr. Takahashi Deputy Refinery Manager
Vice-Chairman Engineering Dep. Manager
Shinko Plantech HSSE Dep. Manager
Mr. Sakai
Secretariat
Chiyodakosho
Mr.Koichi Yokoyama
FLG/LE Area NIP.FLS/SR/BOI Area INT/PV Area FCC Area Instrument Inspection Electrocity
Representative Representative Representative Representative Representative Representative Representative
Chiyodakosho Nippon Express Shinko Plantech NS Engineering Sanko Nippon .Inspection Fuji Electric
Mr. Arai Mr. Narita Mr. Isa Mr. Kawai Mr. Yonezawa Mr.Koda Mr. Okuno
資料 -⑥-2
Prohibited Matter
平成 20 年 5月 3日
東亜石油㈱京浜製油所水江工場 平成20年度触媒更新工事
災 害 防 止 協 議 会
NO.20 承認 作成
1.An unqualified person must not carry out the work that
昨日(5/2)は午後より一斉清掃に、全員参加でご協力頂き有難うございました。日頃から綺麗な aqualification needs
現場が、廃棄物の分類もしっかりと守られ、より一層綺麗になりました。この綺麗な環境を、
一仕事・一片付けを実施し継続して頂くようお願い致します。
2. Reason A certain person was unqualified and opereted a forklift and
1 .災防協 からの 連 絡事項
caused an accident
1)昨日(5/2)は予定通り第3回合同パトロールが実施されました。パトロール開始前に各元請
事業者対象の研修会が実施され、「俺たちの安全、災害から自分を守る為に!」のビ 3. Example When the person carried out a load with a forklift, he have
デオが放映されました。その内容要旨をお伝えします。
broken a shutter at the upper part of the forklift.
➀ 自分の安全を守る為にはどうするか?
1 自分の安全を他人に頼るな!
2 現場には様ざまな危険がある事を、自分で気づく事。
3 現場になれると、危険を危険と思わなくなる。
4 作業手順を理解する事。 4. Illustration
災害に遭ってから後悔しても遅い。災害は時も、人も、場所も選ばない! Hey!Kid Don't Get on with no license
自分の安全は、自分で守る事!
2))昨日(5/2) の合同パトロールの中で、入槽作業で、入槽管理板(入槽許可証と入槽禁止札)
の、使用方法が徹底されていない箇所があるとの指摘が有りました。徹底願います。 Ha-ha Very
easy ,esay!
入槽管理はまず測定、入槽時は緑札、
R-1
承認 検討 作成
マーク 改訂内容 日付 承認 検討 作成
統括安全衛生管理 重点目標・ スローガン 及び 重点推進項目
※顧客安全衛生管理重点目標 ※統括安全衛生管理重点目標 ※統括スローガン ※統括安全衛生重点推進項目
3月 4月 5月 6月
期 間 17 31 1 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 1
月 月 火 土 日 月 火 水 木 金 土 日 月 火 水 木 金 土 日 月 火 水 木 金 土 日 月 火 水 木 金 土 日 月 火 水 木 金 土 日 月 火 水 木 金 土 日 月 火 水 木 金 土 日
1課 工事期間(39日間)
(FLG)
工事期間(21日間)
顧 (FLS)
客 工事期間(31日間)
基 (NIP)
本 工事期間(17日間)
工 (BOI)
程 2課 PV INT 工事期間(24日間)
INT/PV
3課 工事期間(21日間)
(FCC)
Scaffolding
1.足場工事 Insulation
Insulation
2.保温耐火工事 3.塗装工事 Coating
Coating 4.機器開放工事Dismantle Cleaning
5.機器配管清掃工事 Re-Assembling
6.機器復旧工事 Blind Plate
7.仕切板挿入撤去工事 Valve/Instrument
8.弁&計装機器脱着工事 9.補修工事 Hot Work 10.配管工事 Piping 11.検査工事Inspection Human Error
12.ヒューマンエラー
■交通災害 ■交通災害 ■交通災害 ■交通災害 ■交通災害 ■交通災害 ■交通災害 ■交通災害 ■交通災害 ■交通災害 ■交通災害 ■教育不足・経験不足
■墜落災害 ■墜落災害 ■墜落災害 ■墜落災害 ■墜落災害 ■墜落災害 ■墜落災害 ■墜落災害 ■墜落災害 ■墜落災害 ■墜落災害 ・未熟練・無知
業 種 別 ■重機災害 ■重機災害 ■重機災害 □重機災害 ■重機災害 ■重機災害 ■重機災害 ■重機災害 ■重機災害 ■重機災害 □重機災害 ■慣れ、危険軽視、
□火気使用による災害 □火気使用による災害 □火気使用による災害 □火気使用による災害 □火気使用による災害 □火気使用による災害 ■火気使用による災害 ■火気使用による災害 ■火気使用による災害 ■火気使用による災害 ■火気使用による災害 集団欠陥、うっかり、
Predicted
予想される ■酸欠災害 □酸欠災害 □酸欠災害 ■酸欠災害 ■酸欠災害 ■酸欠災害 □酸欠災害 □酸欠災害 ■酸欠災害 □酸欠災害 ■酸欠災害 悪習慣、ぼんやり
Incident □感電事故等の災害 □感電事故等の災害 □感電事故等の災害 ■感電事故等の災害 ■感電事故等の災害 ■感電事故等の災害 □感電事故等の災害 □感電事故等の災害 ■感電事故等の災害 ■感電事故等の災害 ■感電事故等の災害 ■近道、省略、能率本能
災 害 □残圧&残油による災害 □残圧&残油による災害 □残圧&残油による災害 ■残圧&残油による災害 □残圧&残油による災害 ■残圧&残油による災害 ■残圧&残油による災害 ■残圧&残油による災害 ■残圧&残油による災害 ■残圧&残油による災害 □残圧&残油による災害 ■場面行動…一点に集
□危険&有害物質による □危険&有害物質による □危険&有害物質による ■危険&有害物質による ■危険&有害物質による ■危険&有害物質による ■危険&有害物質による ■危険&有害物質による ■危険&有害物質による ■危険&有害物質による ■危険&有害物質による 中し廻りが見えない
災害 災害 災害 災害 災害 災害 災害 災害 災害 災害 災害 ■錯覚
□耐圧試験&高圧JET時の □耐圧試験&高圧JET時の □耐圧試験&高圧JET時の □耐圧試験&高圧JET時の ■耐圧試験&高圧JET時の ■耐圧試験&高圧JET時の □耐圧試験&高圧JET時の □耐圧試験&高圧JET時の ■耐圧試験&高圧JET時の □耐圧試験&高圧JET時の □耐圧試験&高圧JET時の ■機能低下、疾病、
■:該当項目 災害 災害 災害 災害 災害 災害 災害 災害 災害 災害 災害 疲労、体質
■標識不備による災害 ■標識不備による災害 ■標識不備による災害 ■標識不備による災害 ■標識不備による災害 ■標識不備による災害 ■標識不備による災害 ■標識不備による災害 ■標識不備による災害 ■標識不備による災害 ■標識不備による災害 ■意識レベルの低下
■保護具未使用による ■保護具未使用による ■保護具未使用による ■保護具未使用による ■保護具未使用による ■保護具未使用による ■保護具未使用による ■保護具未使用による ■保護具未使用による ■保護具未使用による ■保護具未使用による ■緊急時のパニック
災害 災害 災害 災害 災害 災害 災害 災害 災害 災害 災害
■無資格作業による災害 ■無資格作業による災害 ■無資格作業による災害 ■無資格作業による災害 ■無資格作業による災害 ■無資格作業による災害 ■無資格作業による災害 ■無資格作業による災害 ■無資格作業による災害 ■無資格作業による災害 ■無資格作業による災害
1.交通災害の防止 2.墜落災害防止 3.重機災害防止 4.火気使用による 5.酸欠災害防止 6.感電事故等の災害防止 7.残圧&残油による 8.危険&有害物質による 9.耐圧試験&高圧JET時の 10.標識の活用 11.資格者作業 12..ヒューマンエラーによる
①法定速度遵守 ①安全教育の実施 ①安全教育の実施 災害防止 ①安全教育の実施 ①安全教育の実施 災害の防止 災害の防止 災害防止 ①立入禁止 ①玉掛 災害の防止
②構内速度遵守 ②KYKの実施 ②KYKの実施 ①安全教育の実施 ②KYKの実施 ②KYKの実施 ①安全教育の実施 ①安全教育の実施 ①安全教育の実施 ②開口部注意 ②足場 ①事前教育
③免許証の確認 ③TBMの実施 ③TBMの実施 ②KYKの実施 ③TBMの実施 ③TBMの実施 ②KYKの実施 ②KYKの実施 ②KYKの実施 ③頭上注意・危険 ③溶接 ②フォローアップ教育
予想される ④保険等の確認 ④作業場の巡視 ④作業場の巡視 ③TBMの実施 ④作業場の巡視 ④作業場の巡視 ③TBMの実施 ③TBMの実施 ③TBMの実施 ④高所作業中 ④クレーン ③唱和による意識高揚
Counter ⑤通門証の確認 ⑤機工具の点検 ⑤機工具の点検 ④作業場の巡視 ⑤機工具の点検 ⑤電動工具の点検 ④作業場の巡視 ④作業場の巡視 ④作業場の巡視 ⑤入槽作業 ⑤ユニック ④掲示板等の啓蒙活動
災 害 の ⑥指定場所の駐車 ⑥足場の確認 ⑥車輌始業前点検 ⑤機工具の点検 ⑥内部環境の確認 ⑥許可機器の使用 ⑤機工具の点検 ⑤機工具の点検 ⑤機工具の点検 ⑥耐圧試験中 ⑥フォークリフト ⑤標語等の啓蒙活動
measures ⑦指定場所の駐輪 ⑦昇降設備の確認 ⑦立入禁止措置 ⑥逆火防止器設置の確認 ⑦酸素濃度の測定確認 ⑦アースの設置 ⑥残圧の確認 ⑥火源となるものを ⑥検査済の圧力計の使用 ⑦建設機械 ⑥報連相の励行
対 策 ⑧消化器の携帯 ⑧手摺の確認 ⑧作業半径の確認 ⑦ホース&ジョイント部漏れ確認 ⑧有毒ガスの測定確認 ⑧活線作業の禁止 ⑦残油の確認 近づけない ⑦加昇圧の禁止 11.保護具適切使用 ⑧有機溶剤 ⑦現場の確認
⑨マフラーにスパノンの取付 ⑨開口部の処理 ⑨吊り位置の確認 ⑧ガス検知 ⑨監視人の配置 ⑨タコ足配線の禁止 ⑧風下作業は極力さける ⑦防爆機器の使用 ⑧監視人の配置 ①保護具の点検 ⑨ボイラー整備士 ⑧現場指示の励行
⑩危険地区の乗入禁止 ⑩安全帯の使用 ⑩アウトリガーの確認 ⑨ピットシールの確認 ⑩強制換気の実施 ⑩漏電遮断器のテスト ⑨保護具の使用 ⑧風下作業は極力さける ⑨合図の確認 ②安全帯 ⑩各種NDI ⑨現物の確認
⑪無免許運転の厳禁 ⑪上下作業の確認 ⑪地盤の確認 ⑩パージの確認 ⑪内部との連絡法の取決 ⑪雨天時の保護養生 ⑩周囲の確認 ⑨保護具の使用 ⑩ホース、ジョイント部漏れ確認 ③防塵メガネ ⑩現物指示の励行
⑫飲酒運転の厳禁 ⑫監視人の配置 ⑫合図者,監視人 ⑪消火器の設置 ⑫避難方法の取決 ⑫行先表示の確認 ⑪整理整頓清掃の励行 ⑪保護養生 ⑪保護具の使用 ④防塵マスク ⑩指差呼称の実施
⑬構内交通ルールの厳守 ⑬物体投下の禁止 ⑬周囲の確認 ⑫火花飛散防止養生 ⑬人員の確認 ⑬取扱責任者標示の確認 ⑭立入禁止措置 ⑫通路横断部のホース養生 ⑤手袋 ⑪TBM/KYKの実施
⑭左右・前後の確認 ⑭周囲の確認 ⑭往来ロープの設置 ⑭立入禁止措置 ⑭入槽札の使用確認 ⑭接続部の確認 ⑩周囲の確認 ⑬立入禁止措置 ⑥エアーラインマスク ⑫チェックリストの活用
⑮安全通路の歩行 ⑮昇降時の手荷物禁止 ⑮ユニック車の警告灯 ⑭散水の実施 ⑮整理整頓清掃の励行 ⑮通路横断部ケーブル保護 ⑪整理整頓清掃の励行 ⑭周囲の確認 ⑦バックアップシステム
Inspection ⑬作業手順書の活用
⑯工具袋及び箱の使用 確認 ⑮周辺の可燃物撤去 ⑯通路の確保 ⑯周囲の確認 ⑮整理整頓清掃の励行 ⑧ライフゼム ⑭健康診断書確認
⑰整理整頓清掃の励行 ⑯ユニック車の警報 ⑯退場時火元確認 ⑰保護具の着用 ⑰整理整頓清掃の励行 ⑯通路の確保 ⑮監督者評価表の活用
⑱通路の確保 設備確認 ⑰整理整頓清掃の励行 ⑱酸欠標示板の掲示 ⑱通路の確保 ⑯イエローカード制の導入
3月 4月 5月 6月
期 間 17 31 1 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 1
月 月 火 土 日 月 火 水 木 金 土 日 月 火 水 木 金 土 日 月 火 水 木 金 土 日 月 火 水 木 金 土 日 月 火 水 木 金 土 日 月 火 水 木 金 土 日 月 火 水 木 金 土 日
朝
安全 礼
朝礼会 朝礼会 朝礼会 朝礼会 朝礼会 朝礼会 朝礼会 朝礼会 朝礼会 朝礼会 朝礼会 朝礼会 朝礼会 朝礼会 朝礼会 朝礼会 朝礼会 朝礼会 朝礼会 朝礼会 朝礼会 朝礼会 朝礼会 朝礼会 朝礼会 朝礼会 朝礼会 朝礼会 朝礼会 朝礼会 朝礼会 朝礼会 朝礼会 朝礼会 朝礼会 朝礼会 朝礼会 朝礼会 朝礼会 朝礼会 朝礼会 朝礼会 朝礼会 朝礼会 朝礼会 朝礼会 朝礼会 朝礼会 朝礼会
行 事 対策 会 ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・
会議 ・
安全 安全 安全 安全 安全 合同 安全 安全 安全 安全 安全 安全 合同 安全 安全 安全 安全 安全 安全 合同 安全 安全 安全 安全 安全 安全 合同 安全 安全 安全 安全 安全 安全 合同 安全 安全 安全 安全 安全 安全 合同 安全 安全 安全 安全 安全 安全 安全 安全
パ
(客先) 13:00 パトロール パトロール パトロール パトロール パトロール パトロール パトロール パトロール パトロール パトロール パトロール パトロール パトロール パトロール パトロール パトロール パトロール パトロール パトロール パトロール パトロール パトロール パトロール パトロール パトロール パトロール パトロール パトロール パトロール パトロール パトロール パトロール パトロール パトロール パトロール パトロール パトロール パトロール パトロール パトロール ハ ゚トロール パトロール パトロール パトロール パトロール パトロール パトロール パトロール パトロール
~
ト
ロ
ー
・ ・ . ・ . ・ ・ ・ ・
14:30 ル 一斉 一斉 安全 一斉 一斉 一斉 一斉 一斉
清掃 清掃 大会 清掃 清掃 清掃 清掃 清掃
安 未定
発 全 自
行 事 足 反
祈 主
会 - 省 元
願 災 パ
(災防協) 会
防 ト
請
15:00 祭 解 各
~
協 ロ
ー
散 社
式
17:00 ル
電気 電気 火気 電気 火気 火気 3S 3S 足場 足場 重機 重機 酸欠 酸欠 電気 電気 火気 火気 3S 3S 足場 足場 3S 3S 3S 3S 足場 足場 3S 3S 足場 足場 3S 3S 足場 ユニ ユニ 保護 足場 保護 3S 3S 足場 足場 3S 3S 足場 ユニ 保護 3S 3S 足場
点検重点項目
点検 点検 点検 点検 点検 点検 点検 点検 点検 点検 点検 点検 点検 点検 点検 点検 点検 点検 点検 点検 点検 点検 点検 点検 点検 点検 点検 点検 点検 点検 点検 点検 点検 点検 点検 ック ック 具 点検 具 点検 点検 点検 点検 点検 点検 点検 ック 具 点検 点検 点検
備 考
Safety Activity in Refinery
1. Safety Ceremony
2. 5S is the first step of safety activity
3. The information tells to be plain and surely
4. Emphasize existence of the safety patrol corps
5. The division indication is plain
6. The work in the furnace arrange a watchperson
7. Life is kept by a small device
8. The device improves by work efficiency
9. The bad smell is one of the pollution, too
10. The safe confirmation use plural eyes
1
1. Wish for a Safety (Shinto Ceremony)
2 5S (Seiri Seitone Seisou Seiketsu Shituke)
Holding a high “able to eat off the floor” standard for work site
Seiketsu 清潔 せいけつ cleanliness and organization, the fourth S of 5S, original
meaning in Japanese is “sanitize”
Maintaining strict discipline in the work site so that all rules and
procedures defined by the first, second, third, fourth S’s are
Shitsuke 躾 しつけ followed until they are improved, the fifth S of 5S,original
meaning in Japanese is “discipline”
3 Safety Management with the use of board
Liquefied N2 tanker & vaporizer Liquid soap & Oiler OFF-Limit & Under-pressurizing
Plate anchor
7 Measure for Safety and Security (1)
DO NOT ENTER !
Protective Clothing
Worker is protected from heat and Fine-coke
dust by the suit.
Plant-air is introduced into the suit from top,
so it is kept cool and prevented entering coke.
9 TOA use the Steam Header for Reducing Stench
Seal Nozzle
Thermometer
Oily Pit-manhole
10
Seal Gas Check Incombustible Sheet & sandbag
Plant Reliability
Maintenance Cost
Maintenance Planning Process
PU1 PU2 PU3 OM
Production Unit 6 3 7 5
Work Request
-Operator- Each PUs raise many WR every day.
NO. of WR is fluctuate every day.
Mobilisation
Labour
Required NO. of Contractor Labour(Max.)
Execution
Yearly plan
Apr-1 Apr-2 Apr-3 Apr-4 May-1 May-2 May-3 May-4 Jun-1 Jun-2 Jun-3 Jun-4
3 months plan
Day1 Day2 Day3 Day4 Day5 Day6 Day7 Day8 Day9 Day10 Day11 Day12 Day13 Day14
2 weeks plan
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24
Daily plan
Mobilisation
Labour
Required NO. of Contractor Labour(Max.)
Time
To be assigned contractor labour permanently.
Constant labour mobilisation
30
Fat-Rat Study
Progress monitoring
•Addenda work management
Number
Date
SDM Work Flow
SDM should be planned before 18 month of next T/A.
Result Data
Planed Inspection
Data
18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 1 2
0
C&P Strategy Definition *Starting Preliminary Discussion with Selected Contractors
*S/D Kick-off Meeting
1
Long Term Business Plan
*Premises Definition Finalized
*30% Cost Estimate
2 *KPI's Definition
S/D Preliminary Development
*Net Work Planning Completed
*10% Cost Estimate
*Job List and S/D Duration Challenging
3
S/D Work Development *Main Job List Frozen
*Bidding Contract Package Finalized
*Contract Awarded
*Planning, Scheduling
4 and Optimisation
S/D Detailed Planning *Final Approved S/D Scheduling
5
Pre S/D Work *Final Pre-S/D Meeting
6
*S/D Start
S/D Execution
*Safety Induction Course
7
Post S/D Review *Joint Final Report
Priority H M L L:Reflected
Setting 14days
scheduling
CONSEQUENCE PROBABILITY
Likely in Several
Likely in
People Assets Environment Reputation A Improbable B Possible C D next 1-2 E times per
next 10 yrs
years year
No No No
No impact 0
injury loss Effect
Limited
L
Lost time loss Minor Limited
accident effect impact 2
(<10MY)
Considerable
Permanent loss Localized Considerable
3
Disability
(<100MY)
Effect impact
M
Major
Single loss Major Major
4
Fatality Effect National
(<1BY)
Multiple
Massive
loss Massive Major
H
5
Fatality Effect International
(>1BY)
Trouble Experience
in Japan
◆ Burst of Hot Condensate Water Pipe
Maintenance Information
HP Turbine
S.W
Condensate Condenser
Vaporizer
HP FW
Deaerator S.W
Preheater
Desalter
Fuel Grand condenser
←BF W
Pressure Vessel
Coolant Pump
Burst
LP FW
Preheater S.W : Sea Water
BFW : Boiler Feed Water
Burst piping Simple Drawing
Support
Orifice
Support
Orifice
Flow Welding
Line
Flow
Burst piping (Cont. : Possible Cause)
Turbulence
Reduced
to 340 mm
I.D.
540 mm
Orifice
Other Information (1/2)
B E H
C F I
Representative Inspection (2/3)
Representative Inspection (3/3)
肉厚トレンドによる測定点変更
Digital Micro Scoop Result on Pipe Inside
Top
3D 1/2D
1D
Bt’m
◆ Rupture of Furnace Tube
Temp
Press Reactor
Flow Control
RT Coking ○ - ○ - - ○*
Sensitization Sensitization ○ - ○ - - -
Metallographic Metallurgical
Tube ○ - ○ - - ○
Test structure
UT Thickness ○ ○ ○ ○ ○ ○
PT Surface flaw ○ - ○ - ○ ○
Bricks VT Damage ○ ○ ○ ○ ○ ○
Other VT Bending - - - ○ ○ ○
* Decoking : The lowest of No.1/4 coils by pig @2000 (after 16 years operation)
Other Information (2/2)
Result of investigation after accident
Tube Material
Good (VT, Dimensions, Macro-/Micro-structure, Hardness,
Chemical Composition)
Welding Line
Good (Macro-/Micro-structure)
Flow rate of A/B pass
Not Good A=11,500 – 12,500 B/D
(Unbalance) B=15,000 B/D
Burner
Not Good (The amount of combustion of the burner had been
biased to the center.)
Coking
Not Good (Coking was partly found.)
Root Cause Analysis
Direct Cause Creep Damage
Why Creep Damage occurred ?
Biased combustion operation of furnace
Rise of heating tube surface temperature
Why Temp. rose ?
Form coking in the Tube
Why Mainte. Staff could not find coking ?
Formation of coking
in place not expected
1.3 Effective Inspection Method
for Static Equipment
Inspection Area of Static Equipment
Inspection Method
VT (visual test), UT (ultrasonic thickness
test), RT (radiographic test)
Inspection Schedule
The inspection is advanced from installation
year's old device one by one.
Example of Inspection Result
Corrosion control
Rust resisting painting under insulation
Aluminizing of anchor bolt
Attach of reinforcement plate
Cl‐ concentration limitation of insulation
material(≦500ppm )
TIPICAL DAMAGES OF R-HDS REACTOR
by UT, ( PT )
by MT, PT, ( UT )
by MT, PT, UT
(3) Skirt Attachment with
Skirt Band
by MT, PT
by MT, PT
(5) Catalyst Retaining Ring
Attachments
( Fillet Weld )
by UT, ( MT, PT )
by UT, ( MT, PT )
(6) Circumference Welds
between Cylindrical shell
and Head
( Butt Joint )
by UT
(12) Clad
( Base and Clad Material )
by UT
1.4 Risk Based Optimization of Maintenance
◆ Quantification
• Degree of consequence can be relatively easy. In general the consequences are divided into
categories from 4 to 5 like the Risk Matrix refer to RAM application after page 4.
• Exposure coefficient is simple and easy, because the plants are operated continuously for
24 hours, it is 1.0 namely 100%. But In start-up and shut-down, there may be some
exceptional cases.
Table-2 The example of the risks different by the situation of the plant
Europe/America Japan
Threats The small fire of the heat insulator ⇒
Likelihood Possible ⇒
Exposure Continuous ⇒
Damage of the heat insulator $1,000
Consequence Damage of the heat insulator $1,000
Damage of plant Shutdown $1.0MM
Risk Low Extremely High
The same threat brings different degree of consequences by the situation of the plant.
According to the risk analysis at a certain place, the degree of risk becomes low so it can
not be accepted, but another place, it can be accepted .
Under the same scenario, but those risks should be managed by different methods.
Risk Assessment Example
The corrosion problem in top-section of distillation tower
and its countermeasure
◆ The Outline of Damage
Although the corrosion problems are not urgent, the leakage to the outside might
happen during the next operating period.
The leakage becomes the threat to the goal which is the prevention of the unexpected
plant shutdown during the next operating period.
The inspection section made a request to replace the whole distillation column for
new one during T/A maintenance.
If nothing would be carried out during T/A maintenance, the possibility of problem
was estimated to 30% during next operation. This estimation was based on increasing
corrosion rate of tower top section.
The evaluation result agrees with the key-word that the possibility is lower than
“toss-up” , higher than “unlikely”
◆ The Exposure
The distillation column is continuously operated , so the exposure coefficient is
The above alternative plans affect only the possibility of the threats by risk calculation.
But, in the calculation, the influence of Exposure and Consequence should also be considered,
We make the dike around the tank to prevent the liquid diffusion that leaks out of it. As a
result exposure and possibility will not be affected but consequence will be affected.
◆ The J-Factor
We call the state which takes no measures the “alternative plan zero”. Alternative plan-0
is used as a standard to rank other plans.
Here, below J-factor is defined. J-Factor is used to evaluate the risk reduced by
executing Alternative plan and its cost.
◆ The team decides “the must items” and “the want items”
The team decides the three items which must be achieved.
1. Avoid the catastrophic HSE accident.
2. Repair within less than 8 days.
3.Avoid the leak to the outside all over the next operating period.
• The “Want items ” are evaluated by the scales from (-5) to (+5) .
(+5) means that they completely satisfy the requested item. ( 0 ) means that they can not
replace with the present conditions. (-5) means a minus effect.
• Example
The “Want item:No-2 The smallest cost of repairing.” is scored as seen in Table-3-a.
Plan-0(Do nothing) is the highest score(5), because “ Do nothing ” means that it costs
nothing. So it is the most efficient for a cost effectiveness. Plan-1(On line monitoring)
is score(4).
Plan-2, Plan-3, Plan-4 include capital expense of different level, so their score are as seen
table-3-b
Table-3-a Scoring of Repairing Cost
Plan Plan-0 Plan-1 Plan-2 Plan-3 Plan-4
Repairing cost 0 20M$ 1000M$ 750M$ 600M$
Score 5 4 -5 -3 -2
Countermeasure of Plan-4 is the cladding of the top section. This method require long
periods of time. The repair work can’t be finished in 8days, so it is inevitable that plan-4
infects minus effect to the T/A maintenance.
◆ Decision Making Matrix
The “Must items” are sorted every alternative plans into category “ Yes=Y ” or “ No=N ”.
The “Want items” are scored with respect to each alternative plan.
Score = Scale × Importance factor
Table-4 Decision Making Matrix
Decision Making Matrix Plan-0 Plan-1 Plan-2 Plan-3 Plan-4
Avoid a catastrophic HSE accident. N Y Y Y Y
Must
Deregulation
Change Demand Flooding of Activity Non-sink ship mind
Over Capacity Aging / Skill tradition Sectional Barriers
Conventional method
Cost/Profit is fixed amount guarantee
Current method
Profit security is a self-responsibility
Deregulation Process in Japan’s Oil Industry
1962 Petroleum Industry Law
1976 Petroleum Reserve Law (Oil Stockpiling)
Deregulation
1986 Specific Law on the Import of Petroleum Products
(Importers have to fulfill the following conditions : Refining, Stockpiling and
Quality Adjustment for Gasoline, Kerosene & Gas Oil)
1987 Automatic Approval of Secondary Unit
1989 Gasoline Production Quota Abolished
1990 Service Station Construction & Conversion Abolished
1992 Crude Throughput Quota Abolished
1996 Specific Law Abolished : Free Product Import
(Re-regulated Law : Product Stockpiling Obligation, Product Quality Control)
1997 Free Product Export
1998 Introduction of Self-Serve Service Stations
2001 Overall Review : Petroleum Industry Law abolished
Trend of Oil Demand Ratio in Japan
Heavy Fuel Oil Light Fuel Oil Diesel Gas Oil Kerosene Jet Fuel Naphtha Gasoline
100%
17 21 Gasoline 25.5
24.0 25.9 27.1 27
80% 13
Oil Dem and Ratio
1 15
19.6 Kerosene 15.0
11 2 20.7 22.4 22.2
60% 12 1.9
10 2.1 Gas Oil 17.5
12.3 2.4 2.7
10 11.8 10.4
18 10.9
40%
17.2 16.1 16.4 16.3 ABTM 41.8
12
20% 38 12.1 12.3 9.8
10.7
20
12.9 11.2 10.1 11.6
0% A/L Crude
1980 1990 2000 2004 2006 2007
Heavy fuel oil demand has been decreasing continuously,
Because 1. Power Generation Industry converted fuel from oil to natural gas
and 2. Steel Manufacturing Industry is decreasing its production
due to the disadvantageous competition.
Trend of Distillation Capacity and Crude oil throughput of Japan
5000
Topper Capacity
4000
3000
Crude oil
Throughput
2000
90% Deregulation
80%
77.4% ‘73 1st step 2nd step
70%
60%
50% 1st Oil crisis 2nd Oil crisis 3rd Oil crisis
40%
30%
20%
10%
0%
1965 1970 1975 1980 1985 1990 1995 2000 2005
Merge
ZA(Zero Accident) Goal : Excellent Company
Special-Committee Tool : TPM
・5S (Total Productive Maintenance)
5S ・Autonomous Maintenance
Skill-Up(Operater/Engineer) ・Safety
Enhancement(Plant Engineering) ・Kaizen(Improvement)
TO
Standardization A
TPM
Part Ⅰ
Outline of TOA TPM-activity
Pre-Ezamination 11
Declaration 1/7
Kick-off 6/11
Final-Audit
TPM Award
Staff
MBO Manage. Model Autonomous Maintenace by Operators
(Autonomous Model
Development to operetor 0-step ~ 3rd-step 1st-step ~ 4th-step 4th-step ~ 7th-step
Maintenace)
BPR
Model Office-Work Process Restructuring
(Office-Work) Develo. 2nd~4th step Development 5th ~ 6th step Development
Scoring
•Swift Review & Feedback Evaluation
Ranking
Maintenance By Operator:MBO
• Objective
- Encourage operators’ “my plant consciousness”
+ Overhaul pumps
+ Detect disorder of pumps and examine a root cause
+ Make various improvements
- Improve Equipment Reliability
(“Zero” unplanned plant shutdown)
• Progress
Trend of MBO Activity
Pieces
Overhaul
Office Work Activity:J-TPM(1)
• Objective
- Keep the office clean/tidy
- Reduce document volume (-50%)
- Streamline work process :BPR(-50%)
• Progress
Before After
Office Work Activity: J-TPM(2)
• Objective
- Keep the office clean/tidy
- Reduce document volume (-50%)
- Streamline work process :BPR(-50%)
Progress
Document Volume Electronic File Volume
FM
74 0 MB 44,600
800
45,000
40,000
600 Hit
35,000
400 32 2 300 30,000 27,000
22,300
25,000
200
20,000
0 15,000
2002 current 2005Target 2002 current 2005Target
TPM, do you imagine
how to lead what kind of activity?
What method pushing forward TPM ?
Under the nine major pillars and consulting with JIPM ,
we carried out TPM activity.
Prev.-Maint.
Profit-MAX
TPM-in Office
Autono.- Maint.
Education-Skill
Cost-MIN
Design-Manag.
Quality-Maneg.
role
HSSE
m Committee
a
t
Division r
i
x
Personnel
General
Accounting
Financial
Production
Control
Engineering
HSSE
Mizue Fact.
Ogimachi Fact.
◎ : Lead Division
Model activity by managerial class
Autonomous maintenance become the basics in TPM.
We carried out “Model activity of autonomous maintenance by
the managerial class, before introducing them into a worksite.
1,000
800
643
600 471
386
400 273
222
143
200 56 87
13 30
0
’02/5 ’04/8 2005/8
Visible Result of the activity that We can expect
Reinforcement of the competitive power
•Increase in equipment productivity. (Reducing troubles of equipments)
•Loweing maintenance and production costs.
•Keeping good quality
•Eliminating bottleneck of process.
•Increasing equipment availability. (Increase plant capacity.)
30 28
28
Cost good
良い 60 83 80
20
20
20
40
good
10
20 44 40 PM
0
17
0
2002 2003 2004 2005 Target
目標
2002 2003 2004 2005 Target
年度
Fiscal year
Invisible
Result of the activity that We can expect
A change of the consciousness and personal growth
•Confidence(I tried and I did it)
•Improvement(I will continue to improve)
•A challenge(I will do more)
•Tenacity(I will definitely do it)
•Self-growth(Solution ability, negotiation power)
NO.
R A T IO
150
4 Better
40
Better 100 Better
2 20
50
0 0 0
2002 2003 2004 2005 BM 2002 2003 2004 2005 BM
2002 2003 2004 2005 BM
No1. Model Activity of Autonomous Maintenance
Model Activity of Autonomous Maintenance
by Management level Employees.
Model Activity Area
Member : Mr. Saito. (TPM ), Mr. Furuya. ( Engineering section)
Mr. Nishikawa. ( SDM ), Mr. Yuki (HSSE)
Duration : Three months ( Total 200 hr)
Reason : This area is very dirty and wet. In addition, there is equipments
without the need ,and the work environment does not have any
room so danger of the work-related accident occurring.
Conclusion : We can do it if we do it
Model Activity of Autonomous Maintenance
by Management level Employees.
Before
After
Step 1 Attach tags to the defect points of the pump
This step is the first step of autonomous maintenance activity. it is extremely important to fix defects
point and defects substance.
We were supposed to attach a tags, but we made a mark with tapes because there were too many bad
points like a pictures. (We picked up more than 300 bad points)
Step 2 Removal of the inessentials
We removed this additive injection facilities since confirmed necessity in the technical and
operation section. We crushed concrete basements since we took permission to use fire.
Remove gearbox Remove timing gear Remove bearing cover Mark with center punch
Why did We challenge that it was such a carelessness?
Step 5 Work on Finish
Generally We did not paint the base, but painted it with the
Repairing of concrete base hard epoxy resin paints. The purpose is to easily wipe off a dirt.
Before insulation, pump discharge pipes were painted with heat-
resistant prevention of rust paint.
Pump, cooling-fan and other fittings were painted three-layer .
Step 6 What do you think of this neat figure?
No2. Model Activity of Autonomous Maintenance
Small centrifugal pump were overhauled
by Engineering Division Manager Team
Attach tags to the defect points of the equipment. This is BFW cut-in pump of FCC WHB
Before Seiri-Seiton(5S)
Is it a dump site here not a warehouse?
Someone purchased these for SDM, but keep something which remained first of all,
these were the result that repeated this for more than 30 years.
The first step of 5S is to throw away these things that seem to be used at a glance again.
They disposed of discarded things more than 20cars by 2ton truck.
Tobacco-stained of the
fire detector sensor
TPM Part-2
GRM-Max
Skill-up
Education
Cost-Min
HSSE
GRM Cost cut Reliability CDSC
Auto.Maintenance 「Base Activity」 J-TPM
Why will we do TPM ?
Competitor’s Creed
SHELL MARTINEZ,CALIFORNIA
EMRE ROTTERDAM,NETHERLANDS
TOA KEIHIN,JAPAN
EXXON BAYTOWN,TEXAS
LAGOVEN AMUAY,VENEZUELA
世界地図
1976
1982
1983
1986
1986
100
200
300
400
500
600
700
800
900
0
Days
240 418
339
447
’82~
493
71
580
744
736
Amuay
894
382
427
420
’86~
343
639
449
667
67 717
789
806
Baytown
333
736
417
50
’83~
772
1048
1099
685
671
1065
Martinez
591
608
570
’86~ 684
1048
1063
1年
1196
42
94
295
300
Rotterdam
3年
301
2年
246
271
300
278
334
Flexicoking Unit Run Days
308
282
307
324
’76~
347
288
265
TOA
262
318
294
312
320
318
452
198
695
690
Thank you for your attention