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End-User Interview
SAP is software that records the maintenance work history on components . It tells the user how often the equipment fails , when it fails , and the type of work orders entered on the asset . “ Recently I evaluated a cooling water heat exchanger , which was part of a jacketed system of a major compressor . The problem was a decrease in exchanger performance over time . If the heat exchanger fails , it can lead to production shutdowns . The team worked to collect data , perform the analysis , and make recommendations resulting in 30 % improvement in equipment performance ”, Tami shared .
exchangers , which resulted in production and financial impacts :
• D - Dig up the data
• Analyse data
• R- Recommend
• E- Execute and evaluate .” Design is a big factor in heat exchanger reliability ; everything from ensuring the correct metallurgy and configuration to determining the process compatibility . Digging up data includes collecting historical and current documentation , such as specification sheets , operating performance over time , and process conditions . Data also includes referencing standards , guidelines , and best practices . Heat exchanger standards include API 660 for shell and tube heat exchangers , API 510 for the inspection of pressure vessels , and ASME Section 8 for new construction of pressure vessels . The next “ DARE ” step is analysing the data by using techniques such as Root Cause Analysis to understand what happened and prevent it from happening again . Next , the team identifies recommendations , such as making modifications to the shell or bundle of the heat exchanger , updating maintenance activities , and collaborating with the vendor on the process treatment chemistry . The last step is to execute the recommendations and evaluate the outcome for improvements in performance . Metrics are used to measure and make adjustments in parameters over time . DARE to be reliable is the use of techniques to optimize performance in people , equipment , and systems .” When failures take place , Tami and her team work together to determine what is needed for the repair , especially in terms of maintenance . During shutdowns , evaluations of auxiliary equipment are included in the scope , such as replacing rupture disks and cleaning equipment to have a clear path to relieve pressure . “ The goal is to be proactive , keep everyone safe , and maintain the processes within the equipment before there is an interruption or failure in production . It is important to understand the safety , environmental , and business impacts beforehand , to determine what can be done to avoid failure scenarios and mitigate risks ,” she added .
Achieving reliability Challenges to achieve heat exchanger reliability are found in ensuring that recommendations and solutions are not only identified but also implemented . Tami described the most enjoyable part of her career as being able to collaborate with her co-workers to improve the safety , environmental , and business performance of the company . In sharing her experiences , Tami says , “ The connection between reliability and safety is important to me . Unreliable processes can cause injury and loss to people , equipment , and systems . Mitigating risks starts by being proactive and using reliability techniques such as a Failure Mode Effects Analysis ( FMEA ). This is where we go through every component , such as heat exchanger tubes and baffles and understand how each part could fail . We will evaluate all the possible outcomes and identify recommendations with the team ,” she said . Team members actively engage to proactively address potential failure modes and prevent disruptions in production or safety incidents . Whenever special expertise is needed , the correct professional is looped in by the sub-teams to determine a viable solution . Staying committed and personally invested are crucial to the success of the team . “ There are often great recommendations made by the team , and we can come up with those solutions , but if we do not stay on top of these decisions , without properly implementing what was discussed , the probability of another failure , or the same failure , occurring can still exist ,” Tami elaborates .
Maintenance and cleaning “ When a heat exchanger undergoes a cleaning process , our team is responsible for selecting a vendor who is familiar with the processes and applications in our facility . When it comes to maintenance practices , our vendors often have their own set of services that we vet to ensure the most stringent practices are followed ,” Tami said . At the beginning of this process , whether it is cleaning the asset or maintaining it , Tami consults her team , resources , and the contractor to review the preliminary scope of work . “ For field execution , we discuss all possibilities of failure , or what may go wrong in each aspect of completing the
“ Capitalizing on technological advancements helps reduce costs and enhance safety , while bridging knowledge gaps for a more sustainable and efficient industry .”
Tami Glasper . www . heat-exchanger-world . com Heat Exchanger World September 2024
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