02. Chien Luoc Bao Duong Nm Dpm

CHIN LC BO DNG CA NH MY M PH M

Trnh by: Nguyn Thanh Sn, Ph Phng K Thut, Nh my m Ph M

www.dpm.vn 1 Bo co chin lc bo dng Nh my m Ph M

GII THIU V NH MY M PH M 1

CC HOT NG BO DNG TRN TH GII

2

M HNH CHIN LC BO DNG CA NH MY M PH M

3

KT QU GHI NHN 4

2 Bo co chin lc bo dng Nh my m Ph M

7/30/2014

GII THIU V NH MY M PH M 1

3 Bo co chin lc bo dng Nh

my m Ph M 7/30/2014

GII THIU V NH MY M PH M

4

Nh my m Ph M a ch: KCN Ph M 1, H. Tn Thnh, Tnh B Ra Vng Tu. Ch u t: Tng cng ty Du Kh Vit Nam. Cng ngh: an Mch & Italia Nguyn liu u vo: Kh ng hnh m Bch H, kh thin nhin t bn trng cn Nam sn v cc b khc thuc thm lc a pha Nam.

Sn phm chnh ca Nh my: -NH3: khong 1,350 tn/ngy (cng ngh Haldor Topsoe an Mch). -Urea: khong 2,385 tn/ngy (Cng ngh SnamProgetti Italia). -in: 21MW.


my m Ph M 7/30/2014

CC HOT NG BO DNG TRN TH GII 2


my m Ph M 7/30/2014

Th h th 3: Bo dng ngn nga, d on: da theo tin cy, ti u ha vic lp k hoch Cc cng c v k thut bo dng: RCM, RBI, CBM,

FMEA, RCA,

1940 1950 1960 1970 1980 1990 2000 2010

Gia

t

ng

hi

u q

u

v

hi

u s

u

t

Th h th 2: Bo dng nh k: bo dng theo thi gian, thay th chi tit theo khuyn co Vendor Th h th nht:

Sa cha khi c h hng

Cao

Tru

ng b

nh

Thp

LCH S PHT TRIN HOT NG BO DNG TRN TH GII


my m Ph M 7/30/2014

Mc tiu chnh ca

RCM?

Gim chi ph bo dng bng cch tp trung vo cc chc nng quan trng ca cc h thng, nhm loi b cc hnh ng bo dng khng cn thit.

RCM phn loi cc thit b c hnh thc bo dng hp l


my m Ph M 7/30/2014

RCM (Reliability Centered Maintenance)

RCM l mt qu trnh c s dng xc nh cc cng vic cn phi lm m bo thit b lun vn hnh iu kin mong mun ca ngi s dng

RCM (Reliability Centered Maintenance)

8

lm tt RCM cn gii quyt 7 cu hi c bn:

Cc chc nng v tiu chun hot ng ca thit b khi vn hnh l g?

Bng cch no dn n thit b h hng cc chc nng ca n?

Cc nguyn nhn gy ra cc h hng ?

iu g xy ra khi h hng xy ra?

Cch thc xy ra cc h hng?

Cn lm g d on v ngn nga h hng?

Cn phi lm g nu khng th tm ra nguyn nhn loi tr?

Bo co chin lc bo dng Nh my m Ph M

7/30/2014

PMO (Planed Maintenance Optimization)

9

PMO thu thp cc dng h hng (Failure Mode) bit t chng trnh bo dng hin ti, a ra nh gi cc Failure Mode, nh gi nh hng cho tng dng h hng v la chn hnh thc bo dng ph hp.

PMO gip ci thin cng tc lp k hoch bo dng theo cch sau:

iu chnh li ni dung, tn sut cng vic bo dng.

Loi b cng vic trng lp

Tin ti hnh thc bo dng theo tnh trng.

B sung cng vic cn thit ngn nga cc h hng c th xy ra (trong lch s xy ra).

Phn b khi lng cng vic cho cc ngun lc bo dng v vn hnh.

Bo co chin lc bo dng Nh my m Ph M

7/30/2014

RBI (Risk Based Inspection)

RBI l mt phng php da trn mc ri ro kim tra nh gi thit b theo API 580&581.

Phng php ny nhm phn loi mc ri ro ca thit b ra k hoch v phng php kim tra tnh trng thit b.

RBI s dng cho thit b tnh, ng ng v van an ton da theo mc quan trng ca thit b trong h thng.

Ma trn xp loi ri ro


my m Ph M 7/30/2014

RCA (Root Cause Analysis)

RCA l phng php x l cc vn h hng m mc tiu l tm ra nguyn nhn gc r khc phc v loi b.

RCA thng c coi l mt qu trnh lp v thng c xem nh mt cng c ca ci tin lin tc.

RCA tr thnh mt phng php chuyn nghip ch ng, RCA c th d bo kh nng xy ra mt s kin, ngay c trc khi n c th xy ra.

RCA p dng trong mi lnh vc: phn tch h hng, an ton, sc kho, cht lng sn xut...


my m Ph M 7/30/2014

RCA (Root Cause Analysis)


my m Ph M 7/30/2014

FMEA (Failure Mode and Effect Analysis)

FMEA l mt cng c dng phn tch cc nguyn nhn gy ra cc dng h hng, tn sut h hng, hu qu h hng ca cc thit b quan trng c th xy ra trong thc t. T a ra hnh ng khc phc trong tng lai.


my m Ph M 7/30/2014

CBM (Condition Based Maintenance)

CBM l hnh thc bo dng da trn vic gim st s thay i tnh trng ca thit b.

C th kim sot thng trc (on line), hoc nh k xc nh tnh trng my.

Ch ln k hoch dng my x l sau khi chn on chnh xc tnh trng my.


my m Ph M 7/30/2014

Chc nng chnh ca CMMS l

qun l thit b v tn kho.

My tinh hoa qun l cng

vic bo dng

Cc cng vic bo dng c sp xp v ln lch nhm ti

u hoa vt t ph tng,

ngun lao ng v cng c. Cung cp thng

tin v c tinh ky thut ca thit b

Cng vic c qun l tp

trung (cng vic, con ngi, thit

b )

T ng xut ra k hoch bo

dng nh k

CMMS (Computerized Maintenance Management System)


my m Ph M 7/30/2014

CMMS l

mt phn mm lu tr c s d liu v cc thng

tin ca hot ng cng tc

bo dng ca Nh my.

M HNH CHIN LC BO DNG CA NH MY M PH M

3


my m Ph M 7/30/2014

M HNH CHIN LC BO DNG ANG C P DNG TI NH MY PM

PM/PdM

WORK ORDER

CMMS

FIELD

CBM

RCM/PMO

RBI

RCA FMEA


my m Ph M 7/30/2014

a CMMS vo hot ng tt trong thc hin ti a cc chc nng ca CMMS, vi tnh ha cng tc qun l bo dng thit b nh my.

Duy tr v nng cao hiu qu ca h thng MMS system1, ng thi nghin cu a cc cng c, k thut khc vo cng tc theo di tnh trng thit b in v TH (CBM).

p dng RCA trong vic tm nguyn nhn cc h hng ca cc thit b quan trng ca nh my.

p dng RBI trong vic theo di, kim tra v chn on tnh trng thit b tnh.

p dng FMEA vo nh gi ri ro kh nng gy ra h hng v a ra bin php nhm lm gim v loi tr h hng.

Ti u ha vic lp k hoch v la chn hnh thc bo dng hp l nh thc hin PMO/RCM

MC TIU THC HIN

7/30/2014 18 Bo co chin lc bo dng Nh

my m Ph M

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L TRNH THC HIN

Giai on Cng vic trin khai Giai

on

I Chun b

Xc nh thc trng cng tc bo dng nh my.

Xc nh yu cu v mc tiu thc hin La chn m hnh chin lc bo dng sa

cha

2 nm (2010-

2012)

II

Hon

thin CMMS.

Xy

dng RBI

Xc nh ngun lc (ngn sch, thi gian v nhn lc).

Duy tr khai thc v hon thin cc chc nng CMMS

Duy tr khai thc h thng MMS (CBM). Duy tr phn tch RCA (iu tra s c, h hng

lp li). Xy dng RBI Xc nh hnh thc bo dng hp l Cp nht ni dung v tn sut BD Ci tin lin tc qua KPIs.

2 nm (2012-

2013)

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L TRNH THC HIN

Giai on Cng vic trin khai Giai

on

III

Phn

tch

PMO

Duy tr khai thc v hon thinCMMS

Duy tr khai thc MMS (CBM).

Duy tr khai thc RBI

Phn tch PMO

Xc nh li hnh thc bo dng hp l

Ti u ha ni dung v tn sut BD

Ci tin lin tc qua KPIs.

3 nm

(2014-

2016)

IV

Phn

tch

RCM

Phn tch FMEA

Thu thp d liu phn tch t RBI, CBM, FMEA,

RCA, CMMS

Xc nh li hnh thc bo dng hp l

Ti u ha ni dung v tn sut BD

Ci tin lin tc qua o lng KPIs.

5 nm

(sau

2016)

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SCH LC BO DNG

Cn c vo chin lc bo dng ra, Nh my ban hnh sch lc bo dng nh my m Ph M: Nhm cung cp cc thng tin cn thit xy dng mt

chng trnh bo dng an ton, t hiu qu v mt kinh t v k thut.

t c mc ich trn, sch lc bo dng m t cch thc qun l cc hot ng bo dng nhm m bo an ton, sc kho cho con ngi; quan tm n mi trng; bo ton s nguyn vn cho h thng v thit b; duy tr s vn hnh n nh, hiu qu.

Sch lc bo dng cng m t cch thc qun l cc thit b, quy nh vai tr v trch nhim ca cc c nhn tham gia qun l cng tc bo dng, m bo s ph hp vi cc quy nh ca cng ty, quy nh ca nh nc, cc iu kin thc t, cc tiu chun k thut.

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Stt Lnh vc cng nhn

D kin 2015-2020

1 o Lng T ng Ha 6 7

2 Cng Ngh 3 4

3 in 1 3

4 KTTB, C Kh 4 6

O TO NHN LC

Nhm nng cao nng lc ca khi BD, PVFCCo trin khai mt s bc: - y mnh cng tc o to ni b - o to trong nc v nc ngoi, u tin v tr quy hoch - nh k t chc thi kim tra kin thc khi bo dng - Xy dng v pht trin i ng chuyn gia cho cng tc bo

dng trong cc lnh vc (nm 2014 c 14 chuyn gia c cng nhn).

KT QU GHI NHN 4


my m Ph M 7/30/2014

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KPI O LNG HOT NG BO DNG

STT Ch s KPI nm 2013 VT Kt qu Ch tiu

1 % hng mc sa cha khn cp % 0.03% < 5%

2 % hng mc BDSC c k hoch thc hin

% 85.3% > 80%

3 % hng mc BDSC theo KH thc hin so vi k hoch

% 98.5% > 90%

4

Tng s gi ngng nh my tr so vi k hoch (BDTT, SC ngn hn)

Ngy -1.5 3-5 Tun

5 % ngun nhn lc bo dng c o to hng nm

% 70.6% >5%

6 Kh nng sn sng cho thit b critical nh my

% 99% >96%

Trn trng cm n!


my m Ph M 7/30/2014

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02. Chien Luoc Bao Duong Nm Dpm