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Spreading the Degradation Management Message

The pilot project on corrosion management was successful. The time was right to build on this to get our message on degradation management across. We decided to spread a simple message around the site to prepare the ground for a big reliability initiative and change the mindset of the group at all levels. In its essence, the message was:

  • • Like accidents, failures are not inevitable...degradation can be managed.
  • • Like safety, degradation is a joint responsibility.

There is a simple recipe for managing degradation:

  • • Buy and use inherently-reliable equipment.
  • • Operate and maintain it well.
  • • Focus on critical equipment.
  • • Use risk-based inspection techniques to optimize efforts.
  • • Eliminate repeat failures by effective use of RCA.

Lessons

  • 1. Compartmentalization of departments produces sub-optimal decisions and, all too often, conflict.
  • 2. Inspection emphasis should be on problem solving rather than symptom monitoring.
  • 3. When embarking on a significant change, start small and pilot the change in an area with a high probability of success. Advertise success and then spread the change quickly to other areas. [1] [2] [3]
  • 7. Use the knowledge available in all sections of the facility and align on required end results.
  • 8. Make reliability and degradation management (like safety) everyone's responsibility.

Principles

Large organizations have a tendency to work in silos. These create data islands. By working in isolation, organizational synergies can be lost. Therefore, breaking down these barriers is an important role for management. Computer systems can help or hinder data integration within the facility, so they have to be designed carefully.

  • [1] Gain stakeholder agreement of all new approaches. Have a roadmap anda change management plan.
  • [2] Define plant operating envelopes and operate within them.
  • [3] Highlight excursions and any significant implications.
 
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