EQUIPMENT VISUALS FOR PROCESS OPERATIONS

1. Offshore platform located in the Gulf of Mexico. This file is licensed under the Creative Commons Attribution 2.0 Generic license EQUIPMENT VISUALS FOR PROCESS OPERATIONS Rotterdam chemical plant.jpg, Eric Burgers, is licensed under the Creative Commons Attribution 2.0 Generic License Using visuals to improve equipment operability, maintainability & reliability Presenter: Robert (Bob) Williamson President, Strategic Work Systems Oil refinery, Anacortes Refinery (Tesoro Corporation), This file is licensed under the Creative Commons Attribution 2.5 Generic license

2. Our Challenges… • The Petro-Chemical (Chemical, Oil, & Gas) industry depends on reliable equipment to produce high-quality products in a safe and an environmentally sound manner. • Challenges facing our industry include… • An aging workforce • Skill shortage • New technologies & automation • Steep employee learning curve • Training efficiency & effectiveness • Error-free human performance • More stringent regulatory requirements • Continually improving efficiencies in everything we do • Facilities exposed to harsh environments & weather extremes • Operating in remote areas on-shore and off-shore • Establishing cost-effective ways to improve equipment and process reliability can be an ongoing challenge. Offshore platform located in the Gulf of Mexico. This file is licensed under the Creative Commons Attribution 2.0 Generic license Rotterdam chemical plant.jpg, Eric Burgers, is licensed under the Creative Commons Attribution 2.0 Generic License Oil refinery, Anacortes Refinery (Tesoro Corporation), This file is licensed under the Creative Commons Attribution 2.5 Generic license

3. Improving Performance & Reliability… Offshore platform located in the Gulf of Mexico. This file is licensed under the Creative Commons Attribution 2.0 Generic license Making equipment and processes more reliable, easier to operate, and easier to maintain are very worthwhile goals. There are many proven methods for improving performance and reliability. However some of the most overlooked and lowest cost improvement tools are known as equipment visuals. Rotterdam chemical plant.jpg, Eric Burgers, is licensed under the Creative Commons Attribution 2.0 Generic License Oil refinery, Anacortes Refinery (Tesoro Corporation), This file is licensed under the Creative Commons Attribution 2.5 Generic license

4. Equipment Visuals… Offshore platform located in the Gulf of Mexico. This file is licensed under the Creative Commons Attribution 2.0 Generic license • Equipment visuals include a wide variety of equipment-specific and task-specific visual cues that … • Improve efficiency & effectiveness of our interaction with equipment • Serve as reminders or warnings • Communicate process settings & procedures • Makes equipment easier to inspect • Reduces equipment-specific training time • Reduces problem-solving time Rotterdam chemical plant.jpg, Eric Burgers, is licensed under the Creative Commons Attribution 2.0 Generic License Oil refinery, Anacortes Refinery (Tesoro Corporation), This file is licensed under the Creative Commons Attribution 2.5 Generic license

5. Equipment Visuals… Offshore platform located in the Gulf of Mexico. This file is licensed under the Creative Commons Attribution 2.0 Generic license • Gauge Marking & Labeling • Equipment Lubrication • Replacement Parts Identification • Equipment & Component Identification • Fluids & Levels • Checklists & Procedures • Condition Monitoring • Positioning • Pipe and Valve Identification, Contents & Flow • Lockout & Tag-out Rotterdam chemical plant.jpg, Eric Burgers, is licensed under the Creative Commons Attribution 2.0 Generic License Oil refinery, Anacortes Refinery (Tesoro Corporation), This file is licensed under the Creative Commons Attribution 2.5 Generic license

6. Equipment Visuals… Offshore platform located in the Gulf of Mexico. This file is licensed under the Creative Commons Attribution 2.0 Generic license • Gauge Marking & Labeling: • Allowable Range • Name of process Cooper-Bessemer Separable Compressor, public domain Cooper-Bessemer Integral Engine Compressor, public domain ?

7. Equipment Visuals… Offshore platform located in the Gulf of Mexico. This file is licensed under the Creative Commons Attribution 2.0 Generic license • Gauge Marking & Labeling: • Allowable Range • Name of process • Cut & apply Cooper-Bessemer Separable Compressor, public domain Cooper-Bessemer Integral Engine Compressor, public domain MARKWARE Lean Tools Software

8. Equipment Visuals… Offshore platform located in the Gulf of Mexico. This file is licensed under the Creative Commons Attribution 2.0 Generic license • 2. Equipment Lubrication: • Lube type • Interval • Amount • Method Cooper-Bessemer Separable Compressor, public domain Cooper-Bessemer Integral Engine Compressor, public domain

9. Equipment Visuals… Offshore platform located in the Gulf of Mexico. This file is licensed under the Creative Commons Attribution 2.0 Generic license • 3. Replacement Parts Identification: • Part Name • Part # • Size Cooper-Bessemer Separable Compressor, public domain Cooper-Bessemer Integral Engine Compressor, public domain

10. Equipment Visuals… Offshore platform located in the Gulf of Mexico. This file is licensed under the Creative Commons Attribution 2.0 Generic license • 3. Replacement Parts Identification: • Location ID (Rack, shelf, bin) • Part # Cooper-Bessemer Separable Compressor, public domain Cooper-Bessemer Integral Engine Compressor, public domain

11. Equipment Visuals… Offshore platform located in the Gulf of Mexico. This file is licensed under the Creative Commons Attribution 2.0 Generic license • 3. Replacement Parts Identification: • Part description (Inside cabinet) • Part #, Location • Image Cooper-Bessemer Separable Compressor, public domain Cooper-Bessemer Integral Engine Compressor, public domain

12. Equipment Visuals… Offshore platform located in the Gulf of Mexico. This file is licensed under the Creative Commons Attribution 2.0 Generic license • 4. Equipment & Component Identification: • Name • ID # • Safety Cooper-Bessemer Separable Compressor, public domain Cooper-Bessemer Integral Engine Compressor, public domain

13. Equipment Visuals… Offshore platform located in the Gulf of Mexico. This file is licensed under the Creative Commons Attribution 2.0 Generic license • 4. Equipment & Component Identification: • Name • ID # • Safety Cooper-Bessemer Separable Compressor, public domain Cooper-Bessemer Integral Engine Compressor, public domain

14. Equipment Visuals… Offshore platform located in the Gulf of Mexico. This file is licensed under the Creative Commons Attribution 2.0 Generic license • 4. Equipment & Component Identification: • Sizes Cooper-Bessemer Separable Compressor, public domain Cooper-Bessemer Integral Engine Compressor, public domain

15. Equipment Visuals… Offshore platform located in the Gulf of Mexico. This file is licensed under the Creative Commons Attribution 2.0 Generic license • 5. Fluids & Levels: • Proper level • Easy to see • Fluid type Cooper-Bessemer Separable Compressor, public domain Cooper-Bessemer Integral Engine Compressor, public domain

16. Equipment Visuals… Offshore platform located in the Gulf of Mexico. This file is licensed under the Creative Commons Attribution 2.0 Generic license • 5. Fluids & Levels: • Fluid type • NFPA or GHS • Safety info Cooper-Bessemer Separable Compressor, public domain Cooper-Bessemer Integral Engine Compressor, public domain NFPA NFPA & GHS GHS

17. Equipment Visuals… Offshore platform located in the Gulf of Mexico. This file is licensed under the Creative Commons Attribution 2.0 Generic license • 6. Checklists & Procedures: • Step-by-step, brief • Visual cues • Attached • Detailed work instruction backup Cooper-Bessemer Separable Compressor, public domain Cooper-Bessemer Integral Engine Compressor, public domain

18. Equipment Visuals… Offshore platform located in the Gulf of Mexico. This file is licensed under the Creative Commons Attribution 2.0 Generic license • 6. Checklists & Procedures: • Visual cues • Labeled • History Cooper-Bessemer Separable Compressor, public domain Cooper-Bessemer Integral Engine Compressor, public domain Part 2: Equipment Labeling

19. Equipment Visuals… Offshore platform located in the Gulf of Mexico. This file is licensed under the Creative Commons Attribution 2.0 Generic license • 7. Condition Monitoring: • What’s important • Where to inspect • Visual Cooper-Bessemer Separable Compressor, public domain Cooper-Bessemer Integral Engine Compressor, public domain

20. Equipment Visuals… Offshore platform located in the Gulf of Mexico. This file is licensed under the Creative Commons Attribution 2.0 Generic license • 7. Condition Monitoring: • What’s important • Where to inspect • Instrument point Cooper-Bessemer Separable Compressor, public domain Cooper-Bessemer Integral Engine Compressor, public domain

21. Equipment Visuals… Offshore platform located in the Gulf of Mexico. This file is licensed under the Creative Commons Attribution 2.0 Generic license • 8. Positioning: • Valves & switches • Normal (open or closed) Cooper-Bessemer Separable Compressor, public domain Cooper-Bessemer Integral Engine Compressor, public domain

22. Equipment Visuals… Offshore platform located in the Gulf of Mexico. This file is licensed under the Creative Commons Attribution 2.0 Generic license • 9. Pipe and Valve Identification, Contents & Flow: • Source & destination • ID & Location • Color coded (as required) Cooper-Bessemer Separable Compressor, public domain Cooper-Bessemer Integral Engine Compressor, public domain

23. Equipment Visuals… Offshore platform located in the Gulf of Mexico. This file is licensed under the Creative Commons Attribution 2.0 Generic license • 10. Lockout & Tag-out: • Energy source • Procedure (attached) • Tags Cooper-Bessemer Separable Compressor, public domain Cooper-Bessemer Integral Engine Compressor, public domain

24. EQUIPMENT VISUALS FOR PROCESS OPERATIONS Offshore platform located in the Gulf of Mexico. This file is licensed under the Creative Commons Attribution 2.0 Generic license Summary… • Begin applying “visuals” as the equipment is being designed & built, installed, started up… • Put critical information ON the equipment • Be specific & purposeful • Error-proof operations & maintenance • Training reminders: Right the first time • Backed up by detailed work instructions • Avoid “visual clutter” • PM your visuals: • Replace damaged or missing visuals • Update Rotterdam chemical plant.jpg, Eric Burgers, is licensed under the Creative Commons Attribution 2.0 Generic License Oil refinery, Anacortes Refinery (Tesoro Corporation), This file is licensed under the Creative Commons Attribution 2.5 Generic license Robert (Bob) Williamson

25. QUESTIONS ? Robert (Bob) Williamson Strategic Work Systems Tel: 828-894-5338 Email: robertMW2@cs.com www.swspitcrew.com • To order: • Go to www.bradyid.com • Search on part # 113242

26. VISUAL EQUIPMENT SOLUTIONS www.bradyid.com/petrochem www.bradyid.com • Create onsite and on demand: • Safety and facility signs • Pipe and valve identification • Equipment and control panel labels • Wire and cable marking • Shelf / rack / bin labels • Whitepapers and articles • Webcasts (including this one!) • Regulatory information • Product information • Launching end of Dec, 2012 Outdoor durable! Chemical resistant!