Grupo Energia Bogota (GEB) ISO 55000 Corporate Transformation
Grupo Energia Bogota (GEB) is a public utility corporation with more than 125 years of history.
SASOL in South Africa, is responsible for around 50% of the total domestic fuel and lubricants market, largely through its world-leading coal-to-gas-to-oil conversion technologies. The Secunda site comprises the largest such production facility, some 10km x 4km of integrated process plant, with over 23,000 pressure vessels and a feedstock obtained from 5 coal mines operating 24/7. Great pressure has been applied to the unit production costs, product quality, and operational flexibility of the plant, and significant investment has been made in new technologies and ways of working. A more integrated Operational Reliability approach would be far-reaching in education, organization structure, and in potential benefits.
The first pilot studies of component activities (maintenance tasks, spares requirements, problem-solving/root cause analysis) revealed scope for multi-million dollar potential savings or performance improvements. A Reliability group was established to coordinate and facilitate the adoption of such methods, and a more systematic (criticality targeted) roll-out of RCM and RBI studies ensued. At the same time, a number of further studies were performed using the Decision Support Tools™ cost/risk optimization tools to explore not just what is worth doing, but the optimal amount, interval or timing of the tasks. These showed further spectacular benefits in cases ranging from turbo compressor inspections and maintenance, valve reliability and design, gas turbine rotor spares, pipeline corrosion monitoring and electrical protection system testing.
The study considered the top maintenance and risk areas, each modeled using Decision Support Tools DST™ to allow exploration of data uncertainty. This modeling identified the optimum maintenance or inspection interval, and the cost/risk penalty for deviating from the optimum. In cases where a 4-yearly turnaround cycle was found to be unachievable (too costly and/or risky), alternative designs, configurations or operating strategies were also evaluated. Such de-bottlenecking revealed considerable scope for cost/risk/performance savings, worth a total of $7.5m/year and representing a payback for the necessary capital investments involved averaging just 3 months.
The cost, performance and risk implications of current 2-yearly and proposed 4-yearly shutdown cycles were then quantified, and key decision drivers identified. This study revealed that an extension from the current 2-yearly shutdown to 4-yearly would hold net cost/risk improvements worth $2.8m/year. Combined with the improvements available from the ‘debottlenecking’ actions identified in individual equipment studies, this represents a total benefit from the study of $3.5m/year. This is based on conservative estimates for total cost, availability and risk effects, and includes ‘worst case’ projections for the associated risks (so the ‘most likely’ benefits are even greater).
Examples of individual study results include:
Change SAS Reactor Coil Guide beams to a new design, carbon steel or stainless steel to allowing 4-yearly inspection.
Install a second pilot unit on each Hot Quench Tower & Separator Drum Pilot Operated Relief Valve, allowing on-line maintenance of pilot and 4-yearly on the main valve.
In addition to the individual study results, the team assessed the current policy of conducting Planned Shutdowns on a 2 yearly major turnaround (15 days), plus 2.5 events per month of average 4 hours downtime (unplanned). The study recommended a 4-yearly turnaround, with a slightly higher frequency of minor stoppages in the second half of cycle. The business impact $4-9 million per year average production increase (£5.6m and $7m SAS trains respectively)
The Woodhouse Partnership would be delighted to show you how the SALVO process and Decision Support Tools™ can be implemented to benefit your business, contact us now for a free initial consultation. We look forward to hearing from you.
“We were facing the apparently urgent replacement for obsolete equipment to the order of tens of millions of pounds. With SALVO™ we were able to reduce this by 60% and renegotiate support arrangements for the foreseeable future.”
Grupo Energia Bogota (GEB) is a public utility corporation with more than 125 years of history.
Mutual Energy has been recognised for effective asset management of critical infrastructure by achieving ISO 55001 certification.
This study was commissioned to ascertain the business case for re-tubing and to evaluate the life cycle cost benefits of alternative materials.
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With over 32 years of Asset Management, Reliability and, Mechanical Engineering experience in leadership, technical, and operational roles in Oil & Gas, and the Petrochemical industry. Pedro brings a proven track record of success in developing and implementing asset management processes and tools, to facilitate communication between engineers and managers, while establishing a direct connection between business objectives and frontline engineering and operational actions, with strong considerations of Fit for Purpose and Life Cycle cost factors.
Pedro is a strong advocate and Change Agent for cross-functional collaboration between departments orientated to achieve alignment of objectives for the development of efficient and effective asset management solutions. Pedro heads up our Australiasia business unit.
Victoria is a Principal Consultant & our Product Manager for the SALVO Decision-Making Framework.
She has over 20 years’ asset management experience, across transport, energy and defence sectors and is a specialist in asset management decision-making and risk management.
With plenty of hands-on experience developing optimized, risk-based asset maintenance and renewal strategies, and deploying these to develop multi-year investment plans, her industry positions include the Head of Asset Management (Electrical Utility), Manager Network Risk & Performance (Electrical Utility), Associated Director, Safety and Engineering Systems (Government Transport Agency), Team Leader, Asset & Risk Management Systems (Electrical Utility), Team Leader, Structural Safety, Risk & Reliability (Government Highways Agency)
Patrick is a specialist in data-enabled business transformation design and executive-level delivery governance to enable asset- and workforce-intensive organizations to deliver better customer and operational outcomes. He has 30 years of experience in the industry, working at the executive and board levels with critical national infrastructure organizations to shape and lead major value-realization programs with data and digital enablers at their core.
His core skills include Data strategy, Transformation design, Strategic roadmap development, Transformation governance and assurance, Transformation leadership, Business data services operating model design, Data skills and leadership development, and Leadership coaching, and mentoring.
Patrick is also a graduate of the Australian Institute of Company Directors (GAICD).
Susan Steyn is a seasoned expert with over 30 years of experience in Management, Operations, Business Development, and Supply Chain across diverse industries. Her core focus lies in spare parts management and inventory optimization. Throughout her career, Susan has held key leadership roles in multinational companies such as GE, Dow, Roche, Bayer, Lloyds Register, and Woodhouse Partnership.
With a strong background in strategic leadership, P&L management, and lean manufacturing, Susan has consistently driven business turnarounds and growth. She excels in international global business management and has a proven track record of expanding market presence and building strong client relationships.
As a Six Sigma Black Belt and PMP certified professional, Susan is adept at implementing process improvements and managing complex projects. Her expertise in data analysis, project management, and ERP systems ensures effective spare part management and optimal inventory levels.
Susan’s contributions to various companies include revenue growth, cost reduction, successful software launches, and the establishment of strategic alliances. Her commitment to diversity and inclusion, coupled with her leadership in team building and mentorship, have created a culture of excellence in every organization she has worked with.
Overall, Susan Steyn is a results-oriented leader with a passion for leveraging data-driven decision-making and innovative strategies to optimize spare parts management, reduce downtime risks, and enhance profitability in any business environment.
José Luis cuenta con una experiencia exitosa en multi-industrias públicas y privadas, donde desempeñó cargos gerenciales, líder de aplicación técnica especializada, puestos operativos y en mantenimiento, así como en áreas de consultoría sustentando nivel operativo, táctico y estratégico.
Ha formado parte de proyectos de mejoramiento de gestión de activos, confiabilidad operacional, integridad y mantenimiento en Latinoamérica en diferentes empresas creando valor al negocio con resultados técnicos y económicos importantes.
Facilitador e instructor acreditado en temas relacionados con la gestión de activos, mejores prácticas, metodologías de administración gerencial y técnicas especializadas.
Mechanical Engineer with 31 years of experience. Specialist in implementation processes of activities
associated with Asset Management under the ISO 55001 approach, Implementation of diagnostic
programs and audits of management systems, Specialist in applying reliability methodologies such as
Reliability-Centered Maintenance, risk-based inspection, Cause Analysis Root, Life Cycle Cost Analysis,
Condition Based Maintenance, Failure Modes and Effects Analysis, Mechanical Integrity among others.
He has been an Equipment Mechanical Integrity Engineer, an experienced user of traditional NonDestructive Testing such as Ultrasound, Infrared Thermography, Superficial Techniques, Industrial
Radiography.
He has led and participated in countless applications in the field of reliability and condition monitoring,
with special emphasis on the generation and execution of policies and maintenance plans aimed at
achieving the “minimum total business impact” guaranteeing Safety, Hygiene and Environment
standards.
Over his 28 plus year span in the industrial sectors with working technical backgrounds in Project & Construction Management, Asset Operations and Maintenance Reliability Management, and being certified in various courses of study; Damien has gained the knowledge and experience and has had proven successes throughout his tenure in the Oil, Gas, Petro-Chemical and Construction sectors. Establishing his-self in the various sectors, Damien’s first experience and success started in the Construction Sector in estimating engineering. This was the stepping stone for Damien and has paved the way for his passion and continued success in supporting People, Process, and Systems in an organization.
Damien has held positions in local, international and multi-national corporations and comes from a working background in the fields of environmental, operations, project and construction management, operations maintenance and reliability management, planning, supervisory management, and has proven his abilities to succeed in each field.
Rich was an Engineer and Project Manager professional at the New York Power Authority for over 30-years. In addition to being the first Project Manager for the Niagara Project Upgrade, Rich rose to be the Vice President of Engineering having started in Operations Engineering decades earlier. Rich went on to be Vice President, Transmission and Substation at AECOM responsible for hundreds of millions of dollars in design and construction. Rich joined Woodhouse Partnership, North America and participates in aligning organization towards ISO 55000 and many reliability studies supporting DST.
Executive in Operational Excellence, Asset Management and Best Practices in Projects, Operations and Maintenance in the Energy and Industrial Sector.
Consultant, Instructor and International Lecturer on issues related to project management (risk management), operational reliability, strategic management of operations, maintenance, Asset Management in the energy sector (ISO 55001) and Applied Data Analytics.
PMP, CMRP, IAM and CAMA certifications, being recognized by the SMRP in 2019 as CMRP of the Year https://smrp.org/2019-CMRP-Winners.
George has over twenty-five years of experience as a consulting engineer providing design, planning, program and project management, and strategic asset management services for asset-intensive organizations in the Americas, Africa, and the Middle East. His primary focus has been in the public infrastructure sector; as a result, he has intimate knowledge of the assets, processes, and resources necessary to deliver and sustain safe, reliable services to the customers of public asset-owning organizations.
George has assisted organizations with the development of PAS 55, ISO 55000, and GFMAM AM Landscape aligned asset management systems (AMS), has performed gap analyses of their AMS against industry standards and best practices, and has guided them through the creation of strategic asset management plans (SAMPs), asset management plans (AMPs), AM policy and supporting documents. He has undertaken asset risk modelling to ascertain organizations’ capability to sustain their desired levels of service. George has performed asset health-informed lifecycle cost modelling and forecasting capital and operational expenditures over near and long-term planning horizons.
With 30 years’ experience in utilities, oil & gas, transport and other sectors, John is one of the most widely known experts in integrated asset management projects for some of the largest companies in the world.
John is a Founder and Life Fellow of the IAM; he has written 4 books, chaired the development of BSI PAS55 and represents the UK on the ISO55000 committee.
He also led the international MACRO and SALVO collaboration projects in optimised asset management decision-making.