Effective Shut Planning and Management · 2016-11-30 · When shit happens Multi-Hearth Shaft...

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We have over 20 years’ experience as a predominant

maintenance solutions provider

Effective Shut Planning and

Management “From a contractors perspective”

MESNZ Maintenance Conference 2015

Presenter: Dave Young

Operations and Marketing

Manager, Integrated Maintenance

Group

Introduction

Planning, Scheduling

and Client Interface

Types of work packages

Supervision

Nation Wide Shut

Calendars

Health & Safety and how

Technology can play a

part

Case Study – An example of

when shit happens

QA/QC

Skilled Staff where do they

come from

Innovation

Conclusion


TODAY

We all have some involvement in Shuts

whether we are:

Plant owners

• Maintenance or Production

Contractors

• Primary maintenance contractor

• Maintenance contractor

• Health and Safety coordinators

• Riggers & Scaffolders

• Cleaners


SCHEDULING AND

PLANNING

• Mobilising small groups of tradespeople at short notice is nearly

always achievable but resourcing for larger events takes time and good planning is key.

• Often Major Shuts will clash, putting pressure on available resources whether it be Labour, Rigging and Scaffolding, Cranage etc.

• Absolutely critical that the contractor gets accurate scheduling information in a timely manner.


• Daily communication with the Plant Owner is critical.

Measurement of task completion to date needs to be in actual hours not percentage.

• Emergent or variation work procedures and decision making needs to be very timely and work order generation should not

hold up progress.

“Two weeks out from a major event and the labour requirements are still unknown but we will probably need 100 Fitters, 35 Welders, 30 Rigger scaffolders with Quality Supervision and can we have the same ones we had last shut”


SCHEDULING AND

PLANNING


Plant Owner Management Model

• Staff are managed and supervised by the plant owner.

• Typically used for PM checks and small maintenance jobs

• Majority of IP remains with client

SHUT PLANNING AND

PACKAGES

Packaged Work Contractor Ownership Model (Becoming more of the norm)

• Contractors manage the complete jobs or tasks.

• Provide supervised skilled and

semi-skilled labour and are in control of all coordination and outcomes

• Difficult to retain IP and plant

owners become more reliant on contractors for job knowledge

SHUT PLANNING AND

PACKAGES


QUALITY SUPERVISION

• How shuts are managed is extremely important to a

successful and safe shut or event outcome?

• Who provides the Supervision? Plant owner or

Contractor?

• Who’s responsible if a serious accident or a major rework

occurs? Plant Owner or Contractor?

• Quality Supervision on the ground is extremely important

when managing large groups of casual or plant

unfamiliar staff.


NATION WIDE SHUT

CALENDAR


• Nation wide industry shut Calendar and Coordination

(Cooperation between large Industrial Organisations)

Currently one in place.

• Currently in place but not utilised to generate

discussions only used as an awareness tool.

• In the future, large corporations will need to utilise this

tool more efficiently in order to share resourcing.

TECHNOLOGY AND HEALTH

& SAFTEY

• The recent changes in Health and Safety will drive

us all to be smarter in how we operate.

• The following is one example of how the rapid

change in technology can make a difference.

• All the hours spent on PlayStation may have a part

to play in the future.


KILN AND VESSEL

DEMOLITION

• Kiln and Demolition work is very hazardous and

dangerous.

• Manual machines were the norm and although the

operator was protected to a degree we needed to

eliminate all risks of personal injury.

• Heat was another major consideration and the

downtime waiting for vessels to cool prior to entry

being allowed and safe.


ELIMINATION THROUGH

TECHNOLOGY

Remote control Excavators and Skid Steers eliminate all

human risk factors

Advantages

• Total Elimination of Human interaction inside the

danger zones and often operators can have better

visibility to perform tasks.

• Ability to enter vessels at higher temperatures

reducing downtime.


CASE STUDY

When shit happens

Multi-Hearth Shaft Segment Replacement

• Job involved replacing three segments of shaft

• One new section was manufactured in NZ and two sections

were manufactured in China

• After closer inspection the two Chinese manufactured sections

appeared to have some casting faults

• Paint was removed around the webs and it was identified that

bog had been used to fill in casting defects

• Fortunately we were able to replace the badly damaged

section with the locally manufactured one and reuse the

remaining sections

• The two Chinese sections were scraped



LEARNINGS

Importance of QA /QC (especially if importing

components):

• Quality controls need to be robust when importing

critical components

• Make sure you allow enough time to go to plan B if

components are not to standard. Inspect

components immediately on receipt.

• Quality checks where possible on Critical

components should be down at source of

manufacture. Use of third party offshore inspection!

• Buy Kiwi made

Where will we get these skills

from in the future?

• Project Management / Support

• Scheduling / Planning

• HSE Management Specialists

• Senior Supervisors, Leading Hands and Team Leaders

• Quality Managers & CBIP Inspectors

• Fabricators

• Procurement

• Asset Management / Procurement

• Human Resources & Casual Talent Recruitment

• Transport & Machinery Specialists

• Civil


• Skilled Trades Personnel

Welders (ASME, 4711) Specialist Stainless Steel Welders Fitters Trade Assistants / Labourers Confined Space & Gas/Safety Watches Machinery Operators Breathing Apparatus & Rescuers Scaffolders & Riggers (dual training)


CURRENTLY

• Specialist Maintenance Shut companies

• Local Maintenance companies

• Permanent and Casual Staff

• Percentage of local Workshop Staff

• Retired and semi retired employees

• Moon lighters – Permanent employees wanting to

supplement their income


IN THE FUTURE

With the impending Technical staff shortage we will be

relying more and more on:

• Temporary imported Staff (Overseas)

• Semi Skilled staff/Labourers fully Supervised

• Dragging specialist labour out of retirement

• Using Technology to document actual work procedures

visually i.e. Go pro video etc. Graphical presentations

using 3d modelling


INNOVATION

• Repairs and maintenance (carry out major repairs or

rebuilds offsite in local workshops where possible)

Modularisation

• Drones – Used in inspecting tanks and vessels

replacing time consuming and costly rigging and

scaffolding or abseiling techniques

• Continuous improvement and challenging the ways

specific tasks or jobs have been done in the past will

lead to further efficiency's

EFFECTIVE AND TIMELY

SHUTS

Robust Health and Safety Plan and Isolation Process

Accurate and timely planning and scheduling

Timely subcontractor engagement and Communication

Quality Supervision

Innovative thinking and the use of Technology


Effective Shut Planning and Management · 2016-11-30 · When shit happens Multi-Hearth Shaft...

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Transcript of Effective Shut Planning and Management · 2016-11-30 · When shit happens Multi-Hearth Shaft...