Post on 07-Aug-2020
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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
MESNZ Maintenance Conference 2015
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
MESNZ Maintenance Conference 2015
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.
MESNZ Maintenance Conference 2015
• 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”
MESNZ Maintenance Conference 2015
SCHEDULING AND
PLANNING
MESNZ Maintenance Conference 2015
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
MESNZ Maintenance Conference 2015
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.
MESNZ Maintenance Conference 2015
NATION WIDE SHUT
CALENDAR
MESNZ Maintenance Conference 2015
• 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.
MESNZ Maintenance Conference 2015
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.
MESNZ Maintenance Conference 2015
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.
MESNZ Maintenance Conference 2015
MESNZ Maintenance Conference 2015
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
MESNZ Maintenance Conference 2015
MESNZ Maintenance Conference 2015
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
MESNZ Maintenance Conference 2015
• 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)
MESNZ Maintenance Conference 2015
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
MESNZ Maintenance Conference 2015
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
MESNZ Maintenance Conference 2015
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
MESNZ Maintenance Conference 2015