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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

• utcomes
• Difficult to retain IP and plant
• wners 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
• ccurs? 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
• perator 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