Document

Step Change Process Improvements For Projects & Turnarounds Through Mobile Task Management Software

Donald J. Frieden, President & CEO, SAT Corporation

© 2007 SAT Corporation. All rights reserved. SAT Corporation Proprietary & Confidential

What We Will Discuss….

• What are the challenges and compelling automation opportunities in today's Capital Project environment?

• How can Mobile Technology improve project execution through project status updates and asset tracking?

• How can Mobile and Auto-ID Technology reduce the duration of Plant Maintenance Outages?


3

Capital Projects Landscape

• NIST estimates that $ 15.8 billion in profits are lost in U.S. capital facilities every year– 6.8 Billion lost in EPC phase– 9.7 Billion lost in MRO phase

• Important because the platform for effective asset lifecycle management during the MRO phase is created during EPC


4

Capital Project Landscape

• The Construction and Capital Project industry lags behind manufacturing and transportation for asset management and field-force automation.

• Information delivery and data processing in the field has been traditionally paper-based.

• Tools for automated information authoring, transfer, and collection is rapidly increasing, but adoption of mobile technology and asset identification to enable the front-line workforce is severely lacking.

• In the next decade, successful project execution will be measured by a companies ability to effectively manage it’s stranded assets (people, equipment, and work processes).


5

Capital Project Opportunity

• Enterprise Systems for Capital Project Management are being deployed by owner/operators and other project stakeholders (EPC), but are seldom integrated.

ERP (Oracle, JDE, SAP, etc.)PPM (Primavera, MS Project, etc.)CAD/CAM/Document and Engineering Management (Intergraph, CATIA, etc.)Enterprise Knowledge Management Systems-new breed of aggregators designed to provide a backbone for all plant information (SmartPlant, etc.)Specific “Point” Applications (Completion, Safety, QA/QC, etc.)

• Very little field level application of technology to process this information exists today, which limits the effectiveness and productivity of all facets of construction execution.


6

Example of a Disconnect

Task updates or material staging

not timely, dependent tasks

left in “wait”mode

Crew waiting because

dependent tasks not updated in

project schedule

http://www.raps.bur.st/20000822/im2207e.jpg


7

Domino Theory

1. Cumulative task cycle time delays

3. Project overruns and demobilization delays

4. First year Operability Effected

2. Critical path of project slips


8

Capital Project Improvement Opportunities

Fabrication/Construction

Testing/Acceptance

Operations Decommission/Retrofit

ProjectDesign

ProjectPlanning

ProjectDefinition

Current grassroots/capital projects have the opportunity to take advantage of the availability of this important Information to reduce implementation costs and adoption of mobile technology during EPC Cycle

• Equipment data sheets

• Process flow diagrams

• Vendor/Supplier SOP’s

• Testing Results• Etc.

Results:• Lower Implementation Cost• Capture of early operation

asset data (First Year Operability)• Quicker deployment• Better overall ROI


9

Reducing EPC Costs and Improving FYO

Fewer Schedule Delaysand Reduction

in Cost Overruns

Fewer Asset Failuresand Reduction in Lifting Costs

Shorter more efficient schedules from a reduction of redundant and duplicated tasks to facilitate faster “look- ahead” views

Reduced maintenance costs earlier in asset’s life from early identification of precursors and consistent delivery of best practices that prevent unplanned downtime

What if you could have?

Asset Lifecycle Management

Engineering, Procurementand

Construction

These results

First Oil/Gas


The Turnaround Challenge

TurnaroundSuccess

Time

Cost

Safety

Quality

Sarbanes-OxleyFlawless Execution

Six-Sigma

Utilization

Balanced-ScorecardLean

OSHA

RBI

RCMBest P

ractices


The Turnaround Environment

• For the past 10 years Owner/Operators and service providers have focused on improving performance by deploying improved project management, estimating (time/cost), risk evaluation, and safety methodologies………

• Both labor rates and materials of construction costs are marketplace driven.

• Scope control and work efficiencies are the remaining areas to focus to control duration and costs.


Capturing real, verified task execution data including quantitative per cent complete, earned value, asset “as found", test results, field notes, EH&S and other information can:• Enable a safer work environment by insuring task status on

hazardous environment tasks (entry, etc.)• Eliminate redundant and duplicated tasks• Quantitatively verify task completion so dependent tasks can start

earlier• Capture important asset data during construction, testing,

commissioning

Turnaround Opportunities

http://office.microsoft.com/search/redir.aspx?assetid=TC010774551033&QueryID=sMf7e7zEx0&respos=1


The Process

• Project Steps by Craft• General IntelaTrac Procedures• JSA, Etc.

Job Steps Created in Primavera

http://www.primavera.com/index.asp


Mobile User Interface

Tools T ?

Login

K

Test VBase Area

Login ID Admin V

Everyone V

Test

Role

Password

X Change password after logon

Logon

Test VTAR ID •

Base Area – Work Area Sort

•

Task ID – From Primavera

•

Logon ID / Password – From IntelaTrac

•

Role – From IntelaTrac

User logs onto the Mobile IntelaTrac Application


Primavera Data Categories Added to IntelaTrac

• Status Started• Status Finished• Duration % Completed• Actual Hours• Craft• Activity ID• Activity Description



1. User selects the equipment type from the dropdown

2. User selects a specific Activity ID for Status Update



• Percentage Complete• Status Start• Status Finish• Notes – Available free

text or drop down list data entry for this activity

• Create Work Notification from this screen as required

User Updates Activity Status


The Process

Special Procedures as needed for:• Blinding• Inspection• LOTO



Integrated Procedures

• Procedure assignment to Activity using the Primavera P3E interface with embedded browser to Procedure Instances that have been created in IntelaTrac for:– Vessel Entry– Vessel Closure– Mechanical Inspection, Scaffold Inspection, QA/QC– Equipment shut down or start up– Safety Observation, Job Safety Analysis (JSA)– Pre Start Up Safety Review (PSSR)– Scope Change or Request for Additional Work– Crane or Equipment Inspection– Permits– PSV identification and status– Etc.


The Process

Completed Job Steps Update in Primavera

• Job Step Updates• New Job Steps



22

Mechanical Completion/Commissioning

Test Certificate Attached

Seals fitted to operating arm and adjustment cap

Check valve against data sheet

Flanges protected and sealed

Valve tested

Signed By: GM (FAB), IM (HOOKUP)Outstanding Signatures: IC, GE (SUPR)Description xxx

T101

SignOffTransferAdd to Punchlist

Completion Check Safety/Relief Valves

Tag No.

SRVDesc

Details

35768PO No.

Area

System

Sub-system

T101

S-504 Lower

23

001234 5012MC No. Comm. Pack

Verify valve ID (SCAN)

Check gaskets, flanges and final installation


23

Electronic Mechanical Completion/Commissioning

Test Certificate Attached

Seals fitted to operating arm and adjustment cap

Check valve against data sheet

Flanges protected and sealed

Valve tested

Signed By: GM (FAB), IM (HOOKUP)Outstanding Signatures: IC, GE (SUPR)Description xxx

T101

SignOffTransferAdd to Punchlist

Completion Check Safety/Relief ValvesTag No.

SRVDesc

Details

35768PO No.

Area

System

Sub-system

T101

S-504 Lower

23

001234 5012MC No. Comm. Pack

Verify valve ID (SCAN)

Check gaskets, flanges and final installation

OK Cancel

NESecurity Group


What are some of the benefits?

• Planners/Supervisors– Time saved in reduced task status updates– Potential of 15% reduction in time required for

management of tasks per full time equivalent (FTE) per shift

• Ad-hoc work items– More efficient management of added scope tasks– Potential of reduction of management effort for

these tasks of 35-40%• Dependent task reaction/staging

requirements– More efficient execution of dependent tasks, i.e.

insulation, cleaning, etc.


26

Enabling Task Management During Projects

Function Post Project

• Operations routine duty rounds

• Maintenance PM rounds

• I & E inspections

• HSE compliance rounds

• Training field workers

• Offsites tank gauging & lineups

• QA lab sample rounds

During Projects

start-up/commissioning

NDE/inspections

loop tests/calibration

incident investigation

training verification

hydro/vacuum tests

NDE/source inspection


RFID for Supply Chain of Serialized Equipment

Field Name Count ValueEPC-IS 20 255.255.100.11-855004

OEM Data Count Value

manufacture 14 Dresser Rand

model_number 19 DR02-01-3313-CL-414

serial_number 10 PR87073489

manf_date 2 20-Jan-03

Plant Owner Data Count Value

equipment 18 DR234-876-290-5209

functional_location 10 36-EM-10A

PID_number 16 INT99605-231-702

operation_number 12 MP0003-96296

description 40 Overhead Fan Motor

Owner IssuesTagged AssetTo Contractor

OEM InstallsRFID Tag at

Manufacturing

Plant Owner Receives

Tagged Asset

Future Maintenance Routines triggered

By RFID tag

ContractorInstalls Assetand Loop Test


Thank You

Questions and Answers?

Document

Documents

Transcript of Document