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Effective Shut Planning and Management “From a contractors perspective” MESNZ Maintenance Conference 2015 “ “ We have over 20 years’ experience as a predominant Presenter: Dave Young Operations and Marketing maintenance solutions provider Manager, Integrated Maintenance Group

TODAY Introduction Case Study – An example of   when shit happens Planning, Scheduling  and Client Interface QA/QC  Types of work packages Skilled Staff where do they   come from Supervision  Innovation  Nation Wide Shut  Calendars Conclusion  Health & Safety and how  Technology can play a part MESNZ Maintenance Conference 2015

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

SCHEDULING AND PLANNING 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

SHUT PLANNING AND PACKAGES Plant Owner Management Staff are managed and • Model supervised by the plant owner. Typically used for PM checks • and small maintenance jobs Majority of IP remains with client • MESNZ Maintenance Conference 2015

SHUT PLANNING AND PACKAGES Packaged Work Contractor Contractors manage the • Ownership Model complete jobs or tasks. (Becoming more of the norm) 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 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 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. MESNZ Maintenance Conference 2015

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

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 • MESNZ Maintenance Conference 2015

Where will we get these skills from in the future? Skilled Trades Personnel Project Management / Support • • Welders (ASME, 4711) Scheduling / Planning • Specialist Stainless Steel Welders HSE Management Specialists • Fitters Senior Supervisors, Leading Hands • Trade Assistants / Labourers and Team Leaders Confined Space & Gas/Safety Quality Managers & CBIP Inspectors Watches • Machinery Operators Fabricators • Breathing Apparatus & Rescuers Procurement • Scaffolders & Riggers (dual Asset Management / Procurement • training) Human Resources & Casual Talent • Recruitment Transport & Machinery Specialists • Civil • 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 MESNZ Maintenance Conference 2015

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