Gray2K - The Great Shift Change Ready or Not, Here It Comes!

Transcription

1 Q&A and Technology Forum Plant Automation & Decision Support October 7-9, 2013 Sheraton Dallas Hotel Dallas, TX PD-13-8 Gray2K - The Great Shift Change Ready or Not, Here It Comes! Presented By: Blair Morgan General Manager Innovatia Saint John, NB Canada Am erican Fuel & Petrochem ical Manufacturers 1667 K Street Suite 700 W ashington, D C voi c e fax www. afpm.org

2 This paper has been reproduced for the author or authors as a courtesy by the American Fuel & Petrochemical Manufacturers (AFPM). Publication of this paper does not signify that the contents necessarily reflect the opinions of the AFPM, its officers, directors, members, or staff. Requests for authorization to quote or use the contents should be addressed directly to the author(s)

3 Innovatia Overview A Knowledge Management company Founded in employees 1,500 customers in 29 countries We create and deliver documentation, technical training and technical support Research & Development leaders in content re use methodologies Offices in Saint John (Canada), Calgary (Canada), Houston (USA) and globally PD-13-8 Page 1

4 Identifying Tribal Knowledge Competitive Advantage Market Position Proprietary Technologies Intellectual Property Tribal Knowledge Operations Knowledge Impacts Best to Worst PD-13-8 Page 2

5 Industry Turnover Projections Industry Personnel Demographics Projected Retirements Next Generation Generation Lite Jersey Shore, Kardashians, Bieber Green Energy, Save the Earth, Climate Change Industry Market Shifts Athabasca, Eagle Ford, Bakken, Marcellus Sweet Crude Refining Capacity Petrochemicals NGL, LNG PD-13-8 Page 3

6 Eagle Ford Shale Drilling permits PD-13-8 Page 4

7 What can we do? Man who waits for roast duck to fly into mouth must wait a very, very long time. Chinese Proverb Best time to plant a tree was 20 years ago. The second best time is today. Chinese Proverb PD-13-8 Page 5

8 Knowledge Management Playing Field Demand Executive Decision Support Quarters Days Hours Minutes Operating Plan Integration & Optimization Shift Worker Scheduling Raw Materials Supply Planning Product Demand / Capacity Planning Operations Performance Analysis Energy/ Utilities Mgmt. Operations Scheduling On-Line Optimization Advanced Control Regulatory Control Oil Accounting Custody of Receipts/ Shipments Oil Movements & Inventory Control Laboratory/ Quality Mgmt. Sample Mgmt. Test Results Reliability Management Maintenance Management Overview Materials Management Turnaround/ Construction Management Work Order Planning & Scheduling Labor Availability Emergency Work Order Planning & Scheduling Equipment Records/Maint. History Contracted Services Management Engineering Documents Management Financial Planning, Analysis & Reports Accounting Personnel & Training Payroll Health & Safety Hazardous Materials Tracking Environ. Controls Planning & Scheduling Process Units Oil Movements Quality Maintenance Eng. Finance Doc. Mgmt. Admin. & Regulatory Source: Solomon & Assoc.. PD-13-8 Page 6

9 Knowledge Management Opportunities Demand Executive Decision Support Quarters Days Hours Minutes Operating Plan Integration & Optimization Shift Worker Scheduling Raw Materials Supply Planning Product Demand / Capacity Planning Operations Performance Analysis Energy/ Utilities Mgmt. Operations Scheduling On-Line Optimization Advanced Control Regulatory Control Oil Accounting Custody of Receipts/ Shipments Oil Movements & Inventory Control Laboratory/ Quality Mgmt. Sample Mgmt. Test Results Reliability Management Maintenance Management Overview Materials Management Turnaround/ Construction Management Work Order Planning & Scheduling Labor Availability Emergency Work Order Planning & Scheduling Equipment Records/Maint. History Contracted Services Management Engineering Documents Management Financial Planning, Analysis & Reports Accounting Personnel & Training Payroll Health & Safety Hazardous Materials Tracking Environ. Controls Planning & Scheduling Process Units Oil Movements Quality Maintenance Eng. Finance Doc. Mgmt. Admin. & Regulatory Source: Solomon & Assoc.. PD-13-8 Page 7

10 Knowledge Management Solution Elements Personnel Existing Future Strategies Operational Excellence Reliability Management Process Safety Management Technology Hardware Software PD-13-8 Page 8

11 Knowledge Management Personnel Personnel Cannibalization Hire from the other guy Secure Existing Personnel HR Strategies HR Development Strategies for New Hires DACUM Competency Management Technical Certification Program Lamar IT Robust Client Specific Training Programs Training Simulators STEM Programs Develop the Personnel Pipeline PD-13-8 Page 9

12 Knowledge Management Strategies Strategies Operational Excellence / Reliability Management Best Practices Consistent Deployment Continual Improvement Process Safety Management Regulatory Compliance PD-13-8 Page 10

13 Knowledge Management Technologies Technologies Hardware Personal Digital Assistants (PDAs) PD-13-8 Page 11

14 New Form Factor PDAs PD-13-8 Page 12

15 Knowledge Management Technologies Software Enterprise Asset Management Systems Field Data Collection Operations Data Maintenance Data EHS Data Procedure Development / Deployment Operations Procedures Maintenance Procedures Operator Driven Reliability Procedures PD-13-8 Page 13

16 2011 PSM National Emphasis Program review PSM area cited % Mechanical integrity 19 Process safety information 18 Procedures 17 Process hazard analysis 16 Management of change 10 Incident investigation 7 Compliance audits 4 Contractors 3 Operator training 2 Employee participation 2 OSHA has issued citations to 58 of the 60 refineries that they opened inspections. Total of 986 citations, that s 17 citations per inspection The other 2 (of the 60 refineries) are still under investigation and citations are yet to be released PD-13-8 Page 14

17 Site Safe Incidents: Procedural Deficiencies Wrong revision 4% Check off misused 4% Undefined 5% Incorrect information 7% No details included 7% No procedure 43% Ambiguous instructions 1% No check off 1% Wrong sequence 1% Procedure too difficult 2% Info not required 10% Situation not covered 15% PD-13-8 Page 15

18 Asset level: An industry focus Industry Best Practices are migrating to asset level: Procedures are often available at a unit level and generic asset/procedure type Work is performed at an asset level Plant areas and specific installations can change the operating characteristics from one area to another within a plant Procedures written at an asset level are easier to track their use Designed Right Installed Right Operated Right Maintained Right Asset Operating Procedures PD-13-8 Page 16

19 Traditional Approach Traditional approach has technicians authoring no tracking or audit for author or execution, and a bottleneck for reviewing procedures and the knowledge is in the heads of the workers. A site with 65,000 assets requires man years of effort using traditional development A Big Problem Requiring a New Approach PD-13-8 Page 17

20 Potential Approaches Word Processing Manual writing of procedures, potentially using Word templates and styles to assist with formatting, often with the use of samples to provide guidance Assisted Writing Manual writing of procedures, with assistance of writing and style recommendations to improve consistency Single Source Authoring Object configuration of procedures enables content to be written once and re used many times. Integrated with EAM, style and formatting managed by the system. Procedure deployment tracked at the statement level. PD-13-8 Page 18

21 The Science of Single Source Pump A24 Start-Up Each st atement is created once and reused many times ac ross multiple p rocedures. Statement Database 1. Install check valve 2. Open bleeds to collection Disable automatic pump start 22. Leave vents and drains open 90. Open lines to steam trap 125. Verify vacuum seal 126. Shut down main line 495 Unique statements 93,670 Instances of those statements used 17. Disable automatic pump start 22. Leave vents and drains open 90. Open lines to steam trap Compressor B3 Bypass 22. Leave vents and drains open 38. Commission Seal Pot 293. Bypass Hot Slide Pump A24 Prep for Maintenance 8. Close and tag suction block valve 22. Leave vents and drains open 90. Open lines to steam trap Exchange D21 Shutdown 90. Open lines to steam trap 252. Verify lube supply Pump A55 Start-Up 17. Disable automatic pump start 158. Open, lock and tag motor breaker PD-13-8 Page 19

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23 Summary Personnel Existing Future Strategies Operational Excellence / Reliability Management Process Safety Management Technologies Hardware Personal Digital Assistants (PDAs) PD-13-8 Page 21

24 Summary Technologies Software Enterprise Asset Management Systems Field Data Collection Procedure Development / Deployment Single Source Content Management Software 90% Savings in Procedure Development / Deployment Digitally Deployed through PDAs MOC Tools Integrated with existing EAMs, EHS, etc. Audit Trail Investigations, regulatory compliance PD-13-8 Page 22

25 Conclusion A journey of a thousand miles begins with a single step. Chinese Proverb PD-13-8 Page 23

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