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

Donald J. Frieden, President & CEO, SAT Corporation

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? © 2007 SAT Corporation. All rights reserved.

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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

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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). 4 © 2007 SAT Corporation. All rights reserved.

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Capital Project Opportunity • Enterprise Systems for Capital Project Management are being deployed by owner/operators and other project stakeholders (EPC), but are seldom integrated. ¾ ¾ ¾ ¾ ¾

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. 5 © 2007 SAT Corporation. All rights reserved.

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Example of a Disconnect Crew waiting because dependent tasks not updated in project schedule

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Domino Theory

4. First year Operability Effected

3. Project overruns and demobilization delays

2. Critical path of project slips

1. Cumulative task cycle time delays

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Capital Project Improvement Opportunities 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

Project Definition

Project Planning

Project Design

Fabrication/ Construction

Testing/ Acceptance

Operations

Decommission /Retrofit

Results: • • • •

Lower Implementation Cost Capture of early operation asset data (First Year Operability) Quicker deployment Better overall ROI

• • • • •

Equipment data sheets Process flow diagrams Vendor/Supplier SOP’s Testing Results Etc.

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Reducing EPC Costs and Improving FYO What if you could have?

Engineering, Procurement and Construction

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

These results

Fewer Schedule Delays and Reduction in Cost Overruns

First Oil/Gas

Asset Lifecycle Management

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

Fewer Asset Failures and Reduction in Lifting Costs

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The Turnaround Challenge OS M C R

Sar ban

Ut i li

za tio

Co st

Turnaround Success

es-O xley Sa

ecard

st e B

Flawless Execution

RBI

fe ty

Balanc ed-Sco r

ty i l a Qu

ce i t ac r P

a m ig S ix

Ti m

a Le

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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.

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Turnaround Opportunities 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

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The Process

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

Job Steps Created in Primavera

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Mobile User Interface User logs onto the Mobile IntelaTrac Application Login Base Area Test

TAR ID Test

Role Everyone

Password Test

• Base Area – Work Area Sort • Task ID – From Primavera • Logon ID / Password – From IntelaTrac

Logon

• Role – From IntelaTrac X Change password after logon Tools T ?

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Primavera Data Categories Added to IntelaTrac • • • • • • •

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

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Mobile User Interface 1. User selects the equipment type from the dropdown

2. User selects a specific Activity ID for Status Update

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Mobile User Interface User Updates Activity Status • • • •

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 © 2007 SAT Corporation. All rights reserved.

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The Process

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

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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. © 2007 SAT Corporation. All rights reserved.

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The Process

Completed Job Steps Update in Primavera

• Job Step Updates

• New Job Steps

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Mechanical Completion/Commissioning Completion Check Safety/Relief Valves Tag No.

T101

Area

SRV 35768

System

PO No. MC No.

001234

Desc

T101 S-504 Lower

Sub-system 23 Comm. Pack

5012

Verify valve ID (SCAN) Check valve against data sheet Valve tested Test Certificate Attached Seals fitted to operating arm and adjustment cap Flanges protected and sealed Check gaskets, flanges and final installation

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

Add to Punchlist

Transfer

SignOff

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Electronic Mechanical Completion/Commissioning Completion Check Safety/Relief Valves Tag No.

T101

Area

SRV 35768

System

PO No. MC No.

001234

Desc

T101 S-504 Lower

Sub-system 23 Comm. Pack

5012

Verify valve ID (SCAN)

Security Group

Check valve against data sheet

NE OK

Valve tested

Cancel

Test Certificate Attached Seals fitted to operating arm and adjustment cap Flanges protected and sealed Check gaskets, flanges and final installation

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

Add to Punchlist

Transfer

SignOff

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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%

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Enabling Task Management During Projects Function

Post Project

During Projects

• Operations

routine duty rounds

start-up/commissioning

• Maintenance

PM rounds

NDE/inspections

• I&E

inspections

loop tests/calibration

• HSE

compliance rounds

incident investigation

• Training

field workers

training verification

• Offsites

tank gauging & lineups

hydro/vacuum tests

• QA

lab sample rounds

NDE/source inspection

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RFID for Supply Chain of Serialized Equipment

OEM Installs RFIDName Tag at Field Manufacturing EPC-IS

Plant Owner Receives Count Tagged Asset 20

OEM Data

Owner Issues Tagged Asset Value To Contractor

255.255.100.11-855004

Count 14

Dresser Rand

model_number

DR02-01-3313-CL-414

serial_number

PR87073489

manf_date

20-Jan-03

Count

Value

equipment

DR234-876-290-5209

functional_location

36-EM-10A

PID_number

INT99605-231-702

operation_number

MP0003-96296

description

Overhead Fan Motor

Future Maintenance Routines triggered By RFID tag

Value

manufacture

Plant Owner Data

Contractor Installs Asset and Loop Test

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Thank You

Questions and Answers?

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