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Plant Operations Management

Plant Operations Management. A well-managed plant means having full control over all events, planned or unplanned. Welcome to a world where plant operations and management software work hand-in-hand giving you full visibility and control, right down to task level. 1.0.0.0. Agenda.

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Plant Operations Management

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  1. Plant Operations Management A well-managed plant means having full control over all events, planned or unplanned. Welcome to a world where plant operations and management software work hand-in-hand giving you full visibility and control, right down to task level. 1.0.0.0

  2. Agenda • Overview 3 • Operating Log – What, Why? 4 • Operating Log upgrade 5 • Why change 6 • New Features 7

  3. Overview PlantVue addresses critical business challenges such as • Outage control • Out of normal maintenance (Detailed and summarised views) • Compliance to safety regulations (Per task) • Enforcement of minimum skill availability on a team-level • Staff roster and scheduling (Live and simulated shifts) • Real-time auditable reporting on management level • Auditable Shift Handovers to enforce accountability PlantVue has a solid track-record with state- and privately owned power plants in South Africa Although PlantVue was created for a nuclear power plant initially, the PlantVue processes and controls are applicable to operations management in any industrial plant

  4. Business Objectives PlantVue was created to assist with the business goals associated with a production plant. The key-points that PlantVue addresses are: Compliance to employee and plant safety Lower downtime Lower risk Enforces accountability Fully auditable Indicators for Management- and Executive-level reporting

  5. Continuous Process Management – 24/7

  6. Operations Aspects of operations that PlantVue controls: Permits to Work Temporary Operating Instructions Out-of-Normal Isolatable Points Breaker Lists Plant Status Checklists Shift handover changes Categorised Log Entries Standby Rosters (Automated updates and notifications via SMS) Executive Reports Simulations Standard Operating Procedures (Link to document management system) Links to HR, Scheduled Maintenance and Asset Register system Safety and team skill complement and training compliance Pre- and post-task recommissioning checks Plant operators are responsible for the safety of the teams that perform the duties in the plant, such as maintenance, repairs and inspections. These duties typically carry with them various risks that the plant operator needs to be constantly aware of, some of which require certain skills or abilities or others that require work areas to be isolated and/or secured before tasks can be executed.

  7. Managing your plant For management: Single-page overview across your organization For the operators:

  8. PlantVue Architecture COO / CEO Plant Artisan Plant Operator

  9. Application Suite

  10. Staff control

  11. Staff • Comprehensive system for staff and shift roster management. • A reduced version can be executed out of the OPSLOG for direct shift applicable options. • Personal details can be ‘red-lined’ by any staff member on his own data, to be verified by a proper authorised person. • Leave booking can be proposed by any staff member and is only effective if approved by a proper authorised person. • A TOIL system is available for ‘Time-Off’ compensation for overtime. • Manager warnings for: • Leave not approved • TOIL outstanding • ‘Holes’ in shift staff allocation • Each shift position can be pre-specified with requirements ito. Qualification, skill and appointed position. • Calendar shift cycle can be printed for any applicable year. • The Active position register acts as a window into a specific day on shift. If a position is not filled, a staff assister will guide the authorised person to find an appropriate staff member to fill the position.

  12. Staff - continued Staff details include: • Person Profile • Leave / Off shift booking of staff members • A Person per roster position graphical display • Proposed Personal detail management • Shift Cycle options include: • Required shift configuration • Calendar Shift Cycle • Active Position Register • Shift Organisational Structure • Configuration options include: • Access Profile • Organisational structure • Shift Cycle • Leave / Off shift types • Shift Positions • Qualifications and Skills • Public Holidays • Leave Zones • User Groups Reports Include: Regulations (PSR / HVR Expiry) Permit Access Individual Group Member List Qualifications (Expiry)

  13. Standby Roster Standby framework totally configured per site. Multiple Standby Rosters are possible. Start / End time for daily standby can be set. Phone Numbers allocated can be personal or a shared standby phone. Security level controlled for posting of standby personnel. Integrated with OPSLOG for callout of standby person Automatic Log Entry on confirmation of callout. New: Interfaces with SMS cellphone system for SMS dispatch.

  14. Plant Not Available - PNA Monitors Plant Not Available expressed as a percentage over a time period. Interfaces with the OPSLOG Plant Status Registers. Feedback given to OPS via OPSLOG regarding any Register Entry. Log Entries and Permits are linked to Register items for auditing puposes. Certain business processes can be automated based on site specifics. Browser for OPS Logs and Permits included to scan for possible affected items. System can be maintained standalone.

  15. Production Minutes Production Minutes framework totally configured by Site (based on meeting formats). Various Meetings can each have a framework with a roll-up to a high (or higher) level Meeting. Outstanding items are automatically rolled over to the next Meeting. Meeting Item Types can be preset for the possible status condition of an item. Each status change is monitored and history available since forst creation. Responsible section / person can be attached to an outstanding item. Estimated response dates can be set – and will be alarmed to the responsible person.

  16. Checklists Used for template design of Shift or non shift checklists. OPS Shift Handover checklists can be designed. Any checklist can be completed / reviewed using the standalone system. Reading variable design can be done with proper authorisation Checklist Items have the following features: • Numeric or status results • Expected values • Normal operating range specification • Hi, HiHi, Lo, LoLo Alarm limits • Rate Alarms • Graphical last 10 point trend per item • Trend indication • Notification required option • Reading status indication Comments can be attached to a result

  17. Requalifications Acts as Planning Tool for day to day permit activities. Workflow of permits are managed until dispatched to OPS. Permits can be launced using a SAP ‘inbasket’. Attachments can be added to a permit, including: • Safety Cetificate • RAD Certificate (nuclear) • Modification control • Work Package control • KO implications Non OPS permits can be completely handled with the CPTWS standalone. OPS Permits can be pre-supplied with isolations. Warnings can be electronically issued to OPS for Urgent permit requests.

  18. Operations Log Writing of a legal OPS LOG Permit implementation according to design requirements in line with legislation Fully audited

  19. Screen-shots and reports

  20. Workflow Engine Workflow is controlled by: • System Origin which created the item • Executing system for the current action • Allowed workflow status • Allowed status to be moved to • Edit types availble to the current state • Qualification of staff member • Skill of staff member • Staff Group membership • OPS Shift Appointed Position

  21. Outagage Management • Allows for complete outage templates to be designed before the outage. • Controlled release of permits to the ‘Live’ system (‘actualisation’). • Permits can be grouped in work packages. • Indication of release of permits – monitor outstanding permits. • Templates can be fine tuned and re-used for future outages. • Major and minor outages are covered. • Block and Master permit formats supported. • Re-release of permits (with revision change) can be done. • Outage can be monitored ito plant blocking at any stage of the outage.

  22. Recommissioning System • A similar system to the Outage Management • Controls recommissioning requirements based on equipment worked on • Verifies unit state for sproper planning to synchronise recommissioning activities • Template can be created and re-used as required • Builds up a log of all requiements during an outage, and ensures all recommissioning will be done before the end of the outage

  23. Staff System

  24. Standby Roster

  25. Plant Not Available

  26. Production Minutes

  27. Checklists

  28. Call-Out Report

  29. Executive Report

  30. Ops Log Report

  31. Usage models

  32. Approach The PlantVue software architecture lends itself to run as a scalable application base. This means that it can be run as contained unit, as a larger client-server installation with multiple integration points, or any combination in-between. Return True offers PlantVue in either a pre-paid licence or a monthly rental licence. The monthly rental is available for a 5 year contract. *Prices are in US$ for a minimum configuration of modules for one site and is valid for new contracts up to 30 Sep 2014

  33. Company Overview

  34. History Return True was started in Cape Town, South Africa in 2009 with the mission to create a blueprint for the most sustainable software development company in South Africa. Our method was to assemble a team of highly skilled individuals that are experts in the field of mobile applications, web applications, service-oriented architecture, real-time database systems and Business Intelligence. Our vision is to use our abilities, skill and diligence to be the choice software product development company in South Africa. Since 2009 Return True has been involved in a mixture of projects and products including industrial laundry processing, plant operations, virtual vending services, international funds transfer software, mobile business software and mobile games (iOS/Android/Windows 8 Mobile), cellular relays, medical aid and many more. Today Return True is responsible for the entire application life-cycle for 9 production systems, 6 of which are on behalf of our customers. Our product-approach to software development includes scoping, business analysis, specifications, development, automated testing, deployment, documentation, commissioning, support, handover and continuous upgrades.

  35. Industry experience - years

  36. Technical experience - years

  37. THANK YOU For more information on PlantVue, integration possibilities or additional modules by Return True for your plant, make contact with your agent or directly with Return True. More products by Return True: Policy Link Happy People iScratch ExamVue http://www.returntrue.co.za

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