Process Diagrams Logistics

7/25/2019 Process Diagrams Logistics

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Process Diagrams



Process Diagrams

Purpose

To provide logical, sequential flow diagrams that explain in detail the functional

requirements of various roles within the Turnaround organisation during the

Preparation Phase

Contents

Page 1 Logistics – General requirements Logistics – !ntegration with Planning and Procurement

" Logistics – #caffolding, !nsulation and Painting

$ Logistics – Cranes and Transportation

% Logistics – !nfrastructure and &elfare

' Logistics – #ervices and (aterials

) Logistics – *ul+wor+ control

Logistics – !solation *linds

- Logistics – .ightshift

1/ Logistics – #tores

11 Planning – (ethodolog0

1 perations – *loc+ing out Permits 1" Pro2ects – Pro2ect methodolog0



Turnaround (anager appoints aLogistics Coordinator

Logistics Process. Diagram No 1 – General Requirements

Logistics Coordinator and T34(anager anal0se requirementsand agree on the ma+e5up of The Logistics Team

Preparation 6ngineers provide Logistic Coordinator with listsof 7ul+wor+ and prepares aplot plan showing the location

of the ma2or 2o7s on each plant

T34 (anager presents theLogistics Team rganogramto the #teering Group fordiscussion and approval!f re2ected or requires modif0ing

#caffold Coord modifies the

rganogram and resu7mits it

&hen #teering Group approverganogram, Turnaround (gr8!ssues letters of appointment#igned 70 the senior manager

&hen #teering Group approverganogram, Turnaround (gr8!ssues letters of appointment

#igned 70 the senior manager

&hen #teering Group approverganogram, Turnaround (gr8!ssues letters of appointment#igned 70 the senior manager

Logistics Coord 7riefs eachteam mem7er and explains

the 2o7 requirements 9using the flow charts:

Logistics Coord manages the pre5shutdown wor+ with the#upport of the Logistics Team

Logistics Coord reports to theT34 (anager on progress on

3n agreed regular 7asis

Logistics Coord manages theT34 execution phase with#upport form the LogisticsTeam

Includes;Dail0 !nternal T34 meetings;(onomeros meetings;&ritten progress updates;utput of contractor meetings;utput of trou7leshooting;(emos, e5mails etc

IncludesPlanning < (anaging=;(aterials;6quipments;Cranes;Transportation;#caffold;!nsulation;Painting;Decontamination;!solation 7linds;#ite infrastructure < welfare

Logistics Coord reports to theT34 (anager on progress on

3n agreed regular 7asis

Logistics Coord, when T34 isCompleted, ensures that thesite is demo7ilised < cleaned

Logistics Coord, de7riefs theLogisitics Team and recordslearning for improvements

Logistics Coord demo7ilisesThe Logistics team



Logistics Process. Diagram No 2 – Integration with Planning Procurement

Prep Eng. peci!iesrequirements

"Resources "#aterials "Equipment "er$ices "%tilities "&acilities' (erti!ication ) Goods Inward Inspection

Prep Eng transmitsrequest to Proc (oord*#a+ include apre!erred supplier,

Proc (oordIdenti!ies supplier )

and o-tains price ) deli$er+

Proc. (oord transmitsprice and deli$er+ datato Planner *i! required,

Prep Eng agreesRequests procurement

to proceed

Prep Eng disagrees,Requests Proc Coord.to find alternative

Proc. (oord placespurchase order on

supplier

Proc CoordT ransmits copy toLogistics Coord

Turnaround Manager & Procurement Coord agree expediting needs

upplier deli$ers goods

tores (oord recei$es )checs i! goods are !it!or purpose

Prep Eng arranges goodsInward inspection *i! required, Turnaround Manager

decides how quarantinedgoods will e dealt with

Re!ects"#tores Coord returnsgoods to supplier forreplacement

$ives writtenconcession"

Passes “Boxed” list to Prep Eng.

If required, Proc Coord reports progress of deliveries to Prep Eng

tores (oord in!ormsLogistic (oord whengoods are a$aila-le

Prep Engineer informsLogistic Coord !ere "!en goods are required

Logistic (oord creates aprogram !or distri-utiono! all goods

/n agreed dates0

Logistic (oordrranges !or goods to -edrawn !rom stores

La+s out site as per plotplan

Logistic Coord regularly updates Prep Engineer on progress of logistic

program

%ogistics Program for distriution of

'solation linds (on)site*Proprietar+ items (on)site if possile or in la+ down areas near to site*arications (on)site if possile or in la+ down areas near to site*#mall spares and common stoc- oxed in satellite stores%a+)down areas for foul items, clean items and new itemsCranes and other heav+ plant (in agreed positions for da+ of event*#ervices / scaffold, lagging etc

acilities / water washing etc 0ccommodation / offices, cains etc 'nfrastructure / temporar+ cales paths piping etc.

tores (oord -o3es4materials as per the

-ills o! material

Logistic 5eam locates ) palletises isolation-linds using lists supplied -+ /perations

Logistic (oord creates site plot plan

tores (oord putsaccepted4 goods

in the stores

#tores Coord quarantines1re!ect2 items & informsTurnaround manager

Proc (oord in!orms5urnaround manager o! Red 6one deli$eries

/R

Prep Eng c!ec#“Boxed” items

tores (oord ad$isesPrep Eng o! deli$er+



Logistics Coordinator allocatesscaffold responsi7ilities

#caffold Coordinator lists allscaffold requirements and

creates a #caffold Plan

Preparations 6ngineers identif0 thescaffold requirements < transmitthem to Logistics Coordinator

ca!!old plan

;Prioritises critical scaffolds;Lists >load 7earing? #caffold;#hows all required scaffolds;#chedules scaffold 7uilds;6stimates *uild times;6stimates resources required;3n0 other critical features

Insulation;Lists insulation removal;!ndicates extent of removal at each location;@ighlight haAards 9as7estosB:;List insulation re5instatement < new insulation requirementsPainting;List painting tas+s

Logistics Process. Diagram No 7 – ca!!old0 Insulation and Painting

Logistics, #caffold andTurnaround Coords meet tofinalise < approve Plan

Logistics Coord advises ProcCoord of resource < materialrequirements

Proc Coord procures scaffold!nsulation < painting resource< materials for agreed dates

#caffold Coord explains tas+,< safet0 requirements and passes Permit to resource

#caffolders 7uilds or modifies#caffold and advise #caffoldCoord when it is completed

#caffold Coord inspects thescaffold then advises 3rea

Coord it is read0 to use

ca!!old inspection

;@as it 7een 7uilt to specification;!s it properl0 secured;!s there a means of protecting people from >falling o72ects?

ca!!olders preparation

;3re scaffolders competent;@ave the0 read the Permit;Do the0 understand the ris+s;Do the0 have the correct PP6;Do the0 have safet0 harnesses

&or+ crew use scaffold toperform scheduled tas+s

!f scaffold requires modificationr additional scaffold is required&or+ crew inform the #caffoldCoordinator

&hen wor+ is complete 3reaCoord ensures support wor+is complete 5 !nsulation andpainting etc

upport wor

; inal !nspection or chec+s; Lagging reinstated; Lighting removed;3n0 other support wor+

3rea Coord informs #caffoldCoord scaffold use complete

#caffold Coord instructs the #caffolders to strip scaffold

#caffolders strip #caffold< advise #caffold Coordwhen it is completed

#caffold Coord hands 7ac+the Permit to &or+

ps Permit !ssuer signs off The permit

Plan is re2ected requires modif0ing

#caffold Coord modifies planand then resu7mits it

Proc Coord 0dvises Cost Coord of resources & material needed

#uppliers provide wee-l+ hireand other costs to scaffoldCoord for approval

#caffold Coord approves andthen passes to Cost Coord

Cost Coord monitors costs& advises %ogistics Coordof current status

Cost Coord records costs in T0R cost report

#caffold Coord reports additional wor- costs to Cost Coord

#caffold Coord lists < applies for Permits to &or+

Permit !ssuer issues requiredPermits for #caffold 7uilds

3rea Coord accepts permit

#caffold Coord issues permitto resource

!f requires, insulators remove

!nsulation as specified

#caffold Coord advises Cost

Coord < Logistics Coord whenhe scaffold is dismantled



Logistics Coordinator allocatesCrane responsi7ilities

Crane Coordinator identifiescrane requirements and

Creates a Crane Plan 3ndTransportation Plan

Crane Coord lists compan0 cranes<vehicles < informs Logistics Coordof an0 additional cranes or Eehiclesrequired

(rane plan;#hows all required cranes;Dates when required;Prioritises critical lifts

;Lists all other lifts;#chedules lifts 9< t0pe of crane:;6stimates lift times;6stimates resources required;#hows crane movements5ransportation PlanDetails vehicle requirements=;&agons;Personnel vehicles;Trailers;or+lift truc+s;ther requirements;Details dates required

Logistics Process. Diagram No 8 – (ranes and 5ransportation

Logistics < Crane Coordmeet with Prep 6ngs tofinalise < approve Plans

Crane Coord organises lifting#tudies with #afet0 Coord

Crane supplier moves craneto required position and setsup for lifting

Crane #upplier carries outlifts under direction of the

Crane Coord

Crane Coord < 3rea Coordchec+ that all lifts for thetas+ have 7een completed

Crane Coord organises next Lifting tas+

&hen all lifts are completed Crane Coord < Logistics

Coord agree demo7ilisation date for crane

Crane supplier removes thecrane from site on agreed

date

Crane Coord lists < applies for Permits to &or+

Permit !ssuer issues requiredPermits for Crane Lifts

Crane Coord accepts Permit

Proc Coord advises Cost Coordof all Cranes and vehicles to ehired

Crane suppliers generateCrane 3ire #heet & givesto Crane Coord for approval

Logistics Coord procures cranesuppliers through Proc Coord

Crane Coord hands 7ac+PermitPermit !ssuer signs off permit

Crane Coord 7riefs Cranesupplier on lift and safet0

requirements and issues Permit

Crane Coord approves andthen passes to Cost Coord

Cost Coord monitors craneCosts and advises %ogisticsCoord of current status

Cost Coord records costs inT0R cost report

Plan is re2ected requires modif0ing

Crane Coord modifies plan andthen resu7mits it

!f additional lifts are requiredCrane8 Coord Ealidates andapproves8

Crane Coord reports additional wor- costs to Cost Coord

Preparations 6ngineers identif0crane requirements < transmitthem to Logistics Coordinator

Crane Coord allocates vehiclesas required

Crane Coord ensures vehicles are fuelled and serviced

Crane Coord organises allhired in vehicles

Crane Coord ensures vehicles are demo7ilised at the earliest possi7le date

Crane Coord reports transport costs to Cost Coordinator

5RNP/R55I/N



Logistics Coordinator allocates!nfrastructure responsi7ilities

!nfrastructure Coordinatorcreates an infrastructure plan

Preparation 6ngineers suppl0 dataon resource num7ers to LogisticsCoord

In!rastructure plan#hows all requirements for,;3ccommodation 9ca7ins etc:;&ashing < changing facilities;Toilets and other a7lutions;Casinos < other food outlets;Temporar0 services 9water, electric, phone, computer lin+s:;Drainage water

;Pedestrian routes;Eehicle routes;6mergenc0 services routes;4estricted areas 97arriers, signs:;#ecurit0 requirements;ther requirements

Logistics Process. Diagram No 9 : In!rastructure

Logistics Coord meets with T34Team to finalise and approve the infrastructure plan

!nfra Coord lists all goods <services that require procuring

!nfra Coord supervises la0ingout and connection of all goodsand services

!nfra Coord monitors wor+ andchec+s that wor+ is completedto specification

&hen all T34 is completed!nfra Coord < LogisticsCoord agree demo7ilisation

dates for all installations

!nfra Coord supervises theremoval of all installations

form site

!nfra Coord arranges for the regular cleaning and servicing of all installations during the Turnaround

Proc Coord 0dvises Cost Coord of all goods and services to e procured or hired

Plan is re2ected needs modif0ing

!nfrastructure Coord modifies planand then resu7mits it

Logistics Coord procures goods< services through Proc Coord

!nfra Coord prepares the site toreceive goods < services

Proc Coord arranges deliver0 ofgoods and services

!nfra Coord lists < applies for

Permits Permit !ssuer issues required

permits

!nfra Coord accepts Permit

ite la+out;3ccommodation suppliers install

ca7ins, change rooms, toilets etc;Contractors or (onomeros la0 in=

5Temporar0 plum7ing < ca7ling 5 &ater drainage 5 *arriers < signs 9restrictions: 5Eehicle routes < speed limits 5pedestrian routes and 7arriers 5La0 down areas 5Toxic refuges 5fire assem7l0 points 5ther facilities

!nfra Coord 7riefs personnel engaged on site la0out of the safet0 requirements < Permits

7efore wor+ commences

La+out (hecs

;3ccommodation is safe < secureand in the designated locations; 3ll furniture < fittings have 7een supplied and are fit for purpose;3ll temporar0 lines are safel0 installed and protected;3ll electric and computer linesare functioning

;3ll 7arriers are erected;3ll signs are visi7le and in the designated locations;Eehicle and pedestrian routes are clearl0 mar+ed;ther chec+s

(leaning and ser$icing;Cleaning of resource ca7ins, toilets, washrooms, casino8 offices < other accommodation;General cleaning of the site for good house+eeping;#ervicing of heav0 plant;4eplenishing of diesel tenders;4eplacement of an0 item that is damaged or 7rea+s down

'nstallation suppliers provide'nstallation and wee-l+ hirecosts to 'nfrastructure Coordfor approval

4elfare Coord approves andthen passes to Cost Coord

Cost Coord monitors the'nfrastructure costs & advises%ogistics Coord of status

Cost Coord records costs in T0R cost report

!f additional support serviceswor+ is required !nfra Coord

validates and approves8

'nfra. Coord reports additional wor- costs to Cost Coord

!nfra Coord agree required dates< details of goods and services



Logistics Coordinator allocates(aterials responsi7ilities

#ervices Coordinator creates (aterials #ervices 9(#: Plan

#5ERIL PLN#aterials;(aterials in (onomeros stores;(aterials to 7e procuredfrom external suppliers

;4ed Fone (aterialser$ices

*(onomeros or Contract:;Decontamination;&aste disposal;Plant hire tools;Eehicles;#tand70 men guardians;&or+shops;ffsite services;ther services

Logistics Process. Diagram No ; – er$ices and #aterials

#ervices Coord applies for Permits to &or+

Permit !ssuer issues requiredPermits for Crane Lifts

#ervices Coord accepts Permit

Proc Coord advises

Cost Coord of all #ervices to e hired

Matl. Coord approves andthen passes to Cost Coord

Cost Coord monitors serviceCosts and advises %ogisticsCoord of current status


Preparations 6ngineers identif0 thematerials requirements < transmitthem to (aterials Coordinator

Logistics Coord procures allservices through Proc Coord

#ervices suppliers providewee-l+ hire and other costs

to Matl. Coord for approval

Logistic Coord chec+s plan and accepts or re2ects

#ervices Coord provides #toresCoord with T34 material >7ox?list – defined 70 tas+

#tores Coord 7oxes up all T34(aterials as per list

#tores manager organises theinstallation of T34 stores andla05down areas

#ervices Coord withdraws T34>*oxed? and other materialsfrom stores and relocates them!n T34 satellite stores

n agreed date #ervices Coordwithdraws materials from T34satellite stores and la0s themut on the 2o75site

!f plan is re2ected, #ervicesCoord amends it

#ervices Coord 7riefs personnelengaged in support services on

safet0 requirements andPermits 7efore wor+ commences

#ervices Coord supervisesthe carr0ing out of support services tas+s

#ervices Coord monitorswor+ < chec+s that tas+ is

completed to specification

#ervices Coord prepares siteto receive support services

!f additional support services wor+ is required #ervices Coord Ealidates, approves < if required, applies for Permit

Matl. Coord reports additional wor- costs to Cost Coord

&hen wor+ is complete= #ervices Coord hands 7ac+the Permit to &or+

ps Permit !ssuer signs off The permit

&hen T34 wor+ is complete#ervices Coord < LogisticsCoord agree demo7ilisation

dates for all installations

#ervices Coord supervises

removal of all services from site

''81'81'8/1



Logistics Coordinator allocates*ul+wor+ responsi7ilities

*ul+wor+ Coordinator createsa *ul+wor+ Control Plan

<ulwor Plan; Lists different t0pes of items 9CE, !E, 4E, pumps, motors etc:; Designates either change out or overhaul of item in wor+shops; or >change out?, designates new or >overhauled spare? to 7e used; !dentifies removal date and date of >latest allowa7le return to site?; !dentifies (onomeros or external

wor+shop for overhaul of items; Displa0s timed program of wor+ and priorities for each wor+shop; Defines the method of >tagging? required to identif0 items8

Proc Coord advises CostCoord of all new items to

e procured

%ogistics Coord approves &then passes to Cost Coord

Cost Coord monitors 45shopcosts and advises %ogisticsCoord of current status


Logistics Coord and *ul+wor+Coords meet with &or+shop(anagers to create a *ul+wor+

program

4or-shops provide costs to%ogistics Coord for approval

Logistic Coord chec+s plan andeither accepts or re2ects

!f plan is re2ected, *ul+wor+Coord amends it to suit

65wor-. Coord reports cost of additional wor- to Cost Coord

Prep 6ngs prepare *ul+wor+Control #heets and transmitthem to *ul+wor+ Coordinator

<ulwor Program;@ow man0 of each t0pe of item to 7e overhauled in each wor+shop;the identit0 tag for each item that designates its plant and location;3 priorit0 list identif0ing >Critical? items to 7e overhauled first;Chec+ that all item spares are

availa7le and moved to &shop;The deliver0 date to wor+shop ofeach item

;The required overhaul completion date for each item;3n0 wor+shop testing required;3 price for each item overhaul;3ction to ta+e in event of dela0

Logistics Coord provides ProcCoord with list of an0 new itemsthat require procuring

Proc Coord procures new itemsfor required dates

Preparation 5 *ul+wor+ Coordorganises for vehicles, or+5

lift truc+s and la0s out palletsfor Transportation of items

*ul+wor+ Coord supplies 3reaCoord with lists of items to 7eremoved and laid on pallets

3rea Coord allocates wor+ to therelevant 3rea #upervisors

6xecution – wor+ crews remove!tems and la0 them on pallets

*wor+ Coord arranges for thetransportation of items to the

wor+shop on agreed date

&or+shop completes overhaul to agreed specification and date

*wor+ Coord resolves pro7lems!f possi7le

&or+shop overhauls items as per the agreed priorit0 list and alerts

*wor+ Coord if an0 pro7lem ordela0 occurs

*wor+ Coord arranges deliver0of overhauled and handover to#upervisors on agreed date

!f not 5 reports pro7lem to 3rea 6ngineer who resolves it

&or+ crews re5install items

*wor+ Coord arranges deliver0

of new and >overhauled spare?items to plant and handover to#upervisors on agreed dates

*wor+ Coord if required, for foul!tems arranges decontamination

Logistics Process. Diagram No = – <ulwor (ontrol



Logistics Coordinator allocates!solation responsi7ilities

!solation Coordinator createsTurnaround isolation Plan


!solation Coord marshals allavaila7le 7linds

Logistic Coord chec+s plan andeither accepts or re2ects

!f plan is re2ected, !solationCoord amends it to suit

Plant Chief provides individual*lind Lists for all T34 2o7s

Logistics Coord provides ProcCoord with list of an0 new 7lindsthat require procuring

Proc Coord procures new 7lindsfor required dates

!solation Coord informs LogisticsCoord of an0 shortages

!solation Coord prepares newand existing 7linds for use

n agreed date isolation Coordsupervises the la0ing out of theisolation 7linds on the plant asclose to 2o7 location as possi7le9hung on the 2o7 if possi7le:

!f, for an0 reason, additional7linds are required during the

T34, !solation Coord informsLogistic Coord

During the T34, !solation Coordmoves 7linds as required

Logistics Process. Diagram No > – Isolation <linds

Prep 6ngs prepare lists of 2o7s 3nd transmit to Plant Chiefs I/L5I/N PLN

#hows the following;.um7ers and t0pes of 7linds;@ow man0 required;La0out locations for da0 1 of T34;*linds that have to 7e switched after da0 one

<LIND #R?LING;Gather together all availa7le

7linds from= ;Plant areas < Control rooms ;Plant stores < General stores ;ffices < ones 2ust l0ing a7out;3s+ as man0 people as possi7le if the0 +now the location of an0 7lind;4ecord num7er and t0pes of 7linds found;Chec+ off availa7le 7linds against individual 7lind lists

required for da0 1 if the T34;Consult T34 schedule to find out when *linds from one 2o7 can 7e transferred to another ;Compare num7ers availa7le against num7ers required

Proc Coord reports cost oflinds to Cost Coord

Preparation;Paint mild steel 7linds with a coat of rust inhi7iting paint

;Clean stainless steel 7linds of oil grease and contaminants;Paint plate t0pe and rating on exposed face of 7lind;Pac+age the 7linds up into sets required for da0 1 isolations;Provide an0 studs, nuts, washers < gas+ets required 9designated 70 plant surve0:;Provide a safet0 >Lollipop? for all hidden 7linds;&rap items in plastic sheet and write the tas+ num7er on the

pac+age;!f the 7linds are large, store them

on a pallet until required

Logistic Coord allocates storagespace for 7lind store

&hen T34 is completed the !solation Coord returns all7linds to *lind #tore

*linds supplier delivers new7linds to *linds store

6lind

#afet+ %ollipop indicatesthat there is a lind inthis location (striped for 3igh visiilit+*



Pre5shutdown 5 Logistics Coordinator*riefs .ightshift Coord on 4oles andresponsi7ilities

6xecution – .ightshift Coordinator@andles all logistic requirements

during the nightshift

Logistics Process. Diagram No @ – Nightshi!t

Da0shift 3rea 6ngineers informLogistics Coordinator of wor+requirements for nightshift

Logistics Coordinator ma+es out alist of logistic requirements for the

nightshift

Logistics Coordinator instructs the relevant mem7ers of the Logistics

team to ensure all materials and service providers are arranged

and in place for nightshift

RequirementsIncludes -ut not limited to ;(aterials < consuma7les;6quipment and tools;#caffold 7uild;#caffold (odification;!nsulation re5installation;Lighting;Eentilation

Logistics Coord 7riefs the .ightshiftCoord on nightshift wor+ to 7e done

< hands over the >requirements? list

.ightshift Coord ensures that allLogistics wor+ is carried out

!f there are an0 requests for extraLogistics wor+ during the shift, the

.ightshift Coord does whatever is4equired to meet the need8

Especiall+ on (ritical Path Ao-s

.ightshift Coord reports progressPerformance and pro7lems to the

Logistic Coordinator during the @andover period at the and of the nightshift

.ightshift Coord wor+s each night#hift until nightshift wor+ is complete

Logistics Coord and .ightshiftCoord agree when nightshift wor+is complete


Logistics Coord reports cost

of extra wor+ to Cost Coord

.ightshift Coord reports an06xtra wor+ done during theshift to the Logistics Coord

!f necessar0, Logistics Coordrequests Proc Coord to 7u0goods or services to replacethose used on extra wor+

Proc Coord procures goods <#ervices and advises CostCoord of costs



Preparation engineer informs ProcCoord of material requirements

Logistics Process. Diagram No 1B – tores

#aterial ProcessIncludes -ut not limited to;Detailed materials lists;4eception of material;Goods inward inspection;Huarantine facilit0;*rea+down of materials

70 individual tas+;Pac+aging requirements;La7elling requirements;Palletising requirements;Liaison with #ervices Coord

Proc Coord 7riefs Logistics Coord onmaterials required

Logistics Coord agrees T34 #toresrequirements with #tores (anager

#tores manager allocates storagespace for T34 materials

#tores manager appoints a #toresCoord < 7riefs Coord on roles and

responsi7ilities

Logistics Coord 7riefs #tores Coordon T34 material process

#tores Coord la0s out T34 storagearea to suit T34 requirements

#uppliers deliver T34materials to T34 #tores

Proc Coord moves T34materials from generalstores to T34 stores

#tores Coord lists materials thatneed procured to store, wrapPalletise < La7el T34 materials

Proc Coord procures materials

#tores Coord advisesProc Coord of deliveries

3rea 6ng arranges goodsinward inspection 9if it is4equired:

#tores Coord pac+ages T34 materials then *oxes and La7els them

#tores Coord advises Logisticseam on progress of *oxing tas+s

Logistic Coord allocates material*oxes to satellite stores on Plants

Logistic Coord delivers material *oxesTo satellite stores

or *oxes to 7e delivered to site duringPre5shutdown phase, #atellite stores!ssue *oxes to #ervices Coordinator

!ssue continues until all pre5shutdown(aterials have 7een issued

During execution, #atellite stores issuematerials as required

Post –event, #tores Coord arranges;4eturn5to5stores of surplus items;4emoval of satellite stores

;4einstatement of stores area

#ervices Coord #upervises the4emoval of the #atellite #tores

Logistics Coord creates roles 3nd responsi7ilities for #toresCoordinator function

!f #tores manager requires an0changes to the requirements,Logistic Coord amends to suit



cquire 7asic list of wor+

ppl+ wor+list filtering tolist of wor+ to create aTurnaround &or+list

Austi!+&h0 are we doing this 2o7B!s it a Turnaround 2o7B&h0 are we doing it this wa0B(lari!+&hat needs to 7e doneBTo what specificationB(ategorise!s it ma2or minor 7ul+wor+BPlanning level requiredBPrioritise&hat do we plan firstB@ow long have we gotB!s there an existing planB

rom Earious sources

rrange &or+list (eetings&ith 2o7 requesters

(hallenge e$er+thing

(reate a plot plan thatshows the location ofeach ma2or and minor tas+ on the plant

(reate schedule sheetsfor all 7ul+wor+ tas+s8

gree < freeAe wor+liston agreed date

/perate the s0stem for latewor+ authorisation8

(reate separate valvecontrol sheets

(reate a detailed planfor each ma2or tas+

(op+ to the Logisticscoordinator to allowearl0 site la05out

(op+ to Plant Teamto allow identificationof isolation 7linds and7loc+ing out of permits

peci!+;3 step5705step 2o7 method;3 complete *ill of (aterials

;3n equipment list;3 list of services required;(anpower requirements;Io7 safet0 anal0sisInclude;#upporting documents;Permit reference num7er ;@aAard chec+list

(reate a tas+ networ+for each ma2or tas+

(onsider clustering tas+s toreduce time and effort

peci!+ critical path andduration

rrange meetings withplant engineers andor pro2ect engineers8

!nvolve #afet0 Coord

(hallenge e$er+thing

(hallenge Planning Process. Diagram No 11 : #ethodolog+

Communications utline 4equirements Detailed 4equirements

5he golden rule

3ll unnecessar0 wor+ outJ 3ll necessar0 wor+ inJ

4or-list control is the most critical activit+ ecause all

other elements of the event are ased on the wor-list

peci!+ Pre5shutdown wor+4equirements and transmitthem to Logistics Coord

Estimate durations to identif0critical path and transmit toTurnaround Coordinator

&or Duration Dri$en E$ents

;Perform CP compression 9theor0 of constraints:

;3ppl0 >stretch target?

;3ppl0 >what if? scenario

#ind:set Cuestion

>&hat will it ta+e to dothe 2o7 in K timeB?

;6liminate tas+B;#implif0 tas+B;Parallel wor+ingB;!ncreased resourcesB;.ew shift patternB;.ew methodB;.ew techniqueB

;.ew technolog0B;Contractor challengeB

(reate a product to product#chedule for the event

<alance extra profit fromproduction gains againstextra cost of compression



Preparation 6ngineer develops anoutline method statement for all(a2or tas+s and a schedule sheetfor all 7ul+wor+ tas+s

Preparation 6ngineer arranges ameeting with Permit !ssuer and4is+ 3ssessor

(eeting reviews method @CLsand methods for or each tas+, andas+ the % haAard Huestions

Permit Types

1 Cold work

2 Hot Work

3 Excavation7 Special Risk Area

5 Electrical

6 Confined Space Entry

7 Weld on ive E!"ip#ent

$ %Hot &ap' (rillin)

Preparation 6ngineer defines t0peof Permit9s: required for the tas+

The 5 Questions1 Is the task in a hazardous area?

2 Will the task have any induced hazards?

3 Will the work reuire any preparation?

! Will the work reuire isolation?

5 Will the work reuire special procedures?

4is+ 3ssessor anal0ses tas+ todefine haAard then fills out @aAardChec+list and !ndicates additional

ris+ assessment required 9if an0:

Turnaround (anager appoints 4is+ 3ssessor

#tandard @CL form

Permit to wor+ issuer *loc+s outPermits to &or+ using the dataprovided 70 the meeting and thencross references permits withtas+ code num7ers

Preparation 6ngineer transmitstas+s and permit requirementsto 4is+ 3ssessor

Permit to wor+ issuer archives

7loc+ed out permits until the0are required

Permit to wor+ issuer list of the7loc+ed out permits to Prepsengineer

Any Special *roced"res re!"ired+, ine disconnections for vessel openin)

2 Cold c"ttin) of lines for weldin)

3 Re#ovin) red"ndant )as free - isolated pipework

. /e0icle entry into 0a1ardo"s areas

5 Handlin) of co#pressed )as cylinders

6 se of radioactive so"rces and #aterials

7 Work on live flare and low4down syste#

$ solation of sections of fire #ain

perations Process Diagram .o 1 5 *loc+ing out permits



Turnaround (anager liaiseswith Pro2ect 6ngineer on the

pro2ects to 7e carried outduring the Turnaround

(ompleted Plan elements;Detailed Io7 (ethod;Critical path schedule 9with times:;Tagging and Permit requirements;Io7 #afet0 3nal0sis;Test requirements 9pressure test etc:;3n0 special requirements or restrictions;Complete *ill of (aterials 9all items:;Deliver0 dates for all material;!dentification of 46D F.6 materials;List of contractors to 7e used;List of inspection requirements;.um7ers and t0pes of resources

;6stimate of man5hours;6stimate of installation costs;List of equipment required 9cranes etc:;List of services required 9scaffold etc:;e0 dates for Preparation"e0 dates for 6xecution;!ndex of support documents;4eference to technical specifications

Process Diagram .o 1" 5 Pro2ects

Plant team defines Processrequirements

Pro2ect engineer develops plan

Pro2ect 6ng8 and T34 manager review plan identif0 issues thatcould prevent the Pro2ect from7eing read0 in time for T34

Pro2ect 6ngineer transmits *illof materials to Procurement

Pro2ect 6ngineer does whatis necessar0 to resolve an0

issues List o! #aterials *with material specs,;a7ricated Eessels;Pumps, motors, valves, spare parts;rifice plates, 7ursting discs etc;6lectrical item pac+ages;!nstrument item pac+ages;Plate steel 9individual or fa7ricated:;.on ferrous metals 9individual or fa7ricated:;Pipes 9lengths or fa7rications:;langes, studs, nuts, washers;Gas+ets;3n0 other material requirements

Procurement procures materials< informs Pro2ect 6ngineer when

the0 are delivered

Pro2ect 6ng < procurementarrange contractor strateg0and selection

Procurement engagescontractors

Pro2ect 6ng visits site withLogistics Coordinator and

operations #upervisor toassess logistic requirements

5as upport assessment requirements;.um7er and t0pes of cranes required;3n0 other vehicles required;3n0 other plant required 9weld sets etc:;.um7er and t0pe of scaffolds required 9must 7e consistent with 2o7 method and include an0 modification during event:;!nternal scaffold requirements;3n0 !nsulation removal reinstatement

9mar+ed clearl0 >7etween K and K?:;Lighting8 ventilation, weather protection;&eld ca7le and air hose routes;Location of gas 7ottles 9ox05acet0lene etc:;La0 down areas for large items;3n0 7arriers, warning signs or other safet0 restrictions;3n0 other specific requirements;Dates support items need to 7e installed

Pro2ect 6ng 7riefs contractoron site wor+ requirements

Logistics Coord ensures thatall logistic requirements are!n position 7efore start date

Contractor prepares a methodstatement, schedule and aris+ assessment

!f issue requires management!nput he informs the #teering

Group

#teering Group does >whatever itTa+es to resolve issue and then

3uthorises action

6xecution wor+ crew carries outthe agreed wor+ to the agreedprogram

Plant team issues contactor &ith Permit to wor+ and 7riefs&or+ crew on safet0 issues

6xecution Pro2ect 6ng monitorsperformance < progress < reportsthem to Control (eeting dail0

6xecution wor+ crew completesThe wor+ and provides Pro2ect6ng with all documentation

Pro2ect 6ng hands completedtas+ over for commissioning

!f required, Pro2ect 6ng supportsCommissioning team

Pro2ect 6ng de7riefs pro2ect wor+team to gain learning for future

Pro2ect 6ng regularl0 reportsprogress < !ssues to T34 (gr8

Documents

Process Diagrams Logistics