Sphera Case Studies Turnaround Excellence is Now Operational

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	Turnaround Excellence is Now Operational Sphera

Turnaround Excellence is Now Operational

Sphera

Technology Category	Functional Applications - Remote Monitoring & Control Systems
Applicable Industries	Oil & Gas
Applicable Functions	Maintenance Quality Assurance
Use Cases	Predictive Maintenance
Services	Software Design & Engineering Services System Integration
Challenge	The operator of one of the Middle East’s largest and most complex oil refineries was committed to adopting best-in-class industrial practices, recognizing international management standards, and ensuring compliance with all requirements regarding quality, health, safety and the environment (QHSE). As part of its commitment, and in accordance with its company standards, the operator is required to complete a turnaround (TAR) every five years. Performing a TAR on a site this large and complex involved substantial operational risks as a result of potentially hazardous work activities. With more than 2,300 separate pieces of equipment, 40,843 separate but interrelated jobs and no historical activity to act as a guide, the TAR required meticulous planning and exemplary execution to mitigate risks and ensure deadlines were met safely and efficiently. Read More
About Customer	The customer is an operator of one of the Middle East’s largest and most complex oil refineries. The refinery is a 3000-acre site with 20 plants and produces 18 million tons per annum (mtpa) of petroleum-based products and 2 mtpa of ethylene and propylene derivatives. The operator is committed to adopting best-in-class industrial practices, recognizing international management standards, and ensuring compliance with all requirements regarding quality, health, safety and the environment (QHSE). As part of its commitment, and in accordance with its company standards, the operator is required to complete a turnaround (TAR) every five years. Read More
Solution	Sphera was chosen to support the planning and execution of the site’s major turnaround. The ORM for Operations solution delivers a standardized and repeatable approach to managing TAR activities. Its powerful visualization capabilities give users real-time insight into the operational status of any aspect of the plant, enabling them to make better, more informed decisions for improved risk management across a facility. In addition to the proven benefits of ORM for Operations, Sphera was chosen because of its global expertise and experience in developing JSAs and risk assessments. Sphera supported and offered guidance at every stage of the turnaround process - from planning through to execution. Sphera worked closely with its client to prepare and approve best-in-class JSA templates to be implemented universally across all 40,843 tasks. By drawing on predetermined hazards and controls that had been collected over 25 years in the field, Sphera’s turnaround subject matter experts worked to meet the operator’s stringent safety standards. Read More Log in to view content
Contents

Technology Category

Functional Applications - Remote Monitoring & Control Systems

Applicable Industries

Oil & Gas

Applicable Functions

Maintenance

Quality Assurance

Use Cases

Predictive Maintenance

Services

Software Design & Engineering Services

System Integration

Challenge

The operator of one of the Middle East’s largest and most complex oil refineries was committed to adopting best-in-class industrial practices, recognizing international management standards, and ensuring compliance with all requirements regarding quality, health, safety and the environment (QHSE). As part of its commitment, and in accordance with its company standards, the operator is required to complete a turnaround (TAR) every five years. Performing a TAR on a site this large and complex involved substantial operational risks as a result of potentially hazardous work activities. With more than 2,300 separate pieces of equipment, 40,843 separate but interrelated jobs and no historical activity to act as a guide, the TAR required meticulous planning and exemplary execution to mitigate risks and ensure deadlines were met safely and efficiently.

About Customer

The customer is an operator of one of the Middle East’s largest and most complex oil refineries. The refinery is a 3000-acre site with 20 plants and produces 18 million tons per annum (mtpa) of petroleum-based products and 2 mtpa of ethylene and propylene derivatives. The operator is committed to adopting best-in-class industrial practices, recognizing international management standards, and ensuring compliance with all requirements regarding quality, health, safety and the environment (QHSE). As part of its commitment, and in accordance with its company standards, the operator is required to complete a turnaround (TAR) every five years.

Solution

Sphera was chosen to support the planning and execution of the site’s major turnaround. The ORM for Operations solution delivers a standardized and repeatable approach to managing TAR activities. Its powerful visualization capabilities give users real-time insight into the operational status of any aspect of the plant, enabling them to make better, more informed decisions for improved risk management across a facility. In addition to the proven benefits of ORM for Operations, Sphera was chosen because of its global expertise and experience in developing JSAs and risk assessments. Sphera supported and offered guidance at every stage of the turnaround process - from planning through to execution. Sphera worked closely with its client to prepare and approve best-in-class JSA templates to be implemented universally across all 40,843 tasks. By drawing on predetermined hazards and controls that had been collected over 25 years in the field, Sphera’s turnaround subject matter experts worked to meet the operator’s stringent safety standards.

Impact #1	Managed risk-based activity and safety-critical tasks relating to TAR and simultaneous operations in a standardized manner
Impact #2	Created a total of 40,843 JSAs for more than 2,300 equipment job packs in just two months
Impact #3	Ensured adherence to strict internal safety standards and enabled a safe, standardized and consistent TAR approach

Impact #1

Managed risk-based activity and safety-critical tasks relating to TAR and simultaneous operations in a standardized manner

Impact #2

Created a total of 40,843 JSAs for more than 2,300 equipment job packs in just two months

Impact #3

Ensured adherence to strict internal safety standards and enabled a safe, standardized and consistent TAR approach

Benefit #1	63 Client Approved JSA Templates Developed
Benefit #2	12 Additional Specific RAT, (IDLH, Flares, Loading Arms, Furnaces etc.)
Benefit #3	40,843 JSA Produced (4,959 Hot, 3,445 BC, 838 CSE)

Benefit #1

63 Client Approved JSA Templates Developed

Benefit #2

12 Additional Specific RAT, (IDLH, Flares, Loading Arms, Furnaces etc.)

Benefit #3

40,843 JSA Produced (4,959 Hot, 3,445 BC, 838 CSE)

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Overview

Turnaround Excellence is Now Operational

Operational Impact

Quantitative Benefit