plant operations management a well-managed plant means having full control over all events, planned...

Plant Operations ManagementA 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

Return True (Pty) Ltd, South Africa

T: +27 21 556 2861 | @: [email protected]

www.returntrue.co.za

Software for

Efficient Plants

Agenda

•Overview 3

•Operating Log – What, Why? 4

•Operating Log upgrade 5

•Why change 6

•New Features 7




Software for

Efficient Plants

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




Software for

Efficient Plants

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




Software for

Efficient Plants

Continuous Process Management – 24/7

PlantVue

Process Data

Legislation

Documentation

Human ResourcesCapacity

Planning

Messaging and Communicatio

ns

Production

Maintenance Managemen

t

External Systems




Software for

Efficient Plants

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.




Software for

Efficient Plants

Managing your plant

For management:

Single-page overview across your organization

For the operators:




Software for

Efficient Plants

PlantVue Architecture

Database

Business Rules / Information ManagementAccess Control

Workflow Engine

Reading / Status Values Legislative Control Auditability

Reporting

Management Reporting Executive Reporting

Plant Artisan COO / CEOPlant Operator




Software for

Efficient Plants

Application Suite

OPS Interface

StaffAdmin

Production Minutes

Recommissioning

SMS InterfaceStandb

y

Reporting

Outage

Checklists

Document transfer

Plant Not Available




Software for

Efficient Plants

Staff control

Human Resources

SkillsShift

Position

Shift Annual Percentage

Rate

LeaveAppointed Position

Qualifications

Training

Minimum Team Skill

Standby

Red-cards




Software for

Efficient Plants

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.




Software for

Efficient Plants

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)




Software for

Efficient Plants

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.




Software for

Efficient Plants

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.




Software for

Efficient Plants

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.




Software for

Efficient Plants

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




Software for

Efficient Plants

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.




Software for

Efficient Plants

Operations Log

Writing of a legal OPS LOG

Permit implementation according to design requirements in line with

legislation

Fully audited

Screen-shots and reports




Software for

Efficient Plants

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




Software for

Efficient Plants

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.




Software for

Efficient Plants

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




Software for

Efficient Plants

Staff System




Software for

Efficient Plants

Standby Roster




Software for

Efficient Plants

Plant Not Available




Software for

Efficient Plants

Production Minutes




Software for

Efficient Plants

Checklists




Software for

Efficient Plants

Call-Out Report




Software for

Efficient Plants

Executive Report




Software for

Efficient Plants

Ops Log Report

Usage models




Software for

Efficient Plants

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.

Model

Up-front licence

Monthly rental year 1





Annual licence renewal fee

Pre-paid 250 000 - - - - - 37 500

Rental 87 500 6 000 6 300 6 600 7 000 7 300 0

*Prices are in US$ for a minimum configuration of modules for one site and is valid for new contracts up to 30 Sep 2014

Company Overview




Software for

Efficient Plants

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.




Software for

Efficient Plants

Industry experience - years

Mobile20%

Hospitality3%

HR6%

ISP6%

Insurance9%

Retail6%

eCommerce11%

Workforce Management

1%

Point of Sale4%

Stock manage-

ment2%

Financial switching

5%

Banking16%

Content Management System11%




Software for

Efficient Plants

Technical experience - years

Relational databases26%

Continuous Integration6%

Web applications25%

Automated Testing5%

Mobile apps (iOS/Android)

8%

Behaviour-Driven Development

2%

Windows applications23%

Data warehousing5%

THANK YOUFor 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 PeopleiScratch

ExamVue

http://www.returntrue.co.za

plant operations management a well-managed plant means having full control over all events, planned...

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management software

production plant

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plantfor management

nuclear power plant

efficient plantsmanaging

plantvue controls