Furmanite Blended Crew Solution - Safest Turnaround Money Can Buy

The need is to be ready to assist our customers with both our highly skilled technicians and specialty tools and machines - whenever they need us, even in peak seasons when personnel resources are strained. That means a commitment from us to offer technicians skilled for various jobs. 

 

The Solution is to cross-train highly skilled line isolation technicians to a help on synergistic tasks. A high-level line isolation technician cross-trains to assist a high-level heat treatment technician; A high-level Line Isolation/Weld Test technician cross-trains to assist a multi-cert NDE technician. In this way highly- specialized technicians are not sitting idle waiting on other vendors to complete a task or service but instead are being fully utilized enabling a single Furmanite technician to provide services previously performed by 2 or 3 individuals.

The Former Approach Previously, our customers would need to hire three or four vendors for the job. Now, Furmanite can provide the technicians needed to enhance safety with one team working together, reducing time to completion, and providing cost savings. Additionally, quality is enhanced by using the same supervisor and team on the project. 

The proof was determined when an independent P6 scheduler who would, utilizing actual turnaround data, calculate the project differences. Both the actual historical former approach and Furmanite Blended Crew solution data were loaded into P6 and the findings calculated.

 
 

The Findings:

1. An actual scope from a typical 15 sequential cut pipe job was analyzed, including demolition, cold cutting, cut location and machining, line isolation, hydro testing using an HID, mag particle testing, and X-Ray-i.e. "The Real Job Test." 
2. Durations and man hours were reduced within Blended Crew as there was a sole source of accountability and communication/direction to field craft vs. using multiple vendors. 
3. Sole source contracting limits the amount of overhead/ indirect hours needed thus reducing the daily/shift head count of people performing non-continuous work in the field. 
4. Duration of the real job test revealed a reduction in overall duration of 7 days. 
5. Punch list review reveals that the Blended Crew has indirects/overhead that are 75% less than using multiple vendors. 

Total reduction of Blended Crew man hours was 552 hours, which does not include the reduction of Direct Craft hours lost on waiting for testing/machining or isolation services to perform their task.

P6 Data

 

Project Start Date April 7 Blended CrewSM Multiple Vendors Contracted

 

Completion Date May 23 May 29

 

QC/QA Reports One Source Four Sources

 

Hours Billed 1,245 1,797

 

Per Diem Days 237 432

 

Lodging Days 237 432

 

Purchase Orders One Four

 

Supervisors One Four

 

Time on Tools Continuous Three crew change outs per joint

Shared Learning Opportunity - Hot Tapping - IP 100

What happened?

   Hot Tap technicians failed to complete a small bore hot tap on 150 PSI / 370 ^oF / steam project.

What went wrong?

    The technicians failed to inspect the dogs on the IP100 when mounting the cutter assembly on the boring bar thus the 4” hot tap on a 6” pipe 150# flanged  system the entire shell cutter / driver / pilot bit & coupon fail into pipe when backing out of the cut.

Investigation Results

     Technician did not stop after making the connection with the “D” ring into the boring bar noticing there was good bit of rocking and twisting movement  between the bar and cutter driver.

     Pre-job planning did not address how to proceed if there was slop in the final connection of boring bar and cutter.

            Two bad boring bar photos   

   Two good boring bar photos

 

How do we prevent it from happening again?

  Always follow the written procedures. If something does not look right or requires any deviations all Furmanite have the responsibility to utilize their “STOP WORK AUTHORITY”.  Any planned activity or job can be rescheduled so the issues can be addressed with the customer. Do NOT continue until all changes and concerns have been addressed and resolved.

What actions do I take?

                 Furmanite’s Pipe Line Intervention Engineers need to modify the IP100 procedures so as to put a go no go step in the form that states what is acceptable gapping in the dogs on the boring bar. This will allow technicians to have a more complete procedure to follow.

                 Review this Shared Learning with all employees