KBC undertook an extensive assessment of a Japanese multi-site refiner’s Operation Management Systems which identified that on-stream & shutdown maintenance practices was resulting in a loss of availability due to short turnaround cycle length and long duration of Turnarounds. KBC applied our TOP™ methodology over three sites to improve stakeholder alignment, organizational change as well as challenge scope and conduct schedule optimization.
Achieve world class performance in turnaround by reducing work scope, schedule and costs whilst also allowing increased availability and associated revenue.
KBC’s applied a thirteen month Turnaround Optimization Program, with structured reviews from TR-0 to TR-4 in head office and the three refineries
KBC provided awareness of modern turnaround practices and tools, with agreement on gaps and areas of improvement on the whole turnaround process leading to optimizing the work scope through rigorous work selection and risk based awareness training of employees.
The budget was minimized along with the schedule through monitoring and control strategies on contractor performance and allocation of resources.
KBC provided knowledge transfer for efficient execution of turnarounds throughout review process and streamlined shutdown and start-up procedures as well as the contractor on-boarding process.
Implementation of the TOP program achieved a 10% - 15% reduction of turnaround work scope. Over $50 million benefits were gained through increased availability and shorter turnaround length with $11 million quick wins achieved during the initial phases of the study.
‘’We are very happy with the work performed by KBC as this has enabled us to implement opportunities after thorough discussion and full agreement on the gaps identified in the existing turnaround strategy and methodology. KBC Subject Matter Experts are highly experienced in world class turnarounds and helped us in achieving quick wins of 11M USD by optimizing shutdown & start up procedures, turnaround scope and schedule. Additional long term improvement opportunity has been identified for future events with ongoing multi-million dollar annualized benefits. ‘’
WHITEPAPER
Aug 15, 2019
Europe’s refiners, through their industry organization Fuels Europe, have set out their long-term ambitions in a new program called Vision 2050. Putting this vision into practice will require Europe’s refiners to rethink and rebuild their long-term strategies, along the way transforming their organizations into modern, flexible knowledge-based enterprises. Read more in this market insight by KBC Chief Economists.
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NEWS
Oct 22, 2018
The hub will reduce energy costs and emissions of Singapore-based companies by 10 per cent through delivery of energy management and optimization solutions and next generation analytics via the Cloud.
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BLOG
Nov 6, 2018
Duncan Micklem, Strategy Director
Rising operational costs, a retiring knowledge pool and aging, inflexible infrastructure are just three of a number of threats the process industries currently face. These challenges, however, can be resolved if plants adopt an efficient Digitalization strategy. Here, Duncan Micklem, Director of Business Strategy at KBC, argues why urgent action needs to be taken and the time to Digitalize is now.
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