Solving Refining & Petrochemicals Workforce Development Challenges with Performance Improvement Tools

Solving Refining & Petrochemicals Workforce Development Challenges

with Performance Improvement Tools

Bruce MantheyVice President

Global Process IndustriesGSE Systems, Inc

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“There are concerns that not being able to get the right people at the right time for the right cost could inevitably threaten the overall delivery of projects on time and within budget.”

Workforce Related Project Risks Findings Report

Unexpected Consequences of Improved Reliability & Control Technology

Source: Dynamic Performance Management

SEVERAL KEY HUMAN PERFORMANCE FACTORS FROM BP TEXAS CITY INVESTIGATION

1. Lack of technically trained personnel during startup

2. Outdated and ineffective operating procedures

3. Inadequate operator training program

Workforce Development Not Addressed in Traditional Control System Vendor Approach

Enter lifecycle earlyFocus on engineering lifecycleGain mindshare & account control

Graphic courtesy of Statoil

How can you help him become an expert?

Help him understand The Why!

Create e-learning environment

SIMULATION &

TRAININGTECHNOLOGI

ES

Impact of Simulation and Training Processes & Technologies

Reduced “Time to Autonomy”

Improved process safely

Improved process understanding

Improved operator effectiveness

Better handle process upsets

Reduced environmental incidents

Reduced equipment damage

Increased plant availability

Faster turn-arounds & start-ups

Web-based Tutorials High-fidelity Universal Simulators Custom OTS

Training Cos.

Use Technology to Help Bridge the Workforce Development Gap

DCS Vendors

Process Fundamentals

Web-based Tutorials

High-fidelity Universal Simulators

Instructor Led

MentoringKnowledge

Transfer

Unit Specific Experiential

LearningCustom OTS

Process ControlWeb-based

Tutorials

Instructional Systems DesignNecessary Step 0.1

(1) Analysis• Competencies Required Training• Job performance requirements• Requisite skills and knowledge

(2) Design• Training plan• Venue & media• Training & learning objectives/activities

(3) Development• Learning guides• Lesson plans/evaluations• Resources & support materials

(4) Implementation• Documentation: learning activities &

evaluations• Job performance measurement & record

keeping

(5) Evaluation

How O&M Technicians Learn

• Web Tutorials• Instructor-Led

• Startup/Shutdown• Control Sim.

• Structured OJT• Optimization• Trouble-shooting

• Simulations• Normal

• Abnormal/Upsets

• PFDs, PIDs• Tutorials (WBT)• Equipment Descr.• Procedures

Tell me!

Let me!

Show me!

Help me!

Shaikh, Ahmad

3D Interactive Immersive YouTube Video

What is the value of performance improvement tools?

How much would you save if you could eliminate just 1 unplanned shutdown per year?

How much would you save if you could eliminate 1 day in a turn-around?

How much is 1 less reportable incident worth?

We have come a long way since 1901, but we still need to…

Help him understand The Why!

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Bruce E. MantheyVice President – Marketing & Sales

Global Process Industry

[email protected]+1 (410) 970-7800