Maintenance

MAINTAINING THE PERFORMANCE OF YOUR PRODUCTION FACILITY

The Ortec group offers complete, preventive and corrective maintenance of industrial sites, is committed to your projects and guarantees maximum availability of production facilities at the best possible cost.
Our versatile teams perform all types of tasks from situation audits and planning of optimization tasks to implementation.

Our services :

Quality – at the heart of our approach
The Ortec group’s development is anchored on a continuous improvement initiative based on:

The maintenance policies defined by the group are oriented towards the performance and continuing validity of the solutions proposed and are ideally suited to its customers’ production strategies.
The Ortec group is constantly developing in order to anticipate future challenges even more effectively and has designed methods and tools to evaluate all types of project. Whether they concern one-off tasks or multi-year contracts, these productivity analyses allow proactive action to be taken (prevention, assessment, analysis, corrective action) ensuring the targets set are achieved.

Maintenance from A to Z
To allow work to be carried out in the best possible conditions and to adapt to the organizational requirements of its customers, the Ortec group manages all stages in the maintenance of facilities :

Sectors of activity :

Composed of multidisciplinary teams with strong skilled backgrounds, the Ortec Group offers maintenance services to middle to large industry companies in various sectors like :

* Qualité de l'Hygiène de la Sécurité et de l'Environnement,MASE reference (Manuel d'Amélioration Sécurité des Entreprises,i.e : companies safety improvement handbook) : defines best practices of maintenance in a permanent quality upgrade policy.
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Ortec Expertise in unit shutdowns in “ Maintenance & Entreprise ”

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Ortec Expertise in unit shutdowns in “Maintenance & Entreprise”

Publishing date 11/09/2017

Maintenance Shutdowns– the Ortec Group’s expertise at its best

Organisation methods, management of teams, preparation, difficulties, etc. Ortec Group experts discuss the challenges of major maintenance shutdowns and their historic know how in industrial maintenance, in an exclusive interview for the “Maintenance & Entreprise” magazine.

In this special file, discover how the Ortec Group innovates in the sector and how it sets up other differentiating tools to accompany the major industrial players in optimising operation of their installations while limited production shutdown times.

Challenges and specific features
Innovations & tools
Preparation, planning & methods

Managers of the Ortec Group’s Global Services Division and Shutdowns and General Contracting Department share their expertise in the file “Good management of major maintenance shutdowns” published in the “Maintenance & Entreprise” magazine.


Read this article in issue 646, July, August, September 2017.
http://www.maintenance-entreprise.com 

Interview made by Valérie Brenugat

 

GOOD MANAGEMENT OF MAJOR MAINTENANCE SHUTDOWNS

ORTEC Group:

From digital to organisation

Julien Einaudi, director of the Global Services Centre and Roland Girier, Shutdowns and General Contracting Manager, explain management of major maintenance shutdowns in the Ortec Group.

MAINTENANCE & ENTREPRISE: WHAT ARE THE CHALLENGES OF MAJOR MAINTENANCE SHUTDOWNS?

Roland Girier and Julien Einaudi: The strategic challenges of major maintenance shutdowns on petrochemical units are reinforced safety and reliability of equipment, improved energy efficiency and performances increased by large investment projects.

 

M.E.: WHAT ARE THE INNOVATIONS IN THE SECTOR?

  1. E.: Digital occupies a leading place in the Ortec Group’s innovation approach. We digitise our methods in maintenance shutdown activities as in our other activities by connecting our men working in the field Digital allows us to improve the quality of our services, to gain precision, speed and efficiency, all of which are differentiating factors offering added value to our customers. Our aim for maintenance shutdowns is to digitise all processes. This is a very pragmatic approach because every site problem is analysed and leads to a study on how to achieve optimisation by digital monitoring. The first theme is related to improved communication (shared documentation, fewer mails). The second theme is based on the principle of CAMM1. We attempt to apply it to a shutdown in the same way as it will be performed in a company, from dematerialisation of the entire information recording part (using Atex tablet computers), including their integration into their integration into databases and going as far as their processing.

 

M.E.: WHAT IS THE PURPOSE OF THE MAJOR MAINTENANCE SHUTDOWNS?

R.G.: To guarantee smooth running production on a petrochemicals site, the regulations impose that our clients have their equipment inspected in periodic inspections at intervals of 3 or 6 years, so that they are in good operating condition for persons and for the environment in the broad sense.

Our customers are looking for reliability and an increase in the load factor, in other words to minimise the number of possible unplanned shutdowns between two shutdowns.

 

M.E.: WHAT TEAM MANAGES MAJOR SHUTDOWNS?

R.G and J. E.: The Shutdowns and General Contracting Department in the Ortec Group works with its specialist teams to manage major cycle shutdowns of petrochemical plants, with control over preparation, planning, design, methods, internal and external resource management skills, and specialised services and recognised know how in this activity sector, in all French petrochemical zones. The Department can call upon different branch offices in the Ortec Group. A major shutdown involves about 2 500 persons and 600 000 hours of work.

 

Digital occupies a leading place in the Ortec Groups innovation approach.

 

M.E.: WHAT ARE THE DIFFERENT PHASES IN MAJOR MAINTENANCE SHUTDOWNS?

R.G and J. E.: The first phase: preparation. Preparation is handled by the project manager and his team composed of all-trade preparers. This shutdown preparation project must also have its planning, broken down into detail by its major phases. Each of the hundreds of work actions must be prepared so that workers have everything they need and so that they can do their work efficiently. The second step is the work. A specific organisation chart for the shutdown defines the responsibilities of each person and the organisation. Moreover, a planning manager is designated to set the rhythm and to manage details. At least one daily meeting is organised between the different managers (including minutes) to update the shutdown planning as a function of progress and unforeseen factors. Work supervisors work in the field to perform their rounds and to make inspections at stop points defined with the service providers. To do the work necessary for major maintenance shutdowns, equipment has to opened and cleaned so that it can be inspected, and the different inspections are then made by ultrasound, dye penetration or X-rays for welds. Once the equipment has been reclosed, the inspection may include a test to qualify the equipment for a new cycle. Finally, maintenance shutdowns also include metallurgy, boilerwork and pipework.

 

M.E.: WHAT ARE THE SPECIFIC FEATURES OF MAJOR SHUTDOWNS?

R.G and J. E.: A maintenance shutdown can be compared with a Formula 1 race. Precision and speed are its main characteristics: to minimise shutdown on stand, to continuously optimise time, tools and organisations. An extremely precise organisation is necessary over a very short period, on average 4-5 weeks (in petrochemicals), to rigorously program all maintenance operations.

 

M.E.: HOW ARE MAJOR SHUTDOWNS PREPARED FOR?

R.G and J. E.: Major shutdowns require tested methods, specialised teams and experience and the capacity to manage complex projects.

 

M.E.: WHAT ORGANISATION METHODS DO YOU USE DURING MAJOR SHUTDOWNS?

R.G and J. E.: We have optimised methods which we have developed over more than 30 years, and associated methods and procedures. This is our expertise built up during this activity performed continuously over 30 years, recognised by our clients.

 

M.E.: WHAT TOOLS DO YOU USE?

R.G and J. E.: Dedicated tools developed internally by the Ortec Group, and continuously enriched. There are no tools available on the market at the present time. Our tools are all special purpose and are developed internally.

 

A shutdown is a big lesson in humility, it is always exciting.

 

M.E.: WHAT DIFFICULTIES MIGHT YOU ENCOUNTER?

R.G.: A shutdown is a big lesson in humility, because it is always exciting, but sometimes thankless because the boundary between success and failure is so thin.

J.E: Recruiting professionals to continue to provide a long-term service.

 

1 Computer Aided Maintenance Management

 

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