Oil Sands Project Revolutionizes Inspection Process with Jovix

A Canadian Oil Sands mining project located in Alberta, Canada’s Athabasca region, will mine and process 110 million tonnes of oil sand per year, yielding an average of 194,000 barrels of bitumen per day at full production. Jovix has been deployed on the secondary extraction, which is the final area to be completed to bring the project to first oil by the end of 2017 and ramp-up in the Spring of 2018.

Jobsite Challenges

  • Project inspects materials from over 250 suppliers.
  • Inspectors used manually-produced checklists to inspect materials and equipment. These checklists could be generic, insufficient, or incorrect.
  • With so many vendors, shipment instructions varied. The lack of standardized processes for receipt inspections made it difficult to train new receivers. Also, manual receipt inspections were difficult to track, store, and retrieve. Before data entry, scalability could only be performed by scanning or photocopying the physical documents.
  • Whether from receipt inspections, preservation or maintenance inspections, data entry coordinators manually entered all inspection checklists into Excel, and these spreadsheets were aggregated to build reports. This risky manual process was not only flawed, but also an expensive use of labor. Additionally, there was a variable and oftentimes large time gap between when the inspector submitted checklists and when the reports were populated, meaning the reporting was rarely up to date.

The Goal?
Efficiency & Visibility

Solution

The Jovix Inspection Program was deployed on the project to provide a full materials inspection management service. This includes initial receipt inspections, which are used as an automatic trigger to flag and quarantine OS&Ds when required. The simple setup makes training easy and provides immediate visibility into the discrepancies between the project’s inspections and vendor inspections for the same equipment. Additionally, Jovix gives the project the ability to schedule recurring inspections in order to provide preventative maintenance and preservation of materials.

Implementation

  • The Jovix team equipped the project with rugged tablets, and materials were tagged with active RFID tags. These tags were chosen for the project due to their durability, long battery life, read range, and non-line-of-sight data transmission. Once the tag is attached to the material, it “pings” a signal every 3 seconds that can be received by the tablet.
  • Approximately 60,000 pipe spools and 140,000 structural steel pieces were tagged by Korean fabricators. Pipe supports, bulks, and structural connections were shipped within tagged crates.
  • Mechanical, electrical, and instrumentation materials were tagged at offsite staging laydown yards or mod yards.
  • Cable was cut into engineered lengths and loaded onto supplier-tagged reels.
  • Once received, all remaining items were tagged on-site.
  • The Jovix Inspection Program was launched in early 2015, and the first inspection occurred on April 20. As of December 2017, there have been 89,243 inspections.
  • Jovix automatically generates receipt inspections on initial vendor shipments. Each template (195 in total) is outfitted to specific vendor requirements for every material and recurs on custom schedules to preserve and maintain materials. The templates feature task instructions and observation questions that promote proper inspections, whether it’s maintenance, calibration, sensor reading, axle and motor turning, lubrication, or oil misting.
  • Rules ensure that failed inspections are automatically flagged and quarantined where applicable.
  • Types of Inspections: Component Check, Crate Shipment Inspection, Electrical Preservation & Maintenance (P&M) Inspection, HVAC P&M, Initial Preservations (Electrical, Mechanical, Piping, and Vessel), Mechanical P&M, Paint/Coating Inspection, Piping P&M, Post-Receipt OS&D, Receipt Inspection, Vessel P&M
  • Between the owners, EPC, and the business partners of the project, there are 169 Jovix users.

Results

  • Currently tracking at 98% success rate for all punch items
  • Saves 5-15 minutes per inspection
    • LOW: 5 minutes per inspection
      • 6,800 hours ($100/hr.)
      • $680,000 saved
    • HIGH: 15 minutes per inspection
    • 21,250 hours ($100/hr.)
    • $2,125,000 saved
  • Captures and closes punches in advance of commissioning and startup and walk-downs
    • Estimated cost savings / avoidance of $500,000
  • Standardizes the process flow between the EPC, partners, owners, and field inspectors, and provides everyone access to the same real-time data on the condition of construction material assets, thereby increasing efficiency
  • Inspectors are able to:
    • Create and start an inspection with a mobile tablet.
    • Take and edit photos, and capture changes over time.
    • Submit completed inspections to supervisor.
    • Complete inspection so other inspectors know they don’t need to inspect until next cycle.
  • Inspection Coordinators, Supervisors, and Managers are able to:
    • View details, generate reports, monitor KPIs, and assign fails to be addressed.
      • Alert the correct people when something is incorrect.
      • Time-stamp the notice of damage or failure.
    • Hold employees accountable for performing inspections (signature declaration, etc.).
    • Complete and approve inspections.
  • Reduces the inefficiencies of managing indirect labor inspectors by:
    • Scanning material for verification leads to greater accuracy.
    • Ensuring task completion compliance.
    • Reducing manual data entry (no paper to gather and enter into the system).
    • Collecting pictures and signature acknowledgment as proof of work.
  • Continuous Improvement & Change Management:
    • Location / Status / Care, Custody & Control-Driven
    • Transparent, time-stamped, single source of information
    • Inspection criteria can be exported, analyzed, compared, improved and changed; whether the changes are immediate needs or for future project deployments (scalability).
    • Changing engineering requirements can be updated by management and executed on the very next inspection run.

Oil Sands Project Revolutionizes Inspection Process with Jovix

In Summary

The Jovix Inspections Program has been successfully deployed from the project to various contractors and partners, resulting in digitalized records that have revolutionized how inspections will be used on future projects. Jovix’s dynamic functionality allows managers to export, analyze, and improve inspection questions. This ensures that the best possible quality measures are in place, and optimizes both risk mitigation and efficiencies.

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©2019 Atlas RFID Solutions - Give us a call at  +1.205.383.4428
©2019 Atlas RFID Solutions
Give us a call at  +1.205.383.4428
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