Introducing Spartakus APM’s New Features

Shutdowns, turnovers, and walk downs are critical yet challenging processes in industrial settings. Traditional methods often involve manual data entry and fragmented reporting that led to lost data and increased turnover downtime.

These challenges not only strain resources but also affects productivity and reliability. That is why we have developed a new module in Spartakus APM’s: the Shutdown, Turnover, and Walk Down Tool.

This tool introduces a scalable, reusable, and smart digital solution that simplify how organizations manage STOs.

The Problem: Challenges in Shutdowns, Turnovers, and Walk Downs

In industrial environments, shutdowns, turnovers, and walk downs are essential for maintaining equipment reliability and operational efficiency. However, the current manual processes often fall short, leading to significant inefficiencies:

• Data Loss: Critical information collected during these activities is frequently lost or not reusable, creating gaps in asset history and performance tracking.
• Time-Consuming Manual Processes: Technicians spend excessive time recording data on paper or spreadsheets, which is prone to errors and delays.
• Lack of Standardization: Without a unified system, reporting becomes inconsistent, making it difficult to analyze trends or make informed decisions.

These challenges have a direct impact on operations, resulting in:

• Increased Shutdown Downtime:  Lengthy manual processes and data errors prolong shutdowns and walk downs, reducing equipment availability.
• Higher Operational Costs:  Inefficient resource allocation and redundant tasks drive up maintenance expenses.
• Reduced Reliability and Productivity:  Without accurate and reusable data, organizations struggle to optimize maintenance strategies and prevent failures.

Recognizing these issues, Spartakus APM developed the Shutdown, Turnover, and Walk Down Tool in response to requests from partners seeking a more efficient and standardized approach.

Introducing the New Module: Key Features and Capabilities

The Shutdown, Turnover, and Walk Down module helps simplify industrial maintenance by digitizing and optimizing these essential processes. It improves workflow efficiency and ensures more accurate data management.

Key Features:

1. Test Schemes Library:

• The tool includes a comprehensive library of tests for various asset types, such as pressure transmitters, temperature transmitters, and control valves.
• Users can customize test parameters, including tolerance, adjustment limits, and linearity errors, to suit specific needs.
• The ability to add visual inspections and technician tasks ensures thorough and consistent evaluations.

2. Walk Downs Management:

• The tool simplifies walk downs by reusing previously collected data, such as tag numbers, areas, and ranges, eliminating the need for redundant data entry.
• Assets can be assigned to specific walk down events, ensuring organized and efficient inspections.

3. Mobile App Integration:

• The mobile app allows technicians to pre-populate data from previous shutdowns and turnovers, saving time and reducing errors.
• Users can add pictures, enter asset identification details (e.g., loop number, manufacturer, model), and perform calibration tests directly in the field.
• The app calculates errors and evaluates ranges during calibration, providing real-time feedback on asset performance.
• Visual inspections can be conducted, and critical issues can be highlighted for immediate attention.

4. Offline Mode:

Technicians can collect data offline and synchronize it later, ensuring uninterrupted workflows even in remote or low-connectivity areas.

Scalability and Adaptability:

The tool is designed to be scalable and adaptable, supporting a wide range of asset types, including rotative and electrical equipment. This flexibility ensures that organizations can use the tool across diverse operations, from pressure transmitters to motors and beyond.

Benefits of the New Tool

The Shutdown, Turnover, and Walk Down Tool delivers significant benefits that address the challenges of traditional methods:

• Enhanced Data Reusability:  Data collected during shutdowns and walk downs is stored digitally, making it reusable for future events and improving consistency across reports.
• Better Decision-Making:  The tool provides actionable insights through features like the asset health dashboard and reporting tools, enabling organizations to make informed maintenance decisions.
• Cost and Time Savings:  Reduced downtime, fewer errors, and optimized resource allocation translate into substantial cost savings and increased productivity.
• Future-Proofing:  The tool is designed to integrate with other systems, such as IFS, and support future expansions, ensuring long-term value for users.

Real-World Application: A Walkthrough of the Tool

Imagine a scenario where a manufacturing plant is preparing for a scheduled shutdown. Using the Shutdown, Turnover, and Walk Down Tool, the maintenance team can:

1. Set Up the Event: Assign assets to the shutdown event and pre-populate data from previous activities.
2. Conduct Walk Downs: Technicians use the mobile app to perform inspections, capture photos, and enter calibration values. The app calculates errors and evaluates ranges in real time.
3. Identify Issues: Visual inspections highlight critical issues, such as leaks or wear, which are documented for immediate action.
4. Synchronize Data: At the end of the shift, data is synchronized, and reports are generated, providing a comprehensive overview of asset health.

The outcome? Reduced downtime, improved data accuracy, and enhanced technician productivity, all achieved through a digital process.

Conclusion

The Shutdown, Turnover, and Walk Down Tool helps improve industrial maintenance by reducing inefficiencies in traditional methods. It supports organizations in managing shutdowns, turnovers, and walk downs more effectively, leading to better efficiency, reliability, and cost control.

Raphael Tremblay,
Spartakus Technologies
[email protected]