How Delek streamlined its turnaround management with the GOARC Safety 4.0 platform
Delek US is a diversified downstream energy company with multiple assets in petroleum refining, logistics, asphalt, renewable fuels and convenience store retail. The Company owns and operates four inland refineries with a combined crude oil throughput capacity of 302,000 barrels per day, serving local and regional markets.
The Company’s refining operations are known for their strong safety record and drive for excellence. Delek’s priority is maintaining the health and safety of its employees, contractors and surrounding communities in which it operates, with a commitment to maintaining the highest standards of personal and process safety.
Refining operations involve high risk, variable and potentially hazardous processes and conditions. The company was looking for a proactive, technology-based, data-driven approach to turnaround management with new standards to ensure optimal risk management, efficiency, security and operational excellence.
Ensuring efficient turnaround maintenance planning, scheduling and execution that considers all elements and processes of plant operations
Delek faced the challenge of ensuring efficient turnaround maintenance planning, scheduling and execution that takes into account all elements and processes of plant operations: time and cost management, resources, facilities, shift management and worker safety. A turnaround maintenance event typically requires dealing with numerous work permits, much more than during regular operations, and the ability to access reliable data across all processes and assets while obtaining the right level of approvals from management in a timely manner is critical to the Success of servicing execution.
Prioritizing process safety and risk mitigation along with proactive asset management and organizational maintenance best practices are key to efficiently managing planned downtime and reducing incidents during the turnaround phase.
Delek wanted to integrate processes and data sources to ensure access to comprehensive, real-time data on planned activities, potential safety or hazard conflicts, and the ability to save time and resources with data-based management decisions and approvals while meeting production targets and maintaining process safety and continuity operational excellence.
Digital transformation for effective time and resource management with a systemic solution with real-time data integration for optimal risk management during turnaround maintenance
GOARC’s digital security solution for turnaround management combines security protocols, active processes and data in one system. The dynamic solution provided Delek with tailor-made 24/7 data visibility and access capabilities based on process security. Real-time information, delivered directly to one source from all systems and active tasks, enables management to effectively plan and efficiently manage turnaround shutdowns, startups, and execution activities.
Cross-organizational access to security logs and work policies ensures operational best practices
An efficient digital permit-to-work module to handle numerous permits without delays anytime, anywhere
Improved process safety with real-time data on connected employees, identification of potential safety or hazard conflicts, reliable digital operator rounds and shift handovers
Anytime, anywhere access, insight and transparency
The implementation of GOARC’s Safety 4.0 platform for specific parts of turnaround management streamlined operations and planning functions for optimal risk control, asset availability and asset management across the enterprise. Enhanced anytime, anywhere access to data provides management with critical, real-time insights to improve security, productivity and ensure best practices.
The time- and cost-saving digital system greatly improved the management and efficiency of planned downtime, resulting in improved uptime and production rates. The system minimizes risk and maximizes safety while increasing production efficiency and revenue.
25-30% reduction in process cycle time
Over 60% fewer process errors
70% more validation and confirmation of work permits
3-5% reduction in schedule as a result of increased productivity
Reduced 7-10,000 contractor hours 10,000 x $40 = ~$280,000-400,000
7-10,000 less employee hours 10,000 x $40 = ~$280,000-400,000
15-20,000 hours of productivity